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Oshkosh Corporation JLG 1250AJP, Service And Maintenance Manual

The Oshkosh Corporation JLG 1250AJP is a powerful and reliable aerial work platform. Ensure safe and efficient operation with the comprehensive Operation and Safety Manual. Download this essential manual for free from our website, giving you the knowledge and confidence to operate this exceptional product safely.

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viii

3121171

TABLE OF CONTENTS

  

SECTION NO.    

   TITLE

  PAGE NO.

Step 7 - Position 7  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-85
Step 8 - Position 8  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-86
Step 9 - Position 9  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-87
Step 10 - Position 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-88
Step 11 - Position 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-89

6.16

Boom Control System (BCS) Violation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90

“UNLOCK BOOM” Calibration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-90

6.17

CANbus Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-140

CANbus Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-146
Load Moment Pin Troubleshooting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-159

SECTION

7  - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1

General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2

Multimeter Basics  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-1
Backprobing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-1
Min/Max  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-1
Polarity  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-1
Resistance Measurement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-2
Continuity Measurement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-3

7.3

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

7.4

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

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

7.5

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

Applying Silicone Dielectric Compound to AMP Connectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-6
Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-8
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-8
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-8

7.6

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

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

7.7

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

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

7.8

Electrical Schematics  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

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Summary of Contents for JLG 1250AJP

Page 1: ...Service and Maintenance Manual Model 1250AJP PN 3121171 May 31 2019 Rev S AS NZS G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 2: ...with a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 3: ...otentially 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 your hand to check for leaks Use a piece of card board or paper to search for leaks Wear gloves to help protect hands from spraying fluid C MAINTENANCE FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHI...

Page 4: ...Revised G January 17 2007 Revised H November 9 2007 Revised I March 20 2008 Revised J August 21 2008 Revised K March 18 2010 Revised L October 26 2011 Revised M December 7 2012 Revised N June 11 2013 Revised O September 9 2015 Revised Revised Revised Revised P June 22 2017 Q May 30 2018 R June 29 2018 S May 31 2019 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 5: ...n and Maintenance 2 1 Pre Start Inspection 2 1 Pre Delivery Inspection 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 Installation 2 2 Component Disassembly and Reassembly 2 3 Pressure Fit Parts 2 3 Bearings 2 3 Gaskets 2 3 Bolt Usage and Torque Appli...

Page 6: ...Installation 3 16 3 13 Drive Hub If Equipped With Rexroth 3 17 Disassembly 3 17 Cover Disassembly 3 17 First Stage Planetary 7 Disassembly 3 17 Second Stage Planet Gears 1 Disassembly 3 17 First Stage Planetary 7 Assembly 3 18 End Cover Unit 8 Assembly 3 18 Final Assembly 3 18 Initial Start up And After Repairs 3 18 Oil Change Interval Gear Drive 3 18 3 14 Drive Hub If Equipped With Bonfiglioli 3 ...

Page 7: ...le Bearing Mounting Bolts Condition Check 3 105 Turntable Bearing Wear Measurement 3 106 Turntable Bearing Removal 3 111 Turntable Bearing Installation 3 111 3 23 Swing Speed Proportioning 3 114 3 24 Chassis Tilt Indicator System 3 114 3 25 Rotary Coupling 3 115 3 26 Generator 3 118 Every 250 hours 3 118 Every 500 hours 3 118 Overload Protection 3 119 Inspecting Brushes Replacing Brushes and Clean...

Page 8: ...RTI 3 3 228 DTC 1615 Microprocessor Failure A D 3 230 DTC 1616 Microprocessor Failure interrupt 3 232 DTC 1625 CAN J1939 Shutdown Request 3 234 DTC 1626 CAN J1939 Transmit Tx Fault 3 235 DTC 1627 CAN J1939 Receive Rx Fault 3 236 DTC 1628 CAN Address Conflict Failure 3 237 DTC 1629 J1939 TSC1 Message Receipt Loss 3 239 DTC 1652 TPS1 Loss of Communications 3 240 DTC 2111 Unable to Reach Lower TPS 3 ...

Page 9: ...llation 4 72 4 26 Tower Lift Cylinder 4 74 Removal 4 74 Installation 4 78 4 27 Main Lift Cylinder 4 82 Removal 4 82 Installation 4 85 4 28 Main Boom Telescope Cylinder 4 86 Removal 4 86 Installation 4 90 4 29 Powertrack Maintenance 4 92 One Piece Bracket Maintenance 4 92 Two Piece Bracket Maintenance 4 94 Snap Rings and Screws 4 95 4 30 Hose Routing Procedure 4 101 4 31 Electronic Platform Levelin...

Page 10: ... 22 Assembly Instructions for Adjustable Port End Metric MFF Fittings 5 30 Assembly Instructions for Metric ISO 6149 MPP Port Assembly Stud Ends 5 38 Assembly instructions for Adjustable Port End BSPP Fittings 5 40 Assembly Instructions for Flange Connections FL61 and FL62 5 48 Double Wrench Method 5 51 FFWR and TFFT Methods 5 52 Adjustable Stud End Assembly 5 52 O ring Installation Replacement 5 ...

Page 11: ...nstructions 6 19 Chassis Pin Module Function 6 29 BLAM Pin Module Function 6 30 6 6 System Test 6 44 Test from the Platform 6 44 Test from the Ground Station 6 47 6 7 Calibrating Steer 6 52 6 8 Calibrating Drive 6 55 6 9 Calibrating Boom Valves 6 58 6 10 LSS System 6 61 Diagnostic Menu 6 62 Calibration Procedure 6 63 Testing Evaluation 6 68 Troubleshooting 6 69 6 11 Resetting The MSSO System 6 70 ...

Page 12: ...7 2 Continuity Measurement 7 2 Current Measurement 7 3 7 3 Applying Silicone Dielectric Compound to Electrical Connections 7 3 7 4 Dielectric Grease Application 7 4 Installation 7 4 AMP Mate N Lok 7 4 AMP Faston 7 4 AMP Micro Fit 7 4 AMP Mini Fit Jr 7 4 Mini Fit Sr 7 5 DIN Connectors 7 5 Exceptions 7 5 7 5 AMP Connector 7 6 Applying Silicone Dielectric Compound to AMP Connectors 7 6 Assembly 7 6 D...

Page 13: ...2 of 2 3 20 3 16 Drive Hub Identification Plate 3 21 3 17 Hub Assembly 3 23 3 18 Gearbox engaged 3 25 3 19 Gearbox Disengaged 3 26 3 20 Drive Hub If Equipped with Bonfiglioli 3 29 3 21 Drive Hub Special Tools Sheet 1 of 4 3 47 3 22 Drive Hub Special Tools Sheet 2 of 4 3 48 3 23 Drive Hub Special Tools Sheet 3 of 4 3 49 3 24 Drive Hub Special Tools Sheet 4 of 4 3 50 3 25 Bearing Track Spacer Mounti...

Page 14: ...nt 3 3 110 3 71 Turntable Bearing Removal 3 112 3 72 Turntable Bearing Torque Sequence 3 113 3 73 Rotary Coupling Seal Installation 3 115 3 74 Rotary Coupling Installation 3 116 3 75 Rotary Coupling Port Location 3 117 3 76 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings 3 120 3 77 Deutz Engine Dipstick 3 121 3 78 Engine Oil Viscosity 3 122 3 79 Cold Weather Package 3 125 3 ...

Page 15: ...2 of 3 4 48 4 34 Tower Boom Powertrack Installation Sheet 3 of 3 4 49 4 35 Boom Sensor Locations Overall View Sheet 1 of 2 4 50 4 36 Boom Sensor Locations Overall View Sheet 2 of 2 4 51 4 37 Boom Sensor Locations Tower Lift Cylinder Angle Sensor 4 52 4 38 Boom Sensor Locations Dual Capacity Length Main Boom Transport 4 53 4 39 Boom Sensor Locations Tower Boom Transport Length 4 54 4 40 Boom Sensor...

