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JLG 740A, Service And Maintenance Manual

The JLG 740A Service And Maintenance Manual is a crucial resource for all owners. This comprehensive manual covers all aspects of the product's maintenance and functionality. It can be downloaded for free from our website, ensuring easy access and hassle-free assistance for your JLG 740A.

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SECTION 6 - JLG CONTROL SYSTEM

6-10

– JLG Lift –

3121160

FRO

M

:

MEN

U

:

PER

S

O

N

A

LITIES

MENU:

MACHINE S

E

TUP

TO:

MENU

:

CA

L

I

B

R

ATIONS

MODEL NU

M

B

E

R

:

400S

ENGINE:

FORD EF

I

 

GAS

G

L

O

W

 PLUG:

N

O

 GLOW 

PLUGS

ENGINE SHUT

D

O

W

N

:

ST

A

R

TER LOCKO

U

T

:

ENABLED

DI

S

A

BLED

TI

LT

:

5

 D

E

GREES

JIB:

NO

4

 WHEEL ST

E

E

R

:

NO

SOFT

 T

OUCH:

NO

GEN SET/WEL

D

E

R:

NO

H & T

 

L

I

G

HTS:

NO

C

ABLE SWIT

C

H

:

NO

L

O

AD

 S

YSTEM:

NO

LOAD

 S

E

N

S

O

R

:

4 UN

D

E

R

 

PL

A

TFORM

FUNCTION C

U

T

O

UT:

NO

GRO

U

N

D ALARM:

NO

DR

IV

E

:

4W

D

MODEL NU

M

B

E

R

:

450A

MODEL NU

M

B

E

R

:

510A

MODEL NU

M

B

E

R

:

600S

MODEL NU

M

B

E

R

:

600A

MODEL NU

M

B

E

R

:

600SC

MODEL NU

M

B

E

R

:

601S

MODEL NU

M

B

E

R

:

740A

MODEL NU

M

B

E

R

:

800A

ENGINE:

FORD EF

I

 

D/F

ENGINE:

DEUTZ F

4

 

TIER1

ENGINE:

DEUTZ F

3

 

TIER1

ENGINE:

CAT. 30

2

4

C

ENGINE:

ENGINE:

CAT. 30

4

4

C

PERKINS

 4

04C

G

L

O

W

 PLUG:

A

I

R

 INTAKE

ENGINE SHUT

D

O

W

N

:

ST

A

R

TER LOCKO

U

T

:

DISABLED

EN

A

B

LED

TI

LT

:

4

 D

E

GREES

TI

LT

:

3

 D

E

GREES

TI

LT

:

4

 

D

E

GREES + CUT

TI

LT

:

3

 

D

E

GREES + CUT

JIB:

YES

4

 WHEEL ST

E

E

R

:

YE

S

SOFT

 T

OUCH:

YES

GEN SET/WEL

D

E

R:

BELT DRIVE

H & T

 

L

I

G

HTS:

YES

C

ABLE SWIT

C

H

:

YE

S

L

O

AD

 S

YSTEM:

W

A

RN

 O

NLY

L

O

AD

 S

YSTEM:

C

U

TO

U

T

 PLATFORM

L

O

AD

 S

YSTEM:

C

U

TO

U

T

 ALL

L

O

AD

 S

YSTEM:

S

P

EC

I

A

L 1

LOAD

 S

E

N

S

O

R

:

1 ON

 

R

O

T

A

T

O

R

FUNCTION C

U

T

O

UT:

BOOM CUTO

U

T

FUNCTION C

U

T

O

UT:

DRIVE CUT

O

U

T

FUNCTION C

U

T

O

UT:

DRIVE CUT

 

E

&

T

GRO

U

N

D ALARM:

DRI

V

E

GRO

U

N

D ALARM:

DES

C

E

NT

GRO

U

N

D AL

A

R

M

:

MOT

I

O

N

D

R

I

V

E

:

2

W

D

ENGINE:

DEUTZ F

4

 

TIER2

ENGINE:

DEUTZ F

3

 

TIER2

G

L

O

W

 PLUG:

I

N

-

CYLINDER

ENGINE:

FORD GA

S

 

TIER2

ENGINE:

FORD D/

F

 

TIER2

MODEL NU

M

B

E

R

:

800S

ENGINE:

ENGINE:

DEUTZ E

C

M

DUAL FU

E

L

 ECM

D

R

I

V

E

:

2

W

D

 

W

/

 

2

-

S

P

E

E

D

MA

R

K

ET:

AN

S

I

 USA

MA

R

K

ET:

AN

S

I

 EXPORT

MA

R

K

ET:

CS

A

MA

R

K

ET:

CE

MA

R

K

ET:

AU

S

T

RALIA

MA

R

K

ET:

JA

P

A

N

FLYWHEEL T

E

E

T

H

:

110 TEETH

FLYWHEEL T

E

E

T

H

:

133 TEETH

T

E

M

P

E

R

A

T

U

R

E

:

C

E

L

S

I

U

S

T

E

M

P

E

R

A

T

U

R

E

:

F

A

H

R

E

N

H

E

I

T

G

E

N

 SET 

CUTOUT:

M

O

T

I

ON ENABLED

G

E

N

 SET 

CUTOUT:

M

O

T

I

ON CUTOUT

L

E

V

E

L

I

N

G

 

M

O

D

E

:

A

L

L

 

F

U

N

C

T

I

O

N

S

L

E

V

E

L

I

N

G

 

M

O

D

E

:

L

I

F

T

/

T

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L

E

S

C

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E

Fig

u

re

 6-9.

  A

n

alyz

er

 F

low

 C

h

ar

t,

 V

ers

ion 

5.X

 Software 

- Sheet 3 

o

f 4

Summary of Contents for 740A

Page 1: ...Service and Maintenance Manual Models 740A 740AJ P N 3121160 January 8 2013 ...

Page 2: ......

Page 3: ...ally dangerous pres sures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be discon nected with minimal fluid loss...

Page 4: ...INTRODUCTION A 2 JLG Lift 3121160 REVISON LOG Original Issue November 4 2002 Revised September 8 2003 Revised March 10 2006 Revised September 28 2007 Revised June 3 2008 Revised January 8 2013 ...

Page 5: ...ecifications 1 6 1 18 Major Component Weights 1 7 1 19 Pressure Settings 1 7 1 20 Critical Stability Weights 1 7 1 21 Operator Maintenance 1 8 Draining Oil Build Up From The Propane Regulator 1 12 Propane Fuel Filter Replacement 1 13 Propane Fuel System Pressure Relief 1 14 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 General 2 1 Preparation Inspection and Maintenance 2...

Page 6: ...ing Option 3 3 To Disengage Drive Motors and Brakes Free Wheel for Emergency Towing 3 3 To Engage Drive Motors and Brakes Normal Operation 3 3 3 4 Torque Hub Drive 3 4 Disassembly 3 4 Cleaning and Inspection 3 4 Repair 3 4 Assembly 3 6 3 5 Drive Brake Ausco Prior to S N 56875 3 12 Disassembly 3 12 Inspection 3 12 Assembly 3 12 3 6 Drive Brake Mico S N 56875 to 83332 3 14 Disassembly 3 14 Assembly ...

Page 7: ...ier Sub Assembly 3 69 3 17 Swing Brake S N 0300068040 to Present 3 72 Disassembly 3 72 Assembly 3 72 3 18 Swing Motor S N 0300068040 to Present 3 74 Disassembly 3 74 Inspection and Cleaning 3 76 Assembly 3 76 Timing Procedure 3 78 3 19 Rotary Coupling 3 81 3 20 Tilt Alarm Switch Prior to S N 0300062045 3 85 Manual Adjustment 3 85 3 21 Spark Arrester Cleaning Instructions 3 85 3 22 Generator 3 88 E...

Page 8: ...ic Pressure Regulator EPR Assembly Replacement 3 135 Temperature Manifold Absolute Pressure TMAP Sensor 3 136 Electronic Throttle Control Replacement 3 137 Mixer Replacement 3 138 Coolant Hose Replacement 3 138 Vapor Hose Replacement 3 138 Engine Control Module Replacement 3 139 Heated Exhaust Gas Oxygen Sensor Replacement 3 139 3 30 GM Engine LPG Fuel System Diagnosis 3 139 Fuel System Descriptio...

Page 9: ...ng a Fixed End Bracket 4 10 Replacing a Moving End Bracket 4 10 Replacing a One Piece Bracket 4 11 4 5 Main Boom Assembly 4 12 Removal 4 12 Disassembly 4 13 Inspection 4 13 Assembly 4 13 4 6 Upright 4 14 Removal 4 14 Upright Level Cylinder Removal 4 14 4 7 Tower Boom Assembly 4 14 Removal 4 14 Inspection 4 15 Assembly 4 15 Installation 4 15 Tower Out of Sync 4 16 4 8 Articulating Jib Boom 4 18 Rem...

Page 10: ...Sensor Faulted 4 64 Tower Lift Down Output Short to Ground or Open Circuit 4 64 Tower Lift Down Output Short to Battery 4 64 Platform Indicator Output Short to Ground or Open Circuit 4 64 Platform Indicator Output Short to Battery 4 64 Ground Indicator Output Short to Ground 4 64 Ground Indicator Output Short to Battery 4 64 Turntable Sensor Not Calibrated Message 4 64 Turntable Sensor Faulted 4 6...

Page 11: ...ylinder Removal 5 13 Tower Lift Cylinder Installation 5 13 Slave Cylinder Removal 5 13 Slave Cylinder Installation 5 13 5 7 Hydraulic Pump W hayes Pump drive Coupling Lubrication 5 14 5 8 Pressure Setting Procedures 5 14 Main Relief Steer Swing and Lift Down 5 14 4 Wheel Steer If Equipped 5 18 5 9 Hydraulic oil change out procedure 5 19 5 10 Hydraulic Component Start Up Procedures and Recommendati...

Page 12: ...sistance Measurement 7 2 Continuity Measurement 7 2 Current Measurement 7 3 7 3 Applying Silicone Dielectric Compound to Electrical Connections 7 3 7 4 AMP Connector 7 4 Applying Silicone Dielectric Compound to AMP Connectors 7 4 Assembly 7 4 Disassembly 7 6 Wedge Lock 7 6 Service Voltage Reading 7 6 7 5 Deutsch Connectors 7 8 DT DTP Series Assembly 7 8 DT DTP Series Disassembly 7 8 HD30 HDP20 Ser...

Page 13: ...rive Brake Ausco 3 13 3 5 Drive Brake Mico S N 56875 to 83332 3 15 3 6 Drive Brake S N 83332 to Present 3 18 3 7 600S Drive Motor Cutaway 3 20 3 8 Flow Control Pilot Valves 3 26 3 9 Drive Motor Adjustment Prior to S N 83332 3 27 3 10 Drive Motor Cross Section 3 28 3 11 Removing the Shaft Seal 3 28 3 12 Loop Flushing Spool 3 29 3 13 Loop Flushing Spool 3 31 3 14 Plugs Fittings and Speed Sensor 3 31...

Page 14: ...iliary Pump Sheet 1 of 2 3 86 3 52 Auxiliary Pump Sheet 2 of 2 3 87 3 53 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings 3 89 3 54 EFI Component Location 3 101 3 55 ECM EPM Identification 3 104 3 56 Typical Fuel System 3 106 3 57 LPG System Components S N 0300077500 to Present 3 111 3 58 EMR 2 Engine Side Equipment 3 114 3 59 Deutz EMR 2 Troubleshooting Flow Chart 3 115 3 60...

Page 15: ...4 7 Boom Valve and Limit Switches Location 4 20 4 8 Transportation Switch Installation CE Only 4 21 4 9 Tower Power Track Installation Sheet 1 of 2 4 22 4 10 Tower Power Track Installation Sheet 2 of 2 4 23 4 11 Platform Section Replacement 4 24 4 12 Location And Thickness Of Wear Pads 4 24 4 13 Actuator Timing 4 27 4 14 Rotator Assembly HELAC 4 28 4 15 Rotator Exploded View S N 0300067538 to Pres...

Page 16: ...Prior to Version 5 X Software Sheet 3 of 4 6 6 6 6 Analyzer Flow Chart Prior to Version 5 X Software Sheet 4 of 4 6 7 6 7 Analyzer Flow Chart Version 5 X Software Sheet 1 of 4 6 8 6 8 Analyzer Flow Chart Version 5 X Software Sheet 2 of 4 6 9 6 9 Analyzer Flow Chart Version 5 X Software Sheet 3 of 4 6 10 6 10 Analyzer Flow Chart Version 5 X Software Sheet 4 of 4 6 11 6 11 Control Module Location 6 ...

Page 17: ... to S N 99884 Sheet 5 of 6 7 18 7 27 Electrical Schematic Deutz EMR2 GM Engines Prior to S N 99884 Sheet 6 of 6 7 19 7 28 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 1 of 6 7 20 7 29 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 2 of 6 7 21 7 30 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 3 of 6 7 22 7 31 Electrical Schema...

Page 18: ...l EAL 224H Specs 1 6 1 23 UCon Hydrolube HP 5046 1 6 1 24 Exxon Univis HVI 26 Specs 1 6 1 25 Cylinder Specifications 1 6 1 26 Major Component Weights 800AJ 1 7 1 27 Pressure Settings 1 7 1 28 Critical Stability Weights 1 7 1 29 Lubrication Specifications 1 8 2 1 Inspection and Maintenance 2 2 2 2 Cylinder Drift 2 4 2 3 Inspection and Preventive Maintenance Schedule 2 6 3 1 Wheel Torque Chart 3 2 3...

Page 19: ...Instability 5 25 5 11 System Pressure Not Reaching Pressure Compensator Setting 5 26 5 12 High Inlet Vacuum 5 26 6 1 Analyzer Abbreviations 6 2 6 2 Machine Configuration Programming Information Prior to Software Version P5 3 6 18 6 3 Machine Configuration Programming Information Software Version P5 3 to P6 1 6 22 6 4 Machine Configuration Programming Information Software Version P6 1 to Present 6 ...

Page 20: ...xviii JLG Lift 3121160 LIST OF TABLES TABLE NO TITLE PAGE NO This page left blank intentionally ...

Page 21: ... minutereserveCapacity 12VDC Horsepower 74 3000RPM full load Cooling System 16Quarts 15 14L SparkPlug AWSF 52 C SparkPlug Gap 0 044in 1 117mm Table 1 3 Deutz F4M2011F Specifications Type Liquid Cooled Oil Fuel Diesel Oil Capacity Cooling System Crankcase Total Capacity 5Quarts 4 5L 11Quarts 10 5L w Filter 16Quarts 15L IdleRPM 1000 LowRPM 1800 HighRPM 2800 Alternator 55Amp beltdrive Fuel Consumptio...

Page 22: ...applied hydraulically released discbrakes Table 1 8 Swing System Specifications SwingMotorDisplacement 4 9cu in 80cm3 SwingBrake Automaticspringappliedhydraulically released discbrakes SwingHub Ratio 50 1 Table 1 9 Hydraulic Drive Pump Specifications Pump Output 35 5GPM 134lpm 2800RPM Pump Displacement 2 8 cu in 46cm3 Charge Pump Displacement 0 85cu in 14cm3 Charge Pump Output 9 5GPM 37lpm 2800RPM...

Page 23: ...o 100 F 29to38 C Table 1 15 Dimensional Data TurningRadius Outside 14ft 6in 4 42m TurningRadius Inside 11ft 0in 2 13m BoomElevation 740A Above Grade BelowGrade 80ft 3in 24 46m 15ft 7in 4 75m BoomElevation 740AJ Above Grade BelowGrade 80ft 3in 24 46m 13ft 1in 3 99m MachineHeightStowed 9ft 9 5in 2 98m MachineLength Stowed 36ft 6in 11 13m MachineWidth 8ft 0in 2 44m Wheelbase 10ft 0in 3 05m Table 1 16...

Page 24: ... course Drive Forward Record Time Drive Reverse Record Time Platform Rotate Platform level and completely rotated one direction Rotate the opposite direction Record Time Rotate the other direction Record Time Articulating Jib Platform level and centered with the boom Start with the Jib down Jib Up Record Time Jib Down Record Time Test Notes 1 Stop watch should be started with the function not with...

Page 25: ...pport to RotatorBolts 50 ft lbs 68 Nm As required RotatorCenter Bolt 480 ft lbs 651 Nm As required Swing BearingBolts 190 ft lbs 260 Nm 50 600 Starter orAux Pump Solenoid Contacts Coil 95in lbs 10 5Nm 40in lbs 4 5Nm Asrequired Oxygen Sensor Ford Engine 29 5 40ft lbs 40 54Nm AtInstallation MegajectorMounting Bolts FordEngine 60in lbs 7Nm Asrequired Lockoff Solenoid Ford Engine 8 12ft lbs 11 16Nm At...

Page 26: ...pe Synthetic Biodegradable Specific Gravity 1 082 Pour Point Max 58 F 50 C pH 9 1 Viscosity at 0 C 32 F 340 cSt 1600SUS at 40 C 104 F 46 cSt 215SUS at 65 C 150 F 22 cSt 106SUS Viscosity Index 170 Table 1 24 Exxon Univis HVI 26 Specs Specific Gravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at 100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that this oil ...

Page 27: ...weight 4805 2180 TurntableComplete IncludingEngine 11025 5001 ChassisComplete 12620 5724 Machine Complete GVW 33100 15020 NOTE The above components are separate assemblies example TURNTABLE COMPLETE does not include booms upright lift cylinders or platform The weights of these components must be added for the total weight Table 1 27 Pressure Settings Upper boomLiftDownRelief 1400PSI 97Bar Swing Re...

Page 28: ...ing Bearing Internal Ball Bearing Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Access Figure 1 1 Operator Maintenance and Lubrication Diagram Table 1 29 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350 F 177 C Excellentwaterresistanceandadhesivequalities and beingof extremepr...

Page 29: ...ck position and Check port at 3 o clock position Pour lubri cant into fill port until it just starts to flow out of check port 4 Hydraulic Return Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator 5 Hydraulic Charge Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition I...

