Service and Maintenance Manual Models T350 P/N - 3121198 January 9, 2013
INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
INTRODUCTION REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised Revised A-2 - January 15, 2005 - July 15, 2005 - August 26, 2005 - December 12, 2005 - February 24, 2006 - May 1, 2007 - September 28, 2011 - January 9, 2013 – JLG Lift – 3121198
TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A B C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. 2.4 2.5 2.6 TITLE PAGE NO. Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3121198 TITLE PAGE NO. Combination Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Bleeding the Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 iv TITLE PAGE NO. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57 Throttle & Choke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 Fuel Valve Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 4 - BOOM & PLATFORM 4.1 4.2 4.3 4.4 4.5 Boom and Cylinder AssemblY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-26. 3-26. 3-27. 3-28. 4-1. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-7. 5-7. 5-7. 5-8. 5-9. 5-10. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 3121198 TITLE PAGE NO. Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NO. 6-7. 6-8. 6-9. 6-10. 6-11. 7-1. 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7-11. 7-12. 7-13. 7-14. 7-15. 7-16. 7-17. 7-18. 7-19. 7-20. 7-21. 7-22. 7-23. 7-24. 7-25. 7-26. 7-27. 7-28. 7-29. 7-30. 7-31. 7-32. 7-33. viii TITLE PAGE NO. Ground Module - Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 Ground Module - Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 2-1 2-2 2-3 3-1 3-2 3-3 3-4 3-5 3-25 5-1 5-2 6-1 6-2 6-3 6-4 6-5 7-1 3121198 TITLE PAGE NO. Operating & Towing Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Electric Power Unit Specifications . . . . . . . . . . . . .
LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally.
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 CAPACITIES Table 1-2. Capacities Table 1-1. Operating & Towing Specifications Tongue Weight (ANSI): 252 lbs.(114 kg) Maximum Allowable Tow Speed: (Do NOT exceed legal speed limit) 65 mph (105 kph) Maximum Work Load (Capacity) w/Rotator 440 lbs. (200 kg) Maximum Work Load (Capacity) w/o Rotator 500 lbs. (230 kg) Maximum Work Load (Capacity) w/Rotator & Panel Tray 320 lbs.
SECTION 1 - SPECIFICATIONS 1.5 ENGINE 1.7 Battery Hydraulic Oil Table 1-5. Battery Specifications BCI Group Size 51R Cranking Performance 550 amps @ 32°F (0°C) 450 amps @ 0°F (-18°C) Reserve Capacity 80 minutes @ 32°F (0°C) 1.6 LUBRICATION Table 1-7. Hydraulic Oil Hydraulic System Operating Temperature Range DIMENSIONAL DATA Table 1-6. Dimensional Data Overall Length Surge Brake, 2" ball Surge Brake, 2" ball w/platform rotator Electric brake,2" ball - 20 ft 3 in (6.
SECTION 1 - SPECIFICATIONS 1.8 MAJOR COMPONENT WEIGHTS 1.9 Table 1-9. Component Weights Component Frame (bare) Pounds Kilograms 592 269 Turntable (bare) 127 58 Booms & Cylinders Assy. 1130 513 Main Boom 626 284 Engine Assy. (Incl. Tray) 116 53 Engine (bare) 57 26 Master Cylinder 18 8 Axle 140 64 PRESSURE SETTINGS Cold temperatures have a significant impact on pressure readings. JLG Industries Inc.
SECTION 1 - SPECIFICATIONS 1. 2. 3. 4. Wheel Bearings Hydraulic Oil Hydraulic Filter & Breather Swing Bearing 5. 6. 7. 8. Swing Bearing Teeth Swing Drive Engine Fuel Tank 9. 10. 11. 12. Trailer Jack Surge Brake Coupler & Hitch Ball Jockey Wheel Bearing Figure 1-1. Operator Maintenance & Lubrication Diagram 1.10 OPERATOR MAINTENANCE & LUBRICATION 1. Wheel Bearings NOTE: Lubrication intervals are based on machine operation under normal conditions.
SECTION 1 - SPECIFICATIONS 2. Hydraulic Oil 4. Swing Bearing Lube Point(s) - Fill Cap Capacity - 4 gal. (15.1 L) Lube - HO Interval - Check oil daily, change after, then every 1200 hours of operation. Lube Point(s) - 1 Grease Fitting Capacity - As Required Lube - MPG Interval - Every month or 50 hours Comments - Rotate the bearing back and forth to ensure grease is distributed evenly the whole way around the bearing. 3. Hydraulic Filter & Breather 5.
SECTION 1 - SPECIFICATIONS 7. Engine 10. Surge Brake Capacity - See Engine Manual. Lube - EO, 10W30 API SJ Interval - Check level daily; change per manufacturer’s engine manual. Comments - Adjust final oil level by mark on dipstick Lube Point(s) - Fill Cap Capacity - No more than 1/2" (13 mm) from top of reservoir Lube - DOT 3 or 4 Brake Fluid Interval - Check before each tow. Flush the system yearly or when system is known to be contaminated 8. Fuel Tank 11.
SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.
SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.
SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 11 3 0.5 5.03 3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.
SECTION 1 - SPECIFICATIONS NOTES: 1-14 – JLG Lift – 3121198
SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Responsibility Service Qualification Reference Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - GENERAL Component Disassembly and Reassembly When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.
SECTION 2 - GENERAL 2.3 LUBRICATION AND INFORMATION F (-29° C). However, use of this oil will give poor performance at temperatures above 120° F (49°C). Systems using DTE 13 oil should not be operated at temperatures above 200° F (94° C) under any condition. Hydraulic System 1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc.
SECTION 2 - GENERAL 2.4 CYLINDER DRIFT TEST 2.5 Maximum acceptable cylinder drift is to be measured using the following methods. PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. 1. Pinned joints should be disassembled inspected if the following occurs: Platform Drift Measure the drift of the platform to the ground. Lower booms (if equipped) slightly elevated, main boom fully extended with the rated load in the platform and power off.
SECTION 2 - GENERAL 2.6 WELDING ON JLG EQUIPMENT NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the machine on an external structure, or component, • Ground on frame and weld on any other area than the chassis. • Ground on turntable and weld on any other area than the turntable. Do the Following When Welding on JLG Equipment • Ground on the platform/support and weld on any other area than the platform/support. • Disconnect the battery.
SECTION 2 - GENERAL Table 2-3.
SECTION 2 - GENERAL NOTES: 2-8 – JLG Lift – 3121198
SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 BREAKING-IN A NEW TRAILER 3.2 Retighten Lug Nuts at First 10, 25 & 50 Miles Wheel lugs can shift and settle quickly after being first assembled, and must be checked after the first 10, 25 and 50 miles of driving. Failure to perform this check could result in a wheel coming loose from the trailer, causing a crash leading to death or serious injury.
SECTION 3 - CHASSIS & TURNTABLE pressure of the linings against the drum produces a slight drag. the shoes and brake drums until the desired stop is accomplished. 5. Remount the wheel and brake drum. Brake Controller 6. Repeat the above procedure on all brakes. A tow vehicle brake controller is required. These controllers have gain control to vary the amount of current to the brakes, and a level control which sets the controller's inertia sensor to sense deceleration.
SECTION 3 - CHASSIS & TURNTABLE reverse is significantly less effective than in the forward direction. 1. 2. 3. 4. 5. Anchor Post Wheel Cylinder Hold Down Spring Primary Shoe Adjuster Assembly 6. 7. 8. 9. Parking Brake The parking brake is cable operated. The parking cable body is mounted to the brake backing plate. The cable end is attached to the internal parking brake lever to actuate the brake.
