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Oshkosh JLG 1500SJ, Service And Maintenance Manual

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3121262

– JLG Lift –

ix

                                      

TABLE OF CONTENTS

SECTION NO.                                  TITLE

                                                                      

       PAGE NO

.

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

Installation of Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
AMP Seal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Exclusions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5

7.4

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-7
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-9
Wedge Lock  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-9
Service - Voltage Reading  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-9

7.5

Deutsch Connectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-11
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-12
HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7-12

Summary of Contents for JLG 1500SJ

Page 1: ...Service and Maintenance Manual Model 1500SJ P N 3121262 March 7 2016...

Page 2: ......

Page 3: ...raulic 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...

Page 4: ...262 REVISON LOG Original Issue September 12 2011 Revised November 9 2011 Revised March 26 2012 Revised May 16 2012 Revised January 10 2013 Revised February 20 2013 Revised May 22 2013 Revised Septembe...

Page 5: ...1 Annual Machine Inspection 2 1 Preventive 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 Disas...

Page 6: ...llation 3 16 Installation of the Wheel Drive on the Machine 3 16 Start Up and Running In 3 16 General Information 3 17 Connecting the Brake 3 17 Filling up the Gearbox with Lubricating Oil 3 17 Gearbo...

Page 7: ...e Swing Bearing Removal 3 100 Turntable Swing Bearing Installation 3 112 Swing Bearing Torque Values 3 119 3 19 Swing Speed Proportioning 3 120 3 20 Chassis Tilt Indicator System 3 120 3 21 Generator...

Page 8: ...5 DTC 563 Battery Voltage VBat High 3 167 DTC 601 Microprocessor Failure FLASH 3 169 DTC 604 Microprocessor Failure RAM 3 171 DTC 606 Microprocessor Failure COP 3 173 DTC 642 5 Volt External Low Volta...

Page 9: ...ing Axle Extend Retract Restrictions 4 10 Dual Capacity 4 10 Jib Control During Over Under Moment 4 10 Boom Recovery Mode 4 10 4 3 Boom Removal and Installation 4 12 Removal 4 12 Installation 4 14 4 4...

Page 10: ...g Methods 5 4 Assembly And Torque Specifications 5 5 Assembly Instructions for American Standard Pipe Thread Tapered NPTF Connections 5 6 Assembly Instructions for British Standard Pipe Thread Tapered...

Page 11: ...t the Jib Valve 5 124 5 7 Drive Pumps 5 130 Troubleshooting Procedure 5 130 Charge Pressure Relief Valve Adjustment 5 133 Mechanical Centering of Pump 5 134 Hydraulic Centering of Control Modules 5 13...

Page 12: ...Lock Pin Switch 6 40 Sensor 8 Jib Stow Angle Sensor 6 40 Sensor 9 Jib Lift Cylinder Angle Sensor 6 40 Sensor 10 Dual Capacity Jib Transport Length Switches 6 41 Sensor 11 Platform Level Cylinder Angle...

Page 13: ...asurement 7 2 Current Measurement 7 3 7 3 Applying Silicone Dielectric Compound to Electrical Connections 7 3 Installation of Dielectric Grease 7 4 Deutsch HD DT DTM DRC Series 7 4 AMP Seal 7 4 AMP Ma...

Page 14: ...x JLG Lift 3121262 TABLE OF CONTENTS SECTION NO TITLE PAGE NO This page left blank intentionally...

Page 15: ...ive Hub 3 24 3 18 Drive Hub Special Tools Sheet 1 of 4 3 42 3 19 Drive Hub Special Tools Sheet 2 of 4 3 43 3 20 Drive Hub Special Tools Sheet 3 of 4 3 44 3 21 Drive Hub Special Tools Sheet 4 of 4 3 45...

Page 16: ...2 of 5 3 137 3 74 EMR2 Fault Codes Sheet 3 of 5 3 138 3 75 EMR2 Fault Codes Sheet 4 of 5 3 139 3 76 EMR2 Fault Codes Sheet 5 of 5 3 140 3 77 1st page of Diagnostic Information for a Given Fault 3 143...

Page 17: ...val 5 52 5 20 Composite Bearing Installation 5 53 5 21 Rod Seal Installation 5 53 5 22 Cylinder Head Seal Installation 5 53 5 23 Wiper Seal Installation 5 54 5 24 Installation of Head Seal Kit 5 54 5...

Page 18: ...t 5 74 5 75 Boom Lift Cylinder 5 75 5 76 Tapered Bushing Removal 5 76 5 77 Composite Bearing Installation 5 77 5 78 Rod Seal Installation 5 77 5 79 Cylinder Head Seal Installation 5 77 5 80 Wiper Seal...

Page 19: ...109 5 136 Jib Control Valve Identification Sheet 2 of 2 5 110 5 137 Jib Control Valve Torque and Resistance Specifications Sheet 1 of 2 5 111 5 138 Jib Control Valve Torque and Resistance Specificatio...

Page 20: ...30 Boom Sensor Calibration Position 10 6 103 6 31 Fault Code Light Location 6 108 7 1 Voltage Measurement DC 7 1 7 2 Resistance Measurement 7 2 7 3 Continuity Measurement 7 2 7 4 Current Measurement D...

Page 21: ...x Wiring Diagram Sheet 2 of 2 7 39 7 47 Electrical Schematic Sheet 1 of 18 7 41 7 48 Electrical Schematic Sheet 2 of 18 7 42 7 49 Electrical Schematic Sheet 3 of 18 7 43 7 50 Electrical Schematic Shee...

Page 22: ...uration 3 147 4 1 Troubleshooting 4 104 5 1 NPTF Pipe Thread 5 6 5 2 BSPT Pipe Thread 5 7 5 3 37 Flare JIC Thread Steel 5 9 5 4 37 Flare JIC Thread Aluminum Brass 5 10 5 5 45 Flare SAE Steel 5 12 5 6...

Page 23: ...31 Flange Code FL61 FL62 Inch Fasteners 5 45 5 32 Flange Code FL61 FL62 Metric Fasteners 5 46 5 33 Platform Valve Specifications 5 107 5 2 Fitting Torque Specifications 5 108 5 33 Platform Valve Speci...

Page 24: ...xx JLG Lift 3121262 LIST OF TABLES TABLE NO TITLE PAGE NO This page left blank intentionally...

Page 25: ...0psi 317Bar Table 1 2 Dimensional Data TurningRadius AxlesRetracted Outside Inside 22ft 6in 6 8m 14ft 5in 4 4m TurningRadius AxlesExtended Inside Outside 8ft 2 4m 19ft 4in 5 9m MachineHeight stowed 9f...

Page 26: ...Size 12 00 24 Tire WheelWeight 960lbs 435 4kg MaxTireLoad 28600lbs 12973kg Table 1 5 Deutz TD2011L4 Specifications Type LiquidCooled NumberofCylinders 4 Bore 3 7in 94mm Stroke 4 4in 112mm TotalDisplac...

Page 27: ...Lb Gal 60 F 7 35 Pour Point Max 46 F 43 C Flash Point Min 442 F 228 C Viscosity Brookfield cPat 18 C 2700 at40 C 55cSt at100 C 9 3cSt ViscosityIndex 152 Table 1 7 Hydraulic Oil Hydraulic System Opera...

Page 28: ...1 12 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 this oil be c...

Page 29: ...SECTION 1 SPECIFICATIONS 3121262 JLG Lift 1 5 4 4 4 15 4 5 13 7 8 1 10 11 9 12 14 2 3 6 16 16 Figure 1 1 Maintenance and Lubrication Diagram...

Page 30: ...l Plug Capacity 79 ounces 2 3 L Lube GL 5 Interval Check level every 150 hrs Change every 1200 hours of operation Fill to cover ring gear 3 Swing Brake Lube Point s Fill Plug Capacity 2 7 ounces 80 ml...

Page 31: ...t s Level Fill Plug Capacity 0 5 quarts 0 5 liters 10 Lube EPGL Interval Change after first 150 hours then every 1200 hours of operation Comments Place Fill port at 12 o clock position and Check port...

Page 32: ...Cap Spin on Element Capacity 5 Quarts 4 5 L Cooling System 11 Quarts 10 5 L w Filter 16 Quarts 15 L Total Capacity Lube EO Interval Check level daily change every 500 hours or six months whichever co...

Page 33: ...Fuel Strainer Deutz Lube Point s Replaceable Element Interval Every year or 600 hours of operation 12 Oil Change w Filter CAT Lube Point s Fill Cap Spin on Element Capacity 10 5 Quarts 10 L Lube EO I...

Page 34: ...indicated by the condition indicator 15 Platform Filter Lube Point s Replaceable Element Interval Change after first 50 hours and then every year or 600 hours of operation thereafter 16 Boom Lube Poin...

Page 35: ...SECTION 1 SPECIFICATIONS 3121262 JLG Lift 1 11 Figure 1 3 Torque Chart Sheet 1 of 5 SAE Fasteners Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue...

Page 36: ...SECTION 1 SPECIFICATIONS 1 12 JLG Lift 3121262 Figure 1 4 Torque Chart Sheet 2 of 5 SAE Fasteners Torq ue Tor que Torq ue Torqu e To rqu e...

Page 37: ...SECTION 1 SPECIFICATIONS 3121262 JLG Lift 1 13 Figure 1 5 Torque Chart Sheet 3 of 5 SAE Fasteners Cl amp L oa d To rque To rqu e Torq ue Torqu e Tor que Torq ue...

Page 38: ...SECTION 1 SPECIFICATIONS 1 14 JLG Lift 3121262 Figure 1 6 Torque Chart Sheet 4 of 5 METRIC Fasteners To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue...

Page 39: ...SECTION 1 SPECIFICATIONS 3121262 JLG Lift 1 15 Figure 1 7 Torque Chart Sheet 5 of 5 METRIC Fasteners Torq ue To rqu e Tor qu e To rqu e To rqu e To rq ue...

Page 40: ...SECTION 1 SPECIFICATIONS 1 16 JLG Lift 3121262 NOTES...

Page 41: ...r 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 f...

Page 42: ...their 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 et...

Page 43: ...against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the ori...

Page 44: ...se oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil supplied with the machine consult local sup plier for assistance in selecting the prop...

Page 45: ...e cleaned with a solvent to remove all 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 ensu...

Page 46: ...2 1 2 WearPads 1 2 1 2 CoversorShields 1 2 1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 BoomAssembly 14 PlatformAssembly Platform 1 2 Railing 1 1 2 Gate 5 1 1 5 Floor 1 1 2 Rotator 9 5 15 Lanyar...

Page 47: ...Pumps 1 9 1 2 9 HydraulicCylinders 1 9 7 2 1 2 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 9 1 2 1 2 HydraulicHoses Lines andFittings 1 9 12 1 2 9 12 1 2 9 12 HydraulicReservoir Cap andBreather 1...

Page 48: ...ation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwhenreleased 7 Cleanand...

Page 49: ...180 F 82 C 40 F 40 C 30 F 34 C 20 F 29 C 10 F 23 C 0 F 18 C 10 F 12 C 20 F 7 C 30 F 1 C 40 F 4 C 50 F 10 C 60 F 16 C 70 F 21 C 80 F 27 C 90 F 32 C 100 F 38 C 110 F 43 C 120 F 49 C AMBIENT AIR TEMPERAT...

Page 50: ...A HYDRAULIC OIL COOLER CONSULT JLG SERVICE 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 ABO...

Page 51: ...been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without writte...

Page 52: ...xles not fully extended the boom is restricted to operation within the transport position If a signal from any axle extend sensing switch is lost when the boom beyond the transport position the axle s...

Page 53: ...lected steering mode based on the position of the inside front wheel If the steer select switch is changed without the footswitch depressed or the EMS is off the wheels will not move until the footswi...

Page 54: ...ment of the drive steer control 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 sy...

Page 55: ...t or Right arrow key until you see Press ENTER the screen should read Swing and drive functions can now be used to swing the turn table in the correct direction to return the boom between the rear whe...

Page 56: ...SECTION 3 CHASSIS TURNTABLE 3 6 JLG Lift 3121262 Figure 3 5 Chassis Component Location Sheet 1 of 2...

Page 57: ...tionValve 6 SteerValve Rear 7 SteerAngleSensor RightRear 8 AxleLimitSwitch RightRear 9 AxleLimitSwitch LeftRear 10 SteerAngleSensor LeftRear 11 ChassisModule 12 Swivel CollectorRing 13 AxleLockoutPres...

Page 58: ...SECTION 3 CHASSIS TURNTABLE 3 8 JLG Lift 3121262 Figure 3 7 Turntable Component Location Sheet 1 of 2...

Page 59: ...lTemperatureSwitch 9 OilPressureSwitch 10 IntakeHeaters 11 In HeadGlowPlugs 12 EngineSpeedSensor 13 Starter 14 DrivePumps 15 StarterRelay 16 GlowPlugRelay 17 Swivel 18 Alarm 19 MainControlValve 20 Aux...

Page 60: ...121262 3 1 2 6 DETAIL A DETAIL B 5 4 Figure 3 9 Oscillating Axle Sheet 1 of 2 AXLESTOPSHIMMINGPROCEDURE 1 ALLFOURWHEELSOFTHEMACHINESHOULD BEONALEVEL SURFACEWITHTHETURNTABLESQUARETOTHEFRAME 2 SHIMAXLES...

Page 61: ...latesofAxleWeldments Typical16Places D AssembletoFrontandRearPlatesofAxleBoxes Typical8Places E AssembletoTopPlateofAxleWeldment Typical4Places Torque Selectappropriatebolttoensure0 5 0 062inches 12 7...

Page 62: ...SECTION 3 CHASSIS TURNTABLE 3 12 JLG Lift 3121262 Figure 3 11 Axle Loctite Application...

Page 63: ...r Assembly 3 Steer Cylinder 4 Steer Cylinder Pivot Pin 5 King Pin 6 Axle Figure 3 12 Steering Installation Table 3 2 Steering Assembly Notes A ApplyJLGThreadlockerP N0100011 B ApplyJLGThreadlockerP N0...

Page 64: ...DING 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 inder is f...

Page 65: ...lly drive machine up ascension ramp until left front wheel is on top of block 5 Telescope the boom out of the transport position 6 Drive machine off of block and ramp back onto the level surface 7 Hav...

Page 66: ...fitted 2 Torque the bolts to 63 5 ft lbs 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 Atta...

Page 67: ...raphic documentation and drawings are supplied for educational purposes so as to safely and properly carry out maintenance operations Minor deviations from pictures of this manual may appear on the ac...

Page 68: ...SECTION 3 CHASSIS TURNTABLE 3 18 JLG Lift 3121262 Figure 3 14 Hub Assembly 1 M18x1 5 Filling drainingandoillevelplugs 2 7 16 20UNF 2B Brakeport...

Page 69: ...ew minutes stop and check the oil level 5 If necessary refill with lubricant oil Approximate oil capacity 2 liters 10 Gearbox Disengagement The gearbox is supplied with mechanical disengagement THE DI...

Page 70: ...1 Unscrew the 2 socket head screws M8x16 4 grade 8 8 of the end cover 7 with a male hex head wrench 2 Rotate the cap nut 5 3 Take out the cap nut 5 4 Turn the cap nut 5 upside down As result the pin 3...

Page 71: ...le the gearbox Changing the Lubricating oil 1 Check that the gearbox axis is horizontal Rotate the gearbox housing until the drain plug is on the bottom of the vertical axis of the end cover 2 Unscrew...

Page 72: ...a that is in line with work and health safety in the workplace guidelines Disassembly Procedure NOTE Below are all the steps to follow during Disassembly and Assembly Numbers in brackets in the text c...

Page 73: ...il it compresses the springs 45 2 Remove the circlip 47 and remove the special tool 3 Remove the spring retainer disc 46 4 Mark the position of the springs 45 as a reference for the reassembly 5 Remov...

Page 74: ...17 2ndStageSunGear 18 2ndReductionAssembly 19 Circlip 20 3rdReductionAssembly 21 Spacer 22 RingNut 23 GearboxHousing 24 Bearing 25 Spacer 26 Spacer 27 O ring 28 Spacer 29 HalfSeal 30 SealRing 31 Flan...

Page 75: ...move the spacer 39 from the brake piston 44 9 Remove the internal O Ring seal 41 and the backup ring 40 from their seat in the spacer 39 10 Remove the external O Ring seal 38 and the backup ring 37 fr...

Page 76: ...l tool 6689960240 15 Tighten the 2 screws M5x16 grade 8 8 of the cover by a torque wrench to 18 4 ft lbs 25 Nm 16 By using pliers remove the elastic ring 11 from the splined shaft 14 17 Remove the spe...

Page 77: ...he cap nut 5 20 Remove the pin 3 21 Remove the O ring seal 2 from its seat in the end cover 7 22 Unscrew the draining filling level oil plugs 6 by a male hex head wrench 23 Unscrew the 10 screws M10X2...

Page 78: ...9 from its seat in the end cover 7 26 Remove the 1st stage sun gear 10 27 Remove the 1st reduction assembly 16 28 Remove the 2nd stage sun gear 17 29 Remove the 2nd reduction assembly 18 30 By using...

Page 79: ...ub 31 NOTE In order to proceed with the gearbox disassembly it is now necessary to remove it from the machine and bring it to a properly equipped workshop 33 By using a drill remove the caulkings on t...

