Service and Maintenance Manual
Model
601S
P/N - 3120866
February 26, 2014
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
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.
– JLG Lift –
THIS PAGE LEFT BLANK INTENTIONALLY
– JLG Lift –
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.
Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.
Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure
feed lines to system components can then be disconnected with minimal fluid loss.
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.
3120866 |
– JLG Lift – |
A-1 |
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 |
TABLE OF CONTENTS
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
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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
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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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TABLE OF CONTENTS (continued) |
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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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TABLE OF CONTENTS (continued) |
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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
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LIST OF FIGURES |
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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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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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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 |
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
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ix |
TABLE OF CONTENTS (Continued)
This page left blank intentionally.
x |
– JLG Lift – |
3120866 |
SECTION 1 - SPECIFICATIONS
98.4 Liters (26 gal.)
Approx. 121 liters (32 U.S. Gallons), 98.4 L (26 gal.) to the full mark on sight gauge.
Gasoline/Diesel Power - 140.8 liters (37.2 gal.)
0.50 liters (17 ounces).
NOTE: Torque hubs should be one half full of lubricant.
Ford LRG-425 Gas w/Filter - 4.25 liters (4.5 quarts). Deutz F3M1011F Diesel w/Filter - 6 liters (6.3 quarts).
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.
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).
Horsepower - 54 @ 2400 RPM, full load.
Cooling System - 15 liters (16 Quarts).
Manufacturer/ModelDeutz 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.
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.
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 |
SECTION 1 - SPECIFICATIONS
Swing Motor Displacement - 75 cm[3] (4.62 cu. in.)
Swing Brake - Automatic spring applied hydraulically released disc brakes.
Swing Hub Ratio - 50:1.
2.56 m (8 ft. 4.75 in.).
Over Drive Axle - 8.44 m (27 ft. 8.125 in.)
7.9 GPM (29.90 lpm).
Pump Displacement - 16 cm[3] (1.02 cu. in.) Clockwise Rotation.
2WS/4WD - 2.42 m (7 ft. 11.4375 in.)
2.48 m (8 ft. 1.50 in.)
9.84 lpm(2.6 GPM) @ 82.7 BAR (1200 PSI) Pump Displacement - 14 cm[3] (.244 cu. in.) DC Motor.
Clockwise Rotation.
Return - Bypass Type.
10 Microns Absolute.
Charge.
10 Microns Absolute.
Hydraulic Strainers (In Tank).
30Microns.
Travel Speed.
4WD - 6.44 Km/hr. (4 mph)
Gradeability.
(4WD) 45%.
6.2 m (20 ft. 4.6 in.)
5.25 m (14 ft. 3.9 in.).
+18.36 m (60 ft. 2 13/16 in.) -1.87 m (6 ft. 1 11/16 in.).
10,211 kg (22,510 lbs.).
Machine Orientation When Doing Speed
Tests
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.
Telescope: 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 horizontal. Results should be recorded for a 15.24 m (50 ft.) course. Drive Forward, Record Time. Drive Reverse, Record Time.
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 |
SECTION 1 - SPECIFICATIONS
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 & |
43-136 |
4WD) |
|
|
|
*Max 10% Difference Between Left & Right |
|
**Max 15% Difference Between Left & Right |
|
|
|
|
4150130 - E |
Table 1-2. Torque Requirements
Description |
Torque Value |
Interval Hours |
|
(Dry) |
|||
|
|
||
|
|
|
|
|
|
|
|
Bearing To |
240 ft. lbs. |
50/600* |
|
Chassis |
(326 Nm) |
|
|
|
See Note |
|
|
|
|
|
|
Bearing To |
240 ft. lbs. |
50/600* |
|
Turntable |
(326 Nm) |
|
|
|
See Note |
|
|
|
|
|
|
Wire Rope |
15 FT. LBS |
150 |
|
|
(20 Nm) |
|
|
|
|
|
|
Wheel Lugs |
170 FT. LBS. |
150 |
|
|
(231 Nm) |
|
|
|
|
|
*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.
3120866 |
– JLG Lift – |
1-3 |
SECTION 1 - SPECIFICATIONS
Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD).
When Outside |
|
Temperature is |
Use SAE Viscosity Number |
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 |
|
Temperature is |
Use SAE Viscosity Number |
Consistently |
|
Below +10°F. (+12°C.) |
*5W-20 |
Below +60°F. (+16°C.) |
5W-30 |
-10°F. to +90°F. (-23°C. to |
10W-30 |
+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.
Single Viscosity Oil (CD-SE, CD-SF).
When Outside Temperature is |
Use SAE Viscosity |
Consistently |
Number |
-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 |
|
Temperature is |
Use SAE Viscosity Number |
Consistently |
|
-40°F. to +75°F. (-40°C. to |
*5W-30 (Synthetic) |
+24°C.) |
|
-15°F. to +70°F. (-26°C. to |
10W-30 |
+21°C.) |
|
-15°F. to +85°F. (-26°C. to |
10W-40 |
+30°C.) |
|
Above -5°F. (-21°C.) |
15W-40 |
-5°F. to +75°F. (-21°C. to |
15W-30 |
+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.
1-4 |
– JLG Lift – |
3120866 |
SECTION 1 - SPECIFICATIONS
Table 1-3. Hydraulic Oil
HYDRAULIC SYSTEM |
|
OPERATING |
SAE VISCOSITY GRADE |
TEMPERATURE RANGE |
|
|
|
+0° to +180° F (-18° C to |
10W |
+83° C) |
|
|
|
+0° F to +210° F (-18° C to |
10W-20, 10W-30 |
+99° C) |
|
|
|
+50° F to +210° F (+10° C to |
20W-20 |
+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) |
|
|
|
|
Viscosity |
|
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 |
|
|
|
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 Industries for proper recommendations.
|
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 classification GL-5 or MIL-Spec MIL-L- |
|
2105 |
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.
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).
3120866 |
– JLG Lift – |
1-5 |
SECTION 1 - SPECIFICATIONS
Table 1-6. Cylinder Specifications
DESRIPTON |
BORE |
STROKE |
ROD DIA. |
|
|
|
|
|
|
|
|
Lift |
6.00 |
44.6875 |
3 |
|
(152.4) |
(1135.1) |
(76.2) |
|
|
|
|
Telescope |
3.5 |
177.75 |
2.5 |
|
(88.9) |
(4514.9) |
(63.5) |
|
|
|
|
Steer |
2.5 |
10.75 |
1.25 |
|
(63.5) |
(273.1) |
(31.8) |
|
|
|
|
Lockout (2wd) |
4 |
3.875 |
1.5 |
|
(101.6) |
(98.4) |
(38.1) |
|
|
|
|
Master |
3 |
8.5 |
1.5 |
|
(76.2) |
(215.9) |
(38.1) |
|
|
|
|
Slave Level |
3 |
8.5 |
1.5 |
|
(76.2) |
(215.9) |
(38.1) |
|
|
|
|
Table 1-7. Major Component Weights
Component |
LB. |
KG. |
|
|
|
Platform Control Console |
250 |
113 |
|
|
|
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 |
|
|
|
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTERWEIGHT, ENGINE & PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABIL-
ITY.
Table 1-8. Critical Stability Weights
Component |
|
LB. |
KG. |
|
|
|
|
Tire and Wheel (Foam Filled) |
Size (14 - 17.5) |
436 |
198 |
|
|
|
|
Tire and Wheel (Pneumatic) |
Size (14 - 17.5) |
165 |
75 |
|
|
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Engine |
Ford |
460 |
209 |
|
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Deutz |
534 |
242 |
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Continental |
558 |
253 |
|
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Counterweight |
Weight |
2900 |
1315 |
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|
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Platform |
6 ft. (1.83 M) |
205 |
93 |
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|
|
8 ft. (2.44 M) |
230 |
105 |
|
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|
1-6 |
– JLG Lift – |
3120866 |
SECTION 1 - SPECIFICATIONS
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.
Figure 1-1. Serial Number Locations
3120866 |
– JLG Lift – |
1-7 |
SECTION 1 - SPECIFICATIONS
Figure 1-2. Lubrication Diagram
1-8 |
– JLG Lift – |
3120866 |
SECTION 1 - SPECIFICATIONS
Table 1-9. Lubrication Chart
|
|
Number/Type |
|
|
Interval |
Hours |
|
||
|
Components |
Capacity |
Lube |
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|
Comments |
|
|
Lube Points |
3 Months |
6 Months |
1 Year |
2 Years |
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150 hrs |
300 hrs |
600 hrs |
1200 hrs |
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Lubrication |
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1 |
Swing Bearing |
2 Grease Fittings |
A/R |
MPG |
X |
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Remote Access |
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2 |
Swing Drive Hub |
Level/Fill Plug |
0.5 liters (1/2 Full) |
EPGL |
|
|
|
X |
Check level every 150 hrs/change1200hours |
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|
|
3 |
Wheel Drive Hub |
Level/Fill Plug |
0.5 liters (1/2 Full) |
EPGL |
|
|
|
X |
Check level every 150 hrs/change1200hours |
|
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|
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|
|
|
|
|
|
4 |
Hydraulic Return Filter |
N/A |
N/A |
N/A |
|
X |
|
|
Change after first 50 hrs. and every 300 hrs. |
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thereafter or as indicated by Condition Indica- |
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tor. |
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5 |
Hydraulic Charge Filter |
N/A |
N/A |
N/A |
|
X |
|
|
Change after first 50 hrs. and every 300 hrs. |
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thereafter or as indicated by Condition Indica- |
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tor. |
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6 |
Hydraulic Oil |
Fill Cap |
116 liters Tank |
HO |
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|
X |
Check level daily/change 1200 hours |
|
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124 liters. System |
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7 |
Suction Strainers (in |
2 |
N/A |
N/A |
|
|
|
X |
Remove and clean at time of hydraulic oil |
|
tank) |
|
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change. |
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Engines |
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8 |
Oil Change w/Filter - |
Fill Cap/Spin-on Element |
4.25 Liters |
EO |
X |
|
|
|
Check level daily/change 150 hrs. |
|
Ford LRG425 |
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9 |
Oil Change w/Filter - |
Fill Cap/Spin-on Element |
6 Liters Crankcase |
EO |
|
|
X |
|
Check level daily/change 1000 hrs. or one |
|
Deutz |
|
*4.75 Liters Cooler |
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|
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year, whichever comes first. Adjust final oil |
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level by mark on dipstick. |
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10 |
Fuel Filter - Ford |
Replaceable Element |
N/A |
N/A |
|
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X |
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11 |
Fuel Filter - Deutz |
Replaceable Element |
N/A |
N/A |
|
|
X |
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12 |
Air Filter - Ford |
Replaceable Element |
N/A |
N/A |
|
X |
|
|
Or as indicated by Condition Indicator. |
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|
|
|
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13 |
Air Filter - Deutz |
Replaceable Element |
N/A |
N/A |
|
X |
|
|
Or as indicated by Condition Indicator. |
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NOTES: |
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|
|
KEY TO LUBRICANTS |
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Lubrication intervals are based on machine operation under normal |
** When changing oil in the Deutz oil cooledengine, drain boththecrankcaseand |
EO |
Engine Oil |
||||||
conditions. For machines used in multi shift operations and/or |
the cooler. When refilling it is acceptable to overfill the crankcase (10.7 liters, |
EPGL |
Extreme Pressure Gear Lube |
||||||
exposed to hostile environments or conditions, lubrication frequen- |
capacity of both crankcase and cooler combined). Start engine, allow the engine |
HO |
Hydraulic Fluid (Mobil #424 or equivalent) |
||||||
cies must be increased accordingly. |
|
to run until the thermostat opens (approximately 105 degrees C) cooler will fill up |
MPG |
Multi-Purpose Grease |
|||||
|
|
|
within minutes; shut down and wait for approximately two minutes. Check oil |
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||||
|
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level, fill oil to max marking on the dipstick. |
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||
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|
3120866 |
– JLG Lift – |
1-9 |
SECTION 1 - SPECIFICATIONS
UNPLATED CAP SCREWS
VALUES FOR ZINC PLATED BOLTS ONLY
UNBRAKO1960SERIES SOCKETHEADCAPSCREW |
WITHLOC-WELPATCH |
TORQUE |
(asreceived) |
NM |
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|
|
|
|
|
|
|
|
|
|
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|
|
|
18 |
19 |
34 |
37 |
61 |
68 |
95 |
102 |
149 |
156 |
210 |
224 |
285 |
298 |
495 |
542 |
793 |
861 |
1173 |
1241 |
1681 |
1871 |
2373 |
2549 |
3145 |
3308 |
4122 |
4433 |
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CLAMPLOAD (KG) |
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|
|
|
|
|
1442 |
1651 |
2377 |
2631 |
3493 |
3983 |
4822 |
5384 |
6437 |
7253 |
8256 |
9208 |
10251 |
11612 |
15150 |
16919 |
20956 |
23088 |
27488 |
30074 |
34610 |
38828 |
43954 |
48671 |
52391 |
59648 |
63731 |
71669 |
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8NUTS |
|
(LOCTITE |
)242OR271 |
NM |
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|
|
18 |
21 |
41 |
41 |
68 |
75 |
109 |
122 |
163 |
183 |
224 |
258 |
326 |
359 |
570 |
631 |
895 |
983 |
1342 |
1492 |
1898 |
2136 |
2712 |
2983 |
3559 |
4068 |
4712 |
5322 |
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||||||||||||||||||||||||||||||||||
TORQUE |
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|||||||||||||||||||||||||
OR(DRY |
263).LOC |
NMNM NM |
1 |
1 |
2 |
2 |
4 |
4 |
5 |
6 |
12 |
14 |
25 |
27 |
48 |
48 61 |
75 85 |
81 95 |
109130 |
122146 |
149188 |
176209 |
231244 |
244277 |
380408 |
434456 |
624658 |
678724 |
922 |
1003 |
1302 |
1464 |
1844 |
2034 |
24132586 |
2766 |
32003430 |
36073856 |
|
||||||||||||
&BOLTSGRADE |
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|
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(LOCTITE |
262) |
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30 |
34 |
54 |
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|
931 |
1079 |
1396 |
1566 |
1970 |
2183 |
|
2935 |
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(LUB.) |
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SAEGRADE8 |
|
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|
245 2 |
272 2 |
372 3 |
417 3 |
572 5 |
599 5 |
717 7 |
817 8 |
1297 16 |
1488 19 |
2141 34 |
2821 34 |
3175 61 |
3583 68 |
4332 95 |
4854 109 |
5783 149 |
6532 163 |
7539 204 |
8278 231 |
9231 298 |
10433 326 |
13653 515 |
15241 570 |
18870 814 |
20775 895 |
23360 1220 |
27080 1356 |
31162 1736 |
34927 1953 |
38554 2468 |
43818 2712 |
47174 3227 |
53570 3688 |
57380 4284 |
142200 4827 |
|
|||||||||||
CLAMP LOAD (KG) |
|
||||||||||||||||||||||||||||||||||||||||||||||||||
GRADE2NUTS |
TORQUE |
(LUB.) |
NMNM NM |
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12 |
16 |
22 26 |
23 29 |
38 48 |
43 54 |
61 75 |
68 81 |
92 115 |
108 136 |
133 163 |
148 183 |
183 224 |
207 258 |
325 387 |
363 448 |
523 644 |
576 705 |
785 915 |
858 997 |
968 1139 |
10871254 |
13681593 |
15161762 |
17922068 |
20422373 |
23792746 |
26763118 |
platedfasteners. |
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(LOCTITE |
)242OR271 |
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GRADESAE5BOLTS& |
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(LOCTITE |
262) |
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applynotdo tocadium |
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1 |
1 |
2 |
2 |
3 |
3 |
4 |
4 |
9 |
10 |
18 |
19 |
31 |
34 |
48 |
68 |
75 |
88 |
109 |
122 |
149 |
176 |
271 |
298 |
434 |
475 |
651 |
719 |
814 |
895 |
1139 |
1247 |
1492 |
1708 |
1980 |
2224 |
||||||||||||
CLAMP |
LOAD (KG) |
1721 |
1911 |
2632 |
2772 |
4084 |
4264 |
5085 |
5836 |
91611 |
105214 |
151523 |
167826 |
224141 |
254048 |
308568 |
342575 |
4105102 |
4854122 |
5262149 |
5874163 |
6532204 |
7394231 |
9662353 |
10796407 |
13336583 |
14697637 |
17509868 |
19142949 |
191871085 |
215461193 |
244041519 |
270351681 |
290761980 |
331132278 |
353812630 |
397812983 |
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|
|
(DRYOR |
263)LOC. |
NM |
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(SQ.CM) |
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values |
THREAD |
STRESS AREA |
|
0.0153 |
0.0168 |
0.0232 |
0.0258 |
0.0356 |
0.0374 |
0.0445 |
0.0508 |
0.0808 |
0.0925 |
0.1331 |
0.1473 |
0.1969 |
0.2230 |
0.2700 |
0.3015 |
0.3604 |
0.4061 |
0.4623 |
0.5156 |
0.5740 |
0.6502 |
0.8484 |
0.9474 |
1.1735 |
1.2929 |
1.5392 |
1.6840 |
1.9380 |
2.1742 |
2.4613 |
2.7254 |
2.9337 |
3.3401 |
3.5687 |
4.0132 |
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Thesetorque |
|
BOLT DIA. (CM) |
|
0.2845 |
|
0.3505 |
|
0.4166 |
|
0.4826 |
|
0.6350 |
|
0.7938 |
0.9525 |
1.1112 |
1.2700 |
1.4288 |
1.5875 |
1.9050 |
2.2225 |
2.5400 |
2.8575 |
3.1750 |
3.4925 |
3.8100 |
|||||||||||||||||||||||||||
|
THD |
|
|
|
40 |
48 |
32 |
40 |
32 |
36 |
24 |
32 |
20 |
28 |
18 |
24 |
16 |
24 |
14 |
20 |
13 |
20 |
12 |
18 |
11 |
18 |
10 |
16 |
9 |
14 |
8 |
12 |
7 |
12 |
7 |
12 |
6 |
12 |
6 |
12 |
Note: |
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SIZE |
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4 |
|
6 |
|
8 |
|
10 |
|
1/4 |
|
5/16 |
3/8 |
7/16 |
1/2 |
9/16 |
5/8 |
3/4 |
7/8 |
1 |
1-1/8 |
1-1/4 |
1-1/2 |
1-1/2 |
SAE GRADE 5 SAE GRADE 8
Figure 1-3. Torque Chart
1-10 |
– JLG Lift – |
3120866 |
SECTION 2 - 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.
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 further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.
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 Operator’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 performing 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 recognized 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 service 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 performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.
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. recognizes a Factory-Certified Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG product model. Reference 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 manual 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.
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, training, 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.
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– JLG Lift – |
2-1 |
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Type |
Frequency |
Primary |
Service |
Reference |
|
Responsibility |
Qualification |
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|
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|
Pre-Start Inspec- |
Prior to use each day; or |
User or Operator |
User or Operator |
Operator and Safety Manual |
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tion |
At each Operator change. |
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|
|
|
|
|
|
|
|
|
Pre-Delivery |
Prior to each sale, lease, or |
Owner, Dealer, or User |
Qualified JLG |
Service and Maintenance |
|
Inspection |
rental delivery. |
|
Mechanic |
Manual and applicable JLG |
|
|
|
|
|
inspection form. |
|
|
|
|
|
|
|
Frequent Inspec- |
In service for 3 months or 150 hours, which- |
Owner, Dealer, or User |
Qualified JLG |
Service and Maintenance |
|
tion |
ever comes first; or |
|
Mechanic |
Manual and applicable JLG |
|
|
Out of service for a period of more than 3 |
|
|
inspection form. |
|
|
months; or |
|
|
|
|
|
Purchased used. |
|
|
|
|
|
|
|
|
|
|
Annual Machine |
Annually, no later than 13 months from the |
Owner, Dealer, or User |
Factory-Certified |
Service and Maintenance |
|
Inspection |
date of the prior inspection. |
|
Service Technician |
Manual and applicable JLG |
|
|
|
|
|
inspection form. |
|
|
|
|
|
|
|
Preventative |
At intervals as specified in the Service and |
Owner, Dealer, or User |
Qualified JLG |
Service and Maintenance |
|
Maintenance |
Maintenance Manual. |
|
Mechanic |
Manual |
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|
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|
The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.
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.
1.The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.
2.At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.
3.Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.
1.Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.
2.Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.
3.If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.
2-2 |
– JLG Lift – |
3120866 |
SECTION 2 - GENERAL
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.
When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.
1.When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.
2.Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.
3.If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.
4.Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.
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.
1.Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.
2.Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)
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.
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.
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.
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.
Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.
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– JLG Lift – |
2-3 |
SECTION 2 - GENERAL
1.The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.
2.The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles.
3.Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.
4.It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.
NOTE: Metal particles may appear in the oil or filters of new machines due to the wear-in of meshing components.
1.Refer to Section 1 for recommendations for viscosity ranges.
2.JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.
NOTE: Start-up of hydraulic system with oil temperatures below -15 degrees F (-26 degrees C) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of -15 degrees F (-26 degrees C).
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.
1.Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.
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 contaminants 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.
Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart.
2-4 |
– JLG Lift – |
3120866 |