JLG M400 Service Manual

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Service and Maintenance Manual

Model

E400A/AJP

E400A/AJPnarrow

M400A/AJP

M400A/AJPnarrow

P/N - 3121827

March 20, 2014

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.

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

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

C MAINTENANCE

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

• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.

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

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

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

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

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

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

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL

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

BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

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

B HYDRAULIC SYSTEM SAFETY

• BATTERY SHOULD ALWAYS BE DISCONNECTED-

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

3121827 – JLG Lift – A-1

DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

INTRODUCTION

REVISON LOG

Original Issue - August 15, 2000 Revised - October 1, 2001 Revised - December 18, 2001 Revised - April 11, 2002 Revised - May 24, 2004 Revised - September 17, 2007 Revised - January 21, 2008 Revised - January 27, 2009 Revised - January 7, 2013 Revised - April 26, 2013 Revised - October 24, 2013 Revised - March 20, 2014

A-2 – JLG Lift – 3121827

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

SECTION 1 - SPECIFICATIONS

1.1 Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

1.5 Hydraulic Pump/Electric Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.6 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.7 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.8 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.9 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Machine Orientation When Doing Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.10 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.11 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.12 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.13 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.14 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.15 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.16 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.17 Operator Maintenance & Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

SECTION 2 - GENERAL

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

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

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

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

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

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

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION 3 - CHASSIS & TURNTABLE

3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Setting Wheel Bearing End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Greasing Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 Drive Hub (Part No. 2780236) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Dissembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Disassembly of the first stage planetary assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Disassembly of second stage planet gears (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Assembly of first stage planetary assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Assembly of end cover unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Initial Start-up And After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Oil Change Interval-Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Setting of Tapered Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Securing of the Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.4 Drive Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.5 Speed Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Speed Sensor Installation Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Verification w/ Analyzer Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.6 Positrac/Tilt module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.7 Swing Motor - S/N 0300135649 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Preparation Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Two Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

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3.8 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Replacement of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Swing Bearing Torque Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Checking Worm Gear End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Adjusting End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3.9 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Battery Maintenance, Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Charging Sequence of Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Battery Charging (On Board Charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Optional On Board Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3.10 Battery Charger (S/N 0300059350 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Battery Charger Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell . . . . . . . 3-52

Checking/Changing the Battery Charger Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3.12 Generator (Prior to S/N 88539) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Dynamo and Dynamo Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Dynamo Output Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Control Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Start Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Engine Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Start Control Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Fuel Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Fuel Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Engine Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Alternator Output Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Engine Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Timing Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

To Connect the JLG Control System Analyzer to the Generator . . . . . . . . . . . . . . . . . . . . . 3-57

Alarms and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Output Current and Voltage Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Priming the Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

3.13 Generator (S/N 88539 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Dynamo and Dynamo Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Dynamo Output Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Control Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Start Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Engine Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Start Control Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Fuel Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Glow Plug Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Fuel Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Engine Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3121827 – JLG Lift – iii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

Engine Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

Alternator Output Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

RBS Engine/Generator Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

System Status and Performance Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

System Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

RBS Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

RBS shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

RBS Alarms and Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Resetting the RBS Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

APU Engine Start Battery Boosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

3.14 Supplementary fuse for apu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72

Tools And Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

SECTION 4 - BOOM & PLATFORM

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

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

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2 Upper (Main) Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

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

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

4.3 Mid Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 Lower Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.5 Upper Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 Mid and Lower Lift Cylinder Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.7 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4.8 Boom Synchronizing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4.9 Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.10 Footswitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4.11 Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

iv – JLG Lift – 3121827

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

4.12 Helac Rotary actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Tools Required for Assembly/Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Testing the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4.13 Powertrack Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Removing a Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Installing a New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Replacing Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Replacing Moving End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

SECTION 5 - HYDRAULICS

5.1 Lubricating O-Rings in the Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Cup and Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Double Acting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cylinder Without Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cylinders With Dual Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.5 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Upper Lift Down Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Lower Lift Down Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Telescope Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Platform Level Up Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Platform Level Down Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Steer Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Jib Lift (Up and Down) Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Jib Swing Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Releveling Valve Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

3121827 – JLG Lift – v

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 6 - JLG CONTROL SYSTEM

6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Help Descriptions and Fault Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Analyzer Diagnostics Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

System Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS

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

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

7.3 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7.4 Checking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

Basic Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7.5 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .7-22

7.6 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 7-23

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7.7 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

vi – JLG Lift – 3121827

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2. Operator Maintenance & Lubrication Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

2-1. Engine Operating Temperature Specifications - Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3-3. Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-1. Drive Hub - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-2. Drive Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-3. Speed Sensor Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-4. Frame Mounted Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-5. Frame Mounted Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-6. Voltage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3-7. Steering Components and Spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-8. Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3-9. Tilt Sensor Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-10. Swing Motor - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-11. Swing Motor - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-12. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-13. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-14. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-15. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

3-16. Swing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

3-17. Remote LED Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

3-18. Battery Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

3-19. Batteries and Battery Charger (Prior to S/N 0300059350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

3-20. On Board Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

3-21. Battery Charger ((S/N 0300059350 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

3-22. Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55

3-23. Generator System Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58

3-24. Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

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

4-2. Upper Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-3. Mid Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-4. Lower Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-5. Upper Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-6. Wear Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-7. Location of Components - Articulating Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-8. Jib/Platform Components and Attaching Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

3121827 – JLG Lift – vii

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

4-9. Platform Support Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-10. Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-11. Rotary Actuator (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-12. Rotary Actuator (Cutaway View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-13. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

5-1. Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-2. Level Cylinder - A Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-3. Level Cylinder - AJ & AJP Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-4. Lower Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-5. Mid Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-6. Upper Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-7. Master Cylinder - A Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-8. Master Cylinder - AJ Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-9. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-10. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-11. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-12. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-13. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-14. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-15. Gar-Max Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-16. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-17. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

5-18. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

5-19. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

5-20. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-21. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-22. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-23. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

5-24. Jib Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5-25. Brake/Steer Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23

5-26. HydraForce Cartridge Torque Value Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5-27. Main Valve Components Prior to S/N 62642 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

5-28. Main Valve Components S/N 62642 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3. Analyzer Flow Chart (Software Version 3.x) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-4. Analyzer Flow Chart (Software Version 3.x) - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-5. Analyzer Flow Chart (Software Version 3.x) - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

7-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19

7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

7-7. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24

7-8. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24

7-9. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24

viii – JLG Lift – 3121827

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

7-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27

7-14. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

7-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

7-18. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30

7-19. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

7-20. Electrical Schematic - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

7-21. Electrical Schematic - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33

7-22. Electrical Schematic - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34

7-23. Electrical Schematic - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35

7-24. Hydraulic Schematic - M400A/E400A - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36

7-25. Hydraulic Schematic - M400A/E400A - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37

7-26. Hydraulic Schematic - M400AJ/E400AJ - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38

7-27. Hydraulic Schematic - M400AJ/E400AJ - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39

7-28. Hydraulic Schematic - M400AJ/E400AJ - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

7-29. Hydraulic Schematic - M400AJP/E400AJP - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-30. Hydraulic Schematic Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42

3121827 – JLG Lift – ix

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-3 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-5 Hydraulic Pump/Electric Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-6 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-7 Tire Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-8 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-9 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-10 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-11 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-12 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-13 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-14 Pressure Settings - Prior to S/N 0300062642 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-15 Pressure Settings - S/N 0300062642 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-16 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-17 Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-18 Mobil EAL H Series Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-19 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

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

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Drive Brake Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-3 Swing Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-11 Battery Charger Fault Codes (Delta-Q). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

3-4 Battery Algorithms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53

3-5 RBS Prestart Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

3-6 RBS Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

3-7 RBS Shutdown Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

3-8 Generator System Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3-9 Controller Interface Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66

3-10 RBS Alarms and Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

3-11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

4-1 Wear Pad Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

5-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

5-2 Cylinder Piston Nut Torque Specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

5-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

5-4 Pressure Settings - Prior to S/N 0300062642 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-5 Pressure Settings - S/N 0300062642 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

6-1 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-2 Machine Setup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-3 JLG Control System Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-4 Help Descriptions and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-5 DIAGNOSTICS - Menu Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

6-6 System Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

6-7 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-8 Diagnostic Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

7-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-3 Turntable Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-4 Chassis Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5 Hydraulic System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

7-6 Electrical System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

. .7-10

x – JLG Lift – 3121827

SECTION 1. SPECIFICATIONS

Table 1-3. Battery Charger

Input 110 VAC,60 HZ

Output 48 VDC (25 Amps)

Batteries (8) 6 Volt, 370 Amp Hour (20 hour rate)

Table 1-4. Drive System

Drive Motor 48 VDC, 12.5 H.P. @ 3200 rpm.

continuous, rotation - reversible

Drive Brake- spring-applied, hydraulically released

Table 1-5. Hydraulic Pump/Electric Motor Assembly

Motor 48 VDC, 2.14 H.P. @ 2700 rpm.

Pump 0.098 in.[3]/rev. (1.6 cm[3]/rev.).

Pump Output 2.96 gpm (11.2 lpm) @ 3400 psi (234 Bar).

Table 1-6. Generator

Alternator Output 58 volts @ 45 Amps

RPM’s under max. load 3100

Start Battery 12 volts

Engine Oil 10W30 (Refer to Engine Manual)

Dynamo 12 volt, 15 amp DC

Dynamo Output Fuse 20 amps DC

Control Fuse 15 amps DC

Table 1-7. Tire Data

Size E/M400A, E/M400AJP

240/55 - 17.5 Pneu. non marking 240/55 - 17.5 Foam Filled 26 x 7 x 20 non marking 240/55 - 17.5 Pneu. 240/55 - Foam Filled

Size E/M400Anarrow, E/M400AJPnarrow

25 x 7 x 12 - non marking 22 x 6 x 17.5 - non marking

Tire Pressure (pneumatic) 90 psi. (6.2 Bar)

Max. Tire Load E/M 400Anarrow E/M400AJP E/M400AJPnarrow

5160 lbs. (2343 kg) 6300 lbs. (2860 kg) 7200 lbs. (3268 kg)

Ground Bearing Pressure E/M 400A E/M 400Anarrow E/M400AJP E/M400AJPnarrow

80 psi (5.6kg/cm2) 95 psi (6.6 kg/cm

)

80 psi (5.6 kg/cm

)

185 psi (13.0 kg/cm

)

SECTION 1 - SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

Table 1-1. Operating Specifications

Maximum Work Load (Capacity) U nr e st r i ct e d:

Maximum Travel Grade (Gradeablility

Maximum Travel Grade (Side Slope)

Machine Weight (GVW) E 40 0 An a rr ow M 40 0 An a rr ow E 40 0 AJ P M 40 0 AJ P E 40 0 AJ Pn a rr ow M 40 0 AJ Pn a rr ow

System Voltage 48 volts

Battery Life per Charge 7 hours continuous

Battery Recharge Time C ha r ge r G en e ra t o r

17 hours from full discharge

500 lb. (230 kg)

30%

13100 lbs. (5942 kg) 13300 lbs. (6033 kg) 13700 lbs. (6214 kg) 13930 lbs. (6318 kg) 14900 lbs. (6759 kg) 15130 lbs. (6862 kg)

6.2 hours

1.2 CAPACITIES

Table 1-2. Capacities

Generator Fuel Tank

4 Gallons (15.1 L)

1.5 HYDRAULIC PUMP/ELECTRIC MOTOR ASSEMBLY

5°

1.6 GENERATOR

1.7 TIRES

Hydraulic Oil Tank

E/M 400A, E/M 400Anarrow

E/M400AJP, E/M400AJPnarrow

Hydraulic System (Including Tank)

Torque Hub, Drive*

*Torque hubs should be one h alf full of lubricant.

1.3 BATTERY CHARGER

1.4 DRIVE SYSTEM

3121827 – JLG Lift – 1-1

4 gallons. (15.14 liters)

5 Gallons (19 L)

9 Gallons (34.1 L)

19 ounces (0.50 L)

SECTION 1 - SPECIFICATIONS

Table 1-9. Function Speeds

Function Seconds

Main Lift Up 30-24

Main Lift Down 29-23

Turntable Swing Right & Left 360° 81-67*

Telescope Out - E400AJP, M400AJP, E400AJPn, M400AJPn

10-6

Telescope Out - E400An, M400An, E400A, M400A 18-14

Telescope In - E400AJP, M400AJP, E400AJPn, M400AJPn

15-10

Telescope In - E400An, M400An, E400A, M400A 28-23

Platform Rotate (4 ft.) - Right & Left 180° - E400AJP, M400AJP, E400AJPn, M400AJPn

20-24**

Platform Rotate (5 ft.) - Right & Left 180° - E400AJP, M400AJP

16-19**

Platform Rotate - Right & Left 180° - E400An, M400An, E400A, M400A

17-14**

Jib Up 25-26

Jib Down 24-25

Jib Swing 18-25

Lower Lift Up 33-27

Lower Lift Down 26-22

High Drive - Fwd.& Rev. E400AJP/M400AJP (200 ft.)

42-44***

3.2 mph. (5.1 kph)

High Drive - Fwd.& Rev. E400AJPn/M400AJPn (200 ft.)

45-50***

3.0 mph. (4.8 kph)

Drive above Horiz. (ANSI) - Fwd.& Rev. E400A, E400AJP/M400A, M400AJP ( 50 ft . )

50-53***

0.64 mph (1 kph)

Drive above Horiz.(ANSI)- Fwd.& Rev. E400An/ E400AJPn/M400n, M400AJPn ( 50 f t . )

78-85***

0 .44 mph. (0.7 kph)

Drive above Horiz. (CE) - Fwd.& Rev. E400AJP/ M400AJP ( 50 ft . )

107-112***

0.32 mph (0.5 kph)

Drive above Horiz.(CE) - Fwd.& Rev. E400An/ E400AJPn/M400An/ M400AJPn ( 50 f t . )

78-85***

0 .44 mph. (0.7 kph)

Drive above Horiz.(CE) - Fwd.& Rev. E400A/M400A ( 50 f t . )

67-71***

0 .48 mph. (0.8 kph)

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

**Swing Left to Swing Right should be within 15% of each other.

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

4150273 N

1.8 DIMENSIONAL DATA 1.9 FUNCTION SPEEDS

Table 1-8. Dimensional Data

Machine Height (stowed) E /M 4 00 A JP E /M 4 00 A JP na r ro w E/M 400A E/M 400Anarrow

Machine Width E/M 400A E/M 400Anarrow E /M 4 00 A JP E /M 4 00 A JP na r ro w

Machine Length (stowed) E/M 400A E/M 400Anarrow E /M 4 00 A JP E /M 4 00 A JP na r ro w

Wheel Base 6 ft. 7.0 in. (2.00 m)

Tr ac k W i dt h E/M 400A, E/M400AJP E/M 400Anarrow, E/M400AJPnarrow

Ground Clearance E/M 400A, E/M400AJP E/M 400Anarrow, E/M400AJPnarrow

Working Height 46 ft. 0 in. (14.02 m)

Platform Height 40 ft. 0 in. (12.19 m)

Up and Over Platform Height 21 ft. 5 in. (6.55 m)

Horizontal Reach @ Maximum Up and Over E/M 400A, E/M 400Anarrow E /M 4 00 A JP, E/M400AJPnarrow

Tail Swing (Any Position) E/M 400A, E/M400AJP, E/M400AJPnarrow

- 0 in. E/M 400Anarrow - 4 in.

Turning Radius (Inside) E/M 400A E/M 400Anarrow E /M 4 00 A JP E /M 4 00 A JP na r ro w

Turning Radius (outside) 10 ft.- 4 in. (3.15 m)

E/M 400A, E/M400AJP, E/

6 ft. 7 in. (2.0 m)

6 ft. 5.75 in. (1.31m)

6 ft. 7 in. (2.0 m)

6 ft. 5.75 in. (1.97 m)

5 ft. 9 in. (1.75 m)

4 ft. 11 in. (1.50 m)

5 ft. 9 in. (1.75 m.)

4 ft. 11 in. (1.49 m.)

18 ft. 1 in. (5.50 m) 18 ft. 1 in. (5.50 m)

22.0ft. (6.7 m)

22.0 ft. (6.7 m)

Tr ac k Wi d th

5 ft. 0 in. (1.51 m)

4 ft. 3.75 in.(1.31 m)

8.5 in. (0.22 m) 5 in. (0.13 m)

21 ft. 2 in. (6.41 m)

22 ft.-5 in. (6.83 m)

Tail Swing (Any Position)

M400AJPnarrow - 0 in.

E/M 400Anarrow - 4 in.

2 ft. 0 in. (0.61 m)

2 ft. 10 in. (0.86 m)

2 ft.- 0 in. (0.61 m)

2 ft.-10 in. (0.86 m)

1-2 – JLG Lift – 3121827

SECTION 1 - SPECIFICATIONS

Machine Orientation When Doing Function Tests

1. LIFT: Boom retracted, telescope retracted. Lift up, record time. Lift down, record time.

2. SWING: Boom at full elevation, telescope retracted. Swing the turntable to the end stop. Swing the opposite direction. Record time. Swing the other direction, record time.

3. TELESCOPE: Boom at full elevation, telescope retracted. Telescope out, record time. Telescope in, record time.

4. DRIVE: Test should be done on a smooth, level surface. Start approximately 25 feet from starting point so that the unit is at a maximum speed when starting the test. Results should be recorded for a 200 foot course. Drive forward, record time. Drive reverse, record time.

5. DRIVE (ABOVE HORIZONTAL): Test should be done on a smooth, level surface. The platform speed control knob should be selected out of creep speed. This verifies that the switches are working when the boom is above horizontal. Results should be recorded for a 50 ft. course. Drive forward, record time. Drive reverse, record time.

6. PLATFORM ROTATE: Platform level and completely rotated one direction. Rotate the opposite direction, record time. Rotate the other direction, record time.

7. JIB: Platform level and centered with the boom. Start with the jib down. Jib up, record time. Jib down, record time.

8. LOWER LIFT: Upper boom horizontal, telescoped in. Lower lift up, record time. Lower lift down, record time.

9. JIB SWING: Platform level and centered with the boom. Start with the jib horizontal. Begin with jib swing fully to left. Swing fully to right. Record time. Swing to the left, record time.

NOTE: Stop watch should be started with the function, not

with the controller or switch.

All speed tests are run from the platform.

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

The function speeds may vary due to cold thick hydraulic oil. Tests should be run with oil tempera-

ture above 100

Some flow control functions may not work with the speed control knob in the creep position.

F. ( 3 8o C)

1.10 TORQUE SPECIFICATIONS

Table 1-10. Torque Requirements

Description Tor q ue Va l ue Interval Hours

Wheel Lugs 170 ft. lbs. (230 Nm) 150

Swing Bearing (Loctite)

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

190 ft. lbs.(260Nm) 50/600*

3121827 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Table 1-12.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

Telescope Cylinder

85 38.5

Upper Upright

225 102

Lower Upright

97 44

Turn ta ble

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

11,800 5352

Jib

320 145

1.11 CYLINDER SPECIFICATIONS

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

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

Table 1-11. Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Upper Lift Cylinder

Mid Lift Cylinder

Lower Lift Cylinder

Telescope Cylinder

Master Cylinder (E/M400A)

Master Cylinder (E/M400AJP)

Slave Cylinder (E/M400A)

3.00

(76.2)

3.00

(76.2)

4.00

(101.6)

2.00

(50.8)

2.00

(50.8)

3.00 (75)

2.00

(50.8)

28.3125 (719.1)

21.25

(539.7)

23.25

(590.5)

(2337)

9.375

(238.1)

11.5

(292)

9.375

(238.1)

1.50

(38.1)

1.50

(38.1)

2.25

(57.1)

1.25

(31.8)

1.00

(25.4)

1.25 (32)

1.00

(25.4)

1.12 MAJOR COMPONENT WEIGHTS

Slave Cylinder (E/M400AJP)

3.00 (75)

11.6

(295.5)

1.25 (32)

SELECT LIFTING EQUIPMENT WITH CAPACITY CAPABLE OF

Rotator Cylinder

Steer Cylinder (Double Rod)

Jib Cylinder

1.875 (47.6)

2.50

(63.5)

63.5 (2.5)

15.250 (387.3)

4.06

(103.1)

233.6 (9.2)

1.00

(25.4)

1.75

(44.5)

44.5

(1.75)

SAFELY SUPPORTING WEIGHT.

1-4 – JLG Lift – 3121827

SECTION 1 - SPECIFICATIONS

1.13 CRITICAL STABILITY WEIGHTS

Table 1-13. Critical Stability Weights

Component KG. LB.

Counterweight

Tire & Wheel (foam-filled)

Platform (4ft [1.2 m])

Platform (5 ft. [1.5 m])

Battery (each)

1746 3850

94 207

41 90

45 100

54 120

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.

1.14 PRESSURE SETTINGS

Table 1-14. Pressure Settings - Prior to S/N 0300062642

Circuit PSI Bar

Main Control Valve

Lift Down Relief 550 38

Tower Lif t Down Relief

Telescope In Relief (A/AJ) 2150 148

Telescope In Relief (AJP) 3000 207

Platform Level Up Relief 2500 17 2

Platform Level Down Relief 1500 10 3

Brake/Steer Valve

Steer Relief

Steer Relief - AJPn

Main Relief - E400A/M400A

Main Relief - E400AJ/M400AJ

Jib Valve

Jib Relief (Up and Down)

1700 117

2300 159

110 0 76

3200 221

3400 234

1500 103

Table 1-15. Pressure Settings - S/N 0300062642 to

Present

Circuit PSI Bar

Main Control Valve

Lift Down Relief 800 55

Tower Lif t Down Relief (E/M400A) Prior to S/N 86022

Tower Lif t Down Relief (E/M400A) S/N 86022 to Present

Tower Lif t Down Relief (E/M400AJP) Prior to S/N 91053

Tower Lif t Down Relief (E/M400AJP) S/N 91053 to Present

1700 117

2600 179

1700 117

2600 179

Telescope Relief (A) 3000 207

Telescope Relief (AJ & AJP) 3100 214

Platform Level Up Relief 3000 207

Platform Level Down Relief 1200 83

Brake/Steer Valve

Steer Relief - AJP/A

Steer Relief - An

Steer Relief - AJPn

Main Relief

2300 159

110 0 7 6

1400 96.5

3400 234

Jib Valve

Jib Relief Up

Jib Swing Relief

2200 152

3000 207

Releveling Valve

Releveling Relief (E/M400A) Prior to S/N 86022

Releveling Relief (E/M400A) S/N 86022 to Present

Releveling Relief (E/M400AJP) Prior to S/N 91053

Releveling Relief (E/M400AJP) S/N 91053 to Present

1200 83

2200 152

1200 83

2200 152

Jib Swing Relief

3000 207

Releveling Valve

Releveling Relief

1200 83

3121827 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Figure 1-1. Serial Number Locations

Table 1-18. Mobil EAL H Series Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 32

Specific Gravity .950

Pour Point -59°F (-51°C)

Flash Point 514°F (268°C)

Weight

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

Viscosity

at 40° C 33.1 cSt

at 100° C 6.36 cSt

Viscosity Index 147

1.15 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 missing, 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.

Lubrication Specifications

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

lubrication procedures.

Table 1-17. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Point, 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

1.16 LUBRICATION

Table 1-16. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

to + 180o F(-18o to +83o C)

+0o to + 210o F(-18o to +99o C)

+50o to + 210o F(+10o to +99o 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 ser-

1-6 – JLG Lift – 3121827

vice.

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil DTE 11M is desired, contact JLG Industries for proper recommendations.

S.A.E. Viscosity

Grade

10W

10W-20, 10W30

20W-20

SECTION 1 - SPECIFICATIONS

Figure 1-2. Operator Maintenance & Lubrication Diagram

3121827 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Table 1-19. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping poin t of 350

degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 poun ds minimum).

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classifi-

cation 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 L ubricant, Gredag 741 Grease. (JLG Part No.

3020022)

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.

D ie se l - AP I C C /C D c la ss , M I L-L- 21 04 B/ MI L-L- 2 10 4C .

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

1.17 OPERATOR MAINTENANCE & LUBRICATION

NOTE: The following numbers correspond to those in Fig-

ure 1-2., Operator Maintenance & Lubrication Diagram.

2. Swing Bearing/Worm Gear Teeth

Lube Point(s) - 2 Grease Fittings Capacity - Spray On Lube - Mobiltac 375NC Interval - A/R Comments - If necessary install grease fittings into

worm gear housing and grease bearings.

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

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTISHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY.

1. Swing Bearing

Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

1-8 – JLG Lift – 3121827

Comments - Remote Access

3. Hydraulic Tank

Lube Point(s) - Fill Cap Capacity - 4 Gal. (15.1 L) Lube - HO Interval - Check Level daily; Change every 2 years or

1200 hours of operation.

Comments - On new machines, those recently over-

hauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir.

SECTION 1 - SPECIFICATIONS

4. Hydraulic Return Filter

Interval - Change after first 50 hrs. and every 6

months or 300 hrs. thereafter.

Comments - Under certain conditions, it may be

necessary to replace the hydraulic filter on a more frequent basis. A common symptom of a dirty filter is sluggishness experienced in hydraulic functions.

5. Wheel Drive Hub

6. Wheel Bearings

Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation

7. Spindles/Bushing

Capacity - A/R Lube - Lithium Lubricant Interval - Every 2 years or 1200 hours of operation Comments - At Spindle/Bushing Replacement; Coat

I.D. of bushings prior to installing king pins.

8. Boom Pivot Pins/Bushing

Capacity - A/R Lube - Lithium Lubricant Interval - Every 2 years or 1200 hours of operation Comments - At boom pivot pins/bushing replace-

ment; Coat I.D. of bushings prior to installing pivot pins.

Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of

operation; change every 2 years or 1200 hours of operation

3121827 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

9. Engine

Lube Point(s) - Fill Cap Capacity - Refer to Engine Manual Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accor-

dance with engine manual.

1-10 – JLG Lift – 3121827

SECTION 1 - SPECIFICATIONS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N

Description

0100011

242

Vibra-TITE

121

Medium Strength (Blue)

0100019

271

Vibra-TITE

140

High Strength (Red)

0100071

262

Vibra-TITE

131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0 .4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

or Vibra-

TITE

131)

Torque

Lubricated

Torque

(Loctite® 242

or 271

OR Vibra-TIT E

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)

3121827 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000456040 553550 7900 50 70 45 60 35 50 9550 70 95 65 90 50 70

10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120 16400 155 210 140 190 115 155 18250 170 230 155 210 130 175 20350 210 285 190 260 160 220 23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310

77000 1445 1965 1300 1770 1085 1475 87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430 118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140) K=.18

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry or Loctite® 263)

K= 0.20

1-12 – JLG Lift – 3121827

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K = .17

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

SECTION 1 - SPECIFICATIONS

3121827 – JLG Lift – 1-13

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242TM or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

1-14 – JLG Lift – 3121827

Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

Torque

(Lub)

Torque

(Loctite® 262

OR Vibra-

TITE

131)

Torque

(Loctite®

242

or 271

OR Vibra-

TITE

111 or

140)

Sq mm K N [N.m] [N.m] [N.m] [N. m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)

3121827 – JLG Lift – 1-15

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

K = 0.20

Torque

(Lub OR Loctite®

242

or 271TM OR

Vibra-TITE

111 or

140)

K= 0.18

Torque

(Loctite® 262

Vibra-TITE

131)

K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22

4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9

8 1.25 36.60 22.8 36.5 32.8 27.4 10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150

16 2 157 97.8

315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 A ND DOES NOT

REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

1-16 – JLG Lift – 3121827

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

Torque

(Dry or Loctite®

263

)

K = .17

Torque

(Lub OR Loctite®

242

or 271

OR Vibra-TITE

111 or 140)

K = .16

Torque

(Loctite® 262

OR Vibra-TITE

131)

K = .15

Sq mm kN [N.m] [N.m] [N.m]

30.55.03

3.5 0.6 6.78

40.78.78

50.814.20

6120.1012.5 13 12 11

7128.9018.0 21 20 19

8 1.25 36.60 22.8 31 29 27 10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT

REPRESENT FULL STRENG TH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

3121827 – JLG Lift – 1-17

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

SECTION 1 - SPECIFICATIONS

NOTES:

1-18 – JLG Lift – 3121827

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

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

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

Annual Machine Inspection

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

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

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

Preventive Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

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

3121827 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Typ e Frequency

Pre-Start Inspection Prior to use each day; or

At each Operator change.

Pre-Delivery

Inspection

Frequent Inspection In service for 3 months or 150 hours, which-

Annual Machine

Inspection

Preventive

Maintenance

Prior to each sale, lease, or

rental delivery.