Page 80: ...f seal 29 from the flanged hub 31 41 By using a screwdriver remove the 2nd half seal 29 from the gearbox housing 23 NOTE The gearbox disassembly ends with the above operation All items are now availab...

Page 81: ...ces in contact with or C must be perfectly clean and dry b Make sure that sealing surfaces D of metal rings E are free from scratches dinges or foreign sub stances metallic ring surfaces must be perfe...

Page 82: ...n the seal ring 30 AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL 29 8 By using a hoist place the gearbox housing 23 on the flanged hub 31 9 By using a press and a metallic stopper push the ge...

Page 83: ...nch with an input multiplier torque of 71 3 ft lbs 96 5 4 5 Nm corresponding to an output multiplier torque of 3688 184 ft lbs 5000 250 Nm 12 Stake the ring nut 22 near 2 seats at 180 of the flanged h...

Page 84: ...assemblies of the 3rd reduction 20 against the shoulder until assembly is complete 16 By using pliers assemble the circlips 19 in the flanged hub pin seats 31 17 Assemble the 2nd reduction assembly 18...

Page 85: ...10x25 1 grade 12 9 by a torque wrench at 62 7 ft lbs torque 85 Nm 24 Insert the plugs 6 into the oil draining filling holes of the end cover 7 Torque the plugs to 52 7 ft lbs 70 10 Nm 25 Assemble the...

Page 86: ...Torque the 2 screws M8x16 4 grade 8 8 to 18 4 ft lbs 25 Nm 29 Insert the 1st washer 12 in the splined shaft 14 30 Insert the spring 13 in the splined shaft 14 31 Insert the splined shaft 14 in the equ...

Page 87: ...Nm 34 By using pliers assemble the elastic ring 11 into its seat in the splined shaft 14 35 Insert the disengagement shaft kit 15 in the flanged hub 31 36 By using pliers assemble the circlip 36 into...

Page 88: ...scs and 4 steel discs have been assembled 40 Fit the internal O ring seal 41 and the backup ring 40 into their seats in the spacer 39 41 Fit the external O ring seal 38 and the backup ring 37 into the...

Page 89: ...ls A and backup rings B must be fitted in the seats according the mutual position as shown in the scheme 45 Insert the brake piston 44 inside the flanged hub 31 paying attention not to damage the seal...

Page 90: ...g retainer disc 46 49 Install the special tool 6689960310 on the flanged hub 31 and turn the screw until it compresses the springs 45 50 Assemble the circlip 47 in its seat and remove the spe cial too...

Page 91: ...ith the manometer with a base scale of 100 bars to the brake release port 2 Open the flow valve and release the brake with the pilot pressure of 50 bar 3 Close the flow valve and keep the brake releas...

Page 92: ...SECTION 3 CHASSIS TURNTABLE 3 42 JLG Lift 3121262 Figure 3 18 Drive Hub Special Tools Sheet 1 of 4...

Page 93: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 43 Figure 3 19 Drive Hub Special Tools Sheet 2 of 4...

Page 94: ...SECTION 3 CHASSIS TURNTABLE 3 44 JLG Lift 3121262 Figure 3 20 Drive Hub Special Tools Sheet 3 of 4...

Page 95: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 45 Figure 3 21 Drive Hub Special Tools Sheet 4 of 4...

Page 96: ...ed for assembling and disassembling 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 mounti...

Page 97: ...ECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 47 LOCTITE 2701 197 5 210 110 30 130 210 N 4 Hole to 90 40 25 5x45 M 1320 M 1321 Figure 3 24 Bearing Spacer Mounting CO16117 Figure 3 25 Assembly Diagram...

Page 98: ...Figure 3 26 Wrench For Ring Nut A A 50 180 275 305 n 12 Fori a 30 35 20 H7 0 021 0 n 12 Hole to 30 n 12 Hole to 30 6 5 n 12 Spot facing to 30 10 5 n 4 Hole to 90 M10 20 6 5 T U 15 32 10 5 80 3 0 3 0 3...

Page 99: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 49 M 1020 M 1126 M 1125 VTCEI M6X12 n 12 VTCEI M10X60 n 4 M 1126 Figure 3 30 Assembly Diagram 2...

Page 100: ...ift 3121262 46 48 5 70 5 80 50 88 5 3 5 M8 20 0 0 1 20 0 1 0 2 93 5 105 8 5 13 5 9 20 8 5 5 t u 12 2 5x15 39 5 M 1546 M 1548 M 1547 40 5 46 VTCEI M8X16 n 1 Figure 3 31 Tools For Assembling Bearing 3rd...

Page 101: ...he lubricant in a container 2 Release the screws to disassemble the motor flange tak ing care not to damage the O Ring 3 Release the screws from the release cover and pull the pin out 4 Remove the BR2...

Page 102: ...SECTION 3 CHASSIS TURNTABLE 3 52 JLG Lift 3121262 Figure 3 32 Reggiana Riduttori Hub Sheet 1 of 2...

Page 103: ...0 Input Shaft Bearing 21 Ring 22 Disengagement 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 Gear...

Page 104: ...Remove the release joint together with the spring 8 Disassemble the 40 outer snap rings and using an extractor remove the planetary gears from the spindle pins 9 Loosen the M6x6 socket headless screw...

Page 105: ...14 Fit the ball bearing into the input shaft and lock it with a 40 outer snap ring Then mount the motor shaft in the spindle and lock with a BR68 ring Lubricate the bearing Assembly 1 Make sure all t...

Page 106: ...160 inner snap ring Check the brake leakage if any as well as the static torque and minimum opening pressure 6 Prepare the hub support mounting on it the two roller bearing outer tracks Place the fir...

Page 107: ...t the final torque of 30daNm alter nate tightening and some setting turns Check the roll torque with seal which must be within 1 1 5 daNm NOTE Place the ring nut with its convex part facing the roller...

Page 108: ...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 the hub onto the support making the two h...

Page 109: ...ng it with the BR250 ring 19 Fit the O Ring 2 163 suitably greased onto the motor coupling flange S D LC KC Mount the flange on the spindle with 6 M8x25 socket cap screws at the torque of 2 4daNm with...

Page 110: ...ECTION 3 CHASSIS TURNTABLE 3 60 JLG Lift 3121262 1 SwingDrive 2 InnerRaceBearingBolt 3 SwingBearing 4 OuterRaceBearingBolt 5 TurntableLockPin 6 RemoteBearingLubricationFittings Figure 3 34 Swing Syste...

Page 111: ...ith consistency 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 air checker starts to f...

Page 112: ...ench 4 Using a wrench loosen jam nuts on Elbow Fittings 36 and remove fittings from Brake 26 and Motor Control Valve 32 5 Remove O ring Plugs 21 from Motor Control Valve 32 6 Remove Motor Control Valv...

Page 113: ...otor 10 2 Pull Motor 10 straight up and remove Motor 10 from Brake 26 3 Remove Gasket 31 from between Brake 26 and Motor 10 4 Remove Brake 26 from Main Torque Hub Assembly and dump oil out of Brake 26...

Page 114: ...4 Remove Thrust Washer 8 from end of Sun Gear 13 5 Remove Sun Gear 13 6 Remove Thrust Washers 16 and Thrust Bearing 15 from between Input Cover 6 and Carrier 3A Subas sembly 7 Remove Ring Gear 4 from...

Page 115: ...Bearing Cone 1D during this step 4 Remove the Bearing Cone 1F from the Housing 1G 5 Invert the Housing 1G and remove the Lip Seal 1B if not already removed when Output Shaft 1A was pressed out of Hou...

Page 116: ...Planet Shaft 3E from the Carrier 3A Use a small punch to remove the Roll Pin 3G from the Planet Shaft 3E 3 Slide the Planet Gear 3F two Ball Indented Thrust Washers 3H and the two Thrust Washers 3B o...

Page 117: ...8 Press or tap the Bearing Cone 1F onto the Output Shaft 1A until it is seated in the Bearing Cup 1E 9 Install Bearing Spacer 1H onto Output Shaft 1A and against Bearing Cone 1F 10 Install Retaining R...

Page 118: ...e end of Cluster Gear 3F facing the roll pin hole in the carrier place the cluster gear into position in Carrier 3A and push Planet Shaft 3E through the Clus ter Gear 3F without going all the way thro...

Page 119: ...ASSIS TURNTABLE 3121262 JLG Lift 3 69 3A Carrier 3B TangedThrustWasher 3C NeedleBearing 3D ThrustWasher 3E PlanetShaft 3F ClusterGear 3G RollPin 3H BallIndentedWasher Figure 3 41 Swing Drive Carrier S...

Page 120: ...ASSIS TURNTABLE 3 70 JLG Lift 3121262 3A Carrier 3B TangedThrustWasher 3C NeedleBearing 3D ThrustWasher 3E PlanetShaft 3F ClusterGear 3G RollPin 3H BallIndentedWasher Figure 3 42 Swing Drive Carrier S...

Page 121: ...installation The side of the Ring Gear 4 with an X or punch mark stamped 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...

Page 122: ...NTABLE 3 72 JLG Lift 3121262 2 InternalGear 4 RingGear 5 O Ring 6 InputCover 8 HexBolt 13 SunGear 15 ThrustBearing 16 ThrustWasher 17 HexBolt 18 ShoulderBolt 19 Lockwasher 20 PipePlug Figure 3 43 Swin...

Page 123: ...the holes 3 Place Motor 10 into Brake pilot against the Gasket 31 4 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 fla...

Page 124: ...o 15 ft lbs 18 to 21 Nm 4 Assemble Tube 35 into Elbow Fittings 36 and torque 13 to 15 ft lbs 18 to 21 Nm 5 Install O ring Plugs 21 into Motor Control Valve 32 and torque 30 to 31 ft lbs 42 to 43 Nm 6...

Page 125: ...e Remove hydraulic supply from brake checking to ensure that the friction plates 3 6 have engaged thus preventing rota tion of brake shaft 1 RELEASE PRESSURE DURING BENCH TESTING SHOULD BE LIMITED TO...

Page 126: ...sembly can now be fully dismantled and parts examined 2 Remove 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...

Page 127: ...rrect brake operation it is important that the backing rings are assembled opposite ti the pressurized side of piston 9 5 Correctly orientate piston 9 aligning spaces with the two dowel pin holes and...

Page 128: ...5 Gasket 6 OuterPlate 7 Gasket 8 Cylinder 9 Piston 10 DeepGrooveBallBearing 11 InternalRetainingRing 12 RotaryShaftSeal 13 SocketHeadCapScrew 14 ShakeproofWasher 15 O Ring 16 BackingRing 17 O Ring 18...

Page 129: ...cross the Torq link components from end cover 2 to housing 18 to facilitate reassembly orientation where required Loosen two shuttle or relief valve plugs 21 for disassembly later if included in end c...

Page 130: ...ded the orifice plug in the end cover 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 Comm...

Page 131: ...close inspection of end cover commutator manifold 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 commu...

Page 132: ...ing service procedures Marking the surface of 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 stato...

Page 133: ...ns of rust and corrosion which might prevent 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...

Page 134: ...anging dimen sional characteristics Inspect tapped holes for thread damage If the housing is defective in these areas dis card the housing assembly 21 If the housing 18 assembly has passed inspection...

Page 135: ...the beginning of bearing bushing counter bore should be measured and noted before removing the bearings bushings This will facilitate the correctreassembly ofnewbearings bushings 22 If the bearings b...

Page 136: ...ng components were removed for replacement thoroughly coat and pack a new outer bearing bushing 19 with clean corrosion resistant grease recommended in the material section Press the new bearing bushi...

Page 137: ...flush to 0 03 inch 76 mm below the housing wear plate contact face Use the opposite end of the bearing mandrel that was used to press in the outer bearing bushing 19 3 Press a new dirt and water seal...

Page 138: ...UP WASHER 25 WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER 17 NEW BACKUP WASHER 25 AND NEW SEAL 16 6 Assemble thrust washer 14 then thrust bearing 15 that was removed from the Torqlink...

Page 139: ...nsert it into the housing 18 seal ring groove NOTE One or two alignment studs screwed finger tight into housing 18 bolt holes approximately 180 degrees apart will facilitate the assembly and alignment...

Page 140: ...n the original rotor drive link spline contact A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines...

Page 141: ...onto manifold 7 with seal ring side up 19 If shuttle valve components items 21 were removed from the end cover 2 turn a plug 21 loosely into one end of the valve cavity in the end cover A 3 16 inch A...

Page 142: ...her components into place with a final torque of 22 26 ft lbs 45 55 ft lbs 61 75 N m for the seven 3 8 24 threaded bolts NOTE The special bolts required for use with the relief or shuttle valve 24 end...

Page 143: ...nk 10 splines NOTE If the manifold side of the rotor was etched during Torqlink disassembly this side should be up If the rotor is not etched and does not have a counterbore use the drive link spline...

Page 144: ...stamped with an X on the surface below the teeth and marked with yellow paint in the tooth space 3 Torque the shoulder screw shown below to 660 foot pounds 896 Nm with Loctite 271 4 Remove the turntab...

Page 145: ...rbox is to be filled with 79 ounces 2 3 L of API Service Classification GL 5 Extreme Pressure Gear Lube Fill to cover the ring gear The Swing Brake is to be filled half full 2 7 ounces 80 ml with DTE2...

Page 146: ...existing bolts for looseness 1 Check the frame to bearing attach bolts as follows a Fully elevate the main boom See Figure 3 53 b At the position indicated on Figure 3 53 try to insert a 0 0015 feele...

Page 147: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 97 Figure 3 53 Swing Bearing Tolerance Boom Placement Sheet 1 of 2...

Page 148: ...SECTION 3 CHASSIS TURNTABLE 3 98 JLG Lift 3121262 Figure 3 54 Swing Bearing Tolerance Boom Placement Sheet 2 of 2...

Page 149: ...own in Figure 3 54 Swing Bearing Tolerance Boom Placement Sheet 2 of 2 Read the measurement recorded on the dial indicator gauge 3 If the measurement is greater than 0 094 in 2 387 mm the swing bearin...

Page 150: ...Lower the platform to the ground or onto blocking to support the weight of the jib 2 Tag and disconnect the electrical harnesses that run to the jib If necessary loosen the guide block to allow the ha...

Page 151: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 101 Figure 3 56 Swing Bearing Removal Sheet 1 of 4...

Page 152: ...SECTION 3 CHASSIS TURNTABLE 3 102 JLG Lift 3121262 Boom Jib Assembly 20 650 lbs 9 370 kg 287 729 cm Main Boom Pivot CENTER OF GRAVITY Figure 3 57 Swing Bearing Removal Sheet 2 of 4...

Page 153: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 103 Boom Assembly 10 791 lbs 4 895 kg Main Boom Pivot 227 576 5 cm CENTER OF GRAVITY Figure 3 58 Swing Bearing Removal Sheet 3 of 4...

Page 154: ...HASSIS TURNTABLE 3 104 JLG Lift 3121262 C L ROTATION Note Attach Lifting Device to Turntable Cutouts Closest to This Side of Turntable Turntable 12 850 lbs 5 825 kg Figure 3 59 Swing Bearing Removal S...

Page 155: ...l 7 Disconnect the jib protractor sensor linkage from the boom 8 Remove the bolt and keeper pin securing the jib level cylinder pivot pin and remove the pin Place blocking or a soft material under the...

Page 156: ...es that run from the powertrack to the ground control station The connector inside the ground control box will have to be removed from the wires to allow the harness to be pulled out of the control bo...

Page 157: ...4 Have a container or absorption material ready to catch residual hydraulic fluid Disconnect the pressure hose from the end of the main control valve Cap or plug all openings 15 Remove the cover from...

Page 158: ...evice to support the weight of the boom lift cylinder NOTE To assist in determining when the lift cylinder is properly supported use the JLG Analyzer and select Diagnostics Moment Actual Moment and ge...

Page 159: ...ulic fluid NOTE The hood assembly weighs approximately 72 lbs 33 kg 26 Attach an adequate lifting device to the rear hood assembly 27 Remove the attaching hardware securing the side of the hood 28 Rem...

Page 160: ...s to the center sup port to prevent any damage to the hoses during the remainder of the procedure 33 Remove the hardware securing the swing brake to the swing drive and lay the swing brake and motor t...

Page 161: ...emove the swing bearing inner race bolts Remove the bolts on the inside of the turntable first leaving 3 4 bolts on both sides of the outside of the turntable to be removed last NOTE The turntable ass...

Page 162: ...swing bearing weighs approximately 300 lbs 136 kg 41 Attach an adequate lifting device to the swing bearing and remove it from the frame Turntable Swing Bearing Installation 1 Remove the attaching har...

Page 163: ...this section 7 Install grease fittings into the bearing and also install two pins to facilitate turning the bearing by hand and for alignment of the turntable 8 Using the pins turn the bearing slowly...

Page 164: ...aving the rear lifting device in place to gain full access to all bolts and torque the bolts according to the torquing procedures in this section 14 After all swing bearing bolts are torqued the rear...

Page 165: ...15 17 Position the swing drive mounting bolts and backlash adjusting shim JLG p n 4071041 Set backlash following the procedures in this section 18 Attach the swing bearing remote lubrication lines to...

Page 166: ...s and secure the pin in place with the keeper pin and bolt Torque the bolt to 285 ft lbs 388 Nm 22 Raise the boom enough to gain access to the lift cylin der rod pivot fitting 23 Attach a lifting devi...

Page 167: ...the jib and position it in front of the boom 29 Place something under the front of the jib that will allow it to slide or move along the ground easily Attach a lift ing device to the rear of the jib a...

Page 168: ...ce with the keeper pin and bolt Torque the bolt to 165 ft lbs 224 Nm 32 Place the mounting bracket on the jib valve and bolt the jib valve to the fly boom section 33 Install the wiring harnesses and h...

Page 169: ...nd proper operation 38 Perform a boom calibration as described in Section 6 under Calibrating the Boom Sensors Swing Bearing Torque Values 1 Outer Race 190 ft lbs 258 Nm w Loctite 2 Inner Race 190 ft...

Page 170: ...settings 5 0 and 8 0 degrees The smaller angle is used for the purpose of warning the operator by means of the chassis tilt light in the platform display panel Additionally when used in conjunction wi...

Page 171: ...eck the drive belt for proper tension Every 500 hours Every 500 hours of operation service the generator brushes and slip rings Hostile environments may require more fre quent service Every 500 hours...

Page 172: ...ith slip rings View alignment through the air vents in the stator barrel The brushes must ride completely on the slip rings INSPECTING BRUSHES Remove the end panel Inspect the wires Remove the brush h...

Page 173: ...ss Replace 2 7 16 in 1 2 in 11 12 mm New 3 2 3 Brushes must ride completely on slip rings Acceptable Unacceptable Brush Position On Slip Rings Figure 3 61 Inspecting Generator Brushes Replacing Brushe...

Page 174: ...f the system the auxiliary power functionality differs from the primary power functional ity The auxiliary power lift down function supplies pilot pres sure to the lift cylinder allowing gravity to lo...

Page 175: ...the glow plugs will continue post glow after the engine has started for three times the machine digit setting Checking Oil Level 1 Switch the engine off before checking oil level 2 Make sure the mach...

Page 176: ...E OIL THERE IS A RISK OF SCALDING DO NOT LET USED OIL RUN INTO THE SOIL COLLECT THE USED OIL IN A CON TAINER SUITABLE FOR DISPOSAL OR RECYCLING DISPOSE OF THE USED ENGINE OIL IN ACCORDANCE WITH ENVIRO...

Page 177: ...ridge and make sure there are no leaks Replacing the Fuel Filter WHEN WORKING ON THE FUEL SYSTEM MAKE SURE THERE ARE NO OPEN FLAMES OR SPARKS IN THE AREA DO NOT SMOKE WHEN WORKING ON THE FUEL SYSTEM 1...

Page 178: ...s doses the fuel quantity in accordance with the performance requirements The exact position of the regulating rod is reported back and if necessary is corrected by means of the control rod travel sen...

Page 179: ...POWERSUPPLY COOLANTTEMPERATURE SENSOR CONTROLRODPOSITION SENSOR ACTUATOR FLYWHEELSPEED SENSOR OILPRESSURE SENSOR JLGSYSTEMUSESJLGANALYZERTOREPORTFAULTS DIAGNOSISINTERFACE CAN BUS JLGSYSTEMUSESTHIS TOC...

Page 180: ...detected Unplug the vehicle side engine module connector Verify there is 12V across pins 1 Ground 14 Battery Verify there is 60 Ohms across pins 12 13 CAN High Low Can you start the engine Verify the...

Page 181: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 131 Figure 3 67 Deutz EMR 2 Vehicle Side Connection Diagram...

Page 182: ...SECTION 3 CHASSIS TURNTABLE 3 132 JLG Lift 3121262 Figure 3 68 Deutz EMR 2 Engine Side Connection Diagram Sheet 1 of 2...

Page 183: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 133 Figure 3 69 Deutz EMR 2 Engine Side Connection Diagram Sheet 2 of 2...

Page 184: ...SECTION 3 CHASSIS TURNTABLE 3 134 JLG Lift 3121262 Figure 3 70 EMR 2 Engine Plug Pin Identification...

Page 185: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 135 Figure 3 71 EMR 2 Vehicle Plug Pin Identification...

Page 186: ...SECTION 3 CHASSIS TURNTABLE 3 136 JLG Lift 3121262 Figure 3 72 EMR2 Fault Codes Sheet 1 of 5...

Page 187: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 137 Figure 3 73 EMR2 Fault Codes Sheet 2 of 5...

Page 188: ...SECTION 3 CHASSIS TURNTABLE 3 138 JLG Lift 3121262 Figure 3 74 EMR2 Fault Codes Sheet 3 of 5...

Page 189: ...SECTION 3 CHASSIS TURNTABLE 3121262 JLG Lift 3 139 Figure 3 75 EMR2 Fault Codes Sheet 4 of 5...

Page 190: ...SECTION 3 CHASSIS TURNTABLE 3 140 JLG Lift 3121262 Figure 3 76 EMR2 Fault Codes Sheet 5 of 5...

Page 191: ...limit values Since experience has shown that rape seed oil methylester RME exceeds the limit values less often that other esters it is expressly recommended to use only rape seed oil methyester DEUTZ...

Page 192: ...y by heat and water Penetration by water is usually caused by condensation of the water in the air Water does not dissolve in fuel so that the pene trating water collects at the bottom of the tank The...

Page 193: ...xternal Hardware Input Output This identifies the hardware that either sends an input to the ECM or is driven by and ECM output Check Condition This defines what condition to troubleshoot the fault co...

Page 194: ...SSIS TURNTABLE 3 144 JLG Lift 3121262 DTC XXXX Diagnostic Condition Note Helpful tips used to aid troubleshooting Yes No Troubleshooting flow chart Figure 3 78 2nd Page of Diagnostic Information for a...

Page 195: ...Code PFI PortFuelInjection DVOM DigitalVoltageandOhmMeter highimpedance PGN ParameterGroupNumber ECI EControlsInc PWM PulseWidthModulated ECIPP EControlsInc ProprietaryProtocol RAM RandomAccessMemory...

Page 196: ...ilTemperature Vsw Switched IgnitionVoltage FSS FaultSnapshot WGP Waste GatePressure FT FuelTemperature GCP GlobalControlPlatform HDGCP Heavy DutyGlobalControlPlatform On RoadHeavy Duty HEGO HeatedExha...

Page 197: ...on the applica tion and engine calibration There are 4 CAN SPN FMI lists available in the DGC software set contact EControls Inc for a list of CAN SPN FMIs The data capture at the occurrence of a faul...

Page 198: ...or reading is cool the sensor reads higher voltage and lower when warm This fault will help protect the engine in the event of over tem perature When the coolant exceeds x deg F and engine RPM exceeds...

Page 199: ...is a thermistor tem perature sensitive resistor located in the engine coolant Some engines use an ECT sensor that is located in the coolant near the thermostat Some engines use a CHT Cylinder Head Te...

Page 200: ...ect ECT sensor from harness Key On Engine Off System Mode Stopped Sensor signal circuit shorted to ground check wire harness for ground short Faulty ECM Faulty ECT Sensor Yes No Does DST display an EC...

Page 201: ...hat is located in the coolant near the thermostat Some engines use a CHT Cylinder Head Temperature sensor that is located in the coolant in the cylin der head If the engine is equipped with an ECT sen...

Page 202: ...SECTION 3 CHASSIS TURNTABLE 3 152 JLG Lift 3121262...

Page 203: ...ble resistor and voltage divider circuit or 2 a non contact hall effect sensor to determine throttle actu ator position and is located within the throttle actuator There are two types of throttle actu...

Page 204: ...SECTION 3 CHASSIS TURNTABLE 3 154 JLG Lift 3121262...

Page 205: ...Throttle Position Sensor uses either 1 a variable resistor and voltage divider circuit or 2 a non contact hall effect sensor to determine throttle actu ator position and is located within the throttl...

Page 206: ...SECTION 3 CHASSIS TURNTABLE 3 156 JLG Lift 3121262...

Page 207: ...wer when warm This fault will help protect the engine in the event of over tem perature When the coolant exceeds x deg F and engine RPM exceeds y RPM for the latch time this fault will set Diagnostic...

Page 208: ...t will set anytime the engine RPM exceeds the limit set in the diagnostic calibration for the latch time or more This speed overrides any higher max governor speeds pro grammed by the user This fault...

Page 209: ...tion is used to determine crankshaft position with respect to TDC cylinder 1 compression and the rotational engine speed Determina tion of the crankshaft position and speed is necessary to prop erly a...

Page 210: ...ition that set fault based on fault snapshot Is crank sensor a VR magnetic pick up Is the wiring OK Faulty wireharness twist circuit Is wiring between sensor and ECM properly twisted No Does fault onl...

Page 211: ...position with respect to TDC cylinder 1 compression and the rotational engine speed Determina tion of the crankshaft position and speed is necessary to prop erly activate the ignition fuel injection...

Page 212: ...riction in the oil flow path or can be a sign of a malfunc tioning oiling system Additionally for normally open type oil pressure switches a high pressure indication while the engine is off is a sympt...

Page 213: ...can be undesirable because it can cause oil to leak past seals and rings can be a result of a restriction in the oil flow path or can be a sign of a malfunc tioning oiling system For systems that use...

Page 214: ...limit set in diagnostic calibration Yes Does DTC 524 reset Faulty connection at sensor Faulty ECM Faulty Oil Pressure Switch open circuit Faulty engine oiling system verify with mechanical gauge No Y...

Page 215: ...sound audible warning or illuminate secondary warning lamp disable adaptive fueling correction for remainder of key cycle Non emissions related fault The battery voltage powers the ECM and must be wi...

Page 216: ...SECTION 3 CHASSIS TURNTABLE 3 166 JLG Lift 3121262...

Page 217: ...Illuminate MIL and or sound audible warning or illuminate secondary warning lamp disable adaptive fueling correction for remainder of key cycle Non emissions related fault The battery voltage powers...

Page 218: ...SECTION 3 CHASSIS TURNTABLE 3 168 JLG Lift 3121262...

Page 219: ...ault The ECM has checks that must be satisfied each time an instruction is executed Several different things can happen within the microprocessor that will cause this fault If this fault sets the ECM...

Page 220: ...SECTION 3 CHASSIS TURNTABLE 3 170 JLG Lift 3121262...

Page 221: ...read from or written to at any time Data stored in RAM include DTCs when fault configuration is set to Battery Power Retained adaptive fuel learn tables octane adapta tion table misfire adaption table...

Page 222: ...SECTION 3 CHASSIS TURNTABLE 3 172 JLG Lift 3121262...

Page 223: ...d or overspeed condition Non emissions related fault The ECM has checks that must be satisfied each time an instruction is executed Several different things can happen within the microprocessor that w...

Page 224: ...SECTION 3 CHASSIS TURNTABLE 3 174 JLG Lift 3121262...

Page 225: ...cceptable thresh old This may be due to a short in the wire harness malfunc tioning device or failure of the ECM power output circuitry Diagnostic Aids Measure the 5 volt output of the ECM while cycli...

Page 226: ...acceptable thresh old This may be due to a short in the wire harness malfunc tioning device or failure of the ECM power output circuitry Diagnostic Aids Measure the 5 volt output of the ECM while cycl...

Page 227: ...M has checks that must be satisfied each time an instruction is executed Several different things can happen within the microprocessor that will cause this fault The ECM will reset itself in the event...

Page 228: ...M has checks that must be satisfied each time an instruction is executed Several different things can happen within the microprocessor that will cause this fault The ECM will reset itself in the event...

Page 229: ...Key On Engine Running System Data Mode Clear System Fault Does SFC 555 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circuits...

Page 230: ...M has checks that must be satisfied each time an instruction is executed Several different things can happen within the microprocessor that will cause this fault The ECM will reset itself in the event...

Page 231: ...Key On Engine Running System Data Mode Clear System Fault Does SFC 556 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circuits...

Page 232: ...has checks that must be satisfied each time an instruction is executed Several different things can happen within the microprocessor that will cause this fault The ECM will reset itself in the event...

Page 233: ...ey On Engine Running System Data Mode Clear System Fault Does SFC 513 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circuits...

Page 234: ...ECM has checks that must be satisfied each time an instruction is executed Several different things can happen within the microprocessor that will cause this fault The ECM will reset itself in the eve...

Page 235: ...pt Key On Engine Running System Data Mode Clear System Fault Does SFC 512 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circu...

Page 236: ...e secondary warning lamp Non emissions related fault In some situations external controllers may send a request to the ECM to shutdown engine operation and stop the engine This request may be sent in...

Page 237: ...de smart actuators smart sensors dash panels and gauges and other microcomputers Each smart sensor actuator or control ler incorporates a CAN transceiver that interprets logic level signals on the net...

Page 238: ...e smart actuators smart sensors dash panels and gauges and other microcomputers Each smart sensor actuator or control ler incorporates a CAN transceiver that interprets logic level signals on the netw...

Page 239: ...s may be but are not limited to other engine ECMs slave diagnostic tools smart gauges smart sensors powertrain control units vehicle con trollers actuators etc The network permits several devices to c...

Page 240: ...SECTION 3 CHASSIS TURNTABLE 3 190 JLG Lift 3121262...

Page 241: ...speed to this commanded speed if possible When operating in this mode the ECM expects to receive TSC1 mes sages on a regular interval When this message is not received the ECM must operate the engine...

Page 242: ...gital position feedback the ECM receives a constant data stream from the throttle actuator If the communication is absent or inter rupted the ECM can no longer control the position of the throttle Thi...

Page 243: ...e used to control the idle stability and limit engine speed based on operating conditions The Throttle Position Sensor uses either 1 a variable resistor and voltage divider circuit or 2 a non contact...

Page 244: ...SECTION 3 CHASSIS TURNTABLE 3 194 JLG Lift 3121262...

Page 245: ...o control the idle stability and limit engine speed based on operating conditions The Throttle Position Sensor uses either 1 a variable resistor and voltage divider circuit or 2 a non contact hall eff...

Page 246: ...that causes the throt tle to move to a near 0 position when powered off This causes the engine to shutdown following a key off If the ECM detects the throttle position to be above x volts when the key...

Page 247: ...Microprocessorfailure COP 629 31 99 DTC1612 Microprocessorfailure RTI1 629 31 100 DTC1613 Microprocessorfailure RTI2 629 31 101 DTC1614 Microprocessorfailure RTI3 629 31 102 DTC1615 Microprocessorfai...

Page 248: ...e counterweight has been removed ensure the retaining bolts are torqued to the proper value as shown in Figure 3 79 Counterweight Bolt Torque APPLY THREADLOCKER P N 0100019 TO BOLT AND THREADS IN COUN...

Page 249: ...he controls are live the enabled light will be illuminated in the platform display panel When the time limit has been reached the enabled light will turn off and the controls will be dead or disabled...

Page 250: ...FORM 4 2 JLG Lift 3121262 Figure 4 1 Boom Component Location Sheet 1 of 2 1 BoomAngleSensor 1 Right 2 BoomCableProximitySensor 3 BoomLengthSensor 4 BoomAngleSensor 2 Left 5 BoomLength AngleModule 6 Li...

Page 251: ...tomSide 9 JibControlModule 10 PlatformLevelSensor 2 Left Secondary 11 PlatformControlValve 12 PlatformLevelSensor 1 Right Primary 13 JibTransportProximitySensors 14 JibSwingRotarySensor BottomSide 15...

Page 252: ...n the envelope or when telescoping out Envelope tracking is disabled with any envelope or moment violations or failures The envelope tracking function ality and be turned off using the manual position...

Page 253: ...r action The machine can be in either capacity mode of the dual capacity system for this system check 4 2 BOOM JIB SYSTEM FUNCTIONALITY Main Lift Jib Velocity Control To improve the control of the mai...

Page 254: ...nd DOWN arrow keys will toggle the override from off to on Once turned on operating the jib lift function will cause jib level to be activated NOTE Using this override may set the JIB LEVELING SYSTEM...

Page 255: ...ed inline with the main boom or if the machine is in the stowed state Jib Swing Functionality The jib swing function is only used to stow the jib for trans port and taking the jib out of the stowed po...

Page 256: ...verride is accessible in Access Level 1 Using the Left and Right arrow keys until the screen shown below is reached Press ENTER the screen should read To enable the override mode 58237 must be entered...

Page 257: ...control system will unlock the jib lock pin and jib swing left until the jib is in line with the main boom determined by the jib swing angle sensor If the jib is in line the control system will attem...

Page 258: ...acity will be removed since the jib is restricted from swinging in all cases except when the machine is in the transport state In order to switch from the 500 capacity mode to 1000 capacity mode the j...

Page 259: ...er is pressed using the Up or Down arrow key will turn the boom recovery on or off Once turned on main boom lift down will be enabled and main telescope in will be enabled to recover the boom After th...

Page 260: ...pulled out of the control box 3 Have a container or absorption material ready to catch residual hydraulic fluid Disconnect the pressure line going into the platform filter taking care to slowly bleed...

Page 261: ...led out from the turntable 8 Using the Main Lift Crackpoint option under the Calibra tions menu lift the boom enough to access the boom lift cylinder rod pivot pin NOTE The boom assembly weighs approx...

Page 262: ...he pivot pin 12 Lower the lift cylinder until it rests on the turntable 13 Attach an adequate lifting device to support the rear of the boom 14 Remove the bolt and keeper pin securing the boom pivot p...

Page 263: ...LG Threadlocker P N 0100019 to the bolt threads and secure the pin in place with the keeper pin and bolt Torque the bolt to 285 ft lbs 388 Nm 4 Raise the boom enough to gain access to the lift cylin d...

Page 264: ...ontal 10 Connect all electrical harnesses as tagged during removal Reinstall the wiring into the connector plug in the ground control box as tagged during removal 11 Position the hoods in place on the...

Page 265: ...he boom is below horizontal ensure that the boom is not on the boom rest 2 Use an adequate lifting device to support the weight of the jib and platform assembly 3 Tag and disconnect the hoses and elec...

Page 266: ...boom Pull the disconnected tube back to allow room to dis connect the lower tube 9 Unbolt the lower powertrack tube from the outer mid boom section and the mounting bracket from the inner mid boom sec...

Page 267: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 19 1 Boom Base 2 Boom Inner Mid 3 Boom Outer Mid 4 Boom Fly Figure 4 2 Boom Assembly Sheet 1 of 7...

Page 268: ...ter Mid Extend Block 2 Outer Mid Retract Sheave 3 Rope Retainer Block 4 Retract Rope Retainer Plate 5 Rope Retainer Block 6 Fly Retract Sheave 7 Retract Rope Retainer Plate 8 Lock Plate 9 Tele Cylinde...

Page 269: ...3121262 JLG Lift 4 21 1 Upper Rear Wear Pad 2 Shim 3 Telescope Cylinder 4 Trunnion Keeper Block 5 Lower Rear Wear Pad 6 Shim 7 Tele Cylinder Pulley Assembly 8 Bottom Rear Wear Pad 9 Shim Figure 4 2 Bo...

Page 270: ...Lift 3121262 1 Sheave Deflector 2 Sheave Deflector 3 Rope Retainer Block 4 Fly Extension Sheave 5 Rope Retainer Block 6 Rope Retainer Block 7 Level Cylinder 8 Front Lower Wear Pad 9 Lock Plate Figure...

Page 271: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 23 1 Front Upper Wear Pad 2 Shim 3 Front Side Wear Pad 4 Shim 5 Lock Plate Figure 4 4 Boom Assembly Sheet 5 of 7...

Page 272: ...OOM PLATFORM 4 24 JLG Lift 3121262 1 Outer Mid Extend Rope 2 Fly Extend Rope 3 Fly Retract Rope 4 Outer Mid Retract Rope 5 Proximity Switch Spring 6 Switch Adjustment Block Figure 4 5 Boom Assembly Sh...

Page 273: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 25 Figure 4 6 Boom Assembly Sheet 7 of 7...

Page 274: ...ts securing the side wear pads to the front of the base boom and remove the pads and shims 12 Remove the boom length plate 13 Remove the cover over the boom length limit switch at the front of the boo...

Page 275: ...gth sensor 16 Tag and disconnect the hydraulic hoses from the tele scope cylinder Cap or plug all openings 17 Remove the front side top and lower wear pads from the boom base section 18 Remove the kee...

Page 276: ...d extend cables along with the Broken Cable proximity switch spring and adjustment plate 22 Remove the cable mounting plate 23 Remove the cover plate from the bottom of the boom and remove the sheave...

Page 277: ...o turn the trunnion in a vertical position 27 Pull the inner mid outer mid and fly boom sections out of the base boom section Use additional lifting devices and reposition any lifting straps as necess...

Page 278: ...e to the telescope cylinder and pull the cylinder along with the outer mid extend cables out of the inner mid boom section Reposition the lifting device as necessary to balance the cylinder 30 Remove...

Page 279: ...ract cable adjustment nuts and remove the adjustment nuts from the fly boom retract cables and from the fly boom extend cables at the front of the inner mid boom sec tion 34 Pull the fly boom extend c...

Page 280: ...e cable retainer blocks and sheave blocks for the fly boom retract cables at the front of the inner mid boom section NOTE When pulling the outer mid and fly boom sections out of the inner mid boom sec...

Page 281: ...retainer plates cable retainer blocks sheaves and bushings from the rear of the outer mid boom section 41 Remove the front wear pads from the outer mid boom section 42 Remove the upper rear wear pads...

Page 282: ...e outer mid boom section NOTE When pulling the fly boom section out of the outer mid boom section make sure the fly boom retract cables do not catch at the rear of the boom section 45 Attach a lifting...

Page 283: ...h boom section to a minimum depth of 3 to 4 feet 1 to 1 25 m The fly boom section only needs Super Lube applied to the insertion end Super Lube is also to be moderately applied to all outer sur faces...

Page 284: ...fly boom section Place tape over the wire ends to keep them in place during assembly 2 Fabricate a special fixture as shown below to keep four extend wire ropes from crossing over each other 3 Install...

Page 285: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 37 Ft Lbs Nm A 165 224 B 165 224 C 35 49 D 50 70 Figure 4 7 Boom Assembly Torque Values...

Page 286: ...SECTION 4 BOOM PLATFORM 4 38 JLG Lift 3121262 SECTION A A 0100011 0100011 0100019 0100011 0100011 0100019 0100019 Figure 4 8 Locations for Threadlocker Application Sheet 1 of 4...

Page 287: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 39 0100011 0100011 0100011 0100011 0100011 Figure 4 9 Locations for Threadlocker Application Sheet 2 of 4...

Page 288: ...SECTION 4 BOOM PLATFORM 4 40 JLG Lift 3121262 0100011 0100011 0100011 0100011 0100011 0100011 0100011 0100011 0100011 0100011 0100011 Figure 4 10 Locations for Threadlocker Application Sheet 3 of 4...

Page 289: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 41 0100011 0100011 0100011 Figure 4 11 Locations for Threadlocker Application Sheet 4 of 4...

Page 290: ...e bolts to 50 ft lbs 68 Nm 6 Install the fly boom section most of the way into the outer mid boom section leaving enough of the fly out so there is adequate slack in the fly boom extend cables to allo...

Page 291: ...bushings while guiding the wire ropes into the sheave grooves Apply moly paste lubri cant on the inside diameter of the sheave bushing cup Ensure the sheaves move freely Apply JLG Threadlocker P N 010...

Page 292: ...ion 18 Attach the fly boom retract cables in the inner mid boom section to the receptacles at the rear of the outer mid boom section 19 Put tape over the holes to keep the cable ends from jumping out...

Page 293: ...et of the outer mid section sticking out of the inner mid section 22 Push the retract cable ends into the mounting recepta cles and install the cable sheaves and adjustment nuts 23 Push the outer mid...

Page 294: ...diameter of the sheave composite bearings Install the retract sheaves and bushings while guiding the wire ropes into the sheave grooves Apply moly paste lubri cant on the inside diameter of the sheav...

Page 295: ...nto the cable pulley at the rod end of the telescope cylinder 31 Install the other end of the outer mid extend cables into the cable guide block 32 Route the cables around the sheave on the cylinder a...

Page 296: ...inder trunnion blocks and shims 37 Using Super Lube lubricate all wear surfaces on the inside of the boom base section and the outside of the inner mid boom section 38 Insert the inner mid boom sectio...

Page 297: ...ch a source of auxiliary hydraulic power and retract the boom enough to allow installation of the cable adjustment plate at the rear of the base boom sec tion and install the plate 45 Install the brok...

Page 298: ...4846765 to pre vent the pin from being damaged and use a hammer to remove the pin To make the tool refer to Figure 4 12 Load Pin Removal Tool JLG P N 4846765 If the Load Pin Removal Tool is not availa...

Page 299: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 51 Figure 4 12 Load Pin Removal Tool JLG P N 4846765...

Page 300: ...s and hoses to move more freely 3 Remove the jib valve protection plate 4 Have a container or absorption material ready to catch residual hydraulic fluid Tag and disconnect the hydrau lic hoses that r...

Page 301: ...ace blocking under the cylinder rod or a soft material under the cylinder rod to protect the rod from being scratched NOTE The jib and platform assembly weighs approximately 2100 lbs 953 kg 9 Attach a...

Page 302: ...boom 2 Place something under the front of the jib that will allow it to slide or move along the ground easily Attach a lift ing device to the rear of the jib allowing the front to pivot on the ground...

Page 303: ...threads and secure the pin in place with the keeper pin and bolt Torque the bolt to 165 ft lbs 224 Nm 5 Place the mounting bracket on the jib valve and bolt the jib valve to the fly boom section 6 Ins...

Page 304: ...001118868 A JIB ROTARY ACTUATOR JIB LIFT CYLINDER PLATFORM LEVEL CYLINDER JIB BASE BOOM JIB FLY BOOM PLATFORM LEVEL CYLINDER PLATFORM ROTARY ACTUATOR PLATFORM ROTARY ACTUATOR JIB POWER TRACK JIB LOCK...

Page 305: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 57 Figure 4 14 Jib Assembly Sheet 2 of 3...

Page 306: ...PRESS FIT JIB ROTATOR BEARING HOUSING JIB PIVOT BEARING HOUSING JIB PIVOT BEARING HOUSING SECTION A A ALIGN CUTOUT IN CAP LOCK PIN CYLINDER CAP AS SHOWN Loctite RC 609 Threadlocker TORQUE 220 FT LBS 2...

Page 307: ...of lubrication 4 At the rear of the machine apply lubricant to the side top and bottom surfaces of the fly boom outer mid and inner mid specifically to wear pad contact paths To pre vent misdiagnosis...

Page 308: ...bolt and keeper pin securing the retaining pin at the rear of the cylinder and remove the pin 6 Carefully lift the cylinder from the machine Installation 1 Attach a lifting or jacking device to the p...

Page 309: ...rm to help align the components 9 Install the retaining pin and keeper pin 10 Apply JLG Threadlocker P N 0100011 to the bolts and install the bolts to secure the keeper pins Torque the bolt at the rod...

Page 310: ...7 Retract the jib telescope cylinder 8 Tag and disconnect the hoses going to the jib telescope cylinder 9 Place blocking underneath the cylinder to prevent it from falling when the retaining bolts ar...

Page 311: ...bolts Do not tighten the bolts at this time 4 Connect the hydraulic hoses to the cylinder as tagged during removal 5 Lower the jib enough to enable easier access to the attachment holes in the jib fly...

Page 312: ...ilar device in place to support the weight of the cylinder 3 Remove the bolt and keeper pin that secure the jib lift cylinder barrel pivot pin Remove the jib lift cylinder bar rel pin 4 Lower the cyli...

Page 313: ...ey fit properly Apply an anti seize compound to the attachment holes in the cylinder rod and barrel 1 Lift the cylinder into position to install the jib lift rod pivot pin Install the pivot pin 2 Secu...

Page 314: ...leakage 4 11 JIB STRAIGHT SHIMMING PROCEDURE See Figure 4 16 Jib Straight Shimming 1 Install the jib lock cylinder and fully extend the rod through the bearing housings in the jib rotator and jib piv...

Page 315: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 67 SHIMS NOMINAL QTY SHOWN TORQUE 20 FT LBS 27 Nm PIVOT PAD MOUNT JIB ROTATOR BOTTOM PLATE WEAR PAD Figure 4 16 Jib Straight Shimming...

Page 316: ...safety precautions outlined in the JLG Service Maintenance Manuals 4 The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris toward the nearest e...

Page 317: ...END RADIUS TELESCOPE EXTEND HOSE TELESCOPE TANK HOSE INSIDE OF BEND RADIUS HOSES AND CABLES SHOULD BE AGAINST THE OUTSIDE RADIUS OF THE POWER TRACK HOSES AND CABLES SHOULD NOT BE PULLED TIGHT AGAINST...

Page 318: ...SECTION 4 BOOM PLATFORM 4 70 JLG Lift 3121262 Figure 4 18 Powertrack Hosing Sheet 2 of 3...

Page 319: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 71 Figure 4 19 Powertrack Hosing Sheet 3 of 3...

Page 320: ...t Maintenance 1 Place the powertrack on a workbench 2 Remove the screws from the bars on one side of the powertrack on the first link 3 Remove the screws from the flat bar on the other side of the pow...

Page 321: ...Lift 4 73 5 Slide the poly roller off of the round bar 6 Hold the round bar to remove the other screw 7 Slide the flat bar out 8 Remove the snap ring from one side of the bracket 9 Remove the snap rin...

Page 322: ...ink and slide the bracket side up and over the extrusion on the link 11 Repeat the previous step on the other side 12 Slide the bracket off of the powertrack Two Piece Bracket Maintenance 1 Loosen the...

Page 323: ...the snap rings and pins 6 Remove the screws from the bar Remove the snap ring and pin 7 Slide the link out Snap Rings and Screws WHEN PERFORMING MAINTENANCE ON THE POWERTRACK MAKE SURE TO DISCARD AND...

Page 324: ...n snap ring is shown below A snap ring that is not seated is shown below A seated and closed snap ring is shown below 10 24 x 0 812 button torx socket head with blue locking patch Tighten to 45 50 in...

Page 325: ...little or no movement NOTE Delayed movement of the fly boom indicates loose wire ropes Eight Year Inspection 1 Mandatory wire rope and sheave replacement Additional inspection required if a Machine is...

Page 326: ...nt threads 1 Ensure the machine is placed on firm level ground 2 Before making any adjustments position the boom assembly in the fully retracted position 3 Take preliminary measurements of the positio...

Page 327: ...e 4 21 proceed to the Fly Boom Section Positioning procedure in this section NOTE Because the Outer Mid Boom is used to control the move ment of the Fly Boom any repositioning of the Outer Mid Boom Se...

Page 328: ...E ROPE TENSIONING PROCEDURE ONLY AS NECESSARY TO ACHIEVE PROPER TENSION IF THE BOOMS HAVE BEEN PROPERLY POSITIONED AND THERE IS NOT ENOUGH ADJUSTMENT REMAINING ON THE WIRE ROPES TO ACHIEVE TORQUE THE...

Page 329: ...120043 torque the Outer Mid Boom Extend Adjustment Nuts to 80 ft lb 108 Newton meters alternating between the two ropes until both maintain the required torque 10 Using tool JLG p n 4120040 torque the...

Page 330: ...e values are correct proceed to the next step 13 Retract the boom 2 3 feet 0 5 1 m Do not fully retract or bottom out the boom 14 Verify the Fly Boom and Outer Mid Boom Extend wire rope torques a If t...

Page 331: ...ION 4 BOOM PLATFORM 3121262 JLG Lift 4 83 BASE BOOM INNER MID BOOM NOTE Boom shown in fully retracted position OUTER MID BOOM FLY BOOM 9 5 0 5 241 13 mm 3 5 0 5 90 5 13 mm Figure 4 21 Wire Rope Tensio...

Page 332: ...SECTION 4 BOOM PLATFORM 4 84 JLG Lift 3121262 Figure 4 22 Outer Mid Boom Extend Retract Cables...

Page 333: ...SECTION 4 BOOM PLATFORM 3121262 JLG Lift 4 85 Figure 4 23 Fly Boom Extend Retract Cables...

Page 334: ...SECTION 4 BOOM PLATFORM 4 86 JLG Lift 3121262 1 2 Socket 2 3 4 Socket 3 Retaining Bolt Figure 4 24 Wire Rope Adjustment Tools Optional...

Page 335: ...eplaces the conventional hydrau lic method of platform leveling To control electronic platform leveling the platform is equipped with a pair of tilt sensors one primary and one sec ondary mounted to t...

Page 336: ...rm or the ground is received auto matic platform leveling will cease and the appropriate output will be commanded to turn on When the toggle switch is released after second the current filtered value...

Page 337: ...lines cause the shaft to rotate When the control valve is closed oil is trapped inside the housing preventing piston movement and locking the shaft firmly in position The shaft is supported radially b...

Page 338: ...t 11 FELT MARKER Highlights timing marks and outlines troubled areas Permanent ink is recommended 12 T HANDLE SCREW EXTRACTOR 13 HEX WRENCH SET Removal and replacement of port plugs and set screws 106...

Page 339: ...e port plugs 106 1 106 2 and drain oil Inspect oil for signs of contamination i e water metal shavings 2 Remove the cap screws 113 that cover the end cap lock pins 109 3 Using a 1 8 3 mm drill bit dri...

Page 340: ...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 ACC...

Page 341: ...RE 103 1 Screw 103 2 Washer 106 1 PortPlug 106 2 PortPlug 109 LockPin 113 Capscrew SEALS 200 T Seal 202 T Seal 204 O ring 205 CupSeal 207 BackupRing 304 1 ExclusionSeal BEARINGS 302 WearGuide 304 Thru...

Page 342: ...etween models One set indicates the timing between the piston sleeve 3 and the housing 1 upper photo the second set between the piston and the shaft lower photo To ensure correct rotation and accurate...

Page 343: ...ter gear There should now be timing marks on the housing 1 ring gear the piston 3 and the shaft 2 13 To remove the piston 3 use a rubber mallet and a plas tic mandrel so the piston and housing bore ar...

Page 344: ...on 21 Remove the inside diameter piston seal 200 Inspection PRIOR TO ASSEMBLY OF ACTUATOR THESE STEPS MUST BE CLOSELY FOL LOWED TO ENSURE PROPER OPERATION OF THE ACTUATOR 1 Clean all parts in a solven...

Page 345: ...stall the thrust washer 304 onto shaft 2 and end cap 4 3 Install the exclusion seal 304 1 into the appropriate grooves on the shaft 2 and end cap 4 around the out side edge of the thrust washer 304 4...

Page 346: ...ne end of backup ring in the lower groove and feed the rest in using a circular motion Make sure the wedged ends overlap correctly Insert the other back up ring in upper groove Repeat both of these st...

Page 347: ...to damage the piston seals Do not engage the piston gear teeth yet 12 Looking at the actuator from the end opposite the shaft flange use the existing timing marks to align the gear teeth on the shaft...

Page 348: ...read the end cap 4 onto the shaft 2 Make sure the wear guide remains in place on the end cap as it is threaded into the housing 1 17 Tighten the end cap 4 using a metal bar In most cases the original...

Page 349: ...de 8 bolts New bolts should be installed with a new valve Loctite 242 should be applied to the shank of the three bolts at the time of installation 4 Torque the 1 4 inch bolts 110 to 120 inch pounds 1...

Page 350: ...SECTION 4 BOOM PLATFORM 4 102 JLG Lift 3121262 Figure 4 29 Rotator Counterbalance Valve...

Page 351: ...liters 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 clea...

Page 352: ...ctiononpage 24ofthismanual e Re buildtheactuator Removeallrustthenpolish Replacementpartsmaybeneeded f Re buildtheactuator Usefluidthatiscompatiblewith sealsandbearings 2 Operationiserraticornotrespon...

Page 353: ...Rotator Torque 1 Torque the center bolt to 350 ft lbs 475 Nm 2 Torque the bottom bolts in a crossing star pattern to 170 ft lbs 230 Nm 3 Torque the top bolts in a crossing star pattern to 300 ft lbs...

Page 354: ...Torqueto40ft lbs 55Nm JLGThreadlockerP N0100011 Torque85ft lbs 116Nm Torque480ft lbs 340 365Nm Checktorqueevery150hoursofoperation Figure 4 31 Platform Support Torque Values NOTE If any rotator bolts...

Page 355: ...oil prior to assembly Cup and Brush The following is needed to correctly oil the o ring in this man ner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while usin...

Page 356: ...rm and drip 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...

Page 357: ...se Connections 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 metri...

Page 358: ...ctor will 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...

Page 359: ...ed however 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 firs...

Page 360: ...e number 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 mate...

Page 361: ...male fitting the 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...

Page 362: ...UIRED THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAM AGE 3 Torque assembly to value listed in Table Table 5 3 37 Flare JIC Thread Steel or Table 5 4 37 Flare JIC Thread Alu...

Page 363: ...0 46 11 60 0 50 12 70 14 15 15 19 20 21 1 to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 22 23 24 30 31 33 1 to1 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...

Page 364: ...4 5 1 2 20 0 46 11 60 0 50 12 70 9 10 10 12 13 14 1 to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 14 15 16 19 20 21 1 to1 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...

Page 365: ...LUBRICATION OR SEALANT IS REQUIRED THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAM AGE Torque fitting to value listed in Table 5 5 45 Flare SAE Steel and Table 5 6 45 Flare...

Page 366: ...98 25 00 1 06 27 00 84 88 92 114 119 125 Aand Bthreaddimensionsforreferenceonly SeeFFWRandTFFTMethodsforFFWRprocedurerequirements Table 5 6 45 Flare SAE Aluminum Brass TYPE FITTING IDENTIFICATION Tor...

Page 367: ...config uration of the connection ALUMINUM BRASS FITTINGS OR ALUMINUM BRASS MATING COMPONENTS indicate either the following material configu rations STEEL fittings with ALUMINUM or BRASS mating compo...

Page 368: ...2to3 4 6 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...

Page 369: ...y square 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...

Page 370: ...20 1 5to1 75 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 Th...

Page 371: ...zing splatter splits burrs or other foreign 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...

Page 372: ...12 135 142 149 183 193 202 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 Torqu...

Page 373: ...35 37 39 47 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 29...

Page 374: ...gs refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 12 thru Table 5 17 while using the Double Wrench Method a The table headings identif...

Page 375: ...2 1 87 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 HEX TYPE PLUGS STUD ENDS with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size...

Page 376: ...2 1 87 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 STUD ENDS with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Size A To...

Page 377: ...12 1 87 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 ADJUSTABLE STUD END with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Th...

Page 378: ...2 1 87 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 ADJUSTABLE STUD END with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread...

Page 379: ...8 12 1 87 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 UNF in mm Min Nom Max Min No...

Page 380: ...2 1 31 33 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 UNF in mm Min Nom Max...

Page 381: ...fittings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 18 Table 5 19 Table 5 20 Table 5 21 Table 5 22 or Table 5 23 while using the...

Page 382: ...51 53 65 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...

Page 383: ...01 125 132 137 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...

Page 384: ...153 66 70 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...

Page 385: ...53 65 69 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...

Page 386: ...32 137 M22x1 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...

Page 387: ...85 89 110 115 121 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...

Page 388: ...gs thread the fitting by hand until contact 5 For Adjustable fittings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 24 while using th...

Page 389: ...12 M10x1 6 11 12 12 15 16 16 15 16 17 20 22 23 M12x1 5 8 18 19 20 25 26 27 26 28 29 35 38 39 M14x1 5 10 26 28 29 35 38 39 33 35 36 45 47 49 M16x1 5 12 30 32 33 40 43 45 41 43 45 55 58 61 M18x1 5 15 33...

Page 390: ...M27x2 22 48 51 53 65 69 72 81 86 90 110 117 122 M30x2 62 65 68 84 88 92 114 120 125 155 163 169 M33x2 25 78 82 86 106 111 117 150 157 164 203 213 222 M38x2 88 93 97 119 126 132 153 161 168 207 218 22...

Page 391: ...fittings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 25 Table 5 26 Table 5 27 Table 5 28 Table 5 29 or Table 5 30 while using the D...

Page 392: ...73 90 95 99 133 140 146 180 190 198 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...

Page 393: ...2 133 140 146 180 190 198 133 140 146 180 190 198 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 3...

Page 394: ...79 187 230 243 254 103 108 113 140 146 153 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 34...

Page 395: ...95 99 199 209 219 270 283 297 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 7...

Page 396: ...G3 4A 20 133 140 146 180 190 198 133 140 146 180 190 198 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 56...

Page 397: ...66 70 73 90 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 MATER...

Page 398: ...t splits scratches dirt foreign matter or burrs 2 See Figure for O ring installation instructions 3 Pre lubricate the O ring with Hydraulic Oil 4 Position flange and clamp halves 5 Place lock washers...

Page 399: ...105 110 116 111 116 122 150 158 165 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...

Page 400: ...97 101 68 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 16...

Page 401: ...back up wrench 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...

Page 402: ...the connection has been 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 F...

Page 403: ...or nicks If 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 widt...

Page 404: ...der port block Discard o rings 4 Place the cylinder barrel into a suitable holding fixture 5 Mark cylinder head and barrel with a center punch for easy realignment Using an allen wrench loosen the cyl...

Page 405: ...8 18 19 20 22 23 23 22 1 ThreadLocker 2 LockingPrimer 3 LoctiteRC609 4 Bolt 5 TaperedBushing 6 Head 7 Barrel 8 Rod 9 Piston 10 NotUsed 11 WearRing 12 BackupRing 13 BackupRing 14 O ring 15 O ring 16 Ro...

Page 406: ...ress 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 barrel tube for...

Page 407: ...rings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and...

Page 408: ...and back up rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 8 Assemble the tapered bushing loosely into the piston and inse...

Page 409: ...ES 15 With barrel clamped securely and while adequately sup porting the rod insert the piston end into the barrel cyl inder Ensure that the piston t seal is not damaged or dislodged 16 Continue pushin...

Page 410: ...alance valves from the cylinder port block Discard o rings 4 If necessary remove the bleeder valve 5 Place the cylinder barrel into a suitable holding fixture 6 Mark cylinder head and barrel with a ce...

Page 411: ...24 25 11 11 1 Barrel 2 Rod 3 Piston 4 Bushing 5 Head 6 CounterbalanceValve 7 ThreadlockingCompound 8 LockingPrimer 9 LoctiteRC609 10 Bolt 11 Bearing 12 Plug 13 Bolt 14 NotUsed 15 WearRing 16 BackupRi...

Page 412: ...or scoring tapering ovality or other damage 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 nece...

Page 413: ...rings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and...

Page 414: ...and back up rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 8 Assemble the tapered bushing loosely into the piston and inse...

Page 415: ...OULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 15 With barrel clamped securely and while adequately sup porting the rod insert the piston end into the barrel cyl inder Ensure that the pi...

Page 416: ...emove the counterbalance valves from the cylinder port block Discard o rings 4 Place the cylinder barrel into a suitable holding fixture 5 Mark cylinder head and barrel with a center punch for easy re...

Page 417: ...dlocker 2 Bolt 3 TaperedBushing 4 Plug 5 Plug 6 Bolt 7 Spacer 8 HoldingValve 9 CounterbalanceValve 10 Barrel 11 Rod 12 Head 13 Piston 14 WasherRing 101 WearRing 102 BackupRing 103 O ring 104 O ring 10...

Page 418: ...t the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 3 Inspect threaded portion of rod for excessive damage D...

Page 419: ...rings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and...

Page 420: ...hat the o ring and back up rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 9 Assemble the tapered bushing loosely into the...

Page 421: ...D PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 16 With barrel clamped securely and while adequately sup porting the rod insert the piston end into the...

Page 422: ...Remove the cylinder length sensor from the cylinder See Section 5 4 Cylinder Length Sensor 4 Remove the counterbalance valves from the cylinder port block Discard o rings 5 Place the cylinder barrel...

Page 423: ...olt 9 Setscrew 10 Spacer 11 NotUsed 12 NotUsed 13 Barrel 14 Head 15 Rod 16 CylinderLengthSensor 17 RetainerCap 18 CounterbalanceValve 101 LockRing 102 BackupRing 103 WearRing 104 BackupRing 105 O ring...

Page 424: ...y in an approved cleaning sol vent 2 Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 3 Inspect thr...

Page 425: ...rings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and...

Page 426: ...hat the o ring and back up rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 9 Assemble the tapered bushing loosely into the...

Page 427: ...YLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 17 With barrel clamped securely and while adequately sup porting the ro...

Page 428: ...e counterbalance valve and pressure regulator valve from the cylinder port block Discard o rings 4 Place the cylinder barrel into a suitable holding fixture 5 Mark cylinder head and barrel with a cent...

Page 429: ...6 NotUsed 7 Head 8 Rod 9 Barrel 10 Plug 11 NotUsed 12 GuideRing 13 LockRing 14 BackupRing 15 O ring 16 WearRing 17 RodWiper 18 RodSeal 19 BackupRing 20 O ring 21 WearRing 22 Piston 23 WasherRing 24 N...

Page 430: ...d cleaning sol vent 2 Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 3 Inspect threaded portion o...

Page 431: ...rings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and...

Page 432: ...and tight ensuring that the o ring and back up rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 9 Assemble the tapered bushi...

Page 433: ...URFACES 16 With barrel clamped securely and while adequately sup porting the rod insert the piston end into the barrel cyl inder Ensure that the piston seals are not damaged or dislodged 17 Continue p...

Page 434: ...Section 5 4 Cylinder Length Sensor 4 Remove the counterbalance valve and holding valve from the cylinder port block Discard o rings 5 Place the cylinder barrel into a suitable holding fixture 6 Mark c...

Page 435: ...Bolt 14 Bolt 15 Setscrew 16 Spacer 17 HoldingValve 18 CounterbalanceValve 19 CylinderLengthSensor 20 RetainerCap 21 Barrel 22 Rod 101 WearRing 102 BackupRing 103 LockRing 104 BackupRing 105 O ring 106...

Page 436: ...CTION 1 Clean all parts thoroughly in an approved cleaning sol vent 2 Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Repla...

Page 437: ...rings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and...

Page 438: ...and tight ensuring that the o ring and back up rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 9 Assemble the tapered bushi...

Page 439: ...AMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 16 With barrel clamped securely and while adequately sup porting the rod insert the piston end into the barrel cyl inder Ensure that the piston seals a...

Page 440: ...from the holding fixture Remove the cylinder head gland and discard all seals on the cylinder head CLEANING AND INSPECTION 1 Clean all parts thoroughly in an approved cleaning sol vent 2 Inspect the c...

Page 441: ...C SCHEMATICS 3121262 JLG Lift 5 87 1 2 3 4 101 102 103 104 105 106 107 108 1 Head 2 Lubricant 3 Barrel 4 Rod 101 WearRing 102 BackupRing 103 WearRing 104 O ring 105 O ring 106 RodWiper 107 Seal 108 Se...

Page 442: ...d gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end 5 Place a new wear ring and t seal in the outer piston diameter grooves...

Page 443: ...the power source Adequately support the cylinder rod if applicable 3 Place the cylinder barrel into a suitable holding fixture 4 Mark cylinder cap and barrel with a center punch for easy realignment U...

Page 444: ...Lift 3121262 2 1 4 3 12 13 9 7 11 8 10 14 6 5 1684314 D 1 CylinderCap 2 Rod 3 Head 4 Barrel 5 Nut 6 Piston 7 BackupRing 8 WearRing 9 WearRing 10 O ring 11 O ring 12 Wiper 13 PistonSeal 14 Loctite 222...

Page 445: ...and for ovality and tapering Replace as necessary 10 Inspect threaded portion of head for damage Dress threads as necessary 11 Inspect seal and o ring grooves in head for burrs and sharp edges Dress...

Page 446: ...y thread the lock nut onto the rod to secure the piston in place Torque to 400 ft lbs 542 Nm 9 Remove the cylinder rod from the holding fixture 10 Place a new wear ring and t seal in the outer piston...

Page 447: ...bly from the barrel using care not to damage the threads or any other components sur face 6 Clamp the rod mount and support the rod assembly with the chrome surface protected Remove the piston assembl...

Page 448: ...7 PadSupport 8 O ring 9 O ring 10 RodSeal 11 BackupRing 12 RodWiper 13 WearRing 14 Plug 15 Plug 16 WearRing 17 PistonSeal 18 Capscrew 19 Lockwasher 20 Nut 21 Capscrew 22 ShuttleValve 23 Counterbalance...

Page 449: ...d and slide onto rod rod wiper end first using cau tion not to damage rod wiper or seal on rod end 2 Slide stop tube with o ring onto rod Do not scratch rod chrome 3 For pistons with threaded I D appl...

Page 450: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 96 JLG Lift 3121262 Figure 5 115 Jib Telescope Cylinder Head Gland Detail Figure 5 116 Jib Telescope Piston Detail...

Page 451: ...heck valves counterbalance valves and relief valve from the cylinder port block Discard o rings 4 Place the cylinder barrel into a suitable holding fixture 5 Mark cylinder head and barrel with a cente...

Page 452: ...8 Barrel 9 Rod 10 NotUsed 11 WearRing 12 BackupRing 13 WearRing 14 O Ring 15 O Ring 16 BackupRing 17 RodWiper 18 T Seal 19 RodSeal 20 RetainingRing 21 WearPad 22 Piston 23 Capscrew 24 Capscrew 25 Caps...

Page 453: ...r scoring tapering ovality or other damage 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 neces...

Page 454: ...ings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent 15 If applicable inspect port block fittings and h...

Page 455: ...the o ring and back up rings are not damaged or dislodged NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 9 Assemble the tapered bushing loosely into the pist...

Page 456: ...and while adequately sup porting the rod insert the piston end into the barrel cyl inder Ensure that the piston seals are not damaged or dislodged 17 Continue pushing the rod into the barrel until the...

Page 457: ...y 186 lbs 84 kg and the platform level cylinder weighs approximately 76 lbs 34 kg 2 Support the weight of the jib cylinder and remove the bolt and keeper pin that secure the cylinder barrel retaining...

Page 458: ...SCHEMATICS 5 104 JLG Lift 3121262 7 Using an allen wrench remove the bolts securing the retaining cap and remove the cap 8 Pull sensor out of the cylinder DO NOT use the wiring harness to pull the sen...

Page 459: ...nto the sensor bore DO NOT tap on the wiring harness 2 Install the cap and secure in place with the retaining bolts 3 Apply lubricant JLG P N 3020039 to the setscrew and install the setscrew Torque th...

Page 460: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 106 JLG Lift 3121262 Figure 5 132 Platform Valve Identification...

Page 461: ...able 5 33 Platform Valve Specifications Item Torque Ohms ft lbs Nm 1 PressureCheckPort 17 18 23 24 5 2 PressureCompensa tor 25 30 34 41 3 ReliefValve 25 30 34 41 4 ReliefValve 25 30 34 41 5 PressureCo...

Page 462: ...HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 108 JLG Lift 3121262 Figure 5 134 Platform Valve Fitting Torque Specifications Table 5 2 Fitting Torque Specifications Torque ft lbs Nm 1 24 32 5 2 24 32 5...

Page 463: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121262 JLG Lift 5 109 Figure 5 135 Jib Control Valve Identification Sheet 1 of 2...

Page 464: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 110 JLG Lift 3121262 Figure 5 136 Jib Control Valve Identification Sheet 2 of 2...

Page 465: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121262 JLG Lift 5 111 Figure 5 137 Jib Control Valve Torque and Resistance Specifications Sheet 1 of 2...

Page 466: ...fications Item Torque Ohms ft lbs Nm 1 PressureCompensa tor 25 30 34 41 2 PressureCompensa tor 25 30 34 41 3 JibLiftValve 16 20 22 27 9 8 4 JibTeleValve 16 20 22 27 7 2 5 JibLevelValve 16 20 22 27 9 8...

Page 467: ...NFORMATION HYDRAULIC SCHEMATICS 3121262 JLG Lift 5 113 Figure 5 139 Jib Control Valve Fitting Torque Specifications Table 5 4 Fitting Torque Torque ft lbs Nm 1 24 32 5 2 60 81 3 40 54 4 24 32 5 5 15 2...

Page 468: ...LG Lift 3121262 1 AuxLiftDown 2 TeleOut 3 LiftUp 4 SwingRight 5 Dump 6 SwingRelief 7 SwingLeft 8 LiftDown 9 LiftUpRelief 10 LiftDownRelief 11 LiftFlow 12 TeleIn 13 TeleOutRelief 14 TeleInRelief 15 Tel...

Page 469: ...Nm Ft Lbs Nm 1 25 30 33 9 40 6 9 30 35 40 6 47 4 2 25 30 33 9 40 6 10 30 35 40 6 47 4 3 30 35 40 6 47 4 11 30 40 6 4 30 35 40 6 47 4 12 30 35 40 6 47 4 5 30 35 40 6 47 4 13 30 35 40 6 47 4 6 30 35 40...

Page 470: ...e select switch to the ground controls and start the engine 3 Locate the oil sampling valve on the front of the main control valve 4 Unscrew the knurled end which is attached to the chain 5 Place a dr...

Page 471: ...onnector from the lift down coil 3 Activate lift down The gauge should read 3400 psi 234 4 bar 4 To make an adjustment to this pressure on a Rexroth pump go to the engine compartment and locate the fu...

Page 472: ...e TELESCOPE OUT 1 Install a high pressure gauge at the M8 port of the main valve bank Plug the telescope out hose either at the valve bank port 8 or at the inlet of the telescope cylin der V1 2 Activa...

Page 473: ...sure that the wheel spindle is aligned straight with the extended axle weldment 1 Position the machine with both front and rear axles fully extended 2 Install the Analyzer in the platform control box...

Page 474: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 120 JLG Lift 3121262 Figure 5 142 Steer Pressure Adjustments...

Page 475: ...counterclockwise to decrease pressure 6 Remove the pressure gauge from MS2 port and install on the MS1 port which is on the right side of the front axle steer valve closest to the right front wheel s...

Page 476: ...or a few seconds after the rod has been fully extended The MS2 port should read 2000 psi 179 Bar If the pressure is not correct adjust the relief valve mounted next to MS2 port clockwise to increase o...

Page 477: ...MS3 port which is on the left side of the rear axle steer valve clos est to the left rear wheel spindle Position the steer switch to activate the right rear steer cylinder until the rod is in the ful...

Page 478: ...ction 1 Install a high pressure gauge at MLB 2 Connect the analyzer to the ground control connector 3 Position the main boom on the boom rest and the jib to horizontal 4 Using the analyzer press the R...

Page 479: ...will activate the jib level up function 11 When the function bottoms out pressure should read 2600 psi 180bar 12 If necessary to adjust pressure CW increases and CCW decreases setting Jib level up adj...

Page 480: ...hould read JIB SWING Press ENTER 8 Enter code 58237 and Press ENTER The screen should read SERVICE MODE JIB SWING AND JIB LEVEL 9 Press ENTER again The screen will read JIB LEVEL OVERRIDE OFF Use the...

Page 481: ...t the jib back to level go into override mode for jib leveling Turne the override mode to On and press the ESCAPE key until out of the Service Modes menu 13 Go to the Diagnostics Boom Sensors menu Use...

Page 482: ...essure to 2850 psi 196 5 Bar Turning the adjustment clockwise increases pressure turning the adjustment counterclockwise decreases pressure JIB TELESCOPE IN 1 Install a high pressure gauge at the MTA...

Page 483: ...essure to 2800 psi 193 Bar Turning the adjustment clockwise increases pressure turning the adjustment counterclockwise decreases pressure JIB LIFT DOWN 1 Install a high pressure gauge at the MJA port...

Page 484: ...engaged No Engage wheel drive s Yes If yes proceed to step 2 a 2 Transmission does not propel the machine diesel engine running properly Charge Pump Relief Valve a Is there any charge pressure at port...

Page 485: ...ure less than 15 psi 1 bar gauge pressure No Correct problem restricting case drain oil flow oil cooler blockage pinched hoses etc Yes Proceed to step 3 f f Stroke pump in both directions while measur...

Page 486: ...Check electrical system for signal problem b With electrical connectors removed and machines wheels jacked off the ground and engine running momentarily apply 12 volt DC signal battery volt age to a p...

Page 487: ...pump case drain from oil cooler check flow rate from charge pumps Is the flow rate 3 8 GPM 14 4 LPM with diesel idle speed of 1200 rpm No Refer to charge pump removal inspection procedure 11 Transmis...

Page 488: ...e equal Tighten jam nut stop the pump drive remove the hose con necting ports X1 and X2 Hydraulic Centering of Control Modules PREPARATION FOR ADJUSTMENT When control modules are exchanged or replaced...

Page 489: ...one turn equals approximately 377 psi 26 bar 4 After adjustment is completed torque jam screw ref item 4 to 5 ft lb 7 Nm 5 Install relief valve assembly into pump reinstall cover ref item 1 to proper...

Page 490: ...er Elements a After commissioning or re build b At every 500 operating hours or when filter indica tor shows a dirty element c With the suction strainer the strainer should be renewed as soon as charg...

Page 491: ...he reservoir breather A dirty or clogged breather will affect all machine functions b The air oil cooler surfaces and engine radiator should be cleaned at the same time c If hose connections are disas...

Page 492: ...JLG Lift 3121262 Removal and Installation of Shaft Seal Remove the retaining ring with snap ring pliers Screw in sheet metal screw into the holes fitted with rubber Pull out shaft seal with pliers Pre...

Page 493: ...YDRAULIC SCHEMATICS 3121262 JLG Lift 5 139 5 8 FUNCTION PUMP Spare Parts 1 Sealing kit existing spare parts shaft sealing ring o rings and a circlip 2 Drive Shaft 3 Bearing set miscellaneous parts Fig...

Page 494: ...piston rod plug spring stopper max flow hex nut and hex head nut 7 DFR pilot valve Sealing the Drive Shaft BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED DURING THE REMOVAL OF THE SHAFT SEALING RIN...

Page 495: ...he snap ring 6 Assemble the snap ring in the correct position Disassembly and Assembly of the Complete Unit 1 Disassemble the pilot valve 2 Mark the position of the port plate and remove the socket sc...

Page 496: ...shim 7 Unscrew the cap nut and remove it 8 Loosen the fixing nut of the stopper max flow and disas semble it 9 Turn in the stopper max flow to get swivel angle zero 10 Disassemble the rotary group in...

Page 497: ...ble the control piston while moving the swash plate 15 The swash plate must be lifted a little bit to disassemble the piston rod 16 Remove the swash plate 17 Remove the spring 18 Remove both bearing s...

Page 498: ...n 24 A bearing puller is used to disassemble the external bearing ring of the taper roller bearing inside the port plate Take care of the surface of the port plate 25 The spring has additional pretens...

Page 499: ...ve Check control valve drilling position at the pump housing and fit together Adjustments TAPER ROLLER BEARING INITIAL TENSION Cast Iron pump housing must have initial tension of the bear ings 0 to 0...

Page 500: ...CTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 146 JLG Lift 3121262 Figure 5 144 Function Pump Pressure and Flow Control Sheet 1 Figure 5 145 Function Pump Pressure and Flow Control Sheet...

Page 501: ...hose attached to the pump control Port X 2 Remove the four 4 socket head cap screws that attach the control to the pump Insure that the three 3 0 rings are also removed with the control 3 Hydraulic fl...

Page 502: ...re they are open Inspect all parts for burrs scor ing debris etc NOTE On the mounting surface of the control housing between the oil ports is what appears to be a slotted head screw IT IS NOT A SCREW...

Page 503: ...of the machine is accomplished by a flow divider combiner car tridge installed in the Traction Control Manifold There is a flow divider combiner for each side Each flow divider combiner also has a ble...

Page 504: ...e located on the Traction Manifold This disables the machine s ability to release the brakes Stroke the transmission pumps slightly less than 20 and check the setting of the high pressure cross port r...

Page 505: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121262 JLG Lift 5 151 Thispageleftblankintentionally...

Page 506: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 152 JLG Lift 3121262 Figure 5 147 Hydraulic Schematic Sheet 1 of 10...

Page 507: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121262 JLG Lift 5 153 Figure 5 148 Hydraulic Schematic Sheet 2 of 10 1001120628 F...

Page 508: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 154 JLG Lift 3121262 Figure 5 149 Hydraulic Schematic Sheet 3 of 10...

Page 509: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121262 JLG Lift 5 155 Figure 5 150 Hydraulic Schematic Sheet 4 of 10 1001120628 F...

Page 510: ...A B L1 M3 LOP 500 PSI SWIVEL PORTS M4 M5 C1 C2 M14 F00A F00B L3 MD MB MC C D CW CW E MLOP TRACTION MANIFOLD PORT 6 PORT 2 See Sheet 2 P Port Steer Valve See Sheet 2 P Port Steer Valve PORT 1 PORT 5 P...

Page 511: ...t back to tank 30 Mesh 3 PSI Bypass OSCILLATING AXLE CIRCUIT CHARGE PUMP FILTER B5 200 BYPASS 50 PSI CHARGE PUMP 1 025 in3 Front Pump Fire coil C1 flow to port A measure at port M4 Fire coil C2 flow t...

Page 512: ...G P T R T1 T2 PS 5000psi S REAR AXLE Oil Cooler Suction Strainer 60 Mesh 238 Micron 3 PSI Bypass TRACTION MANIFOLD PORT 6 PORT 2 See Sheet 2 P Port Steer Valve See Sheet 2 P Port Steer Valve PORT 1 PO...

Page 513: ...YDRAULIC SCHEMATICS 3121262 JLG Lift 5 159 B A G1 G G1 G FRONT AXLE DRIVE SYSTEM REXROTH PUMPS L L1 L L1 PORT 7 LEFT MOTOR FRONT DRIVE BRAKES OSCILLATING AXLE CIRCUIT B A P V P V Figure 5 154 Hydrauli...

Page 514: ...RATIO 1 26 1 JIB LIFT CYLINDER BORE 5 19 63 sq in ROD 2 5 4 91 sq in ANNULAR 14 73 sq in STROKE 25 15 RATIO 1 33 1 JIB CONTROL VALVE T C2 C1 V1 V2 V1 V2 TO GR PORT ON MAIN CONTROL VALVE TO PORT ON HI...

Page 515: ...PLATFORM CONTROL VALVE T C2 C1 V1 V2 V2 V1 JIB BOOM FUNCTIONS PLATFORM LEVEL CYLINDER BORE 3 5 9 62 sq in ROD 1 5 1 76 sq in ANNULAR 7 85 sq in STROKE 14 79 RATIO 1 23 1 PLATFORM ROTATOR 14 1 cu in 3...

Page 516: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 162 JLG Lift 3121262 NOTES...

Page 517: ...steering func tions The main lift swing and drive are controlled by individual joy sticks with steering being controlled by a rocker switch built into the top the drive joystick To activate Drive Lift...

Page 518: ...t be connected 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...

Page 519: ...imes 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 displ...

Page 520: ...t the above 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...

Page 521: ...level 1 which 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 CHANGI...

Page 522: ...E T ELEVATED 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 HARDWAR...

Page 523: ...LNUMBER 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 VERSIO...

Page 524: ...aultsettings bold willvarydependingonthemodelselectionwithselection 5beingtheinitialdefaultsetting MARKET 3 0 1 2 3 4 5 ANSIUSA ANSIEXPORT CSA CE AUSTRALIA JAPAN 0 ENGINE 4 1 2 3 4 DEUTZF4TIER1 DeutzB...

Page 525: ...omfunctionstocreepwhentiltedmorethan4 degreesandaboveelevation alsodisallowstowerliftup towertelescopeout drive maintelescopeout andmainliftup 3DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocr...

Page 526: ...4 NO Noloadsensorinstalled WARNONLY Functionsincreep overloadlamplit platformalarmbeeps 5secON 2secOFF CUTOUTPLATFORM Allfunctionscutout overloadlamplit platformalarmbeeps 5secON 2secOFF CUTOUTALL All...

Page 527: ...oundswhenliftdownisactive Option MOTION Motionalarmsoundswhenanyfunctionisactive Option 0 Certainmarketselectionswillalterdefaultsetting OSCILLATINGAXLE 19 0 1 NO Nooscillatingaxlesysteminstalled YES...

Page 528: ...1 1 1 1 1 1 GenSet Welder 0 0 0 0 0 0 1 1 1 1 1 1 2 2 2 2 2 2 GenSetCutout 0 0 0 0 0 0 1 1 1 1 1 1 Head Taillights 0 0 0 0 0 0 1 1 1 1 1 1 LoadSystem 0 0 0 0 0 0 X 1 X X 1 1 X 2 X 2 2 2 X 3 X 3 3 3 X...

Page 529: ...ECELX Xs Displays adjustsdrivedeceleration 0 1to3 0sec 1 3 MINforwardXX Displays adjustsminimumforwarddrivespeed 0to35 1 MAXforwardXXX Displays adjustsmaximumforwarddrivespeed 0to100 100 44 48 seeorie...

Page 530: ...ustsmaximumswingleftspeed 0to100 65 115 125 seeorientation CREEPLEFTXX Displays adjustsmaximumswingleftspeed 0to65 52 NOTE usedwhencreepswitchonpumppotis active MINRIGHTXX Displays adjustsminimumswing...

Page 531: ...ed 0to100 70 PLATFORMROTATE ACCELX Xs Displays adjustsbasketrotateacceleration 0 1to5 0sec 1 DECELX Xs Displays adjustsbasketrotatedeceleration 0 1to3 0sec 0 5 MINLEFTXX Displays adjustsminimumbasketr...

Page 532: ...0to65 48 MAXLEFTXXX Displays adjustsmaximumjibleftspeed 0to100 70 60 68 180 MINRIGHTXX Displays adjustsminimumjibrightspeed SameasCreepspeed 0to65 55 MAXRIGHTXXX Displays adjustsmaximumjibrightspeed...

Page 533: ...SWINGXXX Displays adjustsfixedswingspeed 0to100 60 PLATFORMLVLXXX Displays adjustsfixedbasketlevelspeed 0to100 75 PLATFORMROTXXX Displays adjustsfixedbasketrotatespeed 0to100 75 MAINTELEXXX Displays...

Page 534: ...trol boom horizontal jib horizontal 500 lb capacity selected DRIVE FORWARD Max high speed low torque setting drive 200 ft front wheels to front wheels Timed after machine has obtained maximum speed DR...

Page 535: ...es are stored into the ground module i e Personalities or Calibrations Interlocks Any device that sends an electrical input For an example a limit switch proximity switch etc Platform Level The GROUND...

Page 536: ...SECTION 6 JLG CONTROL SYSTEM 6 20 JLG Lift 3121262 Figure 6 2 Control System Block Diagram...

Page 537: ...bration Instructions Calibration Procedure ReasonsforRe calibration SteeringCalibration Groundmodulereplacement Chassismodulereplacement Steersensorremovalorreplacement Persistentwheelmisalignment Dri...

Page 538: ...TIVATE ACCESS LEVEL CODE 00000 MENU SERVICE MODE SERVICE MODE JIB SWING JIB SWING JIB LEVEL JIB SWING SWING ENVELOPE JIB SWING JIB LOCK PIN JIB SWING BOOM RECOVERY Figure 6 3 Analyzer Flow Chart See F...

Page 539: ...262 JLG Lift 6 23 Figure 6 4 Analyzer Flow Chart Personalities Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available depe...

Page 540: ...JLG Lift 3121262 Figure 6 5 Analyzer Flow Chart Machine Setup Software Version 7 X NOTE The layout shown includes all possible ana lyzer screens Please note that some screens may not be available dep...

Page 541: ...1262 JLG Lift 6 25 Figure 6 6 Analyzer Flow Chart Calibrations Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available depe...

Page 542: ...Lift 3121262 Figure 6 7 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 1 of 3 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be availabl...

Page 543: ...LG Lift 6 27 Figure 6 8 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 2 of 3 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be availabl...

Page 544: ...Lift 3121262 Figure 6 9 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 3 of 3 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be availabl...

Page 545: ...SECTION 6 JLG CONTROL SYSTEM 3121262 JLG Lift 6 29 Figure 6 10 Control Module Location...

Page 546: ...UTPUT 5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT 6 GROUND GROUND INPUT 7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT 8 TOWER TELESCOPE POWER DIGITAL OUTPUT 9 TELESCOPE FLOW CONTROL DIGITAL OUTPUT 10 LIFT...

Page 547: ...EILD GROUND INPUT 19 SPARE PIN GROUND INPUT 20 SPARE ANALOG INPUT 1 ANALOG INPUT 21 PUSH TO TEST DIGITAL INPUT 22 TOWER BOOM TRANSPORT ANGLE DIGITAL INPUT 23 GROUND CONTROL ENABLE DIGITAL INPUT 24 CAN...

Page 548: ...ET LEVEL UP DIGITAL INPUT 18 BASKET ROTATE RIGHT DIGITAL INPUT 19 JIB UP DIGITAL INPUT 20 JIB RIGHT DIGITAL INPUT 21 TOWER DOWN DIGITAL INPUT 22 MAIN BOOM TRANSPORT ANGLE CLOSED DIGITAL INPUT 23 UPPER...

Page 549: ...Power Feed Thru to J1 2 Ground Front Axles Limit Switch Rear Axles Limit Switch Drive Orientation Switch Oscillating Axle Pres Sw Turntable Angle Sensor 1 Turntable Angle Sensor 2 Spare Analog Front...

Page 550: ...Input 8 Main Boom Ang 1 Gravity Digital Input 9 Main Boom Ang 2 Gravity Digital Input 10 Spare Analog Analog Input 11 Right Drive Pump Forward Digital Output 12 Right Drive Pump Reverse Digital Output...

Page 551: ...4 Master Ground Connect Power Input 5 Master Ignition Connect Power Input 6 CANbus High Serial I O 7 CANbus Low Serial I O 8 CANbus Shield Serial I O 9 CANbus Terminator Serial I O 10 CANbus Terminat...

Page 552: ...SECTION 6 JLG CONTROL SYSTEM 6 36 JLG Lift 3121262 Figure 6 17 Analyzer Connecting Points PLATFORM CONNECTION GROUND CONTROL CONNECTION...

Page 553: ...the rear wheels The Boom Control System BCS uses a number of sensors to measure the position of the boom The sensors used to deter mine main boom and jib boom position are shown in Figure 6 18 Control...

Page 554: ...JIB TELESCOPE PROXIMITY SENSORS MAIN BOOM STRING POT MAIN BOOM PROTRACTOR SENSOR JIB LOCK PIN PROXIMITY SENSORS PLATFORM LEVEL SENSORS JIB ROTATE SENSORS WIRE ROPE PROXIMITY SENSOR JIB LEVEL PROTRACT...

Page 555: ...nsor 4 Main Boom Cylinder Angle Sensor This sensor s function is to measure Main Boom angle in rela tionship to the turntable A rotary type sensor is mounted to the Turntable and attached to the Main...

Page 556: ...ctive proximity switch mounted to the Jib Pivot weldment with both Normally Open and Normally Closed con tacts wired into the control system Sensor 8 Jib Stow Angle Sensor This sensor is used to measu...

Page 557: ...el Cylinder Angle Sensor This sensor is used to measure Platform angle in relationship to the Jib A linear position sensor is located inside the Plat form Level cylinder to measure cylinder stroke and...

Page 558: ...tate angle sen sor and the Jib lock pin sensing proximity switch 6 8 CAN GATEWAY The CAN gateway is located in the ground control box To decrease overall bus loading the CAN gateway module divides the...

Page 559: ...2 Plug the analyzer into the connector at the base of the platform control box 3 Before proceeding ensure that the switches on the plat form console are in the following positions a Drive speed switch...

Page 560: ...want to acti vate the system test hit Enter again to activate 7 Follow the flow path in Figure 6 19 System Test Flow Chart Platform Tests and go through the component tests Hit the ESC key during any...

Page 561: ...SECTION 6 JLG CONTROL SYSTEM 3121262 JLG Lift 6 45 Figure 6 19 System Test Flow Chart Platform Tests...

Page 562: ...tton to reach SYSTEM TEST Hit Enter The analyzer will prompt you asking if you want to acti vate the system test hit Enter again to activate 6 Follow the flow path in Figure 6 20 System Test Flow Char...

Page 563: ...SECTION 6 JLG CONTROL SYSTEM 3121262 JLG Lift 6 47 Figure 6 20 System Test Flow Chart Ground Station Tests...

Page 564: ...withitsEEPROMstoredpersonalitysettingsatswitchon Checkand ifnecessarycorrect allpersonalitysettings OPENFSW Inplatformmode thefootswitchmustbeopenatthestartofthetest CLOSEFSW Inplatformmode thefootswi...

Page 565: ...eckswitch wiring CHECKXXXXXXXJOY Thenamedjoystickappearstobefaulty Checkjoystick TESTINGLAMPS Indicatesthatthelampstestisbeginning Eachlampisenergizedinturn apromptasksforcon firmationthatthelampislit...

Page 566: ...Promptsdisplayedduringtheoperatorinputtestbelowmessages CLOSEXXXXXXX Thenamedswitchshouldbeclosed OPENXXXXXXX Thenamedswitchshouldbeopened XXXXXXXXXXXXXXTOMAX Thenamedjoystickshouldbepushedtoitsfullex...

Page 567: ...sorindrivejoystick DisplayedifJOYSTICKTYPE 1 QPRX2 ACTIVE NOTACTIVE DisplaysstatusofQ Proxsensorindrivejoystick DisplayedifJOYSTICKTYPE 1 TWOSPEED OP CL Displaysstatusoftwospeedswitchinputifselectedmo...

Page 568: ...hepumppot NotdisplayedifTOWERLIFT NO machinedigit 0 JIB UP DOWNXXX Displaysjibliftswitchdirection demand NOTE demandiscontrolledbythe pumppot NotdisplayedifJIB NO machinedigit 0 JIB RIGHT LEFTXXX Disp...

Page 569: ...Displaysmeasuredcoolanttemperature OILPRS LOW OKorXXPSI Displaysmeasuredoilpressure FUELSELECT GAS LP Displaysstatusoffuelselectswitch DisplayedifMODELNUMBER 2 AMB TEMP XXXC Displaysmeasuredambientai...

Page 570: ...UT OP CL Displaysstatusofboomlengthretractedlimitswitch DisplayedifMODEL NUMBER 6 TLIFTPROX OP CL Displaysstatusoftowerliftproximityswitch DisplayedifTOWERPROX SWITCHES 1 TTELEPROX OP CL Displaysstatu...

Page 571: ...utstatus Notdisplayedifassociated configurationdigit 0 LIGHTS OP CL Displaysheadandtaillightswitchinputstatus Notdisplayedifassociated configurationdigit 0 BSKTILT1 XX X Displaysindicatedplatformtilta...

Page 572: ...ES NO DisplaysthestatusofPipeRacksselectedduringboomsensorcalibration DisplayedifMODELNUMBER 7or8 CAMERAMOUNT YES NO DisplaysthestatusofCameraMountselectedduringboomsensorcalibration DisplayedifMODELN...

Page 573: ...momentpin SKYWELDER YES NO DisplaysthestatusofSkyWelderselectedduringboomsensorcalibration DisplayedifMODELNUMBER 7or8 SKYCUTTER YES NO DisplaysthestatusofSkyCutterselectedduringboomsensorcalibration...

Page 574: ...inA Dcountsorrawangleifcali brated A DANG2 XXXXX Displaysthecurrentindicatedboomangle2inA Dcountsorrawangelifcali brated CANSTATISTICS CANStatisticsasdetectedbytheGroundModule RX SEC XXX Displaysthenu...

Page 575: ...splaysthemainliftupcalibrationpoint ULIFTDOWN XXX Displaysthemainliftdowncalibrationpoint UTELEIN XXX Displaysthemaintelescopeincalibrationpoint UTELEOUT XXX Displaysthemaintelescopeoutcalibrationpoin...

Page 576: ...ableatAccessLevel2 ENTERresetsrentaldatalogtimetozero VERSIONS GMSW PX X Displaysgroundmodulesoftwareversion GMHWREV XXXX Displaysgroundmodulehardwarerevision GMSN XXXXXX Displaysgroundmoduleserialnum...

Page 577: ...e and wheel parallel with the frame Two methods to help ensure proper calibration are the use of a carpenter s square to square the spindle to the axle or aligning the two wheels on one side using a s...

Page 578: ...nd Start the engine 4 The analyzer screen should read 5 Use the arrow button to reach ACCESS LEVEL 2 Hit Enter 6 Enter the Access Code 33271 7 Use the right Arrow key to reach CALIBRATIONS Hit Enter 8...

Page 579: ...is then leave off the control The display will read FRT LEFT and show the numeric calibration value for that wheel 13 Hit Enter The screen will read 14 Repeat steps 10 thru 12 for left rear steer 15 L...

Page 580: ...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 the arro...

Page 581: ...The screen will read 10 Hit Enter again The screen will read 11 Hit Enter again The screen will read 12 Activate the Drive Joystick forward full stroke until the machine just begins to move then leav...

Page 582: ...o The screen will show 14 Hit Enter The screen will read 15 Repeat steps 10 thru 12 for left reverse drive 16 Left Reverse Drive Calibration will be followed by Right Forward Drive Calibration which w...

Page 583: ...operate normally Cycling the EMS will clear the fault and allow the operator to operate the machine as a new level set point is taken VALVE DRIVER ERRORS There are three possible level valve driver er...

Page 584: ...ear the fault Operable functions shall be in the creep mode except while below elevation When both sensors appear to be working but have measure ments that disagree by 5 5 The following will occur 1 A...

Page 585: ...following personalities Refer to the Personality Ranges Defaults table for proper setting values Basket Level Up Min Basket Level Up Max Basket Level Down Max Jib Up Min Jib Down Min 8 Recycle EMS ST...

Page 586: ...ib U D if configured Start up the machine and exercise each above platform function from the ground eight 8 to ten 10 times for 5 seconds in each direction 11 Return the personality settings back to t...

Page 587: ...movement 12 Hit ENTER again CAL COMPLETE message should appear 13 Engine should again return to idle 14 Hit ESC should return to BASKET U CRKPT screen 15 Hit RIGHT ARROW to get to the BASKET D CRKPT...

Page 588: ...nector 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 the arrow button to reach ACCESS LEVEL 2 Hit Enter 6 En...

Page 589: ...The screen will read 9 Hit enter The screen will read 10 Hit Enter The screen will read 11 Hit Enter again The screen will read 12 Activate the Lift Up function by fully stroking the joy stick until...

Page 590: ...it Enter The screen will read 15 Repeat steps 10 thru 12 for the Lift Down function 16 After completing all the Tele Calibrations hit ESC twice to go back to CALIBRATIONS 6 15 CALIBRATING TELESCOPE CR...

Page 591: ...4 The analyzer screen should read 5 Use the arrow button to reach ACCESS LEVEL 2 Hit Enter 6 Enter the Access Code 33271 7 Use the right Arrow key to reach CALIBRATIONS Hit Enter 8 Use the arrow keys...

Page 592: ...ill not advance to CAL COMPLETE if the crack point is set at a lesser value 12 While reading the crack point setting on the analyzer activate the Tele Out function until the boom starts to move or unt...

Page 593: ...3121262 JLG Lift 6 77 14 Hit Enter The screen will read 15 Hit Enter The screen will read 16 Repeat steps 10 thru 12 for the Tele In function 17 After completing all the Tele Calibrations hit ESC twic...

Page 594: ...tions must be met a Steering previously calibrated b Axles extended c Wheels straight d Turntable centered e Boom fully retracted f Boom angle is less than 45 g Machine on firm level ground 2 Position...

Page 595: ...e TILT SENSOR The screen should read 10 Press ENTER 11 When prompted swing turntable 180 to opposite end of chassis 12 Press ENTER The screen should read 13 Upon completing swing calibration swing tur...

Page 596: ...can be performed on an individual basis 1 Position the Platform Ground select switch to the Ground position 2 Plug the analyzer into the connector inside the Ground control box 3 Pull out the Emergen...

Page 597: ...8 Use the arrow keys to reach the JIB SENSORS The screen should read 9 Press ENTER The screen should read 10 Press ENTER The screen should read as shown below When it does activate boom lift until th...

Page 598: ...esired jib sensor calibration The available sensor calibrations are JIB LIFT JIB LEVEL JIB SWING PLATFORM LEVEL 12 If the operator presses enter at the jib lift sensor calibra tion prompt the screen s...

Page 599: ...ey ESC will take the system back to the initial jib lift calibration display NOTE At this point the left or right arrow key may be used to skip to any of the other jib sensor calibrations 16 Hitting t...

Page 600: ...ib is at the mechanical stop the operator must hit ENTER again The screen will show 19 When the system completes this step the next screen will show 20 Press ENTER The screen should read 21 Operate ji...

Page 601: ...wn below The control system will jib level down and stop the jib leveling command 24 When the system completes the previous step the screen will read 25 Hitting the escape key ESC will take the system...

Page 602: ...or calibration The screen will show 27 Press Enter The screen shown below will be displayed At this point use the platform rotate right function switch to swing the jib right 28 When the jib reaches t...

Page 603: ...tch to swing the jib left 31 When the jib is at the mechanical stop press ENTER The screen will show 32 At the finish of the jib swing lift calibration the jib lock pin will be locked by the control s...

Page 604: ...ENTER key at this point will continue the cali bration sequence The screen will show 36 Press Enter The screen shown below will be displayed At this point use the platform level up function switch to...

Page 605: ...control system will stop the platform level and the screen will show 41 Pressing ENTER will take you back to the beginning and escape ESC will take you to the initial screen Calibrating the Jib Level...

Page 606: ...TER again 10 You will hear engine go to 1800 rpm 11 Using UP ARROW increase the value until you see the jib level movement 12 Hit ENTER again CAL COMPLETE message should appear 13 Engine should again...

Page 607: ...step by step procedure to calibrate the boom sensors 1 Before the boom sensors can be calibrated the follow ing conditions must be met a Steering telescope crack points and tilt previously calibrated...

Page 608: ...screen should read 6 Use the arrow button to reach ACCESS LEVEL 2 Hit Enter 7 Enter the Access Code 33271 8 Use the right Arrow key to reach CALIBRATIONS Hit Enter 9 Use the arrow keys to reach BOOM...

Page 609: ...et hit Enter The screen will read 12 After verifying all load personnel or material is removed from the platform hit Enter The screen will read 13 After visually verifying that the jib is horizontal h...

Page 610: ...ting telescope in to verify the boom is fully retracted hit Enter The screen will read 17 Use the up down arrows to select YES if the accessory is installed NO if it is not installed and hit enter The...

Page 611: ...e the up down arrows to select YES if the accessory is installed NO if it is not installed and hit enter The screen will read 21 Use the up down arrows to select YES if the accessory is installed NO i...

Page 612: ...ng sure the machine is in Calibration Position 1 hit Enter The screen will read 24 Lift up to stop full stroke of cylinder for Calibration Position 2 When the machine is in that position hit Enter The...

Page 613: ...180 degrees centered over opposite end of chas sis for Calibration Position 3 When the machine is in the proper position hit Enter The screen will read When Position 3 calibrating is complete the scre...

Page 614: ...ad Swing the machine back 180 degrees centered over original end of chassis for Calibration Position 4 When the machine is in the proper position hit Enter The screen will read When Position 4 calibra...

Page 615: ...ift 6 99 27 Press Enter The screen will read Telescope out to stop boom must be fully extended for Calibration Position 5 When the machine is in the proper position hit Enter The screen will read Figu...

Page 616: ...When the machine is in the proper position hit Enter The screen will read 29 Lift down to stop boom must be on boom rest for Cali bration Position 7 When the machine is in the proper position hit Ente...

Page 617: ...te the screen will read Press Enter The screen will read 30 Lift until the function stops controller will stop at 5 degrees above horizontal for Calibration Position 8 When the machine is in the prope...

Page 618: ...ess mark controller will be close operator must position the pointer to center line on decal within 0 25 6 mm for Calibration Position 9 When the boom is in the proper position hit Enter The screen wi...

Page 619: ...creen will read 32 Telescope in to green witness mark controller will find the position operator must visually verify the position When the boom is in the proper position the screen will read Pressing...

Page 620: ...red angle The display will read 34 Operate the Telescope Out function switch The control system will stop the boom at the desired length The dis play will read 35 Operate the Jib Telescope Out functio...

Page 621: ...he jib is telescoped in to the mechanical stop Press ENTER The display will read 38 Operate the Boom Telescope In function switch The control system will stop the boom at the desired length The displa...

Page 622: ...lescoped in to the stop The display will read 42 Operate the Boom Lift Down function until the main boom is lifted down to the rest The display will read 43 Press ENTER The display will read 44 After...

Page 623: ...stop on colored stripe matching the capac ity indicator If the boom does not stop on the correct stripe the system must be repaired by JLG authorized Service Personnel before the machine can be used 5...

Page 624: ...EM 6 108 JLG Lift 3121262 1001125195 B 1702566 B 1702565 B 1705170 A 1705744 A 1706741A 1001125194 A 1702938 PLATFORM CONTROL MODULE GROUND CONTROL MODULE FAULT CODE LIGHT FAULT CODE LIGHT Figure 6 31...

Page 625: ...TSENSOROUTOFRANGE TheChassisistilted 19 degreesformorethen4sec onds Notreportedduringpower up 0016 00 16 ENVELOPEENCROACHED HYDRAULICSSUSPENDED Thereisanenvelopeviolation Envelopecontrolsystem equippe...

Page 626: ...is 3 08Vor 3 83V Resistivejoysticks Thereisa 1Vrange around thesevaluesduetoresistortoler ances 2218 22 18 L SJOY OUTOFRANGELOW TheL SJoystickreferencevolt ageislow Resistivejoysticks thesefaults dono...

Page 627: ...17 25 17 DRIVEPREVENTED TILTED ABOVEELEVATION Drivingisnotpossiblewhilethe vehicleistiltedandaboveeleva tionANDisconfiguredtopre ventdrivewhiletiltedand aboveelevation 2521 25 21 JIBSWINGPREVENTED IN1...

Page 628: ...eequippedvehi clesonly 3326 33 26 LEFTFORWARDDRIVEPUMP SHORTTOBATTERY ThereisaShorttoBatterytothe LeftForwardDriveValve ChassisModuleequippedvehi clesonly 3328 33 28 LEFTREVERSEDRIVEPUMP SHORTTOGROUND...

Page 629: ...e StartRelay Dieselenginesonly 3363 33 63 STARTSOLENOID OPENCIRCUIT ThereisanOpenCircuittothe StartRelay Dieselenginesonly 3364 33 64 STARTSOLENOID SHORTTOBATTERY ThereisaShorttoBatterytothe StartRela...

Page 630: ...GROUND ThereisaShorttoGroundtothe PlatformLevelDownOverride Valve Electroniclevelingsystem equippedvehiclesonly 3392 33 92 PLATFORMLEVELDOWNOVERRIDEVALVE OPENCIRCUIT ThereisanOpenCircuittothe Platform...

Page 631: ...GravityLiftDownequippedvehi clesonly 33152 33 152 LIFTPILOTVALVE SHORTTOBATTERY ThereisaShorttoBatterytothe LiftPilotValve GravityLiftDownequippedvehi clesonly 33153 33 153 LIFTDOWNAUXVALVE SHORTTOGR...

Page 632: ...scopeFlowControl Valve 33309 33 309 MAINTELESCOPEFLOWCONTROLVALVE SHORTTOBATTERY ThereisaShorttoBatterytothe MainTelescopeFlowControl Valve 33311 33 311 MAINLIFTFLOWCONTROLVALVE SHORTTOGROUND Thereisa...

Page 633: ...352 35 2 JIBLEVELUPVALVE SHORTTOBATTERYOROPENCIRCUIT 353 35 3 JIBLEVELDOWNVALVE SHORTTOGROUND 354 35 4 JIBLEVELDOWNVALVE SHORTTOBATTERYOROPENCIRCUIT 355 35 5 JIBLIFTUPVALVE SHORTTOGROUND 356 35 6 JIB...

Page 634: ...t Deutzengineonly Oilpressure is 8PSIformorethen10sec ondsafterenginestart Ford Deutzengineonly 4313 43 13 THROTTLEACTUATORFAILURE TheengineRPMis XXXfor morethenXXseconds 4314 43 14 WRONGENGINESELECTE...

Page 635: ...artbeat for30sec 6629 66 29 CANBUSFAILURE TELEMATICSCANBUSLOADING TOOHIGH X Telematicsonly 6639 66 39 CANBUSFAILURE JIBCONTROLMODULE 6640 66 40 CANBUSFAILURE JIBLIFTANGLESENSOR 6641 66 41 CANBUSFAILUR...

Page 636: ...i brated Electroniclevelingsystem equippedvehiclesonly 837 83 7 PLATFORMLEVELSENSOR 1 SHORTTOBATTERY ThereisaShorttoBatterytothe PlatformLevelSensor 1 Electroniclevelingsystem equippedvehiclesonly 838...

Page 637: ...NSOR 1 OUTOFRANGEHIGH 8327 83 27 JIBSWINGSENSOR 2 OUTOFRANGELOW 8328 83 28 JIBSWINGSENSOR 2 OUTOFRANGEHIGH 8329 83 29 JIBSWINGSENSORS NOTCALIBRATED 8330 83 30 JIBSWINGSENSORS DISAGREEMENT 8331 83 31 J...

Page 638: ...range EnvelopeControlequippedvehi clesonly 8412 84 12 BOOMANGLESENSOR 2 INVALIDANGLE BoomAngleSensor 2outof range EnvelopeControlequippedvehi clesonly 8413 84 13 WRONGTELESCOPERESPONSE Boomtelescopei...

Page 639: ...lePressure Switchindicatespressurewhile notdrivingordoesnotindicate pressurewhiledrivingand restrictedtotransport ElectricallyreleasedOscillated Axlesequippedvehiclesonly 862 86 2 AXLEEXTENDVALVE SHOR...

Page 640: ...aShorttoGroundtothe RightRearSteerRightValve 8616 86 16 RIGHTREARSTEERLEFTVALVE SHORTTOBATTERYOROPENCIRCUIT ThereisaShorttoBatteryoran OpenCircuittotheRightRear SteerLeftValve 8617 86 17 RIGHTREARSTEE...

Page 641: ...ShorttoBatterytothe FrontRightSteerSensor 8632 86 32 FRONTLEFTSTEERSENSOR SHORTTOGROUNDOROPENCIRCUIT ThereisaShorttoGroundoran OpenCircuittotheFrontLeft SteerSensor 8633 86 33 FRONTLEFTSTEERSENSOR SHO...

Page 642: ...mModulehas reportedthatitsADS1213chip hasstoppedassertingitsinter rupt 9918 99 18 HIGHRESOLUTIONA2DFAILURE REINITLIMIT ThePlatformModulehas reportedthatitsADS1213chip hadtobereset3ormoretimes 9919 99...

Page 643: ...KPOINTSNOTCALIBRATED TheDriveCrackpointshavenot beencalibrated 9935 99 35 BLAMSENSORSUPPLYOUTOFRANGEHIGH TheBoomAngleSensorssupply voltageishigh BLAMequippedvehiclesonly 9936 99 36 BLAMSENSORSUPPLYOUT...

Page 644: ...LG Lift 3121262 99159 99 159 JIBLIFTANGLESENSOR INTERNALERROR 99160 99 160 FUNCTIONSLOCKEDOUT JIBCONTROLMODULESOFTWAREVERSION IMPROPER Table 6 8 Diagnostic Trouble Code Chart DTC Flash Code Sequence F...

Page 645: ...id damaging 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 th...

Page 646: ...ot auto 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 con...

Page 647: ...n male and female pins To prevent electrical malfunction caused by low level con ductivity between pins when wet Use the following procedure to apply Silicone Dielectric Com pound to the electrical co...

Page 648: ...a syringe for small connectors 2 Apply dielectric grease to the female contact fill it approximately full see example below 3 Leave a thin layer of dielectric grease on the face of the connector 4 As...

Page 649: ...ons DIN Connectors This connector is typically used on hydraulic valves Follow the installation instructions Exclusions A limited number of connectors do not benefit from dielectric grease or may be p...

Page 650: ...no practical 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 necto...

Page 651: ...as shipped position See Figure 7 7 Proceed as follows 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 7 9 2 Pull back on the contact wire wit...

Page 652: ...the wedge 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...

Page 653: ...n the 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 NO...

Page 654: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 10 JLG Lift 3121262 Figure 7 13 Connector Installation...

Page 655: ...ng toward exterior locking mechanism The wedgelock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP...

Page 656: ...used 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...

Page 657: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 13 Figure 7 20 Jib Electrical Components...

Page 658: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 14 JLG Lift 3121262 Figure 7 21 Chassis Electrical Components Sheet 1 of 2...

Page 659: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 15 Figure 7 22 Chassis Electrical Components Sheet 2 of 2...

Page 660: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 16 JLG Lift 3121262 Figure 7 23 Turntable Electrical Components Sheet 1 of 2...

Page 661: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 17 Figure 7 24 Turntable Electrical Components Sheet 2 of 2...

Page 662: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 18 JLG Lift 3121262 Figure 7 25 Console Box Harness Sheet 1 of 2...

Page 663: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 19 Figure 7 26 Console Box Harness Sheet 2 of 2...

Page 664: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 20 JLG Lift 3121262 Figure 7 27 Platform Valve Harness Sheet 1 of 2...

Page 665: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 21 Figure 7 28 Platform Valve Harness Sheet 2 of 2...

Page 666: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 22 JLG Lift 3121262 Figure 7 29 Jib Valve Harness Sheet 1 of 3...

Page 667: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 23 Figure 7 30 Jib Valve Harness Sheet 2 of 3...

Page 668: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 24 JLG Lift 3121262 Figure 7 31 Jib Valve Harness Sheet 3 of 3...

Page 669: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 25 Figure 7 32 Boom Length and Angle Harness Sheet 1 of 2...

Page 670: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 26 JLG Lift 3121262 Figure 7 33 Boom Length and Angle Harness Sheet 2 of 2...

Page 671: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 27 Figure 7 34 Main Terminal Box Harness Sheet 1 of 4...

Page 672: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 28 JLG Lift 3121262 Figure 7 35 Main Terminal Box Harness Sheet 2 of 4...

Page 673: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 29 Figure 7 36 Main Terminal Box Harness Sheet 3 of 4...

Page 674: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 30 JLG Lift 3121262 Figure 7 37 Main Terminal Box Harness Sheet 4 of 4...

Page 675: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 31 Figure 7 38 Turntable Harness Sheet 1 of 3...

Page 676: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 32 JLG Lift 3121262 Figure 7 39 Turntable Harness Sheet 2 of 3...

Page 677: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 33 Figure 7 40 Turntable Harness Sheet 3 of 3...

Page 678: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 34 JLG Lift 3121262 Figure 7 41 Pump Harness...

Page 679: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 35 Figure 7 42 Chassis Harness Sheet 1 of 3...

Page 680: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 36 JLG Lift 3121262 Figure 7 43 Chassis Harness Sheet 2 of 3...

Page 681: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 37 Figure 7 44 Chassis Harness Sheet 3 of 3...

Page 682: ...LK 000 31 01 BLK 000 31 11 TAN 3 2 TAN 3 2 TAN 3 3 TAN 3 3 BRN 13 2 BRN 13 2 BRN 14 2 BRN 14 2 BLU 28 2 BLU 28 2 BLU 27 2 BLU 27 2 BRN 29 2 BRN 29 2 BRN 30 2 BRN 30 2 GRY 23 2 GRY 23 2 GRY 24 2 GRY 24...

Page 683: ...53 2 BRN ORN 53 2 RED YEL 54 4 WHT YEL 39 1 WHT YEL 48 6 BRN WHT 47 6 BRN WHT 47 5 BRN WHT 47 8 ORN RED 49 103 ORN RED 49 101 ORN RED 49 100 RED YEL 54 5 YEL RED 2 2 1 YEL RED 2 3 2 ORN RED 49 17 ORN...

Page 684: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 40 JLG Lift 3121262 This page left blank intentionally...

Page 685: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 41 Figure 7 47 Electrical Schematic Sheet 1 of 18...

Page 686: ...1 SW76 2 1 YEL RED 2 10 4 YEL RED 2 10 4 YEL RED 2 10 3 YEL RED 2 10 3 YEL RED 2 10 8 YEL RED 2 10 8 YEL RED 2 10 9 YEL RED 2 10 9 YEL RED 2 10 16 PUMP POT GENERIC SW118 1 2 3 4 5 6 YEL RED 2 10 5 YEL...

Page 687: ...Y 23 1 GRY 23 1 GRY 24 1 GRY 24 1 BRN 30 1 BRN 30 1 BRN 29 1 BRN 29 1 WHT 60 4 WHT 59 1 ORN RED 49 42 ORN RED 49 40 ORN RED 49 40 BLU 27 1 BLU 27 1 BLU 28 1 BLU 28 1 BLU ORN 52 12 BLU ORN 52 12 BRN 13...

Page 688: ...3 X117 SEE SHEET 2 ZONE E 1 1 2 3 4 5 GRAY BLACK BLUE WHITE BROWN PROXIMITY SENSOR JIB TRANSPORT 2 SN136 1 2 4 3 PROXIMITY SENSOR JIB TRANSPORT 1 SN137 1 2 4 3 X138 SEE SHEET 2 ZONE C 1 1 2 3 4 5 6 7...

Page 689: ...L BLK 18 AWG BLK WHT 12 AWG BLK 000 45 2 12 YEL RED 2 30 1 YEL RED 2 8 10 12 PNK 26 3 4 PNK 25 3 4 YEL RED 2 21 1 YEL RED 2 3 1 GRN CAN1 LOW GRN CAN1 LOW YEL CAN1 HIGH YEL CAN1 HIGH BLK CAN1 SHIELD BL...

Page 690: ...0 56 1 BLK BLK 000 55 2 BLK 000 56 2 BLK 000 55 1 BLK 000 55 3 BLK 000 56 3 ORN 8 3 1 ORN 8 3 1 ORN 8 2 1 ORN 8 2 1 BLK 000 10 BLK 000 10 ORN 7 3 1 ORN 7 3 1 ORN 7 2 1 ORN 7 2 1 BLK 000 27 2 BLK 000 2...

Page 691: ...1 TAN 55 21 TAN 55 22 TAN 55 22 BLK 000 33 BLK 000 33 BRN WHT 47 12 BRN WHT 47 12 BLU ORN 52 2 BLU ORN 52 2 BLK 000 34 BLK 000 34 BLK 000 36 1 BLK 000 35 7 BLK 000 35 7 BLK 000 35 2 BLK 000 35 2 BLU O...

Page 692: ...Sheet_4 T T Boom 8 B SHIELD Sheet_4 T T Boom 8 B BLK CAN2 SHIELD YEL CAN1 H_GTWY YEL CAN1 H_GTWY GRN CAN1 L_GTWY GRN CAN1 L_GTWY YEL RED 2 2 1 YEL RED 2 3 2 ORN RED 49 17 X146 SEE SHEET 3 ZONE H 8 1...

Page 693: ...2 40 04 YEL RED 2 40 04 YEL RED 2 40 05 YEL RED 2 40 05 YEL RED 2 40 08 YEL RED 2 40 08 YEL RED 2 40 09 YEL RED 2 40 09 YEL RED 2 40 10 LIGHT 1000 CAP LB238 1 2 WHT 21 2 WHT 22 2 BLK 000 31 01 BLK 000...

Page 694: ...IGHT V163 1 2 LEFT FRONT STEER LEFT V164 1 2 RIGHT FRONT STEER LEFT V165 1 2 RETRACT FRONT AXLES V166 1 2 FRONT AXLES EXTEND V167 1 2 YEL 9 1 YEL 9 1 YEL 9 2 YEL 9 2 YEL 10 1 YEL 10 1 YEL 10 2 YEL 10...

Page 695: ...K 000 12 04 BLK 000 12 11 BLK 000 12 09 BLK 000 12 08 BLK 000 12 10 BLK 000 12 06 BLK 000 12 07 BLK 000 12 05 BLK 000 12 03 S172 S173 YEL WHT 43 1 YEL WHT 43 1 YEL WHT 44 1 YEL WHT 44 1 YEL WHT 39 2 Y...

Page 696: ...3 14 15 16 17 18 19 20 21 22 23 24 25 X62 PUMP CONNECTOR SEE SHEET 4 1 2 3 4 5 6 X273 DEUTZ DIAGNOSTIC PORT A B K L BLK 000 1 BLK 000 1 ORN RED 49 198 ORN RED 49 198 ORN RED 49 199 ORN RED 49 199 YEL...

Page 697: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121262 JLG Lift 7 53 This Page Left Blank Intentionally...

Page 698: ...LIGHT RIGHT FRONT 1 1 LEFT REAR LIGHT 1 1 RIGHT REAR LIGHT 1 1 87 30 87a 85 86 RELAY HEAD TAIL LIGHT 1 2 3 4 5 CONNECTED TO B ON AUX POWER RELAY 1 BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK WHIT...

Page 699: ...PLATFORM SENSOR 1 RL502 86 1 RL502 85 1 1 RL502 87A 1 RL502 30 1 RL502 87 87 30 87a 85 86 1 RL503 86 1 RL503 85 1 1 RL503 87A 1 RL503 30 1 RL503 87 87 30 87a 85 86 YEL RED P3 YEL RED P9 1 ORN RED P5 O...

Page 700: ...5A MS932 B A C D E F G H RED 48 13 GLOW 8AWG ORG 248 23 1 GLOW SENSE 18AWG ORG 248 23 1 GLOW SENSE 18AWG BLK 248 23 GLOW SENSE 0 75mm BLK 148 26 FUEL PUMP RELAY CONTROL GND 0 75mm RED 148 3 ECM PWR 2...

Page 701: ...X941 1 2 3 4 X942 1 2 3 4 BLK 148 64 WATER IN FUEL SW 16AWG BLK 148 57 WATER IN FUEL SW RTN 16AWG BLK 148 64 WATER IN FUEL SW 0 75mm BLK 148 57 WATER IN FUEL SW RTN 0 75mm RED 1 148 135 ECM PWR 8AWG B...

Page 702: ...D E F G H J X5 1 2 3 4 5 6 7 8 9 10 11 12 WHT IGNITION S3 WHT IGNITION BLK GROUND S2 BLK GROUND BLK GROUND S1 BLK GROUND RED BEACON PWR RED BEACON PWR WHT IGNITION RED CAN HIGH RED CAN HIGH BLK CAN LO...

Page 703: ...ING ENABLE LAMP LB373 1 2 BLK BLK ORN BLK ORN RED RED ORN CRIBBING ENABLE SW SW374 MS377 1 1 2 MS377 2 1 2 MS377 3 1 2 X378 TO CRIBBING MODULE J1 1 2 3 4 5 6 7 8 9 10 11 12 J7 CONNECT TO GROUND CONTRO...

Page 704: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 60 JLG Lift 3121262 NOTES...

Page 705: ......

Page 706: ...de Ihlpohl Germany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5...

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