Page 30: ...accor dance with engine manual 9 Oil Change w Filter Deutz Lube Point s Fill Cap Spin on Element Capacity 11 Quarts 10 5 L Crankcase Lube EO Interval Every Year or 1200 hours of operation Comments Check level daily Change in accor dance with engine manual Refer to Figure 1 2 Deutz Engine Dipstick MINIMUM LEVEL OIL HOT MINIMUM OIL LEVEL MINIMUM LEVEL OIL COLD NOTE Hot oil checks should not be made ...

Page 31: ...able Element Interval Every Year or 600 hours of operation 13 Fuel Filter Gasoline GM Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation 14 Air Filter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator 15 Electronic Pressure Regulator LP only Interval 3 Months or 150 hours of operation Commen...

Page 32: ...UID AND FLOW FREELY FROM THE REGULATOR 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 running close the manual tank valve and run the engine out of fuel 4 Push in the Emergency Switch once the engine stops 5 Disconnect the electrical connection to the LPG fuel temperature sensor in...

Page 33: ... ING 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 the filter hous ing 5 Install the filter into the housing 6 Install the retaining bolt into the filter housing 7 Install the filter up to the bottom of the electric lock off 8 Tighten the filter retaining bolt to 106 ...

Page 34: ... PROPANE FUEL SYSTEM PRES SURE WHERE APPLICABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS To relieve propane fuel system pressure 1 Close the manual 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 WORK AREA IS WELL VENTILATED BEFORE DISCONNECTIN...

Page 35: ...SECTION 1 SPECIFICATIONS 3121160 JLG Lift 1 15 Figure 1 4 Torque Chart SAE Fasteners Sheet 1 of 3 ...

Page 36: ...SECTION 1 SPECIFICATIONS 1 16 JLG Lift 3121160 Figure 1 5 Torque Chart SAE Fasteners Sheet 2 of 3 ...

Page 37: ...SECTION 1 SPECIFICATIONS 3121160 JLG Lift 1 17 Figure 1 6 Torque Chart SAE Fasteners Sheet 3 of 3 ...

Page 38: ...SECTION 1 SPECIFICATIONS 1 18 JLG Lift 3121160 Figure 1 7 Torque Chart METRIC Fasteners Sheet 1 of 3 ...

Page 39: ...SECTION 1 SPECIFICATIONS 3121160 JLG Lift 1 19 Figure 1 8 Torque Chart METRIC Fasteners Sheet 2 of 3 ...

Page 40: ...SECTION 1 SPECIFICATIONS 1 20 JLG Lift 3121160 Figure 1 9 Torque Chart METRIC Fasteners Sheet 3 of 3 ...

Page 41: ...machine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection duri...

Page 42: ...their contain ers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an ey...

Page 43: ...values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices See Torque Chart Section 1 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Keep the syste...

Page 44: ...300 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifications appearing in this man ual If unable to obtain the same type of oil supplied with the machine consult local supplier for assis tance in selecting the proper equivalent Avoid mix ing petroleum and synthetic base oils JLG Industries recommends changing the hydraulic oil annually 2 Use...

Page 45: ...using should be blown out to remove all dirt and debris bearings and bearing housings must be free of all contamination b Bearing pins should be cleaned with a solvent to remove all grease and oil filament wound bearing are a dry joint and should not be lubri cated c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam age the bearing during installation and o...

Page 46: ...Pads 1 2 1 2 CoversorShields 1 2 1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly 9 Platform 1 2 1 2 Railing 1 2 1 1 2 Gate 5 1 1 5 Floor 1 2 1 1 2 Rotator 9 5 15 LanyardAnchoragePoint 2 1 2 10 1 2 10 TurntableAssembly 9 SwingBearingorWormGear 1 2 14 1 2 3 13 14 OilCoupling 9 SwingDriveSystem TurntableLock 1 2 5 1 2 5 Hood HoodProps HoodLatches 5 1 2 5 ChassisAssembly 9 Tires 1 1...

Page 47: ...icSystem 9 HydraulicPumps 1 9 1 2 9 HydraulicCylinders 1 9 7 2 1 2 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 9 1 2 1 2 HydraulicHoses Lines andFittings 1 9 12 1 2 9 12 1 2 9 12 HydraulicReservoir Cap andBreather 11 1 9 2 1 5 1 5 24 HydraulicFilter 1 9 7 7 HydraulicFluid 11 7 11 7 11 ElectricalConnections 1 20 20 Instruments Gauges Switches Lights Horn 1 5 23 General OperatorsandSafetyManuals...

Page 48: ...ureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwhenreleased 7 Cleanandfreeofdebris 8 Interlocksfunctionproperly 9 Checkforsignsofleakage 10 Decalsinstalledandlegible 11 Checkforproperfluidlevel 12 Checkforchafingandproperrouting 13 Checkforpropertolerances 14 ...

Page 49: ... OIL COOLER CONSULT JLG SERVICE 180 F 82 C 40 F 40 C 30 F 34 C 20 F 29 C 10 F 23 C 0 F 18 C 10 F 12 C 20 F 7 C 30 F 1 C 40 F 4 C 50 F 10 C 60 F 16 C 70 F 21 C 80 F 27 C 90 F 32 C 100 F 38 C 110 F 43 C 120 F 49 C AMBIENT AIR TEMPERATURE PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE NO OPERATION BEL...

Page 50: ...SECTION 2 GENERAL 2 10 JLG Lift 3121160 Figure 2 2 Engine Operating Temperature Specifications Ford 4150548 E ...

Page 51: ...SECTION 2 GENERAL 3121160 JLG Lift 2 11 Figure 2 3 Engine Operating Temperature Specifications GM 4150548 E ...

Page 52: ...SECTION 2 GENERAL 2 12 JLG Lift 3121160 NOTES ...

Page 53: ...r 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 the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG Industries Inc do not replace a foam filled or ballast filled tire assembly with a pneumatic tire W...

Page 54: ...ain any residual hydrau lic fluid place container under the lockout cylinder 5 With the left lock out cyl retracted open the bleeder on top of the cylinder then have an operator from the platform on high engine feather drive Activate drive just enough so the engine is under load but not enough to stall the engine 6 Close the bleeder when there is a steady stream of oil and not air 7 With the axle ...

Page 55: ... may be necessary acti vate DRIVE to release cylinders 9 Place the 6 inch 15 2 cm high block with ascension ramp in front of right front wheel 10 Place DRIVE control lever to FORWARD and care fully drive machine up ascension ramp until right front wheel is on top of block 11 Carefully activate SWING control lever and position boom over left side of machine 12 With boom over left side of machine pl...

Page 56: ...overed until use 3 Inspect bearing mounting surfaces on spindle hub input shaft and carrier Replace components as nec essary 4 Inspect all geared components for chipped or bro ken teeth and for excessive or uneven wear pat terns 5 Inspect carrier for damage especially in anti roll pin and planet shaft hole areas 6 Inspect all planet shafts for scoring or other dam age 7 Inspect all threaded compon...

Page 57: ...g and Inspection procedures Replace parts as necessary h Apply a coat of grease or petroleum jelly to clus ter gear bore i Place sixteen needle rollers into cluster gear bore j Place spacer into opposite side of cluster gear and against needle rollers k Place second set of sixteen needle rollers into cluster gear l Apply grease or petroleum jelly to tang side of two thrust washers Place thrust was...

Page 58: ... 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 Cleaning and Inspection procedures Replace parts as necessary d Place washer 31 spring 32 and washer 31 in that order onto input shaft Install retaining ring into input shaft groove to secure spacers and spring to shaft Assembly 1 Using a suitable press pres...

Page 59: ...hub onto spindle 1 with large open end up 5 Place bearing cone 6 over end of spindle and into bearing 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 ring 9 completely into spindle groove and against bearing shim Ensure retaining ring is entirely in groove 8 Place internal gear 12 onto ...

Page 60: ...roove 11 Place input shaft assembly 35 into spindle bore with unsplined end facing out 12 Place thrust spacer 36 over input shaft 35 with counter bore side facing spindle 13 Locate the four counter reamed holes in the face of the hub mark them for later identification 14 Place o ring 22 into hub counter bore Use petro leum or grease to hold o ring in place Slight stretch ing of o ring may be neces...

Page 61: ... holding ring gear input gear and cluster gears in mesh place small side of cluster gears into mesh with internal gear On ring gear locate hole marked X over one of counter bored holes in hub NOTE If gears do not mesh easily or carrier assembly does not rotate freely then remove carrier and ring gear and check cluster gear timing 18 Install input gear 37 into carrier meshing with large diameter cl...

Page 62: ...l check plug in cover located approximately 90 degrees from oil fill plug in hub 23 Locate four shoulder bolts 42 90 degrees apart into counter bored holes in hub marked in step 13 Torque shoulder bolts to 47 ft lbs 64 Nm 24 Install bolts 41 in remaining holes Torque bolts to 47 ft lbs 64 Nm 25 Place coupling 1 into spindle and onto input shaft 26 Fill hub one half full of EPGL 90 lubricant before...

Page 63: ...ternal Gear 13 Carrier 14 Thrust Washer 15 NeedleRoller 16 Spacer 17 PistonShaft 18 ClusterGear 19 RollPin 20 Not Used 21 ClusterGear 22 O ring 23 Cover 24 CoverCap 25 Bolt 26 DisconnectCap 27 DisconnectRod 28 O ring 29 O ring 30 PipePlug 31 Washer 32 Spring 33 RetainingRing 34 RetainingRing 35 InputShaft 36 Thrust Spacer 37 InputGear 38 Not Used 39 Thrust Washer 40 Thrust Bearing 41 Bolt 42 Shoul...

Page 64: ... found to be in good condition Assembly NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY IN THE CASE OF SPRINGS SPACE THE SPRINGS AS SHOWN IN FIGURE 3 4 1 Worn o rings and damaged or worn Teflon backup rings must be replaced prior to assembly 2 The ...

Page 65: ...in 4 Ball Bearing 5 RetainingRing 6 Seal 7 SpringRetainer 8 Small CompressionRing 9 LargeCompressionRing 10 Shaft 11 PrimaryDisc 12 RotatingDisc 13 NotUsed 14 StationaryDisc 15 Piston 16 BackupRing 17 O ring 18 BackupRing 19 O ring 20 Bleeder Screw 21 PowerPlate 22 ProtectivePlug 23 Washer 24 Bolt 25 Gasket ...

Page 66: ...it is flush with bearing shoulder Note direction of seal 3 Press bearing 18 into position until it bottoms out on borestep NOTE Cover plate 16 must be supported as indicated in Figure 1 4 Install retaining ring 20 in cover plate 16 5 Press shaft 10 into bearing 18 until it bottoms on shoulder NOTE Bearing 18 inner race and cover plate 16 must be supported as indicated in Figure 1 during this opera...

Page 67: ...PressurePlate 4 CaseSeal 5 O ring 6 BackupRing 7 Piston 8 O ring 9 Backup Ring 10 Shaft 11 StatorDisc 12 RotorDisc 13 ReturnPlate 14 Springs 15 Dowel Pin 16 CoverPlate 17 Oil Seal 18 Bearing 19 Retaining Ring 20 Retaining Ring Figure 3 5 Drive Brake Mico S N 56875 to 83332 ...

Page 68: ...red Discplatesworn Thethicknessofthediscstacksetsthe torquelevel Athinstackreducestorque Checkdiscthickness Springsbrokenorhavetakenaperma nentset Brokenorsetspringscancausereduced torque arareoccurrence Checkreleasepressure Seespring replacement Brakedragsorrunshot Lowactuationpressure Thebrakeshouldbepressurizedtomini mumof1 38bar 20psi overthefull releasepressureundernormaloperating conditions ...

Page 69: ...ge or fatigue 5 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 not to damage seal lip 2 Apply ring of Loctite 641 or equivalent adhesive to full circumference of housing 2 bearing recess adjacent to shoulder Apply complete coverage of Loctite 641 to...

Page 70: ...ft 2 Housing 3 FrictionPlate 4 Pressure Plate 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 BackupRing 19 DowelPin 20 Plug 21 Plug 22 Spring Natural 23 Spring Blue Figure 3 6 Drive Brake S N 83332 to Present ...

Page 71: ...nan 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 corresponding to the order retain ing plate and retaining ball Swash Plate Parts of the control device control piston piston rod plug spring stopper max flow hex nut and hex head nut Spare parts kit DFR pil...

Page 72: ...RNTABLE 3 20 JLG Lift 3121160 Replacing the Drive Shaft Seal 1 Remove the snap ring 2 Change the shaft seal and check its sliding surface drive shaft and housing grease the sealing ring Figure 3 7 600S Drive Motor Cutaway ...

Page 73: ...hold the sealing ring in the correct position in the pump housing 5 Assemble the snap ring 6 Assemble the snap ring in the correct position Disassembly and Assembly 1 Disassemble the pilot valve 2 Mark the position of the port plate and remove the socket screw from the port plate 3 Remove the port plate together with the valve plate hold the valve plate so that the plate can t fall down ...

Page 74: ...r roller bearing 6 Remove the adjustment shim 7 Unscrew the cap nut and remove it 8 Loosen the retaining nut of the stopper max flow and remove it 9 Turn in the stopper max flow to get swivel angle zero 10 Disassemble the rotary group in horizontal position 11 Disassemble the stopper max flow ...

Page 75: ... max flow 13 Disassemble the plug 14 Disassemble the control piston while moving the swash plate 15 The swash plate must be lifted a little bit to disas semble the piston rod 16 Disassembly of the swash plate 17 Remove the spring 18 Remove both bearing shells 19 Remove the drive shaft ...

Page 76: ... housing 23 Remove the O ring Lifting of the valve plate isn t shown 24 A usual commercial bearing puller is used to disas semble the external bearing ring of the taper roller bearing inside the port plate Take care not to dam age the surface of the port plate 25 The spring has additional pretension while you dis assemble the three pressure pins inside the cylinder ...

Page 77: ...drive direction Note spare parts exist as cw and ccw valve plates 4 Pumps counterclockwise driven must have a posi tion of the valve plate 4 degrees de centered in ccw position 5 Assembly of the port plate and the pump housing Note the correct position of the drilling that connects high pressure to the control valve Check control valve drill position at the pump housing and fit together Taper Roll...

Page 78: ...SECTION 3 CHASSIS TURNTABLE 3 26 JLG Lift 3121160 NOTE Differential volume if you are rotating the threaded pin each rotation is appr 3 1 cm3 Figure 3 8 Flow Control Pilot Valves ...

Page 79: ... While screwing in the threaded pin you will be able to reduce the flow from Vg max to 50 of Vg max 3 9 DRIVE MOTOR ADJUSTMENT PROCEDURE PRIOR TO S N 83332 1 Remove the cap nut from adjustment screw 2 Loosen jam nut on the adjustment screw and make adjustment 3 Measure from top of jam nut to the end of adjust ment screw Refer to Figure 3 9 Drive Motor Adjust ment Prior to S N 83332 4 Tighten jam n...

Page 80: ...ully pry out the shaft seal 3 To avoid damaging the shaft during removal install a large sheet metal screw into the chuck of a slide hammer Drive the screw into the seal surface and use the slide hammer to pull the seal 4 Discard the seal INSPECT THE COMPONENTS Inspect the new seal the motor housing seal bore and the sealing area on the shaft for rust wear and contami nation Polish the shaft and c...

Page 81: ...tion Also check springs and poppet for wear INSTALLATION 1 Install orifice poppet 13 2 Install shift spool 12 3 Install spring retaining washers onto springs 10 and 11 4 Carefully install centering springs 7 8 and 9 5 Install new O rings 6 4 and 5 6 Using a 1 4 in hex wrench torque plug 3 to 20 ft lbs 27 Nm 7 Using a 11 16 in internal hex torque plugs 2 and 1 to 27 ft lbs 37 Nm 2 6 9 11 1 4 8 10 1...

Page 82: ...eservoir andoilsupplytothepump Insufficientamountofhydraulicfluidwillnotmeetthecooling demandsofthesystem Fillthereservoirtotheproperlevel Inspecttheheatexchanger ifsoequipped Iftheheatexchangerfails orbecomesobstructed itmaynot meetthecoolingdemandsofthesystem Ensurethatheatexchangerisreceivingadequateairflowand thattheheatexchangerisingoodoperatingcondition Repair orreplaceasnecessary Checkthesy...

Page 83: ...speed sensor lock nut 14 if equipped Then remove the speed sensor using a Vi inch hex wrench Units with out speed sensor have an O ring plug 15 installed in that location remove it with a Va inch internal hex wrench 10 Using a 1 4 inch internal hex wrench remove control line plugs 16 17 Discard O rings Using a 3 mm hex wrench remove cavity plug 18 if equipped with two line control from X2 cavity 1...

Page 84: ...e last two digits of the valve plate part number are stamped on its surface 16 Remove and discard the O rings 27 28 17 Remove the rear shaft bearing 29 from the endcap with a bearing puller The bearing may be difficult to remove with a puller Try this as an alternative Pack the bearing cavity with heavy grease After the shaft is removed insert it into the bearing cavity and tap lightly with a soft...

Page 85: ...haft seal 34 Discard the seal To avoid damaging the shaft during seal removal Install a large sheet metal screw into the chuck of a slide hammer Drive the screw into the seal surface and use the slide hammer to pull the seal 21 Remove the inner snap ring 35 and the shaft bearing assembly 22 Remove the snap ring 36 retaining the shaft front bearing Pull the bearing 37 off of the shaft 38 Table 3 6 ...

Page 86: ...ld down pins 48 and retaining ring 49 from the cylinder block NOTE Most repairs do not require block spring removal Perform this procedure only if you suspect problems with the block spring RISK OF PERSONAL INJURY COMPRESSING THE BLOCK SPRING REQUIRES FORCE OF ABOUT 80 TO 90 LBF 350 TO 400 N USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON ABLE EFFORT ENSURE THE SPRING IS SECURE BEFORE AT...

Page 87: ...ith scored or excessively rounded slipper edges Measure the slipper foot thickness Replace any piston assemblies with excessively worn slip pers Check the slipper axial end play Replace any piston assemblies with excessive end play Minimum slipper foot thickness and maximum axial end play are given in the table below CYLINDER BLOCK Measure the cylinder block height Replace blocks worn beyond the m...

Page 88: ...iding the surface condition meets specifi cations shown Measure the swashplate thickness from the journals to the running face Replace swashplate if damaged or worn beyond minimum specification Replace swashplate if the difference in thickness from one side to the other exceeds specification Inspect the journal bearings for damage or excessive wear Replace journal bearings if scratched warped or e...

