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JLG 601S, Service And Maintenance Manual

The Titanium 601S Operating Manual is available for free download on our website. This comprehensive manual provides step-by-step instructions, troubleshooting tips, and important safety guidelines to help you maximize the performance and longevity of your Titanium 601S. Get your manual now at manualshive.com.

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SECTION 5 - HYDRAULICS

5-6

– JLG Lift –

3120746

5. Using suitable protection, clamp the cylinder rod in

a vise or similar holding fixture as close to piston as
possible.

6. Carefully thread the piston on the cylinder rod hand

tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.

7. Thread piston onto rod until it abuts the spacer end

and install the tapered bushing.

NOTE:

When installing the tapered bushing, piston and mat-
ing end of rod must be free of oil.

WHEN REBUILDING THE MASTER, SLAVE, LIFT, OR TELESCOPE
CYLINDERS, APPLY LOCTITE #242 TO TAPERED BUSHING
BOLTS, THEN TIGHTEN SECURELY. (TABLE 5-1, CYLINDER HEAD
AND TAPERED BUSHING TORQUE SPECIFICATIONS).

8. Install the bolts in tapered bushing using loctite

#242. (See Table 5-1, Cylinder Head and Tapered
Bushing Torque Specifications.)

9. Remove the cylinder rod from the holding fixture.

10. Place new guide locks and seals in the applicable

outside diameter grooves of the cylinder piston.
(See Figure 5-10., Piston Seal Kit Installation).

11. Position the cylinder barrel in a suitable holding fix-

ture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.

12. With barrel clamped securely, and while adequately

supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.

13. Continue pushing the rod into the barrel until the cyl-

inder head gland can be inserted into the barrel cyl-
inder.

14. Secure the cylinder head gland using the washer

ring and socket head bolts. (Table 5-1, Cylinder

Figure 5-10.  Piston Seal Kit Installation

Figure 5-11.  Tapered Bushing Installation

Summary of Contents for 601S

Page 1: ...Service and Maintenance Manual Model 601S P N 3120746 November 22 2016 ...

Page 2: ......

Page 3: ...connection at the base of the platform control box as shown by the arrow ADE System Identification All machines after S N 60444 incorporate the ADE system The following machine serial num bers prior to S N 60444 also utilize ADE 58993 58998 59222 59223 59275 59281 59315 59319 59352 59358 59361 59769 60253 60254 60286 and 60242 ...

Page 4: ... JLG Lift THIS PAGE LEFT BLANK INTENTIONALLY ...

Page 5: ...d that the machines hydraulic systems operate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pres sure prior to disconnecting or removing any portion of the system Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines...

Page 6: ...LG Lift 3120746 REVISON LOG Original Issue March 1998 February 1 1999 February 14 2001 August 24 2001 April 18 2002 August 6 2003 February 26 2014 November 22 2016 Revised Revised Revised Revised Revised Revised Revised ...

Page 7: ...Boom Elevation 1 2 Machine Weight approximately 1 2 Machine Height Stowed 1 2 Machine Length Stowed 1 2 Machine Width 1 2 Wheel base 1 2 1 4 Function Speeds 1 2 Machine Orientation When Doing Speed Tests 1 2 Test Notes 1 3 1 5 Torque Requirements 1 3 1 6 Lubrication 1 4 Ford LRG425 Engine 1 4 Deutz F3M1011F Engine 1 4 Hydraulic Oil 1 5 Lubrication Specifications 1 5 1 7 Pressure Settings 1 5 Rexro...

Page 8: ...2 5 Pins and Composite Bearing Repair Guidelines 2 5 2 6 Welding on JLG Equipment 2 6 Do the Following When Welding on JLG Equipment 2 6 Do NOT Do the Following When Welding on JLG Equipment 2 6 2 7 Applying Silicone Dielectric Compound to Electrical Connections 2 6 2 8 AMP Connector 2 7 Applying Silicone Dielectric Compound to AMP Connectors 2 7 Assembly 2 7 Disassembly 2 9 Wedge Lock 2 9 Service...

Page 9: ...Adjustment Procedures 3 45 3 12 Swing Bearing 3 45 Turntable Bearing Mounting Bolt Condition Check 3 45 Wear Tolerance 3 46 Swing Bearing Replacement 3 46 Swing Bearing Torque Value 3 49 3 13 Swing Brake Ausco 3 49 Disassembly 3 49 Inspection 3 50 Assembly 3 50 3 14 Swing Motor 3 52 Disassembly 3 52 Reassembly 3 53 Motor Timing 3 54 3 15 Tilt Alarm Switch Machines with External Tilt Sensor 3 56 Ma...

Page 10: ...ue Procedures 4 9 4 3 Wear Pads 4 10 Main Boom 4 10 4 4 Wire Rope 4 11 Inspection 4 11 Three Month Inspection 4 11 12 Year or 7000 Hour Replacement 4 11 Additional Replacement Criteria 4 11 4 5 Limit Switches and Cam Valve Adjustment 4 12 Limit Switch Functional Check 4 13 4 6 Rotator Helac 4 14 Disassembly 4 14 Inspection 4 15 Assembly 4 16 4 7 Drive Card Setup Procedures 4 18 Lift Swing and Driv...

Page 11: ...Swing and Lift Down 5 20 Platform Level 5 20 4 Wheel Steer If Equipped 5 20 5 8 Directional Control Valve 5 24 5 9 Hydraulic Pump W Hayes Pump Drive Coupling Lubrication 5 24 5 10 Hydraulic Component Start Up Procedures and Recommendations 5 24 SECTION 6 JLG CONTROL SYSTEM ADE 6 1 Introduction 6 1 6 2 To Connect the JLG Control System Analyzer 6 3 6 3 Using the Analyzer 6 3 6 4 Changing the Access...

Page 12: ...3 32 3 15 Shaft Seal 3 32 3 16 Shaft Front Bearing 3 32 3 17 Swash Plate Servo Piston 3 33 3 18 Cylinder Kit Disassembly 3 33 3 19 Servo Piston 3 36 3 20 Cylinder Kit Assembly 3 37 3 21 Swash Plate and Journal Bearing 3 37 3 22 Shaft and Front Bearing 3 38 3 23 Cylinder Kit Installation 3 38 3 24 Servo Spring and Minimum Angle Stop 3 38 3 25 Valve Plate and Rear Bearing 3 39 3 26 End Cap 3 39 3 27...

Page 13: ...ing Sleeve from Housing 4 15 4 21 Actuator Timing 4 16 4 22 Rotator Assembly Helac 4 17 4 23 Control Card 4 19 5 1 Cylinder Barrel Support 5 2 5 2 Cap Screw Removal 5 3 5 3 Cylinder Rod Support 5 3 5 4 Tapered Bushing Removal 5 4 5 5 Gar Max Bearing Installation 5 4 5 6 Rod Seal Installation 5 5 5 7 Poly Pak Piston Seal Installation 5 5 5 8 Wiper Seal Installation 5 5 5 9 Installation of Head Seal...

Page 14: ...atic Deutz Engine Sheet 2 of 2 7 7 7 7 Electrical Schematic Ford Dual Fuel Engine Sheet 1 of 2 7 8 7 8 Electrical Schematic Ford Dual Fuel Engine Sheet 2 of 2 7 9 7 9 Electrical Schematic Ford EFI Engine Sheet 1 of 2 7 10 7 10 Electrical Schematic Ford EFI Engine Sheet 2 of 2 7 11 7 11 Electrical Schematic ADE Machines Sheet 1 of 4 7 12 7 12 Electrical Schematic ADE Machines Sheet 2 of 4 7 13 7 13...

Page 15: ...s End Play 3 34 3 7 Cylinder Block Measurements 3 34 3 8 Position Controller Truth Table 3 63 3 9 ECM Diagnostic Trouble Codes 3 70 3 10 EPM Diagnostic Trouble Codes 3 71 4 1 Flow Control Card Settings 4 19 4 2 Flow Control Card Ramp Time 4 19 4 3 Function Speeds 4 19 5 1 Cylinder Head and Tapered Bushing Torque Specifications 5 7 5 2 Holding Valve Torque Specifications 5 7 6 1 Personality Ranges ...

Page 16: ...x JLG Lift 3120746 TABLE OF CONTENTS Continued This page left blank intentionally ...

Page 17: ...ttery 85 Amphour 550 Cold Cranking Amps 12 VDC Fuel Consumption Low RPM 3 45 GPH 13 06 lph High RPM 4 60 GPH 17 41 lph Horsepower 54 2400 RPM full load Cooling System 16 Quarts 15 14 l Engine Diesel Liquid Cooled Manufacturer Model Deutz F3M1011F Oil Capacity 5 Quarts 4 5 l Cooling System 6 3 Quarts 6 L w Filter 11 3 Quarts 10 7 L Total Capacity Low RPM 1800 High RPM 2800 Alternator 60 Amp belt dr...

Page 18: ...EDS Machine Orientation When Doing Speed Tests Lift Telescope Retracted Lift Up Record Time Lift Down Record Time Swing Boom at Full Elevation Telescope Retracted Swing the Turntable off center and stop Swing the oppo site direction and start the test when the turntable is cen tered up This eliminates ramp up and down on the controller affecting times Telescope Boom at Full Elevation Telescope Ret...

Page 19: ...s Function Time LiftUp 46 60 LiftDown 33 43 SwingRight Left 79 101 TelescopeOut 50 67 TelescopeIn 35 40 PlatformRotateRight Left 16 25 DriveForward Reverse 4WD 37 45 DriveAboveHorizontal Forward Reverse 2WD 4WD 43 136 Max10 DifferenceBetweenLeft Right Max15 DifferenceBetweenLeft Right 4150130 E Table 1 2 Torque Requirements Description Torque Value Dry Interval Hours Bearing To Chassis 240 ft lbs ...

Page 20: ...n When Outside Temperature is Consistently Use SAE Viscosity Number Below 10 F 12 C 5W 20 Below 60 F 16 C 5W 30 10 F to 90 F 23 C to 32 C 10W 30 Above 10 F 23 C 10W 40 or 10W 50 Above 20 F 7 C 20W 40 or 20W 50 Not recommended for severe service including high RPM operation When Outside Temperature is Consistently Use SAE Viscosity Number 20 F to 25 F 29 C to 4 C 10W 5 F to 50 F 15 C to 10 C 20W 20...

Page 21: ...fs 4WS Front Rear 1500 PSI 103 4 Bar Platform Level Forward 2800 PSI 193 06 Bar Backward 1800 PSI 124 11 Bar Table 1 3 Hydraulic Oil HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE SAE VISCOSITY GRADE 0 to 180 F 18 C to 83 C 10W 0 F to 210 F 18 C to 99 C 10W 20 10W 30 50 F to 210 F 10 C to 210 C 20W 20 Table 1 4 Mobil DTE 13M Specs ISO Viscosity Grade 32 Specific Gravity 0 877 Pour Point Max 40 F 40 ...

Page 22: ...8 4 1 5 38 1 Master 3 76 2 8 5 215 9 1 5 38 1 SlaveLevel 3 76 2 8 5 215 9 1 5 38 1 Table 1 7 Major Component Weights Component LB KG PlatformControlConsole 250 113 PlatformLevelCylinder 46 21 MainBoom IncludesLiftCyl Rotator andSupport 3527 1600 TurntableComplete includingengine 7315 3318 ChassisComplete w pneumatictires 10400 4718 ChassisComplete w foam filledtires 11680 5300 MachineComplete GVW ...

Page 23: ...1 11 SERIAL NUMBER LOCATIONS A serial number plate is affixed to the left rear side of the frame If the serial number plate is damaged or missing the machine serial number is stamped on the left side of the frame Figure 1 1 Serial Number Locations ...

Page 24: ... 17 ENGINE LOCATED ON OPPOSITE SIDE OF MACHINE FROM VIEW SHOWN 11 Remove fill cap plate from tank to gain access to strainers 30 MADE IN USA 60 90 120 150 180 210 100 80 60 40 20 0 F C FULL ADD NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION Figure 1 2 Lubrication Diagram ...

Page 25: ... 12 Oil Change w Filter Ford LRG425 FillCap Spin onElement 4 5Quarts EO X Checkleveldaily change150hrs 13 Oil Change w Filter Deutz FillCap Spin onElement 6 3QuartsCrankcase 5QuartsCooler EO X Checkleveldaily change1000hrs orone year whichevercomesfirst Adjustfinaloil levelbymarkondipstick 14 Fuel Filter Ford ReplaceableElement N A N A X 15 Fuel Filter Deutz ReplaceableElement N A N A X 16 Air Fil...

Page 26: ...SECTION 1 SPECIFICATIONS 1 10 JLG Lift 3120746 Figure 1 3 Torque Chart ...

Page 27: ...machine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection duri...

Page 28: ...their contain ers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an ey...

Page 29: ...orque Application 1 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 short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the ...

Page 30: ...ment it will be necessary to heat the oil with a low density 100VAC heater to a mini mum temperature of 15 degrees F 26 degrees C 3 The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent This will allow start up at temperatures down to 20 degrees F 29 degrees C However use of this oil will give poor performance at temperatures above 120 degrees F 49...

Page 31: ...rom the joint during operation 2 Filament wound bearings should be replaced if any of the following is observed a Frayed or separated fibers on the liner surface b Cracked or damaged liner backing c Bearings that have moved or spun in their hous ing d Debris embedded in liner surface 3 Pins should be replaced if any of the following is observed pin should be properly cleaned prior to inspection a ...

Page 32: ... at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors This procedure applies to all plug connections not enclosed in a box Sili cone grease should not be applied to connectors with external seals 1 To prevent oxidati...

Page 33: ...ng a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole plug into this ...

Page 34: ... be closed to its locked position Release the locking latches by squeezing them inward See Figure 2 4 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 2 5 Figure 2 3 Connector Assembly Figure 2 Figure 2 4 Connector Assembly Figure 3 Figure 2 5 Connector Assembly Figure 4 ...

Page 35: ...ing end These slots accommodate 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 READ INGS It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point This practice should be discouraged when dealing w...

Page 36: ...SECTION 2 GENERAL 2 10 JLG Lift 3120746 Figure 2 7 Connector Installation ...

Page 37: ...arPads 1 2 1 2 CoversorShields 1 2 1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly 9 Platform 1 2 1 2 Railing 1 2 1 1 2 Gate 5 1 1 5 Floor 1 2 1 1 2 Rotator 9 5 LanyardAnchoragePoint 2 1 2 10 1 2 10 TurntableAssembly 9 SwingBearingorWormGear 1 2 14 1 2 3 13 14 OilCoupling 9 SwingDriveSystem TurntableLock 1 2 5 1 2 5 Hood HoodProps HoodLatches 5 1 2 5 ChassisAssembly 9 Tires 1 16...

Page 38: ...icSystem 9 HydraulicPumps 1 9 1 2 9 HydraulicCylinders 1 9 7 2 1 2 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 9 1 2 1 2 HydraulicHoses Lines andFittings 1 9 12 1 2 9 12 1 2 9 12 HydraulicReservoir Cap andBreather 11 1 9 2 1 5 1 5 24 HydraulicFilter 1 9 7 7 HydraulicFluid 11 7 11 7 11 ElectricalConnections 1 20 20 Instruments Gauges Switches Lights Horn 1 5 23 General OperatorsandSafetyManuals...

Page 39: ...ureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwhenreleased 7 Cleanandfreeofdebris 8 Interlocksfunctionproperly 9 Checkforsignsofleakage 10 Decalsinstalledandlegible 11 Checkforproperfluidlevel 12 Checkforchafingandproperrouting 13 Checkforpropertolerances 14 ...

Page 40: ...SECTION 2 GENERAL 2 14 JLG Lift 3120746 This page left blank intentionally ...

Page 41: ...ssary replace bearings as a complete set ensuring that they remain covered until use 3 Inspect bearing mounting surfaces on spindle hub input shaft and carrier Replace components as nec essary 4 Inspect all geared components for chipped or bro ken teeth and for excessive or uneven wear pat terns 5 Inspect carrier for damage especially in anti roll pin and planet shaft hole areas 6 Inspect all plan...

Page 42: ...ashers 14 from carriers d Remove sixteen needle rollers 15 from cluster gear bore e Remove spacer 16 from cluster gear bore and remove second set of sixteen needle rollers 15 f Repeat steps a through e for remaining two cluster gears g Clean and inspect all parts in accordance with Cleaning and Inspection procedures Replace parts as necessary h Apply a coat of grease or petroleum jelly to clus ter...

Page 43: ...hamfered side of hole in planet shaft is lined up with pin hole in carrier o Drive anti roll pin flush into carrier hole locking planet shaft into place p repeat steps h through o for remaining two cluster gears 3 Input Shaft Assembly EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL AND INSTALLATION a Carefully remove retaining ring 33 from coun terbore in the spindle 1 and discard reta...

Page 44: ...5 with large inside diameters facing out into hub 7 counter bores 2 Place bearing cone 4 into bearing cup 3 in small end of hub 3 Press new seal 2 into hub counter bore with flat metal side facing in Use a flat object to ensure that seal is pressed evenly and is flush with hub face 4 Lower hub onto spindle 1 with large open end up 5 Place bearing cone 6 over end of spindle and into bearing cup ...

Page 45: ...9 completely into spindle groove and against bearing shim Ensure retaining ring is entirely in groove 8 Place internal gear 12 onto end of spindle 9 Install thrust washers and thrust bearing 39 40 on the portion of the spindle which extends into the internal gear 10 Install retaining ring 34 into input shaft retaining ring groove 11 Place input shaft assembly 35 into spindle bore with unsplined en...

Page 46: ...g in place Slight stretch ing of o ring may be necessary to insure proper seating 15 Place carrier assembly on a flat surface with large gears up and positioned as shown Find punch marked tooth on each large gear and locate at 12 o clock straight up from each planet pin Marked tooth will be located just under carrier on upper two gears 16 With shoulder side of ring gear 21 facing down place ring g...

Page 47: ...h easily or carrier assembly does not rotate freely then remove carrier and ring gear and check cluster gear timing 18 Install input gear 37 into carrier meshing with large diameter cluster gears 18 Counter bore in bore of input gear must be to outside of carrier assembly 19 After inserting at least one shoulder bolt in the proper location rotate the carrier Check freedom of rotation and timing 20...

Page 48: ... check plug in cover located approximately 90 degrees from oil fill plug in hub 23 Locate four shoulder bolts 42 90 degrees apart into counter bored holes in hub marked in step 13 Torque shoulder bolts to 47 ft lbs 64 Nm 24 Install bolts 41 in remaining holes Torque bolts to 64 Nm 47 ft lbs 25 Place coupling 1 into spindle and onto input shaft 26 Fill hub one half full of EPGL 90 lubricant before ...

Page 49: ...SECTION 3 CHASSIS TURNTABLE 3120746 JLG Lift 3 9 Figure 3 1 Torque Hub Drive Fairfield ...

Page 50: ... on bench Lubricate lips of seals 4 and 5 and lower hub onto spindle 3 Hub should be centered as it is lowered over spindle 3 to prevent seal damage 4 Assemble bearing cone 11 over spindle 3 and into bearing cup 10 Replace thrust washer 12 over spindle end splines and on bearing cone 11 5 Select the thickest ring 13 that can be assembled into the ring groove of the splined end of spindle 3 above b...

Page 51: ...SECTION 3 CHASSIS TURNTABLE 3120746 JLG Lift 3 11 Figure 3 2 Torque Hub Drive Auburn Gear ...

Page 52: ... Assembly THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY IN THE CASE OF SPRINGS SPACE THE SPRINGS AS SHOWN IN THE FIGURE 1 Worn o rings and damaged or worn Teflon backup rings must be replaced prior to assembly 2 The cylinder of the power plate piston and o rings must be clean prior to assembly and pre lubed with the system h...

Page 53: ...SECTION 3 CHASSIS TURNTABLE 3120746 JLG Lift 3 13 Figure 3 3 Drive Brake Assembly Ausco ...

Page 54: ...sh with bearing shoulder Note direction of seal 3 Press bearing 18 into position until it bottoms out on borestep NOTE Cover plate 16 must be supported as indicated in Figure 1 4 Install retaining ring 20 in cover plate 16 5 Press shaft 10 into bearing 18 until it bottoms on shoulder NOTE Bearing 18 inner race and cover plate 16 must be supported as indicated in Figure 1 during this opera tion 6 I...

Page 55: ... Washer 3 PressurePlate 4 CaseSeal 5 O ring 6 BackupRing 7 Piston 8 O ring 9 Backup Ring 10 Shaft 11 StatorDisc 12 RotorDisc 13 ReturnPlate 14 Springs 15 Dowel Pin 16 CoverPlate 17 Oil Seal 18 Bearing 19 Retaining Ring 20 Retaining Ring Figure 3 4 Drive Brake Mico ...

Page 56: ...red Discplatesworn Thethicknessofthediscstacksetsthe torquelevel Athinstackreducestorque Checkdiscthickness Springsbrokenorhavetakenaperma nentset Brokenorsetspringscancausereduced torque arareoccurrence Checkreleasepressure Seespring replacement Brakedragsorrunshot Lowactuationpressure Thebrakeshouldbepressurizedtomini mumof1 38bar 20psi overthefull releasepressureundernormaloperating conditions ...

Page 57: ...3 17 3 5 DRIVE MOTOR PRIOR TO S N 85132 Spare Parts Kits Sealing kit existing spare parts shaft sealing ring 6 differ ent O rings and a circlip sealing mat perbunan Same sealing kit like shown above only seal material changed to Viton Drive shaft ...

Page 58: ...etaining ball Swash Plate Parts of the control device control piston piston rod plug spring stopper max flow hex nut and hex head nut Spare parts kit DFR pilot valve Replacing the Drive Shaft Seal 1 Remove the snap ring 2 Change the shaft seal and check its sliding surface drive shaft and housing grease the sealing ring 3 Be careful while you seal the drive shaft use an adhesive tape to protect th...

Page 59: ...n in the pump housing 5 Assemble the snap ring 6 Assemble the snap ring in the correct position Disassembly and Assembly 1 Disassemble the pilot valve 2 Mark the position of the port plate and remove the socket screw from the port plate 3 Remove the port plate together with the valve plate hold the valve plate so that the plate can t fall down ...

Page 60: ...r roller bearing 6 Remove the adjustment shim 7 Unscrew the cap nut and remove it 8 Loosen the retaining nut of the stopper max flow and remove it 9 Turn in the stopper max flow to get swivel angle zero 10 Disassemble the rotary group in horizontal position 11 Disassemble the stopper max flow ...

Page 61: ... max flow 13 Disassemble the plug 14 Disassemble the control piston while moving the swash plate 15 The swash plate must be lifted a little bit to disas semble the piston rod 16 Disassembly of the swash plate 17 Remove the spring 18 Remove both bearing shells 19 Remove the drive shaft ...

Page 62: ... housing 23 Remove the O ring Lifting of the valve plate isn t shown 24 A usual commercial bearing puller is used to disas semble the external bearing ring of the taper roller bearing inside the port plate Take care not to dam age the surface of the port plate 25 The spring has additional pretension while you dis assemble the three pressure pins inside the cylinder ...

Page 63: ...drive direction Note spare parts exist as cw and ccw valve plates 4 Pumps counterclockwise driven must have a posi tion of the valve plate 4 degrees de centered in ccw position 5 Assembly of the port plate and the pump housing Note the correct position of the drilling that connects high pressure to the control valve Check control valve drill position at the pump housing and fit together Taper Roll...

Page 64: ...SECTION 3 CHASSIS TURNTABLE 3 24 JLG Lift 3120746 NOTE Differential volume if you are rotating the threaded pin each rotation is appr 3 1 cm3 Figure 3 5 Flow Control Pilot Valves ...

Page 65: ...troller if it s DFR design then open the adjustable orifice and increase force of the spring FR FR If swivel angle is in the mid position adjust differential pressure 14 bar adjustable orifice is partly closed Mechanical flow limiter While screwing in the threaded pin you will be able to reduce the flow from Vg max to 50 of Vg max ...

Page 66: ... the cap nut from adjustment screw 2 Loosen jam nut on the adjustment screw and make adjustment 3 Measure from top of jam nut to the end of adjust ment screw See Figure 3 6 Drive Motor Adjust ment 4 Tighten jam nut install cap nut NOTE The o ring must be seated in groove in cap nut Figure 3 6 Drive Motor Adjustment ...

Page 67: ...ully pry out the shaft seal 3 To avoid damaging the shaft during removal install a large sheet metal screw into the chuck of a slide hammer Drive the screw into the seal surface and use the slide hammer to pull the seal 4 Discard the seal INSPECT THE COMPONENTS Inspect the new seal the motor housing seal bore and the sealing area on the shaft for rust wear and contami nation Polish the shaft and c...

Page 68: ...ation Also check springs and poppet for wear INSTALLATION 1 Install orifice poppet 13 2 Install shift spool 12 3 Install spring retaining washers onto springs 10 and 11 4 Carefully install centering springs 7 8 and 9 5 Install new O rings 6 4 and 5 6 Using a 1 4 in hex wrench torque plug 3 to 20 ft lbs 27 Nm 7 Using a 11 16 in internal hex torque plugs 2 and 1 to 27 ft lbs 37 Nm 2 6 9 11 1 4 8 10 ...

Page 69: ...nd oilsupplyto thepump Insufficient amount ofhydraulic fluidwill not meetthecool ingdemands ofthe system Fillthereservoirto theproper level Inspecttheheatexchanger if so equipped If theheat exchangerfails orbecomesobstructed itmay notmeetthe coolingdemands ofthesystem Ensurethatheatexchangerisreceivingadequateairflow and thatthe heatexchangerisingood operatingcondition Repairorreplaceas necessary ...

Page 70: ...peed sensor lock nut 14 if equipped Then remove the speed sensor using a Vi inch hex wrench Units with out 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 control line plugs 16 17 Discard O rings Using a 3 mm hex wrench remove cavity plug 18 if equipped with two line control from X2 cavity 11...

Page 71: ...te part number are stamped on its surface 16 Remove and discard the O rings 27 28 17 Remove the rear shaft bearing 29 from the endcap with a bearing puller The bearing may be difficult to remove with a puller Try this as an alternative Pack the bearing cavity with heavy grease After the shaft is removed insert it into the bearing cavity and tap lightly with a soft mallet on the splined end The gre...

Page 72: ...oid damaging the shaft during seal removal Install a large sheet metal screw into the chuck of a slide hammer Drive the screw into the seal surface and use the slide hammer to pull the seal 21 Remove the inner snap ring 35 and the shaft bearing assembly 22 Remove the snap ring 36 retaining the shaft front bearing Pull the bearing 37 off of the shaft 38 Table 3 5 Displacement Identifiers of Grooves...

Page 73: ...old down pins 48 and retaining ring 49 from the cylinder block NOTE Most repairs do not require block spring removal Perform this procedure only if you suspect problems with the block spring RISK OF PERSONAL INJURY COMPRESSING THE BLOCK SPRING REQUIRES FORCE OF ABOUT 80 TO 90 LBF 350 TO 400 N USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT ENSURE THE SPRING IS SECURE BEFORE AT...

Page 74: ...th scored or excessively rounded slipper edges Measure the slipper foot thickness Replace any piston assemblies with excessively worn slip pers Check the slipper axial end play Replace any piston assemblies with excessive end play Minimum slipper foot thickness and maximum axial end play are given in the table below CYLINDER BLOCK Measure the cylinder block height Replace blocks worn beyond the mi...

Page 75: ...iding the surface condition meets specifi cations shown Measure the swashplate thickness from the journals to the running face Replace swashplate if damaged or worn beyond minimum specification Replace swashplate if the difference in thickness from one side to the other exceeds specification Inspect the journal bearings for damage or excessive wear Replace journal bearings if scratched warped or e...

Page 76: ...ompress the seal by installing the piston head into the servo cavity in the end cap and let it stand for at least five minutes 2 After piston seal has relaxed lubricate and install servo piston into the housing bore Align the piston with the ball socket facing the inside of the housing RISK OF PERSONAL INJURY COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF 350 TO 400 N OF FORCE USE A PRES...

Page 77: ...til needed 6 Install the journal bearings 13 into the housing seats Use assembly grease to keep the bearings seated during assembly Ensure the locating nubs drop into the cavities in the seats If you re reusing the bearings install them in the original location and orientation Lubricate the journal bearings 7 Install the swashplate 14 into the housing Tilt the swashplate and guide the servo lever ...

Page 78: ...it 19 onto the shaft Install with the slippers facing the swashplate Rock the shaft to align the block splines and slide the cylinder kit into place Orient the motor with the shaft pointing down ward and verify the cylinder kit swashplate journal bearings and servo piston are all secure and prop erly installed 11 Lubricate and install the servo spring 20 and mini mum angle stop 21 into the housing...

Page 79: ...e endcap 25 onto the housing with the endcap screws 26 Check to ensure the endcap will properly seat onto the housing without interfer ence Improper assembly of the internal compo nents may prevent the endcap from seating properly Ensure the O rings seat properly when installing the endcap 16 Using an 8 mm internal hex wrench tighten the end cap screws Tighten the screws in opposite corners slowly...

Page 80: ...seal Install seal support washer 28 and snap ring 29 19 Install remaining plugs and fittings to the housing Refer to the drawing below for wrench sizes and installation torques 29 28 27 27 ShaftSeal 28 Seal SupportWasher 29 SnapRing Figure 3 27 Shaft Seal 1 4 in 45 Nm 33 ft lbs 5 16 in 85 Nm 63 ft lbs 5 16in 85 Nm 63 ft lbs 1 4 in 45 Nm 33 ft lbs 9 16 in 170 Nm 125 ft lbs 3 mm 2 03 to 3 39 Nm 1 5 ...

Page 81: ...o ensure the pump and motor stay filled with oil install case drain lines into the upper most case drain ports 5 Install a 0 to 500 psi 0 to 35 bar gauge in the charge pressure gauge port of the pump to monitor system pressure during start up 6 While watching the pressure gauge run the engine at the lowest possible speed until system pressure builds to normal levels minimum 160 psi 11 bar Once sys...

Page 82: ...ling valve knob out To Engage Drive Motors and Brakes Normal Operation 1 If equipped move steer tow valve to steer position by pushing valve knob in 2 Connect both drive hubs by inverting disconnect cap in center of hub 3 Remove chocks from wheels as required DISCONNECT CAP DISCONNECT CAP REVERSED DRIVE HUB DRIVE HUB Drive Hub Engaged Drive Hub Disconnected Figure 3 30 Disconnecting the Drive Hubs...

Page 83: ...pump forward or reverse as shown 7 Close bleeder screws when all air is dissipated bled 8 Perform oscillating axle lockout test 9 If necessary repeat steps 1 thru 8 Oscillating Axle Lockout Test LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure boom is fully retracted lowered and cen tered between driv...

Page 84: ...ntrol lever to REVERSE and drive machine off of block and ramp 13 Have an assistant check to see that right front wheel remains locked in position off of ground 14 Carefully activate SWING control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed posi tion lockout cylinders should release and allow wheel to rest on ground it may be necessary act...

Page 85: ...ue chart after lubricating the bolt threads with loctite 271 After replacing and retorquing bolt or bolts recheck all existing bolts for looseness Check the frame to bearing Attach bolts as follows 1 Elevate the fully retracted boom to 70 degrees full elevation 2 At the positions indicated on Figure 3 36 try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow ...

Page 86: ...reased drive power required c Noise d Rough rotation 5 If bearing inspection shows no defects reassemble and return to service THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT IT IS HERE THAT THE STRESSES OF LIFT ING ARE CONCENTRATED AT THE CENTER OF ROTATION BECAUSE OF THIS PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION Swing Bearing Replacement 1...

Page 87: ...osely install the bolts and washers through the frame and outer race of bearing IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH MENT BOLTS THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE c Refer to the Figure 3 39 Swing Bearing Torque Sequence Swing Bearing Torquing Sequence Spray a light coat of Safety Solvent 13 on the new...

Page 88: ...SECTION 3 CHASSIS TURNTABLE 3 48 JLG Lift 3120746 Figure 3 38 Swing Bearing Tolerance Boom Placement ...

Page 89: ... 2 Remove the following parts stationary discs 14 rotating discs 12 primary disc 11 torque pins 3 springs 8 9 and the spring retainer 7 NOTE If the bearing and seal are removed for any reason both must be replaced 3 Further disassembly is not recommended and should not be attempted unless necessary to replace the bearing 4 the seal 6 or the shaft 10 If further disassembly is needed proceed as foll...

Page 90: ...uid THE DEPTH THE PISTON IS INSTALLED INTO THE POWER PLATE IS CRITICAL THE SURFACE OF THE PISTON AT THE CUTOUTS MUST BE FLUSH TO 0 120 IN BELOW THE SURFACE OF THE POWER PLATE DO NOT EXCEED THE 0 120 DEPTH OR THE PIS TON WILL COCK RESULTING IN A COMPLETE LOSS OF BRAK ING 3 Assemble the piston 15 into the power plate 21 using a shop press being careful not to damage the o rings or Teflon back up rin...

Page 91: ...SECTION 3 CHASSIS TURNTABLE 3120746 JLG Lift 3 51 Figure 3 40 Swing Brake Assembly Ausco ...

Page 92: ...se just enough clamping force to hold the motor securely Protect the mounting flange with soft vise jaws 2 Remove the 7 cap screws from the end cap and dis assemble the motor as shown 3 Unclamp the motor and remove the output shaft thrust needle bearing and thrust bearing race 4 Clamp the motor in a vise so the mounting flange is on top Clamp across the port area Do not clamp on motor housing Use ...

Page 93: ... metal parts in clean solvent Blow them dry with pressur ized air Do not wipe parts dry with paper towels or cloth Lint in a hydraulic system will cause damage Check the key way and chamfered area of the output shaft remove any nicks burrs or sharp edges that could damage the shaft seal during assembly NOTE Always use new seals when reassembling hydraulic motors DURING REASSEMBLY LUBRICATE THE NEW...

Page 94: ...iming dot on shaft BE SURE THE SLOTS IN THE SPACER PLATE PROVIDE PAS SAGE FOR HYDRAULIC FLUID AS WELL AS THE CAP SCREWS IF THE SPACER PLATE IS FLIPPED THE MOTOR WILL NOT OPERATE 3 Lightly stretch lubricate and install the second of the three larger diameter seals in the groove in the Geroler Standard Timing Align any star point with threaded hole noted for the location of the timing dot Reverse Ti...

Page 95: ...screw 2 Exclusion Seal 3 Mounting Flange 4 Backup Ring 5 Pressure Seal 6 Seal 7 Bearing Race 8 Needle Thrust Bearing 9 Key 10 Output Shaft 11 Housing 12 Seal 13 Drive 14 Spacer Plate 15 Seal 16 Geroler 17 Seal 18 End Cap 19 Capscrew Figure 3 42 Swing Motor ...

Page 96: ...out causing deformation or any type of dam age to the spark arrester repeatedly tap on the arrester near the cleanout plug This may be enough to begin drainage of the spark trap 3 An industrial vacuum cleaner can do a complete job at this point a Or IN A SAFE AREA start the engine Then alternate between low idle and high idle for two to three minutes b Or operate the engine as required by the appl...

Page 97: ...red valve using High Engine pot Turn CW to increase CCW to decrease speed See diagram on page 43 E 331 Electronics Adjustment Locations Mounting Actuator The Actuator may be mounted in any attitude there is no preferred orientation With no power applied the Actuator is spring loaded to the minimum fuel position The Actuator output shaft rotates toward the maximum fuel position against this spring ...

Page 98: ...ng These forces cannot be felt when the engine is not run ning Therefore start the engine while carefully controlling the speed by hand and feel for binding or airload forces Needle bearings on the butterfly shaft are available on many industrial carburetors to deal with this problem Any tendency on the butterfly stick must be corrected Mounting Controller Select a reasonably cool dry and vibratio...

Page 99: ...SECTION 3 CHASSIS TURNTABLE 3120746 JLG Lift 3 59 ...

Page 100: ...is past full travel If you suspect you may have over adjusted the High Engine pot or have lost track of where you are turn the pot 25 30 turns CCW then back 10 12 turns CW to get back into the range of normal adjustment Single Turn Adjustment Gain Factory Adjust This pot is 3 8 square and has a 1 8 plastic screw in its center Be gentle This pot turns 270 degrees and over turning will break the int...

Page 101: ...gine pot as needed to obtain the speed desired 8 The start lockout adjustment is factory set If neces sary he starter lockout pot may be adjusted to obtain dropout of the starter as the engine attains running speed Normally this is around 500 RPM 9 The overspeed adjustment is factory set If neces sary it may be readjusted to shut off ignition power at a different engine speed by means of the over ...

Page 102: ...e to full fuel position c Increase engine speed carefully At some engine speed Governor arm should move to low fuel position d By carefully varying engine speed you should be able to cause the Governor arm to pause momentarily near the middle of its travel This engine speed is the speed for which the Gover nor is adjusted If grossly incorrect reset High Engine Pot e With the engine running at low ...

Page 103: ...than 1 2 to 1 ball dia 3 19 THROTTLE CHECKS AND ADJUSTMENTS DEUTZ ENGINE PRIOR TO S N 61306 General The throttle control system on the Deutz engine includes the positional controller and the actuator Four LEDs are incorporated in the controller They are as follows Red failure signals a problem with the system needs service or adjustment Green clutch engaged operation normal while sys tem is powere...

Page 104: ...ghtly before lever makes contact with throttle lever stop Failure to do so will burn out actuator Controller Status Clutch engaged no actuator movement Clutch engaged actuator extending Clutch engaged actuator retracting Controller fault clutch disengaged and no actuator movement Failure Modes Immediate Red Light Action 1 Recycle power to determine if the problem is inter mittent 2 The input volta...

Page 105: ...t linkage and reset each potentiometer for correct operation 5 If failure continues to occur replace unit Only green light on and no actuator movement Action 1 Adjust trim potentiometers 2 If problem continues replace unit 3 20 AUTOMATIC CHOKE ADJUSTMENT FORD ENGINE 1 At 70 F the choke plate should be open 1 32 not touching the choke bore 2 If the ambient temperature is not 70 F an additional adju...

Page 106: ...edures under Checking the Carburetor If after following those procedures the engine still does not start continue with Checking the Ignition 2 Engine Not Receiving Fuel If after cranking the engine for a period of time and there is no white smoke coming out of the exhaust tube follow the procedures under Checking the Fuel Checking the Carburetor After cranking the engine for a period of time there...

Page 107: ...y have failed a Ignition module series AA AB and FA prior to date code 1889 may need replaced refer to Ford Technical Bulletin FF 91 99 b Check the vacuum advance tube attached to the ignition module for secure connection Try to start the engine 3 22 CHECKING THE FUEL The engine may not be getting fuel to the carburetor 1 Check the fuel shutoff solenoid a Must have 12 volt while cranking the engin...

Page 108: ...hen performing a visual physical inspection check Inspect engine for modifications or aftermarket equip ment that can contribute to the symptom verify that all electrical and mechanical loads or accessory equip ment is OFF or disconnected before performing diag nosis Inspect engine fluids for correct levels and evidence of leaks Inspect vacuum hoses for damage leaks cracks kinks and improper routi...

Page 109: ...he Engine Module to calculate the ignition sequence The CKP sensor initiates the reference pulses which the Engine Module uses to calculate RPM and crankshaft position CAMSHAFT POSITION CMP SENSOR AND SIGNAL The camshaft position CMP sensor sends a CMP signal to the Engine Module The Engine Module uses this signal as a sync pulse to trigger the injectors in the proper sequence The Engine Module us...

Page 110: ...T Sensor High Voltage 35 Intake Air Temperature IAT Sensor High Voltage 41 Fuel Pump High Voltage 42 Heated Oxygen Sensor HO2S High Voltage 43 Engine Coolant Temperature ECT Sensor Low Voltage 45 Intake Air Temperature IAT Sensor Low Voltage 51 Low Oil Pressure 52 Crankshaft Position CKP Sensor Extra Missing Pulses 53 Camshaft Position Sensor CMP Sensor Illegal Pattern 54 Engine Control Module ECM...

Page 111: ...mits it is limited at 35 When this condition occurs the EPM perceives the engine to be running rich 125 Closed Loop Multiplier High Natural Gas This fault sets if the Closed Loop multiplier exceeds the limits of nor mal operation When the multiplier cannot correctly modify the fuel flow within its limits it is limited at 35 When this fault occurs it is because the EPM perceives the engine to be ru...

Page 112: ...1 will be enforced During this fault maximum throttle position is 50 and the MIL light will flash twice per second 214 IAT Higher Than Expected 2 This fault will set if the Intake Air Temperature is greater than 210 deg F and engine RPM is greater than 1000 The MIL light will be on during this active fault and the engine will shut down 215 Oil Pressure Low This fault canbe configured two different...

Page 113: ... psia 254 Excessive Knock Signal This fault will set if the Knock Sensor input to the EPM is greater than 4 5 volts while MAP is less than 8 psia and knock spark retard is at maximum 311 Injector Driver 1 Open 2 5L This fault will set if the EPM detects low feedback voltage on the inter nalinjectorwhiletheinjectordrivecircuitisintheoff stateandbattery voltage is greater than 9 volts 312 Injector D...

Page 114: ...l firings which require the adaptive dwell to be greater than allowed with the battery voltage above 11 volts The purpose of this fault is to detect an open or high impedance circuit to the coil or an open primary coil 414 Coil Driver 2 Shorted 2 5L This fault will set if the EPM detects 10 coil firings in which the adap tivedwellislessthanallowedandbatteryvoltageislessthan16volts The purpose of t...

Page 115: ...e key on cycle If the active fault is no longer present the MIL light will flash at 2 Hz for the remainder of the key on cycle This is a reminder that the Low Rev Limit is still enforced 522 FPP2 Low Voltage Thisfaultwillsetifsignalvoltageislessthan0 2voltsatanyoperating condition while the key is on If the voltage is less than 0 2 then FPP2 is considered out of specification At this point the EPM...

Page 116: ... the remainder of the key on cycle If the active fault is no longer present the MIL light will flash at 2 Hz for the remainder of the key on cycle This is a reminder that the Low Rev Limit is still enforced 551 Max Govern Speed Override This fault will set anytime the engine RPM exceeds 4500 for 2 sec onds or more continuously This speed overrides any higher max governor speeds programmed by the u...

Page 117: ... is cleared This fault should be erased after diagnosis by removing battery power It will not self erase During this active fault Power Derate level2 willbeenforced When this is enforced maximum throttle position will be 20 This is enforced until the fault is manually cleared 616 RAM failure This fault will set if the EPM detects a problem accessing or writing information to RAM This fault will no...

Page 118: ...lly erasable programmable read only mem ory EEPROM is a permanent memory chip that is located within the Engine Module The EEPROM contains the pro gram and the calibration information that the Engine Module needs to control engine operations If the Engine Module is replaced the new Engine Module will need to be programmed An IBM compatible com puter and software containing the correct program and ...

Page 119: ...SECTION 3 CHASSIS TURNTABLE 3120746 JLG Lift 3 79 Figure 3 46 EFI Component Location ...

Page 120: ...metric pressure BARO If the Engine Module detects a voltage that is significantly lower than the estimated MAP value for 2 or more consec utive seconds DTC 14 will be set A signal voltage signifi cantly higher than the estimated MAP value for 2 or more consecutive seconds will set DTC 24 ENGINE CONTROL MODULE ECM ENGINE PERFORMANCE MODULE EPM The engine will be controlled by one of two different E...

Page 121: ... practices such as charging the battery with an arc welder Take proper precautions to avoid static damage to the Engine Module Refer to Electrostatic Discharge Dam age for more information THROTTLE POSITION TP SENSOR The throttle position TP sensor is a potentiometer con nected to the throttle shaft on the throttle body which is built into the electronic governor The Engine Module monitors the vol...

Page 122: ...SECTION 3 CHASSIS TURNTABLE 3 82 JLG Lift 3120746 Figure 3 47 ECM EPM Identification ECM EPM ...

Page 123: ...the part has been handled while sliding across a seat while sitting down from a standing position or while walking a distance touch a known good ground before installing the part Fuel System FUEL INJECTOR The Electronic Fuel Injection EFI fuel injector is a sole noid operated device controlled by the Engine Module The Engine Module energizes the solenoid which opens a valve to allow fuel delivery ...

Page 124: ... engine by control ling the amount of time that the fuel injector is ON The best mixture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most efficient combustion Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a closed loop system The Engine Module monitors signals from several sensors ...

Page 125: ...ted to the top of the engine and dis tributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines ELECTRONIC GOVERNOR AND THROTTLE BODY In the 2 5L EFI industrial engine throttle control is achieved by using an electronic governor which is con trolled by the Engine Module The electronic governor consists of a throttle body an electronically ...

Page 126: ...ECT has reached 160 F 71 C Seven minutes has elapsed since starting the engine After these conditions are met the engine is said to be operating in closed loop In closed loop The Engine Module continuously adjusts the air fuel ratio by respond ing to signals from the HO2S except at wide open throt tle When the HO2S reports a lean condition low sensor signal voltage the Engine Module responds by in...

Page 127: ...tronic ignition system uses a coil pack with one ignition coil for each two cylinders in the engine Each cyl inder is paired with its opposing cylinder in the firing order so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust The spark that occurs in the cylinder on the exhaust stroke is referred to as a waste spark The primary coils in the coil pack are tr...

Page 128: ...SECTION 3 CHASSIS TURNTABLE 3 88 JLG Lift 3120746 This page left blank intentionally ...

Page 129: ...roximately 20 inches 50 8 cm to gain access to the slave lev eling cylinder e Supporting the slave cylinder remove the hard ware from pin 3 Using a suitable brass drift and hammer remove pin 3 from the fly boom f Tag and disconnect hydraulic lines to the slave leveling cylinder Use a suitable container to retain any residual hydraulic fluid Cap hydraulic lines and ports Remove the slave cylinder 3...

Page 130: ... CARE MUST BE TAKEN NOT TO DROP THE PUSHBAR ONTO THE WIRE ROPE ADJUST MENT THREADS FAILURE TO DO SO WILL RESULT IN DAMAG ING THREADS h Using a suitable brass drift and hammer remove the push bar pin from the turntable upright i Remove hardware securing the boom pivot pin to the turntable upright j Using a suitable brass drift and hammer remove the pivot pin from the turntable upright k Using all a...

Page 131: ...y Place telescope cylinder on a suitable trestle a Remove hardware from the wear pads remove wear pads from cylinder b Remove hardware from the wire rope guard remove guard from cylinder c Remove hardware from the sheave pin remove pin and sheave from cylinder 9 Remove hardware which secures the wear pads to the front of base boom section remove wear pads from the top sides and bottom of the base ...

Page 132: ...SECTION 4 BOOM PLATFORM 4 4 JLG Lift 3120746 Figure 4 5 Boom Assembly Cutaway Sheet 1 of 2 ...

Page 133: ...SECTION 4 BOOM PLATFORM 3120746 JLG Lift 4 5 Figure 4 6 Boom Assembly Cutaway Sheet 2 of 2 ...

Page 134: ...o fly boom Route wire rope back through holes in the side of the fly boom section Inspection NOTE When inspecting pins and bearings Ref to para graph 2 39 Pins and Gar Max Bearing Repair Guidelines 1 Inspect all sheaves extend and retract wire ropes and telescope cylinder for excessive groove wear burrs or other damage Replace sheaves as neces sary 2 Inspect extend and retract wire rope sheave bea...

Page 135: ... dimensions of the mid section to determine the number of shims required for proper lift 3 Install side top and bottom wear pads to the aft end of fly section shim evenly to the measurements of the inside of mid section 4 Install retract wire ropes into aft end of fly section route wire ropes thru holes in side of fly boom sec tion and pull into slot 5 Install side top and bottom wear pads to the ...

Page 136: ...CYLIN DER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM CARE MUST BE TAKEN TO MOVE THE CYL INDER SLOWLY INTO POSITION DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEM BLIES 19 Align the cylinder with the slots at aft end of mid boom section then secure cylinder with mounting hardware 20 Align holes in aft end of the fly boom section with holes in wire rope moun...

Page 137: ...ft ing device in order to position boom lift cylinder so that holes in the cylinder rod end and boom struc ture are aligned Insert the lift cylinder pin ensuring that location of hole in pin is aligned with attach point on boom 9 Align holes in boom structure with hole in master cylinder Insert the master cylinder pin ensuring that location of hole in pin is aligned with attach point on boom 10 Ad...

Page 138: ...ut bottoming out telescope cylinder and check torque on the extend wire ropes NOTE Step 8 and 9 may need to be repeated to equalize the torque on all 4 wire ropes 10 After all wire ropes have been properly torqued install nylon collar locknuts Remove all clamping devices and install all covers and guards Check the boom for proper function 4 3 WEAR PADS Main Boom 1 Shim up wear pads to within 1 32 ...

Page 139: ...use or any signs of abnormalities 2 Check rope tension by deflecting the ropes by hand properly tensioned ropes should have little or no movement 12 Year or 7000 Hour Replacement 1 Mandatory wire rope and sheave replacement Additional inspection required if 1 Machine is exposed to hostile environment or condi tions 2 Erratic boom operation or unusual noise exists 3 Machine is idle for an extended ...

Page 140: ...SECTION 4 BOOM PLATFORM 4 12 JLG Lift 3120746 4 5 LIMIT SWITCHES AND CAM VALVE ADJUSTMENT Adjust switches and cam valve as shown in Limit Switches Adjustment Figure 4 14 Limit Switches Adjustments ...

Page 141: ...as follows Main Boom Length Switch a Lift main boom to approximately horizontal b Telescope boom out until 500 lb 230 kg light comes on may need to used auxiliary power to position boom correctly c Mark the wear pad location on the main fly boom d Telescope the main boom to full extension e Measure from the mark on the fly boom to the wear pad The dimension should be 125 to 127 317 5 to 322 5 cm M...

Page 142: ...le hammer and chisel remove the por tion of end cap securing setscrew 4 Using a torch apply heat to the setscrews on the bottom of actuator 5 Remove the two 2 setscrew 4 from bottom of actuator 1 Discard setscrew 6 Place two 2 3 8 x16NC bolts in threaded holes in bottom of the actuator Using a suitable bar unscrew the end cap 5 Remove the end cap from actuator 1 Figure 4 15 Removing Portion of End...

Page 143: ...rts as necessary NOTE A small amount of wear in the spline teeth will have little effect on the actuator strength New spline sets are manufactured with a backlash of about 0 005 in per mating set After long service a backlash of about 0 015 per set may still be acceptable in most cases depending on the required accuracy of the application 3 Check the ring gear for wear and weld damage to the pins ...

Page 144: ...tical position install the piston sleeve 3 in timed relation to the housing 1 DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY AS IT WILL MARK THE CYLINDER BORE NOTE The timing marks the small punch marks on the face of each gear must be aligned for proper shaft orientation See Actuator Timing 5 Install the shaft 2 into housing 1 by aligning the proper punched timing marks See Actuator Tim ing 6 Te...

Page 145: ...SECTION 4 BOOM PLATFORM 3120746 JLG Lift 4 17 Figure 4 22 Rotator Assembly Helac ...

Page 146: ...justment potentiometer clockwise will increase the ramp time To set the ramp down time hold the joystick in the extreme position Release the joystick and watch the meter for the time it takes the output to go from the maximum current setting to 0 current Adjust P2 until this time matches the time in table 2 Rotating the adjustment potentiometer clockwise will increase the ramp time Follow the same...

Page 147: ...l 750to850mA 450to550mA DriveForward 40to60mA 150to200mA DriveReverse 40to60mA 150to200mA Figure 4 23 Control Card Table 4 2 Flow Control Card Ramp Time Function RampTime LiftUp RampUpTime 4 00sec RampDownTime 3 00sec LiftDown RampUpTime 4 00sec RampDownTime 3 00sec SwingRight RampUpTime 4 00sec RampDownTime 3 00sec SwingLeft RampUpTime 4 00sec RampDownTime 3 00sec DriveForward RampUpTime 4 30sec ...

Page 148: ...SECTION 4 BOOM PLATFORM 4 20 JLG Lift 3120746 This page left blank intentionally ...

Page 149: ...ased the spool automatically returns to neutral prohibiting any flow through the circuit Relief Valves Relief valves are installed at various points within the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control Th...

