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SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121714

5-81

c.

Unscrew cylinder head with hook spanner wrench.
Refer Figure 5-67.

6.

Attach a suitable pulling device to the cylinder rod end.

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

7.

With the barrel clamped securely, apply pressure to the
rod pulling device and carefully withdraw the complete
rod assembly from the cylinder barrel.

Figure 5-64. Cylinder Head Removal

Figure 5-65. Cylinder Rod Support

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Summary of Contents for E450A

Page 1: ...Service and Maintenance Manual Models E450A E450AJ M450A M450AJ SN 0300208529 to Present PN 3121714 November 30 2018 Rev D AS NZS...

Page 2: ......

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

Page 4: ...INTRODUCTION A 2 3121714 REVISON LOG Original Issue A October 31 2016 Revised B August 23 2017 Revised C June 29 2018 Revised Covers Revised D November 30 2018...

Page 5: ...on and Frequent Inspection 2 1 Annual Machine Inspection 2 1 Preventative Maintenance 2 1 2 2 Service and Guidelines 2 2 General 2 2 Safety and Workmanship 2 2 Cleanliness 2 2 Components Removal and I...

Page 6: ...ly 3 21 Output Planet Gear Assembly 3 21 Output Carrier Assembly 3 22 Hub spindle Assembly 3 22 Cover Assembly 3 23 Main Assembly 3 23 3 6 Drive Motor 3 26 Removal 3 26 Disassembly 3 26 Inspection 3 2...

Page 7: ...or 3 67 Alternator Output Current Sensor 3 68 Engine Speed Sensor 3 68 RBS Engine Generator Controller 3 68 Warnings and Safety Precautions 3 69 System Controls 3 69 System Status and Performance Moni...

Page 8: ...n Assembly and Torque Specification 5 3 Tapered Thread Types 5 3 Straight Thread Types Tube and Hose Connections 5 3 Straight Thread Types Port Connections 5 4 Flange Connection Types 5 4 Tightening M...

Page 9: ...sure Setting Procedures 5 130 Main Relief 5 130 Main Lift Down Relief 5 130 Lower Lift Down Relief 5 130 Telescope Relief 5 130 Platform Level Up Relief 5 131 Platform Level Down Relief 5 131 Steer Re...

Page 10: ...Side High Side 7 4 7 4 Applying Silicone Dielectric Compound to Electrical Connections 7 4 Installation of Dielectric Grease 7 5 Deutsch HD DT DTM DRC Series 7 5 AWP Seal 7 5 AMP Mate N Lok 7 6 DIN C...

Page 11: ...0 3 18 Drive Hub Sheet 1 of 2 3 24 3 19 Drive Hub Sheet 2 of 2 3 25 3 20 Drive Motor 3 28 3 21 Swing Bearing Feeler Gauge Check 3 29 3 22 Swing Bearing Tolerance Boom Placement 3 30 3 23 Swing Bearing...

Page 12: ...lation 5 64 5 35 Cylinder Barrel Support 5 65 5 36 Cylinder Head Removal 5 65 5 37 Cylinder Rod Support 5 65 5 38 Jib Lift Cylinder SN 0300208529 to Present SN B300001429 through B300002486 5 66 5 39...

Page 13: ...00239756 to Present 5 92 5 83 Upper Lift Cylinder E450AJ M450AJ SN B300002487 to Present 5 93 5 84 Composite Bearing Installation 5 95 5 85 Rod Seal Installation 5 95 5 86 Cylinder Head Seal Installat...

Page 14: ...ope Cylinder Removal 5 129 5 146 Jib Valve Location 5 132 5 147 Hydraulic Component Location 5 133 5 148 Steer Valve Pressure Adjustment 5 134 5 149 Steer Valve Component 5 135 5 150 Steer Valve Torqu...

Page 15: ...2 6 16 Platform Module Sheet 2 of 2 6 33 7 1 Voltage Measurement DC 7 1 7 2 Resistance Measurement 7 2 7 3 Continuity Measurement 7 2 7 4 Current Measurement DC 7 3 7 5 Application to Female Contacts...

Page 16: ...54 7 54 Platform Console Harness with SkyGuard and 1 Cell LSS Sheet 2 of 4 7 55 7 55 Platform Console Harness with SkyGuard and 1 Cell LSS Sheet 3 of 4 7 56 7 56 Platform Console Harness with SkyGuard...

Page 17: ...10 Bulkhead Fittings BH INCH 5 19 5 11 Bulkhead Fittings BH METRIC 5 20 5 12 O ring Boss ORB Table 1 of 6 5 23 5 13 O ring Boss ORB Table 2 of 6 5 24 5 14 O ring Boss ORB Table 3 of 6 5 25 5 15 O ring...

Page 18: ...ing Settings 6 12 6 4 Personality Ranges Defaults 6 13 6 5 Function Speeds 6 23 6 6 Machine Setup Descriptions 6 34 6 7 JLG Control System Flash Codes 6 34 6 8 Help Descriptions and Fault Flash Codes...

Page 19: ...5m TurningRadius Inside 2ft 0 61m MaximumTireLoad E450A M450AJ E450AJ 6100lbs 2 767kg 6900lbs 3 130kg GroundBearingPressure E450A M450AJ E450AJ 64psi 4 5kg cm2 75psi 5 2kg cm2 SystemVoltage 48volts Ba...

Page 20: ...7in 7 49m 25ft 3in 7 7m HorizontalReach MaximumUpand Over E450A M450AJ E450AJ 23ft 1in 7 0m 23ft 9in 7 24m MachineWidth 5ft 9in 1 75m WheelBase 6ft 7 0in 2 00m WorkingHeight 51ft 0in 15 54m PlatformHe...

Page 21: ...dable ISOViscosityGrade 32 46 SpecificGravity 922 PourPoint Max 25 F 32 C FlashPoint Min 428 F 220 C OperatingTemp 0to180 F 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 37cSt at100 C...

Page 22: ...SECTION 1 SPECIFICATIONS 1 4 3121714 Figure 1 2 Maintenance Lubrication Diagram...

Page 23: ...s NOTE OG will allow better cycle times than Mobiltac375NC however Mobiltac375NC must be used in dusty environ ments If the swing function becomes noisy and or rough lubricate the bearing teeth DO NOT...

Page 24: ...recheck oil level in reservoir 4 Hydraulic Return Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter Comments Under certain conditions it may be neces sary to replace...

Page 25: ...le Bushing Replacement Coat I D of bushings prior to installing king pins 8 Boom Pivot Pins Bushing Capacity A R Lube Lithium Lubricant Interval Every 2 years or 1200 hours of operation Comments At bo...

Page 26: ...SECTION 1 SPECIFICATIONS 1 8 3121714 Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 5 Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue...

Page 27: ...SECTION 1 SPECIFICATIONS 3121714 1 9 Figure 1 4 Torque Chart SAE Fasteners Sheet 2 of 5 Torq ue Tor que Torq ue Torqu e To rqu e...

Page 28: ...SECTION 1 SPECIFICATIONS 1 10 3121714 Figure 1 5 Torque Chart SAE Fasteners Sheet 3 of 5 Cl amp Load Torque To rque Torq ue Torqu e Tor que Torq ue...

Page 29: ...SECTION 1 SPECIFICATIONS 3121714 1 11 Figure 1 6 Torque Chart METRIC Fasteners Sheet 4 of 5 To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue...

Page 30: ...SECTION 1 SPECIFICATIONS 1 12 3121714 Figure 1 7 Torque Chart METRIC Fasteners Sheet 5 of 5 Torq ue To rqu e Tor qu e To rqu e To rqu e To rq ue...

Page 31: ...lease or rental delivery The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or...

Page 32: ...containers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc sho...

Page 33: ...the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can ca...

Page 34: ...ood grade mineral oils with viscosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil or filters of new machin...

Page 35: ...temper ature Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature before beginning this test Measure drift at cylinder rod with a calibrated dial indicator In an area free of o...

Page 36: ...l grease and oil Filament wound bearing are a dry joint and should not be lubricated unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scra...

Page 37: ...2 CoversorShields 1 2 1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly Platform 1 2 Railing 1 1 2 Gate 1 5 1 5 Floor 1 1 2 Rotator 5 9 15 LanyardAnchoragePoint 1 2 10 1 2 10 Turntabl...

Page 38: ...ies 1 9 19 BatteryFluid 11 11 BatteryCharger 5 5 FuelReservoir Cap andBreather 1 2 5 1 5 Hydraulic ElectricSystem HydraulicPumps 1 2 9 HydraulicCylinders 1 2 7 9 1 2 9 CylinderAttachmentPinsandPinReta...

Page 39: ...thepriorinspection PerformanceCodes 1 Checkforproperandsecureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 Opera...

Page 40: ...OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE EX XON UNI VIS HVI 26 MOBI L DTE 13 40 F 40 C 30 F 34 C 20 F 29...

Page 41: ...oad rating and size of original Tire tread contact width equal or greater than origi nal Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manuf...

Page 42: ...o set the end play 6 The units should be checked visually to make sure the cotter pins are installed and that the correct compo nents have been used Each unit must also be checked for the proper feel...

Page 43: ...CTION 3 CHASSIS TURNTABLE 3121714 3 3 1 DustCap 2 CotterPin 3 SpindleNut 4 SpindleWasher 5 StudNut 6 BearingCone 7 Hub 8 BearingCone 9 Seal 10 Spindle Figure 3 1 Spindle Assembly 2780241 C 1001180839...

Page 44: ...ngleSensor 3 SteerValve 4 Motor Pump 5 BatteryCharger 6 Battery 7 HydraulicTank 8 SwingBearing 9 SwingMotor 10 DriveModule Right Master 11 DriveModule Left Slave 12 DriveHub 13 DriveMotor 14 DriveBrak...

Page 45: ...er Analyzer PN 1600244 Cable PN 1600633 into port J9 on the power module or port J1 on the platform module 3 Use the right arrow key to curse over to ACCESSLEVEL 2 Depress Enter 4 Use Up Down arrow ke...

Page 46: ...TO 12V DC DC CONVERTER POWER STUD CONTACTOR RHT CONTACTOR LFT GROUND STUD LFT PWR MOD U LFT PWR MOD B LFT PWR MOD B LFT PWR MOD W 11X TORQUE CONTROLLER STUDS TO 7 N M MAX LFT MTR U LFT MTR V LFT MTR...

Page 47: ...SECTION 3 CHASSIS TURNTABLE 3121714 3 7 RL 1 IGNITION RELAY RL 2 VOTE RELAY OPTIONAL INVERTER Figure 3 5 Relay...

Page 48: ...SECTION 3 CHASSIS TURNTABLE 3 8 3121714 FC 1 48V B 20A FC 3 OPTION FUSE 5A FC 2 12V SYSTEM 15A FC 601 DELTA Q 30A NOTE CHARGER FUSE SHOULD BE IN PLACE Figure 3 6 System Fuses...

Page 49: ...SECTION 3 CHASSIS TURNTABLE 3121714 3 9 FC 4 IGNITION RELAY FUSE 20A Figure 3 7 Ignition Relay Fuse...

Page 50: ...SECTION 3 CHASSIS TURNTABLE 3 10 3121714 POWER STUD IP 408 RIGHT BRAKE 10Amp IP 409 LEFT BRAKE 10Amp Figure 3 8 Drive Fuses...

Page 51: ...SECTION 3 CHASSIS TURNTABLE 3121714 3 11 1001116232 A Figure 3 9 Drive Limit Switch...

Page 52: ...eerLink 6 CotterPin 7 CastleNut 8 ThrustWasher 9 LipSeal 10 BearingCone 11 InnerBearingCup 12 WheelStud 13 Hub 14 LugNut 15 OuterBearingCup 16 OuterBearingCone 17 TangedWasher 18 CastleNut 19 DustCap...

Page 53: ...onsistency Leak Test Main Unit The purpose of a leak test is to make sure the unit is air tight You can tell if your unit has a leak if the pressure gauge read ing on your leak checking fitting starts...

Page 54: ...move the First Stage Sun Gear 10 if applicable NOTE On units with ratios greater than 36 1 numerically there will not be a separate First Stage Sun Gear 10 as the gear teeth will be integral to the In...

Page 55: ...g Gear 1G Housing 4 Output Carrier Subassembly 5 Retaining Ring 6 Cover Assembly 6G Retaining Ring 9 Input Shaft 10 First Stage Sun Gear 11 Second Stage Sun Gear 18 O ring 19 Flat Head Bolt 20 Retaini...

Page 56: ...The Roll Pins 4G should not be reused when reassembling the unit 4 Slide the Planet Gear Sub assembly 4 out of the Output Carrier 4A being careful to not drop the Needle Bear ings 4C in the process 5...

Page 57: ...SECTION 3 CHASSIS TURNTABLE 3121714 3 17 4B Thrust Washer 4C Needle Bearing 4D Thrust Spacer 4F Planet Gear Figure 3 14 Planet Gear...

Page 58: ...Using a 1 8 diameter punch drive the Roll Pin 4G out of the Planet Shaft 3E NOTE The Roll Pins 4G should not be reused when reassembling the unit 4 Slide the Planet Gear 3F and the two Thrust Washers...

Page 59: ...off of Spindle 1A Remove Boot Seal 1Q from Hub 1G if applicable 6 If necessary press 9 Studs 1H out of Hub 1G Locate Hub 1G on Seal 1B end 7 Remove Seal 1B from Hub 1G NOTE The Seal 1B should NOT be...

Page 60: ...Disen gage Cap 68 from Cover 6A 4 Pull Disengage Rod 6D out from Cover 6A 5 Use appropriate tool to remove O Ring 6E from inter nal groove in Cover 6A 6 Remove two O Ring Pipe Plugs 6F from Cover 6A N...

Page 61: ...anner described in Step 5 8 Now insert Planet Shaft 3E through the opposite planet shaft hole on Carrier 3A Use an alignment punch or similar tool to align the roll pin holes on Carrier 3A and Planet...

Page 62: ...ssembly NOTE Refer to Figure 3 16 Hub Spindle NOTE Spray a light film of oil on all component parts during assembly 1 Place Hub 1 G into pressing base Press nine Studs 1H into Hub NOTE Use enough pres...

Page 63: ...oles on Hub 1G and Ring Gear 1F 4 Install three shipping Capscrews 19 into ring gear and hub Torque them to 15 20 ft lbs 5 Place Output Carrier Sub Assembly 4 into mesh with Spindle 1A splines 6 Place...

Page 64: ...SECTION 3 CHASSIS TURNTABLE 3 24 3121714 1 0 Figure 3 18 Drive Hub Sheet 1 of 2...

Page 65: ...rier 3B Thrust Washer 3C Needle Bearing 3E Planet Shaft 3F Planet Gear 4A Output Carrier 4B Thrust Washer 4C Needle Bearing 4D Thrust Spacer 4E Planet Shaft 4F Planet Gear 4G Roll Pin 4H Thrust Washer...

Page 66: ...brake 36 onto the drive motor Remove the drive brake 6 Remove the terminal base 6 from the stator 2 7 Remove the temperature sensor 27 from the stator 2 8 Remove the screws 22 from the retaining plat...

Page 67: ...e sensor 27 to the stator 2 16 Install the terminal base 6 onto the stator 2 17 Install the screws 7 18 Install the terminal board 3 onto the terminal base 6 19 Attach the three nuts 4 and relevant wa...

Page 68: ...Ring 10 ShaftSeal 11 Bearing 12 Washer 13 Sensor 14 Screw 15 Wedge 16 Connector 17 MalePin 18 EndShield 19 Seal 20 Seal 21 Cover 22 Screw 23 RetainingPlate 24 Bearing 25 RetainerClip 26 Screw 27 Tempe...

Page 69: ...eck the frame to bearing Attach bolts as follows a Elevate the fully retracted boom to 70 degrees full elevation b At the positions indicated on Figure 3 22 try and insert the 0 0015 feeler gauge betw...

Page 70: ...ecord the distance between the swing bearing and turntable See Figure 3 23 2 At the same point with the boom positioned over the side of the machine the Upper Boom fully elevated and the Mid Lower Boo...

Page 71: ...bearing to the frame Discard the bolts Use suit able lifting equipment to remove the bearing and rotation box assembly from the frame move to a clean suitably supported work area h Remove the two cap...

Page 72: ...the inner race of the bearing aligns with the scribed mark on the turntable If a new swing bearing is used ensure that the filler plug fitting is at 90 degrees from the fore and aft centerline of the...

Page 73: ...714 3 33 MAE36590 CG CL 3 9 99 06 mm Figure 3 25 Swing Bearing Removal E450A Gross Weight includes all components except Chassis 8256 lbs 3745 Kg Note CG location may vary slightly depending on the ex...

Page 74: ...21714 MAE36600 CG 8 5 216 mm CL Figure 3 26 Swing Bearing Removal E450AJ M450AJ Gross Weight includes all components except Chassis 8426 lbs 3822 Kg Note CG location may vary slightly depending on the...

Page 75: ...rm 2 If tolerance exceeds 0 010 reduce end play to less than 0 005 Refer to Adjusting End Play Adjusting End Play 1 Remove end plate 2 Measure and record total thickness of existing shim pack 3 Determ...

Page 76: ...SECTION 3 CHASSIS TURNTABLE 3 36 3121714 Figure 3 27 Swing Components...

Page 77: ...TABLE 3121714 3 37 3 8 SWING MOTOR IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED IN EXCESS OF 200 F 93 3 C SEALS IN THE SYSTEM CAN SHRINK HARDEN OR CRACK THUS LOSING THEIR SEALING ABILITY Figure 3...

Page 78: ...ignificantlossofspeedunderload 1 Lackofsufficientoilsupply 2 Highinternalmotorleakage 3 Severelywornordamagedinternalsplines 4 Excessiveheat a Checkforfaultyreliefvalveandadjustorreplaceasrequired b C...

Page 79: ...rSet 8A Rotor 8B StatorHalf 8C StatorVane 8D StatorHalf 9 WearPlate 10 DriveLink 11 ThrustBearing 12 CouplingShaft 13 InnerBushing 14 ThrustWasher 15 ThrustBearing 16 Seal 17 BackupRing 18 Housing 19...

Page 80: ...ENTS ARE FLAMMABLE BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX IMUM AIR PRES...

Page 81: ...Be sure the end cover valve apertures are free of contamination Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces Replace end cover as necessary NOTE A polis...

Page 82: ...a matched set 8 Remove manifold 7 and inspect for cracks surface scor ing brinelling or spalling Replace manifold if any of these conditions exist A polished pattern on the ground surface from commut...

Page 83: ...pen cil before removal will ensure correct reassembly of rotor into stator and rotor set into motor Marking all rotor com ponents and mating spline components for exact reposi tioning at assembly will...

Page 84: ...coupling shaft bearing and seal sur faces for spalling nicks grooves severe wear or corro sion and discoloration Inspect for damaged or worn internal and external splines or keyway Replace cou pling...

Page 85: ...nging dimen sional characteristics Inspect tapped holes for thread damage If the housing is defective in these areas dis card the housing assembly 19 If the housing 18 assembly has passed inspection t...

Page 86: ...eginning of bearing bushing counterbore should be measured and noted before removing the bearings bushings This will facilitatethe correct reassembly of newbearings bushings 20 If the bearings bushing...

Page 87: ...re at the mounting flange end of the housing using the appro priate sized bearing mandrel as described which will control the bearing bushing depth The housing requires the use of bearing mandrel to p...

Page 88: ...against the mounting flange 5 Assemble a new backup ring 17 new backup washer 25 and new seal 16 with the seal lip facing toward the inside of the motor into their respective counterbores in housing...

Page 89: ...clean grease to a new seal ring 4 and insert it into the housing 18 seal ring groove NOTE One or two alignment studs screwed finger tight into hous ing 18 bolt holes approximately 180 degrees apart w...

Page 90: ...ust be down against wear plate for drive link clearance and to maintain the original rotor drive link spline contact A rotor set without a counterbore and that was not etched before disassembly can be...

Page 91: ...g 6 over alignment studs onto the manifold 18 Assemble a new seal ring 3 flat side up into commuta tor 5 and assemble commutator over the end of drive link 10 onto manifold 7 with seal ring side up 19...

Page 92: ...r to radially align the end cover into its original position 20 Assemble the bolts 1 and screw in finger tight Remove and replace the two alignment studs with bolts after the other bolts are in place...

Page 93: ...r counterbore down if applicable into stator and onto wear plate 9 with rotor splines into mesh with drive link 10 splines 4 Assemble six vanes or as many vanes that will readily assemble into the sta...

Page 94: ...vanes using minimum force 6 Place second stator half on a fl at surface with seal ring groove up Apply a small amount of grease to a new seal ring 4 and assemble it into stator half ring groove 7 Asse...

Page 95: ...ensure that it functions prop erly Optional On Board Generator EXHAUST GAS HAZARD RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PLATFORM CON TROL BO...

Page 96: ...SECTION 3 CHASSIS TURNTABLE 3 56 3121714 GENERATOR Figure 3 30 On Board Generator...

Page 97: ...DED OUTLET IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK DO NOT USE GROUND ADAPTERS OR MODIFY PLUG DO NOT TOUCH UNINSULATED PORTION OF OUT PUT CONNECTOR OR UNINSULATED BATTERY TERMINAL DISCONNECT THE A...

Page 98: ...ver Indicatesahighbatterypackvoltage 2 Batteryvoltage low Auto recover Indicateseitherabatterypackfailure batterypacknotconnectedtochargerorbatteryvolts percellislessthan0 5VDC Checkthebatterypackand...

Page 99: ...SECTION 3 CHASSIS TURNTABLE 3121714 3 59 1 ACVoltage InputCable 2 BatteryChargeSignalCable 3 DCPowerCabletoBatteries Figure 3 31 Battery Charger E450A AJ...

Page 100: ...SECTION 3 CHASSIS TURNTABLE 3 60 3121714 1 ACVoltage InputCable 2 BatteryChargeSignalCable 3 DCPowerCabletoBatteries Figure 3 32 Battery Charger M450AJ...

Page 101: ...o be higher than 1 0V per cell and all con nections are good return the charger for service 3 Flashes Charge Timeout Indicates the battery failed to charge within the allowed time This could occur if...

Page 102: ...battery charge algorithm If the bat tery pack is new the algorithm will need to be changed if the pack is not the same as the old one for instruc tions on how to determine and change the battery char...

Page 103: ...ut of the alternator is full wave recti fied and presented to the output terminals Output rating 58 0V at 45A Voltage regulation and current limiting is provided by the RBS Engine Generator Controller...

Page 104: ...igure 3 33 Generator 4 TemperatureSensor 5 VoltageRegulator 6 Alternator 7 Starter 8 StarterSolenoid 9 OilFilter 10 FuelFilter 1 GlowPlugRelay 2 FuelControlRelay 3 StartControlRelay 4 FuelSolenoid 5 F...

Page 105: ...pped with a 12VDC starter which pro vides the mechanical power to crank the engine Electrical power for the starter is provided by the start battery The starter is energized by the start control relay...

Page 106: ...et on the right side of the engine Glow Plug Control Relay The glow plug control relay energizes the glow plug It is energized by the engine generator controller pin J2 27 The glow plug control relay...

Page 107: ...engine This solenoid has a pull coil energized by the start control relay and a hold coil energized by the fuel control relay The fuel solenoid is located on the right side of the engine Engine Low O...

Page 108: ...rator con troller to determine starter cut out overspeed fault and underspeed fault If the signal is not present at the engine generator controller the unit will fault with a loss of speed signal indi...

Page 109: ...L TO START SETTINGS CURRENT AND VOLTAGE SETTINGS TIME DELAY SETTINGS CRANK SETTINGS SPEED TIME AND GLOW PLUG SETTINGS 30 Outputvoltage 31 Speedsensing 5V 32 Outputcurrentsense 33 Notused 34 Notused 35...

Page 110: ...e starts orOvercrankfaultisindicated after3failedcrankcycles Timedelaybypass RBSwaitsuntilnormalengineoperat ingconditionsarereachedbeforeLow oilpressureandUnderspeedfaultsare monitored Calltostartrem...

Page 111: ...Shutdown 1 2 HighEngineTemp Over248 F 120 C Shutdown 1 3 Overspeed Over3800RPM Shutdown 1 4 Underspeed1 Below2000RPM Shutdown Overcrank 3failedcrankcyclesCalltostartremoved Calltostartremoved 1 5 NoS...

Page 112: ...sor 1 3 Overspeed Verifysettingofgovernorlever Readjust ifrequired RefertoKubotaWorkshopmanualWSMOC60 80 95 1 4 Underspeed Ensurethereisanadequatesupplyoffueltotheengine Ensurethereisanadequatesupplyo...

Page 113: ...R BATTERY TO START AN APU MAY CAUSE AN EXPLOSION DO NOT ATTEMPT TO JUMP START AN APU WITH A LOW ACID LEVEL IN THE BATTERY THE VOLTAGE OF THE BOOSTER BATTERY MUST BE RATED AT 12V THE AMP HOUR CAPACITY...

Page 114: ...e ties JLG PN 4240033 Wire Side cutters 5 32 Allen Key Crimping tool Procedure BEFORE BEGINNING THIS PROCEDURE ENSURE THAT ALL SOURCES OF POWER ARE DISCONNECTED FROM THE APU This procedure is common f...

Page 115: ...posing the conductors of the harness 5 Cut wire 106 going to the Engine Generator Controller after the existing connection point and install the con ductors that lead to the new inline fuse holder Use...

Page 116: ...SECTION 3 CHASSIS TURNTABLE 3 76 3121714 NOTES...

Page 117: ...n remove the platform 3 Using a suitable lifting device support the platform sup port NOTE The platform support weighs approximately 77 lbs 35 kg 4 Remove the bolts and locknuts securing the support t...

Page 118: ...r bolt 3 Apply JLG Threadlocker PN 0100011 to the bolts and locknuts securing the support to the rotator and install the bolts and locknuts 4 Torque the nut on the rotator center bolt to 250 270 ft lb...

Page 119: ...B C D Torqueto40ft lbs 55Nm JLGThreadlocker 0100011 Torqueto250 270ft lbs 339 366Nm Checktorqueevery150hoursofoperation Figure 4 2 Platform Support Torque Values NOTE If any rotator bolts are replace...

Page 120: ...orting the slave cylinder remove the hardware from pin Using a suitable brass drift and hammer remove pin from the fly boom 6 Tag and disconnect hydraulic lines to the slave leveling cylinder Use a su...

Page 121: ...long entire length 5 Remove bolts 1 securing the push tube on the fly boom section 6 Remove bolts 2 that attaches rail to the push tube on the main boom section 7 With powertrack supported and using a...

Page 122: ...ic fluid Cap hydraulic lines and ports NOTE The Main Boom weighs approximately 450lbs 204kg c Using a suitable lifting equipment adequately sup port boom weight along entire length d Remove hardware s...

Page 123: ...ove powertrack Inspection 1 Inspect boom pivot pin for wear scoring or other dam age and for tapering or ovality Replace pin as neces sary 2 Inspect lift and master cylinder pins for wear scoring or o...

Page 124: ...ximately 450lbs 204kg 1 Using suitable lifting equipment position boom assem bly on upright so that boom pivot holes in both boom and upright are aligned 2 Install boom pivot pin ensuring that locatio...

Page 125: ...anual for your machine Periodic maintenance and inspection is vital to the proper operation of the machine The fre quency of service and maintenance must be increased as environment severity and frequ...

Page 126: ...WING ANGLES ARE USED TO SET THE UPPER LIMIT SWITCH IF IT IS AN AJ MODEL THE JIB IS TO BE COMPLETELY LOWERED MAKE SURE THE LOWER BOOM IS COMPLETELY LOWERED ALL ANGLES ARE TAKEN FROM THE MIDDLE OF THE U...

Page 127: ...SECTION 4 BOOM PLATFORM 3121714 4 11 Figure 4 5 Platform Components and Attaching Hardware M450A E450A...

Page 128: ...ng fly boom pivot attach points for scoring tapering and ovality or other damage Replace pins as necessary 3 Inspect inner diameter of articulating fly boom pivot bearings for scoring distortion wear...

Page 129: ...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...

Page 130: ...ns of piston and shaft Arrows indicate direction they will rotate The hous ing with integral ring gear remains stationary As fluid pressure is applied the piston is displaced axially while the helical...

Page 131: ...Shaft 3 PistonSleeve 4 EndCap 109 LockPin 113 Capscrew 200 T Seal 202 T Seal 204 O Ring 205 CupSeal 207 BackUp Ring 302 WearGuide 304 ThrustWasher 304 1 WiperSeal 400 StopTube Optional 401 Counterbala...

Page 132: ...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 AC...

Page 133: ...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 16 drill bit to a depth of 1 2 12 7mm todrill out the entire pin 4 Install the en...

Page 134: ...shaft 2 use a felt marker to clearly indicate the timing marks between shaft and pis ton This will greatly simplify timing during assembly 10 Remove the shaft 2 It may be necessary to strike the thre...

Page 135: ...g gear teeth mark the pis ton 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 inspection 15 Remove the wear guides 302 from the end cap...

Page 136: ...tank and dry with com pressed air prior to inspecting Carefully inspect all criti cal areas for any surface finish abnormalities Seal grooves bearing grooves thrust surfaces rod surface housing bore...

Page 137: ...ns 2 Install the thrust washer 304 onto shaft 2 and end cap 4 3 Install the wiper seal 304 1 green O ring into it s groove on the shaft 2 and end cap 4 around the out side edge of the thrust washer 30...

Page 138: ...ring in the lower groove and feed the rest in using a cir cular motion Make sure the wedged ends overlap cor rectly Repeat this step for the outer seal 202 8 Insert the piston 3 into the housing 1 as...

Page 139: ...king from the view shown use the existing timing 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 mall...

Page 140: ...stays in place on the end cap as it is threaded into the housing 1 18 Tighten the end cap 4 In most cases the original holes for the lock pins will line up 19 Place the lock pins 109 provided in the...

Page 141: ...New bolts should be installed with a new valve JLG Threadlocker PN 0100011 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 in lbs 1...

Page 142: ...ng the Actuator If the equipment is available the actuator should be tested on a hydraulic test bench The breakaway pressure the pres sure at which the shaft begins to rotate should be approxi mately...

Page 143: ...is purged 1 Connect a 3 16 inside diameter x 5 16 outside diame ter x 5 foot clear vinyl drain tube to each of the two bleed nipples Secure them with hose clamps Place the vinyl tubes in a clean 5 ga...

Page 144: ...onpage 24ofthismanual e Re buildtheactuator Removeallrustthenpolish Replacementpartsmaybeneeded f Re buildtheactuator Usefluidthatiscompatiblewith sealsandbearings 5 Operationiserraticornotresponsive...

Page 145: ...Actual hose and cable arrangements will be differ ent 1 Clamp the bar and poly roller tightly so they do not spin when removing the screw With a small ratchet and a t 20 torx bit remove the 8 32 x 0 5...

Page 146: ...attachment MOVE THE CABLES HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM KEEP THE HOSES AND CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON THEM 4 insert the tool into the rol...

Page 147: ...out by using a center punch with a hammer NOTE It may be necessary to loosen the fixed end brackets from the machine in order to twist and pull the track section enough to disconnect the links 6 Usin...

Page 148: ...ORM 4 32 3121714 7 Remove the link from the other section of the pow ertrack using a screwdriver Installing a New Link 1 Squeeze the peanut cut out end of the new link into the half shear female end o...

Page 149: ...t end of the track section into it A screwdriver may be necessary to do this 3 After the new link is installed in the powertrack the round half shears will not fit properly in the peanut cut outs yet...

Page 150: ...4 34 3121714 In this position the round half shears will rotate into the peanut cut outs 5 The parts shown below will be used to connect the new link to the powertrack 6 Push pin through center hole t...

Page 151: ...ation steps for all center holes that have the rivets removed NOTE When installing snap rings make sure they are seated in pin groove and closed properly 8 Hold new aluminum round bar tightly then ins...

Page 152: ...SECTION 4 BOOM PLATFORM 4 36 3121714 NOTE Maximum tightening torque is 18 20 in lbs 9 Pull up on the other end of the round bar and slide the new poly roller onto the bar...

Page 153: ...link with no space in between the link and underside of screw head Maximum tightening torque is 18 20 in lbs Replacing Fixed End Brackets 1 Remove the rivets the same way as shown under the link remov...

Page 154: ...enter Pin Snap Ring 3 Take the new bracket and install bracket center pin and snap ring Repeat on the other bracket if replacing it as well NOTE When installing snap rings make sure they are seated in...

Page 155: ...et the same way as shown in the link removal instructions Repeat on other bracket if replacing it as well MOVE THE CABLES HOSES OUT OF THE WAY DURING THE GRINDING PROCESS TO PROTECT THEM KEEP THE HOSE...

Page 156: ...locations and install snap rings Repeat with other moving end if replacing as well NOTE When installing snap rings make sure they are seated in pin groove and closed properly 4 When complete make sure...

Page 157: ...hen activate Sky Guard sensor 2 Once sensor has been activated ensure telescope out function stops then telescope in function operates for a short duration Additionally verify Soft Touch SkyGuard indi...

Page 158: ...laced immediately If the status of the switch relay remains CLOSED while the Sky Guard sensor is actively engaged a power or ground wire may not be making good contact or may be loose or broken Addi t...

Page 159: ...ssembly Cup and Brush The following is needed to correctly oil the o ring in this man ner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the brush wit...

Page 160: ...p from the bottom of the fitting This should signify an even coating of oil on the fitting 3 O ring Boss type fittings will require more pressure in able to immerse more of the fitting into the satura...

Page 161: ...ions JIC 37 flare per SAE J514 SAE 45 flare per SAE J512 ORFS o ring face seal per SAE J1453 MBTL metric flareless bite type fitting pressure rating L medium per ISO 8434 DIN 2353 MBTS metric flareles...

Page 162: ...ll no longer thread onto the mating part when tightened by hand or fin gers Finger Tight is relative to user strength and will have some variance The average torque applied by this method is 3 ft lbs...

Page 163: ...r care should be taken not to introduce sealant into the system d Avoid applying sealant to the area of the threads where the sealant will be forced into the system This is generally the first two thr...

Page 164: ...r of turns per Table 5 1 NPTF Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 5 1 NPTF Pipe Thread are applicable for the following material co...

Page 165: ...number of turns per Table 5 2 BSPT Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 5 2 BSPT Pipe Thread are applicable for the following mater...

Page 166: ...D THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE 3 Torque assembly to value listed in Table 5 3 37 Flare JIC Thread Steel or Table 5 4 37 Flare JIC Thread Aluminum Brass...

Page 167: ...50 12 70 14 15 15 19 20 21 1to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 22 23 24 30 31 33 1to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 42 44 46 57 60 63 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0 87 22 20 60 63 66 81...

Page 168: ...20 0 46 11 60 0 50 12 70 9 10 10 12 13 14 1to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 14 15 16 19 20 21 1to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 27 29 30 37 39 41 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0 87 22...

Page 169: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 11 This page left blank intentionally...

Page 170: ...OR SEALANT IS REQUIRED THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE 4 Torque fitting to value listed in Table 5 5 45 Flare SAE Steel and Table 5 6 45 Flare SAE Alumin...

Page 171: ...0 84 88 92 114 119 125 1 4to1 2 Aand Bthreaddimensionsforreferenceonly SeeFFWRandTFFTMethodsforTFFTprocedurerequirements Table 5 6 45 Flare SAE Aluminum Brass TYPE FITTING IDENTIFICATION Torque Turns...

Page 172: ...tion of the connection ALUMINUM BRASS FITTINGS OR ALUMINUM BRASS MATING COMPONENTS indicate either the following material configurations a STEEL fittings with ALUMINUM or BRASS mating components b ALU...

Page 173: ...11 16 16 0 63 15 90 0 69 17 50 20 21 22 27 28 30 1 4to1 2 1 2to3 4 8 13 16 16 0 75 19 10 0 81 20 60 26 28 29 35 38 39 1 4to1 2 1 2to3 4 10 1 14 0 94 23 80 1 00 25 40 39 41 43 53 56 58 1 4to1 2 1 2to3...

Page 174: ...e If necessary replace fitting or tube 2 Lubricate thread and cone of fitting body or hardened pre assembly tool as well as the progressive ring and nut threads 3 Slip nut and progressive ring over tu...

Page 175: ...22 M30x2 27 90 30 00 7 50 22 20 1 5to1 75 28 M36x2 33 90 36 00 7 50 28 20 1 5to1 75 35 M45x2 42 90 45 00 10 50 35 30 1 5to1 75 42 M52x2 49 90 52 00 11 00 42 30 1 5to1 75 TYPE Tube O D ThreadM Size A...

Page 176: ...oreign material If necessary replace fitting or adapter 2 Remove the locknut from the bulkhead assembly 3 Insert the bulkhead side of the fitting into the panel or bulkhead bracket opening 4 Hand thre...

Page 177: ...149 183 193 202 14 15 16 12 170 179 187 230 243 254 16 17 16 12 200 210 220 271 285 298 20 111 16 12 245 258 270 332 350 366 24 2 12 270 284 297 366 385 403 TYPE Dash Size Thread Size Torque Ft Lb N...

Page 178: ...7 50 53 15 M22x1 5 44 47 50 60 64 68 18 M26x1 5 70 75 80 95 102 108 22 M30x2 115 120 125 156 163 169 28 M36x2 150 157 164 203 213 222 35 M45x2 155 162 169 210 220 229 42 M52x2 220 230 240 298 312 325...

Page 179: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 21 This page left blank intentionally...

Page 180: ...Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 12 thru Tables 5 17 O RING BOSS ORB while using the Double Wrench Method NOTE The table headings identify the strai...

Page 181: ...60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HEX TYPE PLUGS STUD ENDS with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thread S...

Page 182: ...60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION STUD ENDS with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Size A Torque Ft L...

Page 183: ...7 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thread Size...

Page 184: ...60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Size A T...

Page 185: ...47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque Ft Lb or in lb N m UNF in mm Min Nom M...

Page 186: ...30 20 15 8 12 1 63 41 30 24 17 8 12 1 87 47 60 32 21 2 12 2 50 63 50 TYPE FITTING IDENTIFICATION ZERO LEAK GOLD HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque Ft Lb or in lb N m UNF in mm Mi...

Page 187: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 29 This page left blank intentionally...

Page 188: ...ng or nut to value listed in Table 5 18 Table 5 19 Table 5 20 Metric Flat Face Port MFF L Series and Table 5 21 Table 5 22 Table 5 23 Metric Flat Face Port MFF S Series while using the Double Wrench M...

Page 189: ...69 72 103 108 113 140 146 153 M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209 M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374 M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550 M48x2...

Page 190: ...2 137 66 70 73 90 95 99 M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198 M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341 M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495 M48x2...

Page 191: ...0 73 90 95 99 M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149 M33x2 28 266 280 293 360 380 397 166 175 183 225 237 248 M42x2 35 398 418 438 540 567 594 266 280 293 360...

Page 192: ...72 125 132 138 170 179 187 M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297 M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450 M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594 M48x2 38...

Page 193: ...2x1 5 18 100 105 110 135 142 149 100 105 110 135 142 149 M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198 M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342 M42x2 35 332 349 365 450 473...

Page 194: ...115 121 92 97 101 125 132 137 59 62 65 80 84 88 M22x1 5 18 89 94 98 120 127 133 100 105 110 135 142 149 M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 M33x2 28 266 280 293 360 380 397 M42x2...

Page 195: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 37 This page left blank intentionally...

Page 196: ...djustable fittings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 24 Metric Pipe Parallel O ring Boss MPP while using the Double Wrenc...

Page 197: ...93 237 249 262 M33x2 25 120 126 132 160 171 179 230 242 253 310 328 343 M38x2 135 142 149 183 193 202 235 247 259 319 335 351 M42x2 30 155 163 171 210 221 232 245 258 270 330 350 366 M48x2 38 190 200...

Page 198: ...Table 5 25 Table 5 26 Table 5 27 British Standard Parallel Pipe Port BSPP L Series and Table 5 28 Table 5 29 Table 5 30 British Standard Parallel Pipe Port BSPP S Series while using the Double Wrench...

Page 199: ...9 133 140 146 180 190 198 G1A 28 111 117 122 150 159 165 243 255 267 330 346 362 G1 1 4A 35 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 42 214 225 235 290 305 319 465 489 512 630 663 694 M...

Page 200: ...146 180 190 198 133 140 146 180 190 198 G1A 28 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 35 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 42 398 418 438 540 567 594 398 418 438...

Page 201: ...243 254 103 108 113 140 146 153 G1A 28 236 248 260 320 336 353 148 156 163 200 212 221 G1 1 4A 35 398 418 438 540 567 594 295 313 5 332 400 425 450 G1 1 2A 42 516 542 568 700 735 770 332 349 365 450...

Page 202: ...209 219 270 283 297 G1A 25 111 117 122 150 159 165 251 264 276 340 358 374 G1 1 4A 30 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 38 214 225 235 290 305 319 516 542 568 700 735 770 MATERIA...

Page 203: ...133 140 146 180 190 198 133 140 146 180 190 198 G1A 25 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 30 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 38 398 418 438 540 567 594 398...

Page 204: ...0 95 99 89 94 98 120 127 133 G3 4A 20 92 97 101 125 132 137 170 179 187 230 243 254 G1A 25 236 248 260 320 336 353 G1 1 4A 30 398 418 438 540 567 594 G1 1 2A 38 516 542 568 700 735 770 MATERIAL BSPP T...

Page 205: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 47 This page left blank intentionally...

Page 206: ...ng Installation Replacement for O ring installa tion instructions 3 Pre lubricate the O ring with Hydraulic Oil 4 Position flange and clamp halves 5 Place lock washers on bolt and bolt through clamp h...

Page 207: ...16 111 116 122 150 158 165 40 2 50 64 3 50 88 90 1 2 13 77 81 85 105 110 116 111 116 122 150 158 165 48 3 00 76 4 19 106 43 5 8 11 155 163 170 210 221 231 218 228 239 295 310 325 56 3 50 89 4 75 120 6...

Page 208: ...71 75 92 97 101 40 2 50 64 3 50 88 90 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 48 3 00 76 4 19 106 43 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 56 3 50 89 4 75 120 65 M16x2 155 163 170 210...

Page 209: ...ench If two wrenches are not used inadvertent component rotation may occur which absorbs torque and causes improper joint load and leads to leaks For hose connections the layline printed on the hose i...

Page 210: ...en properly tightened mark a straight line across the connecting parts not covering the dots to indicate the connection has been properly tightened Adjustable Stud End Assembly For Adjustable Stud End...

Page 211: ...f any are found replace O ring 2 Ensure proper O ring to be installed Many O rings look the same but are of different material different hard ness or are slightly different diameters or widths 3 Use a...

Page 212: ...ower source Adequately support the cylinder rod if applicable 3 Remove counterbalance valve from the cylinder port block Discard o rings 4 Place the cylinder barrel into a suitable holding fixture 5 U...

Page 213: ...ring 9 Retainer 10 Spacer 11 O ring 12 BackupRing 13 WiperSeal 14 RodSeal 15 O ring 16 O ring 17 Bushing 18 CounterbalanceValve 19 Plug 20 Plug 21 CounterbalanceValve Figure 5 17 Platform Level Slave...

Page 214: ...iameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as nec essary 6 Inspect threaded portion...

Page 215: ...inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a l...

Page 216: ...roove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal 12 Position the cylinder barrel in a suitable holding fixture EXTREME CARE SHOULD BE TAKEN WHE...

Page 217: ...rod if applicable 3 Remove counterbalance valve from the cylinder port block Discard o rings 4 Place the cylinder barrel into a suitable holding fixture 5 Using a pin face spanner wrench unscrew the c...

Page 218: ...upRing 11 RodSeal 12 WiperSeal 13 RetainingRing 14 O ring 15 Retainer 16 CounterbalanceValve 17 CounterbalanceValve 18 Plug 19 Plug 20 O ring Figure 5 27 Platform Level Slave Cylinder E M450AJ SN 0300...

Page 219: ...to 50 55 ft lbs 68 75 Nm Torque to 7 ft lbs 10 Nm 1 Barrel 2 Rod 3 Piston 4 Head 5 Bushing 6 PistonSeal 7 O ring 8 WearRing 9 O ring 10 BackupRing 11 RodSeal 12 WiperSeal 13 WearRing 14 O ring 15 Loc...

Page 220: ...or scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston...

Page 221: ...necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a light film of hydraulic oil to all components prior to assemb...

Page 222: ...ce new piston seal and wear rings in the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal 12 Position the cylinder barre...

Page 223: ...if applicable 3 Remove counterbalance valve from the cylinder port block Discard o rings 4 Place the cylinder barrel into a suitable holding fixture 5 Using a pin face spanner wrench unscrew the cyli...

Page 224: ...alve 8 Bushing 9 Sleeve 10 Locknut 11 Retainer 12 WiperSeal 13 RodSeal 14 O ring 15 BackupRing 16 O ring 17 O ring 18 O ring 19 Plug 20 O ring 21 PistonSeal 22 RetainingRing 23 WearRing Figure 5 38 Ji...

Page 225: ...bs 10 Nm Torque to 34 38 ft lbs 46 52 Nm Torque to 50 55 ft lbs 68 75 Nm 6 11 1 Barrel 2 Rod 3 Head 4 Piston 5 Bushing 6 Bushing 7 CounterbalanceValve 8 Bushing 9 Sleeve 10 Locknut 11 Plug 12 WiperSea...

Page 226: ...er barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or...

Page 227: ...ct piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a light f...

Page 228: ...from the holding fixture 12 Place new piston seal and wear rings in the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal...

Page 229: ...he cyl inder Shut down and disconnect the power source Adequately support the cylinder rod if applicable 3 Remove cartridge holding valve from the cylinder port block Discard o rings 4 Place the cylin...

Page 230: ...nd EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 7 With the barrel cl...

Page 231: ...10 Plug 11 Setscrew 12 PistonSeal 13 WearRing 14 O ring 15 WearRing 16 O ring 17 RodSeal 18 WiperSeal 19 Bushing Figure 5 51 Lower Lift Cylinder E450A SN 0300235601 through 0300239755 E450AJ M450AJ S...

Page 232: ...t lbs 41 47 Nm Torque to 885 ft lbs 1200 Nm Torque to 13 ft lbs 17 Nm 1 11 1 Barrel 2 Rod 3 Head 4 WiperSeal 5 Retainer 6 RodSeal 7 BackupRing 8 WearRing 9 O ring 10 Spacer 11 O ring 12 Piston 13 Pist...

Page 233: ...Torque to 398 ft lbs 539 Nm Torque to 11 ft lbs 15 Nm 18 Figure 5 53 Lower Lift Cylinder E450AJ M450AJ SN 0300239253 to Present SN B300002462 through B300002486 1 Barrel 2 Rod 3 Retainer 4 Piston 5 H...

Page 234: ...rque to 498 608 ft lbs 675 825 Nm Torque to 597 730 ft lbs 810 990 Nm Figure 5 54 Lower Lift Cylinder E450AJ M450AJ SN B300002487 to Present 1 Barrel 2 Rod 3 Head 4 Piston 5 Spacer 6 LockingPiece 7 Lo...

Page 235: ...If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 3 Inspect threaded portion of rod for excessive damage Dress threads as necessary 4 Inspect inner surface of cylinder ba...

Page 236: ...plicable inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE A...

Page 237: ...from the holding fixture 12 Place new piston seal and wear rings in the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal...

Page 238: ...e cyl inder Shut down and disconnect the power source Adequately support the cylinder rod if applicable 3 Remove cartridge holding valve from the cylinder port block Discard o rings 4 Place the cylind...

Page 239: ...REME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 7 With the barrel clamped...

Page 240: ...10 CartridgeValve 11 Plug 12 Setscrew 13 WearRing 14 PistonSeal 15 O ring 16 WearRing 17 O ring 18 BackupRing 19 RodSeal 20 WiperSeal 21 Bushing Figure 5 66 Mid Lift Cylinder E450A SN 0300235601 throu...

Page 241: ...3 10 9 22 22 22 11 11 11 12 12 7 17 22 1 Barrel 2 Rod 3 Retainer 4 Piston 5 Head 6 Locknut 7 Washer 8 Spacer 9 CartridgeValve 10 CartridgeValve 11 Plug 12 Plug 13 Setscrew 14 WearRing 15 PistonSeal 16...

Page 242: ...orque to 30 35 ft lbs 41 47 Nm 8 6 1 Barrel 2 Rod 3 Piston 4 Head 5 Spacer 6 LockingPiece 7 Locknut 8 Bushing 9 RodSeal 10 PistonSeal 11 WiperSeal 12 WearRing 13 O ring 14 O ring 15 O ring 16 O ring 1...

Page 243: ...nspect threaded portion of rod for excessive damage Dress threads as necessary 4 Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality...

Page 244: ...le inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a...

Page 245: ...new piston seal and wear rings in the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal 13 Position the cylinder barrel i...

Page 246: ...he cyl inder Shut down and disconnect the power source Adequately support the cylinder rod if applicable 3 Remove cartridge holding valve from the cylinder port block Discard o rings 4 Place the cylin...

Page 247: ...end EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 7 With the barrel...

Page 248: ...CartridgeValve 10 Plug 11 Setscrew 12 Setscrew 13 WearRing 14 PistonSeal 15 O ring 16 WearRing 17 O ring 18 RodSeal 19 WiperSeal Figure 5 80 Upper Lift Cylinder E450A SN 0300235601 through 0300239755...

Page 249: ...7 ft lbs 9 Nm Torque to 4 ft lbs 5 Nm Torque to 199 ft lbs 270 Nm Torque to 30 35 ft lbs 41 47 Nm 1 Barrel 2 Rod 3 Retainer 4 Piston 5 Head 6 Locknut 7 Spacer 8 Bushing 9 CartridgeValve 10 Plug 11 Se...

Page 250: ...s 270 Nm Torque to 4 ft lbs 5 Nm Torque to 30 35 ft lbs 41 47 Nm 13 14 13 17 11 1 Barrel 2 Rod 3 Retainer 4 Piston 5 Head 6 Locknut 7 Spacer 8 Bushing 9 CartridgeValve 10 Plug 11 Setscrew 12 Setscrew...

Page 251: ...to 30 35 ft lbs 41 48 Nm Torque to 34 38 ft lbs 46 52 Nm 8 3 Figure 5 83 Upper Lift Cylinder E450AJ M450AJ SN B300002487 to Present 1 Barrel 2 Rod 3 Piston 4 Head 5 Spacer 6 LockingPiece 7 Locknut 8...

Page 252: ...f cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston su...

Page 253: ...plicable inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE A...

Page 254: ...wear rings in the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal 14 Position the cylinder barrel in a suitable holdin...

Page 255: ...nd disconnect the power source Adequately support the cylinder rod if applicable 3 Place the cylinder barrel into a suitable holding fixture 4 Using a spanner wrench unscrew the cylinder head from the...

Page 256: ...3121714 1 Barrel 2 Rod 3 Head 4 Piston 5 WearRing 6 PistonSeal 7 O ring 8 Retainer 9 Spacer 10 O ring 11 BackupRing 12 RodSeal 13 WiperSeal 14 O ring 15 O ring 16 Bushing Figure 5 92 Master Cylinder...

Page 257: ...for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as nec essary 6 Inspect threaded portion of pist...

Page 258: ...inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a l...

Page 259: ...ings in the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal 12 Position the cylinder barrel in a suitable holding fixtu...

Page 260: ...equately support the cylinder rod if applicable 3 Place the cylinder barrel into a suitable holding fixture 4 Using a pin face spanner wrench unscrew the cylinder head from the barrel 5 Attach a suita...

Page 261: ...2 Rod 3 Head 4 Piston 5 Bushing 6 O ring 7 RetainingRing 8 WiperSeal 9 O ring 10 RodSeal 11 BackupRing 12 O ring 13 O ring 14 WearRing 15 PistonSeal 16 Retainer Figure 5 102 Master Cylinder E M450AJ S...

Page 262: ...12 14 15 16 3 14 13 7 10 4 8 6 5 5 Torque to 442 5 ft lbs 600 Nm 1 Figure 5 103 Master Cylinder E M450AJ SN B3000024867 to Present 1 Barrel 2 Rod 3 Piston 4 Head 5 Bushing 6 O ring 7 WearRing 8 Wiper...

Page 263: ...reads as necessary 4 Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage an...

Page 264: ...inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a li...

Page 265: ...wear rings in the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal 11 Position the cylinder barrel in a suitable holdin...

Page 266: ...urce Adequately support the cylinder rod if applicable 3 Place the cylinder barrel into a suitable holding fixture 4 Using a hook spanner loosen and remove spanner nut from cylinder barrel 5 Attach a...

Page 267: ...714 5 109 1 Wiper 2 SpannerNut 3 RetainingRing 4 LipSeal 5 WearRing 6 BackupRing 7 O ring 8 Guide 9 Barrel 10 Tube 11 Piston 12 WearRing 13 Seal 14 O ring 15 O ring 16 Rod 17 Rod Figure 5 113 Steer Cy...

Page 268: ...barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or r...

Page 269: ...side diameter groove of the cylinder guide 4 Install the guide gland on the rod ensuring that the wiper and lip seals are not damaged or dislodged Push the guide along the rod to the rod end 5 Push th...

Page 270: ...rrel clamped securely and while adequately sup porting the rod insert the piston end into the barrel cyl inder Ensure that the piston loading o ring and seal are not damaged or dislodged 15 Screw both...

Page 271: ...nterbalance valve and fittings from the cyl inder port block Remove wear pads from the cylinder 4 Place the cylinder barrel into a suitable holding fixture 5 Mark cylinder head and barrel with a cente...

Page 272: ...cer 6 CounterbalanceValve 7 Bolt 8 Plug 9 Setscrew 10 EndCap 11 Locknut 12 WearRing 13 CapSeal 14 O ring 15 WearRing 16 O ring 17 BackupRing 18 RodSeal 19 WiperSeal 20 LockingPrimer 21 Fitting 22 CapF...

Page 273: ...ing or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as nec...

Page 274: ...e inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a...

Page 275: ...the outer piston diameter groove A tube with I D slightly larger than the O D of the piston is recommended to install the solid seal 12 Position the cylinder barrel in a suitable holding fixture EXTR...

Page 276: ...Shut down and disconnect the power source Adequately support the cylinder rod if applicable 3 Remove counterbalance valve and fittings from the cyl inder port block Remove wear pads from the cylinder...

Page 277: ...BE TAKEN WHEN REMOVING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 7 With the barrel clamped securely apply p...

Page 278: ...ceValve 7 Bolt 8 Plug 9 EndCap 10 Locknut 11 WearRing 12 CapSeal 13 O ring 14 O ring 15 WearRing 16 O ring 17 BackupRing 18 RodSeal 19 WiperSeal 20 JLGThreadLocker 21 LockingPrimer 22 Fitting 23 CapFi...

Page 279: ...37 ft lbs 46 50 Nm 16 19 18 4 20 15 14 5 13 3 10 11 12 11 1 8 9 9 6 7 2 1 Barrel 2 Rod 3 Piston 4 Head 5 Spacer 6 CounterbalanceValveAssembly 7 Bolt 8 Plug 9 Fitting 10 Locknut 11 WearRing 12 CapSeal...

Page 280: ...k inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as nec essary 6 Inspect threade...

Page 281: ...e inspect piston rings for cracks or other damage Replace as necessary ASSEMBLY NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual NOTE Apply a...

Page 282: ...ommended to install the solid seal 12 Position the cylinder barrel in a suitable holding fixture EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF...

Page 283: ...CTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 125 0 1 220 66 0 0 1 7 1 5 0 67 5 1 5 0 220 66 0 0 7 1 5 2 5 835 7 833 5 835 7 2 5 220 66 0 2 5 7 1 5 0 1 7 6 23 1 5 Figure 5 141 Components Bo...

Page 284: ...l end attach pin 2 6 Carefully remove the main lift cylinder from the boom and place in a suitable work area Main Boom Lift Cylinder Installation NOTE Coat I D of bushings with specified lubricant pri...

Page 285: ...ve out the cylinder barrel pin 4 6 Remove the lifting device from the mid lift cylinder 7 Carefully remove cylinder from boom Place in a suitable work area Mid Boom Lift Cylinder Installation NOTE Coa...

Page 286: ...er barrel pin 6 6 Carefully remove cylinder from boom Place in a suitable work area Lower Boom Lift Cylinder Installation NOTE Coat I D of bushings with specified lubricant prior to installing pins NO...

Page 287: ...the cylinder and remove the cylinder from the boom assem bly 11 Carefully lift the cylinder clear of the boom assembly and lower to the ground or suitably supported work area Main Boom Telescope Cylin...

Page 288: ...when fully extended 5 6 PRESSURE SETTING PROCEDURES NOTE Cold temperatures have a significant impact on pressure readings JLG Industries Inc recommends operating the machine until hydraulic system has...

Page 289: ...vel Up 2 Adjust Platform Level Up Relief to value given in Figure 5 151 Main Valve Pressure Adjustment Platform Level Down Relief 1 Install the pressure gauge at the B1 port on the back of the Main Co...

Page 290: ...m out jib up or down Releveling Valve Relief 1 Install a pressure gauge at port G on the main valve 2 Adjust the lower lift down pressure relief to the value given in Figure 5 151 Main Valve Pressure...

Page 291: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 133 RELEVELING VALVE MAIN CONTROL VALVE JIB VALVE STEER VALVE HYBRID JIB VALVE MAE32890 Figure 5 147 Hydraulic Component Location...

Page 292: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 5 134 3121714 STEER RELIEF Figure 5 148 Steer Valve Pressure Adjustment...

Page 293: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 135 STEER RELIEF Figure 5 149 Steer Valve Component...

Page 294: ...5 136 3121714 1001177364 G MAE32360G 1 A 2 B 3 4 Table 5 33 Cartridge Torque Values Ft Lbs Nm 1 35 40 47 54 2 25 34 3 25 30 34 41 4 20 27 Table 5 34 Coil Torque Values Ft Lbs Nm A 4 5 5 7 B 10 12 13...

Page 295: ...IFT DOWN RELIEF ADJUST TO 2600 psi 179 26 Bar TELESCOPE RELIEF ADJUST TO 3000 psi 206 84 Bar PLATFORM LEVEL RELIEF BACKWARD ADJUST TO 1200 psi 82 73 Bar PLATFORM LEVEL RELIEF FORWARD ADJUST TO 3000 ps...

Page 296: ...DESCENT HAND PUMP SWING ARREST VALVE TELESCOPE OUT VALVE BYPASS UNLOADING RELIEF FLOW REGULATOR TOWER LIFT UP AND DOWN VALVE TELESCOPE IN VALVE PLATFORM ROTATE VALVE PLATFORM UP AND DOWN VALVE SWING...

Page 297: ...39 1001180554 F MAE32320F 1 2 1 2 2 2 A 1 B 1 C 2 A 2 1 B 1 B 1 A 1 A Table 5 35 Cartridge Torque Values Ft Lbs Nm 1 25 34 2 20 27 Table 5 36 Coil Torque Values Ft Lbs Nm A 10 12 13 16 B 7 10 9 13 C 4...

Page 298: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 5 140 3121714 Table 5 37 Cartridge Torque Values Ft Lbs Nm 3 20 27 1001097777 B MAE32330B 3 2 1 Figure 5 154 Releveling Valve Torque Specification...

Page 299: ...14 5 141 1001097775 C MAE32380C 2 1 A Table 5 38 Cartridge Torque Values Ft Lbs Nm 1 25 34 2 20 27 Table 5 39 Coil Torque Values Ft Lbs Nm A 5 7 Figure 5 155 Jib Valve Torque Specification SN 03002085...

Page 300: ...C INFORMATION SCHEMATICS 5 142 3121714 1001216920 C MAE32370C 2 1 2 2 Table 5 40 Cartridge Torque Values Ft Lbs Nm 1 25 34 2 20 27 Figure 5 156 Jib Valve Torque Specification SN 0300233452 to Present...

Page 301: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 143 This page left blank intentionally...

Page 302: ...IN TELE OUT S1 S2 PB P T1 ROTATOR 41 L T2 G R P SWING S1 S2 LOWER LIFT UPPER LIFT R1 R2 ROTATOR 49 P1 P2 015 015 E450A E400A NARROW PLATFORM SLAVE CYL BORE 2 3 14 SQ IN ROD 1 785 SQ IN ANNULUS 2 35 S...

Page 303: ...SQ IN E400A NARROW UPPER LIFT CYL BORE 3 7 065 SQ IN ROD 1 75 2 405 SQ IN ANNULUS 4 660 SQ IN A B D C T1 T2 T3 T4 P P V V P P V V 29 26 30 38 28 27 PURGING AIR FROM CIR LR MC MID CYL LOWER CYL LOWER L...

Page 304: ...R IN EXTEND ONLY 43 G 33 39 TC TR TELE IN TELE OUT S1 S2 PB P T1 ROTATOR 41 L T2 G R P SWING S1 S2 UPPER LIFT R1 R2 ROTATOR 49 P1 P2 015 015 48 E450A E400A NARROW PLATFORM SLAVE CYL BORE 2 3 14 SQ IN...

Page 305: ...D CYL LOWER LIFT ANNULUS 3 14 STROKE 22 842 RATIO 1 5 1 V2 V1 1 2 T P JIB CYL BORE 2 5 4 908 SO IN ROD 1 5 1 77 SQ IN 45 44 JIB VALVE MAIN VALVE ASSY LR LC T1 P V 20 19 2 12 4 25 STEER CYL BORE 2 3 14...

Page 306: ...ONLY 43 G 33 39 TC TR TELE IN TELE OUT S1 S2 PB P T1 ROTATOR 41 L T2 G P SWING S1 S2 UPPER LIFT R1 R2 ROTATOR 49 P1 P2 015 015 48 E450A E400A NARROW PLATFORM SLAVE CYL BORE 2 3 14 SQ IN ROD 1 785 SQ...

Page 307: ...PURGING AIR FROM CIR BLEEDER FITTING FOR MID CYL LOWER LIFT SIDE SWING MAIN VALVE ASSY LR LC T1 P V 20 19 2 12 4 25 STEER CYL BORE 2 3 14 SQ IN ROD 1 25 1 22 SQ IN ANNULUS 1 92 SQ IN T2 UPPER LIFT E45...

Page 308: ...R10 31 0 N W 6113160 EMERGENCY DESCENT 20 MANUAL HAND PUMP HP10 21A 0 N A 0 47 IN3 22 FILTER HIGH PRESSURE 10 2 ABSOLUTE G1761 23 ELECTRIC MOTOR PUMP ASSEMBLY 48VDC 24 MOTOR GEROTOR TYPE FIXED 3 2 CU...

Page 309: ...SECTION 5 BASIC HYDRAULIC INFORMATION SCHEMATICS 3121714 5 151 This page left blank intentionally...

Page 310: ...LE IN TELE OUT S1 S2 PB P T1 ROTATOR 41 L T2 G R P SWING S1 S2 LOWER LIFT UPPER LIFT R1 R2 ROTATOR 49 P1 P2 015 015 E450A E400A NARROW PLATFORM SLAVE CYL BORE 2 3 14 SQ IN ROD 1 785 SQ IN ANNULUS 2 35...

Page 311: ...ANNULUS 5 305 SQ IN E400A NARROW UPPER LIFT CYL BORE 3 7 065 SQ IN ROD 1 75 2 405 SQ IN ANNULUS 4 660 SQ IN A B D C T1 T2 T3 T4 P P V V P P V V 29 26 30 38 28 27 PURGING AIR FROM CIR BLEEDER FITTING F...

Page 312: ...REGENERATIVE CIR IN EXTEND ONLY 43 G 33 39 TC TR TELE IN TELE OUT S1 S2 PB P T1 ROTATOR 41 L T2 G R P SWING S1 S2 UPPER LIFT R1 R2 ROTATOR 49 P1 P2 015 015 48 E450A E400A NARROW PLATFORM SLAVE CYL BO...

Page 313: ...CYL LOWER LIFT ANNULUS 3 14 STROKE 22 842 RATIO 1 5 1 V2 V1 1 2 T P JIB CYL BORE 2 5 4 908 SO IN ROD 1 5 1 77 SQ IN 45 44 JIB VALVE MAIN VALVE ASSY LR LC T1 P V 20 19 2 12 4 25 STEER CYL BORE 2 3 14...

Page 314: ...IR IN EXTEND ONLY 43 G 33 39 TC TR TELE IN TELE OUT S1 S2 PB P T1 ROTATOR 41 T2 G P SWING S1 S2 UPPER LIFT R1 R2 ROTATOR 49 P1 P2 015 015 48 E450A E400A NARROW PLATFORM SLAVE CYL BORE 2 3 14 SQ IN ROD...

Page 315: ...CIR MID CYL LOWER LIFT SIDE SWING MAIN VALVE ASSY LR LC T1 P V 20 19 2 12 4 25 STEER CYL BORE 2 3 14 SQ IN ROD 1 25 1 22 SQ IN ANNULUS 1 92 SQ IN T2 UPPER LIFT E450A UPPER LIFT CYL BORE 3 7 065 SQ IN...

Page 316: ...0 EMERGENCY DESCENT 20 MANUAL HAND PUMP HP10 21A 0 N A 0 47 IN3 22 FILTER HIGH PRESSURE 10 2 ABSOLUTE G1761 23 ELECTRIC MOTOR PUMP ASSEMBLY 48VDC 24 MOTOR GEROTOR TYPE FIXED 3 2 CU IN SWING 25 COUNTER...

Page 317: ...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 motor contro...

Page 318: ...nected backwards 2 Power up the Control System by turning the lower key to the platform or ground position and pulling both emer gency stop buttons on Using the Analyzer With the machine power on and...

Page 319: ...STARTUP 2 1 indicates a power up When a top level menu is selected a new set of menu items may be offered for example DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed...

Page 320: ...steps if the correct access level is not dis played or you can not adjust the personality settings Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1 and a perso...

Page 321: ...will permit you to change all machine personality settings There is a setting that JLG strongly recommends that you do not change This setting is so noted below ELEVATION CUTBACK CHANGING THIS SETTING...

Page 322: ...LEVATED TILTED ELEV ELEVATION ENG ENGINE EXT EXTEND F FRONT FL FLOW FNT FRONT FOR FORWARD FWD FORWARD FSW FOOTSWITCH FUNC FUNCTION G GROUND GND GROUND GRN GREEN GM GROUNDMODULE H HOURS HW HARDWARE HWF...

Page 323: ...ER SPD SPEED STOW STOWED STOWD STOWED SW SWITCHorSOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ TORQUE TRN TRANSPORT T T TURNTABLE T TOWER TURNTBL TURNTABLE TWR TOWER U UPPERorUP V VOLT VER VERSION VLV...

Page 324: ...nging the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values MODELNUMBER 1 1 2 3 4 5 E300 E400 E...

Page 325: ...SI USA ANSIExport CSA JAPAN 3 CE AUS GB GROUNDALARM 5 1 2 3 4 NO Nogroundalarminstalled DRIVE Travel alarmsounds whenthedrivefunctionis active DESCENT Descentalarmsoundswhenliftdownisactive MOTION Mot...

Page 326: ...s Certainmarketselections willlimitloadsystem optionsoralterdefaultset ting 1 2 3 NO Nodrivecutout BOOMCUTOUT Boomfunctioncutoutwhiledrivingaboveelevation DRIVECUTOUT Driveandsteercutoutaboveelevation...

Page 327: ...spluggedin CUTOUTALL Driveandbottomfunctionisdisabledwhenbatterychargerispluggedin 1 PLATLVLOVRCUT 18 1 2 NO Platformlevelfunctionsaboveelevation YES Platformleveldoesnotfunctionaboveelevation 1 10012...

Page 328: ...1 1 2 2 2 2 2 2 2 Head TailLights 1 1 1 1 1 1 1 2 2 2 2 2 2 2 LoadSystem X 1 X 1 1 1 1 X 2 X X X 2 X X 3 X X 3 3 X X 4 X 4 X 4 4 FunctionCutout 1 1 1 X 1 1 1 X 2 2 2 2 2 2 3 3 3 X 3 3 3 DisplayUnits 1...

Page 329: ...DUCED MAXimum speed MAXimum Reverse Drive 50 to 74 60 ELEVATED MAXimum speed ANSI 5 to 15 7 ELEVATED MAXimum speed CE 5 to 15 7 CREEP MAXimum speed 5 to 15 7 STEER ACCELeration 0 1 to 5 0s 2 0s DECELe...

Page 330: ...30 MINimum DOWN speed 1 to 15 15 MAXimum DOWN speed 51 to 80 55 CREEP maximum DOWN speed 16 to 50 30 TELESCOPE ACCELeration 0 1 to 5 0s 1 5s DECELeration 0 1 to 5 0s 1 5s MINimum IN speed 1 to 15 1 M...

Page 331: ...Ximum UP speed 36 to 60 40 CREEP maximum UP speed 16 to 35 20 MINimum DOWN speed 1 to 15 1 MAXimum DOWN speed 36 to 60 40 CREEP maximum DOWN speed 16 to 35 20 PLATFORM ROTATE ACCELeration 0 1 to 5 0s...

Page 332: ...1 to 80 42 Jib SWING 41 to 75 45 Platform LEVEL 36 to 80 38 PlatformROTATE 25 to 50 28 ALARM HORN Volume HORN 25 to 100 100 Volume ALARM 25 to 100 75 TEMPERATURECUT LOW Cutout set 30 to 0C 30C OFFset...

Page 333: ...AT ROT OUTPUT LEFT XXX PUMP SPEED CMD XXX PUMP SPEED OUTPUT XXX PUMP SPEED CURRENT XXXA PUMP ENABLE ON PUMP OP MODE OFF FUNCTION SPEED SETTING XXX CREEP SW CLOSED CREEP MODE OFF FLW CNTRL VLV XXX DIAG...

Page 334: ...OPEN TELE IN SW OPEN TELE OUT SW OPEN JIB LIFT UP SW OPEN JIB LIFT DN SW OPEN JIB SWING LT SW OPEN JIB SWING RT SW OPEN PLAT LEVEL UP SW OPEN PLAT LEVEL DN SW OPEN PLAT ROT LEFT SW OPEN PLAT ROT RGHT...

Page 335: ...T XXXXX DATALOG CYCLES TOWER UP XXXXX DATALOG CYCLES TOWER DN XXXXX DATALOG CYCLES LIFT UP XXXXX DATALOG CYCLES LIFT DN XXXXX DATALOG CYCLES TELE IN XXXXX DATALOG CYCLES TELE OUT XXXXX DATALOG CYCLES...

Page 336: ...IB LIFT UP CREEP xx JIB LIFT DOWN MIN xx JIB LIFT DOWN MAX xxx JIB LIFT DOWN CREEP xx PERSONALITIES JIB SWING JIB SWING ACCEL x xS JIB SWING DECEL x xS JIB SWING LEFT MIN xx JIB SWING LEFT MAX xx JIB...

Page 337: ...Y N 2 LOAD SENSING ACC WEIGHT XXXLB 2 LOAD SENSING PLATFORM EMPTY 2 LOAD SENSING CAL COMPLETE 2 LOAD SENSING CAL FAILED 2 CALIBRATIONS STEER SENSOR 2 STEER SENSOR CALIBRATE 2 STEER SENSOR RIGHT TO MAX...

Page 338: ...me Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode Creep light on Panel must be energized Verify that machine will Tower Up and Down Return Knob to fully clockwise Main lif...

Page 339: ...FUNCTION SPEED Table 6 5 Function Speeds Function Speed In Seconds MainLiftUp 24 30 MainLiftDown 23 29 TurntableSwingRight Left360 67 81 NOTE SwingLefttoSwingRightshouldbewithin10 ofeachother Telescop...

Page 340: ...SECTION 6 JLG CONTROL SYSTEM 6 24 3121714 PLATFORM CONTROL MODULE Figure 6 7 Control Module Location Sheet 1 of 2...

Page 341: ...SECTION 6 JLG CONTROL SYSTEM 3121714 6 25 GROUND CONTROL MODULE GENERATOR CONTROL MODULE Figure 6 8 Control Module Location Sheet 2 of 2...

Page 342: ...SECTION 6 JLG CONTROL SYSTEM 6 26 3121714 Figure 6 9 Analyzer Connecting Points PLATFORM CONNECTION GROUND CONTROL CONNECTION...

Page 343: ...SECTION 6 JLG CONTROL SYSTEM 3121714 6 27 CONNECTOR Figure 6 10 Power Module LH 1001192212 D...

Page 344: ...SECTION 6 JLG CONTROL SYSTEM 6 28 3121714 Figure 6 11 Power Module RH CONNECTOR 1001178339 E...

Page 345: ...D LEFT FORWARD DIGITAL OUTPUT 11 MAIN LIFT UP SOLENOID DIGITAL OUTPUT 12 JIB UP SOLENOID DIGITAL OUTPUT 13 UNUSED DIGITAL OUTPUT 14 PLATFORM JIB ROTATE SOLENOID GROUND AWD SOLENOID GROUND GROUND INPUT...

Page 346: ...1 TERMINATOR TERM I O 18 CAN1 SHIELD GROUND INPUT 19 UNUSED GROUND GROUND INPUT 20 UNUSED ANALOG INPUT 21 UNUSED DIGITAL INPUT 22 UNUSED DIGITAL INPUT 23 UNUSED DIGITAL INPUT 24 CAN1 LOW SERIAL I O 25...

Page 347: ...18 PLATFORM ROTATE RIGHT DIGITAL INPUT 19 JIB UP DIGITAL INPUT 20 JIB RIGHT DIGITAL INPUT 21 TOWER LIFT DOWN DIGITAL INPUT 22 UNUSED DIGITAL INPUT 23 MAIN LIFT UP DIGITAL INPUT 24 BATTERY VOLTAGE FOR...

Page 348: ...35 SPEED PUMP POTENTIOMETER ANALOG INPUT CONNECTOR PIN ASSIGNMENT FUNCTION J2 GRAY 1 UNALLOCATED JIB RT DIGITAL INPUT 2 UNALLOCATED JIB LT DIGITAL INPUT 3 UNUSED BATTERY VOLTAGE BATTERY VOLTAGE 4 DRIV...

Page 349: ...L DOWN ME DIGITAL OUTPUT 23 VALVE RETURN GROUND 24 SKYGUARD RETURN GROUND 25 JIB UP ME DIGITAL OUTPUT 26 JIB DOWN ME DIGITAL OUTPUT 27 JIB RIGHT ME DIGITAL OUTPUT 28 JIB LEFT ME DIGITAL OUTPUT 29 PLT...

Page 350: ...nce function JIB Displays adjustsjibpresence GROUNDALARM Displays adjustsgroundalarmpresence function Table 6 7 JLG Control System Flash Codes Code Description 2 1 2 2 2 3 2 5 3 1 3 2 3 3 4 2 4 4 6 6...

Page 351: ...limited to cutback speed because the vehicle is above elevation RUNNING AT CREEP TILTED AND ABOVE ELEVATION All function speeds are limited to creep because the vehicle it tilted and above elevation...

Page 352: ...her PUMP SWITCHES LOCKED SELECTED BEFORE EMS FWS A boom function lower lift telescope basket level basket rotate jib was selected before and during footswitch closure PUMP SWITCHED LOCKED SELECTED BEF...

Page 353: ...not switch off when EMS or keyswitch is turned off 3 3 Flash code 3 3 indicates that a contactor coil is short circuited OVERLOADED VALVE SUPPLY CHECK WIRING There is a high current draw from the val...

Page 354: ...n with speed control PUMP POINT A LOW CHECK POWER CIRCUITS Pump point A is near 0V when the pump MOSFETs are off This is probably due to a power STALLED TRACTION MOTOR The power module traction MOSFET...

Page 355: ...are failsafe remained tripped when the traction MOSFETs were turned off POWER MODULE FAILURE HWFS CODE 14 The hardware failsafe tests failed because the line contactor could still be energized when th...

Page 356: ...E SWUNG State of DOS switch prox energized when in line to close normally open contacts DRV ORIENT STATE CONFIRMED REQUIRED InLine and DOS Active Confirmed DRV ORNT OVR SW CLOSED OPEN State of Drive O...

Page 357: ...eep Switch Input CREEP MODE ON OFF Displaysstatus of Creep Mode FLOW CONTRL VLV XXX Duty cycle of flow control proportional valve SYSTEM MAIN CONTACTOR ENABLED DISABLED Status of Main Contactor report...

Page 358: ...orted by associated PM RIGHT MOTOR SPEED XXX RPM Motor encoder speed reported by associated PM LEFT MOTOR SPEED XXX RPM Motor encoder speed reported by associated PM RIGHT MOTOR OFF REGEN DRIVE MOTOR...

Page 359: ...eer direction and percentage command as reported from PM Platform Mode TRUE JOYSTICK SWING LEFT RIGHT XXX Lift Swing Joystick Swing direction and percentage command as reported from PM Platform Mode T...

Page 360: ...RRIDE SW OPEN CLOSED Status of Platform SkyGuard Override Switch Input if MACHINE SETUP SKYGUARD YES MSSO SW OPEN CLOSED Status of MSSO switch MACHINE SETUP MARKET CE and Ground mode TRUE OPTIONS H T...

Page 361: ...PLATFORM LOAD CELL 2 XXX XKG Gross weight reading of Cell 2 PLATFORM LOAD CELL 3 XXX XKG Gross weight reading of Cell 3 PLATFORM LOAD CELL 4 XXX XKG Gross weight reading of Cell 4 CAN STATISTICS CAN...

Page 362: ...nput lower lift down LLD If the switch is faulty or the wiring is faulty the controller will not move on to the next input The controller will continue to wait for the closure of the input If the oper...

Page 363: ...YorOPEN CIRCUITorSHORTTOGROUND oradvancetestaftershortdelay OPENFOOTSWITCH WaitforFootswitchtoopentheadvance FLOWCTRLVALVE SHORTTOBATTERYorOPEN CIRCUITorSHORTTOGROUND oradvancetestaftershortdelay PRIO...

Page 364: ...tforjoysticktoreach 100 thenadvance CREEPSWITCHCCW OPENorCLOSED advancedtestafterswitchtoggles CREEPSWITCHCW OPENorCLOSED advancedtestafterswitchtoggles FUNCSPDTOMAX FUNCSPDTOMIN CLHORN OPENorCLOSED a...

Page 365: ...dtestafterswitchtoggles displayonifMACHINESETUP SOFTTOUCH YES RELEASESOFTTOUCH OPENorCLOSED advancedtestafterswitchtoggles displayonifMACHINESETUP SOFTTOUCH YES CHECKINGGROUNDINPUTS CLSWINGRIGHT OPENo...

Page 366: ...NCENABLE OPENorCLOSED advancedtestafterswitchtoggles OPFUNCENABLE OPENorCLOSED advancedtestafterswitchtoggles CLMSSOSWITCH OPENorCLOSED advancedtestafterswitchtoggles displayonlyifMACHINESETUP MARKET...

Page 367: ...wheels on one side using a stretched string 1 Position the Platform Ground select switch to the Plat form position 2 Plug the analyzer into the connector at the base of the platform control box 3 Pul...

Page 368: ...is then leave off the control The display will read Right Steer Maximum value 12 Hit Enter The screen will read 13 The display will read steering Center position value 14 Hit Enter The screen will rea...

Page 369: ...previously calibrated b Wheels straight c Turntable centered d Boom fully retracted e Boom angle is less than 45 f Machine on firm level ground 3 Position the Platform Ground select switch to the Pla...

Page 370: ...ter The screen will read 12 When prompted swing turntable 180 to opposite end of chassis 13 Hit Enter The screen will read 14 Upon completing swing calibration swing turntable 180 back to the stowed p...

Page 371: ...he Plat form position 2 Plug the analyzer into the connector at the base of the platform control box 3 Pull out the Emergency Stop switch and Start the engine 4 The analyzer screen should read 5 Use t...

Page 372: ...SECTION 6 JLG CONTROL SYSTEM 6 56 3121714 10 Hit Enter The screen will read 11 Hit Enter The screen will read 12 Hit Enter The screen will read 13 Hit Enter The screen will read...

Page 373: ...SECTION 6 JLG CONTROL SYSTEM 3121714 6 57 14 Hit Enter The screen will read 15 After few seconds the screen will read 16 Hit ESC twice to go back to CALIBRATIONS...

Page 374: ...ent is permitted by a Removing the excess platform load until actual plat form load is less than Rated Load b Operation of the overriding emergency system Auxiliary Power Unit c By an authorized perso...

Page 375: ...12 Diagnostic Menu Descriptions Diagnostics Menu Displayed on Analyzer 1st Line Parameter Displayed on Analyzer 2nd Line Parameter Value Displayed on Analyzer 2nd Line Description PLATFORMLOAD STATE O...

Page 376: ...oximately level for calibra tion Level the platform from ground control if neces sary to within 5 4 To access the Calibration Menu use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top...

Page 377: ...ccessory Weights Use the up and down analyzer keys to enter the accessory weight s in lbs When all the accessory weights are entered press ENTER The screen will read LO A D S E N S I N G accessory xxx...

Page 378: ...than 575 lbs 261 kg If the platform weight is not within the allowed range the calibration attempt will be unsuccessful and the Analyzer will show the following 10 Press ENTER The control system will...

Page 379: ...y Reductions and Table 6 15 Pipe Rack Capacity Reduc tions Table 6 14 SkyGlazier Capacity Reductions Capacity PLATFORM OVRLD PLATFORM OVRLD RESTRICT 500lb 227kg 400lb 181kg n a 550lb 250kg 400lb 181kg...

Page 380: ...SECTION 6 JLG CONTROL SYSTEM 6 64 3121714 14 Press ENTER If calibration is successful the screen will read...

Page 381: ...oad Visual Warning at the Ground Controls should flash and the Audible Warning at Platform and Ground should sound for 5 seconds On 2 seconds Off However the controls should remain functional when usi...

Page 382: ...theywillleaveconductiveresidue Moistureshouldbeallowedtoevaporateor acceleratedwithaheat gun uselowheatandbecarefullytonotmeltconnectormaterials Moistureintrusionintothemoldedportionof theconnector ca...

Page 383: ...onsole NOTE If performing the procedure from the platform console the Emergency Stop switch on the ground console must also be pulled out 4 Pull out the Emergency Stop switch 5 The analyzer screen sho...

Page 384: ...CONTROL SYSTEM 6 68 3121714 12 Press Enter The screen will read 13 Press Enter The JLG Control System will reset an active 873 DTC and the MSSO System will be reset Press Escape to return to the CALI...

Page 385: ...TCHOPEN MachineisinPlatformMode Platformcreepswitchinput HIGH FaultRUNNINGATCREEP TILTEDANDABOVE ELEVATION DTC0013 isnotactive Platformcreepswitchinput Low 00 13 RUNNINGATCREEP TILTEDANDABOVEELE VATIO...

Page 386: ...rmorGround mode SteerRightandSteerLeftarenolongersimulta neousHIGH steerandfullDrivespeedpermit tedaftercontrolsareinitialized 22 11 FSWINTERLOCKTRIPPED MachineisinPlatformMode AMachineEnabledstatehas...

Page 387: ...Wwhilethemachineis notEnabled 22 46 FUNCTIONPROBLEM JIBSWINGRIGHTPER MANENTLYSELECTED ThemachineisinPlatformmodeandtheJibSwing Rightinput HighatStartup JibSwingRightinput LOWwhilethemachine isnotEnabl...

Page 388: ...heEnabledstate 23 107 FUNCTIONPROBLEM LIFTUPPERMANENTLY SELECTED ThemachineisinGroundmodeandtheLiftUp input HighatStartUp Functionswitchreturnstoneutralandthe machineisnotintheEnabledstate 23 108 FUNC...

Page 389: ...Steer Notallofthetriggerconditionsaremet 25 18 DRIVEPREVENTED BOOMSELECTED MACHINESETUP FUNCTIONCUTOUT DRIVE CUTOUT TheboomisAboveElevation TheoperatorisattemptingtoactivateDriveor Steer Notallofthet...

Page 390: ...atthelinecon tactordriveroutputfailedshortorcontactorcoilis disconnected opencircuit Powercycle 33 4 LIFTUPVALVE OPENCIRCUIT TheUGMdetectsanopencircuitattheLiftUpSole noid UGMnolongerdetectsOC Speedre...

Page 391: ...CIR CUIT UGMdetectsanopencircuitatplatformrotateright output UGMnolongerdetectsOC SpeedrestrictionsremovedafterCntIni 33 99 PLATFORMROTATERIGHTVALVE SHORTTO BATTERY UGMdetectsashorttobatteryatplatform...

Page 392: ...cle 33 178 JIBROTATERIGHTVALVE OPENCIRCUIT MACHINESETUP JIBPLUS YES UGMdetectsanopencircuitatthejibrotateright output UGMnolongerdetectsOC SpeedrestrictionsremovedafterCntIni 33 179 JIBROTATERIGHTVALV...

Page 393: ...ut UGMnolongerdetectsOC SpeedrestrictionremovedafterCntIni 33 627 LIFTBYPASSVALVE SHORTTOGROUND TheUGMdetectsSTGatliftbypassoutput Powercycle 33 628 LIFTBYPASSVALVE SHORTTOBATTERY TheUGMdetectsSTBatli...

Page 394: ...nsremovedaftercontrolsinitialized 44 20 BATTERYDEEPLYDISCHARGED UGMdeterminesthattheSOC relatedtotheBat teryhasreachedtheDeeplyDischargedcondition BasedonSOC only notVoltagethreshold No audibleannunci...

Page 395: ...Nmessagesfromthe LSSmodulein1000ms Notallofthetriggerconditionsaremet motion restrictionsremovedaftercontrolsinitialized 66 13 CANBUSFAILURE EXCESSIVECANBUSERRORS UGMobservesmorethan22errorframesperse...

Page 396: ...sstalledduringactivetraction FortheUGMcommandedspeed CreepAND RIGHT 30 SteerAngle 45 LEFT the reportedavgmotorencoderfeedback 70counts sfor5seconds 1 685Hz Avgmotorencoderfeed backevaluateona1srunning...

Page 397: ...ed DriveCreepHzforallTractionmodules Powercycle 82 1 LSSCELL 1ERROR MACHINESETUP LOADSYSTEM NO TheUGM detectsthatLSSisreportingerrorwithCell 1 Notallofthetriggerconditionsaremet motion restrictionsrem...

Page 398: ...initialized 86 68 STEERSENSOR NOTCALIBRATED UGMdeterminesthatthesteeringsensorhasnot beencalibrated UGMEEPROMvaluesaredefault donotmatchMTM orUGMfailstosuccessfullyread frommemorythreetimesduringStart...

Page 399: ...hatthevaluesmatch Powercycled 99 44 CURRENTFEEDBACKGAINSOUTOFRANGE Oneormoreofthecurrentfeedbackgainsthatare calculatedandwrittentoflashmemoryduringthe JDESmanufacturingtestprocessaredetectedas beingo...

Page 400: ...entisbeingmeasuredisnotzerowhen expectedtobezeroatStartuporduringstandby Powercycle 99 243 REARLEFTMODULE INTERNALERROR ApplicablePowerModuledeterminesthattheSlip Profileisinerror Powercycle 99 244 RE...

Page 401: ...wercapacitorbankofthePowerModuleis notchargingproperly increasingvoltage at Startup Powercycle 99 261 REARRIGHTMODULE A DFAILURE ApplicablePowerModuledeterminesthatan internalAnalogInputerrorexists Po...

Page 402: ...nfromallPower Modules ThePowerModulemajorversionnumber isnotcompliantwiththeversionspecifiedonthe Softwaresectionofthisdocument Notallofthetriggerconditionsaremet 99 281 FUNCTIONSLOCKEDOUT IMPROPERMOT...

Page 403: ...amaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the co...

Page 404: ...uto 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 continu...

Page 405: ...to determine what termi nals will be connected The test is similar to testing a switch with two terminals a Place one meter lead on the common contact and the other on a different contact in the same...

Page 406: ...he voltage drop across the switch This could mislead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load mea...

Page 407: ...emale contact fill it approximately full see example below 3 Leave a thin layer of dielectric grease on the face of the connector 4 Assemble the connector system immediately to prevent moisture ingres...

Page 408: ...nnect Follow the installation instruc tions DIN Connectors This connector is typically used on hydraulic valves Follow the installation instructions Exclusions A limited number of connectors do not be...

Page 409: ...ractical way to remove the dielectric grease replacement of female contacts required The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 con nector sys...

Page 410: ...y 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 assem bling the housing to the header it is pos...

Page 411: ...edge lock must be closed to its locked position Release the locking latches by squeezing them inward See Figure 7 10 4 Slide the wedge lock into the housing until it is flush with the housing See Figu...

Page 412: ...e forward or mating end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading DO NOT PI...

Page 413: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 11 Figure 7 13 Connector Installation...

Page 414: ...ard exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented They may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Seri...

Page 415: ...wire cavities insert sealing plugs for full envi ronmental sealing HD30 HDP20 Series Disassembly 11 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be remo...

Page 416: ...the table below followed by a unique sequential number An optional suffix letters numbers may be added when multiple terminations occur at one device Terminals that are not loaded into connectors are...

Page 417: ...ctor Powermodule RockerSwitch SW Sensor Angle SN Fuel Length Limit Load Pressure Proximity Speed Temperature Terminals Pins T Sockets MaleBlades FemaleBlades Rings Forks ToggleSwitch DPDT SW DPST SPDT...

Page 418: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 16 3121714 Figure 7 20 Platform Console Harness Sheet 1 of 4 1001191318 H...

Page 419: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 17 Figure 7 21 Platform Console Harness Sheet 2 of 4...

Page 420: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 18 3121714 Figure 7 22 Platform Console Harness Sheet 3 of 4...

Page 421: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 19 Figure 7 23 Platform Console Harness Sheet 4 of 4...

Page 422: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 20 3121714 Figure 7 24 Platform Beacon Harness 1001153344 B...

Page 423: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 21 This page left blank intentionally...

Page 424: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 22 3121714 Figure 7 25 Load Sensing System Harness LSS Sheet 1 of 2 1001192283 D...

Page 425: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 23 T391 Figure 7 26 Load Sensing System Harness Sheet 2 of 2...

Page 426: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 24 3121714 Figure 7 27 Main Valve Harness Sheet 1 of 3 1001178794 I...

Page 427: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 25 Figure 7 28 Main Valve Harness Sheet 2 of 3...

Page 428: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 26 3121714 Figure 7 29 Main Valve Harness Sheet 3 of 3...

Page 429: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 27 This page left blank intentionally...

Page 430: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 28 3121714 Figure 7 30 Turntable Harness Sheet 1 of 3 1001178793 H...

Page 431: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 29 Figure 7 31 Turntable Harness Sheet 2 of 3...

Page 432: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 30 3121714 Figure 7 32 Turntable Harness Sheet 3 of 3...

Page 433: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 31 This page left blank intentionally...

Page 434: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 32 3121714 Figure 7 33 Ground Control Panel Harness Sheet 1 of 3 1001179991 I...

Page 435: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 33 Figure 7 34 Ground Control Panel Harness Sheet 2 of 3...

Page 436: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 34 3121714 Figure 7 35 Ground Control Panel Harness Sheet 3 of 3...

Page 437: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 35 This page left blank intentionally...

Page 438: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 36 3121714 Figure 7 36 Chassis Traction Harness Sheet 1 of 4 1001178629 I...

Page 439: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 37 Figure 7 37 Chassis Traction Harness Sheet 2 of 4...

Page 440: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 38 3121714 Figure 7 38 Chassis Traction Harness Sheet 3 of 4...

Page 441: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 39 Figure 7 39 Chassis Traction Harness Sheet 4 of 4...

Page 442: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 40 3121714 Figure 7 40 Chassis to Turntable Harness 1001178405 G...

Page 443: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 41 This page left blank intentionally...

Page 444: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 42 3121714 Figure 7 41 Chassis Steer Brake Harness Sheet 1 of 2 1001188528 F...

Page 445: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 43 Figure 7 42 Chassis Steer Brake Harness Sheet 2 of 2...

Page 446: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 44 3121714 Figure 7 43 Chassis Head Tail Light Harness Sheet 1 of 2 1001190741 F...

Page 447: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 45 Figure 7 44 Chassis Head Tail Light Harness Sheet 2 of 2...

Page 448: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 46 3121714 X628 Figure 7 45 Inverter IGN Harness 1001192293 C...

Page 449: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 47 J8_1 Figure 7 46 Platform Work Light Harness 1001120484 B...

Page 450: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 48 3121714 Figure 7 47 Generator IGN Harness Sheet 1 of 2 1001192024 D...

Page 451: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 49 X617 Figure 7 48 Generator IGN Harness Sheet 2 of 2...

Page 452: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 50 3121714 RL 502 Figure 7 49 SkyGuard Harness Sheet 1 of 2 1001192292 B...

Page 453: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 51 X506 Figure 7 50 SkyGuard Harness Sheet 2 of 2...

Page 454: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 52 3121714 X7B 9 Figure 7 51 Soft Touch Harness Sheet 1 of 2 1001193419 C...

Page 455: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 53 X7B 12 Figure 7 52 Soft Touch Harness Sheet 2 of 2...

Page 456: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 54 3121714 Figure 7 53 Platform Console Harness with SkyGuard and 1 Cell LSS Sheet 1 of 4 1001217621 A...

Page 457: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 55 This page left blank intentionally Figure 7 54 Platform Console Harness with SkyGuard and 1 Cell LSS Sheet 2 of 4...

Page 458: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 56 3121714 Figure 7 55 Platform Console Harness with SkyGuard and 1 Cell LSS Sheet 3 of 4...

Page 459: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121714 7 57 Figure 7 56 Platform Console Harness with SkyGuard and 1 Cell LSS Sheet 4 of 4...

Page 460: ...L N A RL502 86 2 WHT P4 18 AWG GXL N A X500 3 CONNECTOR PART NUMBER 1001186432 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TERMINAL P N SEAL P N TO 30 WHT P9 1 18 AWG GXL 1001116720 IP114 1 85 WHT P5...

Page 461: ...RNESS SHEET 5 GROUND CONTROL WIRING GROUND PANEL HARNESS SHEET 6 CHASSIS WIRING TRACTION HARNESS CHASSIS TO TURNTABLE SHEET 7 OPTIONS GENERATOR SHEET 8 OPTIONS CHASSIS HEAD TAIL LIGHT INVERTER IGN SHE...

Page 462: ...WHT 88 1 HEAD TAIL LT YEL 5 14 6 YEL 5 14 6 WHT 27 0 JIB UP WHT 28 0 JIB DN YEL 5 14 3 YEL 5 14 3 WHT 13 0 MAIN TELE IN WHT 13 0 MAIN TELE IN WHT 122 1 DOS WHT 122 1 DOS WHT 125 2 CREEP MODE WHT 125 2...

Page 463: ...OTSWITCH WHT 1 28 LSS GND WHT 1 28 LSS GND WHT 23 0 3 PLAT ROT LFT WHT 23 0 3 PLAT ROT LFT WHT 24 0 3 PLAT ROT RHT WHT 24 0 3 PLAT ROT RHT WHT 27 0 3 JIB UP WHT 27 0 3 JIB UP WHT 28 0 3 JIB DN WHT 28...

Page 464: ...8AWG BLK WHT 12AWG ORG 12AWG YEL BLK 18AWG RED BLK 18AWG ORN BLK 18AWG X50A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 LOCATED UNDER CONSOLE BOX LSS MODULE OPTIONAL CO44 J2 1 2 3 4 5 6 7 8 9 10 1...

Page 465: ...4B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 RED 12AWG BLK 12AWG SHIELD BLK 18AWG RED 18AWG BLU 18AWG ORG 18AWG YEL 18AWG BRN 18AWG BLU BLK 18AWG BLK WHT 12AWG ORG 12AWG YEL BLK 18AWG RED BLK 18...

Page 466: ...HT 24 0 4 PLAT ROT RHT WHT 27 0 4 JIB UP WHT 27 0 4 JIB UP WHT 28 0 4 JIB DN WHT 28 0 4 JIB DN BLK 4 27 1 1 RTN BLK 4 27 1 2 RTN WHT 38 2 CURNT FBACK S65 S80 S78 S81 S64 BLK 4 13 2 RTN BLK 4 13 1 RTN...

Page 467: ...O YEL CAN1 HI WHT 49 10 VOTE RELAY YEL 5 2 1 IGN MODE YEL 5 2 2 IGN 18AWG YEL 5 10 1 IGN 12AWG BLK 4 0 1 INSTR GND 12GXL BLK 4 0 1 INSTR GND 12GXL WHT 4 52 INSTR GND YEL 5 10 1 2 IGN 12AWG YEL 5 33 IG...

Page 468: ...TWR DN WHT 22 1 SWG RHT WHT 21 1 SWG LFT WHT 31 0 1 SIDE SWG RHT WHT 31 0 1 SIDE SWG RHT YEL 5 15 4 YEL 5 15 4 YEL 5 15 3 YEL 5 15 7 YEL 5 15 7 YEL 5 15 6 YEL 5 15 6 YEL 5 15 5 YEL 5 15 5 WHT 32 0 1...

Page 469: ...1 SWG LFT WHT 31 0 1 SIDE SWG RHT YEL 5 15 4 YEL 5 15 4 YEL 5 15 3 YEL 5 15 3 YEL 5 15 2 YEL 5 15 2 YEL 5 15 6 YEL 5 15 5 YEL 5 15 5 YEL 5 15 1 YEL 5 15 1 SWING SW128 1 3 2 4 5 6 WHT 32 0 1 SIDE SWG L...

Page 470: ...RY BT177 1 BT177 1 BATTERY BT178 1 BT178 1 BATTERY BT179 1 BT179 1 MAIN CONTACTOR TH 2 1 1 TH 2 2 1 TH 2 1 2 TH 3 1 1 TH 12 1 TH 3 1 RED EPDM 1 AWG RED EPDM 1 AWG RED EPDM 4 AWG BLK 2 2 12AWG BLK EPDM...

Page 471: ...O210 W 1 CO210 B 1 CO210 B 1 CO210 P 1 1 1 1 1 1 WHT CONTACTOR LS WHT CONTACTOR LS BLK GND ADDR BLK GND ADDR WHT 6 8 IGN PWR 48 VOLT WHT 6 8 IGN PWR 48 VOLT METAL BRAID DRIVE MOTOR FR MS214 U 1 MS214...

Page 472: ...0 108 109 2 105 105 S711 106 103 103 UA108 DYNAMO 15A 102 101 IN2 IN1 V Vout TRG GND VOLTAGE 250 WATT REGULATOR SBL SBL BLK RED YLW GRN UA128 ENGINE OIL TEMPERATURE SENSOR GND OUT Vs UA135 V ENGINE SP...

Page 473: ...3 GLOW PLUG KOBOTA ENGINE S786 3 48VDC 2 2 3 SYSTEM 48 VDC SYSTEM 0 VDC FUEL SOLENOID STARTER SOLENOID MANUAL CALL TO START LOW OIL PRESSURE AMBIENT TEMP ENGINE OIL TEMP SPEED SENSING INPUT RS232 12V...

Page 474: ...LIGHT 16AWG WHT 3 12 4 LIGHT 16AWG WHT 3 12 3 LIGHT 16AWG WHT 3 12 3 LIGHT 16AWG BLK 1 22 1 GND 16AWG BLK 1 22 1 GND 16AWG BLK 1 22 2 GND 16AWG BLK 1 22 2 GND 16AWG BLK 1 22 4 GND 16AWG BLK 1 22 4 GN...

Page 475: ...1 2 3 4 5 GENERIC RL619 1 2 3 4 5 WHT 8 4 1 IGN 48VOLT S620 WHT 8 4 2 IGN 48VOLT WHT 8 4 2 IGN 48VOLT WHT 8 4 4 IGN 48VOLT WHT 8 6 WHT 8 6 WHT 8 8 GEN DISTRESS PWR WHT 8 8 GEN DISTRESS PWR WHT 8 7 WH...

Page 476: ...WHT 98 7 BAT LOW WHT 98 7 BAT LOW WHT 122 2 DOS WHT 122 2 DOS WHT 127 1 SYS FAULT WHT 127 1 SYS FAULT WHT 128 1 OVERLOAD WHT 128 1 OVERLOAD WHT 129 1 TILT WHT 129 1 TILT WHT 98 3 1 4 BAT CHG WHT 98 3...

Page 477: ...LOW GRN CAN1 LOW YEL CAN1 HIGH YEL CAN1 HIGH WHT 81 0 GND MODE RX WHT 81 0 GND MODE RX WHT 5 11 3 WHT 5 11 3 YEL CAN1 HIGH YEL CAN1 HIGH GRN CAN1 LOW GRN CAN1 LOW GRN CAN1 LOW GRN CAN1 LOW YEL CAN1 H...

Page 478: ...B 1 2 3 4 5 6 WHT P2 WHT P6 WHT P6 WHT P3 WHT P3 WHT P1 WHT P1 S191 WHT P5 S192 WHT P4 5 4 3 2 1 1001173941 K MAE31940K B C D E F G H 5 4 3 2 1 G H E F C D A B 87 30 87a 85 86 87 30 87a 85 86 PLTFM SN...

Page 479: ......

Page 480: ...CorporateOffice JLGIndustries Inc 1JLGDrive McConnellsburg PA17233 9533USA 717 485 5161 Corporate 877 554 5438 CustomerSupport 717 485 6417 VisitourwebsiteforJLGWorldwideLocations www jlg com 3121714...

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