Page 89: ... 3 Install the piston seal over the O ring Installing the piston seal stretches it making it diffi cult to install the servo piston in its bore Allow 30 minutes for the seal to relax after installation To speed up seal relaxation compress the seal by installing the piston head into the servo cavity in the end cap and let it stand for at least five minutes 2 After piston seal has relaxed lubricate ...

Page 90: ...of the 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 aside on a clean sur face until needed 6 Install the journal bearings 13 into the housing seats Use assembly grease to keep the bearings seated during assembly Ensure the locating nubs drop into th...

Page 91: ...it 19 onto the shaft Install with the slippers facing the swashplate Rock the shaft to align the block splines and slide the cylinder kit into place Orient the motor with the shaft pointing down ward and verify the cylinder kit swashplate journal bearings and servo piston are all secure and prop erly installed 11 Lubricate and install the servo spring 20 and mini mum angle stop 21 into the housing...

Page 92: ...e endcap 25 onto the housing with the endcap screws 26 Check to ensure the endcap will properly seat onto the housing without interfer ence Improper assembly of the internal compo nents may prevent the endcap from seating properly Ensure the O rings seat properly when installing the endcap 16 Using an 8 mm internal hex wrench tighten the end cap screws Tighten the screws in opposite corners slowly...

Page 93: ...seal Install seal support washer 28 and snap ring 29 19 Install remaining plugs and fittings to the housing Refer to the drawing below for wrench sizes and installation torques 29 28 27 27 ShaftSeal 28 Seal SupportWasher 29 SnapRing Figure 3 30 Shaft Seal 1 4 in 45 Nm 33 ft lbs 5 16 in 85 Nm 63 ft lbs 5 16in 85 Nm 63 ft lbs 1 4 in 45 Nm 33 ft lbs 9 16 in 170 Nm 125 ft lbs 3 mm 2 03 to 3 39 Nm 1 5 ...

Page 94: ...luid 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 upper most case drain ports 5 Install a 0 to 500 psi 0 to 35 bar gauge in the charge pressure gauge port of the pump to monitor system pressure during start up 6 While watching the pressure gauge run the engine at the lowest possible speed until ...

Page 95: ...1 to 120 ft lbs 17kgm w 242 Loc tite 4 Torque Items 2 to 285 ft lbs 40kgm w 171 Loc tite 5 Position swing drive to approx location of bearing gear max eccentric tooth high spot 6 With bearing free to slide shim between pinion gear and the bearing teeth to 008 012 20mm 30mm backlash 7 Alternately torque setscrews item 4 to 30 ft lbs 42 Nm run jam nut tight against the 1 block 8 Torque item 3 to 165...

Page 96: ...ontal See Figure 3 35 b At the positions indicated on Figure 3 36 try to insert a 0015 feeler gauge between the bolt and hardened washer at the arrow indicated posi tion c Ensure that the 0015 feeler gauge will not pene trate under the bolt head to the bolt shank d Swing the turntable 90 degrees and check some selected bolts at the new position e Continue rotating the turntable at 90 degrees inter...

Page 97: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 45 Figure 3 34 Swing Bearing Tolerance Boom Placement Sheet 1 of 2 ...

Page 98: ...SECTION 3 CHASSIS TURNTABLE 3 46 JLG Lift 3121160 Figure 3 35 Swing Bearing Tolerance Boom Placement Sheet 2 of 2 ...

Page 99: ... CENTER OF ROTATION BECAUSE OF THIS PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION Swing Bearing Replacement 1 Removal a From Ground Control station operate the boom adequately to provide access to frame opening to rotary coupling NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND OR BLOCKING b Attach an ...

Page 100: ...he bearing aligns with the scribed line on the frame If a new swing bearing is used ensure that the filler plug fitting is at 90 degrees from the fore and aft center line of the frame JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE IT IS IMPERATIVE THAT SUCH REPLACE...

Page 101: ... brack ets apply a light coating of Loctite 242 to the attaching bolts and secure the yoke to the turn table with the mounting hardware k Connect the hydraulic lines to the rotary cou pling as tagged prior to removal l At ground control station use boom lift control to lower boom to stowed position m Using all applicable safety precautions activate the hydraulic system and check the swing sys tem ...

Page 102: ... Thrust Washers 3B will be removed with the Cluster Gear 3F 13 The Needle Rollers 3C and Spacer 3D are now removed from the Cluster Gear 3F WHEN REBUILDING OR REPAIRING THE UNIT THE RETAINING RING 1I O RINGS 5 AND SEAL 1B SHOULD ALWAYS BE REPLACED Assembly 1 With the Hub Shaft Sub assembly resting on the Shaft 1A install Internal Gear 2 The Spline of the Internal Gear 2 bore will mesh with the Spl...

Page 103: ...rge gears Be sure that punch marks remain in correct location during Ring Gear installation The side of the Ring Gear with an X stamped on it should be up 7 While holding Ring Gear 4 and Cluster Gears 3F in mesh place small side of Cluster Gears 3F into mesh with the Internal Gear 2 and Input Gear 13 On the Ring Gear locate the hole marked X over one of the marked counterbored holes Step 3 in Hub ...

Page 104: ...EDGES OF THE COUNTERBORE WHILE SEATING THIS O RING 12 The Cover 6 is now installed on this assembly Tak ing care to correctly align Pipe Plug hole 20 with those in the Hub 1J usually 90 to one another Locate the 4 counterbore holes in Hub 1G marked in Step 3 and install 4 Shoulder Bolts 13 A slight tap with a hammer may be necessary to align Shoul der Bolt with Hub 1G counterbore 13 Install regula...

Page 105: ... into Hub 1G taking care to insure cup start square with the bore of Hub 1G 3 Invert Hub 1G and press Bearing Cup 1E into intercounterbore of Hub 1G 4 Returning the Hub 1G to locate on the large diame ter end the Output Shaft 1A is carefully installed into the Hub 1G 5 The Shaft Seal 1B is installed over the Output Shaft 1A and into the counterbore of the Hub 1G Care should be taken to insure the ...

Page 106: ...talled into the groove provided in the Output Shaft 1A This Retaining Ring 1l should never be reused in a repair or rebuild EYE PROTECTION SHOULD BE WORN DURING THIS PROCE DURE 10 A soft metal punch should be used to insure that this Retaining Ring 11 is completely seated in the groove of the Output Shaft 1A EYE PROTECTION SHOULD BE WORN DURING THIS PROCE DURE 11 Upon completion of Step 10 rap the...

Page 107: ...eedle Rollers into Cluster Gear bore 3 Place Spacer washer into opposite side of Cluster Gear and against Needle Rollers 4 Place second set of sixteen Needle Rollers into Clus ter Gear 5 Apply grease or petroleum jelly to the tang side of two Thrust Washers Place Thrust Washers against bosses in Carrier with washer tang fitting into slot in Carrier outside diameter NOTE Some old style Carriers wil...

Page 108: ...th the small pin hole 7 Line up Cluster Gear and thrust Washers with hole in Carrier and slide Planet Shaft through Line up chamfered side of hole in Planet Shaft with pin hole in Carrier 8 Drive Anti Roll Pin flush into Carrier hole thereby locking Planet Shaft into place 9 Repeat these steps for remaining two Cluster Gears to complete Carrier Sub Assembly ...

Page 109: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 57 Figure 3 39 Swing Hub ...

Page 110: ...to be in good condition Assembly NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY IN THE CASE OF SPRINGS SPACE THE SPRINGS AS SHOWN IN FIGURE 3 40 1 Worn o rings and damaged or worn Teflon backup rings must be replaced prior to assembly 2 The cylind...

Page 111: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 59 Figure 3 40 Swing Brake Assembly Ausco Prior to S N 0300068040 ...

Page 112: ... mounting flange with soft vise jaws 2 Remove the 7 cap screws from the end cap and dis assemble the motor as shown 3 Unclamp the motor and remove the output shaft thrust needle bearing and thrust bearing race 4 Clamp the motor in a vise so the mounting flange is on top Clamp across the port area Do not clamp on motor housing Use just enough clamping force to hold the motor securely 5 Remove the f...

Page 113: ... dry with paper towels or cloth Lint in a hydraulic system will cause damage Check the key way and chamfered area of the output shaft remove any nicks burrs or sharp edges that could damage the shaft seal during assembly NOTE Always use new seals when reassembling hydraulic motors DURING REASSEMBLY LUBRICATE THE NEW SEALS WITH A PETROLEUM JELLY LIKE VASELINE ALSO LUBRICATE MACHINED SURFACES AND BE...

Page 114: ...iming dot on shaft BE SURE THE SLOTS IN THE SPACER PLATE PROVIDE PASSAGE FOR HYDRAULIC FLUID AS WELL AS THE CAP SCREWS IF THE SPACER PLATE IS FLIPPED THE MOTOR WILL NOT OPERATE 3 Lightly stretch lubricate and install the second of the three larger diameter seals in the groove in the Geroler Standard Timing Align any star point with threaded hole noted for the location of the timing dot Reverse Tim...

Page 115: ...xclusionSeal 3 Mounting Flange 4 Backup Ring 5 PressureSeal 6 Seal 7 Bearing Race 8 NeedleThrust Bearing 9 Key 10 OutputShaft 11 Housing 12 Seal 13 Drive 14 SpacerPlate 15 Seal 16 Geroler 17 Seal 18 End Cap 19 Capscrew Figure 3 42 Swing Motor Prior to S N 0300068040 ...

Page 116: ... cone 1F Bearing cone 1D will remain on the same output shaft 1A The seal 1B will be automatically removed during this procedure NOTE If bearing replacement is necessary the bearing cups can be removed with a slide hammer puller driven out with a punch 11 To remove the cluster gears 3F from the carrier 3A drive the anti roll pin 3G into the planet shaft 3E may now be tapped out of the carrier Afte...

Page 117: ...ocate at 12 0 clock straight up from each planet pin Marked tooth will be located just under the car rier 3A on upper two gears 3F 6 With shoulder side of ring gear 4 facing down place ring gear over into mesh with large gears Be sure that punch marks remain in correct location during ring gear installation The side of the ring gear with an x stamped on it should be up 7 While holding ring gear 4 ...

Page 118: ...talled into the counterbore of the carrier 3 11 Place O ring 5 into cover 6 counterbore Use petroleum jelly to hold O ring in place BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEAT ING THIS O RING 12 The cover 6 is now installed on this assembly Tak ing care to correctly align pipe plug hole 20 with those in the hub 1J usually 90 to one another Locate the 4 counterbore holes in hub 1G marked in...

Page 119: ... operation if the unit is mounted horizontally and completely filled if mounted vertically In vertical mounting application case oil circula tion is recommended Hub Shaft Sub Assembly 1 Press bearing cone 1D onto shaft 1A 2 Press bearing cup 1C into hub 1G taking care to insure cup start square with the bore of the hub 3 Invert hub 1G and press bearing cup 1E into inter counterbore of hub 1G 4 Ret...

Page 120: ...e 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 installed at this time in the assembly 8 Bearing spacer 1H is installed around the output shaft 1A and locates on bearing cone 1F 9 Retaining ring 1I installed into groove provided in the output shaft 1A This retaining ring 1I should never be reused in a re...

Page 121: ...ut shaft 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 used right away it should be oiled and covered to help prevent rust ing Carrier Sub Assembly 1 Apply a coat of grease or petroleum jelly to cluster gear bore 2 Place sixteen needle rollers into clu...

Page 122: ...ill 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 cluster gear and thrust washer with hole in carrier and slide planet shaft through Line up cham fered side of hole in planet shaft with pin hole in car rier 8 Drive anti roll pin flush into carri...

Page 123: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 71 Figure 3 43 Swing Drive Hub Fairfield S N 0300068040 to Present ...

Page 124: ...h bearing shoulder Note direction of seal 3 Press bearing 18 into position until it bottoms out on borestep 4 Install retaining ring 20 in cover 16 5 Press shaft 9 into bearing 18 until it bottoms on the shoulder Bearing 18 inner race must be sup ported during this operation 6 Install retaining ring 19 on shaft 9 7 Insert dowel pins 15 spring retainer 14 and springs 13 in cover 16 NOTE Be sure to ...

Page 125: ...o Present ItemsIncludedinRepairKit 1 Capscrew 2 PressurePlate 3 Case Seal 4 O ring 5 Backup Rings 6 Piston 7 O rings 8 Backup Rings 9 Shaft 10 StatorDisc 11 RotorDisc 12 ReturnPlate 13 Springs 14 SpringRetainer 15 Dowel Pin 16 Cover 17 Oil Seal 18 Bearing 19 Retaining Ring 20 Retaining Ring ...

Page 126: ...how motor in a vise we recom mend that you keep the motor in a vise during disassem bly Follow the clamping procedures explained throughout the manual 1 Place motor in vice and clamp across edge of flange with output shaft down When clamping use protec tive device on vice such as special soft jaws pieces of hard rubber or board 2 remove cap screws and seal washers 3 Remove end cap 4 Remove seal fr...

Page 127: ...ired to remove screw Use small flame pro pane torch to heat small area of housing where screw enters see figure below Be careful not to overheat hous ing and damage motor Gradually apply torque to screw with socket wrench as heat is applied for 8 to 10 seconds As soon as screw breaks loose remove heat from hous ing Continue turning screw until it is completely removed 15 Carefully remove flange fr...

Page 128: ...e new seals when reassembling motor DO NOT STRETCH SEALS BEFORE INSTALLING THEM Cleanliness is extremely important in the successful appli cation of Loctite Before Loctite can be applied the parts should be cleaned as follow NOTE Fully cured Loctite resists most solvents oils gaso line and kerosene and is not affected by cleaning operations It is not necessary to remove cured Loc tite that is secu...

Page 129: ... tube and firmly push seal seat with a rotating action AFTER INSTALLING SEAL IN FLANGE EXAMINE SEAL CONDI TION IF DAMAGED OR IMPROPERLY INSTALLED YOU MUST REPLACE IT BEFORE CONTINUING WITH REASSEMBLY 7 Install 49 mm 1 937 in I D seal in flange 8 It is recommended to apply a light coat of Loctite Primer NF in tapped holes of housing Allow primer to dry for at least 1 minute Do not force dry with ai...

Page 130: ...w screws make sure they are correct length 22 mm 0 875 in under head length See parts book for correct part number GEROTOR END 1 Reposition motor with gerotor end up then clamp across ports Do not clamp on side of housing TO AID INSTALLATION OF SEALS APPLY LIGHT COAT OF CLEAN PETROLEUM JELLY TO SEALS DO NOT STRETCH SEALS BEFORE INSTALLING THEM IN GROOVE 2 Pour approximately 35 cc of clean hydrauli...

Page 131: ... to disengage star from drive or disturb gerotor seal 2 Install drive spacer if applicable 3 Install 73 mm 2 875 in seal in end cap Carefully place end cap on gerotor 4 Install cap screws and seal washers if applicable in end cap Pre tighten screws to 7 4 Nm 40 in lbs Make sure seal washers are properly seated Then torque screws to 27 28 Nm 235 250 in lbs in sequence as shown above ...

Page 132: ... Race 8 NeedleBearingThrust 9 Output Shaft 10 SealWasher When Applicable 11 Capscrew 12 Plug O ringS A 13 EndCap 14 Seal 15 DriveSpacer WhenApplicable 16 Gerotor 17 Seal 18 SpacerPlate 19 Drive 20 Seal 21 Housing 22 Plug 23 Seal 24 Plug O ring S A End Ported Motors 25 O ring 26 O ring 27 Optional Base BlockMounting Kit 28 Capscrew Figure 3 45 Swing Motor ...

Page 133: ...ge the spool and seals if left in place 2 Remove snap ring 7 from end 3 Remove thrust ring 3 from the same end 4 Remove center body 1 from housing 3 5 Cut off old seals 2 4 5 6 Assemble lip seals 2 in direction shown in Figure 3 46 Rotary Coupling Seal Installation 7 Reassemble O ring 4 8 Heat cap seals 5 in hydraulic oil for 5 minutes at 300 F 149 C 9 Assemble cap seals over O rings 10 Reinsert c...

Page 134: ...SECTION 3 CHASSIS TURNTABLE 3 82 JLG Lift 3121160 1 CenterBody 2 Seal 3 Housing 4 O ring 5 Seal 6 Thrust Ring 7 SnapRing 8 Valve Block Axle Oscillation Figure 3 47 Rotary Coupling Cutaway ...

Page 135: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 83 Figure 3 48 Rotary Coupling Port Location ...

Page 136: ... 15 14 13 12 11 8 3 8 2 5 1 4 8 6 1 Loctite 242 2 Bolt 3 Bolt 4 Bolt 5 Bracket 6 RotaryCoupling 7 Spool 8 RetainingRing 9 Plug 10 TorqueLug 11 Ring 12 Seal 13 O ring 14 Bearing 15 Cap Seal 16 O ring 17 Valve 18 CheckValve 19 Case 20 PlungerValve Figure 3 49 Rotary Coupling Installation ...

Page 137: ... been tightened too far Loosen the X nut and repeat steps 2 through 4 LIMIT SWITCHES ADJUSTMENTS 3 21 SPARK ARRESTER CLEANING INSTRUCTIONS 1 1 Remove the cleanout plug in the bottom of spark arrester muffler 2 Without causing deformation or any type of dam age to the spark arrester repeatedly tap on the arrester near the cleanout plug This may be enough to begin drainage of the spark trap 3 An ind...

Page 138: ...SECTION 3 CHASSIS TURNTABLE 3 86 JLG Lift 3121160 A B D D B C Figure 3 51 Auxiliary Pump Sheet 1 of 2 ...

Page 139: ...aft 15 Key 16 Retaining Ring 17 Gear 18 GearHousing 19 BetaPlug 20 Screw 21 DowelBushing 22 ValveBlock 23 Screw 24 NeedleBearing 25 Pin 26 IdlerShaft 27 Ball 28 Spring 29 Spring 30 Gasket 31 AdjustmentScrew 32 HexCap 33 O ring 34 LogicValve 35 I D Label 36 ShearPin 37 PlasticCap 38 PlasticCap 39 PlasticCap A Torque180to216inch pounds 20to24Nm B Torque114to150inch pounds 13to17Nm C Torque144to180in...