Page 150: ...at a rate of 6 8 drops per minute or more the piston seals are defective and must be replaced 5 If no repairs are necessary or when repairs have been made replace counterbalance valve and care fully connect hydraulic hoses to cylinder port block 6 If used remove lifting device from upright or remove prop from below main boom activate hydraulic sys tem and run cylinder through one complete cycle to...

Page 151: ...er rod end as applicable EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 9 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 10 Using suitable protection clamp the cylinder...

Page 152: ...diameter for scoring or other damage and for ovality and tapering 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 nec essary 12 Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary 13 If applicab...

Page 153: ...al into the applicable cylinder head gland groove Install a new wear ring into the applicable cylinder head gland groove 1 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head 2 Install washer ring onto rod carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the ...

Page 154: ...ushing Torque Specifications 9 Remove the cylinder rod from the holding fixture 10 Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston See Figure 5 10 Piston Seal Kit Installation 11 Position the cylinder barrel in a suitable holding fix ture EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER ...

Page 155: ... Value Wet Lift Cylinder 240 ft lbs 325 Nm 30ft lbs 41Nm SlaveCylinder 30 ft lbs 41 Nm 5 ft lbs 9 Nm Master Cylinder 30 ft lbs 41 Nm 5 ft lbs 9 Nm Telescope Cylinder 50 ft lbs 68 Nm 9 ft lbs 12 Nm Lockout Cylinder 80 ft lbs 109 Nm N A SteerCylinderPistonNutTorqueSpecifications SteerCylinder LBS NM 150 ft lbs 204 Nm Figure 5 12 Rod Assembly Installation Table 5 2 Holding Valve Torque Specifications...

Page 156: ...uring cable adjustment block to aft end of the base boom section and remove block 9 Remove hardware securing telescope cylinder to aft end of the mid boom section WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM CARE MUST BE TAKEN TO MOVE THE CYLINDER SLOWLY INTO POSITION DAMAGE T...

Page 157: ...the machine on a flat and level surface Start the engine and place the main boom in the horizon tal position Shut down engine and prop the boom 2 Remove the hardware retaining the cylinder rod attach pin to the boom Using a suitable brass drift drive out the cylinder rod attach pin 3 Using auxiliary power retract the lift cylinder rod completely 4 Disconnect cap and tag the main boom lift cylinder...

Page 158: ...e return lines oil cooler and return filter Gauge Information M1 SystemPressure PortA 10 000PSIor600BarGauge 9 16 18O ring Fitting M2 SystemPressure PortB 10 000PSIor600BarGauge 9 16 18O ring Fitting M3 Charge Pressure 1000PSI or60BarGauge 9 16 18O ring Fitting orTeeinto Charge PressureFilter OutletLine L1 L2 CasePressure 1000PSI or60BarGauge 1 1 16 12O ring Fitting S Charge Pump Inlet Vacuum Vacu...

Page 159: ...SECTION 5 HYDRAULICS 3120746 JLG Lift 5 11 Figure 5 14 Troubleshooting System Operating Hot Figure 5 15 Troubleshooting Transmission Operates in One Direction Only ...

Page 160: ...SECTION 5 HYDRAULICS 5 12 JLG Lift 3120746 Figure 5 16 Troubleshooting System Response is Sluggish ...

Page 161: ...g or does not have the proper setting THE RELIEF VALVES ARE FACTORY SET AND SHOULD NOT BE TAMPERED WITH EXCEPT FOR REPLACING THE ENTIRE CAR TRIDGE DISASSEMBLY MAY CHANGE THE SETTING AND CAUSE ERRATIC UNIT OPERATION OR PREMATURE FAILURE PUMP CHARGE RELIEF VALVE If charge pressure is low less than 220 psi 15 2 Bar above case pressure the charge relief valve should be inspected Inspect for foreign ma...

Page 162: ...r on the neu tral adjustment side Install a spacer or sprocket approximately 0 75 in 19 mm long under the servo cover opposite the neutral adjustment 4 Re install the bolts and tighten until the servo cover on the neutral adjustment side of the pump sepa rates 0 125 in 3 mm from the housing Turn the cover and remove and inspect the orifice NOTE The Displacement Control may first have to be removed...

Page 163: ...ppropriate control adjustment EDC NEUTRAL ADJUSTMENT 1 Remove the electrical connector at the EDC Remove the servo cross port line installed while making the swash plate neutral adjustment and install a 0 to 300 PSI 0 to 21 BAR gauge in each servo port THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND WORK FUNCTION DISCONNECTED ETC WHILE PERFORMING THE PRO...

Page 164: ...s are used on Series 40 M46 pumps and motors These seals can be replaced without major disas sembly of the unit However replacement of the shaft seal requires removal of the pump from the machine 1 Remove the retaining ring from the housing 2 Carefully remove the seal from the housing bore The face of the seal may be punctured with a sharp instrument such as a screw driver to aid in prying the sea...

Page 165: ...eign material It is recommended that the O ring and back up ring be replaced NOTE Bypass valves are available with integral bypass ori fices for specific applications Refer to the appropri ate Service Parts Manual for more information 2 Reinstall the bypass valve into the housing Torque to 7 to 10 ft lbs 9 5 13 6 Nm CHARGE CHECK AND HIGH PRESSURE RELIEF VALVES 1 Remove the charge check and high pr...

Page 166: ...SE ERRATIC UNIT OPERATION OR PREMATURE FAILURE CHARGE PRESSURE RELIEF VALVE 1 Remove charge relief valve hex plug 2 Remove the spring and poppet from the housing Do not alter the shims or interchange parts with another valve Inspect the poppet and mating seat in the end cap for damage or foreign material 3 Reinstall the poppet spring and plug with shims and O ring into the housing Torque the plug ...

Page 167: ...ring on the bottom of the control housing Lightly lubricate all O rings with clean petro leum jelly prior to assembly The control spool and sleeve are a matched set and are not available sepa rately 7 Reinstall the control orifice plugs into their passages and replace the servo piston covers 8 Install the control inlet screen plug and torque to 20 to 30 in lbs 2 2 to 3 4 Nm Always install a screen...

Page 168: ...1 Bar h With the aid of an assistant activate swing left or right i While monitoring pressure gauge adjust swing relief to 1700 PSI 117 2 Bar j With the aid of an assistant activate lift down k While monitoring pressure gauge adjust lift down relief to 1500 PSI 103 4 Bar Platform Level a Install pressure gauge at quick disconnect on port M3 on main valve b With the aid of an assistant activate pla...

Page 169: ... 21 1 Front Steer Right Relief 2 Swing Left Right 3 Front Steering Right 4 Swing Right 5 Lift Down 6 Steer Dump 7 Platform Level Relief Up 8 Tele Out 9 Platform Rotate Right 10 Platform Level Down Figure 5 19 Main Control Valve Sheet 1 of 2 ...

Page 170: ...ont Steer Left Relief 2 Front Steering Left 3 Swing Left 4 Upper Lift Down Relief 5 Main Relief 6 Lift Up 7 Flow Control 8 Tele In 9 Platform Rotate Left 10 Platform Level Down Relief 11 Platform Level Up Figure 5 20 Main Control Valve Sheet 2 of 2 ...

Page 171: ...SECTION 5 HYDRAULICS 3120746 JLG Lift 5 23 A 18 20 ft lbs 24 5 27 2 Nm B 25 27 ft lbs 34 36 7 Nm Torque Valve Bolts to 60 in lbs 7 Nm Figure 5 21 Main Control Valve Torque Values ...

Page 172: ...ining units pump or motors need to be inspected for damage and contamination and the entire hydraulic system will need to be flushed and the fluid replaced Failure to do so may cause considerable damage to the entire system The inlet line leading from the reservoir to the pump must be filled prior to start up Check the inlet line for property tightened fittings and make sure it is free of restrict...

Page 173: ...he system hoses should be retightened to their specified torque Once charge pressure has been established increase speed to normal operating RPM Charge pressure should be as indicated in the pump model code If charge pres sure is inadequate shut down and determine the cause for improper pressure INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA TOR S ABILITY TO CONTROL THE MACHINE Shut down the eng...

Page 174: ...SECTION 5 HYDRAULICS 5 26 JLG Lift 3120746 This page left blank intentionally ...

Page 175: ...min speed and max speed for all boom drive and steering functions The upper lift swing and drive are controlled by individual joysticks with steering being controlled by a rocker switch built into the top the drive joystick To activate Drive Lift and Swing simply pull up on the slide lock location on the joystick and move the handle into the direction desired The control system will control the vo...

Page 176: ...SECTION 6 JLG CONTROL SYSTEM ADE 6 2 JLG Lift 3120746 Figure 6 1 EPBCS Block Diagram ...

Page 177: ...s To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS SYSTEM TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATIONS view only If you press ENTER at the HELP PRESS ENTER display and a fault is present the analyze...

Page 178: ...SECTION 6 JLG CONTROL SYSTEM ADE 6 4 JLG Lift 3120746 Figure 6 2 Analyzer Connecting Points PLATFORM CONNECTION GROUND CONTROL CONNECTION ...

Page 179: ...pressing the ESC key 6 4 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER When the analyzer is first connected you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level This ensures that a setting can not be accidentally altered To change the access level the correct password must be entered To enter...

Page 180: ...SECTION 6 JLG CONTROL SYSTEM ADE 6 6 JLG Lift 3120746 Figure 6 3 Control Module and Fault Code Indicator Location ...

Page 181: ...Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value...

Page 182: ...machine person ality settings There is a setting that JLG strongly recommends that you do not change This setting is so noted below ELEVATION CUTBACK CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER FORMANCE OF YOUR MACHINE ITS IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONEN...

Page 183: ...SECTION 6 JLG CONTROL SYSTEM ADE 3120746 JLG Lift 6 9 Figure 6 4 Analyzer Flow Chart Sheet 1 of 3 ...

Page 184: ...SECTION 6 JLG CONTROL SYSTEM ADE 6 10 JLG Lift 3120746 Figure 6 5 Analyzer Flow Chart Sheet 2 of 3 ...

Page 185: ...SECTION 6 JLG CONTROL SYSTEM ADE 3120746 JLG Lift 6 11 Figure 6 6 Analyzer Flow Chart Sheet 3 of 3 ...

Page 186: ...0 to 35 4 For Max 0 to 100 22 Rev Min 0 to 35 4 Rev Max 0 to 100 22 Elevated Max 0 to 50 17 Creep Max 0 to 50 25 Engine RPM 800 to 2900 1800 LIFT Accel 0 1 to 5 0 2 0 Decel 0 1 to 3 0 0 7 Min Up 0 to 60 40 Max Up 0 to 100 70 Creep Up 0 to 65 55 Min Down 0 to 60 40 Max Down 0 to 100 75 Creep Down 0 to 75 55 Engine RPM 800 to 2900 1800 SWING Accel 0 1 to 5 0s 2 0 Decel 0 1 to 3 0s 1 8 Min Left 0 to ...

Page 187: ...SKETLEVEL Engine RPM 800 to 2900 1500 BASKETROTATE Engine RPM 800 to 2900 1500 STEER Max 0 to 100 100 Engine RPM 800 to 2900 1800 GROUNDMODE Upper Lift Up 0 to 100 60 Upper Lift Down 0 to 100 60 Swing 0 to 100 60 4150365 3 Table 6 1 Personality Ranges Defaults FUNCTION PERSONALITY RANGE DEFAULTS ...

Page 188: ...X because thevehicleis aboveelevation TESTS ACTIVE RECYCLEEMS TOEND Thesystemtests havebeen activated normalvehicleoperationis notallowed 1 1 Flashcode1 1indicates a sleep mode NOT REQUIRED 2 1 Flashcode2 1indicates problems with footswitch 2 FSWFAULTY Thetwo foot switchsignalsdo notagree EMSrecycle required KEYSWITCHFAULTY Bothplatformandground modes areselected simultaneously 2 2 Flashcode2 2ind...

Page 189: ... 2 5 Flashcode2 5indicates thatafunction isprevented duetoa cutout 4 BOOMPREVENTED DRIVE SELECTED A boomfunction isselectedwhileadrivefunction isselectedand drive cutoutis configured topreventsimultaneousdrive boom operation DRIVEPREVENTED ABOVE ELEVATION Driveisselectedwhileaboveelevationanddrivecutoutisconfigured to prevent drive DRIVEPREVENTED BOOM MOVEMENTSELECTED Driveisselectedwhileaboomfunc...

Page 190: ...d BATTERY TOO LOW SYSTEM SHUTDOWN Batteryvoltageis below6V EMSrecyclerequired 5 5 Flashcode5 5indicates problemswith vehicleengineRPMortheencoder 8 SPEED SENSORREADING INVALID SPEED Speed sensorisindicating animpossiblenumberofpulses This is probablydue toafaulty speed sensor SPEED INPUT LOST This indicates thatthecontrol systemhasdeterminedthatthediesel enginespeedinputtothesystemhasbeenlost This...

Page 191: ...lashcode9 9indicates problems withthecontroller 11 PLATFORMMODULEFAILURE hwfs CODE1 Platformmodule V Low FEThasfailed GROUND MODULE FAILURE hwfs CODE1 Groundmodule V Low FEThasfailed Table 6 2 Help Fault Codes Displayed Faults and Descriptions Prior to S N 66939 ...

Page 192: ...es problems with footswitch 2 FSW FAULTY The two footswitch inputs have read the same state for more than one sec ond KEYSWITCH FAULTY Both platform and ground modes are selected simultaneously 2 2 Flashcode2 2indicatesproblemswithdrive steerselection Except where noted these faults are not reported during 2 second power up sequence 3 DRIVE LOCKED JOYSTICK MOVED BEFORE FOOT SWITCH Drive was select...

Page 193: ...A platformboomfunction lowerlift telescope basket level basketrotate jib was selected before key switch or footswitch closure PUMP SWITCHES LOCKED SELECTED BEFORE AUX POWER A ground boom function lower lift telescope basket level basket rotate jib was selected before aux power LIFT SWING WITH NO QPROX This fault only occurs with inductive joysticks It occurs if the joystick is moved out of the neu...

Page 194: ...t is con figured to prevent simultaneous drive boom operation DRIVE PREVENTED TILTED ABOVE ELEVATION Drive is selected while tilted and above elevation and tilt is configured to cutout drive MODEL CHANGED HYDRAULICS SUSPENDED CYCLE EMS User changed the model number using the analyzer User must cycle power before the hydraulics system will be active again 11 2 7 Flash code 2 7 indicates that the ac...

Page 195: ...SHORT TO BAT TERY LP START ASSIST SHORT TO GROUND LP START ASSIST OPEN CIR CUIT LP START ASSIST SHORT TO BATTERY MAIN DUMP SHORT TO GROUND MAIN DUMP OPEN CIRCUIT MAIN DUMP SHORT TO BAT TERY PARKING BRAKE SHORT TO GROUND PARKING BRAKE OPEN CIR CUIT PARKING BRAKE SHORT TO BATTERY STARTSOLENOIDSHORTTO GROUND START SOLENOID OPEN CIR CUIT STARTSOLENOIDSHORTTO BATTERY STEER DUMP SHORT TO GROUND Table 6 ...

Page 196: ...T TO GROUND HEAD TAIL LIGHT OPEN CIR CUIT HEAD TAIL LIGHT SHORT TO BATTERY BASKET UP OVERRIDE SHORT TO GROUND Only occurs on machines with electronic leveling systems BASKETUPOVERRIDEOPEN CIRCUIT Only occurs on machines with electronic leveling systems BASKET UP OVERRIDE SHORT TO BATTERY Only occurs on machines with electronic leveling systems BASKET UP SHORT TO GROUND BASKET UP OPEN CIRCUIT BASKE...

Page 197: ...UND BASKET RIGHT SHORT TO GROUND BASKET RIGHT OPEN CIR CUIT BASKET RIGHT SHORT TO BATTERY JIB UP SHORT TO GROUND JIB UP OPEN CIRCUIT JIB UP SHORT TO BATTERY JIB DOWN SHORT TO GROUND JIB DOWN OPEN CIRCUIT JIB DOWN SHORT TO BAT TERY JIB LEFT SHORT TO GROUND JIB LEFT OPEN CIRCUIT JIB LEFT SHORT TO BAT TERY JIB RIGHT SHORT TO GROUND JIB RIGHT OPEN CIRCUIT JIB RIGHT SHORT TO BAT TERY TOWER UP SHORT TO ...

Page 198: ... OPEN CIR CUIT LIFT UP DUMP SHORT TO BATTERY LIFT DOWN HOLDING SHORT TO GROUND LIFT DOWN HOLDING OPEN CIRCUIT LIFT DOWN SHORT TO BAT TERY HOUR METER OPEN CIRCUIT This fault cannot be detected during normal operation It may be reported during self test FORD ECM POWER OPEN CIRCUIT This fault cannot be detected during normal operation It may be reported during self test FORD ECM POWER SHORT TO BATTER...

Page 199: ...KET UP SHORT TO BATTERY OR OPEN CIRCUIT Only occurs on machines with electronic basket leveling BASKET DOWN SHORT TO BATTERY BASKET DOWN SHORT TO GROUND bASKET DOWN OPEN CIR CUIT BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT Only occurs on machines with electronic basket leveling BASKET LEFT SHORT TO BATTERY BASKER LEFT SHORT TO GROUND BASKET LEFT OPEN CIRCUIT BASKET RIGHT SHORT TO BATTERY BASKET R...

Page 200: ...e is installed the Ford ECM has reported a low oil pressure fault OIL PRESSURE SHORT TO BATTERY If a Deutz engine is installed this indicates that the oil pressure sensor is reading above 6 6 volts OIL PRESSURE SHORT TO GROUNd If a Deutz engine is installed this indicates that the oil pressure sensor is reading below 0 1 volts for more than 5 seconds This fault is not detected during crank COOLANT...

Page 201: ...e 7 7 indicates problems with a motor NOT REQUIRED 9 9 Flash code 9 9 indicates problems with the controller 11 PLATFORM MODULE SOFT WARE UPDATE REQUIRED PlatformmodulecodeistoooldtosupporttheEIMorBPEloadsensorand the machine is configured to use one of these two sensors The PM code must be updated to a newer version HIGH RESOLUTION A2D FAIL URE INTERRUPT LOST The ADS1213 chip in the platform modu...

Page 202: ...will indicate that it is tilted at all times This calibration data is pro grammed into the unit at the factory CHASSIS TILT SENSOR GAIN OUT OF RANGE Indicates that the chassis tilt sensor calibration has become corrupted Table 6 3 Help Fault Codes Displayed Faults and Descriptions S N 66939 to Present Fault Flash Code Communicated Displayed on Analyzer Fault Description Priority ...

Page 203: ...ingonmodelselec tion 1 2 3 4 5 6 7 8 9 10 11 FORDEFIGAS FordLRG425EFIGas Tier1 FORDEFID F FordLRG425EFIdualfuel Tier1 DEUTZF4TIER1 DeutzF4M1011FDiesel Tier1 DEUTZF3TIER1 DeutzF3M1011FDiesel Tier1 CAT 3024C CAT3024CDiesel Tier2 CAT 3044C CAT3044CDiesel Tier2 DEUTZF4TIER2 DeutzF4M2011Diesel Tier2 DEUTZF3TIER2 DeutzF3M2011Diesel Tier2 FORDGASTIER2 FordLRG425EFIGas Tier2 FORDD FTIER2 FordLRG425EFIDual...

Page 204: ...ion alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan4degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainliftup 3DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan3degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainlift...

Page 205: ...erloadlamplit platformalarmbeeps 5 secON 2secOFF CUTOUTALL Allfunctionscutout flashoverloadlight 500mSon 500mSoff platform alarmbeeps 5secON 2secOFF SPECIAL1 Functionsincreep overloadlamplit disablesmaintelescopeout mainlift up platformalarmbeeps 5secON 2secOFF 0 LOADSENSOR 16 OnlyvisibleifLoadSensor Menuselectionisnot0 Marketselectionswilllimit certainloadsensoroptions 0 1 1ONROTATOR Usetheon boa...

Page 206: ... 0 DRIVE 19 Onlyvisibleundercertain modelselections 0 1 2 4WD Fourwheeldrive 2WD Twowheeldrive 2WDW 2 SPEED Twowheeldrivewith2 speedvalve 0 TEMPERATURE 20 0 1 CELSIUS Celsiusunitselection FAHRENHEIT Fahrenheitunitselection 1 LEVELINGMODE 21 Onlyvisibleon800Smodels 0 1 ALLFUNCTIONS Platformlevelwithallfunctions LEVELLIFT TELESCOPE Platformlevelonliftandtelescopeonly 0 4150364 14 Table 6 4 Machine C...

Page 207: ...iguration Programming Information Software Version P5 3 to Present Configuration Label Digit Number Description Default Number MODELNUMBER 1 1 2 3 4 5 6 7 8 9 10 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S 1 MARKET 2 0 1 2 3 4 5 ANSIUSA ANSIEXPORT CSA CE AUSTRALIA JAPAN 0 ...

Page 208: ...ECM DUALFUELECM GM PSI3 0LDualFuel Tier2 11 FLYWHEELTEETH 4 Thismenuitemisonly visibleifDeutzengine selections3or4are selected 0 1 133TEETH 133flywheelteeth 110TEETH 110flywheelteeth 1 GLOWPLUG 5 0 1 2 NOGLOWPLUGS Noglowplugsinstalled AIRINTAKE Glowplugsinstalledintheairintakeonthemanifold IN CYLINDER Glowplugsinstalledineachcylinder 2 STARTERLOCKOUT 6 0 1 DISABLED Automaticpre glowtimedeterminedb...

Page 209: ...vation alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan4degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainliftup 3DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan3degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainl...

Page 210: ...oadsensorinstalled WARNONLY Functionsincreep overloadlamplit platformalarmbeeps 5secON 2 secOFF CUTOUTPLATFORM Allfunctionscutout overloadlamplit platformalarmbeeps 5 secON 2secOFF CUTOUTALL Allfunctionscutout flashoverloadlight 500mSon 500mSoff platform alarmbeeps 5secON 2secOFF SPECIAL1 Functionsincreep overloadlamplit disablesmaintelescopeout mainlift up platformalarmbeeps 5secON 2secOFF 0 LOAD...

Page 211: ...nctionisactive Option DESCENT Descentalarmsoundswhenliftdownisactive Option MOTION Motionalarmsoundswhenanyfunctionisactive Option 3 DRIVE 20 Onlyvisibleundercertain modelselections 0 1 2 4WD Fourwheeldrive 2WD Twowheeldrive 2WDW 2 SPEED Twowheeldrivewith2 speedvalve 0 TEMPERATURE 21 Certainmarketselections willalterdefaultsetting 0 1 CELSIUS Celsiusunitselection FAHRENHEIT Fahrenheitunitselection...

Page 212: ...ULTY 2 2 CLEARSWHENFAULTISREMOVED D SJOY QPROXBAD 2 2 CLEARSWHENFAULTISREMOVED L SJOY QPROXBAD 2 3 CLEARSWHENFAULTISREMOVED D SJOY OUTOFRANGELOW 2 2 CLEARSWHENFAULTISREMOVED D SJOY OUTOFRANGEHIGH 2 2 CLEARSWHENFAULTISREMOVED L SJOY OUTOFRANGELOW 2 3 CLEARSWHENFAULTISREMOVED L SJOY OUTOFRANGEHIGH 2 3 CLEARSWHENFAULTISREMOVED D SJOY CENTERTAPBAD 2 2 CLEARSWHENFAULTISREMOVED L SJOY CENTERTAPBAD 2 3 C...

Page 213: ...TSHORTTOBATTERY 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT MAINDUMPSHORTTOGROUND 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT MAINDUMPOPENCIRCUIT 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT MAINDUMPSHORTTOBATTERY 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT PARKINGBRAKESHORTTOGROUND 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT PARKINGBRAKEOPENCIRCUIT 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT PARKINGBRAKESHORTTOBATTERY 3 ...

Page 214: ...YCLEDTOCLEARFAULT BASKETLEFTSHORTTOGROUND 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT BASKETLEFTOPENCIRCUIT 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT BASKETLEFTSHORTTOBATTERY 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT BASKETRIGHTSHORTTOGROUND 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT BASKETRIGHTOPENCIRCUIT 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT BASKETRIGHTSHORTTOBATTERY 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAU...

Page 215: ... 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT UPPERINSHORTTOBATTERY 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT UPPEROUTSHORTTOGROUND 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT UPPEROUTOPENCIRCUIT 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT UPPEROUTSHORTTOBATTERY 3 3 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT FUELSENSORSHORTTOBATTERY 3 3 CLEARSWHENFAULTISREMOVED FUELSENSORSHORTTOGROUND 3 3 CLEARSWHENFAULTISREMOVED OILPRES...

Page 216: ...DFAULTCODE54 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODE55 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODE56 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODE57 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODE61 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODE62 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODE63 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODE64 4 3 CLEARSWHENFAULTISREMOVED FORDFAULTCODEUNKNOWN 4 3 CLEARSWHENFAULTISR...

Page 217: ...ANBUSFAILURE 6 6 CLEARSWHENFAULTISREMOVED LOADSENSORNOTCALIBRATED 9 9 CLEARSWHENFAULTISREMOVED TILTSENSORNOTCALIBRATED 9 9 CLEARSWHENFAULTISREMOVED EEPROMFAILURE CHECKALLSETTINGS 9 9 REQUIRESEMSTOBERECYCLEDTOCLEARFAULT PLATFORMMODULEFAILURE HWFSCODE1 9 9 CLEARSWHENFAULTISREMOVED GROUNDMODULEFAILURE HWFSCODE1 9 9 CLEARSWHENFAULTISREMOVED Table 6 6 Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL...

Page 218: ...stsminimum reversedrivespeed MAXREVERSE Displays adjustsmaximumreversedrivespeed ELEVATED MAX Displays adjustsmaximumdrivespeed NOTE used whenelevation cutout switches arelimiting maximumspeed CREEPMAX Displays adjustsmaximumdrivespeed NOTE used whencreepswitch on pump pot isactive STEERMAX Displays adjuststhemaximumsteerspeed LIFT ACCEL Displays adjustsupperliftacceleration DECEL Displays adjusts...

Page 219: ...djustsminimum telescopein speed MAXIN Displays adjustsmaximumtelescopeinspeed MIN OUT Displays adjustsminimum telescopeoutspeed MAXOUT Displays adjustsmaximumtelescopeoutspeed BASKETLEVEL ACCEL Displays adjustsbasketlevelacceleration DECEL Displays adjustsbasketleveldeceleration MIN UP Displays adjustsminimum basketlevelup speed MAXUP Displays adjustsmaximumbasketlevelup speed MIN DOWN Displays ad...

Page 220: ... MIN RIGHT Displays adjustsminimum jib rightspeed MAXRIGHT Displays adjustsmaximumjib rightspeed STEER MAXSPEED Displays adjustsmaximumsteer speed whichapplieswhenvehiclespeedis atminimum GROUND MODE LIFTUP Displays adjustsfixedliftup speed LIFTDOWN Displays adjustsfixedliftdownspeed SWING Displays adjustsfixedswingspeed TELE Displays adjustsfixedtelescope speed BASKETLEVEL Displays adjustsfixedba...

Page 221: ...E demand iscontrolledby thepump pot ROT LEFT Displays basketrotateswitch direction demand NOTE demand iscontrolledby thepump pot UTELE IN Displays telescopeswitch direction demand NOTE demand iscontrolledby thepump pot JIBUP Displays jib lift switchdirection demand NOTE demand iscontrolledby thepump pot Not displayed ifJIB NO JIBLEFT Displays jib swing switchdirection demand NOTE demand iscontroll...

Page 222: ...TE Notdisplayed if load 0 DATALOG ON Displays totalcontrolleron EMS time ENGINE Displays engine run time DRIVE Displays totalcontrollerdriveoperation time LIFT Displays total controllerliftoperation time SWING Displays totalcontrollerswingoperationtime TELE Displays totalcontrollertele operationtime MAX TEMP Displays maximum measured heatsink temp MIN TEMP Displays minimum measured heatsink temp M...

Page 223: ... hydraulic and electrical systems The first rule for troubleshooting any circuit that is hydrau lically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechanic...

Page 224: ...SECTION 7 SCHEMATICS 7 2 JLG Lift 3120746 Figure 7 1 Electrical Components Installation Prior to S N 62137 Sheet 1 of 2 ...

Page 225: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 3 Figure 7 2 Electrical Components Installation Prior to S N 62137 Sheet 2 of 2 ...

Page 226: ...SECTION 7 SCHEMATICS 7 4 JLG Lift 3120746 Figure 7 3 Electrical Components Installation S N 62137 to Present Sheet 1 of 2 ...

Page 227: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 5 Figure 7 4 Electrical Components Installation S N 62137 to Present Sheet 2 of 2 ...

Page 228: ...SECTION 7 SCHEMATICS 7 6 JLG Lift 3120746 Figure 7 5 Electrical Schematic Deutz Engine Sheet 1 of 2 ...

Page 229: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 7 Figure 7 6 Electrical Schematic Deutz Engine Sheet 2 of 2 1870074 C ...

Page 230: ...SECTION 7 SCHEMATICS 7 8 JLG Lift 3120746 Figure 7 7 Electrical Schematic Ford Dual Fuel Engine Sheet 1 of 2 ...

Page 231: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 9 Figure 7 8 Electrical Schematic Ford Dual Fuel Engine Sheet 2 of 2 1870077 A ...

Page 232: ...SECTION 7 SCHEMATICS 7 10 JLG Lift 3120746 Figure 7 9 Electrical Schematic Ford EFI Engine Sheet 1 of 2 ...

Page 233: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 11 Figure 7 10 Electrical Schematic Ford EFI Engine Sheet 2 of 2 1870127 A ...

Page 234: ...SECTION 7 SCHEMATICS 7 12 JLG Lift 3120746 Figure 7 11 Electrical Schematic ADE Machines Sheet 1 of 4 ...

Page 235: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 13 Figure 7 12 Electrical Schematic ADE Machines Sheet 2 of 4 1870132 G ...

Page 236: ...SECTION 7 SCHEMATICS 7 14 JLG Lift 3120746 Figure 7 13 Electrical Schematic ADE Machines Sheet 3 of 4 ...

Page 237: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 15 Figure 7 14 Electrical Schematic ADE Machines Sheet 4 of 4 1870132 G ...

Page 238: ...SECTION 7 SCHEMATICS 7 16 JLG Lift 3120746 Figure 7 15 Hydraulic Schematic Sheet 1 of 4 ...

Page 239: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 17 Figure 7 16 Hydraulic Schematic Sheet 2 of 4 2792338 A ...

Page 240: ...SECTION 7 SCHEMATICS 7 18 JLG Lift 3120746 Figure 7 17 Hydraulic Schematic Sheet 3 of 4 ...

Page 241: ...SECTION 7 SCHEMATICS 3120746 JLG Lift 7 19 Figure 7 18 Hydraulic Schematic Sheet 4 of 4 2792338 A ...

Page 242: ...SECTION 7 SCHEMATICS 7 20 JLG Lift 3120746 This page left blank intentionally ...

Page 243: ......

Page 244: ...21 Ritterhude Ihlpohl Germany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia S R L Via Po 22 20010 Pregnana Milanese MI Italy 39 0 2 9359 5210 39 0 2 9359 5211 Email ricambi jlg com JLG EMEA B V Polaris Avenue 63 2132 JH Hoofdorf The Nether...

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