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JLG 600AJ, Service And Maintenance Manual

The JLG 600AJ Service and Maintenance Manual is essential for ensuring the proper care and longevity of your equipment. Easily download this manual for free from manualshive.com to access detailed instructions on how to properly service and maintain your JLG 600AJ, keeping it in top working condition.

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31215031

vii

 

TABLE OF CONTENTS

SECTION NO.   

  TITLE

PAGE NO

.

7.3

Applying Silicone Dielectric Compound Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-3

7.4

Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
AMP Faston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
AMP Micro-Fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
AMP Mini Fit Jr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Mini Fit Sr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Carling Switch Connectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5

7.5

AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-6

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-6
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8
Wedge Lock  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8
Service - Voltage Reading  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-8

7.6

Deutsch Connectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-10

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-10
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-10
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11
HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11

7.7

Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-12

Telematics-Ready (TCU) Plug  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-12

7.8

Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-16

Connector Labels  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-16
Component Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-16

7.9

Wiring Harness Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-18

7.10

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-38

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Summary of Contents for 600AJ

Page 1: ...Service and Maintenance Manual Model 600AJ PVC 2001 31215031 October 10 2019 Rev A AS NZS G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 2: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 3: ...ic systems operate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pressure prior to discon necting or removing any portion of the system C MAINTENA...

Page 4: ...INTRODUCTION A 2 31215031 REVISON LOG Original Issue A October 10 2019 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 5: ...2 1 General 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection 2 1 Pre Delivery Inspection and Frequent Inspection 2 1 Annual Machine Inspection 2 1 Preventive Maintenance 2 1 2 2 Se...

Page 6: ...Disassembly 3 19 Cover Assembly 3 19 Input Carrier Sub Assembly 3 19 Output Planet Gear Sub Assembly 3 19 Spindle Brake Sub Assembly 3 20 Hub Spindle Sub Assembly 3 20 Cover Sub Assembly 3 21 Main Ass...

Page 7: ...65 Every 500 hours 3 65 Overload Protection 3 66 Inspecting Brushes Replacing Brushes and Cleaning Slip Rings 3 66 3 20 Deutz D2 9 L4 T4F Engine 3 68 Check Oil Level 3 70 Change Engine Oil 3 70 Chang...

Page 8: ...embly 4 21 Installation 4 22 4 13 Jib Assembly 4 22 Removal 4 22 Disassembly 4 22 Inspection 4 23 Installation 4 23 4 14 Boom Cleanliness Guidelines 4 24 4 15 Rotary Actuator 4 25 Theory of Operation...

Page 9: ...Upright Level Cylinder Installation 5 8 Tower Boom Lift Cylinder Removal 5 9 Tower Lift Cylinder Installation 5 10 Tower Telescope Cylinder Removal 5 10 Tower Telescope Cylinder Installation 5 10 5 5...

Page 10: ...alyzer Kit Instructions 6 1 Introduction 6 1 Connect JLG Control System Analyzer 6 2 Using the Analyzer 6 2 Changing the Access Level of the Hand Held Analyzer 6 3 Adjusting Parameters Using the Hand...

Page 11: ...nnectors 7 5 7 5 AMP Connector 7 6 Assembly 7 6 Disassembly 7 8 Wedge Lock 7 8 Service Voltage Reading 7 8 7 6 Deutsch Connectors 7 10 DT DTP Series Assembly 7 10 DT DTP Series Disassembly 7 10 HD30 H...

Page 12: ...15 3 14 Output Carrier Disassemb 3 16 3 15 Input Carrier Disassembly 3 16 3 16 Hub Spindle Disassembly 3 17 3 17 Spindle Brake Disassembly 3 18 3 18 Torque Hub Cover 3 19 3 19 Hub Assembly 3 22 3 20...

Page 13: ...R 2 Troubleshooting Flow Chart 3 78 3 80 Deutz EMR 2 Vehicle Side Connection Diagram 3 79 3 81 Deutz EMR 2 Engine Side Connection Diagram Sheet 1 of 2 3 80 3 82 Deutz EMR 2 Engine Side Connection Diag...

Page 14: ...ter Cylinder Assembly 5 18 5 25 Cylinder Barrel Support 5 19 5 26 Marking Cylinder for Alignment 5 19 5 27 Cylinder Rod Support 5 19 5 28 Main Boom Lift Cylinder Assembly 5 20 5 29 Tapered Bushing Rem...

Page 15: ...Bearing 5 42 5 83 Hydrolock Piston Seal Installation 5 43 5 84 Piston Seal Kit Installation 5 43 5 85 Rod Assembly Installation 5 43 5 86 Cylinder Barrel Support 5 44 5 87 Removing Spanner Nut 5 44 5...

Page 16: ...Measurement DC 7 3 7 5 Connector Assembly Figure 1 7 6 7 6 AMP Connector 7 6 7 7 Connector Assembly Figure 2 7 7 7 8 Connector Assembly Figure 3 7 7 7 9 Connector Assembly Figure 4 7 7 7 10 Connector...

Page 17: ...of 18 7 41 7 45 Electrical Schematic Sheet 5 of 18 7 42 7 46 Electrical Schematic Sheet 6 of 18 7 43 7 47 Electrical Schematic Sheet 7 of 18 7 44 7 48 Electrical Schematic Sheet 8 of 18 7 45 7 49 Elec...

Page 18: ...tion Table 2WS 3 65 3 10 Coupling Port Information Table 4WS 3 65 3 11 Engine Fault Codes Deutz Engine 3 89 3 12 Fault Code Cross Reference List Ford Engine 3 111 3 13 CAN to DTC Cross Reference Ford...

Page 19: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 20: ...3m 11ft 2in 3 4m TurningRadius Inside 2WS 4WS 11ft 5in 3 48m 5ft 6in 1 68m TurningRadius Inside 7ftChassis 2WS 4WS 12ft 2in 3 71m 5ft 7in 1 7m MaximumTireLoad 12 500lb 5670kg GroundBearingPressure 600...

Page 21: ...Amp FuelConsumption 0 65GPH 2 46LPH Table 1 2 Deutz D2011L04 Fuel Diesel OilCapacity CoolingSystem Crankcase TotalCapacity 5Quarts 4 5L 11Quarts 10 5L w Filter 16Quarts 15L IdleRPM 1000 LowRPM 1800 Hi...

Page 22: ...ue Dry Interval Hours BearingToChassis 190ft lb 260Nm 50 600 BearingToTurntable 190ft lb 260Nm 50 600 WireRope 15ft lb 20Nm 150 WheelLugs 170ft lb 231Nm 150 EngineMountingBolts 165ft lb 231Nm A R Engi...

Page 23: ...20 C 68 F 109cSt at40 C 104 F 47 5cSt at100 C 212 F 9 5cSt ViscosityIndex 190 Table 1 7 Mobil EAL 224H Type Synthetic Biodegradable ISOViscosityGrade 32 46 SpecificGravity 922 PourPoint Max 25 F 32 C...

Page 24: ...32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends this oil be checked on a yearly basis for viscosity SECTION 1 SP...

Page 25: ...Figure 1 1 Operator Maintenance and Lubrication Diagram Deutz D2011 SECTION 1 SPECIFICATIONS 1 6 31215031 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 26: ...Figure 1 2 Operator Maintenance and Lubrication Diagram Deutz TD2 9 SECTION 1 SPECIFICATIONS 31215031 1 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 27: ...Figure 1 3 Operator Maintenance and Lubrication Diagram Ford MSG 425 SECTION 1 SPECIFICATIONS 1 8 31215031 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 28: ...RE BASED ON MACHINE OPERATION UNDER NOR MAL CONDITIONS FOR MACHINES USED IN MULTI SHIFT OPERATIONS AND OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD...

Page 29: ...hrs thereafter or as shown by Condition Indicator 6 Hydraulic Charge Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as shown by Condition Indicator 7 Hydraulic...

Page 30: ...nts Check level daily Change in accordance with engine manual B Oil Change w Filter Deutz D2 9 Lube Point s Fill Cap Spin on Element Capacity 9 6 Quarts 9 0 L Crankcase and Filter Lube EO Interval Eve...

Page 31: ...nual 10 A Fuel Filter Deutz On Engine Lube Point s Replaceable Element Interval Every Year or 600 hours of operation B Fuel Filter Deutz TD2 9 On Turntable Lube Point s Replaceable Element Interval Ch...

Page 32: ...months or 300 hours of operation or as indicated by the condition indicator B Air Filter Deutz D2 9 Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as shown by c...

Page 33: ...lue 1001095650 243 Vibra TITE 122 Medium Strength Blue 0100019 271 Vibra TITE 140 High Strength Red 0100071 262 Vibra TITE 131 Medium High Strength Red NOTE Loctite 243 can be substituted in place of...

Page 34: ...00 90 122 65 88 100 136 80 108 9 16 12 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 18 0 5625 0 2030 12950 120 163 90 122 135 184 109 148 5 8 11 0 6250 0 2260 14400 150 203 110 149 165 224 135 18...

Page 35: ...0 150 90 120 9 16 12 0 5625 0 1820 16400 155 210 140 190 115 155 18 0 5625 0 2030 18250 170 230 155 210 130 175 5 8 11 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 23000 240 325 215 29...

Page 36: ...000 0 1599 10700 75 100 71 97 65 88 9 16 12 0 5625 0 1820 11600 90 120 87 118 80 109 18 0 5625 0 2030 12950 105 145 97 132 90 122 5 8 11 0 6250 0 2260 14400 130 175 120 163 115 156 18 0 6250 0 2560 16...

Page 37: ...0 90 120 9 16 12 0 5625 0 1820 16400 130 175 125 170 115 155 18 0 5625 0 2030 18250 145 195 135 185 130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 18...

Page 38: ...175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 315 430...

Page 39: ...130 175 5 8 11 0 6250 0 2260 20350 180 245 170 230 160 220 18 0 6250 0 2560 23000 205 280 190 260 180 245 3 4 10 0 7500 0 3340 30100 320 435 300 415 280 380 16 0 7500 0 3730 33600 355 485 335 455 315...

Page 40: ...4 30 36 7 88 66 79 97 14 2 115 50 0 140 105 126 154 16 2 157 68 3 219 164 197 241 18 2 5 192 83 5 301 226 271 331 20 2 5 245 106 5 426 320 383 469 22 2 5 303 132 0 581 436 523 639 24 3 353 153 5 737 5...

Page 41: ...1 75 84 30 52 5 125 115 95 14 2 115 71 6 200 180 150 16 2 157 97 8 315 280 235 18 2 5 192 119 5 430 385 325 20 2 5 245 152 5 610 550 460 22 2 5 303 189 0 830 750 625 24 3 353 222 0 1065 960 800 27 3...

Page 42: ...3 40 38 12 1 75 84 30 36 7 75 70 66 14 2 115 50 0 119 110 105 16 2 157 68 3 186 175 165 18 2 5 192 83 5 256 240 225 20 2 5 245 106 5 362 340 320 22 2 5 303 132 0 494 465 435 24 3 353 153 5 627 590 555...

Page 43: ...55 12 1 75 84 30 52 5 105 100 95 14 2 115 71 6 170 160 150 16 2 157 97 8 265 250 235 18 2 5 192 119 5 365 345 325 20 2 5 245 152 5 520 490 460 22 2 5 303 189 0 705 665 625 24 3 353 222 0 905 850 800 2...

Page 44: ...ental delivery The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purch...

Page 45: ...n an unstable position Ensure adequate support is provided when raising a portion of the equipment Cleanliness 1 The most important single item in preserving the long service life of a machine is to k...

Page 46: ...ays use new replacement hardware when installing locking fasteners Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too sh...

Page 47: ...must be poured from orig inal container into another clean all possible contami nants from service container Always clean filter mesh element and replace cartridge any time oil is changed 3 Inspect a...

Page 48: ...earing area wear b Flaking peeling scoring or scratches on pin surface c Rusting of pin in bearing area 4 Re assembly of pinned joints using filament wound bearings a Housing should be blown out to re...

Page 49: ...1 2 3 BoomAssembly 14 PlatformAssembly Platform 1 2 Railing 1 1 2 Gate 1 5 1 5 Floor 1 1 2 Rotator 5 9 15 5 9 15 LanyardAnchoragePoint 1 2 10 1 2 10 TurntableAssembly SwingBearing 1 2 14 1 2 3 13 14 O...

Page 50: ...HydraulicCylinders 1 2 7 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 2 9 1 2 HydraulicHoses Lines andFittings 1 2 9 12 1 2 9 12 HydraulicReservoir Cap andBreather 1 2 5 9 1 5 HydraulicFilter 1 7...

Page 51: ...damage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwhenreleased 7 Cleanandfreeofdebris 8 Interlocksfu...

Page 52: ...4150548 E SECTION 2 GENERAL 31215031 2 9 Figure 2 1 Engine and Hydraulic Operating Temperature Specifications Deutz G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 53: ...4150548 E SECTION 2 GENERAL 2 10 31215031 Figure 2 2 Engine and Hydraulic Operating Temperature Specifications Ford MSG 425 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 54: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 55: ...ds both tires on the same axle should be the same Wheel Replacement Rims installed on each product model have been designed for stability requirements which consist of track width and load capacity Si...

Page 56: ...left front wheel 2 From platform control station start engine 3 Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of...

Page 57: ...7 10 5 6 2 3 7FT 2 1M WIDE MACHINES OSCILLATING 17 24 20 OR 19 25 26 27 FIXED 16 23 19 21 18 22 MAE1260 Figure 3 2 Axle Installation Sheet 1 of 2 SECTION 3 CHASSIS TURNTABLE 3 4 31215031 G o t o D i...

Page 58: ...twasher 10 Thrustwasher 11 Shim 12 Stop Plate 13 Capscrew 14 Shim 15 Shim 16 AxleWeldment 17 Bolt 18 Bolt 19 Bearing 20 AxleLockoutCylinderAssembly 21 Pin 22 KeeperPin 23 Thrustwasher 24 Flatwasher 25...

Page 59: ...28 24 33 47 46 39 40 43A 43 40 39 45 48 44 42 49 41 38 37 23 32 29 25 19 38 36 21 35 28 26 18 22 33 MAE1920 Figure 3 4 Steering Installation 8ft 2 4m Wide Machines Without Tow Package Sheet 1 of 2 SEC...

Page 60: ...Bolt 20 Bushing 21 Bushing 22 SteerCylinderAssembly 23 Hubassembly 24 Pin 25 KingPin 26 Pin 27 Pin 28 KeeperPin 29 KeeperPin 30 Tie Rod 31 Spindle 32 Spindle 33 Thurstwasher 34 Thurstwasher 35 Thurst...

Page 61: ...53 47 66 61 37 60 42 37 60 41A 41 63 43 33 65 39 52 29 30 30 29 56 59 49 54 32 35 60 62 36 60 35 53 46 31 60 40 60 60 57 44 34 38 61 48 53 45 36 64 31 20 MAE1930 58 Figure 3 6 Steering Installation 8f...

Page 62: ...ng 36 Bushing 37 Bushing 38 Bushing 39 CapHub 40 SteerCylinderAssembly 41 Hub 41A WheelStud 42 Link 43 Nut 44 Pad 45 Pin 46 Pin 47 Pin 48 Pin 49 Pin 50 Pin 51 Pin 52 CotterPin 53 KeeperPin 54 KeeperPi...

Page 63: ...21 5 20 16 17 3 8 7 24 14 5 20 10 35 15 20 5 23 8 19 36 22 2 1 1 2 25 13 4 9 18 12 11 11A 26 29 5 20 16 28 30 20 5 16 7 33 27 5 20 15 27 34 REAR AXLE 10 35 14 20 5 7 31 32 MAE2070 SECTION 3 CHASSIS TU...

Page 64: ...59 73 65 73 66 46 73 55 64 41 49 71 54 43 51 43 54 67 69 58 41 64 60 72 47 72 41 57 64 FRONT AXLE WITH TOW MAE2130 Figure 3 9 Steering Installation 7ft 2 1m Wide Machines Sheet 2 of 3 SECTION 3 CHASSI...

Page 65: ...1 Spindle 32 Spindle 33 Thurstwasher 34 Thurstwasher 35 Plug 36 SlottedNut 37 CupBearing 38 ConeBearing 39 Thurstwasher 40 Bolt 41 Bolt 42 Bolt 43 Screw 44 Bushing 45 Bushing 46 Bushing 47 Bushing 48...

Page 66: ...tion or defects Some gear packages roll with more difficulty than others Do not be concerned if gears seem to roll hard as long as they roll with consistency LEAK TEST The purpose of a leak test is to...

Page 67: ...r 5 RetainingRing 6A CoverPlate 6B DisengageCap 6C Bolt 6D DowelPin 6E O Ring 6F PipePlug 6G RetainingRing 7 Coupling 8A BrakePiston 8B PressurePlate 8C RetainingRing 8D O Ring 8E BackupRing 8F O Ring...

Page 68: ...rasp loose end with pliers and pull out Retaining Ring 4 Remove Cover Subassembly 6 NOTE Carefully pressurize unit with air to pop cover off 5 Remove Input Carrier Subassembly 3 6 Remove Input Shaft 9...

Page 69: ...r 4F 16 Repeat Steps 12 15 for remaining Planet Gears 4F 17 Remove Thrust Washer 4H from Spindle 1A counter bore Figure 3 14 Output Carrier Disassemb Input Carrier Disassembly 1 Using a 1 8 diameter p...

Page 70: ...supporting unit on Hub 1D flange press Spindle 1A out of Hub 1D 5 Lift Hub 1D off of Spindle 1A Remove Boot Seal 1Q from Hub 1D if applicable 6 If necessary press nine Studs 1H out of Hub 1D Locate Hu...

Page 71: ...8A until spring force is relieved from Pressure Plate 8B Remove Flat Head Capscrews 22 and Pressure Plate 8B from brake cavity in Spindle 1A 4 Remove Compression Springs 8L from Piston 8A 5 Using an a...

Page 72: ...of Carrier 3A opposite splined end End of planet shaft that does NOT have the roll pin hole should be inserted into carrier FIRST 5 Place one Thrust Washer 3B on end of Planet Shaft 3E Make sure the f...

Page 73: ...il on bearings dur ing installation 1 Press Bearing Cup of part 1C position A into Hub using pressing tool 2 Turn hub over and press Bearing Cup of part 1C posi tion B into hub using pressing tool T 3...

Page 74: ...install Retaining Ring 20 in groove on Output Sun 11 7 Place Input Shaft 9 spline end into mesh with Internal Coupling 7 splines 8 With modified spline end facing up place Output Gear 11 in mesh with...

Page 75: ...stWasher 5 RetainingRing 6A Cover 6B DisengageCap 6C Bolt 6D DowelPin 6E O Ring 6F PipePlug 6G RetainingRing 7 Coupling 8A BrakePiston 8B PressurePlate 8C RetainingRing 8D O Ring 8E BackupRing 8F O Ri...

Page 76: ...SECTION 3 CHASSIS TURNTABLE 31215031 3 23 Figure 3 20 Bearing Cup Pressing Tool Figure 3 21 Seal Pressing Tool G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 77: ...TURNTABLE 3 24 31215031 Figure 3 22 Bearing Cup Pressing Tool Figure 3 23 Drift Pin for Lining Up Thrust Washers with Output Planet Gear G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 78: ...rive motors are low to medium power two position axial pis ton motors incorporating an integral servo piston They are designed for operation in open and closed circuit applications The standard contro...

Page 79: ...slide hammer to pull seal 4 Discard seal INSPECTION Inspect new seal motor housing seal bore and sealing area on shaft for rust wear and contamination Polish shaft and clean housing if necessary INSTA...

Page 80: ...centering springs 7 8 and 9 using pliers 5 Remove spring retaining washers 10 and 11 6 Remove shift spool 12 7 Remove orifice poppet 13 INSPECTION Inspect new O rings and the sealing area for rust wea...

Page 81: ...rvoirandoil supplytopump Insufficientamountofhydraulicfluidwillnotmeetsystemcooling demands Fillreservoirtoproperlevel Inspectheatexchanger if equipped Ifheatexchangerfails orbecomesobstructed itmayno...

Page 82: ...using a Vi inch hex wrench Units without speed sensor have an O ring plug 15 installed in that location remove it with a Va inch internal hex wrench 10 Using a 1 4 inch internal hex wrench remove cont...

Page 83: ...discard O rings 27 28 17 Remove rear shaft bearing 29 from endcap with a bear ing puller Bearing may be difficult to remove with a puller Try this as an alternative Pack bearing cavity with heavy grea...

Page 84: ...ont bearing Pull bearing 37 off shaft 38 23 Turn housing over and remove swashplate 39 by lifting on end opposite servo lever 24 Remove servo piston 40 Remove piston seal 41 and O ring 42 from servo p...

Page 85: ...washer 53 from cylinder block Inspection After disassembly wash all parts including end cap and hous ing thoroughly with clean solvent and allow to air dry Blow out oil passages in housing and endcap...

Page 86: ...below mini mum specification SWASHPLATE AND JOURNAL BEARINGS Inspect running face servo ball joint and swashplate journal surfaces for damage or excessive wear Some material transfer may appear on th...

Page 87: ...w O ring 1 and piston seal 2 to servo piston 3 Install piston seal over O ring Installing piston seal stretches it making it difficult to install servo piston in its bore Allow 30 minutes for seal to...

Page 88: ...a clean surface until needed 6 Install journal bearings 13 in housing seats Use assem bly grease to keep bearings seated during assembly Ensure locating nubs drop into seat cavities If reusing bearin...

Page 89: ...ers fac ing swashplate Rock the shaft to align block splines and slide cylinder kit into place Orient motor with shaft pointing downward and verify cylinder kit swashplate journal bearings and servo p...

Page 90: ...p from seating properly Ensure O rings seat properly when installing endcap Figure 3 44 End Cap 16 Using an 8 mm internal hex wrench tighten endcap screws Tighten screws in opposite corners slowly and...

Page 91: ...rtain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid 1 Fill reservoir with recommended hydraulic fluid Always filter fluid through a 10...

Page 92: ...ttings as necessary after installation 9 Shut down engine and remove pressure gauge Replace plug at charge pressure gauge port 10 Check fluid level in reservoir Add clean filtered fluid if necessary M...

Page 93: ...switch to enable Drive steer high drive will remain disabled When the DOS is enabled the DOS indicator will be illuminated continuously and a 3 second enable timer will be started and will continue fo...

Page 94: ...s and a traction control manifold that includes three flow dividers combiners Drive speed is varied by a combination of drive pump dis placement engine integrated motor generator speed and motor displ...

Page 95: ...qualize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings or gaskets are located The exact location of a leak can usually be detected by brushing a soap and water soluti...

Page 96: ...osen jam nuts on Elbow Fittings 30 and remove fittings from Brake 6 and Motor Control Valve 32 5 Remove O ring Plugs 23 from Motor Control Valve 32 6 Remove Motor Control Valve 32 from Motor 31 by rem...

Page 97: ...Housing 6 4 Remove the Springs 8L from the piston 5 Apply less than 50 psi 3 45 bar air to the brake port to remove Brake Piston 8A THE PISTON MAY MOVE QUICKLY EYE PROTECTION SHOULD BE WORN DURING TH...

Page 98: ...ubassembly 6 Remove Ring Gear 4 from Housing 1G 7 Remove O ring 5 from between Ring Gear 4 and Housing 1G 8 Remove Carrier Sub Assembly 9 Remove Thrust Washer 11 from between Carrier Sub Assembly and...

Page 99: ...out of the Housing 1G NOTE The Lip Seal 1B will be pressed out of the Housing 1G by the Bearing Cone 1D during this step 4 Remove the Bearing Cone 1E from the Housing 1G 5 Use a bearing puller to rem...

Page 100: ...Planet Shaft 3E from the Carrier 3A Use a small punch to remove the Roll Pin 3D from the Planet Shaft 3E 3 Slide the Planet Gear 3F the two Thrust Washers 3B out of the Carrier 3A 4 Remove both rows o...

Page 101: ...NOTE Refer to Figure 3 53 1 Apply a liberal Coat of grease to the bore of Cluster Gear 3F This will enable the Needle Rollers 3C to be held in place during assembly 2 Install the first row of Needle...

Page 102: ...arks punch marks remain in correct location during Ring Gear 4 installation The side of the Ring Gear 4 with an X or punch mark stamped on it should be up 19 While holding Ring Gear 4 and Cluster Gear...

Page 103: ...l Valve Assembly NOTE Refer to Figure 3 49 1 Lay assembly down with motor ports facing up Remove the two plastic plugs in the motor ports being careful not to lose the O ring in each port Assemble the...

Page 104: ...tShaft 1B LipSeal 1C Bearing 1E Bearing 1G Housing 1H ThrustWasher 1I RetainingRing 1J PipePlug 2 InternalGear 3 CarrierAssembly 4 RingGear 5 O Ring 5A O Ring 6 BrakeHousing 8 SunGear 11 ThrustWasher...

Page 105: ...2 Lockwasher 23 PipePlug 26 O Ring 28 LiftingLug 29 Bolt 30 Elbow 35 Tube 101 Bolt 102 EndCover 103 CommutatorSeal 104 RingSeal 105 Commutator andRingAssy 106 Ring 107 Manifold 108 RotorSet 109 WearPl...

Page 106: ...h a uniform coating of mini mum thickness no runs drips etc Procedure For Setting Swing Gear Backlash Set backlash to 0 010 in to 0 015 in 0 254 mm 0 381 mm using the following procedure 1 Place the m...

Page 107: ...rength Threadlocking Compound and torque jack bolt 50 ft lbs 68 Nm 8 Apply High Strength Threadlocking Compound and tighten jam nut 9 Torque mounting bolts to 340 ft lbs Nm 10 Remove shim and discard...

Page 108: ...ed on Figure 3 56 try and insert the 0 0015 in 0 0381 mm feeler gauge between the bolt head and hardened washer at the arrow indicated position c Assure that the 0 0015 in 0 0381 mm feeler gauge will...

Page 109: ...ble as shown in Fig ure 3 57 Swing Bearing Tolerance Measuring Point 3 If difference is greater than 0 079 in 2 00 mm is deter mined the swing bearing should be replaced 4 If a difference less than 0...

Page 110: ...ING POINT MEASURING POINT A TOWER BOOM FULLY ELEVATED AND MAIN BOOM LEVEL B MAIN BOOM FULLY ELEVATED MAF23640 Figure 3 58 Swing Bearing Tolerance Measurement Location Boom Placement G o t o D i s c o...