Page 140: ...rushes and Cleaning Slip Rings Refer to Figure 3 53 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings INSPECTING BRUSH POSITION Inspect brush alignment with slip rings 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 assembly Pull the br...

Page 141: ...ess Replace 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 53 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings 1 BrushHolderAssembly 2 Brushes 3 SlipRings ...

Page 142: ... source of the problem If no matching symptom is available analyze the com plaint and develop a plan for diagnostics utilizing the wir ing diagrams technical assistance and repair history Intermittent conditions may be resolved by using a check sheet to pinpoint the circuit or electrical system compo nent Some diagnostic charts contain Diagnostic Aids which give additional information about a syst...

Page 143: ...e last fuel injection pulse and the engine will continue to nun As long as the fault is present the engine can be restarted It will run in the previously established injection sequence ENGINE COOLANT TEMPERATURE ECT SENSOR The engine coolant temperature ECT sensor is a g thermistor a resistor which changes value based on tem perature mounted in the engine coolant stream Low coolant temperature pro...

Page 144: ...ant Temperature ECT Sensor High Voltage 35 Intake Air Temperature IAT Sensor High Voltage 41 Fuel Pump High Voltage 42 Heated Oxygen Sensor HO2S High Voltage 43 Engine Coolant Temperature ECT Sensor Low Voltage 45 Intake Air Temperature IAT Sensor Low Voltage 51 Low Oil Pressure 52 Crankshaft Position CKP Sensor Extra Missing Pulses 53 Camshaft Position Sensor CMP Sensor Illegal Pattern 54 Engine ...

Page 145: ...mits it is limited at 35 When this condition occurs the EPM perceives the engine to be running rich 125 Closed Loop Multiplier High Natural Gas This fault sets if the Closed Loop multiplier exceeds the limits of nor mal operation When the multiplier cannot correctly modify the fuel flow within its limits it is limited at 35 When this fault occurs it is because the EPM perceives the engine to be ru...

Page 146: ...1 will be enforced During this fault maximum throttle position is 50 and the MIL light will flash twice per second 214 IAT Higher Than Expected 2 This fault will set if the Intake Air Temperature is greater than 210 deg F and engine RPM is greater than 1000 The MIL light will be on during this active fault and the engine will shut down 215 Oil Pressure Low This fault canbe configured two different...

Page 147: ... psia 254 Excessive Knock Signal This fault will set if the Knock Sensor input to the EPM is greater than 4 5 volts while MAP is less than 8 psia and knock spark retard is at maximum 311 Injector Driver 1 Open 2 5L This fault will set if the EPM detects low feedback voltage on the inter nalinjectorwhiletheinjectordrivecircuitisintheoff stateandbattery voltage is greater than 9 volts 312 Injector D...

Page 148: ...l firings which require the adaptive dwell to be greater than allowed with the battery voltage above 11 volts The purpose of this fault is to detect an open or high impedance circuit to the coil or an open primary coil 414 Coil Driver 2 Shorted 2 5L This fault will set if the EPM detects 10 coil firings in which the adap tivedwellislessthanallowedandbatteryvoltageislessthan16volts The purpose of t...

Page 149: ...e key on cycle If the active fault is no longer present the MIL light will flash at 2 Hz for the remainder of the key on cycle This is a reminder that the Low Rev Limit is still enforced 522 FPP2 Low Voltage Thisfaultwillsetifsignalvoltageislessthan0 2voltsatanyoperating condition while the key is on If the voltage is less than 0 2 then FPP2 is considered out of specification At this point the EPM...

Page 150: ... the remainder of the key on cycle If the active fault is no longer present the MIL light will flash at 2 Hz for the remainder of the key on cycle This is a reminder that the Low Rev Limit is still enforced 551 Max Govern Speed Override This fault will set anytime the engine RPM exceeds 4500 for 2 sec onds or more continuously This speed overrides any higher max governor speeds programmed by the u...

Page 151: ... is cleared This fault should be erased after diagnosis by removing battery power It will not self erase During this active fault Power Derate level2 willbeenforced When this is enforced maximum throttle position will be 20 This is enforced until the fault is manually cleared 616 RAM failure This fault will set if the EPM detects a problem accessing or writing information to RAM This fault will no...

Page 152: ...mmand to compensate High HO2S voltage indicates a rich mixture which will result in a lean command to compensate A constant voltage below 200 mV for 10 consecutive sec onds will set OTC 32 A constant voltage above 650 mV for 10 consecutive seconds will set OTC 42 INTAKE AIR TEMPERATURE IAT SENSOR The intake air temperature IAT sensor is a thermistor which changes its resistance based on the temper...

Page 153: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 101 Figure 3 54 EFI Component Location ...

Page 154: ...erforms the diagnostic function of the system It can recognize operational problems alert the operator through the Malfunction Indicator Lamp MIL and store diagnostic trouble codes DTCs DTCs identify the prob lem areas to aid the technician in making repairs The Engine Module supplies either 5 or 12 volts to power various sensors or switches The power is supplied through resistances in the Engine ...

Page 155: ...electronic governor The Engine Module monitors the voltage on the signal line and calculates throttle position As the throttle valve angle is changed the TP sensor signal also changes At a closed throttle position the output of the TP sensor is low As the throttle valve opens the output increases so that at wide open throttle WOT the output voltage should be above 4 volts The Engine Module calcula...

Page 156: ...SECTION 3 CHASSIS TURNTABLE 3 104 JLG Lift 3121160 Figure 3 55 ECM EPM Identification ECM EPM ...

Page 157: ...the part has been handled while sliding across a seat while sitting down from a standing position or while walking a distance touch a known good ground before installing the part Fuel System FUEL INJECTOR The Electronic Fuel Injection EFI fuel injector is a sole noid operated device controlled by the Engine Module The Engine Module energizes the solenoid which opens a valve to allow fuel delivery ...

Page 158: ... engine by control ling the amount of time that the fuel injector is ON The best mixture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most efficient combustion Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a closed loop system The Engine Module monitors signals from several sensors ...

Page 159: ...nted to the top of the engine and dis tributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines ELECTRONIC GOVERNOR AND THROTTLE BODY In the 2 5L EFI industrial engine throttle control is achieved by using an electronic governor which is con trolled by the Engine Module The electronic governor consists of a throttle body an electronically...

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

Page 161: ...tronic ignition system uses a coil pack with one ignition coil for each two cylinders in the engine Each cyl inder is paired with its opposing cylinder in the firing order so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust The spark that occurs in the cylinder on the exhaust stroke is referred to as a waste spark The primary coils in the coil pack are tr...

Page 162: ...ic regulator outputs a specific pressure needed at the mixer to maintain the desired air to fuel ratio The megajector accepts LPG vapor at the regulator outlet pressure 1 5 to 2 5 inches 3 8 to 6 3 cm of H2O and reduces it to a pressure value commanded by the EPM The pressure command is sent by the EPM over the CAN link via the megajector harness The megajector outlet pressure has units of inches ...

Page 163: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 111 Megajector Regulator LockoffSolenoid Figure 3 57 LPG System Components S N 0300077500 to Present Mixer ...

Page 164: ...ant hoses at the regulator and make sure they are both warm to verify proper coolant circulation If the fuel system is operating properly the Megajector has an internal failure and must be replaced DTC 354 Megajector delivery pressure lower than expected This code will set if the difference between the Megajector actual pressure and the Megajector com manded pressure is less than 4 00 inches 10 1 ...

Page 165: ...on a Connections Check power ground and CAN circuits at the Megajector in addition to all elec trical connections Repair as necessary and retest b Megajector Megajector has an internal failure Contact JLG Industries for further assistance 3 26 DEUTZ EMR 2 S N 85331 TO PRESENT The EMR2 consists of the sensors the control unit and the actuator Engine side controls as well as the JLG Control System a...

Page 166: ...ondition into the zero position After the programming that is carried out over the ISO9141 interface the EMR2 possesses a motor specific data set and this is then fixedly assigned to the engine Included in this are the various application cases as well as the customer s wishes regarding a particular scope of function Each EMR2 module is matched by serial number to the engine Modules cannot be swap...

Page 167: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 115 Figure 3 59 Deutz EMR 2 Troubleshooting Flow Chart ...

Page 168: ...SECTION 3 CHASSIS TURNTABLE 3 116 JLG Lift 3121160 Figure 3 60 Deutz EMR 2 Vehicle Side Connection Diagram ...

Page 169: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 117 Figure 3 61 Deutz EMR 2 Engine Side Connection Diagram Sheet 1 of 2 ...

Page 170: ...SECTION 3 CHASSIS TURNTABLE 3 118 JLG Lift 3121160 Figure 3 62 Deutz EMR 2 Engine Side Connection Diagram Sheet 2 of 2 ...

Page 171: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 119 Figure 3 63 EMR 2 Engine Plug Pin Identification ...

Page 172: ...SECTION 3 CHASSIS TURNTABLE 3 120 JLG Lift 3121160 Figure 3 64 EMR 2 Vehicle Plug Pin Identification ...

Page 173: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 121 Figure 3 65 EMR2 Fault Codes Sheet 1 of 5 ...

Page 174: ...SECTION 3 CHASSIS TURNTABLE 3 122 JLG Lift 3121160 Figure 3 66 EMR2 Fault Codes Sheet 2 of 5 ...

Page 175: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 123 Figure 3 67 EMR2 Fault Codes Sheet 3 of 5 ...

Page 176: ...SECTION 3 CHASSIS TURNTABLE 3 124 JLG Lift 3121160 Figure 3 68 EMR2 Fault Codes Sheet 4 of 5 ...

Page 177: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 125 Figure 3 69 EMR2 Fault Codes Sheet 5 of 5 ...

Page 178: ...Check the Positive and Negative battery cables for any corrosion build up rubbing or chafing check connec tion on the chassis to insure they are tight Check the entire engine wire harness for rubbing chaf ing cuts or damaged connections repair if necessary Check all wire harness connectors to insure they are fully seated and locked Check ignition coil and spark plug cables for harden ing cracking ...

Page 179: ...ions Do not over tighten 6 Check the sealing ring on drain plug for any dam age 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 over tighten 7 Fill the crankcase with oil 8 Start the engine and check for oil leaks 9 Stop the engine and check the oil level to insure the oil level is at FULL 10 Dispose of the oil and filte...

Page 180: ... shut the 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 SYSTEM WITH THE RADIATOR CAP OFF 5 Next verify that the 2 coolant hoses on the EPR are warm If they are not warm repeat step 3 and 4 oth erwise continue to step 6 A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIATOR HOSE AN...

Page 181: ...one controls the LPG fuel system during LPG operation Fuel Filter Propane fuel like all other motor fuels is subject to con tamination from outside sources Refueling of the equip ment s tank and removal of the tank from the equipment can inadvertently introduce dirt and other foreign matter into the fuel system It is therefore necessary to filter the fuel prior to entering the fuel system componen...

Page 182: ...LACE IT WITH AN OEM REPLACEMENT PART ONLY Air Fuel Mixer The air valve mixer is an air fuel metering device and is completely self contained The mixer is an air valve design utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking to full load The mixer is mounted in the air stream ahead of the throttle control device When the engine begins to crank it draws in air w...

Page 183: ...n maximum effect from the catalyst and accurate control 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 which receives input data from sensors fitted to the engine and fuel sys tem and then outputs various signals to control engine operation One specific function of the controller is to maintain clos...

Page 184: ... THE AIR 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 pressure and temperature sensor manifold fuel filter and fuel rail Gasoline Fuel Pump The Gasoline is stored as a liquid in the fuel tank and in drawn into the fuel system by an electric fuel pump ...

Page 185: ... less frequent then when the engine is operat ing at higher RPMs The engine has been calibrated to deliver the precise amount of fuel for optimum perfor mance and emission control 3 29 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel System Pressure Relief THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI 21 5 BAR TO MINIMIZE THE RISK OF FIRE AND PER SONAL INJURY RELIEVE THE PROPANE FUEL SYSTEM...

Page 186: ...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 bottom of the filter hous ing 5 Install the filter into the housing 6 If equipped install the retaining bolt into the filter housing 7 Install the filter up to the bottom of the electric lock off 8 Tighten the filter bowl retai...

Page 187: ...emove 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 USE A LIQUID PIPE THREAD SEALANT WHEN INSTALLING FITTINGS CHECK ALL THE O RINGS ON THE VAPOR AND WATER FITTINGS FOR ANY DAMAGE REPLACE IF NECESSARY LUBE ALL THE O RINGS WITH AN O RING LUBE BEFO...

Page 188: ...ARRANTY 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 EPR Installation Temperature Manifold Absolute Pressure TMAP Sensor REMOVAL 1 Disconnect the TMAP electrical connector 2 Remove the two retaining bolts 3 Remove the TMAP INSTALLATION NOTE Apply...

Page 189: ...y mixer 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 DEVICE TO ADAPTER O RINGS 1 Install the O ring on throttle body Press it down to the bottom of the surface 2 Install the two quad seals Install one seal at a time to insure the seal does not roll...

Page 190: ...le Control Device Replacement 4 Start the engine and leak check all fittings and con nections Coolant Hose Replacement REMOVAL 1 Drain the coolant 2 Using hose clamp pliers disconnect both hose clamps on each hose 3 Remove the hose from each of the fittings INSTALLATION NOTE Use hose material and lengths specified by JLG 1 Install the hose clamps to each hose and set the clamp back on each hose to...

Page 191: ...rous engine sensor and output data from the Electronic Pres sure Regulator EPR The ECM will then determine the target fuel calibration and command the EPR to reposition the voice coil to the proper position which subsequently reposition the secondary lever in the pressure regulator to maintain proper control The EPR and ECM will continue to communicate back and forth during normal operation In the...

Page 192: ...ols Required 7 16 Open end wrench for test port plugs DVOM GM J 39200 Fluke 88 or equivalent 12 volt test light Diagnostic Scan Tool Diagnostic Display tool Pressure Gauges IMPCO ITK 2 Test kit Water Column Gauge Manometer GM 7333 6 or equivalent 0 10 PSI Gauge Test Description The numbers below refer to step numbers on the diagnos tic table 5 This step determines if the LPR requires replacement 6...

Page 193: ...iagnosis GotoStep7 7 1 Inspecttheairintakestreambetweenthemixerassemblyandthethrottle bodyforleaks 2 InspectthefuelhoseconnectionbetweentheLPRandmixerassemblyfor damageorleakage 3 Inspectanyvacuumhosesforleaks Wasaproblemfoundandcorrected GotoStep26 GotoStep22 8 1 Connectawatercolumngaugeoramanometertothesecondarytestportof thelowpressureregulator LPR 2 Cranktheengineandobservethepressurereadingfo...

Page 194: ...ep21 17 1 RemovetheLPGfuelfilter LPL 2 RemovethefilterfromtheLPL 3 EmptythecontentsoftheinletsideoftheLPGfuelfilterontoacleansurface 4 InspectthecontentsoftheLPGfuelfilterforanexcessiveamountofforeign materialorwater Ifnecessary locateandrepairthesourceofcontamination 5 VerifytheLPGfuelfilterisnotrestrictedorplugged Wasaproblemfound GotoStep19 GotoStep18 18 Thefuelsupplysystemorhosesarepluggedorre...

Page 195: ...plugintheLPRsecondarychamber 2 Ifyouweresenttothisroutinebyanotherdiagnosticchart returntotheprevi ousdiagnosticprocedure Istheactioncomplete SystemOK 26 1 Disconnectalltestequipment 2 Installtheprimaryandsecondarytestportplugs 3 Starttheengine 4 UsingSNOOPorequivalent leakcheckthetestportplugs Istheactioncomplete SystemOK Table 3 12 LPF Fuel System Diagnosis STEP ACTION VALUE S YES NO ...

Page 196: ...heignitionwiresforthefollowingconditions Cracking Hardness Properrouting Carbontracking Checkthewiringforthefollowingitems Properconnections pinchesorcuts Thefollowingsymptomtablescontaingroupsofpossiblecausesforeachsymptom Theorderoftheseproceduresis notimportant Ifthescantoolreadingsdonotindicatetheproblems thenproceedinalogicalorder easiesttocheckor mostlikelytocausefirst Intermittent DEFINITIO...

Page 197: ...atics Checkbatterypower ignitionpowerandgroundcircuitstotheECM RefertoEngineControlSchematics Verifyvolt ageand orcontinuityforeachcircuit SensorChecks ChecktheTMAPsensor ChecktheMagneticpickupsensor RPM FuelSystemChecks Important AclosedLPGmanualfuelshutoffvalvewillcreateanostartcondition Checkforairintakesystemleakagebetweenthemixerandthethrottlebody Verifyproperoperationofthelowpressurelock off...

Page 198: ...veisnottripped Checkmixermoduleassemblyforproperinstallationandleakage Verifyproperoperationofthelowpressurelock offsolenoids VerifyproperoperationoftheEPR Checkforairintakesystemleakagebetweenthemixerandthethrottlebody Checkthefuelsystempressures RefertotheFuelSystemDiagnosis IgnitionSystemChecks Note LPGbeingagaseousfuelrequireshighersecondaryignitionsystemvoltagesfortheequivalentgasolineoperat ...

Page 199: ...cylindermisfire VerifythatthesparkplugsarecorrectforusewithLPG R42LTS Removethesparkplugsinthesecylindersandcheckforthefollowingconditions Insulationcracks Wear Impropergap Burnedelectrodes Heavydeposits Visually Physicallyinspectthesecondaryignitionforthefollowing Ignitionwiresforarcing cross firingandproperrouting Ignitioncoilsforcracksorcarbontracking EngineMechanicalChecks Performacylindercomp...

Page 200: ...tionalCheck Checkformanifoldvacuumorairinductionsystemleaks Checkthegeneratoroutputvoltage Backfire DEFINITION Thefuelignitesintheintakemanifold orintheexhaustsystem makingaloudpoppingnoise PreliminaryCheck RefertoImportantPreliminaryChecks IgnitionSystemChecks Important LPG beingagaseousfuel requireshighersecondaryignitionsystemvoltagesfortheequivalent gasolineoperatingconditions Theignitionsyste...