Page 16: ...ylinder Prior to 0300239155 5 69 5 32 Jib Cylinder SN 0300239156 to Present 5 70 5 33 Steer Cylinder Prior to SN 0300201017 5 71 5 34 Steer Cylinder SN 0300201017 through 0300238558 5 72 5 35 Steer Cylinder SN 0300238559 to Present 5 73 5 36 Tower Boom Telescope Cylinder SN 0300201017 through 0300243458 5 74 5 37 Tower Boom Telescope Cylinder SN 0300243459 to Present 5 75 5 38 Main Boom Telescope ...

Page 17: ...ressure and Flow Control Sheet 3 5 142 5 86 Hydraulic Schematic Sheet 1 of 8 5 146 5 87 Hydraulic Schematic Sheet 2 of 8 5 147 5 88 Hydraulic Schematic Sheet 3 of 8 5 148 5 89 Hydraulic Schematic Sheet 4 of 8 5 149 5 90 Hydraulic Schematic Sheet 5 of 8 5 150 5 91 Hydraulic Schematic Sheet 6 of 8 5 151 5 92 Hydraulic Schematic Sheet 7 of 8 5 152 5 93 Hydraulic Schematic Sheet 8 of 8 5 153 6 1 Hand ...

Page 18: ... 25 Wiring Harness Installation Sheet 5 of 7 7 22 7 26 Wiring Harness Installation Sheet 6 of 7 7 23 7 27 Wiring Harness Installation Sheet 7 of 7 7 24 7 28 Electrical Schematic Sheet 1 of 21 7 25 7 29 Electrical Schematic Sheet 2 of 21 7 26 7 30 Electrical Schematic Sheet 3 of 21 7 27 7 31 Electrical Schematic Sheet 4 of 21 7 28 7 32 Electrical Schematic Sheet 5 of 21 7 29 7 33 Electrical Schemat...

Page 19: ...3 22 3 3 Suggested Lubricants According SAE 80W 90 and SAE 85W 140 API GL5 Grade 3 24 3 4 Drive Hub Maintenance Schedule 3 26 3 5 Troubleshooting 3 27 3 6 Bearing Model Marking Identification 3 107 3 7 Turntable Bearing Wear by Bearing Model 3 107 3 8 Coupling Port Information Table 3 118 3 9 Engine Fault Codes 3 146 3 10 J1939 Diagnostic Lamp Configuration 3 196 4 1 Hose Cable Pull Chart 4 47 4 1...

Page 20: ...eners 5 50 5 33 Cylinder Head and Tapered Bushing Torque Specifications 5 88 5 34 Holding Valve Torque Specifications 5 88 5 35 Torque Specs for Relief Valves into Port Block 5 129 5 36 Tightening Torques 5 140 6 1 Analyzer Abbreviations 6 5 6 2 Machine Configuration Programming Information Version P7 24 6 7 6 3 Machine Personality Settings and Speeds 6 13 6 4 Reasons for Re Calibration 6 19 6 5 S...

Page 21: ...with a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 22: ...apacities HydraulicTank 53 3gal 201 7L FuelTank 31gal 117L HydraulicSystem 65 4gal 247 5L DriveHub Bonfiglioli ReggianaRiduttori 0 53qt 0 5L 10 1 59qt 1 5L 10 Table 1 3 Chassis Specifications MaximumTravelGradeWithboominstowedposition Gradeability 45 MaximumTravelGradeWithboominstowedposition SideSlope 5 TurningRadius AxlesRetracted Outside Inside 22ft 6in 6 8m 14ft 5in 4 4m TurningRadius AxlesExt...

Page 23: ...on 1 36gph 5 14Lph IdleEngineRPM 1200 MidEngineRPM 1800 HighEngineRPM 2475 Table 1 7 Deutz BF4M2011 Specifications Prior to SN 0300127698 Type LiquidCooled NumberofCylinders 4 Bore 3 7in 94mm Stroke 4 4in 112mm TotalDisplacement 190cu in 3108cm CompressionRatio 17 5 FiringOrder 1 3 4 2 MaxPowerOutput 87hp 65kW OilCapacity CoolingSystem w Filter TotalCapacity 5qt 4 5L 11qt 10 5L 16qt 15L AverageFue...

Page 24: ...sofoperationand every600hoursthereafter SeeTurntableBearinginSection3 NOTE When maintenance becomes necessary or a fastener has loosened refertotheTorqueChartforpropertorquevalue Table 1 11 Component Weights Component LBS KG Tire Wheel 445 50D710 FF 867 393 445 65 24 Solid 960 435 4 DriveHub Motor BONFIGLIOLI 267 121 REGGIANARIDUTTORI 306 138 EngineAssembly CATC3 4 551 250 DeutzBF4M2011 544 247 De...

Page 25: ...ty 0 877 PourPoint Max 40 F 40 C FlashPoint Min 330 F 166 C Viscosity at40 C 33cSt at100 C 6 6cSt at100 F 169SUS at210 F 48SUS cpat 20 F 6 200 ViscosityIndex 140 Table 1 15 UCon Hydrolube HP 5046 Type Synthetic Biodegradable SpecificGravity 1 082 PourPoint Max 58 F 50 C pH 9 1 Viscosity at0 C 32 F 340cSt 1600SUS at40 C 104 F 46cSt 215SUS at65 C 150 F 22cSt 106SUS ViscosityIndex 170 Table 1 16 Mobi...

Page 26: ...Specs SAEGrade 10W30 ISO 55 Gravity API 29 0 Density Lb Gal 60 F 7 35 PourPoint Max 46 F 43 C FlashPoint Min 442 F 228 C Viscosity Brookfield cPat 18 C 2700 at40 C 55cSt at100 C 9 3cSt ViscosityIndex 152 Table 1 20 Exxon Univis HVI 26 Specs SpecificGravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that thi...

Page 27: ... 13 15 10 12 2 3 6 7 21 19 MAE37800 Figure 1 1 Lubrication Operator Maintenance Diagram Deutz 2011 CAT Engines Figure 1 2 Lubrication Operator Maintenance Diagram Deutz 2 9 Engine G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 28: ...Point s Fill Plug Capacity 79 oz 2 3 L Lube GL 5 Interval Check level every 150 hours Change every 1200 hours of operation Fill to cover ring gear 3 Swing Brake Lube Point s Fill Plug Capacity 2 7 oz 80 ml Lube DTE24 Interval Check level every 150 hours Change every 1200 hours of operation Table 1 21 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof3...

Page 29: ...50 hours then every1200 hours of operation Comments Place Fill port at 12 o clock position and Check port at 8 o clock position Pour lubricant into fill port until it just starts to flow out of check port C Wheel Drive Hub Reggiana Riduttori S N 134389 to Present Lube Point s Level Fill Plug Capacity 0 5 qt 0 5 L 10 Lube EPGL Interval Change after first 150 hours then every 1200 hours of operation...

Page 30: ...ricted Figure 1 3 Hydraulic Return Filter Condition Indicator Prior to SN 139396 Red FilterRestricted FilterBypassed Green FilterGood NotRestricted Figure 1 4 Hydraulic Return Filter Condition Indicator SN 139396 to Present G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 31: ...icator if equipped 7 Main Valve Filter Lube Point s Replaceable Element Interval Change after first 50 hours and every 300 hours thereafter 8 Hydraulic Oil Lube Point s Fill Cap Capacity 55 gal 208 L Tank Lube HO Interval Check level daily Change every 2 years or 1200 hours of operation FULLLEVEL HOTOIL FULLLEVEL COLDOIL G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t...

Page 32: ...rk on dipstick 11 Oil Change w Filter Deutz TCD2 9 L4 Lube Point s Fill Cap Spin on Element Capacity 2 4 Gallon 8 9 L Lube EO Interval Check level daily change every 500 hours or six months whichever comes first Adjust final oil level by mark on dipstick 12 Oil Change w Filter CAT Lube Point s Fill Cap Spin on Element element can be accessed from below engine tray Capacity 10 5 qt 10 L Lube EO Int...

Page 33: ...eplaceable Element Interval Every year or 500 hours of operation 15 Fuel Strainer Deutz 2011 Lube Point s Replaceable Element Interval Every year or 600 hours of operation 16 Fuel Pre Filter Deutz TCD2 9 Lube Point s Replaceable Element Interval Drain water daily Change every year or 500 hours of operation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 34: ...eutz TCD2 9 Lube Point s Fill Cap Capacity 3 2 Gallon 12 1 L Lube Anti Freeze Interval Check level daily change every 1000 hours or 2 years whichever comes first 19 Air Filter Deutz 2011 CAT Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as shown by the condition indicator DEUTZ D2011 CAT G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p...

Page 35: ...ents Check Dust Valve daily 21 Platform Filter Lube Point s Replaceable Element Interval Change after first 50 hours and then every year or 600 hours of operation thereafter 22 Optional Fuel Filter Water Separator Lube Point s Replaceable Element Interval Drain water daily Change every year or 600 hours of operation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 36: ...1 SPECIFICATIONS 3121171 1 15 Figure 1 5 Torque Chart SAE Fasteners Sheet 1 of 5 Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 37: ...ION 1 SPECIFICATIONS 1 16 3121171 Figure 1 6 Torque Chart SAE Fasteners Sheet 2 of 5 Torq ue Tor que Torq ue Torqu e To rqu e G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 38: ...FICATIONS 3121171 1 17 Figure 1 7 Torque Chart SAE Fasteners Sheet 3 of 5 Cl amp L oa d To rque To rqu e Torq ue Torqu e Tor que Torq ue G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 39: ...SPECIFICATIONS 1 18 3121171 Figure 1 8 Torque Chart SAE Fasteners Sheet 4 of 5 To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 40: ...PECIFICATIONS 3121171 1 19 Figure 1 9 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 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 41: ...with a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 42: ...spection shall be accomplished for each machine in service for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environ ment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Sche...

Page 43: ...ents Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 If a component must be removed on an angle keep in mind the capacity of an eyebolt or similar bracket less ens as the angle between the supporting struc...

Page 44: ...ign with openings in 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 cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If ...

Page 45: ...il 1 Refer to Section 1 for recommendations for viscosity ranges 2 JLG recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 NOTE Start up of hydraulic system with oil temperatures below 15 degrees F 26 degrees C is not recommended If it is necessary to start the system in a sub zero environment it will be necessary to heat the oil with a low den...

Page 46: ...ncy for materials to change size in response to a change in 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 obstructions cylinder must have load applied and appropriately positioned to detect drift Cylinder leakage is acceptable if it passes this te...

Page 47: ...ld not be lubricated unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scratches which would damage the bear ing during installation and operation 2 6 WELDING ON JLG EQUIPMENT NOTE This instruction applies to repairs or modifications to the machine and to welding performed from the machine on an external structure or component Do the Fol...

Page 48: ...iling 1 1 2 Gate 1 1 5 Floor 1 1 2 Rotator 15 15 LanyardAnchoragePoint 1 2 10 1 2 10 TurntableAssembly SwingBearingorWormGear 1 2 14 1 2 3 13 14 OilCoupling 9 11 23 9 11 23 SwingDriveSystem 11 11 TurntableLock 1 2 5 1 2 5 Hood HoodProps HoodLatches 5 1 2 5 ChassisAssembly Tires 16 17 18 16 17 18 WheelNuts Bolts 15 15 WheelBearings 14 24 OscillatingAxle LockoutCylinderSystems 5 8 OutriggerorExtenda...

Page 49: ... 9 11 Hydraulic ElectricSystem HydraulicPumps 1 2 9 1 2 9 HydraulicCylinders 1 2 7 9 1 2 7 9 CylinderAttachmentPinsandPinRetainers 1 2 9 1 2 9 HydraulicHoses Lines andFittings 1 2 9 12 1 2 9 12 HydraulicReservoir Cap andBreather 1 2 5 9 11 1 2 5 9 11 24 HydraulicFilter 7 7 HydraulicFluid 7 11 7 11 ElectricalConnections 1 20 1 20 Instruments Gauges Switches Lights Horn 5 23 General OperationandSafe...

Page 50: ...ge cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwhenreleased 7 Cleanandfreeofdebris 8 Interlocksfunctionproperly 9 Checkforsignsofleakage 10 Decalsinstalledandlegible 11 Checkforproperfluidlevel 12 Checkforchafingandproperrouting 13 Checkforpropertolerances 14 Properlylubricated 15 Torquedtoproperspec...

Page 51: ...SECTION 2 GENERAL 2 10 3121171 Figure 2 1 Engine Operating Temperature Specifications Deutz 1001159163 B G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 52: ...Mineral Oils Vegetable Oils Synthetic Synthetic Polyol Esters Readily Biodegradable Virtually Non toxic Fire Resistant Mobilfluid424 55 145 X MobilDTE10Excel32 32 164 X X UnivisHVI26 26 376 X MobilEALHydraulicOil 47 176 X X X MobilEALEnvirosynH46 49 145 X X X Quintolubric888 46 50 185 X X X X Readilybiodegradableclassificationindicatesoneofthefollowing CO2Conversion 60 perEPA560 6 82 003 CO2Conver...

Page 53: ...180 F 82 C PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE NO OPERATION BELOW THIS AMBIENT TEMPERATURE MOBIL 424 10W 30 HYDRAULIC SPECIFICATIONS NO OPERATION ABOVE THIS AMBIENT TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO N...

Page 54: ...with a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell ...

Page 55: ... has not exceeded allowable criteria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Refer to the JLG Parts Manual for part number of approved tires for a particular machine model If not using a JLG approved replacement tire we recommend replacement tires have the following charac teristics Equal or greater ply load rating an...

Page 56: ...mediately have a service garage or dealer tighten lug nuts to the proper torque Over tightening will result in breaking studs or permanently deforming mounting stud holes in the wheels 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten nuts in the following sequence 3 Tighten nuts in stages Following the recommended sequence tighten nuts per whe...

Page 57: ...osition see Section 4 2 Trans port Position Sensing System If a signal from any axle extend sensing switch is lost when the boom is beyond the transport position the axle set indicator will flash and drive steer func tions will be disabled until the boom is brought back into the transport position The steering angle will be automatically limited to 25 degrees anytime the axles are not fully extend...

Page 58: ... without the footswitch being depressed or when the EMS is off the wheels will not move until the footswitch is depressed and a steering or drive command has been initiated The steering angles are limited to 25 degrees anytime the axles are not fully extended See the Axle Extension System see Section 3 2 Axle Extension System for interaction with the axle extension system If a wheel cannot achieve...

Page 59: ...rol handle The system indicates to the operator the need to match the black and white direc tional arrows on the platform control panel to the arrows on the chassis The system uses a proximity switch mounted on the hydraulic swivel an indicator light and a spring return override switch on the platform display panel The proximity switch trips when the turntable is swung 45 degrees off cen ter of th...

Page 60: ...SECTION 3 CHASSIS TURNTABLE 3 6 3121171 Figure 3 5 Chassis Component Location Sheet 1 of 2 0274670 D G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 61: ...7 SteerAngleSensor RightRear 8 AxleLimitSwitch RightRear 9 AxleLimitSwitch LeftRear 10 SteerAngleSensor LeftRear 11 ChassisModule 12 Swivel CollectorRing 13 AxleLockoutPressureSwitch 14 SteerAngleSensor LeftFront 15 AxleLimitSwitch LeftFront Figure 3 6 Chassis Component Location Sheet 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 62: ...SECTION 3 CHASSIS TURNTABLE 3 8 3121171 Figure 3 7 Turntable Component Location Sheet 1 of 2 0274670 D G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 63: ...ratorControlBox 17 Taillight 18 Taillight 19 TowerLiftCylinderLoadPin 20 TowerLiftCylinderAngleSensor 21 AuxiliaryPowerUnit 22 Headlight TaillightRelay 23 AuxiliaryPowerRelay 24 TowerLiftEnableValve 25 TowerTeleEnableValve 26 MainControlValve 27 MainLiftEnableValve 28 Alarm 29 Horn 30 FuelLevelSensor 31 GroundControlBox 32 BLAMModule 33 Headlight 34 StrobeLight Figure 3 8 Turntable Component Locat...

