JLG E45A-AJ Service Manual

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Model

BS E N ISO 9001 CertificateN o. 6917

M45A M45AJ E45A E45AJ

CORPORATE OFFICE

JLG INDUST RIES, INC. 1 JLG Drive McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417

Issued: August 5, 1999 PRINTED IN U.S.A. 3120884 Updated: Fe bruary 15, 2000

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE) Kilmartin Place, T a nnoc hs ide Park, Uddingston, Scotland, G71 5PH Telephone: 01698 811005 Fax: 0169 8 811055

AUSTRALIAN OFFICE

JLG INDUSTRIES (AUSTRALIA) P.0. Box 972 11 Bolwarra Road Port MacQuarie N.S.W. 44 Australia Telephone: 1 (065) 811111

SERVICE & MAINTENANCE

INTRODUCTION

SECTION A. INTRODUCT ION - MAINT ENA NCE SA FETY

PRECAUTIONS

A GENERAL

This section contains the general s afety precaution s 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 themsel ves 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 considerat ion when engaging in the maintenance of equipment. Always be conscious of weight. Never atte mpt 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 MAINTENANC E, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should b e made to reli eve any s ystem pressure prior to discon nectin g or removin g any portio n of the system.

C MAINTENANCE

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

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

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

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

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

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

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

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

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

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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

3120884 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

August 5, 1999 - Original Issue 2-40 - Updated 8-30-99 1-1 and 1-2 - Updated 10-7-99 2-50 - Updated 10-7-99 2-52 thru 2-54 - Updated 10-7-99 1-1 - Updated 2-15-00 3-1 - Updated 2-15-00 3-5 - Updated 2-15-00 3-16 - Updated 2-15-00

A-2 – JLG Lift – 3120884

TABLE OF CONTENTS

TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRE CAU TIONS

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

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

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

SECTION 1 - SPECIFICATIONS

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

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

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

1.4 Function Speeds (M45A/E45A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Function Speeds (M45AJ/E45AJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.7 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.8 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.9 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.10 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.11 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.12 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SECTION 2 - PROCEDURES

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

2.2 Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Lubrication Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.4 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.5 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.6 Cylinder Checking Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2.7 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.8 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.9 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2.10 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2.11 Rotator - Helac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

2.12 Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

2.13 Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2.14 Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2.15 Mid and Lower Lift Cylinder Bleeding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.16 Boom Synchronizing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.17 Dri v e Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

2.18 Drive Brake - Mico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

2.19 Pins and Gar-max Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

2.20 Speed Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

2.21 Footswitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

2.22 Positrac/Tilt module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

2.23 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

2.24 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

2.25 Gene r ator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

2.26 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

SECTION 3 - TROUBLESHOOTING

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

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

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

3120884 – JLG Lift – i

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-3. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

2-1. On Board Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-2. Batteries and Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-4. Capscr e w Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-5. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-6. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-7. Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-8. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-9. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-10. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-11. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-12. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2

2-13. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-14. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-15. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 3

2-16. Upper Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-17. Mid Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2-18. Lower Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-19. Upper Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

2-20. Wear Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-21. Platform Components and Attaching Hardware (M45A & E45A). . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-22. Location of Components - Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

2-23. Rotator Assembly (Helac). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

2-24. Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-25. Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-26. Removing Sleeve from Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

2-27. Actuator Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

2-28. Boo m Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

2-29. Location of Component s - Articulating Ji b Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-30. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2-32. Swi ng Bearing Tolerance Measuring Po in t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

2-31. Swing Bearing Tolerance Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

2-33. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

2-34. Swi ng Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

2-35. Dri v e Hub - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

2-36. Drive Brake - Mico. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

2-37. Speed Sensor Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

2-38. Frame Mounted Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

2-39. Steering Components and Spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

2-40. Dri v e Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

2-41. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

2-42. Jib Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-43. Brake/Steer Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

2-44. Mai n Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 4

2-45. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

2-46. Analyzer Flow Chart - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

2-47. Analyzer Flow Chart - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

2-48. Generator Componen t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71

2-49. Generator System Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

ii – JLG Lift – 3120884

TABLE OF CONTENTS

LIST OF FIGURES (continued)

FIGURE NO. TITLE PAGE NO.

3-1. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 0

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

3-3. Platform Electrical Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-4. Platform Electrical Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-5. Turntable Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-6. Frame Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-7. On Board Generator Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-8. Hydraulic Schematic - M45A/E45A - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-9. Hydraulic Schematic - M45A/E45A - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-10. Hydraulic Schematic - M45AJ/E45AJ - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-11. Hydraulic Schematic - M45AJ/E45AJ - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

1-4 Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-5 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

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

2-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-2 Cylinder Piston Nut Torque Specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-4 Wear Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

2-4 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

2-5 Personality Ranges/Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

2-6 Machine Setup Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

2-7 JLG Control System Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

2-8 Help Descriptions and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

2-9 DIAGNOSTICS - Menu Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

2-10 System Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

2-11 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

2-12 RBS Prestart Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

2-13 RBS Startup Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

2-14 RBS Shutdown Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

2-15 Generator System Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73

2-16 Preventive Maintenance and Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

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

3-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3 Turntable Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-4 Chassis Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

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

3-6 Electrical System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3120884 – JLG Lift – iii

TABLE OF CONTENTS

This Page Left Blank Intentionally .

iv – JLG Lift – 3120884

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES Hydraulic Oil Tank

19 liters (5 gallons)

Generator Fuel Ta nk

15.1 liters (4 gallons)

Drive Axle

Torque Hubs - 0.5 liters (19 oz.)

1.2 COMPONENT DATA Battery Charger

Input, 110 VAC,60 HZ Output, 48 VDC (25 Amps) Batteries (8) 6 Volt, 370 AmpHour (20 hour rate)

Drive System

Drive Motor - 48 VDC, 12.5 H.P. @ 3200 rpm. continuous, rotation - reversible

Drive Brake- spring-applied, hydraulic all y release d Tires - IN240/55-17.5 pneumatic or foam filled Tire Pressure - 6.2 Bar (90 psi)

1.3 PERFORMANCE DATA Travel Speed

5.2 kph (3.2 mph)

Gradeability

30% (16.7 degrees)

Turning Radius (Inside)

0.61 m (2ft. 0 in.)

Turning Radius (Curb to Curb)

3.15 m (10 ft. 4 in.)

Tail Swing (Any Position)

Upper Boom Speed

Lift Up - 27 seconds Lift Down - 26 seconds

Lower Boom Speed

Lift Up - 30 seconds Lift Down - 24 seconds.

Swing Speed - 360 Degrees

90 seconds / rev.

Hydraulic Pump/Electric Motor Assembly

Motor - 48 VDC, 2.14 H.P. @ 2700 rpm. Pump - 1.6 cm[3]/rev. (0.098 in.[3]/rev.) Pump Output - 11.2 lpm (2.96 gpm) @ 222 Bar (3200 psi)

Machine Weight

E45A - 5,811 kg (12,800 lb.) M45A - 5,811 kg (12,800 lb.) E45AJ - 6690 kg (14,750 lb.) M45AJ - 6690 kg (14,750.)

Max. Tire Load

M45A, E45A - 2,767 kg (6100 lbs.). M45AJ, E45AJ - 3,130 kg (6900 lbs.)

Updated 2-15-00

3120884 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Ground Bearing Pressure

M45A, E45A - 6.2 Bar (95 psi) M45AJ, E45AJ - 7.6 Bar (110 psi)

Machine Height (stowed)

M45A, E45A - 1.99 m (6 ft. 6.25 in.) M45AJ, E45AJ - 2.0 m (6ft. 7 in.)

Machine Length (stowed)

M45A, E45A - 5.69 m (18 ft. 8.0 in.) M45AJ, E45AJ - 6.45 m (21 ft. 2 in.)

Up and Over Platform Height

M45A, E45A - 7.49 m (24 ft. 7 in.) M45AJ, E45AJ - 7.7 m (25 ft. 3in.)

Horizontal Reach @ Maximum Up and Over

M45 A, E45A - 7.0 m (23 ft. 1 in.) M45AJ, E45AJ - 7.24 m (23 ft. 9 in.)

Machine Width

1.75 m (5 ft. 9 in.)

Wheel Base

2.00 m (6 ft. 7.0 in.)

Working Height

15.54 m (51 ft. 0 in.)

1.4 FUNCTION SPEEDS (M45A/E45A)

Lift Up - 30-24 seconds Lift Down - 29-23 seconds Tower Lift Up - 33-27 seconds Tower Lift Down - 26-22 seconds Telescope Out - 18-14 seconds Telescope In - 28-23 seconds

Swing Left 360° - 81-67 seconds* Swing Right 360° - 81-67 seconds* Rotate Left 180° - 17-14 seconds Rotate Right 180° - 18-15 seconds High Drive - Fwd. & Rev. (60.9 m) - 42-44 seconds**

above Horiz. - Fwd. & Rev. (15.2 m) - 67-71 seconds**

Drive

*Swing Left to Swing Right should be within 10% of each other. **Drive Forward to Drive Reverse should be within 10% of each

other.

1.5 FUNCTION SPEEDS (M45AJ/E45AJ)

Lift Up - 30-24 seconds Lift Down - 29-23 seconds Tower Lift Up - 33-27 seconds Tower Lift Down - 26-22 seconds

Platform Height

13.72 m (45 ft. 0 in.)

Track Width

1.51 m (5 ft. 0 in.)

Ground Clearance

M45, E45 - 0.22 m (8.5 in.) M45AJ, E45AJ - 0.20 m (8 in.)

System Voltage

48 volts

Battery Life per Charge

7 hours continuous

Jib Up - 25-26 seconds Jib Down - 24-25 seconds Telescope Out - 12-9 seconds Telescope In - 19-15 seconds Swing Left 360° - 81-67 seconds* Swing Right 360° - 81-67 seconds* Rotate Left 180° - 17-14 seconds Rotate Right 180° - 18-15 seconds High Drive - Fwd. & Rev. (60.9 m) - 42-44 seconds**

above Horiz. - Fwd. & Rev. (15.2 m) - 107-112 seconds**

Drive

*Swing Left to Swing Right should be within 10% of each other. **Drive Forward to Drive Reverse should be within 10% of each

other.

Battery Recharge Time

Charger - 17 hours from full discharg e Generator - 6.2 hours

Updated 10-7-99

1-2 – JLG Lift – 3120884

SECTION 1 - SPECIFICATIONS

1.6 TORQUE SPECIFICATIONS

Table 1-1.Torque Requirements

Description Torque V alue Interval Hours

Wheel Lugs 170 ft. lbs.

(230 Nm)

Swing Bearing

(Dry)

Swing Bearing

((Loctite)

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

220 ft. lbs.

(298 Nm)

240 ft. lbs.

(326 Nm)

150

50/600*

1.7 LUBRICATION Hydraulic Oil

Table 1-2.Hydraulic Oil

Hydraulic System

Operating

Temperature Range

+0 to + 180 F

(-18 to +83 C)

+0 to + 210 F

(-18 to +99 C)

+50 to + 210 F

(+10 to +99 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.

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 viscos ities. If use of hydraulic oil ot her than Mobil DTE 11M is desired, contact JLG Industries for proper recommendations.

S.A.E. Viscosity

Grade

10W

10W-20, 10W30

20W-20

Lubrication Specifications

Table 1-3.Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of

350 degrees 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. Mobil DTE-11M

OG* Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Com-

pound. (JLG Part No. 3020027)

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.

LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG

Part No. 3020022)

EO Engine (crankca se) Oil. Gas - API SF/SG cl ass, MIL-L-

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

*MPG may be substituted for these lubricants, if necessary, but service intervals will be reduced.

NOTE: Refer to Lubrication Chart, Figure1-2, for specific

lubrication procedures.

Table 1-4. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Poi nt, Max -40 F (-40 C)

Flash Point, Min. 330 F (166 C)

Viscosity

at 40° C 15 cSt at 100° C 4.1 cSt at 100° F 80 SUS at 210° F 43 SUS

cp at -30° F 3.200

Viscosity Index 140

3120884 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Table 1-5.Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Upper Lift Cylinder

3.00

(76.2)

28.3125 (719.1)

1.50

(38.1)

Mid Lift Cylinder 3.00

(76.2)

21.25

(539.7)

1.50

(38.1)

Lower Lift Cylinder 4.00

(101.6)

23.25

(590.5)

2.25

(57.1)

T elescope Cylinder 2.00

(50.8)

(2337)

1.25

(31.8)

Master Cylinder 2.00

(50.8)

9.375

(238.1)

1.00

(25.4)

Slave Cylinder 2.00

(50.8)

9.375

(238.1)

1.00

(25.4)

Rotator Cylinder 1.875

(47.6)

15.250 (387.3)

1.00

(25.4)

Steer Cylinder (Double Rod)

2.50

(63.5)

4.06

(103.1)

1.75

(44.5)

1.8 PRESSURE SETTINGS Main Valve

Upper Lift Down Relief - 38 bar (550 psi) Mid/Lower Lift Down Relief - 117 bar (1700 psi) Telescope In Relief - 148 bar (2150 psi) Platform Level Up Relief - 172 bar (2500 psi) Platform Level Down Relief - 83 bar (1200 psi)

Steer/Brake Valve

Steer Relief - 159 bar (2300 psi) Main Relief - 221 bar (3200 psi)

Jib Valve

Jib Relief (Up and Down) - 103 bar (1500 psi)

1.9 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in.), with the met-

ric equivalent, millimeters (mm), given in parentheses.

1.10 MAJOR COMPONENT WEIGHTS

Table 1-6.Major Component Weights

Component LB. KG.

Platform and Support 215 97.5 Upper Boom Complete 810 367 Mid Boom Complete 550 249 Lower Boom Complete 550 249 Upper Lift Cylinder 89 40 Mid Lift Cylinder 95 43 Lower Lift Cylinder 110 50 T elescope Cy linder 85 38 .5 Upper Upright 225 102 Lower Uprig ht 97 44 Turntable 948 430 Battery Box (incl. batteries) 600 272 Chassis (w/ pneu. tires) 4,295 1948 Chassis (w/ foam-filled tires) 4,695 2130 Counterweight 3850 1746 Machine Complete (E45A) 14,000 6356 Machine Complete (M45A) 14,300 6492

SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF SAFELY SUPPORTING WEIGHT.

1.11 CRITICAL STABILITY WEIGHTS

Table 1-7.Critical Stability Weights

Component LB. KG.

Counterweight 3850 1746 Tire & Wheel (foam-filled) 207 94 Platform (4ft [1.2 m]) 90 41

1-4 – JLG Lift – 3120884

Platform (5 ft. [1.5 m]) 100 45 Battery (each) 120 54

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

SECTION 1 - SPECIFICATIONS

1.12 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the left rear of frame, in front of left rear wheel. If the serial number plate is damaged or missi ng, the machine

serial number is stamped on the top left side of the frame and the top left side of the turntable. In addition, the serial number is stamped on top of the end of the upper boom, mid boom, and lower boom at the left rear of the booms.

Figure 1-1. Serial Number Locations

3120884 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Diagram

1-6 – JLG Lift – 3120884

Table 1-8. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

Components

Number/Type

Lube Points

Capacity Lube

Lubrication

Swing Bearing

Swing Bearing /

Worm Gear Teeth*

Hydraulic Fluid (Oil)

Hydraulic Filter

Wheel Drive Hub

Wheel Bearing

Spindles/Bushing

Boom Pivot Pins/

Bushing

Engine

NOTES: KEY TO LUBRIC ANTS

Lubrication intervals are base d on machine operation under nor mal conditions. For machines used in multi shift operations and/or ex posed to hostile environments or conditions, l ubrication frequencies must be increased accordingly .

* If necessary install grease fitt ings into worm gear housing and grease bea rings.

1 Grease Fittin g or by

brush

Spray On A/R Mobiltac

Fill Cap 15 liters (tank) HO X Check o il every 10 hou rs of operation.

N/A N/A N/A X Replace filter element after first 50 hours and

Fill Plug/Hal f Full 0.5 liter (1/2 Full) EPGL X Check o il level at side plug on hub dail y.

Repack A/R MPG X

N/A A/R LL At Spindle/Bushing Repl acement Coat I.D. of bushings pri or to installin g king

N/A A/R LL At boom pivot pin s/bushing re placement Coat I.D. of bushi ngs prior to in stalling pins.

Fill Cap R efer to Engi ne

A/R MPG X More freq uent lubricati on intervals may b e

X More freq uent lubricati on intervals may be

375NC

EO Check daily . Change in acco rdance with

Manual

EPGL

required

required.

Change oil every 1 200 hours of opera tion.

every 300 hours t hereafter .**

Change after fir st 150 hours then e very 1200 hours of operatio n.

pins.

engine manual.

Engine Oil Extreme Pressure Ge ar Lube

Hydraulic Fluid (Mobil DTE-11M)

MPG

Multi-Purpose Gre ase Synthetic Lithiu m Lubricant

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

** Under certain conditions, it may be necessary to replace the h ydraulic filter on a more frequent basis. A common symptom of a dirty filter is sluggishness experienced in hydraulic func tions.

3120884 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Figure 1-3. Torque Chart

1-8 – JLG Lift – 3120884

SECTION 2. PROCEDURES

SECTION 2 - PROCEDURES

2.1 GENERAL

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

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

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

2.2 SERVICING AND MAINTENANCE GUIDELINES

General

The following inf ormation is prov ided to a ssist you in t he use and application of servicing and maintenance procedures contained in this chapter.

Safety and Workmanship

Your safety and that of others is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never atte mpt 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.

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.

Component Removal and Installation

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

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

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

Component Disassembly and Reassembly

When disassembling or r e assembling a compon ent, complete the procedural steps in sequence. Do not part ially 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, ot her than those recommended, without obtaining proper approval.

Pressure Fit Parts

When assembling pressure fit parts, use an “anti-seize” or molybdenum disulfid e base co mpound to l ubricate the mating surface.

Cleanliness

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals and filters are provided to keep oil supplies clean; however, these items must be maintained on a s chedu led ba sis i n o rder to func tion properly.

2. At any time when hydraulic oil lines are disconnected, clear adjacent areas as well as the openings

3120884 – JLG Lift – 2-1

SECTION 2 - PROCEDURES

Bearings

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

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 be installed.

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 in sta lled on a sh aft, apply pres su re to the inner race.

Gaskets

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

Bolt Usage and Torque Application

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.

Hydraulic Lines and Electrical Wiring

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

Hydraulic System

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

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

Lubrication

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

Batteries

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

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in Lubricati on Chart.

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.

2-2 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

2.3 LUBRICATION INFORMATION Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g.; inadequate hydr aulic oil, allowi ng moisture, grease, filings, sealing componen ts, sand, etc. to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up.

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 at the specified intervals required in Section 1. Always examine filters for evidence of metal particles.

3. Cloudy oils indicate a high moisture content which permits organic gr ow t h, res ulting in oxidation or corrosion. If this conditi on occurs, the system mu st be drained, flushed, and refilled with clean oil.

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

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

machines due to the wear-in of meshing components.

Hydraulic Oil

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

2. JLG recommends Mobil DTE-11 Hydra ulic O il, wh ich has an SAE viscosity of 10W and a viscosity index of

140.

NOTE: Start-up of hydraulic system with oil temperatures

below -29 degrees C. is not recommended. If it is necessar y to sta r t the sy ste m in a sub- zero envi ron ment, it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of

-29 degrees C.

sesses the same antiwear and rust protection ch aracteristics as mineral oils, but will not adversely affect ground water or the environment when spilled or leaked in small amounts. Mobil EAL224H has a

viscosity of 34 cST at 40° C and a viscosity index of

213. The operating range of this oil is -18° C to +83° C.

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

CLOUDY AFTER EXPOSURE TO LOW TEMPERATURES FOR EXTENDED PERIODS OF TIME. THE CLOUDINESS WILL DISAPPEAR WHEN THE OIL IS WARME D TO AT L EAST 1 0 C AND AG ITATED. DO NOT ATTEMPT TO "THIN" THE OIL WITH NO.2 DIESEL FUEL. FOR BEST RESULTS, STORE THE OIL ABOVE FREEZING.

NOTE: Accidentally mixing Mobil EAL224 H hydraulic oil wi th

other mineral oils will cause no loss of performance characteristics. However, biodegradability may be reduced and toxicity may be increased, depending on the oil and level of contamination.

Changing Hydraulic Oil

1. Use of any of the recommended 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 ex ceeding 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 ch an ging the hydraulic oil every two years.

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 dow n, 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.

3. Some machines may be specially equipped with Mobil EAL224H biodegradable and non-toxic hydraulic oil. This oil is vegetable oil based and pos-

3120884 – JLG Lift – 2-3

SECTION 2 - PROCEDURES

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always th e best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose requirements. Should any question arise regarding the use of greases in maintenance stock, consul t your local supp lier for eval uation. Refer to Section 1 for an expl anation of the lub ricant ke y designations appearing in the Lubrication Chart.

2.4 BATTERY MAINTENANCE AND CHARGING

Battery Maintenance, Qu arterly

1. Open battery compartment cover to allow access to battery terminals and vent caps.

WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTROLYTE COVERS THE PLATES.

NOTE: When adding distilled water to batteries , no n-metalli c

containers and/or funnels must be used. To avoid electrolyte overflow, add distilled water to

batteries after charging. When adding water to the battery, fill only to level

indicated or 9.5 mm above separators.

3. Remove battery cables from each battery post one at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or ammonia) and wire brush. Replace cables and/or cable clamp bolts as re quired.

4. Clean battery post with wire brush then re-connect cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly.

5. When all cables and terminal posts have been cleaned, ensure all cables are properly positioned and do not get pinched. Close battery compartment cover.

6. Start hydraulic system and ensure that it functions properly.

Optional On Board Generator

EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY.

WHEN THE GENERATOR EN ABLE CONTROL LOCATED IN T HE PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE GROUND EMERGENCY STOP SWITCH IS ON (PULLED OUT), THE GENERATOR WILL START AUTOMATICALLY WHEN THE BATTERIES REACH A LOW-CHARGE STATE, AUTOMATICALLY CHARGING THE BATTERIES. THE GENERATOR WILL A LSO AUTOMATICALLY STAR T IF THE G ENERATOR ST ART BATTERY IS LOW.

2. Remove all vent caps and inspect electrolyte level of each cell. Electrolyte level should be to the ring approximately one inch from top of battery. Fill batteries with distilled water only. Replace and secure all vent caps.

2-4 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-1. On Board Generator

3120884 – JLG Lift – 2-5

SECTION 2 - PROCEDURES

NOTE: The engine will automatically shut down under the

following conditions: High Engine Oil Temperature

Low Engine Oil Pressure Engine Overspeed Generator Overvoltage Batteries fully charged

TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING BATTERIES.

Battery Charging (On Board Charger)

1. For maximum battery life:

a. Avoid completely discharging the batteries. b. Fully charge the batteries each day the machine

is used.

c. Charge the batteries at available times between

charging.

d. Be sure the battery fluid covers the battery

plates before charging, but to avoid overflow, do not top off the fluid level until charging.

2. To charge the batteries, connect the charger to a 115 volt source with a 15 amp minimum capacity.

3. The Charger will shut off automatically when the batteries are fully charged.

4. The charge cycle is complete when the ammeter reads 0 amps. Any reading indicates the charge cycle is not complete.

5. Depleted batteries will take approximately 17 hours to charge.

2.5 CYLINDERS - THEORY OF OPERATION Upper Boom Lift, Mid Boom Lift, Lower

Boom Lift, T e lescope, Slave, Master , Rotator, and Steer

A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

Figure 2-2. Batteries and Battery Charger

2-6 – JLG Lift – 3120884

Holding valves are used in the Lift circuits to prevent retraction of the cylin der rod should a hydr aulic line rupture or leak develop between t he cylin der and it s relat ed control valve.

2.6 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylin-

der component is repl ac ed o r wh en im pro pe r syste m operation is suspected.

Cylinder Without Counterbalance Valves (Steer, Master, and Rotate)

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

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

3. Activate hydraulic system, and activate cylinder extend function.

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

5. With cylinder fully retracted, shut down motor and carefully disconnect hydraulic hose from cylinder extend port.

6. Activate hydraulic system and activate cylinder retract function. Check extend port for leakage.

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

Cylinders With Single Counterbalanc e Valve (Upper Lift Cylinder)

SECTION 2 - PROCEDURES

WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 2.5 CM BELOW THE MAIN BOOM. IF WORKING ON LOWER BOOM LIFT CYLINDER, RAISE LOWER BOOM HALFWAY, FULLY ELEVATE UPPER BOOM AND ATTACH OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING APPROXIMATELY 2.5 CM OF SLACK IN CHAIN O R SLING FOR TEST PURPOSES.

2. After completing the above, shut down hydraulic system and allow machine to si t for 10-15 minutes. This is done to relieve pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block.

3. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the following cylinder repairs must be made. If the retract port is leaking, the piston is leaking, the piston seals are defective and must be replaced. If the extend port is leaking, the counterbalance is defective and must be replaced.

4. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports.

5. Remove boom prop/overhead crane, activate hydraulic sy s t e m and run cyl inder throug h complete cycle to check for leaks and operation.

Cylinders With Dual Counterb alance Valve (Lower Lift, Mid Lift, Telescope, and Sla ve Cylinders)

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

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

WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE

THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

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

APPROXIMATELY 2.5 CM BELOW THE MAIN BOOM. IF WORKING ON LOWER BOOM LIFT CYLINDER, RAISE LOWER BOOM HALFWAY, FULLY ELEVATE UPPER BOOM AND ATTACH OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING APPROXIMATELY 2.5 CM OF SLACK IN CHAIN O R SLING FOR TEST PURPOSES.

3120884 – JLG Lift – 2-7

SECTION 2 - PROCEDURES

2. When working on the platform slave cylinder, stroke platform slave level cylinder forward until platform sits at a 45 degree angle.

3. After completing the above, shut down hydraulic system and allow machine to sit f or 10-15 minutes. This is done to relieve pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block.

4. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the following cylinder repairs must be made. If the retract port is leaking, the piston is leaking, the piston seals are defective and must be replaced. If the extend port is leaking, the counterbalance is defective and must be replaced.

5. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge there should not be any further leakage from the ports. If leakage occurs at a rate of 6-8 drops per minute or more, the piston seals are defective and must be replaced.

6. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports.

7. Remove boom prop/overhead crane, activate hydraulic system and run cylinder through complete cycle to check for leaks and operation.

source. Adequa te ly s upport the cylinder rod, if applicable.

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

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

Figure 2-3. Cylinder Barrel Support

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

2.7 CYLINDER REPAIR

NOTE: The following are general procedures that apply to

all of the c ylinde rs on th is mac hine. Pr ocedur es that apply to a specific cylinder will be so noted.

Disassembly

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

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

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power

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

6. Using a spanner wrench, loosen the end cap or

7. Attach a suitable pulling device to the cylinder rod

2-8 – JLG Lift – 3120884

Figure 2-4. Capscrew Removal

cylinders.

head retainer, and remove from cylinder barrel.

port block end or cylinder rod end, as applicable.

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

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

SECTION 2 - PROCEDURES

12. Remove the bushing from the piston.

Figure 2-6. Tapered Bushing Removal

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

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

Figure 2-5. Cylinder Rod S upport

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

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

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

15. Remove piston spa cer, if applicable, from the rod.

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

Cleaning and Inspection

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

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

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

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

5. Inspect threaded portion of b arrel fo r dam age. Dress threads as necessary.

6. Inspect pist on surface f or damage and s coring and for distortion. Dress piston surface or replace piston as necessary.

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

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

3120884 – JLG Lift – 2-9

SECTION 2 - PROCEDURES

Figure 2-7. Gar-Max Bearing Installation

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

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

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

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

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

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

dirt etc. to facilitate bearing installation.

b. Inspect steel bushing for wear or other damage.

If steel bushing is worn o r damaged, rod/bar rel must be replaced.

c. Lubricate inside of the steel bushing with WD40

prior to bearing installation.

d. Using an arbor of the correct size, carefully

press the bearing into steel bushing.

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper

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

prior to assembly.

1. A speci al tool is use d to install a new rod seal into the applicable cylinder head gland groove.

NOTE: Install pin into the Gar-Max bearing dry. Lubrication

is not required with nickel plated pins and bearings.

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

15. If applic able, inspect port block fitt ings and holdi ng valve. Replace as necessary.

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

17. If applicable, inspect piston rings for cracks or other damage. Replace as nece s sa ry.

Figure 2-8. Rod Seal Installation

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

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

Figure 2-9. Wiper Seal Installation

2-10 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

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

Figure 2-10. Installation of Head Seal Kit

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

5. Carefully slide the piston spacer on the rod.

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

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

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

one side. This side faces the solid seal.(See magnified insert in Figure 2-11.)The split of seals and backup rings are to be positioned so as not to be in alignment with each other.

Figure 2-11. Piston Seal Kit Installation

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

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

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

NOTE: When installing the tapered bushing, piston and ma t-

ing end of rod must be free of oil.

WHEN REBUILDING THE STEER, LOWER LIFT, LEVEL CYLINDER, OR UPPER LIFT CYLINDER, APPLY LOCTITE #242 TO TAPERED BUSHING BOLTS, THEN TIGHTEN SECURELY.

3120884 – JLG Lift – 2-11

SECTION 2 - PROCEDURES

Figure 2-12. Tapered Bushing Installation

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

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

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

b. Tap each space once; this means the tapered

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

Figure 2-13. Seating the Tapered Bearing

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

15. Remove the cylinder rod from the holding fixture.

16. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (See Figure 2-11., Piston Seal Kit Installation)

a. Place the shaf t against the cylinder rod and in

contact with the bushing in the spaces between the capscrews.

Figure 2-14. Poly-Pak Piston Seal Installat ion

2-12 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

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

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

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

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

20. Secure the cylinder head gland using the washer ring and socket head bolts.

Table 2-1.Cylinder Head and Tapered Bushing Torque

Specifications

Description

E.A.R. Cylinder

Level Cylinder (M45AJ)

Master Cylinder

(M45AJ)

Table 2-2. Cylinder Piston Nut Torque Specifications)

Description

Upper Lift Cylinder

Mid Lift Cylinder

Head Torque V alue

(Wet)

30 ft. lbs (41 Nm)

30 ft. lbs.

(41 Nm)

Nut Torque Valve (Wet)

200 ft. lbs.

(270 Nm)

400 ft. lbs.

(542 Nm)

Tapered Bushing

Torque Value (Wet)

5 ft. lbs.

(7 Nm)

5 ft. lbs.

(7 Nm)

5 ft. lbs.

(7 Nm)

Setscrew

Torque Value

(Dry)

100 in. lbs.

(11 Nm)

100 in. lbs.

(11 Nm)

Figure 2-15. Rod Assembly Installation

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

22. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings as applicable. (See Table 2-3, Holding Valve Torque Specifications).

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

Lower Lift Cylinder

Level Cylinder (M45 A) 80 ft. lbs.

Master Cylinder (M45A)

Table 2-3. Holding Valve Torque Specificatio ns

Description Torque Value

SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.

RACINE - 1 3/8 HEX 1 3/16 - 12 THDS. 75-80 ft. lbs.

400 ft. lbs.

(542 Nm)

(108 Nm)

80 ft. lbs.

(108 Nm)

100 in. lbs.

(11 Nm)

100 in. lbs.

(11 Nm)

100 in. lbs.

(11 Nm)

(41-48 Nm)

(61-68 Nm)

(204-217 Nm)

(68-75 Nm)

(102-109 Nm)

RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs.

(136-149 Nm)

3120884 – JLG Lift – 2-13

SECTION 2 - PROCEDURES

Figure 2-16. Upper Boom Lift Cy linder Removal

2.8 CYLINDER REMOVAL AND INSTALLATION

Upper (Main) Boom Lift Cylinder Removal

1. Place the machine on a flat and level surface. Place the Upper Boom in a horizontal position. Place Lower and Mid Booms 5 degree above horizontal. Shut down machine and prop boom.

2. Tag, disco nnec t a nd ca p th e up per boom lift cylind er hydraulic lines and ports.

3. Remove the hardware securing the cylinder rod attach pin #1 to the boom. Using a suitable brass drift, drive out the cylinder rod attach pin #1.

3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports.

4. With function speed switch at its slowest setting, extend the cylinder rod until attach pin hole aligns with those in boom. Using a suitable drift, drive the cylinder rod attach pin #1 through the aligned holes. Secure the pin in place with pin retaining hardware.

5. Cycle cylinder completely to check for proper functioning. Place boom in stowed position. Check hydraulic fluid level and adjust accordingly.

Mid Boom Lift Cylinder Removal

1. Place machine on flat and level surface. Place the Upper Boom in a horizontal position. Place the Mid Boom in a 10 degree elevated position. Support Upper Boom with a prop. Support upright with an overhead cran e.

2. Using slings, restrain the lower lift cylinder.

3. Remove the hardware securing the cylinder rod attach pin #3 to the boom. Using an appropriate brass drift, drive out the cylinder rod attach pin #3.

4. Secure the cylinder with suitable slings or supports as required. Remove the hardware securing the barrel end attach pin #2. Using a suitable brass drift, drive out the barrel end attach pin #2.

5. Remove the cylinder from the boom and place in a suitable work area.

Upper (Main) Boom Lift Cylinder In stallation

NOTE: Coat I.D. of bushings with specified lubricant prior to

installing pins.

1. Install Lift Cylinder in place using suitable slings or supports, aligning attach pin mounting holes on upright.

2. Using a suitable drift, drive the barrel end attach pin #2 through the mounting holes in the lift cylinder and upright. Secure in place with pin retaining hardware.

Figure 2-17. Mid Boom Lift Cylinder Removal

4. Tag, disconnect and cap the lift cylinder hydraulic lines and ports.

5. Remove the hardware securing the barrel end attac h pin #4 to the boom. Using an appropriate brass drift, drive out the cylinder barrel pin #4.

6. Carefully remove cylinder from boom. Place in a suitable work area.

2-14 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Mid Boom Lift Cylinder Installation.

NOTE: Co at I. D. of bushings wit h spe cif ied l ubr ic ant pr ior t o

installing pins.

1. With the booms positioned and supported, place cylinder in position and secure in place using slings.

2. Install the cylinder barrel pin #4, being sure to align the hole in the cylinder barrel pin with the retaining pin screw hole. When holes alig n, in s t all hard ware.

3. Correctly install hydraulic lines to cylinder as previously tagged. Extend cylinder rod slowly until attach pin hole aligns with those in boom.

4. Using a suitable brass drift, drive the cylinder rod attach pin #3 through the aligned holes. Secure the pin in place using retaining hardw are.

5. Remove boom prop and overhead crane. Take the lift cylinder through one complete cycle to assure correct functioning. Place boom in stowed position. Check hydraulic fluid and adjust accordingly.

Lower Boom Lift Cylinder Removal

1. Place machine on flat and level surface. Place the Upper Boom in a horizontal position. Place the Mid and Lower Booms in a 10 degree elevated position. Support Upper Boom with a prop. Support upright with an overhead crane.

2. Using slings, restrain the lower lift cylinder.

4. Tag, disconnect and cap the lift cylinder hydraulic lines and ports.

5. Remove the hardware securing the barrel end attac h pin #6 to the boom. Using an appropriate brass drift, drive out the cylinder barrel pin #6.

6. Carefully remove cylinder from boom. Place in a suitable work area.

Lower Boom Lift Cylinder Installation

NOTE: Co at I. D. of bushings wi th spe cif ied lubr ic ant pr io r to

installing pins.

1. With the booms positioned and supported, place cylinder in position and secure in place using slings.

2. Install the cylinder barrel pin #6, being sure to align the hole in the cylinder barrel pin with the retaining pin screw hole. When holes align, install hardwa re.

3. Correctly install hydraulic lines to cylinder as previously tagged. Extend cylinder rod slowly until attach pin hole aligns with those in boom.

4. Using a suitable brass drift, drive the cylinder rod attach pin #5 through the aligned holes. Secure the pin in place using retaining hardware.

5. Remove boom prop and overhead crane. Take the lift cylinder through one complete cycle to assure correct functioning. Place boom in stowed position. Check hydraulic fluid and adjus t acc ord ingly.

3. Remove the hardware securing the cylinder rod attach pin #5 to the boom. Using an appropriate brass drift, drive out the cylinder rod attach pin #5.

Figure 2-18. Lower Boom Lift Cylinder Removal

3120884 – JLG Lift – 2-15

SECTION 2 - PROCEDURES

Upper Boom Telescope Cylinder Removal

1. Place machine on flat and level surface, with Upper Boom in the horizontal position. Extend Upper Boom until fly attach pin #1 is accessible on fly.

Figure 2-19. Upper Telescope Cylinder Removal

2. Support Upper Boom basket end with a prop . Support Upper Upright end with an overhead cran e.

3. Tag, disconnect hydraulic li nes to telescop e cyli nder. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports.

4. Remove the retaining rings that retain the telescope cylinder rod to the fly boom.

5. Using a suitable brass drift, carefully drive the telescope cylinder rod pin #1 from the fly boom.

6. Remove the four (4) bolts securing the telescope cylinder barrel end to the base boom.

NOTE: Care should be taken when removing the telescope

cylinder, do not leave cylinder rest on powertrack which could cause damage to powertrack.

9. Using anoth er lifting device , support the rod end of the cylinder and remove the cylinder from the boom assembly.

10. Carefully lift the cylinder clear of the boom assembly and lower to the ground or suitably supported work area.

Upper Boom Telescope Cylinder Installation

1. Attach a hydraulic power supply to the telescope cylinder ports. Using suitable supports or lifting devices at each end of the cylinder, extend the rod so that the cylinder pin attach holes are the same distance apart as the boom pin attach holes.

2. Using suitable lifting equipment, carefully lower the cylinder to the boom assembly.

3. Using anoth er lifting device , support the rod end of the cylinder and install the cylinder into the boom assembly.

4. Remove lifting devices from the telescope cylinder.

5. Carefully install the telescope cylinder rod pin #1 through the fly boom and secure it with the retaining rings.

6. Carefully install the telescope cylinder barrel end to base, securing cylinder to the base boom with four (4) bolts and hardware.

7. Remove applicable hydraulic line and port caps and correctly connect the hydraulic lines to the telescope cylinder. Ensure all hoses are correctly routed.

8. Remove boom prop and overhead crane. Activate hydraulic system.

9. Using all applicable safety precautions, operate the boom functions. Check for correct operation and hydraulic leaks. Secure as necessary.

10. Check fluid level of h ydrauli c tank a nd ad d as nec essary.

7. Using a suitable brass drift, carefully drive the telescope cylinder pin from the base boom.

8. Attach a suitable sling to the telescope cylinder. Using a suitable lifting device attached to the sling carefully pull the telescope cylinder from the boom assembly.

2-16 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

2.9 WEAR PADS

1. Shim up wear pads until snug to adjacent surface.

2. Replace wear pads when w orn to thickne ss shown below.

2.10 BOOM MAINTENANCE Removal

1. Remove the platform/support as follows: a. Disconnect electrical cable from control con-

sole.

b. Using an overhead crane or suitable lifting

device, strap support the platform/support.

c. Remove hardware from pin #1. Using a suitable

brass drift and hammer, remove pin #1 from the platform support.

d. Supporting the platform/support, remove the

hardware from pin #2. Using a suitable brass drift and hammer, remove pin #2 from the fly boom and remove the rotator.

e. Supporting the slave cylinder, remove the hard-

ware from pin #3. Using a suitable brass drift and hammer, remove pin #3 from the fly boom.

f. Tag and disconnect hydraulic lines to the slave

leveling cylinder. Use a suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports. Remove the slave cylinder.

2. Remove the boom from upright as follows:

Table 2-4. Wear Pad Thic kness

Pad

A 0.75" 19 mm 0.375" 9.5 mm B 0.5" 13 mm 0.3125" 8 mm C 0.5" 13 mm 0.3125" 8 mm

3. Adjust wear pads as follows: a. Loosen jam nut on adjustment bolt, turn bolt CW

b. After adjustments have been made, tighten the

Thickness of

New Pad

Figure 2-20. Wear Pad Thickness

until wear pad is snug to adjacent surface.

jam nuts on wear pad bolts.

Replace When Worn to:

a. Remove hardware securing the cover plate on

the side of the base bo om section and remove hose clamps. Disconnect wiring harness from ground control harness connector.

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

b. Tag and disconnect hydraulic lines from boom

to control va lve. Use a s uitable conta iner to retain any residual hydraulic fluid. Cap hydraulic lines and ports.

c. Using a suitable lifting equipment, adequately

support boom weight along entire length.

3120884 – JLG Lift – 2-17

SECTION 2 - PROCEDURES

Figure 2-21. Platform Components and Attac h i ng Hardware (M45A & E45A)

2-18 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

d. Remove hardware securing the lift cylinder pin

#1. Using a suitable bra ss drift and hammer, remove pin #1 from the base boom.

e. Remove hardware securing the master cylinder

pin #2. Using a suitable brass drift and hammer, remove pin #2 from the base boom.

f. Remove hardware securing the base boom pin

#3. Using a suitable bra ss drift and hammer, remove pin #3 from the upright.

g. Using all applicable safety precautions, carefully

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

Disassembly Boom Sections

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

2. Using a portable power source, attach hose to telescope cylinder port block. Using all applicable safety precautions, activate hydraulic system and extend cylinder to gain access to cylinder rod pin #1. Shut down hydraulic system.

3. Carefully disconnect hydrau lic ho se from retrac t port of cylinder. There will be init ial weepi ng of hydrau lic fluid which can be caught in a suitable container. After initial discharge, there should be no further leakage from the retract port.

4. Remove hardware securing telescope cylinder #1 to the fly boom section, then remove pin from fly.

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

WHEN REMOVING TELESCOPE CYLINDER FROM BOOM SECTIONS. CARE SHO ULD BE TAKEN NOT TO LET CY LINDER RES T ON POWERTRACK WHICH COULD CA USE DAMAGE TO POWERTRACK.

Figure 2-22. Location of Componen ts - Boo m

Removal

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

3120884 – JLG Lift – 2-19

SECTION 2 - PROCEDURES

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

8. Remove hardware securing the front cover on base boom section.

9. Loosen jam nut s on front wear pad a dju st me nts and loosen adjustments.

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

11. Remove wire clamp on the inside of the fly nose.

12. Manually push the fly boom section into base boom section to gain access to the powertrack attachment bolts on the right side of the base boom secti on.

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

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

15. Remove hydraulic lines and electrical cables from powertrack.

16. Remove hardware securing powertrack to the base boom section. Remove powertrack.

Inspection

1. Inspect boom pivot pin for wear, scoring or other damage, and for tapering or ovality. Replace pin as necessary.

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

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

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

5. Inspect wear pads for wear as shown in Section 2.9, Wear Pads.

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

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

Assembly

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

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

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

4. Using suitable lifting equipment, slide fly section into the base section until p ower trac k atta ch po int alig ns with holes in side of base section.

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

2-20 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

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

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

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

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

10. Secure the sling and lifting device at the telescope

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

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

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

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

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

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

15. Disconnect auxiliary power source from telescope cylinder.

Installation

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

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

3. Using all applicable safety precautions, operate lifting equipment in order to position boom lift and master cylinders so that holes in cylin der rod ends and boom structure are aligned. I ns ert cylinder pins.

4. If necess ary, gently tap pins i nto posit ion wit h a soft headed mallet, ensuring that attach holes in pins are aligned with attach holes in boom structure. Secure with hardware.

5. Connect all hosing and wiring.

6. Install the slave leveling cylinder to the boom assembly.

7. Install the platform to the boom assembly.

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

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

10. Shut down machine systems and check for leakage.

2.11 ROTATOR - HELAC Disassembly

1. Place actuator on a clean workbench.

2. Remove all hydraulic fittings.

3. Remove the nut from the bottom of the tie rod assembly.

3120884 – JLG Lift – 2-21

SECTION 2 - PROCEDURES

Figure 2-23. Rotator Assembl y (Helac)

2-22 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

4. Place two (2) 3/8"x16NC bolts in threaded holes in bottom of the actuator. Using a suitable bar, unscrew the end cap (5). Remove the end cap from the actuator housing (1).

Figure 2-24. Removing End Cap

5. Remove the shaft (2) from piston sleeve (3) and the actuator housing (1).

6. Remove piston sleeve (3) from housing (1).

Figure 2-26. Remov ing Sleeve from Housing

7. Remove all seals and bearings from grooves. Discard seals.

Inspection

1. Clean all parts thoroughly.

Figure 2-25. Removing Shaft from Housing

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

NOTE: A small amount of wear in the spline teeth will have

little effect on the actuator strength. New spline sets are manufactured with a backlash of about 0.005 in. per mating set. After long service, a backlash of about 0.015 per set may stil l be acceptable in most cases, depending on the required accuracy of the application.

3. Check the ring gear for wear and weld damage to the pins.

4. Inspect the cylinder bore for wear and scratches.

3120884 – JLG Lift – 2-23

SECTION 2 - PROCEDURES

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Install new seal (7 and 6) on the piston sleeve (3).

NOTE: Apply a coat of grease to the thrust ring before slid-

ing onto the shaft.

2. Install new seal (13), thrust washer (16) and bearing (15) on shaft (2).

NOTE: Apply a coat of grease to the thrust washer before

sliding onto the end cap.

3. Install new seals (9), back-up ring (10), cap bearing (14), bearing packing (13) and thrust ring (16) on end cap (4).

4. Place the actuator in the vertical position, install the piston sleeve (3) in timed relation to the housing (1).

DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY, AS IT WILL MARK THE CYLINDER BORE.

NOTE: The timing marks (the small punch marks on the

face of each gear), must be aligned for proper shaft orientation. (See Actuator Timing.)

5. Install the shaft (2) into ho using (1) by aligning the proper punched timing marks.

Figure 2-27. Actuator Timing

6. Temporarily tape the threaded portion of the shaft will help installation past the shaft seals (masking tape).

7. Install the tie rod assembly and secure in place with the nut.

2.12 BOOM LIMIT SWITCHES

Refer to Figure 2-28. , Boom Limit Switc hes for adjustments to be made to the two Bo om Limit S witches which bolt in place on the upright.

2-24 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-28. Boom Limit Switc h es

3120884 – JLG Lift – 2-25

SECTION 2 - PROCEDURES

Figure 2-29. Location of Components - Articulating

Jib Boom

2.13 ARTICULATING JIB BOOM Removal

1. For platform/support removal see platform/support removal diagram. See Section 2.10, Boom Maintenance.

2. Position the articulating jib boom level with ground.

3. Remove mounting hardware from slave leveling cylinder pin #1. Using a suitable brass drift and hammer, remove the cylinder pin from articulating jib boom.

2. Inspect articulating fly boom pivot attach points for scoring, tapering and ovality, or other damage. Replace pins as necessary.

3. Inspect inner diameter of articulating fly boom pivot bearings for sc oring, di stortion, wear, or other damage. Replace bearings as necessary. (See Section

2.7, Cylinder Repair For Bearing Replacement).

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

5. Inspect inner diameter of rotator attach point bearings for scori ng, distortion, wea r, or other damage. Replace bearing as necessary. (See Section 2.7, Cylinder Repair For Bearing Replacement).

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

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

Assembly

4. Remove mounting hardware from articulating jib boom pivot pin #2. Usi ng a suitable bra ss drift and hammer, remove the pivot pin from boom assembly.

Disassembly

1. Remove mounting hardware from articulating jib boom pivot pins #3 and #4. Usin g a suitable br ass drift and hammer, remove the pins from articulating jib boom pivot weldment.

2. Remove mounting hardware from rotator support pins #5 and #6. Using a suitable brass drift and hammer, remove the pins from rotator support.

3. Remove mounting hardware from lift cylinder pin #7. Using a suita ble br ass d rift a nd ha mmer, remove the cylinder pin from articulating jib boom.

Inspection

NOTE: When inspecting pins and bearings refer to Section

2.19, Pins and Gar-max Bearing Repair Guidelines.

1. Inspect articulating fly boom pivot pin for wear, sco ring, tapering and ovality, or other damage. Replace pins as necessary.

mallet, install pivot pin #2 into fly boom assembly and secure with mounting hardware.

NOTE: For location of components See Section 2-29., Loca-

tion of Components - Articulating Jib Boom.

1. Align li ft cylinder with attach hol es in articula ting jib boom. Using a soft head mallet, install cylinder pin #7 into articulating jib boom and secure with mounting hardware.

2. Align rotator support with attach hole in articulating jib boom. Using a soft head mallet, install rotator support pin #6 into articulating jib boom and secure with mounting hardware.

3. Align bottom tubes with attach holes in rotator support. Using a soft head mallet, install rotator support pin #5 into articulating jib boom and secure with mounting hardware.

4. Align articulating jib boom with attach hole in articulating jib boom pivot weldment. Using a soft head mallet, install rotator support pin #4 into articulating jib boom and secure with mounting hardware.

5. Align bottom tubes with attach holes in articulating jib boom pivot weldment. Using a soft head mallet, install rotator support pin #3 into articulating jib boom pivot weldment and secure with mounting hardware.

6. Align articulating jib boom pivot weldment with attach holes in fly boom a ssemb ly. Using a soft head

2-26 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

7. Align the slave leveli ng cylind er with attach h oles in articulating jib boom pivot weldment. Using a soft head mallet, install slave leveling cylinder pin #1 into articulating jib boom pivot weldment and secure with mounting hardware.

2.14 SWING BEARING Turntable Bearing Mounting Bolt Condition

Check

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

ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter. If during this check any bolts are found to be missing or loose, replace missing or loose bolts with new bolts and torque to the value specified in the torque chart, after lubric ating the bolt threads with loctite #271. After replacing and retorquing bolt or bolts recheck all existing bolts for looseness.

1. Check the frame to bearing. Attach bolts as follows: a. Elevate the fully retracted boom to 70 degrees

(full elevation).

b. At the posit ions indicated on Figure 2-31. t r y and

insert the .0015" feeler gauge between the bolt head and hardened washer at the arrow indicated posit ion.

c. Assure that the .0015" feeler gauge will not pen-

etrate under the bolt head to the bolt shank.

d. Swing the turntable 90 degrees, and check

some selected bolts at the new position.

e. Continue rotating the turntable at 90 degrees

intervals until a sampling of bolts have been checked in all quadrants.

2. Check the turntable to bearing. Attach bolts as fol-

lows:

head and hardened washer at the arrow indicated positio n.

Figure 2-30. Swing Bearing Feeler Gauge Check

Wear Tolerance

1. With the boom positioned over the side of the machine, the Upper Boom horizontal with telescope fully extended and Mid/Lower Boom stowed, (See Figure 2-31.), using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. (See Figure 2-32.)

2. At the same point, with the boom positioned over the side of the machine, the Upper Boom fully elevated and the Mid/Lower Boom fully elevated, (See Figure 2-31.) using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable (See Figure 2-32.).

a. Elevate the fully retracted boom to 70 degrees

(full elevation).

b. At the posit ions indicated on Figure 2-30. t r y and

insert the .0015" feeler gauge between the bolt head and hardened washer at the arrow indicated posit ion.

c. Lower the boom to horizontal and fully extend

the boom.

d. At the position indicated on Figure 2-30. try and

insert the .0015" feeler gauge between the bolt

Figure 2-32. Swing Beari ng Tolerance Measuring Poin t

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

3120884 – JLG Lift – 2-27

SECTION 2 - PROCEDURES

Figure 2-31. Swing Bearing Tolerance Boom Placement

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

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

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

Replacement of Swing Bearing

1. Removal.

a. Attach an adequate support sling to the boom

and draw all slack from sling. Prop o r block the boom if feasible.

b. Tag and disconnect hydraulic lines running

through center of turntable and frame. Use a

suitable container to retain any residual hydraulic fluid. Cap lines and ports.

c. Attach suitable overhead lifting equipment to the

base of turntable weldment.

d. Use a suitable tool to scribe a line on the inner

race of the swing bearing and on the underside of the turntable. This will aid in aligning the bearing upon installation. Remove bolts, nuts and washers which attach the turntable to the bearing inner race. Discard nuts and bolts.

e. Use the lifting equipment to carefully lift the com-

plete turntable a ssembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame mounted components.

f. Carefully place the turntable on a suitably sup-

ported trestle.

g. Use a suitable tool to scribe a line on the outer

race of the swing bearing and the frame. This line will aid in aligning the bearing upon installation. Remove the bolts and washers which

2-28 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

attach the outer race of the bearing to the frame. Discard the bolts. Use su itable lifting equipment to remove the bearing and rotation box assembly from the fram e; move to a clean, su itably supported work area.

h. Remove the two capscrews securing the bear-

ing to the rotation box to separate the two for inspection.

2. Installation. a. Install bearing to rotation box with two cap-

screws, so that fill plug of bearing is as close to gear as bolt pattern will allow. Do not tighten capscrews.

b. Line up high spot (blue) of bearing with center

tooth of worm gear. Set backlash to 0.20 - 0.25 mm (0.008 - 0.010 inch). Tighten capscrews as shown in Figure 2-3 3., Swing Bea ring Torquing Sequence.

c. Apply Tribol Molub-Alloy 936 Open Gear Com-

pound to bearing and worm gear teeth.

d. Grease bearing with Mobilith SHC Bearing

Grease. Grease fitting is on inside wall of inner race of bearing.

NOTE: If Tribol Molub-Alloy 936 Open Gear Compound or

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

e. Using suitable lifting equipment, install bearing/

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

g. Following the torque sequence diagram shown

in Figure 2-33., tighten the bolts to an initial torque of 175 ft. lbs. (237 Nm). Then following the same sequence, tighten to a final torque of

240 ft. lbs. (326 Nm). h. Remove lifting equipment from bearing. i. Use suitable lifting equipment to carefully posi-

tion the turntable assembly above the machine

frame. j. Carefully lower the turntable onto the swing

bearing. Ensure that the scribed line of the inner

race of the bearing aligns with the scribed mark

on the turntable. If a new swing bearing is used,

ensure that the filler plug fitting is at 90 degrees

from the fore and aft centerline of the turntable. k. Apply a light coating of Loctite 271 to the new

bearing bolt s and in stall th rough the turnt able

and inner race of bearing. l. Following the torque sequence shown in Figure

2-33., tighten the bolts to an initial torque of 237

Nm (175 ft. lbs.). Then following the same

sequence, tighten t he bolts to 3 26 Nm (240 ft.

lbs.). m. Remove the lifting equipment. n. Route hydraulic lines through center of turntable

and frame and connect as tagged prior to

removal. o. Using all applicable safety precautions, activate

the hydraulic system and functionally check

swing system for proper and safe operation.

Swing Bearing Torque Values

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

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

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

f. Apply a light coating of Loctite 271 to the new

bearing bolts and loosely install the bolts and washers th rough th e frame an d outer r ace of bearing.

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

Checking Worm Gear End Play

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

performed on the worm gear end play.

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

3120884 – JLG Lift – 2-29

SECTION 2 - PROCEDURES

Allowable Tolerance

.001 to .005

()

2. If tolerance exceeds .010", reduce end play to less than .005". Refer to Adjusting End Play.

Adjusting End Play

1. Remove end pla te .

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

3. Determine thickness of shim pack required to obtain .001" - .005" end play.

thicker shims and replacing with thinner shims, included in kit.

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

6. Recheck end play .

Fig 2 Adjusting End Play.

SHIMS

END PLATE

4. Adjust shim pack thickness as required to obtain proper end play. Reduce end play by removing

Figure 2-33. Swing Bearing Torquing Sequence

2-30 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-34. Swing Components

3120884 – JLG Lift – 2-31

SECTION 2 - PROCEDURES

2.15 MID AND LOWER LIFT CYLINDER BLEEDING PROCEDURE

NOTE: Bleeding procedure should only be necessary if

rebuilding or replacing lift cylinder.

1. Check oil level in the hydraulic oil tank (all booms must be retracted).

2. Lay an oil drip pan under the rod end port block (Mid Cylinder) and crack bleeder open from the fitting in the port block.

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

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

5. Raise the lower boom approx. 30.5 cm, then close bleeder while the boom is still moving.

6. Lift down all the way.

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

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

2.16 BOOM SYNCHRONIZING PROCEDURE

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

1. Remove all personnel from the platform.

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

3. From Ground Control, activate the lift control switch, raise Lower Boom 1.8 m (6 feet).

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

5. Activate Lower Boom Down, fully lower boom.

6. Repeat st ep 1 thru 5 if nec e ssary.

2.17 DRIVE HUB Setting of Tapered Roller Bearings

NOTE: The numbers in parentheses ( ) reference the figure

Drive Hub- Cutaway.

1. De-grease threads of the spindle (60) and shaft nut (4).

2. Spin the shaft nut onto spindle by hand to insure the threads are in good condition.

3. Apply Loctite 270 evenly to threads of the shaft nut.

4. Rotate the support ring repeatedly in one direction only, during setting of the tapered roller bearings.

5. Tighten shaft nut to 850 Nm (626 ft. lbs.).

6. Do not use the hub for 24 hours to allow the Loctite to harden properly.

7. Do not fill with oil for 24 hours to allow the Loctite to harden properly.

Securing of the Shaft Nut

1. After proper bearing setting is completed, use a suitable punch to place ball (24) 1.1 to 1.3 mm (0.04 to

0.05 inches) into the spindle thread. Then set ball (24) in position by punching in expander (25).

2-32 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-35. Drive Hub - Cutaway

3120884 – JLG Lift – 2-33

SECTION 2 - PROCEDURES

2.18 DRIVE BRAKE - MICO Disassembly

1. Remove pressure plate (3) from cover (21) by removing cap screws (1) and washers (2).

PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXIMATELY 680 KGF (1500 LBS). THE FOUR CAP SCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE, 1361 KGF (3000 LBS) MINIMUM, THE PRESSURE PLATE CAN BE HELD IN POSITI ON WHILE REMOVING THE CAP SCREWS AND WASHERS

2. Remove case seal (4) from cover (21).

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

4. Remove o-ring (5), back-up ring (6), o-ring (8) and back-up ring (9) from piston (7).

5. Remove stack assembly, consisting of stator disc (11), sensor ring (12), rotor disc (13), and plate (14) from cover (20).

6. Remove dowel pins (20), springs (15) and spring retainer (16) from cover (21). Note number and pattern of springs.

7. Remove retaining ring (17) from cover (21).

8. Remove shaft (10) by pressing or using a soft mallet on male end of shaft (10).

9. Remove retaining ring (19) and bearing (18) from shaft (10).

10. Press rotary oil seal (22) from cover (21).

Assembly.

NOTE: Lubricate all rubber components from the repair kit

with clean type fluid used in the system.

NOTE: Disc (13 &11) and plate (14) must remain dry dur-

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

7. Place a new friction disc (13) on shaft (10) until it contacts plate (14). Install stator disc (11).

8. Install new o-ring (5), new back-up ring (6), new oring (8) and new back-up ring (9) on piston (7). Note order of o-rings. Insert pi ston (7) i nto pressure pla te (3). Be careful not to shear o-rings or back-up rings.

9. Install new case seal (4) in cover (21).

10. Position pressure plate (3) on cover (21) aligning dowel pins (20) with holes in pressure plate.

11. Install cap screws (1) and washers (2) and tighten evenly to draw pressure plate (3) to cover (21). Torque cap screws 74.6 N-m (55 lb.-ft.).

NOTE: A hydraulic press will simplify installation of

pressure plate on cover. Clamp pressure plate in position while tightening the cap screws.

IF HYDROSTATIC BENCH TESTING IS PERFO RMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED

137.9 BAR (2000 PSI) UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.

Bleeding

1. Install brake in system and connect pressure lines.

2. Bleed pressure release section of brake by pressurizing side inlet port and allowing air to escape from top port. Pressure should not exceed 6.9 bar (100 lb) during bleeding.

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

1. Clean all parts thoroughly before assembly.

2. Press new rotary seal (22) into cover (21). Note direction of seal.

3. Install new bearing (18) and retaining ring (19) on shaft (10).

4. Install shaft assembly and retaining ring (17) in cover (21)

5. Install dowel pins (20), spring retainer (16) and springs (15) in cover plate (21). Be sure to use the same number of springs and spring pattern as recorded during disassembly.

6. Position plate (14) on springs (15).

2-34 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-36. Drive Brake - Mico

3120884 – JLG Lift – 2-35

SECTION 2 - PROCEDURES

2.19 PINS AND GAR-MAX BEARING REPAIR GUIDELINES

Filament wound bearing s .

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

a. Excessi ve sloppiness in joi nt s. b. Noise originating from the join t during op eration .

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

a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing. c. Bearings tha t ha ve mo ved or sp un in the i r ho us-

ing.

d. Debris embedded in liner surface.

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

a. Detectable wear in the bearing area. b. Flaking, pealing, scoring, or scratches on the pin

surface.

c. Rusting of the pin in the bearing area.

4. Re-assembly of pi nned joints using fila ment wound bearings.

a. Housing should be blown out to remove all dirt

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

b. Bearing / pins should be cleaned with a solvent

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

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

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

2.20 SPEED SENSOR ADJUSTMENT

For proper drive operation, the spe ed sensors must be properly installed and adjusted. The sensor operates on a leading pulse to show direction. If installed wrong, the sensor will not be able to sense the proper direction.

IF BOTH SPEED SENSORS ARE INSTALLED WRONG, THE CONTROLLER WILL THINK THE MACHINE IS ON A HILL AND WILL GO INTO FULL SPEED MODE IMMEDIATELY WHEN DRIVE IS SELECTED. THE MACHINE WIL L NOT STOP UNLE SS THE FOOTSWITCH IS RELEASED OR THE EMS IS PUSHED IN.

IF ONLY ONE SENSOR IS INSTALLED WRONG, THE CONTROLLER SENSES A PROBLEM AND THE MACHINE WILL ONLY DRIVE AT CREEP SPEED. IF BOTH SENSORS ARE ADJUSTED TOO FAR OUT, THE CONTROL SYSTEM CONTROLLER WILL NOT DRIVE THE MACHINE.

Adjustment Procedure

1. Back off the locking nut and o-ring.

2. Thread the sensor in until it bottoms out (don’t use

excessive force).

3. Back-off 1-2 turns and align the notch with the axis of the brake. Refer to Figure 2-37., Speed Sensor Orientation.

4. Use a 1/2" wrench to hold the sensor and a 11/16" wrench to snug the lock nut to the brake.

2-36 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-37. Speed Sensor Orientation

3120884 – JLG Lift – 2-37

2-38 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-38. Frame Mounted Electrical Components

3120884 – JLG Lift – 2-39

Figure 2-39. Steering Components and Spindles

SECTION 2 - PROCEDURES

Figure 2-40. Drive Components

2.21 FOOTSWITCH ADJUSTMENT

Adjust switch so that functions will operate when pedal is at center of travel. If switch operates within last 1/4 inch (6.35 mm) of travel, top or bottom, it should be adjusted.

Updated 8-30-99

2.22 POSITRAC/TILT MODULE

When installing a new positrac/tilt module, always ensure that it is calibrated using the JLG Control System analyzer before operating the machine. Refer to Section 2.24, JLG Control System Analyzer Kit Instructi ons. Use a st andard bubble level in two different directions to ensure that the

machine’s frame is level prior to installing the new positrac/tilt module.

1. Place the machine on a flat, level surface. Check for level by placing a bubble level on the frame in both directions.

2. Plug in the analyzer (Analyzer - p/n 1600244, Cable p/n 1600633) into port J9 on the power module or port J1 on the platform module.

3. Use the right arrow key to curse over to "ACCESS LEVEL 2". Depress Enter.

2-40 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

4. Use Up/Down arrow keys to enter the following password "33271". Depress Enter.

5. Use the right arrow key to curse over to "LEVEL VEHICLE". Depress Enter. Depress Enter again.

6. Verify that the tilt reading is now "0.0; 0.0".

TO ASSURE PROPER OPERATION, THE MACHINE MUST B E LEVEL WHEN INSTALLING AND CALIBRATING A NEW POSITRAC/TILT MODULE.

2.23 PRESSURE SETTING PROCEDURES Main Relief

1. Install pressure gauge at port “G” on Steer/Brake valve.

2. Activate and bottom out either Upper or Lower Lift Up. Adjust Main Relief to value in Pressure Setti ngs chart.

Upper Lift Down Relief

1. With pressure gauge at “G” port on main valve, activate and bottom out Upper Lift Down.

2. Adjust Upper Lift Relief to value in the Pressure S ettings chart.

Mid/Lower Lift Down Relief

1. With pressure gauge at “G” port on main valve, activate and bottom out Mid/Lower Lift Down.

2. Adjust Mid/Lower Lift Relief to value in the Pressure Settings chart.

Figure 2-41. Tilt Sensor Location

Telescope In Relief

1. With pressure gauge at “G” port on main valve, activate and bottom out Telescope In.

2. Adjust Telescope In Relief to value in the Pressure Settings chart.

3120884 – JLG Lift – 2-41

SECTION 2 - PROCEDURES

Platform Level Up Relief

1. With pressure gauge at “G” port on main valve, activate and bottom out Platform Level Up.

2. Adjust Platform Level Up Relief to value in the Pressure Settings chart.

Platform Level Down Relief

1. With pressure gauge at “G” port on main valve, activate and bottom out Platform Level Down.

2. Adjust Platform Level Down Relief to value in the Pressure Settings chart.

Steer Relief

1. With pressure gauge at “G” port on steer/brake valve, activate and bottom out Steer Left or Right.

2. Adjust Steer Relief to value in the Pressure Settings chart.

3. Shut down hydraulic system and remove pressure gauge.

Table 2-4.Pressure Settings

Function PSI Bar

Main Valve

Upper Lift Down Relief 550 38 Mid/Lower Lift Down Relief 1700 117 T elescope In Relief 2150 148 Platform Level Up Relief 2500 172 Platform Level Down Relief 1200 83

Brake/Steer Valve

Steer Relief 2300 159 Main Relief 3200 221

Jib Valve

Jib Relief (Up a nd Down) 1500 103

Figure 2-42. Jib Valve Location

2-42 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-43. Brake/Steer Valve Components

3120884 – JLG Lift – 2-43

SECTION 2 - PROCEDURES

Figure 2-44. Main Valve Components

2-44 – JLG Lift – 3120884

2.24 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS

SECTION 2 - PROCEDURES

Figure 2-45. Control Module Location

Introduction

WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUDING OPTIONS.

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 52 BAR (750 PSI) AT A

MINIMUM DISTANCE OF 30.5 CM (12 INCHES) AWAY FROM THESE COMPONENTS. IF ELECTRICAL /ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

The JLG designed Control System is a 48 volt based motor control unit installed on the boom lift.

The JLG Control System has reduced the need for exposed terminal strips, diodes and trimpots and provides simplicity in viewing and adjusting the various personality settings for smooth control of: acceleration, decelerati on, creep and max.-speed for all boom, drive, and steer ing functions.

3120884 – JLG Lift – 2-45

SECTION 2 - PROCEDURES

The upper lift, swing, and d rive a re con trolled b y indi vidu al joysticks, with steeri ng bein g con trolled by a rocker s witc h built into the top the drive joystick. To activate Drive, Lift, and Swing simply pull up on the slide lock location on the joystick and move the handle into the direction desired.

The motor controll er will cont rol current output, as programmed for smoo th op erati on an d ma ximum c ycle ti me. Ground control speeds for all boom functions can also be programmed into the motor controller. The motor controller also feature s an ad justabl e time l imit for posit ive traction.

The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for troubl eshooting. Optional equipment includes an hour meter, beacon light, function cutout, and ground alarm. These options may be added later but must be programmed into t he motor controlle r when installed.

The Control System may be accessed in one of two ways: Utilizing a custom designed, hand held analyzer (Analyzer, JLG part no. 1600244 & Cable, J LG part no.

1600633) which will display two lines of i nformation at a time, by scrolling through the program.

NOTE: Eac h module has a label with the JLG par t numbe r

and a serial number which contain s a date code.

To Connect the JLG Control System Analyzer

1. Connect the four pin end of the cable supplied with the analyzer, to the motor controller module located in the platform box or at the power module and connect the remaining end of the cable to the analyzer.

NOTE: The cable has a four pin connector at each end of

the cable; the cable cannot be connected backwards.

2. Power up the Control System by turning the lower key to the platform or ground position and pulling both emergency stop buttons on.

Using the Analyzer

With the machine power on and the analyzer connected properly, the analyzer will display the following:

The following instruct io ns are for using the hand held ana lyzer.

HELP: PRESS ENTER

At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed menu item, press ENTER. To cancel a selected menu item, press ESC.; then you will be able to scroll using the right and left arrow keys to select a different menu item.

2-46 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

The top level menus are as follows:

HELP DIAGNOSTICS ACTIVATE TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP LEVEL VEHICLE (level 1 only) CALIBRATION S (view only)

If you press ENTER, at the HELP : PRESS ENTER display, and a fault is present, the analyzer display will scroll the fault across the screen. If there was no fault detected, the display will read: HELP: EVERYTHING OK. If powered up at the ground station, the display will read: GROUND OK.

If ENTER is pressed again, the display moves to the following display:

Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu. In some cases, such as DRIVE, the next level is the parameter or information to be changed. Refer to the flow chart for what menus are available within the top level menus. You may only view the pers onality settings for selected menus while in access level 2. Remember, you may always cancel a selected menu item by pressing the

ESC. key.

Changing the Access Level of the Hand Held Analyzer

When the analyzer is first connected, you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level, the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu. For example:

LOGGED HELP 1: STARTUP (2/1)

At this point, the analyzer will display the last fault the system has seen, if any are present. You may scroll through the fault logs to view what the last 25 faults were. Use the right and left arrow keys to scroll through the fault logs. To return to the beginning, press ESC. two times. STARTUP (2/1) indicates a power up.

When a top level menu is selected, a new set of menu items may be offered: for example:

DRIVE BOOM SYSTEM DATALOG VERSIONS

MENU: ACCESS LEVEL 2

Press ENTER to select the ACCESS LEVEL menu. Using the UP or DOWN arrow keys, enter the first digit of

the password, 3. Then using the RIGHT arrow key, position the cursor to

the right one space to enter the second digit of the password.

Use the UP or DOWN arrow key to enter the second digit of the password which is 33271.

3120884 – JLG Lift – 2-47

SECTION 2 - PROCEDURES

Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly:

MENU: ACCESS LEVEL 1

Adjusting Parameters Using the Hand Held Analyzer

Once you have gained access to level 1, and a per sonality item is selected, press the UP or DOWN arrow keys to adjust its value, for example:

Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.

PERSONALITIES: DRIVE ACCEL 1.0s

There will be a minimu m and maximum fo r the val ue to ensure efficient operation. The Value will not increase if the UP arrow is presse d when at t he max imum va lue nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular personality. If the value does not change when pressing the up and won arrows, check the access level to ensure you are at access level 1.

2-48 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Machine Setup

When a machine digit item is selected, pr ess the UP or DOWN arrow keys to adjust its value, for example:

There is a setting that JLG strongly recommends that you do not change. This setting is so noted below:

ELEVATION CUTBACK

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.

ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC CO MPONENTS, JLG IN DUSTRIES INC. RE COMMENDS A MAXIMUM PRESSURE OF 52 BAR (750 PSI) AT A MINIMUM DISTANCE OF 30.5CM (12 INCHES) AWAY FROM THESE COMPONENTS. IF ELECTRICAL /ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

GROUND AL ARM: 2 = DRIVE

The effect of the machine digit value is disp layed along with its value. The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving. There are certain settings allowed to install optional features or select the machine model.

When selection the machine model to match the size of the machine, the personality settings will all default to the factory recommended setting.

NOTE: Refer to Table 2-5, Personality Ranges/Defaults, and

Table 2-6, Machine Setup Descriptions in this Service Manual f or the rec omme nded factory settings.

NOTE: Password 33271 will give you access to level 1,

which will permit you to change all machine personality settings.

3120884 – JLG Lift – 2-49

SECTION 2 - PROCEDURES

Machine Personality Settings

NOTE: Personality settings can be adjusted within the

adjustment range in order to achieve optimum machine performance.

Table 2-5. Personality Ranges/Defaults

FUNCTION PERSONALITY RANGE DEFAULTS

DRIVE ACCELeration 0.5s to 5.0s 1.0

DECELeration 0.1s to 2.0s 0.5 MINimum speed 0 to 25% 3 MAXimum speed 0 to 100% 100 ELEVATED MAXimum speed 0 to 25% 20

CREEP MAXimum speed 0 to 45% 30 POSITRAC time 0 to 60s 10 POSITRAC current 50-250 A 170A

10 for CE spec E45AJ

LOWER LIFT ACCELeration 0.5 to 5.0s 1.0

DECELeration 0.0 to 3.0s 0.5 MINimum UP speed 0 to 30% 19 MAXimum UP speed 0 to 100% 95 MINimum DOWN speed 0 to 20% 7 MAXimum DOWN speed 0 to 100% 47

UPPER LIFT ACCELeration 0.5 to 5.0 2.0

DECELeration 0.1 to 3.0 1.0 MlNimum UP speed 0 to 20 9 MAXimum UP speed 0 to 100 67 CREEP Maximum UP speed 0 to 50 30 MINimum DOWN speed 0 to 10 2 MAXimum DOWN speed 0 to 100 40 CREEP maximum DOWN speed 0 to 30 10

Updated 10-7-99

2-50 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Table 2-5. Personality Ranges/Defaults

FUNCTION PERSONALITY RANGE DEFAULTS

SWING ACCELeration 0 .5 t o 5.0s 2.7

DECELeration 0.0 to 3.0s 1.8 MINimum LEFT speed 0 to 10% 1 MAXimum LEFT speed 0 to 60% 25 CREEP maximum LEFT speed 0 to 35% 15 MINimum RIGHT speed 0 to 10% 1 MAXimum RIGHT speed 0 to 60% 25 CREEP maximum RIGHT speed 0 to 35% 15

TELEscope ACCELeration 0.5 to 5.0 1.0

DECELeration 0.1 to 3.0 0.5 MINimum IN speed 0 to 20 8 MAXimum IN speed 0 to 100 60 MINimum OUT speed 0 to 20 5 MAXimum OUT speed 0 to 100 70

BASKET LEVEL ACCELeration 0.5 to 5.0 1.0

DECELeration 0.1 to 3.0 1.0 MINimum UP speed 0 to 20 8 MAXimum UP speed 0 to 50 20 MlNimum DOWN speed 0 to 20 5 MAXimum DOWN speed 0 to 60 14

BASKET ROTATE ACCELeration 0.5 to 5.0 1.5

DECELeration 0.1 to 3.0 1.0 MlNimum LEFT speed 0 to 15 2 MAXimum LEFT speed 0 to 100 23 MINimum RIGHT speed 0 to 15 2 MAXimum RIGHT speed 0 to 100 27

3120884 – JLG Lift – 2-51

SECTION 2 - PROCEDURES

FUNCTION PERSONALITY RANGE DEFAULTS

JIB ACCELeration 0.5 to 5.0 1.5

DECELeration 0.5 to 3.0 0.5 MINimum UP speed 0 to 50 9 MAXimum UP speed 0 to 100 50 MINimum DOWN speed 0 to 25 6 MAXimum DOWN speed 0 to 100 35 MINimum RIGHT speed 0 to 50 5 MAXimum RIGHT speed 0 to 100 20 MINimum L E FT speed 0 to 50 5 MAXimum LEFT speed 0 to 100 20

STEER M INimum speed 0 to 100 75

Table 2-5. Personality Ranges/Defaults

MAXimum speed 0 to 100 100

GROUND MODE Lower LIFT UP speed 0 to 100 73

Lower LIFT DOWN speed 0 to 100 36 UPPER LIFT speed 0 to 100 51 SWING speed 0 to 100 19 TELEscope speed 0 to 100 53 BASKET ROTATE speed 0 to 100 21 BASKET LEVEL speed 0 to 100 30 JIB SWING speed 0 to 100 N/A JIB LIFT speed 0 to 100 45

Updated 10-7-99

2-52 – JLG Lift – 3120884

2. TILT SENSOR

SECTION 2 - PROCEDURES

Table 2-6. Machine Setu p Desc riptions

MODEL NUMBER... Displays/adjusts machine model

NOTE: all personalities reset to default

when model number is altered TILT... Displays/adj usts tilt sensor function DRIVE CUTOUT ... Displays/adjusts drive cutout switch

presence/ function FUNCTION CUTOUT ... Displays/adjusts function cutout switch

presence/function JIB. . . Displays/adjusts jib presence GROUND ALARM... Displays/adjusts ground alarm pres-

ence/ function PLATFORM ALARM... Displays/adjusts platform alarm pres-

ence/ function BATTERY MONITOR... Displays/adjusts battery monitor , which

indicates “WATE R BATTERIES” after a

number of charge/discharge cycles

Machine Configuration Programming Information

NOTE: The following information is to be used when working

with the MACHINE SETUP menu. When configuring the machine, the machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default values.

Default settings will be shown in bold type.

1. MODELS (names may change)

1=E300

2=M45; E45

When tilted the tilt light is lit (continuously) and drive speed is reduced to the creep speed setting

1=5 degree - reduces the maximum speed of all platform functions to creep when tilted and above elevation. Reduces drive speed to creep when tilted. (Domestic/Japan)

2=3 degree - reduces the maximum speed of all platform functions to creep when tilted and above elevation. Reduces drive speed to creep when tilted. (European/Australian)

3=3 degree - cuts out dr ive and reduces functions to creep speed when active and above elevation. Reduces drive speed to creep when tilted only. (Option)

NOTE: Any of the selections above will light the tilt lamp

when a tilted condition occurs and will sound the platform alarm when the machine is tilted and above elevation.

3. DRIVE CUTOUT

0=Battery Charger Cutout - cuts out drive when the battery charger is plugged in

1= Battery Charger Cutout and Simultaneous Drive and Boom functions disabled above elevation (European/Australian) 2= Battery Charger Cutout and Drive Cutout above elevation (Option)

4. FUNCTION CUTOUT LIMIT SWITCH

0= No Function Cutout

1= Cuts out all boom functions when switch opens (Option) 2= Cuts out all functions when the switch opens (Option)

5. JIB

0=No jib installed

1=Jib installed which has up and down movements only (Option) 2=Jib installed which has up and down movements and side to side movements (Option)

6. GROUND ALARM

0= No ground alarm installed

1= Travel Alarm - Sounds when the drive function is active (Option) 2= Descent Alarm - Sounds when either lift down is active (Option)

Updated 10-7-99

3120884 – JLG Lift – 2-53

SECTION 2 - PROCEDURES

3= Motion Alarm - Sounds when any function is active (Option)

7. PLATFORM ALARM

0= Sounds continuously when above elevation and tilted only.

1= Sounds continuously when above elevation and tilted, and in conjunction with fault code flashes (Option)

8. BATTERY MONITOR

0=No Battery Monitor

1-20= Number of Charge/Discharge Cycles

Level Vehicle Description

A NEW TILT MODULE WI LL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.

DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.

Help Descriptions and Fault Flash Codes

Table 2-7. JLG Control System Flash Codes

Code Description

2-1 2-2 2-3 2-5 3-1 3-2 3-3 3-5 4-2 4-4 5-5 6-6 7-7 9-9

Faulty Footswitch/EMS Drive/Steer inputs/Footswitch Interlocks Boom function inputs/Lift-Swing Joystick Function Cutout/Drive Cutout Contactors miswired/Motors miswired Line contactor welded Contactor short circuit or valve short circuit Brake pressure input Controller Overtemperature Battery voltage out of range Speed Sensor input CANbus inputs Traction /Pump motor wiring or mot or faulty Power Module Failure

LEVEL VEHICLE YES:ENTER, NO:ESC

Not available at password level 2 ENTER confirms that vehicle is currently level, and zeroes the tilt sensor measurements

Updated 10-7-99

2-54 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Table 2-8. Help Descriptions and Fault Flash Codes

Flash Code Description

No flash code is indicated for the following help messages; they are intended to hint at a possible problem if the vehicle is n ot behaving as expected.

EVERYTHING OK The "normal" help message in platform mode

GROUND MODE OK The "normal" help message in ground mode

BRAKES RELEASED Indicates manual brake release in groun d mo de

DRIVING AT CREEP - TILTED Drive speed is limited to creep because the vehicle is tilted.

FWS OPEN A drive or boom function has been selected but footswitch is open.

PUMP MOTOR AT CURRENT LIMIT Pump current has reached controller current limit or safe operating area limit.

RUNNING AT CREEP - CREEP SWITCH OPEN All function speeds are limited to creep because the creep switch is open.

RUNNING AT CUTBACK - ABOVE ELEVATION All function speeds are limited to cutback speed because the vehicle is above elevation.

RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All function speeds are limited to creep because the vehicle it tilted and above elevation.

TESTS ACTIVE - RECYCLE EMS TO E N D The system tests have been activated; normal vehicle operatio n is not allo wed.

TIL T MODULE FAILURE: BAD TILT SENSOR There is a problem with the tilt sensor interface circuitry; the controller defaults to massively tilted and does not try to prevent vehicle roll on the grade.

TRACTION MOTOR AT CURRENT LIMIT Traction current has reached controller current limit or safe operating area limit.

WATER BATTERIES The batteries have been charged a number of times (set by machine digit) and need a top-up; when this is done the count will reset

2/1

Flash code 2/1 indicates problems with the footswitch.

FWS FA ULTY The two footswitch signals do not agree. EMS recycle required.

START UP Neither EMS input is active - the system is just switching on or is discharging the capacitor bank. A welded line contactor might also ca us e t his

3120884 – JLG Lift – 2-55

SECTION 2 - PROCEDURES

Table 2-8. Help Descriptions and Fault Flash Codes

2/2

2/3

Flash code 2/2 indicates problems with drive & steer selection.

DRIVE JOYSTICK FAULTY The drive joysti ck center tap is out of va l id range, or the wipe r is wire-off.

DRIVE LOCKED - JOYSTICK MOVED BEFORE EMS/FWS Drive was selected before and during footswitch closure.

FWS INTERLOCK TRIPPED Footswitch was closed for seven s e conds with no function selected.

STEER LOCKED - SELECTED BEFORE EMS/FWS Steer was selected before and during footswitch closure.

STEER SWITCHES FA ULTY Both steer switches are active together.

WAITING FOR FWS TO BE OPEN Footswitch was closed whe n pl atform mode was select e d.

JOYSTICK F AUL TS - CHECK PLATFORM BOX WIRING More than one of the drive, lift and swing joystick center tap or wiper voltages is out of range. This is probably due to a short-circuit across a joystick port.

Flash code 2/3 indicates problems with boom function selection.

LIFT/SWING JOYSTICK FAULTY The lift or swing Joystick center tap is out of valid range, or the wiper is wire-off.

LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE EMS/FWS Upper Lift or swing was selected before and during footswitch closure.

PUMP POT FAULTY The pump pot is open-circuit; all platform boom functions except upper lift & swing will run at creep.

PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM A boom function (lower lift, telescope, basket level, basket rotate, jib) has both directions selected together.

PUMP SWITCHES LOCKED - SELECTED BEFORE EMS/FWS A boom function (lower lift, telescope, basket level, basket rotate, jib) was selected before and during footswitch closur e .

PUMP SWITCHED LOCKED - SELECTED BEFORE EMS A ground boom function (lower lift, telescope, basket level, basket rotate, jib) was selected before keyswitch.

SWING/LIFT JOYSTICK FAULTY The swing joystick center tap is out of valid range, or the wiper is wire-off.

2-56 – JLG Lift – 3120884

Table 2-8. Help Descriptions and Fault Flash Codes

SECTION 2 - PROCEDURES

2/5

3/1

3/2

Flash code 2/5 indicates that a function is prevented due to a cutout.

BOOM PREVENTED - DRIVE SELECTED A boom function is selected while a drive function is selected and drive cutout is configured to prevent simultaneous drive & boom operation.

BOOM PREVENTED - FUNCTION CUTOUT ACTIVE A boom function is selected while function cutout is active and configured to cutout boom functions.

DRIVE & BOOM PREVEN TED - FUNCTION CUTOUT ACTIVE Drive or a boom function is selected while function cutout is active and configured to cutout all functions.

DRIVE PREVENTED - ABOVE ELEVATION Drive is selected while above elevation and drive cutout is configured to prevent drive.

DRIVE PREVENTED - BOOM MOVEMENT SELECTED Drive is selected while a boom function is selected and drive cutout is configured to prevent simultaneous drive & boom operation.

DRIVE PREVENTED - CHARGER CONNECTED Drive is selected while the charger is on (indicated by drive cutout being active) and drive cutout is configured to prevent drive.

DRIVE PREVENTED - TILTED AND ABOVE ELEVATION Drive is selected while drive cutout is active and drive cutout is configured to prevent drive.

TILT MODULE FAILURE: NOT COMMUNICATING There is a problem with the positrac/tilt module; the controller defaults to massively tilted and does not try to prevent vehicle roll on the grade.

Flash code 3/1 indicates that a contactor did not close when energized.

LINE & DIRECTION CONTACTORS MISWIRED When the line contactor was closed tracti on point A went high (and the capacito r bank charge did not increase to battery supply) - this occurs if the line contactor coil wiring is swapped with that for a direction contactor coil.

OPEN-CIRCUIT FORWARD DIRECT IO N CONTACTOR OR TRACTION MOTOR T raction point A did not go high when forward contactor was energized (this could be due to traction motor open-circuit or a power wiring error).

OPEN-CIRCUIT LINE CONTACTOR OR TRACTION MOTOR The capacitor bank charge did not increase to battery supply when line contactor was energized (this could be due to a power wiring error).

OPEN-CIRCUIT REVERSE DIRECTION CONTACTOR Traction point A did not go high when reverse contactor was energized (this could be due to traction motor open-circuit or a power wiring error).

Flash code 3/2 indicates that a contactor did not open when energized.

WELDED LINE CONTACTOR The capacitor bank charge did not decrease from battery supply when line contactor was deenergized (this could be due to a power wiring error). WARNING: If the line contactor is welded, the controller will not switch off when EMS or keyswitch is turned off.

3120884 – JLG Lift – 2-57

SECTION 2 - PROCEDURES

Table 2-8. Help Descriptions and Fault Flash Codes

3/3

3/5

4/2

4/4

5/5

Flash code 3/3 indicates that a contactor coil is short-circuited.

OVERLOADED VALVE SUPPLY-CHECK WIRING. There is a high current draw f rom the valve supply when no valve is energized; this is probably due to a wiring error at the ground module.

SHORT-CIRCUIT FORWARD CONTACTOR COIL The forward contactor was not energized when required, due to coil overcurrent protection.

SHORT-CIRCUIT LINE CONTACTOR COIL The line contactor was not energized when required, due to coil overcurrent protection.

SHORT-CIRCUIT REVERSE CONTACTOR CO IL The reverse contactor was not energized when required, due to coil overcurrent protection.

Flash code 3/5 indicates that there is a brake pressure problem.

BRAKES DID NOT LOCK Brake pressure did not clear when the brake valve was deenergized.

BRAKES DID NOT RELEASE No brake pressure was detected when running the pump motor and energizing the brake valve

Flash code 4/2 indicates that the controller is ov er temperature.

CONTROLLER TOO HOT - PLEASE WAIT The controller heatsink temperature reached 75 degrees. The controller is shut down until it cools to below 70 degrees.

Flash code 4/4 indicates problems with the battery supply.

BATTERY LOW Battery voltage is below 40V. This is a warning - the controller does not shut down.

BATTERY TOO HIGH - SYSTEM SHUT DOWN Battery voltage is above 62V. EMS recycle required.

BATTERY TOO LOW - SYSTEM SHUT DOWN Battery voltage is below 33V. EMS recycle required.

Flash code 5/5 indicates problems with vehicle speed or the encoder.

NO VEHICLE MOVEMENT DETECTED AT MAXIMUM POWER No speed was measured with traction motor full on. This could be due to a traction motor f ault, a power wiring error, a speed encoder faul t, the brake s not r eleasi ng (al though brak e Pres sure is OK) or th e veh icle being overloaded so that the motor cannot turn the wheels.

DRIVE PREVENTED - BOTH SPEED ENCODERS FAULTY Both speed encoder input voltages are out of range.

LEFT SPEED ENCODER FAULTY The left speed encoder input voltages are out of range. The vehicle will continue to drive at cutback using the right speed encoder.

RIGHT SPEED ENCODER FAULTY The right speed encoder input voltages are out of range. The vehicle will continue to drive at cutback using the left speed encoder .

SPEED ENCODERS READING INVALID SPEED One or both speed encoders is indicating an impossible number of pulses. This is probably due to a faulty speed encoder.

VEHICLE RUNAWAY - CHECK SPEED ENCODERS Speed in the wrong direction was measured with traction motor full on. This is probably due to the speed encoder being fitted incorrectly; it could also be due to a speed encoder fault or faults as for "NO VEHICLE MOVEMENT DETECTED" with the vehicle on a grade.

2-58 – JLG Lift – 3120884

Table 2-8. Help Descriptions and Fault Flash Codes

SECTION 2 - PROCEDURES

6/6

7/7

Flash code 6/6 indicates problems with the CANbus.

48V PROTECTION TRIPPED - CHECK INTER-MODULE WIRING The power module is not receiving acknowledgments from the platform or ground modules to transmitted data, and the prote c t io n circuit which supplies the platform and ground modules has t ripped. This is probably due to wiring problems at the platform or ground module.

CANbus FAILURE: GROUND MODULE The power module is receiving fr om the platfo rm module but not the ground modul e. This should n ot be possible!

CANbus FAILURE: PLATFORM MODULE The power module is receiving from the ground module but not the platform module. This is probably due to wiring problems between the platform and ground modules.

CANbus FAILURE: POWER MODULE The power module is not receiving acknowledgments from the platform or ground modules to transmitted data. This is probably due to wiring problems between the ground and power modules.

Flash code 7/7 indicates problems with a motor.

CAPACITOR BANK FAULT - CHECK POWER CIRCUITS The capacitor bank is not charging. This is probably due to a power wiring error causing illegal current drain; it could also be due to a very low battery supply.

OPEN-CIRCUIT PUMP MOTOR Pump point A is collapsing when the pump MOSFETs are pulsed. This is probably due to an open circuit pump motor or a power wiring error.

OPEN-CIRCUIT DIRECTIONAL CONTACTOR OR TRACTION MOTOR Traction point A is collapsing when the traction MOSFETs are pulsed. This is probably due to an open circuit traction moto r or a power wi ring error. NOTE: This fault is u nlikely to be seen du e to in teracti on with speed control...

PUMP POINT A LOW - CHEC K POW ER CI RCUITS Pump point A is near 0V when the pump MOSFET s are off. This is probably due to a power

STALLED TRACTION MOTOR The power module traction MOSFET protection circuit is active. This is due to massive current drain and could be a stalled traction motor or a power wiring error.

STALLED PUMP MOTOR The power module pump MOSFET protection circuit is active. This is due to massive current drain and could be a stalled pump motor or a power wiring error.

TRACTION MOTOR OVERLOA DED The traction motor has been operating in current limit at a low pe rcentage on for a period of time greater than 10 seconds.

PUMP MOTOR OVERLOADED The pump motor has b een operating in current limit at a low percentage on for a p eriod of time greater than 10 seconds.

TRACTION CURRENT AT ZERO - CHECK SHUNT WIRI NG Traction current measurement is at zero. This is probably due to an open-circuit between the current measurement shunt and the power module.

TRACTION POINT A HIGH - CHECK POWER CIRC UI TS Traction point A is near battery supply when neither direction contactor is energized and the traction MOSFETs are off. This could be due to a welded direction contactor or a power wiring error.

TRACTION POINT A LOW - CH EC K POWER CIRCUITS Traction point A is near 0V when neither direction contactor is energized and the traction MOSFETs are off. This could be due to a power wiring error.

3120884 – JLG Lift – 2-59

SECTION 2 - PROCEDURES

Table 2-8. Help Descriptions and Fault Flash Codes

9/9

Flash code 9/9 indicates problems with the controller.

POWER MODULE FAILURE: CONTACTOR DRIVE CODE 1 A contactor remained energized when turned off.

POWER MODULE FAILURE: HWFS CODE 2 The hardware failsafe tests did not complete because traction point A is not safe, or the hardware failsafe is permanently tripped.

POWER MODULE FAILURE: HWFS CODE 3 The hardware failsafe tests did not complete because a c on tactor wa s energized when all should be turned off

POWER MODULE FAILURE: HWFS CODE 4 The hardware failsafe tests did not complete because the hardware failsafe tripped immediately when the traction MOSFETs were turned on.

POWER MODULE FAILURE: HWFS CODE 10 The hardware failsafe tests failed because the hardware failsafe did not trip within the allowed test time.

POWER MODULE FAILURE: HWFS CODE 11 The hardware failsafe tests failed because the hardware failsafe tripped too slowly.

POWER MODULE FAILURE: HWFS CODE 12 The hardware failsafe tests failed becau s e the hardw are failsafe tripped too quickly.

POWER MODULE FAILURE: HWFS CODE 13 The hardware failsafe tests failed because the hardware failsafe remained tripped when the traction MOSFETs were turned off.

POWER MODULE FAILURE: HWFS CODE 14 The hardware failsafe tests failed because the line contactor could stil l be energized when the h ardware fai lsafe was tripped

POWER MODULE FAILURE: HWFS CODE 15 The hardware failsafe tests failed because the contactor drive failsafe did not trip within the allowed test time.

POWER MODULE FAILURE: HWFS CODE 16 The hardware failsafe tes ts failed be cause the conta ctor drive fai lsafe tripp e d too slowly.

POWER MODULE FAILURE: HWFS CODE 17 The hardware failsafe tests failed because the contactor drive failsafe tripped too quickly.

POWER MODULE FAILURE: HWFS TEST STALLED The hardware failsafe tests did not complete, but no reason can be determined.

POWER MODULE FAILURE: BAD TEMPERATURE SENSOR The temperature sensor measurement is invalid, this is probably due to a disconnected wire within the power module. The possibility of other disconnected wires (which could cause dangerous system function) means that the controller is shut down.

POWER MODULE FAILURE: S/C LINE CONTACTOR DRIVER The line contactor energized when the footswitch was closed, before it was turned on, this is probably due to a failed driver within the power module, although it could be due to bad power module wirings

2-60 – JLG Lift – 3120884

3120884 – JLG Lift – 2-61

Figure 2-46. Analyzer Flow Chart - Sheet 1 of 2

SECTION 2 - PROCEDURES

2-62 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-47. Analyzer Flow Chart - Sheet 2 of 2

SECTION 2 - PROCEDURES

Analyzer Diagnostics Menu Structu re

In the foll owing structure descriptions, an intended item is selected by pressing ENTER; pressing ESC steps back to

Table 2-9. DIAGNOSTICS - Menu Descriptions

DRIVE DRIVE . . . Displays drive joystick dire ction & demand SPEED . . . Displays vehicle direction & speed POSITRAC . . . Displays positrac status STEER . . . Displays steer switch direction & demand

NOTE: steer demand is inversely proportional to vehicle speed BRAKES . . . Displays brake control system status CREEP . . . Displays pump pot creep switch status BOOM

LL.... Displays lower li ft switch direction & demand

NOTE: demand is controlled by the pump pot UL . . Displays upper lift joystick direction & demand SWING . . . Displays swing joystick dir ection & demand LEVEL .. . Displays basket level switc h direction & demand

NOTE: demand is controlled by the pump pot TELE . . . Displays telescope swit ch direction & demand

NOTE: demand is controlled by the pump pot ROTA TE . . D isplays basket r otate switch direct ion & demand

NOTE: demand is controlled by the pump pot JIB (U/D) .. Displays jib lift switch direction & demand

NOTE: demand is controlled by the pump pot Not displayed if

JIB = NO JIB (L/R) Display s jib swing switch direction & demand

NOTE: demand is controlled by the pump pot Not displayed if

JIB = NO PUMP POT ... Displays pump pot demand CREEP . . . Displays pump pot creep switch status SYSTEM TRACTION . . . Displays measured traction motor current PUMP ... Displays measured pu mp motor current VAL VE . . . Displays measured valve (12V supply) current

NOTE: this includes current for the ground alarm & hourmeter ,

but not for any lamps BATTERY . . . Displays measured battery voltag e TEMPERATURE . . . Displays measured hea tsink temperature FSW1 . . . Displays footswitch s tatus FSW2 . . . Displays footswitch s tatus

NOTE: FSW2 is wired to the platform module DRIVE CUTOUT ... Displays drive cutout sw itch status ELEV . CUTOUT .. . Displays elevation cutout swi tch status FUNC. CUTOUT ... Displays function cutout switch status BRAKES . . . Displays brake pressure switch status MAN.RELEASE . . . Displays manual brake release switch status

the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow keys alter a value if allowed

3120884 – JLG Lift – 2-63

SECTION 2 - PROCEDURES

TIL T . . . Displa ys measured vehicle tilt

DAT ALOG MAX.TEMP . . . Displays maximum measured heatsink temp. MIN.TEMP . . . Displays minimum measured heatsink temp. MAX . BATTERY . . Displays maximum measured battery voltage ON . . . Displays total controller on (EMS) time DRIVE . . . Displays total controller drive operation time PUMP ... Displays total controller pump running time

LIFT . .. Displays total controller lift operation time SWING . . . Displa ys total controller swing operation time TELE . . . Displays total controller tele operation time RENTAL . . . Displays total controller operation time

ERASE RENTAL YES:ENTER, NO:ESC ENTER

VERSIONS POWER Displays power software version PLATFORM Displays platform software version

GROUND Displays ground software version POSITIL T Displays positilt software version ANALY ZER Displays analyzer software version

Table 2-9. DIAGNOSTICS - Menu Descriptions

The first value indicates tilt in die forwards reverse direction (pitch) The second value indicates tilt in the left/ right direc tion (roll)

NOTE: includes all boom functions, steer and brake release

NOTE: can be reset Not available at password level 2

Enter resets rental datalog time to zero

2-64 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

System Self Test

The system self test is utilized to locate typical problems. See Table 2-10, System Test Descriptions and Ta ble 2-11, System Test Messages for infor mation concerning the tests performed and available messages in this mode.

1. When the keyswitch is in the platform position and the self test enabled, the self test function will test all valves, contactors, platform inputs, indicator lamps, and system alarms for various fault conditions.

When the keyswitch is in the ground position, the self test function will test all valves, the line contactor, ground control inputs, a nd the g rou nd ala rm ou tput for various fault conditions.

2. In order to test the inputs on the machine, the controller will ask the service technician to perform various tasks at the appropriate operator control station . An example of this is "Close LLU Switch". The controller expects the operator to close the lower lift up switch. When the controller sees that the lower lift

Table 2-10. System Test Descriptions

ACTIVATE TESTS YES:ENTER , NO:ESC

RUN SYSTEM TEST ENTER starts system test

Not available once tests are activated ENTER activates system tests NOTE: cannot be done while co ntroller is in use (footswitch closed) and for a short time afterwards

Not available until tests are activ ated D isplays messag es while system test runs Some m essages are prompts, requiring user interven t ion. ENTER can be pres sed if a faul t is f ound, t o confi rm that the fault has been noted and to continue the system test. NOTE: a flashing message is critical, and prevents the system test running

up switch has been closed, it will move on to the next input, lower lift down LLD. If the switch is faulty or the wiring is faulty, the controller will not move on to the next input. The controller will continue to wait for the closure of the input. If the operator knows the switch is fau lty and wants to contin ue the tests he must simply press the enter key on the analyzer to continue.

3. After the controller has conducted the tests from the chosen operator station, it will display "TESTS CO MPLETE". This indicates that the controller has checked all inputs and outputs for that station.

IN ORDER FOR THE MACHINE TO FUNCTION AFTER THE SELF TEST IS COMPLETE, POWER MUST BE RECYCLED USING THE EMS OR THE KEYSWITCH.

3120884 – JLG Lift – 2-65

SECTION 2 - PROCEDURES

Table 2-11. System T est Messages

RUNNING Initial display when system test is run; certain "critical" checks are made. Problems which can be reported incl ude:

ONLY 1 ANALYZER!

Do not connect two Analyzers while running the system test.

BAD POWER WIRING

The capacitor bank is not charged or pump point A is low or traction point A is high or low. Check all power wiring.

LINE CONT WELDED

The capacitor bank is at battery voltage. Check line contactor. Check all power wiring.

BATTE RY TOO LOW

The system test cannot run with battery voltage below minimum.

BATTE RY TOO HIGH

The system test cannot run with battery voltage above maximum.

CHECK CAN WIRING

The system test cannot run in platform mode unless data is being received from the platform, ground and positrac/tilt modules. The system test cannot run in ground mode unless data is being received from the ground and positrac/tilt modules.

CHECK LEF T SPD.

There is an open- or short- circuit in the left speed encoder wiring. Check left speed encoder.

CHECK RIGHT SPD.

There is an open- or short- circuit in the right speed encoder wiring. Check right speed encoder.

CHECK SHUNT

The traction current measurement is open-circuit. Check wiring between power module and contactor panel.

BAD PUMP WIRING

Pump point A is not high, probably caused by an open-circuit pump motor or wiring. Check all power wiring. Check pump motor.

BAD POWER MODULE

An internal problem was detected in the power module.

BAD POWER WIRING

Traction point A is high, probably caused by incorrect faction motor wiring. Check all power wiring. Check traction motor.

HIGH TILT ANGLE

The vehicle is very tilted, or the tilt sensor has been damaged. Check tilt sensor.

HOT POWER MODULE

The heatsink temperature exceeds 75 C; this is only a warning.

BAD I/O PORTS

The controller detected a problem with its internal circuits at switchon. If other problems are also detected, the controller may need replacing.

SUSPECT EEPROM

The controller detected a problem with its EEPROM stored personality settings at switchon. Check and, if necessary correct, all personality settings.

WAIT :CAPBANK H I

This message can be displayed if the system test is run shortly after the vehicle was used; after a short wait, it should clear.

OPEN FWS

In platform mode, the footswitch must be open at the start of the test.

CLOSE FWS

In platform mode, the footswitch must be closed when this message is displayed; the foot switch MUST BE KEPT C LOSED during the valve & cont actor tests.

BAD FWS

The two footswitch signals are not changing together, probably because one is open-circuit. One footswitch signal ("FSW1") is routed to the power module, the other ("FSW2") is routed to the platform module. Check footswitch and wiring.

2-66 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Table 2-11. System T est M essages

TESTING VAL VES Indicates that the valve test is beginning.

Each valve is alternately energized and de-energized; checks are made for open-and short- circuit

valve coils.

The valves are tested in the order: PROP (main proportional), LL U, LL D, UL U, UL D, SWING L,

SWING R, SWING REST , LEVE L U, LEVEL D, ROT A TE L, ROT ATE R, JIB U, JIB D,

TELE I, TELE O, BYP ASS, STEER L, STEER R, STEE R PROP , BRAKE NOTE: in platform mode, the footswitch must be closed. NOTE: jib valves are not tested if JIB = NO Problems which can be reported include:

CANT TEST V AL VES

There is a wiring problem which prevents the valve test from functioning correctly. Check valve wi ring. Check ground alarm wiring.

valvename S/C

The named valve is drawing too much current so is presumed to be short-circuit. Check valve wi ring.

valvename O/C

The named valve is drawing too little current so is presumed to be open-circuit. Check valve wi ring.

VAL VE TEST DONE Indicates that the valve test is complete (with or without faults). TESTING CONTS Indicates that the contactor test is beginning.

In platform mode, the forward & reverse direction contactors are energized and de-energized; checks are made that they

close & open correctly and for short-circuit coils. In platform and ground mode, the line contactor is energized and de-energized; checks are made that it closed & opened

correctly and fo r a short-circuit coil. In platform mode, the positrac contactors are energized and de-energized; checks are made for short-circuit and open-

circuit coils. Problems which can be reported include:

CANT TEST CONTS

There is a wiring problem which prevents the contactor test from functioning correctly. Check power wiring. Check contactor wiring.

BAD CONT WIRING

There is a wiring problem which caused the capacitor bank to be charged when a direction contactor was

energized; probably the wiring to the contactor coils is incorrect. Check contactor wiring. Check power wiring.

contname WELDED

The named contactor appears to have not opened. Check named contactor. Check power wiring.

contname COIL S/C

The named contactor coil overloaded its driver circuit so is presumed to be short-circuit. Check contactor wiring.

contname DIDN’T CLOSE

The named contactor appears to have not closed. Check contactor wiring. Check power wiring.

CONT TEST DONE Indicates that the contactor test is complete (with or without faults).

3120884 – JLG Lift – 2-67

SECTION 2 - PROCEDURES

Table 2-11. System T est Messages

CHECKING INPUTS Indicates that the inputs test is beginning.

Every input is checked to ensure that it is in its "normal" position; function switches should be open,

cutout switches should be closed, joysticks should be in neutral.

In platform mode, inputs are tested in the order: UL U, UL D, UL JOY., SWING L, SWING R,

SWING JOY ., LEVEL U, L EVEL D, PUMP POT ., ROT A TE L, ROT ATE R, LL U, LL D, JIB U, JIB D, TELE I, TELE O, DRIVE FWD, DRIVE REV, DRIVE JOY., STEER L, STEER R, POSITRAC, DRIVE C/O, ELEV . C/O, FUNC. C/O, BRAKE PRES

In ground mode, inputs are tested in the order: ROTA TE L, ROTA TE R, LEVEL U. LEVEL D, JIB U.

JIB D, TELE I, TELE O, UL U, UL D, LL U, LL D, SWING L, SWING R, ELEV. C/O,

FUNC. C/O, BRAKE PRES, MAN. BR AKE NOTE: switches which are not in use (due to the settings of machine digits) are not checked. NOTE: the pump pot is checked only for a wire-off condition; it can be at any demand from creep to

maximum.

Problems which can be reported include:

CHECK switchname

The named switch is not in its "normal" position. Check switch & wiring.

CHECK switchname J OY .

The named joystick appears to be faulty. Check joystick.

INPUTS DONE Indicates that the inputs test is complete (with or without faults). TESTING LAMPS Indicates that the lamps test is beginning.

Each lamp is energized in turn; a prompt asks for confirmation that the lamp is lit - ENTER must be

pressed to continue the test. Lamps are tested in the order: ENABLE, FAUL T , TILT, CREEP, POSlTRAC, WA TER. NOTE: lamps which are not in use (due to the settings of machine digits) are not checked. NOTE: lamps are only tested in platform mode.

Problems which can be reported include:

lampname S/C

A short-circuit condition appeared while the named lamp was being tested, presumably because it is short-circui t.

LAMP TEST DONE Indicates that the lamps test is complete. TESTING ALARMS Indicates that the alarms test is beginning.

Each alarm is energized in turn; a prompt asks for confirmation that the alarm is sounding - ENTER

must be pressed to continue the test. Alarms are tested in the order: P.ALARM, G.ALARM. NOTE: the platform alarm is only tested in platform mode. NOTE: the gr ound alarm i s not tested if G ROUND ALARM = NO.

Problems which can be reported include:

alarmnam e S/C

A short-circuit condition appeared while the named alarm was being tested, presumably because it is short-circui t.

ALARM TEST DONE

Indicates that the alarms test is complete

2-68 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Table 2-11. System T est M essages

TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends.

If ENTER is pressed, each operator input is prompted for in turn. In platform mode, operator inputs are tested in the order: UL U, UL D, SWING L, SWING R, LEVEL U, LEVEL D,

PUMP POT, CREEP , ROT ATE L, ROTA TE R, LL U, LL D, JIB U, JIB D, TELE I, TELE O, DRIVE FWD, DRIVE REV , STEER L, STEER R, POSITR AC

In ground mode, operator inputs are tested in the order: ROTAT E L, ROTA TE R. LEVEL U. LEVEL D, JIB U. JIB D,

TELE I, TELE O. UL U. IJL D, LL U. LL D, SWING L, SWING R NOTE: the jib switches are not tested if JIB = NO. Prompts displayed during the operator input test include:

CLOSE switchname

The named switch should be closed.

OPEN switchname

The named switch should be opened.

joystickname direction TO MAX

The named joystick should be pushed to its full extent in the named direction.

joystickname direction TO MIN

The named joystick should be returned to neutral from the named direction.

PUMP POT TO MAX

The pump pot should be turned to maximum.

PUMP POT TO MIN

The pump pot should be turned to minimum.

MULTIPLE CLOSURE

More than one operator input is closed; if only one has been operated, there could be a short between two inputs.

TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and should now be rectified.

Press ESC to return to the R UN SYSTEM TEST Analyzer menu.

3120884 – JLG Lift – 2-69

SECTION 2 - PROCEDURES

2.25 GENERATOR

NOTE: Throughout the Generator section, the abbreviations

RBS and CTS are used. RBS stands for Rotary Battery System, which is the generator system. CTS stands f or Ca ll To Start, which is the el ec tronic inputs which signal the generator to start and charge the batteries.

The generator consists of a drive engine, controller, and related components.

• Alternator

The alternator is a brushless, D C output alte rnator. The 3 phase output of the alternator is full wave rectified and directed to the output terminator .

The output rating is 58 volts DC at 55 amps. Voltage regulation and current limiting is provided by the Engine/Generator Controller.

The rectifier diodes and output current sensor are located in the alternator end.

• Dynamo and Dynamo Voltage Regulator

The engine is equipped with a 12 Volt, 15 Amp DC output dynamo.

• Dynamo Output Fuse

The dynamo output fuse is used to protect the output of the dynamo. This fuse is rated at 20 Amps DC, slow blow and is located on the left side of the engine.

• Control Fuse

This fuse provides power to the engine/generator and the relays for start control, fuel control, and pre-heater. This fuse is rated at 15 Amps DC and is located on the right side of the engine.

• Start Battery

A 12 volt lead-acid battery is utilized to provide starting power for the generator and power for the generator controls. This battery is charged by the engine dynamo and dynamo regulator when the engine is running.

• Start Control Rela y

The start control relay energizes the solenoid of the engine starter and the pull coil of the engine fuel solenoid. The start control relay is located on the fuel solenoid bracket on th e right side of the en gine. Th e start co ntrol relay is energized by the engine/generator controller.

• Fuel Control Relay

The fuel control relay energizes the hold coil of the fuel solenoid. The fuel con trol relay is energi zed by the engine/generator controller.

• Fuel Solenoid

The fuel solenoid actuates the run/stop lever of the engine. This solenoid has a pull and hold coil. The pull coil is energized by the start control relay and t he hold coil is energized by the fuel control relay.

• Engine Oil Temperature Sensor

The engine oil temperature sensor is used to sense t he temperature of the oil in the sump of the engine. This sensor provides a signal to the engine/generator controller for high engine temperature shutdown.

• Alternator Output Current Sensor

The alternator output curren t se nsor pr ovid es a si gnal p roportional to the output current of the alternator to the engine/generator controller. This signal is used by the controller to regulate the current output of the alternator. The output current is regulated at 55 Amps DC. The alternator output current sensor is located inside the rear cover of the alternator.

• Engine Speed Sensor

The engine speed sensor provides a signal proportional to the rotational speed of the engine to the engine/generator controller. This signal is used by the co ntro ller to determine starter cut-out, overspeed fault, and underspeed fault. This signal has failsafe protection, if it is not present at the controller, the unit will fault with a loss of speed signal indication. The engine speed sensor is located inside the recoil starter cover at the front of the engine.

• Engine Starter

The engine is equipped with a 12 Volt DC starter. This starter provides mechanical pow er to crank the engine. Electrical power for the starter is provided by the start battery . The starter is energized by the start control relay.

• Engine Low Oil Pressure Switch

The engine is equipped with a low oil p ressure switch. T he switch is closed when the oil pressure is below 14.2 psi (1 Bar).

2-70 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-48. Generator Components

3120884 – JLG Lift – 2-71

SECTION 2 - PROCEDURES

Timing Sequences

• RBS Prestart Sequence

1. Time Delay Engine Start (TDES) TDES is the perio d which the RBS waits to verify th at

the CTS is valid rather than a transient condition.

2. Time Delay Pre-Heat (TDPH) TDPH, if enabled, occurs after TDES has elapsed

and the engine temperature is below the factory set engine preheat temperature setting. The engine preheater will be energized for the factory set preheat delay period.

Table 2-12. RBS Prestart Sequence

CTS (Call to Star t) TDES (Engine Start) Preheat Delay RBS Startup Sequence

• RBS Startup Sequence

1. Crank Time The RBS will crank for a period up to the crank time

or until the engine starts.

2. Rest Time If the engine does not successfully start, the RBS will

wait for the rest time before attempting to crank the engine again.

3. Crank Cycles

4. Time Delay Bypass (TDBP) Once the engine starts, TDBP must elapse before

low oil pressure and underspeed shutdowns are activated. This allows the engine to come up to normal operating conditions before enabling these shutdowns are monitored.

Table 2-13. RBS Startup Sequence

Crank Time -> Rest Time (Until Engine Start or # of Crank Cycles)

TDBP Bypass Normal Running Operation

• RBS Shutdown Sequence

Once all CTS conditions ha ve been remo ved, the RBS will begin the shutdown sequen ce. If a CTS cond ition i s initiated during the shutdown sequence, the RBS will return to normal running operation until the CTS is removed.

1. Time Delay Engine Run (TDER) Once the CTS condition is removed, the TDER

period begins. This period ensures that no further CTS conditions occur prior to the cooldown period.

2. Time Delay Cooldown (TDC) Once the TDER period ends, the alternator output is

reduced to a minimal level in order to allow the engine to cool down for the TDC period. If a CTS is received during the TDC period, the CTS must last for at least the TDES period for the RBS to return to normal running operation.

The RBS will attempt to start the engine up until the number of crank cycles is reached. If the RBS does not start, an Overcrank fault is indicated.

Table 2-14. RBS Shutdown Sequence

Remove CTS TDER Engine Run TDC Cooldown Engine Stop

2-72 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

To Connect the JLG Control System Analyzer to the Generator

The JLG Control System Analyzer can be used to monitor generator settings and conditions. Connect the analyzer as follows:

1. Connect the four pin end of the cable supplied with the analyzer, to the connector behind the ground control module located on the left side of the machine next to the g rou n d cont ro l st at ion a nd co nnect the remaining end of the cable to the analyzer. The ground control mo dul e co ntai ns the s ettin gs for the generator.

NOTE: The cable has a four pin connector at each end of

the cable; the cable cannot be connected backwards.

2. Power up the A nalyzer by pulling out the ground station EMS and positioning the Generator Enable switch on the platform control box to the "on" position. Refer to Figure 2-49., Generator System Analyzer Flow Chart

Alarms and Fault Flash Codes

In the event of an RB S al arm, a fl ash code will be issued and an alarm indicated on the analyzer.

NOTE: Alarms must be reset once the fault has been cor-

rected.

Table 2-15. Generator System Flash Codes

Code Alarm Description

1-1

1-2

1-3

1-4

1-5

2-1

2-2

2-3 2-4

Continuous

Off

• Low Oil Pressure

Enabled once TDBP (time delay bypass) period has elapsed after engine startup. If the low engine oil pressure switch closes, the engine will stop immediately and a low oil pressure alarm will be indicated.

• High Engine Temperature

If the engine oil temperature exceeds the high engine temperature setting, the engine will stop immediately and a low oil pressure alarm will be indicated.

Low Oil Pressure Shutdown due to low engine

High Engine Temperature

Engine Overspeed Shutdown due to high engine

Engine Underspeed/Overcrank

No Speed Signal Shutdown due to loss of

Overvoltage Shutdown due to high output

Engine Starting System fault

Not Used Not Used Loss of Voltage

Sense Unit Disabled No Faults. RBS enabled and

Unit Disabled RB S o ff o r di sa bl ed; Wi ll not

oil pressure Shutdown due to high engine

oil temperature

speed Shutdown due to engine

overcrank or underspe ed

speed signal

voltage Alarm not a shu tdown; Indi-

cates problem with the engine starting system

Shutdown due to loss of voltage sensing

can respond to any CTS

respond to any CTS

3120884 – JLG Lift – 2-73

2-74 – JLG Lift – 3120884

SECTION 2 - PROCEDURES

Figure 2-49. Generator System Analyzer Flow Chart

SECTION 2 - PROCEDURES

• Overspeed

If the engine speed exceeds the overspeed limit, the engine will stop immediately and an overspeed alarm will be indicated.

• Underspeed

Enabled once TDBP (time delay bypass) period has elapsed after engine st artup. If the engine spee d drops below the unde rspeed lim it, th e engine will stop im mediately and an engine underspeed alarm will be indicated.

• Overcrank

If the engine fails to start after a set number of start attempts, the RB S will cease atte mpts to restart and an engine overcrank alarm will be indicated.

• No Speed Signal

In the event of a loss of speed signal, the RBS will shutdown and an engine no speed signal alarm will be indicated. This shutdown is delayed by a factory set period to ensure the fault was not momentary.

• Overvoltage

If the voltage measured at the alternator output exceeds the high voltage setting, the RBS will stop immediately and an RBS high output alarm will be indicated. This shutdown is delayed by a factory set period to ensure the fault was not caused by a transient condition. This feature protects the batteries and load from high DC voltages.

Output Current and Voltage Settings

• Normal/Extended Output Voltage

The normal/extended output voltage setting is the voltage at which the alternator changes under normal operating conditions.

• Current Limit

The current limit setting determines the maximum alternator output current.

• High Voltage Shutdown Level

This setting determines the alternator output voltage at which the high voltage shutdown occurs . This p rotects the load from abnormally high voltages.

• Finish Charging Current

The finish charging current determin es the level of the current alternator output must drop below for a low battery voltage CTS to be re moved . This ensure s that th e bat teries have accepted sufficient charge prior to shutting down the RBS. This level is used along with the low battery voltage remove CTS leve l to determine when the RB S removes the CTS after a low battery voltage CTS. If the charging curre nt falls b elow th e finis h chargin g current while another CTS is active, the RBS will contin ue to operate at the nor mal/ex tende d outpu t vol tage unti l all CT S’s are removed.

• Engine Starting System Fault

Indicates a problem with either the engine start battery, engine magneto, or magneto voltage regulator.

• Loss Of Voltage Sense

If the voltage measured at the alternator output is less than half of the system nominal voltage, the RBS will stop immediately and an RB S loss of voltage sen se alarm wil l be indicated. This feature prote cts the batteries and l oad from high DC voltages due to a loss of output control.

• Run Inhibited

The RBS unit is disabled by the run in h ibited input.

3120884 – JLG Lift – 2-75

SECTION 2 - PROCEDURES

2.26 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the "A REA" to be inspected, and the "INTERVAL" at which the ins pection is t o take place. Under the "AREA" of the table, the various systems along with components that make up that system are listed. The "INTERVAL" portion of the table is divided into five columns represen ting the various insp ection time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regula tions th at may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or conditions and depending on the location and use of the machine.

JLG Industries requires that a complete annual inspection be performed in accordance with the "Annual Machine Inspection Report" form. Forms are supplied with each new machine and are also available from JLG Customer Service. Forms must be completed and returned to JLG Industries.

The inspection and maintenance code numbers are as follows:

1. Check for proper and secure installation.

2. Check for visible damage and legibility.

3. Check for proper fluid level.

4. Check for any structural damage; cracked or broken welds; bent or warped surfaces.

5. Check for leakage.

6. Check for presence of excessive dirt or foreign material.

7. Check for proper operation and freedom of movement.

8. Check for excessive wear or damage.

9. Check for proper tightness and adjustment.

10. Drain, clean and refill.

11. Check for proper operation while engine is running .

12. Check for proper lubrication.

13. Check for evidence of scratches, nicks or rust and for straightness of rod.

14. Check for condition of element; replace as necessary.

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE "ANNUAL MACHINE INSPECTION REPORT" FORM.

This machine requires periodic safety and maintenance inspections by a JLG Dealer. A decal located on the turntable affords a place to record (stamp) inspection dates. Notify dealer if inspection is overdue.

15. Check for proper inflation.

16. Clean or replace suction screen.

17. Drain and clean.

* To be performed quart erly. ** Inspection and Maintenance Code 10, 12, 16 to per-

formed every two years.

2-76 – JLG Lift – 3120884

BOOM

Platform Platform Gate

AREA

SECTION 2 - PROCEDURES

Table 2-16.Preventive Maintenance and Inspection Schedule

INTERVAL

DAILY WEEKLY

1,4 1,4 12

MONTHLY 3 MONTH 6 MONTH YEARL Y

Platform Rotator

Footswitch

Controllers

Switches

Lift Up/Platform Down Disable

Switch* Placards and Decals

Control T ags

Valves

Carrier (Hoses and Cables)

10.

Lockout Cylinders (If equipped)

11.

Pins

12.

Bushings

13.

Wear Pads

14.

Cylinders

15.

Drift T est*

17.

5,11

1,11 1,11 1,11

1,7,9

1,2 1,2 1,11 5,6 14,8 15

8 8 8

1,5,6,13

3120884 – JLG Lift – 2-77

SECTION 2 - PROCEDURES

Table 2-16.Preventive Maintenance and Inspection Schedule

AREA

TURNTABLE

Engine Oil (see mfg. manual)

DAILY WEEKLY

INTERVAL

MONTHLY

3 MONTH 6 MONTH YEARLY

Battery

Radiator

Air Cleaner

Exhaust System

Spark Arrester

Engine Mount

Ground Controls

Main Hydraulic Pump

Auxiliary Power Pump

10.

Valves

11.

Hydraulic Filters

12.

Hydraulic Hoses

13.

Hydraulic Oil T ank**

14.

Breather Hydraulic T ank

15.

Fuel Tank

16.

Cylinders

17.

35 35 114 11,5 11,517

1 1,2,11 15 15 1,11 5 14 5 15 354

6,14

3,5 4

1,5,6,13 4

Hood Doors

18.

T urntable Locking Pin

19.

Horizontal Limit Switch

20.

Oil Coupling

21.

Placards and Decals

22.

Swing Bearing

23.

Swing Brake

24.

Swing Hub

25.

1 1,7 1,7

1,2

19, 12 1,5,6 8

3,9

2-78 – JLG Lift – 3120884

CHASSIS

Wheel and Tire Assembly

AREA

SECTION 2 - PROCEDURES

Table 2-16.Preventive Maintenance and Inspection Schedule

INTERVAL

DAILY WEEKLY

18,9,15

MONTHLY

3 MONTH 6 MONTH YEARLY

Drive Motors

Drive T orque Hubs**

Drive Brakes

Steer Cyli nders

Steer Compone nts

Lockout Cylinders (if

equipped)* Hydraulic Hoses

Placards and Decals

Wheel Bearings

10.

Swing Bearing/Worm Gear

11.

1,5,6 1,5,6 3

1,5,6 1 1,5,6,13 14,68 15,138

1 1,2

19,12

3120884 – JLG Lift – 2-79

SECTION 2 - PROCEDURES

This page left blank intentionally.

2-80 – JLG Lift – 3120884

SECTION 3 - TROUBLESHOOTING

SECTION 3. TROUBLESHOOTING

3.1 GENERAL

This section contains troubleshooting info rmation to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qual ified guidance should be obtained before proceeding with any maintenance.

3.2 TROUBLESHOOTING.

The troubleshooting procedures applicable to the aerial platform are listed and defined i n Tables 3-1 through 3-6. As an aid to table use, the aerial platform is divided into four major groups, each covered separately within this section. These groups are as follows: elevation system, chassis assembly, hydraulic system and electrical system.

Each malfunction with in an indi vidual group or sy stem is followed by a listing of probable causes which will enable determination of t he applicable remedial action . The probable causes and the remedial action should, where possible, be checked in the order listed in the tables.

It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.

It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems. For this reason, every effort has

been made to ensure that all likely problems in these areas are given the fullest possible treatment. In the remaining machine groups, only those proble ms which are symptomatic of greater problems which have more that one probable cause and remedy are included. This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section.

The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the circuit is lack ing hydraul ic oil and electrical control power. This can be ascertained by overriding the bypass valve so that oil is available to the function valv e, then overriding the function valve mechanicall y. If the function performs satisfactorily, the problem exists with the control circuit.

3.3 HYDRAULIC CIRCUIT CHECKS.

The reference for improper function of a hydraulic system, where the cause is not immediately apparent, should be the Troubleshooting Chart. The best place to begin the problem analysis is at the power source (pump). Once it is determined that the pump is serviceable, then a systematic check of the circuit components, beginni ng with the control, would follow. For aid in troubleshooting, refer to the Illustrated Parts Manu al for hydraul ic diagrams o f the various circuits

Updated 2-15-00

3120884 – JLG Lift – 3-1

SECTION 3 - TROUBLESHOOTING

Table 3-1.Platform Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Automatic leveling inoperative.

Hydraulic system oil low. Replenish oil as necessary. Dual check valves dirty/inoperative. Clean or replace as necessary.

Platform will not maintain level attit ude.

No response to platform levelin g controls.

Restricted or broken hydraulic line or fitting on

Clean, repair, or replace line or fitting.

slave cylinder or main lift cylinder. Worn seal(s) in slave level or main lift cylinder. Replace seal(s). Counterbalance valve in slave cylinder defec-

Replace counterbalance valve.

tive. Slave level or main lift cylinder not functioning

properly.

Counterbalance valve on slave leveling cylinder

Slave level or main lift cylinder not functioning properly.

Replace v alve.

improperly adjusted or not functioning properly. Worn seal(s) in slave level or main lift cylinder. Replace seal(s). Damaged slave level or main lift cylinder. Repair or replace cylinder.

Level function not activated within 7 seconds

Recycle footswit ch.

after footswitch was depressed. Level control switch inoperative. Repair or replace control switch lever. Hydraulic system oil low. Replenish oil as necessary. Proportional Flow Regulator not powered. Wiring: Run System Test Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Directional valve not functioning properly. Repair or replace valve. No electric power to directional control valve. See proper wiring diagram/Run System Test. Slave cylinder not functioning properly. Repair or replace pump.

Platform will not adjust "up" or "down" to level.

Hydraulic pump not functioning properly. Run System Test. Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting. Slave cylinder not functioning properly. Repair or replace cylinder. Electrical failure. See proper wiring diagram/Run System T est. Orifice plugged. Clean orifice.

3-2 – JLG Lift – 3120884

SECTION 3 - TROUBLESHOOTING

Table 3-1.Platform Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Proportional Flow Regulator not powered. Check wiring/Run System T est. Personalities not set correctly Check settings.

3120884 – JLG Lift – 3-3

SECTION 3 - TROUBLESHOOTING

Table 3-2.Boom Assembly - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Valve spool sticking.

CONTROL VAL VES

Valve leaking.

Dirt in oil causing excessive temperature buildup.

Moisture in oil. Flush system and change oil using recom-

Incorrect valve mounting causing warping of the unit.

Valve spool scored. Remove valve and repair or replace as neces-

Tie-bolts in valve over torqued. Correctly torque bolts. Return spring weak or broken. Remove valve and repair or replace as neces-

Relief valve m alfunctioning caus ing excessive pressure within valve.

Dirt or other foreign material under seal. Remove and repair valve as necessary. Valve spool scored. Remove valve and repair or replace as neces-

Excessive back pressure caused by restricted return line to r eservoir.

Flush system and change oil using recommended viscosity

mended viscosity Loosen valve and check mounting. Repair as

necessary.

sary.

sary. Check pressure delivery to and from valve and

repair or replace as necessary.

sary. Remove line and clear obstruction or replace line

as necessary.

Damaged valve seals. Remove valve and repair or replace as neces-

sary.

BOOM ELEV ATION SYS TEM.

No response to lift control switch/Joystick.

Lift function not activated within 7 seconds after footswitch was depressed.

Lift control switch inoperative. Repair or replace control switch/Run System

Lift cylinder holding valve inoperative. Repair or replace holding valve. Bypass valve not operating. Determine cause and repair or replace valve. Electrical malfunction. See wiring diagram/Run System Test. Hydraulic system oil low. Replenish oil as necessary.

Recycle footswit ch.

Test.

3-4 – JLG Lift – 3120884

JLG E45A-AJ Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual