JLG 601S Service Manual

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Service and Maintenance Manual

Model

601S

P/N - 3120866

February 26, 2014

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A Machine that incorporates the ADE (Advanced Design Electronics) system can be outwardly identified by the analyzer connection at the base of the platform control box as shown by the arrow.

ADE System Identification

All machines after S/N 60444 incorporate the ADE system. The following machine serial numbers prior to S/N 60444 also utilize ADE: 58993, 58998, 59222, 59223, 59275, 59281, 59315, 59319, 59352, 59358, 59361, 59769, 60253, 60254, 60286, and 60242

– JLG Lift –

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THIS PAGE LEFT BLANK INTENTIONALLY

– JLG Lift –

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INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

AGENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial plat form. 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 dam age 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 equi pment. 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/OPER ATO R.

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 pres sure prior to disconnecting or removing any portion of the system.

feed lines to system components can then be disconnected with minimal fluid loss.

CMAINTENANCE

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 SECURE 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 SAFELY 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

3120866 – JLG Lift – A-1

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INTRODUCTION

REVISON LOG

July 15, 1999 - Original Issue September 9, 1999 - Revised February 6, 2001 - Revised August 30, 2001 - Revised April 19, 2002 - Revised August 7, 2003 - Revised February 26, 2014 - Revised

A-2 – JLG Lift – 3120866

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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

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic System (Including Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Torque Hub, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Engine - Diesel (Liquid-Cooled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Gear Pump (at 1800 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Hydraulic Filter - In-line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Turning Radius (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Turning Radius (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Weight approximately . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Height (Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Length (Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Wheel base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Ford LRG425 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Deutz F3M1011F Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

SECTION 2 - GENERAL

2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

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

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

3120866 – JLG Lift – i

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TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.7 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.8 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 2-7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

SECTION 3 - CHASSIS & TURNTABLE

3.1 Torque Hub, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2 Torque Hub, Drive (Auburn Gear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.3 Drive Brake - Ausco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.4 Drive Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.5 Drive Motor (Prior to S/N 85132). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Replacing the Drive Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

ii – JLG Lift – 3120866

Page 9

TABLE OF CONTENTS

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

Assembly Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Taper Roller Bearing Initial Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Testing and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.6 Drive Motor Adjustment Procedure (Prior to S/N 85132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3.7 Drive Motor (S/N 85132 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.8 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 3-42

To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.9 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Oscillating Axle Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3.10 Steer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

3.11 Swing Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3.12 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

3.13 Swing Brake - Ausco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

3.14 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3.15 Tilt Alarm Switch (Machines with External Tilt Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3.16 Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3.17 Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57

Changing from Gasoline to LP Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Changing from LP Gas to Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3.18 Electric Governor Installation and Adjustments - Ford Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Quick-start Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Mounting-Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Mounting-Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Check-Out and Initial Start-Up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Multi-Turn Adjustment (High Engine, Mid Engine, Overspeed, Starter Lockout). . . . . . . . . 3-61

Single-Turn Adjustment (Gain, Factory Adjust). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

3.19 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61306) . . . . . . . . . . . . . . . . . . . .3-64

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Failure Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

3.20 Automatic Choke Adjustment - Ford Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

3.21 Cold Weather Starting Difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Checking the Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Checking the Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

3.22 Checking the Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69

3.23 Ford EFI Engine (machines after S/N 58209) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

Performing Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

EFI Diagnostics (S/N 58209 to S/N 60188) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Engine Module and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85

SECTION 4 - BOOM & PLATFORM

4.1 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Disassembly Boom Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.2 Boom Rope Torquing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.3 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.4 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Three Month Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Eight Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.5 Limit Switches and Cam Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4.6 Rotator - Helac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.7 Drive Card Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Lift, Swing, and Drive Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Flow Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.8 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

SECTION 5 - HYDRAULICS

5.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Systems Incorporating Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Systems Incorporating Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Solenoid Control Valve - Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder . . . . . . . . 5-1

Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

5.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.5 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Boom Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6 Variable Displacement pump (M46 series). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Inspections and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Minor Repair and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.7 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

Main Relief, Steer, Swing and Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

4 Wheel Steer (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5.8 Directional Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5.9 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5.10 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . . 5-24

SECTION 6 - JLG CONTROL SYSTEM (ADE)

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6.3 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6.4 Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.5 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6.6 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.7 Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.8 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6.9 Analyzer Diagnostics Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

SECTION 7 - SCHEMATICS

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

3120866 – JLG Lift – v

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TABLE OF CONTENTS (Continued)

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

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

1-2. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

2-1. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-2. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-3. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-4. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-5. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-6. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-7. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

3-1. Torque Hub, Drive (Fairfield). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-2. Torque Hub, Drive (Auburn Gear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-3. Drive Brake Assembly (Ausco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-4. Drive Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3-5. Flow Control Pilot Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-6. Drive Motor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-7. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-8. Removing the Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-9. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-10. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-11. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-12. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-13. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-14. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-15. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-16. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-17. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-18. Cylinder Kit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-19. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-20. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-21. Swash Plate and Journal Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-22. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-23. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-24. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-25. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3-26. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3-27. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3-28. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-29. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-30. Disconnecting the Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

3-31. Oscillating Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3-32. Brake Valve Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3-33. Drive Manual Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3-34. Steer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

3-35. Swing Torque Hub Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-36. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

3-37. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

3-38. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-39. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

3-40. Swing Brake Assembly (Ausco) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

3-41. End Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52

3-42. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55

3-43. Tilt Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-44. Addco Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65

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TABLE OF CONTENTS

LIST OF FIGURES (continued)

FIGURE NO. TITLE PAGE NO

3-45. Malfunction Indicator Light and Test Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

3-46. EFI Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-81

3-47. ECM/EPM Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-84

3-48. Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

4-1. Location of Components - Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2. Location of Components - Rotator and Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-3. Location of Components - Boom Powertrack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-4. Disassembly of Proximity Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-5. Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-6. Boom Assembly Cutaway - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-7. Boom Assembly Cutaway - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-8. Boom Assembly Cutaway - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-9. Disassembly Wire Rope Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-10. Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-11. Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-12. Installing the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-13. Reassembly of Components - Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-14. Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-15. Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-16. Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-17. Limit Switches Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-18. Removing Portion of End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-19. Heating Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-20. Removing Setscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-21. Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-22. Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4-23. Removing Sleeve from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4-24. Actuator Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-25. Rotator Assembly (Helac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-26. Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-3. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-5. Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-7. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-8. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-9. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-10. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-11. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-12. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-13. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-14. Troubleshooting - Neutral Difficult or Impossible to Find . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-15. Troubleshooting - System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-16. Troubleshooting - Transmission Operates in One Direction Only . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-17. Troubleshooting - System Response is Sluggish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-18. Troubleshooting - System Will Not Operate in Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-19. Variable Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-20. Main Control Valve - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

5-21. Main Control Valve - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-22. Main Control Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23

6-1. EPBCS Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

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TABLE OF CONTENTS (Continued)

LIST OF FIGURES (continued)

FIGURE NO. TITLE PAGE NO

6-3. Control Module and Fault Code Indicator Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-4. Analyzer Flow Chart - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-5. Analyzer Flow Chart - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-6. Analyzer Flow Chart - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

7-1. Electrical Components Installation (Prior to S/N 62137) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . .7-2

7-2. Electrical Components Installation (Prior to S/N 62137)- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . .7-3

7-3. Electrical Components Installation (S/N 62137 to Present)-Sheet 1 of 2. . . . . . . . . . . . . . . . . . . .7-4

7-4. Electrical Components Installation (S/N 62137 to Present)-Sheet 2 of 2. . . . . . . . . . . . . . . . . . . .7-5

7-5. Electrical Schematic - Deutz Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-6. Electrical Schematic - Deutz Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-7. Electrical Schematic - Ford Dual Fuel Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-8. Electrical Schematic - Ford Dual Fuel Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7-9. Electrical Schematic - Ford EFI Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-10. Electrical Schematic - Ford EFI Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-11. Electrical Schematic - ADE Machines - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-12. Electrical Schematic - ADE Machines - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-13. Electrical Schematic - ADE Machines - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-14. Electrical Schematic - ADE Machines - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-15. Hydraulic Schematic - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-16. Hydraulic Schematic - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7-17. Hydraulic Schematic - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-18. Hydraulic Schematic - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19



                             

viii – JLG Lift – 3120866

Page 15

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-4 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-5 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-8 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-9 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3 Inspection and Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

3-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-2 Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-3 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-4 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-5 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-6 Slipper Foot Thickness & End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-7 Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-8 Position Controller Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64

3-9 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72

3-10 EPM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-73

4-1 Flow Control Card Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-2 Flow Control Card Ramp Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

4-3 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

5-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

6-1 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-2 Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66939. . . . . . . . . . . . . . . . .6-14

6-3 Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present . . . . . . . . . . . . . .6-18

6-4 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6-5 Fault Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

6-6 ADJUSTMENTS - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

6-7 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

3120866 – JLG Lift – ix

Page 16

TABLE OF CONTENTS (Continued)

This page left blank intentionally.

x – JLG Lift – 3120866

Page 17

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank

98.4 Liters (26 gal.)

Hydraulic Oil Tank

Approx. 121 liters (32 U.S. Gallons), 98.4 L (26 gal.) to the full mark on sight gauge.

Hydraulic System (Including Tank)

Gasoline/Diesel Power - 140.8 liters (37.2 gal.)

Torque Hub, Drive

0.50 liters (17 ounces).

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

Engine Crankcase

Ford LRG-425 Gas w/Filter - 4.25 liters (4.5 quarts).

Deutz F3M1011F Diesel w/Filter - 6 liters (6.3 quarts).

1.2 COMPONENT DATA

Engine - Gas. (Water-Cooled)

Manufacturer/Model - Ford LRG-425.

Oil Capacity.

4.25 liters (4.5 Quarts) w/Filter.

Idle RPM - 1000.

Low RPM - 1800.

Horsepower - 54 @ 2400 RPM, full load.

Cooling System - 15 liters (16 Quarts).

Engine - Diesel (Liquid-Cooled)

Manufacturer/Model- Deutz F3M1011F.

Oil Capacity.

4.5 liters (5 Quarts) Cooling System.

6 liters (6.3 Quarts) w/Filter.

10.7 liters (11.3 Quarts) Total Capacity.

Low RPM - 1800.

High RPM - 2800.

Alternator - 60 Amp, belt drive.

Battery - 1000 Cold Cranking Amps, 210 Minutes Reserve Capacity, 12 VDC.

Horsepower - 48 @ 3000 RPM, full load.

Drive System

Tires - 14 x 17.5, G 14 ply rating, directional tread, pneumatic, tire pressure - 6 Bar (90 PSI).

Drive Motor Displacement.

Standard - 46 cm[3] max. 18 cm[3] min.

(2.8 cu. in. max. 1.1 cu. in. min.)

Drive Hub Ratio.

Standard - 43:1 (4WD).

Drive Brake - Automatic spring applied, hydraulically released disc brakes.

High RPM - 2800.

Alternator - 40 Amp, Belt Drive.

Battery - 85 Amphour, 550 Cold Cranking Amps, 12 VDC.

Fuel Consumption.

Low RPM - 13.06 lph (3.45 GPH).

High RPM - 17.41 lph (4.60 GPH).

       

Steer System

Tires - 14 x 17.5, G 14 ply rating, directional tread, pneumatic, tire pressure - 6 Bar (90 PSI)

Tires - 14 x 17.5, G 14 ply rating, directional tread, foam filled.

Toe-in, adjust for 6.35 mm overall.

        

3120866 – JLG Lift – 1-1

Page 18

SECTION 1 - SPECIFICATIONS

Swing System

Swing Motor Displacement - 75 cm[3] (4.62 cu. in.)

Swing Brake - Automatic spring applied hydraulically released disc brakes.

Swing Hub Ratio - 50:1.

Hydraulic Gear Pump (at 1800 RPM)

7.9 GPM (29.90 lpm).

Pump Displacement - 16 cm[3] (1.02 cu. in.)

Clockwise Rotation.

Auxiliary Power Pump

9.84 lpm(2.6 GPM) @ 82.7 BAR (1200 PSI)

Pump Displacement - 14 cm[3] (.244 cu. in.)

DC Motor.

Clockwise Rotation.

Hydraulic Filter - In-line

Return - Bypass Type.

10 Microns Absolute.

Charge.

10 Microns Absolute.

Hydraulic Strainers (In Tank).

30 Microns.

1.3 PERFORMANCE DATA

Travel Speed.

4WD - 6.44 Km/hr. (4 mph)

Gradeability.

(4WD) 45%.

Machine Height (Stowed)

2.56 m (8 ft. 4.75 in.).

Machine Length (Stowed)

Over Drive Axle - 8.44 m (27 ft. 8.125 in.)

Machine Width

2WS/4WD - 2.42 m (7 ft. 11.4375 in.)

Wheel base

2.48 m (8 ft. 1.50 in.)

1.4 FUNCTION SPEEDS

Machine Orientation When Doing Speed Te st s

Lift: Telescope Retracted. Lift Up, Record Time, Lift Down,

Record Time.

Swing: Boom at Full Elevation. Telescope Retracted. Swing the Turntable off center and stop. Swing the opposite direction and start the test when the turntable is centered up. This eliminates ramp up and down on the controller affecting times.

Te l es c o pe : Boom at Full Elevation; Telescope Retracted; Telescope Out, Record Time. Telescope In, Record Time.

Drive (Forward/Reverse): Test should be done on a smooth level surface. Drive Select Switch should be set to High Engine. Start approximately 7.62 m (25 ft.) from the starting point so that the unit is at maximum speed when starting the test. Results should be recorded for a 60.96 m (200 ft.) course. Drive Forward, Record Time. Drive Reverse, Record Time.

Drive (Above Horizontal): Test should be done on a smooth level surface. Drive Select Switch should be set to Low Engine. The boom should be raised above horizon tal. Results should be recorded for a 15.24 m (50 ft.) course. Drive Forward, Record Time. Drive Reverse, Record Time.

Turning Radius (Outside)

6.2 m (20 ft. 4.6 in.)

Turning Radius (Inside)

5.25 m (14 ft. 3.9 in.).

Boom Elevation

+18.36 m (60 ft. 2 13/16 in.) -1.87 m (6 ft. 1 11/16 in.).

Machine Weight approximately

10,211 kg (22,510 lbs.).

Platform Rotate: Platform level and completely rotated one direction. Rotate the opposite direction, Record Time. Rotate the other direction, Record Time.

Articulating Jib: Platform level and centered with the boom. Start with the Jib down. Jib Up, Record Time. Jib Down, Record Time.

     



1-2 – JLG Lift – 3120866

Page 19

SECTION 1 - SPECIFICATIONS

Te s t N o t e s

1. Stop watch should be started with the function, not with the controller or switch.

2. All speed tests are run from the platform. These speeds do not reflect the ground control operation.

3. The platform speed knob control must be at full speed (turned clockwise completely).

4. Function speeds may vary due to cold, thick hydraulic oil. Test should be run with the oil temperature above 38° C (100° F).

5. Some flow control functions may not work with the speed knob clicked into the creep position.

Table 1-1. Function Speeds (In Seconds)

Function Time

Lift Up 46-60

Lift Down 33-43

Swing Right & Left* 79-101

Telescope Out 50-67

Telescope In 35-40

Platform Rotate Right & Left** 16-25

Drive Forward & Reverse (4WD) 37-45

Drive Above Horizontal - Forward & Reverse (2WD & 4WD)

*Max 10% Difference Between Left & Right **Max 15% Difference Between Left & Right

43-136

4150130 - E

1.5 TORQUE REQUIREMENTS



Table 1-2. Torque Requirements

Description

Bearing To Chassis

Bearing To Tur nt ab le

Wire Rope 15 FT. LBS

Wheel Lugs 170 FT. LBS.

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

NOTE: When maintenance becomes necessary or

a fastener has loosened, refer to the Torque Chart to determine proper torque value.



Tor qu e Va l u e

(Dry)

240 ft. lbs.

(326 Nm) See Note

240 ft. lbs.

(326 Nm) See Note

(20 Nm)

(231 Nm)

Interval Hours

50/600*

150

3120866 – JLG Lift – 1-3

Page 20

SECTION 1 - SPECIFICATIONS

1.6 LUBRICATION

Ford LRG425 Engine

Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD).

When Outside

Tem pe ra t u r e i s

Consistently

-10°F. to +60°F *10W

(-24°C. to +16°C.) *10W

+10°F. to +90°F *10W

(+12°C. to +32°C.) 20W-20

Above +32°F. (+0°C.) 30

Above +50°F. (+10°C.) 40

Multi-Viscosity Oil. (SF, SF-SE, SF-CC, SF-CD)

*Not recommended for severe service, including high RPM operation

When Outside

Tem pe ra t u r e i s

Consistently

Below +10°F. (+12°C.) *5W-20

Below +60°F. (+16°C.) 5W-30

-10°F. to +90°F. (-23°C. to +32°C.)

Above -10°F. (-23°C.) 10W-40 or 10W-50

Above +20°F. (+7°C.) 20W-40 or 20W-50

*Not recommended for severe service, including high RPM operation

NOTE: Crankcase oil must be high quality detergent type

meeting API service classification SF, SH, SG.

Use SAE Viscosity Number

10W-30

Deutz F3M1011F Engine

Single Viscosity Oil (CD-SE, CD-SF).

When Outside Temperature is

Consistently

-20°F. to +25°F. (-29°C. to +4°C.) *10W

+5°F. to +50°F. (+15°C. to +10°C.) 20W-20

+40°F. to +85°F. (+4°C. to +30°C.) 30

Above 75°F. (24°C.) 40

Multi Viscosity Oil (CD-SE, CD-SF)

*This viscosity can be used at colder temperatures with engine oil preheating.

When Outside

Te m p e r a t u r e i s

Consistently

-40°F. to +75°F. (-40°C. to +24°C.)

-15°F. to +70°F. (-26°C. to +21°C.)

-15°F. to +85°F. (-26°C. to +30°C.)

Above -5°F. (-21°C.) 15W-40

-5°F. to +75°F. (-21°C. to +24°C.)

*This viscosity can be used at colder temperatures with engine oil preheating.

NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C or

have properties of API classification CC/CD grades.

Use SAE Viscosity

Number

Use SAE Viscosity Number

*5W-30 (Synthetic)

10W-30

10W-40

15W-30

1-4 – JLG Lift – 3120866

Page 21

SECTION 1 - SPECIFICATIONS

Hydraulic Oil

Table 1-3. Hydraulic Oil

HYDRAULIC SYSTEM

OPERATING

TEMPERATURE RANGE

+0° to +180° F (-18° C to

+83° C)

+0° F to +210° F (-18° C to

+99° C)

+50° F to +210° F (+10° C to

+210° C)

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

to API Service Classification GL-3, and sufficient 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 below 20° F (-7 degrees

C), JLG Industries recommends the use of Mobil DTE 13M.

Table 1-4. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max -40F (-40C)

Flash Point, Min. 330F (166C)

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

SAE VISCOSITY GRADE

10W

10W-20, 10W-30

20W-20

Viscosity

Lubrication Specifications

Table 1-5. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum drip-

ping point of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oil) meeting API

service class ifi cation GL-5 o r MIL-Spec MIL-L2105

HO Hydraulic Oil. API service classification GL-3,

e.g. Mobilfluid 424.

EO Engine (crankcase) Oil. Gas - API SF, SH, SG

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

NOTE: Refer to Lubrication Chart, for specific lubrication

procedures.



1.7 PRESSURE SETTINGS

Main Relief - 3000 PSI (206.85 Bar).

Upper Boom Lift Down - 1500 PSI (103.4 Bar).

Swing - 1700 PSI (117.2 Bar).

Steer - 1800 PSI (124.11 Bar).

Steer Reliefs - 4WS Front & Rear - 1500 PSI (103.4 Bar).

Platform Level Forward - 2800 PSI (193.06 Bar).

Backward - 1800 PSI (124.11 Bar).



NOTE: 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 Indus tries for proper recommendations.

3120866 – JLG Lift – 1-5

Page 22

SECTION 1 - SPECIFICATIONS

1.8 CYLINDER SPECIFICATIONS

Table 1-6. Cylinder Specifications

DESRIPTON BORE STROKE ROD DIA.

Lift 6.00

(152.4)

Telescope 3.5

(88.9)

Steer 2.5

(63.5)

Lockout (2wd) 4

(101.6)

Master 3

(76.2)

Slave Level 3

(76.2)

44.6875 (1135.1)

177.75

(4514.9)

10.75

(273.1)

3.875 (98.4)

8.5

(215.9)

8.5

(215.9)

1.9 MAJOR COMPONENT WEIGHTS

Table 1-7. Major Component Weights

(76.2)

2.5

(63.5)

1.25

(31.8)

1.5

(38.1)

1.5

(38.1)

1.5

(38.1)

1.10 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTERWEIGHT, ENGINE & PLAT FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABIL-

ITY.

Table 1-8. Critical Stability Weights

Component

Tire and Wheel (Foam Filled) Size (14 - 17.5) 436 198

Tire and Wheel (Pneumatic) Size (14 - 17.5) 165 75

Engine Ford 460 209

Deutz 534 242

Continental 558 253

Counterweight Weight 2900 1315

Platform 6 ft. (1.83 M) 205 93

8 ft. (2.44 M) 230 105

LB. KG.

Component

Platform Control Console 250 11 3

Platform Level Cylinder 46 21

Main Boom (Includes Lift Cell., Rotator, and Support) 3527 1600

Turntable Complete (including engine) 7315 3318

Chassis Complete (w/pneumatic tires) 10400 4718

Chassis Complete (w/foam-filled tires) 11680 5300

Machine Complete (GVW) - 2WD w/pneumatic tires 22000 9979

Machine Complete (GVW) - 4WD w/pneumatic tires 22510 10211

LB. KG.

        

1-6 – JLG Lift – 3120866

Page 23

SECTION 1 - SPECIFICATIONS

Figure 1-1. Serial Number Locations

1.11 SERIAL NUMBER LOCATIONS

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.



     

3120866 – JLG Lift – 1-7

Page 24

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Diagram

1-8 – JLG Lift – 3120866

Page 25

Table 1-9. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Components

Lubrication

Swing Bearing

Swing Drive Hub

Wheel Drive Hub

Hydraulic Return Filter

Hydraulic Charge Filter

Hydraulic Oil

Suction Strainers (in

tank)

Engines

Oil Change w/Filter -

Ford LR G425

Oil Change w/Filter -

Deutz

Fuel Filter - Ford

Fuel Filter - Deutz

Air Filter - Ford

Air Filter - Deutz

Number/Type

Lube Points

Capacity Lube

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

2 Grease Fittings A/R MPG X Remote Access

Level/Fill Plug 0.5 lite rs (1/2 Full) EPGL X Check level every 150 hrs/change 1200 hours

N/A N/A N/A X Change after first 50 hrs. and every 3 00 hrs.

Fill Cap 116 liters Tank

124 liters. System

HO X Check level daily/change 1200 hours

thereafter or as indicated by Condition Indica tor.

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

change.

Fill Cap/Spin-on Element 4.25 Liters EO X Check level daily/change 150 hrs.

Fill Cap/Spin-on Element

6 Liters Crankcase *4.75 Liters Cooler

EO X Check level daily/change 1000 hrs. or one

year, whichever comes first. Adjust final oil level by mark on dipstick.

Replaceable Element N/A N/A X

Replaceable Element N/A N/A X O r as indicated by Condition Indicator.

NOTES: KEY TO LUBRICANTS

Lubrication intervals are based on machine operation under normal conditions. For machines used in mu lti shift operations and/or exposed to hostile environments or condit ions, lubrication frequen cies must be increased accordingly.

** When changing oil in the Deutz oil cooled engine, drain both the crankcase and the cooler. When refilling it is acceptable to over fill the crankcase (10.7 liters, capacity of both crankcase and cooler combined) . Start engine, allow the engine

to run until the thermostat opens (ap proximately 105 degrees C) cooler will fill up within minutes; shut down and wait for approximately tw o minutes. Check oil level, fill oil to max marking on th e dipstick.

EPGL

MPG

Engine Oil Extreme Pressure Gear Lube Hydraulic Fluid (Mobil #424 or equivalent) Multi-Purpose Grease

3120866 – JLG Lift – 1-9

Page 26

SECTION 1 - SPECIFICATIONS

SIZE

1-1/2

3.8100

3.4925

4.0132

39781

2983

2224

3118

4827

4712

4068

3559

2983

2712

2136

1898

1492

3200

2766

2413

2034

1844

1464

4284

3688

3227

2712

2468

1953

1736

1356

983

895

631

570

359

326

258

224

183

1003

922

678

624

434

380

244

231

176

149

895

814

570

515

326

298

231

204

163

149

142200

57380

53570

47174

43818

38554

34927

31162

27080

23360

20775

18870

15241

13653

10433

9231

8278

7539

6532

5783

4854

4332

3583

3175

2821

2141

1488

1297

817

717

599

572

417

372

272

245

1708

2373

1247

1762

895

1254

719

997

475

705

298

448

176

258

1980

2746

1492

2068

1139

1593

814

1139

651

915

434

644

271

387

149

224

122

183

136

109

163

115

2278

2630

1980

1519

1681

1193

949

1085

868

583

353

637

407

231

163

204

149

122

102

33113

35381

29076

24404

19187

17509

13336

9662

6532

5262

4105

3085

3425

2540

1678

2241

1515

1052

583

426

277

191

916

508

408

263

172

27035

21546

19142

14697

10796

7394

5874

4854

3.3401

3.5687

2.9337

2.4613

1.9380

1.5392

1.1735

0.8484

0.5740

0.4623

0.3604

0.2700

0.1969

0.1331

0.0925

0.0508

0.0808

0.0445

0.0356

0.0232

0.0153

0.0374

0.0258

0.0168

2.7254

2.1742

1.6840

1.2929

0.9474

0.6502

0.5156

0.4061

0.3015

0.2230

0.1473

3.1750

2.8575

2.5400

2.2225

1.9050

1.5875

1.4288

1.2700

1.1112

0.9525

0.7938

0.6350

0.4826

0.4166

0.3505

0.2845

1-1/4

1-1/8

7/8

3/4

5/8

9/16

1/2

7/16

5/16

3/8

1/4

THD

SAE GRADE 5 BOLTS & GRADE 2 NUTS

SAE GRADE 5

SAE GRADE 8

SAE GRADE 8 BOLTS & GRADE 8 NUTS

UNBRAKO 1960 SERIES

SOCKET HEAD CAP SCREW

WITH LOC-WEL PATCH

BOLT

DIA.

(CM)

CLAMP

LOAD

(KG)

CLAMP

LOAD

(KG)

CLAMP LOAD

(KG)

TORQUE

(DRY OR

LOC. 263)

(DRY OR

LOC. 263)

(LOCTITE

262)

(LOCTITE

262)

(LOCTITE

)

242 OR 271

(LOCTITE

)

242 OR 271

TORQUE

(as received)

(LUB.)

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

THREAD

STRESS

AREA

(SQ. CM)

1220

109

3607

1302

122

163

5322

1342

122

VALUES FOR ZINC PLATED BOLTS ONLY

UNPLATED

CAP SCREWS

108

133

148

183

207

325

363

523

576

785

858

968

1087

1368

1516

1792

2042

2379

2676

102

149

156

210

224

285

298

495

542

793

861

1173

1241

1681

1871

2373

2549

3145

3308

4122

4433

71669

63731

59648

52391

48671

43954

38828

34610

30074

27488

23088

20956

16919

15150

11612

10251

9208

8256

7253

6437

5384

4822

3983

3493

2631

2377

1651

1442

1079

931

724

658

456

408

277

244

209

188

146

130

1396

1566

1970

2183

2586

2935

3430

3856

Figure 1-3. Torque Chart

1-10 – JLG Lift – 3120866

Page 27

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or local regulations for fur ther requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Opera tor’s and Safety Manual for completion procedures for the Pre-Start Inspection. The Operator and Safety Manual must be read in its entirety and understood prior to per forming the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recog nized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a Factory-Certified Service Technician on an annual basis, no later than thirteen (13) months from the date of the prior Annual Machine Inspection. JLG Industries, Inc. rec ognizes a Factory-Certified Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG product model. Refer ence the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this

inspection.

Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection. Reference the appropriate areas of this man ual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, train

ing, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.

     



3120866 – JLG Lift – 2-1

Page 28

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Typ e Frequency

Pre-Start Inspection

Pre-Delivery

Inspection

Frequent Inspec-

tion

Annual Machine

Inspection

Preventative Maintenance

In service for 3 months or 150 hours, which-

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental delivery.

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as specified in the Service and

Maintenance Manual.

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 book.

Safety and Workmanship

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.

Cleanliness

1. The most important single item in preserving the long service life of a machine is to keep dirt and for eign 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.

  



Primary

Responsibility

User or Operator User or Operator Operator and Safe ty Manual

Owner, Dealer, or User Qual ified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Certified

Owner, Dealer, or User Qualified JLG

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 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 contain ers until they are ready to be used.

Service

Qualification

Mechanic

Service Technician

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

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 eye bolt 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.

2-2 – JLG Lift – 3120866

Page 29

SECTION 2 - GENERAL

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

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

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 bear ing 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.

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.

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.

Bolt Usage and Torque Application

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.

     

3120866 – JLG Lift – 2-3



Page 30

SECTION 2 - GENERAL

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 (suc tion) 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 opera tion. 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 speci fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles.

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 oper ating, are recommended for use.

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

machines due to the wear-in of meshing compo nents.

Hydraulic Oil

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

3. The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent. This will allow start up at temperatures down to -20 degrees F (-29 degrees C). However, use of this oil will give poor performance at temperatures above 120 degrees F (49 degrees C). Systems using DTE 13 oil should not be operated at temperatures above 200 degrees F (94 degrees C) 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 man ual. 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.

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 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 evalua tion. Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

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 -15 degrees F (-26 degrees C) is not recom mended. 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 mini mum temperature of -15 degrees F (-26 degrees C).

2-4 – JLG Lift – 3120866

Page 31

SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured using the following methods.

Platform Drift

Measure the drift of the platform to the ground. Lower booms (if equipped) slightly elevated, upper boom fully extended with the rated load in the platform and power off. Maximum allowable drift is 2 inches (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following.

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

Drift is to be measured at the cylinder rod with a calibrated dial indicator. The cylinder oil must be at ambient temperature and temperature stabilized.



The cylinder must have the normal load, which is the normal platform load applied.



If the cylinder passes this test, it is acceptable.

NOTE: This information is based on 6 drops per minute cyl-

inder leakage.

               

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

1. Pinned joints should be disassembled and inspected if the following occurs:

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

2. Filament wound bearings should be replaced if any of the following is observed:

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their hous-

ing.

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection):

a. Detectable wear in the bearing area.

b. Flaking, pealing, scoring, or scratches on the pin

surface.

c. Rusting of the pin in the bearing area.

4. Re-assembly of pinned joints using filament wound bearings.

a. Housing should be blown out to remove all dirt

and debris...bearings and bearing housings must be free of all contamination.

b. Bearing / pins should be cleaned with a solvent

to remove all grease and oil...filament wound bearing are a dry joint and should not be lubricated.

c. Pins should be inspected to ensure it is free of

burrs, nicks, and scratches which would damage the bearing during installation and operation.

3120866 – JLG Lift – 2-5

Page 32

SECTION 2 - GENERAL

2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to

the machine and to welding performed from the machine on an external structure, or component,

Do the Following When Welding on JLG Equipment

• Disconnect the battery.

• Disconnect the moment pin connection (where fitted)

• Ground only to structure being welded.

Do NOT Do the Following When Welding on JLG Equipment

• Ground on frame and weld on any other area than the chassis.

• Ground on turntable and weld on any other area than the turntable.

• Ground on the platform/support and weld on any other area than the platform/support.

• Ground on a specific boom section and weld on any other area than that specific boom section.

• Allow pins, wear pads, wire ropes, bearings, gearing, seals, valves, electrical wiring, or hoses to be between the grounding position and the welded area.

FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)

                     

2.7 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS

Silicone Dielectric Compound must be used on all electrical connections for the following reasons:

• To prevent oxidation at the mechanical joint between male and female pins.

• To prevent electrical malfunction caused by low level conductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. This procedure applies to all plug connections not enclosed in a box. Sili cone grease should not be applied to connectors with external seals.

1. To prevent oxidation, silicone grease must be packed completely around male and female pins on the inside of the connector prior to assembly. This is most easily achieved by using a syringe.

NOTE: Over a period of time, oxidation increases electrical

resistance at the connection, eventually causing circuit failure.

2. To prevent shorting, silicone grease must be packed around each wire where they enter the outside of the connector housing. Also, silicone grease must be applied at the joint where the male and female con nectors come together. Any other joints (around strain reliefs, etc.) where water could enter the connector should also be sealed.

NOTE: This condition is especially common when machines

are pressure washed since the washing solution is much more conductive than water.

3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only.

NOTE: Curing-type sealants might also be used to prevent

shorting and would be less messy, but would make future pin removal more difficult.

2-6 – JLG Lift – 3120866

Page 33

SECTION 2 - GENERAL

Figure 2-1. Connector Assembly Figure 1

Figure 2-2. AMP Connector

2.8 AMP CONNECTOR

Applying Silicone Dielectric Compound to AMP Connectors

Silicone Dielectric Compound must be used on the AMP connections for the following reasons:

• To prevent oxidation at the mechanical joint between male and female pins.

• To prevent electrical malfunction caused by low level conductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.

1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by using a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside the header. When assembling the housing to the header, it is possible that the housing will become air locked, thus preventing the housing latch from engaging.

2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.

3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.

Assembly

Check to be sure the wedge lock is in the open, or asshipped, position

1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 2-3.).

2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the

contact

(See Figure 2-1.). Proceed as follows:

(See Figure 2-3.).

3120866 – JLG Lift – 2-7

Page 34

SECTION 2 - GENERAL

Figure 2-3. Connector Assembly Figure 2

Figure 2-4. Connector Assembly Figure 3

Figure 2-5. Connector Assembly Figure 4

3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them

(See Figure 2-4.).

inward

4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 2-5.).

2-8 – JLG Lift – 3120866

Page 35

SECTION 2 - GENERAL

Figure 2-6. Connector Disassembly

Disassembly

1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs.

2. Pry open the wedge lock to the open position.

3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed.

NOTE: The wedge lock should never be removed from the

housing for insertion or removal of the contacts.

Wedge Lock

The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.

               



Service - Voltage Reading

DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies the effectiveness of the con nector seals and could result in system failure.

3120866 – JLG Lift – 2-9

Page 36

SECTION 2 - GENERAL

Figure 2-7. Connector Installation

2-10 – JLG Lift – 3120866

Page 37

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Boom Assembly

Boom Weldments 1,2,4 1,2,4

Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12

Pivot Pins and Pin Retainers 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pads 1,2 1,2

Covers or Shields 1,2 1,2

Extend/Retract Chain or Cable Systems 1,2,3 1,2,3

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 5 1 1,5

Floor 1,2 1 1,2

Rotator 9,5

Lanyard Anchorage Point 2 1,2,10 1,2,10

Turntable Assembly

Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14

Oil Coupling 9

Swing Drive System

Turntable Lock 1,2,5 1,2,5

Hood, Hood Props, Hood Latches 5 1,2,5

Chassis Assembly

Tires 1 16,17 16,17,18 16,17,18

Wheel Nuts/Bolts 1 15 15 15

Wheel Bearings 14,24

Oscillating Axle/Lockout Cylinder Systems 5,8

Outrigger or Extendable Axle Systems 5,8 5,8

Steer Components

Drive Motors

Torque Hubs 11 11

Functions/Controls

Platform Controls 5 5 6 6

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

Annual

(Yearly)

Inspection

Every 2

Years

3120866 – JLG Lift – 2-11

Page 38

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

Ground Controls 5 5 6 6

Function Control Locks, Guards, or Detents 1,5 1,5 5 5

Footswitch 1,5 5 5

Emergency Stop Switches (Ground & Platform) 5 5 5

Function Limit or Cutout Switch Systems 5 5

Capacity Indicator 5

Drive Brakes 5

Swing Brakes 5

Boom Synchronization/Sequencing Systems 5

Manual Descent or Auxiliary Power 5 5

Power System

Engine Idle, Throttle, and RPM 3 3

Engine Fluids (Oil, Coolant, Fuel) 11 9,11 11 11

Air/Fuel Filter 1,7 7 7

Exhaust System 1,9 9 9

Batteries 5 1,9 19

Battery Fluid 11 11 11

Battery Charger 5 5

Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5

Hydraulic/Electric System

Hydraulic Pumps 1,9 1,2,9

Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9

Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2

Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12

Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 1 20 20

Instruments, Gauges, Switches, Lights, Horn 1 5,23

General

Operators and Safety Manuals in Sto rage Box 21 21 21

ANSI and EMI Manuals/Handbooks Installed 21

Capacity Decals Installed, Secure, Legible 21 21 21

All Decals/Placards Installed, Secure, Legible 21 21 21

Annual

(Yearly)

Inspection

Every 2

Years

2-12 – JLG Lift – 3120866

Page 39

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21

General Structural Condition and Welds 2,4 2,4

All Fasteners, Pins, Shields, and Covers 1,2 1,2

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 21 21 21, 22

Paint and Appearance 7 7

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footnotes:

Prior to use each day; or at each Operator change

Prior to each sale, lease, or delivery

In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased use d

Annually, no later than 13 months from the date of the prior inspection

Performance Codes: 1 - Check for proper and secure installation 2 - Visual inspection for damage, cracks, distortion or excessive wear 3 - Check for proper adjustment 4 - Check for cracked or broken welds 5 - Operates Properly 6 - Returns to neutral or "off" position when released 7 - Clean and free of debris 8 - Interlocks function properly 9 - Check for signs of leakage 10 - Decals installed and legible 11 - Check for proper fluid level 12 - Check for chafing and proper routing 13 - Check for proper tolerances 14 - Properly lubricated 15 - Torqued to proper specification 16 - No gouges, excessive wear, or cords showing 17 - Properly inflated and seated around rim 18 - Proper and authorized components 19 - Fully charged 20 - No loose connections, corrosion, or abrasions 21 - Verify 22 - Perform 23 - Sealed Properly 24 - Drain, Clean, Refill

Annual

Inspection

(Yearly)

Every 2

Years

3120866 – JLG Lift – 2-13

Page 40

SECTION 2 - GENERAL

This page left blank intentionally.

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Page 41

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TORQUE HUB, DRIVE

Disassembly

1. Position hub over suitable container and remove drain plugs (10) from unit. Allow oil to completely drain, then replace drain plugs.

2. Remove eight bolts (41) and four shoulder bolts (42) securing cover assembly to hub (7). Remove cover assembly (23) and discard o-ring seal (22).

3. Lift carrier assembly and top thrust washer and thrust bearing(39, 40) from hub. Thrust washer may stick inside cover.

4. Pry ring gear (21) loose from hub and remove it. Remove o-ring seal (22) from hub counter bore and discard it.

5. Remove input gear (37) and thrust spacer (36) from input shaft assembly and remove input shaft assem bly from hub.

6. Lift internal gear (12) and thrust washer and thrust bearing (39, 40) from hub. Thrust washer may stick to bottom of carrier.

7. Remove retaining ring (9) from spindle (1) and discard; lift hub from spindle.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

8. Remove inside bearing cone (6) and bearing shim (8).

9. If necessary, pry seal (2) out of hub using screwdriver or pry bar. With seal removed, outside bearing cone (4) can be removed.

10. If necessary, remove inner and outer bearing cones (3, 5) using a suitable slide hammer puller.

WHEN REBUILDING TORQUE HUB, REMOVE AND REPLACE ALL O-RINGS AND RETAINING RINGS.

Cleaning and Inspection

1. Thoroughly clean all parts in an approved cleaning solvent.

2. Inspect bearing cups and cones for damage, pitting, corrosion, or excessive wear. If necessary, replace

bearings as a complete set ensuring that they remain covered until use.

3. Inspect bearing mounting surfaces on spindle, hub, input shaft and carrier. Replace components as nec essary.

4. Inspect all geared components for chipped or broken teeth and for excessive or uneven wear patterns.

5. Inspect carrier for damage, especially in anti-roll pin and planet shaft hole areas.

6. Inspect all planet shafts for scoring or other damage.

7. Inspect all threaded components for damage including stretching, thread deformation, or twisting.

8. Inspect seal mounting area in hub for burrs or sharp edges. Dress applicable surfaces or replace compo nents as necessary.

9. Inspect cover for cracks or other damage, and oring sealing area for burrs or sharp edges. Dress applicable surfaces or replace cover as necessary.

Repair

1. Cover Assembly.

a. Remove two bolts (25) securing disconnect cap

(26) to cover (23) and remove cap.

b. Remove two bolts (25) securing cover cap (24)

to cover and remove cap.

c. Remove disconnect rod (27) from cap and

remove o-rings (28, 29) from cover cap. Discard o-rings.

d. If necessary, remove pipe plug (30) from cover.

e. Clean and inspect parts in accordance with

Cleaning and Inspection procedures. Replace parts as necessary.

f. If removed, screw pipe plug into cover.

g. Slip o-ring (29) over cover cap and against face.

h. Place o-ring (28) into cover cap internal groove.

Disconnect rod may be used to push o-ring into groove.

i. Place cover cap into cover with large hole

located over pipe plug. Secure cover cap to cover with two bolts. Torque bolts to 7.9-9.0 Nm (70-80 in. lbs.).

j. Place disconnect cap over cover cap with nipple

facing out and secure with two bolts. Torque bolts to 7.9-9.0 Nm (70-80 in. lbs.).

3120866 – JLG Lift – 3-1

Page 42

SECTION 3 - CHASSIS & TURNTABLE

k. Turn cover over and push disconnect rod into

cover cap. Rod will be held in place by friction from o-ring.

2. Carrier Assembly.

a. Drive anti-roll pin (19) into planet shaft (17) using

a suitable punch.

b. Using a suitable press, press planet shaft from

carrier (13). After planet shaft is removed, drive anti-roll pin from shaft.

c. Remove cluster gear (18) and thrust washers

(14) from carriers.

d. Remove sixteen needle rollers (15) from cluster

gear bore.

e. Remove spacer (16) from cluster gear bore and

remove second set of sixteen needle rollers (15).

f. Repeat steps (a) through (e) for remaining two

cluster gears.

g. Clean and inspect all parts in accordance with

Cleaning and Inspection procedures. Replace parts as necessary.

j. Place spacer into opposite side of cluster gear

and against needle rollers.

k. Place second set of sixteen needle rollers into

cluster gear.

h. Apply a coat of grease or petroleum jelly to clus-

ter gear bore.

i. Place sixteen needle rollers into cluster gear

bore.

l. Apply grease or petroleum jelly to tang side of

two thrust washers. Place thrust washers against bosses in carrier with washer tang fitting into slot in carrier outside diameter.

3-2 – JLG Lift – 3120866

Page 43

SECTION 3 - CHASSIS & TURNTABLE

m. While keeping thrust washers in place, slide

cluster gear into carrier with larger gear on side with small pin hole.

n. Line up cluster gear and thrust washers with

hole in carrier and slide planet shaft through. Ensure chamfered side of hole in planet shaft is lined up with pin hole in carrier.

a. Carefully remove retaining ring (33) from coun-

terbore in the spindle (1) and discard retaining ring.

b. Remove two spacers (31) and spring (32) from

input shaft.

c. Clean and inspect all parts in accordance with

Cleaning and Inspection procedures. Replace parts as necessary.

d. Place washer (31), spring (32), and washer (31),

in that order, onto input shaft.

e. Install retaining ring into input shaft groove to

secure spacers and spring to shaft.

o. Drive anti-roll pin flush into carrier hole, locking

planet shaft into place.

p. repeat steps (h) through (o) for remaining two

cluster gears.

3. Input Shaft Assembly.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL AND INSTALLATION

3120866 – JLG Lift – 3-3

Page 44

SECTION 3 - CHASSIS & TURNTABLE

Assembly

1. Using a suitable press, press new bearing cups (3,

5), with large inside diameters facing out, into hub (7) counter bores.

2. Place bearing cone (4) into bearing cup (3) in small end of hub.

4. Lower hub onto spindle (1) with large open end up.

5. Place bearing cone (6) over end of spindle and into bearing cup.

3. Press new seal (2) into hub counter bore with flat metal side facing in. Use a flat object to ensure that seal is pressed evenly and is flush with hub face.

6. Place bearing shim (8) over end of spindle and against bearing cone.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

3-4 – JLG Lift – 3120866

Page 45

SECTION 3 - CHASSIS & TURNTABLE

7. Install new retaining ring (9) completely into spindle groove and against bearing shim. Ensure retaining ring is entirely in groove.

8. Place internal gear (12) onto end of spindle.

10. Install retaining ring (34) into input shaft retaining ring groove.

11. Place input shaft assembly (35) into spindle bore with unsplined end facing out.

9. Install thrust washers and thrust bearing (39, 40) on the portion of the spindle which extends into the internal gear.

12. Place thrust spacer (36) over input shaft (35) with counter bore side facing spindle.

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Page 46

SECTION 3 - CHASSIS & TURNTABLE

13. Locate the four counter reamed holes in the face of the hub, mark them for later identification.

14. Place o-ring (22) into hub counter bore. Use petroleum or grease to hold o-ring in place. Slight stretching of o-ring may be necessary to insure proper seating.

15. Place carrier assembly on a flat surface with large gears up and positioned as shown. Find punch marked tooth on each large gear and locate at 12 o’clock (straight up) from each planet pin. Marked tooth will be located just under carrier on upper two gears.

16. With shoulder side of ring gear (21) facing down, place ring gear over (into mesh with) large gears. Ensure punch marks remain in correct location dur ing ring gear installation.

                       

3-6 – JLG Lift – 3120866

Page 47

SECTION 3 - CHASSIS & TURNTABLE

17. While holding ring gear, input gear, and cluster gears in mesh, place small side of cluster gears into mesh with internal gear. On ring gear, locate hole marked ‘X’ over one of counter bored holes in hub.

NOTE: If gears do not mesh easily or carrier assembly does

not rotate freely, then remove carrier and ring gear and check cluster gear timing.

18. Install input gear (37) into carrier, meshing with large diameter cluster gears (18). Counter bore in bore of input gear must be to outside of carrier assembly.

19. After inserting at least one shoulder bolt in the proper location, rotate the carrier. Check freedom of rotation and timing.

20. Install thrust washers and thrust bearing (39, 40) into carrier counter bore.

21. Place o-ring (22) into cover assembly counter bore. Use petroleum jelly or grease to hold o-ring in place.

3120866 – JLG Lift – 3-7

Page 48

SECTION 3 - CHASSIS & TURNTABLE

22. Place cover assembly over ring gear with oil level check plug in cover located approximately 90 degrees from oil fill plug in hub.

23. Locate four shoulder bolts (42), 90 degrees apart into counter bored holes in hub marked in step (13). Torque shoulder bolts to 47 ft. lbs. (64 Nm.

24. Install bolts (41) in remaining holes. Torque bolts to 47 ft. lbs. (64 NM.

25. Place coupling (1) into spindle and onto input shaft.

26. Fill hub one-half full of EPGL 90 lubricant before operation.

3-8 – JLG Lift – 3120866

Page 49

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-1. Torque Hub, Drive (Fairfield)

3120866 – JLG Lift – 3-9

Page 50

SECTION 3 - CHASSIS & TURNTABLE

3.2 TORQUE HUB, DRIVE (AUBURN GEAR)

Disassembly

1. Position hub over suitable container and remove drain plugs (27) from unit. Allow oil to completely drain, then replace drain plugs.

2. Remove twelve bolts (25) and flat washers (26) and the cover from the hub (9). The thrust washer (21) and the disengage plunger (22) usually remain with cover (24) when it is removed. Remove thrust washer (21), disengage plunger (22) and o-ring (23) from the cover (24), discard o-ring seal (23).

3. Remove primary sun gear (20) from input shaft (2).

4. Remove the primary carrier assembly (19).

5. Remove the secondary carrier assembly (18). It may be necessary to remove the ring gear (17) first, if difficulty is encountered removing the carrier.

6. Remove the input shaft (2) from spindle (3). Remove the retaining rings (14), washers (15), and spring (16) from input shaft (2) only if replacement is required.

NOTE: The retaining rings (14), washers (15) and disen-

gage spring (16) are not included in unit equipped with a cast iron disengage cover (29).

7. If not previously removed (see step 5), remove ring gear (17) from hub (9). It may be necessary to strike ring gear (17) with a rubber mallet to loosen from hub (9).

8. Remove the retaining ring (13) from groove in spindle (3).

NOTE: Use a retaining ring expander tool to remove retain-

ing ring (13).

9. Lift hub (9) from spindle (3). If bearings are not a loose fit, it may be necessary to press spindle (3) from hub (9).

10. Remove oil seals (4) and (5) and bearing cones (6 &

11) from the hub (9). Inspect bearing cups (7 & 10) in position and remove only if replacement is required.

Assembly

2. Assemble bearing cone (6) into cup (7) at seal end of hub (9) and press a new seal (5) into hub. Install boot seal (4) on the hub (9) if hub is so equipped.

3. Position spindle (3) upright on bench. Lubricate lips of seals (4) and (5) and lower hub onto spindle (3). Hub should be centered as it is lowered over spindle (3) to prevent seal damage.

4. Assemble bearing cone (11) over spindle (3) and into bearing cup (10). Replace thrust washer (12) over spindle end splines and on bearing cone (11).

5. Select the thickest ring (13) that can be assembled into the ring groove of the splined end of spindle (3) above bearing. Bearing should have from 0.000 -

0.006 inches (0.00 - 0.15 mm) of end play when proper retaining ring (13) is installed.

6. For hubs equipped with the standard spring disconnect or optional quick disconnect, assemble a washer (15), spring (16), a second washer (15), and retaining ring (14) in the middle grooves of the input shaft (2). Install second retaining ring (14) in groove near small end of input shaft.

7. Assemble the splined end of the input shaft (2) down into spindle (3).

8. Assemble the secondary carrier assembly (18) to spindle (3) at splines.

9. Clean mating surfaces and apply a bead of silicone sealant to face of hub (9) that mates with ring gear (17). Assemble ring gear (17) to hub (9), being care ful to align bolt holes.

10. Assemble the primary carrier assembly (19) into the ring gear (17). It will be necessary to rotate carrier to align secondary sun gear (part of primary carrier assembly (19)) with planet gear teeth in secondary carrier assembly (18). Assemble primary sun gear (20) over input shaft (2). Rotate primary sun gear (20) to align input shaft (2) to gear splines and gear teeth in primary carrier assembly (19).

11. Lubricate o-ring (23) and assemble in groove inside cover hole, then push disengage plunger (22) into cover with pointed end facing inside of hub.

NOTE: These parts (22 & 23) are not included in hubs pro-

duced with a cast iron disengage cover (29).

12. For hubs with the standard spring disengage, assemble the thrust washer (21) with tangs engaged with cover (24). Note: A small amount of grease applied to the back side of thrust washer (21) will hold washer in place.

1. If necessary press new bearing cups (7 & 10) in each end of the hub (9). It is recommended that bearing cups (7 & 10) and cones (6 & 11) be replaced in sets.

13. Assemble cover (24), aligning holes of cover and ring gear. Assemble the twelve bolts (25) and flat washer (26). Torque bolts to 61 - 67 Nm (45 - 50 ft. lbs.).

3-10 – JLG Lift – 3120866

Page 51

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-2. Torque Hub, Drive (Auburn Gear)

3120866 – JLG Lift – 3-11

Page 52

SECTION 3 - CHASSIS & TURNTABLE

3.3 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 replaced.

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.With shaft protrusion downward, remove end cover (13) by removing capscrews (12).

2. 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 PIS TON WILL COCK RESULTING IN A COMPLETE LOSS OF BRAKING.

3. 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).

4. 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.

5. Press the shaft into the housing until it stops on the bearing. Support the inner race of the bearing during the press operation.

6. 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.

Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.

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.

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

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

                



3-12 – JLG Lift – 3120866

Page 53

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-3. Drive Brake Assembly (Ausco)

3120866 – JLG Lift – 3-13

Page 54

SECTION 3 - CHASSIS & TURNTABLE

3.4 DRIVE BRAKE - MICO

Disassembly

1. Remove pressure plate (3) from cover plate (16) by removing cap screws (1) and washers (2).

PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 907 KGF (2000 IBS). THE TWO CAP SCREWS MUST BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE, 1361 KGF (3000 IBS) MINIMUM, THE PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS. COVER PLATE (16) MUST BE SUPPORTED AS SHOWN IN

NOTE: Not all models use the same number of springs or

NOTE: Cover plate (16) must be supported as shown in FIG-

NOTE: Cover plate (16) must be sup¦ported as indicated in

FIGURE 3-4.

2. Remove case seal (4) from cover plate (16).

3. Remove piston (7) from pressure plate (3).

4. Remove a-ring (5), back-up ring (6), a-ring (8) and

back-up ring (9) from piston (7).

5. Remove stator disc (11), rotor disc (12) and return plate (13) from cover (16).

spring pattern.

6. Remove dowel pins (15) and springs (14) from cover plate (16). Record this information for assembly purposes.

7. Remove retaining ring (19) from cover plate (16).

8. Remove shaft (10) by pressing or using a soft mallet

on male end of shaft (10).

URE 3-4.

9. Remove retaining ring (20) from cover plate (16) and press out oil seal (17) and bearing (18) if required.

Figure 3-4.

Assembly

LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH CLEAN TYPE FLUID USED IN THE SYSTEM.

1. Use an alkaline wash to clean parts before assembly.

NOTE: Cover plate (16) must be supported as indicated in

Figure 1.

4. Install retaining ring (20) in cover plate (16).

5. Press shaft (10) into bearing (18) until it bottoms on

shoulder.

NOTE: Bearing (18) inner race and cover plate (16) must be

supported as indicated in Figure 1 during this opera tion.

6. Install retaining ring (19) on shaft (10).

7. Insert dowel pins (15) and springs (14) in cover plate

(16).

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly.

8. Position return plate (13) on springs (14).

NOTE: Discs (11 & 12) and return plate (13) must remain

dry during installation. No oil residue must be allowed to contaminate disc surfaces.

9. Install rotor disc (12) and stator disc (13).

10. Install o-ring (5), back-up ring (6), a-ring (8) and

back-up ring (9) on piston (7). Note order of a-rings and back-up rings. Insert piston (7) into pressure plate (3).

NOTE: Be careful not to shear o-rings or back-up rings. Be

careful not to scratch or mar piston.

11. Install new case seal (4) in cover plate (16).

12. Position pressure plate (3) on cover plate (16) align-

ing dowel pins (15) with holes in pressure plate.

13. Install cap screws (1) and washers (2) and tighten evenly to draw pressure plate (3) to cover plate (16). Torque cap screws 65.1-67.8 N-m (48-50 Ib-ft).

NOTE: A hydraulic press will simplify installation of pressure

plate on cover. Clamp pressure plate in position while tighten¦ing the cap screws. Cover plate (16) must be supported as indicated in

Figure 3-4.

2. Press oil seal (17) into cover plate (16) until it is flush with bearing shoulder. Note direction of seal.

3. Press bearing (18) into position until it bottoms out on borestep.

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE MUST NOT EXCEED

134.5 BAR (500 PSI).

3-14 – JLG Lift – 3120866

Page 55

SECTION 3 - CHASSIS & TURNTABLE

1. Capscrew

2. Washer

3. Pressure Plate

4. Case Seal

5. O-ring

6. Backup Ring

7. Piston

8. O-ring

9. Backup Ring

10. Shaft

11. Stator Disc

12. Rotor Disc

13. Return Plate

14. Springs

15. Dowel Pin

16. Cover Plate

17. Oil Seal

18. Bearing

19. Retaining Ring

20. Retaining Ring

Figure 3-4. Drive Brake - Mico

3120866 – JLG Lift – 3-15

Page 56

SECTION 3 - CHASSIS & TURNTABLE

Bleeding

1. Install brake in system and connect pressure lines.

2. Bleed pressure release section of brake by pressur-

izing side inlet port and allowing air to escape from

Table 3-1. Troubleshooting

PROBLEM CAUSE EXPLANATION ACTION

Brake slips Excessive pressure in hydraulic system If there is back pressure in the actuation

line of the brake, holding torque will be reduced.

Oil in brake if designed for dry use Wet linings generate 67% of the dry

torque rating. If the brake has oil in it, check the type of oil hydraulic or gearbox. 1 . Gearbox oil

2. Hydraulic oil

Disc plates worn The thickness of the disc stack sets the

torque level. A thin stack reduces torque.

Springs broken or have taken a permanent set

Brake drags or runs hot Low actuation pressure The brake should be pressurized to mini-

Bearing failure If the bearing should fail, a large amount of

Brake will not release Stuck or clogged valve Brakes are designed to come on when

Bad o-rings If release piston will not hold pressure,

Discs frozen These brakes are designed for only lim-

Broken or set springs can cause reduced torque - a rare occurrence.

mum of 1.38 bar (20 psi) over the full release pressure under normal operating conditions. Lower pressures will cause the brake to drag thus generating heat.

drag can be generated.

system pressure drops below stated release pressure. If pressure cannot get to brake, the brake will not release.

brake will not release.

ited dynamic braking. A severe emergency stop or prolonged red uced release pressure operation may result in th is type of damage.

top port. Pressure should not exceed 6.9 bar (100 psi) during bleeding.

3. Apply sufficient pressure to release brake and check for proper operation in system.

Check filters, hose size, restrictions in other hydraulic components.

Replace oil seal in brake. Check motor seal Check piston seals

NOTE: Internal components will

Check disc thickness.

Check release pressure. (See spring replacement).

Place pressure gauge in bleed port & check pressure with system on.

Replace bearing.

Place pressure gauge in bleed port check for adequate pressure. Replace inoperative line or component.

Replace o-rings.

Replace disc stack.

need to be inspected, cleaned and replaced as required.

3-16 – JLG Lift – 3120866

Page 57

SECTION 3 - CHASSIS & TURNTABLE

3.5 DRIVE MOTOR (PRIOR TO S/N 85132)

Spare Parts Kits

Sealing kit, existing spare parts: shaft sealing ring, 6 different O-rings and a circlip (sealing mat.: perbunan)

Same sealing kit like shown above only seal material changed to Viton

Drive shaft

3120866 – JLG Lift – 3-17

Page 58

SECTION 3 - CHASSIS & TURNTABLE

Bearing set/miscellaneous parts

Rotary group complete 9 pistons, cylinder sub-assembly, valve plate (cw or ccw corresponding to the order) retaining plate and retaining ball.

Spare parts kit DFR pilot valve

Replacing the Drive Shaft Seal

1. Remove the snap ring

Swash Plate

Parts of the control device: control piston, piston rod, plug, spring stopper max flow, hex. nut, and hex. head nut

2. Change the shaft seal and check its sliding surface (drive shaft) and housing, grease the sealing ring.

3. Be careful while you seal the drive shaft, use an adhesive tape to protect the splines.

3-18 – JLG Lift – 3120866

Page 59

SECTION 3 - CHASSIS & TURNTABLE

4. Assemble the sealing ring. The fitting tool will hold the sealing ring in the correct position in the pump housing.

5. Assemble the snap ring.

Disassembly and Assembly

1. Disassemble the pilot valve.

2. Mark the position of the port plate and remove the socket screw from the port plate.

6. Assemble the snap ring in the correct position.

3. Remove the port plate together with the valve plate (hold the valve plate so that the plate can’t fall down).

3120866 – JLG Lift – 3-19

Page 60

SECTION 3 - CHASSIS & TURNTABLE

4. Remove the O-ring.

5. Disassemble the taper roller bearing.

8. Loosen the retaining nut of the stopper max flow and remove it.

9. Turn in the stopper max flow to get swivel angle zero.

6. Remove the adjustment shim.

7. Unscrew the cap nut and remove it.

10. Disassemble the rotary group in horizontal position.

11. Disassemble the stopper - max. flow.

3-20 – JLG Lift – 3120866

Page 61

SECTION 3 - CHASSIS & TURNTABLE

12. Remove the threaded pin (stopper - max.flow)

13. Disassemble the plug.

14. Disassemble the control piston while moving the swash plate.

16. Disassembly of the swash plate.

17. Remove the spring.

18. Remove both bearing shells.

19. Remove the drive shaft.

15. The swash plate must be lifted a little bit to disassemble the piston rod.

3120866 – JLG Lift – 3-21

Page 62

SECTION 3 - CHASSIS & TURNTABLE

20. Remove the snap ring.

21. Disassemble the sealing ring.

23. Remove the O-ring. Lifting of the valve plate isn’t shown.

24. A usual commercial bearing puller is used to disassemble the external bearing ring of the taper roller bearing inside the port plate. Take care not to damage the surface of the port plate.

22. The external front bearing ring is pulled out of the pump housing.

25. The spring has additional pretension while you disassemble the three pressure pins inside the cylinder.

3-22 – JLG Lift – 3120866

Page 63

SECTION 3 - CHASSIS & TURNTABLE

Assembly Notes

1. Measurement of the taper roller bearing pretension.

2. Note that there is a correct connection of the piston rod and the swash plate.

4. Pumps counterclockwise driven must have a position of the valve plate 4 degrees de-centered in ccw position.

5. Assembly of the port plate and the pump housing: Note the correct position of the drilling that connects high pressure to the control valve. Check control valve drill position at the pump housing and fit together.

3. Pumps clockwise driven must have a position to the valve plate 4 degrees out of center in the same direction de-centered like drive direction. (Note spare parts exist as cw and ccw valve plates.)

Taper Roller Bearing Initial Tension

Cast iron pump housing must have initial tension of the

bearings: 0........0,05 mm, grind Pos. 12 if necessary.

3120866 – JLG Lift – 3-23

Page 64

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Differential volume if you are rotating the threaded pin -

each rotation is appr. 3,1 cm3.

Figure 3-5. Flow Control Pilot Valves

3-24 – JLG Lift – 3120866

Page 65

Te s t i n g a n d S e t u p

DR: When pressure line is closed adjust the pressure of the controller (if it’s DFR design then open the adjustable orifice and increase force of the spring - FR -).

FR: If swivel angle is in the mid position adjust differential pressure 14 bar adjustable orifice is partly closed).

SECTION 3 - CHASSIS & TURNTABLE

Mechanical flow limiter: While screwing in the threaded pin you will be able to reduce the flow from Vg max to 50% of Vg max.

3120866 – JLG Lift – 3-25

Page 66

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-6. Drive Motor Adjustment

3.6 DRIVE MOTOR ADJUSTMENT PROCEDURE (PRIOR TO S/N 85132)

1. Remove the cap nut from adjustment screw.

2. Loosen jam nut on the adjustment screw and make adjustment.

3. Measure from top of jam nut to the end of adjustment screw. (See Figure 3-6., Drive Motor Adjustment.)

4. Tighten jam nut, install cap nut.

NOTE: The “o” ring must be seated in groove in cap nut.

                          



3-26 – JLG Lift – 3120866

Page 67

SECTION 3 - CHASSIS & TURNTABLE

Bias spring

Servo piston

Swashplate

Output

Shaft

Piston

Slipper

Cylinder Block

Endcap

Shaft Seal

Bearing

Minimum Angle Stop

Valv

e plate

Figure 3-7. Drive Motor Cross Section

1. Snap Ring

2. Support Washer

3. Shaft Seal

Figure 3-8. Removing the Shaft Seal

3.7 DRIVE MOTOR (S/N 85132 TO PRESENT)

Description

The drive motors are low to medium power, two-position axial piston motors incorporating an integral servo piston. They are designed for operation in both open and closed circuit applications. The standard control is a direct acting single line hydraulic control. The integral servo piston con trols motor displacement.

The motors are spring biased to maximum displacement and hydraulically shifted to minimum displacement. Minimum and maximum displacement can be set with fixed internal stops. The large diameter servo piston allows smooth acceleration and deceleration with relatively large circuit orificing.

Shaft Seal Replacement

REMOVAL

1. Remove the snap ring (1) retaining the shaft seal and support washer.

3120866 – JLG Lift – 3-27

2. Remove the support washer (2).

3. Carefully pry out the shaft seal (3).



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

4. Discard the seal.

INSPECT THE COMPONENTS

Inspect the new seal, the motor housing seal bore, and the sealing area on the shaft for rust, wear, and contami nation. Polish the shaft and clean the housing if necessary.

INSTALLATION

1. Cover the shaft splines with an installation sleeve to protect the shaft seal during installation.

2. Install a new shaft seal with the cupped side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal.

3. Install seal support washer.

4. Install snap ring.

5. Remove the installation sleeve.

Page 68

SECTION 3 - CHASSIS & TURNTABLE

(37 Nm)

27 ft.lbs.

11/16 in

(37 Nm)

27 ft.lbs.

11/16 in

(27 Nm)

20 ft.lbs.

5/8 in

1. Plug

2. Plug

3. Plug

4. O-ring

5. O-ring

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

12. Shift Spool

13. Orifice Poppet

Figure 3-9. Loop Flushing Spool

Loop Flushing Valve

REMOVAL

1. Using a 11/16 in internal hex wrench remove plug (1) and (2).

INSPECT THE COMPONENTS

Inspect new O-rings and the sealing area for rust, wear, or contamination. Also check springs and poppet for wear.

INSTALLATION

1. Install orifice poppet (13).

2. Install shift spool (12).

3. Install spring retaining washers onto springs (10 and

11).

4. Carefully install centering springs (7, 8, and 9).

5. Install new O-rings (6, 4, and 5).

6. Using a 1/4 in hex wrench torque plug (3) to 20 ft. lbs. (27 Nm).

7. Using a 11/16 in internal hex, torque plugs (2 and 1) to 27 ft.lbs. (37 Nm).

2. Using a 1/4 in hex wrench remove plug (3).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

         

3-28 – JLG Lift – 3120866



Page 69

Troubleshooting

Item Description Action

Check oil level in reservoir and oil supply to the motor.

Table 3-2. Excessive Noise and/or Vibration

Insufficient hydraulic fluid could lead to cavitation that would cause system noise.

SECTION 3 - CHASSIS & TURNTABLE

Fill the reservoir to the proper level and ensure that oil suppl y to the motor is adequate and the lines are unobstructed.

Check for air in the system.

Inspect the output shaft couplings.

Inspect the output shaft alignment.

Hydraulic oil viscosity above limits.

Item Description Action

Check oil level in reservoir and oil supply to the pump.

Inspect the heat exchanger, (if so equipped).

Check the system relief valves.

Air trapped within the system lines, or the motor itself, could result in cavitation that would cause system noise.

A loose or incorrect shaf t coupling will produce vibrations that could result in system noise.

Misaligned shafts create excessive frictional vibration that could result in system noise.

Viscosity above acceptable limits will result in cavitation that would lead to system noise.

Table 3-3. System Operating Hot

Insufficient amount of hydraulic fluid will not meet the cooling demands of the system.

I f t he h ea t ex ch a ng er f ai l s, or becomes obstructed, it may not meet the cooling demands of the system.

If a system relief valve becomes unseated for an extended period of time or fails for any other reason, the system could become overheated.

Ensure that all of the system lines and components are purged of air.

Ensure that the correct coupling is used and that it fits properly onto the shaft.

Ensure that the shafts are properly aligned.

Replace hydraulic oil with appropriate fluid for operating conditions.

Fill the reservoir to the proper level.

Ensure that heat exchanger is receiving adequate air flow and that the heat exchanger is in good operating condition. Repair or replace as necessary.

Repair or replace any malfunctioning relief valves as applicable and verify that the loads on the machine are not excessive.

Table 3-4. Won’t Shift or Slow to Start

Item Description Action

Check the signal line to the servo control por t.

Check that the correct supply and drain orifices are properly installed, and are not obstructed.

Obstructed or restricted flow through the servo control signal lines could result in slow shif t or no shift conditions within the motor.

Supply and drain orifices determine the shift rate of the motor. The smaller the orifice, the longer the time it takes to shift the motor. Obstruction will also increase shift times.

Ensure that the signal lines are not obstructed or restricted and that signal pressure is adequate to shift the motor.

Ensure that the proper control orifices are installed in the motor and verify that they are not obstructed. Clean or replace as necessary.

3120866 – JLG Lift – 3-29

Page 70

SECTION 3 - CHASSIS & TURNTABLE

1. Plug

2. Plug

3. Plug

4. O-ring

5. O-ring

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

12. Shift Spool

13. Orifice Poppet

Figure 3-10. Loop Flushing Spool

182114

14. Lock Nut

15. O-ring Plug

16. Control Line Plug

17. Control Line Plug

18. Cavity Plug

19. Drain Plug

20. Drain Plug

21. Work Port Plug

Figure 3-11. Plugs, Fittings, and Speed Sen-

sor

Disassembly

NOTE: Removal of the endcap voids warranty.



During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up.



Replace all O-Rings and gaskets.



It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.



1. Using a 11/16 in wrench remove plug (1) and (2).

2. Using a 5/8 in hex wrench remove plug (3).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

3-30 – JLG Lift – 3120866

8. Remove all fittings from the unit. Discard any O-rings on the fittings.

9. Using an 11/16 inch hex wrench, loosen the speed sensor lock nut (14) if equipped. Then remove the speed sensor using a Vi inch hex wrench. Units with

out speed sensor have an O-ring plug (15) installed in that location; remove it with a Va inch internal hex wrench.

10. Using a 1/4 inch internal hex wrench, remove control line plugs (16, 17). Discard O-rings. Using a 3 mm hex wrench, remove cavity plug (18, if equipped with two-line control) from X2 cavity.

11. Using a 5/16 inch internal hex wrench, remove drain plugs (19, 20). Discard O-rings.

12. Using a 9/16 inch internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings.

Page 71

SECTION 3 - CHASSIS & TURNTABLE

22. Screw

23. End Cap

24. O-ring

Figure 3-12. End Cap

292725

25. Valve Plate

26. End Cap

27. O-ring

28. O-ring

29. Angle Stop

30. Servo Spring

Figure 3-13. Valve Plate & Rear Shaft Bearing

13. Using an 8 mm internal hex wrench, remove the endcap screws (22).

14. Remove the endcap (23). Remove O-ring (24) from the housing or endcap.



When the endcap screws are removed, pressure from the servo spring will cause the endcap to bind on the shaft. Press down on the portion of the end cap covering the servo piston and hold the endcap level while removing.



TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE PLATE.

15. Remove the valve plate (25) and timing pin (26) from the endcap.



Each displacement has a unique valve plate. For identification, the last two digits of the valve plate part number are stamped on its surface.

16. Remove and discard the O-rings (27, 28).

17. Remove the rear shaft bearing (29) from the endcap with a bearing puller.



The bearing may be difficult to remove with a puller. Try this as an alternative: Pack the bearing cavity with heavy grease. After the shaft is removed, insert it into the bearing cavity and tap lightly with a soft mallet on the splined end. The grease will force the bearing out. Use caution not to drive the bearing past the rear shaft journal as the bearing may become trapped on the shaft and damaged.

3120866 – JLG Lift – 3-31

18. Remove minimum angle stop (29) and servo spring (30) from the housing.

Page 72

SECTION 3 - CHASSIS & TURNTABLE

31. Cylinder Kit Assembly

Figure 3-14. Cylinder Kit

32. Snap Ring

33. Suppor t Washer

34. Shaft Seal

Figure 3-15. Shaft Seal

35. Inner Snap Ring

36. Snap Ring

37. Bearing

38. Shaft

Figure 3-16. Shaft & Front Bearing

19. Turn the housing on its side and remove the cylinder kit assembly (31). Set the assembly aside, being careful not to scratch the running surface.

NOTE: Grooves on the surface of the cylinder kit identify its

displacement:

Table 3-5. Displacement Identifiers

the support washer (33) and carefully pry out the shaft seal (34). Discard the seal.



To avoid damaging the shaft during seal removal. Install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal.

# of Grooves Frame L Frame K

1 25 38

2 30 45

3 35 - -

21. Remove the inner snap ring (35) and the shaft / bearing assembly.

22. Remove the snap-ring (36) retaining the shaft front bearing. Pull the bearing (37) off of the shaft (38).

20. Turn the housing over and remove the snap ring (32)

3-32 – JLG Lift – 3120866

retaining the shaft seal and support washer. Remove

Page 73

SECTION 3 - CHASSIS & TURNTABLE

Lift here

39. Swashplate

40. Servo Piston

41. Piston Seal

42. O-ring

43. Journal Bearings

Figure 3-17. Swash Plate & Servo Piston

51505253464948

474544

44. Piston

45. Slipper Retainer

46. Cylinder Block

47. Ball Guide

48. Holddown Pins

49. Retaining Ring

50. Block Spring Washer

51. Spiral Retaining Ring

52. Block Spring

53. Inner Block Spring Washer

Figure 3-18. Cylinder Kit Disassembly

23. Turn housing over and remove the swashplate (39) by lifting on the end opposite the servo lever.

24. Remove the servo piston (40). Remove the piston seal (41) and O-ring (42) from the servo piston. Discard the seal and O-ring.

25. Remove the journal bearings (43) from the housing. If the bearings are to be reused, note the location and orientation of each bearing for reassembly.

3120866 – JLG Lift – 3-33

26. Remove pistons (44) and slipper retainer (45) from the cylinder block (46).



The pistons are not selectively fitted, however units with high hourly usage may develop wear patterns. Number the pistons and bores for reassembly if they are to be reused.

27. Remove the ball guide (47), hold-down pins (48), and retaining ring (49) from the cylinder block.

NOTE: Most repairs do not require block spring removal.

Perform this procedure only if you suspect problems with the block spring.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED.

Page 74

SECTION 3 - CHASSIS & TURNTABLE

Table 3-7. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A)

50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)

Cylinder Block Surface Flatness

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

28. Turn the block over. Using a press, apply pressure on the block spring washer (50) to compress the block spring. Compress the spring enough to safely remove the spiral retaining ring (51). While maintain ing pressure, unwind the spiral retaining ring (51). Carefully release the pressure and remove the outer block spring washer (50), block spring (52), and inner block spring washer (53) from the cylinder block.

Inspection

After disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and allow to air dry. Blow out oil passages in the housing and endcap with compressed air. Conduct inspection in a clean area and keep all parts free from contamination. Clean and dry parts again after any rework or resurfacing.

PISTON

Inspect the pistons for damage and discoloration. Discolored pistons may indicate excessive heat; do not reuse.

SLIPPERS

Inspect the running surface of the slippers. Replace any

piston assemblies with scored or excessively rounded slipper edges. Measure the slipper foot thickness. Replace any piston assemblies with excessively worn slip pers. Check the slipper axial end-play. Replace any piston assemblies with excessive end-play.

Minimum slipper foot thickness and maximum axial endplay are given in the table below.

Table 3-6. Slipper Foot Thickness & End Play

Measurement L Frame K Frame

Slipper Foot Thickness

Piston/Slipper End Play

(in.)

2.71

(0.11)

4.07

(0.16)

0.15

(0.006)

CYLINDER BLOCK

Measure the cylinder block height. Replace blocks worn beyond the minimum height specification. Inspect the run ning surface of the cylinder block. Replace or resurface worn or scratched blocks. Blocks may be resurfaced to the specifications shown in the drawing, provided resurfacing will not reduce the block height below the minimum specification.

Table 3-7, Cylinder Block Measurements.

3-34 – JLG Lift – 3120866

Page 75

SECTION 3 - CHASSIS & TURNTABLE

Slipper retainer

Ball guide

3.83 mm [0.151 in] min.

0.025 mm [0.001 in]

0.0076 mm [0.00030 in]

convex max

25.8 mm [1.015 in]

24.6 mm [0.969 in]

Thickness equality side to side:

0.05 mm [0.002 in]

0.0025 mm [0.0001 in]

BALL GUIDE AND SLIPPER RETAINER

Inspect the ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat. Do not reuse.

VALVE PLATE

The condition of the valve plate is critical to the efficiency of the motor. Inspect the valve plate surfaces carefully for excessive wear, grooves, or scratches. Replace or resurface grooved or scratched valve plates. Measure the valve plate thickness and replace if worn beyond the minimum specification. Valve plates may be resurfaced to the specifications shown in the drawing, provided resurfacing will not reduce the thickness below the minimum specification.

Replace swashplate if the difference in thickness from one side to the other exceeds specification.

Inspect the journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively worn. The polymer wear layer must be smooth and intact.

SHAFT BEARINGS

Inspect bearings for excessive wear or contamination. Rotate the bearings while feeling for uneven movement. Bearings should spin smoothly and freely. Replace bear ings that appear worn or do not rotate smoothly.

SWASHPLATE AND JOURNAL BEARINGS

Inspect the running face, servo ball-joint, and swashplate journal surfaces for damage or excessive wear. Some material transfer may appear on these surfaces and is acceptable providing the surface condition meets specifi cations shown. Measure the swashplate thickness from the journals to the running face. Replace swashplate if

SHAFT

Inspect the motor shaft. Look for damage or excessive wear on the output and block splines. Inspect the bearing surfaces and sealing surface. Replace shafts with dam aged or excessively worn splines, bearing surfaces, or sealing surfaces.

damaged or worn beyond minimum specification.

3120866 – JLG Lift – 3-35

Page 76

SECTION 3 - CHASSIS & TURNTABLE

1. O-ring

2. Piston Seal

3. Servo Piston

Figure 3-19. Servo Piston

SERVO PISTON AND MINIMUM ANGLE STOP

Inspect the minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. Replace if necessary.

LOOP FLUSHING SPOOL

Inspect the loop flushing spool. Check for cracks or damage. Replace if necessary.

Assembly

1. Install new O-ring (1) and piston seal (2) to the servo piston (3). Install the piston seal over the O-ring.



Installing the piston seal stretches it, making it difficult to install the servo piston in its bore. Allow 30 minutes for the seal to relax after installation. To speed up seal relaxation, compress the seal by installing the piston head into the servo cavity in the end-cap and let it stand for at least five minutes.



3-36 – JLG Lift – 3120866

2. After piston seal has relaxed, lubricate and install servo piston into the housing bore. Align the piston with the ball socket facing the inside of the housing.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED.

3. Install the inner block spring washer (4), block spring (5), and outer washer (6) into the cylinder block. Using a press, compress the block spring

Page 77

SECTION 3 - CHASSIS & TURNTABLE

4. Block Spring Washer

5. Block Spring

6. Outer Washer

7. Spiral Retaining Ring

8. Retaining Ring

9. Holddown Pins

10. Ball Guide

11. Piston

12. Slipper Retainer

Figure 3-20. Cylinder Kit Assembly

13. Journal Bearings

14. Swash Plate

Figure 3-21. Swash Plate and Journal Bearing

enough to expose the retaining ring groove. Wind the spiral retaining ring (7) into the groove in the cylinder block.

6. Install the journal bearings (13) into the housing seats. Use assembly grease to keep the bearings seated during assembly. Ensure the locating nubs drop into the cavities in the seats. If you're reusing the bearings, install them in the original location and orientation. Lubricate the journal bearings.

4. Turn the block over and install the retaining ring (8), hold-down pins (9), and ball guide (10) to the cylin der block.

5. Install the pistons (11) to the slipper retainer (12). Install the piston/retainer assembly into the cylinder block. Ensure the concave surface of the retainer seats on the ball guide. If you're reusing the pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder kit aside on a clean sur face until needed.

     

3120866 – JLG Lift – 3-37

  

7. Install the swashplate (14) into the housing. Tilt the swashplate and guide the servo lever ball into its socket in the servo piston rod. Ensure the swash

plate seats into the journal bearings and moves freely. Lubricate the running surface of the swashplate.

 

       

          

Page 78

SECTION 3 - CHASSIS & TURNTABLE

15. Front Shaft Bearing

16. Shaft

17. Snap Ring

18. Snap Ring

Figure 3-22. Shaft and Front Bearing

19. Cylinder Kit

Figure 3-23. Cylinder Kit Installation

20. Servo Spring

21. Minimum Angle Stop

Figure 3-24. Servo Spring and Minimum

Angle Stop

8. Press front shaft bearing (15) onto shaft (16). Press bearing onto shaft with lettering facing out. Lubricate bearing rollers. Install snap-ring (17) onto shaft.

10. Verify swashplate and bearings are properly seated. Install the cylinder kit (19) onto the shaft. Install with the slippers facing the swashplate. Rock the shaft to align the block splines and slide the cylinder kit into place. Orient the motor with the shaft pointing downward and verify the cylinder kit, swashplate, journal bearings, and servo piston are all secure and properly installed.

11. Lubricate and install the servo spring (20), and minimum angle stop (21) into the housing bore.

9. While holding the swashplate in place, turn the housing on its side. Install the install shaft/bearing assembly into housing from the flange end. Install the snap-ring (18).

                 

3-38 – JLG Lift – 3120866



Page 79

SECTION 3 - CHASSIS & TURNTABLE

3 mm

[0.12 in]

2 mm

[0.08 in]

22. Rear Shaft Bearing

23. Timing Pin

24. Valve Plate

Figure 3-25. Valve Plate and Rear Bearing

8 mm

(47-61 Nm)

35-45 ft.lbs.

25. End Cap

26. Screw

Figure 3-26. End Cap

12. Press the rear shaft bearing (22) into the endcap. Install the bearing with letters facing out. Press until bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) above endcap surface.

15. Install the endcap (25) onto the housing with the endcap screws (26). Check to ensure the endcap will properly seat onto the housing without interference. Improper assembly of the internal components may prevent the endcap from seating properly. Ensure the O-rings seat properly when installing the endcap.

13. Install timing pin (23) into its bore in the endcap. Install the pin with its groove facing toward or away from the shaft. Press the pin until the end protrudes

0.12 ±0.01 in (3 ±0.25 mm) above endcap surface.

14. Install the valve plate (24) onto the endcap. Install the valve plate with the yellow surface toward the cylinder block. Align the slot in the valve plate with the timing pin. Apply a liberal coat of assembly grease to the endcap side of the valve plate to keep it in place during installation.

          

3120866 – JLG Lift – 3-39

16. Using an 8 mm internal hex wrench, tighten the endcap screws. Tighten the screws in opposite corners slowly and evenly to compress the servo spring and properly seat the endcap. Torque endcap screws 35-45 ft.lbs. (47-61 Nm).

17. Before installing the shaft seal, ensure the shaft turns smoothly with less than 120 in.lbs. (13.5 Nm) of force. If the shaft does not turn smoothly within the specified maximum force, disassemble and check the unit.



 



          

Page 80

SECTION 3 - CHASSIS & TURNTABLE

27. Shaft Seal

28. Seal Suppor t Washer

29. Snap Ring

Figure 3-27. Shaft Seal

1/4 in

(45 Nm)

33 ft.lbs.

5/16 in (85 Nm)

63 ft.lbs.

5/16in

(85 Nm)

63 ft.lbs.

1/4 in (45 Nm)

33 ft.lbs.

9/16 in

(170 Nm)

125 ft.lbs.

3 mm

(2.03 to 3.39 Nm)

1.5 to 2.5 ft.lbs.

Figure 3-28. Plugs and Fittings Installation

18. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with the cup side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal. Install seal support washer (28) and snap ring



(29).

19. Install remaining plugs and fittings to the housing. Refer to the drawing below for wrench sizes and installation torques.

                             

3-40 – JLG Lift – 3120866

Page 81

SECTION 3 - CHASSIS & TURNTABLE

(27 Nm)

20 ft.lbs.

5/8 in

(37 Nm)

27 ft.lbs.

11/16 in

30. Orifice Poppet

31. Shift Spool

32. Spring

33. Spring

34. Spring

35. Spring

36. Spring

37. O-ring

38. O-ring

39. O-ring

40. Plug

41. Plug

42. Plug

Figure 3-29. Loop Flushing Spool

20. Install orifice poppet (30).

Initial Start-up Procedures

Follow this procedure when starting-up a new motor or when installing a motor that has been removed.

Prior to installing the motor, inspect for damage incurred during shipping. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.

1. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter when pouring into the reservoir. Never reuse hydraulic fluid.

2. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks.

3. Fill the pump and motor housing with clean hydraulic fluid. Pour filtered oil directly into the upper most case drain port.

4. To ensure the pump and motor stay filled with oil, install case drain lines into the upper most case drain ports.

21. Install shift spool (31).

22. Install spring retaining washers onto springs (32 and

33).

5. Install a 0 to 500 psi (0 to 35 bar) gauge in the charge pressure gauge port of the pump to monitor system pressure during start up.

23. Carefully install centering springs (34, 35, and 36).

6. While watching the pressure gauge, run the engine

24. Install new O-rings (37, 38, and 39).

25. Using a 5/8 in wrench torque plug (40) to 20 ft.lbs. (27 Nm).

26. Using a 11/16 in wrench, torque plugs (41 and 42) to 27 ft.lbs. (37 Nm).

                 

3120866 – JLG Lift – 3-41

at the lowest possible speed until system pressure builds to normal levels (minimum 160 psi [11 bar]). Once system pressure is established, increase to full operating speed. If system pressure is not main tained, shut down the prime mover, determine cause, and take corrective action.

7. Operate the hydraulic system for at least fifteen minutes under light load conditions.

8. Check and adjust control settings as necessary after installation.

9. Shut down the prime mover and remove the pressure gauge. Replace plug at the charge pressure gauge port.

10. Check the fluid level in the reservoir; add clean filtered fluid if necessary. The motor is now ready for operation.

  

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SECTION 3 - CHASSIS & TURNTABLE

DISCONNECT CAP

DISCONNECT

CAP

(REVERSED)

DRIVE

HUB

DRIVE

HUB

Drive Hub Engaged

Drive Hub Disconnected

Figure 3-30. Disconnecting the Drive Hubs

3.8 FREE WHEELING OPTION

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.

1. Chock wheels securely if not on flat level surface.

2. Disconnect both drive hubs by inverting disconnect caps in center of hubs.

3. If equipped, move steer/tow selector valve to float (tow) position by pulling valve knob out.

                                        

To Engage Drive Motors and Brakes (Normal Operation)

1. If equipped, move steer/tow valve to steer position by pushing valve knob in.

2. Connect both drive hubs by inverting disconnect cap in center of hub.

3. Remove chocks from wheels as required.

3-42 – JLG Lift – 3120866

Page 83

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-31. Oscillating Valve Adjustment

Figure 3-32. Brake Valve Wiring Connection

Figure 3-33. Drive Manual Control Valve

3.9 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TEST

Lockout Cylinder Bleeding

ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE.



MAKING SURE MACHINE IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, BRAKE WIRE IS DISCONNECTED.

1. Making sure machine is on a level surface and rear

2. Center boom over rear axle making sure that cam



wheels are blocked, brake wire is disconnected.

valve is depressed.

4. Use suitable containers to retain any residual hydraulic fluid, place containers under each lockout cylinder.

5. Open all four bleeder screws (two on each lockout cylinder).

6. Start the engine, position drive control lever on the main hydraulic pump forward or reverse as shown.

7. Close bleeder screws when all air is dissipated (bled).

3. Using a Phillips screwdriver, remove screw from connection on the brake valve and remove connec tor as shown.

8. Perform oscillating axle lockout test.

9. If necessary, repeat steps 1 thru 8.

Oscillating Axle Lockout Test

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and cen-

tered between drive wheels prior to beginning lockout cylinder test.

1. Place a 15 cm (6 inch) high block with ascension ramp in front of left front wheel.

2. From platform control station, activate machine hydraulic system.

3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/TORQUE SELECT control switches to their respective LOW positions.

4. Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block.

3120866 – JLG Lift – 3-43

5. Carefully activate SWING control lever and position boom over right side of machine.

Page 84

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-34. Steer Adjustments

6. With boom over right side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.

7. Have an assistant check to see that left front wheel remains locked in position off of ground.

8. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate DRIVE to release cylinders.

9. Place the 15 cm (6 inch) high block with ascension ramp in front of right front wheel.

10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block.

11. Carefully activate SWING control lever and position boom over left side of machine.

12. With boom over left side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.

13. Have an assistant check to see that right front wheel remains locked in position off of ground.

#2 to contact axle. Steer full right and adjust LH item #2 to contact axle. (2WS/4WD)

14. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate DRIVE to release cylinders.

3.10 STEER ADJUSTMENTS

NOTE: Spindles do not stop on cylinder stroke. Adjust steer-

ing stops as follows: Adjust item #1 to achieve 39° inside turn angles. Steer full left and adjust RH item

3-44 – JLG Lift – 3120866

Page 85

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-35. Swing Torque Hub Adjustment

3.11 SWING HUB

Adjustment Procedures

1. Ensure swing drive is located on bearing gear max eccentric tooth (high spot).

2. With mounting free to slide, shim between pinion and bearing gear teeth to achieve 0.020 - 0.030 mm backlash.

3. Install a pry bar into hole in turntable base plate and pry swing hub back tight against shim and bearing.

4. Torque bolts according to the torque chart in Section

3.12 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 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).

2. At the positions indicated on Figure 3-36., Swing Bearing Bolt Feeler Gauge Check, 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 on Figure 3-36., Swing Bearing Bolt Feeler Gauge Check try and insert the

0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

3. Lower the boom to horizontal and fully extend the



boom.

     

3120866 – JLG Lift – 3-45

Page 86

SECTION 3 - CHASSIS & TURNTABLE

.0015" Feeler Gauge

Figure 3-36. Swing Bearing Bolt Feeler Gauge Check

SWING

BEARING

FRAME REF.

TURNTABLE REF.

MEASURING

POINT

Figure 3-37. Swing Bearing Tolerance Measuring

Point

4. At the position indicated on Figure 3-36., Swing Bearing Bolt Feeler Gauge Check. try and insert the

0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFT ING ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION.

Wear Tolerance

1. From the underside of the machine, at rear center,

2. At the same point, with the boom at horizontal and

3. If a difference greater than 1.40 mm (0.057 in.) is

4. If a difference less than 1.40 mm (0.057 in.) is deter-

5. If bearing inspection shows no defects, reassemble

with the boom fully elevated and fully retracted, as shown in ( Boom Placement) A, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. ( Swing Bearing Tolerance Measuring Point)

fully extended, and the tower boom fully elevated as shown in ( Boom Placement) B, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. (Figure 3-37., Swing Bearing Tolerance Measuring Point)

determined, the swing bearing should be replaced.

mined, and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the following:

a. Metal particles in the grease.

b. Increased drive power required.

c. Noise.

d. Rough rotation.

and return to service.



Figure 3-38., Swing Bearing Tolerance

Figure 3-37.,

Figure 3-38., Swing Bearing Tolerance



Swing Bearing Replacement

1. Removal.

a. From Ground Control station, operate the boom

adequately to provide access to frame opening or, if equipped, to rotary coupling.

NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING.

b. Attach an adequate support sling to the boom

and draw all slack from sling. Prop or block the boom if feasible.

c. From inside turntable, remove mounting hard-

ware which attach rotary coupling retaining yoke brackets to turntable.

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

d. Tag and disconnect the hydraulic lines from the

fittings on the top of the rotary coupling. Use a suitable container to retain any residual hydrau lic fluid. Immediately cap lines and ports.

  

3-46 – JLG Lift – 3120866

Page 87

SECTION 3 - CHASSIS & TURNTABLE

e. Attach suitable overhead lifting equipment to the

base of the turntable weldment.

f. 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 bear ing upon installation. Remove the bolts and washers which attach the turntable to the bearing inner race. Discard the bolts.

g. Use the lifting equipment to carefully lift the com-

plete turntable assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame-mounted components.

h. Carefully place the turntable on a suitably sup-

ported trestle.

i. 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 installa tion. 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 from the frame, then move the bearing to a clean, suitably supported work area.

2. Installation.

a. Using suitable lifting equipment, carefully lower

the swing bearing into position on the frame. Ensure the scribed line of the outer race of the bearing aligns with the scribed line on the frame. If a new swing bearing is used, ensure that the filler plug fitting is at 90 degrees from the fore and aft center line of the frame.

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

c. Refer to the Figure 3-39., Swing Bearing Torque

Sequence. Swing Bearing Torquing Sequence. Spray a light coat of Safety Solvent 13 on the new bearing bolts. Then apply a light coating of

Loctite #271 to the new bearing bolts, and install the bolts and washers through the frame and outer race of the bearing. Tighten the bolts to an initial torque of 326 Nm w/Loctite.

d. Remove the lifting equipment from the bearing.

e. Using suitable lifting equipment, carefully posi-

tion the turntable assembly above the machine frame.

f. Carefully lower the turntable onto the swing

bearing, ensuring that the scribed line of the inner race of the bearing aligns with scribed line 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 center line of the turntable.

g. Spray a light coat of Safety Solvent 13 on the

new bearing bolts. Then apply a light coating of Loctite #271 to the new bearing bolts, and install the bolts and washers through the turnta ble and inner race of the bearing.

h. Following the Torque Sequence diagram shown

in Figure 3-39., Swing Bearing Torque Sequence, tighten the bolts to a torque of 326 Nm w/Loctite.

i. Remove the lifting equipment.

j. Install the rotary coupling retaining yoke brack-

ets, apply a light coating of Loctite #242 to the attaching bolts and secure the yoke to the turntable with the mounting hardware.

k. Connect the hydraulic lines to the rotary cou-

pling as tagged prior to removal.

l. At ground control station, use boom lift control

to lower boom to stowed position.

m. Using all applicable safety precautions, activate

the hydraulic system and check the swing system for proper and safe operation.

b. 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 ATTACH MENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

 



3120866 – JLG Lift – 3-47

Page 88

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-38. Swing Bearing Tolerance Boom Placement

3-48 – JLG Lift – 3120866

Page 89

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-39. Swing Bearing Torque Sequence

Swing Bearing Torque Values

1. Outer Race - 326 Nm (240 ft. lbs.) w/Loctite.

2. Inner Race - 326 Nm (240 ft. lbs.) w/Loctite.

3. See Swing Bearing Torquing Sequence.

CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERA TION, AND EVERY 600 HOURS THEREAFTER.

         

3.13 SWING 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),

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

rotating discs (12), primary disc (11), torque pins (3), springs (8&9), and the spring retainer (7).

both must be replaced.

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

3120866 – JLG Lift – 3-49

Page 90

SECTION 3 - CHASSIS & TURNTABLE

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.With shaft protrusion downward, remove end cover (13) by removing capscrews (12).

THE DEPTH THE PISTON IS INSTALLED INTO THE POWER PLATE IS CRITICAL. THE SURFACE OF THE PISTON AT THE CUTOUTS MUST BE FLUSH TO 3.04 MM (0.120 IN) BELOW THE SURFACE OF THE POWER PLATE. DO NOT EXCEED THE 3.04 MM (0.120 IN) DEPTH OR THE PISTON WILL COCK RESULTING IN A COMPLETE LOSS OF BRAKING.

Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact surfaces. Replace as necessary.

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.

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

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

                   



4. 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.

5. Press the shaft into the housing until it stops on the bearing. Support the inner race of the bearing during the press operation.

6. 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.

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

3-50 – JLG Lift – 3120866

Page 91

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-40. Swing Brake Assembly (Ausco)

3120866 – JLG Lift – 3-51

Page 92

SECTION 3 - CHASSIS & TURNTABLE

1. Seal

2. Spacer Plate

3. Seal

4. Geroler

5. Seal

6. End Cap

7. Capscrew

8. Drive

Figure 3-41. End Cap Removal

3.14 SWING MOTOR

Cleanliness is extremely important when repairing hydraulic motors. Work in a clean area. Before disconnecting the hydraulic lines, clean the port area of the motor. Before disassembly, drain oil from the motor. Then plug the ports and thoroughly clean the exterior of the motor. Check the output shaft, remove any burrs, nicks, or sharp edges.

Disassembly

1. Clamp the motor in a vise so the shaft is vertical and the end cap is on the top. Clamp on the mounting flange, use just enough clamping force to hold the motor securely. Protect the mounting flange with soft vise jaws.

2. Remove the 7 cap screws from the end cap and disassemble the motor as shown.

3. Unclamp the motor and remove the output shaft, thrust needle bearing, and thrust bearing race.

   

4. Clamp the motor in a vise so the mounting flange is on top.Clamp across the port area. Do not clamp on motor housing. Use just enough clamping force to hold the motor securely.

5. Remove the four cap screws that hold the mounting flange to the motor housing.

THESE SCREWS WERE LOCTITED DURING ASSEMBLY. DO NOT EXCEED 500 IN. LBS (56 NM) OF REMOVAL TORQUE

3-52 – JLG Lift – 3120866

Page 93

SECTION 3 - CHASSIS & TURNTABLE

If the Loctite is holding the screws too tightly, heat the motor housing, with a propane torch, while turning screw. Apply heat to where the screw threads into the motor housing. Apply just enough heat to remove screw, do not over heat the motor housing or mounting flange.

Reassembly

Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow them dry with pressur ized air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage. Check the key way and chamfered area of the output shaft; remove any nicks, burrs, or sharp edges that could damage the shaft seal during assembly.

NOTE: Always use new seals when reassembling hydraulic

motors.

DURING REASSEMBLY LUBRICATE THE NEW SEALS WITH A PETROLEUM JELLY LIKE VASELINE. ALSO LUBRICATE MACHINED SURFACES AND BEARINGS WITH CLEAN HYDRAU LIC FLUID.

1. Remove all of the old Loctite from the mounting flange cap screws and their threaded holes. The threads must be clean and dry for the new Loctite to hold properly.

2. Lubricate and install the output shaft, needle thrust bearing, and bearing race into the housing.

6. Remove the mounting flange from the motor housing. The exclusion seal, pressure seal, and back - up ring will come off with the mounting flange.

7. Carefully remove the exclusion seal, pressure seal, and back - up ring from the mounting flange. A seal removal tool may be fabricated by bending and rounding the end of a small blade screwdriver.

DO NOT DAMAGE THE MOUNTING FLANGE WHERE THE SHAFT PASSES THROUGH IT.

DO NOT PERMIT OIL TO GET INTO THE FOUR THREADED HOLES.

3. Lubricate the exclusion seal and press it into its seat in the mounting flange.

4. Lubricate and install the back - up ring and pressure. Use a seal installation tool to press the pressure seal into place.

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3. Lightly stretch, lubricate and install the second of the three larger diameter seals in the groove in the Geroler.



Standard Timing: Align any star point with threaded hole noted for the location of the timing dot.



Reverse Timing: Align any star valley with the threaded hole noted for the location of the timing dot.

4. Rotate the geroler to align the screw holes and install driver spacer if applicable.

5. Lubricate and install the last one of the three larger diameter seals in the groove in the end cap.

6. Install the end cap and seven cap screws.

7. Tighten the cap screws, in a criss - cross pattern, to 300 in lbs. (34 Nm).



BE SURE THE EXCLUSION SEAL AND PRESSURE SEAL ARE UNDAMAGED AND PROPERLY SEATED.

5. Clamp the motor in the vise so the output shaft is vertical and down. Clamp on the mounting flange.

6. Pour clean hydraulic fluid into the motor to provide start - up lubrication.

7. Lubricate and install one of the three largest diameter seals in the groove in the motor housing.

8. Install the drive.

NOTE: If the splined ends of the Drive are different lengths,

install the longer end into the shaft.

Motor Timing

1. Align shaft timing dot with any bolt hole. Bolt hole will be used for timing reference.

2. Install spacer plate, and note the position of the threaded hole in housing aligned with the timing dot on shaft.

BE SURE THE SLOTS IN THE SPACER PLATE PROVIDE PASSAGE FOR HYDRAULIC FLUID AS WELL AS THE CAP SCREWS. IF THE SPACER PLATE IS FLIPPED THE MOTOR WILL NOT OPERATE.

8. The level down relief valve is located right next to the check port. Turn clockwise to increase and counter clockwise to decrease.

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1. Capscrew

2. Exclusion Seal

3. Mounting Flange

4. Backup Ring

5. Pressure Seal

6. Seal

7. Bearing Race

8. Needle Thrust Bearing

9. Key

10. Output Shaft

11. Housing

12. Seal

13. Drive

14. Spacer Plate

15. Seal

16. Geroler

17. Seal

18. End Cap

19. Capscrew

Figure 3-42. Swing Motor

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Figure 3-43. Tilt Switch Adjustment

3.15 TILT ALARM SWITCH (MACHINES WITH EXTERNAL TILT SENSOR)

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

Manual Adjustment

1. Park the machine on a flat, level surface. Ensure machine is level and tires are filled to rated pressure.

NOTE: Ensure switch mounting bracket is level and securely

attached.

2. 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.

3. With the electrical connections complete, using bubble level on top of indicator, slowly tighten or loosen the three flange nuts until indicator is level.

3.16 SPARK ARRESTER CLEANING INSTRUCTIONS

1. Remove the cleanout plug in the bottom of spark arrester (muffler).

2. Without causing deformation (or any type of damage to the spark arrester) repeatedly tap on the arrester near the cleanout plug. This may be enough to begin drainage of the spark trap.

3. An industrial vacuum cleaner can do a complete job at this point.

a. Or, IN A SAFE AREA, start the engine. Then

alternate between low idle and high idle for two to three minutes.

b. Or, operate the engine as required by the appli-

cation for two to three minutes.

4. Install the cleanout plug. (See Preventive Maintenance and Inspection Schedule.

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).



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3.17 DUAL FUEL SYSTEM

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.

Changing from Gasoline to LP Gas

1. Start the engine from the ground control station.

2. Open the hand valve on the LP gas supply tank by turning counterclockwise.

BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP GAS.

3. While the engine is operating, place the three position LPG/Gasoline switch at the ground control station to the center “off” position. Allow the engine to operate without load, until the engine begins to “stumble” from lack of gasoline.

4. As the engine begins to “stumble”, place the switch to the LPG position, allowing the LP fuel to be sent to the fuel regulator.

Changing from LP Gas to Gasoline

1. With engine operating on LP under a no load condition, throw the LPG/Gasoline switch at the ground control station to the “Gasoline” position.

2. If engine “stumbles” because of lack of gasoline, place the switch to the LPG position until engine regains smoothness, then return the switch to the Gasoline position. Repeat as necessary until engine runs smoothly on gasoline.

3. Close the hand valve on the LP gas supply tank by turning clockwise.

3.18 ELECTRIC GOVERNOR INSTALLATION AND ADJUSTMENTS - FORD ENGINE

General

These instructions presume no electrical test equipment other than a multimeter for making the electrical measure ments called for on the following pages. If no suitable meter is available, an inexpensive but adequate meter, part number 22-188 is available from any local Radio Shack store.

Many “governor problems” turn out to be installation problems, particularly in first-time applications. Careful attention to the directions provided will go far toward a successful installation made in the least amount of time.

Quick-start Installations

If you are experienced in installing and adjusting Electric Governor, follow these steps. Otherwise, refer to the more detailed instructions starting with “MOUNTING-ACTUA TOR”.

1. Mount Actuator rigidly to engine location which will permit a short, straight linkage to the carburetor or fuel valve. Avoid very hot areas.

2. Mount controller in a dry, fairly cool location. Accessibility for adjusting is required.

3. Wire per appropriate included schematic, using #16 wire.

4. Set up fuel linkage. This is critical, so review the section titled “LINKAGE”.

5. Hold linkage for safety, and start engine.

6. Adjust engine speed to desired valve using High Engine pot. Turn CW to increase, CCW to decrease speed. (See diagram on page 43 E-331 Electronics Adjustment Locations.)

Mounting-Actuator

The Actuator may be mounted in any attitude — these is no preferred orientation.

With no power applied, the Actuator is spring-loaded to the minimum fuel position. The Actuator output shaft rotates toward the maximum fuel position against this spring through electrical power from the controller. This rotation is CW (clockwise) on one side of the Actuator, and CCW (counterclockwise) on the other. If necessary, reverse the Actuator on its mounting plate so that the desired direction of rotation is on the desired side to match the fuel system direction of travel.

Before selecting the mounting location, consider the linkage that will be required to connect the Actuator output arm to the butterfly or fuel valve. Read the following sec tion on linkages before deciding on a mounting location!

Mount Actuator rigidly to engine location which will permit a short, straight linkage to the carburetor or fuel valve. Avoid very hot areas.

Linkage

1/4" -28 threaded rod and low friction rod-end bearings are recommended for linkage materials.

Keep the linkage as short and as straight as possible.

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The linkage must not rub against the engine, brackets, hoses, etc. The linkage must be free of friction and lost motion or “slop”.

The following sketch indicates the proper linkage geometry for most installations.

Note that the angle between the carburetor arm and the rod is 70 degrees with the engine at idle. This is highly desirable! Note also that the Actuator arm travels equally on either side of a 90 degree angle with the rod. This angular arrangement will give the proper mechanical gain for good stability and performance. It may be necessary to rotate the carburetor arm relative to the butterfly to achieve this. This can usually be done, and is usually worth the effort! Below are some workable installations, with good linkages. Remember, the Actuator can be turned 180 degrees on its mounting to “reverse” the spring-loaded direction. Also, the Actuator can be mounted in any attitude.

The needed travel of the carburetor determines how far out on the Actuator arm the rod is to be attached. In most cases, the carburetor should be moved from closed to above 10 degrees from full open as the Actuator is moved min. to max. THEN ALTER THE LENGTH OF THE ROD SLIGHTLY (PERHAPS 0.030"), SO THAT THE ACTUATOR IS JUST OFF ITS INTERNAL STOP, AND IS PULLING THE BUTTERFLY AGAINST ITS STOP. This insures that the car

buretor can fully close to idle on load dumps, minimizing overspeeds.

Examine the system for springs, such as carburetor return springs. These should be removed. Some automotive car buretors (as opposed to industrial carburetors) contain internal springs for accelerator pumps, etc. These may make good governing difficult, or even impossible. For this, and other reasons, industrial carburetors are much to be preferred.

Move the linkage slowly through its travel, and look for any binding or unexplained forces. Correct any before going further.

Many “governing” problems are really caused by binding of the butterfly and its shaft in the carburetor. This is

caused by loading due to vacuum under the butterfly and atmospheric pressure above when the engine is running. These forces cannot be felt when the engine is not run ning. Therefore, start the engine while carefully controlling the speed by hand, and feel for binding or airload forces. Needle bearings on the butterfly shaft are available on many industrial carburetors to deal with this problem. Any tendency on the butterfly stick must be corrected.

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Mounting-Controller

Select a reasonably cool, dry, and vibration free location.

The rear cover will probably need to be removed during set-up in order to make adjustments for speed setting and gain. You may wish to defer final installation until this is done.

After completing these adjustments, replace cover. Mount so that water cannot pool on this cover. Always mount the controller with the strain relief down. This will prevent water from entering thru the cable, also place the vent hole in the bottom of the controller down.

Wiring

See wiring diagram for details of hook-up.

Use #16 wire minimum.

Keep all wiring to the Governor as short as is practical.

Go directly from the controller ground terminal (B of the 8 pin connector) by dedicated wire, to the battery “minus” terminal. If this cannot be done, for some reason, go by dedicated wire to a very good engine ground.

A properly functioning engine electrical system will supply

13.5 - 14.8 VDC when the engine is running. If wiring size is adequate, with good connections and proper grounds, you will get this reading between the wires terminals A & B of the 8 pin connector when the Governor is controlling engine speed. Verify this.

Improper hook-up can damage electronics. Re-check wiring before applying power.

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JLG 601S Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

AGENERAL

B HYDRAULIC SYSTEM SAFETY

CMAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank

Hydraulic Oil Tank

Hydraulic System (Including Tank)

Torque Hub, Drive

Engine Crankcase

1.2 COMPONENT DATA

Engine - Diesel (Liquid-Cooled)

Drive System

Steer System

Swing System

Hydraulic Gear Pump (at 1800 RPM)

Auxiliary Power Pump

Hydraulic Filter - In-line

1.3 PERFORMANCE DATA

Machine Height (Stowed)

Machine Length (Stowed)

Machine Width

Wheel base

1.4 FUNCTION SPEEDS

Machine Orientation When Doing Speed Te st s

Turning Radius (Outside)

Turning Radius (Inside)

Boom Elevation

Machine Weight approximately

Te s t N o t e s

1.5 TORQUE REQUIREMENTS

1.6 LUBRICATION

Ford LRG425 Engine

Deutz F3M1011F Engine

Hydraulic Oil

Lubrication Specifications

1.7 PRESSURE SETTINGS

1.8 CYLINDER SPECIFICATIONS

1.9 MAJOR COMPONENT WEIGHTS

1.10 CRITICAL STABILITY WEIGHTS

1.11 SERIAL NUMBER LOCATIONS

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

Preparation, Inspection, and Maintenance

Pre-Start Inspection

Pre-Delivery Inspection and Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

2.2 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

Lubrication and Servicing

Bolt Usage and Torque Application

2.3 LUBRICATION AND INFORMATION

Hydraulic System

Hydraulic Oil

Changing Hydraulic Oil

Lubrication Specifications

2.4 CYLINDER DRIFT TEST

Platform Drift

Cylinder Drift

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

2.6 WELDING ON JLG EQUIPMENT

Do the Following When Welding on JLG Equipment

Do NOT Do the Following When Welding on JLG Equipment