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SECTION 5 - HYDRAULICS

3121259

– JLG Lift –

5-3

5.2

HYDRAULIC CYLINDERS

Holding (counterbalance) valves are used in the Lift, Level, Jib,
Telescope, and Axle Lockout circuits to prevent retraction of
the cylinder rod should a hydraulic line rupture or a leak
develop between the cylinder and its’ related holding valve.

NOTE:

The steer cylinder weighs approximately 37.2 lbs (16.9 kg).

NOTE:

The tower lift cylinder weighs approximately 76 lbs (34.5
kg).

NOTE:

The upper lift cylinder weighs approximately 97 lbs (44 kg).

NOTE:

The master cylinder weighs approximately 35.3 lbs (16 kg).

NOTE:

The level cylinder weighs approximately 37.4 lbs (17 kg).

NOTE:

The jib lift cylinder weighs approximately 55 lbs (25 kg).

NOTE:

The telescope cylinder weighs approximately 52.7 lbs (23.9
kg).

NOTE:

The axle oscillation lockout cylinder weighs approximately
26.2 lbs(11.9 kg).

Disassembly and Assembly Instructions

1.

Make sure the work area is large enough for the entire
cylinder and clean and free of dirt. Ensure the cylinder
can be secured firmly in place during disassembly.

2.

Prepare all the necessary tools and replacement parts.
Refer to Table 5-2, Required Tools.

General Information

1.

Clean any burrs or contamination from the surface of
the cylinder before disassembly.

2.

Handle every part with care. Each part is precision made
and hitting parts together or letting them fall could
damage the machined surfaces.

3.

Do not twist or strike parts to get them apart. This will
damage the part and/or threads, resulting in leakage
and poor function.

4.

Do not let the cylinder in a disassembled condition for a
long period of time. It only takes a short period of time
for the parts to rust.

Standard of Maintenance

Parts and seals should be replaced according to the conditions
as follows.

1.

Bushings - 1/4 of the bushing is worn off.

2.

Seal and Slide Ring - Replace during disassembly.

3.

Pin Bushing - When it is worn down.

4.

Rod - Bent or warped more than 0.5mm/1m.

Inspection After Assembly

Table 5-1. Inspection After Assembly

Operation Inspection Without
Load

There is no problem when fully extended 5 times without load

Dimension

Check the retracted length and stroke

Inspection of the Surface

When each of the cylinders are pressurized with test pressure on the piston end, it should not be loose and have no change in pressure or external
leakage

Inspection of external leakage

Check the oil leakage at the rod area. Refer to Figure 5-1., Acceptable Oil Leakage on Cylinder Rod.

Inspection of internal leakage

Leakage Unit: ml/ 10 minutes

Bore (mm)

Leakage (ml)

Bore (mm)

Leakage (ml)

Bore (mm)

Leakage (ml)

Remark

32

0.4

100

4

160

10

40

0.6

125

5.6

180

12.6

50

1

140

6

200

15.6

63

1.6

220

20

80

2.3

250

22

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Содержание 340AJ

Страница 1: ...Service and Maintenance Manual Model 340AJ P N 3121259 June 27 2017...

Страница 2: ......

Страница 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...

Страница 4: ...INTRODUCTION A 2 JLG Lift 3121259 REVISON LOG Original Issue May 6 2011 Revised January 17 2012 Revised July 9 2013 Revised June 27 2017...

Страница 5: ...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 Disassembly a...

Страница 6: ...le Brake Subassembly Disassembly 3 15 Cover Disassembly 3 16 Planet Gear Subassembly 3 18 Spindle Brake Subassembly 3 19 Housing Spindle Subassembly 3 21 Housing Ring Gear Subassembly 3 22 Cover Subas...

Страница 7: ...tdown 3 76 3 18 GM Dual Fuel Engine 3 81 Communications with the JLG Control System 3 81 Engine Start 3 81 Oil Pressure 3 81 Engine Speed 3 81 Coolant Temperature 3 81 Fuel Select 3 81 3 19 Fuel Reser...

Страница 8: ...e 5 36 Electrical Displacement Control EDC 5 37 Disassembly 5 39 Inspection 5 44 Assembly 5 48 Port Locations and Gauge Installation 5 56 Fastener Size and Torque Chart 5 57 Plug Size and Torque Chart...

Страница 9: ...ion Procedure 6 39 Testing Evaluation 6 44 Troubleshooting 6 45 6 7 Resetting The MSSO System 6 46 6 8 System Fault Messages 6 48 SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 1 General 7 1 7 2...

Страница 10: ...vi JLG Lift 3121259 TABLE OF CONTENTS SECTION NO TITLE PAGE NO Thispageleftblankintentionally...

Страница 11: ...3 13 3 10 Housing Spindle 3 14 3 11 Spindle Brake Subassembly Figure 1 3 15 3 12 Spindle Brake Subassembly Figure 2 3 15 3 13 Spindle Brake Subassembly Figure 3 3 16 3 14 Cover 3 17 3 15 Planet Gear 3...

Страница 12: ...hematic 3 74 3 56 Engine Glow Plug Schematic 3 74 3 57 Glow Plug Relay 3 74 3 58 Engine Throttle Actuator Schematic 3 75 3 59 Proportional Fuel Rack Actuator Schematic 3 76 3 60 Engine Starter Schemat...

Страница 13: ...Identification 5 33 5 24 Drive Pump Cross Sectional View 5 34 5 25 High Pressure Relief and Charge Check Valve with Bypass Valve in charging mode 5 35 5 26 High Pressure Relief and Charge Check Valve...

Страница 14: ...n 7 10 7 14 DT DTP Contact Installation 7 11 7 15 DT DTP Contact Removal 7 11 7 16 HD HDP Contact Installation 7 12 7 17 HD HDP Locking Contacts Into Position 7 12 7 18 HD HDP Contact Removal 7 12 7 1...

Страница 15: ...3121259 JLG Lift xi LIST OF FIGURES FIGURE NO TITLE PAGE NO Thispageleftblankintentionally...

Страница 16: ...N FMI Cross Reference Chart 3 88 4 1 Troubleshooting 4 25 5 1 Inspection After Assembly 5 3 5 2 Required Tools 5 5 5 3 Special Tools 5 6 5 4 Piston Nut Torque 5 11 5 5 Gland Torque 5 11 5 6 Main Contr...

Страница 17: ...8 Machine Configuration Programming Settings 6 36 6 9 Diagnostic Menu Descriptions 6 38 6 10 Accessory Weights 6 40 6 11 SkyGlazier Capacity Reductions 6 42 6 12 Pipe Rack Capacity Reductions 6 42 6...

Страница 18: ...xiv JLG Lift 3121259 LIST OF TABLES TABLE NO TITLE PAGE NO Thispageleftblankintentionally...

Страница 19: ...gRadius Inside 5 1 52m TurningRadius Outside 13 3 96m MachineHeight stowed 6 7 2m MachineHeight storage 7 1 2 17m MachineLength stowed 18 2 5 52m MachineLength storage 13 1 3 98m UpandOverPlatformHeig...

Страница 20: ...obil 424 is desired contact JLG Industries for proper recommenda tions Major Component Weights DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION FOR EXAMPLE BA...

Страница 21: ...MainLift Boomretracted telescopein Mainliftup recordtime Main liftdown recordtime Swing Boomatfullelevation telescoperetracted Swingtheturnta bletotheendstop Swingtheoppositedirection recordtime Swin...

Страница 22: ...SECTION 1 SPECIFICATIONS 1 4 JLG Lift 3121259 1 5 5 3 4 5 2 9 7 6 8 5 Figure 1 1 Operator Maintenance and Lubrication Diagram...

Страница 23: ...Point s Grease Fitting Capacity A R Lube Lubriplate 930 AAA Interval A R Lube Point s Grease Fitting Capacity A R Lube Mobil SHC 460 Interval A R DO NOT OVERGREASE BEARINGS OVERGREASING BEARINGS WILL...

Страница 24: ...aulic Tank Return Filter and Breather Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter Comments For breather element twist top to replace 5 Wheel Drive Hub Lube Point s Leve...

Страница 25: ...M Lube Point s Fill Cap Spin on Element Capacity 3 1 Quarts 3 L w Filter Lube EO Interval Check level daily change every 500 hours or six months whichever comes first Adjust final oil level by mark on...

Страница 26: ...SECTION 1 SPECIFICATIONS 1 8 JLG Lift 3121259 Figure 1 2 Torque Chart Sheet 1 of 5 SAE Fasteners Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue...

Страница 27: ...SECTION 1 SPECIFICATIONS 3121259 JLG Lift 1 9 Figure 1 3 Torque Chart Sheet 2 of 5 SAE Fasteners Torq ue Tor que Torq ue Torqu e To rqu e...

Страница 28: ...SECTION 1 SPECIFICATIONS 1 10 JLG Lift 3121259 Figure 1 4 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...

Страница 29: ...SECTION 1 SPECIFICATIONS 3121259 JLG Lift 1 11 Figure 1 5 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...

Страница 30: ...SECTION 1 SPECIFICATIONS 1 12 JLG Lift 3121259 Figure 1 6 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...

Страница 31: ...ch machine in service for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as env...

Страница 32: ...in in 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 cab...

Страница 33: ...necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt...

Страница 34: ...drained flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good gra...

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

Страница 36: ...ment wound bearing are a dry joint and should not be lubricated unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam...

Страница 37: ...1 2 1 2 Bearings 1 2 1 2 WearPads 1 2 1 2 CoversorShields 1 2 1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly Platform 1 2 Railing 1 1 2 Gate 1 1 5 Floor 1 1 2 Rotator 9 5 15 Lanya...

Страница 38: ...5 FuelReservoir Cap andBreather 1 5 1 5 Hydraulic ElectricSystem HydraulicPumps 1 2 9 HydraulicCylinders 1 2 7 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 2 9 1 2 HydraulicHoses Lines andFittings...

Страница 39: ...ofthepriorinspection PerformanceCodes 1 Checkforproperandsecureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 Ope...

Страница 40: ...at 40 C cSt Typical Viscosity Index Mineral Oils Vegetable Oils Synthetic Synthetic Polyol Esters Readily Biodegradable Virtually Non toxic Fire Resistant Mobilfluid424 55 145 X MobilDTE10Excel32 32...

Страница 41: ...ION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE Figure 2 2 Engine Oil Operation Chart GM 1001120075 A NOTICE MACHINE OPERATION USING NON JLG APPROVED ENGINE OIL OR OPERATI...

Страница 42: ...SECTION 2 GENERAL 2 12 JLG Lift 3121259 NOTES...

Страница 43: ...anges such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in an unsafe condition regarding stability Wheel Installation It is extr...

Страница 44: ...e drive pump is automatically restricted to approxi mately 0 75 mph 1 2 kph See Drive System in this section for more detail on the drive speeds and see Chassis Tilt Indicator System in this section f...

Страница 45: ...20 16 Remove the o ring 19 17 Remove the cardan shaft 18 Assembly 1 Carefully lift from under the gear set to prevent parts from falling out Lay the gearwheel set so the o ring groove is upwards Mark...

Страница 46: ...roleum jelly and install them in the balance plate grooves 9 Install the guide pin 27 in the end cover 32 10 Install the balance plate in the end cover 32 11 Grease the spacer 30 with petroleum jelly...

Страница 47: ...1 33 34 13 DrainPlug 14 Washer 15 NotUsed 16 MountingFlange 17 O ring 18 CardanShaft 19 O ring 20 GearSet 21 NotUsed 22 ValveDrive 23 PressurePlate 24 GuidePin 25 ChannelPlate 26 StopRing 27 DiscValve...

Страница 48: ...LG Lift 3121259 PORT 10 PORT 4 PORT A PORT B DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR PORT CASE PORT 16 PORT 6 PORT B PORT A PORT BRAKE TORQUE HUB TORQUE HUB Figure 3 3...

Страница 49: ...E 3121259 JLG Lift 3 7 PORT B DRIVE MOTOR PORT B MOTOR DRIVE PORT A DRIVE MOTOR BRAKE PORT TORQUE HUB PORT CASE MOTOR DRIVE DRIVE MOTOR TORQUE HUB PORT 15 PORT 11 PORT A DRIVE MOTOR Figure 3 4 Left Fr...

Страница 50: ...121259 PORT B MOTOR DRIVE TORQUE HUB DRIVE MOTOR PORT A MOTOR DRIVE PORT CASE MOTOR DRIVE PORT BRAKE TORQUE HUB FLOW DIVIDER VALVE PORT 5 PORT 7 PORT 17 PORT B DRIVE MOTOR DRIVE MOTOR PORT 12 PORT A F...

Страница 51: ...ft 3 9 TORQUE HUB DRIVE MOTOR PORT BRAKE DRIVE MOTOR CASE PORT PORT A PORT B DRIVE MOTOR DRIVE MOTOR DRIVE MOTOR PORT B DRIVE MOTOR DRIVE MOTOR FLOW DIVIDER VALVE PORT A PORT 7 PORT 5 PORT 18 PORT 13...

Страница 52: ...gauge read ing on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize Leaks will most likely occur at the pipe plugs the main seal or wherever o ring...

Страница 53: ...the unit The unit can be carefully pressurized with air to pop the cover subassembly out of the unit 5 Remove O Ring 17 from groove in Cover Subassembly 6 6 Remove the Sun Gear 11 7 Loosen and remove...

Страница 54: ...t 3121259 Figure 3 7 Main Disassembly Figure 1 6 Cover 6G RetainingRing 15 IDPlate 17 O ring Figure 3 8 Main Disassembly Figure 2 1E RingGear 4E PlanetShaft 4F PlanetGear 4G RollPin 4H ThrustWasher 9...

Страница 55: ...he Loctite that was used to secure the bearing nut on to the Spindle 1 A NOTE The holes in the bearing nut for the set screws were staked for retention of the set screws The holes will need to be clea...

Страница 56: ...SECTION 3 CHASSIS TURNTABLE 3 14 JLG Lift 3121259 Figure 3 10 Housing Spindle 1A Spindle 1B LipSeal 1C BallBearing 1D Housing 1F BearingNut 1G Setscrew 1H Stud...

Страница 57: ...ach bolt half way out and then finish backing them out Remove Motor Adaptor 1N If necessary remove Retaining Ring 8C knock Ball Bearing 8B out of mounting adaptor coun terbore and check Quad Seal 1K a...

Страница 58: ...ternal groove of Coupling 7 using Truarc 0100 or equivalent pliers 9 Remove the Thrust Washer 1M and Spring 1L out of the bore of Coupling 7 10 Knock Ball Bearing 8B out of Spindle 1A counterbore if n...

Страница 59: ...SECTION 3 CHASSIS TURNTABLE 3121259 JLG Lift 3 17 Figure 3 14 Cover 2 ThrustSpacer 6A Cover 6B DisengageCap 6C Bolt 6D DowelPin 6E O ring 6F PipePlug 6K O ring...

Страница 60: ...between the ends of the two rollers which form the space and then slid parallel to the other rollers into place 3 Place Spacer 4D into the bore of the Planet Gear 4F 4 Repeat Step 2 to put in second r...

Страница 61: ...into the Spindle 1A aligning with the scallop cuts 3 Place Brake Rotor 8J on top of Brake Stator 8K 4 Repeat steps 2 and 3 until there are a total of nine Brake Stators 8K and eight Brake Rotors 8J i...

Страница 62: ...les and then install the smaller twelve Springs 8M into the Springs 8L already installed into the brake piston 15 Press Ball Bearing 8B in the Mounting Adaptor 1N and then install Retaining Ring 8C in...

Страница 63: ...to press in studs Don t use excessively high pressures to press in studs or the housing may crack 5 Secure Spindle Brake Subassembly with the flange down and then lower the Housing 1D onto Spindle 1A...

Страница 64: ...hole described in Step 2 on Spindle 1A The end of the planet shaft that does NOT have the roll pin hole should be inserted into the spindle FIRST 4 Now insert Planet Shaft 4E through the first set of...

Страница 65: ...onto Housing 1D Align the three shipping cap screw holes on Housing 1D and Ring Gear 1E 9 Install three Shipping Cap Screws 19 into Ring Gear 1E and Housing 1G Torque them to15 20 ft lbs 10 With the n...

Страница 66: ...Washer 2 that mates with pocket side of the Cover 6A making sure that tangs on washer seats into pockets 5 Install O Ring Pipe Plugs 6F into Cover 6A The plugs should be hand tight The Cover Subassem...

Страница 67: ...d shaft into Input Coupling 7 3 Bleed brake Increase hydraulic pressure gradually while trying to rotate the input until brake just starts to release Note this pressure Make sure the pressure falls in...

Страница 68: ...OR 2 THRUSTSPACER 4B THRUSTWASHER 4C NEEDLEBEARING 4D THRUSTSPACER 4E PLANETSHAFT 4F PLANETGEAR 4G ROLLPIN 4H THRUSTWASHER 5 RETAININGRING INTERNAL 6A COVER 6B DISENGAGECAP 6C BOLT 6D DOWELPIN 6E O RI...

Страница 69: ...SECTION 3 CHASSIS TURNTABLE 3121259 JLG Lift 3 27 Figure 3 24 Bearing Pressing Tool...

Страница 70: ...SECTION 3 CHASSIS TURNTABLE 3 28 JLG Lift 3121259 Figure 3 25 Seal Pressing Tool Figure 3 26 Drift Pin for Lining Up Thrustwashers with Output Planet Gear...

Страница 71: ...SECTION 3 CHASSIS TURNTABLE 3121259 JLG Lift 3 29 Figure 3 27 Bearing Nut Wrench...

Страница 72: ...is supplied via Drive Pump charge pressure When the control system detects that the Main Boom is below horizontal and swung between the rear tires two control valves are actuated to supply charge pre...

Страница 73: ...WEAR PAD DETAIL SECTION B B TORQUE 178 FT LB 241 NM TORQUE 35 FT LB 47 NM TORQUE 40 5 FT LB 55 NM WEAR PAD SHIMS KEEPER AXLE PIVOT PIN BEARING THRUST WASHER LOCKOUT CYLINDER B A A B NOTE MAKE SURE TH...

Страница 74: ...e for preventing the machine from reaching an unstable position The 6 angle is used only for the purpose of automatically slowing drive speed when this angle is reached and the boom is in Transport po...

Страница 75: ...it Significantlossofspeedunderload 1 Lackofsufficientoilsupply 2 Highinternalmotorleakage 3 Severelywornordamagedinternalsplines 4 Excessiveheat a Checkforfaultyreliefvalveandadjustorreplaceasrequired...

Страница 76: ...will need to know to service the motor Thoroughly clean off all outside dirt especially from around fittings and hose connections before disconnect ing and removing the motor Remove rust or corrosion...

Страница 77: ...spection 1 Place the motor in a soft jawed vice with coupling shaft 12 pointed down and the vise jaws clamping firmly on the sides of the housing 18 mounting flange or port bosses Remove manifold port...

Страница 78: ...Commutator 6 CommutatorRing 7 Manifold 8 RotorSet 8A Rotor 8B StatorHalf 8C StatorVane 8D StatorHalf 9 WearPlate 10 DriveLink 11 ThrustBearing 12 CouplingShaft 13 InnerBushing 14 ThrustWasher 15 Thrus...

Страница 79: ...f the commutator 5 is normal Discoloration would indicate excess fluid temperature thermal shock or excess speed and require system investigation for cause and close inspection of end cover commutator...

Страница 80: ...12 with the rotor set and wearplate You may have to shift the rotor set on the wearplate to work the drive link out of the rotor and wearplate Inspect the rotor set in its assembled form for nicks sc...

Страница 81: ...the rotor lobe to roller vane clear ance at both ends of rotor 11 Remove drive link 10 from coupling shaft 12 if it was not removed with rotor set and wear plate Inspect drive link for cracks and worn...

Страница 82: ...is permissible If wear exceeds 0 020 inches 0 51 mm diametrically replace coupling shaft NOTE A slight polish is permissible in the shaft bearing areas Anything more would require coupling shaft repl...

Страница 83: ...ring rollers must be firmly retained in the bearing cages but must rotate and orbit freely All rollers and thrust washers must be free of brinelling and corrosion The bushing 19 or 13 to coupling shaf...

Страница 84: ...areas SINCE THEY ARE FLAMMABLE BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX I...

Страница 85: ...w be pressed into its counter bore in housing 18 flush to 0 03 inch 0 76 mm below the housing wear plate con tact face Use the opposite end of the bearing mandrel that was used to press in the outer b...

Страница 86: ...l 8 Be sure that a generous amount of clean corrosion resis tant grease has been applied to the lower outer hous ing bearing bushing 19 Install the coupling shaft 12 into housing 18 seating it against...

Страница 87: ...e motor 10 Install drive link 10 the long splined end down into the coupling shaft 12 and engage the drive link splines into mesh with the coupling shaft splines NOTE Use any alignment marks put on th...

Страница 88: ...rd the wear plate 9 14 Apply clean grease to a new seal ring 4 and assemble it in the seal ring groove in the rotor set contact side of manifold 7 NOTE The manifold 7 is made up of several plates bond...

Страница 89: ...2 and assemble end cover over the alignment studs and onto the commutator set If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing 18 The cor...

Страница 90: ...t cannot be readily assembled by hand can be assembled by the following proce dures 1 Place stator onto wear plate 9 with seal ring 4 side down after following assembly procedures 1 through 13 Be sure...

Страница 91: ...ry 3 Assemble rotor counterbore down if applicable into stator half and onto wear plate 9 with rotor splines into mesh with drive link 10 splines NOTE Use any marking you applied to rotor set componen...

Страница 92: ...upling shaft rotation 4 Use test stand if available to check operation of the motor Installation Refer to Figure 3 31 Swing Motor Removal and Installation 1 Carefully insert the swing motor into the s...

Страница 93: ...IS TURNTABLE 3121259 JLG Lift 3 51 3 Install eyebolts as specified in Figure 3 33 Eyebolt for Counterweight in the counterweight 4 Securely strap the booms together to prevent any movement during the...

Страница 94: ...equipped remove the LP fuel tank on the side of the frame It may also be desirable to remove the tank retaining brackets to gain additional clearance to work 6 Remove the access covers on either side...

Страница 95: ...t 3 53 7 Pull out the engine tray as far as it will go Unbolt the charge filter bracket so it can be moved aside for more working area 41 81 40 135 20 35 M20x2 5Thread Figure 3 33 Eyebolt for Counterw...

Страница 96: ...ove the drive orientation and lockout switches so they don t get broken during the removal procedure 11 Swing the engine tray back into position and secure it in place with the retaining bolt 12 Attac...

Страница 97: ...nuggly to secure the turn table s position on the swing bearing assembly but do not torque them at this time and keep the lifting device in place to support the weight of the turntable 6 Coat the bear...

Страница 98: ...ation 2 At the positions indicated in the figure below try and insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position 3 Lower the boom to horizontal a...

Страница 99: ...S TURNTABLE 3121259 JLG Lift 3 57 90 POSITION POINT OF MINIMAL BACKLASH MARKED WITH AN X AND ALSO BLUE PAINT TO THE FRAME IN THIS POSITION 90 POSITION BEARING BODY TO TURNTABLE AS SHOWN Figure 3 36 Be...

Страница 100: ...front of the Pinion 21 4 Remove eight 5 16 12 point cap screws 4 from gear pinion cap 18 Pry cap from housing Cover plate 19 will come off with cap Note where sealant is on Cover and plate so when as...

Страница 101: ...ilSeal 10 PipePlug 11 GreaseFitting 12 GreaseFitting 13 GreaseFitting 14 SlewRing 15 Bearing 16 GreaseRing 17 Bearing 18 GearCap 19 CoverPlate 20 WormCap 21 OutputPinion 22 MotorAdapter 23 FaceSeal 24...

Страница 102: ...ual to total thickness of shims just set aside Apply sealant LocTite 515 to both sides of each of these shims and tighten screws take care not to twist these screws off Clean extra sealant from surfac...

Страница 103: ...RANSPARENT FOR ROUTING CLARITY ROUTE HOSES CABLES THROUGH GUIDE ROD ON BASE BOOM ROUTE HOSES CABLES THROUGH GUIDE ROD ON FLY BOOM LOWER UPRIGHT UPPER UPRIGHT HOSE CABLE PULL LENGTHS UPPER DESCRIPTION...

Страница 104: ...LOOKING TOWARDS UPPER UPRIGHT AC CABLE WIRE BUNDLE TO UPRIGHT HYDRAULIC MANIFOLD 18 6 CABLE TO MAIN BOOM LIMIT SWITCHES ORIENTATION LOOKING TOWARDS LOWER UPRIGHT SYSTEM TANK TOWER LIFT CYLINDER TANK T...

Страница 105: ...USE CABLE TIE IN TURNTABLE AREA EVERY 200 250mm USE CABLE TIES AS REQUIRED DETAILE 50 12 MAINTAIN HOSE CABLE LOOP AT THIS DIMENSION FROM CYLINDER ENDCAP 110 10 DETAIL D JIB LINK CUT AWAY DETAIL F TOW...

Страница 106: ...18 GA 5 BLUE 18 GA 6 YELLOW 18 GA 7 BROWN 18 GA 8 PLUG N A 9 RED BLACK 18 GA 10 ORANGE 12 GA 11 BLUE BLACK 18 GA 12 RED 12 GA 13 ORANGE BLACK 18 GA 14 PLUG N A 15 YELLOW BLACK 18 GA 16 BLACK 12 GA 17...

Страница 107: ...E HORIZONTAL TO RESET SWITCH SWITCH SW242 OF LOWER BOOM HARNESS DETAIL Q MAIN BOOM LIMIT SWITCHES MAIN BOOM TO BE 1 BELOW HORIZONTAL TO 3 ABOVE HORIZONTAL TO TRIP SWITCH 1 TO 4 BELOW HORIZONTAL TO RES...

Страница 108: ...3121259 SEE DETAIL S DETAILS SYSTEM TANK TOWER LIFT CYLINDER TANK TOWER LIFT CYLINDER PRESSURE AC CABLE MAIN LIFT CYLINDER PRESSURE SYSTEM PRESSURE BOOM CABLE LOWER BOOM HARNESS Figure 3 44 Cable Ins...

Страница 109: ...IL T DETAIL T UPRIGHT BACK PLATE SHOWN TRANSPARENT CONNECTOR V61 OF UPPER BOOM HARNESS CONNECTOR V59 OF UPPER BOOM HARNESS CONNECTOR V62 OF UPPER BOOM HARNESS CONNECTOR V60 OF UPPER BOOM HARNESS Figur...

Страница 110: ...ift 3121259 SEE DETAIL U DETAIL U FLY VALVE COVER SHOWN TRANSPARENT CONNECTOR V57 OF UPPER BOOM HARNESS CONNECTOR V56 OF UPPER BOOM HARNESS CONNECTOR V55 OF UPPER BOOM HARNESS Figure 3 46 Cable Instal...

Страница 111: ...Engine Cranking Engine Starting Engine Running ENGINE STOPPED ENGINE RUNNING ENGINE CRANKING ENGINE STARTING RPM greater than 800 for 1 4 second RPM greater than 800 for 1 4 second RPM 0 for 1 2 seco...

Страница 112: ...he Engine Shutdown switch must not be activated 10 The Start Switch has been in the deselected position after the Engine State changes to Engine Stopped from Engine Running or Engine Starting 3 14 ENG...

Страница 113: ...e Engine State is Engine Running 2 The operator is not shutting down the engine 3 The Control System is configured for a generator 4 The Platform Generator Switch is Enabled and Selected 3 15 ENGINE C...

Страница 114: ...is a short hose between the mechanical lift pump and the injection pump 2 Actuate the priming lever on the mechanical lift pump until fuel comes out of the fuel hose 3 Attach the fuel hose and secure...

Страница 115: ...e Engine Speed Sensor The engine speed sensor is a variable reluctance sensor used to measure engine speed by monitoring the flywheel teeth while the engine is running Figure 3 51 Engine Oil Pressure...

Страница 116: ...cold starting The ground module controls the glow plugs and uses a relay to switch battery current Figure 3 54 Engine Coolant Sensor 5V 270 Ohm J1 15 Input Engine Block Ground Ground Module Engine Oi...

Страница 117: ...that limits the opening of the fuel rack to control speeds between the Idle and High Engine positions The two actuators function together to achieve smooth engine speed transitions Refer to Table 3 7...

Страница 118: ...includes a one way blocking diode that prevents reverse energy flow into the Ground Module during engine power down This terminal is continuously energized after startup Fuel Pump The Kubota fuel pum...

Страница 119: ...77 1 2 3 4 5 6 7 8 9 10 11 12 13 1 FuelTank 2 CoolantRecoveryTank 3 Alternator 4 OilFilter 5 Starter 6 MainPump 7 GearPump 8 Battery 9 AirFilter 10 Muffler 11 StarterRelay 12 FullSpeedRelay 13 GlowPl...

Страница 120: ...t 3121259 1 2 3 4 5 6 7 8 9 10 11 1 CoolantRecoveryTank 2 Muffler 3 MainPump 4 GearPump 5 AirFilter 6 FuelFilter WaterSeparator 7 FuelPump 8 FuelLevel SendingUnit 9 FuelTank 10 Radiator 11 PressureCap...

Страница 121: ...NNECTION ON MAIN PUMP V83 TO C1 COIL CONNECTION ON MAIN PUMP NEGATIVE GROUND TERMINAL 1 Radiator 2 RadiatorMount 3 EngineOilFilter 4 MidEngineHarness 5 EngineHarness 6 StarterRelay 7 FullSpeedRelay 8...

Страница 122: ...10 11 12 13 1 Muffler 2 MainPump 3 GearPump 4 NegativeBatteryTerminal 5 NegativeBatteryPost 6 Battery 7 PositiveBatteryTerminal 8 PositiveBatteryPost 9 FuelSupplyLine 10 FuelReturnLine 11 Radiator 12...

Страница 123: ...Engine Start The Ground Module energizes terminal J1 11 to engage the starter The engine ECU considers the engine started when RPMs are greater than 800 and continues in the Run mode unless engine RPM...

Страница 124: ...CHASSIS TURNTABLE 3 82 JLG Lift 3121259 1 2 3 4 5 6 7 8 9 10 1 FuelTank 2 CoolantRecoveryTank 3 Radiator 4 OilFilter 5 Starter 6 MainPump 7 GearPump 8 Battery 9 Muffler 10 FuelMixer Figure 3 66 GM Eng...

Страница 125: ...TABLE 3121259 JLG Lift 3 83 2 1 3 4 5 6 7 8 9 10 1 CoolantRecoveryTank 2 FuelTank 3 Radiator 4 OilFilter 5 Negative GroundTerminal 6 PositiveTerminal 7 MainPump 8 GearPump 9 Battery 10 Muffler Figure...

Страница 126: ...COIL CONNECTION ON MAIN PUMP VENT HOSE FROM CARBON CANISTER TO LP MIXER PURGE POINT 1 2 3 4 5 6 7 8 9 10 11 1 Alternator 2 SupplyFuelHose 3 ReturnFuelHose 4 MainPump 5 FuelPumpHarness 6 Air FuelMixer...

Страница 127: ...ick 2 Relays 3 Muffler 4 MainPump 5 GearPump 6 NegativeBatteryCable 7 NegativeBatteryPost 8 Battery 9 PositiveBatteryCable 10 PositiveBatteryPost 11 Air FuelMixer 12 AirFilter 13 FuelPump 14 FuelMixer...

Страница 128: ...TO ENGINE EC210 NEGATIVE TERMINAL ON FUEL PUMP EC210 POSITIVE TERMINAL ON FUEL PUMP 1 2 3 4 5 6 7 8 9 10 1 FuelLevelSensor 2 FuelLock offValve 3 Muffler 4 AirMixerValve 5 GearPump 6 FuelPumpHarness 7...

Страница 129: ...M CARBON CANISTER 1 1 2 3 4 5 6 7 8 9 10 11 12 11 12 13 1 AirMixerValve 2 Muffler 3 GearPump 4 Battery 5 Alternator 6 FuelLevelSensor 7 FuelTank 8 CarbonCannister 9 CoolantRecoveryTank 10 EngineOilFil...

Страница 130: ...O2Open Inactive 520208 10 171 AdaptiveLearnHighGasoline 520200 0 172 AdaptiveLearnLowGasoline 520200 1 182 FuelTempGasolineLowVoltage 174 4 183 FuelTempGasolineHighVoltage 174 3 187 FuelTempLPGLowVolt...

Страница 131: ...iveLearnLowLPG 520202 1 1165 LPGCatMonitor 520213 10 1171 LPGPressureHigherThanExpected 520260 0 1172 LPGPressureLowerThanExpected 520260 1 1173 EPRCommLost 520260 31 1174 EPRVoltageSupplyHigh 520260...

Страница 132: ...minute After 1 minute the engine will shut off for a sec ond time and the machine will return to the Engine Shut down fault mode The machine will then stay in this mode until the fuel level is returne...

Страница 133: ...ft 3 91 3 22 COUNTERWEIGHT If the counterweight has been removed ensure the retaining bolts are torqued to the proper value as shown in Figure 3 73 Counterweight Bolt Torque Torque to 150 ft lbs 204 N...

Страница 134: ...SECTION 3 CHASSIS TURNTABLE 3 92 JLG Lift 3121259 NOTES...

Страница 135: ...e switches are normally closed and unactuated when in the transport position Above transport angle is recognized when the main boom travels from the stowed position to 2 above horizontal it resets at...

Страница 136: ...NOTE The telescope cylinder weighs approximately 53 lbs 24 kg 6 Using a suitable lifting device remove telescope cylin der from the rear of the boom sections 7 Remove hardware securing the front wear...

Страница 137: ...oom 1 Using JLG P N 0100011 thread locking compound or equivalent install the bottom wear pads and shims as noted during disassembly on the rear of the fly section Torque the retaining bolts to 40 ft...

Страница 138: ...portable power supply to the cylinder to extend or retract the cylinder for alignment Install the retaining pin and secure it in place with the retaining ring 6 Using JLG P N 0100011 thread locking co...

Страница 139: ...4 BOOM PLATFORM 3121259 JLG Lift 4 5 1 4 6 8 7 3 9 5 2 1 MasterCylinder 2 UpperLiftCylinder 3 Jib 4 MainBoom 5 LevelCylinder 6 UpperUpright 7 MidBoomLink 8 MidBoom 9 JibCylinder Figure 4 1 Main Boom A...

Страница 140: ...SECTION 4 BOOM PLATFORM 4 6 JLG Lift 3121259 3 7 5 2 6 1 4 1 Rotator 2 JibCylinder 3 JibPivot 4 PlatformSupport 5 HoseCarrier 6 LowerJibLink 7 UpperJibLink Figure 4 2 Jib Platform Support...

Страница 141: ...uires 3 Debris and foreign matter inside of the boom can cause premature failure of components and should be removed Methods to remove debris should always be done using all applicable safety precauti...

Страница 142: ...FILTER PORT HYD TANK HYD TANK HYD TANK RETURN FILTER PORT PORT P1 UPRIGHT VALVE PORT V2 TELE CYL PORT V1 TELE CYL PORT T1 UPRIGHT UPRIGHT VALVE VALVE UPRIGHT VALVE TO TELE LIFT CYL LIFT CYL PORT T2 P...

Страница 143: ...RT BARREL END MASTER CYL PORT ROD END MASTER CYL FLY BOOM LEVEL CYL FLY BOOM VALVE JIB LIFT CYL LEVEL CYL PORT P1 HELAC PORT P2 HELAC PORT R1 FLY BOOM VALVE PORT R2 FLY BOOM VALVE PORT P PORT P2 UPRIG...

Страница 144: ...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...

Страница 145: ...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...

Страница 146: ...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...

Страница 147: ...aft 3 PistonSleeve 4 EndCap HARDWARE 103 1 Screw 103 2 Washer 106 1 PortPlug SEALS 200 T Seal 202 T Seal 204 O ring 205 CupSeal 207 BackupRing 304 1 WiperSeal BEARINGS 302 WearGuide 304 ThrustWasher A...

Страница 148: ...ARE 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 Thr...

Страница 149: ...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...

Страница 150: ...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...

Страница 151: ...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...

Страница 152: ...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...

Страница 153: ...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...

Страница 154: ...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...

Страница 155: ...ead 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 h...

Страница 156: ...e 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 12...

Страница 157: ...SECTION 4 BOOM PLATFORM 3121259 JLG Lift 4 23 Figure 4 8 Rotator Counterbalance Valve...

Страница 158: ...iters is purged 1 Connect a 3 16 inside diameter x 5 16 outside diame ter x 5 foot clear vinyl drain tube to each of the two bleed nipples Secure them with hose clamps Place the vinyl tubes in a clean...

Страница 159: ...tiononpage 24ofthismanual e Re buildtheactuator Removeallrustthenpolish Replacementpartsmaybeneeded f Re buildtheactuator Usefluidthatiscompatiblewith sealsandbearings 2 Operationiserraticornotrespons...

Страница 160: ...A B D C D A B C D Torqueto35ft lbs 48Nm Loctite 242 Torque250 270ft lbs 340 365Nm Checktorqueevery150hoursofoperation Figure 4 9 Platform Support Torque Values NOTE If any rotator bolts are replaced...

Страница 161: ...he following is needed to correctly oil the o ring in this man ner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the brush with the other hand to dip...

Страница 162: ...e bottom of the fitting This should signify an even coating of oil on the fitting 3 O ring Boss type fittings will require more pressure in able to immerse more of the fitting into the saturated spong...

Страница 163: ...he surface of the cylinder before disassembly 2 Handle every part with care Each part is precision made and hitting parts together or letting them fall could damage the machined surfaces 3 Do not twis...

Страница 164: ...ift 3121259 A B C D E 2mm 1mm F G Checktheoilleakagestatusontherodsurfacewithaflowof20cc 40cc OilleakageinanamountasshowninexampleAisunac ceptable ExamplesB Gareacceptable OILRING Figure 5 1 Acceptabl...

Страница 165: ...G Lift 5 5 Table 5 2 Required Tools Item No Description Quantity 1 Flat headScrewdriver 1 2 AllenWrenchSet 1Set 3 Vise 1 4 SpannerWrench 1Set 5 Punch 1 6 TorqueWrench 1Set 7 PlasticHammer 1 8 Crescent...

Страница 166: ...lace with caulking Using a spanner wrench unscrew the gland from the barrel It is easier to do this with rod pulled out 5cm from the gland If there is no caulking continue with the disassembly process...

Страница 167: ...GIVE ATTENTION TO THE FOLLOWING IT IS POSSIBLE FOR THE ROD TO FALL AND BE DAMAGED WHEN REMOVED FROM THE BARREL IF NOT PROPERLY SUP PORTED PLACE SUPPORT UNDER THE BARREL AS SHOWN BELOW 5 Place the Rod...

Страница 168: ...rded after removal They can not be reused 10 Remove the gland seal a Remove the rod seal and backup ring b Remove the retaining ring with a flat head screw driver prior to removing the dust wiper and...

Страница 169: ...KAGE 1 Pin bushing assembly Coat the opening with oil to aid in assembly and press the bushing into the rod as shown below 2 Gland seal assemblies a Coat the opening with oil to aid in assembly and pr...

Страница 170: ...the groove c Using a proper tool press the piston seal onto the piston When installing the piston seal it is stretched while passing over the head d Install the wear ring assembly by spreading it apar...

Страница 171: ...er barrel end so that it locks the cylinder head in place and it does not unscrew from the barrel If there is no caulking hole caulking is not necessary 8 Test operation a Install the cylinder on a ma...

Страница 172: ...10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 PoppetValve 18 CheckValve 19 Plug 20 O ring 21 Orifice 22 MPRBearing 23 Plug 24 O ring Figure 5 2 Tower Lift Cylinder 1...

Страница 173: ...Ring 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 Spacer 18 O ring 19 PoppetValve 20 CheckValve 21 Plug 22 O ring 23 Orifice 24 MPRBearing 25 Plug 26 O ring Figure 5 3 Upper Lift...

Страница 174: ...1259 1 Tube 2 Rod 3 Gland 4 DustWiper 5 RetainingRing 6 RodSeal 7 BackupRing 8 DryBearing 9 O ring 10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 MRPBearing 18 Plug Fi...

Страница 175: ...g 8 DryBearing 9 O ring 10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 Nut 17 MRPBearing 18 CounterbalanceValve 19 CounterbalanceValve 20 Plug 21 O ring 22 Plug 23 O ring 24...

Страница 176: ...istonSeal 14 WearRing 15 O ring 16 PistonRing 17 HexNut 18 MRPBearing 19 MRPBearing 20 PoppetValve 21 CheckValve 22 CounterbalanceValve 23 Plug 24 O ring 25 Orifice 26 Plug 27 O ring Figure 5 6 Jib Cy...

Страница 177: ...HYDRAULICS 3121259 JLG Lift 5 17 1 Tube 2 Rod 3 Piston 4 Gland 5 DustWiper 6 RodSeal 7 DryBearing 8 O ring 9 BackupRing 10 O ring 11 WearRing 12 PistonSeal 13 MRPBearing Figure 5 7 Steer Cylinder 100...

Страница 178: ...DryBearing 9 O ring 10 BackupRing 11 O ring 12 Piston 13 PistonSeal 14 WearRing 15 O ring 16 HexNut 17 Spacer 18 O ring 19 CounterbalanceValve 20 CounterbalanceValve 21 LoadShuttleValve 22 Plug 23 Pl...

Страница 179: ...g 6 WearRing 7 CounterbalanceValve 8 Bleeder 9 Plug 10 O ring 11 Plug 12 O ring 13 NotUsed 14 NotUsed 15 Plug 16 O ring 17 Plug 18 O ring Figure 5 9 Axle Lockout Cylinder Torque22ft lbs 30Nm Max 10011...

Страница 180: ...SECTION 5 HYDRAULICS 5 20 JLG Lift 3121259 1 6 2 4 5 3 1 ReturnFilter 2 Breather 3 FillCap 4 InternalBaffle 5 DrainPlug 6 OilLevelGauge Figure 5 10 Hydraulic Tank...

Страница 181: ...BS 24 32 Nm THREADLOCKER P N 0100011 UPRIGHT CONTROL VALVE TORQUE 10 14 FT LBS 14 19 Nm FLY BOOM CONTROL VALVE TORQUE 10 14 FT LBS 14 19 Nm THREADLOCKER P N 0100011 TORQUE 10 14 FT LBS 14 19 Nm THREAD...

Страница 182: ...0 14 FT LBS 14 19 Nm THREADLOCKER P N 0100011 MAIN CONTROL VALVE THREADLOCKER P N 0100011 MANUAL PUMP PUMP HANDLE HYDRAULIC TANK VALVE MOUNT PLATE FLOW DIVIDER VALVE TORQUE 18 24 FT LBS 24 32 Nm THREA...

Страница 183: ...IN CHARGE PUMP FILTER CHARGE PUMP FILTER OUTLET SIDE PORT A PORT B MAIN PUMP MAIN PUMP GAUGE PORT MA MAIN PUMP MAIN PUMP GAUGE PORT MB PORT X3 MAIN PUMP MAIN PUMP FLOW DIVIDER VALVE PORT 3 PORT 1 PORT...

Страница 184: ...MAIN VALVE PORT 20 PORT M4 MAIN VALVE MAIN VALVE MAIN VALVE PORT 1 MAIN VALVE HYDRAULIC TANK RETURN PORT HYD TANK VALVE BOTTOM PORT M4 PORT 1 PORT 2 RETURN PORT HYDRAULIC TANK FLOW DIVIDER VALVE PORT...

Страница 185: ...2 PORT M1 OUTLET SIDE PUMP FUNCTION PUMP FUNCTION OUTLET SIDE PORT P1 PORT P2 VALVE MAIN VALVE MAIN VALVE MAIN VALVE MAIN SWING MOTOR PORT B MOTOR SWING PORT A MOTOR SWING OUTLET CHARGE PUMP PORT FILT...

Страница 186: ...35 4 2 Solenoid wIntegralRelief Valve 24 26 32 7 35 4 3 SolenoidValve 16 20 24 4 27 1 4 SolenoidValve 16 20 24 4 27 1 5 ReliefValve 19 21 25 8 28 6 6 FlowControlValve 19 21 25 8 28 6 7 FlowControlValv...

Страница 187: ...CS 3121259 JLG Lift 5 27 V75 LIFT UP V79 TOWER LIFT UP V72 FLOW CONTROL V73 SWING RIGHT V74 SWING LEFT V80 STEER LEFT V81 STEER RIGHT V70 HIGH FLOW DUMP V240 LOW FLOW DUMP Figure 5 17 Main Control Val...

Страница 188: ...Flow Divider Specifications Item Torque Ohms ft lbs Nm 1 SolenoidValve 4 5 5 4 6 8 2 SolenoidValve 4 5 5 4 6 8 3 SolenoidValve 4 5 5 4 6 8 4 Pilot DirectionalValve 46 54 62 6 73 4 5 FlowDividerValve 7...

Страница 189: ...7 PORT B MOTOR DRIVE PORT 12 PORT A MOTOR DRIVE PORT B MOTOR DRIVE PORT A MOTOR DRIVE PORT 7 PORT 5 PORT 18 PORT 13 PORT 3 PORT 1 PORT 23 PORT 14 PORT 2 VALVE MAIN PORT 20 PORT 2 PORT 1 VALVE MAIN POR...

Страница 190: ...5 PORT 11 PORT 9 PORT 8 PORT 21 PORT 22 PRIMARY OSCILLATING AXLE VALVE PRIMARY OSCILLATING AXLE VALVE PRIMARY OSCILLATING AXLE VALVE PRIMARY OSCILLATING AXLE VALVE SECONDARY OSCILLATING AXLE VALVE SEC...

Страница 191: ...SECTION 5 HYDRAULICS 3121259 JLG Lift 5 31 V213 BYPASS V212 BRAKE V97 OSC AXLE 2 SECONDARY V96 OSC AXLE 1 PRIMARY V213 BYPASS V212 BRAKE Figure 5 21 Flow Divider Valve Identification Sheet 3 of 3...

Страница 192: ...ELAC PORT R2 PORT R1 To PORT P1 HELAC PORT J1 PORT J2 To PORT V1 JIB LIFT CYL To PORT V2 JIB LIFT CYL Figure 5 22 Fly Boom Control Valve Identification NOTE Solenoid Valves are torqued 19 21 ft lbs 25...

Страница 193: ...V2 LIFT CYL PORT P1 VALVE UPRIGHT PORT V2 TELE CYL PORT V1 TELE CYL PORT T1 VALVE UPRIGHT PORT V2 VALVE UPRIGHT PORT V2 TELE CYL PORT V1 VALVE UPRIGHT PORT V1 TELE CYL Figure 5 23 Upright Control Valv...

Страница 194: ...C and the other half to port B or D Front and rear sections have independent porting in the center section As each piston cycles in and out of its bore fluid is drawn from one port and displaced to th...

Страница 195: ...ive heat generating pressure control valve for the pur pose of limiting excessive system pressures The charge check function replenishes the low pressure side of the working loop with charge oil Each...

Страница 196: ...s level is nominally set with the pump running at 1800 min 1 rpm For external charge flow the CPRV is set with a flow of 30 l min 8 US gal min In forward or reverse charge pressure will be slightly lo...

Страница 197: ...e servo piston moves the swashplate A swashplate feedback link opposing control links and a linear spring provide swashplate position force feedback to the solenoid The control system reaches equilib...

Страница 198: ...the pump to neutral position The EDC is a displacement flow control Pump swashplate position is proportional to the input command and therefore vehicle or load speed excluding influence of efficiency...

Страница 199: ...s DO NOT DAMAGE THE HOUSING BORE SHAFT OR BEARING WHEN REMOVING THE SHAFT AND SHAFT SEAL 2 Remove the snap ring J200 using snap ring pliers 3 Use an adequate press to remove the bearing from the shaft...

Страница 200: ...WITH A 26 MM 12 POINT SOCKET INSTALL A NEW COIL TORQUE NUT TO 5 NM 3 7 FT LBS 2 Remove solenoids D025 Remove and discard O rings D025A DO NOT DISASSEMBLE INTERNAL PARTS OF CONTROL INTERNAL PARTS ARE...

Страница 201: ...SSURE LIMITER REMOVAL 1 Using a 14 mm wrench remove pressure limiter car tridges L300 and L400 NOTE Pressure limiter L300 L400 is available as complete unit only Seal L022 is available separately 2 Re...

Страница 202: ...lean area pro tecting them from contamination 5 Remove and discard gasket G150 6 If necessary remove bushing G550 using a suitable puller 7 Remove locating pins B010 NOTE If necessary use a hook to re...

Страница 203: ...VO PISTON TO DAMAGE INTERNAL MACHINED SUR FACES OF PUMP SERVO PISTON REMOVAL Tilt swashplate up to disengage servo arm from piston Remove the servo piston assembly E100 SWASHPLATE AND SWASHPLATE BEARI...

Страница 204: ...spring washer block spring and inner block spring washer C40 from the cylinder block RISK OF PERSONAL INJURY COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 350 TO 400 N 80 TO 90 LBF USE A PRESS SUFFICIE...

Страница 205: ...of damage or heavy wear Inspect the shaft surface where it meets the shaft seal Replace the shaft if a groove exists at the sealing land surface where it meets the shaft seal Clean the sealing area w...

Страница 206: ...unning face and the bottom surface Perform a magnetic particle inspection to detect cracks Replace if any cracks exist ENDCAP Inspect the endcap Inspect all machined surfaces for scratches or pits Car...

Страница 207: ...Inspect slider block for wear or damage Replace if necessary Inspect springs for warping or cracking Replace entire assem bly if springs are damaged Inspect servo piston for wear cracks or damage Rep...

Страница 208: ...above surface or 0 72 mm 0 028 in below surface of seal carrier 4 Install the shaft assembly into the front housing Cover the shaft with an installation sleeve to protect it during installation of th...

Страница 209: ...icate and install slider block EOT 5 SERVO PISTON INSTALLATION Install servo piston assembly E100 Ensure swashplate pin fits properly in servo slider block EOT5 SERVO CYLINDER INSTALLATION 1 Lubricate...

Страница 210: ...TING TO INSTALL THE SPIRAL RETAINING RING RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED 3 Turn the block over and install the hold down pins C25 and ball guide C15 into the cylinde...

Страница 211: ...p Lubricate and press the bushings G550 into the end cap to depth shown below NOTE Ensure that bushing is properly installed Improper installa tion resulting in improper depth or misalignment will res...

Страница 212: ...81 Ib ft 7 Use torque sequence shown below CHARGE PUMP INSTALLATION NOTE Charge pump components are available as a complete kit only Kit includes S300 S250 SI 00 SI 50 and S200 1 Install new seal S30...

Страница 213: ...LATION 1 Install new O ring V024 2 Using a 22 mm wrench install the charge pressure relief valve VI0 3 Torque to 52 Nm 38 Ib ft PRESSURE LIMITER INSTALLATION 1 Lubricate and install O rings L022 2 Usi...

Страница 214: ...3mm hex wrench EDC CONTROL ASSEMBLY 1 Install new O rings D025A into solenoids D025 and attach solenoids with capscrews D050 using 4 mm internal hex wrench Torque to 8 Nm 6 ft lbs 2 Replace screen D08...

Страница 215: ...ed reinstall using a 3 mm internal hex wrench Torque to 2 5 Nm 1 8 ft lbs 2 Install dowel pins D300 3 Install new gasket D150 4 Position control on pump housing Remove plug on top of control to visual...

Страница 216: ...e gauges frequently to ensure accuracy Use snubbers to protect gauges Table 5 7 Port information Port identifier Port size Wrench size Pressure obtained Gauge size bar psi L1 L2 11 16 12UNF28 9 16inte...

Страница 217: ...18mm 77Nm 58ft lbs K400 Rearcover auxpadmountingbolt 8mminternalhex 92Nm 68ft lbs L010 Pressurelimiteradjustscrew 8mm NA L300 L400 Pressurelimitercartridge 14mm 30Nm 22ft lbs L024 Pressurelimiterlocki...

Страница 218: ...SECTION 5 HYDRAULICS 5 58 JLG Lift 3121259 Figure 5 32 Fasteners and Plugs Sheet 1 of 2...

Страница 219: ...SECTION 5 HYDRAULICS 3121259 JLG Lift 5 59 Figure 5 33 Fasteners and Plugs Sheet 2 of 2...

Страница 220: ...ill inlet line from reservoir to pump Ensure construc tion plug in control is closed after filling 6 Disconnect the pump from all control input signals 7 Close construction plug removed in step 4 AFTE...

Страница 221: ...ANDERS TO PROTECT AGAINST UNIN TENDED MOVEMENT SECURE THE MACHINE OR DISABLE DISCONNECT THE MECHANISM WHILE SERVICING CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID THE MAN UFACTURER S WARRANTY...

Страница 222: ...andhighpressurerelief valvesandadjustorreplaceasnecessary Systempressure Frequentorlongtermoperationoversystemreliefsetting createsheatinsystem Measuresystempressure Ifpressureistoohigh reduce loads T...

Страница 223: ...nreservoir Lowoillevelcausessluggishresponse Fillreservoir Highpressurereliefvalves pressurelimitersettings Incorrectpressuresettingsaffectssystemreactiontime Adjustorreplacehighpressurereliefvalves L...

Страница 224: ...st for leaks CHARGE PRESSURE RELIEF VALVE ADJUSTMENT NOTE Ensure charge pressure is properly set before checking pressure limiter 1 Install a 50 bar 1000 psi pressure gauge in charge pres sure gauge p...

Страница 225: ...serial plate gives the factory setting of the PL Pressure Limiter The PL setting is referenced to charge pressure Subtract charge pressure from system pressure gauge readings to compute the effective...

Страница 226: ...orque 7 Shut down the prime mover Remove gauges and replace plugs Table 5 15 Pressure Limiter Settings Pressure limiter setting HPRV setting 150 200 180 230 200 250 230 280 250 300 280 330 300 350 330...

Страница 227: ...djusting screw to achieve the desired maxi mum displacement Set the adjusting screw against the servo piston by feel before counting turns Refer to the table below for change per turn Clockwise rotati...

Страница 228: ...Use a 4mm internal hex wrench to hold the neutral adjusting screw D015 stationary while loosening the locknut D060 with a 13mm wrench 3 Observe pressure gauges If necessary turn adjusting screw D015 t...

Страница 229: ...find wrench sizes and plug torques in the Plug size and torque chart SERVO ADJUSTMENT SIDE M4 1 Run prime mover at 1800 rpm 2 If using a PWM signal to set mechanical neutral start with the electronic...

Страница 230: ...7 Before replacing the pump replace all filters and drain the hydraulic system Flush the system lines and fill the reservoir with the correct filtered hydraulic fluid 8 Fill the pump with clean filte...

Страница 231: ...Nm 4 lb ft 7 Install coil using a 12 point 26 mm socket Torque coil nut to 5 Nm 3 7 ft lbs 8 Reconnect electrical connections and test the pump for proper operation Shaft Seal Roller Bearing and Shaf...

Страница 232: ...ring diameter is less than 38 84 mm 1 53 in when installed on the shaft 7 Install the shaft bearing assembly into the pump 8 Lubricate and install a new O ring J260 onto seal car rier J275 Press a new...

Страница 233: ...ugh full range of con trols to ensure proper operation Check for leaks Charge Pressure Relief Valve Replace the charge pressure relief valve V010 as a complete unit Do not attempt to repair the intern...

Страница 234: ...ding with disassembly it may be necessary to prepare some subassemblies separately The details for preparing each subassembly are given in the following section Also some general recommendations are g...

Страница 235: ...DO NOT scribe inter nal surfaces PROCEDURE 1 Clamp the unit Clamp the unit in a vice from the flange side Make sure the vice jaws are clean and have smooth sur faces to prevent damage to the pump Clam...

Страница 236: ...SECTION 5 HYDRAULICS 5 76 JLG Lift 3121259 Figure 5 39 Gear Pump Cutaway...

Страница 237: ...ts side and carefully remove the bearing block and gear set To accomplish this hold the pump body and push with your fingers on the rear bear ing block Mark the relative positions of the gear mesh dri...

Страница 238: ...ng internal snap ring pliers remove the snap ring 10 Remove the shaft seal Check the shaft seal quality and remove if necessary To remove pry the bottom of the shaft seal and force it out while rotati...

Страница 239: ...p ring pliers Ensure the snap ring fits securely in its groove This is necessary to retain the shaft seal 4 Install pressure seals Prepare the pressure seals by lightly lubricating them with grease In...

Страница 240: ...ion 8 Prepare the bearing blocks Clean the two bearing blocks Inspect the flat surfaces of the bearing blocks for burrs or scratches on the edges If necessary remove burrs with very fine emery paper T...

Страница 241: ...ny excess lubrication and grease from the mat ing surfaces of the pump body Ensure that these sur faces are dry and free of contamination before moving on to the next step 12 Install the dowel pins In...

Страница 242: ...gainst the direction of the flow if the unit is a unidi rectional motor If the unit is a bidirectional motor the arrow does not appear on the cover Ensure that all the pressure seals stay in place dur...

Страница 243: ...re tighten the capscrews Then using a torque wrench tighten them to the proper torque Torque 44 54 Nm 32 40 ft lbs 18 Install socket head capscrews Using a 4 mm internal hex wrench install the socket...

Страница 244: ...ervoir 2 Checkinletlineforleaks 3 Checkpressureatpumpinlet Recommendedinletpressure 0 8to3 0barabsolute 0 6 Minimumatcoldstart Description Excessiveairwillcausecavitationsound Excessiveairwillcausecav...

Страница 245: ...adjustable and is located on the T port face of the valve block The steer relief valve is located right next to the swing relief valve To check install a pressure gauge at port M2 Activate steer right...

Страница 246: ...SECTION 5 HYDRAULICS 5 86 JLG Lift 3121259 Figure 5 40 Oil Sampling Port...

Страница 247: ...sed motor con trol unit installed on the boom lift The JLG Control System provides simplicity in viewing and adjusting the various personality settings for smooth control of acceleration deceleration...

Страница 248: ...des real time status information about the control system as a diagnostic aid 3 SYSTEM TEST This menu is used to activate and then interact with the Control System s self test functionality Starting t...

Страница 249: ...le the cable cannot 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...

Страница 250: ...s a power up When a top level menu is selected a new set of menu items may be offered for example SYSTEM DATALOG VERSIONS ENGINE OPER CONTROLS Pressing ENTER with any of the above displayed menus will...

Страница 251: ...eat 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 Service Access a...

Страница 252: ...ecommended setting NOTE Refer to Table 6 6 Machine Model Adjustment for the rec ommended factory settings NOTE Password 33271 will give you Service Access which will permit you to change all machine p...

Страница 253: ...ILTED ELEV ELEVATION ENG ENGINE EXT EXTEND F FRONT FL FLOW FNT FRONT FOR FORWARD FWD FORWARD FSW FOOTSWITCH FUNC FUNCTION G GROUND GND GROUND GRN GREEN GM GROUNDMODULE H HOURS HW HARDWARE HWFS HARDWAR...

Страница 254: ...R SN SERIALNUMBER 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...

Страница 255: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 9 PLATFORM MODULE GROUND MODULE Figure 6 2 Control Module Location...

Страница 256: ...SECTION 6 JLG CONTROL SYSTEM 6 10 JLG Lift 3121259 Figure 6 3 Ground Module Sheet 1 of 4...

Страница 257: ...AL OUTPUT 6 FUEL GROUND GROUND INPUT 7 PLATFORM LEVEL DOWN SOLENOID DIGITAL OUTPUT 8 RIGHT FRONT STEER SOLENOID DIGITAL OUTPUT 9 TOWER LIFT DOWN SOLENOID DIGITAL OUTPUT 10 UNUSED PLATFORM ROTATE LEFT...

Страница 258: ...UND INPUT 20 OSCILLATING AXLE COIL 2 ANALOG INPUT 21 UNUSED TOWER TELESCOPE PROXIMITY DIGITAL INPUT 22 UNUSED DIGITAL INPUT 23 UNUSED DIGITAL INPUT 24 CAN1 LOW SERIAL I O 25 UNUSED GROUND GROUND INPUT...

Страница 259: ...L OUTPUT 14 PLATFORM OVERLOADED INDICATOR DIGITAL OUTPUT 15 UNUSED BOOM MALFUNCTION INDICATOR DIGITAL OUTPUT 16 AUXILIARY POWER FUNCTION ENABLE DIGITAL INPUT 17 PLATFORM LEVEL UP DIGITAL INPUT 18 PLAT...

Страница 260: ...T TOUCH LIMIT SWITCH POWER BATTERY VOLTAGE 8 FOOTSWITCH SIGNAL DIGITAL INPUT 9 GENERATOR ON SIGNAL DIGITAL INPUT 10 7 REFERENCE VOLTAGE 7 REFERENCE VOLTAGE 11 LOAD CELL INPUT 1 ANALOG INPUT 12 LOAD CE...

Страница 261: ...REFERENCE VOLTAGE 35 SPEED PUMP POTENTIOMETER DIGITAL INPUT CONNECTOR PIN ASSIGNMENT FUNCTION J2 GRAY 1 UNALLOCATED DIGITAL INPUT 2 UNALLOCATED DIGITAL INPUT 3 BATTERY VOLTAGE HS DIGITAL INPUT 4 DRIVE...

Страница 262: ...owerLift Up J4 10 Down J4 21 Lift Up J4 23 Down J4 33 Telescope In J4 7 Out J4 30 JibLift Up J4 19 Down J4 8 PlatformLevel Up J4 17 Down J4 5 PlatformRotate Left J4 6 Right J4 18 Table 6 3 Platform Co...

Страница 263: ...c cessfulCANBuscommunication Successfulcommunication VerifyhealthyCANBusandpresenceofPlatformMod ule Successfulcommunication Ifapplicable confirmpresenceofLSSsystem Successfulcommunication CANBus2 Ifa...

Страница 264: ...rgizeandverifycurrentpath TelescopeInValve NoSTB OC NoSTG energizeTeleInandOutsimultaneously TelescopeOutValve NoSTB OC NoSTG energizeTeleInandOutsimultaneously LevelUpValve NoSTB OC NoSTG energizeLev...

Страница 265: ...e NoSTB OC NoSTG energizeJibUp JibDownValve NoSTB OC DonotcheckSTG RotateLeftValve NoSTB OC NoSTG energizeRotateLeftandRightsimultaneously RotateRightValve NoSTB OC NoSTG energizeRotateLeftandRightsim...

Страница 266: ...CTION 6 JLG CONTROL SYSTEM 6 20 JLG Lift 3121259 1 A O Figure 6 9 Analyzer Top Level Menu See Figure 6 15 See Figure 6 16 See Figure 6 13 See Figure 6 12 See Figure 6 14 See Figure 6 11 See Figure 6 1...

Страница 267: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 21 Figure 6 10 Analyzer Diagnostics Menu Sheet 1 of 4...

Страница 268: ...SECTION 6 JLG CONTROL SYSTEM 6 22 JLG Lift 3121259 Figure 6 11 Analyzer Diagnostics Menu Sheet 2 of 4...

Страница 269: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 23 Figure 6 12 Analyzer Diagnostics Menu Sheet 3 of 4...

Страница 270: ...SECTION 6 JLG CONTROL SYSTEM 6 24 JLG Lift 3121259 Figure 6 13 Analyzer Diagnostics Menu Sheet 4 of 4...

Страница 271: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 25 Figure 6 14 Analyzer Personalities Menu Sheet 1 of 2...

Страница 272: ...SECTION 6 JLG CONTROL SYSTEM 6 26 JLG Lift 3121259 Figure 6 15 Analyzer Personalities Menu Sheet 2 of 2...

Страница 273: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 27 Figure 6 16 Analyzer Machine Setup Menu...

Страница 274: ...SECTION 6 JLG CONTROL SYSTEM 6 28 JLG Lift 3121259 Figure 6 17 Analyzer Calibrations Menu...

Страница 275: ...tedMax 250 850mA 790mA Mid EngineElevatedMax 250 975mA 900mA MaxTorqueCreep 250 750mA 725mA Mid EngineCreep 250 890mA 850mA STEER Accel 0 0 5 0sec 0 8sec Decel 0 0 5 0sec 0 1sec MinRight 10 100 35 Max...

Страница 276: ...T Accel 0 0 5 0sec 1 2sec Decel 0 0 5 0sec 0 5sec MinUp 250 1400mA 400mA MaxUp 250 1400mA 1075mA CreepUp 250 1400mA 575mA MinDown 10 70 32 MaxDown 10 70 53 CreepDown 10 70 48 PLATFORMLEVEL Accel 0 0 5...

Страница 277: ...n 250 1400mA 750mA Telescope 250 1400mA 1250mA JibUp 250 1400mA 1075mA JibDown 10 70 53 PlatformLevel 250 1400mA 1250mA PlatformRotate 250 1400mA 1250mA NOTE Personality settings can be adjusted anywh...

Страница 278: ...wheelteeth 1 Thismenuitemisnotvisible GLOWPLUG 5 1 2 3 NOGLOWPLUGS Noglowplugsinstalled AIRINTAKE Glowplugsinstalledintheairintakeonthemanifold IN CYLINDER Glowplugsinstalledineachcylinder 3 Thismenui...

Страница 279: ...nswilllimittiltoptionsandalterdefaultsetting Note Anyoftheselectionsabovewilllightthetiltlampwhenatiltedconditionoccursandwillsoundtheplatformalarmwhenthemachineisalsoaboveelevation JIB 10 1 2 NO Noji...

Страница 280: ...CUTE T Drive steercutoutaboveelevationandtilted 1 Onlyvisibleundercertainmarketselections Certainmarketselectionswilllimitfunctioncutoutoptionsoralterdefaultsetting GROUNDALARM 19 1 2 3 4 NONE Nogroun...

Страница 281: ...telematics optionsisdisabled YES ClearSky telematics optionisenabled 1 CRIBBINGOPTION 24 1 2 NO CribbingOptionisdisabled 1 YES CribbingOptionisenabled 1 4150364 A Table 6 7 Machine Configuration Prog...

Страница 282: ...2 2 2 GenSetCutout 1 1 1 1 1 1 2 2 2 2 2 2 Head Taillights 1 1 1 1 1 1 2 2 2 2 2 2 CableBreakSwitch 1 1 1 1 1 1 LoadSystem 1 1 1 1 1 1 X 2 X X X 2 X 3 X 3 3 3 X 4 X 4 X 4 X 5 X X X X FunctionCutout 1...

Страница 283: ...ovement is permitted by a Removing the excess platform load until actual plat form load is less than Rated Load b Operation of the overriding emergency system Auxiliary Power Unit c By an authorized p...

Страница 284: ...e 6 9 Diagnostic Menu Descriptions Diagnostics Menu Displayed on Analyzer 1st Line Parameter Displayed on Analyzer 2nd Line Parameter Value Displayed on Analyzer 2nd Line Description PLATFORMLOAD STAT...

Страница 285: ...approximately level for calibra tion Level the platform from ground control if neces sary to within 5 4 To access the Calibration Menu use the LEFT and RIGHT Arrow keys to select CALIBRATION from the...

Страница 286: ...6 10 Accessory Weights Use the up and down analyzer keys to enter the accessory weight s in lbs When all the accessory weights are entered press ENTER The screen will read LOAD SENSING accessory xxxlb...

Страница 287: ...ess than 575 lbs 261 kg If the platform weight is not within the allowed range the calibration attempt will be unsuccessful and the Analyzer will show the following 10 Press ENTER The control system w...

Страница 288: ...acity Reductions and Table 6 12 Pipe Rack Capacity Reduc tions Table 6 11 SkyGlazier Capacity Reductions Capacity PLATFORM OVRLD PLATFORM OVRLD RESTRICT 500lb 227kg 400lb 181kg n a 550lb 250kg 400lb 1...

Страница 289: ...SECTION 6 JLG CONTROL SYSTEM 3121259 JLG Lift 6 43 14 Press ENTER If calibration is successful the screen will read...

Страница 290: ...Overload Visual Warning at the Ground Controls should flash and the Audible Warning at Platform and Ground should sound for 5 seconds On 2 seconds Off However the controls should remain functional whe...

Страница 291: ...rsastheywillleaveconductiveresidue Moistureshouldbeallowedtoevaporateor acceleratedwithaheat gun uselowheatandbecarefullytonotmeltconnectormaterials Moistureintrusionintothemoldedportionof theconnecto...

Страница 292: ...rm console NOTE If performing the procedure from the platform console the Emergency Stop switch on the ground console must also be pulled out 4 Pull out the Emergency Stop switch 5 The analyzer screen...

Страница 293: ...ROL SYSTEM 3121259 JLG Lift 6 47 12 Press Enter The screen will read 13 Press Enter The JLG Control System will reset an active 873 DTC and the MSSO System will be reset Press Escape to return to the...

Страница 294: ...n Ground Mode display will read GROUND MODE OK Pressing ENTER again will cause the Analyzer to display the current Help description followed by its Diagnostic Trouble Code DTC Help Messages larger tha...

Страница 295: ...223 FUNCTIONSWITCHESLOCKED SELECTEDBEFOREENABLE 2224 FOOTSWITCHSELECTEDBEFORESTART 2247 FUNCTIONPROBLEM PLATFORMROTATELEFTPERMANENTLYSELECTED 2248 FUNCTIONPROBLEM PLATFORMROTATERIGHTPERMANENTLYSELECTE...

Страница 296: ...BOOMPREVENTED DRIVESELECTED 2516 DRIVEPREVENTED ABOVEELEVATION 2517 DRIVEPREVENTED TILTED ABOVEELEVATION 2518 DRIVEPREVENTED BOOMSELECTED 2520 FUNCTIONSLOCKEDOUT CONSTANTDATAVERSIONIMPROPER 331 BRAKE...

Страница 297: ...ROUND 33101 JIBLIFTUPVALVE OPENCIRCUIT 33102 JIBLIFTUPVALVE SHORTTOBATTERY 33103 JIBLIFTDOWNVALVE SHORTTOGROUND 33104 JIBLIFTDOWNVALVE OPENCIRCUIT 33105 JIBLIFTDOWNVALVE SHORTTOBATTERY 33106 TOWERLIFT...

Страница 298: ...CURRENTFEEDBACKREADINGLOST 33419 FLOWCONTROLVALVE CURRENTFEEDBACKREADINGLOST 33420 TRACTIONLOCKVALVE SHORTTOBATTERY 33421 TRACTIONLOCKVALVE OPENCIRCUIT 33422 TRACTIONLOCKVALVE SHORTTOGROUND 33423 OSCI...

Страница 299: ...GLOST 441 BATTERYVOLTAGETOOLOW SYSTEMSHUTDOWN 442 BATTERYVOLTAGETOOHIGH SYSTEMSHUTDOWN 443 LSSBATTERYVOLTAGETOOHIGH 444 LSSBATTERYVOLTAGETOOLOW 445 BATTERYVOLTAGELOW 662 CANBUSFAILURE PLATFORMMODULE 6...

Страница 300: ...FUNCTIONSLOCKEDOUT PLATFORMMODULESOFTWAREVERSIONIMPROPER 9911 FUNCTIONSLOCKEDOUT LSSMODULESOFTWAREVERSIONIMPROPER 9915 CHASSISTILTSENSORNOTGAINCALIBRATED 9919 GROUNDSENSORREFVOLTAGEOUTOFRANGE 9920 PLA...

Страница 301: ...sisisconsideredTilted CreepModeisactive LowerMachineandplaceon firm levelsurface RUNNINGATCREEP PLAT FORMSTOWED 00301 PlatformisinStowedPosition LiftDownandLevelDown functionspeedmaximumsare limitedto...

Страница 302: ...CKED JOYSTICK MOVEDBEFOREFOOTSWITCH 2212 TheControlSystemdetectsoneofthefollowingconditions ThemachineisinPlatformModeandthedrivejoystickisnotinthe neutralpositionimmediatelyfollowingStartUp Themachin...

Страница 303: ...dSwinginPlatform Mode Iffaultoccursbyengagingthe footswitchafterthecontrol thenmachineisnotpermitted toentertheMachineEnabled state ReturnLift Swingcontrolsto neutralwhilenotinthe Enabledstate ReturnL...

Страница 304: ...gesunderappropriate menuinDIAGNOSTICS OPER CONTROLSonAnalyzer Replacetheswitchiffaulty FUNCTIONPROBLEM TELE SCOPEINPERMANENTLY SELECTED 2251 ThemachineisinPlatformmodeandthetelescopeswitchissending ac...

Страница 305: ...IAGNOSTICS BOOM 234 TheGroundModuledetectsoneofthefollowingconditions ThemachineisinGroundModeandbothdirectioninputsofthe followingboomcontrolsareenergizedatthesametime Engine Start Aux Telescope Plat...

Страница 306: ...Replacethe switchifdefective FUNCTIONPROBLEM JIBLIFT UPPERMANENTLYSELECTED 2370 ThemachineisinGroundmodeandtheJibLiftswitchisselectedand tryingtoactivatetheJibLiftUpfunctionatstartup JibLiftUpandDown...

Страница 307: ...PROBLEM TOWERLIFTDOWNPERMA NENTLYSELECTED 23106 ThemachineisinGroundmodeandtheTowerLiftswitchisselected andtryingtoactivatetheTowerLiftDownfunctionatstartup TowerLiftUpandDownprohib ited Withthemachin...

Страница 308: ...ORMLEVELDOWNPERMA NENTLYSELECTED 23112 ThemachineisinGroundmodeandthePlatformLevelswitchis selectedandtryingtoactivatethePlatformLevelDownfunctionat startup PlatformLevelUpandDown prohibited Withthema...

Страница 309: ...machinechangesfromBelowEleva tiontoAboveElevation Allboomfunctionsaredis abled StopoperatinganyDriveor Steerfunctions Activatethe Boomfunction DRIVEPREVENTED ABOVE ELEVATION 2516 Themachineissetuptocu...

Страница 310: ...ut GroundModuleLiftUpand Downoutputsaredisabled Inspectwiringforphysical damageandcheckforwire continuity Cyclepowertoclear thefault LIFTDOWNVALVE OPEN CIRCUIT 336 TheGroundModuledetectsanopencircuita...

Страница 311: ...ECU groundmodulewillonlyevaluatefor opencircuitconditionsuntilfirstStartisattemptedforeachpower cycleduetopossibilityofECUopeninggroundsolenoidreturnpath todisableStartandcausingerroneousdiagnostics N...

Страница 312: ...werto clearthefault GENSET WELDER SHORTTO BATTERY 3375 TheGroundModuledetectsashorttobatteryattheGenSet Welder output TheGroundModuleGenerator relayoutputisdisabled butthe GroundModuleconsidersthe Gen...

Страница 313: ...dforcontinuity throughthiscircuit Inspect wiringforphysicaldamage Cyclepowertoclearthefault PLATFORMLEVELUPVALVE SHORTTOBATTERY 3384 TheGroundModuledetectsashorttobatteryatthePlatformLevel UpValveoutp...

Страница 314: ...lveoutput TheGroundModulesuspends TowerLiftUp Downcom mandsandrevertstoOpen LoopCurrentcontrolforTower Lift TowerLiftspeedislimited toCreepafterbothTowerLift Up Downcontrolshavebeen returnedtoneutrala...

Страница 315: ...andcheckforwire continuity Checkforcoildam ageorshortingconditionin connector Cyclepowertoclear thefault THROTTLEACTUATOR OPEN CIRCUIT 33131 TheGroundModuledetectsanopencircuitattheThrottleActuator ou...

Страница 316: ...existsontheGroundMod uleoutputpinfordiagnostic purposes Inspectwiringfor physicaldamage Cyclepower toclearthefault TELESCOPEINVALVE SHORT TOGROUND 33190 TheGroundModuledetectsashorttogroundattheTelesc...

Страница 317: ...rcontinuity throughthiscircuit Withthe solenoiddisconnected an opencircuitvoltageofnearly 8 0VexistsontheGroundMod uleoutputpinfordiagnostic purposes Inspectwiringfor physicaldamage Cyclepower toclear...

Страница 318: ...rphysical damageandcheckforwire continuity Cyclepowertoclear thefault DRIVEFORWARDVALVE SHORTTOGROUND 33319 TheGroundModuledetectsashorttogroundattheDriveForward Valveoutput GroundModuleDriveForward a...

Страница 319: ...VES SHORTTO BATTERY 33412 TheGroundModuledetectsashorttobatteryateithertheSwing RightorSwingLeftvalve GroundModuleSwingLeftand Rightoutputsaredisabledand openthegroundcurrentreturn pathisopencircuited...

Страница 320: ...anded currentisbeingdivertedfrom thegroundreturnpath Inspect wiringforphysicaldamageand checkforwirecontinuityanda lowresistancereturnpath Cyclepowertoclearthefault SWING CURRENTFEEDBACK READINGLOST 3...

Страница 321: ...iftUp andDownoutputsaredisabled andopenthegroundcurrent returnpath Inspectwiringforphysical damageandcheckforwire continuity Cyclepowertoclear thefault PLATFORMROTATELEFT VALVE OPENCIRCUIT 349 ThePlat...

Страница 322: ...hysicaldamage Cyclepowertoclearthefault JIBLIFTUPVALVE SHORTTO GROUND 3417 ThePlatformModuledetectsashorttogroundattheJibLiftUpValve outputandreportsittotheGroundModule JibLiftUpoutputisdisabled JibLi...

Страница 323: ...servestate changeonAnalyzerunder DIAGNOSTICS ENGINE ENGINEOILPRESS COOLANTTEMPERATURE SHORTTOGROUND 435 MACHINESETUP ENGINE KUBOTAD1105 GroundModulecoolanttemperatureinput J1 14 detectsavoltage lessth...

Страница 324: ...msandEngineoilpressureisnotLOW GroundModuletolimitall functionspeedstocreep but runatHighEnginespeeduntil theoilpressuredropstoalow value GroundModuletodis ableGeneratorrelayoutput untilgeneratoropera...

Страница 325: ...han9volts DisableallGroundModule valveoutputsexceptthose usedduringEmergency Descent TowerLiftDown Lift Down JibUp Down If MACHINESETUP H T LIGHTS YESor ENGINE KUBOTAD1105turnofflights anddisableglowp...

Страница 326: ...hisrequiredto resumeoperation Withpoweroff disconnectthe boomcableatthebottomof thePlatformbox Withamulti meter verifythattheresistance betweentheCAN1HandCAN1L pinsoftheboomcableis approximately120ohm...

Страница 327: ...ClearSkyTCU CHASSISTILTSENSORNOT CALIBRATED 813 Thetiltsensorhasnotbeencalibrated TheGroundModulereportsa faultedchassistiltangleof90 degrees CalibratetheTiltsensortoclear thefault CHASSISTILTSENSOROU...

Страница 328: ...slatchedwithinagivenkeycycle Possiblesensorhardwareissue LSSSTRAINGAUGE2 STAG NANT 8223 Thecontrolsystemhasdeterminedthatthestraingauge2readingin theloadsensorisstagnant notchanging Iftheplatformisnot...

Страница 329: ...ult onceannunciatedislatchedwithinagivenkeycycle Possiblesensorhardwareissue LSSSTRAINGAUGE2 INITIAL IZATIONERROR 8229 Theshearbeamisreportinganinitializationissuewiththestrain gauge2sensor Iftheplatf...

Страница 330: ...agivenkeycycle Possiblesensorhardwareissue LSSSTRAINGAUGE1 NOT INSTALLED 8234 Theshearbeamisreportinganotinstalledissuewiththestraingauge 1sensor Iftheplatformisnotoverloadedthemachinewillbeplacedinto...

Страница 331: ...onsformachine response Notallofthetriggerconditions aremet DRIVE BOOMPREVENTED PLATFORMOVERLOADED 827 ThePlatformisOverloadedand MachineSetup LOADSYSTEM CUTOUTPLATFORM Platform Modeisactive andconditi...

Страница 332: ...etoOver loaded Cyclepowertoclearthefault LSSINTERNALERROR PIN EXCITATION 993 TheGroundModuledetectsanLSSreportofimproperexcitation voltage TheGroundModulesetsthe PlatformLoadStatetoOver loaded Cyclepo...

Страница 333: ...ODE1 9923 TheGroundModuledetectsfaultyhardware Noresponserequired Cyclepowertoclearthefault if faultsremains replaceboard FUNCTIONSLOCKEDOUT MACHINENOTCONFIGURED 9924 Themachineispoweredupandnomodelha...

Страница 334: ...ONIMPROPER 9979 GroundModuledetectsadisagreementwithinternalchecksonthe versionofsoftware Allmachineandenginefunc tionsaredisabled i e com mandengineshutdownanddo notpermitstart Cyclepowertoclearthefa...

Страница 335: ...onotreportFault ReportFault ReportFault DonotreportFault Donotreportfault Activatecreepmodeallfunctions DonotpermitMachineEnable no creeplight Overloadshallhavenoeffecton functionspeeds Overloadshallh...

Страница 336: ...SECTION 6 JLG CONTROL SYSTEM 6 90 JLG Lift 3121259 NOTES...

Страница 337: ...ng the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec...

Страница 338: ...to ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Continuity Measurement Some meters require a separate button press to enable audible continui...

Страница 339: ...ure to apply Silicone Dielectric Com pound to the electrical connectors This procedure applies to all plug connections not enclosed in a box Silicone grease should not be applied to connectors with ex...

Страница 340: ...hin layer of dielectric grease on the face of the connector 4 Assemble the connector system immediately to prevent moisture ingress or dust contamination 5 Pierce one of the unused wire seals prior to...

Страница 341: ...N 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 permane...

Страница 342: ...omponents with the M12 con nector system AMP JUNIOR TIMER This type of connector uses back seals for moisture integrity However the low force contacts cannot displace dielectric grease and create elec...

Страница 343: ...pplication for this connector is on David Clark Intercom connections in Aerial Work Platforms 7 4 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open or as shipped position See Figur...

Страница 344: ...dge 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 Figur...

Страница 345: ...forward or mating end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick Service Voltage Reading DO NOT PIE...

Страница 346: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 10 JLG Lift 3121259 Figure 7 13 Connector Installation...

Страница 347: ...ard 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 Serie...

Страница 348: ...ire 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 remov...

Страница 349: ...OX SHEET 3 PLATFORM AND BOOM COMPONENTS SHEET 4 CHASSIS TURNTABLE AND UGM SHEET 5 GROUND USER INTERFACE SHEET 6 ENGINE KUBOTA AND GENERATOR SHEET 7 ENGINE GM VENDOR SCHEMATIC SHEET 8 MIDENGINE HARNESS...

Страница 350: ...H IGN WHT 2 17 8 SWITCH IGN WHT 13 1 MAIN TELE IN WHT 13 1 MAIN TELE IN WHT 14 1 MAIN TELE OUT WHT 14 1 MAIN TELE OUT WHT 2 17 9 SWITCH IGN WHT 2 17 9 SWITCH IGN WHT 53 1 AUX POWER WHT 53 1 AUX POWER...

Страница 351: ...RLOAD WHT 56 1 TILTED WHT 56 1 TILTED WHT 48 1 GLOW PLUGS WHT 48 1 GLOW PLUGS WHT 39 3 1 4 FUEL LVL WHT 39 4 1 2 FUEL LVL WHT 39 5 3 4 FUEL LVL WHT 0 22 FUEL GND WHT 39 6 FULL FUEL LVL GENERIC EMERGEN...

Страница 352: ...T3 1 T4 TO SHEET 2 X2 INSIDE PLATFORM BOX 1 T5 1 T6 1 BLU BLK BLU BLK ORN BLK YEL BLK BRN BLK BLK RED BLK RED X2 1 2 3 4 5 6 7 8 9 10 11 12 GENERIC FOOT SWITCH SW43 1 2 3 SHLD TP CAN CABLE SHLD TP CA...

Страница 353: ...ED BLK 18AWG ORN BLK 18AWG SHLD SHLD BLK 12AWG X5 12 16 1 2 3 5 4 6 7 8 11 14 17 19 18 10 15 9 13 X7 TO SHEET 4 BOOM CABLE X7 12 16 1 2 3 5 4 6 7 8 11 14 17 19 18 10 15 9 13 T2 1 T3 1 T4 1 T5 1 T6 1 B...

Страница 354: ...3 TWR LIFT UP STEER LEFT GENERIC V80 1 2 STEER RIGHT GENERIC V81 1 2 DRIVE REVERSE GENERIC V82 1 2 DRIVE FORWARD GENERIC V83 1 2 WHT 9 2 STEER LFT WHT 9 2 STEER LFT WHT 10 2 STEER RT WHT 10 2 STEER R...

Страница 355: ...STROBE GENERIC LB104 1 2 WHT 0 13 1 TWR VLV RTN RED 1 9 B RED 1 9 1 B S143 WHT 0 18 VLV GND WHT 0 18 VLV GND WHT 2 16 1 IGN WHT 2 16 IGN S145 WHT 73 2 OSC AXLE 2 WHT 73 2 OSC AXLE 2 S146 WHT 73 1 OSC...

Страница 356: ...LFT WHT 53 2 AUX ENABLE WHT 53 2 AUX ENABLE WHT 2 14 SWITCH IGN WHT 2 14 SWITCH IGN WHT 45 2 START WHT 45 2 START WHT 2 14 1 SWITCH IGN WHT 2 14 1 SWITCH IGN WHT 2 14 2 SWITCH IGN WHT 2 14 2 SWITCH I...

Страница 357: ...17 2 LAMP GND WHT 0 17 2 LAMP GND WHT 0 17 3 LAMP GND WHT 0 17 3 LAMP GND WHT 0 17 4 LAMP GND WHT 0 17 4 LAMP GND WHT 0 17 5 LAMP GND WHT 0 17 5 LAMP GND WHT 0 17 6 LAMP GND WHT 0 17 6 LAMP GND WHT 0...

Страница 358: ...PLUGS 12AWG WHT 84 2 GLOW PLUGS 12AWG RED 1 10 1 B 12AWG RED 1 10 2 B 12AWG RED 1 10 5 B 12AWG RED 1 10 6 B 12AWG RED 1 10 6 B 12AWG RED 1 10 3 B 12AWG RED 1 10 4 B 12AWG WHT 83 1 OIL PRESSURE WHT 83...

Страница 359: ...OR HARNESS X42 TO VOLTAGE REGULATOR 1 2 3 4 5 X28 TO GENERATOR TO GENERATOR CASE TO ENGINE BLOCK 1 2 3 X35 TO SHEET 8 X35 A B T30 TO E STOP 2A2 1 T31 TO SHEET 4 GND BUS POS 5 1 S236 WHT 0 33 GND WHT 5...

Страница 360: ...75 TERMINAL 1 4 SPADE FEMALE PED_12160825 CONNECTOR PED_12177150 TERM GOLD PED_12160826 LOCK PED_12089678 SEAL PED_12162834 CONNECTOR PED_12124075 TERMINAL PED_12162193 CONNECTOR PED_12124075 TERMINAL...

Страница 361: ...SEAL PED_15305171 CAVITY PLUG PED_15358639 CLIP PED_15326840 CONNECTOR PED_15326269 TERMINAL PED_12191153 SEAL PED_15305171 CAVITY PLUG PED_15358639 CLIP PED_15317363 LOCK CAP CONNECTOR 2 WITH MATING...

Страница 362: ...THROTTLE ACT WHT 80 1 THROTTLE ACT WHT 0 43 THROTTLE RTN WHT 0 43 THROTTLE RTN CO66 J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 X175 TO SHEET 4...

Страница 363: ...G H J K L M N P R S NC RED TP CAN CABLE BLK TP CAN CABLE SHLD WHT 85 1 FULL THROTTLE X40 A B C D E F G H WHT 2 21 IGN 16AWG Sheet_4 3 H WHT 82 2 SPEED VCC T362 TO ESTOP 1B2 1 T363 TO KEYSWITCH POS 1...

Страница 364: ...K RED 1 12 B 12AWG WHT 0 45 1 GND WHT 0 45 1 GND LEFT FRONT GENERIC LB390 1 2 LEFT REAR GENERIC LB391 1 2 RIGHT FRONT GENERIC LB392 1 2 RIGHT REAR GENERIC LB393 1 2 CHASSIS LIGHT OPTION J8 1 2 J8_1 1...

Страница 365: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3121259 JLG Lift 7 29 This page left blank intentionally...

Страница 366: ...2 0 50mm ROD 1 3 32mm STROKE 38 5 978mm OSCILLATING AXLE CYLINDERS BARREL 2 75 69 85mm STROKE 2 75 69 85mm STEER CYLINDER BARREL 2 5 65mm ROD 1 75 45mm STROKE 5 5 139mm JIB ROTATE FLY BOOM VALVE T P J...

Страница 367: ...c REDUCTION 170 7 1 CHARGE FILTER MICRON LEVEL 5 BYPASS VALVE 43 PSI 3 BAR DRIVE PUMP 2 75 cu in 45 cc 4060 PSI 280 BAR Max 377 PSI 26 BAR Charge 0 73 cu in 12cc Charge Pump Displacement P1 Main relie...

Страница 368: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 32 JLG Lift 3121259 NOTES...

Страница 369: ......

Страница 370: ...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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