JLG 450AJ Service Manual

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Service and Maintenance Manual

Model

450A

450AJ

3120869

February 16, 2000

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

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.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECU RE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SA FELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

3120869 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

May, 1998 - Original Issue August 5, 1999 - Revised 2-54 thru 2-57 - Updated 10-12-99 2-59 - Updated 10-12-99 1-4 thru 1-6 - Updated 11-1-99 2-26 - Updated 11-1-99 1-2 and 1-3 - Updated 2-16-00 2-59 thru 2-62 - Updated 2-16-00

A-2 – JLG Lift – 3120869

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

B Hydraulic System Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Component Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Specifications and Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.5 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.7 Pressure Settings - PSI (Bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.8 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.10 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.11 Function Speeds (in Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1.12 Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

SECTION 2 - PROCEDURES

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.4 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.5 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.6 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.7 Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2.8 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.9 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.10 Mid and Lower Lift Cylinder Bleeding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2.11 Hydraulic Pump (gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2.12 Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2.13 Worm gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2.14 Boom Synchronizing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2.15 Extend-A-Reach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2.16 Adjustment Procedure For Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2.17 Torque Hub (Prior to S/N 39594) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

2.18 Torque Hub (S/N 39594 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

2.19 Drive Brake (Ausco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

2.20 Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

2.21 Lift Up and Platform Level Down Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

2.22 Throttle Checks and Adjustments - Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

2.23 Drive and Steer Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

2.24 Lift and Swing Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

2.25 Function Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

2.26 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

2.27 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

2.28 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .2-59

2.29 Semi-Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

2.30 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

3120869 – JLG Lift – i

TABLE OF CONTENTS

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

2-1. Location of Components - Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2-2. Location of Components - Removal of Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3. Location of Components - Front Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-4. Boom Prop Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-5. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-6. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-7. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-8. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-9. Gar-Max Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-10. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-11. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-12. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-13. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-14. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-15. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-16. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-17. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

2-19. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-18. Swing Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

2-20. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

2-21. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-22. Synchronizing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2-23. Extend-A-Reach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-24. Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

2-25. Ring Gear/Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

2-26. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-27. Torque Hub (Prior to S/N 39594) - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-28. Torque Hub (Prior to S/N 39594) - Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2-29. Torque Hub (S/N 39594 to Present) - Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

2-30. Cluster Gear Punch Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

2-31. Drive Brake (Ausco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

2-32. Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

2-33. Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

2-34. Addco Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

2-35. Drive and Steer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

2-36. Lift and Swing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

2-37. Function Control Card Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

2-38. Tilt Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

2-39. Main Valve (Proportional Controls) - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

2-40. Main Valve (Proportional Controls) - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

2-41. Valve Location - Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

ii – JLG Lift – 3120869

TABLE OF CONTENTS

LIST OF FIGURES (continued)

FIGURE NO. TITLE PAGE NO.

3-1. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-2. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-3. Electrical Schematic - Boom, Turntable, Chassis - Deutz - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . .3-22

3-4. Electrical Schematic - Boom, Turntable, Chassis - Deutz - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . .3-23

3-5. Electrical Schematic - Platform -Deutz - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-6. Electrical Schematic - Platform -Deutz - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-7. Hydraulic Schematic - Proportional Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-3 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-4 Mobil EAL Envirosyn H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-5 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-7 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-8 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-2 Holding Valve Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-3 Hydraulic Pump Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-4 Position Controller Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

2-5 Adjustment Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2-6 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

3-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3 Turntable Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-4 Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-5 Hydraulic System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-6 Electrical System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3120869 – JLG Lift – iii

TABLE OF CONTENTS

This Page Left Blank Intentionally.

iv – JLG Lift – 3120869

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank - 62.5 liters

Hydraulic Oil Tank - 106 liters

Torque Hub - 0.5 liters

NOTE: Torque hubs should be one half full of lubricant.

Engine Crankcase (Ford LRG425) - 4.5 L

Engine Crankcase (Deutz F3M1011F) - 6 L

1.2 COMPONENT DATA

Engine - Deutz F3M1011F

Fuel - Diesel

No. of Cylinders - 3

BHP at Max. RPM - 48

RPM Setting (No Load) - Mid - 1500

1.3 TIRES

12x16.5

1.4 SPECIFICATIONS AND PERFORMANCE DATA

Max. Platform Height - 13.8 M

Max. Horizontal Reach - 7.3 M

Unrestricted Rated Capacity - 230kg

Maximum Capacity - 230 kg

Maximum Tire Load (450A) - 3230 kg

Maximum Tire Load (450AJ) - 3357 kg

Overall Width - 1.98 m

Tai lsw in g - Z ero

Stowed Height - 2.24 m

Stowed Length - 6.15 m

Wheelbase - 1.98 m

Ground Clearance - 28 cm

Platforms - 0.76m x 1.22M

0.76m x 1.52M

0.76m x 1.83M

Rated Gradeability - 2WD -30% 4WD - 40%

• Pneumatic - 6 Bar

•Weight: 58 kg

12x16.5

• Fo am-Filled

• Weight: 149 kg

33/1550x16.5

• Pneumatic - 6 Bar

•Weight: 61 kg

33/1550x16.5

• Fo am-Filled

• Weight: 179 kg

33/16LL x 16.1

• Pneumatic - 3 bar

• Weight: 41.5 kg

33/16LL x 16.1

• Foam-Filled

• Weight: 193 kg

System Voltage - 12 Volts

Max. Hydraulic System Operating Pressure - 207 bar

Travel Speed (2WD) - 7.2 kph

Travel Speed (4WD) - 3.6 mph

Ground Bearing Pressure (450A)

12x16.5 pneu. - 3.23 kg/cm 12x16.5 FF - 3.93 kg/cm 33/1550x16.5 pneu. - 2.46 kg/cm 33/1550x16.5 FF - 3.51 kg/cm

Ground Bearing Pressure (450AJ)

12x16.5 pneu. - 3.37 kg/cm 12x16.5 FF - 4.07 kg/cm 33/1550x16.5 pneu. - 2.53 kg/cm 33/1550x16.5 FF - 3.65 kg/cm

3120869 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.5 TORQUE REQUIREMENTS

wear and rust protection characteristics as mineral oils, but will not adversely affect ground water or the environment when spilled or leaked in small amounts. Mobil

Table 1-1.Torque Requirements

Description Torque Value Interval Hours

Wheel Lugs 170 ft. lbs.

Semi-Track

Wheel Lugs

Swing Bearing

(Dry)

Swing Bearing

((Loctite)

(231 Nm)

90 ft. lbs.

(122 Nm)

220 ft. lbs.

(298 Nm)

240 ft. lbs.

(326 Nm)

150

50/600*

EAL224H has a viscosity of 34 cST at 40° C and a viscosity index of 213. The operating range of this oil is -18° C to +83° C.

IT IS RECOMMENDED THAT MOBIL EAL224H HYDRAULIC OIL BE STORED ABOVE FREEZING (0° C) AS THE OIL MAY APPEAR

CLOUDY AFTER EXPOSURE TO LOW TEMPERATURES FOR EXTENDED PERIODS OF TIME. THE CLOUDINESS WILL DISAPPEAR WHEN THE OIL IS WARMED TO AT LEAST 10° C AND AGITATED. DO NOT ATTEMPT TO "THIN" THE OIL WITH NO.2 DIESEL FUEL. FOR BEST RESULTS, STORE THE OIL ABOVE FREEZING.

* Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter.

NOTE: Accidentally mixing Mobil EAL224 H hydraulic oi l with

other mineral oils will cause no loss of performance characteristics. However, biodegradability may be

1.6 LUBRICATION

Hydraulic Oil

Table 1-2.Hydraulic Oil

Hydraulic System

Operating

Temperature Range

+0° to + 18 0° F

(-18° to +83 ° C)

+0° to + 21 0° F

(-18° to +99 ° C) +50° to + 2 10° F

(+10° to + 99° C

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient

S.A.E. Viscosity

Grade

10W

10W-20, 10W30

20W-20

reduced and toxicity may be increased, depending on the oil and level of contamination.

Lubrication Specifications

Table 1-3.Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpos e Grease having a minimum d ripping point of 350

degrees F. Excellent water resistance and adhesive qualities; and being of extreme p ressure type (Timken OK 40 po unds minimum).

EPGL Extreme Pressu re Gear Lube (oil) meeting API Se r-

vice Classification GL-5 or Mil-Spec Mil-L-2105.

HO Hydraulic Oil. API Service Classification GL-3, SAE

10W-20, Viscosity Index 152, e.g. Kendall Hyken 052.

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-

2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L2104C.

chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of

152.

NOTE: When temperatures remain consistently below 20

degrees F. (-7 degrees C.), JLG Industries recommends the use of Mobil DTE11.

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

Some machines may be specially equipped with Mobil EAL224H biodegradable and non-toxic hydraulic oil. This oil is vegetable oil based and possesses the same anti-

Updated 2-16-00

NOTE: Refer to Lubrication Chart for spe cific lubricatio n pr o-

cedures..

Table 1-4. Mobil EAL Envirosyn H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point, Max -44° F (-44° C)

Flash Point, Min. 500° F (260° C)

Weight

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity In dex 153

7.64 lb. per gal. (0.9 kg per liter)

1-2 – JLG Lift – 3120869

SECTION 1 - SPECIFICATIONS

1.7 PRESSURE SETTINGS - PSI (BAR)

Main Relief

Main Relief - 3000 (207)

Lift Up - 3000 (207) - Governed by Main Relief

Lift Down - 2500 (172) - Governed by Level Down Relief

Level Down - 2500 (172)

Level Up - 2500 (172)

Swing (Right & Left) - 1750 (121)

Drive

Drive - Pre-Set 4500 (310)

1.8 MAJOR COMPONENT WEIGHTS

Table 1-5.Major Component Weights

Component LB. KG.

6 ft Platform 160 73 5 ft. Platform 145 66 4 ft. Platform 130 59 Extend-A-Reach 230 104 Upper Boom (450A) 985 447 Upper Boom (450A J) 1250 567 Upper Upright 212 96 Tower Boom 515 234 Lower Upright 100 45 Tower Link 150 68 Turntable 3560 1615 Engine Tray 890 404 Hydraulic Tray 225 102 Tail Counterweight 3410 1547 Bolt-on T/T Cwt. ( AJ) 487 221 Chassis (12x16.5 pneu. t ires) 4200 1905 12x16.5 pneu. Tire & Wheel 130 59 12x16.5 F/F Tire & Wheel 305 138 33/15.5x16.5 pneu. Tire & Wheel 150 68 33/15.5x16.5 F/F Tire & Whee l 374 170 33/16LL x 16.1 pneu Tire & Wheel 91.5 41.5 33/16LL x 16.1 F/F Tire & Wheel 426 193.4

1.9 CRITICAL STABILITY WEIGHTS

Table 1-6.Critical Stability Weights

Component LB. KG.

Ford Engine 339 154 Deutz Engine 441 200 Isuzu Engine 389 176 6 ft Platform 160 73 5 ft. Platform 145 66 4 ft. Platform 130 59 Bolt-on T/T Cwt. (AJ) 487 221 12x16.5 pneu. Tire & Wheel 130 59 12x16.5 F/F Tire & Wheel 305 138 33/15.5x16.5 pneu. Tire & Wh eel 150 68 33/15.5x16.5 F/F Tire & Whee l 374 170 33/16LL x 16.1 pneu Tire & Wheel 91.5 41.5 33/16LL x 16.1 F/F Tire & Wheel 426 193.4

1.10 CYLINDER SPECIFICATIONS

Table 1-7.Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Oscillation 2.5 in.

(63.5 mm)

Lower Lift 4.5 in.

(114.3 mm)

Mid Lift 4. 0 in.

(101.6 mm)

Upper Lift 3.5 in.

(88.9 mm)

Telescope 2 in.

(50.8 mm)

Level 4.0 in.

(101.6 mm)

Jib 3.0 in.

(76.2 mm)

Rotate 1. 5 in.

(38.1 mm)

4.125 in.

(104.8 mm)

21.5 in.

(546.1 mm)

18.8 in.

(479.5 mm)

24.4 in.

(619.4 mm)

83.75 in.

(2127.25 mm)

10.9 in.

(277.5 mm)

18.4 in.

(467.4 mm)

9.3 in.

(236.2 mm)

(44.45 mm)

(63.5 mm)

(50.8 mm)

(63.5 mm)

(31.75 mm)

(38.1 mm)

1.75 in.

2.5 in.

2.0 in.

2.5 in.

1.25 in.

1.5 in.

0.75 in.

(19 mm)

Updated 2-16-00

3120869 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Figure 1-1. Lubrication Diagram

Updated 11-1-99

1-4 – JLG Lift – 3120869

Components

Lubrication

Swing Bearing - Internal

Ball Bearing

Swing Bearing - Teeth

End Bearings - Worm

Gear*

Wheel Bearings (2WD

Only)

Wheel Drive Hub

Hydraulic Return Filter

Hydraulic Charge Filter

Hydraulic Oil

Suction Strainer s (In Tank)

Steer Cylinder

Oscillation Cylinders

SECTION 1 - SPECIFICATIONS

Table 1-8. Lubrication Chart

Interval Hours

Number/Type

Lube Points

2 Grease Fitt ing A/R MPG X

Spray On A/R OGL X More frequent lubrication intervals may be

2 A/R MPG X Remove grease fittings and install plugs after

Repack A/R MPG X

Level/Fill Plug 0.5 liters (1/2 full) EPGL X Change after first 150 hours then every 1200

N/A N/A N/A X Change after first 50 hours and every 300

F il l C a p 116 li t er s Tan k

2 N/A N/A X Remove and clean at time of hydraulic oil

4A/RMPGX

2A/RMPGX

Capacity Lube

124 liters System

3 Months 150 hrs

6 Months 300 hrs

1 Year

600 hrs

2 Years

1200 hrs

required.

greasing.

hours of operation.

hours thereafter or as indicated by condition indicator.

HO X Check level daily.

Change every 1200 hours.

change.

Comments

Engines

Oil Change w/Filter - Ford

Oil Change w/Filter - Deutz

Oil Change w/Filter - Isuzu

Fuel Filter - Ford

Fill Cap/Spin-on

Element

Fill Cap/Spin-on

Element

Fill Cap/Spin-on

Element

Replaceable

5 Quarts (4 .7 L) EO X Check leve l daily; change every 150 hour s.

Adjust fina l oil level by m ark on dipstick .

6 liters crankcase **4. 5 liters cooler

5.6 liters crankcase

6.1 liters w/ cooler

EO X Check level da ily; change eve ry 600 hours.

Adjust fina l oil level by m ark on dipstick .

EO X Check level da ily; change eve ry 150 hours.

Adjust fina l oil level by m ark on dipstick .

N/A N/A X

Element

Fuel Filter - Deutz

Fuel Filter - Isuzu

Replaceable

Element

Replaceable

N/A N/A X

Element

Air Filter - Ford

Replaceable

N/A N/A X Or as indicated by condition indicator

Element

Updated 11-1-99

3120869 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Table 1-8. Lubrication Chart

Interval Hours

Components

Air Filter - Deut z

Air Filter - Isuzu

NOTES: KEY TO LUBRICANTS

Lubrication intervals are based on machine operation under normal conditions. For machines used in multi shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.

* If necessary install grease fittings into worm gear housing and grease bearings.

DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN BLOWING OUTER SEAL IN HOUSING.

**When changing oil in the Deutz oil cooled engine, drain both the crankcase and the cooler. When refilling it is acceptable to overfill crankcase (10.5 L), capacity of both crankcase and cooler combined). Start engine, allow the engine to run until the thermostat opens (approximately 105 degrees C) cooler will fill up within minutes; shut down and wait for approximately two minutes. Check oil level, fill oil to max marking on dipstick.

Number/Type

Lube Points

Replaceable

Element

Replaceable

Element

Capacity Lube

N/A N/A X Or as indicated by condition indicator

3 Months 150 hrs

6 Months 300 hrs

1 Year

600 hrs

2 Years

1200 hrs

EPGL

HO MPG OGL

Engine Oil Extreme Pressure Gear Lube Hydraulic Fluid (Mobil DTE-11M) Multi-Purpose Grease Open Gear Lubricant - Mobiltac 375 or equivalent

Comments

Updated 11-1-99

1-6 – JLG Lift – 3120869

SECTION 1 - SPECIFICATIONS

1.11 FUNCTION SPEEDS (IN SECONDS)

450A

Main Boom Lift Up - 22-38 Main Boom Lift Down - 12-24 Tele In - 12-24 Tele Out - 20-32 Swing - 85-110 Rotate (Left & Right) - 16-25

450AJ

Main Boom Lift Up - 22-38 Main Boom Lift Down - 12-24 Tele In - 9-20 Tele Out - 14-30 Swing - 85-110 Rotate (Left & Right) - 16-25 E-A-R Up - 9-24 E-A-R Down - 12-24

1.12 SERIAL NUMBER LOCATION

A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame.

xxxxxxx

SERIAL NUMBER

PLATE

SERIAL NUMBER

STAMPEDON FRAME

Figure 1-2. Serial Number Locations

3120869 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

TORQUE

(as received)

UNPLATED

CAP SCREWS

UNBRAKO 1960 SERIES

WITH LOC-WEL PATCH

SOCKET HEAD CAP SCREW

CLAMP LOAD

)

(LOCTITE

242 OR 271

262)

(LOCTITE

(LUB.)

TORQUE

(KG)

1442

1651

2377

2631

3493

3983

102

4822

5384

122

109

149

156

6437

7253

183

163

130

146

122

109

210

224

8256

9208

224

258

188

209

149

176

285

298

10251

11612

326

359

244

277

231

244

495

542

15150

16919

570

631

408

456

380

434

793

861

20956

23088

895

983

658

724

624

678

1173

1241

27488

30074

1492

1342

931

1079

922

1003

1681

1871

34610

38828

1898

2136

1396

1566

1464

1302

2373

2549

43954

48671

2712

2983

1970

2183

1844

2034

3145

3308

52391

59648

3559

4068

2586

2935

2413

2766

4122

4433

63731

71669

4712

5322

3430

3856

3200

3607

SAE GRADE 8

SAE GRADE 5

VALUES FOR ZINC PLATED BOLTS ONLY

(DRY OR

SAE GRADE 8 BOLTS & GRADE 8 NUTS

CLAMP

(LOCTITE

TORQUE

(DRY OR

SAE GRADE 5 BOLTS & GRADE 2 NUTS

CLAMP

AREA

STRESS

THREAD

DIA.

BOLT

LOC. 263)

(KG)

LOAD

)

242 OR 271

262)

(LUB.)

LOC. 263)

(KG)

LOAD

(SQ. CM)

(CM)

245

272

172

191

0.0153

0.0168

0.2845

372

417

263

277

0.0232

0.0258

0.3505

572

599

408

426

0.0356

0.0374

0.4166

717

817

508

583

0.0445

0.0508

0.4826

1297

1488

916

1052

0.0808

0.0925

0.6350

2141

2821

1515

1678

0.1473

0.1331

0.7938

3175

3583

2241

2540

0.2230

0.1969

0.9525

109

4332

4854

3085

3425

0.3015

0.2700

1.1112

149

163

5783

6532

115

136

108

102

122

4105

4854

0.4061

0.3604

1.2700

204

231

7539

8278

163

183

133

148

109

122

149

163

5874

5262

0.5156

0.4623

1.4288

298

326

9231

10433

224

258

183

207

149

176

204

231

7394

6532

0.6502

0.5740

1.5875

515

570

15241

13653

387

448

325

363

271

298

353

407

9662

10796

0.9474

0.8484

1.9050

814

895

18870

20775

644

705

523

576

434

475

583

637

14697

13336

1.2929

1.1735

2.2225

1220

1356

23360

27080

915

997

785

858

651

719

868

949

19142

17509

1.6840

1.5392

2.5400

1736

1953

31162

34927

968

1087

814 1139

895 1254

1085

1193

21546

19187

2.1742

1.9380

2.8575

2468

2712

38554

43818

1593

1762

1368

1516

1139

1247

1519

1681

27035

24404

2.7254

2.4613

3.1750

3227

3688

47174

53570

2068

2373

1792

2042

1492

1708

1980

2278

29076

33113

2.9337

3.3401

3.4925

4284

4827

57380

142200

2746

3118

2379

2676

1980

2630

35381

3.5687

4.0132 39781 2983 2224

3.8100

Figure 1-3. Torque Chart

THD

SIZE

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1-1/8

1-1/4

1-1/2

Note: These torque values do not apply to cadium plated fasteners.

1-8 – JLG Lift – 3120869

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

This section provides information necessary to perform maintenance on the aerial platform. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

The maintenance procedures included consist of servicing and component removal and installation, disassembly and assembly, inspection, lubrication and cleaning. Information on any special tools or test equipment is also provided where applicable.

2.2 SERVICE AND GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship

nent is disconnected, cap or cover all openings to prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

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.

Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.

Cleanliness

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or compo-

3120869 – JLG Lift – 2-1

SECTION 2 - PROCEDURES

Bearings

1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.

1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

2.3 LUBRICATION AND INFORMATION

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., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles.

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SECTION 2 - PROCEDURES

3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.

Hydraulic Oil

1. Refer to Section 1 for recommendations for viscosity ranges.

2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -26 de grees C (- 15 degrees F ) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of -26 degrees C (-15 degrees F).

3. The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent. This will allow start up at temperatures down to -29 degrees C (-20 degrees F). However, use of this oil will give poor performance at temperatures above49 degrees C (120 degrees F). Systems using DTE 11 oil should not be operated at temperatures above 94 degrees C (200 degrees F) under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed after 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 manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

nants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

2.4 CYLINDERS - THEORY OF OPERATION

Systems Incorporating Double Acting Cylinders

Cylinders are of the double acting type. Systems incorporating double acting cylinders are as follows: Slave Level, Master Level, Lift, Telescope, Axle Lockout and Steer. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

Systems Incorporating Holding Valves

Holding valves are used in the - Lift, Telescope, Lockout, and Slave Level circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contami-

3120869 – JLG Lift – 2-3

SECTION 2 - PROCEDURES

2.5 VALVES - THEORY OF OPERATION

Solenoid Control Valve

Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral) the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir. A typical control valve consist of 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 shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is spring loaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

Relief Valves

Relief valves are installed at various points within the hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control. The relief valve provides an alternate path for the continuing flow from the pump, thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of the system valve bank. Relief pressures are set slightly higher than the load requirement, with the valve diverting excess pump delivery back to the reservoir when operating pressure of the component is reached.

2.6 BOOM MAINTENANCE

IF PERFORMING MAINTENANCE ON THE BOOM, DO NOT USE A LIFTING DEVICE TO LIFT THE BOOMS UNLESS THE HOLDING VALVES HAVE BEEN REMOVED FIRST. FAILURE TO DO SO WILL RESULT IN SEVERE DAMAGE TO THE BOOM.

Removal of the Boom Assembly

1. Remove the platform and platform support as follows:

a. Disconnect electrical cable from control con-

sole.

b. Tag and disconnect the hydraulic lines running

to the rotate cylinders. Cap the hydraulic lines and ports.

c. Using an overhead crane or suitable lifting

device, use nylon support straps to support the platform/support.

NOTE: When removing the retaining pin from the rod end of

the level cylinder, make sure the cylinder is properly supported.

d. Remove bolts and keeper pins that secures the

retaining pins. Using a suitable brass drift and hammer, remove the retaining pins from the platform support.

LIFT CYLINDER PIVOT PIN

BOOM PIVOT

LEVEL LINK PIVOT

Figure 2-1. Location of Components - Boom Removal

2-4 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

2. Remove the boom from the turntable as follows: a. Disconnect wiring harness from ground control

harness connector.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

b. Tag and disconnect hydraulic lines from boom

to control valve. Use a suitable container to retain any residual hydraulic fluid. Cap all hydraulic lines and ports.

c. Using a suitable lifting equipment, adequately

support boom weight along entire length.

d. Remove the bolts and keeper pins securing the

lift cylinder pivot pin. Using a suitable brass drift and hammer, remove the pivot pin from the lower boom.

NOTE: To gain access for removal of the pivot pins, it may

be necessary to remove the ground control box, hydraulic and fuel tanks, and the counterweight.

e. Remove hardware securing the level link pivot

pin. Using a suitable brass drift and hammer, remove the pin from the level link and turntable.

f. Remove hardware securing the lower boom

pivot pin. Using a suitable brass drift and hammer, remove pin from the turntable.

g. Using all applicable safety precautions, carefully

lift boom assembly clear of turntable and lower to ground or suitable supported work surface.

Disassembly of the Main Boom

1. Loosen jam nuts on aft end of fly boom wear pad adjustment and loosen adjustments.

2. Using a portable power source, attach hose to telescope cylinder port block. Using all applicable safety precautions, activate hydraulic system and extend cylinder to gain access to cylinder rod retaining pin. Shut down hydraulic system.

3. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After initial discharge, there should be no further leakage from the retract port.

4. Remove hardware securing telescope cylinder to the fly boom section, then remove pin from fly.

5. Remove hardware securing telescope cylinder to the base boom section.

WHEN REMOVING TELESCOPE CYLINDER FROM BOOM SECTIONS. CARE SHOULD BE TAKEN NOT TO LEAVE CYLINDER REST ON POWERTRACK WHICH COULD CAUSE DAMAGE TO POWERTRACK.

FLY BOOM

RETAINING RING

BASE BOOM

TELESCOPE CYLINDER

Figure 2-2. Location of Components - Removal of Telescope Cylinder

3120869 – JLG Lift – 2-5

SECTION 2 - PROCEDURES

Figure 2-3. Location of Components - Front Wear Pads

6. Using a suitable lifting device, remove telescope cylinder from boom sections.

7. Using a piece of tape, mark the length of hoses and wires from front of fly boom and bottom of base boom for reassembly.

8. Remove hardware securing the front wear pads on base boom section, remove wear pads.

9. Remove hardware securing the powertrack to the aft end of the fly boom section.

10. Using a suitable lifting device, remove fly boom from boom section.

11. Remove hydraulic lines and electrical 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 ovality. Replace pins as necessary.

2. Inspect lift cylinder pins for wear, scoring or other damage, and for tapering or ovality. Ensure pin surfaces are protected prior to installation. Replace pins as necessary.

3. Inspect telescope cylinder rod attach pin for wear, scoring or other damage. Replace pin as necessary.

4. Inspect inner diameter of boom pivot bushings for scoring, distortion, wear or other damage. Replace bushings as necessary.

5. Inspect wear pads for wear.

6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary.

7. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary.

Assembly of the Main Boom

1. Install power track to the attach point on the base boom section. Secure power track with the attaching hardware.

2. Install hydraulic lines and electrical cables into the power track.

3. Install wear pads to the aft end of the fly section.

4. Using suitable lifting equipment, slide fly section into the base section until power track attach point aligns with holes in side of base section.

5. Attach the power track to the aft end of fly boom section. Secure power track with the attaching hardware.

6. Using suitable lifting equipment, slide fly boom section out to gain access to telescope cylinder attach pin hole.

7. Measure the distance between the telescope cylinder port block attach point on base boom section and the attach point on fly boom section.

8. Connect a suitable auxiliary hydraulic power source to the telescope cylinder port block.

9. Extend the telescope cylinder the distance of the two attach points.

10. Secure the sling and lifting device at the telescope

cylinder’s approximate center of gravity, and lift the cylinder to the aft end of the boom assembly.

WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM, CARE MUST BE TAKEN NOT TO DAMAGE THE POWER TRACK ASSEMBLY.

11. Slowly slide the telescope cylinder into boom assembly, align rod end with attach point in fly section. Insert pin and secure with retaining ring.

12. Align bolt holes at aft end of base boom section with telescope cylinder port block. Secure telescope cylinder with hardware.

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SECTION 2 - PROCEDURES

13. Install wear pads at end of base boom section. Using shims, adjust the adjustable wear pads to zero clearance. Adjust pads alternately side to side, so that fly boom section is centered in base boom section.

14. Retract boom section fully. Using shims, adjust wear pads at aft end of boom section to zero clearance. Adjust pads alternately side to side, so that fly boom section is centered in base boom section.

15. Disconnect auxiliary power source from telescope cylinder.

Installation of the Boom Assembly

1. Using suitable lifting equipment, position boom assembly on turntable so that boom pivot holes in both boom and turntable are aligned.

2. Install boom pivot pin, ensuring that location of the hole in pivot pin aligns with attach point on upright.

3. Using all applicable safety precautions, operate lifting equipment in order to position boom lift cylinder and level link so that holes in cylinder rod end and level link are aligned with the one in the turntable. Insert cylinder pins.

4. If necessary, gently tap pins into position with a soft headed mallet, ensuring that attach holes in pins are aligned with attach holes in boom structure. Secure with hardware.

5. Connect all hosing and wiring.

6. Install the platform to the boom assembly.

7. Connect all hosing and wiring at platform control station.

8. Using all safety precautions, operate machine systems and extend and retract boom for four or five cycles.

9. Shut down machine systems and check for leakage.

2.7 DRIFT TEST

NOTE: It is recommended that the machine be shut down in

the test mode for at least one hour prior to beginning the drift test. This will allow the oil temperature in the cylinder to stabilize with the ambient temperature. Thermal expansion or retraction of the hydraulic oil can greatly affect cylinder movement.

Telescope Cylinder

NOTE: Switches referenced in this pro ce dur e are loc ated on

the Ground Control Panel.

1. Activate hydraulic system, properly set extendable axles and position boom in stowed position; adhere to all safety precautions.

BEFORE RAISING AND EXTENDING BOOM, ENSURE THAT AREAS ABOVE AND BELOW BOOM AND PLATFORM AND AHEAD OF PLATFORM ARE CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL.

2. Position LIFT control switch to UP and hold until boom reaches horizontal.

3. Position TELESCOPE control switch to OUT and hold until boom extends approximately 1.2 meters (4 feet); measure from end of base section to end of mid section.

4. Position LIFT control switch to UP and hold until boom reaches maximum elevation. Shut down engine.

5. Tag and carefully disconnect the hydraulic lines to the telescope cylinder at control valve.

6. Observe oil flow from cylinder lines. Oil leaking from extend port hose indicates a leaking counterbalance valve. Oil leaking from retract port hose indicates leakage by cylinder piston.

7. Leave boom elevated in test position for approximately one hour.

BEFORE LOWERING BOOM, ENSURE THAT AREAS BELOW BOOM AND PLATFORM ARE CLEAR OF ALL PERSONNEL AND OBSTRUCTIONS.

3120869 – JLG Lift – 2-7

SECTION 2 - PROCEDURES

8. Position LIFT control switch to DOWN and hold until boom reaches horizontal; check boom length against measurement. If boom has retracted more than 2.5 cm (1 inch) and oil is leaking around rodend of telescope cylinder (check with light and inspection mirror), seals are defective and require replacement, or cylinder rod is scored and cylinder requires overhaul or replacement. If boom has retracted and oil is leaking from counterbalance valve, the valve is either improperly adjusted, or defective and requires replacement.

9. Connect hydraulic lines to control valve.

Lift Cylinder

NOTE: Switches referenced in thi s p r oc edu re are lo ca ted on

the Ground Control Panel.

1. Activate hydraulic system, properly set extendable axles and position boom in stowed position; adhere to all safety precautions.

NOTE: Tape measure or cord should be at least 2 meters (6

feet) long for use in this test.

2. Attach tape measure or cord to bottom of platform.

BEFORE RAISING BOOM, ENSURE THAT AREAS ABOVE AND BELOW BOOM AND PLATFORM ARE CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL.

3. With boom fully retracted, place LIFT control switch to UP and hold until platform is approximately 2 meters (6 feet) above ground level. Shut down engine.

4. Tag and carefully disconnect hydraulic lines to lift cylinder at control valve. Use a suitable container to retain any residual hydraulic fluid.

5. Observe oil flow from cylinder lines. Oil leaking from extend port hose indicates a leaking counterbalance valve. Oil leaking from retract port hose indicates leakage by cylinder piston.

6. Leave boom elevated in test position for approximately one (1) hour.

7. With tape measure or cord used for reference, check to see whether boom has lowered (crept) more than 7.5 cm (3 inches).

8. If boom has lowered and oil is leaking around rodend cap of cylinder, seals in cylinder are defective and require replacement. If boom has lowered and oil is leaking from the counterbalance valve, the valve is either improperly adjusted or defective and requires replacement.

ENSURE THAT HYDRAULIC LINES ARE CONNECTED AS MARKED PRIOR TO BEING DISCONNECTED.

9. Connect hydraulic lines to control valve.

2.8 CYLINDER CHECKING PROCEDURE

IF PERFORMING MAINTENANCE ON THE BOOM CYLINDERS, DO NOT USE A LIFTING DEVICE TO LIFT THE BOOMS UNLESS THE HOLDING VALVES HAVE BEEN REMOVED FIRST. FAILURE TO DO SO WILL RESULT IN SEVERE DAMAGE TO THE BOOM.

NOTE: Cylinder check must be performed anytime a system

component is replaced or when improper system operation is suspected.

Cylinders Without Counterbalance Valves Master Cylinder and Steer Cylinder

1. Using all applicable safety precautions, activate engine and fully extend cylinder to be checked. Shut down engine.

2. Carefully disconnect hydraulic hoses from retract port of cylinder. There will be some initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should be no further drainage from the retract port.

3. Activate engine and extend cylinder.

4. If cylinder retract port leakage is less than 6-8 drops per minute, carefully reconnect hose to port and retract cylinder. If leakage continues at a rate of 6-8 drops per minute or more, 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 port for leakage.

7. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, than activate cylinder through one complete cycle and check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made.

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SECTION 2 - PROCEDURES

Cylinders With Dual Counterbalance Valves Slave Level, Lift, and Telescope

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate hydraulic system.

IF WORKING ON THE PLATFORM LEVEL CYLINDER, STROKE PLATFORM LEVEL CYLINDER FORWARD UNTIL PLATFORM SITS AT A 45 DEGREES ANGLE.

2. Shut down hydraulic system and allow machine to sit for 10-15 minutes. If machine is equipped with bang-bang or proportional control valves, turn IGNITION SWITCH to ON, move control switch or lever for applicable cylinder in each direction, then turn IGNITION SWITCH to OFF. If machine is equipped with hydraulic control valves, move control lever for applicable cylinder in each direction. This is done to relieve pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block.

3. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should be no further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the counterbalance valve is defective and must be replaced.

2.9 CYLINDER REPAIR

NOTE: The following are general procedures that apply to

all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. 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 applicable.

3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings.

4. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge, there should be no further leakage from the ports. If leakage occurs at a rate of 6-8 drops per minute or more, the piston seals are defective and must be replaced.

5. If no repairs are necessary or when repairs have been made, replace counterbalance valve and carefully connect hydraulic hoses to cylinder port block.

6. If used, remove lifting device from upright or remove prop from below main boom, activate hydraulic system and run cylinder through one complete cycle to check for leaks.

3120869 – JLG Lift – 2-9

SECTION 2 - PROCEDURES

Figure 2-4. Boom Prop Configuration

2-10 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

4. Place the cylinder barrel into a suitable holding fixture.

Figure 2-5. Cylinder Barrel Support

5. Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cylinder head retainer cap screws, and remove cap screws from cylinder barrel.

7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

Figure 2-6. Capscrew Removal

NOTE: St eps 6 applies only t o the lower lift and tele scope

cylinders.

6. Using a spanner wrench, loosen the end cap or head retainer, and remove from cylinder barrel.

Figure 2-7. Cylinder Rod Support

9. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.

10. Loosen and remove the cap screw(s), if applicable, which attach the tapered bushing to the piston.

11. Insert the cap screw(s) in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the cap screw(s) until the bushing is loose on the piston.

3120869 – JLG Lift – 2-11

SECTION 2 - PROCEDURES

Figure 2-8. Tapered Bushing Removal

12. Remove the bushing from the piston.

13. Screw the piston CCW, by hand, and remove the piston from cylinder rod.

14. Remove and discard the piston o-rings, seal rings, and backup rings.

15. Remove piston spacer, if applicable, from the rod.

16. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer plate, if applicable. Discard the o-rings, back-up rings, rod seals, and wiper seals.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.

7. Inspect threaded portion of piston for damage. Dress threads as necessary.

8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.

9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.

10. Inspect threaded portion of head for damage. Dress threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.

12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.

13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.

a. Thoroughly clean hole, (steel bushing) of burrs,

dirt etc. to facilitate bearing installation.

b. Inspect steel bushing for wear or other damage.

If steel bushing is worn or damaged, rod/barrel must be replaced.

c. Lubricate inside of the steel bushing with WD40

prior to bearing installation.

d. Using an arbor of the correct size, carefully

press the bearing into steel bushing.

NOTE: Ins tall pin in to the Gar- Max bearin g dry. Lubricati on

is not required with nickel plated pins and bearings.

4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress threads as necessary.

6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.

Figure 2-9. Gar-Max Bearing Installation

14. Inspect travel limiting collar or spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.

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SECTION 2 - PROCEDURES

15. If applicable, inspect port block fittings and holding valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

cylinder seal kit is us ed . Se e your JLG P a rts Manua l. Apply a light film of hydraulic oil to all components

prior to assembly.

1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.

2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head gland groove.

Figure 2-11. Wiper Seal Installation

3. Place a new o-ring and back-up seal in the applicable outside diameter groove of the cylinder head.

Figure 2-10. Rod Seal Installation

WHEN INSTALLING "POLY-PAK" PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

Figure 2-12. Installation of Head Seal Kit

4. Install washer ring onto rod, carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable.

5. Carefully slide the piston spacer on the rod.

6. If applicable, correctly place new o-ring in the inner piston diameter groove. (The backup ring side facing the O-ring is grooved.)

3120869 – JLG Lift – 2-13

SECTION 2 - PROCEDURES

Figure 2-13. Piston Seal Kit Installation

7. If applicable, correctly place new seals and guide lock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D.of the piston is recommended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on

one side. This side faces the solid seal.(See magnified insert in Figure 2-13.)The split of seals and backup rings are to be positi oned so a s not t o be in alignment with each other.

WHEN REBUILDING THE STEER, AXLE OSCILLATION, LOWER LIFT, LEVEL CYLINDER, UPPER LIFT CYLINDER, OR E.A.R. CYLINDERS, APPLY LOCTITE #242 TO TAPERED BUSHING BOLTS, THEN TIGHTEN SECURELY. (SEE TABLE 2-1 AND 2-2. TORQUE SPECIFICATIONS).

11. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) through the drilled holes in the bushing and into the tapped holes in the piston.

8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.

9. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and back-up rings are not damaged or dislodged.

10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing.

NOTE: When installing the tapered bushing, piston and m at-

ing end of rod must be free of oil.

Figure 2-14. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in rotation to the specified torque value. (See Table 2-1, Cylinder Head and Tapered Bushing Torque Specifications.)

13. After the screws have been torqued, tap the tapered bushing with a hammer (500 to 750 gram) and brass shaft (approximately 19 mm in diameter) as follows;

a. Place the shaft against the cylinder rod and in

contact with the bushing in the spaces between the capscrews.

2-14 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

b. Tap each space once; this means the tapered

bushing is tapped 3 times as there are 3 spaces between the capscrews.

Figure 2-15. Seating the Tapered Bearing

14. Retorque the capscrews evenly and progressively in rotation to the specified torque value. (See Table 2-1, Cylinder Head and Tapered Bushing Torque Specifications.)

15. Remove the cylinder rod from the holding fixture.

16. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (See Figure 2-28. Piston Seal Kit Installation.)

18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged.

19. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

20. Secure the cylinder head gland using the washer ring and socket head bolts. See Table 2-1 and 2-3. Torque Specifications.)(

Figure 2-17. Rod Assembly Installation

21. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

22. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings as applicable. (See Table 2-2. Holding Valve Torque Specifications).

Figure 2-16. Poly-Pak Piston Seal Installation

17. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

3120869 – JLG Lift – 2-15

SECTION 2 - PROCEDURES

Table 2-1.Cylinder Head and Tapered Bushing Torque

Specifications

Description

Upper Lift Cylinder

Upper Lift Cylinde r (AJ)

Mid Cylinder

Lower Cylinder N/A

E.A.R. Cylinder

Tele Cylinder N/A

Level Cylinder

Axle Oscillation

Cylinder

Steer Cylinder

Head Torque Value

(Wet)

50 ft. lbs.

(68 Nm)

80 ft. lbs.

(109 Nm)

80 ft. lbs. (109 Nm)

30 ft. lbs

(41 Nm)

80 ft. lbs. (109 Nm)

30 ft. lbs.

(41 Nm)

30 ft. lbs.

(41 Nm)

Tapered Bushing

Torque Value (Wet)

9 ft. lbs

(12 Nm)

9 ft. lbs

(12 Nm)

9 ft. lbs

(12 Nm)

9 ft. lbs

(12 Nm) 5 ft. lbs.

(9 Nm)

5 ft. lbs.

(9 Nm)

5 ft. lbs.

(9 Nm)

N/A

2.10 MID AND LOWER LIFT CYLINDER BLEEDING PROCEDURE

NOTE: Bleeding procedure should only be necessary if

rebuilding or replacing lift cylinder.

1. Check oil level in the hydraulic oil tank (all booms must be retracted). Lay an oil drip pan under the rod end port block (Mid Cylinder) and crack bleeder open from the fitting in the port block.

2. From the platform, turn the speed control knob to the slow position.

3. Lift up very slowly. This will force any air out of the circuit. If the lower boom is not extending, turn the speed control up very slowly until the lower boom starts to move.

4. Raise the lower boom approx. 30.5 cm (1 foot), then close bleeder while the boom is still moving.

5. Lift down all the way.

6. Repeat this procedure until all air has been purged from the circuit. Re-check the hydraulic oil level.

7. To test, cycle the lower lift function 3-4 times to see if both cylinders stop at the same time when fully extended.

Table 2-2.Holding Valve Torque Specification

Description Torque Value

SUN - 7/8 HEX M20 x 1. 5 THDS. 30-35 ft.lbs.

(41-48 Nm)

SUN - 1 1/8 HEX 1-14 UNS THDS.

SUN - 1 1/4 HEX M36 x 2 THDS.

RACINE - 1 1/8 HEX 1 1/16-12 THDS.

RACINE - 1 3/8 HEX 1 3/16-12 THDS.

RACINE - 1 7/8 HEX 1 5/8-12 THDS.

IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD.

45-50 ft.lbs. (61-68 Nm)

150-160 ft.lbs.

(204-217 Nm)

50-55 ft.lbs. (68-75 Nm)

75-80 ft.lbs.

(102-109 Nm)

100-110 ft.lbs.

(136-149 Nm)

2.11 HYDRAULIC PUMP (GEAR)

Disassembly

NOTE: The following gene ral in struction s also apply to m ulti-

ple section gear pumps, the only extra parts are the coupling between the drive s ha fts and the center dis tance plate which divides the two pump sections. This repair procedure also applies to the "W" series Gear Motors.

1. It is very important to work in a clean work area when repairing hydraulic products. Plug ports and wash exterior of pump with a proper cleaning solvent before continuing.

2-16 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

2. Remove port plugs and drain oil from pump.

3. Use a permanent marker pen to mark a line across the mounting flange, gear housing and end cover. This will assure proper reassembly and rotation of pump.

4. Remove key from drive shaft if applicable.

8. Lift and remove end cover.

9. Carefully remove gear housing and place on work bench. Make sure the rear bearing block remains on the drive and idler shafts.

5. Clamp the mounting flange in a protected jaw vise with the pump shaft facing down.

6. Loosen the four metric hex head bolts.

7. Remove pump from vise and place on clean work bench, remove the four hex head bolts and spacers if applicable.

10. Remove rear bearing block from drive and idler shafts.

3120869 – JLG Lift – 2-17

SECTION 2 - PROCEDURES

11. Remove idler shaft from bearing block.

12. Remove drive shaft from mounting flange. There is no need to protect the shaft seal as it will be replaced as a new item.

14. Turn the mounting flange over, with the shaft seal up, and remove the retaining ring with proper snap ring pliers.

15. Remove the oil seal from mounting flange, be careful not to mar or scratch the seal bore.

16. Remove the dowel pins from the gear housing. Do not lose pins.

13. Remove the front bearing block.

17. Remove seals from both bearing blocks and discard.

2-18 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Inspect Parts For Wear

1. Clean and dry all parts thoroughly prior to inspection. It is not necessary to inspect the seals as they will be placed as new items.

2. Check drive shaft spine for twisted or broken teeth, check keyed drive shaft for broken or chipped keyway. No marks or grooves on shaft in seal area, some discoloration of shaft is allowable.

3. Inspect both the drive gear shaft and idler gear shafts at the bearing points and seal area for rough surfaces and excessive wear.

4. Inspect gear face for scoring or excessive wear. If the face edge of gear teeth are sharp, they will mill into the bearing blocks. If wear has occurred, the parts are unusable.

5. Inspect bearing blocks for excessive wear or scoring on the surfaces which are in contact with the gears. Also inspect the bearings for excessive wear or scoring.

6. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing to show a clean "wipe" on the inside surface on the intake side. There should not be excessive wear or deep scratches and gouges.

3120869 – JLG Lift – 2-19

SECTION 2 - PROCEDURES

General Information

It is important that the relationship of the mounting flange, bearing blocks and gear housing is correct. Failure to properly assemble this pump will result with little or no flow at rated pressure.

Reverse Shaft Rotation of Pump

NOTE: This pump is not bi-rotational, if the shaft rotation

must be changed the following procedure must be followed.

Reversing the shaft rotation of the "W" series gear pump may be accomplished by rotating, as a group, the two

bearing blocks and the gear housing 180° in relationship to the remaining parts of the pump. This procedure will place the pressure port on the opposite side of the pump from its original position.

Assembly

NOTE: New seals should be installed upon reassembly of

pump or motor. deter to page 8 for the necessary kit part numbers for the W-600, W-900 and W-1500 pumps and motors.

bore. Uniform pressure must be used to prevent misalignment or damage to the seal.

2. Install retaining ring in groove in seal bore of mounting flange.

1. Install new shaft seal in mounting flange with part lumber side facing outboard. Press the seal into the seal lore until the seal reaches the bottom of the

3. Place front and back bearing blocks on a clean surface with the E-seal grooves facing up. Apply a light coating of petroleum jelly in the grooves. Also coat the E-seal and backup with the petroleum jelly, this will help keep the seals in place during reassembly.

4. Place the E-seals, flat side outward, into the grooves in both bearing blocks. Follow by carefully placing the backup ring, flat side outward, in the groove made by the E-seal and the groove in the bearing block. (Note: in the W900 series pump, in the center

of the backup ring and E-seal there is a notch make sure that these notches line up so the backup ring will set flush with the E-seal). The backup ring in the

W1500 pump is symmetrical.

2-20 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

5. Place mounting flange, with shaft seal side down, on a clean flat surface.

6. Apply a light coating of petroleum jelly to the exposed face of the front bearing block.

7. Insert the drive end of the drive shaft through the bearing block with the seal side down, and the open side of the E-seal pointing to the intake side of the pump.

8. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the shaft seal. Remove the seal sleeve from shaft.

11. Install two dowel pins in the holes in the mounting flange or two long dowel pins through gear housing if pump is a multiple section pump.

12. To install the O-rings in the gear housing, apply a light coating of petroleum jelly in the grooves on both sides of the gear housing. Also coat the new Orings and install them in the grooves.

13. Gently slide the gear housing over the rear bearing block assembly, slide housing down until the housing engages the dowel pins. Press firmly in place with hands, do not force or use any tool. Check to

9. Install the idler gear shaft in the remaining position in the bearing block. Apply a light coat of clean oil to the face of the drive and idler gears.

10. Pick up the rear bearing block, with seal side up and with open end of the E-seal facing the intake side of the pump, place over the drive and idler gear shafts.

make sure the in-take port in the housing is on the same side as the open end of the E-seal and that the marked lines on the mounting flange and gear housing are in alignment.

3120869 – JLG Lift – 2-21

SECTION 2 - PROCEDURES

14. The surface of the rear bearing block should be slightly below the face of the gear housing. If the bearing block sits higher then the rear face of the gear housing then the E-seal or o-ring have shifted out of the groove. If this is the case, remove the gear housing and check for proper seal installation.

15. Install the two remaining dowel pins in the rear of the gear housing, if applicable, and place the end cover over the back of the pump.

19. Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution. If the drive shaft binds, disassemble the pump and check for assembly problems, then reassemble the pump.

20. The name plate located on the end cover contains the build date code and the model number. Please refer to this information when corresponding with the J.S. Barnes Service Department.

Table 2-3.Hydraulic Pump Bolt Torque Chart

Pump Series Thread Size

Tor que

Values, Black

Oxide End

Cover

Torque

Values, Zinc

Plated End

Cover

16. Install the four spacers, if applicable, and hex head bolts through the bolt holes in the end cover, hand tighten.

17. Place mounting flange of the pump back in the protected jawed vise and alternately torque the bolts to the torque specifications in the torque chart. All

torque figures are for "dry torque” bolts.

18. Remove pump from vise.

W-600

W-900

W-1500

M 8 x 1.25

M 10 x 1.5

M 12 x 1.75

18-21 ft.lb.

24-30 Nm

50-55 ft.lb.

68-75 Nm

80-85 ft.lb.

108-115 Nm

16-18 ft.lb.

21.7-24.4 Nm

38-43 ft.lb.

51.5-58.3 Nm

68-73 ft.lb.

92.2-99 Nm

2-22 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Placing Pump Back Into Service

1. If shop test stand is available, the following procedure for testing rebuilt pumps is recommended:

a. Mount pump on test stand making sure that the

proper level of clean oil is available in the reservoir. Check suction line for leaks and obstructions.

b. Start pump and run for three minutes at zero

pressure.

c. Intermittently load pump to 34.5 Bar (500 psi) for

three minutes.

d. Intermittently load pump to 69 Bar (1000 psi) for

three minutes.

e. Intermittently load pump to 138 Bar (2000 psi)

for three minutes.

f. Remove pump from test stand and check for

freeness of drive shaft. Check pump for signs of external leakage.

2. If shop test stand is not available, the following procedure for testing rebuilt pumps is recommended:

a. For engine driven pumps, mount pump on

equipment and run pump at 1/2 engine speed at zero pressure for three minutes.

b. By operating control valve, build pressure inter-

mittently for three minutes.

c. Increase engine speed to full throttle and build

pressure intermittently for three minutes.

d. Stop engine and check pump for external leaks.

2. At the positions indicated on the figure titled Swing Bearing Tolerance Boom Placement. Try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

3. Assure that the 0.0015" feeler gauge will not penetrate under the bolt head to the bolt shank.

4. Swing the turntable 90 degrees, and check some selected bolts at the new position.

5. Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants.

Check the turntable to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full elevation).

2. At the positions indicated in the figure below, try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

.0015" Feeler Gauge

2.12 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check.

NOTE: This check is designed to replace the existing bear-

ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of

Figure 2-19. Swing Bearing Feeler Gauge Check

3. Lower the boom to horizontal and fully extend the boom.

4. At the position indicated on Figure 2-30. try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

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 loose bolts with new bolts and torque to the value specified in the torque chart, after lubricating the bolt threads with loctite #271. After replacing and retorquing bolt or bolts recheck all existing bolts for looseness.

Check the frame to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full elevation).