SECTION 3 - CHASSIS & TURNTABLE 3. With a screwdriver or standard adjusting tool, rotate the starwheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn. 4. Rotate the starwheel in the opposite direction until the wheel turns freely with a slight lining drag. 5. Replace the adjusting hole cove and lower the wheel to the ground. 6. Repeat the above procedure on all brakes.
SECTION 3 - CHASSIS & TURNTABLE Bearing Lubrication 1. Pry the seal out of the hub with a screwdriver. Never drive the seal out with the inner bearing as you may damage the bearing. Bearings should be lubricated every 12 months or 12,000 miles. The procedure to repack bearing cones is as follows: 1. Place a quantity of grease into the palm of your hand. 2.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. Grease Seal Inner Bearing Cone Inner Bearing Cup Brake Assembly 5. 6. 7. 8. Hub Assembly Wheel Stud Outer Bearing Cup Outer Bearing Cone 9. 10. 11. 12. Spindle Washer Spindle Nut Cotter Pin Grease Cap 13. Wheel Nut 14. Hub Figure 3-3.
SECTION 3 - CHASSIS & TURNTABLE WHEEL CYLINDERS Inspect for leaks and smooth operation. Clean with brake cleaner and flush with fresh brake fluid. Hone or replace as necessary. The following tire wear diagnostic chart will help you pinpoint the causes and solution of tire wear problems. Table 3-1. Tire Wear BRAKE LINES Wear Pattern Check for cracks, kinks, or blockage. Flush with fresh brake fluid. Bleed system to remove all air. Replace as necessary.
SECTION 3 - CHASSIS & TURNTABLE Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque. 3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. Table 3-2. Wheel Torque Chart - ANSI, ANSI Export, CSA, Aus WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE.
SECTION 3 - CHASSIS & TURNTABLE PLACE THE SPARE ON THE HOOK PROVIDED ON THE MOUNTING FIXTURE AND THEN FOLLOW DIRECTOINS BELOW ROTATE THE SPARE SO THE TWO HOLES LINE UP WITH THE TWO SLOTS IN THE MOUNTING PLATE AND INSERT CARRIAGE BOLTS THROUGH FROM THE BACK SIDE. ASSEMBLE WHEEL NUTS TO THIS SIDE INSERT CARRIAGE BOLTS SO THAT THE SQUARE NECKS ARE IN SLOTS ON THIS SIDE AS SHOWN Figure 3-4.
SECTION 3 - CHASSIS & TURNTABLE 3.7 HYDRAULIC BRAKE COUPLER Troubleshooting IF ANY OF THE FOLLOWING CONDITIONS DEVELOP, TRAILER MUST NOT BE USED UNTIL PROPER CORRECTIVE ACTION IS TAKEN. Table 3-4.
SECTION 3 - CHASSIS & TURNTABLE Bleeding the Brake System 8. After bleeding has been completed, re-check fluid level in the master cylinder. DO NOT USE BRAKE FLUID DRAINED FROM THE BRAKE SYSTEM IN REFILLING THE MASTER CYLINDER. USED BRAKE FLUID CAN BE CONTAMINATED FROM THE SYSTEM. 1. Remove the master cylinder filler cap and fill reservoir with DOT type 3 or 4 automotive brake fluid. 2. Check all hydraulic line fittings and connections to make sure they are leak free.
SECTION 3 - CHASSIS & TURNTABLE 4. Close the release handle. The release handle will close freely with finger pressure when the ball is properly inserted into the ball socket. 9. Cross safety chains under the tongue and securely attach to bumper or frame of tow vehicle. FAILURE TO USE SAFETY CHAINS COULD DAMAGE THE TRAILER BOOM. 10. Retract the jack fully. Place the caster wheel in the stowed position. 11.
SECTION 3 - CHASSIS & TURNTABLE travel. Plush the lever knob down to engage the locking notch. 3. Check brake fluid level in the master cylinder reservoir. Keep filled to within 1/2" (13 mm) from the top of the reservoir. Use only a DOT type 3 or 4 brake fluid. 4. Flush the system yearly or when system is known to be contaminated. NOTE: Wheel bearings and seals should be inspected and packed at this time.
SECTION 3 - CHASSIS & TURNTABLE 3.8 COMBINATION COUPLER General Maintenance 1. Frequently check brake fluid level. Fluid must be approved, clean, and uncontaminated. THE WEIGHT RATING OF THE COUPLER IS DEPENDENT UPON THE CORRECT BOLTS BEING USED. USE THE BOLTS PROVIDED WITH THE COUPLER. IF BOLTS ARE MISSING, REFER TO THE PARTS MANUAL AND OBTAIN REPLACEMENT BOLTS OR USE THE EXACT SIZE, GRADE, AND NUMBER OF BOLTS AS SPECIFIED.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. Not Used Not Used Push Rod Shock Absorber Release Handle Master Cylinder 7. Gasket 8. 9. 10. 11. 12. Boot Stop Not Used Locknut Not Used 13. 14. 15. 16. 17. 18. Spring Bolt Cap Lanyard S-Hook Bolt 19. 20. 21. 22. 23. 24. Not Used Bolt Flatwasher Link Flatwasher Locknut 25. 26. 27. 28. 29. 30. Block Bushing Flatwasher Flatwasher Flatwasher Bracket 31. 32. 33. 34. 35. 36. Shipping Plug Not Used Not Used Piston Housing Hitch Figure 3-5.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. Not Used Not Used Not Used Pin Not Used Damper Shock Outer Case 8. 9. 10. 11. 12. Lockwasher Cotter Pin Cable with Hooks Hook Emergency Lever Spring Plate 13. Bolt 14. 15. 16. 17. 18. Bolt Lockwasher Lanyard S-Hook Push Rod & Piston Assembly 19. Nut 20. 21. 22. 23. Gasket Reservoir Fitting w/ Orifice Emergency Lever Guide 24. Boot 25. Pin 26. 27. 28. 55. Upper Slider Lower Slider Side Spacer Channel Centered Slider Figure 3-6.
SECTION 3 - CHASSIS & TURNTABLE 3.9 HITCH COUPLER & AXLE (CE ONLY) COUPLING To insure continuing reliability and road safety in traffic, the maintenance tasks have to be performed at the prescribed intervals. Maintenance, repairs, and replacement of wearing parts for the chassis and the braking system may only performed by a qualified garage. To couple the trailer, place the open ball coupler (X position) on the ball of the towing vehicle so that it clicks into place audibly.
SECTION 3 - CHASSIS & TURNTABLE IF THE INDICATOR IS IN THE RED "-" ZONE, THE COUPLING IS NOT PROPERLY CLOSED, AND THE TRAILER MUST NOT BE TOWED! POSITION OF THE COUPLING POINT ON THE TRAILER TO ACHIEVE THE CORRECT DRIVING AND BRAKING BEHAVIOR IN THE TRAILER, IT IS ABSOLUTELY ESSENTIAL FOR THE COUPLING HEIGHTS OF THE TOWING VEHICLE AND THE TRAILER TO MATCH. The position of the coupling point on the trailer must be in a range of 430 ± 35 mm above the horizontal tire contact surface.
SECTION 3 - CHASSIS & TURNTABLE Coupling Head Maintenance 9. If the damper has been released the rear mounting bracket will need to be re-fitted. This means that the damper needs to be compressed so the bolts can be installed. WARNING: Proceed with caution! Compress the damper with the lever and secure the mounting bracket bolts. REPLACING Prior to replacing the coupling head, it is essential to confirm the condition of the damper. Test the Damper as outlined under DAMPER REACTION TEST. 1.
SECTION 3 - CHASSIS & TURNTABLE Damper Maintenance c. Knock out the retaining pin and remove the rear bolt, this will allow the damper to move forward and contact the front bolt. The dampers assembled within the overrun coupling is pressurized. During assembly, the damper is reloaded and compressed in order that the coupling operates correctly. Care must be exercised when working on, handling, and disposing of the coupling/damper.
SECTION 3 - CHASSIS & TURNTABLE Brake Maintenance REPLACING BRAKE SHOES WHEEL BRAKES The linings of the wheel brakes are wearing parts, so their condition must be checked every 3000 miles (5000 km) or every year, whichever comes first, using the view holes on the wheel backing plates. Place the trailer on stands with all wheels off of the ground. WARNING: The handbrake should be released and the handbrake locking bolt installed.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. Flanged Screw Flanged Screw Hub/Drum Assembly Dust Cap Flanged Nut Bearing 7. 8. 9. 10. 11. Circle Clip Brake Shoe (Secondary) Brake Shoe (Primary) Tension Spring (Top) Tension Spring (Bottom) 12. 13. 14. 15. 16. Tension Spring (Center) Compression Spring Spreader Adjusting Key Adjusting Bolt Bolt 17. 18. 19. 20. 21. Adjustment Hole Plug Protective Shield Drawbar Eye Protective Sleeve Brake Cable Figure 3-7.
SECTION 3 - CHASSIS & TURNTABLE 7. Undo the locknut on the brake rod (front to rear) adjacent to the compensator. Slacken the second nut on the brake rod. Remove the half shell from the backplate and detach the brake cable. ADJUSTMENT NOTE: When adjusting the brake drum, only turn the wheel in the direction of forward rotation. 1. Turn each wheel in the direction of forward rotation.
SECTION 3 - CHASSIS & TURNTABLE Adjustment and Readjustment of the Overrun Braking System ADJUSTMENT PROCEDURE 1. Brake ADJUSTING THE BRAKING SYSTEM a. Loosen the linkage Preparations: 1. Place the trailer on jacks with the wheels off of the ground. 2. Release the handbrake b. Tighten the adjusting screw (12) (on the outside of the brake plate, opposite the cable entry[13]), turning clockwise until the wheel can only be turned with difficulty or not at all. 3.
SECTION 3 - CHASSIS & TURNTABLE d. The compression spring may only be lightly pretensioned and must not become fully compressed when activated. CHECK THE EXPANDING LOCKING MECHANISM AND CONTROL CABLE. THE EXPANDING LOCK COMPENSATOR MUST NOT BE PRE-TENSIONED IN THE BRAKE. DO NOT ATTEMPT TO COMPENSATE FOR EASE OF MOVEMENT CAUSED BY BRAKE LINING WEAR BY READJUSTING (SHORTENING) THE BRAKE LINKAGE, BY WAY OF THE LINKAGE SCREW FASTENINGS. 1. Readjustment: a.
SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-5.
SECTION 3 - CHASSIS & TURNTABLE 3.10 COUPLER ASSEMBLY (S/N 0030002099 TO PRESENT) To disengage the breakaway mechanism, first release the brake line pressure by briefly opening a bleeder valve. Extend the coupler forward to gain access to the 1/2" hole on the top of the coupler housing as shown below. Engaging Manual Lockout Lever The manual lockout lever is used to control the brake pressure being applied to the trailer when backing up.
SECTION 3 - CHASSIS & TURNTABLE 4 3 5 6 24 9 1 2 21 20 17 19 8 16 7 23 14 18 13 22 15 13 11 12 10 1. 2. 3. 4. 5. 6. Cover Master Cylinder Gasket Cap Capscrew Capscrew 7. 8. 9. 10. 11. 12. Housing Lanyard/Pushrod Top Slide Bottom Slide Damper Shock Spacer 13. 14. 15. 16. 17. 18. Spacer Capscrew Capscrew Locknut Locknut Bracket 19. 20. 21. 22. 23. 24. Alignment Button Pin Breakaway Roller Spacer Lever Fitting Figure 3-9.
SECTION 3 - CHASSIS & TURNTABLE Actuator Maintenance 1. Frequently check brake fluid level (fluid must be DOT3 or 4 approved, clean and uncontaminated). 2. Maintain a film of oil on the pivot points and safety latch spring using SAE 30W motor oil. 2. Make sure mounting bolts are properly tightened 15 to 20 ft lbs (20 to 27 Nm) without deformation of coupler. 3. Inspect entire actuator, replace any bent, worn or damaged parts immediately. 4.
SECTION 3 - CHASSIS & TURNTABLE 3.11 TRAILER JACK (SOLID WHEELS) the plunger pin snaps into the proper mounting bracket hole. Installation 1. Place the jack against the trailer tongue and position the mounting straps on the opposite side of the tongue. Place the straps so the flat side is against the tongue. 2. Install the bolts through the bracket and straps. Position the jack so the top bolts rest directly on the top of the tongue and the bottom bolts are as close to the tongue as possible.
SECTION 3 - CHASSIS & TURNTABLE 3.12 SWING MOTOR (PRIOR TO S/N 0030000960) Assembly HANDLE NOTE: This motor may also be used on some machines manufactured between S/N 0030000960 to 0030001050. HANDLE Removal 1. Remove the two bolts securing the motor to the swing drive. SPLIT TUBE SPACER 2. Lift the motor up to gain access to the hydraulic lines and tag and disconnect the lines running to the motor. Cap or plug all openings. SPACER NUT BOLT ROLLER 1. Place one spacer over the bolt. 2.
SECTION 3 - CHASSIS & TURNTABLE 6. Remove the rotor assembly and wear plate. Remove the body seals from the rotor and housing and discard the seals. 7. Remove the drive link pin and drive link from the motor and lay aside. 8. Gently tap the shaft upward through the housing and remove through the rear of the housing. Turn the shaft over and remove the cooling plug. Assembly FOR PROPER OPERATION, THE MOTOR DEPENDS ON THE CORRECT ORIENTATION OF PARTS AS WELL AS THE CORRECT INTERNAL TIMING. 1.
SECTION 3 - CHASSIS & TURNTABLE 7. Install the high pressure seal into the groove in the housing. 7. To seat the seal carrier against the wire ring, gently tap the drive link down until the end of the shaft is nearly flush with the rear surface of the housing. 8.
SECTION 3 - CHASSIS & TURNTABLE 11. Lower the rotor onto the drive link making sure the timing mark on the drive link is aligned with a peak on the rotor as shown in Figure 3-12., Timing Mark. TIMING MARK 16. Insert the four bolts and torque to an initial value of 10 ft.lbs. (13.5 Nm). Using a criss-cross pattern, apply a final torque of 50 ft.lbs. (68 Nm). 17. Remove the motor from the vise and place on a clean work surface with the shaft facing up.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. Dust Seal Retainer Ring Backup Shim Housing Seal Body Seal 6. 7. 8. 9. 10. Shaft Seal Thrust Washer Thrust Bearing Wear Plate End Cover 11. 12. 13. 14. 15. Ball Cooling Plug Housing Drive Link Rotor Set 16. 17. 18. 19. Drive Link Pin Bolt Shaft Key Figure 3-13.
SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING MOTOR (S/N 0030001050 TO PRESENT) NOTE: This motor may also be used on some machines manufactured between S/N 0030000960 to 0030001050. 2. Scribe an alignment mark down and across the Torqlink™ components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for disassembly later if included in end cover. 3/ 16 or 3/8 inch Allen wrench or 1 inch hex socket required. Removal 1.
SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 2. End Cover 3. Seal Ring-Commutator 4. Seal Ring 5. Commutator Ring 6. Commutator Ring 7. Manifold 8. Rotor Set 8A.Rotor 8B. Stator or Stator Vane 8C. Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 12. Coupling Shaft 13. Bearing/Bushing, Inner 14. Thrust Washer 15. Thrust Bearing 16. Seal 17. Back-up Washer 18. Housing 18A. O-Ring 19. Bearing/Bushing, Outer 20. Dirt & Water Seal 21. Plug Figure 3-14. Swing Drive Motor 4.
SECTION 3 - CHASSIS & TURNTABLE 5. If the end cover (2) is equipped with shuttle valve components, remove the two previously loosened plugs (21). BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE REMOVED. 7. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs. 8.
SECTION 3 - CHASSIS & TURNTABLE 9. Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard the seal rings (4) that are on both sides of the manifold. NOTE: The manifold is constructed of plates bonded together to form an integral component not subject tofurtherdisassemblyforservice.
SECTION 3 - CHASSIS & TURNTABLE 12. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and discard seal ring (4) from housing (18). 15. Remove coupling shaft (12), by pushing on the output end of shaft.
SECTION 3 - CHASSIS & TURNTABLE 17. Remove thrust bearing (15) and thrust washer (14) Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 19. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required. 18. 20. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics.
SECTION 3 - CHASSIS & TURNTABLE 21. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. The bushing (19) or (13) to coupling shaft diameter clearance must not exceed 0.
SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available. The parts should be available through most OEM parts distributors or Parker approved Torqlink™ distributors. (Contact your local dealer for availability).
SECTION 3 - CHASSIS & TURNTABLE 2. The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/bushing (19). 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing.
SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. 5. On the Torqlinks™ assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of Torqlink™, into their respective counterbores in housing (18) if they were not assembled in procedure 2. 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™.
SECTION 3 - CHASSIS & TURNTABLE THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT #K-70M. NOTE: Mobil Mobilith SHC ® 460 NOTE: A 102Tube (P/N 406010) is included in each seal kit. NOTE: The coupling shaft (12) will be flush or just below the housing wear plate surface on Torqlinks™ when properly seated.
SECTION 3 - CHASSIS & TURNTABLE 12. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (8B). 14. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7). 13. Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines.
SECTION 3 - CHASSIS & TURNTABLE bolt end cover bolt hole relationship to housing port bosses. 17. Assemble the commutator ring (6) over alignment studs onto the manifold. 18. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. 19. If shuttle valve components items #21, were removed from the end cover (2) turn a plug (21), loosely into one end of the valve cavity in the end cover.
SECTION 3 - CHASSIS & TURNTABLE 21. Assemble the 5 or 7 special bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22-26 ft. lbs. 45-55 ft. lbs.(61-75 N m) for the seven 3/8-24 threaded bolts. 22. Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. lbs.
SECTION 3 - CHASSIS & TURNTABLE 3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines. the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force. NOTE: If the manifold side of the rotor was etched during Torqlink disassembly, this side should be up.
SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BEARING Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. Inner Race Bolt Outer Race Bolt Inner Bearing Cup Swing Motor Bearing Swing Arm Figure 3-16.
SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance Swing Bearing Removal 1. From the underside of the machine, at rear center, with the main boom fully elevated and fully retracted, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. See Figure 3-17., Swing Bearing Tolerance Measuring Point 2.
SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Installation ble. If it is not, manually rotate the outer race using the 7/8 hex until the soft spot is located as shown. 1. Place the swing drive on a table. 2. Place the bearing on the housing making sure the grease fitting is aligned in the proper location. 3. On the underside of the bearing, assemble two screws loosely in the counterbored holes. 4.
SECTION 3 - CHASSIS & TURNTABLE shown below. Tighten all bolts to an initial torque of 115 ft.lbs. (155 Nm) w/Loctite. CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS THEREAFTER. Swing Drive Checks THESE TWO BOLTS ARE SHORTER THAN THE REST There are three visual checks that can be used to determine if the swing drive is worn. Gently rock the boom back and forth and look for the following: 1.
SECTION 3 - CHASSIS & TURNTABLE NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-19.
SECTION 3 - CHASSIS & TURNTABLE 3.15 ENGINE Checking RPM Level NOTE: Refer to the engine manufacturer’s manual for detailed operating and maintenance instructions. Throttle & Choke Adjustment 1. Connect the JLG Analyzer to the ground control box. Refer to Section 6.2, To Connect the JLG Control System Analyzer. 2. Set the Analyzer to Access Level 2. Refer to Section 6.4, Changing the Access Level of the Hand Held Analyzer. 1. Start the engine. 3. Use the right arrow key TICS.
SECTION 3 - CHASSIS & TURNTABLE Choke Actuator If a new carburetor is needed, the choke detent must be removed from the new carburetor in order to make the choke actuator function freely. Use the following procedure. 1. Remove the choke set from the carburetor by carefully opening the slot in the choke shaft to remove the choke plate and pull the shaft out the top. 2. Carefully file or grind the choke detent away. 3. Replace the choke shaft and choke plate. Checking Oil Level 4. Remove the dipstick. 1.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. Engine Assembly Fuel Tank Heat Shield Starter 5. 6. 7. 8. Air Filter Carburetor Muffler Dipstick 9. 10. 11. 12. Throttle Relay Voltage Regulator Choke Relay Engine Stop Relay 13. 14. 15. 16. Engine Mounting Plate Throttle Solenoid Actuator Choke Solenoid Actuator Pump 17. 18. 19. 20. Pump Coupling Oil Fill Plug Battery Battery Hold-Down Figure 3-20.
SECTION 3 - CHASSIS & TURNTABLE 3.16 OUTRIGGER CYLINDER AND STABILIZER 5. At the opposite end of the cylinder, remove the bolt and keeper securing the pin and remove the pin. Removal 1. Using the analyzer and service mode, lower the outrigger cylinder to be removed but DO NOT lower enough that the outrigger is supporting any of the machine’s weight. 2. Place an appropriate lifting strap around the cylinder and use an adequate lifting device to support the weight of the cylinder.
SECTION 3 - CHASSIS & TURNTABLE Installation 1. If removed, position the stabilizer in place on the frame and install the pin, keeper, and bolt that connects the stabilizer to the frame. 2. If removed, install the cylinder cover on the cylinder. Using an adequate lifting device, position the cylinder in place on the machine. NOTE: The outrigger cylinder weighs approximately 48 lbs. (22 kg). 3. Install the bolt and keeper securing the pin at the pad end of the stabilizer and install the pin.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. Outrigger Pad Stabilizer Cylinder Cover Cylinder Pad Rod Bolt 7. 8. 9. 10. 11. Keeper Pin Outrigger Pin Retaining Cup Outrigger Cam Pin Figure 3-21.
SECTION 3 - CHASSIS & TURNTABLE 3.17 OUTRIGGER LIMIT SWITCHES A mechanical limit switch at each outrigger senses the outrigger has been set. The control system reports status of each outrigger through the analyzer and also displays a solid lit LED at the ground control when set. All outriggers must be set prior to leveling.
SECTION 3 - CHASSIS & TURNTABLE 4. Repeat step 3 for the left front, right rear, and left rear outriggers. 5. Power to operate the retract function can be supplied from any 12 volt power source. Connect the harness’ red alligator clip to positive and the black alligator clip to negative. 6. Located on the harness is a push button switch. Pushing the switch will activate all five solenoids, the four on the outrigger cylinders and the one on the control valve.
SECTION 3 - CHASSIS & TURNTABLE 3. If the board has been replaced or the tilt sensor is not calibrated, connect an analyzer to the machine at the ground control console and calibrate tilt sensor. Enter Level 2 in Analyzer and use the right arrow key Setup When Machine Is Not on Firm Level Surface and Adjustment Procedure: to scroll to Calibrations. Next use the down arrow to reach TILT SENSOR. ENTER key Then press the . 1. Connect an analyzer to the machine at the ground control console.
SECTION 3 - CHASSIS & TURNTABLE 3.20 DRIVE & SET The Drive & Set Option is used to position the machine after it has been towed to the job site. Before the drive function can be operated, the machine must be in the stowed position and the hand brake set.
SECTION 3 - CHASSIS & TURNTABLE In order to use Drive & Set, the following conditions must be met: Drive & Set Interlocks • The machine must be stowed • Turntable position so basket is over tongue Proximity switch below the tower link (on boom rest) to sense boom is on rest. This switch will self monitor and be able to sense it is alive upon power up. • Telescoped fully in • Boom not elevated 2. Hand brake set switch • Hand brake set Proximity Switch to sense location of brake release cylinder.
SECTION 3 - CHASSIS & TURNTABLE Adjust the limit switch to be 0.125 inches, +0.063 -0 (3.175 mm, +1.600 -0) from the tower link when the boom is fully lowered into the transport position. 3 4 9 10 5 1 8 11 2 7 10 8 * 1. 2. 3. 4. 5. 6. 6 * Apply Loctite #242 and torque bolt to 190 ft. lbs. (258 Nm) Flow Divider Drive Enable Valve Proximity Sensor Propulsion Module Drive Engagement Release Valve Brake Release Cylinder 7. 8. 9. 10. 11.
SECTION 3 - CHASSIS & TURNTABLE 2 Adjust the limit switch so clearance between the switch and cylinder is 0.125 inches, +0.063 -0 (3.175 mm, +1.600 -0). Adjust the switch mounting so the cylinder barrel moves forward completely off the target zone of the limit switch when the parking brake is engaged. 11 3 5 9 1 Figure 3-23.
3-70 – JLG Lift – DRIVE DIRECTIONAL VALVE BOTTOM FLOW DIVIDER TOP DRIVE ENGAGEMENT RELEASE VALVE BRAKE RELEASE CYLINDER Figure 3-24. Drive and Set Circuit DRIVE ENGAGE CYLINDER Right and left motors designation are determined by the operator standing in the platform.
SECTION 3 - CHASSIS & TURNTABLE 3.21 DRIVE MOTOR Disassembly and inspection 1. Place the Torqlink™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port O-Rings (18A) if applicable. 3. Remove the five, six, or seven special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head.
SECTION 3 - CHASSIS & TURNTABLE 1. Special Bolts 2. End Cover 3. Seal Ring-Commutator 4. Seal Ring 5. Commutator Ring 6. Commutator Ring 7. Manifold 8. Rotor Set 8A.Rotor 8B. Stator or Stator Vane 8C. Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 12. Coupling Shaft 13. Bearing/Bushing, Inner 14. Thrust Washer 15. Thrust Bearing 16. Seal 17. Back-up Washer 18. Housing 18A. O-Ring 19. Bearing/Bushing, Outer 20. Dirt & Water Seal 21. Plug Figure 3-25. Swing Drive Motor 5.
SECTION 3 - CHASSIS & TURNTABLE 6. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. 8. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring.
SECTION 3 - CHASSIS & TURNTABLE NOTE: The manifold is constructed of plates bonded together to form an integral component not subject tofurtherdisassemblyforservice.Compare configuration of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set. 10. Remove rotor set (8) and warplane (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces.
SECTION 3 - CHASSIS & TURNTABLE 12. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and discard seal ring (4) from housing (18). 15. Remove coupling shaft (12), by pushing on the output end of shaft.
SECTION 3 - CHASSIS & TURNTABLE 17. Remove thrust bearing (15) and thrust washer (14) Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 19. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required. 18. 20. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics.
SECTION 3 - CHASSIS & TURNTABLE 21. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. The bushing (19) or (13) to coupling shaft diameter clearance must not exceed 0.
SECTION 3 - CHASSIS & TURNTABLE Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. NOTE: Individual seals and seal rings as well as a complete seal kit are available. The parts should be available through most OEM parts distributors or Parker approved Torqlink™ distributors. (Contact your local dealer for availability).
SECTION 3 - CHASSIS & TURNTABLE 2. The Torqlink™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/bushing (19). 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing.
SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. 5. On the Torqlinks™ assemble a new backup washer (17) and new seal (16) with the seal lip facing toward the inside of Torqlink™, into their respective counterbores in housing (18) if they were not assembled in procedure 2. 6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Torqlink™.
SECTION 3 - CHASSIS & TURNTABLE THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT #K-70M. NOTE: Mobil Mobilith SHC ® 460 NOTE: A 102Tube (P/N 406010) is included in each seal kit. NOTE: The coupling shaft (12) will be flush or just below the housing wear plate surface on Torqlinks™ when properly seated.
SECTION 3 - CHASSIS & TURNTABLE 12. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (8B). 14. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7). 13. Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side down and the splines into mesh with the drive link splines.
SECTION 3 - CHASSIS & TURNTABLE bolt end cover bolt hole relationship to housing port bosses. 17. Assemble the commutator ring (6) over alignment studs onto the manifold. 18. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up. 19. If shuttle valve components items #21, were removed from the end cover (2) turn a plug (21), loosely into one end of the valve cavity in the end cover.
SECTION 3 - CHASSIS & TURNTABLE 21. Assemble the 5 or 7 special bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22-26 ft. lbs. 45-55 ft. lbs.(61-75 N m) for the seven 3/8-24 threaded bolts. 22. Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9-12 ft. lbs.
SECTION 3 - CHASSIS & TURNTABLE 3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines. the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force. NOTE: If the manifold side of the rotor was etched during Torqlink disassembly, this side should be up.
SECTION 3 - CHASSIS & TURNTABLE 3.22 BATTERIES (ELECTRIC MACHINES) The electrical system is a 24 volt system, supplied by four, six volt, 220 amp-hour batteries. Two batteries are located on the right side of the frame and two are located on the left side. A gray quick disconnect is used to disconnect electrical power between the batteries and the machine if needed. NOTE: Battery weight is important for stability. Each battery weighs 59 lbs. (26.8 kg). Do not use batteries that are not approved by JLG.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. 6. 7. 8. Contactor Assembly Fuse Clamping Bar Relay Battery Battery Pad Tie Down Strap Rubber Tape Figure 3-26.
SECTION 3 - CHASSIS & TURNTABLE A Apply Dielectric Grease B Torque M6 Bolts to 60 (7 1.4Nm) C Torque nuts on fuse to 120 in.lbs. (13.5 Nm) D Torque contactor nuts to 45 in.lbs. (5 Nm) 1 in.lbs. 9. Sevcon Controller 10. Relay 11. Ground Control Module Figure 3-26.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-26.
SECTION 3 - CHASSIS & TURNTABLE 3.23 BATTERY CHARGER Cover Removal 1. Remove the eight (8) screws on the sides of the charger cover and remove cover. (Prior to S/N 030000236) OPENING THE BATTERY CHARGER WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE CHARGER WARRANTY. IF UNDER WARRANTY REQUEST A REPLACEMENT CHARGER. BEFORE REPLACING ANY COMPONENT, USE THE CHARGER MANUFACTURERS TROUBLESHOOTING GUIDE FOR CHECKING THE INTERNAL AC AND DC CIRCUITS TO DETERMINE WHICH COMPONENT HAS FAILED.
SECTION 3 - CHASSIS & TURNTABLE Printed Circuit Board Replacement Interlock Relay Replacement 1. Disconnect the wide wiring connector from the end of the circuit board. 1. Disconnect the wiring connected to the relay. 2. Remove the two (2) nuts securing the interlock relay to the chassis base. 2. Remove the four (4) screw attaching the card to the front face of the charger chassis. 3. Remove the relay. SCR Rectifier Replacement (Either Side) 1. Remove the wiring from the SCR Rectifier. 2.
SECTION 3 - CHASSIS & TURNTABLE AC Circuit Breaker Replacement DC Circuit Breaker Replacement 1. Disconnect wiring connected to the breaker poles. 1. Remove the wiring from the DC breaker terminals. 2. Remove the two (2) nuts securing the AC breaker to the chassis screws. 2. To remove the breaker from the front face of the charger, on the inside of the charger front face, push in on the tabs located on the sides of the breaker assembly and remove the breaker out the front of the charger.
SECTION 3 - CHASSIS & TURNTABLE Figure 3-27.
SECTION 3 - CHASSIS & TURNTABLE 1. 2. 3. 4. 5. Selector Switch AC Circuit Breaker Interlock Relay Varistor Shunt Assembly 6. 7. 8. 9. 10. DC Harness DC Circuit Breaker SCR Rectifier Transformer Circuit Card Figure 3-28.
SECTION 3 - CHASSIS & TURNTABLE 3.24 BATTERY CHARGER 4.If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error. (S/N 030000199 to 030000225 & S/N 030000236 to Present) Maintenance Instructions 1. For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instructions recommended by the battery manufacturer.
SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-96 – JLG Lift – 3121198
SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM AND CYLINDER ASSEMBLY NOTE: The boom and cylinder assemblies weigh approximately 1130 lbs. (513 kg). Removal 1. Using an adequate supporting device, support the weight of the boom and cylinders assembly. 6. Lift the assembly away from the machine and lower it onto proper supporting devices. Installation NOTE: The boom and cylinder assemblies weigh approximately 1130 lbs. (513 kg). 2.
SECTION 4 - BOOM & PLATFORM 4.2 MAIN BOOM the machine and place it on proper supports for servicing. Removal NOTE: Prior to removing the boom, it will be helpful to extend the boom fly section out far enough to access the telescope cylinder retaining pin if the boom is to be disassembled. 1. Using an adequate lifting device, support the weight of the main boom. NOTE: The main boom weighs approximately 626 lbs. (284 kg). 2. To gain access to the tele cylinder, remove the master cylinder.
SECTION 4 - BOOM & PLATFORM 2. Remove the bolt, keeper pin, and upper pivot pin securing the platform pivot. 5. Remove the bolts securing the telescope cylinder to the boom base section. 3. Remove the pivot from the boom assembly. 6. Remove the retaining rings and attach pins securing the telescope cylinder to the boom fly section. NOTE: The pivot weighs approximately 19 lbs. (9 kg). 4. Remove the slave cylinder. Refer to Section 4.4, Slave Cylinder. 3121198 – JLG Lift – 7.
SECTION 4 - BOOM & PLATFORM NOTE: The telescope cylinder weighs approximately 110 lbs. (50 kg). Assembly 8. Remove the wear pads from the front of the boom base section. 1. If removed, install the wear pads and shims onto the rear of the fly section. Apply loctite #242 to the bolts and torque to 35 ft.lbs. (47 Nm). 9. Pull the fly section out of the base section. 2. Install the fly section into the base section. NOTE: The boom fly section weighs approximately 125 lbs. (57 kg.
SECTION 4 - BOOM & PLATFORM 4. Push the telescope cylinder into the rear of the boom. 6. Apply Loctite #242 to the bolts and secure the telescope cylinder to the boom base section. Torque the bolts to 85 ft. lbs. (115 Nm) NOTE: The telescope cylinder weighs approximately 110 lbs. (50 kg). 7. Install the slave cylinder. Refer to Section 4.4, Slave Cylinder. 5. Install the retaining rings and attach pins securing the telescope cylinder to the boom fly section. 8.
SECTION 4 - BOOM & PLATFORM 9. Install the bolt, keeper pin, and upper pivot pin securing the platform pivot to the boom. NOTE: The main boom weighs approximately 626 lbs. (284 kg). 10. Install the bolt, keeper pin, and lower pivot pin securing the platform pivot to the boom. 2. Install the pivot pin, nut, and bolt securing the top of the timing link to the boom. 3. Install the pivot pin, keeper pin, and bolt securing the rod end of the lift cylinder to the boom. Installation 1.
SECTION 4 - BOOM & PLATFORM 4.3 MASTER CYLINDER Installation 1. Lift the master cylinder into position and install the pivot pin and retaining pin into the barrel end of the cylinder. Removal 1. Swing the boom away from the tongue. 2. Place a suitable support or blocking under the platform pivot. 3. Tag and disconnect the hoses running to the master cylinder. Cap or plug all open ends. 4. Remove the retaining pins and pivot pin from the rod end of the cylinder.
SECTION 4 - BOOM & PLATFORM 4.4 SLAVE CYLINDER Installation 1. Lift the slave cylinder into position and install the pivot pin and retaining pin into the barrel end of the cylinder. Removal 1. Swing the boom away from the tongue. 2. Place a suitable support or blocking under the platform pivot. 3. Tag and disconnect the hoses running to the slave cylinder. Cap or plug all open ends. 4. Remove the retaining pins and pivot pin from the rod end of the cylinder.
SECTION 4 - BOOM & PLATFORM 1. 2. 3. 4. 5. Boom & Cylinders Assembly Keeper Bolt Retaining Pin Pivot Pin Boom Rest 6. 7. 8. 9. 10. Gravity Lock Pin Main Boom Tower Boom Tower Boom Link Master Cylinder 11. 12. 13. 14. 15. Lift Cylinder Upright Timing Link Powertrack Slave Cylinder Figure 4-1.
SECTION 4 - BOOM & PLATFORM 4.5 BOOM SENSORS Boom Elevation Limit Switch There are two mechanical sensors that are standard on the machine which sense the boom state. One is located on the side of the base boom and senses when the boom is fully telescoped in. The other sensor, which is mounted to the side of the upright, senses whether the main boom is elevated and is activated by a cam on the lift cylinder bushing. BOOM ELEVATION LIMIT SWITCH 1. Set the limit switch to trip at 3.
SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEM When assembling connectors in the hydraulic that use oring fittings, it is necessary to lubricate all fittings with hydraulic oil prior to assembly. To lubricate the fittings, use one of the following procedures. 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the fitting, making sure the entire o-ring is completely saturated.
SECTION 5 - HYDRAULICS Dip Method Spray Method NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. This method requires a pump or trigger spray bottle. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this manner: 2. Hold the fitting over a suitable catch can. 3. Spray the entire o-ring surface with a medium coat of oil.
SECTION 5 - HYDRAULICS 5.2 CYLINDER REPAIR Inspection Disassembly DO NOT ATTEMPT TO SERVICE A HYDRAULIC CYLINDER WHILE IT IS INSTALLED. THE CYLINDER MUST BE REMOVED FROM THE MACHINE AND ALL PRESSURE MUST BE RELIEVED. AIR MUST NOT BE USED TO EXTEND OR RETRACT THE CYLINDER. SAFETY GLASSES MUST BE WORN AT ALL TIMES BY SERVICE PERSONNEL. 1. Inspect all seals, backup rings, wipers, and wear rings for tears, grooves, foreign matter, and excessive wear.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Cylinder Head Cylinder Rod Piston Barrel 5. O-ring 6. O-ring 7. Rod Seal 8. Backup Ring 9. 10. 11. 12. Wiper Wear Ring Piston Seal Locknut 13. 14. 15. 16. Bushing Cartridge Cartridge Plug Figure 5-1.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Cylinder Head Cylinder Rod Piston Barrel O-ring 6. O-ring 7. Rod Seal 8. Backup Ring 9. Wiper 10. Wear Ring 11. 12. 13. 14. 15. Piston Seal Locknut Bushing Cartridge Check Cartridge 16. 17. 18. 19. Pilot Check Cartridge Relief Cartridge Plug Spacer Figure 5-2.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. Cylinder Head Cylinder Rod Piston Barrel 5. O-ring 6. O-ring 7. Rod Seal 8. Backup Ring 9. Wiper 10. Wear Ring 11. Piston Seal 12. Locknut 13. Bushing Figure 5-3.
SECTION 5 - HYDRAULICS 19 18 17 19 3 17 5 9 8 4 11 10 11 16 15 13 12 2 14 17 1 17 ORIENT SOLENOID VALVE AS SHOWN 1. 2. 3. 4. 5. Cylinder Rod Cylinder Head Barrel Piston Locknut 6. Not Used 7. Not Used 8. T-Seal 9. Wear Ring 10. O-ring 11. 12. 13. 14. 15. Backup Ring Rod Seal Wear Ring Wiper O-ring 16. 17. 18. 19. Backup Ring Bushing Cartridge Plug Figure 5-4.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Cylinder Head Cylinder Rod Piston Barrel O-ring 6. 7. 8. 9. 10. O-ring O-ring Rod Seal Backup Ring Wiper 11. 12. 13. 14. Wear Ring Wear Ring Piston Seal Locknut 15. 16. 17. 18. Wear Pad Counterbalance Cartridge Counterbalance Cartridge Shuttle Cartridge 19. 20. 21. 22. Plug Bolt Locknut Spacer Figure 5-5.
SECTION 5 - HYDRAULICS Assembly Cylinder INSPECT ALL COMPONENTS AS DESCRIBED UNDER INSPECTION. CLEAN ALL COMPONENTS WITH A LINT-FREE CLOTH. THE BARREL SHOULD BE FLUSHED OUT AND DRAINED. COMPRESSED AIR MUST BE USED TO BLOW OUT THE BARREL BORE AND ALL PORTS. LUBRICATE ALL SEALS WITH HYDRAULIC FLUID PRIOR TO ASSEMBLY. Telescope, Slave, Master 350 ft.lbs. (475 Nm) Lift 150 ft.lbs. (203 nm) FINAL ASSEMBLY 1. Ensure all rags, etc. are removed from the barrel bore.
SECTION 5 - HYDRAULICS 5.3 PRESSURE SETTING PROCEDURE Platform Level Up Cold temperatures have a significant impact on pressure readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal operating temperatures prior to checking pressures. JLG Industries Inc. also recommends the use of a calibrated gauge. Pressure readings are acceptable if they are within ± 5% of specified pressures. 1.
SECTION 5 - HYDRAULICS Figure 5-6.
SECTION 5 - HYDRAULICS Outrigger Up 5.5 1. Install a pressure gauge at the port marked "G" located on top of the block. 2. Plug and cap the hose on port "RA", or activate outrigger in until the cylinders are all bottomed out. 3. The gauge should read 2500 psi. (172.5 bar). 4. The outrigger relief valve is located on the front face below the lift push button manual descent valve. To increase, screw clock wise, to decrease screw counter clock wise. 5.4 HYDRAULIC OIL FILL AT STARTUP 1. Fill the tank.
SECTION 5 - HYDRAULICS Table 5-1. Control Valve Torque Values Ft-Lbs. Nm Ft-Lbs. Nm Ft-Lbs. Nm 1 23-24 31-32.5 5 17-19 23-26 9 4-5 5.5-6.75 2 4.5 6 6 43-48 58-65 10 9.3 12.5 3 13-15 17.5-20 7 24-26 32.5-35.25 11 25-28 34-38 4 28-33 38-45 8 18.5-22 25-30 12 154-170 209-230.5 Figure 5-7.
SECTION 5 - HYDRAULICS Table 5-2. Control Valve Torque Values Ft-Lbs. Nm Ft-Lbs. Nm Ft-Lbs. Nm 1 23-24 31-32.5 5 17-19 23-26 9 4-5 5.5-6.75 2 4.5 6 6 43-48 58-65 10 9.3 12.5 3 13-15 17.5-20 7 24-26 32.5-35.25 11 25-28 34-38 4 28-33 38-45 8 18.5-22 25-30 12 154-170 209-230.5 Figure 5-7.
SECTION 5 - HYDRAULICS 1. 2. 3. 4. 5. Left Drive Valve Shuttle Valve (LS2) Right Drive Valve EP2 EP1 6. 7. 8. 9. Pressure Check Shuttle Valve (LS1) Shuttle Valve (LS3) Counterbalance Valves Figure 5-7.
SECTION 5 - HYDRAULICS Ft-Lbs. Nm A 18-20 24-27 B 30-35 41-47 C 35-40 47-54 Figure 5-8.
SECTION 5 - HYDRAULICS NOTE: All cartridges are torqued 18-20 ft.lbs. (24-27 Nm). The solenoid valve is to be torqued 25-27 ft.lbs. (34-36.5 Nm). There is no torque specification for the filter. 1. 2. 3. 4. 5. 6. Pressure Regulator (PR1) Check Valve (CV1) Relief Valve (RV1) Relief Valve (RV2) Solenoid Valve (SV1) Filter (F1) Figure 5-9.
SECTION 5 - HYDRAULICS Figure 5-10.
SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 INTRODUCTION The JLG designed Control System is a 12 volt based control unit installed on the boom lift. WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS AND PROPERLY CALIBRATE THE TILT SENSOR. IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.
SECTION 6 - JLG CONTROL SYSTEM 6.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER 6.3 USING THE ANALYZER 1. Connect the cable supplied with the analyzer, to the controller module in the ground control box and connect the remaining end of the cable to the analyzer. NOTE: The cable has a four pin connector at each end of the cable; the cable cannot be connected backwards. 2. Power up the Control System by turning the key to the ground position and pulling the emergency stop button on.
SECTION 6 - JLG CONTROL SYSTEM If ENTER is pressed again, the display moves to the following display: 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 which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level, the correct password must be entered.
SECTION 6 - JLG CONTROL SYSTEM Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly: 6.5 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER 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: MENU: ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.
SECTION 6 - JLG CONTROL SYSTEM 6.6 MACHINE SETUP When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: The effect of the machine digit value is displayed along with its value. The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when lifting down. There are certain settings allowed to install optional features or select the machine model.
6-6 (See Figure 6-5.) or (See Figure 6-6.) (See Figure 6-4.) – JLG Lift – Figure 6-2. Analyzer Flow Chart NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration. (See Figure 6-3.
3121198 – JLG Lift – Figure 6-3. Analyzer Flow Chart - Diagnostics NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
6-8 – JLG Lift – Figure 6-4. Analyzer Flow Chart - Personalties NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
SECTION 6 - JLG CONTROL SYSTEM 6.7 SYSTEM TEST 4. The analyzer screen should read: The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures. Platform Test 1. Position the Platform/Ground select switch to the Platform position. 2. Plug the analyzer into the connector at the base of the platform control box. 5. Use the arrow button to reach SYSTEM TEST. Hit Enter.
Figure 6-5.
SECTION 6 - JLG CONTROL SYSTEM Ground Test 5. Use the 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. 1.Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 6. Follow the flow path in Figure 6-6., System Test Flow Chart - Ground Station Tests and go through the component tests.
SECTION 6 - JLG CONTROL SYSTEM 6.8 USER FAULT CODES Table 6-1. User Fault Codes A single digit fault code blinks on the Platform and the Ground control panel to signal the operator of a procedure fault. Refer to Table 6-1, User Fault Codes. Table 6-1.
Figure 6-6.
SECTION 6 - JLG CONTROL SYSTEM J1 NATURAL 35 PIN Refer to Figure 6-8. J7 BLACK 35 PIN Refer to Figure 6-11. J2 GREY 35 PIN Refer to Figure 6-9. J4 BLUE 35 PIN Refer to Figure 6-10. J3 BLACK 14 PIN Refer to Figure 6-10. Figure 6-7.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-8.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-9.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-10.
SECTION 6 - JLG CONTROL SYSTEM Figure 6-11.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2.
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Model Adjustments and Speeds - ANSI & CSA ADJUSTMENT1,4 FUNCTION MODEL TIME RANGE (SECONDS)2,3 MODEL DEFAULTS RANGES5 T350 Electric T350 Gas T500J Electric T500J Gas ACCEL 0.1 to 5.0 sec 0.1 0.1 0.1 0.1 DECEL 0.1 to 3.0 sec 0.1 0.1 0.1 0.1 MIN UP 0 to 25% (75%) 12 53 12 53 MAX UP 0 to 50% (85%) 27 72 27 72 MIN DOWN 0 to 25% (75%) 12 53 12 53 MAX DOWN 0 to 50% (85%) 27 72 27 72 0.1 to 5.0 sec N/A N/A 2.5 2.
SECTION 6 - JLG CONTROL SYSTEM Table 6-3.
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Model Adjustments and Speeds - CE Only ADJUSTMENT1,4 FUNCTION MODEL TIME RANGE (SECONDS)2,3 MODEL DEFAULTS RANGES5 T350 Electric T350 Gas T500J Electric T500J Gas ACCEL 0.1 to 5.0 sec 0.1 0.1 0.1 0.1 DECEL 0.1 to 3.0 sec 0.1 0.1 0.1 0.1 MIN UP 0 to 25% (75%) 12 53 12 53 MAX UP 0 to 50% (85%) 27 72 27 72 MIN DOWN 0 to 25% (75%) 12 53 12 53 MAX DOWN 0 to 50% (85%) 27 72 27 72 0.1 to 5.0 sec N/A N/A 2.5 2.
SECTION 6 - JLG CONTROL SYSTEM 6.9 MACHINE ORIENTATION WHEN SETTING SPEEDS Test Notes LIFT: Telescope retracted, lift up, and record time. Lift down and record time SWING: Boom lift at full elevation, telescope retracted, swing 360 degrees and record time. Swing opposite 360 degrees and record time. TELESCOPE: Boom lift at full elevation, telescope out and record time. Tele in and record time. JIB: Record time for full stroke of jib. 3121198 – JLG Lift – 1.
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Configuration Digit Setting Description Market Default 1 (MODEL#) 0 1 T350 - 35ft. T500 - 50ft. 0 2 (POWER) 0 1 Electric - 24V Battery Engine - Honda Gasoline 0 3 (DRIVE)3 0 1 NO - Drive option not installed. YES - Drive option is installed.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL This section contains basic electrical information and schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing continuity Figure 7-2. Resistance Measurement • First test meter and leads by touching leads together.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an open. If the meter was reading open it should read short. 5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will be connected. The test is similar to testing a switch with two terminals. a.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches 7.4 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate. Silicone Dielectric Compound must be used on all electrical connections for the following reasons: 1.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or asshipped, position (See Figure 7-5.). Proceed as follows: Applying Silicone Dielectric Compound to AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-7. Connector Assembly Figure 2 3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8.). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 2. Pry open the wedge lock to the open position. 3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.6 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly A A B B C C D Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly B A A C C Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact crimp barrel. 1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a positive stop is felt.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS GROUND CONTROL BOX AC OUTLET BOX STROBE LIGHT DRIVE PROXIMITY SWITCHES (OPTIONAL) DRIVE DIRECTIONAL VALVE (OPTIONAL) MOTION ALARM LIFT DOWN PROP VALVE IGNITION RELAY J8 J1 J7 J2 TRANSPORT/ABOVE LEVEL LIMIT SWITCH J3 VALVE/MOTOR/TANK (MOTOR SIDE) (ELECTRIC POWERED MACHINE SHOWN) J4 TELESCOPE LIMIT SWITCH O/R JACK LIMIT SWITCH O/R JACK VALVE O/R JACK VALVE O/R JACK LIMIT SWITCH VALVE/MOTOR/TANK (TANK SIDE) O/R JACK LIMIT SWITCH O/R JACK V
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS PLATFORM CONSOLE LOCATED ON T/T AT LIFT HOOK STOW DRIVE ENABLE VALVE (OPTIONAL) J1 LOCATED AT PLATFORM PIVOT J2 DRIVE MODULE (OPTIONAL) TO ANALYZER B– F1 B+ SEVCON MODULE (ELECTRIC POWERED) JIB VALVE (T500J ONLY) P CONTACTOR (ELECTRIC POWERED) BATTERY CHARGER (ELECTRIC POWERED) F2 M1 M2 BATTERIES (ELECTRIC POWERED) LEFT SIDE MARKER LIGHT WITH DRIVE OPTION ONLY ON TOW VEHICLE TOW VEHICLE CHOKE COIL RIGHT SIDE MARKER LIGHT THROTTLE CO
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Table 7-1. Connector Identification Table 7-1.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Table 7-1. Connector Identification CONNECTOR X095 X096 X097 X098 X099 X100 X101 X102 X103 X104 X105 X106 X107 X108 X109 X110 X111 X112 X113 X114 X115 X116 7-16 DESCRIPTION Engine Mag Pickup Engine Rectifier Engine Throttle Coil Engine Choke Coil Engine Powered, Battery Pos. Engine Powered, Battery Neg. Power Module (Sevcon), BPower Module (Sevcon), B+ Power Module (Sevcon), M1 Power Module (Sevcon), M2 Sevcon Power Cable In-line 6V Batt 1, Pos.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870172 I Figure 7-22.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CE SPECS WITH ELECTRIC BRAKES ANSI & ANSI EXPORT SPECS WITH ELECTRIC BRAKES Figure 7-23.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ANSI & ANSI EXPORT SPECS WITH HYDRAULIC BRAKES 1870185 C Figure 7-24.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AUSTRALIAN & SOUTH AFRICA SPECS WITH HYDRAULIC BRAKES AUSTRALIAN & SOUTH AFRICA SPECS WITH ELECTRIC BRAKES 1870185 C 1870185 C Figure 7-25.
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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-27.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-29.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-30.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-31.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-33.
SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-32 – JLG Lift – 3121198
3121198 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +61 2 65 811111 +61 2 65813058 +55 19 3295 1025 JLG Deutschland GmbH Max-Planck-Str.
