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JLG E450A, Руководство по обслуживанию и ремонту

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SECTION 5 - BASIC HYDRAULIC INFORMATION & SCHEMATICS

3121714

5-93

MAE32740A

1001230299-A

8

2

2

11

6

4

6

15

16

14

9

18

5

12

13

10

17

7

17

1

19*

20**

20**

8

8

* Torque to 30-35 ft. lbs. (41-48 Nm)
** Torque to 34-38 ft. lbs. (46-52 Nm)

8

3

Figure 5-83.  Upper Lift Cylinder - E450AJ/M450AJ (SN B300002487 to Present)

1.

Barrel

2.

Rod

3.

Piston

4.

Head

5.

Spacer

6.

Locking Piece

7.

Locknut

8.

Bushing

9.

Rod Seal

10. Piston Seal
11. Wiper Seal
12. O-ring

13. O-ring
14. O-ring
15. O-ring
16. Backup Ring

17. Wear Ring
18. Wear Ring
19. Counterbalance Valve
20. Plug

Содержание E450A

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

Страница 2: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 129: ...head mallet install pivot pin 2 into fly boom assembly and secure with mounting hardware 7 Align the slave leveling cylinder with attach holes in articulating jib boom pivot weldment Using a soft head...

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

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

Страница 132: ...1 Screw 103 2 Washer 106 1 PortPlug 106 2 PortPlug 109 LockPin 113 Capscrew SEALS 200 T Seal 202 T Seal 204 O ring 205 CupSeal 207 BackupRing 304 1 WiperSeal BEARINGS 302 WearGuide 304 ThrustWasher AC...

Страница 133: ...4 76mm 3 Remove the lock pins using an Easy Out a size 2 is shown If the pin will not come out with the Easy Out use 5 16 drill bit to a depth of 1 2 12 7mm todrill out the entire pin 4 Install the en...

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

Страница 135: ...g gear teeth mark the pis ton and housing with a marker as shown 14 Remove the o ring 204 and backup ring 207 from end cap 4 and set aside for inspection 15 Remove the wear guides 302 from the end cap...

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

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

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

Страница 139: ...king from the view shown use the existing timing marks to line up the gear teeth on the shaft 2 with the gear teeth on the inside of the piston 3 Now tap the flange end of the shaft with a rubber mall...

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

Страница 141: ...New bolts should be installed with a new valve JLG Threadlocker PN 0100011 should be applied to the shank of the three bolts at the time of installation 4 Torque the 1 4 inch bolts 110 to 120 in lbs 1...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 317: ...switch built into the top the drive joystick To activate Drive Lift and Swing simply pull up on the slide lock location on the joystick and move the handle into the direction desired The motor contro...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 404: ...uto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Continuity Measurement Some meters require a separate button press to enable audible continu...

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

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

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

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

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

Страница 410: ...y achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assem bling the housing to the header it is pos...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 479: ......

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

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