Page 64: ... 3 9 Oscillating Axle Sheet 1 of 2 AXLESTOPSHIMMINGPROCEDURE 1 ALLFOURWHEELSOFTHEMACHINESHOULD BEONALEVEL SURFACEWITHTHETURNTABLESQUARETOTHEFRAME 2 SHIMAXLESTOPSTOWITHINTHETHICKNESSOFTHETHINNEST SHIM G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 65: ...FrontandRearPlatesofAxleBoxes Typical8Places E AssembletoTopPlateofAxleWeldment Typical4Places Torque Selectappropriatebolttoensure0 5 0 062inches 12 7 1 587mm threadengagement F AssembletoBottomPlateofAxleBoxWeldment Typical8Places G SeeAxleStopShimmingProcedureonSheet1 1 AxleOscillationCylinder 2 Axle 3 AxlePowertrack 4 ExtensionCylinder 5 AxlePivotPin 6 AxleLimitSwitch 7 AxleStopPin 8 RubberPad...

Page 66: ... 12 3121171 MAE38440 Figure 3 11 Axle JLG Threadlocker Application JLG Threadlocker PN 0100011 JLG Threadlocker PN 0100081 JLG Threadlocker PN 0100019 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 67: ...in 5 KingPin 6 Axle Figure 3 12 Steering Installation Table 3 2 Steering Assembly Notes A ApplyJLGThreadlockerPN0100011 B ApplyJLGThreadlockerPN0100019 C ApplyJLGThreadlockerPN0100035 D PreloadTorque100 300ft lb 140 420Nm onSlotNut G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 68: ...m 3 11 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST Lockout Cylinder Bleeding To start the test the axle must be fully oscillated in one direc tion Start with oscillating the axle so that the left lock out cyl is fully retracted left front tire up and the right lock out cyl Is fully extended right front tire down ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR AXLE PRIOR TO...

Page 69: ...RWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block 5 Telescope boom out of transport position 6 Drive machine off of block and ramp back on level sur face 7 Have an assistant check left front wheel remains locked in position off ground 8 Retract boom back in to transport position Activate drive and the lockout cylinders should release 9 Place the...

Page 70: ...ystem NOTE The drive hub and drive motor assembly weighs approxi mately 267 lbs 121 kg 4 Use a supporting device capable of handling the weight of the drive hub and drive motor and unbolt the drive hub from the frame Remove the entire assembly from the machine 5 Remove the capscrews and washers that secure the drive motor to the drive hub and remove the drive motor Remove and discard the brake gas...

Page 71: ...SCOURAGED REINSTALLATION OF SHAFT NUT 4 REQUIRES A SPECIAL TOOL AND A TORQUE OF 626 FT LB 876 NM FOR PROPER REASSEMBLY THESE COMPONENTS WILL FAIL IF NOT PROP ERLY REASSEMBLED 15 Inspect planetary stage assemblies as complete units Thoroughly clean and check gearing and the bearings for damage and apply new oil If gears or bearings need replacing they must be replaced as complete sets 16 First stag...

Page 72: ...6 Before installation of motor CHECK THERE IS 1 2 mm OF CLEARANCE BETWEEN THE MOTOR SPLINE SHAFT SHOULDER AND THE COUPLER 62 7 Install motor and reconnect hydraulic lines 8 Roll motor so one fill plug is at 12 o clock position and the other is at 3 o clock Fill to bottom of 3 o clock plug with gear oil reinstall plugs Initial Start up And After Repairs Before operating machine make sure drive is f...

Page 73: ...SECTION 3 CHASSIS TURNTABLE 3121171 3 19 Figure 3 14 Drive Hub Sheet 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 74: ...Washer 30 Ring Gear 33 O ring 41 Planet Carrier 42 Sun Gear 43 Sun Gear 45 Planet Pin 46 Roller Bearing 47 Retaining Ring 48 Retaining Ring 51 Cover 52 Thrust Washer 53 Bolt 54 O ring 55 Spring 60 Spindle 61 Piston 62 Coupler 63 Ring Locator 64 Backup Plate 65 Backup Plate 66 Retaining Ring 67 Retaining Ring 68 Retaining Ring 69 Bolt 72 Brake Disc 73 Brake Disc 74 Spring 75 Backup Ring 76 Seal 77 ...

Page 75: ...que bolts to 63 5 ft lb 86 Nm torque Installation of the Wheel Drive on the Machine 1 Clean the mating surfaces from oils or paint and fit the wheel drive on the machine frame 2 Attach the gearbox to the machine frame with the mounting bolts and torque to 178 ft lbs 241 Nm Start Up and Running In If new hubs are being installed it is advised to follow the measures given below 1 Bleed air from ever...

Page 76: ...ducational purposes so as to safely and properly carry out maintenance operations Minor deviations from pictures of this manual may appear on the actual gearbox However these discrepancies are not rele vant to the main parameters or maintenance functions CONNECTING THE BRAKE The gearbox is fitted with a negative multi disk safety brake with hydraulic control release parking brake For information r...

Page 77: ...N 3 CHASSIS TURNTABLE 3121171 3 23 Figure 3 17 Hub Assembly 1 M18x1 5 Filling drainingandoillevelplugs 2 7 16 20UNF 2B Brakeport G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 78: ...oil level 5 If necessary refill with lubricant oil Approximate oil capacity 2 L 10 Gearbox Disengagement THE DISENGAGEMENT OPTION MUST BE CONNECTED OR DISCONNECTED ONLY WHEN GEARBOX IS STOPPED ON FLAT GROUND Table 3 3 Suggested Lubricants According SAE 80W 90 and SAE 85W 140 API GL5 Grade Ambient temperature Oil viscosity 20 C 30 C SAE 80W 90 10 C 45 C SAE 85W 140 Manufacturer Oil Brand SHELL SPIR...

Page 79: ...t head screws M8x16 4 from the end cover 7 with a male hex head wrench 2 Rotate cap nut 5 3 Remove cap nut 5 4 Turn cap nut 5 upside down Pin 3 will be pushed inside to permit disengagement of the gearbox 5 Rotate cap nut 5 Figure 3 18 Gearbox engaged G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 80: ...arbox CHANGING THE LUBRICATING OIL 1 Check gearbox axis is horizontal Rotate gearbox hous ing until drain plug is at bottom of the vertical axis of the end cover 2 Unscrew both plugs Fill and Drain and let the oil flow in a large enough container To facilitate draining the oil must be warm 3 Wait a few minutes until all the oil is drained and then proceed to screw on the plugs 4 Proceed with the o...

Page 81: ...to follow during Disassembly and Assembly Numbers in brackets in the text correspond to the references in the exploded view Initial inspection can be made without disassembling the hub from the machine Before wheel drive disassembling make sure that the oil is drained from the hub Unscrew and remove the nos 2 screws M12 grade 8 8 and remove the hydraulic motor and its O ring seal 48 Table 3 5 Trou...

Page 82: ... springs 45 2 Remove circlip 47 Remove the special tool 3 Remove spring retainer disc 46 4 Mark position of springs 45 for reassembly 5 Remove springs 45 from brake piston seats 44 6 Using pliers remove circlip 36 from its seat in the brake shaft 35 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 83: ...3rdReductionAssembly 21 Spacer 22 RingNut 23 GearboxHousing 24 Bearing 25 Spacer 26 Spacer 27 O ring 28 Spacer 29 HalfSeal 30 SealRing 31 FlangedHub 32 Disc InternalTeeth 33 Disc ExternalTeeth 34 Spacer 35 BrakeShaft 36 Circlip 37 BackupRing 38 O ring 39 Spacer 40 BackupRing 41 O ring 42 O ring 43 BackupRing 44 BrakePiston 45 Springs 46 RetainerDisc 47 Circlip Figure 3 20 Drive Hub If Equipped wit...

Page 84: ... 44 9 Remove internal O Ring seal 41 and backup ring 40 from their seat in the spacer 39 10 Remove external O Ring seal 38 and backup ring 37 from their seat in the spacer 39 11 Remove O ring seal 42 and backup ring 43 from their seats in the flanged hub 31 12 Remove brake discs pack 32 33 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 85: ...15 Tighten two screws M5x16 grade 8 8 in cover with a torque wrench to 18 4 ft lb 25 Nm 16 Usepliers to removeelastic ring 11 fromsplined shaft 14 17 Remove special tool spring 13 and washers 12 18 Turn gearbox upside down Remove two screws M8x16 4 grade 8 8 from end cover 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 86: ...21 Remove O ring seal 2 from its seat in the end cover 7 22 Remove draining filling level oil plugs 6 using a male hex head wrench 23 Remove 10 screws M10X25 1 from end cover 7 24 Remove end cover 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 87: ...7 26 Remove 1st stage sun gear 10 27 Remove 1st reduction assembly 16 28 Remove 2nd stage sun gear 17 29 Remove 2nd reduction assembly 18 30 Using pliers remove circlips 19 from their seats in the flanged hub s pins 31 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 88: ...o proceed with gearbox disassembly remove it from machine and bring it to a properly equipped workshop 33 Use a drill remove caulking on the ring nut 22 34 Using a tackle place torque multiplier ATZ 09 016 0 on ring nut 22 35 Using the torque multiplier ATZ 09 016 0 loosen ring nut 22 36 Remove ring nut 22 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 89: ...n case of oil leaks it may be necessary to check and replace the lifetime seal 29 which means metal rings parts and O ring seals 40 Using a screwdriver remove 1st half seal 29 from the flanged hub 31 41 Using a screwdriver remove 2nd half seal 29 from gearbox housing 23 NOTE Gearbox disassembly ends with the above operation All items are now available for inspection G o t o D i s c o u n t E q u i...

Page 90: ... parts Assembly Apply grease TECNOLUBE SEAL GS730 on gearbox housing 23 1 Follow steps below to prepare the lifetime seal for assembly a Carefully clean seats A and B using if necessary metallic brushes or solvent surfaces in contact with or C must be perfectly clean and dry b Make sure sealing surfaces D of metal rings E are free from scratches dings or foreign substances metallic ring surfaces m...

Page 91: ...y clean metallic faces of the lifetime seal 29 and lubricate surfaces with oil 6 Insert seal ring 30 in its seat in the flanged hub 31 7 Apply grease TECNOLUBE SEAL GS730 on seal ring 30 AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL 29 8 Using a hoist place gearbox housing 23 on flanged hub 31 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 92: ...G STEPS 10 Use a hoist to place the torque multiplier ATZ 09 016 0 on the ring nut 22 11 Using multiplier ATZ 09 016 0 tighten ring nut 22 using a torque wrench with an input multiplier torque of 71 3 ft lb 96 5 4 5 Nm corresponding to an output multiplier torque of 3688 184 ft lb 5000 250 Nm 12 Stake ring nut 22 near two seats at 180 of flanged hub 31 on the right side NOTE Stake Ø 4 5 mm depth 1...

Page 93: ...ins 31 15 Using a rubber hammer and a metal stopper push planet assemblies of the 3rd reduction 20 against the shoulder until assembly is complete 16 Using pliers assemble circlips 19 in flanged hub pin seats 31 17 Assemble 2nd reduction assembly 18 18 Install 2nd stage sun gear 17 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 94: ...s seat in the end cover 7 22 Place end cover 7 on gearbox housing 23 23 Tighten 10 socket head screws M10x25 1 grade 12 9 by a torque wrench to 62 7 ft lb torque 85 Nm 24 Install plugs 6 in oil drain fill holes of the end cover 7 Torque plugs to 52 7 ft lb 70 10 Nm G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 95: ...e MOLYKOTE G6000 Wait 15 minutes for it to completely dry Insert pin 3 in its seat in the end cover 7 27 Install cap nut 5 28 Torque two screws M8x16 4 to 18 4 ft lb 25 Nm 29 Install 1st washer 12 on splined shaft 14 30 Install spring 13 on splined shaft 14 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 96: ...2 correctly in the splined shaft 14 33 Torque two screws M5x16 grade 8 8 of the cover to 18 4 ft lb 25 Nm 34 Using pliers assemble elastic ring 11 into its seat in the splined shaft 14 35 Insert disengagement shaft kit 15 in flanged hub 31 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 97: ... insert one sintered bronze disc with external teeth 33 39 Insert an internally toothed steel disc 32 Repeat opera tion until all five sintered bronze discs and four steel discs are installed 40 Fit internal O ring seal 41 and backup ring 40 into their seats in the spacer 39 41 Fit external O ring seal 38 and backup ring 37 into their seats in the spacer 39 G o t o D i s c o u n t E q u i p m e n ...

Page 98: ... stopper push spacer 39 against flanged hub 31 Do not damage seals already installed 44 Lube seal seats into flanged hub 31 and assemble the O ring seal 42 and the backup ring 43 NOTE O ring seals A and backup rings B must be fitted in seats according mutual position shown below G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 99: ...dy fitted 46 Using a rubber hammer and a metal stopper push brake piston 44 against flanged hub 31 Do not damage seals already installed 47 Insert springs 45 in previously marked brake piston 44 holes 48 Install spring retainer disc 46 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 100: ...tartup and Running In If work on the brake was performed check for oil leaks Follow procedure below 1 Connect pressure pilot line with manometer with a base scale of 100 bars to the brake release port 2 Open flow valve and release brake with pilot pressure of 50 bar 3 Close flow valve and keep brake released 3 minutes or longer 4 Using a manometer check pressure remains constant NOTE If pressure d...

Page 101: ...SECTION 3 CHASSIS TURNTABLE 3121171 3 47 r Figure 3 21 Drive Hub Special Tools Sheet 1 of 4 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 102: ...SECTION 3 CHASSIS TURNTABLE 3 48 3121171 Figure 3 22 Drive Hub Special Tools Sheet 2 of 4 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 103: ...SECTION 3 CHASSIS TURNTABLE 3121171 3 49 Figure 3 23 Drive Hub Special Tools Sheet 3 of 4 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 104: ...SECTION 3 CHASSIS TURNTABLE 3 50 3121171 Figure 3 24 Drive Hub Special Tools Sheet 4 of 4 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 105: ...g the wheel gear RRTD1701TB 1 Hammer 2 Clamps for inner retention rings 3 Clamps for outer retention rings 4 Electric or pneumatic screwdriver 5 Special spacer mounting 6 Torque wrench 7 Hydraulic press 8 Wrench for M6 M8 M10 socket head screws and 1 4 G plug 9 Socket wrench for M6 hexagonal screw Ø30 Ø130 Ø240 Ø224 Ø233 Ø240 N 6 Hole to 120 Ø30 5 10 5x45 15 6 0 60 6 0 A A 35 M 1326 R 5 Figure 3 2...

Page 106: ...1 LOCTITE 2701 Ø197 5 Ø210 110 Ø30 Ø130 Ø210 N 4 Hole to 90 Ø40 25 5x45 M 1320 M 1321 Figure 3 27 Bearing Spacer Mounting CO16117 Figure 3 28 Assembly Diagram 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 107: ... Ø305 n 12 Fori a 30 Ø35 Ø20 H7 0 021 0 n 12 Hole to 30 n 12 Hole to 30 Ø6 5 n 12 Spot facing to 30 Ø10 5 n 4 Hole to 90 M10 20 6 5 T U 15 32 10 5 Ø80 3 0 3 0 30 30 3 0 3 0 M 1125 Figure 3 30 Anti rotation Flange 70 70 Ø 5 0 35 Ø11 Ø17 11 60 10 35 A A 10 35 35 10 M 1020 10 Figure 3 31 Anti rotation Block M6 Ø20 Ø12 30 50 T U 9 M 1126 Figure 3 32 Anti rotation Pin G o t o D i s c o u n t E q u i p ...

Page 108: ...N 3 CHASSIS TURNTABLE 3 54 3121171 M 1020 M 1126 M 1125 VTCEI M6X12 n 12 VTCEI M10X60 n 4 M 1126 Figure 3 33 Assembly Diagram 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 109: ...0 0 1 Ø20 0 1 0 2 Ø93 5 Ø105 Ø8 5 Ø13 5 9 20 8 5 5 t u 12 2 5x15 Ø39 5 M 1546 M 1548 M 1547 Ø40 5 Ø46 VTCEI M8X16 n 1 Figure 3 34 Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 110: ... Release screws to disassemble the motor flange Do not damage O Ring 3 Release the screws from the release cover and pull the pin out 4 Remove the BR250 ring and pull cover out Do not dam age O Ring 5 Pull reduction gears out G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 111: ...SECTION 3 CHASSIS TURNTABLE 3121171 3 57 Figure 3 35 Reggiana Riduttori Hub Sheet 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 112: ...ent Spring 23 Disengagement Shaft 24 Spindle Oil Seal 25 Tapered Roller Bearing 26 Bearing Support 27 Ring Nut 28 Sphere 29 Screw 30 Pinion 31 Reduction Gears 32 Outer Retention Ring 33 Pinion 34 Reduction Gears 35 Outer Retention Ring 36 Pinion 37 O ring 38 Crown Gear 39 Crown Gear Screw 40 O ring 41 Support Tablet 42 O ring 43 Cover 44 Steel Plug 45 Cover Retaining Ring 46 Disengagement Stud 47 ...

Page 113: ...th the spring 8 Disassemble the Ø40 outer snap rings Using an extrac tor remove planetary gears from spindle pins 9 Loosen the M6x6 socket headless screws and remove the 3 16 balls 10 Loosen the ring nut using the special wrench 11 Remove hub support with roller bearing inner track G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 114: ...ring into input shaft and lock it with a Ø40 outer snap ring Install motor shaft in spindle and lock with a BR68 ring Lubricate bearing Assembly 1 Make sure all wheel gear components are devoid of burrs machining residues and are correctly washed 2 Fit ball bearing in input shaft Lock with a Ø40 outer snap ring 3 Install motor shaft in spindle and lock with BR68 ring Lubricate bearing G o t o D i ...

Page 115: ...kage if any as well as the static torque and minimum opening pressure 6 Prepare hub support mounting on it the two roller bear ing outer tracks Place first roller bearing inner track 7 Install oil seal lubricated with grease on support with special spacer mounting see figure A 8 Place hub support already assembled on spindle mak ing sure that the first roller bearing inner track goes cor rectly ag...

Page 116: ... ring nut at the final torque of 30daNm alternate tight ening and some setting turns Check roll torque with seal which must be within 1 1 5 daNm NOTE Place ring nut with convex part facing the roller bearing as shown below 11 Using special tool and hammer make four dents on the spindle thread by the M6 holes of the ring nut 12 Fit the 4 3 16 balls and tighten with LOCTITE 243 the 4 M6x6 socket hea...

Page 117: ... pen make a mark between the snap ring and the bearing Fit the greased spring and the release joint Use grease to fit the O Ring 2 275 in the hub support seat 15 Place hub on support making the two holes coincide for tightening the M10x25 flathead socket screws at the torque of 5daNm 16 Fit the reduction gears and the pinion in the unit G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 118: ...Fit O Ring 2 163 suitably greased on motor coupling flange S D LC KC Mount flange on spindle with 6 M8x25 socket capscrews at the torque of 2 4daNm with LOC TITE 243 Insert pin and perform rotation test according to PGQ 22 standard 20 Mount release cover fastening it with 2 M6x20 hexago nal screws at the torque of 1daNm Mount the 1 4 GAS plugs on the cover at the torque of 1daNm G o t o D i s c o ...

Page 119: ...e 2 InnerRaceBearingBolt 3 SwingBearing 4 OuterRaceBearingBolt 5 TurntableLockPin 6 RemoteBearingLubricationFittings Figure 3 37 Swing System SN 0300201017 through 0300254456 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 120: ... 6 1 SwingDrive 2 InnerRaceBearingBolt 3 SwingBearing 4 OuterRaceBearingBolt 5 TurntableLockPin 6 RemoteBearingLubricationFittings Figure 3 38 Swing System SN 0300254457 to Present G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 121: ... Swing Drive Installation for swing drive maintenance Assembly Disassembly For detail assembly disassembly instructions refer Swing Drive Hub Manual or contact JLG service for more details Installation Ensure mounting plate and mounting location of the base plate are clean and painted with a uniform coating of mini mum thickness no runs drips etc 6 8 5 4 2 7 3 1 MAE38510D 1001228617 D Figure 3 39 ...

Page 122: ... 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 air checker starts to fall after unit has been pres surized and allowed to equalize Leaks will most likely occur at pipe plugs main seal or wherever O rings or gaskets are located The exact location of a leak can usually be detected by brushing a soap a...

Page 123: ... fittings from Brake 26 and Motor Control Valve 32 5 Remove O ring Plugs 21 from Motor Control Valve 32 6 Remove Motor Control Valve 32 from Motor 10 by removing four Bolts 34 and washers 33 1J O RingPlug 10 HydraulicMotor 21 Plug 24 IDPlate 25 DriveScrew 26 HydraulicBrake 32 MotorControlValve 33 Lockwasher 34 HexBolt 35 HydraulicTubing 36 Elbow Figure 3 40 Swing Drive Motor Control Valve Disassem...

Page 124: ...Brake 26 3 Remove Gasket 31 between Brake 26 and Motor 10 4 Remove Brake 26 from Main Torque Hub Assembly and dump oil out of Brake 26 5 Remove O ring 27 between Motor 10 and Brake 26 10 HydraulicMotor 26 HydraulicBrake 27 O Ring 28 LiftLug 29 Bolt 31 Gasket Figure 3 41 Swing Drive Motor and Brake Disassembly SN 0300201017 through 0300254456 G o t o D i s c o u n t E q u i p m e n t c o m t o o r ...

Page 125: ...ear 13 6 Remove Thrust Washers 16 and Thrust Bearing 15 between Input Cover 6 and Carrier 3A Subassembly 7 Remove Ring Gear 4 from Housing 1G 8 Remove O ring 5 between Ring Gear 4 and Housing 1G 9 Remove Carrier 3A Subassembly 10 Remove Thrust Washers 16 and Thrust Bearing 15 between Carrier 3A Subassembly and Internal Gear 2 11 Remove Internal Gear 2 2 InternalGear 4 RingGear 5 O Ring 6 InputCove...

Page 126: ...m Housing 1G 5 Invert Housing 1G and remove Lip Seal 1B if not already removed when Output Shaft 1A was pressed out of Housing 1G 6 Remove Bearing Cone 1D 7 Bearing Cups 1C 1E will remain in Housing 1G NOTE If bearing replacement is necessary Bearing Cups 1C 1E can be removed with a slide hammer puller or driven out with a punch 1A OutputShaft 1B LipSeal 1C TaperedBearingCup 1D TaperedBearingCone ...

Page 127: ...e Roll Pin 3G from Planet Shaft 3E 3 Slide Planet Gear 3F two Ball Indented Thrust Washers 3H and two Thrust Washers 3B out of Carrier 3A 4 Remove both rows of Needle Bearings 3C and Spacer 3D from bore of Planet Gear 3F 5 Repeat Steps 1 thru 4 for the remaining two Cluster Gears 3F 3A Carrier 3B TangedThrustWasher 3C NeedleBearing 3D ThrustWasher 3E PlanetShaft 3F ClusterGear 3G RollPin 3H BallIn...

Page 128: ...ted in Bearing Cup 1E 9 Install Bearing Spacer 1H on Output Shaft 1A and against Bearing Cone 1F 10 Install Retaining Ring 1I in groove of Output Shaft 1A This Retaining Ring 1I should never be reused in a repair or rebuild EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE 11 Tap Retaining Ring 1I with a soft metal punch to ensure Retaining Ring 1I is completely seated in groove of Output Shaft ...

Page 129: ...F facing roll pin hole in the carrier place cluster gear into position in Carrier 3A Push Planet Shaft 3E through Cluster Gear 3F without going all the way through 8 Slide second Thrust Washer 3E between Cluster Gear 3F and Carrier 3A with tang of washer located in the cast slot of Carrier 3A Slide ball indented Thrust Washer 3H onto end of the Planet Shaft with indents against second thrust Washe...

Page 130: ...rustWasher 3C NeedleBearing 3D ThrustWasher 3E PlanetShaft 3F ClusterGear 3G RollPin 3H BallIndentedWasher Figure 3 46 Swing Drive Carrier Sub Assembly SN 0300201017 through 0300254456 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 131: ...tamped on it should be up 9 While holding Ring Gear 4 and Cluster Gears 3F in mesh place small end of Cluster Gears 3F into mesh with the Internal Gear 2 and Input Gear 13 On the Ring Gear 4 locate hole marked X or punch marked over one of the marked counter bored holes Step 5 in Hub 1G Check timing through slots in the carrier Rotate carrier in assembly to check freedom of rotation NOTE NOTE If g...

Page 132: ...ing 6 InputCover 8 HexBolt 13 SunGear 15 ThrustBearing 16 ThrustWasher 17 HexBolt 18 ShoulderBolt 19 Lockwasher 20 PipePlug Figure 3 47 Swing Drive Main Assembly SN 0300201017 through 0300254456 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 133: ... Assemble Lift Lugs 28 onto Hex Bolts 29 Assemble Hex Bolts 29 with Lift Lugs through the Motor 10 and Brake 26 against the motor flange Torque to 35 ft lb 5 Fill Brake 26 with 2 7 oz 80cc of BRAKOILVG32 DTE24 10 HydraulicMotor 26 HydraulicBrake 27 O Ring 28 LiftLug 29 Bolt 31 Gasket Figure 3 48 Swing Drive Motor and Brake Assembly SN 0300201017 through 0300254456 G o t o D i s c o u n t E q u i p...

Page 134: ...s 36 and torque 13 to 15 ft lb 18 to 21 Nm 5 Install O ring Plugs 21 into Motor Control Valve 32 and torque 30 to 31 ft lb 42 to 43 Nm 6 Pressure test brake tube and control valve connections by applying 3000 psi 207 bar pressure to brake bleed port and holding for 1 minute Check for leaks at control valve motor interface and the tube connections Release pressure 7 Install I D Plate 24 on Housing ...

Page 135: ...35 36 37 38 39 41 42 44 43 46 47 5 9 10 11 16 14 17 15 21 19 20 20 22 25 23 19 26 28 27 27 30 40 29 7 7 33 34 45 6 6 18 18 18 18 24 48 49 MAE37600B Figure 3 50 Swing Motor SN 0300254457 to Present Sheet 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 136: ...ctionGear 21 Pinion 22 Ring 23 Spacer 24 Spacer 25 Pinion 26 Ring 27 Washer 28 BrakeHousing 29 Plug 30 Capscrew 31 Seal 32 O Ring 33 SteelDisc 34 Disc 35 Disc 36 Seal 37 O ring 38 PistonBrake 39 SpringBrake 40 ShaftInput 41 O ring 42 Cover 43 Screw 44 O ring 45 Motor 46 LungLifting 47 Capscrew 48 Brakevalveadapter 49 Valve Figure 3 51 Swing Motor SN 0300254457 to Present Sheet 2 of 2 G o t o D i s...

Page 137: ...n plates 3 6 have engaged to prevent rotation of brake shaft 1 RELEASE PRESSURE DURING BENCH TESTING SHOULD BE LIMITED TO 2000 PSI 138 BAR UNLESS BRAKE IS FULLY INSTALLED USING 2 OFF 1 2 UNC MOUNTING BOLTS IN THE THROUGH MOUNTING HOLES 1 BrakeShaft 2 Housing 3 InnerFrictionPlate 4 PressurePlate 5 Gasket 6 OuterPlate 7 Gasket 8 Cylinder 9 Piston 10 DeepGrooveBallBearing 11 InternalRetainingRing 12 ...

Page 138: ...cylinder housing 8 and piston 9 subassembly and dismantle if required removing O ring seals 15 17 and backing rings 16 18 as necessary 3 Remove gasket 7 from housing 2 4 Remove friction plates 3 6 and pressure plate 4 5 Remove 2 off dowel pins 19 6 Remove springs 8 Note quantity and orientation of springs 7 Should it be necessary to replace ball bearing 10 or shaft seal 12 reverse remainder of bra...

Page 139: ...acking rings are assembled opposite to the pressurized side of piston 9 5 Correctly orientate piston 9 aligning spaces with the two dowel pin holes and assemble into cylinder hous ing 2 taking care not to damage seals and carefully lay aside 6 Loctite two off pins 19 in housing 2 followed by pres sure plate 4 and friction plates i e an inner 3 followed by an outer 6 in correct sequence 7 Position ...

Page 140: ... Piston 10 DeepGrooveBallBearing 11 InternalRetainingRing 12 RotaryShaftSeal 13 SocketHeadCapscrew 14 ShakeproofWasher 15 O Ring 16 BackingRing 17 O Ring 18 BackingRing 19 DowelPin 20 HexagonPlug 21 PlasticPlug 21A SocketPressurePlug Figure 3 55 Swing Brake Assembly G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 141: ...r 2 to housing 18 to facilitate reassembly orientation where required Loosen two shuttle or relief valve plugs 21 for disassembly later if included in end cover 3 16 or 3 8 inch Allen wrench or 1 inch hex socket required 3 Remove the five six or seven special ring head bolts 1 using an appropriate 1 2 or 9 16 inch size socket Inspect bolts for damaged threads or sealing rings under the bolt head R...

Page 142: ... 2 must not be removed as they are serviced as an integral part of the end cover 1 SpecialBolts 2 EndCover 3 SealRing Commutator 4 SealRing 5 CommutatorRing 6 CommutatorRing 7 Manifold 8 RotorSet 8A Rotor 8B StatororStatorVane 8C Vane 8D StatorHalf 9 WearPlate 10 DriveLink 12 CouplingShaft 13 Bearing Bushing Inner 14 ThrustWasher 15 ThrustBearing 16 Seal 17 BackupWasher 18 Housing 18A O Ring 19 Be...

Page 143: ...ifold and rotor set 7 Remove commutator ring 6 Inspect commutator ring for cracks or burrs 8 Remove commutator 5 and seal ring 3 Remove seal ring from commutator using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring Inspect commutator for cracks or burrs wear scor ing spalling or brinelling If any of these conditions exist replace commutator and commuta...

Page 144: ...the rotor and stator that is facing UP with etching ink or grease pen cil before removal from Torqlink will ensure correct reas sembly of rotor into stator and rotor set intoTorqlink Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set andTorqlink NOTE Series TG Torqlinks may have a rotor set with t...

Page 145: ...t its withdrawal through the seal and bear ing Crocus cloth or fine emery paper may be used 15 Remove coupling shaft 12 by pushing on the output end of shaft Inspect 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 shaft if any of these conditions ex...

Page 146: ...from vise invert it and remove and discard seal 20 A blind hole bearing or seal puller is required 20 Inspect housing 18 assembly for cracks the machined surfaces for nicks burrs brinelling or corrosion Remove burrs that can be removed without changing dimen sional characteristics Inspect tapped holes for thread damage If the housing is defective in these areas dis card the housing assembly G o t ...

Page 147: ...the housing has passed this inspection the disassembly of the Torqlink is completed NOTE The depth or location of bearing bushing 13 in relation to the housing wear plate surface and the depth or location of bearing bushing 19 in relation to the beginning of bearing bushing counter bore should be measured and noted before removing the bearings bushings This will facilitate the correctreassembly of...

Page 148: ...ement thoroughly coat and pack a new outer bearing bushing 19 with clean corrosion resistant grease recommended in the material section Press the new bearing bushing into the counterbore at the mounting flange end of the housing using the appro priate sized bearing mandrel which will control the bearing bushing depth Torqlink housings require the use of bearing mandrel to press bearing bushing 19 ...

Page 149: ... housing wear plate contact face Use opposite end of bearing mandrel used to press in outer bearing bushing 19 3 Press a new dirt and water seal 20 into the housing 18 outer bearing counterbore The Torqlink dirt and water seal 20 must be pressed in until its flange is flush against the housing G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 150: ... BE ASSEMBLED WITH A NEW BACKUP WASHER 17 NEW BACKUP WASHER 25 AND NEW SEAL 16 6 Assemble thrust washer 14 then thrust bearing 15 removed from the Torqlink NOTE Torqlinks require one thrust washer 14 with thrust bear ing 15 Coupling shaft will be seated directly against the thrust bearing 7 Apply masking tape around splines or keyway on shaft 12 to prevent damage to seal 8 Ensure a generous amount...

Page 151: ...r tight into hous ing 18 bolt holes approximately 180 degrees apart will facilitate the assembly and alignment of components as required in the following procedures The studs can be made by cutting off the heads of either 3 8 24 UNF 2A or 5 16 24 UNF 2A bolts as required that are over 0 5 inch 12 7 mm longer than the bolts 1 used in the Torqlink 10 Install drive link 10 the long splined end down i...

Page 152: ...nstalled using the drive link spline pattern on the rotor splines if apparent to determine which side was down The rotor set seal ring groove faces toward the wear plate 9 14 Apply clean grease to a new seal ring 4 and assemble it in the seal ring groove in the rotor set contact side of manifold 7 NOTE The manifold 7 is made up of several plates bonded together permanently to form an integral comp...

Page 153: ...he end cover A 3 16 inch Allen wrench is required 20 Assemble a new seal ring 4 into end cover 2 and assemble end cover over the alignment studs and onto the commutator set If end cover has only 5 bolt holes make sure cover holes are aligned with the 5 threaded holes in housing 18 The correct 5 bolt end cover bolt hole relationship to housing port bosses NOTE If end cover has a valve 24 or has fiv...

Page 154: ...ired 22 Torque two shuttle valve plug assemblies 21 in end cover assembly to 9 12 ft lb 12 16 N m if cover is so equipped 23 Torque the two relief valve plug assemblies 21 in end cover assembly to 45 55 ft lb 61 75 N m if cover is so equipped One Piece Stator Construction A disassembled rotor 8A stator 8B and vanes 8C that can not be readily assembled by hand can be assembled by the following proc...

Page 155: ... TO PUSH THE ROTOR VANES INTO PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS 4 Assemble six vanes 8C or as many vanes that will read ily assemble into the stator vane pockets 5 Grasp output end of coupling shaft 12 with locking pli ers or other appropriate turning device and rotate cou pling shaft drive link and rotor to seat the rotor and assembled vanes 8C into stator 8B cr...

Page 156: ...w the teeth and marked with yellow paint in the tooth space 3 Torque shoulder screw shown below to 660 ft lb 896 Nm with JLG Threadlocker PN 0100019 4 Remove turntable lock pin 5 Pre torque capscrews shown below to 90 ft lb 122 Nm with JLG Threadlocker PN 0100019 6 Tighten setscrew shown below until pinion is com pletely snug against shim and bearing then back off the setscrew 7 Torque setscrew to...

Page 157: ...L 5 Extreme Pressure Gear Lube Fill to cover the ring gear Swing Brake is to be filled half full 2 7 ounces 80 ml with DTE24 oil 1 2 3 4 Brake Bleed Port Brake Fill Port Gearbox Fill Port Gearbox Drain Port Figure 3 57 Swing Drive Ports SN 0300201017 through 0300254456 Figure 3 58 Swing Drive Lubrication SN 0300201017 through 0300254456 1 195 IN 30 35 mm TOP OF HOUSING TO TOP OF RING GEAR TO BE FI...

Page 158: ... ISO VG 150 oil until oil reaches halfway of the plug opening Close the swing gearbox brake fill port 1 immediately Drain oil through the swing gearbox brake drain port 2 MAE37630 1 2 1 2 Swing Gearbox Brake Fill Port Swing Gearbox Brake Drain Port Figure 3 59 Swing Drive Ports SN 0300254457 to Present G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 159: ... not fit under bolt head to bolt shank as shown in Figure 3 61 Figure 3 61 Frame Side Bearing Bolt Feeler Gauge Check d Check a sample of bolts in this 90 quadrant 45 left and right of indicated position of the bolt circle e Swing turntable 90 degrees and check selected bolts at the new position f Continue rotating turntable at 90 degree intervals until a sampling of bolts have been checked in all...

Page 160: ...ted and centered e Center platform and keep it unloaded 2 Set up dial indicator as follows a Locate dial indicator at rear center of machine next to bearing and opposite counterweight b Position magnetic base of the indicator on vertical member of frame as shown in Figure 3 64 Figure 3 64 Dial Indicator General Location c Position indicator point to measure turntable base plate on doubling plate 3...

Page 161: ...turntable bearing if any of the following condi tions exist a Bearing wear measurement is greater than allowed in Table 3 7 NOTE If bearing markings are illegible use 0 179 in 4 54 mm as the wear measurement b Increased swing power required c Noise is present when turntable is rotated d Rough operation when turntable is rotated Table 3 6 Bearing Model Marking Identification Model Marking 1 1234567...

Page 162: ...SECTION 3 CHASSIS TURNTABLE 3 108 3121171 Figure 3 68 Turntable Bearing Service Boom Placement 1 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 163: ...SECTION 3 CHASSIS TURNTABLE 3121171 3 109 Figure 3 69 Turntable Bearing Service Boom Placement 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 164: ...SECTION 3 CHASSIS TURNTABLE 3 110 3121171 Figure 3 70 Turntable Bearing Service Boom Placement 3 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 165: ...frame Move bearing to a clean suitably supported work area Turntable Bearing Installation 1 Using suitable lifting equipment carefully lower turnta ble bearing into position on frame Ensure scribed line of bearing outer race aligns with scribed line on frame If a new turntable bearing is used ensure spot with mini mum gear backlash stamped with an X or marked with yellow paint is towards centerlin...

Page 166: ...CTION 3 CHASSIS TURNTABLE 3 112 3121171 0 1 2 3 1 4 5 3 3 0 2 4 4 6 7 8 4 9 0 3 1 4 4 Figure 3 71 Turntable Bearing Removal G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 167: ... tagged before removal 14 At ground control station use boom lift control to lower boom to stowed position 15 Using all applicable safety precautions activate hydrau lic system and check swing system for proper and safe operation CHECK FOR MISSING OR LOOSE INNER AND OUTER TURNTABLE BEARING BOLTS AFTER FIRST 50 HOURS OF OPERATION AND EVERY 600 HOURS THERE AFTER Figure 3 72 Turntable Bearing Torque ...

Page 168: ... used with the Beyond Transport Drive Speed Cutback System Section 4 3 Beyond Transport Drive Speed Cutback System the tilt sensor will cause an alarm to sound and automatically place all functions in creep speed mode With the exception of the speed cutback this is a warning sys tem only indicating to the operator the machine has reached the out of level limit The machine will continue to function...

Page 169: ...seals 5 Assemble lip seals in direction shown in Figure 3 73 Rotary Coupling Seal Installation 6 Reassemble O ring 7 Heat cap seals in hydraulic oil for 5 minutes at 300 F 149 C 8 Assemble cap seals over O rings 9 Reinsert center body into housing lube with hydraulic oil 10 Replace thrust ring and snap ring Figure 3 73 Rotary Coupling Seal Installation G o t o D i s c o u n t E q u i p m e n t c o...

Page 170: ...olt 3 Bolt 4 Swivel Bracket 5 Rotary Coupling Collector Ring Assembly 5A Rotary Coupling 5B Rotary Circuit Contactor 6 Locknut 7 Not Used 8 Flatwasher 9 Nut Figure 3 74 Rotary Coupling Installation G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 171: ...SECTION 3 CHASSIS TURNTABLE 3121171 3 117 Figure 3 75 Rotary Coupling Port Location G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 172: ...he generator If operating in a hostile environment clean monthly Table 3 8 Coupling Port Information Table Port No Port Size Description Operating Pressure PSI Bar Proof Pressure PSI Bar 1 12 Return 250 17 375 26 2 10 Steer AxleExtend Pressure 3000 207 4500 310 3 10 DriveA 5000 345 7500 517 4 10 DriveB 5000 345 7500 517 5 10 DriveA Osc AxleLock 5000 345 7500 517 6 10 DriveB Osc AxleLock 5000 345 7...

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