Page 111: ...aid in aligning the bearing upon installation Remove the bolts and washers which attach the outer race of the bearing to the frame Discard the bolts Use suitable lifting equip ment to remove the beari...

Page 112: ...Nm w Threadlock ing Compound 9 Remove the lifting equipment 10 Install the rotary coupling retaining yoke brackets apply a light coating of Medium Strength Threadlocking Com pound to the attaching bol...

Page 113: ...OF THE MACHINE 12 9 in 327 66 mm FORWARD OF THE TURNTABLE BEARING CENTER WITH THE BOOM IN THE HORIZONTAL POSITION HOLE IN T T ROTATION CL CG GROSS WEIGHT 14586 lbs 6616 09 kg UPPER WORK ABOVE TURNTABL...

Page 114: ...sing 11 5 Cut off old seals 14 15 17 18 6 Assemble lip seals 14 in direction shown in Figure 3 62 Rotary Coupling Sheet 2 of 2 7 Reassemble O ring 18 8 Heat cap seals 17 in hydraulic oil for 5 minutes...

Page 115: ...1 O ring 2 Plug 3 CheckValve 4 Screw 5 Plug 6 Spring 7 ValveBlockPlunger 8 ValveBlock 9 O ring 10 Body 11 Housing 12 RetainingRing 13 Ring 14 OilSeal 15 O ring 16 Bearing 17 CapSeal 18 O ring Figure...

Page 116: ...TURNTABLE 31215031 3 63 3 4 1 2 2 3 4 6 7 7 3 1 2 3 4 5 7 7 1 5 7 5 2 3 7 4 2 7 6 5 6 1 7 2 Figure 3 63 Rotary Coupling Port Location 2WS G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 117: ...E 3 64 31215031 1 5 9 7 5 2 8 3 7 4 2 7 6 5 6 1 7 2 3 4 1 2 2 3 4 6 7 7 8 9 9 8 3 1 2 3 4 5 7 7 8 8 Figure 3 64 Rotary Coupling Port Location 4WS G o t o D i s c o u n t E q u i p m e n t c o m t o o...

Page 118: ...eer 2500 172 3750 259 4 1 6 Steer 2500 172 3750 259 5 2 6 16 DriveReverse 4500 310 6750 465 6 1 16 DriveForward 4500 310 6750 465 7 3 8 6 CaseDrain 250 17 375 26 Table 3 10 Coupling Port Information T...

Page 119: ...ith slip rings View alignment through air vents in stator barrel Brushes must ride com pletely on slip rings INSPECTING BRUSHES 1 Remove end panel Inspect wires 2 Remove brush holder assembly Pull bru...

Page 120: ...3 Brushes must ride completely on slip rings Acceptable Unacceptable Brush Position On Slip Rings Figure 3 69 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings 1 BrushHolderAssem...

Page 121: ...Mount 14 MotorMount 15 ShuttleValve 16 CatalyticConverter Muffler 17 RearEngineMount 18 Coupling 19 PumpAdapterPlate 20 PumpAssembly 21 GearPumpAssembly 22 OilDrainHose 23 OilDrainValve 24 PumpCoupler...

Page 122: ...lterServiceIndicator 4 CoolantOverflowHose 5 CoolantLevelSensor 6 FuelPump 7 FuelPre Filter 8 Battery 9 PowerModuleRelay 10 Relay 11 Lanyard 12 HitchPin 13 EngineTray 14 AirFilterAssembly 15 EngineCon...

Page 123: ...lace dipstick until fully seated Change Engine Oil 1 Allow engine to warm up Engine oil should reach approximately 176 F 80 C 2 Make sure machine and engine are level and switch off engine 3 Place oil...

Page 124: ...FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY MAKE SURE NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM 1 Wipe area around filte...

Page 125: ...ControlModule 6 FuelInjector 7 OilCoolerHose 8 ExhaustPipeExtension 9 AirCleaner 10 RightRearEngineMountingPlate 11 ExhaustPipe 12 Coupling 13 PumpAdapterPlate 14 PistonPump 15 GearPump 16 LeftRearEng...

Page 126: ...e 5 HitchPin 6 Relay 7 EngineTray 8 FillerCap 9 OilLubePump 10 OilFilter 11 FuelFilter 12 FuelSupplyPump 13 TemperatureSensor 14 OilPressureSensor 15 SpeedSensor 16 ThrottleActuator 17 TemperatureSens...

Page 127: ...Markings 5 Replace dipstick until fully seated Changing Engine Oil 1 Allow engine to warm up Engine oil should reach approximately 176 F 80 C 2 Make sure machine and engine are level and switch off e...

Page 128: ...WORKING ON FUEL SYSTEM 1 Wipe area around filter to clean any dirt from area 2 Remove fuel filter cartridge Catch any escaping fuel 3 Clean dirt from filter carrier sealing surface 4 Apply light film...

Page 129: ...Install the cleanout plug 3 23 GLOW PLUGS If the glow plug option is enabled in the JLG Control System the glow plug and indicator lamp will be energized when the Power Emergency Stop switch is pulled...

Page 130: ...tor The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running Limp home functions In order to switch the engine off the EMR2 is switched i...

Page 131: ...SECTION 3 CHASSIS TURNTABLE 3 78 31215031 Figure 3 79 Deutz EMR 2 Troubleshooting Flow Chart G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 132: ...SECTION 3 CHASSIS TURNTABLE 31215031 3 79 Figure 3 80 Deutz EMR 2 Vehicle Side Connection Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 133: ...SECTION 3 CHASSIS TURNTABLE 3 80 31215031 Figure 3 81 Deutz EMR 2 Engine Side Connection Diagram Sheet 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 134: ...SECTION 3 CHASSIS TURNTABLE 31215031 3 81 Figure 3 82 Deutz EMR 2 Engine Side Connection Diagram Sheet 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 135: ...SECTION 3 CHASSIS TURNTABLE 3 82 31215031 Figure 3 83 EMR 2 Engine Plug Pin Identification G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 136: ...SECTION 3 CHASSIS TURNTABLE 31215031 3 83 Figure 3 84 EMR 2 Vehicle Plug Pin Identification G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 137: ...SECTION 3 CHASSIS TURNTABLE 3 84 31215031 Figure 3 85 EMR2 Fault Codes Sheet 1 of 5 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 138: ...SECTION 3 CHASSIS TURNTABLE 31215031 3 85 Figure 3 86 EMR2 Fault Codes Sheet 2 of 5 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 139: ...SECTION 3 CHASSIS TURNTABLE 3 86 31215031 Figure 3 87 EMR2 Fault Codes Sheet 3 of 5 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 140: ...SECTION 3 CHASSIS TURNTABLE 31215031 3 87 Figure 3 88 EMR2 Fault Codes Sheet 4 of 5 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 141: ...SECTION 3 CHASSIS TURNTABLE 3 88 31215031 Figure 3 89 EMR2 Fault Codes Sheet 5 of 5 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 142: ...016 5 9 4 ActuatorpositionforEGR Valve 2 9 3 6 or Throttle Valve 4 1 6 1 7 8 notplausible Positionerrorofthrottleflap deviation 7 ThresholdforerrordetectionisaninternalECU threshold Thresholdforerrord...

Page 143: ...pedal signalrangecheckhigh Sensordefect Shortcuttobatteryoropenloop Checkcabling checkacceleratorpedalsensor andifnecessaryreplaceit check connectioncableandifnecessaryrepairor replaceit Ifthesignalis...

Page 144: ...ureVoltageatWaterinFuelSensorand renewharnessifneeded 100 3 732 2 2 4 Sensorerroroilpressure signalrangecheck high Shortcircuittobatteryorcablebreak Checkbatteryandwiring Checkcabling Ifsensornotworki...

Page 145: ...heckhigh SRC Shortcircuittobattery sensorvoltage limit ThesensorrawsignalAir_uRawTCACDs volt age Air_SRCTCACDs uMin_C CheckCAC sensorandifnecessaryreplaceit checkconnectioncableandif necessaryrepairor...

Page 146: ...eshold Cleanradiator checkfandrive checkcoolant level checkcoolingsystemingeneral checkthermostatfunction checkwaterpump 111 1 101 2 3 5 Coolantleveltoolow Coolantleveltoolow leakageincoolingsys tem s...

Page 147: ...checksensorposition Checkcamshaftsensororwiring 190 12 420 2 1 2 Sensorcamshaftdetection Outofrange signaldisrupted nosignal Errorinsensororwiring ThresholdforerrordetectionisaninternalECU threshold...

Page 148: ...ngorder Interruptionof electricconnection InterruptionofelectronicconnectionInjector cylinder1 Checkwiringharness injectorsandifnecessary repairorreplaceit ThresholdforerrordetectionisaninternalECU th...

Page 149: ...ECU threshold 656 5 573 163 Injector6 infiringorder Interruptionof electricconnection InterruptionofelectronicconnectionInjector cylinder6 Checkwiringharness injectorsandifnecessary repairorreplaceit...

Page 150: ...point Timeouterror missingCAN Busmessage CheckCAN Buscabling Bussheduling polar ity shortcircuit powerinterrupt TestprotocolofreceiverandcheckCANfunc tionalrange 975 3 457 2 3 8 PWM Signalfan short ci...

Page 151: ...liefvalve PRV andreset faultwithSerdia 523009 10 833 2 5 3 OpentimeofPressureReliefValve PRV for wearoutmonitoringhadexceeded Railpressurehasexceededthetriggerthresh oldofthepressurelimitingvalve Repl...

Page 152: ...ve PRV OpenPRV ThresholdforerrordetectionisaninternalECU threshold OnlyafterECUreset CheckPRVopeningcounterandifnecessary replaceit checkrail pressuresensorforplausi bilityandifnecessaryreplaceit chec...

Page 153: ...sstillpresent exchangeECU 523612 12 615 555 ECUreportedinternalsoftwareerror Errorreportduetoanerrorintheplausibilityof FunctionCoordination FC and MonitoringModul MM ECUinternalerror Thresholdforerro...

Page 154: ...permittedenergizing time Diagnosticfaultchecktoreporttheerror duetoOverRun ThresholdforerrordetectionisaninternalECU threshold Iferrorisstillpresent exchangeECU 523612 14 973 5 5 5 SoftwareresetCPUSWR...

Page 155: ...ointof meteringunitinoverrunmodenotplausi ble Pressurepumpdeliveryquantityinoverrun exceedsthethresholdbasedonthe pressure ThresholdfordetectionisaninternalECU threshold A Checkbackflowpressure B Chec...

Page 156: ...internalECU threshold 523906 5 834 7 6 1 Electricalfuelpre supplypump openload Cablebreak openload Checkwiringofthefuelfeedpumpcircuit includingrelay ifnecessary repairorreplacewiring 523906 12 835 7...

Page 157: ...524112 9 1671 9 3 6 TimeoutComIntakeThrottleValveActr Notused Notused 524113 9 1681 9 3 7 TimeouterrorofCAN Receive FrameCom RxITVActr Notused Notused 524121 9 1683 9 4 5 TimeouterrorofCAN Receive Fra...

Page 158: ...hese correspond to the diesel fuels in accordance with EN 590 and ASTM D 975 No emission values are guaranteed with the other fuels described It is the obligation of the owner to check the permission...

Page 159: ...OR DIESEL ENGINE OPERATION STRONG TENDENCY TO COKE RISK OF PISTON SEIZURE EXTREMELY HIGH VISCOSITY POOR EVAPORATION BEHAVIOR The conversion of DEUTZ engines to rape seed oil fuel opera tion with conve...

Page 160: ...uctions are provided in the following publications Service Manual 3128849 MAE13920 29 6 7 8 9 10 11 12 13 14 15 17 16 18 19 20 21 22 23 28 24 25 26 27 A 1 2 3 4 5 A Figure 3 90 Ford Engine Installatio...

Page 161: ...ION 3 CHASSIS TURNTABLE 3 108 31215031 MAE13930 30 31 32 33 34 38 37 36 35 Figure 3 91 Ford Engine Installation Sheet 2 of 4 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 162: ...3 CHASSIS TURNTABLE 31215031 3 109 MAE13940 42 39 40 41 43 45 44 46 47 48 49 Figure 3 92 Ford Engine Installation Sheet 3 of 4 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p...

Page 163: ...ittingAssembly 18 O Ring 19 GearPumpandFittingAssembly 20 RearEngineMount 21 OilFilter 22 Starter 23 Dipstick 24 Alternator 25 Thermostat 26 WaterPump 27 FanSpacer 28 FrontLeftEngineMount 29 Fan 30 Co...

Page 164: ...atmonitor 420 134 LPGcatmonitor 1165 135 NGcatmonitor 1166 136 Gasolinecatmonitor 430 141 ALhighgasolinebank1 171 142 ALlowgasolinebank1 172 143 ALhighLPG 1161 144 ALlowLPG 1162 145 ALhighNG 1163 146...

Page 165: ...Open 327 254 Knock1ExcessiveSignal 326 255 Knock2sensorOpen 332 256 Knock2ExcessiveSignal 331 261 FPhighvoltage 92 262 FPlowvoltage 91 271 FTGasolineHighVoltage 183 272 FTGasolineLowVoltage 182 273 FT...

Page 166: ...mpmotorloopopenorhigh sideshortedtoground 628 352 FPumpmotorhigh sideshortedtopower 629 353 Megajectordeliverypressurehigherthanexpected 1171 354 Megajectordeliverypressurelowerthanexpected 1172 355 M...

Page 167: ...2127 523 FPP2higherthanIVSlimit 2116 524 FPP2lowerthanIVSlimit 2140 525 FPP1 2simultaneousvoltagesoutofrange 1121 526 FPP1invalidvoltageandFPP2disagreeswithIVS 2120 527 FPP2invalidvoltageandFPP1disag...

Page 168: ...elaycoilshorttopower 687 714 Fpumprelaycontrolgroundshort 628 715 Fpumprelaycoilopen 627 716 Fpumprelaycoilshorttopower 629 721 Startrelaycontrolgroundshort 616 722 Startrelaycoilopen 615 723 Startrel...

Page 169: ...iredetected 1318 1547 AUXanalogPUD4high 1547 1548 AUXanalogPUD4low 1548 1561 AUXanalogPD2high 1561 1562 AUXanalogPD2low 1562 1563 AUXanalogPD3high 1563 1564 AUXanalogPD3low 1564 1629 J1939TSC1messager...

Page 170: ...ed 51 1 2122 FPP1voltagehigh 91 3 2123 FPP1voltagelow 91 4 2128 FPP2voltagehigh 29 3 2127 FPP2voltagelow 29 4 2115 FPP1higherthanIVS 91 0 2139 FPP1lowerthanIVS 91 1 2116 FPP2higherthanIVS 29 0 2140 FP...

Page 171: ...shorted 659 6 289 Injector10coilshorted 660 6 2300 Sparkcoil1primaryopenorshorttoground 1268 5 2303 Sparkcoil2primaryopenorshorttoground 1269 5 2306 Sparkcoil3primaryopenorshorttoground 1270 5 2309 Sp...

Page 172: ...ure Interrupt 629 31 601 Microprocessorfailure FLASH 628 13 604 Microprocessorfailure RAM 630 12 326 Knock1excessiveorerraticsignal 731 2 219 RPMhigherthanmaxallowedgovernspeed 515 15 1111 RPMabovefue...

Page 173: ...74 3 182 FTlowvoltage 174 4 524 Oilpressuresenderlowpressure 100 1 521 Oilpressuresenderhighpressure 100 0 523 Oilpressuresenderhighvoltage 100 3 522 Oilpressuresenderlowvoltage 100 4 337 Cranksignall...

Page 174: ...undshort 697 5 1632 PWM1 Gauge1shorttopower 697 3 1633 PWM2 Gauge2open groundshort 698 5 1634 PWM2 Gauge2shorttopower 698 3 1635 PWM3 Gauge3open groundshort 699 5 1636 PWM3 Gauge3shorttopower 699 3 16...

Page 175: ...6 3 1421 ERWT1voltagelow 1385 4 1422 ERWT2voltagelow 1386 4 1423 ERWT1higherthanexpectedstage1 1385 15 1424 ERWT2higherthanexpectedstage1 1386 15 1425 ERWT1higherthanexpectedstage2 1385 0 1426 ERWT2hi...

Page 176: ...essagereceiptlosswhilein gear 91 9 1661 PWM6open groundshort 925 5 1662 PWM6shorttopower 925 3 1663 PWM7open groundshort 926 5 1664 PWM7shorttopower 926 3 1547 AUXanalogPull Up Down4highvoltage 713 3...

Page 177: ...has been removed ensure the retaining bolts are torqued to the proper value as shown in Figure 3 94 Counterweight Bolt Torque MAE18160 Torque to 260 ft lbs 353 Nm Figure 3 94 Counterweight Bolt Torqu...

Page 178: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 179: ...all platform controls except auxiliary power will be disabled The ground controls are unaffected 4 3 GROUND CONTROL KEYSWITCH SYSTEM The ground control keyswitch is used for selecting the active contr...

Page 180: ...4 Using a suitable lifting device support the platform sup port NOTE The platform support weighs approximately 125 lbs 56 8 kg 5 Remove the bolts and locknuts securing the support to the rotator 6 Us...

Page 181: ...knuts securing the support to the rota tor and install the bolts and locknuts 4 Torque the nut on the rotator center bolt to 586 ft lbs 795 Nm Torque the retaining bolts to 40 ft lbs 55 Nm 5 Position...

Page 182: ...ockingCompound Torqueto586ft lbs 795Nm Checktorqueevery150hoursofoperation Torque71 5ft lbs 97Nm Figure 4 2 Platform Support Torque Values NOTE If any rotator bolts are replaced all bolts on the rotat...

Page 183: ...embly 6 Supporting the slave cylinder remove the hardware from pin 4 Using a suitable brass drift and hammer remove pin 4 from the fly boom 7 Tag and disconnect hydraulic lines from the slave level in...

Page 184: ...he mid sec tion of the boom 7 With powertrack supported and using all applicable safety precautions remove bolts 3 4 and 5 securing rail to the base boom section Remove powertrack from boom section In...

Page 185: ...d poly roller tightly so they do not spin when removing screw With a small ratchet and a T 20 Torx bit remove 8 32 x 0 500 screw from one side 2 Repeat step 1 and remove screw from other side of track...

Page 186: ...over end of rivet Grind out middle of rivet until rolled over part of rivet falls off Repeat for all rivets to be removed 5 After grinding it may be necessary to use a center punch with a hammer to re...

Page 187: ...15031 4 9 6 Insert flat head screwdriver between links Twist and pull links apart 7 Remove link from other section of powertrack using screwdriver G o t o D i s c o u n t E q u i p m e n t c o m t o o...

Page 188: ...male end of track section 2 Spread half shear female end of new link and slide cut out end of track section into it Use screwdriver if neces sary 3 Round half shears will not fit properly in cut outs...

Page 189: ...half shears will rotate into cut outs 5 Parts shown below connect new link to powertrack 6 Push pin through center hole Slide washer on pin 7 Install snap ring in groove on pin Repeat pin installatio...

Page 190: ...ed properly 8 Install new 8 32 x 0 500 self threading Torx head screw in end of new aluminum round bar Torque to 18 20 in lb 2 2 25 Nm 9 Pull up on other end of round bar Slide new poly roller on bar...

Page 191: ...head is seated against link with no space in between link and underside of screw head Replace Fixed End Brackets REPOSITION CABLES HOSES KEEP COVERED DURING GRINDING TO PREVENT DAMAGE 1 Remove rivets...

Page 192: ...in pin groove and closed properly Replace Moving End Brackets REPOSITION CABLES AND HOSES KEEP COVERED DURING GRINDING TO PRE VENT DAMAGE 1 Remove existing pins and center rivet Remove rivet as shown...

Page 193: ...radius pins and snap rings in original locations Repeat with other moving end if replaced NOTE Ensure snap rings are seated in pin groove and closed properly 4 Make sure both brackets rotate correctly...

Page 194: ...linder pin from base boom using a suit able brass drift and hammer 5 Remove hardware securing master cylinder rod end to base boom section 6 Remove master cylinder pin from base boom using a suitable...

Page 195: ...cylinder through the access plate open ing of the upright 7 Remove hardware and wear pads from top sides and bottom of fly boom section Inspection NOTE Replace worn or damage components as needed 1 In...

Page 196: ...tion Check for 2 10 in 5 08 mm clearance Shim if needed 9 Align cylinder with slots at aft end of base boom section Secure cylinder with mounting hardware Installation 1 Use a suitable lifting device...

Page 197: ...ammer 10 Remove bolt and keeper pin from upright pivot pin 11 Remove pin using a suitable brass drift and hammer Remove upright from tower boom assembly Installation 1 Using suitable lifting device po...

Page 198: ...ing harness from tower boom powertrack 3 Remove mounting hardware which secures the push tubes to the tower fly boom section 4 Remove mounting hardware which secures push tubes to the powertrack Remov...

Page 199: ...nder with attach holes in tower fly boom Using a soft head mallet install the cyl inder pin into tower fly boom and secure with mounting hardware 4 Install side top and bottom wear pads to the aft end...

Page 200: ...ifting device 1 For platform and support removal see Section 4 1 Plat form Control Enable System 2 Position the articulating jib boom level with ground HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMED...

Page 201: ...ign lift cylinder with attach holes in jib assembly Using a soft head mallet install cylinder pin 7 into jib and secure with mounting hardware 2 Align rotator support with attach hole in jib assembly...

Page 202: ...the boom can cause premature failure of components and should be removed Methods to remove debris should always be done using all applicable safety precautions outlined in the JLG Service Maintenance...

Page 203: ...rotate simultaneously The double helix design com pounds rotation shaft rotation is about twice of the piston As hydraulic pressure is applied piston is displaced axially within the housing similar t...

Page 204: ...9 10 7 8 5 13 4 1 15 16 MAF19010 1 Housing 2 Shaft 3 Piston 4 EndCap 5 O Ring 6 ShaftBearing 7 Thrustwasher 8 BearingPacking 9 CapSeal 10 BackupRing 11 RodSeal 12 PistonSeal 13 CapBearing 14 Capscrew...

Page 205: ...it 1 2 12 7mm deep to drill out entire pin NOTE If the pin will not come out with the Easy Out use 5 1 6 in drill bit to a depth of 1 2 in 12 7 mm to drill out the entire pin Do not drill deeper than...

Page 206: ...ent 9 Before removing shaft 2 use a felt marker to clearly indicate timing marks between shaft and piston This simplifies timing during assembly 10 Remove shaft 2 It may be necessary to strike threade...

Page 207: ...ft 2 12 To remove piston 3 use a rubber mallet and plastic mandrel so piston is not damaged 13 At the point when piston gear teeth come out of engagement with housing gear teeth mark piston and housin...

Page 208: ...ain pressure seals 205 cut them with a sharp razor blade Do not to damage seal groove 17 Remove thrust washers 304 from end cap 4 and shaft 2 18 Remove wiper seal 304 1 from end cap 4 and shaft 2 19 R...

Page 209: ...ce finish abnormalities Seal grooves bearing grooves thrust surfaces rod surface housing bore and gear teeth 2 Inspect thrust washers 304 for rough or worn edges and surfaces Measure thickness is with...

Page 210: ...n shaft 2 and end cap 4 3 Install wiper seal 304 1 green 0 ring in groove on shaft 2 and end cap 4 around outside edge of thrust washer 304 4 Use a seal tool install main pressure seal 205 on shaft 2...

Page 211: ...in lower groove and feed the rest in using a circular motion Make sure wedged ends overlap correctly Repeat for outer seal 202 8 Insert piston 3 in housing 1 as shown until outer pis ton seal 202 touc...

Page 212: ...ing marks to line up gear teeth on shaft 2 with gear teeth on inside of piston 3 Tap flange end of shaft with rubber mallet until gear teeth engage 13 Install 2 bolts in threaded holes in flange Using...

Page 213: ...lace on end cap as it is threaded in housing 1 18 Tighten end cap 4 Ensure holes for lock pins line up 19 Place lock pins 109 provided in Helac seal kit in holes with dimple side up Using a punch tap...

Page 214: ...seal it to the actuator housing 3 Bolts that come with valve are Grade 8 bolts Install new bolts with a new valve Apply Medium Strength Thread locking Compound to shanks of the three bolts at time of...

Page 215: ...sed loop and pump hydraulic fluid through them Review hydraulic schematic to determine which hydraulic lines to connect The linear feet and inside diameter of hydrau lic supply lines together with pum...

Page 216: ...tuator Removeallrustthenpolish Replace mentpartsmaybeneeded f Rebuildactuator Usefluidcompatiblewithallsealsand bearings 2 Operationiserraticornotresponsive a Airinactuator a Purgeairfromactuator Seeb...

Page 217: ...e 4 15 Foot Switch Adjustment 4 Install cover and secure with four socket head caps crews Torque to 18 22 in lb 2 3 Nm 4 17 PLATFORM LOAD SENSING SYSTEM The Platform Load Sensing System LSS consists o...

Page 218: ...SkyGuard beacon ensure it flashes when sensor activates 3 With SkyGuard sensor still engaged press and hold yel low Soft Touch SkyGuard override button Operate a function to verify operation can be re...

Page 219: ...loses If the status of the switch relay remains OPEN while the Sky Guard sensor is actively engaged it is possible the sensor has failed and should be replaced immediately If the status of the switch...

Page 220: ...VICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES THE BOLT ON EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTIFICATION THE ANNUAL INSPECTION AND CERTIFICA TION MUST BE PERFORMED B...

Page 221: ...ut and jam nuts Orient the hardware as shown below and with the belleville washers so the gap is pres ent at the outside diameter of the washers install the nuts onto the cable finger tight so the mar...

Page 222: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 223: ...s needed to correctly oil the o ring in this man ner Small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the brush with the other hand to dip into the contai...

Page 224: ...gnify an even coating of oil on the fitting 3 O ring Boss type fittings will require more pressure in able to immerse more of the fitting into the saturated sponge This will also cause more oil to be...

Page 225: ...when improper system operation is suspected Cylinders Without Counterbalance Valves Master Cylinder and Steer Cylinder 1 Using all applicable safety precautions activate engine and fully extend cylind...

Page 226: ...t and Slave Slave Level Lower Lift Upright level Main Telescope and Tower Telescope OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydrau lic...

Page 227: ...2 Hydraulic Cylinder Locations Item Cylinder Item Cylinder 1 TowerBoomLift 6 TowerBoomTelescope 2 UprightLevel 7 PlatformLevelSlave 3 Master 8 JibLift 4 MainBoomLift 9 Steer 5 MainBoomTelescope 10 Axl...

Page 228: ...inder clear of boom assembly Lower to ground or suitably supported work area Main Boom Telescope Cylinder Installation 1 Attach hydraulic power supply to telescope cylinder ports Using suitable suppor...

Page 229: ...nder in place using suitable slings or sup ports Align attach pin mounting holes on upright 2 Using a suitable drift drive barrel end attach pin 3 through mounting holes in lift cylinder and upright I...

Page 230: ...ylinder to tower boom fly assembly rod end pin 3 12 Drive leveling cylinder pin 3 through mounting holes in tower boom fly and leveling cylinder using a suitable drift Remove leveling cylinder Upright...

Page 231: ...Drive out cylinder rod attach pin using a suitable brass drift 5 Tag disconnect and cap tower lift cylinder hydraulic lines and ports 6 Remove mounting hardware securing cylinder barrel pin to turntab...

Page 232: ...e 4 Remove mounting hardware securing powertrack to tower boom assembly Slide powertrack back to move holes and wiring harness for access to telescope cylin der 5 Tag disconnect and cap hydraulic hose...

Page 233: ...IR Tower Boom Lift Cylinder DISASSEMBLY NOTE Refer to Figure 5 8 Tower Boom Lift Cylinder Figure 5 8 Tower Boom Lift Cylinder 1001261003 A MAF23530A NOTE SERVICE INFORMATION NOT AVAILABLE AT TIME OF P...

Page 234: ...from cylinder port block Discard O rings 4 Place cylinder barrel in a suitable holding fixture Figure 5 9 Cylinder Barrel Support 5 Mark cylinder head and barrel with a center punch for easy realignme...

Page 235: ...lve 8 CartridgeValve 9 Capscrew 10 O RingPlug 11 LockRing 12 HydrolockSeal 13 O Ring 14 BackupRing 15 WearRing 16 O Ring 17 BackupRing 18 RodSeal 19 WiperSeal 20 Capscrew 21 O RingPlug MAF06200D 10012...

Page 236: ...LY DO NOT USE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 13 Remove and discard backup ring 13 and O ring 14 from inside grooves of pisto...

Page 237: ...Dress threads as necessary 11 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 12 Inspect cylinder head outside diameter for scoring damage ova...

Page 238: ...der Head Seals 4 Carefully install cylinder head assembly on rod Do not damage or dislodge wiper and rod seals Push head along rod to rod end 5 Carefully slide spacer 6 on rod 6 Install O ring 14 and...

Page 239: ...pscrews evenly and progressively and torque as shown in Figure 5 12 15 Remove cylinder rod from holding fixture 16 Position cylinder barrel in a suitable holding fixture INSERTING ROD OFF CENTER CAN D...

Page 240: ...ylinder DISASSEMBLY NOTE Refer to Figure 5 24 Master Cylinder Assembly 1001251052 A MAF23540A NOTE SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION Figure 5 24 Master Cylinder Assembly G o t o...

Page 241: ...ounterbalance valve and fittings from cylinder port block Discard O rings 4 Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to b...

Page 242: ...CartridgeValve 9 Capscrew 10 Plug 11 O RingPlug 12 WiperSeal 13 RodSeal 14 O Ring 15 BackupRing 16 WearRing 17 O Ring 18 BackupRing 19 LockRing 20 Seal 21 Capscrew MAF06220B 1001228004 B 1 19 1A 2A 11...

Page 243: ...KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 13 Remove and discard backup ring 17 and O ring 18 from inside grooves of piston 4 14 Remove an...

Page 244: ...e Dress threads as necessary 11 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 12 Inspect cylinder head outside diameter for scoring damage ov...

Page 245: ...if applicable on rod 2 Carefully install cylinder head assembly on rod Do not damage or dislodge wiper and rod seals Push head along rod to rod end 4 Carefully slide spacer 5 on rod 5 Install O ring 1...

Page 246: ...pscrews evenly and progressively and torque as shown in Figure 5 28 14 Remove cylinder rod from holding fixture 15 Position cylinder barrel in a suitable holding fixture INSERTING ROD OFF CENTER CAN D...

Page 247: ...O rings 4 Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking compound 5 Mark cylinder head and barrel with...

Page 248: ...earRing 13 Seal 14 O Ring 15 O Ring 16 WearRing 17 O Ring 18 BackupRing 19 RodSeal 20 WiperSeal 21 BackupRing 22 Capscrew 23 FlatWasher 24 WearPad 25 Capscrew 26 Plug MAE32120D 1001228007 D 11 8 1 9 2...

Page 249: ...EW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 13 Remove and discard backup ring 21 O ring 14 backup ring 21 from inside grooves of piston 3 14 Remove and discard two...

Page 250: ...ad for burrs and sharp edges Dress applicable surfaces as necessary 12 Inspect cylinder head outside diameter for scoring damage ovality and tapering Replace as necessary 13 Inspect wear pad assembly...

Page 251: ...install cylinder head assembly 4 on rod Do not damage or dislodge wiper and rod seals Push head along rod to rod end 5 Install O ring 15 in spacer 5 Carefully slide spacer with O ring end facing cylin...

Page 252: ...pscrews evenly and progressively and torque as shown in Figure 5 42 15 Remove cylinder rod from holding fixture 16 Position cylinder barrel in a suitable holding fixture INSERTING ROD OFF CENTER CAN D...

Page 253: ...Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking compound Figure 5 55 Cylinder Barrel Support 5 Mark cyl...

Page 254: ...Plug 10 Capscrew 11 WearRing 12 PistonSeal 13 O Ring 14 BackupRing 15 WearRing 16 RodSeal 17 O Ring 18 BackupRing 19 WiperSeal 20 Capscrew 21 CartridgeValve MAF06230B 7 21 8 1 10 19 16 4 17 18 15 14 1...

Page 255: ...T USE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 13 Remove and discard backup ring 14 O ring 13 and backup ring 14 from inside grooves o...

Page 256: ...pering Replace as necessary 10 Inspect threaded portion of head for damage Dress threads as necessary 11 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as...

Page 257: ...ls 4 Install washer ring 5 if applicable on rod 2 Carefully install cylinder head assembly on rod Do not damage or dislodge wiper and rod seals Push head along rod to rod end 5 Install backup ring 14...

Page 258: ...3 Re torque capscrews evenly and progressively and torque as shown in Figure 5 58 14 Remove cylinder rod from holding fixture 15 Position cylinder barrel in a suitable holding fixture INSERTING ROD OF...

Page 259: ...Cylinder DISASSEMBLY NOTE Refer to Figure 5 71 Platform Level Slave Cylinder 1001251051 A MAF23550A NOTE SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION Figure 5 71 Platform Level Slave Cyli...

Page 260: ...head and barrel with a center punch for easy realignment Using an allen wrench loosen the cyl inder head retainer capscrews and remove capscrews from cylinder barrel 6 Attach a suitable pulling devic...

Page 261: ...stWiper 5 RodSeal 6 WearRing 7 O ring 8 BackupRing 9 Piston 10 HydrolockSeal 11 GuidelockRing 12 O ring 13 BackupRing 14 TaperedBushing 15 Capscrew 16 Capscrew 17 Plug 18 Plug 19 Spacer 20 Counterbala...

Page 262: ...coring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as n...

Page 263: ...to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a light film of hydraulic oil to all components prior to assembly 1 A special tool is used t...

Page 264: ...r dislodged 9 Thread piston onto rod end and install the tapered bushing NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 10 Assemble the tapered bushing loose...

Page 265: ...L SURFACES 17 With barrel clamped secured and adequately support ing the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislo...

Page 266: ...der rod if applicable 3 Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking compound Figure 5 86 Cylinder Ba...

Page 267: ...Ring 4 Setscrew 5 Barrel 6 Rod 7 Head 8 O Ring 9 BackupRing 10 Seal 11 O Ring 12 Wiper 13 SpannerNut 14 CompositeBushing 1001097242 B MAF23520B 150 180 ft lb 203 244 Nm 57 63 ft lb 77 85 Nm 14 14 5 3...

Page 268: ...ring and for distortion Inspect seal and O ring grooves in piston for burrs and sharp edges Dress piston surfaces or replace rod assembly as necessary 6 Inspect rod bushings for excessive wear or dama...

Page 269: ...Head Assembly Figure 5 94 Cylinder Head Seals 5 Install wear ring 2 in piston groove 6 Install seal 3 in piston groove 7 Install setscrew 4 to piston Figure 5 95 Piston Seal and Wear Ring Assembly INS...

Page 270: ...housing bore 4 Remove check valve 9 if required 5 Inspect bore and piston for scoring pitting or excessive wear 6 Remove minor surface blemishes with wet 2000 grit sandpaper Pitting requires replaceme...

Page 271: ...7 4 9 1684465 F Torque to 25 27 ft lb 33 36 Nm FALLING PARTS CAN CAUSE INJURY AND EQUIPMENT DAMAGE CYLINDER ROD CAN FALL OUT WHEN BLEEDER VALVE IS OPENED 1 Barrel 2 Rod 3 Plug 4 PilotPiston 5 WearRin...

Page 272: ...solvent 2 Remove port plugs and drain oil from pump 3 Use a permanent marker pen to mark a line across mounting flange gear housing and end cover This will assure proper reassembly and rotation of pum...

Page 273: ...Shaft seal will be replaced 13 Remove front bearing block 14 Turn mounting flange over with shaft seal up Remove retaining ring with snap ring pliers 15 Remove oil seal from mounting flange Do not mar...

Page 274: ...t and idler gear shafts at bearing points and seal area for rough surfaces and excessive wear 4 Inspect gear face for scoring or excessive wear If face edge of gear teeth are sharp they will mill into...

Page 275: ...tors 1 Install new shaft seal in mounting flange with part num ber side facing out Press seal into seal bore until seal reaches bottom of bore Use uniform pressure to pre vent seal misalignment or dam...

Page 276: ...seal Remove seal sleeve from shaft 9 Install idler gear shaft in remaining position in bearing block Apply a light coat of clean oil to face of drive and idler gears 10 Place rear bearing block over...

Page 277: ...cover over back of pump 15 Install four spacers if applicable and hex head bolts through bolt holes in end cover Hand tighten 16 Place mounting flange of pump in protected jawed vise and alternately t...

Page 278: ...for external leaks 5 7 VARIABLE PUMP Ports and Pressure Gauges Proper servicing of pumps and motors requires pressure mea sured and monitored at various hydraulic circuit points The Series 42 pump has...

Page 279: ...stalla tion of new O rings Pressure setting may be changed for dif ferent charge flows depending on charge pump size and pump speed Factory setting is set relative to case pressure at 1800 rpm Actual...

Page 280: ...rtL2 2 SystemPressurePortB 8 ServoPressureGaugePortL4 3 SystemPressurePortA 9 CaseDrainPortL1 4 SystemPressureGaugePortM1 10 CaseDrainPortL1 non feedback 5 ServoPressureGaugePortM5 11 ChargePressureGa...

Page 281: ...70 100 95 135 4 CaseDrainPortL1 N A N A 5 ChargePressureGaugeM3 N A N A 6 ChargePumpInletPortS 85 115 7 CaseDrainPortL2 N A N A 8 PortN N A N A 9 SystemGaugeM1 M2 N A N A 10 SystemPortsA B 85 115 11...

Page 282: ...d adjust charge pressure if necessary For screw adjustable anti stall charge relief valves an approxi mate rule of thumb is 2 8 bar quarter turn 40 psi quar ter turn 6 Measure charge pressure port M3...

Page 283: ...amage to seal bore in seal carrier If shaft is not being replaced go to step 11 8 Remove shaft and roller bearing assembly from pump or motor 9 Remove retaining ring from roller bearing assembly with...

Page 284: ...y with clean hydraulic oil before assembly 8 Install gerotor drive pin into hole in drive coupling Apply grease or petroleum jelly to keep in place 9 Install drive coupling on pump shaft with smaller...

Page 285: ...n port NOTE Usehighestpossiblecasedrainport Thisensureshousingcon tainsasmuchoilaspossibleandoffersthegreatestamountof lubricationtointernalcomponents NOTE It may be easier to fill housing before inst...

Page 286: ...rt MP 9 2 Activate steer left and right 3 Adjust front steer relief valves 14 to 2050 psi 141 bar in both directions Turn adjuster clockwise to increase pressure or counterclockwise to decrease pressu...

Page 287: ...lescopeOut 3 SwingRight 10 FrontSteerPressureRelief 17 MainUpperBoomPressureRelief 4 MainLiftDown 11 TowerLiftUp 18 MainLiftUp 5 MainUpperBoomPressureReliefValve 12 MainUpperBoomPressureRelief 19 Swin...

Page 288: ...ght 12 RearSteerRight 4 WheelSteerOnly 21 MainUpperBoomPressureRelief 4 SwingRight 13 RearSteerPressureRelief 4 WheelSteerOnly 22 MainLiftUp 5 MainLiftDown 14 FrontSteerPressureRelief 23 SwingLeft 6 M...

Page 289: ...ft lb 7 Nm 1 MAF19020 1 LevelUpReliefValve RV2 6 FlowReliefValve FR1 11 JibUpSolenoid 2 TestPortM1 7 RotateLeftSolenoid 12 JibDownSolenoid 3 LevelDownReliefValve RV1 8 RotateRightSolenoid 13 TestPortM...

Page 290: ...DRAULICS INFORMATION SCHEMATICS 5 68 31215031 5 11 HYDRAULIC SCHEMATICS SHEET 1 Figure 5 108 2 Wheel Steer 2WS Hydraulic Schematic 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 291: ...CTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 31215031 5 69 A Figure 5 109 2 Wheel Steer 2WS Hydraulic Schematic 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t...

Page 292: ...ON 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 70 31215031 SHEET 2 Figure 5 110 4 Wheel Steer 4WS Hydraulic Schematic 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 293: ...ON 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 31215031 5 71 SHEET 1 Figure 5 111 4 Wheel Steer 4WS Hydraulic Schematic 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 294: ...ON 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 72 31215031 SHEET 3 Figure 5 112 2 Wheel Drive 2WD Hydraulic Schematic 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 295: ...ON 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 31215031 5 73 SHEET 3 Figure 5 113 2 Wheel Drive 2WD Hydraulic Schematic 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 296: ...ON 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 74 31215031 SHEET 4 Figure 5 114 4 Wheel Drive 4WD Hydraulic Schematic 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 297: ...ON 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 31215031 5 75 SHEET 4 Figure 5 115 4 Wheel Drive 4WD Hydraulic Schematic 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 298: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 299: ...e main lift swing and drive are controlled by individual joy sticks Steering is controlled by a rocker switch built in the top of the drive joystick To activate Drive Lift and Swing pull up the slide...

Page 300: ...tem by turning the lower key to the platform or ground position and pulling both emer gency stop buttons on Using the Analyzer With the machine power on and the analyzer connected prop erly the analyz...

Page 301: ...el menu is selected a new set of menu items may be offered for example DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed menus will display additional sub menus within...

Page 302: ...yed or you can not adjust the personality settings Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arro...

Page 303: ...e machine personality settings There is a setting that JLG strongly recommends that you do not change This setting is so noted below ELEVATION CUTBACK CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY...

Page 304: ...E EXT EXTEND F FRONT FL FLOW FNT FRONT FOR FORWARD FWD FORWARD FSW FOOTSWITCH FUNC FUNCTION G GROUND GND GROUND GRN GREEN GM GROUNDMODULE H HOURS HW HARDWARE HWFS HARDWAREFAILSAFE I INorCURRENT JOY JO...

Page 305: ...W SWITCHorSOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ TORQUE TRN TRANSPORT T T TURNTABLE T TOWER TURNTBL TURNTABLE TWR TOWER U UPPERorUP V VOLT VER VERSION VLV VALVE WIT WITNESS YEL YELLOW Table 6 1...

Page 306: ...mp Inputs Lamp Inputs Valve Inputs Valve Inputs Throttle Output Deutz Only Function Speed Knob Lift Swing Joystick Drive Steer Joystick Option Switch Inputs Load Cell Input Limit Switch Inputs Engine...

Page 307: ...STICK LIFT MAIN UP XXX LIFT OUTPUT MAIN UP XXX LIFT UP COMMANDED XXXXMA LIFT DOWN COMMANDED XXXXMA LIFT OUTPUT ACTUAL XXXXMA JOYSTICK SWING LEFT XXX SWING OUTPUT LEFT XXX SWING LEFT COMMANDED XXXXMA S...

Page 308: ...OSED TOWER POSITION RETRACTED WIRE ROPE INPUT CLOSED CREEP SWITCH CLOSED CREEP MODE OFF CHASSIS TILT XX X DEGREES CHASSIS TILT X AXIS XX X CHASSIS TILT Y AXIS XX X AUXILIARY POWER SWITCH OPEN HORN SWI...

Page 309: ...LOG RENTAL XXXh XXm DATALOG ERASE RENTAL 1 CLEAR RENTAL YES ENTER NO ESC 1 DIAGNOSTICS VERSIONS GROUND MODULE SOFTWARE XX XX GROUND MODULE COST DATA XX XX GROUND MODULE HARDWARE REV XX GROUND MODULE S...

Page 310: ...LEFT TRACK MIN FORWARD XXX LEFT TRACK MAX FORWARD XXX LEFT TRACK MIN REVERSE XXX LEFT TRACK MAX REVERSE XXX LEFT TRACK ELEV F MAX XXX LEFT TRACK ELEV R MAX XXX LEFT TRACK CREEP F MAX XXX LEFT TRACK CR...

Page 311: ...X TOWER TELESCOPE MAX OUT XXX PERSONALITIES PLATFORM LEVEL PLATFORM LEVEL ACCEL X XS PLATFORM LEVEL DECEL X XS PLATFORM LEVEL MIN IN XXX PLATFORM LEVEL MAX IN XXX PLATFORM LEVEL MIN OUT XXX PLATFORM L...

Page 312: ...ATIONS 1 CALIBRATIONS TILT SENSOR 1 CALIBRATIONS UMS SENSOR 1 CALIBRATIONS FORD ENGINE 1 CALIBRATIONS LOAD SENSOR 1 CALIBRATIONS DEUTZ SETUP 1 TILT SENSOR CALIBRATE 1 UMS SENSOR CALIBRATE 1 UMS SENSOR...

Page 313: ...1 PROP MODULE FF NUM XXXXX 1 PROP MODULE FF DEN XXXXX 1 PROP MODULE I NUM XXXXX 1 PROP MODULE I DEN XXXXX 1 PROP MODULE NEG ERR XXXXX 1 PROP MODULE GAIN FLAG XXXXX 1 PLAT LEVELING 1 LEVEL UP CRPT 1 LE...

Page 314: ...mumSpeed 1to100 50 97 ElevatedMaximumSpeed 1to100 15 62 CreepMaximumSpeed 1to90 20 45 STEER MaximumSpeed 1to100 100 100 MAINLIFT Acceleration 0 0sto5 0s 2 0 2 0 Deceleration 0 0sto3 0s 0 7 0 7 Minimum...

Page 315: ...0 MediumSpeed 0 01to1 00 0 45 0 45 TOWERTELESCOPE Acceleration 0 0sto5 0 1 0 1 0 Deceleration 0 0sto3 0 0 5 0 5 MinimumInSpeed 1to65 45 45 MaximumInSpeed 1to100 100 100 MinimumOutSpeed 1to65 45 45 Max...

Page 316: ...peed 1to100 99 99 MainLiftUp 1to100 74 74 MainLiftDown 1to100 79 79 SwingLeftSpeed 1to100 69 69 MainTelescopeSpeed 1to100 74 74 TowerTelescopeSpeed 1to100 99 99 PlatformRotateSpeed 1to100 84 84 Platfo...

Page 317: ...ndercalibratedzeropoint 0031 00 31 FUELLEVELLOW ENGINESHUTDOWN EngineShutdownhasoccurredduetoFuel Level EMPTYcondition ResponsedescribedinFuel Shutdownsection 0035 00 35 APUACTIVE AuxiliaryPower Emerg...

Page 318: ...20 L SJOY CENTERTAPBAD TheL SJoystickcentertapvoltageis 3 08Vor 3 83V Resistivejoysticks Thereisa 1Vrange aroundthesevaluesdueto resistortolerances 2221 22 21 LIFT SWINGLOCKED JOYSTICKMOVEDBEFOREFOOTS...

Page 319: ...rthisDTC 242 24 2 AMBIENTTEMPERATURESENSOR OUTOFRANGEHIGH AmbientTemperaturesensorreading 85C CheckAmbientTemperature sensorreading 85C 250 25 0 FUNCTIONPREVENTED 259 25 9 MODELCHANGED HYDRAULICSSUSPE...

Page 320: ...ONNECTED Startbatteryisconnected Checkthebattery 330 33 0 GROUNDOUTPUTDRIVER 331 33 1 BRAKE SHORTTOBATTERY ThereisaShorttoBatterytotheBrake Valve CheckHarnessfordamage 332 33 2 BRAKE OPENCIRCUIT There...

Page 321: ...3 62 STARTSOLENOID SHORTTOGROUND ThereisaShorttoGroundtotheStart Relay CheckHarnessfordamage 3363 33 63 STARTSOLENOID OPENCIRCUIT ThereisanOpenCircuittothe StartRelay CheckHarnessfordamage 3364 33 64...

Page 322: ...TFORMROTATELEFTVALVE SHORTTOGROUND ThereisaShorttoGroundtothePlatform RotateLeftValve CheckHarnessfordamage 3395 33 95 PLATFORMROTATELEFTVALVE OPENCIRCUIT ThereisanOpenCircuittothePlatform RotateLeftV...

Page 323: ...aShorttoBatterytotheTower TelescopeOutValve CheckHarnessfordamage 33118 33 118 SWINGRIGHTVALVE SHORTTOGROUND ThereisaShorttoGroundtotheSwing RightValve CheckHarnessfordamage 33119 33 119 SWINGRIGHTVAL...

Page 324: ...nCircuittothe Horn CheckHarnessfordamage 33208 33 208 HORN SHORTTOBATTERY ThereisaShorttoBatterytotheHorn CheckHarnessfordamage 33209 33 209 HORN SHORTTOGROUND ThereisaShorttoGroundtothe Horn CheckHar...

Page 325: ...G TheUGMcommandedcurrent 250mA Thedifferencebetweenthecommanded currentandthemeasuredfeedbackcur rent thelargerof 125mA or 15 of the commandedfunctionMax forlonger than1second TheUGMshallsuspendDrive...

Page 326: ...essfordamage 345 34 5 PLATFORMLEVELDOWNVALVE OPENCIRCUIT ThereisanOpenCircuittothePlatform LevelDownValve CheckHarnessfordamage 346 34 6 PLATFORMLEVELDOWNVALVE SHORTTOBATTERY ThereisashorttoBatterytot...

Page 327: ...isaShorttoGroundtotheJIBRotate RightValve CheckHarnessfordamage 430 43 0 ENGINE 431 43 1 FUELSENSOR SHORTTOBATTERYOROPENCIRCUIT TheFuelSensorreadingis 4 3V EnergizefuelsensorperSys temIndicators 432 4...

Page 328: ...CheckEngine 4333 43 33 SOOTLOADWARNING SEVERE SPN FMI 3715 31 CheckEngine 4334 43 34 ENGINECOOLANT LOWLEVEL MACHINESETUP ENGINE DEUTZEMR4 ECMtransmitsaJ1939DM1messageforan enginecoolantlowlevelfault...

Page 329: ...gSystemModulehasnot beencalibrated UGMtosetPlatformLoad State Overloaded 826 82 6 RUNNINGATCREEP PLATFORMOVERLOADED Allfunctionsatcreep theLoadSensing System indicatesthePlatformisoverloaded ANDisconf...

Page 330: ...ED HydraulicReturnFilterClogged CheckHydraulicReturnFilter 872 87 2 CHARGEPUMPFILTERBYPASSED ChargePumpFilterClogged CheckChargePumpFilter 873 87 3 MACHINESAFETYSYSTEMOVERRIDEOCCURRED MSSO Active Resp...

Page 331: ...lts Disableallmachineand enginefunctions i e com mandengineshutdownand donotpermitstart 9944 99 44 CURRENTFEEDBACKGAINSOUTOFRANGE Thefactorysetcurrentfeedbackgainsare outofrange Againof1isusedforthefa...

Page 332: ...n P6 30 Configuration Label Digit Number Description Default Number MODELNUMBER 1 1 2 3 4 5 600A 740A 800A 601S H800A 1 MARKET 2 1 2 3 4 5 6 7 ANSIUSA ANSIEXPORT CSA CE AUSTRALIA JAPAN GB 1 Certainmod...

Page 333: ...ier2 DEUTZECM EngineControlModule ECM Tier2andTier3 DUALFUELECM GM PSI3 0LDualFuel Tier2 PERKINSECM CATECMT4I CATECMT4F DEUTZEMR4 DeutzEngineControlModule Tier4Final FORDDUALFUEL KUBOTAD1305 13 Certai...

Page 334: ...Reducesthemaximumspeedofallboomfunctionstocreepwhentiltedmorethan4degreesandabove elevation alsodisallowstowerliftup towertelescopeout drive maintelescopeoutandmainliftup 3DEGREES CUT Reducesthemaxim...

Page 335: ...tformmodeonly 1 Onlyvisibleifgenset welderselectionisnotNO H TLIGHTS 15 1 2 NO Noheadandtaillightsinstalled YES Headandtaillightsinstalled 1 CABLESWITCH 16 1 2 NO Nobrokencableswitchinstalled YES Brok...

Page 336: ...GF PSI LBS METRIC DEGC KPA KGS 1 Certainmarketselectionswillalterdefaultsetting LEVELINGMODE 22 1 2 ALLFUNCTIONS Platformlevelwithallfunctions LEVELLIFT TELESCOPE Platformlevelonliftandtelescopeonly 1...

Page 337: ...Disabled YES TempCutoutisEnabled 0 Certainmodelselectionswilllimittempcutoutoptions PLATLVLOVRCUT 30 0 1 NO PlatformLevelOverridewillalwaysbefunctional YES PlatformLevelOverridewillonlybefunctionalwhe...

Page 338: ...ad TailLights 1 1 1 1 1 1 1 2 2 2 2 2 2 2 CableBreakSwitch 1 1 1 1 1 1 1 X X X X X X X LoadSystem X 1 X X X X X X X X X X X X 3 3 3 X 3 3 3 4 4 4 4 X 4 4 FunctionCutout 1 1 1 1 1 1 1 X 2 2 2 2 2 2 3 3...

Page 339: ...heravailable selection ITALICTEXTindicatesthedefaultwhenoptionisfactoryinstalled SHADED CELLSindicatehiddenmenuorselection 1001249337 A Table 6 5 Machine Configuration Programming Settings Software Ve...

Page 340: ...gized Verify that machine will Tower Up and Down Return Knob to fully clockwise MAIN LIFT tower lift fully elevated tower telescope fully extended main telescope fully retracted Main Lift Up record ti...

Page 341: ...d into the creep posi tion 7 Functional speeds may vary due to cold thick hydraulic oil Test should be run with the oil temperature above 38 C 100 F Table 6 6 Function Speeds In Seconds Function Speed...

Page 342: ...rlocks The PLATFORM MODULE reads sensors mounted on the platform assembly and controls Level Up Down valves to maintain setpoint sent from the GROUND MODULE Steer The GROUND MODULE stores crack points...

Page 343: ...s platform load until actual plat form load is less than Rated Load b Operation of the overriding emergency system Auxiliary Power Unit c By an authorized person at the ground control posi tion option...

Page 344: ...ics Menu Displayed on Analyzer 1st Line Parameter Displayed on Analyzer 2nd Line ParameterValue Displayed on Analyzer 2nd Line Description PLATFORMLOAD STATE OK OVERLOAD LSSStatus PLATFORMLOAD ACTUAL...

Page 345: ...the platform from ground control if neces sary to within 5 4 To access the Calibration Menu use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu The screen will read NOTE Th...

Page 346: ...nalyzer keys to enter the accessory weight s in lbs When all the accessory weights are entered press ENTER The screen will read LOAD SENSING accessory xxxlbs Table 6 8 Accessory Weights Accessory Weig...

Page 347: ...ht is not within the allowed range the calibration attempt will be unsuccessful and the Analyzer will show the following 10 Press ENTER The control system will ask for installed accessories The screen...

Page 348: ...apacity Reductions Table 6 9 SkyGlazier Capacity Reductions Capacity PLATFORM OVRLD PLATFORM OVRLD RESTRICT 500lb 227kg 400lb 181kg n a 550lb 250kg 400lb 181kg n a 600lb 272kg 400lb 181kg n a 750lb 34...

Page 349: ...SECTION 6 JLG CONTROL SYSTEM 31215031 6 51 14 Press ENTER If calibration is successful the screen will read G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 350: ...ls should flash and the Audible Warning at Platform and Ground should sound for 5 seconds On 2 seconds Off However the controls should remain functional when using the engine and the Auxiliary Power U...

Page 351: ...houldbeallowedtoevaporateor acceleratedwithaheat gun uselowheatandbecarefullytonotmeltconnectormaterials Moistureintrusionintothemoldedportionof theconnector capillaryactionintothewirebundle ortheShea...

Page 352: ...from the platform console the Emergency Stop switch on the ground console must also be pulled out 4 Pull out the Emergency Stop switch 5 The analyzer screen should read 6 Use the arrow button to reach...

Page 353: ...ter The screen will read 13 Press Enter The JLG Control System will reset an active 873 DTC and the MSSO System will be reset Press Escape to return to the CALIBRATIONS menu G o t o D i s c o u n t E...

Page 354: ...YSTICK MOVED BEFORE ENABLE 2216 D S JOY OUT OF RANGE HIGH 2217 D S JOY CENTER TAP BAD 2219 L S JOY OUT OF RANGE HIGH 2220 L S JOY CENTER TAP BAD 2221 LIFT SWING LOCKED JOYSTICK MOVED BEFORE FOOTSWITCH...

Page 355: ...46 ELECTRIC FAN SHORT TO GROUND 3347 ELECTRIC FAN OPEN CIRCUIT 3348 ELECTRIC FAN SHORT TO BATTERY 3349 ELECTRIC PUMP SHORT TO GROUND 3350 ELECTRIC PUMP OPEN CIRCUIT 3351 ELECTRIC PUMP SHORT TO BATTERY...

Page 356: ...FT VALVE SHORT TO BATTERY 3397 PLATFORM ROTATE RIGHT VALVE SHORT TO GROUND 3398 PLATFORM ROTATE RIGHT VALVE OPEN CIRCUIT 3399 PLATFORM ROTATE RIGHT VALVE SHORT TO BATTERY 33100 JIB LIFT UP VALVE SHORT...

Page 357: ...HT VALVE SHORT TO BATTERY 33180 JIB ROTATE RIGHT VALVE SHORT TO GROUND 33182 LIFT VALVES SHORT TO BATTERY 33186 TELESCOPE OUT VALVE OPEN CIRCUIT 33188 TELESCOPE OUT VALVE SHORT TO GROUND 33189 TELESCO...

Page 358: ...R OPEN CIRCUIT 345 PLATFORM LEVEL DOWN VALVE OPEN CIRCUIT 346 PLATFORM LEVEL DOWN VALVE SHORT TO BATTERY 347 PLATFORM LEVEL DOWN VALVE SHORT TO GROUND 348 PLATFORM LEVEL DOWN VALVE SHORT TO BATTERY OR...

Page 359: ...E COOLANT LOW LEVEL 441 BATTERY VOLTAGE TOO LOW SYSTEM SHUTDOWN 442 BATTERY VOLTAGE TOO HIGH SYSTEM SHUTDOWN 445 BATTERY VOLTAGE LOW 662 CANBUS FAILURE PLATFORM MODULE 664 CANBUS FAILURE ACCESSORY MOD...

Page 360: ...ERRIDE OCCURRED 998 EEPROM FAILURE CHECK ALL SETTINGS 9910 FUNCTIONS LOCKED OUT PLATFORM MODULE SOFTWARE VERSION IMPROPER 9914 PLATFORM MODULE SOFTWARE UPDATE REQUIRED 9915 CHASSIS TILT SENSOR NOT GAI...

Page 361: ...N 6 JLG CONTROL SYSTEM 31215031 6 63 MAE8820 Figure 6 10 Control Module Locations GROUND CONTROL MODULE PLATFORMCONTROL MODULE G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a...

Page 362: ...ION 6 JLG CONTROL SYSTEM 6 64 31215031 Figure 6 11 Analyzer Connecting Points PLATFORM CONNECTION GROUND CONTROL CONNECTION G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r...

Page 363: ...M LEVEL DOWN SOLENOID DIGITAL OUTPUT 8 RIGHT TRACK REVERSE COIL DIGITAL OUTPUT 9 NOT ALLOCATED DIGITAL OUTPUT 10 PLATFORM ROTATE LEFT SOLENOID DIGITAL OUTPUT 11 MAIN LIFT UP SOLENOID DIGITAL OUTPUT 12...

Page 364: ...GLE SWITCH ANALOG INPUT 5 5 VOLTS VOLTAGE OUTPUT 6 CAN TERMINATOR 1 TERM I O 7 CAPACITY LENGTH SWITCH ANALOG INPUT 8 NOT CONNECTED ANALOG INPUT 9 GROUND GROUND INPUT 10 GROUND GROUND INPUT 11 IN OUT O...

Page 365: ...NECTOR PIN ASSIGNMENT FUNCTION J2 GRAY 1 UNALLOCATED DIGITAL INPUT 2 UNALLOCATED DIGITAL INPUT 3 BATTERY VOLTAGE HS DIGITAL INPUT 4 DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT 5 UNALLOCA...

Page 366: ...GNAL DIGITAL INPUT 9 GENERATOR ON SIGNAL DIGITAL INPUT 10 7 7 REFERENCE VOLTAGE REFERENCE VOLTAGE 11 1 LOAD CELL INPUT ANALOG INPUT 12 2 LOAD CELL INPUT ANALOG INPUT 13 UNALLOCATED ANALOG INPUT 14 GRO...

Page 367: ...1001106355 E MAF17690 E Figure 6 16 Platform Control Module China Market J2 GRAY 35 PIN J1 NATURAL 35 PIN J6 BLACK 8 PIN J5 NATURAL 8 PIN J8 POWER J1 BLACK 35 PIN G o t o D i s c o u n t E q u i p m e...

Page 368: ...EFERENCE 7REFERENCE 35 SPEEDPUMPPOTENTIOMETER DIGITALINPUT Connector Pin Assignment Function J2 GRAY 1 UNALLOCATED DIGITALINPUT 2 UNALLOCATED DIGITALINPUT 3 BATTERYVOLTAGE HSDIGITAL 4 DRIVEORIENTATION...

Page 369: ...OUND 24 GROUNDRETURN GROUND 25 UNALLOCATED NOTPOPULATED MEDIGITAL 26 UNALLOCATED NOTPOPULATED MEDIGITAL 27 UNALLOCATED MEDIGITAL 28 UNALLOCATED MEDIGITAL 29 GROUNDRETURN GROUND 30 CANLOW CANLOW 31 CAN...

Page 370: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 371: ...robe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec tor such that the test also checks both terminals of the...

Page 372: ...See multimeter s operation manual Use firm contact with meter leads Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned...

Page 373: ...sed by low level con ductivity between pins when wet Use the following procedure to apply Silicone Dielectric Com pound to the electrical connectors This procedure applies to all plug connections not...

Page 374: ...r the installation of dielectric grease in a connector system Use dielectric grease in a tube for larger connection points or apply with a syringe for small connectors Apply dielectric grease to plug...

Page 375: ...ow we have found dielectric grease is not needed for some applications and in some cases can interfere with the intended connection Dielectric grease shall be used as an exception in other application...

Page 376: ...s follows 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 7 7 2 Pull back on the contact wire with a force of 1 or 2 lbs to be sure the reten...

Page 377: ...d position Release the locking latches by squeezing them inward See Figure 7 8 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 7 9 Figure 7 7 Connector Assembly F...

Page 378: ...mmodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE REA...

Page 379: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 31215031 7 9 Figure 7 11 Connector Installation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 380: ...gelock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly 5 Remove wedgelock using...

Page 381: ...full envi ronmental sealing HD30 HDP20 Series Disassembly 11 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 12 Slide tool along into the insert...

Page 382: ...hicleoperationduringidleconditions Liters TotalIdleHours Totaltimeofengineoperationduringidleconditions Seconds TotalEngineHours Totaltimeofengineoperation Seconds TotalFuelUsed Totalamountoffuelusedd...

Page 383: ...31215031 7 13 MS1619 3 MS1619 1 MS1619 2 X1609 MS1620 1 S1614 S1615 MS1618 2 MS1620 3 MS1620 2 MS1618 3 CO1613 J2 CO1613 J1 X1606 Figure 7 18 Telematics Gateway Harness Sheet 1 of 3 G o t o D i s c o...

Page 384: ...ANH2 18 AWG GXL MS1619 2 A MS1619 3 CAN T 2 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO A YEL CANH2 18 AWG GXL MS1620 2 A B GRN CANL2 18 AWG GXL MS1620 2 B MS1619 2 CAN T 2 CONN POS WIRE COLOR WIRE...

Page 385: ...H2 YEL 18 AWG 233 GXL MS1620 3 A CO1613 J2 10 CAN H1 YEL 18 AWG 157 GXL MS1618 2 A CO1613 J1 10 CAN H2 YEL 18 AWG 1150 GXL MS1619 3 A MS1620 2 A CAN H1 YEL 18 AWG 1079 GXL MS1618 3 A X1606 C 0 0 GND...

Page 386: ...l number An optional suffix letters numbers may be added when multiple terminations occur at one device Terminals that are not loaded into connectors are considered independent components and labeled...

Page 387: ...t Load Pressure Proximity Speed Temperature Terminals Pins T Sockets MaleBlades FemaleBlades Rings Forks ToggleSwitch DPDT SW DPST SPDT SPST Special Valves Simple HV Suppression Examples T67isaringter...

Page 388: ...TCH 600AJ ANSI ANSI EXPORT BRAZILIAN JAPANESE SPECS BOOM LENGTH LIMIT SWITCH HEADLIGHTS TAILLIGHTS DIAGNOSTIC ANALYZER NOTE FOR MODULE IDENTIFICATION REFER TO REVISON LOG PAGE A GROUND CONTROL BOX PLA...

Page 389: ...ATOR CONTROL BOX 7500W GENERATOR RELAYS 7500W SKYPOWER GENERATOR 7500W GENERATOR CONTROL BOX AUX PUMP ALARM MAIN CONTROL VALVE OR BOSCH FUEL REGULATOR GM FUEL REGULATOR GM HARNESS ENGINE CONTROL DEUTZ...

Page 390: ...HT 55 30 T PIN 5 BLACK T PIN 6 RED WHT 55 31 T YEL RED 2 10 10 B YEL RED 2 10 9 CC BLU ORN 52 1 T La PIN 9 YEL RED 2 10 11 B YEL RED 2 10 12 Z PINK 25 1 T PINK 26 1 T YEL RED 2 10 12 AA YEL RED 2 10 1...

Page 391: ...EE 13 5 YEL RED 2 10 5 JJ PP 16 5 YEL RED 2 10 4 FF GG 14 YEL RED 2 10 3 GG C 14 5 YEL RED 2 10 2 C DC 10 75 YEL RED 2 10 1 DC A 9 5 YEL RED 2 10 A T 59 75 YEL RED 2 5 U E 52 5 YEL RED 2 3 W D 54 25...

Page 392: ...EAL PN TO 1 WHT P10 18 AWG GXL 4460465 IP114 2 2 WHT P6 18 AWG GXL 4460465 X5B 2 3 WHT P4 18 AWG GXL 4460465 S192 2 4 WHT P5 18 AWG GXL 4460465 S191 2 IP114 CONNECTOR PART NUMBER SEE NOTE 4 CONN POS W...

Page 393: ...7 H E GRAY 24 1 A GRAY 23 1 A 2 1 2 1 BLACK C 2 1 BLACK F BLUE 27 1 A BLUE 28 1 A 2 1 2 1 BLACK D BLACK E LEVEL DOWN LEVEL UP ROTATE RIGHT ROTATE LEFT 2 1 JIB DOWN JIB UP A B G F C D E GRAY 24 1 PINK...

Page 394: ...BLACK RED ORANGE BLUE YELLOW BROWN HOLE PLUG RED BLK ORANGE 12GA BLU BLK RED 12GA ORN BLK HOLE PLUG 15 YEL BLK 16 BLACK 12GA 17 HOLE PLUG 18 BLK WHT 12GA 19 HOLE PLUG INSTALL ITEM 10 SHRINK TUBING OVE...

Page 395: ...D ORANGE BLUE YELLOW BROWN HOLE PLUG RED BLK ORANGE 12GA BLU BLK RED 12GA ORN BLK HOLE PLUG 15 YEL BLK 16 BLACK 12GA 17 HOLE PLUG 18 BLK WHT 12GA 19 HOLE PLUG INSTALL ITEM 10 SHRINK TUBING OVER END OF...

Page 396: ...WHT 12GA 19 HOLE PLUG 1 SHIELD 2 BLACK 3 RED 4 ORANGE 5 BLUE 6 YELLOW 7 BROWN 8 HOLE PLUG 9 RED BLACK 10 ORANGE 12GA 11 BLU BLK 12 RED 12GA 13 ORN BLK 14 HOLE PLUG 15 YEL BLK 16 BLACK 12GA 17 HOLE PL...

Page 397: ...OW BROWN HOLE PLUG RED BLK ORANGE 12GA BLU BLK RED 12GA ORN BLK HOLE PLUG 15 YEL BLK 16 BLACK 12GA 17 HOLE PLUG 18 BLK WHT 12GA 19 HOLE PLUG COVER SHIELD WITH CLEAR HEAT SHRINK AT BOTH ENDS OF THE HAR...

Page 398: ...I T E 2 1 3 A W H T B L K 1 1 3 S 5 F TOWER LIFT UP T A N 5 3 A BLACK S3 G MAIN TEL IN BROWN 13 3 A BLACK S3 H TOWER TEL IN BROWN 15 3 A BLACK S2 I MAIN LIFT DOWN TAN 4 3 A WHT BLK 33 6 S4 J SWING RI...

Page 399: ...IL SPLICE S4 WHT BLK 11 2 J WHT BLK 11 3 M WHT BLK 11 1 A DETAIL SPLICE S5 WHT BLK 11 1 S5 WHT BLK 33 7 S4 WHT BLK 12 1 T BLACK HORN GROUND C J2 17 J2 30 J2 6 J2 14 BLACK VALVE GND S2 J2 29 BLACK A J2...

Page 400: ...LACK W PIN 3 PIN 3 BLACK K BLACK P VALVE GND VALVE GND BLACK A BLACK O BLACK G BROWN BLACK D 15 3 102 A CC BROWN BLACK M 16 3 102 A DD TAN 5 3 BLACK BB 94 A AA TAN 6 3 94 A BB BLACK H BLACK 5 J K BLAC...

Page 401: ...12 COVER THIS END OF COMPLETED HARNESS TO AVOID DAMAGE TO TERMINALS DURING SHIPPING AND HANDLING RED P BLACK P SHIELD WIRE YEL RED 16 2 1 99 T A B C SOCKET BLACK 8 16 E K 18 E S BLACK 38 CAN BUSS P A...

Page 402: ...WHT YEL 12 48 12 WHT YEL 48 3 FUSE LINK FUSE LINK J1 A R N D A D M F A B A D A J A J A L A K D N A F BLACK BLACK BLACK BLU ORN 52 11 55 47 2 3 4 5 6 7 8 10 12 COVER THIS END OF COMPLETED HARNESS TO A...

Page 403: ...LACK K 2 SPEED ORANGE 55 47 A 2 3 1 BLACK L K RED E BLACK E SHIELD WIRE SHIELD WIRE BLACK BLACK RED RED C BLACK A BLACK C RED A RED SONIC WELDS DETAIL P RED 1 2 10 A BRN ORN 53 2 A BLACK 10 R RED 1 1...

Page 404: ...2 BRN WHT 47 8 BB YEL RED 2 1 99 16 A PLUG BLU ORN 52 5 2 CC PLUG YEL RED 2 20 16 A 1 2 3 4 5 FF BLACK AA 6 7 PLUG 8 PLUG C LOOM STARTS AT THIS POINT BLACK 10 AA NO LOOM RED 1 2 10 A W BATTERY STUD PO...

Page 405: ...AIN HARNESS WITH LOOM DETAIL C FOR BREAKING OUT LOOM FROM MAIN LOOM NO LOOM REQUIRED ON BREAK OUT WIRE C LOOM START B A F LOOM TO CONNECTOR SEE DETAIL R YEL RED 2 63 J SOCKET 35 ORN RED 49 106 J J7 J...

Page 406: ...2 C YEL RED 2 40 3 Q TOWER LIFT SWITCH CONNECTOR TOWER TELE SWITCH CONNECTOR THIS IS THE CENTER OF THE DRAWING YOU NEED PAGE 1 AND PAGE 2 FOR A COMPLETE HARNESS JOIN THE CENTER POINTS OF BOTH DRAWING...

Page 407: ...CTOR YEL RED 2 90 V RED 1 90 O RED 1 91 AB RED EE PIN C BLACK EE PIN D SHIELD EE PIN E BLACK GG PIN A SEE DETAIL Y RED 1 90 Y CC J3 BLACK GG SOCKET 3 BLU ORN 52 75 E SOCKET 9 YEL RED 2 16 UM SOCKET 7...

Page 408: ...WN 15 2 BROWN 16 2 YEL RED 2 21 RED 1 2 10 5K 5K 5 1 4 2 3 7 30 AMP 1 3 4 2 1 22 34 17 21 19 BROWN BLACK BLUE CAN SHIELD CAN LO CAN HI 13 24 18 RED 18 BLACK 18 4 16 7 26 RED ORN GREEN BRN BLK ORN YEL...

Page 409: ...6 DRIVE REVERSE ORANGE 7 2 BLACK ORANGE 8 2 2 SPEED BRAKE 20 23 ORANGE 55 47 ORANGE 55 45 YEL RED 2 21 RED 1 2 10 1 15 4 34 11 8 10 9 19 17 21 30 AMP 1 3 4 2 1 22 34 17 21 19 BROWN BLACK BLUE CAN SHIE...

Page 410: ...H P J8 1 2 P J8A 1 2 X4 C A B X5 C A B YEL RED 2 1 4 YEL RED 2 1 4 BLK GND BLK GND YEL RED 2 1 3 BLK GND BLK CAN L RED CAN H BLK CAN L RED CAN H BLK GND YEL RED 1 BLK CAN L RED CAN H BLK GND YEL RED...

Page 411: ...NERATOR CONTROL BOX B D W REGULATOR GENERATOR PLUG B A RED BRN WHT 47 8 2 86 85 87 30 87a BLU ORN 52 5 2500 W GENERATOR POWERMITE GENERATOR GENERATOR PLUG B A C A B GENERATOR CONTROL BOX BLACK BLU ORN...

Page 412: ...EL RED 2 1 99 1 CAN HI RED 18 CAN LO BLACK 18 CAN SHIELD A B C SEE SHEET 1 ZONE C5 86 85 87 30 87a YEL RED 2 4 1 12 TERMINAL B MTB STATION SELECT SWITCH SHEET 1 ZONE G5 YEL RED 2 6 2 J1 10 ON SHEET 1...

Page 413: ...ORN 52 5 J1 22 ON SHEET 1 ZONE D3 BRN WHT 47 8 2 86 85 87 30 87a YEL RED 2 4 1 12 TERMINAL B MTB STATION SELECT SWITCH SHEET 1 ZONE G5 YEL RED 2 6 2 BLACK J1 10 ON SHEET 1 ZONE D3 BRN WHT 47 8 SEE SHE...

Page 414: ...P 3 0 75mm BLK 248 20 EHXAUST GAS RECIRCULATION 1 5mm BLK 248 19 EHXAUST GAS RECIRCULATION 1 5mm BLK 148 85 EHXAUST GAS RECIRCULATION 0 75mm BLK 148 85 EHXAUST GAS RECIRCULATION 0 75mm BLK 148 82 EHXA...

Page 415: ...G 0 75mm BLK 148 87 COOLANT LEVEL GND 0 75mm BLK 148 26 FUEL PUMP RELAY CONTROL GND 0 75mm X941 1 2 3 4 X942 1 2 3 4 BLK 148 64 WATER IN FUEL SW 16AWG BLK 148 57 WATER IN FUEL SW RTN 16AWG BLK 148 64...

Page 416: ...BEACON MODULE 1 2 3 4 5 6 7 8 9 10 11 12 X3 1 2 X4 TO ENG DIAG CONN NEW A B C D E F G H J X7 CAN TERMINATOR A B C X9 TO ENG DIAG CONN ORIGINAL A B C D E F G H J X5 1 2 3 4 5 6 7 8 9 10 11 12 WHT IGNIT...

Page 417: ...7 30 87a 85 86 RELAY 12V 1 1 1 1 1 87 30 87a 85 86 RELAY 12V 1 1 1 1 1 SEE SHT 1 ZONE H8 PLATFORM SENSOR SEE SHT 1 ZONE D7 SEE ZONE H8 F8 SEE ZONE H6 F6 SEE ZONE H6 F6 X1 BEACON MODULE 1 2 3 4 5 6 7 8...

Page 418: ...ON SHEET 1 ZONE D3 BRN WHT 47 8 86 85 87 30 87a YEL RED 2 4 1 12 TERMINAL B MTB STATION SELECT SWITCH SHEET 1 ZONE G5 YEL RED 2 6 2 BLACK J1 10 ON SHEET 1 ZONE D3 BRN WHT 47 8 SEE SHEET 1 ZONE E5 GEN...

Page 419: ...ON 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 50 31215031 SHEET 8 Figure 7 52 Electrical Schematic Sheet 12 of 18 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a...

Page 420: ...LECTRICAL INFORMATION ELECTRICAL SCHEMATICS 31215031 7 51 SHEET 8 1001251537 B MAF17570B Figure 7 53 Electrical Schematic Sheet 13 of 18 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y...

Page 421: ...S HARNESS GEN 2 PLAT INTERFACE 4 PIN SKYGUARD WHT P2 WHT P1 WHT P3 WHT P6 4 1 5 2 KL BLACK SK 2 ORN RED 49 69 1 YEL RED P3 YEL RED 2 63 1 X5B INTERFACE 87 30 87a 85 86 87 30 87a 85 86 PLTFM SNSR RELAY...

Page 422: ...G GND BLK 0 1 SHIELD 1 RECEIVER 1 WHT 2 1 24 BRN 1 1 24 BLU 3 1 24 WHT BLK 4 SHLD 18 X2 1 2 3 4 1 2 X690 BLK 0 4 SHIELD 14 YEL 3 18 5 SKYG PWR BLK 0 3 SHIELD 3 BLK 1 36 5 SKYG GND X694 1 2 3 EMITTER B...

Page 423: ...30 87a 85 86 RELAY 1 RL1 X1 SKYGUARD SKYLINE 6 PIN HARNESS 2 1 3 4 5 6 X5B WHT IGN_1 18 WHT GND 18 WHT SGC_IN_1 18 WHT SGC_IN_2 18 WHT IGN_9 18 WHT SGC_NC 18 WHT IGN_3 18 WHT SGC_IN_1 18 WHT SGC_IN_2...

Page 424: ...D 0 75mm RED 148 3 ECM PWR S944 RED 148 1 ECM PWR RED 148 5 ECM PWR BLK 148 4 ECM GND S945 BLK 148 2 ECM GND BLK 148 6 ECM GND YEL 2 48 1 IGNITION 16AWG YEL 2 1 99 IGNITION 18AWG S1054 YEL 2 48 4 IGNI...

Page 425: ...W RTN 0 75mm BLK 148 246 ECM GND 8AWG WHT 48 3 START 18AWG YEL 2 48 1 IGNITION 16AWG YEL 2 1 99 IGNITION 18AWG YEL 2 1 99 IGNITION 18AWG S1054 YEL 2 48 4 IGNITION 0 75mm YEL 148 73 FUEL PUMP UB3 18AWG...

Page 426: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 427: ...G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

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