Page 201: ...ystemfordamagedorcollapsedpipes Inspectthemufflerforsignsofheatdistressorforpossibleinternalfailure Checkforpossiblepluggedcatalyticconverter EngineMechanicalCheck Checktheengineforthefollowing Enginecompression Valvetiming Improperorworncamshaft RefertoEngineMechanicalintheServiceManual AdditionalCheck ChecktheECMgroundsforbeingclean tight andintheirproperlocations Checkthegeneratoroutputvoltage ...

Page 202: ...MAP sensorresponseandaccuracy FuelSystemChecks Checkforrichorleansymptomthatcausesthecondition Drivethevehicleatthespeedofthecomplaint Monitoring theoxygensensorswillhelpidentifytheproblem Checkforastickingmixerairvalve VerifyproperoperationoftheEPR Performacylindercompressiontest RefertoEngineMechanicalintheServiceManual ChecktheLPRfuelpressure RefertotheLPGFuelSystemDiagnosis Checkmixermoduleass...

Page 203: ...omplaint Monitoring theoxygensensorswillhelpidentifytheproblem Checkthefuelpressurewhiletheconditionexists RefertoLPGFuelSystemDiagnosis Verifyproperfuelcontrolsolenoidoperation VerifythattheLPGmanualshut offvalveisfullyopen Checkthein linefuelfilterforrestrictions IgnitionSystemChecks CheckfortheproperignitionoutputvoltageusingthesparktesterJ26792ortheequivalent Verifythatthesparkplugsarecorrectf...

Page 204: ...EGO2Open Inactive 520208 10 171 AdaptiveLearnHighGasoline 520200 0 172 AdaptiveLearnLowGasoline 520200 1 182 FuelTempGasolineLowVoltage 174 4 183 FuelTempGasolineHighVoltage 174 3 187 FuelTempLPGLowVoltage 520240 4 188 FuelTempLPGHighVoltage 520240 3 217 ECTHigherThanExpected2 110 0 219 MaxGovernSpeedOverride 515 15 221 TPS2SignalVoltageLow 51 0 222 TPS2SignalLowVoltage 520251 4 223 TPS2SignalHigh...

Page 205: ...tiveLearnLowLPG 520202 1 1165 LPGCatMonitor 520213 10 1171 LPGPressureHigherThanExpected 520260 0 1172 LPGPressureLowerThanExpected 520260 1 1173 EPRCommLost 520260 31 1174 EPRVoltageSupplyHigh 520260 3 1175 EPRVoltageSupplyLow 520260 4 1176 EPRInternalActuatorFault 520260 12 1177 EPRInternalCircuitryFault 520260 12 1178 EPRInternalCommFault 520260 12 1612 RTI1loss 629 31 1613 RTI2Loss 629 31 1614...

Page 206: ...wer requirement considerably during this unloaded state The pressure switch located in the downstream air line senses air demand and upon reducing pressure in discharge line ie air being used will re activate the inlet valve and the compressor again starts to load and pro duce air The discharge air pressure switch will typically be set with a 30 psi 2 0 bar differential pressure Air Filter Unit Th...

Page 207: ...SECTION 3 CHASSIS TURNTABLE 3121160 JLG Lift 3 155 1 Compressor Assembly 2 Air Filter Element 3 Coalescer Spin On Element 4 Oil Filter Element Figure 3 86 Air Compressor ...

Page 208: ...o the hydraulic motor and the outlet from the motor passes to the return line connection on the package Customer to provide both hydraulic feed and return lines The hydraulic motor powers the compressor through a belt drive system Compressor Cooling System The package contains a cooler assembly powered by a 12 volt D C electric fan Oil from the compressor sump passes through this cooler before bei...

Page 209: ...hered to should keep the compressor in top operating condition However it should be understood that these intervals are for normal operation in a good clean environment More frequent inspections oil changes and general maintenance should be carried out in dusty environments high ambient tem peratures or extended light load conditions DO NOT REMOVE CAPS PLUGS OR ANY COMPONENTS WHEN THE COMPRESSOR I...

Page 210: ...cur Water will separate and must be drained from the oil sump daily if necessary In addition to the primary oil char acteristics good water separation is required These lubricants should be applied where condi tions above 32 F 0 C prevail 3 Synthetic Lubricants In so far as know all the elas tomeric components and metals used in the com pressor are fully compatible with Synthetic Hydrocarbon SHC a...

Page 211: ...oning and alignment is important for belt life bearing life and power transmission Correct tensioning and alignment was provided at time of shipment from the factory However since maximum belt elongation will occur within the first 50 hours of operation Of new belts their tension should be checked several times during this period and corrected as required The belts should thereafter be checked per...

Page 212: ... to determine the rated full load pressure setting These can be found in the Specification Section PRESSURE SWITCH LOCATION The pressure switch is located directly behind the cooling fan inside a black plastic box Removing the one single screw from the bottom of the plastic cover allows the cover to be removed exposing the two adjustment screws at the top and also exposes the electrical terminatio...

Page 213: ... compressor oil warm up Commences to pass oil through cooler at 160 F 71 C and is fully open at 185 F 85 C Safety Shutdown Systems Protection for over pressure and or over temperature is provided If either condition should occur the diverter valve should activate to divert hydraulic fluid back to tank and the compressor will stop the reset on instrument panel will pop out and stay out until reset ...

Page 214: ... c Press switch out of adjustment d Defective pressure switch e Motor does not speed up f Belts slipping g Service valve wide open h Sol valve stuck i Leak in air pilot line a CheckforleaksandcorrectToomuch air demand b Check and replace c Reset d Replace e PressureswitchCheckhydraulicflow pressure f Readjust tighten g Close h Replace i Check for leaks correct 3 Compressor over pressures a Press R...

Page 215: ...ean c Check minimum pressure valve d Replace 6 Compressor overheating a Insufficient oil b Restricted cooling air flow c Fan not operating d Plugged oil filter e Cooler core plugged f Pressure set too high g Contaminated cooler core h Running too fast i Thermal Valve element faulty a Check level and top up b Reposition machine c Checkgroundconnection Checkfan switch Checkairpressureswitch Check ci...

Page 216: ...mpressor NOTE evenamomentarydropinsupply hydraulic supply pressure flow may initi ate compressor blowdown to com mence c Pressure relief valve set too low d Leak in seals on pressure relief valve e Airpressuresettoo highforhydraulic system f Leak in solenoid valve cartridge directional flow control valve on mani fold g Check over pressure or over temper ature a Readjust tighten b Check setting on ...

Page 217: ... securing the platform to the platform support then remove the platform 3 Using an overhead crane or suitable lifting device strap support the platform support 4 Remove the six 6 bolts and locknuts securing the support to the rotator 5 Using a suitable brass drift and hammer remove the rotator shaft then remove the support from the rota tor Figure 4 1 Location of Components Platform Support ...

Page 218: ...tite 242 to the eight 8 bolts and lock nuts securing the support to the rotator and install the bolts and locknuts 4 Torque the nut on the rotator center bolt to 480 ft lbs 651 Nm Torque the eight 8 retaining bolts to 50 ft lbs 68 Nm 5 Position the platform on the platform support and install the eight 8 bolts securing the platform to the platform support Torque the bolts to 75 ft lbs 102 Nm 6 Con...

Page 219: ...the hardware from pin 2 Using a suitable brass drift and hammer remove pin 2 from the fly boom and remove the rotator 4 Telescope the fly section out approximately 20 inches 50 8 cm to gain access to the slave leveling cylinder A B D C D E A B C D E Torqueto50ft lbs 68Nm Loctite 242 Torqueto480ft lbs 650Nm Checktorqueevery150hoursofoperation Torqueto85ft lbs 115Nm Figure 4 2 Platform Support Torqu...

Page 220: ...dual hydraulic fluid Cap hydraulic lines and ports 3 Remove hydraulic lines and electrical cables from powertrack 4 Using suitable lifting equipment adequately support powertrack weight along entire length 5 Remove bolt 1 securing the push tube on the fly boom section 6 Remove bolt 2 securing the push tube on the mid boom section 7 With powertrack supported and using all applicable safety precauti...

Page 221: ... 1 Use a small ratchet with a T 25 Torx bit Remove the 10 24 x 0 812 screw If the bar spins then grip the bar and poly tightly with a vise grip 2 Lift up one end of the bar and slide the poly roller off 3 While gripping the bar tightly remove the other 10 24 x 0 812 screw ...

Page 222: ...way this can be done Use a right angle die grinder with a ball double cut bur 2 Insert the tool into the rolled over end of the rivet as shown Grind out the middle of the rivet until the rolled over part of the rivet falls off Repeat this step for all rivets that must be removed 3 After grinding it is sometimes necessary to use a center punch to punch out the rivet from the link ...

Page 223: ... part of the track so the new connec tion point is in the curved part of the track This will allow the round half shears to be rotated in a way they will fit into the peanut shaped cut outs 5 Install the pin into the center hole then slide the washer over the pin Install the snap ring into the groove in the pin ...

Page 224: ...t 3121160 NOTE When installing snap rings make sure they are seated in the pin groove and closed properly 6 Install more pins washers and snap rings into all the links where a rivet was removed CLOSED SNAPRING SNAPRINGNOT CLOSED PROPERLY ...

Page 225: ...TE Maximum tightening torque for the 8 32 screw is 18 20 in lbs 2 2 2 Nm Installing a New Round Bar Poly Roller 1 While tightly holding the round bar install the new 10 24 x 0 812 self threading torx screw Next lift up the other end and slide a new poly roller on Install another 10 24 x 0 812 screw on the other side NOTE Maximum tightening torque for the 10 24 screw is 45 50 in lbs 5 5 6 Nm ...

Page 226: ...bracket then reinstall the pin washer and new snap ring After installing the new bracket make sure that it rotates correctly Replacing a Moving End Bracket 1 Remove bracket by removing all pins washers and snap rings Replace with a new bracket and reinstall the pins washers and new snap rings After install ing a new bracket make sure that it rotates correctly ...

Page 227: ...e Bracket 1 Remove all pins washers and snap rings and slide the bracket off of the links 2 To install a new bracket slide the bracket over the links and reinstall the pins washers and new snap rings After installing the new bracket make sure that it rotates correctly ...

Page 228: ...linder as follows a Using an adequate supporting device support the master cylinder so it doesn t fall when the retaining pins are removed NOTE The master cylinder weighs approximately 58 5 lbs 26 5 kg b Tag and disconnect hydraulic lines from Master Cylinder Use a suitable container to collect any residual hydraulic fluid Cap hydraulic lines and ports c Remove the bolt and keeper pin securing the...

Page 229: ...her damage Ensure pin surfaces are protected prior to installation Replace pins as necessary 4 Inspect inner diameter of boom pivot bearing for scoring distortion wear or other damage Replace bearing as necessary See Section 5 Cylinder Repair for bearing replacement 5 Inspect all wear pads for excessive wear or other damage Replace pads when worn as specified in Figure 4 12 Location And Thickness ...

Page 230: ... barrel end attach pin 2 Tag and disconnect hydraulic lines to the upright lift cylinder Use a suitable container to collect any residual hydraulic fluid Cap hydraulic lines and ports 3 Using an overhead crane or suitable lifting device support the upright lift cylinder remove mounting hardware from the barrel end of the upright lift cylin der and remove the pin 4 Carefully remove the upright lift...

Page 231: ...allet install the cylinder pin into tower fly boom and secure with mounting hardware 4 Secure the sling and lifting device at the tower fly boom assembly s approximate center of gravity 5 Slide tower fly boom assembly into the tower base boom section for a total of 1 32 inch 0 8 mm clear ance 6 Install wear pads into the forward position of the tower base boom section Shim boom if necessary for a ...

Page 232: ...maged so replacing the cartridge might be necessary 2 A relief valve is located in the upright P N 4640929 This relief valve could be leaking back wards out of the loop Replace the cartridge They are pre set 3 The counter balance valve in the piston end of the upright level cylinder There could be a leak path from the valve port to the pilot port Replace the counter balance valve 4 The counter bal...

Page 233: ...pass through it causing the volume to grow between the cylinders Flush the valve out and reinstall it or replace the cartridge The cartridge pressure is pre set so no adjustment can be made 2 The counterbalance valve in the piston end of the upright level cylinder There could be a leak path from the pilot port to the valve port Replace the counterbalance valve 3 The counterbalance valve in the rod...

Page 234: ...r pin from articulating jib boom Inspection NOTE When inspecting pins and bearings Refer to Section 2 Pins and Composite Bearing Repair Guidelines 1 Inspect articulating fly boom pivot pin for wear scor ing tapering and ovality or other damage Replace pins as necessary 2 Inspect articulating fly boom pivot attach points for scoring tapering and ovality or other damage Replace pins as necessary 3 I...

Page 235: ...g jib boom pivot weldment with attach holes in fly boom assembly Using a soft head mallet install pivot pin 2 into fly boom assembly and secure with mounting hardware 7 Align the slave leveling cylinder with attach holes in articulating jib boom pivot weldment Using a soft head mallet install slave leveling cylinder pin 1 into articulating jib boom pivot weldment and secure with mounting hardware ...

Page 236: ...SECTION 4 BOOM PLATFORM 4 20 JLG Lift 3121160 Figure 4 7 Boom Valve and Limit Switches Location 0271989 A ...

Page 237: ...SECTION 4 BOOM PLATFORM 3121160 JLG Lift 4 21 Figure 4 8 Transportation Switch Installation CE Only 0258384 A ...

Page 238: ...SECTION 4 BOOM PLATFORM 4 22 JLG Lift 3121160 Figure 4 9 Tower Power Track Installation Sheet 1 of 2 ...

Page 239: ...SECTION 4 BOOM PLATFORM 3121160 JLG Lift 4 23 Figure 4 10 Tower Power Track Installation Sheet 2 of 2 ...

Page 240: ...platform replace riv ets with 1 4 x 20 NC x 2 grade 5 bolts flatwashers and locknuts 4 11 WEAR PADS Tower Boom 1 Shim up wear pads until 1 32 inch clearance to adja cent surface 2 Replace wear pads when worn to within 1 16 inch 1 59 mm of threaded insert NOTE Wear pads are made of polyethylene these pads are intended to slide on polyurethane painted surfaces 3 When adjusting wear pads removing or ...

Page 241: ...g or adding shims bolt length must also be changed a When adding shims longer bolts must be used to ensure proper thread engagement in insert b When shims are removed shorter bolts must be used so bolt does not protrude from insert and Sheaves and wire rope must be replaced as sets 4 12 ROTATOR HELAC PRIOR TO S N 0300130881 Disassembly 1 Place actuator on a clean workbench 2 Remove all hydraulic f...

Page 242: ...rooves Dis card seals Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary NOTE A small amount of wear in the spline teeth will have little effect on the actuator strength New spline sets are manufactured with a backlash of about 0 005 in per mating set After long service a backlash of about 0 015 per set may still be ac...

Page 243: ...al position install the piston sleeve 3 in timed relation to the housing 1 DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY AS IT WILL MARK THE CYLINDER BORE NOTE The timing marks the small punch marks on the face of each gear must be aligned for proper shaft orientation See Actuator Timing 5 Install the shaft 2 into housing 1 by aligning the proper punched timing marks See Actuator Timing Figure 2...

Page 244: ...SECTION 4 BOOM PLATFORM 4 28 JLG Lift 3121160 Figure 4 14 Rotator Assembly HELAC ...

Page 245: ...nd the lower radial bearing Axially the shaft is separated from the housing by the upper and lower thrust washers The end cap is adjusted for axial clearance and locked in position by set screws or pins Required Tools Upon assembly and disassembly of the actuator there are basic tools required The tools and their intended func tions are as follows 1 Flashlight helps examine timing marks component ...

Page 246: ...nd off all sharp edges of the heated end by using a grinder There may be some slight modifications for your own personal prefer ence PARTS 1 Housing 2 Shaft 3 PistonSleeve 4 EndCap HARDWARE 103 1 Screw 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 304 1 WiperSeal BEARINGS 302 WearGuide 304 ThrustWasher ACCESSOR...

Page 247: ...03 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 304 1 WiperSeal BEARINGS 302 WearGuide 304 ThrustWasher ACCESSORIES 400 StopTube 420 1 Bushing 420 2 Bushing 421 1 Bushing Figure 4 16 Rotator Assembly Drawing S N 030013250 to Present ...

Page 248: ...in to a depth of approximately 3 16 4 76mm 3 Remove the lock pins using an Easy Out a size 2 is shown If the pin will not come out with the Easy Out use 5 1 6 drill bit to a depth of 1 2 12 7mm to drill out the entire pin 4 Install the end cap 4 removal tools provided with the Helac seal kit 5 Using a metal bar or something similar unscrew the end cap 4 by turning it counter clockwise ...

Page 249: ... stop tube if included The stop tube is an available option to limit the rotation of the actua tor 8 Every actuator has timing marks for proper engage ment 9 Prior to removing the shaft 2 use a felt marker to clearly indicate the timing marks between shaft and piston This will greatly simplify timing during assem bly ...

Page 250: ...be timing marks on the housing 1 ring gear the piston 3 and the shaft 2 12 To remove the piston 3 use a rubber mallet and a plastic mandrel so the piston is not damaged 13 At the point when the piston gear teeth come out of engagement with the housing gear teeth mark the piston and housing with a marker as shown 14 Remove the o ring 204 and backup ring 207 from end cap 4 and set aside for inspecti...

Page 251: ...g a sharp razor blade being careful not to damage the seal groove 17 Remove the thrust washers 304 from the end cap 4 and shaft 2 18 Remove the wiper seal 304 1 from its groove in the end cap 4 and shaft 2 19 Remove the piston O D seal 202 20 Remove the piston I D seal 200 You may now pro ceed to the inspection process ...

Page 252: ...st 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 specifications Not less than 0 092 or 2 34 mm 3 Inspect the wear guide condition and measure thick ness not less than 0 123 or 3 12 mm Assembly 1 Gather all the components and tools into one location prior to re assembly Use the ...

Page 253: ...tall the wiper seal 304 1 green 0 ring into it s groove on the shaft 2 and end cap 4 around the outside edge of the thrust washer 304 4 Using a seal tool install the main pressure seal 205 onto shaft 2 and end cap 4 Use the seal tool in a circular motion 5 Install the wear guide 302 on the end cap 4 and shaft 2 ...

