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JLG 680S, Service And Maintenance Manual

The JLG 680S Service and Maintenance Manual is essential for ensuring the proper care and upkeep of your equipment. This manual can be easily downloaded for free from manualshive.com, providing detailed instructions and guidelines for maintaining the JLG 680S to keep it operating at its peak performance.

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3121234

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SECTION NO.                                  TITLE

                                                                        

     PAGE NO

.

                                         

TABLE OF CONTENTS

SECTION

4  - BOOM & PLATFORM

4.1

Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1

Platform Valve Removal (Prior to SN 0300141319) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Platform Valve Installation (Prior to SN 0300141319). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Platform Valve Removal (SN 0300141319 through 0300189341)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3
Platform Valve Installation (SN 0300141319 through 0300189341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-4
Support Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-6
Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7

4.2

Rotator and Slave Cylinder  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-9

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-9

4.3

Main Boom Powertrack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10

4.4

Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-13

One Piece Bracket Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-13
Two Piece Bracket Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-15
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-17

4.5

Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-18

4.6

Main Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-18

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-18
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-19
Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-27
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-31
Telescope Cylinder/Boom Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-32
Telescope Cylinder/Boom Cable Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-33

4.7

Main Lift Cylinder  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-35

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-35
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-36

4.8

Wire Rope  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-37

Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-37
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-37
12 Year or 7000 Hour Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-37
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-37

4.9

Boom Rope Torquing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-38

4.10

Elevation & Capacity Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-39

4.11

Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-43

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-43
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-45
Platform Leveling Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-46
CAN Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-47
Replacing the Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-47
Additional Platform and Jib Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-48
Platform Leveling Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-48

Summary of Contents for 680S

Page 1: ...Service and Maintenance Manual Model 680S Prior to SN 0300189341 P N 3121234 December 05 2017 AS NZS...

Page 2: ......

Page 3: ...systems oper ate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Do not use y...

Page 4: ...INTRODUCTION A 2 3121234 REVISON LOG Original Issue August 28 2006 Revised January 7 2013 Revised November 8 2016 Revised December 05 2017...

Page 5: ...erial Number Location 1 13 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 General 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection 2 1 Pre Delivery Inspect...

Page 6: ...13 Roll Leak and Brake Testing 3 13 Tightening and Torquing Bolts 3 13 Main Disassembly 3 14 Input Carrier Disassembly 3 16 Output Carrier Disassembly 3 17 Housing Spindle Disassembly 3 18 Spindle Br...

Page 7: ...mbly 3 90 3 17 Swing Motor Prior to SN 0300134352 3 92 Disassembly and inspection 3 92 Assembly 3 99 One Piece Stator Construction 3 106 3 18 Swing Hub SN 0300134352 through 0300189341 3 107 Roll Leak...

Page 8: ...87 EPR Assembly 3 187 Low Pressure Regulator LPR 3 188 Air Fuel Mixer 3 188 Electronic Throttle Control ETC 3 189 Engine Control Module 3 189 Heated Exhaust Gas Oxygen Sensor 3 190 Gasoline Multi Poin...

Page 9: ...aintenance 4 15 Snap Rings and Screws 4 17 4 5 Boom Cleanliness Guidelines 4 18 4 6 Main Boom Assembly 4 18 Removal 4 18 Disassembly 4 19 Inspection 4 27 Assembly 4 27 Installation 4 31 Telescope Cyli...

Page 10: ...Main Boom Lift Cylinder 5 9 Platform Level Cylinder 5 15 Steer Cylinder Prior to SN 0300142666 5 21 Steer Cylinder SN 0300142666 through 0300189340 5 26 Telescope Cylinder 5 32 5 3 Pressure Setting Pr...

Page 11: ...NFORMATION SCHEMATICS 7 1 General 7 1 7 2 Multimeter Basics 7 1 Grounding 7 1 Backprobing 7 1 Min Max 7 1 Polarity 7 1 Scale 7 1 Voltage Measurement 7 1 Resistance Measurement 7 2 Continuity Measureme...

Page 12: ...ssembly 3 16 3 12 Output Carrier Assembly 3 17 3 13 Housing Spindle Disassembly 3 18 3 14 Spindle Brake Disassembly 3 19 3 15 Input Carrier Sub Assembly 3 21 3 16 Output Carrier Sub Assembly 3 23 3 17...

Page 13: ...138 3 78 Swing Bolt Feeler Gauge Check 3 139 3 79 Swing Bearing Tolerance Measuring Point 3 139 3 80 Rotary Coupling Prior to SN 0300137913 Sheet 1 of 2 3 142 3 81 Rotary Coupling Prior to SN 0300137...

Page 14: ...3 130 EPR Assembly 3 198 3 131 Counterweight 3 211 4 1 Location of Components Platform Support 4 6 4 2 Platform Support Torque Values 4 8 4 3 Location of Components Rotator and Slave Cylinder 4 9 4 4...

Page 15: ...ng 5 13 5 27 Hydrolock Piston Seal Installation 5 14 5 28 Piston Seal Kit Installation 5 14 5 29 Rod Assembly Installation 5 14 5 30 Cylinder Barrel Support 5 15 5 31 Capscrew Removal 5 15 5 32 Cylind...

Page 16: ...t Locations 5 47 5 85 Load Sensing Control Adjustment 5 53 5 86 Pressure Compensation Control Adjustment 5 53 5 87 Shaft Seal and Retaining Ring 5 54 5 88 Control Assembly 5 54 5 89 Plug Locations Siz...

Page 17: ...ity Measurement 7 2 7 4 Current Measurement DC 7 3 7 5 Application to Plug Male Contacts 7 4 7 6 Use of Seal Plugs 7 5 7 7 Brad Harrison M12 7 6 7 8 Phoenix Contact M12 7 6 7 9 Connector Assembly Figu...

Page 18: ...GM SN 0300139080 through 0300161729 Sheet 8 of 10 7 33 7 42 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 9 of 10 7 34 7 43 Electrical Schematics Caterpill...

Page 19: ...Noise and or Vibration 3 73 3 6 System Operating Hot 3 73 3 7 Won t Shift or Slow to Start 3 73 3 8 Coupling Port Information Table Prior to SN 0300137913 3 141 3 9 Coupling Port Information Table SN...

Page 20: ...TITLE PAGE NO 6 5 Machine Personality Settings and Function Speeds 6 22 6 6 Function Speeds In Seconds 6 24 6 7 Adjustments Personality Descriptions 6 50 6 8 Diagnostic Menu Descriptions 6 52 6 9 Dia...

Page 21: ...ght PlatformEmpty 34 700lbs 15 740kg Withboominstowedposition Table 1 2 Specifications and Performance Data Swing 360 TailSwing 4ft 8in 1 42m Platforms 36in x72in 0 91mx1 83m 36in x96in 0 91mx2 44m Ov...

Page 22: ...90GPH 7 19lph 2 50GPH 9 46lph Horsepower 65 2800RPM fullload Table 1 6 Deutz D2011L04 Specifications SN 0300129454 to 0300189341 Type LiquidCooled Oil Fuel Diesel OilCapacity CoolingSystem Crankcase...

Page 23: ...C Table 1 10 Tire Specifications Size Type Ply Rating Load Range Weight Tire Wheel 15 625 Pneumatic 95psi 6 5Bar 16 H 269lbs 122kg 15 625 Foam Filled 16 H 544lbs 247kg 18 625 Pneumatic 85psi 5 9Bar 1...

Page 24: ...Grade 0 to 180 F 18 to 83 C 10W 0 to 210 F 18 to 99 C 10W 20 10W 30 50 to 210 F 10 to 99 C 20W 20 Table 1 13 Mobilfluid 424 Specs SAEGrade 10W30 ISOGrade 55 Gravity API 29 0 Density Lb Gal 60 F 7 35 P...

Page 25: ...t100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscosity Table 1 19 Component Weights Component Pounds Kilograms Turntable noother componen...

Page 26: ...SECTION 1 SPECIFICATIONS 1 6 3121234 1 3 8 6 4 2 2 17 18 19 9 10 11 12 13 14 15 16 5 3 7 Figure 1 1 Operator Maintenance and Lubrication Diagram...

Page 27: ...Lube MPG Interval Every 2 years or 1200 hours of operation 3 Wheel Drive Hub Lube Point s Level Fill Plug Capacity 17 oz 0 5 L 1 2 Full Lube EPGL Interval Check level every 3 months or 150 hrs of oper...

Page 28: ...nths or 300 hrs thereafter or as indicated by Condition Indi cator 6 Hydraulic Tank Lube Point s Fill Cap Capacity 116 liters Tank 124 liters System Lube HO Interval Check Level daily Change every 2 y...

Page 29: ...on Element JLG P N 7016331 Capacity 11 Quarts 10 5 L Crankcase Lube EO Interval Every Year or 1200 hours of operation Comments Check level daily Change in accordance with engine manual 11 Oil Change...

Page 30: ...int s Replaceable Element Interval Every 6 months or 300 hours of operation 17 Air Filter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the cond...

Page 31: ...LOW FREELY FROM THE REGULA TOR 1 Move the equipment to a well ventilated area Ensure there are no external ignition sources 2 Start the engine and bring to operating temperature 3 With the engine runn...

Page 32: ...INTO THE HOUSING BEFORE INSTALLING NEW SEAL 1 Install the mounting plate to lock off o ring seal 2 If equipped install the retaining bolt seal 3 Install the housing seal 4 Drop the magnet into the bo...

Page 33: ...anual shut off valve on the propane fuel tank 2 Start and run the vehicle until the engine stalls 3 Turn the ignition switch OFF RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM ENSURE THE W...

Page 34: ...SECTION 1 SPECIFICATIONS 1 14 3121234 Figure 1 4 Torque Chart SAE Fasteners Sheet 1 of 5 Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue...

Page 35: ...SECTION 1 SPECIFICATIONS 3121234 1 15 Figure 1 5 Torque Chart SAE Fasteners Sheet 2 of 5 Torq ue Tor que Torq ue Torqu e To rqu e...

Page 36: ...SECTION 1 SPECIFICATIONS 1 16 3121234 Figure 1 6 Torque Chart SAE Fasteners Sheet 3 of 5 Cl amp L oa d To rque To rqu e Torq ue Torqu e Tor que Torq ue...

Page 37: ...SECTION 1 SPECIFICATIONS 3121234 1 17 Figure 1 7 Torque Chart Metric Fasteners Sheet 4 of 5 To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue...

Page 38: ...SECTION 1 SPECIFICATIONS 1 18 3121234 Figure 1 8 Torque Chart Metric Fasteners Sheet 5 of 5 Torq ue To rqu e Tor qu e To rqu e To rqu e To rq ue...

Page 39: ...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 purchased used The f...

Page 40: ...containers 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 sho...

Page 41: ...ssary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usag...

Page 42: ...ined flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade m...

Page 43: ...tem perature Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature before beginning this test Measure drift at cylinder rod with a calibrated dial indicator In an area free of o...

Page 44: ...rease and oil Filament wound bearing are a dry joint and should not be lubricated c Pins should be inspected to ensure it is free of burrs nicks and scratches which would damage the bear ing during in...

Page 45: ...RetractChainorCableSystems 1 2 3 1 2 3 BoomAssembly 1 2 3 4 5 1 2 3 4 5 7 9 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...

Page 46: ...lic ElectricSystem HydraulicPumps 1 2 9 1 2 9 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...

Page 47: ...stallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwhenreleased 7 Cle...

Page 48: ...SECTION 2 GENERAL 2 10 3121234 Figure 2 1 Engine Operating Temperature Specifications Deutz 4150548 E...

Page 49: ...SECTION 2 GENERAL 3121234 2 11 Figure 2 2 Engine Operating Temperature Specifications Ford 4150548 E...

Page 50: ...SECTION 2 GENERAL 2 12 3121234 Figure 2 3 Engine Operating Temperature Specifications Caterpillar 4150548 E...

Page 51: ...SECTION 2 GENERAL 3121234 2 13 Figure 2 4 Engine Operating Temperature Specifications GM 4150548 E...

Page 52: ...SECTION 2 GENERAL 2 14 3121234 NOTES...

Page 53: ...or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by...

Page 54: ...ake sure machine is on a level surface 2 Center boom over rear axle to make sure the cam valve in the rotary coupling is depressed 3 Place chocks under the tires to ensure the machine does not move Re...

Page 55: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 3 This page left blank intentionally...

Page 56: ...13 13 13 13 3 2 15 15 15 13 13 13 14 14 14 24 25 6 8 13 23 22 21 28 27 13 13 23 4 10 20 20 21 12 17 18 19 7 14 16 10 30 30 29 14 15 24 25 25 26 24 14 11 11 9 5 24 Figure 3 1 Axle and Steering Install...

Page 57: ...Housing 8 Spindle 9 PivotPin 10 Washer 11 Bushing 12 Washer 13 Bolt 14 KeeperPin 15 TieRodPin 16 AttachPin 17 TangedWasher 18 BearingNut 19 DustCap 20 CupBearing 21 ConeBearing 22 LipSeal 23 KingPin...

Page 58: ...38 12 13 9 40 20 27 33 19 11 2 5 35 19 26 27 15 4 4 7 14 3 48 57 54 53 52 55 56 60 61 46 59 49 58 47 50 42 36 36 24 29 33 39 21 16 43 44 45 23 37 31 33 18 19 33 30 24 22 22 32 37 41 36 19 28 34 10 8 F...

Page 59: ...RH 26 SteerSpindleAttachPin LH 27 TieRodPin 28 Kingpin 29 AttachPin 30 Pin 31 HitchPin 32 Connectinglink 33 KeeperShaft 34 SpindleWeldment LH 35 SpindleWeldment RH 36 SpecialWasher 37 Thrustwasher 38...

Page 60: ...SECTION 3 CHASSIS TURNTABLE 3 8 3121234 1 4 5 7 6 2 3 1 DriveHub 2 DriveMotor 3 AxleLockoutCylinder 4 Axle 5 SteerCylinder 6 Spindle 7 FlowDividerValve Figure 3 5 Chassis Component Location...

Page 61: ...5 4 3 2 1 SwingDrive 2 RotaryCoupling 3 MainControlValve 4 Battery 5 AuxiliaryPowerPump 6 HydraulicOilTank 7 ReturnFilterAssembly 8 FuelTank 9 Engine 10 PistonPump 11 GearPump 12 HydraulicFilter 13 B...

Page 62: ...gh block with ascension ramp in front of right front wheel 9 Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block 10 With boom...

Page 63: ...gh the access holes in the axle tag and disconnect the hydraulic lines running to the drive motor and drive brake Cap or plug all openings to ensure no dirt enters the hydraulic system NOTE The drive...

Page 64: ...nd slide the drive brake over the studs with the brake port positioned as shown 3 Install a new o ring between the drive brake and drive motor and slide the drive motor over the studs Install the wash...

Page 65: ...eak if the pressure gauge read ing on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal...

Page 66: ...ing 9 from Spindle 1A end of unit 4 Remove Cover Bolts 14 and remove Cover 6 5 Remove O ring 19 and Thrust Spacer 10 from the Cover 6 6 Remove Input Sun Gear 17 from Input Carrier Sub Assembly 3A 7 Re...

Page 67: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 15 Figure 3 10 Main Disassembly Sheet 2 of 2 7 InputShaft 8 OutputSunGear 17 InputSunGear...

Page 68: ...drive the Planet Shaft 3E out of the Carrier 3A 2 Slide the Planet Gear 3F and the two Thrust Washers 3B out of the Carrier 3A 3 Remove the 14 needle Bearings 3C from the bore of the Planet Gear 3F 4...

Page 69: ...punch to remove the Roll Pin 4G from the Planet Shaft 4E 3 Slide the Planet Gear 4F and the two Thrust Washers 4B out of the Carrier 4A 4 Remove the 15 needle Bearings 4C from the bore of the Planet G...

Page 70: ...sing 1E flange press Spindle 1A out of Housing 1E The Seal 1B and B position Bearing Cone 1D should come out of Housing 1E with Spindle 1A 5 Remove A position Bearing Cone 1D from Bearing Cup 1D in Ho...

Page 71: ...ing NOTE The Pressure Plug 12 requires a special tool for installa tion It is not recommended to remove this plug unless it is leaking The plug is called a Koenig Expander The installa tion tool is no...

Page 72: ...between the ends of the two rollers that form the space and then slid parallel to the other rollers into place 3 Set Carrier 3A in an upright position 4 Insert a Planet Shaft 3E into the planet shaft...

Page 73: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 21 Figure 3 15 Input Carrier Sub Assembly 3A Carrier 3B ThrustWashers 3C NeedleBearings 3E PlanetShaft 3F PlanetGear...

Page 74: ...rier 4A 7 Set Carrier 4A in an upright position 8 Insert a Planet Shaft 4E into one of the planet shaft holes on the Carrier 4A The end of the planet shaft that does NOT have the roll pin hole should...

Page 75: ...ASSIS TURNTABLE 3121234 3 23 4A OutputCarrier 4B ThrustWasher 4C NeedleRollers 4E PlanetShaft 4F PlanetGear 4G RollPin 4H ThrustWasher 4I Spring 4J Washer 4K RetainingRing Figure 3 16 Output Carrier S...

Page 76: ...tor 2 9 6 Repeat steps 3 4 until there are a total of 8 Stators 2 9 and 7 Rotors 2 12 installed 7 Place Piston 2 8 such that the smaller O D end is facing upward 8 Grease the large Backup Ring 2 3 and...

Page 77: ...3 17 Spindle Brake Sub Assembly 1 A Spindle 12 PressurePlug 2 1 InternalCirclip 2 2 O ring 2 3 BackupRing 2 4 O ring 2 5 BackupRing 2 6 InternalCirclip 2 7 EndPlate 2 8 Piston 2 9 Stator 2 10 Spacer...

Page 78: ...e Bearing Spacer 1F on top of Bearing Cone 1D 9 Using retaining ring pliers install Retaining Ring 1G into Spindle 1A groove Make sure ring is completely seated in groove NOTE Extra bearing pre load c...

Page 79: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 27 Figure 3 18 Housing Spindle Assembly 1B Seal 1C BearingCups 1D BearingCone 1E Housing 1F BearingSpacer 1G RetainingRing 1H WheelStud...

Page 80: ...rawing at back of manual 4 With the modified spline end facing up place the Out put Sun Gear 8 into mesh with the planet gears from the Output Carrier Sub Assembly 4A 5 Place Input Carrier Sub Assembl...

Page 81: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 29 Figure 3 20 Main Assembly Sheet 2 of 2 6 Cover 9 InputCoupling 10 ThrustSpacer 14 CoverBolts 19 O ring...

Page 82: ...3 CHASSIS TURNTABLE 3 30 3121234 Figure 3 21 Assembly Drawing Without Integral Input Brake Sheet 1 of 2 14 3F 3C 3B 4E 4C 4F 4B 4G 1D 1C 12 16 DETAIL B 4I 4J 4K 9 1A 1B 1E 7 1F 1G 1H 4H 4A 3A 19 10 8...

Page 83: ...ssembly 16 O ringPipePlug 3E PlanetShaft 4G RollPin 10 ThrustSpacer 1F ThrustWasher 3C NeedleBearing 4B ThrustWasher 15 IdPlate 1E Housing RingGear 3B ThrustWasher 4H ThrustWasher 14 12PtFlangeBolt 1N...

Page 84: ...3 CHASSIS TURNTABLE 3 32 3121234 Figure 3 23 Assembly Drawing With Integral Input Brake Sheet 1 of 2 14 3F 3C 3B 4E 4C 4F 4B 4G 1D 1C 12 16 DETAIL B 4I 4J 4K 9 2 1A 1B 1E 7 1F 1G 1H 4H 4A 3A 19 10 8...

Page 85: ...ssurePlug 3F PlanetGear 4K RetainingRing Int 6 CoverSubassembly 16 O ringPipePlug 3E PlanetShaft 4G RollPin 10 ThrustSpacer 1F ThrustWasher 3C NeedleBearing 4B ThrustWasher 15 IdPlate 1E Housing RingG...

Page 86: ...SECTION 3 CHASSIS TURNTABLE 3 34 3121234 Figure 3 25 Assembly Tools Bearing Cone Pressing B Bearing...

Page 87: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 35 Figure 3 26 Assembly Tools Bearing Cone Pressing A Bearing...

Page 88: ...SECTION 3 CHASSIS TURNTABLE 3 36 3121234 Figure 3 27 Assembly Tools Bearing Cup Pressing A B Bearings...

Page 89: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 37 Figure 3 28 Assembly Tools Seal Pressing...

Page 90: ...SECTION 3 CHASSIS TURNTABLE 3 38 3121234 Figure 3 29 Assembly Tools Spacer Brake Disc Installation...

Page 91: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 39 Figure 3 30 Assembly Tools Brake Retaining Ring Installation...

Page 92: ...an Same sealing kit like shown above only seal material changed to Viton Drive shaft Bearing set miscellaneous parts Rotary group complete 9 pistons cylinder sub assembly valve plate cw or ccw corresp...

Page 93: ...ASSIS TURNTABLE 3121234 3 41 Replacing the Drive Shaft Seal 1 Remove snap ring 2 Change the shaft seal and check its sliding surface drive shaft and housing Grease the sealing ring Figure 3 31 Drive M...

Page 94: ...ws how to change the drive shaft seal ing ring but isn t the way of serial assembly the sealing ring is assembled together with the taper roller bearing from inside the pump housing normally to get a...

Page 95: ...he valve plate hold the valve plate so that the plate can t fall down 4 Remove the o ring 5 Disassemble the taper roller bearing near by port plate 6 Remove the adjustment shim 7 Unscrew the cap nut a...

Page 96: ...10 Disassemble the rotary group in horizontal position 11 Disassemble the stopper max flow 12 Remove the threaded pin stopper max flow 13 Disassemble the plug 14 Disassemble the control plate while mo...

Page 97: ...5 16 Disassemble the swashplate 17 Remove the spring 18 Remove both bearing shells 19 Remove the drive shaft 20 Disassemble the snap ring 21 Disassemble the sealing ring 22 The external front bearing...

Page 98: ...tional pretension while you disas semble the three pressure pins inside the cylinder Assembly 1 Assemble the variable displacement pump in reverse order 2 Measurement of the taper roller bearing prete...

Page 99: ...valve plate 4 decentered in counter clockwise position 5 Assembly of the port plate and pump housing NOTE The correct position of the drilling that connects high pres sure to the control valve Check...

Page 100: ...SECTION 3 CHASSIS TURNTABLE 3 48 3121234 NOTE Differential volume if you are rotating the threaded pin each rota tion is appr 3 1 cm3 Figure 3 33 Flow Control Pilot Valves...

Page 101: ...ed 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 Drive Motor Adjustment Procedure 1 Remove the cap nut from adjustment scre...

Page 102: ...running to the drive motor Cap or plug all openings to ensure no dirt enters the hydraulic system NOTE The drive hub and drive motor assembly weighs approxi mately 282 lbs 128 kg 4 Use a supporting d...

Page 103: ...ting cor rosion or excessive wear If necessary 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...

Page 104: ...spacer 16 from cluster gear bore and remove second set of sixteen needle rollers 15 f Repeat steps a through e for remaining two clus ter gears g Clean and inspect all parts in accordance with Cleani...

Page 105: ...fully remove retaining ring 33 from counter bore in the spindle 1 and discard retaining ring b Remove two spacers 31 and spring 32 from input shaft c Clean and inspect all parts in accordance with Cle...

Page 106: ...over end of spindle and into bear ing cup 6 Place bearing shim 8 over end of spindle and against bearing cone EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION 7 Install new retaining r...

Page 107: ...o ring 22 into hub counterbore Use petroleum or grease to hold o ring in place Slight stretching of o ring may be necessary to insure proper seating 15 Place carrier assembly on a flat surface with l...

Page 108: ...ll input gear 37 into carrier meshing with large diameter cluster gears 18 Counterbore in bore of input gear must be to outside of carrier assembly 19 After inserting at least one shoulder bolt in the...

Page 109: ...apart into counterbore 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 47 ft lbs 64 Nm 25 Place coupling 1 into spindle a...

Page 110: ...13 Carrier 14 ThrustWasher 15 NeedleRoller 16 Spacer 17 PistonShaft 18 ClusterGear 19 RollPin 20 NotUsed 21 ClusterGear 22 O ring 23 Cover 24 CoverCap 25 Bolt 26 DisconnectCap 27 DisconnectRod 28 O ri...

Page 111: ...earing 10 for axial float or wear 6 Examine o ring seals 15 17 and backing rings 16 18 for damage Assembly 1 Lightly lubricate rotary shaft seal 12 and assemble to housing 2 taking care not to damage...

Page 112: ...1 Shaft 2 Housing 3 FrictionPlate 4 PressurePlate 5 Gasket 6 OuterPlate 7 Gasket 8 Cylinder 9 Piston 10 BallBearing 11 RetainingRing 12 ShaftSeal 13 Capscrew 14 Lockwasher 15 O ring 16 BackupRing 17 O...

Page 113: ...e end cap voids warranty During assembly coat all moving parts with a film of clean hydraulic oil This assures that these parts will be lubricated during start up Replace all o rings and gaskets It is...

Page 114: ...al hex wrench remove drain plugs 19 20 Discard o rings 12 Using a 9 16 in internal hex wrench remove work port plugs 21 if equipped with axial ports Discard o rings 13 Using an 8 mm internal hex wrenc...

Page 115: ...ith a soft mallet on the splined end The grease will force the bearing out Use caution not to drive the bearing past the rear shaft journal as the bearing may become trapped on the shaft and damaged 1...

Page 116: ...Remove the snap ring 36 retaining the shaft front bearing Pull the bearing 37 off of the shaft 38 23 Turn housing over and remove the swashplate 39 by lifting on the end opposite the servo lever 24 R...

Page 117: ...and inner block spring washer 53 from the cylinder block Inspection After disassembly wash all parts including the end cap and housing thoroughly with clean solvent and allow to air dry Blow out oil p...

Page 118: ...surfacing will not reduce the thickness below the minimum specification SWASHPLATE AND JOURNAL BEARINGS Inspect the running face servo ball joint and swashplate jour nal surfaces for damage or excessi...

Page 119: ...et for damage or excessive wear Replace if necessary LOOP FLUSHING SPOOL Inspect the loop flushing spool Check for cracks or damage Replace if necessary Assembly 1 Install new o ring 1 and piston seal...

Page 120: ...e retainer seats on the ball guide If you re reusing the pistons install them to the original block bores Lubricate the pistons slippers retainer and ball guide before assembly Set the cylinder kit as...

Page 121: ...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 downward and...

Page 122: ...nd cap 25 onto the housing with the end capscrews 26 Check to ensure the end cap will prop erly seat onto the housing without interference Improper assembly of the internal components may prevent the...

Page 123: ...Install seal sup port 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 Se...

Page 124: ...pump and motor housing with clean hydraulic fluid Pour filtered oil directly into the upper most case drain port 4 To ensure the pump and motor stay filled with oil install case drain lines into the...

Page 125: ...oirandoil supplytothepump Insufficientamountofhydraulicfluidwillnotmeetthecoolingdemands ofthesystem Fillthereservoirtotheproperlevel Inspecttheheatexchanger ifso equipped Iftheheatexchangerfails orbe...

Page 126: ...ECT THE COMPONENTS Inspect the new seal the motor housing seal bore and the sealing area on the shaft for rust wear and contamination Pol ish the shaft and clean the housing if necessary INSTALLATION...

Page 127: ...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 spring...

Page 128: ...nect a line from the hydraulic power supply to the brake port 2 Pressurize the brake release port 155 to 200 psi 10 6 to 13 8 bar to release the brake 3 Verify that the brake is released by rotating t...

Page 129: ...g plate and mounting location of the turnta ble baseplate are clean and painted with a uniform coating of minimum thickness no runs drips etc Procedure for Setting Swing Gear Backlash Set backlash to...

Page 130: ...w until the pinion is completely snug against the shim and bearing and then back off the set screw 7 Apply JLG Threadlocker P N 0100019 and torque set screw 50 ft lbs 68 Nm 8 Apply JLG Threadlocker P...

Page 131: ...15 16 FRAME REF 1 Bolt 2 Bolt 3 JamNut 4 ShoulderBolt 5 Setscrew 6 Shim 7 Flatwasher 8 SwingMotor Hub 9 TurntableBearing 10 Bolt 11 Flatwasher 12 Pin 13 SnapPin 14 QuickReleaseRing 15 Chain 16 Hoseand...

Page 132: ...F Bearing cone 1D will remain on the same output shaft 1A The seal 1B will be auto matically removed during this procedure NOTE If bearing replacement is necessary the bearing cups can be removed with...

Page 133: ...on each large gear 3F and locate at 12 0 clock straight up from each planet pin Marked tooth will be located just under the carrier 3A on upper two gears 3F 6 With shoulder side of ring gear 4 facing...

Page 134: ...Thrust washer 11 is installed into the counterbore of the carrier 3 11 Place o ring 5 into cover 6 counterbore Use petro leum jelly to hold o ring in place BEWARE OF SHARP EDGES OF THE COUNTERBORE WH...

Page 135: ...This completes the assembly The unit must be filled one half full of EP 90 lubricant before operation if the unit is mounted horizontally and completely filled if mounted vertically In ver tical mount...

Page 136: ...stalled smooth face up and located just flush with the counterbore face 6 The bearing cone 1F is an interference fit and has to be pressed or tapped on 7 Pipe plugs 1J 1K should be checked and or inst...

Page 137: ...aft 1A twice with a piece of soft metal rod This will release the preload which was on the bearings This completes the hub shaft sub assembly items 1A through 1J If this assembly is not going to be us...

Page 138: ...not have slots and tangs should be located inside boss relief 6 While keeping thrust washers in place slide cluster gear into carrier with the larger gear on the side with the small pin hole 7 Line up...

Page 139: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 87 Figure 3 62 Swing Hub Prior to SN 0300134352...

Page 140: ...Check ball bearing 10 for axial float or wear 6 Examine o ring seals 15 17 and backing rings 16 18 for damage Assembly 1 Lightly lubricate rotary shaft seal 12 and assemble to housing 2 taking care no...

Page 141: ...ousing 3 FrictionPlate 4 PressurePlate 5 Gasket 6 OuterPlate 7 Gasket 8 Cylinder 9 Piston 10 BallBearing 11 RetainingRing 12 ShaftSeal 13 Capscrew 14 Lockwasher 15 O ring 16 BackupRing 17 O ring 18 Ba...

Page 142: ...ection of seal 3 Press bearing 18 into position until it bottoms out on borestep 4 Install retaining ring 20 in cover plate 16 5 Press shaft 9 into bearing 18 until it bottoms on the shoulder Bearing...

Page 143: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 91 Figure 3 64 Swing Brake...

Page 144: ...the Torqlink components from end cover 2 to housing 18 to facilitate reassembly orientation where required Loosen two shuttle or relief valve plugs 21 for disas sembly later if included in end cover 3...

Page 145: ...Ring 7 Manifold 8 RotorSet 8A Rotor 8B StatororStatorVane 8C Vane 8D StatorHalf 9 WearPlate 10 DriveLink 12 CouplingShaft 13 Bearing Bushing Inner 14 ThrustWasher 15 ThrustBearing 16 Seal 17 BackupWas...

Page 146: ...cover for cracks and the bolt head recesses for good bolt head sealing surfaces Replace end cover as necessary NOTE A polished pattern not scratches on the cover from rota tion of the commutator 5 is...

Page 147: ...acement the complete rotor set must be replaced as it is a matched set Inspect the warplane for cracks brinelling or scoring Discard seal ring 4 that is between the rotor set and wearplate NOTE The ro...

Page 148: ...card seal ring 4 from housing 18 13 Remove thrust bearing 11 from top of coupling shaft 12 Inspect for wear brinelling corrosion and a full complement of retained rollers 14 Check exposed portion of c...

Page 149: ...Inspect for wear brinelling corrosion and a full comple ment of retained rollers 18 Remove seal 16 and back up washer 17 from Small Frame housing 18 Discard both 19 Remove housing 18 from vise invert...

Page 150: ...s not pass inspec tion must be replaced If the housing has passed this inspection the disassembly of the Torqlink is com pleted NOTE The depth or location of bearing bushing 13 in relation to the hous...

Page 151: ...components were removed for replacement thoroughly coat and pack a new outer bearing bushing 19 with clean corrosion resistant grease recommended in the material section Press the new bearing bushing...

Page 152: ...sh to 0 03 in 0 76 mm below the housing wear plate contact face Use the opposite end of the bearing man drel that was used to press in the outer bearing bushing 19 3 Press a new dirt and water seal 20...

Page 153: ...R 25 WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER 17 NEW BACKUP WASHER 25 AND NEW SEAL 16 6 Assemble thrust washer 14 then thrust bearing 15 that was removed from the Torqlink NOTE Tor...

Page 154: ...al ring groove NOTE One or two alignment studs screwed finger tight into hous ing 18 bolt holes approximately 180 degrees apart will facilitate the assembly and alignment of components as required in...

Page 155: ...e original rotor drive link spline contact A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if a...

Page 156: ...to manifold 7 with seal ring side up 19 If shuttle valve components items 21 were removed from the end cover 2 turn a plug 21 loosely into one end of the valve cavity in the end cover A 3 16 in allen...

Page 157: ...components into place with a final torque of 22 26 ft lbs 45 55 ft lbs 61 75 Nm for the seven 3 8 24 threaded bolts NOTE The special bolts required for use with the relief or shuttle valve 24 end cove...

Page 158: ...0 splines NOTE If the manifold side of the rotor was etched during Torqlink disassembly this side should be up If the rotor is not etched and does not have a counterbore use the drive link spline cont...

Page 159: ...l after the unit has been pressurized and allowed to equalize 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 u...

Page 160: ...th ends of tube with a wrench 4 Using a wrench loosen 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 R...

Page 161: ...Remove O ring 26 from between Motor 31 and Brake 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...

Page 162: ...her 11 from between Brake Hous ing 6 and Carrier Subassembly 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 Thrus...

Page 163: ...G 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 remove the Bearing Cone...

Page 164: ...en the Planet Shaft is removed 2 Remove the 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 3...

Page 165: ...ft lbs 31 32 Nm Carrier Assembly NOTE Refer to Figure 3 70 Carrier 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 as...

Page 166: ...r gears 3F Be sure that cluster gear timing marks 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...

Page 167: ...80 100 ft lbs 108 136 Nm Motor Control Valve Assembly NOTE Refer to Figure 3 66 Motor Control Valve 1 Lay assembly down with motor ports facing up Remove the two plastic plugs in the motor ports bein...

Page 168: ...rnal Gear 3 Carrier Assembly 3A Carrier 3B Tanged Washer 3C Needle Bearing 3D Thrust Washer 3E Planet Shaft 3F ClusterGear 3G Rollpin 4 Ring Gear 5 O ring 6 O Ring 7 Brake Housing 8 Sun Gear 9 Thrust...

Page 169: ...Motor Assembly 23 Valve Assembly 24 Tube 26 O ring 27 Bolt 28 End Cover 29 Commutator Seal 30 Ring Seal 31 Commutator and Ring Assy 32 Ring 33 Manifold 34 Rotor Set 35 Wear Plate 36 Drive Link 37 Coup...

Page 170: ...n and across the Torqmo tor components from end cover 2 to housing 18 to facilitate reassembly orientation where required Loosen two shuttle or relief valve plugs 21 for disassembly later if included...

Page 171: ...Manifold 8 Rotor Set 8A Rotor 8B Stator or Stator Vane 8D Stator Half 9 Wear Plate 10 Drive Link 11 Not Used 12 Coupling Shaft 13 Bearing Bushing Inner 14 Thrust Washer 15 Thrust Bearing 16 Seal 17 Ba...

Page 172: ...are free of contamination Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces Replace end cover as necessary NOTE A polished pattern not scratches on the cover...

Page 173: ...from the coupling shaft 12 with the rotor set and wear plate You may have to shift the rotor set on the wear plate to work the drive link out of the rotor 8A and wear plate Inspect the rotor set in it...

Page 174: ...roller vane clearance with a feeler gage at this common centerline If there is more than 0 005 in 0 13 mm of clearance replace rotor set NOTE If rotor set 8 has two stator halves 8B 8D and two sets o...

Page 175: ...ear or corro sion and discoloration Inspect for damaged or worn internal and external splines or keyway Replace cou pling shaft if any of these conditions exist NOTE Minor shaft wear in seal area is p...

Page 176: ...al and washers 20 Remove housing 18 from vise invert it and remove and discard seal A blind hole bearing or seal puller is required 21 Inspect housing 18 assembly for cracks the machined surfaces for...

Page 177: ...s not pass inspec tion must be replaced If the housing has passed this inspection the disassembly of the Torqmotor is com pleted NOTE The depth or location of bearing bushing 13 in relation to the hou...

Page 178: ...components were removed for replacement thoroughly coat and pack a new outer bearing bushing 19 with clean corrosion resistant grease recommended in the material section Press the new bearing bushing...

Page 179: ...h to 0 03 in 0 76 mm below the housing wear plate contact face Use the opposite end of the bearing man drel that was used to press in the outer bearing bush ing 19 3 Press a new dirt and water seal 20...

Page 180: ...ing 18 if they were not assembled in procedure 2 ORIGINAL DESIGN LARGE FRAME TF TG TORQMOTORS THAT DO NOT HAVE BACKUP WASHER 25 WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER 17 NEW BACK...

Page 181: ...NOTE The coupling shaft 12 will be flush or just below the hous ing wear plate surface on Torqmotors when properly seated The coupling shaft must rotate smoothly on the thrust bearing package 9 Apply...

Page 182: ...t stator 8B 13 Install the assembled rotor set 8 onto wear plate 9 with rotor 8A counterbore and seal ring side down and the splines into mesh with the drive link splines NOTE It may be necessary to t...

Page 183: ...inside diameter The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set 15 Assemble the manifold 7 over the alignment studs and...

Page 184: ...he 5 threaded holes in housing 18 The correct 5 bolt end cover bolt hole relationship to housing port bosses 20 Assemble the 5 or 7 special bolts 1 and screw in finger tight Remove and replace the two...

Page 185: ...service parts lists or parts list charts for correct service part number if replacement is required 21 Torque the two shuttle valve plug assemblies 21 in end cover assembly to 9 12 ft lbs 12 16 Nm if...

Page 186: ...0 splines NOTE If the manifold side of the rotor was etched during Torqmo tor disassembly this side should be up If the rotor is not etched and does not have a counterbore use the drive link spline co...

Page 187: ...e between the bolt and hardened washer at the arrow indicated posi tion c Ensure that the 0 0015 in feeler gauge will not pen etrate under the bolt head to the bolt shank d Swing the turntable 90 degr...

Page 188: ...SECTION 3 CHASSIS TURNTABLE 3 136 3121234 Figure 3 75 Swing Bearing Tolerance Boom Placement Sheet 1 of 2 BOOM FULLY ELEVATED MEASURING POINT...

Page 189: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 137 Figure 3 76 Swing Bearing Tolerance Boom Placement Sheet 2 of 2 BOOM FULLY EXTENDED AT HORIZONTAL 0 DEGREES MEASURING POINT...

Page 190: ...moval CG C ROTATION 21 53 4 cm Gross Weight 21600 lbs 9798 kg Upper Works above Turntable Bearing Hole in T T L NOTE DO NOT LIFT BOOM 680 S NOTE CG location may vary slightly depending on the exact co...

Page 191: ...HIS PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION Swing Bearing Removal 1 From Ground Control station operate the boom ade quately to provide access to frame opening to ro...

Page 192: ...the new bearing bolts Then apply a light coating of JLG Threadlocker P N 0100019 to the new bearing bolts and install the bolts and wash ers through the frame and outer race of the bearing Tighten th...

Page 193: ...14 in direction shown in Figure 3 81 Rotary Coupling Prior to SN 0300137913 Sheet 2 of 2 7 Reassemble O ring 18 8 Heat cap seals 17 in hydraulic oil for 5 minutes at 300 F 149 C 9 Assemble cap seals...

Page 194: ...SECTION 3 CHASSIS TURNTABLE 3 142 3121234 DETAIL A 1 RotaryCoupling 2 TorqueLug 3 Locknut 4 Flatwasher 5 Bolt 6 Nut 7 Bracket Figure 3 80 Rotary Coupling Prior to SN 0300137913 Sheet 1 of 2...

Page 195: ...g 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 3 81 Rot...

Page 196: ...SECTION 3 CHASSIS TURNTABLE 3 144 3121234 Figure 3 82 Rotary Coupling Port Location Prior to SN 0300137913 5 1660303 B...

Page 197: ...m end 3 Remove thrust ring 6 from the same end 4 Remove center body 1 from housing 3 5 Cut off old seals 2 4 5 6 Remove proximity switch 7 Assemble lip seals 2 in direction shown in Figure 3 83 Rotary...

Page 198: ...146 3121234 10 9 2 1 8 4 5 6 7 3 1 CenterBody 2 Seal 3 Housing 4 O ring 5 Seal 6 ThrustRing 7 SnapRing 8 ValveBlock AxleOscillation 9 O ring 10 ProximitySwitch Figure 3 84 Rotary Coupling Cutaway SN...

Page 199: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 147 Figure 3 85 Rotary Coupling Port Location SN 0300137913 through 0300189341 7 1001106974 B...

Page 200: ...er 10 Washer 11 Seal 12 O ring 13 CapSeal 14 ThrustRing 15 RetainingRing 16 Plug 17 TorqueLug 18 Capscrew 19 O ring 20 O ring 21 Bearing 22 Plug 23 CheckValve 24 PlungerValve 25 Spring 26 Seal 27 Brac...

Page 201: ...hours of service blow out the inside of the genera tor If operating in a hostile environment clean monthly Table 3 9 Coupling Port Information Table SN 0300137913 through 0300189341 Port No Outlets Po...

Page 202: ...ings View alignment through the air vents in the stator barrel The brushes must ride completely on the slip rings INSPECTING BRUSHES Remove the end panel Inspect the wires Remove the brush holder asse...

Page 203: ...eplace 2 7 16 in 1 2 in 11 12 mm New 3 2 3 Brushes must ride completely on slip rings Acceptable Unacceptable Brush Position On Slip Rings Figure 3 87 Inspecting Generator Brushes Replacing Brushes an...

Page 204: ...assembly 3 Disassemble generator parts shown in Figure 3 88 4 Clean all parts with approved solvent and dry with com pressed air if applicable 5 Inspect all part for damage Replace if necessary ASSEM...

Page 205: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 153 This page left blank intentionally...

Page 206: ...SECTION 3 CHASSIS TURNTABLE 3 154 3121234 Figure 3 89 Generator Troubleshooting Circuit Diagram Sheet 1 of 2...

Page 207: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 155 Figure 3 90 Generator Troubleshooting Circuit Diagram Sheet 2 of 2...

Page 208: ...SECTION 3 CHASSIS TURNTABLE 3 156 3121234 Figure 3 91 Generator Electrical Circuit Diagram...

Page 209: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 157 Figure 3 92 Power Board PC1 Electrical Circuit Diagram...

Page 210: ...SECTION 3 CHASSIS TURNTABLE 3 158 3121234 Figure 3 93 Power Board PC2 Electrical Circuit Diagram Sheet 1 of 2...

Page 211: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 159 Figure 3 94 Power Board PC2 Electrical Circuit Diagram Sheet 2 of 2...

Page 212: ...6B PLG2 D TOPLG4 4 6C RC2 D PLG31 9 9A RC5 B TOPLG3 B CustomerSupplied 9B RC3 B PLG1 8 12A PLG2 E TOPLG4 5 12B RC2 E PLG1 9 12C RC4 5 TOBRUSH 13A PLG2 F TOPLG4 6 13B RC2 F PLG31 4 13C RC4 6 TOBRUSH 1...

Page 213: ...gtobrushes andbrushpositiononsliprings Installnewbrushesifnecessary Disconnectleads12and13frombrushes andcheckcontinuityacrossslipringsnominalreadingis26ohms Replacegeneratorifrotorisopen Disconnectst...

Page 214: ...dule 9 RadiatorHose Bottom 10 Radiator 11 RadiatorMountingPlate 12 EngineMountPlate 13 OilFilter 14 FuelInjectionPump 15 Adaptor 16 Coupling 17 Flywheel 18 MufflerBracket 19 EngineMountPlate Rear 20 M...

Page 215: ...33 34 36 31 30 29 35 34 29 Tray 30 BatteryHold down 31 Battery 32 FlexTrim 33 PivotPin 34 Relay 35 FuelPump 36 ExhaustTubeWeldment 37 HitchPin Figure 3 96 Caterpillar Tier IVi Engine Assembly Sheet 2...

Page 216: ...ffler 9 EngineMountPlate FrontLeft 10 EngineMountPlate FrontBottom 11 EngineMountPlate FrontRight 12 EngineMountPlate Rear 13 Coupling 14 GlowPlug 15 InjectorPump 16 ExhaustTube 17 Flywheel 18 PumpAda...

Page 217: ...1 39 40 26 Tray 27 EMR2ControllerModule 28 Battery 29 BatteryHold down 30 HitchPin 31 PivotPin 32 Relay 33 FlexTrim 34 FuelPump 35 Relay 36 FuelFilter 37 OilFilter 38 Thermostat 39 FuelIn lineFilter 4...

Page 218: ...se Bottom 7 AirCleanerAssembly 8 IntakeTube 9 OilDrainValve 10 Muffler 11 ModuleControl 12 OilFilter 13 Coupling 14 PistonPumpAssembly 15 LoadSensingPumpAssembly 16 HitchPin 17 RubberPanel 18 Pin 19 T...

Page 219: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 167 26 Figure 3 100 GM Engine 3 0L Tier III IV Installation Sheet 2 of 2 26 FuelFilter RETURN ON FUEL TANK TO ENGINE TO LP FUEL SHUT OFF 1001114634 F...

Page 220: ...en pulled on The lamp and glow plugs will remain ener gized for the period of time specified by the setting in the JLG Control System Engine start shall be disabled during this period On Deutz engines...

Page 221: ...gine HOT ENGINE OIL CAN CAUSE BURNS AVOID CONTACT WITH HOT OIL WHEN DRAINING COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMEN...

Page 222: ...lube oil fil ter element and spin off 3 Catch any escaping oil 4 Clean any dirt from filter carrier sealing surface 5 Lightly coat new oil filter rubber gasket with clean oil 6 Manually screw in the...

Page 223: ...of the engine and the preconditions throttle position etc the EMR2 controls an actuator that operates the control rod of the injection pump and thus doses the fuel quantity in accordance with the per...

Page 224: ...SECTION 3 CHASSIS TURNTABLE 3 172 3121234 Figure 3 103 EMR 2 Engine Side Equipment...

Page 225: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 173 Figure 3 104 Deutz EMR 2 Troubleshooting Flow Chart...

Page 226: ...SECTION 3 CHASSIS TURNTABLE 3 174 3121234 Figure 3 105 Deutz EMR 2 Vehicle Side Connection Diagram...

Page 227: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 175 Figure 3 106 Deutz EMR 2 Engine Side Connection Diagram Sheet 1 of 2...

Page 228: ...SECTION 3 CHASSIS TURNTABLE 3 176 3121234 Figure 3 107 Deutz EMR 2 Engine Side Connection Diagram Sheet 2 of 2...

Page 229: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 177 Figure 3 108 EMR 2 Engine Plug Pin Identification...

Page 230: ...SECTION 3 CHASSIS TURNTABLE 3 178 3121234 Figure 3 109 EMR 2 Vehicle Plug Pin Identification...

Page 231: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 179 Figure 3 110 EMR2 Fault Codes Sheet 1 of 5...

Page 232: ...SECTION 3 CHASSIS TURNTABLE 3 180 3121234 Figure 3 111 EMR2 Fault Codes Sheet 2 of 5...

Page 233: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 181 Figure 3 112 EMR2 Fault Codes Sheet 3 of 5...

Page 234: ...SECTION 3 CHASSIS TURNTABLE 3 182 3121234 Figure 3 113 EMR2 Fault Codes Sheet 4 of 5...

Page 235: ...SECTION 3 CHASSIS TURNTABLE 3121234 3 183 Figure 3 114 EMR2 Fault Codes Sheet 5 of 5...

Page 236: ...the Positive and Negative battery cables for any cor rosion build up rubbing or chafing check connection on the chassis to insure they are tight Check the entire engine wire harness for rubbing chafin...

Page 237: ...o not over tighten 6 Check the sealing ring on drain plug for any damage replace if necessary wipe the plug with a clean rag and wipe the sealing surface on the pan and reinstall the pan plug Do not o...

Page 238: ...e engine off and continue to step 5 WITH THE ENGINE RUNNING OR WHEN SHUTTING OFF THE ENGINE SOME HEATED COOLANT MAY SPILL OUT DUE TO AIR BURPING OUT OF THE SYS TEM WITH THE RADIATOR CAP OFF 5 Next ver...

Page 239: ...el like all other motor fuels is subject to contamina tion from outside sources Refueling of the equipment s tank and removal of the tank from the equipment can inadver tently introduce dirt and other...

Page 240: ...CE IT WITH AN OEM REPLACEMENT PART ONLY Air Fuel Mixer The air valve mixer is an air fuel metering device and is com pletely self contained The mixer is an air valve design utiliz ing a relatively con...

Page 241: ...imum effect from the catalyst and accurate con trol of the air fuel ratio the emission certified engine is equipped with an onboard computer or Engine Control Unit ECM The ECM is a 32 bit controller w...

Page 242: ...R STREAM OR FUEL LINES Gasoline Multi Point Fuel Injection System MPFI The primary components of the Gasoline Multi Point Fuel Injection MPFI fuel system are the fuel tank electric fuel pump fuel pres...

Page 243: ...frequent then when the engine is operating at higher RPMs The engine has been cali brated to deliver the precise amount of fuel for optimum per formance and emission control 3 28 GM ENGINE FUEL SYSTE...

Page 244: ...AGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL 1 Install the mounting plate to lock off o ring seal 2 Install the retaining bolt seal 3 Install the housing seal 4 Drop the magnet into the bottom of...

Page 245: ...the 3 three nuts from the EPR isolators and the EPR mounting bracket 12 Remove the EPR from the bracket 13 Remove the 3 three mounting isolators INSTALLATION DO NOT USE TEFLON TAPE ON ANY FUEL FITTING...

Page 246: ...OF THE ACTUATOR SECTION PRESSURE REGULATOR SECTION INSTALLATION 1 Install the regulator to the actuator section using the six 6 retaining screws and tighten 70 in lbs 8 Nm 2 Install the EPR refer to...

Page 247: ...er assembly 7 Pull the throttle body assembly from the adapter 8 Remove electronic throttle control device 9 Remove the o rings gasket and discard INSTALLATION LIGHTLY LUBRICATE BOTH THROTTLE CONTROL...

Page 248: ...ontrol Device Replacement 4 Start the engine and leak check all fittings and connec tions Coolant Hose Replacement REMOVAL 1 Drain the coolant 2 Using hose clamp pliers disconnect both hose clamps on...

Page 249: ...ery cable 5 Start engine 6 Check for any DTC codes and clear 7 Verify engine is in closed loop and no warning lights are illuminated Heated Exhaust Gas Oxygen Sensor Replacement REMOVAL 1 Disconnect N...

Page 250: ...y chamber of the LPR by the vacuum generated by air flowing through the mixer This vacuum signal is also used to generate lift for the mixer air valve This vacuum signal is most commonly referred to a...

Page 251: ...leak age 3 Inspectanyvacuumhosesforleaks Wasaproblemfoundandcorrected GotoStep26 GotoStep22 8 1 Connectawatercolumngaugeoramanometertothesecondarytestportofthelowpressure regulator LPR 2 Cranktheengin...

Page 252: ...restricted locateandrepairtheproblem Istheactioncomplete GotoStep26 19 Replacethefuelfilter RefertoFuelFilterReplacement Istheactioncomplete GotoStep26 20 Repairtheopeninthelock offgroundcircuit Isthe...

Page 253: ...itionwiresforthefollowingconditions Cracking Hardness Properrouting Carbontracking Checkthewiringforthefollowingitems Properconnections pinchesorcuts Thefollowingsymptomtablescontaingroupsofpossibleca...

Page 254: ...Checkbatterypower ignitionpowerandgroundcircuitstotheECM RefertoEngineControlSchematics Verifyvoltageand orcontinuityfor eachcircuit SensorChecks ChecktheTMAPsensor ChecktheMagneticpickupsensor RPM F...

Page 255: ...forairintakesystemleakagebetweenthemixerandthethrottlebody Checkthefuelsystempressures RefertotheFuelSystemDiagnosis IgnitionSystemChecks Note LPGbeingagaseousfuelrequireshighersecondaryignitionsystem...

Page 256: ...kvalvesprings Checktheintakeandexhaustmanifoldpassagesforcastingflash FuelSystemChecks Checkthefuelsystem pluggedfuelfilter lowfuelpressure etc RefertoLPGFuelSystemDiagnosis Checktheconditionofthewiri...

Page 257: ...Checktheconnectionateachignitioncoil Checkfordeterioratedsparkplugwireinsulation Checkthesparkplugs ThecorrectsparkplugsforLPGare R42LTS Removetheplugsandinspectthemforthefollowingconditions Wetplugs...

Page 258: ...llowingitems Visuallyandphysically inspectallelectricalconnectionswithinthesuspectedcircuitand orsystems Checkthescantooldata PoorFuelEconomy DEFINITION Fueleconomy asmeasuredbyrefuelingrecords isnoti...

Page 259: ...allationandconnection IgnitionSystemChecks CheckfortheproperignitionoutputvoltageusingthesparktesterJ26792ortheequivalent VerifythatthesparkplugsarecorrectforusewithLPG R42LTS Checkthesparkplugs Remov...

Page 260: ...ein linefuelfilterforrestrictions IgnitionSystemChecks CheckfortheproperignitionoutputvoltageusingthesparktesterJ26792ortheequivalent VerifythatthesparkplugsarecorrectforusewithLPG R42LTS Checkthespar...

Page 261: ...en Inactive 520208 10 171 AdaptiveLearnHighGasoline 520200 0 172 AdaptiveLearnLowGasoline 520200 1 182 FuelTempGasolineLowVoltage 174 4 183 FuelTempGasolineHighVoltage 174 3 187 FuelTempLPGLowVoltage...

Page 262: ...arnLowLPG 520202 1 1165 LPGCatMonitor 520213 10 1171 LPGPressureHigherThanExpected 520260 0 1172 LPGPressureLowerThanExpected 520260 1 1173 EPRCommLost 520260 31 1174 EPRVoltageSupplyHigh 520260 3 117...

Page 263: ...emoved ensure the retaining bolts are torqued to the proper value as shown in Figure 3 131 Counterweight B C B C B C B C A A A CounterweightCasting B ApplyJLGThreadlockerP N0100019toBoltThreadsandtoTh...

Page 264: ...SECTION 3 CHASSIS TURNTABLE 3 212 3121234 NOTES...

Page 265: ...9 1 Remove hardware securing cover to the platform sup port Remove cover 2 Remove hardware securing the mounting bracket to the platform support Take out the mounting bracket along with platform contr...

Page 266: ...m control valve onto the mounting bracket and secure using hardware 2 Install the mounting bracket onto the platform support and secure using hardware 3 Install cover onto the platform support and sec...

Page 267: ...hydraulic lines and ports 2 Remove hardware securing high pressure filter to filter mounting bracket Remove high pressure filter 3 Remove hardware securing filter mounting bracket to valve mount Remov...

Page 268: ...lve to the mounting bracket Remove platform control valve Platform Valve Installation SN 0300141319 through 0300189341 1 Install platform control valve onto the mounting bracket and secure using hardw...

Page 269: ...e with mounting hardware 4 Install filter mounting bracket on side of valve mount and secure with mounting hardware 5 Install high pressure filter onto filter mounting bracket and secure with mounting...

Page 270: ...pproximately 134 5 lbs 61 kg 3 Using a suitable device support the platform support NOTE The platform support weighs approximately 135 lbs 61 kg 4 Remove the bolts and locknuts securing the support to...

Page 271: ...olt 3 Apply JLG Threadlocker P N 0100011 to the eight bolts and locknuts securing the support to the rotator and install the bolts and locknuts 4 Torque the nut on the rotator center bolt to 586 ft lb...

Page 272: ...orqueto40ft lbs 55Nm JLGThreadlockerP N0100011 Torqueto586ft lbs 795Nm Checktorqueevery150hoursofoperation Torqueto75ft lbs 102Nm Figure 4 2 Platform Support Torque Values NOTE If any rotator bolts ar...

Page 273: ...the fly boom and remove slave cyl inder 6 Tag and disconnect hydraulic lines to the slave cylinder Use a suitable container to retain any residual hydraulic fluid Cap hydraulic lines and ports Remove...

Page 274: ...tube on the fly boom section 7 Remove bolt 2 securing the push tube on the mid boom section 8 With powertrack supported and using all applicable safety precautions remove bolts 3 4 and 5 securing rail...

Page 275: ...SECTION 4 BOOM PLATFORM 3121234 4 11 Figure 4 5 Powertrack Installation Main Boom Sheet 1 of 2 0271990 E HOSE AND CABLE CARRIER POWER TRACK SUPPORT...

Page 276: ...234 Figure 4 6 Powertrack Installation Main Boom Sheet 2 of 2 0271990 E HOSES AND CABLES SHOULD NOT BE PULLED TIGHT AGAINST THE INSIDE RADIUS OF THE POWER TRACK HOSES AND CABLES SHOULD BE AGAINST THE...

Page 277: ...ntenance 1 Place the powertrack on a workbench 2 Remove the screws from the bars on one side of the powertrack on the first link 3 Remove the screws from the flat bar on the other side of the powertra...

Page 278: ...1234 5 Slide the poly roller off of the round bar 6 Hold the round bar to remove the other screw 7 Slide the flat bar out 8 Remove the snap ring from one side of the bracket 9 Remove the snap ring fro...

Page 279: ...and slide the bracket side up and over the extrusion on the link 11 Repeat the previous step on the other side 12 Slide the bracket off of the powertrack Two Piece Bracket Maintenance 1 Loosen the scr...

Page 280: ...SECTION 4 BOOM PLATFORM 4 16 3121234 4 Hold the flat bar and remove the screws 5 Remove the snap rings and pins 6 Remove the screws from the bar Remove the snap ring and pin 7 Slide the link out...

Page 281: ...properly Make sure that all snap rings are closed and seated An open snap ring is shown below A snap ring that is not seated is shown below A seated and closed snap ring is shown below 10 24 x 0 812 b...

Page 282: ...t dislodge the debris then water with mild solvents applied via a pressure washer can be used Again the method is to wash the debris toward the nearest exiting point from the boom Make sure that all d...

Page 283: ...f upright and lower to ground or suitably supported work surface Disassembly NOTE The following procedure assumes the boom is removed from the machine 1 Extend the boom approximately 2 ft 0 6 m This w...

Page 284: ...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 M...

Page 285: ...SECTION 4 BOOM PLATFORM 3121234 4 21 This page left blank intentionally...

Page 286: ...SECTION 4 BOOM PLATFORM 4 22 3121234 Figure 4 7 Boom Assembly Cutaway Sheet 1 of 2 10 15 12 6 9...

Page 287: ...way Sheet 2 of 2 4 8 5 14 13 2 3 11 7 1 1 BaseBoom 2 MidBoom 3 FlyBoom 4 TelescopeCylinder 5 ExtendSheave 6 RetractSheave 7 SheaveBlock 8 ExtendCable 9 RetractCable 10 ExtendCableAdjustment 11 Retract...

Page 288: ...24 3121234 Figure 4 9 Boom Components Sheet 1 of 2 1 PivotPin 2 TimingLink 3 TowerWeldment 4 TensionLink 5 BoomPivotPin 6 Upright 7 LiftCylinderPivotPin 8 TowerPin 9 LevelLinkPin 1 2 3 4 5 6 9 8 7 2 3...

Page 289: ...mponents Sheet 2 of 2 1 PivotPin 2 TensionLinkPivotPin 3 LiftCylinderPivotPin 4 LevelCylinderAttachPin 5 LevelCylinder 6 LevelCylinderPivotPin 7 Rotator SEE DETAIL A SEE DETAIL B SEE DETAIL C DETAIL A...

Page 290: ...d of mid boom section remove the wear pads from the top sides and bottom of the mid boom sec tion 12 Remove hardware which secures the sheave guards and sheave assemblies to mid boom section remove sh...

Page 291: ...nsure pin sur faces are protected prior to installation Replace pins as necessary 8 Inspect inner diameter of boom pivot bushing for scor ing distortion wear or other damage Replace bearing as necessa...

Page 292: ...t NOTE To avoid damaging the proximity switch install and adjust the switch AFTER assembling the switch block and compression spring and after torquing the wire ropes To adjust the proximity switch th...

Page 293: ...ctions Shim boom if necessary for a total of 1 16 in 1 6 mm clearance 12 Install wear pads into the forward position of the base boom section Shim boom if necessary for a total of 2 10 in 5 mm clearan...

Page 294: ...r P N 0100011 to the bolts and fasten the telescope cylinder rod to the boom base sec tion with the bolts shims mounting blocks 22 Using a 3 8 drive extension approximately 4 ft 1 2 m long install the...

Page 295: ...able lifting device align main lift cylinder rod end with mounting holes on boom assembly 6 Extend the main lift cylinder by using the auxiliary power switch Using a suitable brass drift and hammer in...

Page 296: ...the boom base sec tion 7 Remove the four bolts shims and attachment blocks that secure the telescope cylinder barrel to the boom mid section WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM IT MAY B...

Page 297: ...of the retraction cables to remove the ends of the cables from the slots in the side of the boom fly section 13 From the rear of the boom pull out the boom retraction cables Telescope Cylinder Boom Ca...

Page 298: ...old the cable in place yet weak enough to break and fall away when the cables are adjusted WHEN PUSHING THE TELESCOPE CYLINDER INTO THE BOOM IT MAY BE NEC ESSARY AT SOME POINT TO TURN THE CYLINDER SLI...

Page 299: ...ined under Section 4 9 Boom Rope Torquing Procedures 15 Run the boom through all lift and telescope functions and check for proper operation or any leakage 4 7 MAIN LIFT CYLINDER Removal 1 Elevate the...

Page 300: ...o remove it from the machine Installation 1 Using an adequate lifting device position the lift cylin der in the machine in the same manner that it was removed NOTE The lift cylinder weighs approximate...

Page 301: ...ion 1 Remove boom covers and visually with flashlight inspect the ropes for rust broken wires frays abuse or any signs of abnormalities 2 Check rope tension by deflecting the ropes by hand Properly te...

Page 302: ...amage the wire rope 5 Repeat the torque procedure in step 4 to the extend wire ropes turntable end 6 Extend the boom 2 3 ft using the telescope function Repeat step 4 7 Retract the boom 1 2 ft using t...

Page 303: ...ort Length Switch 3 Boom Transport Length Switch to trip when boom is 18 1 from fully retracted 4 Boom Capacity Angle Switch to trip when upper boom is 50 to 55 above horizontal 52 is the preferred tr...

Page 304: ...gure 4 18 Elevation Dual Capacity and Transport Switch Information Prior to SN 0300103969 Sheet 2 of 2 0271360 K BOOM CAPACITY ANGLE SWITCH ANSI Only BOOM ELEVATION SWITCH BOOM CAPACITY LENGTH SWITCH...

Page 305: ...sections to trip Transport Length Switch 2 Boom Transport Length Switch to trip when boom is 18 1 from fully retracted 3 Boom Elevation Switch to trip when main boom is 7 to 12 above horizontal 9 is...

Page 306: ...Figure 4 20 Elevation Dual Capacity and Transport Switch Information SN 0300103969 through 0300189341 Sheet 2 of 2 1001091187 E DETAIL B DETAIL A BOOM ELEVATION SWITCH BOOM TRANSPORT LENGTH SWITCH ROU...

Page 307: ...function and a control module that interprets the sensor readings and actuates the lev eling valves PRIMARY AND SECONDARY TILT SENSOR INTERACTION Two tilt sensors mounted on each side of the platform...

Page 308: ...TION COVER SHOWN IN PHANTOM FOR CALRITY SWITCH 1 Figure 4 21 Level Switches 0273695 D SWITCH 1 PIN DESCRIPTION SWITCH HARNESS PIN 1 POWER RED RED PIN 2 PWMOUT GREEN BLUE PIN 3 GROUND BLACK BLACK SWITC...

Page 309: ...the sensors in real time would cause constant correction of the platform position due to machine vibration and inertial changes of the boom Therefore the sensor readings are averaged over time or filt...

Page 310: ...tomatic platform angle con trol will remain active as the control system will use the other sensor to control leveling 2 The level system fault lamp will flash to indicate that the leveling function h...

Page 311: ...mode except while below elevation When both sensors appear to be working but have measure ments that disagree by 5 5 The following will occur 1 All interactions with platform leveling shall cease 2 T...

Page 312: ...bration Procedure STEP 1 SETTING THE PLATFORM VALVE MINIMUMS 1 Put machine into Ground Mode 2 Start machine and plug in Analyzer 3 Go to the Access Level 2 screen 4 Enter 33271 to get into Access Leve...

Page 313: ...in the platform from the valve opening during a leveling operation the crack point is likely too high for this machine A high crack point may also lead to over leveling causing the platform to drift...

Page 314: ...position The shaft is supported radially by the large upper radial bearing and the lower radial bearing Axially the shaft is separated from the housing by the upper and lower thrust washers The end ca...

Page 315: ...haft 3 PistonSleeve 4 EndCap 109 LockPin 113 Capscrew 200 T Seal 202 T Seal 204 O ring 205 CupSeal 207 BackupRing 302 WearGuide 304 ThrustWasher 304 1 WiperSeal 400 CounterbalanceValve 401 Counterbala...

Page 316: ...rew 103 2 Washer 106 1 PortPlug 106 2 PortPlug 109 LockPin 113 Capscrew SEALS 200 T Seal 202 T Seal 204 O ring 205 CupSeal 207 BackupRing BEARINGS 302 WearGuide 304 ThrustWasher 304 1 WiperSeal ACCESS...

Page 317: ...ar guides Directions on making a seal tool are provided at bottom 15 Punch 16 Dowel Pins Removal and installation of end cap Making a Seal Tool The seal tool is merely a customized standard flat head...

Page 318: ...havings 2 Remove the capscrews 113 over end cap lock pins 109 3 Using a 1 8 in 3 18 mm drill bit drill a hole in the cen ter of each lock pin to a depth of approximately 3 16 in 4 76 mm 4 Remove the l...

Page 319: ...00 if equipped with one The stop tube is an available option to limit the rotation of the actuator 9 Every actuator has timing marks for proper engage ment 10 Prior to removing the shaft 2 use a felt...

Page 320: ...ing marks on the housing 1 ring gear the piston 3 and the shaft 2 13 To remove the piston 3 use a rubber mallet and a plas tic mandrel so the piston is not damaged 14 At the point when the piston gear...

Page 321: ...razor blade being careful not to damage the seal groove 18 Remove the thrust washers 304 from the end cap 4 and shaft 2 19 Remove the wiper seal 304 1 from it s groove in the end cap 4 and shaft 2 20...

Page 322: ...bearing grooves thrust surfaces rod surface housing bore and gear teeth 2 Inspect the thrust washers 304 for rough or worn edges and surfaces Measure it s thickness to make sure it is within specific...

Page 323: ...o shaft 2 and end cap 4 3 Install the wiper seal 304 1 green O ring into the groove on the shaft 2 and end cap 4 around the out side edge of the thrust washer 304 4 Using a seal tool install the main...

Page 324: ...ing it around the groove in a circular motion Each T seal has 2 backup rings see drawing for orienta tion Beginning with the inner seal 200 insert one end of backup ring in the lower groove and feed t...

Page 325: ...ng marks are lining up When they do tap the piston 3 in until the gear teeth mesh together Tap the piston into the housing the rest of the way until it bot toms out against the ring gear 11 Install th...

Page 326: ...ROTATED BE CAREFUL NOT TO DISENGAGE THE PISTON AND HOUSE GEARING 14 Install the stop tube 400 onto the shaft end if equipped Stop tube is an available option to limit the rotation of an actuator 15 C...

Page 327: ...iginal holes for the lock pins will line up 18 Place the lock pins 109 provided in the Helac seal kit in the holes with the dimple side up Then using a punch tap the lock pins to the bottom of the hol...

Page 328: ...counter bores of the valve to seal it to the actuator housing 3 The bolts that come with the valve are grade 8 bolts New bolts should be installed with a new valve JLG Threadlocker P N 0100011 should...

Page 329: ...ng the Actuator If the equipment is available the actuator should be tested on a hydraulic test bench The breakaway pressure the pressure at which the shaft begins to rotate should be approximately 40...

Page 330: ...is purged 1 Connect a 3 16 in inside diameter x 5 16 in outside diameter x 5 foot clear vinyl drain tube to each of the two bleed nipples Secure them with hose clamps Place the vinyl tubes in a clean...

Page 331: ...Testing the ActuatorforInternalLeakage e Re build the actuator Remove all rust then polish Replacementpartsmaybeneeded f Re build the actuator Use fluid that is compatible with sealsandbearings 2 Ope...

Page 332: ...until the potentiometer begins to click 5 Plug the analyzer into the port in the platform 6 Select Access Level from Main Menu 7 Enter 33271 8 Select Machine Set Up Load Cell 1 Warn Only 9 Select Mach...

Page 333: ...SECTION 4 BOOM PLATFORM 3121234 4 69 Figure 4 25 Load Sensing Device...

Page 334: ...l be allowed regardless of SkyGuard sensor activa tion IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE BOTH IS SELECTED In Platform Mode NOTE Machine will treat Soft Touch SkyGuard override switch as if it...

Page 335: ...nu or diagnostics menu is to be used to collect the fault information Depending on configuration diagnostics menu will read Diagnostics System Skyguard switch Diagnostics System STOUCH OR SG Pressing...

Page 336: ...SECTION 4 BOOM PLATFORM 4 72 3121234 NOTES...

Page 337: ...assembly Cup and Brush The following is needed to correctly oil the o ring in this man ner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the brush wi...

Page 338: ...ip from the bottom of the fitting This should signify 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 satur...

Page 339: ...r barrel into a suitable holding fixture 5 Mark cylinder head and barrel with a center punch for easy realignment Using an allen wrench loosen the cyl inder head retainer capscrews and remove capscrew...

Page 340: ...TaperedBushing 6 Capscrew 7 CounterbalanceValve 8 Bushing 9 Plug 10 BleederValve 11 WiperSeal 12 RodSeal 13 O ring 14 BackupRing 15 WearRing 16 WearRing 17 T Seal 18 O ring 19 BackupRing 20 WasherRin...

Page 341: ...r scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect threaded portion of barrel for damage Dress threads as necessary 6 Inspect piston surface for dam...

Page 342: ...e if necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See the respective JLG Parts Manual NOTE Apply a light film of hydraulic oil to all components...

Page 343: ...rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 8 Insert the tapered bushing into piston 9 Assemble the tapered bushing loo...

Page 344: ...ylinder Ensure that the piston loading T seal and wear rings are not damaged or dislodged 17 Continue pushing the rod into the barrel until the cylin der head gland can be inserted into the barrel cyl...

Page 345: ...fixture 5 Mark cylinder 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...

Page 346: ...Main Boom Lift Cylinder 1684199 G Torqueto30ft lbs 41Nm Torqueto5ft lbs 7Nm Torqueto300ft lbs 407Nm 1 Rod 2 Bushing 3 Barrel 4 TaperedBushing 5 Capscrew 6 Head 7 Piston 8 Spacer 9 Setscrew 10 Plug 11...

Page 347: ...reads as necessary 4 Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage an...

Page 348: ...able inspect piston rings for cracks or other damage Replace if necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See the respective JLG Parts Manual...

Page 349: ...ylinder rod and hand tight ensuring that the o ring and backup rings are not damaged or dislodged 10 Insert the tapered bushing into piston NOTE When installing the tapered bushing piston and mating e...

Page 350: ...NDER BARREL SURFACES 18 With barrel clamped secured and adequately support ing the rod insert the piston end into the barrel cylinder Ensure that the piston loading hydrolock seals and guidelock rings...

Page 351: ...itable holding fixture 5 Mark cylinder 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 ba...

Page 352: ...Bushing 4 Head 5 Rod 6 Barrel 7 Plug 8 Plug 9 Piston 10 BackupRing 11 GuidelockRing 12 WearRing 13 BackupRing 14 O ring 15 O ring 16 RodSeal 17 WiperSeal 18 HydrolockSeal 19 WasherRing 20 Capscrew 21...

Page 353: ...s necessary 4 Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scori...

Page 354: ...cable inspect piston rings for cracks or other damage Replace if necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See the respective JLG Parts Manual...

Page 355: ...t the o ring and backup rings are not damaged or dislodged 9 Insert the tapered bushing into piston NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 10 Assembl...

Page 356: ...DER BARREL 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 guidelock rings and hydrolock seals...

Page 357: ...l into a suitable holding fixture 4 Using a hook Spanner loosen the spanner nut and remove spanner nut from cylinder barrel 5 Attach a suitable pulling device to the cylinder rod port block end or cyl...

Page 358: ...2 3121234 1 3 14 14 4 5 6 7 8 10 11 12 13 14 14 2 1 Rod 2 Barrel 3 O Ring 4 SpannerNut 5 WiperSeal 6 RetainerRing 7 BackupRing 8 O Ring 9 Seal 10 RodSeal 11 Head 12 Piston 13 Locknut 14 Bushing Figure...

Page 359: ...ng or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as nec essary 6 Inspect threaded portion of piston for dama...

Page 360: ...mbly ensure that the proper cylinder seal kit is used See the respective JLG Parts Manual NOTE Apply a light film of hydraulic oil to all components prior to assembly 1 A special tool is used to insta...

Page 361: ...E 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 11 With barrel clamped secured a...

Page 362: ...barrel into a suitable holding fixture 4 Using a hook Spanner loosen the spanner nut and remove spanner nut from cylinder barrel 5 Attach a suitable pulling device to the cylinder rod port block end o...

Page 363: ...4 4 8 3 13 13 12 10 1 Rod 2 Barrel 3 SpannerNut 4 Seal 5 BackupRing 6 O Ring 7 Head 8 RetainerRing 9 Setscrew 10 Piston 11 Seal 12 Seal 13 Bushing Figure 5 58 Steer Cylinder SN 0300142666 through 030...

Page 364: ...eter 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 nec essary 6 Inspect threaded portion of...

Page 365: ...mbly ensure that the proper cylinder seal kit is used See the respective JLG Parts Manual NOTE Apply a light film of hydraulic oil to all components prior to assembly 1 A special tool is used to insta...

Page 366: ...a suitable holding fixture 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 SU...

Page 367: ...cuffing of the sealing sur faces 8 If the cylinder utilizes a teflon piston seal special care must be taken when installing the new seal Teflon seals are not as elastic as rubber or urethane seals Tef...

Page 368: ...a suitable holding fixture 5 Mark cylinder 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 cylinde...

Page 369: ...crew 2 TaperedBushing 3 Head 4 Barrel 5 Rod 6 WearRing 7 BackupRing 8 BackupRing 9 WearRing 10 O ring 11 O ring 12 RodSeal 13 WiperSeal 14 T Seal 15 Plug 16 Plug 17 Piston 18 WasherRing 19 Capscrew 20...

Page 370: ...eads as necessary 4 Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and...

Page 371: ...cable inspect piston rings for cracks or other damage Replace if necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See the respective JLG Parts Manual...

Page 372: ...the piston on the cylinder rod and hand tight ensuring that the o ring and backup rings are not damaged or dislodged 10 Insert the tapered bushing into piston NOTE When installing the tapered bushing...

Page 373: ...secured and adequately support ing the rod insert the piston end into the barrel cylinder Ensure that the piston loading T seal and wear rings are not damaged or dislodged 19 Continue pushing the rod...

Page 374: ...EMATICS 5 38 3121234 5 8 6 1 2 3 4 7 1 MainControlValve 2 FlowDivider 4WD 3 AuxiliaryPump 4 PlatformValve 5 DualSelectValve 6 HydraulicFilter 7 HighPressureFilter 8 FlowDivider 2WD Figure 5 79 Control...

Page 375: ...stall a low pressure gauge at port M1 of the main valve block A low pressure gauge capable of reading 500 psi 34 5 bar 2 Start the engine from the ground control The gauge should read between 400 440...

Page 376: ...ch holds the main adjustment from turn ing Loosen it 1 turn b Next using the 6 mm wrench adjust the main adjustment clockwise to increase or counterclock wise to decrease This adjustment will be reset...

Page 377: ...ld be cycled and then the crack pressure value calibrated PLATFORM LEVEL UP 1 Install a high pressure gauge at port M1 Activate level up to the end of stroke you should read 2600 psi 179 Bar 2 The lev...

Page 378: ...6 5 4 3 1 2 4641432 D 1 CheckValve 2 PilotValve Lift 3 CheckValve 100psi 6 9Bar 4 TeleOutRelief 5 LiftUpDump 6 SwingRelief 7 SteerRelief 8 SteerFlowRegulator 6gpm 22 7lpm 9 LoadSense Steer 10 LoadSens...

Page 379: ...S 3121234 5 43 1 Figure 5 81 Platform Valve Identification 4641251 B 1 LevelDownRelief 2 LevelUpRelief 3 FlowRegulator 4 RotatorSolenoid 5 PressureSolenoid 6 PlatformLevelSolenoid 7 FlowRegulator 8 Fl...

Page 380: ...le 5 1 Cartridge Torque Values Ft Lbs Nm 1 18 20 24 27 2 33 37 45 50 3 19 21 26 28 4 50 55 68 75 5 19 21 26 28 6 50 55 68 75 7 24 26 33 35 8 70 80 95 108 9 19 21 26 28 10 50 55 68 75 11 24 26 33 35 Ta...

Page 381: ...3121234 5 45 5 4641251 B 1001118473 B Table 5 3 Cartridge Torque Values Ft Lbs Nm 1 20 27 2 20 27 3 20 27 4 20 27 5 20 27 6 25 34 7 20 27 8 20 27 Table 5 4 Coil Torque Values Ft Lbs Nm A 5 7 B 5 7 Fi...

Page 382: ...s to start dry and reduces the efficiency of the pump and can cause pre mature failure PURGING OF THE FUNCTION PUMP SUCTION HOSE Large pockets of air get trapped in this line and must be removed at lo...

Page 383: ...easurement gaugelocationorspecifica tion Thesymbolsabovecanbefoundinthepumpillustrations Thelegendaboveisprovidedto defineeachsymbolandexplainitspurpose Inlet port S SAE J1926 1 1 875 12 System gauge...

Page 384: ...system pressure is established increase to full operating speed If system pressure is not main tained shutdown the engine determine cause and take corrective action Refer to Troubleshooting 8 Operate...

Page 385: ...fvalvesetting Lowexternalreliefvalvesettingwillslowdownsystem Adjustexternalreliefvalvesettingpermanufacturer srec ommendations ExternalreliefsettingmustbeabovePres sureCompensatorsettingforproperoper...

Page 386: ...servoir Insufficienthydraulicfluidwilllimitoutputflowandcause internaldamagetopump Fillthereservoirtoproperlevel Hydraulicfluidviscosityaboveacceptablelimits Fluid viscosity above acceptable limits or...

Page 387: ...nalreliefvalve Chattering external relief valve may cause unstable feed backtopumpcontrol Adjustorreplacereliefvalve Table 5 13 System Pressure Not Reaching Pressure Compensator Setting Item Descripti...

Page 388: ...nspectinletscreen Blockedorrestrictedinletscreenwillcausehighinletvac uum Cleanscreen removeblockage Checkinletpiping Too many fittings bends or long piping will cause high inletvacuum Eliminatefittin...

Page 389: ...ad between 400 440 psi 27 58 30 34 bar 2 Set High pressure relief a Install a high pressure gauge at the MP port of the main valve block b Activate main boom telescope in The gauge should read 2600 ps...

Page 390: ...with clean hydrau lic fluid Place a protective sleeve over the shaft end to prevent damage to the seal during installation PREMATURE BEARING FAILURE CAN RESULT IF THE SHAFT SEAL CONTACTS THE SHAFT BE...

Page 391: ...Clean all parts and lubricate spools springs guides and new o rings with clean hydraulic fluid REASSEMBLY 1 Install the Pressure Compensator spool spherical end first into the Pressure Compensator bor...

Page 392: ...Your configuration may differ but the appropriate wrench size and torque can be found here J041 J043 J044 J046 M14 6mm 27 35 N m 20 26 lbf ft 9 16 in 1 4 in 34 68 N m 25 50 lbf ft J080 J081 J082 M18...

Page 393: ...ies Note Mark the relief valve in relation ship to the cavity it was removed for reassembly pur poses Endcover Inspection Check the bearing press fit in endcover If needles remain in cage move freely...

Page 394: ...om housing 2 Discard the shaft seal gaskets and o rings from all assemblies Replace with new seals upon reassembly ASSEMBLY 1 All parts should be cleaned and critical moving parts lubricated before re...

Page 395: ...on relief valves Install relief valve in its original cavity in endcover that it was removed Torque 100 to 110 ft lbs 136 to 149 Nm 15 Install new o ring on bypass valve or plug Install bypass valve...

Page 396: ...essive scoring Inspect the gerotor pocket inside the charge pump adapter assembly It should not be scored excessively ASSEMBLY 1 If necessary press new bearing or bushing in adapter assembly The beari...

Page 397: ...ween clevis on valve spool aligning holes and install dowel pin retaining with E ring 4 Install new o ring onto input shaft Hold bell crank in position with feedback link slot and align splined hole o...

Page 398: ...troke valve into manifold by hand until top o ring is met by manifold Then wrench tighten to 25 ft lbs 34 Nm max Loosen Nut retaining coil to reposition if necessary and re torque 4 to 5 ft lbs 5 4 to...

Page 399: ...arm out of the detent position The test light will go on Screw in the switch until the light goes off Mark this as position A See Fig ure 5 97 Move the control arm to the detent posi tion and the test...

Page 400: ...ne of the flat washers over the 3 8 in x 3 1 4 in capscrew Put capscrew through the center of the cylinder barrel and apply the second washer Let washer rest on the three pins and retain with nut Turn...

Page 401: ...n steps shown in the diagrams Where appli cable the comment number of the statement appears in the action block of the diagrams RECOMMENDED GAUGE LOCATIONS Gauges Recommended Inlet vacuum gauge 30 PSI...

Page 402: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 66 3121234 Figure 5 100 Fault logic Troubleshooting...

Page 403: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 3121234 5 67 Figure 5 101 Fault logic Troubleshooting...

Page 404: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 68 3121234 Figure 5 102 Fault logic Troubleshooting...

Page 405: ...a Held in a partial or full open position 9 Inspect Inlet Screen or Filter for a Plugged or clogged screen or filter element b Obstructed inlet or outlet c Open inlet to charge pump 10 Check System Pr...

Page 406: ...the fuel flow to the injectors and turn the engine over for 15 seconds 5 Replace the coil wire or return the fuel flow to the injec tors Place the transmission unit in the neutral position start the...

Page 407: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 3121234 5 71 This page left blank intentionally...

Page 408: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 72 3121234 5 7 HYDRAULIC SCHEMATICS Figure 5 103 Hydraulic Schematic Sheet 1of 8 SHEET 1...

Page 409: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 3121234 5 73 A Figure 5 104 Hydraulic Schematic Sheet 2 of 8 SHEET 1 2792678 D...

Page 410: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 74 3121234 Figure 5 105 Hydraulic Schematic Sheet 3 of 8 SHEET 2...

Page 411: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 3121234 5 75 A Figure 5 106 Hydraulic Schematic Sheet 4 of 8 SHEET 2 2792678 D...

Page 412: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 76 3121234 Figure 5 107 Hydraulic Schematic Sheet 5 of 8 SHEET 3...

Page 413: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 3121234 5 77 A Figure 5 108 Hydraulic Schematic Sheet 6 of 8 SHEET 3 2792678 D...

Page 414: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 78 3121234 Figure 5 109 Hydraulic Schematic Sheet 7 of 8 SHEET 4...

Page 415: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 3121234 5 79 A Figure 5 110 Hydraulic Schematic Sheet 8 of 8 SHEET 4 2792678 D...

Page 416: ...SECTION 5 BASIC HYDRAULICS INFORMATION SCHEMATICS 5 80 3121234 NOTES...

Page 417: ...leration deceleration creep min speed and max speed for all boom drive and steering func tions The main lift swing and drive are controlled by individual joy sticks with steering being controlled by a...

Page 418: ...turning the key to the platform or ground position and pulling the emergency stop but tons on this will power the SMART System and the ana lyzer Using the Analyzer The analyzer will display the curren...

Page 419: ...t be known To enter a password first find the appropriate top level menu item MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL item then press UP DOWN arrows and LEFT RIGHT arrows to enter t...

Page 420: ...sed when at the minimum If the value does not change when UP or DOWN is pressed check the access level Machine Setup When a machine digit item is selected press UP DOWN to adjust its value for example...

Page 421: ...iations ABBREVIATION MEANING ACCEL ACCELERATE ACT ACTIVE A D ANALOGDIGITALCONVERTERCOUNT AMB AMBIENT ANG ANGLE AUX AUXILIARY BCS BOOMCONTROLSYSTEM BM BOOMLENGTHANGLEMODULE BLAM BOOMLENGTHANGLEMODULE B...

Page 422: ...FORM P PRESSURE PCV PROPORTIONALCONTROLVALVE PLAT PLATFORM PLT PLATFORM PM PLATFORMMODULE POT POTENTIOMETER PRES PRESSURE PRS PRESSURE PT POINT R REARorRIGHT REV REVERSEorREVISION RET RETRACT ROT ROTA...

Page 423: ...SECTION 6 JLG CONTROL SYSTEM 3121234 6 7 Figure 6 2 ADE Block Diagram...

Page 424: ...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 Ti...

Page 425: ...veelevation alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhentiltedmorethan4 degreesandaboveelevation alsodisallowstowerliftup towertelescopeout drive maint...

Page 426: ...blesmaintelescopeout mainliftup platform alarmbeeps 5secON 2secOFF 0 LOADSENSOR 16 OnlyvisibleifLoadSensor Menuselectionisnot0 Marketselectionswilllimit certainloadsensoroptions 0 1 1ONROTATOR Usetheo...

Page 427: ...HEIT Fahrenheitunitselection 1 LEVELINGMODE 21 Onlyvisibleon800Smodels 0 1 ALLFUNCTIONS Platformlevelwithallfunctions LEVELLIFT TELESCOPE Platformlevelonliftandtelescopeonly 0 4150364 14 Table 6 2 Mac...

Page 428: ...on must be completed before any personality settings can be changed Changing the personality settings first and then changing the model number of the machine configuration will cause the personality s...

Page 429: ...eutzF4M2011Diesel Tier2 DEUTZF3TIER2 DeutzF3M2011Diesel Tier2 FORDGASTIER2 FordLRG425EFIGas Tier2 FORDD FTIER2 FordLRG425EFIDualFuel Tier2 DEUTZECM EngineControlModule ECM Tier2andTier3 DUALFUELECM GM...

Page 430: ...mitted untilpre glowisfinished 0 FUELCUTOUT 7 Thismenuitemisonlyvisi bleifnondualfuelengines areselected 0 1 2 RESTART Engineallowedtoberestartedmultipletimeswhenverylowfuellevelisreached ONERESTART E...

Page 431: ...wertelescopeout drive maintelescopeoutand mainliftup 5DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhentiltedmorethan5 degreesandaboveelevation alsodisallowstowerliftup towertelescopeout...

Page 432: ...nSet WelderMenuselectionis not0 0 1 MOTIONENABLED MotionenabledwhengeneratorisON MOTIONCUTOUT Motioncutoutinplatformmodeonly 0 H TLIGHTS 15 0 1 NO Noheadandtaillightsinstalled YES Headandtaillightsins...

Page 433: ...ATOR Usetheon boardloadsensorforallmodelsexceptthosewhichusetheLevelingPlatform Module 4UNDERPLATFORM UsetheEIMforloadsensing SINGLECELL SingleCell CANbusbasedsensor 1 FUNCTIONCUTOUT 19 Onlyvisibleund...

Page 434: ...ibleon600A 600S and800Smodels 0 1 2 3 SAUERDANFOSS MachineequippedwithSauerDanfossdrivepump EATON MachineequippedwithEatondrivepump M46 XXXX MachineequippedwithM46 XXXXdrivepump 830XXXXX Machineequipp...

Page 435: ...33 0 1 NO TempCutoutisDisabled YES TempCutoutisEnabled 0 PLATLVLOVRCUT 34 0 1 NO PlatformLevelOverridewillalwaysbefunctional YES PlatformLevelOverridewillonlybefunctionalwhenInTransport 0 WATERINFUEL...

Page 436: ...lder 0 0 0 0 0 0 0 1 1 1 1 1 1 1 GenSetCutout 0 0 0 0 0 0 0 1 1 1 1 1 1 1 Head Tail lights 0 0 0 0 0 0 0 1 1 1 1 1 1 1 CableBreak Switch 0 0 0 0 0 0 0 1 1 1 1 1 1 1 LoadSystem 0 0 0 0 0 0 0 X 1 X X X...

Page 437: ...1 X 1 X X 1 PlatLvlOvrCut 0 0 0 0 0 0 0 1 1 1 1 1 1 1 WaterInFuel Sensor X 0 X X X X 0 X 1 X X X X 1 Dual Capacity 0 0 0 0 0 0 0 1 1 1 1 1 1 1 BOLDTEXTindicatesthedefaultsetting Plaintextindicatesano...

Page 438: ...TEDMAXimumspeed 0to50 20 28 CREEPMAXimumspeed 0to50 20 30 EngineRPM 800to2900 1800 1800 STEER MAXimumspeed 0to100 100 100 EngineRPM 800to2900 1800 1800 MAINLIFT ACCELeration 0 1to5 0s 2 5 2 5 DECELera...

Page 439: ...01to1 00 0 10 0 10 EngineRPM 800to2900 1800 1800 PLATFORMROTATE ACCELeration 0 1to5 0s 0 1 0 1 DECELeration 0 1to3 0s 0 1 0 1 MlNimumLEFTspeed 0to65 69 69 MAXimumLEFTspeed 0to100 90 90 MINimumRIGHTspe...

Page 440: ...form Rotate Platform level and completely rotated one direction Rotate 180 degrees and Record Time Rotate the other direction Record Time Test Notes 1 Stop watch should be started with the function no...

Page 441: ...troller Most functions are dispatched and coordinated from this module The PLATFORM MODULE handle sub tasks All charac terized information values are stored into the ground mod ule i e Personalities o...

Page 442: ...SECTION 6 JLG CONTROL SYSTEM 6 26 3121234 Figure 6 3 Analyzer Flow Chart Prior to Version 5 X Software Sheet 1 of 4 NOTE Some screens may not be available depending upon machine configuration...

Page 443: ...N IN X TOWER TELESCOPE MAX IN X TOWER TELESCOPE MIN OUT X TOWER TELESCOPE MAX OUT X BASKET LEVEL ACCEL X XS BASKET LEVEL DECEL X XS BASKET LEVEL MIN UP X BASKET LEVEL MAX UP X BASKET LEVEL MIN DOWN X...

Page 444: ...BER 10 510A MODEL NUMBER 11 740A ENGINE 2 FORD EFI D F ENGINE 3 DEUTZ F4 ENGINE 4 DEUTZ F3 ENGINE 5 CAT 3024C ENGINE 6 CAT 3044C GLOW PLUG 15 15 SECONDS ENGINE SHUTDOWN 0 NO TILT 2 4 DEG TILT 3 3 DEG...

Page 445: ...SECTION 6 JLG CONTROL SYSTEM 3121234 6 29 Figure 6 6 Analyzer Flow Chart Prior to Version 5 X Software Sheet 4 of 4...

Page 446: ...SECTION 6 JLG CONTROL SYSTEM 6 30 3121234 Figure 6 7 Analyzer Flow Chart Version 5 X Software Sheet 1 of 4 NOTE Some screens may not be available depending upon machine configuration...

Page 447: ...SECTION 6 JLG CONTROL SYSTEM 3121234 6 31 Figure 6 8 Analyzer Flow Chart Version 5 X Software Sheet 2 of 4...

Page 448: ...REES TILT 4 DEGREES CUT TILT 3 DEGREES CUT JIB YES 4 WHEEL STEER YES SOFT TOUCH YES GEN SET WELDER BELT DRIVE H T LIGHTS YES CABLE SWITCH YES LOAD SYSTEM WARN ONLY LOAD SYSTEM CUTOUT PLATFORM LOAD SYS...

Page 449: ...LOSED ANGLE XXX X PLATFORM LOAD UMS STATUS STATE OK NORMAL CAN STATISTICS RX SEC X CAN STATISTICS TX SEC X CAN STATISTICS BUS OFF X CAN STATISTICS PASSIVE 1 CALIBRATION DATA LOAD ZERO XXX CALABRATION...

Page 450: ...DRV ORIENTATION SWITCH OPEN DRV ORIENTATION OVERRIDE OPEN DRV ORIENTATION STATUS CONFIRMED DRIVE CONTROL NORMAL CRIBBING MODE DISABLED DIAGNOSTICS BOOM FUNCTIONS JOYSTICK LIFT MAIN UP XXX LIFT OUTPUT...

Page 451: ...LOSED 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 SWITCH OPEN RETURN HYDRAULIC FILTER OPEN CHARGE PU...

Page 452: ...LOG ON XXXh XXm DATALOG ENGINE XXXh XXm DATALOG DRIVE XXXh XXm DATALOG LIFT XXXh XXm DATALOG SWING XXXh XXm DATALOG TELE XXXh XXm DATALOG MAX TEMP XXXF DATALOG MIN TEMP XXXF DATALOG MAX VOLTS XX XV DA...

Page 453: ...T 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 CREEP R MAX XXX TRACK COUNTER ROTATE MAX XXX TO MENU MACHIN...

Page 454: ...NALITIES PLATFORM LEVEL PLATFORM LEVEL ACCEL X XS PLATFORM LEVEL DECEL X XS PLATFORM LEVEL MIN IN XXX PLATFORM LEVEL MAX IN PLATFORM LEVEL MIN OUT XXX PLATFORM LEVEL MAX OUT XXX PERSONALITIES PLATFORM...

Page 455: ...UAL FUEL TO MENU CALIBRATIONS MODEL NUMBER 450A MODEL NUMBER 510A MODEL NUMBER 600S MODEL NUMBER 600A MODEL NUMBER 600SC MODEL NUMBER 601S MODEL NUMBER 740A MODEL NUMBER 800A MODEL NUMBER 800S PERKINS...

Page 456: ...OUT DRIVE CUTOUT FUNCTION CUTOUT DRIVE CUT E T GROUND ALARM MOTION GROUND ALARM NO GROUND ALARM DRIVE GROUND ALARM DESCENT JIB YES 4 WHEEL STEER NO 4 WHEEL STEER YES STOUCH SKYGUARD NONE STOUCH SKYGUA...

Page 457: ...AL CAPACITY NO DUAL CAPACITY YES 20FPM FOR CREEP DRIVE CONTROL ENHANCED DRIVE CONTROL NORMAL DRIVE CONTROL PROPULSION DRIVE PUMP DRIVE PUMP EATON DRIVE PUMP M46 XXXX DRIVE PUMP 830XXXXX BOOM CONTROL N...

Page 458: ...ODULE J1 10 MAX XXX PROP MODULE DEADBAND XXXXX PROP MODULE FF NUM XXXXX PROP MODULE FF DEN XXXXX PROP MODULE I NUM XXXXX PROP MODULE I DEN XXXXX PROP MODULE NEG ERR XXXXX PROP MODULE GAIN FLAG XXXXX P...

Page 459: ...SECTION 6 JLG CONTROL SYSTEM 3121234 6 43 Figure 6 20 Fault Code Light and Module Location PLATFORM CONTROL MODULE GROUND CONTROL MODULE FAULT CODE LIGHT...

Page 460: ...SECTION 6 JLG CONTROL SYSTEM 6 44 3121234 Figure 6 21 Analyzer Connecting Points PLATFORM CONNECTION GROUND CONTROL CONNECTION...

Page 461: ...SECTION 6 JLG CONTROL SYSTEM 3121234 6 45 1 1001103667 Y Figure 6 22 Ground Control Module Sheet 1 of 3...

Page 462: ...SECTION 6 JLG CONTROL SYSTEM 6 46 3121234 1 1001103667 Y Figure 6 23 Ground Control Module Sheet 2 of 3...

Page 463: ...SECTION 6 JLG CONTROL SYSTEM 3121234 6 47 1 1001103667 Y Figure 6 24 Ground Control Module Sheet 3 of 3...

Page 464: ...SECTION 6 JLG CONTROL SYSTEM 6 48 3121234 CONNECTOR 1001141138 D Figure 6 25 Platform Control Module Sheet 1 of 2...

Page 465: ...SECTION 6 JLG CONTROL SYSTEM 3121234 6 49 CONNECTOR 1001141138 D Figure 6 26 Platform Control Module Sheet 2 of 2...

Page 466: ...liftacceleration DECEL Displays adjustsupperliftdeceleration MINUP Displays adjustsminimumupperliftupspeed MAXUP Displays adjustsmaximumupperliftupspeed CREEPUP Displays adjustsmaximumupperliftupspeed...

Page 467: ...EL Displays adjustsjibacceleration DECEL Displays adjustsjibdeceleration MINUP Displays adjustsminimumjibupspeed MAXUP Displays adjustsmaximumjibupspeed MINDOWN Displays adjustsminimumjibdownspeed MAX...

Page 468: ...aysjibliftswitchdirection demand NOTE demandiscontrolledbythepumppot NotdisplayedifJIB NO JIBLEFT Displaysjibswingswitchdirection demand NOTE demandiscontrolledbythepumppot NotdisplayedifJIB NO PUMPPO...

Page 469: ...goperationtime TELE Displaystotalcontrollerteleoperationtime MAX TEMP Displaysmaximummeasuredheatsinktemp MIN TEMP Displaysminimummeasuredheatsinktemp MAX VOLTS Displaysmaximummeasuredbatteryvoltage R...

Page 470: ...CREEP CREEPSWITCHCLOSED 210 21 POWER UP 211 21 POWERCYCLE 212 21 KEYSWITCHFAULTY TheUGMshallassumeastationselectionofGround 213 21 FSWFAULTY TheUGMshallnotEnablethe Machine 220 22 PLATFORMCONTROLS 227...

Page 471: ...tart Auxatfault disableEngineStartbutpermitAuxiliaryPower EmergencyDescent 235 23 FUNCTIONSWITCHESLOCKED SELECTEDBEFOREAUX POWER 236 23 FUNCTIONSWITCHESLOCKED SELECTEDBEFORESTART SWITCH 237 23 STARTSW...

Page 472: ...NDOUTPUTDRIVER 331 33 BRAKE SHORTTOBATTERY CheckHarnessfordamage 332 33 BRAKE OPENCIRCUIT CheckHarnessfordamage 3311 33 GROUNDALARM SHORTTOBATTERY GroundAlarmequippedvehiclesonly 3336 33 ALTERNATORPOW...

Page 473: ...SHORTTOGROUND CheckHarnessfordamage 3383 33 PLATFORMLEVELUPVALVE OPENCIRCUIT CheckHarnessfordamage 3384 33 PLATFORMLEVELUPVALVE SHORTTOBATTERY CheckHarnessfordamage 3388 33 PLATFORMLEVELDOWNVALVE SHO...

Page 474: ...71 33 LIFTDOWNVALVE SHORTTOBATTERY CheckHarnessfordamage 33172 33 LIFTDOWNVALVE SHORTTOGROUND CheckHarnessfordamage 33175 33 JIBROTATELEFTVALVE OPENCIRCUIT CheckHarnessfordamage 33176 33 JIBROTATELEFT...

Page 475: ...eversetoCreep speedaftercontrolsinitialized 33410 33 DRIVE CURRENTFEEDBACKREADINGLOST TheUGMshallsuspendDrive ForwardandReversecommandandreverttoOpenCurrentloopcontrolfor Drive TheUGMshalllimitDriveFo...

Page 476: ...WNVALVE SHORTTOBATTERY CheckHarnessfordamage 3420 34 JIBLIFTDOWNVALVE SHORTTOGROUND CheckHarnessfordamage 3421 34 JIBROTATELEFTVALVE OPENCIRCUIT CheckHarnessfordamage 3422 34 JIBROTATELEFTVALVE SHORTT...

Page 477: ...SFAILURE ACCESSORYMODULE ChecktheWiring 666 66 CANBUSFAILURE ENGINECONTROLLER ECMequippedengineonly 6620 66 CANBUSFAILURE UMSSENSOR 6622 66 CANBUSFAILURE TCUMODULE 6623 66 CANBUSFAILURE GATEWAYMODULE...

Page 478: ...nessfordamage 8650 86 REARRIGHTSTEERVALVE SHORTTOGROUND CheckHarnessfordamage 871 87 RETURNFILTERBYPASSED CheckHydraulicReturnFilter 872 87 CHARGEPUMPFILTERBYPASSED CheckChargePumpFilter 873 87 MACHIN...

Page 479: ...neshutdownand donotpermitstart 9944 99 CURRENTFEEDBACKGAINSOUTOFRANGE Againof1isusedforthefactorygain s thatwasoutof range allfunctionsshallbe placedinCreepmode 9945 99 CURRENTFEEDBACKCALIBRATIONCHECK...

Page 480: ...SECTION 6 JLG CONTROL SYSTEM 6 64 3121234 NOTES...

Page 481: ...nd the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec tor such that th...

Page 482: ...nging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Continuity Measurement Some meters require a separate button press to enable audible continuity te...

Page 483: ...female pins To prevent electrical malfunction caused by low level con ductivity between pins when wet Use the following procedure to apply Silicone Dielectric Com pound to the electrical connectors T...

Page 484: ...ctric grease to plug male connector housing which typically contains sockets contact female termi nals fill it approximately full see example below 3 Leave a thin layer of dielectric grease on the fac...

Page 485: ...low the general guidance for installation DIN Connectors This connector is typically used on hydraulic valves Follow the installation instructions Exclusions A limited number of connectors do not bene...

Page 486: ...connector sys tem ENGINE CONTROL UNIT CONNECTORS moisture integrity However the low force contacts cannot displace dielectric grease and create electrical contact It is possible to use solvents i e co...

Page 487: ...Intercom connections in Aerial Work Platforms MOLEX CMC SERIES CONNECTORS The CMC connector family is a sealed high density connec tion system using matte seal technology for CP 0 635 and 1 50 mm term...

Page 488: ...ved by using 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 assem bling the housing to the header it is possible t...

Page 489: ...ock must be closed to its locked position Release the locking latches by squeezing them inward See Figure 7 12 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 7 1...

Page 490: ...orward or mating 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 PIERC...

Page 491: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 11 Figure 7 15 Connector Installation...

Page 492: ...xterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented They may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Di...

Page 493: ...cavities insert sealing plugs for full envi ronmental sealing HD30 HDP20 Series Disassembly 1 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 2...

Page 494: ...TS GENERATOR SWITCH TO TO SOFT TOUCH SYSTEM LIMIT SWITCH TILT SENSOR 2 TILT SENSOR 1 BOOM VALVES FOOT SWITCH TO ANALYZER NOTE MODULE SHOWN INVERTED FOR CLARITY MAIN CONTROL VALVE TO REAR STEER VALVE F...

Page 495: ...ACLE AT PLATFORM OPTIONAL BOOM CAPACITY LENGTH SWITCH BOOM TRANSPORT LENGTH SWITCH GROUND CONTROL BOX FUEL ON SOLENOID DEUTZ ENGINE DUAL SELECT VALVE ALTERNATOR FORD ENGINE THROTTLE CONTROLLER FORD EN...

Page 496: ...RM WORK LIGHTS ABOVE HORIZONTAL LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH BOOM CAPACITY LENGTH LIMIT SWITCHES BOOM TRANSPORT LENGTH LIMIT SWITCHES BOOM PROX SWITCH HEADLIGHTS TAILLIGHTS DIAGNOSTIC...

Page 497: ...IER III EGR VALVE SWITCH DEUTZ TIER III ENGINE HARNESS DEUTZ SENDING UNIT CAT ENGINE CONTROL DEUTZ FUEL SHUT OFF SWITCH CAT BOSCH FUEL REGULATOR GM FUEL REGULATOR GM HARNESS TACH SENSOR SPEED PICK UP...

Page 498: ...ORM WORK LIGHTS ABOVE HORIZONTAL LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH BOOM CAPACITY LENGTH LIMIT SWITCHES BOOM TRANSPORT LENGTH LIMIT SWITCHES BOOM PROX SWITCH HEADLIGHTS TAILLIGHTS DIAGNOSTI...

Page 499: ...CAT AUX PUMP ENGINE CONNECTOR CAT ACTUATOR CAT BOSCH FUEL REGULATOR GM DGC DCM MODULE CAT FUEL REGULATOR GM HARNESS TACH SENSOR SPEED PICK UP CAT DIAGNOSTIC CAT STROBE LIGHT DRIVE ORIENTATION SWITCH...

Page 500: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 20 3121234 7 7 ELECTRICAL SCHEMATICS Figure 7 28 Electrical Schematics Caterpillar Deutz EMR2 and GM Prior to SN 0300139080 Sheet 1 of 6 SHEET 1...

Page 501: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 21 A SHEET 1 1870221 D Figure 7 29 Electrical Schematics Caterpillar Deutz EMR2 and GM Prior to SN 0300139080 Sheet 2 of 6...

Page 502: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 22 3121234 SHEET 2 Figure 7 30 Electrical Schematics Caterpillar Deutz EMR2 and GM Prior to SN 0300139080 Sheet 3 of 6...

Page 503: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 23 A SHEET 2 1870221 D Figure 7 31 Electrical Schematics Caterpillar Deutz EMR2 and GM Prior to SN 0300139080 Sheet 4 of 6...

Page 504: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 24 3121234 SHEET 3 Figure 7 32 Electrical Schematics Caterpillar Deutz EMR2 and GM Prior to SN 0300139080 Sheet 5 of 6...

Page 505: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 25 A SHEET 3 1870221 D Figure 7 33 Electrical Schematics Caterpillar Deutz EMR2 and GM Prior to SN 0300139080 Sheet 6 of 6...

Page 506: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 26 3121234 Figure 7 34 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 1 of 10 SHEET 1...

Page 507: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 27 A SHEET 1 1001110325 C Figure 7 35 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 2 of 10...

Page 508: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 28 3121234 SHEET 2 Figure 7 36 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 3 of 10...

Page 509: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 29 A SHEET 2 1001110325 C Figure 7 37 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 4 of 10...

Page 510: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 30 3121234 SHEET 3 Figure 7 38 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 5 of 10...

Page 511: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 31 A SHEET 3 1001110325 C Figure 7 39 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 6 of 10...

Page 512: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 32 3121234 SHEET 4 Figure 7 40 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 7 of 10...

Page 513: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 33 A SHEET 4 1001110325 C Figure 7 41 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 8 of 10...

Page 514: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 34 3121234 SHEET 5 Figure 7 42 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 9 of 10...

Page 515: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 35 A SHEET 5 1001110325 C Figure 7 43 Electrical Schematics Caterpillar Deutz EMR2 and GM SN 0300139080 through 0300161729 Sheet 10 of 10...

Page 516: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 36 3121234 5 Figure 7 44 Electrical Schematic 0300161730 to 0300189341 Sheet 1 of 10 SHEET 1...

Page 517: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 37 B SHEET 1 1001141141 C Figure 7 45 Electrical Schematic 0300161730 to 0300189341 Sheet 2 of 10...

Page 518: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 38 3121234 6 SHEET 2 Figure 7 46 Electrical Schematic 0300161730 to 0300189341 Sheet 3 of 10...

Page 519: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 39 A SHEET 2 1001141141 C Figure 7 47 Electrical Schematic 0300161730 to 0300189341 Sheet 4 of 10...

Page 520: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 40 3121234 5 SHEET 3 Figure 7 48 Electrical Schematic 0300161730 to 0300189341 Sheet 5 of 10...

Page 521: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 41 A SHEET 3 1001141141 C Figure 7 49 Electrical Schematic 0300161730 to 0300189341 Sheet 6 of 10...

Page 522: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 42 3121234 4 SHEET 4 Figure 7 50 Electrical Schematic 0300161730 to 0300189341 Sheet 7 of 10...

Page 523: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 43 A SHEET 4 1001141141 C Figure 7 51 Electrical Schematic 0300161730 to 0300189341 Sheet 8 of 10...

Page 524: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 44 3121234 5 SHEET 5 Figure 7 52 Electrical Schematic 0300161730 to 0300189341 Sheet 9 of 10...

Page 525: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 45 A SHEET 5 1001141141 C Figure 7 53 Electrical Schematic 0300161730 to 0300189341 Sheet 10 of 10...

Page 526: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 46 3121234 Figure 7 54 Electrical Schematic GM Sheet 1 of 2 SHEET 1...

Page 527: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121234 7 47 Figure 7 55 Electrical Schematic GM Sheet 2 of 2 SHEET 1 1001131992 A...

Page 528: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 48 3121234 NOTES...

Page 529: ......

Page 530: ...erhude 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 26...

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