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Oshkosh JLG 400S, Руководство по обслуживанию и ремонту

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vi

– JLG Lift –

3120895

TABLE OF CONTENTS

                            

SECTION NO.                                  TITLE                                                                             PAGE NO.

DTC 606- Microprocessor Failure - COP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-184
DTC 642- 5 Volt External Low Voltage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-186
DTC 643- 5 Volt External High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-188
DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-190
DTC 1613- Microprocessor Failure - RTI 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-191
DTC 1614- Microprocessor Failure - RTI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-193
DTC 1615- Microprocessor Failure - A/D  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-195
DTC 1616- Microprocessor Failure - interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-197
DTC 1625- CAN J1939 Shutdown Request  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-199
DTC 1626- CAN J1939 Transmit (Tx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-200
DTC 1627- CAN J1939 Receive (Rx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-201
DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-202
DTC 1629- J1939 TSC1 Message Reciept Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-204
DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-205
DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-206
DTC 2112- Unable to Reach Higher TPS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-208
DTC 9999- Throttle Actuator Failsafe Spring Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-209
DTC to SPN/FMI Table  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   3-210

SECTION 4  - BOOM & PLATFORM

4.1

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-2
Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-5

4.2

Articulating jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-6

4.3

Limit Switch Adjustments  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Boom Horizontal Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-6
Dual Capacity Angle Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-6
Boom Length Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-6

4.4

Drive Card Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-10
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-10
Lift, Swing, and Drive Cards  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-11
Flow Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-11

4.5

Helac Rotary actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Theory Of Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-13
Tools Required for Assembly/Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-16
Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-20
Installing Counterbalance Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-23

Содержание JLG 400S

Страница 1: ...Service and Maintenance Manual Models 400S 460SJ P N 3120895 December 6 2012...

Страница 2: ......

Страница 3: ...dangerous pres sures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Relieve system pressure by cycling the applicable control s...

Страница 4: ...evised October 1 2000 Revised March 27 2001 Revised October 1 2001 Revised January 25 2002 Revised April 10 2002 Revised June 14 2004 Revised September 14 2005 Revised October 1 2005 Revised April 9 2...

Страница 5: ...rator Maintenance and Lubrication 1 7 Draining Oil Build Up From The Propane Regulator 1 10 Propane Fuel Filter Replacement 1 11 Propane Fuel System Pressure Relief 1 11 SECTION 2 GENERAL 2 1 Machine...

Страница 6: ...Planetary Assembly 3 3 Disassembly of the Second Stage Planet Gears 1 3 3 Assembly of First Stage Planetary Assembly 7 3 3 Assembly Of End Cover Unit 8 3 3 Final Assembly 3 3 3 3 Drive Hub Part No 27...

Страница 7: ...2 Oscillating Axle Lockout Test 3 43 3 13 Swing Bearing 3 44 Turntable Bearing Mounting Bolt Condition Check 3 44 Wear Tolerance 3 45 Replacement of Swing Bearing 3 46 Swing Bearing Torque Value 3 47...

Страница 8: ...er 120 240 Volt 3 89 3 23 Troubleshooting of the Sky Welder 3 90 Low Sky Welder Speed 3 90 Low Welding Amps 3 90 No Output on Weld Receptacles or AC Receptacles 3 90 No Ac Output but Weld Output 3 90...

Страница 9: ...n 3 142 3 30 Engine Radiator Fill Procedure Perkins Caterpillar 3 142 3 31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS 3 144 Section Layout 3 144 List of Abbreviations in this Section 3 145 Fa...

Страница 10: ...DTC 1652 TPS1 Loss of Communications 3 205 DTC 2111 Unable to Reach Lower TPS 3 206 DTC 2112 Unable to Reach Higher TPS 3 208 DTC 9999 Throttle Actuator Failsafe Spring Failure 3 209 DTC to SPN FMI Ta...

Страница 11: ...Down 5 18 10 Swing 5 18 5 5 Hydraulic Motor Repair H Series Char lynn 5 18 Disassembly 5 18 Reassembly Shaft End 5 20 Gerotor End 5 22 Timing Procedure 5 23 Standard Rotation 5 23 Reverse Rotation 5 2...

Страница 12: ...3 Automatic Switches 7 4 Switch Wiring Low 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 Serie...

Страница 13: ...ng Temperature Specifications Perkins 2 13 3 1 Drive Hub Part No 2780243 2WD Rear Part No 2780244 4WD Rear 3 4 3 2 Drive Hub Part No 2780246 4WD Steer 3 7 3 3 Cluster Gear Punch Marks 3 17 3 4 Drive B...

Страница 14: ...sht 1 of 2 3 92 3 52 Hydraulic Welder 225 4 sht 2 of 2 3 93 3 53 EMR 2 Engine Side Equipment 3 96 3 54 Deutz EMR 2 Troubleshooting Flow Chart 3 97 3 55 Deutz EMR 2 Vehicle Side Connection Diagram 3 98...

Страница 15: ...try Platform 4 1 4 2 Support Rear Entry Platform 4 1 4 3 Location of Components Boom Removal 4 2 4 4 Articulating Jib 4 6 4 5 Limit Switches 500 1000 LB 230 450 kg Capacity 4 7 4 6 Limit Switches 750...

Страница 16: ...Flow Chart Version 5 X Software Sheet 4 of 4 6 16 6 13 System Test Flow Chart Platform Tests 6 63 6 14 System Test Flow Chart Ground Station Tests 6 65 7 1 Voltage Measurement DC 7 1 7 2 Resistance Me...

Страница 17: ...7 33 7 39 Electrical Schematic Caterpillar Engine Sheet 3 of 6 7 34 7 40 Electrical Schematic Caterpillar Engine Sheet 4 of 6 7 35 7 41 Electrical Schematic Caterpillar Engine Sheet 5 of 6 7 36 7 42...

Страница 18: ...ation Specifications 1 7 2 1 Inspection and Maintenance 2 2 2 2 Cylinder Drift 2 4 2 3 Inspection and Preventive Maintenance Schedule 2 6 3 1 Wheel Torque Chart 3 2 3 2 Excessive Noise and or Vibratio...

Страница 19: ...ts and Descriptions S N 66995 to Present 6 24 6 4 Machine Configuration Programming Information Prior to Software Version P5 3 6 45 6 5 Machine Configuration Programming Information Software Version P...

Страница 20: ...xvi JLG Lift 3120895 LIST OF TABLES TABLE NO TITLE PAGE NO This page left blank intentionally...

Страница 21: ...y 4 5 quarts 4 26 L Low RPM 1000 MidRPM 1800 HighRPM 3000 FuelConsumption Gasoline Intermittent Continuous 6gal hr 5gal hr FuelConsumption LPG Intermittent Continuous 26lbs hr 23lbs hr Spark Plug AWSF...

Страница 22: ...atic 20psi 1 4bar 20 7lbs 9 38kg Table 1 9 Specifications and Performance Data 400S MaximumWorkLoad Capacity Unrestricted Restricted Optional standard 500lbs 230kg 1000lbs 230kg 750lbs 340kg MaximumTr...

Страница 23: ...vated 2WD 4WD 0 75m p h 1 20kmh 46 115sec 50ft GrossMachineWeightStd 2wdMachine PlatformEmpty PneumaticTires 7192kg 15 855lb MaximumSystemVoltage 12VDC Max HydraulicSystemOperatingPres sure 4060psi 28...

Страница 24: ...ight 460SJ 3410 1547 Chassis 12x16 5pneu tires 4200 1905 12 x16 5 pneu Tire Wheel 128 58 12x16 5F F Tire Wheel 440 200 12x21 5 NHS pneu Tire Wheel 55 97 12x21 5 NHS F F Tire Wheel 224 102 14x16 1Sandp...

Страница 25: ...for proper recommenda tions Table 1 16 Cylinder Specifications Cylinder Bore Stroke Rod Dia Oscillation 2 5in 63 5mm 4 125in 104 8mm 1 75in 44 45mm MainLift 5 0in 127 0mm 39 0in 990 0mm 2 5in 63 5mm...

Страница 26: ...erial number is stamped on the left side of the frame Table 1 21 Welder Specifications Model 225 4 Description Specification Weld Amps 225 StrikeWeld 75 Weld Voltage 21 6 28DC Frequency 60Hz KVA 4 2Kw...

Страница 27: ...ll Lube EPGL Interval Check level every 3 months or 150 hrs of operation change every 2 years or 1200 hours of operation 4 Hydraulic Return Filter Interval Change after first 50 hrs and every 6 months...

Страница 28: ...nce with engine manual Refer to Figure 1 3 Deutz Engine Dipstick 10 Oil Change w Filter Isuzu Lube Point s Fill Cap Spin on Element JLG P N 7022111 Capacity 6 qt 5 6L engine 6 5 qt 6 1L w cooler Lube...

Страница 29: ...e Point s Replaceable Element Interval Every Year or 600 hours of operation 15 Fuel Filter Deutz Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 16 Fuel Filter Isuzu Lub...

Страница 30: ...y be required if the fuel supply has been contaminated FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM PERATURE BEFORE DRAINING THIS WILL ALLOW THE OILS TO BE LIQUID AND FLOW FREELY FROM THE REGULAT...

Страница 31: ...olt into the filter housing 7 Install the filter up to the bottom of the electric lock off 8 Tighten the filter retaining bolt to 106 in lbs 12 Nm 9 Open manual shut off valve Start the vehicle and le...

Страница 32: ...2 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 18 0 5625 0 2030 12950 120 163 90 122 135 184 109 148 5 8 11 0 6250 0 2260 14400 150 203 110 149 165 224 135 183 18 0 6250 0 2560 16300 170 230 130...

Страница 33: ...VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 LB IN LB N m IN LB N m IN LB N m 1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17 LB FT LB N m FT LB N m F...

Страница 34: ...485 335 455 315 430 7 8 9 0 8750 0 4620 41600 515 700 485 660 455 620 14 0 8750 0 5090 45800 570 775 535 730 500 680 1 8 1 0000 0 6060 51500 730 995 685 930 645 875 12 1 0000 0 6630 59700 845 1150 795...

Страница 35: ...515 315 430 7 8 9 0 8750 0 4620 41600 605 825 545 740 455 620 14 0 8750 0 5090 45800 670 910 600 815 500 680 1 8 1 0000 0 6060 51500 860 1170 775 1055 645 875 12 1 0000 0 6630 59700 995 1355 895 1215...

Страница 36: ...157 68 3 219 164 197 241 18 2 5 192 83 5 301 226 271 331 20 2 5 245 106 5 426 320 383 469 22 2 5 303 132 0 581 436 523 639 24 3 353 153 5 737 553 663 811 27 3 459 199 5 1080 810 970 1130 30 3 5 561 2...

Страница 37: ...19 5 430 385 325 20 2 5 245 152 5 610 550 460 22 2 5 303 189 0 830 750 625 24 3 353 222 0 1065 960 800 27 3 459 286 0 1545 1390 1160 30 3 5 561 349 5 2095 1885 1575 33 3 5 694 432 5 2855 2570 2140 36...

Страница 38: ...5 365 345 325 20 2 5 245 152 5 520 490 460 22 2 5 303 189 0 705 665 625 24 3 353 220 0 900 845 790 27 3 459 286 0 1315 1235 1160 30 3 5 561 349 5 1780 1680 1575 33 3 5 694 432 5 2425 2285 2140 36 4 8...

Страница 39: ...achine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as enviro...

Страница 40: ...heir contain ers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables et...

Страница 41: ...he text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices See Torque Chart Section 1 Hydraulic Lines and Electrical Wiring...

Страница 42: ...r the first 50 hours of operation and every 300 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifications appearing in this man ual If unable to...

Страница 43: ...ment wound bearings a Housing should be blown out to remove all dirt and debris bearings and bearing housings must be free of all contamination b Bearing pins should be cleaned with a solvent to remov...

Страница 44: ...1 2 1 2 WearPads 1 2 1 2 CoversorShields 1 2 1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly 9 Platform 1 2 1 2 Railing 1 2 1 1 2 Gate 5 1 1 5 Floor 1 2 1 1 2 Rotator 9 5 LanyardAnc...

Страница 45: ...ather 11 9 2 1 5 1 5 Hydraulic ElectricSystem 9 HydraulicPumps 1 9 1 2 9 HydraulicCylinders 1 9 7 2 1 2 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 9 1 2 1 2 HydraulicHoses Lines andFittings 1 9 1...

Страница 46: ...es 1 Checkforproperandsecureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor...

Страница 47: ...SECTION 2 GENERAL 3120895 JLG Lift 2 9 Figure 2 1 Engine Operating Temperature Specifications Deutz 4150548 D...

Страница 48: ...SECTION 2 GENERAL 2 10 JLG Lift 3120895 Figure 2 2 Engine Operating Temperature Specifications Ford 4150548 D...

Страница 49: ...SECTION 2 GENERAL 3120895 JLG Lift 2 11 A M B IE N TA IR T E M P E R A T U R E Figure 2 3 Engine Operating Temperature Specifications Caterpillar 4150548 D...

Страница 50: ...SECTION 2 GENERAL 2 12 JLG Lift 3120895 Figure 2 4 Engine Operating Temperature Specifications GM 4150548 D...

Страница 51: ...SECTION 2 GENERAL 3120895 JLG Lift 2 13 A M B IE N TA IR T E M P E R A T U R E Figure 2 5 Engine Operating Temperature Specifications Perkins 4150548 D...

Страница 52: ...SECTION 2 GENERAL 2 14 JLG Lift 3120895 NOTES...

Страница 53: ...r ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire...

Страница 54: ...when supplying air pressure piston 61 may unexpectedly come out quickly 9 Remove back up rings 75 piston seal 76 back up rings 77 and piston seal 78 10 Compress the disk 59 using a simple fixture or o...

Страница 55: ...ings with snap rings 14 Assembly Of End Cover Unit 8 1 Press sleeve 52 and install O ring into cover 8 2 Install shaft rod into cover 8 3 Install cover into cover 8 and fix cover 51 with hex hd bolts...

Страница 56: ...SECTION 3 CHASSIS TURNTABLE 3 4 JLG Lift 3120895 Figure 3 1 Drive Hub Part No 2780243 2WD Rear Part No 2780244 4WD Rear...

Страница 57: ...ap rings 15 to pull off planet gears 1 together with cylindrical roller bearings 11 from spindle 60 NOTE Further disassembly of the hub is discouraged Rein stallation of the shaft nut 4 requires a spe...

Страница 58: ...29 in spindle 60 2 Install O ring 19 into groove of support ring 6 3 Install planet gears 1 onto planet pins which are part of spindle 60 4 Install snap rings 15 on planet pins of spindle 60 in order...

Страница 59: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 7 Figure 3 2 Drive Hub Part No 2780246 4WD Steer...

Страница 60: ...ghtening and torquing bolts or socket head cap screws in a bolt circle 1 Tighten but do not torque bolt A until snug 2 Go to the opposite side of the bolt circle and tighten bolt B until equally snug...

Страница 61: ...dle out of hub remove seal 1B and bearing cone 1D from the small end of hub 1G Discard the seal 5 Bearing cone 1F should be lying loose in wide end of hub 1G Remove bearing cone 1F from inside hub 1G...

Страница 62: ...cluster gear 3F Discard the needle rollers 5 Remove one spacer 3D from inside cluster gear 3F 6 Remove the remaining 16 needle rollers 3C from the other side of cluster gear 3F Discard the nee dle ro...

Страница 63: ...g onto the planet shaft 3E 7 Following the cluster gear place one more thrust washer 3B onto planet shaft 3E through the opposite planet shaft hole in carrier housing 3A 8 Use an alignment punch or si...

Страница 64: ...flange of the cover cap 3 Insert disconnect rod 6E into cover cap 6B 4 Set cover 6Aon table exterior side up Place cover cap 6B onto cover 6A aligning the pipe plug hole in the cover cap over the pipe...

Страница 65: ...nnect cap 6D and tighten the bolts 9 Using a torque wrench apply 36 to 49 in lbs 4 to 5 Nm of torque to both bolts 6C 10 Apply a light coat of Never Seize to pipe plug 6H and tighten it into the pipe...

Страница 66: ...up sits square with the counterbore before pressing 4 Turn hub 1G over onto its small end Press bearing cup 1E down into the counterbore in the deep end of the hub 1G 5 Set hub 1G onto its large end P...

Страница 67: ...ring 1I over the spacer onto spindle 1A in hub 1G 11 At this point the hub spindle sub assembly is com plete Main Assembly BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O RING 1 Grease o r...

Страница 68: ...ed end Place one spacer 7D onto the smooth end of input shaft 7A 6 Place one spring 7C onto the smooth end of input shaft 7A 7 Place other spacer 7D onto the smooth end of input shaft 7A WEAR SAFETY G...

Страница 69: ...rks in position while installing the carrier into the hub 13 Place the carrier sub assembly 3 and ring gear 4 together into mesh with internal gear 2 aligning the X marked shoulder bolt hole in the ri...

Страница 70: ...RING 16 Set the cover 6A on table interior side up Grease o ring 5 and place it into the counterbore around the edge of cover 6A NOTE The o ring may be stretched or pinched together to make it fit the...

Страница 71: ...olt holes in cover 6 and tighten by hand 20 Place the remaining 12 flatwashers 16 onto the remaining bolt holes in cover 6 21 Place the 12 bolts into the remaining bolt holes in cover 6 and tighten 22...

Страница 72: ...at a pressure of 5 psi for 2 to 3 minutes 26 At this point the main assembly is complete Tool List The following specialized tools are used to assemble this unit The tool diagrams included in this man...

Страница 73: ...ar 2 Hydraulic fittings to adapt hydraulic supply to brake release port on hub Procedure 1 Using appropriate fittings connect a line from the hydraulic power supply to the brake port 2 Pressurize the...

Страница 74: ...e Remove hydraulic supply from brake checking to ensure that the friction plates 3 6 have engaged thus prevent ing rotation of brake shaft 1 RELEASE PRESSURE DURING BENCH TESTING SHOULD BE LIM ITED TO...

Страница 75: ...Remove springs 22 23 7 Should it be necessary to replace ball bearing 10 or shaft seal 12 reverse remainder of brake sub assembly supporting on face c of housing 2 8 Remove internal retaining ring 11...

Страница 76: ...s in cylinder with dowel pins 19 and assemble piston cylinder sub assembly to remain der of brake securing with 6 off socket head cap screws and washers 13 14 Torque to 55ft lbs 75 Nm NOTE The use of...

Страница 77: ...t the shaft seal 3 To avoid damaging the shaft during removal install a large sheet metal screw into the chuck of a slide hammer Drive the screw into the seal surface and use the slide hammer to pull...

Страница 78: ...tion Also check springs and poppet for wear INSTALLATION 1 Install orifice poppet 13 2 Install shift spool 12 3 Install spring retaining washers onto springs 10 and 11 4 Carefully install centering sp...

Страница 79: ...servoir andoilsupplytothepump Insufficientamountofhydraulicfluidwillnotmeetthecooling demandsofthesystem Fillthereservoirtotheproperlevel Inspecttheheatexchanger ifsoequipped Iftheheatexchangerfails o...

Страница 80: ...peed sensor lock nut 14 if equipped Then remove the speed sensor using a Vi inch hex wrench Units with out speed sensor have an O ring plug 15 installed in that location remove it with a Va inch inter...

Страница 81: ...last two digits of the valve plate part number are stamped on its surface 16 Remove and discard the O rings 27 28 17 Remove the rear shaft bearing 29 from the endcap with a bearing puller The bearing...

Страница 82: ...aft seal 34 Discard the seal To avoid damaging the shaft during seal removal Install a large sheet metal screw into the chuck of a slide hammer Drive the screw into the seal surface and use the slide...

Страница 83: ...d down pins 48 and retaining ring 49 from the cylinder block NOTE Most repairs do not require block spring removal Perform this procedure only if you suspect problems with the block spring RISK OF PER...

Страница 84: ...th scored or excessively rounded slipper edges Measure the slipper foot thickness Replace any piston assemblies with excessively worn slip pers Check the slipper axial end play Replace any piston asse...

Страница 85: ...ding the surface condition meets specifi cations shown Measure the swashplate thickness from the journals to the running face Replace swashplate if damaged or worn beyond minimum specification Replace...

Страница 86: ...or the seal to relax after installation To speed up seal relaxation compress the seal by installing the piston head into the servo cavity in the end cap and let it stand for at least five minutes 2 Af...

Страница 87: ...ide before assembly Set the cylinder kit aside on a clean sur face until needed 6 Install the journal bearings 13 into the housing seats Use assembly grease to keep the bearings seated during assembly...

Страница 88: ...t 19 onto the shaft Install with the slippers facing the swashplate Rock the shaft to align the block splines and slide the cylinder kit into place Orient the motor with the shaft pointing down ward a...

Страница 89: ...endcap 25 onto the housing with the endcap screws 26 Check to ensure the endcap will properly seat onto the housing without interfer ence Improper assembly of the internal compo nents may prevent the...

Страница 90: ...eal Install seal support washer 28 and snap ring 29 19 Install remaining plugs and fittings to the housing Refer to the drawing below for wrench sizes and installation torques 29 28 27 27 ShaftSeal 28...

Страница 91: ...uid Pour filtered oil directly into the upper most case drain port 4 To ensure the pump and motor stay filled with oil install case drain lines into the upper most case drain ports 5 Install a 0 to 50...

Страница 92: ...The extra adjustment is needed for the turntable bearing play 3 9 TOE IN ADJUSTMENT 1 Measure from the same point on the tire from the front side then on the back side 2 The tires must be within 0 0...

Страница 93: ...rosene or mineral oil Inspect the spindle for scoring bending thread or other damage File off nicks and burrs A light grease coating on the cone seats will make installa tion easier and help prevent f...

Страница 94: ...seal against the spindle outer end or threads Insert the grease packed outer cone spindle washer and castle nut 5 Tighten the adjusting nut while turning the hub When the hub binds slightly all parts...

Страница 95: ...illated one extended the other retracted 9 Use suitable containers to retain any residual hydraulic fluid place containers under each lockout cylinder 10 With DRIVE CONTROLLER activated and engine at...

Страница 96: ...ust be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter If during this check any bolts are found to be missing or loose replace missing or lo...

Страница 97: ...he turntable 90 degrees and check some selected bolts at the new position 11 Continue rotating the turntable at 90 degrees inter vals until a sampling of bolts have been checked in all quadrants Wear...

Страница 98: ...ailable Tribol Molub Alloy 936 Open Gear Compound or Mobilith SHC Bearing Grease or Multi Purpose Grease MPG can be substituted however the service interval will be shorter 4 Using suitable lifting eq...

Страница 99: ...plate is clean and free of paint runs and drips 2 Mount swing drive motor to mounting plate 3 Position Swing drive to location of bearing gear max eccentric tooth high spot High spot is marked with y...

Страница 100: ...SECTION 3 CHASSIS TURNTABLE 3 48 JLG Lift 3120895 Figure 3 35 Swing Drive Installation...

Страница 101: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 49 Figure 3 36 Swing Motor...

Страница 102: ...t must be removed by pressing on the end of the shaft with a shop press b Using an appropriate tool Pry the seal out from the inside of the brake Take care not to damage the bore Remove the retaining...

Страница 103: ...iner 5 Bearing 6 Shaft 7 LipSeal 8 SnapRing 9 Gasket 10 PrimaryDisc 11 StationaryDisc 12 Gasket 13 PowerPlate 14 BackupRing 15 O ring 16 Piston 17 BackupRing 18 O ring 19 RotatingDisc 20 TorquePin 21...

Страница 104: ...earing shoulder Note direction of seal 3 Press bearing 18 into position until it bottoms out on borestep 4 Install retaining ring 20 in cover 16 5 Press shaft 9 into bearing 18 until it bottoms on the...

Страница 105: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 53 Figure 3 38 Swing Brake S N 64802 to Present...

Страница 106: ...ve Bearing Shim 1H from the Output Shaft 1A 9 The Output Shaft 1A may now be pressed out of the Hub 1G 10 The Bearing Cups 1C 1E will remain in Hub 1G as will Bearing Cone 1F Bearing Cone 1D will rema...

Страница 107: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 55 Figure 3 39 Swing Torque Hub...

Страница 108: ...RE WHILE SEAT ING THE O RING Also at this time locate and mark the 4 counter beamed holes in the face of the Hub 1G This is for Identification later in the assembly 17 Thrust Spacer 9 is installed int...

Страница 109: ...mbly does not rotate freely then remove the Carrier and Ring Gear and check the Cluster Gear timing 21 Input Gear 8 is installed meshing teeth of the large diameter Cluster Gear 3F The counterbore on...

Страница 110: ...olt with Hub 1G counterbore 26 Install regular Grade 8 Bolts 12 into remaining holes 27 Pipe Plugs 20 are to be installed into Cover 6 using a lubricant seal of some sort 28 Torque Shoulder Bolts 13 t...

Страница 111: ...talled over the Output Shaft 1A and into the counterbore of the Hub 1G Care should be taken to insure the seal 1B is being cor rectly installed smooth face up and located just flush with the counterbo...

Страница 112: ...ing 11 is completely seated in the groove of the Output Shaft 1A EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE 11 Upon completion of step 10 rap the internal end of the Output Shaft 1A twice wit...

Страница 113: ...e up chamfered side of hole in Planet Shaft with pin hole in Carrier 8 Drive Anti Roll Pin flush into Carrier hole thereby locking Planet Shaft into place Repeat these steps for remaining two Cluster...

Страница 114: ...a wrench and punch out the out side bolts Drive the machine ahead and take off the tracks If the track is to be rolled up it is best to set the track on edge and roll it Secure the end of the track a...

Страница 115: ...Hole 2 Holes 3 Holes 4 Holes 5 Holes 6 Holes 7 Holes 8 Holes 9 Holes 10 Holes 11 Holes 12 Holes Equals 0 81 in 20 5 mm 1 62 in 41 mm 2 43 in 62 mm 3 25 in 82 5 mm 4 06 in 103 mm 4 87 in 124 mm 5 68 i...

Страница 116: ...SECTION 3 CHASSIS TURNTABLE 3 64 JLG Lift 3120895 A B C D C E Figure 3 40 Auxiliary Pump Sheet 1 of 2...

Страница 117: ...edleBearing 13 Washer 14 Screw 15 Retaining Ring 16 Gear 17 IdlerShaft 18 DrivePin 19 DowelPin 20 Gasket 21 O ring 22 GearHousing 23 I D Label 24 Gasket 25 GearHousing 26 BetaPlug 27 Screw 28 DriveSha...

Страница 118: ...ushes and Cleaning Slip Rings Refer to Figure 3 42 Inspecting Generator Brushes Replacing Brushes and Cleaning Slip Rings INSPECTING BRUSH POSITION Inspect brush alignment with slip rings View alignme...

Страница 119: ...ss Replace 2 7 16 in 1 2 in 11 12 mm New 3 2 3 Brushes must ride completely on slip rings Acceptable Unacceptable Brush Position On Slip Rings Figure 3 42 Inspecting Generator Brushes Replacing Brushe...

Страница 120: ...ng guide lines when performing a visual physical inspection check Inspect engine for modifications or aftermarket equip ment that can contribute to the symptom verify that all electrical and mechanica...

Страница 121: ...ontrol module ECM to calculate the ignition sequence The CKP sensor initiates the reference pulses which the ECM uses to calculate RPM and crank shaft position CAMSHAFT POSITION CMP SENSOR AND SIGNAL...

Страница 122: ...ral hours overnight the engine coolant temperature and intake air temperature displays should be close to each Table 3 9 ECM Diagnostic Trouble Codes Diagnostic Trouble Code Description 11 All Systems...

Страница 123: ...is mounted in the exhaust stream where it can monitor the oxygen content of the exhaust gas The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output This voltage shoul...

Страница 124: ...SECTION 3 CHASSIS TURNTABLE 3 72 JLG Lift 3120895 Figure 3 44 EFI Component Location...

Страница 125: ...above 4 volts with the igni tion ON engine not running or at wide open throttle low vacuum The MAP sensor is used to determine the following Engine vacuum level for engine control purposes Barometric...

Страница 126: ...charging the battery with an arc welder Take proper precautions to avoid static damage to the ECM Refer to Electrostatic Discharge Damage for more information THROTTLE POSITION TP SENSOR The throttle...

Страница 127: ...e part has been handled while sliding across a seat while sitting down from a standing position or while walking a distance touch a known good ground before installing the part Fuel System FUEL INJECT...

Страница 128: ...ngine by control ling the amount of time that the fuel injector is ON The best mix ture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most effi...

Страница 129: ...l lines ELECTRONIC GOVERNOR AND THROTTLE BODY In the 2 5L EFI industrial engine throttle control is achieved by using an electronic governor which is con trolled by the engine control module ECM The e...

Страница 130: ...the HO2S reports a rich condition high sensor signal Voltages the ECM responds by reducing the on time of the fuel injec tors thus leaning out the mixture CAMSHAFT POSITION CMP SENSOR The CMP sensor u...

Страница 131: ...s the positional controller and the actuator Four LEDs are incorporated in the controller They are as follows Red failure signals a problem with the system needs service or adjustment Green clutch eng...

Страница 132: ...roller Set the high engine rpm NOTE Actuator rod travel must stop slightly before lever makes contact with throttle lever stop Failure to do so will burn out actuator Controller Status Clutch engaged...

Страница 133: ...e throttle linkage for any damage or bent components and correct 3 With linkage disconnected check each potentiome ter for operation 4 Reconnect linkage and reset each potentiometer for correct operat...

Страница 134: ...uator must be adjusted to be sure the mechanical stroke is centered and has adjustment outside of the Deutz engine throttle stops This will ensure that the electrical adjustment will be within limits...

Страница 135: ...el the base of the indicator by tightening the three flange nuts through approximately one quarter of its spring travel DO NOT ADJUST THE X NUT DURING THE REMAINDER OF THE PROCEDURE 3 With the electri...

Страница 136: ...SECTION 3 CHASSIS TURNTABLE 3 84 JLG Lift 3120895 Figure 3 49 Valve Location Chassis...

Страница 137: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 85 Figure 3 50 Hyd Tank Installation...

Страница 138: ...line return line and case drain line NOTE Mark pressure line so you don t accidentally reverse the two lines 4 Remove flow regulator from motor four bolts 5 Remove motor from motor mount two bolts 6...

Страница 139: ...ll make sure that the residual magne tism is energized 24 Re install brush holder 25 Check for brush alignment to slip ring 26 Re install the rails 27 Re install the two fan grids 28 Heat the coupling...

Страница 140: ...hind the brush holder 7 Check slip rings 8 Clean and polish with very fine sandpaper 9 Check resistance of rotor armature on slip rings 10 Reading should be a 22 ohms 3 ohms 11 Install new brush holde...

Страница 141: ...Re install motor mount onto welder do not over tighten the threads are aluminum 11 Re align hydraulic motor coupling with welder cou pling and re install hydraulic motor on motor mount 12 Push coupli...

Страница 142: ...heck the fine control put one ohmmeter lead on the seven step switch terminal RL1 the other lead on he orange wire you removed from the Excitation Bridge You should be able by moving the fine control...

Страница 143: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 91 This page left blank intentionally...

Страница 144: ...SECTION 3 CHASSIS TURNTABLE 3 92 JLG Lift 3120895 Figure 3 51 Hydraulic Welder 225 4 sht 1 of 2...

Страница 145: ...ld 15 Front grid 16 Motor mount 17 Flow regulator CC 18 Coupling guard 19 Coupling set 99 20 Bearing 21 Fan 22 Black top hood 23 225 Dc weld impedance transformer 24 Welding rectifier bridge 25 Seven...

Страница 146: ...Weld Power Make sure welder is at proper speed 3600RPM Unplug all external connections A shorted weld cable or genera tor accessory plugged in can cause the welder not to build up Several components c...

Страница 147: ...nsor situated together with the rotation mag nets in a housing of the actuator The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emer gency running...

Страница 148: ...OWERSUPPLY COOLANTTEMPERATURE SENSOR CONTROLRODPOSITION SENSOR ACTUATOR CAMSHAFTSPEED SENSOR OILPRESSURE SENSOR JLGSYSTEMUSESJLGANALYZERTO REPORTFAULTS DIAGNOSISINTERFACE CAN BUS JLGSYS TEMUSESTHISTOC...

Страница 149: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 97 Figure 3 54 Deutz EMR 2 Troubleshooting Flow Chart...

Страница 150: ...SECTION 3 CHASSIS TURNTABLE 3 98 JLG Lift 3120895 Figure 3 55 Deutz EMR 2 Vehicle Side Connection Diagram...

Страница 151: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 99 Figure 3 56 Deutz EMR 2 Engine Side Connection Diagram Sheet 1 of 2...

Страница 152: ...SECTION 3 CHASSIS TURNTABLE 3 100 JLG Lift 3120895 Figure 3 57 Deutz EMR 2 Engine Side Connection Diagram Sheet 2 of 2...

Страница 153: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 101 Figure 3 58 EMR 2 Engine Plug Pin Identification...

Страница 154: ...SECTION 3 CHASSIS TURNTABLE 3 102 JLG Lift 3120895 Figure 3 59 EMR 2 Vehicle Plug Pin Identification...

Страница 155: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 103 Figure 3 60 EMR2 Fault Codes Sheet 1 of 5...

Страница 156: ...SECTION 3 CHASSIS TURNTABLE 3 104 JLG Lift 3120895 Figure 3 61 EMR2 Fault Codes Sheet 2 of 5...

Страница 157: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 105 Figure 3 62 EMR2 Fault Codes Sheet 3 of 5...

Страница 158: ...SECTION 3 CHASSIS TURNTABLE 3 106 JLG Lift 3120895 Figure 3 63 EMR2 Fault Codes Sheet 4 of 5...

Страница 159: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 107 Figure 3 64 EMR2 Fault Codes Sheet 5 of 5...

Страница 160: ...heck the Positive and Negative battery cables for any corrosion build up rubbing or chafing check connec tion on the chassis to insure they are tight Check the entire engine wire harness for rubbing c...

Страница 161: ...ns Do not over tighten 6 Check the sealing ring on drain plug for any dam age replace if necessary wipe the plug with a clean rag and wipe the sealing surface on the pan and reinstall the pan plug Do...

Страница 162: ...hut the engine off and continue to step 5 WITH THE ENGINE RUNNING OR WHEN SHUTTING OFF THE ENGINE SOME HEATED COOLANT MAY SPILL OUT DUE TO AIR BURPING OUT OF THE SYSTEM WITH THE RADIATOR CAP OFF 5 Nex...

Страница 163: ...ff Electronic Pressure Regulator EPR and the fuel mixer module The LPG fuel system operates at pressures which range from 14 0 inches 355 60 mm of water column up to 312 psi 21 5 BAR Components which...

Страница 164: ...it ting fuel to flow to the mixer Propane fuel enters the primary port of the LPR and passes through the primary jet and into the primary exchanger chamber As the propane passes through the heat excha...

Страница 165: ...AVV increases and the air valve is lifted higher thus creat ing a much larger venturi This air valve vacuum is com municated from the mixer venture to the LPR secondary chamber via the low pressure f...

Страница 166: ...ed to measure the amount of oxygen present in the exhaust stream and com municate that to the ECM via an electrical signal The amount of oxygen present in the exhaust stream indicates whether the fuel...

Страница 167: ...temperature manifold assem bly Fuel flows through the feed circuit and is delivered to the fuel injector rail Fuel that enters the bleed circuits through they bypass valve in the manifold is returned...

Страница 168: ...commercially available liquid leak detector or an electronic leak detec tor When using both methods use the electronic leak detector first to avoid contamination by the liquid leak detector Propane F...

Страница 169: ...ers pinch off the hoses on the cool ant lines to the regulator 9 Remove the lock pin from both the water fittings on the regulator housing and remove the fittings and hoses and retain the pin 10 Disco...

Страница 170: ...DIAPHRAGM THIS WILL VOID THE WARRANTY OF THE ACTUATOR SECTION PRESSURE REGULATOR SECTION INSTALLATION 1 Install the regulator to the actuator section using the six 6 retaining screws and tighten 70 in...

Страница 171: ...mixer assembly 7 Pull the throttle body assembly from the adapter 8 Remove electronic throttle control device 9 Remove the O rings gasket and discard INSTALLATION LIGHTLY LUBRICATE BOTH THROTTLE CONT...

Страница 172: ...e Control Device Replacement 4 Start the engine and leak check all fittings and con nections Coolant Hose Replacement REMOVAL 1 Drain the coolant 2 Using hose clamp pliers disconnect both hose clamps...

Страница 173: ...ous engine sensor and output data from the Electronic Pres sure Regulator EPR The ECM will then determine the target fuel calibration and command the EPR to reposition the voice coil to the proper pos...

Страница 174: ...ls Required 7 16 Open end wrench for test port plugs DVOM GM J 39200 Fluke 88 or equivalent 12 volt test light Diagnostic Scan Tool Diagnostic Display tool Pressure Gauges IMPCO ITK 2 Test kit Water C...

Страница 175: ...agnosis GotoStep7 7 1 Inspecttheairintakestreambetweenthemixerassemblyandthethrottle bodyforleaks 2 InspectthefuelhoseconnectionbetweentheLPRandmixerassemblyfor damageorleakage 3 Inspectanyvacuumhoses...

Страница 176: ...p21 17 1 RemovetheLPGfuelfilter LPL 2 RemovethefilterfromtheLPL 3 EmptythecontentsoftheinletsideoftheLPGfuelfilterontoacleansurface 4 InspectthecontentsoftheLPGfuelfilterforanexcessiveamountofforeign...

Страница 177: ...lugintheLPRsecondarychamber 2 Ifyouweresenttothisroutinebyanotherdiagnosticchart returntotheprevi ousdiagnosticprocedure Istheactioncomplete SystemOK 26 1 Disconnectalltestequipment 2 Installtheprimar...

Страница 178: ...eignitionwiresforthefollowingconditions Cracking Hardness Properrouting Carbontracking Checkthewiringforthefollowingitems Properconnections pinchesorcuts Thefollowingsymptomtablescontaingroupsofpossib...

Страница 179: ...tics Checkbatterypower ignitionpowerandgroundcircuitstotheECM RefertoEngineControlSchematics Verifyvolt ageand orcontinuityforeachcircuit SensorChecks ChecktheTMAPsensor ChecktheMagneticpickupsensor R...

Страница 180: ...eisnottripped Checkmixermoduleassemblyforproperinstallationandleakage Verifyproperoperationofthelowpressurelock offsolenoids VerifyproperoperationoftheEPR Checkforairintakesystemleakagebetweenthemixer...

Страница 181: ...ylindermisfire VerifythatthesparkplugsarecorrectforusewithLPG R42LTS Removethesparkplugsinthesecylindersandcheckforthefollowingconditions Insulationcracks Wear Impropergap Burnedelectrodes Heavydeposi...

Страница 182: ...ionalCheck Checkformanifoldvacuumorairinductionsystemleaks Checkthegeneratoroutputvoltage Backfire DEFINITION Thefuelignitesintheintakemanifold orintheexhaustsystem makingaloudpoppingnoise Preliminary...

Страница 183: ...stemfordamagedorcollapsedpipes Inspectthemufflerforsignsofheatdistressorforpossibleinternalfailure Checkforpossiblepluggedcatalyticconverter EngineMechanicalCheck Checktheengineforthefollowing Enginec...

Страница 184: ...AP sensorresponseandaccuracy FuelSystemChecks Checkforrichorleansymptomthatcausesthecondition Drivethevehicleatthespeedofthecomplaint Monitoring theoxygensensorswillhelpidentifytheproblem Checkforasti...

Страница 185: ...mplaint Monitoring theoxygensensorswillhelpidentifytheproblem Checkthefuelpressurewhiletheconditionexists RefertoLPGFuelSystemDiagnosis Verifyproperfuelcontrolsolenoidoperation VerifythattheLPGmanuals...

Страница 186: ...GO2Open Inactive 520208 10 171 AdaptiveLearnHighGasoline 520200 0 172 AdaptiveLearnLowGasoline 520200 1 182 FuelTempGasolineLowVoltage 174 4 183 FuelTempGasolineHighVoltage 174 3 187 FuelTempLPGLowVol...

Страница 187: ...iveLearnLowLPG 520202 1 1165 LPGCatMonitor 520213 10 1171 LPGPressureHigherThanExpected 520260 0 1172 LPGPressureLowerThanExpected 520260 1 1173 EPRCommLost 520260 31 1174 EPRVoltageSupplyHigh 520260...

Страница 188: ...2 CoolantOverflow 3 AirCleaner 4 Radiator 5 Alternator 6 O2Sensor 7 CrankshaftPositionSensor 8 OilDrainValve 9 Muffler 10 PistonPump 11 GearPump 12 MotorMount 13 Start AuxPowerRelays 14 EngineTrayPiv...

Страница 189: ...7 16 O2Sensor 17 Dipstick 18 ControlModule 19 Starter 20 Distributor 21 OilFilter 22 WaterPump 23 CoolantSensor 24 PressureRegulator 25 MAPSensor 26 Mixer 27 PCVValve 28 OilPressureSwitch 29 Coil 30 F...

Страница 190: ...l level between ADD mark Y and FULL mark X on oil level gauge 1 Do not fill the crankcase above FULL mark X NOTE Operating your engine when the oil level is above the FULL mark could cause your cranks...

Страница 191: ...JLG Lift 3 139 2 3 4 5 6 7 8 1 1 Dipstick 2 CrankcaseBreather 3 CoolantSensor 4 OilPressureSensor 5 OilDrainValve 6 OilFilter 7 SpeedSensor 8 FuelFilter Figure 3 84 Perkins Engine Torque to 10 ft lbs...

Страница 192: ...THE ENGINE WITH THE FUEL OFF THIS WILL FILL THE OIL FILTERS BEFORE STARTING THE ENGINE DO NOT CRANK THE ENGINE FOR MORE THAN 30 SECONDS 2 Start the engine and run the engine at LOW IDLE for two minut...

Страница 193: ...ROCEDURE IT S VERY IMPORTANT TO KEEP THE CONTROL LINKAGE PUSHED AGAINST THE STOP 3 Once the adjustments have been made to align the spherical rod end bearing with the control linkage bolt hole lengthe...

Страница 194: ...COOLING SYSTEM SOME ENGINES REQUIRE A SPECIAL RADIATOR FILL PROCEDURE FAILURE TO FOLLOW THIS PROCEDURE CAN RESULT IN DAM AGE TO THE ENGINE THE FOLLOWING FILL PROCEDURE SHOULD ONLY BE PERFORMED WHEN T...

Страница 195: ...o the cold level line Put the fill cap back on the reservoir when done 7 Start the engine and run it long enough to bring the coolant up to operating temperature Turn off the engine ENGINE COOLANT IS...

Страница 196: ...er sends an input to the ECM or is driven by and ECM output Check Condition This defines what condition to troubleshoot the fault condition Fault Condition s This identifies the condition s that set t...

Страница 197: ...c PWM PulseWidthModulated ECIPP EControlsInc Proprietary Protocol RAM RandomAccessMemory ECM EngineControlModule RPM RevolutionsPerMinute ECT EngineCoolantTemperature Rx Receive ECU EngineControlUnit...

Страница 198: ...9 DM1 and DM2 formatted messages DGC ECMs are compliant with J1939 OBD M supporting the Diagnostic Messages above as well as user indicators and CAN data defined in the OBD M protocol Faults available...

Страница 199: ...o cleared TurnonMIL TurnonMIL outputwhenfault becomesactive CL Disable Disableclosed loop whilethefault isactive CL DisableKey Cyc Disableclosed loop whilethefault isactiveand forthe remainderof theke...

Страница 200: ...active in real time Once a fault has become active it is immediately logged as historic and a snapshot and flight data log is saved Figure 3 86 shows an exam ple of the fault page when an active faul...

Страница 201: ...ata Base and Flight Data Custom Definition fields found on the Faults Page The memory location of the FDR is RAM therefore this data is only available if the ECM has not lost battery power In addition...

Страница 202: ...ed Data is presented in two col umns base and custom variables Once retrieved the FSS data may be saved to the PC in text format with an fss extension A FSS saved to a PC may be reviewed in any ASCII...

Страница 203: ...isFaultButton Erasestheselected historicfaultfromtheECM ClearAll FaultsButton Erasesall historicfaultsfromtheECM ViewSnapShot Data Button Retrievesa data snapshot fromtheECMforvariablesdefinedinthebas...

Страница 204: ...SECTION 3 CHASSIS TURNTABLE 3 152 JLG Lift 3120895 Figure 3 90 Snapshot Data Interface Figure 3 91 Flight Data Recorder Interface...

Страница 205: ...an electronic throttle via the throttle command input while the engine is in the Stopped state only The ECM reverts to normal operation if Off state is selected ignition voltage is lost or engine spee...

Страница 206: ...age divider circuit so when the sensor reading is cool the sensor reads higher voltage and lower when warm This fault will help protect the engine in the event of over temperature When the coolant exc...

Страница 207: ...ature sensor is a thermistor temperature sensitive resistor located in the engine cool ant Some engines use an ECT sensor that is located in the coolant near the thermostat Some engines use a CHT Cyli...

Страница 208: ...SECTION 3 CHASSIS TURNTABLE 3 156 JLG Lift 3120895...

Страница 209: ...CT sensor that is located in the coolant near the thermostat Some engines use a CHT Cylinder Head Temperature sensor that is located in the coolant in the cylinder head If the engine is equipped with...

Страница 210: ...SECTION 3 CHASSIS TURNTABLE 3 158 JLG Lift 3120895...

Страница 211: ...RNTABLE 3120895 JLG Lift 3 159 DTC 122 TPS1 Signal Voltage Low Electronic Throttle Actuator w Serial Position Feedback 2 16 13 12 1 5V_ext Vs 5 VDC 5V_rtn TPS1 TPS SER Motor DBW DBW ECM H Bridge 19 TP...

Страница 212: ...ither 1 a variable resistor and voltage divider circuit or 2 a non contact hall effect sensor to determine throttle actuator position and is located within the throttle actua tor There are two types o...

Страница 213: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 161...

Страница 214: ...sensor refer to these fuel injection pump control actuators and their position feedback sensors When the fuel injec tion pump is electronically controlled it can be used to control the idle stability...

Страница 215: ...ll set if TPS1 voltage is higher than the limit set in the diagnostic calibration at any operating condition while the engine is cranking or running The limit is gener ally set to 4 90 VDC In many cas...

Страница 216: ...oltage and lower when warm This fault will help protect the engine in the event of over temperature When the coolant exceeds x deg F and engine RPM exceeds y RPM for the latch time this fault will set...

Страница 217: ...the limit set in the diagnostic calibration for the latch time or more This speed overrides any higher max governor speeds programmed by the user This fault is designed to help prevent engine or equip...

Страница 218: ...e sensor trigger wheel com bination is used to determine crankshaft position with respect to TDC cylinder 1 compression and the rota tional engine speed Determination of the crankshaft posi tion and s...

Страница 219: ...ition that set fault based on fault snapshot Is crank sensor a VR magnetic pick up Is the wiring OK Faulty wireharness twist circuit Is wiring between sensor and ECM properly twisted No Does fault onl...

Страница 220: ...er wheel com bination is used to determine crankshaft position with respect to TDC cylinder 1 compression and the rota tional engine speed Determination of the crankshaft posi tion and speed is necess...

Страница 221: ...due to low oil pressure resulting in higher friction and lack of lubrication In addition high oil pressure can be undesirable because it can cause oil to leak past seals and rings can be a result of...

Страница 222: ...uit shorted to ground in harness Faulty ECM Faulty Oil Pressure Switch short circuit Faulty engine oiling system verify with mechanical gauge No Yes Key On Engine Off System Mode Stopped Does DTC 524...

Страница 223: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 171 Sensor Transducer Type...

Страница 224: ...gh oil pressure can be undesirable because it can cause oil to leak past seals and rings can be a result of a restriction in the oil flow path or can be a sign of a malfunctioning oiling system For sy...

Страница 225: ...24 reset Intermittent Problem No Key Off Disconnect harness from Oil Pressure switch Clear DTC 524 Key On Engine On System Mode Running Operate engine et idle for at least one minute Increase RPM abov...

Страница 226: ...limit set in diagnostic calibration Yes Does DTC 524 reset Faulty connection at sensor Faulty ECM Faulty Oil Pressure Switch open circuit Faulty engine oiling system verify with mechanical gauge No Y...

Страница 227: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 175 Sensor Transducer Type...

Страница 228: ...and or sound audi ble warning or illuminate secondary warning lamp dis able adaptive fueling correction for remainder of key cycle Non emissions related fault The battery voltage powers the ECM and mu...

Страница 229: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 177...

Страница 230: ...tion s Illuminate MIL and or sound audi ble warning or illuminate secondary warning lamp dis able adaptive fueling correction for remainder of key cycle Non emissions related fault The battery voltage...

Страница 231: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 179...

Страница 232: ...s related fault The ECM has checks that must be satisfied each time an instruction is executed Several different things can hap pen within the microprocessor that will cause this fault If this fault s...

Страница 233: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 181...

Страница 234: ...and can be read from or written to at any time Data stored in RAM include DTCs when fault configura tion is set to Battery Power Retained adaptive fuel learn tables octane adaptation table misfire ad...

Страница 235: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 183...

Страница 236: ...damage and or overspeed condition Non emissions related fault The ECM has checks that must be satisfied each time an instruction is executed Several different things can hap pen within the microproce...

Страница 237: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 185...

Страница 238: ...TABLE 3 186 JLG Lift 3120895 DTC 642 5 Volt External Low Voltage Electronic Throttle Actuator w Serial Position Feedback 2 16 13 12 1 5V_ext Vs 5 VDC 5V_rtn TPS1 TPS SER Motor DBW DBW ECM H Bridge 19...

Страница 239: ...e ECM below an acceptable threshold This may be due to a short in the wire harness malfunctioning device or failure of the ECM power output circuitry Diagnostic Aids Measure the 5 volt output of the E...

Страница 240: ...ABLE 3 188 JLG Lift 3120895 DTC 643 5 Volt External High Voltage Electronic Throttle Actuator w Serial Position Feedback 2 16 13 12 1 5V_ext Vs 5 VDC 5V_rtn TPS1 TPS SER Motor DBW DBW ECM H Bridge 19...

Страница 241: ...e ECM above an acceptable threshold This may be due to a short in the wire harness malfunctioning device or failure of the ECM power output circuitry Diagnostic Aids Measure the 5 volt output of the E...

Страница 242: ...lly The ECM has checks that must be satisfied each time an instruction is executed Several different things can hap pen within the microprocessor that will cause this fault The ECM will reset itself i...

Страница 243: ...lly The ECM has checks that must be satisfied each time an instruction is executed Several different things can hap pen within the microprocessor that will cause this fault The ECM will reset itself i...

Страница 244: ...Key On Engine Running System Data Mode Clear System Fault Does SFC 555 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circuits...

Страница 245: ...lly The ECM has checks that must be satisfied each time an instruction is executed Several different things can hap pen within the microprocessor that will cause this fault The ECM will reset itself i...

Страница 246: ...Key On Engine Running System Data Mode Clear System Fault Does SFC 556 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circuits...

Страница 247: ...ly The ECM has checks that must be satisfied each time an instruction is executed Several different things can hap pen within the microprocessor that will cause this fault The ECM will reset itself in...

Страница 248: ...ey On Engine Running System Data Mode Clear System Fault Does SFC 513 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circuits...

Страница 249: ...ually The ECM has checks that must be satisfied each time an instruction is executed Several different things can hap pen within the microprocessor that will cause this fault The ECM will reset itself...

Страница 250: ...pt Key On Engine Running System Data Mode Clear System Fault Does SFC 512 reset with engine idling Fault is intermittent Replace ECM with known good part and retest No Check all power and ground circu...

Страница 251: ...or illuminate secondary warning lamp Non emissions related fault In some situations external controllers may send a request to the ECM to shutdown engine operation and stop the engine This request ma...

Страница 252: ...ica tion include smart actuators smart sensors dash panels and gauges and other microcomputers Each smart sen sor actuator or controller incorporates a CAN transceiver that interprets logic level sign...

Страница 253: ...ca tion include smart actuators smart sensors dash panels and gauges and other microcomputers Each smart sen sor actuator or controller incorporates a CAN transceiver that interprets logic level signa...

Страница 254: ...es These devices may be but are not limited to other engine ECMs slave diagnos tic tools smart gauges smart sensors powertrain con trol units vehicle controllers actuators etc The network permits seve...

Страница 255: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 203...

Страница 256: ...vern the engine speed to this commanded speed if possible When operating in this mode the ECM expects to receive TSC1 messages on a regular interval When this message is not received the ECM must oper...

Страница 257: ...throttle actuator with serial digital position feedback the ECM receives a constant data stream from the throttle actuator If the communication is absent or interrupted the ECM can no longer control...

Страница 258: ...engine speed based on operating conditions The Throttle Position Sensor uses either 1 a variable resistor and voltage divider circuit or 2 a non contact hall effect sensor to determine throttle actuat...

Страница 259: ...SECTION 3 CHASSIS TURNTABLE 3120895 JLG Lift 3 207...

Страница 260: ...speed based on operating conditions The Throttle Position Sensor uses either 1 a variable resistor and voltage divider circuit or 2 a non contact hall effect sensor to determine throttle actuator posi...

Страница 261: ...position when powered off This causes the engine to shutdown following a key off If the ECM detects the throttle position to be above x volts when the key is off as determined by the diagnostic cali...

Страница 262: ...6 Microprocessorfailure COP 629 31 99 DTC1612 Microprocessorfailure RTI1 629 31 100 DTC1613 Microprocessorfailure RTI2 629 31 101 DTC1614 Microprocessorfailure RTI3 629 31 102 DTC1615 Microprocessorfa...

Страница 263: ...et NOTE The outlet pipe must be centered within 1 4 6 35 mm minimum clearance to the exhaust venturi all around the venturi s perimeter If the exhaust pipe touches the venturi it will transfer heat an...

Страница 264: ...SECTION 3 CHASSIS TURNTABLE 3 212 JLG Lift 3120895 NOTES...

Страница 265: ...s 100 to 170 kg depending upon platform configuration These values DO NOT reflect any optional equipment attached to the plat form NOTE When removing the retaining pin from the rod end of the level cy...

Страница 266: ...rntable f Carefully lift boom assembly clear of turntable and lower to ground or suitable supported work surface Disassembly 1 Using a portable power source attach hose to tele scope cylinder port blo...

Страница 267: ...cables from powertrack 12 Remove hardware securing powertrack to the base boom section Remove powertrack Inspection 1 Inspect all boom pivot pins for wear scoring or other damage and for tapering or o...

Страница 268: ...ximately 430 lbs 195 kg 5 Measure the distance between the telescope cylin der port block attach point on base boom section and the attach point on fly boom section 6 Connect a suitable auxiliary hydr...

Страница 269: ...the hole in pivot pin aligns with attach point on upright 3 Using all applicable safety precautions operate lift ing equipment in order to position boom lift cylinder so that holes in cylinder rod en...

Страница 270: ...this point 3 Lower the boom until limit switch resets this should be 1 degree above to 4 degrees below horizontal NOTE Angle indicator should be placed on the top flat sur face of the boom near the p...

Страница 271: ...om 500 to 1000 lbs 230 to 450 kg is 47 but not below 47 angle SEEDETAILA DETAILB DETAILA ABOVEHORIZONTALSWITCH TOACTIVATEWHENBASE BOOMISRAISED5 TO10 ABOVEHORIZONTAL SWITCH TORESETWHENBASEBOOM LOWERED1...

Страница 272: ...50 to 1000 lbs 230 to 450 kg is 47 but not below 47 angle SEEDETAILA DETAILB DETAILA ABOVEHORIZONTALSWITCH TOACTIVATEWHENBASE BOOMISRAISED5 TO10 ABOVEHORIZONTAL SWITCH TORESETWHENBASEBOOM LOWERED1 BEL...

Страница 273: ...EXTENDED 84 375 1 214 3 2 5cm SEEVIEWAFORSWITCHORIENTATION SEEDETAILB SEEDETAILA DETAILB DETAILA ABOVEHORIZONTALSWITCH TOACTIVATEWHENBASE BOOMISRAISED5 TO10 ABOVEHORIZONTAL SWITCH TORESETWHENBASEBOOM...

Страница 274: ...speed This verifies that the switches are working when the boom is above horizontal Results should be recorded for a 50 ft course Drive Forward Record Time Drive Reverse Record Time Platform Rotate P...

Страница 275: ...e Adjust P1 until this time matches the time given in table 2 Rotating the adjustment potentiometer clockwise will increase the ramp time To set the ramp down time hold the joystick in the extreme pos...

Страница 276: ...ive pump is a slow reacting pump with internally built in ramp up and down times Table 4 2 Flow Control Card Settings SModels Function MinimumCurrent MaximumCurrent LiftUp 400mA 1320mA LiftDown 500mA...

Страница 277: ...is displaced axially within the housing similar to the operation of a hydraulic cylinder while the splines cause the shaft to rotate When the con trol valve is closed oil is trapped inside the actuat...

Страница 278: ...ing 2 Shaft 3 PistonSleeve 4 EndCap 109 LockPin 113 CapScrew 200 T Seal 202 T Seal 204 O Ring 205 CupSeal 207 Back Up 302 WearGuide 304 ThrustWasher 304 1 WiperSeal 400 StopTube Optional 401 Counterba...

Страница 279: ...5 1 Housing 2 Shaft 3 PistonSleeve 4 EndCap 109 LockPin 113 CapScrew 200 T Seal 202 T Seal 204 O Ring 205 CupSeal 207 Back Up 302 WearGuide 304 ThrustWasher 304 1 WiperSeal 400 StopTube Optional 401 C...

Страница 280: ...tion of piston sleeve 9 End cap dowel pins removal and installation of end cap sold with Helac seal kit The seal tool is merely a customized standard flat head screwdriver To make this tool you will n...

Страница 281: ...sing a metal bar or something similar un screw the end cap 4 by turning it counter clock wise 6 Remove the end cap 4 and set aside for later inspection 7 Remove the stop tube if included The stop tube...

Страница 282: ...1 Before removing the piston 3 mark the housing 1 ring gear in relation to the piston O D gear There should now be timing marks on the housing 1 ring gear the piston 3 and the shaft 2 12 To remove the...

Страница 283: ...is easi est to cut them using a sharp razor blade being careful not to damage the seal groove 17 Remove the thrust washers 304 from the end cap 4 and shaft 2 18 Remove the wiper seal 304 1 from its g...

Страница 284: ...n edges and surfaces Measure it s thickness to make sure it is within specifications Not less than 0 092 or 2 34 mm 3 Inspect the wear guide condition and measure thick ness not less than 0 123 or 3 1...

Страница 285: ...up rings see drawing for ori entation Beginning with the inner seal 200 insert one end of b u ring in the lower groove and feed the rest in using a circu lar motion Make sure the wedged ends overlap c...

Страница 286: ...Looking from the view shown use the existing tim ing 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...

Страница 287: ...the lock pins Tighten them to 25 in lbs 2 825 Nm Installing Counterbalance Valve Refer to Figure 4 12 Rotator Counterbalance Valve 1 Make sure the surface of the actuator is clean free of any contami...

Страница 288: ...SECTION 4 BOOM PLATFORM 4 24 JLG Lift 3120895 Figure 4 12 Rotator Counterbalance Valve...

Страница 289: ...re cylinder repair must be made 5 With cylinder fully retracted shut down engine and carefully disconnect hydraulic hose from cylinder extend port 6 Activate engine and retract cylinder Check extend p...

Страница 290: ...ROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if...

Страница 291: ...the piston from cylinder rod 13 Remove and discard the piston o rings seal rings and backup rings 14 Remove piston spacer if applicable from the rod 15 Remove the rod from the holding fixture Remove t...

Страница 292: ...into the composite bearing dry Lubrication is not required with nickel plated pins and bearings 14 Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter...

Страница 293: ...6 9 10 20 1684139 D 1 Barrel 2 NotUsed 3 WearRing 4 T Seal 5 WearRing 6 O ring 7 BackupRing 8 Wiper 9 Seal 10 Rod 11 Cap 12 WasherRing 13 Bolt 14 ValveCartridge 15 BleederValve 16 Bushing 17 Loctite...

Страница 294: ...6 Spacer 7 Valve Cartridge 8 O ring Plug 9 Capscrew 10 Washer Ring 11 Loctite 242 12 Locking Primer 13 Seal 14 Lock Ring 15 O ring 16 Backup Ring 17 Wear Ring 18 O ring 19 Backup Ring 20 Rod Seal 21...

Страница 295: ...Head 3 Ring Washer 4 Bolt 5 Rod 5A Bushing 6 ValveCartridge 7 NotUsed 8 O ring Plug 9 O ringPlug 10 Piston 11 TaperedBushing 12 Tube Spacer 13 Not Used 14 LockRing 15 PistonSeal 16 O ring 17 Backup R...

Страница 296: ...Tapered Bushing 6 CompositeBushing 7 Head 8 Barrel 9 Piston 10 Wear Ring 11 CylinderRod 12 Plug 13 Plug 14 NotUsed 15 WearRing 16 WearRing 17 BackupRing 18 BackupRing 19 Seal 20 O ring 21 O ring 22 Po...

Страница 297: ...1 Loctite 242 2 Locking Primer 3 NotUsed 4 Bolt 5 Tapered Bushing 6 Bushing 7 Head 8 Barrel 9 Rod 10 O ringPlug 11 NotUsed 12 Piston 13 HydrolockRing 14 GuidelockRing 15 O ring 16 Backup Ring 17 Wear...

Страница 298: ...Lift 3120895 13 6 2 11 12 3 9 7 10 8 1 8 10 7 9 3 12 11 1684412 A 1 Barrel 2 Rod 3 CylinderHead 4 Anti Seize 5 NotUsed 6 WearRing 7 Backup Ring 8 WearRing 9 O ring 10 O ring 11 Wiper 12 Seal 13 T Sea...

Страница 299: ...Loctite 4 Bolt 5 Bolt 6 Tapered Bushing 7 Head 8 Barrel 9 Rod 10 Piston 11 Not Used 12 Wear Ring 13 Wear Ring 14 Backup Ring 15 Not Used 16 O ring 17 O ring 18 O ring 19 Rod Seal 20 Wiper 21 Backup Ri...

Страница 300: ...t in Figure 5 17 The split of seals and backup rings are to be positioned so as not to be in alignment with each other 8 Using suitable protection clamp the cylinder rod in a vise or similar holding f...

Страница 301: ...r piston See Figure 5 17 Piston Seal Kit Installation 17 Position the cylinder barrel in a suitable holding fix ture EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL INDER ROD HEAD AND PISTON AVOI...

Страница 302: ...the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shi...

Страница 303: ...SECTION 5 HYDRAULICS 3120895 JLG Lift 5 15 Figure 5 22 Main Valve...

Страница 304: ...SECTION 5 HYDRAULICS 5 16 JLG Lift 3120895 Ft Lbs Nm 1 18 20 24 5 27 2 2 4 5 6 5 9 5 3 25 27 34 36 7 4 5 9 5 Figure 5 23 Main Valve Cartridge Torque Values...

Страница 305: ...ng pressures We also recommend using a calibrated gauge Pressure read ings are acceptable if within 5 of specified pres sures NOTE Engine RPM s must be correct Mid engine 1800 and High engine 2800 for...

Страница 306: ...in valve in front of the tank port The relief valve is located on top of the main valve and is the 6th relief valve to the left of the tank port This relief valve should be adjusted to 1600 psi Activa...

Страница 307: ...bled with Loctite to hold them in place The screws will require 300 400 in lbs 11 Nm of torque to break loose and 100 in lbs to remove Do not use impact wrench on Loctite screws This could result in r...

Страница 308: ...ll metal parts in clean solvent Blow dry with air Do not wipe parts with cloth or paper towel because lint or other matter could get into hydraulic system and cause damage Check around key slot and ch...

Страница 309: ...e Carefully press exclu sion seal into place 5 Visually check seal seat in mounting flange for scratches or other marks that might damage the pressure seal Check for cracks in flange that could cause...

Страница 310: ...e pushing down over shaft Be careful not to invert or damage seals 11 After removing bullet clamp motor in vise as shown in Figure 2 49 Make sure shaft cannot fall out Install dry screws and alternate...

Страница 311: ...ined end into shaft b Install spacer plate c Install 2 7 8 in 73 mm I D seal in gerotor seal groove Carefully place gerotor on spacer plate seal side toward spacer plate Standard Rotation Align any st...

Страница 312: ...in 73 mm seal in end cap Carefully place end cap on gerotor 18 Install cap screws and seal washers if applicable in end cap Pretighten screws to 40 in lbs 4 Nm Make sure seals are properly seated Then...

Страница 313: ...SECTION 5 HYDRAULICS 3120895 JLG Lift 5 25 Figure 5 25 Variable Displacement Hydraulic Pump...

Страница 314: ...nut 15 19 ft lb 20 Nm 25 Nm L 9 Stop the prime mover and remove the hose between gauge ports M4 and M5 Remove the pressure gauges installed in gauge ports M1 and M2 Rein stall the plugs in the gauge...

Страница 315: ...start up Check the inlet line for property tightened fittings and make sure it is free of restrictions and air leaks NOTE In most cases the reservoir is above the pump inlet so that the pressure head...

Страница 316: ...to leak from them When oil is observed to leak at the motor the line is full the air has been purged and the system hoses should be retightened to their specified torque Once charge pressure has been...

Страница 317: ...olled by individual joysticks with steering being controlled by a rocker switch built into the top the drive joystick To activate Drive Lift and Swing simply pull up on the slide lock location on the...

Страница 318: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 2 JLG Lift 3120895 Figure 6 2 ADE Block Diagram...

Страница 319: ...enu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The t...

Страница 320: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 4 JLG Lift 3120895 Figure 6 3 Analyzer Connecting Points PLATFORM CONNECTION GROUND CONTROL CONNECTION...

Страница 321: ...item by pressing the ESC key 6 4 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER When the analyzer is first connected you will be in access level 2 which enables you to only view most settings whi...

Страница 322: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 6 JLG Lift 3120895 Figure 6 4 Control Module Location...

Страница 323: ...NALYZER Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum...

Страница 324: ...ge all machine person ality 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 MAY ADVERSELY AFFECT...

Страница 325: ...RIGHT TRACK MIN FORWARD X RIGHT TRACK MAX FORWARD X RIGHT TRACK MIN REVERSE X RIGHT TRACK MAX REVERSE X RIGHT TRACK ELEV F MAX X RIGHT TRACK ELEV R MAX X RIGHT TRACK CREEP F MAX X RIGHT TRACK CREEP R...

Страница 326: ...ER TELESCOPE MIN IN X TOWER TELESCOPE MAX IN X TOWER TELESCOPE MIN OUT X TOWER TELESCOPE MAX OUT X BASKET LEVEL ACCEL X XS BASKET LEVEL DECEL X XS BASKET LEVEL MIN UP X BASKET LEVEL MAX UP X BASKET LE...

Страница 327: ...600C MODEL NUMBER 10 510A MODEL NUMBER 11 740A ENGINE 2 FORD EFI D F ENGINE 3 DEUTZ F4 ENGINE 4 DEUTZ F3 ENGINE 5 CAT 3024C ENGINE 6 CAT 3044C GLOW PLUG 15 15 SECONDS ENGINE SHUTDOWN 0 NO TILT 2 4 DE...

Страница 328: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 12 JLG Lift 3120895 Figure 6 8 Analyzer Flow Chart Prior to Version 5 X Software Sheet 4 of 4...

Страница 329: ...N 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 3120895 JLG Lift 6 13 Figure 6 9 Analyzer Flow Chart Version 5 X Software Sheet 1 of 4 NOTE Some screens may not be available depending upon machine configu...

Страница 330: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 14 JLG Lift 3120895 Figure 6 10 Analyzer Flow Chart Version 5 X Software Sheet 2 of 4...

Страница 331: ...REES TILT 3 DEGREES TILT 4 DEGREES CUT TILT 3 DEGREES CUT JIB YES 4 WHEEL STEER YES SOFT TOUCH YES GEN SET WELDER BELT DRIVE H T LIGHTS YES CABLE SWITCH YES LOAD SYSTEM WARN ONLY LOAD SYSTEM CUTOUT PL...

Страница 332: ...NTABLE SWITCH CLOSED ANGLE XXX X PLATFORM LOAD UMS STATUS STATE OK NORMAL CAN STATISTICS RX SEC X CAN STATISTICS TX SEC X CAN STATISTICS BUS OFF X CAN STATISTICS PASSIVE 1 CALIBRATION DATA LOAD ZERO X...

Страница 333: ...speed 0 to 100 48 ELEVATED MAXimum speed 0 to 50 35 CREEP MAXimum speed 0 to 50 40 Engine RPM 800 to 2900 1800 LIFT ACCELeration 0 1 to 5 0 2 3 DECELeration 0 1 to 3 0 1 1 MlNimum UP speed 0 to 60 41...

Страница 334: ...47 MAXimum DOWN speed 0 to 100 59 Engine RPM 800 to 2900 1500 BASKET ROTATE ACCELeration 0 1 to 5 0 1 5 DECELeration 0 1 to 3 0 0 5 MlNimum LEFT speed 0 to 65 47 MAXimum LEFT speed 0 to 100 65 MINimum...

Страница 335: ...E LIFT UP speed 0 to 100 60 LIFT DOWN speed 0 to 100 60 SWING speed 0 to 100 60 TELEscope speed 0 to 100 70 BASKET ROTATE speed 0 to 100 55 BASKET LEVEL speed 0 to 100 54 JIB LIFT speed 0 to 100 55 41...

Страница 336: ...VATED MAX because thevehicleis aboveelevation TESTS ACTIVE RECYCLEEMS TOEND Thesystemtests havebeen activated normalvehicleoperationis notallowed 1 1 Flashcode1 1indicates a sleep mode NOT REQUIRED 2...

Страница 337: ...EQUIRED 2 5 Flashcode2 5indicates thatafunction isprevented duetoa cutout 4 BOOMPREVENTED DRIVE SELECTED A boomfunction isselectedwhileadrivefunction isselectedand drive cutoutis configured toprevents...

Страница 338: ...erequired BATTERY TOO LOW SYSTEM SHUTDOWN Batteryvoltageis below6V EMSrecyclerequired 5 5 Flashcode5 5indicates problemswith vehicleengineRPMortheencoder 8 SPEED SENSORREADING INVALID SPEED Speed sens...

Страница 339: ...3 9 9 Flashcode9 9indicates problems withthecontroller 11 PLATFORMMODULEFAILURE hwfs CODE1 Platformmodule V Low FEThasfailed GROUND MODULE FAILURE hwfs CODE1 Groundmodule V Low FEThasfailed Table 6 2...

Страница 340: ...islimitedto ELEVATEDMAX becausethevehicleisoutoftrans portposition CHASSISTILTSENSOROUTOF RANGE Thechassistiltsensorhasindicatedatiltanglegreaterthan19degreesfor morethan4seconds Notreportedduring2sec...

Страница 341: ...Flashcode2 3indicatesproblemswithboomfunctionselection 3 LIFT SWINGLOCKED JOYSTICK MOVEDBEFOREFOOTSWITCH Platformupperliftorswingwasselectedbeforeandduringfootswitchclosure PUMPSWITCHESFAULTY CHECK DI...

Страница 342: ...municationslinktotheBLAMmoduleisactive DISCONNECTANALYZERAND CYCLEEMSTOPERFORMBOOM RETRIEVAL ThegroundmodulehasdetectedthatitneedstousetheRS232backupcom municationslinktotheBLAMmodulebutananalyzerisco...

Страница 343: ...TFORWARDDRIVEPUMP SHORTTOGROUND Onlyoccursonmachineswithachassismodule LEFTFORWARDDRIVEPUMP SHORTTOBATTERY Onlyoccursonmachineswithachassismodule LEFTFORWARDDRIVEPUMPOPEN CIRCUIT Onlyoccursonmachinesw...

Страница 344: ...lyoccursonthe1250AJPmachine MAINLIFTPILOTPRESSUREFAIL URE Onlyoccursonthe1250AJPmachine NOMAINLIFTPILOTPRESSURE Onlyoccursonthe1250AJPmachine MAINLIFTPILOTPRESSURE SWITCHFAILURE Onlyoccursonthe1250AJP...

Страница 345: ...IRCUIT Onlyoccursonmachineswithelectroniclevelingsystems BASKETDOWNOVERRIDESHORT TOBATTERY Onlyoccursonmachineswithelectroniclevelingsystems TOWERLIFTAPUVALVESTUCK OPEN Onlyoccurson1250AJP TOWERLIFTEN...

Страница 346: ...ORTTOBATTERY MAINOUTSHORTTOGROUND MAINOUTOPENCIRCUIT MAINOUTSHORTTOBATTERY LIFTUPDUMPSHORTTOGROUND LIFTUPDUMPOPENCIRCUIT LIFTUPDUMPSHORTTOBATTERY LIFTDOWNHOLDINGSHORTTO GROUND LIFTDOWNHOLDINGOPENCIRCU...

Страница 347: ...T Onlyoccurson1250AJP PVGVALVESHORTTOBATTERY Onlyoccurson1250AJP FOXSPAREOUTPUTSHORTTO GROUND OnlyoccursonFoxmachines FOXSPAREOUTPUTSHORTTOBAT TERY OnlyoccursonFoxmachines FOXSPAREOUTPUTOPENCIRCUIT On...

Страница 348: ...TOBATTERY OROPENCIRCUIT Onlyoccursonmachineswithelectronicbasketleveling BASKETLEFTSHORTTOBATTERY BASKERLEFTSHORTTOGROUND BASKETLEFTOPENCIRCUIT BASKETRIGHTSHORTTOBATTERY BASKETRIGHTSHORTTOGROUND BASKE...

Страница 349: ...sequence ENGINEFAULTCODE SPN FMI AllJ1939CANBUSECMswillreportfaultmessaginginthisformat TheSPN numberrepresentswhatisbrokenandFMInumberrepresentshowthecom ponentisbroken FORDFAULTCODEUNKNOWN Anunrecog...

Страница 350: ...U TRAL Mainboomliftpvgvalvedetectedits spoolisstuckintheneutralposition TOWERLIFTPVGVALVESTUCK NEUTRAL Towerboomliftpvgvalvedetectedits spoolisstuckintheneutralposition TOWERTELESCOPEPVGVALVE STUCKNEU...

Страница 351: ...COGNIZEDFAULT Towerboomliftpvgvalvesentanunrecognizedfault TOWERTELESCOPEPVGVALVE SENTUNRECOGNIZEDFAULT Towerboomtelescopepvgvalvesentanunrecognizedfault MAINLIFTPVGVALVEPARAMETERS INCORRECT Themainli...

Страница 352: ...sismoduleisnotreceivingCANmessages Thisisprobablyduetowiringprob lemsbetweenthechassisandgroundmodules CYLINDERLOADPINCANCOMMUNI CATIONSLOST Onlyoccursonmachineswithacylinderloadpin Thegroundmoduleorc...

Страница 353: ...ms Indicatesthatthe secondarybasketlevelingtiltsensorisshortedtobattery AnEMScycleis required BASKETLEVELINGSENSOR2 SHORTTOGROUNDOROPENCIR CUIT Onlyoccursonmachineswithelectroniclevelingsystems Indica...

Страница 354: ...unicationswiththeBLAM AnEMScycleis required ANGLESENSOR 1INVALIDANGLE AnEMScycleisrequired ANGLESENSOR 2INVALIDANGLE AnEMScycleisrequired WRONGTELERESPONSE Theboomtelescopeiscontrarytotheusercommand W...

Страница 355: ...ngintheoppositedirectiontheuseriscommanding TWRCYLANGLESENSOROUTOF RANGELOW Thetowercylinderanglesensorisbelow4721A Dcounts TWRCYLANGLESENSOROUTOF RANGEHIGH Thetowercylinderanglesensorisabove29535A Dc...

Страница 356: ...GE Thehorizontalforceisoutoftheallowedrange LOADPINVERTICALFORCEOUTOF RANGE Theverticalforceisoutoftheallowedrange MOMENTPINSENSORFAULT Themomentpinhasreportedafaultflag LOADPINSENSORFAULT Theloadpinh...

Страница 357: ...ectedontheleftfrontsteerleft valve LTFNTSTEERLTSTG Ashorttogroundhasbeendetectedontheleftfrontsteerleftvalve RTREARSTEERRTSTBOROC Ashorttobatteryoropencircuithasbeendetectedontherightrearsteerright va...

Страница 358: ...eringanglesensor REARLEFTWHEELSENSOROUTOF RANGELOW Ashorttogroundoropencircuithasbeendetectedonthesteeringanglesen sor REARLEFTWHEELSENSOROUTOF RANGEHIGH Ashorttobatteryhasbeendetectedonthesteeringang...

Страница 359: ...treportedduring2secondpower up AnEMScycleisrequired EEPROMFAILURE CHECKALLSET TINGS AcriticalfailureoccurredwiththeEEPROM Personalities machineconfigura tiondigits etcmayberesettodefaultvaluesandshoul...

Страница 360: ...ESA DFAILURE ThehighresolutionAnalogtodigitalconverterintheBLAMmodulehasfailed AnEMScycleisrequired CHASSISSENSORSUPPLYOUTOF RANGELOW Indicatesthatthesupplyvoltageforchassissensorsisbelowtheexpected r...

Страница 361: ...2 3 4 5 6 7 8 9 10 11 12 13 FORDEFIGAS FordLRG425EFIGas Tier1 FORDEFID F FordLRG425EFIdualfuel Tier1 DEUTZF4TIER1 DeutzF4M1011FDiesel Tier1 DEUTZF3TIER1 DeutzF3M1011FDiesel Tier1 CAT 3024C CAT3024CDi...

Страница 362: ...veelevation alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan4degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive main...

Страница 363: ...tout overloadlamplit platformalarmbeeps 5 secON 2secOFF CUTOUTALL Allfunctionscutout flashoverloadlight 500mSon 500mSoff platform alarmbeeps 5secON 2secOFF SPECIAL1 Functionsincreep overloadlamplit di...

Страница 364: ...Option 0 DRIVE 19 Onlyvisibleundercertain modelselections 0 1 2 4WD Fourwheeldrive 2WD Twowheeldrive 2WDW 2 SPEED Twowheeldrivewith2 speedvalve 0 TEMPERATURE 20 0 1 CELSIUS Celsiusunitselection FAHRE...

Страница 365: ...hine Configuration Programming Information Software Version P5 3 to P6 1 Configuration Label Digit Number Description Default Number MODELNUMBER 1 1 2 3 4 5 6 7 8 9 10 400S 450A 510A 600S 600A 600SC 6...

Страница 366: ...EngineControlModule ECM DUALFUELECM GM PSI3 0LDualFuel Tier2 7 FLYWHEELTEETH 4 Thismenuitemisonly visibleifDeutzengine selections3or4are selected 0 1 133TEETH 133flywheelteeth 110TEETH 110flywheelteet...

Страница 367: ...daboveelevation alsoreducesdrivespeedtocreep 4DEGREES CUT Reducesthemaximumspeedofallboomfunctionstocreepwhen tiltedmorethan4degreesandaboveelevation alsodisallowstowerliftup towertele scopeout drive...

Страница 368: ...4 NO Noloadsensorinstalled WARNONLY Functionsincreep overloadlamplit platformalarmbeeps 5secON 2 secOFF CUTOUTPLATFORM Allfunctionscutout overloadlamplit platformalarmbeeps 5 secON 2secOFF CUTOUTALL...

Страница 369: ...hedrivefunctionisactive Option DESCENT Descentalarmsoundswhenliftdownisactive Option MOTION Motionalarmsoundswhenanyfunctionisactive Option 3 DRIVE 20 Onlyvisibleundercertain modelselections 0 1 2 4WD...

Страница 370: ...ne Configuration Programming Information Software Version P6 1 to Present Configuration Label Digit Number Description Default Number MODELNUMBER 1 1 2 3 4 5 6 7 8 9 10 400S 450A 510A 600S 600A 600SC...

Страница 371: ...eutzF3M2011Diesel Tier2 FORDGASTIER2 FordLRG425EFIGas Tier2 FORDD FTIER2 FordLRG425EFIDualFuel Tier2 DEUTZECM EngineControlModule ECM Tier2andTier3 DUALFUELECM GM PSI3 0LDualFuel Tier2 PERKINSECM CATE...

Страница 372: ...pwhentilted morethan4degreesandaboveelevation alsoreducesdrivespeedtocreep 3DEGREES Reducesthemaximumspeedofallboomfunctionstocreepwhentilted morethan3degreesandaboveelevation alsoreducesdrivespeedtoc...

Страница 373: ...talled YES Brokencableswitchinstalled 0 LOADSYSTEM 16 Onlyvisibleundercertain marketselections Certainmarketselections willlimitloadsystem optionsoralterdefaultset ting 0 1 2 3 4 NO Noloadsensorinstal...

Страница 374: ...TOUT Drive steercutoutaboveelevation DRIVECUTE T Drive steercutoutaboveelevationandtilted 0 GROUNDALARM 19 Certainmarketselections willalterdefaultsetting 0 1 2 3 NO Nogroundalarminstalled DRIVE Trave...

Страница 375: ...vecoilsareenergizedfromthePropulsionModule ENHANCED DrivecoilsareenergizedfromtheGroundModuleandthegroundsideof thedrivecoilsarebroughtbacktocurrentfeedbackreturns 2 CLEARSKY 24 0 1 NO Clearsky telema...

Страница 376: ...4 5 0 0 0 1 0 1 0 1 400S HEAD TAIL LIGHTS CABLE BREAK SWITCH LOAD SYSTEM LOAD SENSOR FUNCTION CUTOUT GROUND ALARM DRIVE TYPE TEMPERATURE LEVELING MODE ANSIUSA 0 1 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0...

Страница 377: ...4 5 1 0 0 1 0 1 0 1 460SJ HEAD TAIL LIGHTS CABLE BREAK SWITCH LOAD SYSTEM LOAD SENSOR FUNCTION CUTOUT GROUND ALARM DRIVE TYPE TEMPERATURE LEVELING MODE ANSIUSA 0 1 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0...

Страница 378: ...the Emergency Stop switch and Start the engine 4 The analyzer screen should read 5 Use the arrow button to reach SYSTEM TEST Hit Enter The analyzer will prompt you asking if you want to activate the...

Страница 379: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 3120895 JLG Lift 6 63 Figure 6 13 System Test Flow Chart Platform Tests...

Страница 380: ...he arrow button to reach SYSTEM TEST Hit Enter The analyzer will prompt you asking if you want to activate the system test hit Enter again to activate 6 Follow the flow path in Figure 6 14 System Test...

Страница 381: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 3120895 JLG Lift 6 65 Figure 6 14 System Test Flow Chart Ground Station Tests...

Страница 382: ...speedencoderwiring Checkspeed encoder BADGROUNDMODULE Aninternalproblemwasdetectedinthegroundmodule HIGHTILTANGLE Thevehicleisverytilted 19 3 orthetiltsensorhasbeendamaged Checktilt sensor HOTENGINE T...

Страница 383: ...modeanynon neutralplatformswitchorjoystickisreported any activecutoutsarereported Ingroundmodeanynon neutralgroundswitchesisreported anyactivecutouts arereported NOTE Switches whicharenotinuse duetoth...

Страница 384: ...SIDESWING Promptsdisplayedduringtheoperatorinputtestbelowmessages CLOSEXXXXXXX Thenamedswitchshouldbeclosed OPENXXXXXXX Thenamedswitchshouldbeopened XXXXXXXXXXXXXXTOMAX Thenamedjoystickshouldbepushedt...

Страница 385: ...urer type 1 2 3 Ford LRG425EFIGas Ford LRG425EFIGaswith dual fuel DeutzF4M1011F Diesel DeutzF3M1011F Diesel 1 1 3 GlowPlug 0 NO 1 NUMBEROF MINUTES Display adjusts glowplugpresence and on time 0 1 10 N...

Страница 386: ...epwhen tilted CE AUSTRALIA Mod els450 600 601 and800 1 1 7 TowerLift 0 NO 1 YES Displays adjusts tower liftpresence 0 1 NoTowerLiftinstalled Yes 1 0 8 TowerTele 0 NO 1 YES Displays adjusts tower teles...

Страница 387: ...ofangle sensor 0 1 2 No Angle Sensorinstalled Limitswitchesareinstalled Ananalog sensorisinstalled 1 0 17 lengthSENSOR 0 NO 1 DIGITAL 2 ANALOG Displayspresence functionoflength sensor 0 1 2 NoLength S...

Страница 388: ...dsContinuouslyWhen AboveElevationAnd Tilted Only SoundsContinuouslyWhen AboveElevationAnd Tilted AndInConjunctionWithFault CodeFlashes Option 1 0 21 TowerProx Switches 0 NO 1 YES Displayspresence func...

Страница 389: ...PBAD 2218 L SJOY OUTOFRANGELOW 2219 L SJOY OUTOFRANGEHIGH 2220 L SJOY CENTERTAPBAD 2221 LIFT SWINGLOCKED JOYSTICKMOVEDBEFOREFOOTSWITCH 2222 WAITINGFORFSWTOBEOPEN 2223 FUNCTIONSWITCHESLOCKED SELECTEDBE...

Страница 390: ...RNATORPOWER SHORTTOGROUND 3340 AUXPOWER SHORTTOGROUND 3341 AUXPOWER OPENCIRCUIT 3342 AUXPOWER SHORTTOBATTERY 3346 ELECTRICFAN SHORTTOGROUND 3347 ELECTRICFAN OPENCIRCUIT 3348 ELECTRICFAN SHORTTOBATTERY...

Страница 391: ...RRIDEVALVE SHORTTOGROUND 3392 PLATFORMLEVELDOWNOVERRIDEVALVE OPENCIRCUIT 3393 PLATFORMLEVELDOWNOVERRIDEVALVE SHORTTOBATTERY 3394 PLATFORMROTATELEFTVALVE SHORTTOGROUND 3395 PLATFORMROTATELEFTVALVE OPEN...

Страница 392: ...R SHORTTOBATTERY 33133 PLATFORMCONTROLVALVE SHORTTOGROUND 33134 PLATFORMCONTROLVALVE OPENCIRCUIT 33135 PLATFORMCONTROLVALVE SHORTTOBATTERY 33170 LIFTDOWNVALVE OPENCIRCUIT 33171 LIFTDOWNVALVE SHORTTOBA...

Страница 393: ...FORMLEVELUPVALVE SHORTTOGROUND 344 PLATFORMLEVELUPVALVE SHORTTOBATTERYOROPENCIRCUIT 345 PLATFORMLEVELDOWNVALVE OPENCIRCUIT 346 PLATFORMLEVELDOWNVALVE SHORTTOBATTERY 347 PLATFORMLEVELDOWNVALVE SHORTTOG...

Страница 394: ...ORYMODULE 665 CANBUSFAILURE PROPULSIONMODULE 666 CANBUSFAILURE ENGINECONTROLLER 6620 CANBUSFAILURE UMSSENSOR 671 ACCESSORYFAULT 813 CHASSISTILTSENSORNOTCALIBRATED 815 CHASSISTILTSENSORDISAGREEMENT 816...

Страница 395: ...TTOBATTERY 8650 REARRIGHTSTEERVALVE SHORTTOGROUND 8652 RIGHTTRACKFORWARDVALVE OPENCIRCUIT 8653 RIGHTTRACKFORWARDVALVE SHORTTOBATTERY 8654 RIGHTTRACKFORWARDVALVE SHORTTOGROUND 8655 RIGHTTRACKREVERSEVAL...

Страница 396: ...9921 GROUNDMODULEFAILURE HIGHSIDEDRIVERCUTOUTFAULTY 9922 PLATFORMMODULEFAILURE HWFSCODE1 9923 GROUNDMODULEFAILURE HWFSCODE1 9924 FUNCTIONSLOCKEDOUT MACHINENOTCONFIGURED 9944 CURRENTFEEDBACKGAINSOUTOF...

Страница 397: ...s adjustsminimum reversedrivespeed MAXREVERSE Displays adjustsmaximum reversedrivespeed ELEVATEDMAX Displays adjustsmaximum drivespeed NOTE used whenelevation cutoutswitchesarelimitingmaximumspeed CRE...

Страница 398: ...ys adjustsminimum telescopeinspeed MAXIN Displays adjustsmaximumtelescopeinspeed MIN OUT Displays adjustsminimum telescopeoutspeed MAXOUT Displays adjustsmaximumtelescopeoutspeed BASKETLEVEL ACCEL Dis...

Страница 399: ...speed MIN RIGHT Displays adjustsminimum jibrightspeed MAXRIGHT Displays adjustsmaximum jib rightspeed STEER MAXSPEED Displays adjustsmaximum steer speed whichapplieswhenvehiclespeedis atminimum GROUN...

Страница 400: ...demand NOTE demand iscontrolledby thepump pot ROT LEFT Displays basketrotateswitch direction demand NOTE demand iscontrolledby thepump pot UTELE IN Displays telescopeswitch direction demand NOTE deman...

Страница 401: ...ue NOTE Notdisplayed if load 0 DATALOG ON Displays totalcontrolleron EMS time ENGINE Displays engine run time DRIVE Displays totalcontrollerdriveoperation time LIFT Displays total controllerliftoperat...

Страница 402: ...SECTION 6 JLG CONTROL SYSTEM S N 61718 TO PRESENT 6 86 JLG Lift 3120895 NOTES...

Страница 403: ...es or probe tips specifically designed for this tech nique especially on sealed connectors Whenever possi ble insert probes into the side of the connector such that the test also checks both terminals...

Страница 404: ...o 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 continuit...

Страница 405: ...erminals and open otherwise c If the switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechani...

Страница 406: ...an can measure the voltage at both power ter minals with respect to battery ground The difference between those two measurements is the voltage applied to the load 7 4 APPLYING SILICONE DIELECTRIC COM...

Страница 407: ...inge for small connectors 2 Apply dielectric grease to the female contact fill it approximately full see example below 3 Leave a thin layer of dielectric grease on the face of the connector 4 Assemble...

Страница 408: ...quired in properly sealed enclosures BRAD HARRISON PHOENIX CONTACT M12 The connector uses gold contact material to resist corro sion and an o ring seal for moisture integrity If dielectric grease is m...

Страница 409: ...CLOSURES Application of dielectric grease is not required in properly sealed enclosures To meet criteria the enclosure must be rated to at least IP66 dust tight protected from power ful jets of water...

Страница 410: ...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 assembling the housing to the header it is possib...

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

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

Страница 413: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 11 Figure 7 13 Connector Installation...

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

Страница 415: ...wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly 1 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be remov...

Страница 416: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 14 JLG Lift 3120895 Figure 7 20 Electrical Components Installation w o JLG Control System Sheet 1 of 2...

Страница 417: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 15 Figure 7 21 Electrical Components Installation w o JLG Control System Sheet 2 of 2...

Страница 418: ...ROL BOX FOOTSWITCH ABOVE HORIZONTAL LIMIT SWITCH TRANSPORT LIMIT SWITCH 400S ONLY CAPACITY ANGLE LIMIT SWITCH ALL SPECS EXCEPT CE SPEC GENERATOR SWITCH DEUTZ GM ONLY DEUTZ ONLY J4 J7 PLATFORM WORK LIG...

Страница 419: ...IN CONTROL VALVE GLOW PLUG RELAY AUX RELAY START RELAY STARTER GLOW PLUGS GENERATOR CONTROL BOX ENGINE CONTROL DEUTZ ENGINE HARNESS DEUTZ 2500W GENERATOR FUEL ON SWITCH CAT HYDRAULIC PUMPS TACH SENSOR...

Страница 420: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 18 JLG Lift 3120895 This page left blank intentionally...

Страница 421: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 19 Figure 7 24 On Board Generator Electrical Schematic if equipped...

Страница 422: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 20 JLG Lift 3120895 Figure 7 25 Electrical Schematic Ford Engine w o JLG Control System Sheet 1 of 4...

Страница 423: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 21 Figure 7 26 Electrical Schematic Ford Engine w o JLG Control System Sheet 2 of 4...

Страница 424: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 22 JLG Lift 3120895 Figure 7 27 Electrical Schematic Ford Engine w o JLG Control System Sheet 3 of 4...

Страница 425: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 23 C Figure 7 28 Electrical Schematic Ford Engine w o JLG Control System Sheet 4 of 4...

Страница 426: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 24 JLG Lift 3120895 Figure 7 29 Electrical Schematic Deutz Engine w o JLG Control System Sheet 1 of 4...

Страница 427: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 25 Figure 7 30 Electrical Schematic Deutz Engine w o JLG Control System Sheet 2 of 4...

Страница 428: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 26 JLG Lift 3120895 Figure 7 31 Electrical Schematic Deutz Engine w o JLG Control System Sheet 3 of 4...

Страница 429: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 27 Figure 7 32 Electrical Schematic Deutz Engine w o JLG Control System Sheet 4 of 4...

Страница 430: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 28 JLG Lift 3120895 Figure 7 33 Electrical Schematic Isuzu Engine w o JLG Control System Sheet 1 of 4...

Страница 431: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 29 Figure 7 34 Electrical Schematic Isuzu Engine w o JLG Control System Sheet 2 of 4...

Страница 432: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 30 JLG Lift 3120895 Figure 7 35 Electrical Schematic Isuzu Engine w o JLG Control System Sheet 3 of 4...

Страница 433: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 31 Figure 7 36 Electrical Schematic Isuzu Engine w o JLG Control System Sheet 4 of 4...

Страница 434: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 32 JLG Lift 3120895 Figure 7 37 Electrical Schematic Caterpillar Engine Sheet 1 of 6 NOTE ThisSchematiccoversmachinesbuiltpriorto S N99084...

Страница 435: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 33 Figure 7 38 Electrical Schematic Caterpillar Engine Sheet 2 of 6 1870132 M...

Страница 436: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 34 JLG Lift 3120895 Figure 7 39 Electrical Schematic Caterpillar Engine Sheet 3 of 6 NOTE ThisSchematiccoversmachinesbuiltpriorto S N99084...

Страница 437: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 35 Figure 7 40 Electrical Schematic Caterpillar Engine Sheet 4 of 6 1870132 M...

Страница 438: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 36 JLG Lift 3120895 Figure 7 41 Electrical Schematic Caterpillar Engine Sheet 5 of 6 NOTE ThisSchematiccoversmachinesbuiltpriorto S N99084...

Страница 439: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 37 Figure 7 42 Electrical Schematic Caterpillar Engine Sheet 6 of 6 1870132 M...

Страница 440: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 38 JLG Lift 3120895 Figure 7 43 Electrical Schematic Deutz EMR2 GM Engine Sheet 1 of 6 NOTE ThisSchematiccoversmachinesbuiltpriortoS N99084...

Страница 441: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 39 Figure 7 44 Electrical Schematic Deutz EMR2 GM Engine Sheet 2 of 6 1870191 G...

Страница 442: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 40 JLG Lift 3120895 Figure 7 45 Electrical Schematic Deutz EMR2 GM Engine Sheet 3 of 6 NOTE ThisSchematiccoversmachinesbuilt priortoS N99084...

Страница 443: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 41 Figure 7 46 Electrical Schematic Deutz EMR2 GM Engine Sheet 4 of 6 1870191 G...

Страница 444: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 42 JLG Lift 3120895 Figure 7 47 Electrical Schematic Deutz EMR2 GM Engine Sheet 5 of 6 NOTE ThisSchematiccoversmachinesbuilt priortoS N99084...

Страница 445: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 43 Figure 7 48 Electrical Schematic Deutz EMR2 GM Engine Sheet 6 of 6 1870191 G...

Страница 446: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 44 JLG Lift 3120895 Figure 7 49 Electrical Schematic Hydraulic Welder...

Страница 447: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 45 This page left intentionally blank...

Страница 448: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 46 JLG Lift 3120895 Figure 7 50 Electrical Schematic Deutz GM CAT Engine Sheet 1 of 6 NOTE ThisSchematiccoversmachinesbuiltS N99084toPresent...

Страница 449: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 47 Figure 7 51 Electrical Schematic Deutz GM CAT Engine Sheet 2 of 6 1870215 B...

Страница 450: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 48 JLG Lift 3120895 Figure 7 52 Electrical Schematic Deutz GM CAT Engine Sheet 3 of 6 NOTE ThisSchematiccoversmachinesbuiltS N99084toPresent...

Страница 451: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 49 Figure 7 53 Electrical Schematic Deutz GM CAT Engine Sheet 4 of 6 1870215 B...

Страница 452: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 50 JLG Lift 3120895 Figure 7 54 Electrical Schematic Deutz GM CAT Engine Sheet 5 of 6 NOTE ThisSchematiccoversmachinesbuilt S N99084toPresent...

Страница 453: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 51 Figure 7 55 Electrical Schematic Deutz GM CAT Engine Sheet 6 of 6 1870215 B...

Страница 454: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 52 JLG Lift 3120895 Figure 7 56 Hydraulic Schematic Sheet 1 of 6...

Страница 455: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 53 Figure 7 57 Hydraulic Schematic Sheet 2 of 6 1001093691 A...

Страница 456: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 54 JLG Lift 3120895 Figure 7 58 Hydraulic Schematic Sheet 3 of 6...

Страница 457: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 55 Figure 7 59 Hydraulic Schematic Sheet 4 of 6 1001093691 A...

Страница 458: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 56 JLG Lift 3120895 Figure 7 60 Hydraulic Schematic Sheet 5 of 6...

Страница 459: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 3120895 JLG Lift 7 57 Figure 7 61 Hydraulic Schematic Sheet 6 of 6 1001093691 A...

Страница 460: ...SECTION 7 BASIC ELECTRICAL INFORMATION SCHEMATICS 7 58 JLG Lift 3120895 NOTES...

Страница 461: ......

Страница 462: ...53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lun...

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