3120869 – JLG Lift – 2-23

SECTION 2 - PROCEDURES

REMOTE

Figure 2-18. Swing Bearing Installation

2-24 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Wear Tolerance

1. With the boom positioned over the side of the machine, the Upper Boom horizontal with telescope fully extended and Mid/Lower Boom stowed, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable.

2. At the same point, with the boom positioned over the side of the machine, the Upper Boom fully elevated and the Mid/Lower Boom fully elevated, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable.

TURNTABLE REF.

MEASURING

POINT

FRAME REF.

Figure 2-20. Swing Bearing Tolerance Measuring

Point

3. If a difference greater than 1.40 mm (0.057 in.) is determined, the swing bearing should be replaced.

4. If a difference less than 1.40 mm (0.057 in.) is determined, and any of the following conditions exist, the bearing should be removed.

a. Metal particles in the grease. b. Increased drive power. c. Noise. d. Rough rotation.

5. If bearing inspection shows no defects, reassemble bearing and return to service.

SWING

BEARING

Replacement of Swing Bearing

Removal of the swing bearing is as follows:

1. Attach an adequate support sling to the boom and draw all slack from sling. Prop or block the boom if feasible.

2. Tag and disconnect hydraulic lines running through center of turntable and frame. Use a suitable container to retain any residual hydraulic fluid. Cap lines and ports.

3. Attach suitable overhead lifting equipment to the base of turntable weldment.

4. Use a suitable tool to scribe a line on the inner race of the swing bearing and on the underside of the turntable. This will aid in aligning the bearing upon installation. Remove bolts, nuts and washers which attach the turntable to the bearing inner race. Discard nuts and bolts.

5. Use the lifting equipment to carefully lift the complete turntable assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame mounted components.

6. Carefully place the turntable on a suitably supported trestle.

7. Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame. This line will aid in aligning the bearing upon installation. Remove the bolts and washers which attach the outer race of the bearing to the frame. Discard the bolts. Use suitable lifting equipment to remove the bearing and rotation box assembly from the frame; move to a clean, suitably supported work area.

8. Remove the two capscrews securing the bearing to the rotation box to separate the two for inspection.

Installation of the swing bearing is as follows:

1. Install bearing to rotation box with two capscrews, so that fill plug of bearing is as close to gear as bolt pattern will allow. Do not tighten capscrews.

2. Line up high spot (blue) of bearing with center tooth of worm gear. Set backlash to 0.20 - 0.25 mm (0.008

- 0.010 inch). Tighten capscrews as shown in Figure 2-21., Swing Bearing Torquing Sequence.

3120869 – JLG Lift – 2-25

SECTION 2 - PROCEDURES

3. Apply Mobiltac 375NC Open Gear Compound to bearing and worm gear teeth.

4. Grease bearing with Mobilith SHC Bearing Grease. Grease fitting is on inside wall of inner race of bearing.

NOTE: If

Mobiltac 375NC

Open Gear Compound or Mobilith SHC Bearing Grease are not available, Multi-Purpose Grease (MPG) can be substituted, however the service interval will be shorter.

5. Using suitable lifting equipment, install bearing/rotation box assembly to frame with soft spot (red) 90 degree relative to load axis. If reusing old bearing, ensure that scribed line of outer race of the bearing aligns with the scribed mark on the frame.

JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8 BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.

6. Apply a light coating of Loctite 271 to the new bearing bolts and loosely install the bolts and washers through the frame and outer race of bearing.

IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

7. Following the torque sequence diagram shown in Figure 2-21., Swing Bearing Torquing Sequence, tighten the bolts to an initial torque of 237 Nm (175 ft. lbs.). Then following the same sequence, tighten to a final torque of 326 Nm (240 ft. lbs.).

8. Remove lifting equipment from bearing.

10. Carefully lower the turntable onto the swing bearing. Ensure that the scribed line of the inner race of the bearing aligns with the scribed mark on the turntable. If a new swing bearing is used, ensure that the filler plug fitting is at 90 degrees from the fore and aft centerline of the turntable.

11. Apply a light coating of Loctite 271 to the new bearing bolts and install through the turntable and inner race of bearing.

12. Following the torque sequence shown in Figure 2-

21., Swing Bearing Torquing Sequence, tighten the bolts to an initial torque of 175 ft. lbs. (237 Nm). Then following the same sequence, tighten the bolts to 240 ft. lbs (326 Nm).

13. Remove the lifting equipment.

14. Route hydraulic lines through center of turntable and frame and connect as tagged prior to removal.

15. Using all applicable safety precautions, activate the hydraulic system and functionally check swing system for proper and safe operation.

Figure 2-21. Swing Bearing Torquing Sequence

9. Use suitable lifting equipment to carefully position the turntable assembly above the machine frame.

Swing Bearing Torque Values

1. Dry - 298 Nm (220 ft. lbs.).

2. Loctite - 326 Nm (240 ft. lbs.).

Updated 11-1-99

2-26 – JLG Lift – 3120869

2.13 WORM GEAR

Checking Worm Gear End Play

NOTE: JLG I ndustries req uires that a an nual inspection be

performed on the worm gear end play.

SECTION 2 - PROCEDURES

Fig 2 Adjusting End Play.

1. Using a dial indicator, measure end play of worm gear, by applying side to side movement by hand to platform.

2. If tolerance exceeds 0.254 mm (0.010"), reduce end play to less than 0.127 mm (0.005"). Refer to Adjusting End Play.

Allowable Tolerance

.001 to .005

()

Adjusting End Play

1. Remove end plate.

2. Measure and record total thickness of existing shim pack.

Parts Required 7016682 Shim Kit Includes; 3 of 0.005" thick shims

SHIMS

END PLATE

3 of 0.0075" thick shims 3 of 0.010" thick shims

2.14 BOOM SYNCHRONIZING PROCEDURE

NOTE: If the Lower Boom assembly does not fully lower:

1. Remove all personnel from the platform.

2. Pull the red knob located under the main control valve.

3. From Ground Control, activate the lift control switch, raise Lower Boom 2 meters (6 feet).

4. After raising Lower Boom, release the red knob.

5. Activate Lower Boom Down, fully lower boom.

6. Repeat step 1 thru 5 if necessary.

3. Determine thickness of shim pack required to obtain

0.025 - 0.127 mm (0.001" - 0.005") end play.

4. Adjust shim pack thickness as required to obtain proper end play. Reduce end play by removing thicker shims and replacing with thinner shims, included in kit.

5. Replace end plate and torque bolts to 122 Nm (90 ft.

Figure 2-22. Synchronizing Valve

lbs.).

6. Recheck end play.

3120869 – JLG Lift – 2-27

SECTION 2 - PROCEDURES

2.15 EXTEND-A-REACH

Removal

1. Place the Extend-A-Reach in a horizontal position and support the complete assembly with adequate blocking.

2. Remove the Platform as follows:

a. Disconnect the electrical connectors going into

the platform control box.

b. Remove the bolts, nuts, and washers connect-

ing the platform basket to the platform support.

c. Using a suitable lifting device, remove the plat-

form basket from the platform support.

3. Tag and disconnect the hydraulic lines running to the extend-a-reach. Use a suitable container to collect any residual fluid. Cap the hydraulic lines and ports.

4. Remove the hardware securing the extend-a-reach pivot pin at the boom. Using a suitable brass drift and hammer, remove the pin from the fly boom. Use a suitable lifting device and remove the extend a reach.

2.16 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE

1. With the turntable centered, adjust the bracket with

the washers to push the plunger in 7.9 mm ± 1.6 mm (5/16" ± 1/16").

WASHER

BRACKET

LOCKOUT VALVE

TOP TUBE

BOTTOM TUBE

ROTATE CYLINDER

PLATFORM SUPPORT

PIVOT SHAFT

Figure 2-23. Extend-A-Reach

GUARD

E.A.R. CYLINDER

CHECK VALVE

2-28 – JLG Lift – 3120869

AXLE

PIVOT

SECTION 2 - PROCEDURES

LOCKOUT

VALVE

OSCILLA TION

CYLINDER

SPINDLE

TIE

ROD

Figure 2-24. Front Axle

2. The ideal adjustment is 9.5 mm (3/8"). Do not push the plunger in more that 9.5 mm (3/8"). The extra adjustment is needed for the turntable bearing play.

2.17 TORQUE HUB (PRIOR TO S/N 39594)

Ring Gear/Cover Disassembly

1. Loosen the bolts (1) holding the disengage cap (2) in place. Remove the disengage cap.

2. Remove the disengage rod (3) from the ring gear/ cover (4).

3. Take out the O-ring (5) from the ring gear/cover.

4. Remove the pipe plugs (6) from the ring gear cover.

Carrier Disassembly

1. Stand the carrier (8) on its side.

2. Take a punch and a hammer amid drive the roll pin (9) into the planet shaft (10). Make sure that the pin is in enough to slide the planet shaft (10) out of the carrier (8).

Figure 2-25. Ring Gear/Cover

3. Rotate the planet shaft (10) 180 degrees, then drive the roll pin (9) out of the planet shaft (10) and discard the roll pin (9).

4. Remove the planet gear (11) and the flat tanged washers (12) from the carrier.

3120869 – JLG Lift – 2-29

SECTION 2 - PROCEDURES

Figure 2-26. Carrier

5. Repeat steps 2 thru 4 for the remaining two planet gears.

6. Remove the bearing needles (13) and the thrust spacer (14) from the planet gear (11).

Hub-Spindle Disassembly

7. Using a hammer and a thin barstock punch, drive the cups out of the housing.

Main Disassembly

1. Remove coupling (25) from spindle (21).

2. Remove retaining ring (26) from coupling (25).

3. Remove the hex socket screws (7) from the ring gear cover (4).

4. Remove the ring gear cover (4) from the housing (16).

5. Remove the thrust washer (27) from the counterbore of the carrier (8)

6. Remove the carrier (8) along with the sun gear (28).

7. Remove the input shaft (29). Take out the bottom thrust washer (27).

8. Take off the thrust washer (30) from the spindle counterbore.

9. Remove the internal gear (31) from the spindle (21).

10. Remove the retaining ring (32) from the input shaft (29), and discard the retaining ring.

11. Take the O-Ring (33) out of the 0-Ring groove on the spindle (21).

NOTE: If your unit does not have studs, then skip step 1.

1. Hammer the studs (15) out of the flange of the housing (16).

SAFETY GLASSES MUST BE WORN DURING THIS STEP.

2. Remove the retaining ring (17) from spindle counterbore.

3. Remove the spacer (18) and the spring (19).

4. Using retaining ring pliers, remove the retaining ring (20) from the spindle (21) discard the retaining ring at this time. Remove the thrust spacer (22) from the spindle (21).

5. Place on I-beams and press the top of the spindle through the housing.

NOTE: The outboard bearing and seal will have to be

removed from the spindle. You will have to scrap out the seal and bearing to remove them from the spindle.

6. Remove the inboard bearing (23) from the inboard cup (24).

Carrier Sub-Assembly

1. Put a generous amount of grease into the planet gear (11).

2. Line the inside of the planet gear (11) with sixteen bearing needles (13). Put thrust spacer (14) on top of bearing needles (13), then place 16 more bearing needles (13) on top of the thrust Spacer (14).

3. Repeat step 2 for the two remaining planet gears.

4. Stand carrier on its side. Insert planet shaft (10) into the hole on the side of the carrier (8) with roll pin last.

5. Place flat tanged washer (12) onto the planet shaft so that the bump on the flat tanged washer is located towards the interior of the carrier, and is lined up with the slot on the carrier (8).

2-30 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Figure 2-27. Torque Hub (Prior to S/N 39594) - Exploded View

3120869 – JLG Lift – 2-31

SECTION 2 - PROCEDURES

Figure 2-28. Torque Hub (Prior to S/N 39594) - Cutaway View

2-32 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

6. Place the assembled planet gear (11), large end towards the roll pin onto the planet shaft (10).

7. Push the planet shaft (10) through until it reaches the other side of the planet gear (11). Place the other flat tanged washer (12) onto the shaft so that the bump is on the internal side of the carrier, and is lined up with the slot on the carrier.

8. Push the planet shaft (13) all the way through the carrier (8) until the roll pin holes line up.

9. Using an alignment punch, align the roll pin holes in the carrier (8) with the roll pin holes in the planet shaft (10) and drive the roll pin (9) into the hole until it is flush with the carrier housing.

10. Repeat steps 4 to 10 for the remaining two planet gears.

11. At this point the carrier sub-assembly is complete.

Ring Gear/Cover Sub-Assembly

1. Grease and install O-Ring (5) into ring gear/cover (4).

2. Place disengage cap (2) on ring gear/cover (4) with the nipple facing out.

3. Fasten disengage cap (2) with two bolts (1). Torque bolts to 8 - 9 Nm (70-80 in-lbs).

4. Insert disengage rod (3) into ring gear/cover (2).

5. Install pipe plugs (6) into ring gear/cover (4).

Hub-Spindle Sub-Assembly

NOTE: If your unit does not have studs, skip this step.

1. Place the hub with the large diameter up on a flat surface. Using a bearing cup pressing tool press the inboard cup (24) into the housing (16). Turn the unit over.

2. Using a stud fixture and a hammer, carefully press studs (15) into the housing (16). If there is not a stud fixture available anything that can suspend the housing in the air can be used.

3. With the unit still in the fixture, press in the outboard cup (24).

4. Place outboard bearing (23) into the outboard cup.

5. With the housing still in the stud fixture, with a seal pressing fixture, press the seal (34) with the closed face up into the small diameter of the housing.

6. Place spindle (21) on a flat surface with large diameter down. Coat the seal shoulder with grease.

7. Place the hub onto spindle. Press bearing cone (23) onto the spindle.

8. Press the inboard bearing cone (23) onto the spindle until you get slight drag when rotating the hub.

9. Place the spacer (18) on the bearing cone. Install retaining ring (17) onto spindle (21). Do not use retaining ring pliers.

SAFETY GLASSES MUST BE WORN DURING THIS STEP.

10. Insert Spring (15) into spindle (1A) counterbore. Place Spacer (16) on top of spring. Install retaining ring (17) into spindle counterbore using retaining ring pliers.

Main Assembly

NOTE: All components should receive a generous amount

of lubricant oil as they are being assembled.

1. Place hub-spindle sub-assembly on a flat surface.

2. Grease and install O-Ring (33) onto hub pilot.

3. Install retaining ring (32) onto input shaft (29) using retaining ring pliers.

4. Install input shaft (29) into spindle (21).

5. Install internal gear (31) onto spindle (21) spline.

6. Place thrust washer (27) on spindle (21) pilot.

7. Place thrust washer (20) into spindle (21) counterbore.

8. Time the assembled carrier with the large diameter of the cluster gears facing up. Make sure that all

three punch marks on the gears are in the 12 o’clock position and secure the gear teeth.

9. Install the sun gear (28) into the cluster gears (11). Be sure that the punch marks remain in their correct location.

3120869 – JLG Lift – 2-33

SECTION 2 - PROCEDURES

10. Install carrier sub-assembly with sun gear (28) onto input shaft (29) and into internal gear (31). Rotate the carrier to insure that the timing is correct.

11. Place second washer (27) into the counterbore of the carrier(8).

12. Install Ring gear/cover (4) sub-assembly onto the hub making sure that the holes on the ring gear/ cover (4) match up with the holes on the hub.

13. Secure ring gear/cover (4) to hub using three hex socket screws (7). Torque screws 20 - 27 Nm (15-20 ft-lbs).

14. Install retaining ring (26) into coupling (25) using retaining ring pliers.

15. Insert coupling (25) into spindle (21) counterbore.

16. Roll check unit. To do this, you would turn the number of turns in each direction that the unit is being reduced. For example a 19 to 1 reduction would require 19 turns to the left and 19 turns to the right.

17. Air check unit by plugging up the input diameter of the spindle and filling the unit with air. If the unit retains all of the air after 15 minutes then it is good.

2.18 TORQUE HUB (S/N 39594 TO PRESENT)

NOTE: All index number references in parentheses in the

following paragraphs are in reference to Figure 2-

29., Torque Hub (S/N 39594 to Present) - Cutaway View

23. Remove thrust washer (11) from the counterbore in top of carrier (3A).

24. Remove input gear (8) from the middle of carrier sub-assembly.

25. Lift ring gear (4) off of hub (1G).

26. Lift carrier sub-assembly (3) out of hub (1G).

27. Remove the thrust spacer (9) from input shaft (7) in the middle of spindle (1A).

28. Lift input shaft sub-assembly (7) out of middle of spindle (1A), and stand input shaft (7A) on its splined end.

WEAR SAFETY GLASSES DURING THIS STEP BEING AWARE THAT SPRING AND SPACERS COMPRESSED BY RETAINING RING MAY POP SUDDENLY OFF SHAFT WHEN REMOVING THE RETAINING RING.

29. Using retaining ring pliers, remove the retaining ring (7B) from the groove on the input shaft (7A).

30. Remove one spacer (7D), one spring (7C), and other spacer (7D) from input shaft (7A) on its splined end.

31. Remove thrust washer (11) from around spindle (1A).

32. Lift internal gear (2) out of hub (1G).

Main Disassembly

18. Turn hub (1G) over on its side. Remove coupling (14) from the wide end of the spindle (1A).

19. Mark the location of the shoulder bolt holes on outside of ring gear and hub for easy re-alignment when rebuilding. Remove the four shoulder bolts (13) and twelve bolts (12) from cover (6).

20. Remove the 16 flatwashers (16) from cover (6).

21. Lift cover sub assembly (6) off of ring gear (4), and set cover on the table, interior side facing up.

BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN REMOVING THE O-RING.

22. Remove o-ring (5) from the counterbore around the edge of cover (6A). Discard the o-ring.

NOTE: If o-ring is not in the cover counterbore, it is in the

ring gear counterbore. Remove it from the hub and discard it.

BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN REMOVING THE O-RING.

33. Remove o-ring (5) from the counterbore in hub (1G). Discard o-ring.

Hub-Spindle Disassembly

NOTE: Start with the large end of hub f ac ing up, large end of

spindle facing down.

WEAR SAFETY GLASSES DURING STEP ONE.

1. Remove retaining ring (1I) from around spindle (1A) in hub (1G).

2. Remove spacer (1H) from around the spindle (1A) in hub (1G).

2-34 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Figure 2-29. Torque Hub (S/N 39594 to Present) - Cutaway View

3120869 – JLG Lift – 2-35

SECTION 2 - PROCEDURES

3. Set hub (1G), small end/spindle facing down, up on

something that will support the hub’s flange while it lifts hub up so spindle is not resting on anything. Carefully press or hammer spindle (1A) down out of hub (1G).

NOTE: If seal (1B) and bearing cone (1D) come out of hub

and rest on spindle, remove these parts from the spindle and set them aside. Discard the seal.

4. If seal and bearing cone did not come out of the small end of hub (1G) when the spindle was pressed out of the 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 the bearing cone (1F) from inside of the hub (1G).

NOTE: If using a punch and hammer, make sure not to

strike the counterbore with the punch when removing the bearing cup.

6. Remove the bearing cup (1C) from the counterbore in the small end of the hub (1G).

NOTE: If using a punch and hammer, make sure not to

strike the counterbore with the punch when removing the bearing cup.

7. Turn hub (1G) over and lift it out of the flange-support. Remove the bearing cup (1E) from the counterbore in the wide end of hub (1G).

8. Turn hub (1G) over onto it’s small end. Remove two pipe plugs (1J) from the two pipe plug holes in the side of the hub (1G)

9. Press the studs (1N) out of the hub (1G).

Cover Disassembly

Carrier Disassembly

NOTE: When you remove the needle rollers from the cluster

gears, discard the old needle rollers and use new ones during re-assembly.

1. Using a punch and hammer, drive roll pin (3G) into planet shaft (3E).

NOTE: If the roll pin is not driven all the way into the planet

shaft, the carrier could be damaged when removing the planet shaft from the carrier.

2. Using a punch and hammer, drive planet shaft (3E) out of the planet shaft hole in the carrier housing (3A).

3. When removing planet shaft (3E) from the carrier housing, one thrust washer (3B), one cluster gear (3F), and one more thrust washer (3B) will come off of the planet shaft and come to rest inside the carrier. Remove these parts from inside the carrier.

4. Remove 16 needle rollers (3C) from inside one end of cluster gear (3F). Discard the needle rollers.

5. Remove one spacer (3D) from inside the cluster gear (3F).

6. REmove the remaining 16 needle rollers (3C) from the other side of cluster gear (3F). Discard the needle rollers.

7. Repeat steps 1 thru 6 to remove and disassemble the two remaining clusters.

Assembly of the Carrier

1. Apply grease to the inside of one cluster gear (3F) and line one half of cluster gear with 16 needle rollers (3C).

1. Remove the two bolts (6C) holding the disconnect cap (6D) to the cover (6A).

2. Remove the disconnect cap (6D) from on top of cover cap (6B) and cover (6A).

3. Remove the two bolts (6C) holding the cover cap (6B) and cover (6A).

4. Remove cover cap (6B) from cover (6A).

5. Remove disconnect rod (6E) from cover cap (6B).

6. Pry o-ring (6F) out of the groove inside cover cap (6B). Discard the o-ring.

7. Remove o-ring (6G) from the flange of cover cap (6B). Discard the o-ring.

8. Remove pipe plug (6H) from cover (6A).

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SECTION 2 - PROCEDURES

2. Place one spacer (3D) inside cluster gear (3F) so that it rests on top of the needle rollers.

3. Line the remaining half of cluster gear (3F) with 16 needle rollers.

5. Place one thrust washer (3B) onto the end of planet shaft (3E) inside carrier. Fit tang of thrust washer into the slot on the inside edge of the planet shaft hole.

6. Following the thrust washer, place the cluster gear (3F), large end toward roll pin hole in carrier housing, onto the planet shaft (3E).

4. Set carrier housing (3A) on table, sideways. Insert a planet shaft (3E), roll pin hole last, into one of the planet shaft holes from roll-pin-holed side of carrier housing (3A).

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).

3120869 – JLG Lift – 2-37

SECTION 2 - PROCEDURES

8. Use an alignment punch or similar tool to align the roll pin holes in carrier housing (3A) and planet shaft (3E).

9. Drive roll pin (3G) down into the aligned roll pin holes in carrier housing (3A) and planet shaft (3E).

2. Place the o-ring (6G) onto the cover cap (6B) so that it rests against the flange of the cover cap.

3. Insert disconnect rod (6E) into cover cap (6B).

10. Repeat steps 1 thru 9 to assemble and install the two remaining cluster gears.

Assembly of the Cover

1. Using the disconnect rod, push o-ring (6F) into the groove inside the 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 plug hole in the cover.

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SECTION 2 - PROCEDURES

5. Place two of the cover cap bolts (6C) into any two

bolt hoes that are 180° apart on the cover cap (6B) and tighten bolts.

6. Using a torque wrench, apply 4 to 5 Nm (36 to 49 in. lbs.) of torque to both bolts (6C).

8. Place the two remaining bolts (6C) into the bolt holes in the disconnect 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).

7. With the large end down, place the disconnect cap (6D) onto the cover cap (6B), aligning the pipe plug hole in the disconnect cap over the pipe plug hole in the cover cap.

10. Apply a light coat of "Never-Seize" to pipe plug (6H) and tighten it into the pipe plug hole in the cover (6A).

3120869 – JLG Lift – 2-39

SECTION 2 - PROCEDURES

Hub-Spindle Sub-Assembly

NOTE: Make sure the cup sits square with the counterbore

before pressing.

1. Set hub (1G) onto its large end. Press bearing cup (1C) into the counterbore in the small end of the hub (1G).

2. Pres s the nine st uds (1N) in to the stud ho les in hub (1G).

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. Place bearing cone (1D) into bearing cup (1C).

3. Apply a light coat of "Never-Seize" to two pipe plugs (1J) and tighten them into the two pipe plug holes in the side of the hub (1G).

NOTE: Make sure the cup sits square with the counterbore

before pressing.

6. Press seal (1B) into the small end of hub (1G).

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SECTION 2 - PROCEDURES

7. Oil spindle, then lower hub (1G), small end down, onto spindle (1A).

8. Press bearing cone (1F) onto spindle (1A) in hub (1G).

10. Place retaining ring (1I) over the spacer onto spindle (1A) in hub (1G).

Main Assembly

BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O-RING

1. Grease o-ring (5) and place it into the counterbore in hub (1G).

NOTE: O-ring may be stretched or pin ched to gether to mak e

it fit the counterbore exactly.

9. Place spacer (1H) onto spindle (1A) in hub (1G).

NOTE: Make sure the retaining ring is securely seated in the

groove.

3120869 – JLG Lift – 2-41

SECTION 2 - PROCEDURES

2. Oil all exposed surfaces inside hub (1G).

3. Place internal gear (2) into hub (1G) so that its internal splines mesh with the external splines of spindle (1A). Oil internal gear (2).

5. Stand input shaft (7A) on its splined 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).

4. Place thrust washer (11) around spindle (1A) so it rests on the bottom of the internal gear (2).

7. Place other spacer (7D) onto the smooth end of input shaft (7A).

WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE THAT SPRING AND SPACERS, COMPRESSED BY RETAINING RING, MAY POP SUDDENLY OFF SHAFT IF THE RING IS RELEASED BEFORE IT IS PROPERLY IN PLACE.

2-42 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

8. Using retaining ring pliers, insert retaining ring (7B) into the groove on input shaft (7A) by compressing the spring and spacers together.

9. With large splined end down, place input shaft subassembly (7) into spindle (1A).

10. Place thrust spacer (9) onto input shaft (7).

11. Set carrier sub-assembly (3) on a flat work surface so the large ends of cluster gears (3F) face up. Locate the punch marks on the face of each cluster

gear (3F) and position them at 12 o’clock.

Figure 2-30. Cluster Gear Punch Marks

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SECTION 2 - PROCEDURES

12. With "X" marked side facing up, place the ring gear (4) around cluster gears (3F).

NOTE: This will hold the punch marks 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 ring gear (4) over one of the shoulder bolt holes in the hub. Mark the location of shoulder bolt holes on the outside of ring gear and hub.

NOTE: You may lift the ring gear off the hub to align the

shoulder bolt holes. The ring gear and carrier are installed together only to keep the punch marks on the carrier in place.

14. With the internal splines facing up (counterbore end facing down), place input gear (8) into mesh with carrier sub-assembly (3).

15. Oil all exposed surfaces inside the hub (1G). Place thrust washer (11) into the counterbore in top of the carrier.

BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN YOU INSTALL THE O-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 counterbore exactly.

2-44 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

17. Place cover sub-assembly (6) onto ring gear (4), aligning the pipe plug holes according to the alignment prior to disassembly.

18. Place four flatwashers (16) on top of the bolt holes in the cover sub-assembly.

23. Turn hub (1G) over onto its side. Insert coupling (14) into the end of the spindle (1A).

24. Roll test the unit in both clockwise and counterclockwise directions. Perform the same number of turns in each direction as the ratio of the unit. The ratio is

the last two digits of the model number on the unit’s ID tag.

25. Leak test the unit at a pressure of 0.3 Bar (5 psi) for 2 to 3 minutes.

2.19 DRIVE BRAKE (AUSCO)

Disassembly

1. With the shaft protrusion downward, disassemble the parts in the following order; bolts (24) alternately, washers (23), power plate (21), and gasket.

2. Remove the following parts; stationary discs (14), rotating discs (12), primary disc (11), torque pins (3), springs (8&9), and the spring retainer (7).

NOTE: If the bearing and seal are removed for any reason

both must be re placed.

19. Place shoulder bolts (13) into the four shoulder bolt 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. Torque the shoulder bolts (13) 25 to 34 Nm (18 to 25 ft.lbs.). Torque bolts (12) 25 to 34 Nm (18 to 25 ft.lbs.).

3. Further disassembly is not recommended and should not be attempted unless necessary to replace the bearing (4), the seal (6), or the shaft (10). If further disassembly is needed, proceed as follows;

a. The shaft (10) may be removed by pressing on

the end of the shaft with a shop press.

b. Using an appropriate tool, pry the seal (6) out

from the inside of the brake. Take care not to damage the bore. Remove the retaining ring (5). Tap the bearing (4) out with a plastic mallet.

4. Remove the piston (15) from the power plate (21) by introducing low pressure air into the hydraulic inlet and make sure the piston is directed away from the operator. Remove the o-rings (17&19) and backup rings (16 & 18) from the piston O.D. and I.D. grooves. Do not remove backup rings (16 & 18) unless replacement is necessary because they will be damaged.

3120869 – JLG Lift – 2-45

SECTION 2 - PROCEDURES

1. Housing

2. Gasket

3. Torque Pin

4. Ball Bearing

5. Retaining Ring

6. Seal

7. Spring Retainer

8. Small Compression Spring

9. Large Compression Spring

10. Shaft

11. Primary Disc

12. Rotating Disc

13. Not Used

14. Stationary Disc

15. Piston

16. Back-up Ring

17. O-ring

18. Back-up Ring

19. O-ring

20. Bleeder Screw

21. Power Plate

22. Protective Plug

23. Washer

24. Bolt

25. Gasket

Figure 2-31. Drive Brake (Ausco)

2-46 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Assembly

THERE MAY BE MORE PARTS IN A SERVICE KIT THAN YOUR BRAKE REQUIRES. CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY. IN THE CASE OF SPRINGS, SPACE THE SPRINGS AS SHOWN IN THE FIGURE.

5. Worn o-rings and damaged or worn Teflon backup rings must be replaced prior to assembly.

6. The cylinder of the power plate, piston, and o-rings must be clean prior to assembly and pre-lubed with the system hydraulic fluid.

THE DEPTH THE PISTON IS INSTALLED INTO THE POWER PLATE IS CRITICAL. THE SURFACE OF THE PISTON AT THE CUTOUTS MUST BE FLUSH TO 0.120 IN BELOW THE SURFACE OF THE POWER PLATE. DO NOT EXCEED THE 0.120 DEPTH OR THE PISTON WILL COCK RESULTING IN A COMPLETE LOSS OF BRAKING.

7. Assemble the piston (15) into the power plate (21) using a shop press, being careful not to damage the o-rings or Teflon back-up rings. Visually align the center of the cutouts in the piston with the torque pin (3) holes in the power plate (21).

8. For replacement of the seal; a. Use a shop press to install the bearing (4) into

the housing. Press on the outer surface of the bearing only. Install the retaining ring (5) into the groove.

b. Press the seal (6) into the housing (1) until it is

flush with the face of the housing. The lip of the seal must face towards the bearing.

9. Press the shaft into the housing until it stops on the

bearing. Support the inner race of the bearing during the press operation.

10. Rotating discs must be clean and dry. The lining material and mating surfaces of the stationary discs must be thoroughly clean and free of debris. Worn or scored rotating discs must be replaced.

11. Install bolts (24) with washers (23) in the power plate (21). Tighten sequentially, one turn at a time, until the power plate is properly seated. Torque 142 to 156 Nm (105 to 115 foot-pounds).

3120869 – JLG Lift – 2-47

SECTION 2 - PROCEDURES

Figure 2-32. Switch Adjustment

2.20 BOOM LIMIT SWITCHES

There are no adjustments to be made to the two boom limit switches which bolt in place on the uprights.

2.21 LIFT UP AND PLATFORM LEVEL DOWN DISABLE SWITCH

The purpose of the disable switch is to prevent lift up when the boom is near full elevation and the platform is out of level.

Adjustment

1. Position the proximity switch so that it is just flush with the mounting bracket to ensure that it will not come in contact with the contact plate.

Functional Check

DISABLE SWITCH FUNCTIONAL CHECK MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

1. Tape a small piece of metal to the end of the limit switch (e.g. a coin).

PROXIMITY SWITCH

CONTACT PLATE

COIN

Figure 2-33. Functional Check

2. Using the ground controls, activate level down until the platform basket is under the boom in a position to line up the contact plate with the limit switch.

3. Adjust the proximity switch so there is 0.030 inch (0.8 mm) clearance between the end of the switch and the contact plate or until the light comes on.

2. Using the controls in the platform basket, test the lift up and platform level down functions. Both operations should be locked out and not function.

3. Remove metal (coin) and return machine to service.

2-48 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

2.22 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ ENGINE

General

The throttle control system on the Deutz engine includes 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 engaged; operation normal while system is powered.

• Amber - motor extend

• Amber - motor retract

The controller is designed so that when the system voltage reaches 10.5 volts, the actuator clutch will be released and the motor drive turned off in order to prevent unpredictable operation from occurring.

When a failure condition occurs (i.e. position time-out) the controller will release the clutch and turn off the actuator motor. This will prevent unnecessary motor wear.

Table 2-4.Position Controller Truth Table

Control Wiring

Black Red White Green

GND OFF X X O FF POSITION (Freewheel) GND +12 VDC OFF OFF PO SITION 1 (See Adjustments) GND +12 VDC +12 VDC OF F POSITION 2 (See Adju stments) GND +12 VDC OFF +12 VDC POSITION 3 (See Adjustments) GND +12 VDC +12 VDC +12 VDC POSITION 4 (See Adju stments)

GND = POWER SUPPLY OR BATTERY GROUND OFF = GROUND OR OPEN CIRCUIT

X = DON’T CARE +12 VDC = +12 VOLT POWER SUPPLY OR BATTERY SYSTEM, VIA A 5 AMP FUSE OR CIRCUIT BREAKER

TRIMMER ADJU STMENTS

1 - POSITION 1 CW=RETRACT 2 - POSITION 2 CW=RETRACT 3 - POSITION 3 CW=RETRACT 4 - POSITION 4 CW=RETRACT

Actuator Position

LED INDICATORS

R - RETRACT INDICATOR (AMBER) E - EXTEND INDICATOR (AMBER) C - CLUTCH INDICATOR (GREEN) F - FAILURE INDICATOR (RED)

1. Power the ignition switch at the ground control panel. Set the mid rpm.

2. Supply 12 volts of power to the white wire on the controller. Set the high engine rpm.

NOTE: Actuator rod travel must stop slightly before lever

makes contact wit h throttle lever stop. Failure to do so will burn out actuator.

HIGH#2

MID #1

CCW

CCW EXTEND ACTUATOR (HIGHER)

Figure 2-34. Addco Adjustments - Deutz

Controller Status

Clutch engaged no actuator movement

Clutch engaged actuator extending

Procedure

NOTE: Never run fuel tank dry. Diesel engines cannot be

restarted after running out of fuel until fuel system has been air-v ented o r bl ed of air. See Deutz Instruction Manual for procedure.

3120869 – JLG Lift – 2-49

SECTION 2 - PROCEDURES

Clutch engaged actuator retracting

Controller fault - clutch disengaged and no actuator movement

Failure Modes

Immediate Red Light

Green and either Amber light followed by a red light

then

Action:

1. Recycle power to determine if the problem is intermittent.

2. The input voltage must be greater than 10.5 Vdc.

3. Check wiring for any damage and correct.

4. Disconnect engine harness and actuator connnections.

5. If problem reoccurs return unit.

Action:

1. Inspect and clean wiring connections.

2. Examine throttle linkage for any damage or bent components and correct.

3. With linkage disconnected, check each potentiometer for operation.

4. Reconnect linkage and reset each potentiometer for correct operation.

5. If failure continues to occur, replace unit.

2-50 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Only green light on and no actuator movement

Action:

1. Adjust trim potentiometers.

2. If problem continues, replace unit.

2.23 DRIVE AND STEER CONTROLLER

Controller Theory & Definitions

This controller is specifically designed and manufactured to provide a proportional output to a SUNDSTRAND Dual Coil electro-hydraulic valve. The controller you are about to calibrate has the following features:

PWM Output (Pulse \Width Modulation)

The SUNDSTRAND valve being driven by this controller requires an electrical current, between 20 and 130 milliamps in order to shift the valve spool from minimum to maximum flow. Because of the mass of the spool, shifting it a very small distance would be very difficult to do without overshooting the mark. This overshoot is called hysteresis and makes precise control of the function very difficult. PWM output provides a pulsed current to the spool which actually vibrates the spool so that it is never at rest and very easy to shift. This controller pulses the spool 100 times (cycles) per second and as you move the handle, the electronics change the time period the pulse is on within that cycle. As you move the handle away from center, the on time period or width of the cycle pulse will increase and as you move the handle back towards the center, the pulse will decrease. The percentage of on time to off time of the PWM signal is called the Duty Cycle, if it is on for 80% we call that an 80% duty cycle.

Current Regulated Output

This controller output is also current regulated. This controller was designed to output from 20 to 130 milliamps through a 17 Q coil using a 12 volt supply. Ohms Law dictates that the Current is always equal Voltage divided by Resistance. If the supply voltage or the coil resistance should change, Ohms Law dictates that the output current must also change which will affect the speed of the function accordingly. Because this controller is equipped with a current regulated output, it senses a change in voltage or resistance in the circuit and adjusts the duty cycle of the PWM signal so that the output current remains a constant current. Because the Current is constant and Resistance is machine dependent, the duty cycle will vary in an attempt to supply the required level of output. This feature ensures that the function speed the operator wishes to select always remains the same, within the limits of Ohms Law.

Dual Range

This controller is capable of providing two, independently adjustable, maximum output ranges with the same amount of handle travel. The Hi Range would normally be adjusted for full flow (maximum function speed) of the valve at full handle travel. The LO Range would provide some potion of the Hi Range setting, providing reduced oil flow to the valve, with the handle at full travel. LO Range provides the operator with excellent control of the proportional function with increased resolution for precise maneuverability.

Both outputs are linear between the Threshold setting and their respective setting. The controller is in the Hi Range mode when 12 volts is applied to the (R) terminal. As a fail safe, when system voltage is removed from the (R) terminal, the Lo Range feature is active.

I.R.S (Integrated Ramp System)

This controller is calibrated to provide a maximum ramp time of 2 seconds. This feature limits the rate of change of the output, eliminating a jerky response associated with sudden handle movements. Any change in handle position will result in a smooth change in function speed. The 2 seconds is measured between the Threshold and Hi or LO range setting.

3120869 – JLG Lift – 2-51

SECTION 2 - PROCEDURES

Figure 2-35. Drive and Steer Adjustment

R.T.O. (Ramp Thru Off)

This controller is configured with an enhanced ramp feature that allows the handle to released or moved from one handle extreme to the other without canceling the ramp duration. The RTO duration is factory set to 2 seconds

Adjustment Procedures

NOTE: The following procedures are for a preliminary

adjustment. Final Adjustments are to be based on the function speed of the operation.

NOTE: The trimpot adjustment screws are multi turn

devices. No harm can come to the trimpot if it is turned too much. The trimpot will "click" when the wiper is at the end of the element. It may be necessary to turn the adjustment screw several turns to observe a change in the output.

The most reliable measure of the performance of the function you are fine tuning is to monitor your adjustments until the desired speed is achieved. Have the machine fully operational in an area where obstacles are not present. Use your meter to monitor the current output, and record that number once you have set the function to the proper speed.

The EMS4M11100 is equipped with a ramping option. Adjustment and calibration may be difficult due to outputs ramping up to their set level. When making adjustments, let the output stabilize before recording that setting.

The Drive/Steer controller is set by Milliamps. To adjust the Drive/Steer controller, turn the trimpots clockwise to increase and counterclockwise to decrease milliamps. All of the trimpots are 25 turn type.

1. At the platform control box install an amp meter inline between the orange wires at terminal #10 for forward and terminal #11 for reverse.

2. The threshold trimpot is set at 15 to 25 ma. The Low Range trimpot is set at 60 ma. The High range trimpot is set at 130 ma. To set the Threshold trimpot, stroke the joystick until the red LED glows. With the function speed control off of the snail position, adjust the trimpot to 15 to 25 ma. This should be just enough amperage to start the drive wheels moving.

3. Adjust the High Range trimpot. Stroke the joystick fully with the function speed control off of the snail position. Turn the trimpot until 130 ma is displayed on the meter.

4. Adjust the Low Range trimpot. With the joystick fully stroked and the function speed control at the snail position, adjust the Low Range trimpot until the meter reads 60 ma.

NOTE: Milliamp readings should be the same for Drive for-

ward and reverse.

5. Adjust Ramp to provide a smooth start and stop function.

2-52 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

2.24 LIFT AND SWING CONTROLLER

Adjustment

Figure 2-36. Lift and Swing Adjustment

NOTE: The following procedures are for a preliminary

adjustment. Final Adjustments are to be based on the function speed of the operation.

Lift Swing and function speed control are all adjusted to the same values. Threshold 300ma, Low Range 800 ma, and Hi Range 1200 ma.

1. To adjust Lift and Swing Threshold, and Hi Range trimpots, Pin 5 on the control card requires 12 volts.

2. To adjust the Low Range trimpot, Pin 5 requires no voltage.

3. The function control switch turns power on and off at Pin 5.

4. To check and adjust milliamps on Lift Up and Down, connect an amp meter inline between the tan lines at terminal strip #8.

5. Turn the function speed switch past the snail position, operate the Lift joystick just past the Off position in both directions.

6. Adjust the Threshold trimpot to 300 ma.

7. Fully stroke the joystick and adjust the Hi Range trimpot to 1200 ma.

8. Turn the function speed control to snail position and fully stroke the joystick and adjust Lo Range trimpot to 800 ma.

9. To adjust swing left and right connect the amp meter inline between the white wires at terminal #9. Perform adjustment steps the same as outlined for Lift.

2.25 FUNCTION CONTROL

Rotary Selector Controller Theory & Definitions

This Rotary Selector Controller is specifically designed and manufactured to provide a proportional output to a HYDRAFORCE flow control electro-hydraulic valve. The Rotary Selector Controller you are about to calibrate has the following features:

PWM Output (Pulse Width Modulation)

The HYDRAFORCE valve being driven by this Rotary Selector Controller requires an electrical current, between 360 and 1400 milliamps in order to shift the valve spool from minimum to maximum flow. Because of the mass of the spool, shifting it a very small distance would be very difficult to do without overshooting the mark. This overshoot is called hysteresis and makes precise control of the function very difficult. PWM output provides a pulsed current to the spool which actually vibrates the spool so that it is never at rest and very easy to shift. This Rotary Selector Controller pulses the spool 130 times (cycles) per second and as you move the handle, the electronics change the time period the pulse is on within that cycle. As you move the handle away from center, the on time period or width of the cycle pulse will increase and as you move the handle back towards the center, the pulse will decrease. The percentage of on time to off time of the PWM signal is called the Duty Cycle, if it is on for 80% we call that an 80% duty cycle.

3120869 – JLG Lift – 2-53

SECTION 2 - PROCEDURES

Current Regulated Output

This Rotary Selector Controller output is also current regulated. This Rotary Selector Controller was designed to output from 360 to 1400 milliamps through a 4.7 ohm coil using a 12 volt supply. Ohms Law dictates that the Current is always equal to Voltage divided by Resistance. If the supply voltage or the coil resistance should change, Ohms Law dictates that the output current must also change which will affect the speed of the function accordingly. Because this Rotary Selector Controller is equipped with a current regulated output, it senses a change in voltage or resistance in the circuit and adjusts the duty cycle of the PWM signal so that the output current remains a constant current. Because the Current is constant and Resistance is machine dependent, the duty cycle will vary in an attempt to supply the required level of output. This feature ensures that the function speed the operator wishes to select always remains the same, within the limits of Ohms Law.

Dual Range

This Rotary Selector Controller is capable of providing two, independently adjustable, maximum output ranges with the same amount of handle travel. The Hi Range would normally be adjusted for full flow (maximum function speed) of the valve at full handle travel. The LO Range would provide some portion of the Hi Range setting, providing reduced oil flow to the valve, with the handle at full travel. LO Range provides the operator with excellent control of the proportional function with increased resolution for precise maneuverability. Both outputs are linear between the Threshold setting and their respective setting. The Rotary Selector Controller is in the Hi Range mode when 12 volts is applied to the (R) terminal. As a fail safe, when system voltage is removed from the (R) terminal, the Lo Range feature is active.

I.R.S (Integrated Ramp System)

This Rotary Selector Controller is calibrated to provide a maximum ramp time of 3 seconds. This feature limits the rate of change of the output, eliminating a jerky response associated with sudden handle movements. Any change in handle position will result in a smooth change in function speed. The 3 seconds is measured between the Threshold and Hi or LO range setting.

Adjustment Procedure

Figure 2-37. Function Control Card Adjustment

NOTE: The trimpot adjustment screws are multi turn

1. Disconnect the output wire from the card to terminal

12. Install a volt-ohmmeter in series in this wire and set the volt-ohmmeter to mA.

2. Turn on all power; engine does not need to be running.

3. With the function speed switch turned to the fully CCW position, activate the Telescope out switch and adjust Threshold to 300 mA.

4. With the function speed switch turned to the fully CW position, activate the Telescope out switch and adjust Hi Range to 1100 mA.

5. With the function speed switch turned to the fully CW position, activate the Platform Rotate switch and adjust Lo Range to 800 mA.

6. Set Ramp about 10 turns CW from the fully CCW position.

Updated 10-12-99

2-54 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

2.26 TILT ALARM SWITCH

PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH.

Manual Adjustment

7. Park the machine on a flat, level surface. Ensure machine is level and tires are filled to rated pressure.

NOTE: Ensure switch mounting b r acket is level and s ecu rel y

attached.

8. Level 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.

9. With the electrical connections complete, using bubble level on top of indicator, slowly tighten or loosen the three flange nuts until indicator is level.

10. Individually push down on one corner at a time; there should be enough travel to cause the switch to trip. If the switch does not trip in all three tests, the flange nuts have been tightened too far. Loosen the "X" nut and repeat steps (2). through (4).

2.27 PRESSURE SETTING PROCEDURES

Proportional Sequence Valve

1. Install a pressure gauge at port G1 on the Main Valve and start the engine.

2. The gauge should read between 230 and 325 psi (16 and 22.5 bar). This valve is non-adjustable.

Bang-Bang Sequence Valve

1. Install the pressure gauge at port G2 on the Main Valve.

2. Energize the main dump valve by applying 12 volts to pin 14 at the ground control box. The gauge should read between 230 and 325 psi (16 and 22.5 bar). This valve is non-adjustable.

P1 Main Relief Valve

1. Install the pressure gauge at port G1 on the Main Valve.

2. Remove the hose from port LC. Plug the hose and cap the fitting on the valve block.

3. Activate Lift Up and hold.

4. The pressure gauge should read 3000 +200, -50 psi (207 +14, -3.5 bar).

Figure 2-38. Tilt Switch Adjustment

P2 Main Relief Valve

1. Install the pressure gauge at port G2 on the Main Valve.

2. Activate Tower Lift Down and hold.

3. The pressure gauge should read 3200 +200, -50 psi (220 +14, -3.5 bar).

Updated 10-12-99

3120869 – JLG Lift – 2-55

SECTION 2 - PROCEDURES

Figure 2-39. Main Valve (Proportional Controls) - Sheet 1

Updated 10-12-99

2-56 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Figure 2-40. Main Valve (Proportional Controls) - Sheet 2

Updated 10-12-99

3120869 – JLG Lift – 2-57

SECTION 2 - PROCEDURES

FRONT

REAR FLOW DIVIDER

TWO WHEEL/FOUR WHEEL VALVE

HIGH SPEED

VALVE

BYPASS VALVE

FRONT FLOW DIVIDER

Figure 2-41. Valve Location - Chassis

2-58 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

Swing

1. Remove the hoses at ports S1 and S2 on the Main Valve and plug both hoses.

2. Install pressure gauges into both port S1 or S2.

3. Activate swing fully left or right. Adjust the valve to 1750 +200, -0 psi (121 +14, -0 bar).

Upper Lift Down

1. Remove the hoses at port B2 on the Main Valve and plug the hose.

2. Install pressure gauges into port B2.

3. Activate lift down and hold.

4. The pressure gauge should read 2500 +200, -0 psi (172 +14, -0 bar).

Platform Level Retract

1. Remove the hose from port B1 on the Main Valve and cap it.

2. Install a pressure gauge into port B1.

3. Activate the level down function and hold.

4. The pressure gauge should read 2500 +200, -0 psi (172 +14, -0 bar).

Telescope Relief

1. Remove the hoses at ports TC and TR and plug.

2. Install pressure gauges into both ports TC and TR.

3. Activate Telescope In and Out.

4. The pressure gauge should read 2000 +200, -0 psi (138 +14, -0 bar).

Extend-A-Reach Relief

1. Remove the hoses at ports J1 and J2 and plug.

2. Install pressure gauges into both ports J1 and J2.

3. Activate the Extend-A-Reach up and down.

4. The pressure gauge should read 1500 ±100 psi

(103 ± 7 bar).

Steer Relief

1. Remove the hoses at ports ST1 and ST2 and plug.

2. Install pressure gauges into both ports ST1 and ST2.

3. Activate the steer left and right.

4. The pressure gauge should read 2000 ±100 psi (138 ± 7 bar).

2.28 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS

From a hydrostatic component standpoint, the goal at system start up is to put into functional operation, the hydrostatic system in such a way as to preserve the designed life span of the system. The following start-up procedure should be adhered to whenever a new pump or motor is initially installed into a machine, or a system is restarted after either a pump or motor has been removed and/or replaced.

THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DISCONNECTED, ETC.) WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY. TAKE NECESSARY SAFETY PRECAUTIONS BEFORE MOVING THE VEHICLE/ MACHINE.

Prior to installing the pump and/or motor, inspect the unit(s) for damage that may have been incurred during shipping and handling. Make certain that all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.

Updated 2-16-00

3120869 – JLG Lift – 2-59

SECTION 2 - PROCEDURES

Fill the reservoir with recommended hydraulic fluid. This fluid should be passed through a 10 micron (nominal, no bypass) filter prior to entering the reservoir. The use of contaminated fluid will cause damage to the components, which may result in unexpected vehicle/machine movement.

NOTE: If a pump or motor is being replaced due to internal

damage, the remaining units (pump or motors) need to be inspected for damage and contamination, and the entire hydraulic system will need to be flushed and the fluid replaced. Failure to do so may cause considerable damage to the entire system.

The inlet line leading from the reservoir to the pump must be filled prior to start-up. Check the inlet line for property tightened fittings and make sure it is free of restrictions and air leaks.

NOTE: In most ca ses, the rese rvoir is ab ove the pump inlet

so that the pressure head created by the higher oil level helps to keep the inlet pressures within an acceptable range and prevent high vacuum levels. However, due to hose routing or low reservoir locations, there may be air trapped within this line. It is impor tan t to a ssur e tha t th e ai r is bled fro m th is li ne. This can be accomplished by loosening the hose at the fitting closest the pump. When oil begins to flow, the line is full, the air has be en purge d, and the fi tting can be retightened to its specified torque. If the tank needs to be pressurized in order to start the flow of oil, a vacuum reading should be taken at the inlet of the pump during operation in order to verify that the pump is not being asked to draw an inlet vacuum higher tha n it is capable of.

Be certain to fill the pump and/or motor housing with clean hydraulic fluid prior to start up. Fill the housing by pouring filtered oil into the upper case drain port.

NOTE: It i s highly recommended to use the high est possible

case drain port, this ensures that the housing contains as much o il a s po ssible and o ffers th e grea te st amount of lubrication to the internal component s.

NOTE: In initial start-up conditions, it may be convenient to

fill the housing, just prior to installing the case drain line. Component, (especially motor), location may be such that access to the case drain port after installation is not realistic.

NOTE: Make certain that the oil be ing u sed to fill the comp o-

nent housing is as clean as possible, and store the fill container in such a way as to prevent it from becoming contaminated.

It is recommended that the external control input signal, (electrical connections for EDC), be disconnected at the pump control until after initial start-up. This will ensure that the pump remains in its neutral position.

DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START-UP.

"Jog" or slowly rotate the engine until charge pressure starts to rise. Start the engine and run at the lowest possible RPM until charge pressure has been established. Excess air should be bled from the system lines as close to the motors as possible.

NOTE: With the engine on low idle, "crack", (loosen-don’t

remove), the system lines at the mo tor(s). Conti nue to run the engine at low idle and tighten the system lines as soon as oil is observed to leak from them. When oil is observed to "l ea k" 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 established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code. If charge pressure is inadequate, shut down and determine the cause for improper pressure.

INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERATOR’ S ABILITY TO CONTROL THE MACHINE.

Shut down the engine and connect the external control input signal. Also reconnect the machine function(s), if disconnected earlier. Start the engine, checking to be certain the pump remains in neutral. With the engine at normal operating RPM, slowly check for forward and reverse machine operation.

Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes.

Shut down engine, remove gauges, and plug ports. Check reservoir level and add filtered fluid if needed.

The machine is now ready for operation.

Install a 60 bar (or 1000 psi) pressure gauge in the charge pressure gauge port in order to monitor the charge pressure during start-up.

Updated 2-16-00

2-60 – JLG Lift – 3120869

2.29 SEMI-TRACK

The semi-track option is available in either soft or hard track configurations. The semi-track provides increased traction in rough terrain applications.

Testing the Track

With both sides installed, drive the machine slowly in both directions to see that the track does not catch or hit any part of the machine. Test the machine until it can be driven at top speed and on side slopes without the tracks hitting. In the first few days after use, check the track frequently to see that all bolts are staying tight and that no damage is being caused to the tires or machine.

Removing the Track

If the tracks are muddy, it is a good idea to wash them off or drive the loader through water before removing. If the tracks are going to be stored in the laid out position just as they come off the machine, then move the machine to the storage area to remove the tracks. If the tracks are going to be rolled up and put on a pallet, it is best to remove them on a hard surface. Remove the bolts that hold the track together. These bolts are accessible over the front tires. After the nuts are removed, pound them flush with the pad. Drive the machine ahead until the bolts are at the bottom between tires. Remove the inside bolts by turning them out with a wrench and punch out the outside 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 and put the loose hardware in the end of the track.

SECTION 2 - PROCEDURES

Assuming Normal Wear

It is normal for the bushing to wear down to the bolt and for the link hole to wear oblong till it is ready to break out the end.

Updated 2-16-00

3120869 – JLG Lift – 2-61

SECTION 2 - PROCEDURES

Adjustment

IMPROPER SLACK ADJUSTMENT COULD CAUSE TRACK PARTS TO BREAK.

Place a straight edge long enough to reach from the idler to the drive wheel on the tracks. Measure the maximum amount of track sag from the high point of the track segment to the bottom of the straight edge. Properly adjusted track will have approximately 1 to 2 inches (25 to 50 mm) slack.

To adjust the slack measurement, move the bolts from the first hole to the second to create more slack, or from the second to the first to create less slack.

Move Equals

Table 2-5.Adjustment Chart

1 Hole 2 Holes 3 Holes 4 Holes 5 Holes 6 Holes 7 Holes 8 Holes 9 Holes 10 Holes 11 Holes 12 Holes

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 in

(144 mm)

6.50 in

(165 mm)

7.31 in

(186 mm)

8.12 in

(206 mm)

8.93 in

(227 mm)

9.75 in

(248 mm)

Updated 2-16-00

2-62 – JLG Lift – 3120869

SECTION 2 - PROCEDURES

2.30 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the "AREA" to be inspected, and the "INTERVAL" at which the inspection is to take place. Under the "AREA" of the table, the various systems along with components that make up that system are listed. The "INTERVAL" portion of the table is divided into five columns representing the various inspection time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or conditions and depending on the location and use of the machine.

JLG Industries requires that a complete annual inspection be performed in accordance with the "Annual Machine Inspection Report" form. Forms are supplied with each new machine and are also available from JLG Customer Service. Forms must be completed and returned to JLG Industries.

The inspection and maintenance code numbers are as follows:

1. Check for proper and secure installation.

2. Check for visible damage and legibility.

3. Check for proper fluid level.

4. Check for any structural damage; cracked or broken welds; bent or warped surfaces.

5. Check for leakage.

6. Check for presence of excessive dirt or foreign material.

7. Check for proper operation and freedom of movement.

8. Check for excessive wear or damage.

9. Check for proper tightness and adjustment.

10. Drain, clean and refill.

11. Check for proper operation while engine is running.

12. Check for proper lubrication.

13. Check for evidence of scratches, nicks or rust and for straightness of rod.

14. Check for condition of element; replace as necessary.

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE "ANNUAL MACHINE INSPECTION REPORT" FORM.

This machine requires periodic safety and maintenance inspections by a JLG Dealer. A decal located on the turntable affords a place to record (stamp) inspection dates. Notify dealer if inspection is overdue.

15. Check for proper inflation.

16. Clean or replace suction screen.

17. Drain and clean.

* To be performed quarterly. ** Inspection and Maintenance Code 10, 12, 16 to per-

formed every two years.

3120869 – JLG Lift – 2-63

SECTION 2 - PROCEDURES

Table 2-6.Preventive Maintenance and Inspection Schedule

AREA

BOOM

Platform

Platform Gate

INTERVAL

DAILY WEEKLY

MONTHLY 3 MONTH 6 MONTH YEARLY

1,4

1,4 12

Platform Rotator

Foots witch

Controllers

Switches

Lift Up/Platform Down Disable

Switch*

Placards and Decals

Control Tags

Valv es

Carrier (Hoses and Cab les)

10.

Lockout Cylinders (If equipped)

11 .

Pins

12.

Bushings

13.

Wear Pads

14.

Cylinders

15.

Drift Test*

17.

5,11

1,11

1,7,9

1,2

1,11 5,6

14,8

1,5,6,13

2-64 – JLG Lift – 3120869

AREA

TURNTABLE

Engine Oil (see mfg. manual)

SECTION 2 - PROCEDURES

Table 2-6.Preventive Maintenance and Inspection Schedule

INTERVAL

DAILY WEEKLY

MONTHLY

3 MONTH 6 MONTH YEARLY

Battery

Radiator

Air Cleaner

Exhaust System

Spark Arrester

Engine Mount

Ground Controls

Main Hydraulic Pump

Auxiliary Power Pump

10.

Valv es

11 .

Hydraulic Filters

12.

Hydraulic Hoses

13.

Hydraulic Oil Tank**

14.

Breather Hydraulic Tank

15.

Fuel Tank

16.

Cylinders

17.

114

11,5

11,517

1,2,11

1,11 5

14 5

354

6,14

3,5 4

1,5,6,13 4

Hood Doors

18.

Turntable Locking Pin

19.

Horizontal Limit Switch

20.

Oil Coupling

21.

Placards and Decals

22.

Swing Bearing

23.

Swing Brake

24.

Swing Hub

25.

1,7

1,2

19, 12

1,5,6 8

3,9

3120869 – JLG Lift – 2-65

SECTION 2 - PROCEDURES

Table 2-6.Preventive Maintenance and Inspection Schedule

AREA

CHASSIS

Wheel and Tire Assembly

INTERVAL

DAILY WEEKLY

MONTHLY

18,9,15

3 MONTH 6 MONTH YEARLY

Drive Motors

Drive Torque Hubs**

Drive Brakes

Steer Cylinders

Steer Components

Lockout Cylinders (if

equipped)*

Hydraulic Hoses

Placards and Decals

Wheel Bearings

10.

Swing Bearing/Worm Gear

11.

1,5,6

1,5,6 3

1,5,6

1 1,5,6,13

14,68

15,138

1,2

19,12

2-66 – JLG Lift – 3120869

SECTION 3 - TROUBLESHOOTING

SECTION 3. TROUBLESHOOTING

3.1 GENERAL

This section contains troubleshooting information 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.

3.2 TROUBLESHOOTING

The troubleshooting procedures applicable to the aerial platform are listed and defined in Tables 3-1 through 3-6. As an aid to table use, the aerial platform is divided into four major groups, each covered separately within this section. These groups are as follows: elevation system, chassis assembly, hydraulic system and electrical system.

Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action. The probable causes and the remedial action should, where possible, be checked in the order listed in the tables.

It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.

It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems. For this reason, every effort has

been made to ensure that all likely problems in these areas are given the fullest possible treatment. In the remaining machine groups, only those problems which are symptomatic of greater problems which have more that one probable cause and remedy are included. This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section.

The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power. This can be ascertained by overriding the bypass valve (mechanically or electrically) so that oil is available to the function valve, then overriding the function valve mechanically. If the function performs satisfactorily, the problem exists with the control circuit.

3.3 HYDRAULIC CIRCUIT CHECKS

The reference for improper function of a hydraulic system, where the cause is not immediately apparent, should be the Troubleshooting Chart. The best place to begin the problem analysis is at the power source (pump). Once it is determined that the pump is serviceable, then a systematic check of the circuit components, beginning with the control, would follow. For aid in troubleshooting, refer to the Illustrated Parts Manual for hydraulic diagrams of the various circuits

3120869 – JLG Lift – 3-1

SECTION 3 - TROUBLESHOOTING

Table 3-1.Platform Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Automatic leveling i noperative.

Hydraulic system oil low. Replenish oil as nece ssary.

Dual check valves dirty/inoperative. Clean or replace as necessary.

Platform will not maintain level attitude.

No response to platform leveling controls.

Restricted or broken hy draulic line or fitting on

Clean, repair, or replace line or fitting.

slave cylinder or m ain lift cylinder.

Worn seal(s) in slave level or mai n lift cylinder. Replace seal(s).

Counterbalance valve in slave cylinder defec-

Replace counterbalance valve.

tive.

Slave level or main lift cylinder not functioning properly.

Counterbalance valve on slave leveling cylinder

Slave level or main l ift cylinder not functioning properly.

Replace valve.

improperly adjuste d or not functioning properly.

Worn seal(s) in slave level or mai n lift cylinder. Replace seal(s) .

Damaged slave level or main lift cylinder. Repair or rep lace cylinder.

Level function not act ivated within 7 seconds

Recycle footswitch.

after footswitch wa s depressed.

Level control swit ch inoperative. Repai r or replace control switc h lever.

Hydraulic system oil low. Replenish oil as nece ssary.

System orifice plugg ed/dirty. Clean orifice.

Restricted or brok en hydraulic line or fitting. Clean, repai r, or replace line or fitting.

Control valve not functioni ng properly. Repair or replace valve.

No electric to dump or control valv e. See proper wiring diagram.

Slave cylinder not fu nctioning properly. Repair or replace pump .

Platform will not adjust "up" or "down" to level.

Hydraulic pump not f unctioning properly. Rep air or replace pump.

Restricted or brok en hydraulic line or fitting. Clean, repai r, or replace line or fitting.

Slave cylinder not fu nctioning properly. Repair or replace cy linder.

Electrical failure . See proper wiring diagram.

Orifice plugged. Clean orifice.

3-2 – JLG Lift – 3120869

TROUBLE PROBABLE CAUSE REMEDY

Valve spool sticking.

SECTION 3 - TROUBLESHOOTING

Table 3-2.Boom Assembly - Troubleshooting

CONTROL VALVES

Valve leaking.

Dirt in oil ca using excessive temperature build up.

Moisture in oil. Flush syste m and change oil using recom-

Incorrect valve mounting causing warping of the unit.

Valve spool scored. Remove valve and repair or replace as nec es-

Tie-bolts in valve ove r torqued. Correct ly torque bolts.

Return spring weak or broken. Remov e valve and repair or replace as nec es-

Relief valve malfunctioning causing excessive pressure within valve.

Dirt or other for eign material under seal. Remove and repair va lve as necessary.

Valve spool scored. Remove valve and repair or replace as nec es-

Excessive back pressure caused by restricted return line to reservoir.

Flush system and c hange oil using recommended viscosity

mended viscosity

Loosen valve and c heck mounting. Repair as necessary.

sary.

Check pressure del ivery to and from valve and repair or repla ce as necessary.

sary.

Remove line and clear obstruction or replace line as necessary.

Damaged valve seals. Remove valve and rep air or replace as neces-

sary.

BOOM ELEVATION SYSTEM.

No response to lift control switch.

Lift function not activ ated within 7 seconds after footswitch was depr essed.

Lift control switch inoperative. Repair or replace control switch.

Lift cylinder hold ing valve inoperative. Repair o r replace holding valve.

Dump valve (bypa ss) not operating. Determine cause a nd repair or replace valve.

Electrical malfu nction. See w iring diagram.

Hydraulic system oil low. Replenish oil as nece ssary.

Restricted or broken sup ply line on valve bank or hydraulic pump.

Recycle footswitch.

Clean or replace line .

3120869 – JLG Lift – 3-3

SECTION 3 - TROUBLESHOOTING

Table 3-2.Boom Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Boom will not raise.

Control valve not functioni ng properly. Repair or replace valve.

Lift cylinder not functi oning properly. Repair or replace cylinder

Boom will not lower.

Boom raises and lowers erratically.

Lift function not activ ated within 7 seconds after footswitch was depr essed.

Load capacity exceede d (personnel or equipment on platform).

Hydraulic system oil low. Replenish oil as necessary.

Electrical failure to valves. See proper wiring diagram.

Restricted or brok en hydraulic line or fitting. Clean, repai r, or replace line or fitting.

Control valve not functioni ng properly. Repair or replace valve.

Pressure relief valve not functioning properly. Re-adjust or replace valve.

Bypass valve (dum p) not functioning. Repair or rep lace valve.

Lift cylinder not functi oning properly. Repair or replace cylinder.

Binding lift cyl inder or boom pivot pin. Repair or replace cy linder or pin.

See: Boom will not rai se.

Pressure relief valve not functioning properly. Re-adjust or replace valve.

Holding valve not fun ctioning properly. Re-adjust or r eplace valve.

Recycle footswitch.

Reduce load.(Refer to capacity placard.)

Hydraulic system oi l low. Reple nish oil as required.

Restricted or brok en hydraulic line or fitting. Clean, repai r, or replace line or fitting.

Counterbalance valve on lift cyli nder improperly adjusted or not functioning properly.

Control valve not functioni ng properly. Repair or replace valve.

Worn seals in lift c ylinder. Replace seals.

Cylinder not func tioning properly. Repair o r replace cylinder.

Boom drifts down.

Worn seals in lift c ylinder. Replace seals.

Replace valve.

3-4 – JLG Lift – 3120869

TROUBLE PROBABLE CAUSE REMEDY

Function Speed, Drive Speed and High Engine does not operate below horizontal.

If the boom assembly do es not fully lower.

SECTION 3 - TROUBLESHOOTING

Table 3-2.Boom Assembly - Troubleshooting

Damaged wiring on le vel limit switch. Repair or replace wi ring.

Solenoid failure. Replace solenoid .

Tripped circuit breaker. Reset circuit breaker.

Damaged level li mit switch. Repla ce switch, repair or replac e holder.

Defective relay, main terminal box. Replace relay.

Defective platf orm switch. Rep lace switch.

LOWER LIFT FUNCTIO N.

No response to telesco pe control.

Boom will not extend.

The Mid and Lower Bo oms are out of synchronization.

MAIN TELESCOPE SYSTEM.

Telescope function not a ctivated within 7 seconds after footswitc h was depressed.

Telescope control sw itch inoperative. Rep air or replace control switch.

Hydraulic system oil low. Replenish oil as nece ssary.

Damaged wiring on con trol switch or solenoid valve.

Control valve not functioning pr operly. Repair or replace valve.

Restricted or broken sup ply line on valve bank or hydraulic pump.

Telescope cylinder not functi oning properly. Repair or replace cylinde r.

Hydraulic pump not f unctioning properly. Rep air or replace pump.

Telescope function not a ctivated within 7 seconds after footswitc h was depressed.

Refer to synch ronize procedure.

Recycle footswitch.

Repair or replace wiring.

Clean or replace line .

Recycle footswitch.

Control valve not functioning pr operly. Repair or replace contro l valve.

Restricted or brok en hydraulic line or fitting. Clean, repai r, or replace line or fitting.

Pressure setting i ncorrect. Check pressure/re-adj ust as necessary.

Telescope cylinder not functi oning properly. Repair or replace cylinde r.

3120869 – JLG Lift – 3-5

SECTION 3 - TROUBLESHOOTING

Table 3-2.Boom Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Boom extends and retracts erratically.

No response to swing control.

Hydraulic system oil low. Replenish oil as nece ssary.

Wear pads worn. Replace pads as required.

Restricted or brok en hydraulic line or fitting. Clean, repai r, or replace line or fitting.

Control valve not functioni ng properly. Repair or replace valve.

Worn seals in telescope cyli nder. Replace seals.

Cylinder not func tioning properly. Repair o r replace cylinder.

Counterbalance valve not functioning properly. Replace counterbalanc e valve.

BOOM SWING SYSTEM

Boom will swing in one direction only.

Swing function not activated within 7 seconds after footswitch wa s depressed.

Hydraulic system oil low. Replenish oil as nece ssary.

Swing control swit ch not functioning. Rep air or replace swing control switch.

Restricted or broken sup ply line on valve bank or hydraulic pump.

Control valve not functioni ng properly. Repair or replace valve.

Swing motor not functioni ng properly. Repair o r replace motor.

Restrictor valve(s ) plugged. Clean or replace r estrictor valve.

Foreign objects(s ) wedged between swing motor pinion and s wing gear.

Pressure reduci ng valve in swing circuit mal functioning.

No electric power to valve. See proper wiring diagram.

Restricted or brok en hydraulic line or fitting. Clean, repai r, or replace line or fitting.

Control valve not functioni ng properly. Repair or replace valve.

Recycle footswitch.

Clean or replace line .

Remove objects, c heck for damage, and repair or replace component( s) as required.

Repair or replace pressure reducing valve.

Foreign object(s) wedged between swing motor pinion and swing gear.

Swing control switch not functioni ng properly. Repair or replace swing control switch.

Remove object(s), c heck for damage and repair or replace component( s) as required.

3-6 – JLG Lift – 3120869

TROUBLE PROBABLE CAUSE REMEDY

Boom swings erratically in either direction.

SECTION 3 - TROUBLESHOOTING

Table 3-2.Boom Assembly - Troubleshooting

Hydraulic system oil low. Replenish oil as nece ssary.

Lack of lubricant on swing gear or speed reducer pinion.

Swing motor not fun ctioning properly. Repair or replace swi ng control switch.

Worn or broken teeth on s wing gear or swing motor pinion.

Restrictor valves(s) plugged. Clean or replace restrictor valve.

Lubricate as requ ired. (See Lubrication Chart.)

Replace gear(s) as requi red.

3120869 – JLG Lift – 3-7

SECTION 3 - TROUBLESHOOTING

Table 3-3.Turntable Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Valve Spool Sticking.

CONTROL VALVE.

Valve leaking.

Dirt in oil ca using excessive temperature built up.

Incorrect valve mounting causing warping of the unit.

Valve spool scored. Remove valve and repair or replace as nec es-

Return spring weak or broken. Remov e valve and repair or replace as nec es-

Relief valve malfunctioning causing excessive pressure within valve.

Dirt or other for eign material under seal. Remove and replace v alve as necessary.

Valve spool scored. Repair or replace valve.

Excessive back pressure caused by restricted return line to reservoir.

Damaged valve seals . Repair or replace valve as necessary.

Change oil using recommended viscosity and flush system.

Loosen valve and c heck mounting.Repair as necessary.

sary.

Check pressure del ivery to and from valve and repair or repla ce as necessary.

Remove line and clear obstruction or replace line as necessary.

3-8 – JLG Lift – 3120869

TROUBLE PROBABLE CAUSE REMEDY

Engine will not start.

SECTION 3 - TROUBLESHOOTING

Table 3-4.Chassis Assembly - Troubleshooting

POWER PLANT.

Engine will not start (ignition OK).

Station power selector switch not in required position.

Circuit breaker op en. Determine and cor rect cause; reset circuit

Defective starter motor. Replace starter motor.

Damaged wiring in i gnition circuit (broken wire on starter).

Ignition switch not fu nctioning properly. Rep lace switch.

Ignition relay not fun ctioning properly. Replace relay.

Ignition circuit shorted to ground. See proper wiring diagram.

Battery cable(s) not making contact. Clean and tighten cable(s).

Start lockout not working. See wiri ng diagram. Check relay.

No fuel. Replenish fuel as necessary.

Clogged fuel filter. Replace fuel filter.

Choke solenoid malfunction. Replace choke solenoid.

Restricted or broken fu el line. Clean or replace fuel line.

Actuate switch as r equired.

breaker.

Repair, replace wiring.

Fuel shut-off valve in carburetor stuck or frozen. Repair o r replace fuel shut-off. Check for elec tri-

cal power.

Battery discharged. Charge battery, replace if def ective.

Fuel pump not working. Replace fuel pump.

Cam timing belt jump ed time or broken. Repair or replace timing belt.

Ignition timing slippe d. Rep air timing.

Engine will not acceler ate above low.

Damaged wiring on spe ed control switch or high engine solenoi d.

Drive controller not functioni ng properly. Replace con troller.

Actuator not functioni ng properly. Repair or replace sol enoid.

Excessive load o n engine. Reduce load.

Repair or replace wiring.

3120869 – JLG Lift – 3-9

SECTION 3 - TROUBLESHOOTING

Table 3-4.Chassis Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Engine surges.

Strong fuel odor.

Engine worn badly. Rebuild engine.

Engine improperly timed. Time engine.

Engine overheating. Determine cause of ov erheating and remedy.

Dirty fuel filte r. Replace filter.

Fuel line pinched. Replace fuel line.

Throttle governor no t working properly. Repair or replace govern or.

Governor not adjust ed properly. Correctly adjus t governor.

Fuel tank overfilled . Check fuel tank and i mmediately wipe up spilled

fuel.

Fuel tank damaged. Drain all fuel from tank and remove tank for

replacement or r epair.

One or both wheels will not steer.

One or both front wheels will not rotate or rotate erratically.

Difficulty encountered when moving machine.

Fuel line from tank da maged. Replace fuel line.

Carburetor flooding. Repair, replace or adjus t carburetor.

FRONT FRAME AXLE AREA.

Steering link or tie rod broken or attachi ng hardware missing.

Wheel hub or bearing s damaged or not lubricated.

REAR FRAME AXLE AREA.

Load capacity exceede d. Reduce load. Apply loads only in accordance

Flow divider sti cking. Rep air or replace flow divider.

Machine being moved u p too steep a grade. Remove mach ine from grade and check that

Replace steerin g link, tie rod or hardwa re as necessary.

Replace hub or bearings as necessary and repack bearings with approv ed grease.

with load capacity indicator.

drive system opera tes correctly.

Grade too steep . See WARNING Placard on platform for spec ified

grades and sideslop es.

Towing valve not closed. Close towing valve.

3-10 – JLG Lift – 3120869

TROUBLE PROBABLE CAUSE REMEDY

No response to control.

SECTION 3 - TROUBLESHOOTING

Table 3-4.Chassis Assembly - Troubleshooting

Drive wheel tire tr eads worn smooth. Repla ce tires as necessary and infl ate to speci-

fied pressure.

Drive brakes "draggi ng". Re-adjust pressure .

System pressure too low. Re-adjust pressure.

Drive hub(s) defec tive. Repair or replac e hub.

Engine RPM’s not set. Correctly s et engine RPM.

Drive motors worn. Repair or replace dri ve motors.

Counterbalance valve defective. Rep lace counterbalance valve.

Low amperage on control ler. Correct ly adjust controller.

DRIVE SYSTEM.

Machine will not travel in forward.

Drive function no t activated within 7 seconds after footswitch wa s depressed.

Hydraulic system oil low. Replenish oil as nece ssary.

Hydraulic pump not f unctioning properly. Rep air or replace pump.

Restricted or broken p ump supply line. Clean, repair or replace line.

Restricted or broken l ine on valve bank. Clean, repair or replace line.

Drive motor(s) no t functioning properly. Repair or replace motor(s).

Air in wheel brake c ircuit. B leed circuit, determine and cor rect cause.

Fuse is blow-out on control card. Replace fuse.

Damaged wiring on control swit ch. Repair or replace wiring.

Control switc h not functioning properly. Replace switch.

Brake(s) not releas ing. Determine cause and repair or replace.

Hydraulic system oil low. Replenish oil as nece ssary.

Restricted or broken h ydraulic line or fitting. Clean, repair or r eplace line or fitting.

Control valve not functioning pr operly. Repair or replace valve.

Recycle footswitch.

Drive motor(s) no t functioning properly. Repair or replace motor(s).

Circuit breaker op en. Determine and cor rect cause; reset circuit

breaker.

Counterbalance valve sticking on return side. Adjust return counte rbalance out 3 turns - cycle

drive - return to o riginal position.

3120869 – JLG Lift – 3-11

SECTION 3 - TROUBLESHOOTING

Table 3-4.Chassis Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Motor turns slowly in the direction of the last command.

Motor turns slowly at maxi mum command.

Valve not returning to neutral. Check neutral springs.

Function speed swit ch malfunction. Replace function switch.

Sticking spool due to contamination. Remove end c ap and check spool freedom.

Repair as necessary.

Valve spool is not traveling far enough due to: Repair or replace drive motor (s).

Worn, leaking drive motor(s). Repair or replace drive motor(s).

Engine RPM’s set too low. Properly adjust engine RPM’s.

Low control pressur e supply. Replace pressure regulator if necessary.

Poor response, function shuts off slowly when command is removed.

No response to steer control.

Function speed swit ch malfunction. Replace switch.

Amperage too low o n controller. Correctly adjust controller.

Defective pump, lo w oil volume. Repair or replace pump.

Low spool spring pr eload. Check for correct spring and shi ms in end caps.

Sticking spool due to contamination. Remove end c ap and check spool freedom.

Ramp set too high in controller. Adjust controller.

Sticking control hand le. Rep air or replace controller.

STEERING SYSTEM.

Circuit breaker op en. Determine and cor rect cause; reset circuit

breaker.

Hydraulic system oil low. Replenish oil as nece ssary.

Hydraulic system pr essure too low. Adjust pressur e.

Damaged wiring on con trol switch or solenoid valve.

See proper wiring diagram.

Control switch n ot functioning properly. Rep lace switch.

Restricted or broken hy draulic line on valve bank, hydraulic pump or rotary coupling. (If equipped.)

Clean, repair or re place line.

3-12 – JLG Lift – 3120869

SECTION 3 - TROUBLESHOOTING

Table 3-4.Chassis Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Machine hard to steer or steering is errat ic.

Steering inoperative.

If equipped, swivel c oupling leaking internally. (Seals defective.)

Steer control valv e not functioning properly. Repai r or replace valve.

Steer cylinder not functioning properly. Rep air or replace cylinder.

Hydraulic system oil low. Replenish oil as nece ssary.

Restricted hydraulic line or fitting. Clean, repair or replace line or fitting.

Restricted crosso ver relief valve. Clean or replace valve.

Steer system pressure low. Adjust pressure.

Bent linkage (tie r ods). Repair or replace linkage as required.

Hydraulic pump not f unctioning properly. Rep air or replace pump.

Steer cylinder not functioning properly. Rep air or replace cylinder.

Damaged wiring on con trol switch or solenoid valve.

Solenoid valve not functioning prop erly. Repair or replace val ve.

Control switc h not functioning properly. Replace switch.

Repair or replace coupling.

See proper wiring diagram.

Machine will not steer left or to the right.

Relief valve improperly set or not functioning properly.

Steer cylinder not functioning properly. Rep air or replace cylinder.

Wiring on control switch is damaged. See proper wiring diagram.

Wiring on solenoi d valve damaged. Repair or replace wiring.

Coil in solenoid damag ed. Replace coil.

No oil flow or pres sure to steer circuit. Take pressure reading at steer valve and adjust

Bent cylinder rod. Repai r or replace cylinder.

Damaged tie rod. Replace tie rod.

Crossover relief valve sticking. Repair crossover relief valve.

Cylinder packing defecti ve. Repair or replace cylinder.

Reset, repair or replace valves as require d.

as necessary.

3120869 – JLG Lift – 3-13

SECTION 3 - TROUBLESHOOTING

Table 3-4.Chassis Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Machine wanders; steering no t firm.

Crossover relief valve set too low or not functioning properly.

Steer linkages loo se. Tighten linkage.

Steer wheel toe-in not s et properly. Adju st toe-in for 1/4 inch overall.

Spindle bushings badly worn. Replace bus hings.

Reset, repair or replace valve as required.

3-14 – JLG Lift – 3120869

TROUBLE PROBABLE CAUSE REMEDY

Hydraulic pump noisy.

SECTION 3 - TROUBLESHOOTING

Table 3-5.Hydraulic System - Troubleshooting

HYDRAULIC SYSTEMS - GENERAL.

Pump cavitating. (Vacuum in pump due to oil starvation.)

System overheating.

Air entering system th rough broken line or fitti ng. (Suction Side.)

Suction screen dir ty. Clean su ction screen.

Air bubbles in oi l. (Reservoir oil too low. Replenish oil as required.

Suction hose squeeze d shut. Determine cause and r epair.

Oil filter dirty. Replace hydraulic filter.

Wrong type of hydraulic oi l. Replace hydraulic oil.

Restricted suction line. Clean, repair, or replace line.

Restricted reserv oir air vent. Clean or repl ace vent.

Oil viscosity too high. Drain system and replace with re commended oil.

Air leak in suction side of tank. Repair leak.

Restricted suction strainer. Clean strainer.

Oil viscosity too high. Drain system and replace with re commended oil.

Repair or replace line or fit ting.

(Refer to Hydraulic Oi ls.)

Bypass valve not o perating properly. Repair or replace valve.

Main relief valve set too low. Reset valve as required.

Hydraulic system oil low. Replenish oil as nece ssary.

Port relief set too high. Res et valve as required.

Restricted or bloc ked return line. Repair o r replace line.

3120869 – JLG Lift – 3-15

SECTION 3 - TROUBLESHOOTING

Table 3-5.Hydraulic System - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Pump not delivering oil.

Function sluggish during operation. (System pressure too low.)

Restricted suction line. Clean, repair, or replace line.

Air entering syst em through broken line or fitting. Repair or replace line or fitting.

Broken pump drive shaft/pump coupli ng. Repai r or replace pump/pump coupli ng.

Note: Any time pump or pump drive coupling is removed coat pump and drive coupling splines with Lithium Soap Base Grease (TEXACO CODE 1912 OR E QUIVALENT).

Main relief valve set too low. Reset valve as required.

Pump section not d elivering sufficient oil. Repair o r replace pump section or pump.

Main relief valve stuck in open position. Clean, repair, or replace valve. (Check sys tem oil

for contamination.)

System(s) operate erratically.

Auxiliary hydraulic pump inoperable.

Oil viscosity too low. Drain system and replace with recommended oi l.

(Refer to Hydraulic Oi ls.)

Leak in component, li ne or fitting. Repair or replace component, l ine or fitting.

Scored valve spool; s cored cylinder. Replace val ve; replace cylinder.

Amperage too low o n controller. Correctly adjust controller.

Low sequence press ure. Reset val ve as required.

Low pilot pressure. Reset valve as requir ed.

Wrong/defective spool in d rive section. Repair or rep lace drive section.

Shuttle balls leak ing in proportional valve. Repair or replace valve.

Low voltage in ele ctrical system. Correct low voltage problem.

Sticking or bindi ng valve spools, pistons. Clean, repair, or replace components as

required.

AUXILIARY HYDRAULIC SYSTE M.

Circuit breaker op en. Determine and cor rect cause; reset circuit

breaker.

Engine is running. S hut down engine.

Check valve in system leaki ng. Repair or replace che ck valve.

Battery requires charging or wi ll not hold a charge.

Charge or replace batter y as required.

3-16 – JLG Lift – 3120869

SECTION 3 - TROUBLESHOOTING

Table 3-5.Hydraulic System - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Damaged wiring on control switch or auxil iary pump.

Control switc h not functioning properly. Replace switch.

Restricted or broken h ydraulic line or fitting. Clean, repair or r eplace line or fitting.

Pump motor solenoid not functioni ng properly. Replace sol enoid.

Pump motor not functioning prope rly. Repair or replace moto r.

See proper wiring diagram.

3120869 – JLG Lift – 3-17

SECTION 3 - TROUBLESHOOTING

Table 3-6.Electrical System - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No power to platform controls.

PLATFORM CONTROLS.

15 Amp self-reset c ircuit breaker open. Che ck footswitch to ensure that both switches

are making contact w hen pedal is depressed. Repair or replace footswitch as necessary.

Contact block in foots witch malfunctioning. Repair, replace or adjust contact block as

required.

Faulty power circui t wiring. Check wiring continuity. Refer to proper wiring

diagram.

Select switch in wrong position. Place select switch to correct position.

ENGINE STARTER SYSTEM.

Starter will not crank.

Engine continues to crank.

Discharged battery o r loose battery terminals. Check and charge battery or replace battery as

necessary. Clean and secure batter y terminals.

Starter relay faulty or faulty relay connection s. Using a test meter, check relay coil terminals for

presence of electrical power and for energization of relay coil. Also check relay terminals for correct switching of contacts. Repl ace relay as necessary.

Malfunctioning st arter solenoid or motor. Replace soleno id or motor in accordance with

applicable ma nufacturer’s manual.

Malfunctioning ignition switch. Using a test meter, check ignition switch for cor-

rect switching of contacts. Replace switch as necessary.

Faulty ignition and /or starter circuit wiring. Check wiring continuity. See proper wiring dia-

gram.

Faulty start lockout syste m. See correct wiring diagram.

Faulty start switc h. Replace switch.

Faulty ignition and /or starter circuit wiring. Check wiring continuity. See proper wiring dia-

gram.

Malfunctioning st arter solenoid or motor. Replace soleno id or motor in accordance with

applicable ma nufacturer’s manual.

Faulty start switc h. Replace switch.

3-18 – JLG Lift – 3120869

JLG 450AJ Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual