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Oshkosh JLG 800A, Service And Maintenance Manual

The Oshkosh JLG 800A Service And Maintenance Manual is a vital tool for anyone who owns or operates this versatile equipment. Ensure the longevity of your machine by downloading the manual for free at manualshive.com. Find all the information you need to properly care for and maintain your Oshkosh JLG 800A.

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viii

– JLG Lift –

3120740

TABLE OF CONTENTS

                        

SECTION NO.                                                        TITLE

                                                         

     PAGE NO.

SECTION 7  -  ELECTRICAL INFORMATION & 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
AWP 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

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Summary of Contents for JLG 800A

Page 1: ...Service and Maintenance Manual Model 800A 800AJ Prior to S N 0300183033 P N 3120740 December 18 2015 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 2: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 3: ...igh potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Do not use your hand to check for leaks Use...

Page 4: ...2001 Revised January 14 2003 Revised October 19 2004 Revised July 11 2005 Revised March 7 2006 Revised June 12 2007 Revised May 23 2008 Revised August 5 2011 Revised December 12 2012 Revised December...

Page 5: ...Oil Build Up From The Propane Regulator Prior to S N 0300134626 1 13 Propane Fuel Filter Replacement 1 14 Propane Fuel System Pressure Relief 1 15 SECTION 2 GENERAL 2 1 Machine Preparation Inspection...

Page 6: ...4 Cleaning and Inspection 3 4 Repair 3 4 Assembly 3 6 3 5 Drive Brake Ausco Prior to S N 0300056875 3 12 Disassembly 3 12 Inspection 3 12 Assembly 3 12 3 6 Drive Brake Mico S N 0300056875 to S N 0300...

Page 7: ...bly 3 77 Inspection and Cleaning 3 79 Assembly 3 79 Timing Procedure 3 81 3 19 Rotary Coupling 3 84 3 20 Tilt Alarm Switch Prior to S N 0300065534 3 89 Manual Adjustment 3 89 3 21 Spark Arrester Clean...

Page 8: ...sembly 3 135 Low Pressure Regulator LPR 3 136 Air Fuel Mixer 3 137 Electronic Throttle Control ETC 3 137 Engine Control Module 3 138 Heated Exhaust Gas Oxygen Sensor 3 138 Gasoline Multi Point Fuel In...

Page 9: ...ion 4 22 Tower Out of Sync 4 23 4 9 Upright Monitoring System 4 25 Re Synchronizing Upright 4 25 Calibration Pre ADE Machines 4 27 Calibration ADE Equipped Machines 4 31 Calibration Faults 4 35 Functi...

Page 10: ...y 4 53 4 15 Boom Valve Adjustment 4 53 Tower Boom 4 54 Upper Boom 4 54 4 16 Rotator Prior to S N 0300067538 4 54 Disassembly 4 54 Inspection 4 55 Assembly 4 56 4 17 Rotator Assembly S N 0300067538 to...

Page 11: ...r Removal 5 78 Slave Cylinder Installation 5 78 5 8 Hydraulic Pump W hayes Pump drive Coupling Lubrication 5 78 5 9 Pressure Setting Procedures 5 78 FIRST Set Up the Function Pump 5 78 SECOND Adjustme...

Page 12: ...ing Silicone Dielectric Compound to Electrical Connections 7 3 Installation of Dielectric Grease 7 4 Deutsch HD DT DTM DRC Series 7 4 AWP Seal 7 4 AMP Mate N Lok 7 5 DIN Connectors 7 5 Exclusions 7 5...

Page 13: ...Spool 3 30 3 13 Loop Flushing Spool 3 32 3 14 Plugs Fittings and Speed Sensor 3 32 3 15 End Cap 3 33 3 16 Valve Plate Rear Shaft Bearing 3 33 3 17 Cylinder Kit 3 34 3 18 Shaft Seal 3 34 3 19 Shaft Fr...

Page 14: ...70 EMR2 Fault Codes Sheet 4 of 5 3 131 3 71 EMR2 Fault Codes Sheet 5 of 5 3 132 3 72 Engine Oil Dip Stick 3 133 3 73 Electric Fuel Lock Off 3 135 3 74 EPR Assembly 3 136 3 75 Low Pressure Regulators...

Page 15: ...1 5 12 Seating the Tapered Bearing 5 11 5 13 Piston Seal Kit Installation 5 12 5 14 Rod Assembly Installation 5 12 5 15 Cylinder Barrel Support 5 13 5 16 Capscrew Removal 5 13 5 17 Upright Level Cylin...

Page 16: ...ck Piston Seal Installation 5 36 5 72 Piston Seal Kit Installation 5 36 5 73 Rod Assembly Installation 5 36 5 74 Cylinder Barrel Support 5 37 5 75 Capscrew Removal 5 37 5 76 Master Cylinder 800A 5 38...

Page 17: ...Installation Prior to S N 0300142664 5 60 5 129 Piston Seal Kit Installation S N 0300142664 to S N 0300183033 5 60 5 130 Rod Assembly Installation 5 61 5 131 Cylinder Barrel Support 5 62 5 132 Capscre...

Page 18: ...3332 to S N 0300183033 Sheet 5 of 6 5 108 5 184 Hydraulic Schematic S N 0300083332 to S N 0300183033 Sheet 6 of 6 5 109 6 1 Hand Held Analyzer 6 1 6 2 ADE Block Diagram 6 4 6 3 Analyzer Flow Chart Pri...

Page 19: ...7 34 Electrical Schematic Ford EFI Engine S N 0300048538 to S N 0300065634 Sheet 1 of 2 7 28 7 35 Electrical Schematic Ford EFI Engine S N 0300048538 to S N 0300065634 Sheet 2 of 2 7 29 7 36 Electrica...

Page 20: ...Major Component Weights 800AJ 1 7 1 29 Critical Stability Weights 800A 1 7 1 30 Critical Stability Weights 800AJ 1 7 1 31 Lubrication Specifications 1 9 2 1 Inspection and Maintenance 2 2 2 2 Cylinder...

Page 21: ...ming Information Software Version P6 1 S N 0300065534 to S N 0300183033 6 33 6 5 800A Machine Configuration Programming Settings 6 40 6 6 800 AJ Machine Configuration Programming Settings 6 41 6 7 Mac...

Page 22: ...xviii JLG Lift LIST OF TABLES TABLE NO TITLE PAGE NO This page left blank intentionally G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 23: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 24: ...res IN445 55D19 5 18X19 5FoamFilledTires 34 200lbs 15520kg 34 200lbs 15520kg 34 270lbs 15550kg 34 270lbs 15550kg 33 100lbs 15020kg 33 100lbs 15020kg 33 550lbs 15220kg 33 550lbs 15220kg Table 1 2 Capac...

Page 25: ...umption 0 88GPH 3 33lph Battery 1000ColdCrankingAmps 210minutes ReserveCapacity 12VDC Horsepower 64 2600RPM fullload Table 1 6 Caterpillar 3044C Type FourStrokeCycle Cylinders 4in line Bore 3 70inch 9...

Page 26: ...min 45cm3 max 12cm3 min 2 75cu in max 1 1cu in min 46cm3 max 12cm3 min DriveHubRatio 2WD 4WD 86 7 1 59 3 1 DriveBrake Automaticspringapplied hydraulically releaseddiscbrakes Table 1 11 Drive System S...

Page 27: ...10MicronsAbsolute ChargeFilter 10MicronsAbsolute HydraulicStrainers InTank 30Microns Table 1 18 Torque Requirements Description Torque Value Dry Interval Hours WheelBolts 300ft lbs 407Nm 150 Supportt...

Page 28: ...0 to 210 F 10 to 99 C 20W 20 Table 1 20 Mobilfluid 424 Specs SAE Grade 10W 30 Gravity API 29 0 Density Lb Gal 60 F 7 35 Pour Point Max 46 F 43 C Flash Point Min 442 F 228 C Viscosity Brookfield cPat 1...

Page 29: ...50 88 9 17 50 444 5 1 50 38 1 Lift Jib 3 00 76 2 25 50 647 7 1 50 38 1 Table 1 24 Exxon Univis HVI 26 Specs SpecificGravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at...

Page 30: ...chineComplete GVW w PneumaticTires 34200 15512 85 MachineComplete GVW w FoamFilledTires 33100 15014 NOTE The above components are separate assemblies example TURNTABLE COMPLETE does not include booms...

Page 31: ...CATIONS 1 8 JLG Lift 3120740 9 10 11 12 13 2 3 14 15 16 17 18 21 3 6 3 5 1 8 2 3 20 7 19 4 Figure 1 1 Maintenance and Lubrication Diagram G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 32: ...200 hours of operation 3 Wheel Drive Hub Lube Point s Level Fill Plug Capacity 17 oz 0 5 L 1 2 Full Lube EPGL Interval Check level every 3 months or 150 hrs of operation change every 2 years or 1200 h...

Page 33: ...d by Condition Indicator 6 Hydraulic Charge Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator 7 Hydraulic Tank Lube Point s Fill...

Page 34: ...ge w Filter Isuzu Lube Point s Fill Cap Spin on Element Capacity 8 5 qt 8 0L engine 5 3 qt 5 L cooler Lube EO Interval Change oil after first 50 and every 200 hrs there after Change oil filter after 5...

Page 35: ...Isuzu Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 17 Fuel Filter Caterpillar Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 18 Fuel...

Page 36: ...E DRAINING THIS WILL ALLOW THE OILS TO BE LIQUID AND FLOW FREELY FROM THE REGULATOR 1 Move the equipment to a well ventilated area Ensure there are no external ignition sources 2 Start the engine and...

Page 37: ...ING NEW SEAL 1 Install the mounting plate to lock off O ring seal 2 Install the retaining bolt seal 3 Install the housing seal 4 Drop the magnet into the bottom of the filter housing 5 Install the fil...

Page 38: ...CABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS To relieve propane fuel system pressure 1 Close the manual shut off valve on the propane fuel tank 2 Start and run the vehicle until the engin...

Page 39: ...IFICATIONS 1 16 JLG Lift 3120740 Figure 1 4 Torque Chart Sheet 1 of 5 SAE Fasteners Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o...

Page 40: ...SPECIFICATIONS 3120740 JLG Lift 1 17 Figure 1 5 Torque Chart Sheet 2 of 5 SAE Fasteners Torq ue Tor que Torq ue Torqu e To rqu e G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r...

Page 41: ...IONS 1 18 JLG Lift 3120740 Figure 1 6 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 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e...

Page 42: ...CATIONS 3120740 JLG Lift 1 19 Figure 1 7 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 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 43: ...CATIONS 1 20 JLG Lift 3120740 Figure 1 8 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 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y...

Page 44: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 45: ...rs whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environ ment severity and frequency of usage req...

Page 46: ...t being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eyebolt or similar bracket lessens as the angle between the sup porting structure and the...

Page 47: ...onents as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the speci fied intervals When recommended lubrica...

Page 48: ...a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice h...

Page 49: ...installation and operation 2 6 WELDING ON JLG EQUIPMENT NOTE This instruction applies to repairs or modifications to the machine and to welding performed from the machine on an external structure or...

Page 50: ...etractChainorCableSystems 1 3 5 22 UMSSystemFunctionalCheck 1 2 3 PlatformAssembly 9 Platform 1 2 1 2 Railing 1 2 1 1 2 Gate 5 1 1 5 Floor 1 2 1 1 2 Rotator 9 5 15 LanyardAnchoragePoint 2 1 2 10 1 2 1...

Page 51: ...c ElectricSystem 9 HydraulicPumps 1 9 1 2 9 HydraulicCylinders 1 9 7 2 1 2 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 9 1 2 1 2 HydraulicHoses Lines andFittings 1 9 12 1 2 9 12 1 2 9 12 Hydraulic...

Page 52: ...erandsecureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwhenr...

Page 53: ...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 A M B IE N TA IR T E M P E R A T U R E...

Page 54: ...SECTION 2 GENERAL 2 10 JLG Lift 3120740 Figure 2 2 Engine Operating Temperature Specifications Ford 4150548 E G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 55: ...R O L O N G E DO P E R A T IO NIN A M B IE N TA IRT E M P E R A T U R E S O F100 F 38 C O RA B O V E E X T E N D E DD R IV IN GW IT H H Y D R A U LICO ILT A N K T E M P E R A T U R E SO F180 F 82 C O...

Page 56: ...SECTION 2 GENERAL 2 12 JLG Lift 3120740 Figure 2 4 Engine Operating Temperature Specifications GM 4150548 E G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 57: ...ith a quote for the right part that your machine needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulott...

Page 58: ...tact width equal or greater than origi nal Wheel diameter width and offset dimensions equal to the original Unless specifically approved by JLG Industries Inc do not replace a foam filled or ballast f...

Page 59: ...ed open the bleeder on top of the cylinder then have an operator from the plat form on high engine feather drive Activate drive just enough so the engine is under load but not enough to stall the engi...

Page 60: ...h block with ascension ramp in front of right front wheel 10 Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block 11 Carefully...

Page 61: ...components for chipped or broken teeth and for excessive or uneven wear patterns 5 Inspect carrier for damage especially in anti roll pin and planet shaft hole areas 6 Inspect all planet shafts for sc...

Page 62: ...k Place second set of needle rollers into cluster gear l Apply grease or petroleum jelly to tang side of two thrust washers Place thrust washers against bosses in carrier with washer tang fitting into...

Page 63: ...n and inspect all parts in accordance with Cleaning and Inspection procedures Replace parts as necessary d Place washer 31 spring 32 and washer 31 in that order onto input shaft Assembly 1 Using a sui...

Page 64: ...ining ring 9 completely into spindle groove and against bearing shim Ensure retaining ring is entirely in groove 8 The disengage spacer and spring are installed into the counterbore of the spindle 9 I...

Page 65: ...oleum jelly to hold in place 13 Install retaining ring 34 into input shaft retaining ring groove 14 Place input shaft assembly 35 into spindle bore with unsplined end facing out The action of the spri...

Page 66: ...rrect location during ring gear installation The side of the ring gear with X stamped on it should be up 20 While holding ring gear and cluster gears in mesh place small side of cluster gears into mes...

Page 67: ...level check plug in cover located approximately 90 degrees from oil fill plug in hub 26 Locate four bolts 42 90 degrees apart into counter bored holes in hub marked in step 16 Torque bolts to 47 ft l...

Page 68: ...tWasher 15 NeedleRoller 16 Spacer 17 PlanetShaft 18 ClusterGear 19 RollPin 20 NotUsed 21 ClusterGear 22 O ring 23 Cover 24 CoverCap 25 Bolt 26 DisconnectCap 27 DisconnectRod 28 O ring 29 O ring 30 Pip...

Page 69: ...NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY...

Page 70: ...gRing 6 Seal 7 SpringRetainer 8 SmallCompressionRing 9 LargeCompressionRing 10 Shaft 11 PrimaryDisc 12 RotatingDisc 13 NotUsed 14 StationaryDisc 15 Piston 16 BackupRing 17 O ring 18 BackupRing 19 O ri...

Page 71: ...etaining ring 20 from cover plate 16 and press out oil seal 17 and bearing 18 if required NOTE Cover plate 16 must be supported as indicated in Figure 3 5 Assembly LUBRICATE ALL RUBBER COMPONENTS FROM...

Page 72: ...or mar piston 11 Install new case seal 4 in cover plate 16 12 Position pressure plate 3 on cover plate 16 aligning dowel pins 15 with holes in pressure plate 13 Install cap screws 1 and washers 2 and...

Page 73: ...g 7 Piston 8 O ring 9 BackupRing 10 Shaft 11 StatorDisc 12 RotorDisc 13 ReturnPlate 14 Springs 15 DowelPin 16 CoverPlate 17 OilSeal 18 Bearing 19 RetainingRing 20 RetainingRing Figure 3 5 Drive Brake...

Page 74: ...tacksetsthetorque level Athinstackreducestorque Checkdiscthickness Springsbrokenorhavetakenapermanentset Brokenorsetspringscancausereducedtorque a rareoccurrence Checkreleasepressure Seespringreplacem...

Page 75: ...al float or wear 6 Examine O ring seals 15 17 and backing rings 16 18 for damage Assembly 1 Lightly lubricate rotary shaft seal 12 and assemble to housing 2 taking care not to damage seal lip 2 Apply...

Page 76: ...Gasket 6 OuterPlate 7 Gasket 8 Cylinder 9 Piston 10 BallBearing 11 RetainingRing 12 ShaftSeal 13 Capscrew 14 Lockwasher 15 O ring 16 BackupRing 17 O ring 18 BackupRing 19 DowelPin 20 Plug 21 Plug 22...

Page 77: ...only seal material changed to Viton Drive shaft Bearing set miscellaneous parts Rotary group complete 9 pistons cylinder sub assembly valve plate cw or ccw corresponding to the order retaining plate a...

Page 78: ...g the Drive Shaft Seal 1 Remove the snap ring 2 Change the shaft seal and check its sliding surface drive shaft and housing grease the sealing ring Figure 3 7 Drive Motor Cutaway G o t o D i s c o u n...

Page 79: ...e pump housing 5 Assemble the snap ring 6 Assemble the snap ring in the correct position Disassembly and Assembly 1 Disassemble the pilot valve 2 Mark the position of the port plate and remove the soc...

Page 80: ...emove it 8 Loosen the retaining nut of the stopper max flow and remove it 9 Turn in the stopper max flow to get swivel angle zero 10 Disassemble the rotary group in horizontal position 11 Disassemble...

Page 81: ...moving the swash plate 15 The swash plate must be lifted a little bit to disassemble the piston rod 16 Disassembly of the swash plate 17 Remove the spring 18 Remove both bearing shells 19 Remove the d...

Page 82: ...ate isn t shown 24 A usual commercial bearing puller is used to disassem ble the external bearing ring of the taper roller bearing inside the port plate Take care not to damage the sur face of the por...

Page 83: ...cw and ccw valve plates 4 Pumps counterclockwise driven must have a position of the valve plate 4 degrees de centered in ccw position 5 Assembly of the port plate and the pump housing Note the correc...

Page 84: ...20740 JLG Lift 3 27 NOTE Differential volume if you are rotating the threaded pin each rota tion is appr 3 1 cm3 Figure 3 8 Flow Control Pilot Valves G o t o D i s c o u n t E q u i p m e n t c o m t...

Page 85: ...eaded pin you will be able to reduce the flow from Vg max to 50 of Vg max 3 9 DRIVE MOTOR ADJUSTMENT PROCEDURE PRIOR TO S N 0300083332 1 Remove the cap nut from adjustment screw 2 Loosen jam nut on th...

Page 86: ...oid damaging the shaft during removal install a large sheet metal screw into the chuck of a slide ham mer Drive the screw into the seal surface and use the slide hammer to pull the seal 4 Discard the...

Page 87: ...ear INSTALLATION 1 Install orifice poppet 13 2 Install shift spool 12 3 Install spring retaining washers onto springs 10 and 11 4 Carefully install centering springs 7 8 and 9 5 Install new O rings 6...

Page 88: ...ntamountofhydraulicfluidwillnotmeetthecoolingdemands ofthesystem Fillthereservoirtotheproperlevel Inspecttheheatexchanger ifso equipped Iftheheatexchangerfails orbecomesobstructed itmaynotmeetthe cool...

Page 89: ...hen remove the speed sensor using a Vi inch hex wrench Units without speed sensor have an O ring plug 15 installed in that location remove it with a Va inch internal hex wrench 10 Using a 1 4 inch int...

Page 90: ...t number are stamped on its surface 16 Remove and discard the O rings 27 28 17 Remove the rear shaft bearing 29 from the endcap with a bearing puller The bearing may be difficult to remove with a pull...

Page 91: ...amaging the shaft during seal removal Install a large sheet metal screw into the chuck of a slide ham mer Drive the screw into the seal surface and use the slide hammer to pull the seal 21 Remove the...

Page 92: ...develop wear patterns Number the pistons and bores for reassembly if they are to be reused 27 Remove the ball guide 47 hold down pins 48 and retaining ring 49 from the cylinder block NOTE Most repairs...

Page 93: ...dry parts again after any rework or resurfacing PISTON Inspect the pistons for damage and discoloration Discolored pistons may indicate excessive heat do not reuse SLIPPERS Inspect the running surface...

Page 94: ...ransfer may appear on these surfaces and is acceptable pro viding the surface condition meets specifications shown Mea sure the swashplate thickness from the journals to the running face Replace swash...

Page 95: ...eplace if necessary LOOP FLUSHING SPOOL Inspect the loop flushing spool Check for cracks or damage Replace if necessary Assembly 1 Install new O ring 1 and piston seal 2 to the servo pis ton 3 Install...

Page 96: ...f you re reusing the pistons install them to the original block bores Lubricate the pistons slippers retainer and ball guide before assembly Set the cylinder kit aside on a clean surface until needed...

Page 97: ...lippers facing the swashplate Rock the shaft to align the block splines and slide the cylinder kit into place Orient the motor with the shaft pointing downward and verify the cylinder kit swashplate j...

Page 98: ...nd cap screws 26 Check to ensure the endcap will prop erly seat onto the housing without interference Improper assembly of the internal components may prevent the endcap from seating properly Ensure t...

Page 99: ...snap ring 29 19 Install remaining plugs and fittings to the housing Refer to the drawing below for wrench sizes and installation torques 29 28 27 27 ShaftSeal 28 SealSupportWasher 29 SnapRing Figure 3...

Page 100: ...upper most case drain port 4 To ensure the pump and motor stay filled with oil install case drain lines into the upper most case drain ports 5 Install a 0 to 500 psi 0 to 35 bar gauge in the charge p...

Page 101: ...ositions indicated on Figure 3 35 try to insert a 0015 feeler gauge between the bolt and hardened washer at the arrow indicated position c Ensure that the 0 0015 feeler gauge will not pene trate under...

Page 102: ...SECTION 3 CHASSIS TURNTABLE 3120740 JLG Lift 3 45 Figure 3 33 Swing Bearing Tolerance Boom Placement Sheet 1 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 103: ...SECTION 3 CHASSIS TURNTABLE 3 46 JLG Lift 3120740 Figure 3 34 Swing Bearing Tolerance Boom Placement Sheet 2 of 2 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 104: ...PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION Swing Bearing Replacement 1 Removal a From Ground Control station operate the boom adequately to provide access to frame open...

Page 105: ...19 and install the bolts and washers through the frame and outer race of the bearing Tighten the bolts to an ini tial torque of 190 Ft lbs 260 Nm w JLG Thread locker P N 0100019 d Remove the lifting e...

Page 106: ...40 JLG Lift 3 49 800A Gross Weight 20 700 lbs Upper Works above Turntable Bearing C L CG ROTATION 33 0 Hole in T T Figure 3 37 Swing Bearing Removal 800A G o t o D i s c o u n t E q u i p m e n t c o...

Page 107: ...JLG Lift 3120740 Figure 3 38 Swing Bearing Removal 800AJ 800AJ GrossWeight 20 750lbs Upper Works above Turntable Bearing C L CG ROTATION 31 8 Hole inT T G o t o D i s c o u n t E q u i p m e n t c o m...

Page 108: ...Bearing Torque Sequence NOTE Swing Bearing Torque Sequence is typical for both inner and outer races Machines built prior to S N 0300068040 Machines built S N 0300068040 to S N 0300183033 G o t o D i...

Page 109: ...egrees when the turntable lock is removed if the turntable is not balanced properly 4 Remove turntable lock pin 5 Apply JLG Threadlocker P N 0100019 and pre torque bolt to 30 ft lbs 42 Nm 6 Tighten se...

Page 110: ...haft 1A 9 The Output Shaft 1A may now be pressed out of the Hub 1G 10 The Bearing Cups 1C and 1E will remain in Hub 1G as will Bearing Cone 1F Bearing Cone 1D will remain on the Output Shaft 1A The Se...

Page 111: ...F THE COUNTERBORE WHILE SEATING THIS O RING Also at this time locate and mark the 4 counter beamed holes in the face of the Hub 1G This is for identification later in the assembly 4 Thrust Spacer 9 is...

Page 112: ...o not mesh easily or Carrier Assembly does not rotate freely then remove the Carrier and Ring Gear and check the Cluster Gear timing 8 Input Gear 8 is installed meshing with the teeth of the large dia...

Page 113: ...b 1G counterbore 13 Install regular Grade 8 Bolts 12 into remaining holes 14 Pipe Plugs 20 are to be installed into Cover 6 using a lubricant seal of some sort 15 Torque Shoulder Bolts 13 to 23 27 ft...

Page 114: ...d into the counterbore of the Hub 1G Care should be taken to insure the Seal 1B is being correctly installed smooth face UP and located just flush with the counterbore face 6 The Bearing Cone 1F is an...

Page 115: ...the Output Shaft 1A EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE 11 Upon completion of Step 10 rap the internal end of the Output Shaft 1A twice with a piece of soft metal rod This will releas...

Page 116: ...t have slots and tangs should be located inside boss relief 6 While keeping Thrust Washers in place slide Cluster Gear into Carrier with the larger gear on the side with the small pin hole 7 Line up C...

Page 117: ...SECTION 3 CHASSIS TURNTABLE 3 60 JLG Lift 3120740 Figure 3 40 Swing Hub G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 118: ...ricate all seals and o rings with clean hydraulic oil prior to assembly THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY IN THE C...

Page 119: ...SECTION 3 CHASSIS TURNTABLE 3 62 JLG Lift 3120740 Figure 3 41 Swing Brake Assembly Ausco Prior to S N 0300064566 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 120: ...e the 7 cap screws from the end cap and disas semble the motor as shown 3 Unclamp the motor and remove the output shaft thrust needle bearing and thrust bearing race 4 Clamp the motor in a vise so the...

Page 121: ...aulic system will cause damage Check the key way and chamfered area of the output shaft remove any nicks burrs or sharp edges that could damage the shaft seal during assembly NOTE Always use new seals...

Page 122: ...HE SPACER PLATE PROVIDE PASSAGE FOR HYDRAULIC FLUID AS WELL AS THE CAP SCREWS IF THE SPACER PLATE IS FLIPPED THE MOTOR WILL NOT OPERATE 3 Lightly stretch lubricate and install the second of the three...

Page 123: ...ing 5 PressureSeal 6 Seal 7 BearingRace 8 NeedleThrustBearing 9 Key 10 OutputShaft 11 Housing 12 Seal 13 Drive 14 SpacerPlate 15 Seal 16 Geroler 17 Seal 18 EndCap 19 Capscrew Figure 3 43 Swing Motor P...

Page 124: ...on the same output shaft 1A The seal 1B will be auto matically removed during this procedure NOTE If bearing replacement is necessary the bearing cups can be removed with a slide hammer puller driven...

Page 125: ...planet pin Marked tooth will be located just under the carrier 3A on upper two gears 3F 6 With shoulder side of ring gear 4 facing down place ring gear over into mesh with large gears Be sure that pun...

Page 126: ...er 3 11 Place O ring 5 into cover 6 counterbore Use petro leum jelly to hold O ring in place BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS O RING 12 The cover 6 is now installed on this...

Page 127: ...tally and completely filled if mounted vertically In ver tical mounting application case oil circulation is recom mended Hub Shaft Sub Assembly 1 Press bearing cone 1D onto shaft 1A 2 Press bearing cu...

Page 128: ...s an interference fit and has to be pressed or tapped on 7 Pipe plugs 1J 1K should be checked and or installed at this time in the assembly 8 Bearing spacer 1H is installed around the output shaft 1A...

Page 129: ...ft metal rod This will release the preload which was on the bearings This completes the hub shaft sub assembly items 1A through 1J If this assembly is not going to be used right away it should be oile...

Page 130: ...ed inside boss relief 6 While keeping thrust washers in place slide cluster gear into carrier with the larger gear on the side with the small pin hole 7 Line up cluster gear and thrust washer with hol...

Page 131: ...SECTION 3 CHASSIS TURNTABLE 3 74 JLG Lift 3120740 Figure 3 44 Swing Drive Hub Fairfield S N 0300068040 to S N 0300183033 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 132: ...seal 3 Press bearing 18 into position until it bottoms out on borestep 4 Install retaining ring 20 in cover 16 5 Press shaft 9 into bearing 18 until it bottoms on the shoulder Bearing 18 inner race m...

Page 133: ...1 Capscrew 2 PressurePlate 3 CaseSeal 4 O ring 5 BackupRings 6 Piston 7 O rings 8 BackupRings 9 Shaft 10 StatorDisc 11 RotorDisc 12 ReturnPlate 13 Springs 14 SpringRetainer 15 DowelPin 16 Cover 17 Oi...

Page 134: ...at you keep the motor in a vise during disassembly Follow the clamping procedures explained throughout the manual 1 Place motor in vice and clamp across edge of flange with output shaft down When clam...

Page 135: ...opane torch to heat small area of housing where screw enters see figure below Be careful not to overheat housing and damage motor Gradually apply torque to screw with socket wrench as heat is applied...

Page 136: ...should be cleaned as follow NOTE Fully cured Loctite resists most solvents oils gasoline and kerosene and is not affected by cleaning operations It is not necessary to remove cured Loctite that is sec...

Page 137: ...dry for at least 1 minute Do not force dry with air jet the primer will blow away Use of primer is optional With primer curing time is approximately 15 minutes Without primer curing time is approximat...

Page 138: ...INSTALLATION OF SEALS APPLY LIGHT COAT OF CLEAN PETROLEUM JELLY TO SEALS DO NOT STRETCH SEALS BEFORE INSTALLING THEM IN GROOVE 2 Pour approximately 35 cc of clean hydraulic oil in output shaft cavity...

Page 139: ...f applicable 3 Install 73 mm 2 875 in seal in end cap Carefully place end cap on gerotor 4 Install cap screws and seal washers if applicable in end cap Pre tighten screws to 7 4 Nm 40 in lbs Make sure...

Page 140: ...hen Applicable 11 Capscrew 12 Plug O ring S A 13 End Cap 14 Seal 15 Drive Spacer When Applicable 16 Gerotor 17 Seal 18 Spacer Plate 19 Drive 20 Seal 21 Housing 22 Plug 23 Seal 24 Plug O ring S A End P...

Page 141: ...place 2 Remove snap ring 7 from end 3 Remove thrust ring 3 from the same end 4 Remove center body 1 from housing 3 5 Cut off old seals 2 4 5 6 Assemble lip seals 2 in direction shown in Figure 3 47 Ro...

Page 142: ...740 JLG Lift 3 85 1 CenterBody 2 Seal 3 Housing 4 O ring 5 Seal 6 ThrustRing 7 SnapRing 8 ValveBlock AxleOscillation Figure 3 48 Rotary Coupling Cutaway G o t o D i s c o u n t E q u i p m e n t c o m...

Page 143: ...SECTION 3 CHASSIS TURNTABLE 3 86 JLG Lift 3120740 Figure 3 49 Rotary Coupling Port Location 7 Port G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 144: ...TURNTABLE 3120740 JLG Lift 3 87 4 9 8 3 1 2 4 2 3 8 7 6 7 9 6 5 1 2 7 2 3 6 7 2 1 8 9 7 Figure 3 50 Rotary Coupling Port Location 9 Port G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r...

Page 145: ...etainingRing 9 Plug 10 TorqueLug 11 Ring 12 Seal 13 O ring 14 Bearing 15 CapSeal 16 O ring 17 Valve 18 CheckValve 19 Case 20 PlungerValve Figure 3 51 Rotary Coupling Installation 18 17 20 19 10 9 7 8...

Page 146: ...spark arrester muffler 2 Without causing deformation or any type of damage to the spark arrester repeatedly tap on the arrester near the cleanout plug This may be enough to begin drain age of the spar...

Page 147: ...re 3 53 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings INSPECTING BRUSH POSITION Inspect brush alignment with slip rings View alignment through the air vents in the stator barr...

Page 148: ...3 2 3 Brushes must ride completely on slip rings Acceptable Unacceptable Brush Position On Slip Rings Figure 3 53 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings 1 BrushHolderA...

Page 149: ...g symptom is available analyze the complaint and develop a plan for diagnostics utilizing the wiring dia grams technical assistance and repair history Intermittent conditions may be resolved by using...

Page 150: ...trical current running to the ECM must be shut off To do this disconnect the negative terminal from the battery for a period of approxi mately 15 minutes ECM and Sensors CRANKSHAFT POSITION CKP SENSOR...

Page 151: ...hVoltage 35 IntakeAirTemperature IAT SensorHighVoltage 41 FuelPumpHighVoltage 42 HeatedOxygenSensor HO2S HighVoltage 43 EngineCoolantTemperature ECT SensorLowVoltage 45 IntakeAirTemperature IAT Sensor...

Page 152: ...that is located within the ECM The EEPROM contains the pro gram and the calibra tion information that the ECM needs to control engine opera tions If the ECM is replaced the new ECM will need to be pr...

Page 153: ...SECTION 3 CHASSIS TURNTABLE 3 96 JLG Lift 3120740 Figure 3 55 EFI Component Location G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 154: ...ne not running or at wide open throttle low vacuum The MAP sensor is used to determine the following Engine vacuum level for engine control purposes Barometric pressure BARO If the ECM detects a volta...

Page 155: ...p start with more than 12 volts This could cause damage to the electronic components Do not employ any non standard practices such as charging the battery with an arc welder Take proper precautions to...

Page 156: ...soline propane or natu ral gas Each module can be set up to run an engine on any two of the three fuels in certified closed loop control with vir tually transparent on the fly fuel switching Each modu...

Page 157: ...erHighBank2 Gasoline 132 ClosedLoopMultiplierLowBank2 Gasoline 141 AdaptiveLeanFault HighLimit Gasoline 142 AdaptiveRichFault LowLimitGasoline 143 AdaptiveLearnHigh LPG 144 AdaptiveLearnLow LPG 145 Ad...

Page 158: ...4 2L 314 InjectorDriver 2Shorted 2 5L 314 InjectorDriver 2Shorted 4 2L 315 InjectorDriver 3Open 2 5L 315 InjectorDriver 3Open 4 2L 316 InjectorDriver 3Shorted 2 5L 316 InjectorDriver 3Shorted 4 2L 32...

Page 159: ...HighVoltage 512 FPP1LowVoltage 513 FPP1HigherThanIVSLimit 514 FPP1LowerThanIVSLimit 521 FPP2HighVoltage 522 FPP2LowVoltage 531 TPS1 SignalVoltage High 532 TPS1 SignalVoltage Low 533 TPS2 SignalVoltage...

Page 160: ...tion 613 A DLoss 614 RTI1Loss 615 FlashChecksumInvalid 616 RAMfailure 631 External5VRefLowerThanExpected 632 External5VRefHigherThanExpected 655 RTI2Loss 656 RTI3loss Table 3 12 Diagnostics Fault Code...

Page 161: ...provide fuel at a pressure above the pressure needed by the injectors A fuel pressure regulator in the fuel filter assembly keeps fuel available to the fuel injectors at a constant pressure A return...

Page 162: ...nce and a DTC 32 will set If the pressure is too high excessive odor and or a DTC 42 will result When replacing the fuel filter be sure to use an identical filter regulator assembly A standard fuel fi...

Page 163: ...signal which cannot be read with conventional diagnostic tools such as a voltmeter A 12 volt signal is pulsed on and off at a high rate of speed The width of the on pulse determines the amount of thro...

Page 164: ...capability No mechanical load on the engine More coil cooldown time between firing events Elimination of mechanical timing adjustments Increased available ignition coil saturation time IGNITION COIL...

Page 165: ...sure needed at the mixer to maintain the desired air to fuel ratio The megajector accepts LPG vapor at the regulator outlet pressure 1 5 to 2 5 inches 3 8 to 6 3 cm of H2O and reduces it to a pressure...

Page 166: ...NTABLE 3120740 JLG Lift 3 109 Megajector Regulator LockoffSolenoid Figure 3 57 LPG System Components S N 0300077500 to S N 03000140000 Mixer G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e...

Page 167: ...jector has an internal failure and must be replaced DTC 354 Megajector delivery pressure lower than expected This code will set if the difference between the Megajector actual pressure and the Megajec...

Page 168: ...wire 4 Set up fuel linkage This is critical so review the section titled LINKAGE 5 Hold linkage for safety and start engine 6 Adjust engine speed to desired valve using High Engine pot Turn CW to incr...

Page 169: ...ion The rear cover will probably need to be removed during set up in order to make adjustments for speed setting and gain You may wish to defer final installation until this is done After completing t...

Page 170: ...idle to high engine Mid engine This adjustment is made by turning the 1 8 brass screw clock wise CW to increase speed and counterclockwise CCW to decrease speed The adjustment range of the Mid engine...

Page 171: ...ring is run and checked and that the linkage is properly installed proceed as follows 1 Use multimeter to check battery voltage at battery ter minals and record Now check voltage at the machine connec...

Page 172: ...SECTION 3 CHASSIS TURNTABLE 3120740 JLG Lift 3 115 Figure 3 58 Check Out and Initial Start Up Procedures G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

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