Page 254: ...f b u ring in the lower groove and feed the rest in using a circular motion Make sure the wedged ends overlap correctly Repeat this step for the outer seal 202 7 Insert the piston 3 into the housing 1 as shown until the outer piston seal 202 is touching inside the housing bore 8 Looking from the angle shown rotate the piston 3 until the marks you put on the piston and the hous ing 1 during disasse...

Page 255: ... Do not engage the piston gear teeth yet 11 Looking from the view shown use the existing tim ing marks to line up the gear teeth on the shaft 2 with the gear teeth on the inside of the piston 3 Now tap the flange end of the shaft with a rubber mallet until the gear teeth engage 12 Install 2 bolts in the threaded holes in the flange Using a bar rotate the shaft in a clockwise direction until the we...

Page 256: ... 4 onto the shaft 2 end Make sure the wear guide stays in place on the end cap as it is threaded into the housing 1 17 Tighten the end cap 4 In most cases the original 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 hole 19 Insert the set screws 113 over the...

Page 257: ...unterbores 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 Loc tite 242 should be applied to the shank of the three bolts at the time of installation 4 Torque the 1 4 inch bolts 110 to 120 inch pounds 12 4 to 13 5 Nm Do not torque over 125 inch pounds 14 1 Nm Torque the 5 16 inch bolts 140 inch po...

Page 258: ...purge air from the hydraulic lines connect them together to create a closed loop and pump hydraulic fluid through them Review the hydraulic schematic to deter mine which hydraulic lines to connect The linear feet and inside diameter of the hydraulic supply lines together with pump capacity will determine the amount of pumping time required to fully purge the hydraulic system Bleeding may be necess...

Page 259: ...nonpage24ofthismanual e Re buildtheactuator Removeallrustthenpol ish Replacementpartsmaybeneeded f Re buildtheactuator Usefluidthatiscompati blewithsealsandbearings 2 Operationis erraticornot responsive a Airinactuator a Purgeairfromactuator Seebleedingproce dures 3 Shaftwill not fully rotate a Twistedorchippedgearteeth b Portfittingsareobstructingthepiston a Checkforgearbinding Actuatormaynotbe a...

Page 260: ... and watch the meter for the time it takes the output to go from the maxi mum current setting to 0 current Adjust P2 until this time matches the time in Table 4 3 Ramp time Set ting Rotating the adjustment potentiometer clock wise will increase the ramp time Follow the same procedure for the B output Use P5 for the ramp up adjustment and P6 for the ramp down adjustment Flow Control Card 1 Set the ...

Page 261: ...ol valve Refer to Figure 4 19 4 Raise the tower boom 6 feet 1 8 m 5 Release the red relevel knob 6 Lower the tower boom fully and continue to hold down the switch to Tower Down for an additional 20 seconds 7 Repeat steps 3 thru 6 as necessary until the upright is 90 vertical relative to the chassis Table 4 2 Ramp Current Setting Range FUNCTION MINIMUM CURRENT MAXIMUM CURRENT MAINLIFTUP 450to550mA ...

Page 262: ...oning UPRIGHT MUST BE 90 VERTICAL RELATIVE TO THE CHASSIS CORRECT CORRECT TO AVOID TIPPING IF THIS OCCURS LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELESCOPE FUNCTIONS HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECHNICIAN BEFORE CONTINUING USE OF MACHINE INCORRECT INCORRECT ...

Page 263: ...e ground controls will flash until the initial calibration is per formed 4 To calibrate the Upright Monitoring System through the hand held analyzer you must be in access level 1 To advance to access level 1 scroll to the ACCESS LEVEL menu and press ENTER Using the arrows on the keypad enter the password 33271 and press ENTER NOTE Repeat step 4 if the correct access level is not dis played 5 Calib...

Page 264: ...reen you may view the output of the sensor d Press ENTER and the screen will display the following THE MACHINE MUST BE LEVEL FOR PROPER CALIBRATION e Verify the machine is level and press ENTER The screen will display the following asking you to fully elevate the main boom f Start the machine and fully elevate the main boom After the main boom has been fully ele vated press ENTER The analyzer will...

Page 265: ... get the above message verify that the sensor is installed correctly and verify the sensor connection to the sensor harness is secure Also ensure the red knob is held fully open for the required time If the calibration is executing properly you shall see the following display h When viewing the above display press ENTER The screen will display the following i Lower the tower boom onto the boom sto...

Page 266: ...e screen will automatically change to If the calibration has not been completed suc cessfully the display will automatically change to Repeat step i until the calibration time require ment has been satisfied DO NOT RAISE THE TOWER BOOM AGAIN DURING CALIBRA TION j To correctly complete the calibration process fully retract and fully lower the boom Once the machine is in the stowed position turn off...

Page 267: ...d analyzer you must be in access level 1 To advance to access level 1 scroll to the ACCESS LEVEL menu and press ENTER Using the arrows on the keypad enter the password 33271 and press ENTER 4 Calibrate the upright monitoring system sensor by the following procedure a In access level 1 scroll through the menu items until CALIBRATIONS is displayed on the sec ond line of the analyzer screen The scree...

Page 268: ... RECALIBRATED AS WELL d After selecting UMS SENSOR the following screen will appear NOTE By pressing the left or right arrow keys in this screen you may view the output of the sensor e Press ENTER and the next screen will display the following asking if the machine is on a level surface THE MACHINE MUST BE LEVEL FOR PROPER CALIBRATION f Verify the machine is level and press ENTER The screen will d...

Page 269: ... tank while lift ing the tower boom Raise the tower boom six 6 feet or two 2 meters After elevating the tower the required distance press ENTER If the upright monitoring system did not detect adequate sensor activity the screen will display Should you get the above message verify that the sensor is installed correctly and verify the sensor connection to the sensor harness is secure Also ensure the...

Page 270: ...ction for at least twenty 20 seconds WITHOUT RELEASING THE FUNCTION SWITCH The calibration must recognize continuous activation of the tower down function switch for the required time After the required activation time has passed release the function switch and press ENTER The analyzer will display the fol lowing message If the calibration has been completed success fully the screen will automatic...

Page 271: ...e event the turntable tilt switch input is logic low indi cating that the machine is not level the UMS calibration screens shall display this fault CAL Failed UMS Sensor Raw Output Out Of Range The control system shall display a fault in the event the raw sensor output is greater then 5 for the UMS sensor CAL Failed Turntable Sensor Raw Output Out Of Range The control system shall display a fault ...

Page 272: ...station and turn the key switch to ground controls Start the engine 3 Advance to access level 1 by scrolling to the ACCESS LEVEL menu and press ENTER Using the arrows on the keypad enter the password 33271 and press ENTER 4 Scroll through the top level menu until SERVICE MODE appears Press ENTER to select this menu item After pressing ENTER one of the follow ing screens will be displayed or 5 Scro...

Page 273: ...of power pressing the EMS to the system the upright monitoring system will reset and all functionality will be restored to the machine Service Mode Tower Boom Retrieval The UMS software incorporates a service mode to tempo rarily disengage the UMS and allow a tower lift down oper ation when the UMS has detected a backward stability concern ON ADE EQUIPPED MACHINES DO NOT CONNECT TO THE ANA LYZER C...

Page 274: ...Press ENTER to select this menu item After pressing ENTER one of the follow ing screens will be displayed or 5 Scroll left to right through the above menu items until TOWER LIFT DOWN sub menu appears on the bottom line of the analyzer display Press the ENTER key 6 The controller will now display the following ...

Page 275: ...isabled and the display will read 9 Before using tower lift down adhere to the following Make sure the main boom is fully retracted Make sure the tower boom is fully retracted Slowly lower the tower boom 10 When the platform has been safely lowered to the ground exit the service mode by pressing the Emer gency Stop Switch EMS at the ground controls Upon loss of power pressing the EMS to the sys te...

Page 276: ...SECTION 4 BOOM PLATFORM 4 60 JLG Lift 3121160 THIS SENSOR ON NON ADE MACHINES ONLY Figure 4 21 UMS Sensor Location ...

Page 277: ...SECTION 4 BOOM PLATFORM 3121160 JLG Lift 4 61 ADE MACHINES NON ADE MACHINES Figure 4 22 UMS Module Location ...

Page 278: ... DIGITAL INPUT 2 5 ANALOG INPUT 1 6 DIGITAL INPUT 3 6 ANALOG GROUND 7 DIGITAL OUTPUT 0 PWM IF 7 ANALOG INPUT 2 8 DIGITAL OUTPUT 1 PWM IF 8 ANALOG INPUT 3 NOT POPULATED 9 DIGITAL OUTPUT 2 PWM IF 9 CANBUS HIGH 10 DIGITAL OUTPUT 3 PWM IF 10 CANBUS LOW 11 DIGITAL OUTPUT 4 PWM 11 ANALYZER TRANSMIT 12 DIGITAL OUTPUT 5 PWM 12 ANALYZER RECEIVE J2 GRAY J1 BLACK Figure 4 23 UMS Module Pin Identification ...

Page 279: ... 2 0 for 2 seconds and the Tower Lift Down command is returned to neutral Solution Inspect sensor mounting Verify sensor calibration on level pad Follow the corrective action listed on decal 1702265 located near the red knob of the machine Inspect machine hydraulics Forward Stability Concern Message 2 5 UMS SENSOR FORWARD LIMIT REACHED When the upright angle relative to the turntable is less than ...

Page 280: ...ry has been detected on the Tower Lift Down output Solution Inspect harness and valve Platform Indicator Output Short to Ground or Open Circuit 8 1 PLATFORM INDICATOR OUTPUT SHORT TO GROUND OR OPEN CIRCUIT Short to Ground or open circuit has been detected on the Platform Indicator output Solution Inspect harness Platform Indicator Output Short to Battery 8 1 PLATFORM INDICATOR OUTPUT SHORT TO BAT ...

Page 281: ...rned to neutral Solution Inspect sensor mounting Verify sensor calibration on level pad Follow the corrective action listed on decal 1702265 located near the red knob of the machine Inspect machine hydraulics Forward Stability Concern Message 2 5 UMS SENSOR FORWARD LIMIT REACHED When the upright angle relative to the turntable is less than 4 0 for longer than 1 5 seconds the ground control boom ma...

Page 282: ...Calibrate sensor UMS Sensor Faulted Message 8 1 UMS SENSOR FAULTED If the system detects that the UMS sensor frequency out side the 100Hz 5Hz range or the duty cycle is outside 50 21 range the control system shall report a fault Solution Inspect wire harness going to the sensor and UMS module Inspect sensor mounting Replace sensor Incompatible Software Detected Message 9 9 INCOMPATIBLE SOFTWARE DE...

Page 283: ... inspected prior to each use Replace if there are any signs of wear or damage to any of the components Prior to use inspection should include a visual inspection of the following items Cable Proper tension broken strands corrosion Fittings Loose fittings and fractures damage to hanger Transfastener Damage free and proper sliding Attaching Hardware Loose missing properly tightened Inspecting Cable ...

Page 284: ...e Pull Out Dust or Debris Fittings Loose Fittings Hardware Nuts and Bolts Hanger Corner Bracket Line Tenser Transfastener Installation Installation requires bolting the ends of the cable to the platform with the supplied drilled bolt castle nut and split pin The drilled bolts only need to be tightened enough to fully engage all of the threads of the castle nut and then further just enough to insta...

Page 285: ...SECTION 4 BOOM PLATFORM 3121160 JLG Lift 4 69 Figure 4 24 Fall Arrest System 1 Transfastener 2 Bracket 3 Cable 4 Swage Slip Indicator 5 Turnbuckle 6 Line Tenser ...

Page 286: ...SECTION 4 BOOM PLATFORM 4 70 JLG Lift 3121160 NOTES ...

Page 287: ...The following is needed to correctly oil the o ring in this manner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the brush with the other hand to dip into the container Remove excess hydraulic oil from the brush so an even film of oil is applied on the o ring 2 Holding the fitting over the hydraulic oil container brush an even film of oil around t...

Page 288: ... 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 satu rated sponge This will also cause more oil to be dis persed from the sponge Spray Method This method requires a pump or trigger spray bottle 1 Fill the spray bottle with hydraulic oil 2 Hold the fitting over a s...

Page 289: ...lve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached 5 3 CYLINDERS THEORY OF OPERATION Systems Incorporating Double Acting Cylinders Cylinders are of the double acting type Systems incorpo rating double acting cylinders are as follows Lower Lift Tower Telescope Slave Level Main Level Upper Lift Upper Telescope Master Level Upright Level Arti...

Page 290: ... the counter balance valve from the retract port After initial dis charge there should be no further leakage from the ports If leakage occurs at a rate of 6 8 drops per minute or more the piston seals are defective and must be replaced 5 If no repairs are necessary or when repairs have been made replace counterbalance valve and care fully connect hydraulic hoses to cylinder port block 6 If used re...

Page 291: ...RFACE IN A DIRT FREE WORK AREA 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable 3 If applicable remove...

Page 292: ...cessary 4 Inspect inner surface of cylinder barrel tube for scor ing 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 damage and scoring and for distortion Dress piston surface or replace piston as necessary 7 Inspect threaded portion of piston for damage Dress ...

Page 293: ...t is used See your JLG Parts Manual NOTE Apply a light film of hydraulic oil to all components prior to assembly 1 A special tool is used to install a new rod seal into the applicable cylinder head gland groove WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER L...

Page 294: ...G THE MASTER SLAVE LOWER LIFT UPPER LIFT ARTICULATING FLY BOOM LIFT UPRIGHT LEVEL OR UPPER TELESCOPE CYLINDERS APPLY LOCTITE 242 TO TAPERED BUSHING BOLTS THEN TIGHTEN SECURELY 10 Install the bolts in tapered bushing using loctite 242 11 Remove the cylinder rod from the holding fixture 12 Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston Figure 5 10 P...

Page 295: ...p of loctite 242 2 places at 180 apart Hand tighten nut then tighten 1 4 turn with spanner wrench Figure 5 12 Rod Assembly Installation Table 5 1 Cylinder Torque Specifications CYLINDER HEAD AND TAPERED BUSHING TORQUE SPECIFICATIONS Description Head TorqueValue Wet TaperedBushing TorqueValue Wet UpperLiftCylinder 420ft lbs 570Nm 60ft lbs 81Nm LowerLiftCylinder 420ft lbs 570Nm 30ft lbs 41Nm Articul...

Page 296: ...lines to telescope cyl inder Use suitable container to retain any residual hydraulic fluid Cap hydraulic lines and ports 4 Remove the retaining rings that retain the telescope cylinder rod to the fly boom 5 Using a suitable brass drift carefully drive telescope cylinder rod pin from the fly boom Table 5 2 Holding Valve Torque Specifications HOLDING VALVE TORQUE SPECIFICATIONS Description Torque Va...

Page 297: ...oom and install the mounting hardware 10 Remove boom prop and overhead crane Activate hydraulic system 11 Using all applicable safety precautions operate the boom functions Check for correct operation and hydraulic leaks Secure as necessary 12 Check fluid level of hydraulic tank and adjust as nec essary Main Lift Cylinder Removal 1 Place the machine on a flat and level surface Attach a suitable li...

Page 298: ...ble drift drive the upright level cylinder barrel end pin through the mounting holes of the upright 13 Attach a suitable lifting device to the upright level cylinder 14 Using a suitable drift remove the upright level cylin der rod end pin from the tower fly boom 15 Carefully remove the upright level cylinder from the tower fly boom Place in a suitable work area Upright Level Cylinder Installation ...

Page 299: ...Remove temporary hydraulic lines from cylinder ports and cap lines 6 Remove caps from cylinder hydraulic lines and cor rectly install lines to cylinder as previously tagged 7 Remove main boom support and overhead crane supporting the upright Activate hydraulic system 8 Using all applicable safety precautions operate the boom functions Check for correct operation and hydraulic leaks Secure as neces...

Page 300: ...ments at the top of the pump The stand by adjustment is at the top Using a 17 mm wrench remove the cover nut Be careful not to lose the o ring washer inside the cover nut Loosen the jam nut at the set screw with the 17 mm wrench Using a 3 mm allen wrench adjust clockwise to increase or counterclockwise to decrease After adjusting the pressure tighten the jam nut and replace the cover nut Reconnect...

Page 301: ...60 JLG Lift 5 15 1 Steer Left 2 UpperLiftDown 3 PressureCheckPort 4 PlatformLevel Down 5 PressureCheckPort 6 PlatformLevel Up 7 Swing 8 Steer Right 9 PressureCheckPort 10 Steer Figure 5 14 Main Control Valve Pressure Adjustments ...

Page 302: ...sandreinstallthe bolts 1 Block 2 LoadSensing MainLift 3 Load Sensing 4 Load Sensing Swing 5 Load Sensing 6 Load Sensing Main 7 ReliefValve MainLift 8 ReliefValve Swing 9 Orifice 10 CheckValve TowerLift 11 ReliefValve TowerPlatformLevel 12 Relief Valve Platform Level 13 Relief Valve Front Steer 14 Relief Valve FrontSteer 15 Pilot Check PlatformLevel 16 ControlValve MainLift 17 ControlValve Swing 18...

Page 303: ...SECTION 5 HYDRAULICS 3121160 JLG Lift 5 17 Table 5 3 Cartridge Torque Values Ft Lbs Nm A 18 20 24 5 27 2 B 12 14 16 3 19 C 25 27 34 36 D 33 37 44 9 50 3 E 4 5 5 4 6 8 F 60in lbs 6 7 ...

Page 304: ...l down relief valve is located on the right side of the block above the M4 port Turn clockwise to increase and counterclockwise to decrease 6 Articulating Jib Up Install a high pressure gauge on the gauge port of the jib block located on the top of the main valve block The gauge port has a 12 hose plumbed into it for easy access Activate jib up you should read 2500 psi 172 bar The up relief valve ...

Page 305: ...ting the tower 10 Locate the manual pull valve on the side of the oil tank red knob Disconnect the 1 4 hose port 1 where it connects to the side of the hyd return filter plug the port and place into a container that will hold approx 10 gallons 38 L Start the engine Pull the red knob and hold it open while tower is lifting up Raise the tower 7 8 ft 2 2 5 m and stop Release the red knob and lower th...

Page 306: ...ehicle machine move ment NOTE If a pump or motor is being replaced due to internal damage the remaining units pump or motors need to be inspected for damage and contamination and the entire hydraulic system will need to be flushed and the fluid replaced Failure to do so may cause considerable damage to the entire system 5 11 REXROTH VARIABLE DISPLACEMENT PUMP PRIOR TO S N 0300121643 The variable d...

Page 307: ...SECTION 5 HYDRAULICS 3121160 JLG Lift 5 21 Figure 5 17 Variable Displacement Pump Rexroth ...

Page 308: ... Thesymbolsabovecanbefoundinthepumpillustrations Thelegend aboveisprovidedtodefineeachsymbolandexplainitspurpose Inlet port S SAE J1926 1 1 875 12 System gauge po SAE J1926 1 0 4375 20 Case drain port L1 SAE J1926 1 0 875 14 Outlet port B SAE J1926 1 1 3125 12 Case drain port L2 SAE J1926 1 0 875 14 rt M2 Table 5 5 Gauge and Port Information Port Purpose Range of Pump Fitting M2 Systempressure 0 5...

Page 309: ...bleshooting 7 Operate the hydraulic system for at least fifteen min utes under light load conditions 8 Check and adjust control settings as necessary after installation Refer to Adjustments 9 Shut down the engine and remove the pressure gauge Replace plug at port M2 10 Check the fluid level in the reservoir add clean fil tered fluid if necessary The pump is now ready for operation Troubleshooting ...

Page 310: ...armupbeforeoperationoruse fluidwiththeappropriateviscositygradefor expectedoperatingtemperatures Checkexternalsystemvalving Malfunctioningvalvingmaynotallowsystemto respondproperly Repairorreplacesystemvalvingasrequired Checkpumpcasepressure Highcasepressurewillcausethesystemtobe sluggish Correctcasedrainlinerestrictions Checkpumpinletpressure vacuum Highinletvacuumwillcauselowoutputflow Correctin...

Page 311: ...owoutputflow Correctinletpressureconditions Checkinputspeed Lowinputspeedsdecreaseflow Adjustinputspeed Checkpumprotation Incorrectrotationalconfigurationwillcauselow flow Usepumpwithappropriaterotationalconfigura tion Table 5 10 Pressure or Flow Instability Item Description Action Checkforairinsystem Airinsystemwillcauseerraticoperation ActivatePressureCompensator allowingsystem tobleedair Checki...

Page 312: ...rwear WearofthePressureCompensatorspoolwill causeinternalleakageinthecontrol Replacethespoolasrequired InspectPressureCompensatorspoolforproper orientation Improperorientationwillresultinpooroperation Correctorientationofspool CheckPressureCompensatorcontrolforcon tamination Contaminationmayinterferewithmovementof thePressureCompensatorSpool CleanPressureCompensatorcontrolcompo nents takeappropria...

Page 313: ...THE SHAFT SEAL CONTACTS THE SHAFT BEARING PRESS THE SEAL INTO THE HOUSING ONLY FAR ENOUGH TO CLEAR THE RETAINING RING GROOVE 3 Keeping the seal perpendicular to the shaft press the new seal into the housing just far enough to clear the retaining ring groove Install seal with the cupped side toward the shaft bearing Do not dam age the seal during installation 4 Using the appropriate snap ring plier...

Page 314: ...pensator bore The Pressure Compensator spool is the shorter of the two Using a new O ring install the plug C103 Torque to 8 10 ft lb 11 14 Nm 2 Place the two Pressure Compensator springs onto the spring guide and install into the Pressure Com pensator bore Place a new O ring onto the Pressure Compensator adjustment screw and thread it into the Pressure Compensator bore until flush then make anothe...

Page 315: ...iguration 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 8mm 41 95 N m 30 70 lbf f t M14 6mm 27 35 N m 20 26 lbf f t J040 M14 6mm 27 35 N m 20 26 lbf ft K040 7 8 in 3 8 in 54 136 N m 40 100 lbf ft K045 7 8 in 3 8 in 54 136 N m 40 100 lbf f t Figure 5 20 Plug Location...

Page 316: ...SECTION 5 HYDRAULICS 5 30 JLG Lift 3121160 NOTES ...

Page 317: ...ering functions The upper lift swing and drive are controlled by individual joysticks with steering being controlled by a rocker switch built into the top the drive joystick To activate Drive Lift and Swing simply pull up on the slide lock location on the joystick and move the handle into the direction desired The control system will control the voltage output to the valves and pump as programmed ...

Page 318: ... ForFNT FRONT FL FLOW FORorFWD FORWARD FSW FOOTSWITCH GRN GREEN GM GROUNDMODULE h HOURS HW HARDWARE L orLT LEFT LB POUND LEN LENGTH LIM LIMIT LVL LEVEL m MINUTES MIN MINIMUM MAX MAXIMUM MN MAIN NO NORMALLY OPENor NO NC NORMALLY CLOSED OP OPEN O R OVERRIDE or OUTRIGGER OSC OSCILLATING OVRD OVERRIDE P orPRS PRESSURE PCV PROPORTIONAL CONTROL VALVE PLAT PLATFORM PM PLATFORMMODULE POT POTENTIOMETER PT ...

Page 319: ...SECTION 6 JLG CONTROL SYSTEM 3121160 JLG Lift 6 3 Figure 6 2 ADE Block Diagram ...

Page 320: ...K MIN FORWARD X RIGHT TRACK MAX FORWARD X RIGHT TRACK MIN REVERSE X RIGHT TRACK MAX REVERSE X RIGHT TRACK ELEV F MAX X RIGHT TRACK ELEV R MAX X RIGHT TRACK CREEP F MAX X RIGHT TRACK CREEP R MAX X DRIVE ACCEL X XS DRIVE DECEL X XS DRIVE MIN FORWARD X DRIVE MAX FORWARD X DRIVE MIN REVERSE X DRIVE MAX REVERSE X DRIVE ELEV MAX X DRIVE CREEP MAX X STEER MAX SPEED X MAIN LIFT ACCEL X XS MAIN LIFT DECEL ...

Page 321: ...PE MIN 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 BASKET LEVEL MAX DOWN X BASKET ROTATE ACCEL X XS BASKET ROTATE DECEL X XS BASKET ROTATE MIN LEFT X BASKET ROTATE MAX LEFT X BASKET ROTATE MIN RIGHT X BASKET ROTATE MAX RIGHT X JIB LIFT ACCEL X XS...

Page 322: ...L NUMBER 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 TILT 4 4 DEG CUT TILT 5 3 DEG CUT JIB TOWER LIFT TOWER TELE 0 YES 1 YES 1 YES 4 WHEEL STEER 0 YES SOFT TOUCH 1 YES GEN SET WELDER GEN SET WELDER 1 BELT DRIVE 2 HYD DRIVE H T LIGHTS 1 YES CABLE SW...

Page 323: ...SECTION 6 JLG CONTROL SYSTEM 3121160 JLG Lift 6 7 Figure 6 6 Analyzer Flow Chart Prior to Version 5 X Software Sheet 4 of 4 ...

Page 324: ...SECTION 6 JLG CONTROL SYSTEM 6 8 JLG Lift 3121160 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 325: ...SECTION 6 JLG CONTROL SYSTEM 3121160 JLG Lift 6 9 Figure 6 8 Analyzer Flow Chart Version 5 X Software Sheet 2 of 4 ...

Page 326: ... 3 DEGREES 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 SYSTEM CUTOUT ALL LOAD SYSTEM SPECIAL 1 LOAD SENSOR 1 ON ROTATOR FUNCTION CUTOUT BOOM CUTOUT FUNCTION CUTOUT DRIVE CUTOUT FUNCTION CUTOUT DRIVE CUT E T GROUND ALARM DRIVE GROUND ALARM DESCENT GROUN...

Page 327: ...TCH CLOSED 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 DATA LOAD 500LB XXX DATALOG ON XXH XXM DATALOG ENGINE XH XM DATALOG DRIVE XH XM DATALOG LIFT XH XM DATALOG SWING XH XM DATALOG TELE XH XM DATALOG MAX TEMP XXC DATALOG MIN TEMP XXC DATALOG MAX VOL...

Page 328: ...SECTION 6 JLG CONTROL SYSTEM 6 12 JLG Lift 3121160 Figure 6 11 Control Module Location ...

Page 329: ...SECTION 6 JLG CONTROL SYSTEM 3121160 JLG Lift 6 13 Figure 6 12 Analyzer Connecting Points PLATFORM CONNECTION GROUND CONTROL CONNECTION ...

Page 330: ...on Each individual circuit from the modules is approximately 120 ohms 6 3 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER 1 Connect the four pin end of the cable supplied with the analyzer to the controller module located in the platform box or at the controller module in the ground control box and connect the remaining end of the cable to the analyzer NOTE The cable has a four pin connector at each en...

Page 331: ...ted a new set of menu items may be offered for example DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases such as DRIVE the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the persona...

Page 332: ...r you can not adjust the personality settings 6 6 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pres...

Page 333: ...chine person ality settings There is a setting that JLG strongly recommends that you do not change This setting is so noted below ELEVATION CUTBACK CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER FORMANCE OF YOUR MACHINE ITS IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENT...

Page 334: ...gonmodelselec tion 1 2 3 4 5 6 7 8 9 10 11 FORDEFIGAS FordLRG425EFIGas Tier1 FORDEFID F FordLRG425EFIdualfuel Tier1 DEUTZF4TIER1 DeutzF4M1011FDiesel Tier1 DEUTZF3TIER1 DeutzF3M1011FDiesel Tier1 CAT 3024C CAT3024CDiesel Tier2 CAT 3044C CAT3044CDiesel Tier2 DEUTZF4TIER2 DeutzF4M2011Diesel Tier2 DEUTZF3TIER2 DeutzF3M2011Diesel Tier2 FORDGASTIER2 FordLRG425EFIGas Tier2 FORDD FTIER2 FordLRG425EFIDualFu...

Page 335: ...n alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan4degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainliftup 3DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan3degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainliftup...

Page 336: ...loadlamplit platformalarmbeeps 5 secON 2secOFF CUTOUTALL Allfunctionscutout flashoverloadlight 500mSon 500mSoff platform alarmbeeps 5secON 2secOFF SPECIAL1 Functionsincreep overloadlamplit disablesmaintelescopeout mainlift up platformalarmbeeps 5secON 2secOFF 0 LOADSENSOR 16 OnlyvisibleifLoadSensor Menuselectionisnot0 Marketselectionswilllimit certainloadsensoroptions 0 1 1ONROTATOR Usetheon board...

Page 337: ... DRIVE 19 Onlyvisibleundercertain modelselections 0 1 2 4WD Fourwheeldrive 2WD Twowheeldrive 2WDW 2 SPEED Twowheeldrivewith2 speedvalve 0 TEMPERATURE 20 0 1 CELSIUS Celsiusunitselection FAHRENHEIT Fahrenheitunitselection 1 LEVELINGMODE 21 Onlyvisibleon800Smodels 0 1 ALLFUNCTIONS Platformlevelwithallfunctions LEVELLIFT TELESCOPE Platformlevelonliftandtelescopeonly 0 4150364 14 Table 6 2 Machine Con...

Page 338: ...guration Programming Information Software Version P5 3 to P6 1 Configuration Label Digit Number Description Default Number MODELNUMBER 1 1 2 3 4 5 6 7 8 9 10 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S 1 MARKET 2 0 1 2 3 4 5 ANSIUSA ANSIEXPORT CSA CE AUSTRALIA JAPAN 0 ...

Page 339: ...rolModule ECM DUALFUELECM GM PSI3 0LDualFuel Tier2 7 FLYWHEELTEETH 4 Thismenuitemisonly visibleifDeutzengine selections3or4are selected 0 1 133TEETH 133flywheelteeth 110TEETH 110flywheelteeth 1 GLOWPLUG 5 0 1 2 NOGLOWPLUGS Noglowplugsinstalled AIRINTAKE Glowplugsinstalledintheairintakeonthemanifold IN CYLINDER Glowplugsinstalledineachcylinder 2 STARTERLOCKOUT 6 0 1 DISABLED Automaticpre glowtimede...

Page 340: ...vation alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan4degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainliftup 3DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan3degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainl...

Page 341: ...oadsensorinstalled WARNONLY Functionsincreep overloadlamplit platformalarmbeeps 5secON 2 secOFF CUTOUTPLATFORM Allfunctionscutout overloadlamplit platformalarmbeeps 5 secON 2secOFF CUTOUTALL Allfunctionscutout flashoverloadlight 500mSon 500mSoff platform alarmbeeps 5secON 2secOFF SPECIAL1 Functionsincreep overloadlamplit disablesmaintelescopeout mainlift up platformalarmbeeps 5secON 2secOFF 0 LOAD...

Page 342: ...ctionisactive Option DESCENT Descentalarmsoundswhenliftdownisactive Option MOTION Motionalarmsoundswhenanyfunctionisactive Option 3 DRIVE 20 Onlyvisibleundercertain modelselections 0 1 2 4WD Fourwheeldrive 2WD Twowheeldrive 2WDW 2 SPEED Twowheeldrivewith2 speedvalve 0 TEMPERATURE 21 Certainmarketselections willalterdefaultsetting 0 1 CELSIUS Celsiusunitselection FAHRENHEIT Fahrenheitunitselection ...

Page 343: ...uration Programming Information Software Version P6 1 to Present Configuration Label Digit Number Description Default Number MODELNUMBER 1 1 2 3 4 5 6 7 8 9 10 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S 1 MARKET 2 0 1 2 3 4 5 ANSIUSA ANSIEXPORT CSA CE AUSTRALIA JAPAN 0 ...

Page 344: ...1Diesel Tier2 FORDGASTIER2 FordLRG425EFIGas Tier2 FORDD FTIER2 FordLRG425EFIDualFuel Tier2 DEUTZECM EngineControlModule ECM Tier2andTier3 DUALFUELECM GM PSI3 0LDualFuel Tier2 PERKINSECM CATECM 14 FLYWHEELTEETH 4 Thismenuitemisonly visibleifDeutzengine selections3or4are selected 0 1 133TEETH 133flywheelteeth 110TEETH 110flywheelteeth 1 GLOWPLUG 5 0 1 2 NOGLOWPLUGS Noglowplugsinstalled AIRINTAKE Glo...

Page 345: ...ed morethan4degreesandaboveelevation alsoreducesdrivespeedtocreep 3DEGREES Reducesthemaximumspeedofallboomfunctionstocreepwhentilted morethan3degreesandaboveelevation alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan4degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive maintelescopeoutandmainliftup 3DEGREES CUT Reduce...

Page 346: ... Brokencableswitchinstalled 0 LOADSYSTEM 16 Onlyvisibleundercertain marketselections Certainmarketselections willlimitloadsystem optionsoralterdefaultset ting 0 1 2 3 4 NO Noloadsensorinstalled WARNONLY Functionsincreep overloadlamplit platformalarmbeeps 5secON 2 secOFF CUTOUTPLATFORM Allfunctionscutout overloadlamplit platformalarmbeeps 5 secON 2secOFF CUTOUTALL Allfunctionscutout flashoverloadli...

Page 347: ...e steercutoutaboveelevation DRIVECUTE T Drive steercutoutaboveelevationandtilted 0 GROUNDALARM 19 Certainmarketselections willalterdefaultsetting 0 1 2 3 NO Nogroundalarminstalled DRIVE Travelalarmsoundswhenthedrivefunctionisactive Option DESCENT Descentalarmsoundswhenliftdownisactive Option MOTION Motionalarmsoundswhenanyfunctionisactive Option 3 DRIVE 20 Onlyvisibleundercertain modelselections 0...

Page 348: ...energizedfromthePropulsionModule ENHANCED DrivecoilsareenergizedfromtheGroundModuleandthegroundsideof thedrivecoilsarebroughtbacktocurrentfeedbackreturns 2 CLEARSKY 24 0 1 NO Clearsky telematics optionisdisabled YES Clearsky telematics optionisenabled 0 CRIBBINGOPTION 25 0 1 NO CribbingOptionisdisabled YES CribbingOptionisenabled 0 4150364 19 Table 6 4 Machine Configuration Programming Information...

Page 349: ... 0 0 1 0 1 0 1 740AJ HEAD TAIL LIGHTS CABLE BREAK SWITCH LOAD SYSTEM LOAD SENSOR FUNCTION CUTOUT GROUND ALARM DRIVE TYPE TEMPERATURE LEVELING MODE ANSIUSA 0 1 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0 1 2 0 1 0 1 ANSIEXPORT 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1 CSA 0 1 0 1 0 X X X X 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1 CE 0 1 0 1 0 X 2 3 X 0 1 0 1 X X 0 1 2 3 0 1 2 0 1 0 1 AUSTRALIA 0 1 0 1 0...

Page 350: ...1 2 3 FordLRG425EFIGas FordLRG425EFIGas with dualfuel Deutz F4M1011FDiesel Deutz F3M1011FDiesel 1 1 3 GlowPlug 0 NO 1 NUMBEROF MINUTES Display adjusts glowplugpresence andon time 0 1 10 No glowplugs installed Setting this numbertellsthe controllerhowmanyminutes afterthe EMSispulledto out putto theglowplugsbefore permitting theengineto be started 1 0 4 ENG SHUTDOWN 0 NO 1 SHUTDOWN Displays adjusts ...

Page 351: ...tilted CE AUSTRALIA Mod els450 600 601 and800 1 1 7 TowerLift 0 NO 1 YES Displays adjusts tower lift presence 0 1 No TowerLiftinstalled Yes 1 0 8 TowerTele 0 NO 1 YES Displays adjusts tower telescope presence 0 1 No TowerTelescope installed Yes 1 0 9 Jib 0 NO 1 YES 2 SIDESWING Displays adjustsjib presence 0 1 2 No Jibinstalled Jib installedwhich hasup anddownmovementsonly Jib installedwhich hasup ...

Page 352: ...or 0 1 2 NoAngle Sensorinstalled Limitswitchesareinstalled An analogsensorisinstalled 1 0 17 lengthSENSOR 0 NO 1 DIGITAL 2 ANALOG Displayspresence functionoflength sensor 0 1 2 No LengthSensorInstalled Limitswitchinstalled An analogsensorisinstalled 1 0 18 FUNCTION CUTOUT 0 NO 1 BOOMCUTOUT 2 DRIVECUTOUT 3 DRIVECUTE T Displayspresence functionofdrive cutout 0 1 2 3 NoDrive Cutout BoomFunctionCutout...

Page 353: ...ouslyWhen AboveElevationAnd Tilted Only SoundsContinuouslyWhen AboveElevationAnd Tilted AndInConjunctionWithFault CodeFlashes Option 1 0 21 TowerProx Switches 0 NO 1 YES Displayspresence functionofTower Proximity switches forthe models specified 0 1 NoTowerProx Switches Installed Tower ProxSwitches Installed 1 0 Table 6 5 Machine Configuration Parameters ...

Page 354: ...o 35 4 REVerse MAXimum speed 0 to 100 30 ELEVATED MAXimum speed 0 to 50 15 CREEP MAXimum speed 0 to 45 20 Engine RPM 800 to 2900 1800 TOWER LIFT ACCELeration 0 1 to 5 0s 1 5 DECELeration 0 1 to 3 0 0 5 MlNimum UP speed 0 to 60 39 MAXimum UP speed 0 to 100 100 MINimum DOWN speed 0 to 60 38 MAXimum DOWN speed 0 to 100 100 Engine RPM 800 to 2900 1800 UPPER LIFT ACCELeration 0 1 to 5 0 2 5 DECELeratio...

Page 355: ... to 65 45 MAXimum IN speed 0 to 100 67 MINimum OUT speed 0 to 65 50 MAXimum OUT speed 0 to 100 75 Engine RPM 800 to 2900 1800 TELEscope TOWER ACCELeration 0 1 to 5 0 1 0 DECELeration 0 1 to 3 0 0 5 MINimum IN speed 0 to 65 50 MAXimum IN speed 0 to 100 100 MINimum OUT speed 0 to 65 50 MAXimum OUT speed 0 to 100 100 Engine RPM 800 to 2900 1800 BASKET LEVEL ACCELeration 0 1 to 5 0 2 5 DECELeration 0 ...

Page 356: ...um UP speed 0 to 100 52 MINimum DOWN speed 0 to 65 45 Engine RPM 800 to 2900 1800 STEER MAXimum speed 0 to 100 100 Engine RPM 800 to 2900 1800 GROUND MODE Tower LIFT UP speed 0 to 100 100 Tower LIFT DOWN speed 0 to 100 100 Upper LIFT UP speed 0 to 100 60 Upper LIFT DOWN speed 0 to 100 60 SWING speed 0 to 100 60 Upper TELEscope speed 0 to 100 70 Tower TELEscope speed 0 to 100 100 BASKET ROTATE spee...

Page 357: ...D MAX becausethevehicleis aboveelevation TESTS ACTIVE RECYCLEEMS TOEND Thesystemtests havebeen activated normalvehicleoperationis notallowed 1 1 Flashcode1 1indicates a sleep mode NOTREQUIRED 2 1 Flashcode2 1indicates problems withfootswitch 2 FSWFAULTY Thetwo foot switchsignalsdonotagree EMSrecycle required KEYSWITCHFAULTY Bothplatformand ground modes are selected simultaneously 2 2 Flashcode2 2i...

Page 358: ...lashcode2 5indicates thatafunction isprevented due toa cutout 4 BOOMPREVENTED DRIVE SELECTED A boomfunction isselectedwhileadrivefunction isselectedand drive cutoutis configured topreventsimultaneousdrive boom operation DRIVE PREVENTED ABOVE ELEVATION Driveisselectedwhileaboveelevationanddrivecutoutisconfigured toprevent drive DRIVE PREVENTED BOOM MOVEMENTSELECTED Driveisselectedwhileaboomfunction...

Page 359: ...TERY TOO LOW SYSTEM SHUTDOWN Batteryvoltageis below6V EMS recyclerequired 5 5 Flashcode5 5indicates problemswithvehicleengineRPMortheencoder 8 SPEED SENSORREADING INVALID SPEED Speed sensorisindicating animpossiblenumberofpulses This is probablydue toa faulty speed sensor SPEEDINPUT LOST This indicates thatthecontrol systemhasdeterminedthatthediesel enginespeedinputtothesystemhasbeenlost Thisis pr...

Page 360: ...de9 9indicates problems with thecontroller 11 PLATFORMMODULEFAILURE hwfs CODE1 Platformmodule V Low FEThasfailed GROUND MODULE FAILURE hwfs CODE1 Ground module V Low FEThasfailed Table 6 7 Help Fault Codes Displayed Faults and Descriptions Prior to S N 0300066931 ...

Page 361: ... L SJOY OUTOFRANGELOW 2219 L SJOY OUTOFRANGEHIGH 2220 L SJOY CENTERTAPBAD 2221 LIFT SWINGLOCKED JOYSTICKMOVEDBEFOREFOOTSWITCH 2222 WAITINGFORFSWTOBEOPEN 2223 FUNCTIONSWITCHESLOCKED SELECTEDBEFOREENABLE 2224 FOOTSWITCHSELECTEDBEFORESTART 234 FUNCTIONSWITCHESFAULTY CHECKDIAGNOSTICS BOOM 235 FUNCTIONSWITCHESLOCKED SELECTEDBEFOREAUXPOWER 236 FUNCTIONSWITCHESLOCKED SELECTEDBEFORESTARTSWITCH 237 STARTSW...

Page 362: ...R SHORTTOGROUND 3340 AUXPOWER SHORTTOGROUND 3341 AUXPOWER OPENCIRCUIT 3342 AUXPOWER SHORTTOBATTERY 3346 ELECTRICFAN SHORTTOGROUND 3347 ELECTRICFAN OPENCIRCUIT 3348 ELECTRICFAN SHORTTOBATTERY 3349 ELECTRICPUMP SHORTTOGROUND 3350 ELECTRICPUMP OPENCIRCUIT 3351 ELECTRICPUMP SHORTTOBATTERY 3352 LPLOCK SHORTTOGROUND 3353 LPLOCK OPENCIRCUIT 3354 LPLOCK SHORTTOBATTERY 3355 LPSTARTASSIST SHORTTOGROUND 3356...

Page 363: ... SHORTTOGROUND 3392 PLATFORMLEVELDOWNOVERRIDEVALVE OPENCIRCUIT 3393 PLATFORMLEVELDOWNOVERRIDEVALVE SHORTTOBATTERY 3394 PLATFORMROTATELEFTVALVE SHORTTOGROUND 3395 PLATFORMROTATELEFTVALVE OPENCIRCUIT 3396 PLATFORMROTATELEFTVALVE SHORTTOBATTERY 3397 PLATFORMROTATERIGHTVALVE SHORTTOGROUND 3398 PLATFORMROTATERIGHTVALVE OPENCIRCUIT 3399 PLATFORMROTATERIGHTVALVE SHORTTOBATTERY 33100 JIBLIFTUPVALVE SHORTT...

Page 364: ...BATTERY 33133 PLATFORMCONTROLVALVE SHORTTOGROUND 33134 PLATFORMCONTROLVALVE OPENCIRCUIT 33135 PLATFORMCONTROLVALVE SHORTTOBATTERY 33170 LIFTDOWNVALVE OPENCIRCUIT 33171 LIFTDOWNVALVE SHORTTOBATTERY 33172 LIFTDOWNVALVE SHORTTOGROUND 33175 JIBROTATELEFTVALVE OPENCIRCUIT 33176 JIBROTATELEFTVALVE SHORTTOBATTERY 33177 JIBROTATELEFTVALVE SHORTTOGROUND 33178 JIBROTATERIGHTVALVE OPENCIRCUIT 33179 JIBROTATE...

Page 365: ...PVALVE SHORTTOGROUND 344 PLATFORMLEVELUPVALVE SHORTTOBATTERYOROPENCIRCUIT 345 PLATFORMLEVELDOWNVALVE OPENCIRCUIT 346 PLATFORMLEVELDOWNVALVE SHORTTOBATTERY 347 PLATFORMLEVELDOWNVALVE SHORTTOGROUND 348 PLATFORMLEVELDOWNVALVE SHORTTOBATTERYOROPENCIRCUIT 349 PLATFORMROTATELEFTVALVE OPENCIRCUIT 3410 PLATFORMROTATELEFTVALVE SHORTTOBATTERY 3411 PLATFORMROTATELEFTVALVE SHORTTOGROUND 3412 PLATFORMROTATERIG...

Page 366: ...665 CANBUSFAILURE PROPULSIONMODULE 666 CANBUSFAILURE ENGINECONTROLLER 6620 CANBUSFAILURE UMSSENSOR 671 ACCESSORYFAULT 813 CHASSISTILTSENSORNOTCALIBRATED 815 CHASSISTILTSENSORDISAGREEMENT 816 UMSSENSORNOTCALIBRATED 817 UMSSENSORFAULT 825 LSSHASNOTBEENCALIBRATED 826 RUNNINGATCREEP PLATFORMOVERLOADED 827 DRIVE BOOMPREVENTED PLATFORMOVERLOADED 828 LIFTUP TELEOUTPREVENTED PLATFORMOVERLOADED 831 PLATFOR...

Page 367: ...Y 8650 REARRIGHTSTEERVALVE SHORTTOGROUND 8652 RIGHTTRACKFORWARDVALVE OPENCIRCUIT 8653 RIGHTTRACKFORWARDVALVE SHORTTOBATTERY 8654 RIGHTTRACKFORWARDVALVE SHORTTOGROUND 8655 RIGHTTRACKREVERSEVALVE OPENCIRCUIT 8656 RIGHTTRACKREVERSEVALVE SHORTTOBATTERY 8657 RIGHTTRACKREVERSEVALVE SHORTTOGROUND 8658 LEFTTRACKFORWARDVALVE OPENCIRCUIT 8659 LEFTTRACKFORWARDVALVE SHORTTOBATTERY 8660 LEFTTRACKFORWARDVALVE S...

Page 368: ...UNDMODULEFAILURE HIGHSIDEDRIVERCUTOUTFAULTY 9922 PLATFORMMODULEFAILURE HWFSCODE1 9923 GROUNDMODULEFAILURE HWFSCODE1 9924 FUNCTIONSLOCKEDOUT MACHINENOTCONFIGURED 9944 CURRENTFEEDBACKGAINSOUTOFRANGE 9945 CURRENTFEEDBACKCALIBRATIONCHECKSUMINCORRECT Table 6 8 Analyzer Fault Code Listing DTC Analyzer Text ...

Page 369: ...minimum reversedrivespeed MAXREVERSE Displays adjustsmaximumreversedrivespeed ELEVATEDMAX Displays adjustsmaximumdrivespeed NOTE used whenelevation cutoutswitchesarelimitingmaximumspeed CREEPMAX Displays adjustsmaximumdrivespeed NOTE used whencreepswitch on pump pot isactive STEER MAX Displays adjuststhemaximumsteerspeed LIFT ACCEL Displays adjustsupperliftacceleration DECEL Displays adjustsupperl...

Page 370: ...opeinspeed MAXIN Displays adjustsmaximumtelescopeinspeed MIN OUT Displays adjustsminimum telescopeoutspeed MAXOUT Displays adjustsmaximumtelescopeoutspeed BASKETLEVEL ACCEL Displays adjustsbasketlevelacceleration DECEL Displays adjustsbasketleveldeceleration MIN UP Displays adjustsminimum basketlevelup speed MAXUP Displays adjustsmaximumbasketlevelup speed MIN DOWN Displays adjustsminimum basketle...

Page 371: ... adjustsminimum jibrightspeed MAXRIGHT Displays adjustsmaximumjib rightspeed STEER MAXSPEED Displays adjustsmaximumsteer speed whichapplieswhenvehiclespeedis atminimum GROUND MODE LIFTUP Displays adjustsfixedliftup speed LIFTDOWN Displays adjustsfixedliftdownspeed SWING Displays adjustsfixedswingspeed TELE Displays adjustsfixedtelescope speed BASKETLEVEL Displays adjustsfixedbasketlevel speed BASK...

Page 372: ...TE demand iscontrolledby thepump pot ROT LEFT Displays basketrotateswitch direction demand NOTE demand iscontrolledby thepump pot UTELE IN Displays telescopeswitch direction demand NOTE demand iscontrolledby thepump pot JIBUP Displays jib lift switchdirection demand NOTE demand iscontrolledby thepump pot Not displayed ifJIB NO JIBLEFT Displays jib swing switchdirection demand NOTE demand iscontrol...

Page 373: ...otdisplayed if load 0 DATALOG ON Displays totalcontrolleron EMS time ENGINE Displays engine run time DRIVE Displays totalcontrollerdriveoperation time LIFT Displays total controllerliftoperation time SWING Displays totalcontrollerswingoperationtime TELE Displays totalcontrollertele operationtime MAX TEMP Displays maximum measured heatsink temp MIN TEMP Displaysminimum measuredheatsinktemp MAX VOLT...

Page 374: ...SECTION 6 JLG CONTROL SYSTEM 6 58 JLG Lift 3121160 NOTES ...

Page 375: ...es or probe tips specifically designed for this tech nique especially on sealed connectors Whenever possi ble insert probes into the side of the connector such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed connec tor by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle ...

Page 376: ...to ranging 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 testing Circuit power must be turned OFF before testing continuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads to...

Page 377: ...re applies to all plug connections not enclosed in a box Sili cone grease should not be applied to connectors with external seals 1 To prevent oxidation silicone grease must be packed completely around male and female pins on the inside of the connector prior to assembly This is most easily achieved by using a syringe NOTE Over a period of time oxidation increases electrical resistance at the conn...

Page 378: ... achieved 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 assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole...

Page 379: ... wedge lock must be closed to its locked position Release the locking latches by squeezing them inward See Figure 7 8 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 7 9 Figure 7 7 Connector Assembly Figure 2 Figure 7 8 Connector Assembly Figure 3 Figure 7 9 Connector Assembly Figure 4 ...

Page 380: ...e forward or mat ing end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point This practice should be discourage...

Page 381: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 7 Figure 7 11 Connector Installation ...

Page 382: ...ward exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly 1 Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out 2 To remove the contacts gently pull wire backwards while at the same time releasing the lock...

Page 383: ... wire cavities insert sealing plugs for full environmental 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 Slide tool along into the insert cavity until it engages contact and resistance is felt 3 Pull contact wire assembly out of connector NOTE Do Not twist or insert tool at an angle Figure 7 14 HD H...

Page 384: ...LIMIT SWITCH TOWER BOOM ELEVATION LIMIT SWITCH GENERATOR SWITCH SOFT TOUCH SYSTEM LIMIT SWITCH FOOTSWITCH PLATFORM WORK LIGHTS PRIOR TO S N 0300112885 S N 0300112885 TO PRESENT J2 J1 J8 J3 GROUND CONTROL BOX J4 J7 HEADLIGHTS TAILLIGHTS DIAGNOSTIC ANALYZER TO ANALYZER OR OR Figure 7 18 Electrical Components Installation Sheet 1 of 2 ...

Page 385: ... RELAY AUX RELAY START RELAY STARTER GLOW PLUGS GENERATOR CONTROL BOX ENGINE CONTROL DEUTZ FUEL ON SOLENOID DEUTZ ENGINE HARNESS DEUTZ THROTTLE CONTROL FORD 2500W GENERATOR HYDRAULIC PUMPS 2 SPEED BRAKE VALVE BATTERY ALTERNATOR LP CONVERTOR FORD TACH SENSOR SPEED PICK UP CAT AND DEUTZ BOSCH FUEL REGULATOR GM FUEL REGULATOR GM HARNESS Figure 7 19 Electrical Components Installation Sheet 2 of 2 ...

Page 386: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 12 JLG Lift 3121160 Figure 7 20 Electrical Schematic Deutz Ford Engines Sheet 1 of 2 ...

Page 387: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 13 Figure 7 21 Electrical Schematic Deutz Ford Engines Sheet 2 of 2 1870163 D ...

Page 388: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 14 JLG Lift 3121160 Figure 7 22 Electrical Schematic Deutz EMR2 GM Engines Prior to S N 99884 Sheet 1 of 6 ...

Page 389: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 15 Figure 7 23 Electrical Schematic Deutz EMR2 GM Engines Prior to S N 99884 Sheet 2 of 6 1870199 F ...

Page 390: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 16 JLG Lift 3121160 Figure 7 24 Electrical Schematic Deutz EMR2 GM Engines Prior to S N 99884 Sheet 3 of 6 ...

Page 391: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 17 Figure 7 25 Electrical Schematic Deutz EMR2 GM Engines Prior to S N 99884 Sheet 4 of 6 1870199 F ...

Page 392: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 18 JLG Lift 3121160 Figure 7 26 Electrical Schematic Deutz EMR2 GM Engines Prior to S N 99884 Sheet 5 of 6 ...

Page 393: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 19 Figure 7 27 Electrical Schematic Deutz EMR2 GM Engines Prior to S N 99884 Sheet 6 of 6 1870199 F ...

Page 394: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 20 JLG Lift 3121160 Figure 7 28 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 1 of 6 ...

Page 395: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 21 Figure 7 29 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 2 of 6 1870220 C ...

Page 396: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 22 JLG Lift 3121160 Figure 7 30 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 3 of 6 ...

Page 397: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 23 Figure 7 31 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 4 of 6 1870220 C ...

Page 398: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 24 JLG Lift 3121160 Figure 7 32 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 5 of 6 ...

Page 399: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 25 Figure 7 33 Electrical Schematic Deutz EMR2 GM Engines S N 99884 to Present Sheet 6 of 6 1870220 C ...

Page 400: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 26 JLG Lift 3121160 Figure 7 34 Hydraulic Schematic Sheet 1 of 6 ...

Page 401: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 27 Figure 7 35 Hydraulic Schematic Sheet 2 of 6 2792535 B ...

Page 402: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 28 JLG Lift 3121160 Figure 7 36 Hydraulic Schematic Sheet 3 of 6 ...

Page 403: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 29 Figure 7 37 Hydraulic Schematic Sheet 4 of 6 2792535 B ...

Page 404: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 30 JLG Lift 3121160 Figure 7 38 Hydraulic Schematic Sheet 5 of 6 ...

Page 405: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121160 JLG Lift 7 31 Figure 7 39 Hydraulic Schematic Sheet 6 of 6 2792535 B ...

Page 406: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 32 JLG Lift 3121160 NOTES ...

Page 407: ......

Page 408: ...5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore Technol...

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