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as specified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

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

Safety and Workmanship

Cleanliness

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

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Trained

Owner, Dealer, or User Qualified JLG

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

Service

Qualification

Mechanic

Service Technician

(Recommended)

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

Components Removal and Installation

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

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

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

2-2 – JLG Lift – 3121827

SECTION 2 - GENERAL

Component Disassembly and Reassembly

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

Pressure-Fit Parts

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

Bearings

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

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

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

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

Gaskets

Hydraulic Lines and Electrical Wiring

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

Hydraulic System

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

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

Lubrication

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

Battery

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

Lubrication and Servicing

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

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.

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

2.3 LUBRICATION AND INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

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

3121827 – JLG Lift – 2-3

SECTION 2 - GENERAL

fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles.

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

4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is 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 hydraulic oil, which has an SAE viscosity of 10W and a viscosity index of

140.

NOTE: Start-up of hydraulic system with oil temperatures

below -20 degrees F (-29 degrees C) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of -20 degrees F (-29 degrees C).

Changing Hydraulic Oil

1. Filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils.

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

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

Lubrication Specifications

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

2.4 CYLINDER DRIFT TEST

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

Platform Drift

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

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

8 203.2 0.0038 0.10

9 228.6 0.0030 0.08

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

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

If the cylinder passes this test, it is acceptable.

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

inder leakage.

Max. Acceptable Drift

in 10 Minutes

2-4 – JLG Lift – 3121827

SECTION 2 - GENERAL

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

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

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

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

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

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

ing.

d. Debris embedded in liner surface.

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

a. Detectable wear in the bearing area.

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

surface.

c. Rusting of the pin in the bearing area.

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

2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to

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

Do the Following When Welding on JLG Equipment

• Disconnect the battery.

• Ground only to structure being welded.

Do NOT Do the Following When Welding on JLG Equipment

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

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

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

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

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

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 unless otherwise instructed (i.e. sheave pins).

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

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

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

3121827 – JLG Lift – 2-5

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Boom Assembly

AREA

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

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

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

Pivot Pins and Pin Retainers 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pads 1,2 1,2

Covers or Shields 1,2 1,2

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

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 511,5

Floor 1,2 1 1,2

Rotator 9,5 15

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

Turntable Assembly

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

Oil Coupling 9

Swing Drive System

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

Hood, Hood Props, Hood Latches 51,2,5

Chassis Assembly

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

Wheel Nuts/Bolts 115 1515

Wheel Bearings 14,24

Oscillating Axle/Lockout Cylinder Systems 5,8

Outrigger or Extendable Axle Systems 5,8 5,8

Steer Components

Drive Motors

Torque Hubs 11 11

Annual

(Yearly)

Inspection

Every 2

Years

2-6 – JLG Lift – 3121827

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Inspection

Functions/Controls

AREA

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery or Frequent

Inspection

Platform Controls 55 66

Ground Controls 55 66

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

Footswitch 1,5 5 5

Emergency Stop Switches (Ground & Platform) 555

Function Limit or Cutout Switch Systems 55

Capacity Indicator 5

Drive Brakes 5

Swing Brakes 5

Boom Synchronization/Sequencing Systems 5

Manual Descent or Auxiliary Power 55

Power System

Engine Idle, Throttle, and RPM N/A

Engine Fluids (Oil, Coolant, Fuel) N/A

Air/Fuel Filter 1,7 7 7

Exhaust System 1,9 9 9

Batteries 51,9 19

Battery Fluid 11 11 11

Battery Charger 55

Fuel Reservoir, Cap, and Breather N/A

Hydraulic/Electric System

Hydraulic Pumps 1,9 1,2,9

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

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

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

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

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 12020

Instruments, Gauges, Switches, Lights, Horn 15,23

General

Operators and Safety Manuals in Storage Box 21 21 21

ANSI and EMI Manuals/Handbooks Installed 21

Annual

(Yearly)

Every 2

Years

3121827 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

Capacity Decals Installed, Secure, Legible 21 21 21

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

Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21

General Structural Condition and Welds 2,4 2,4

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

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 21 21 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footnotes:

Prior to use each day; or at each Operator change

Prior to each sale, lease, or delivery

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

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

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

Annual

(Yearly)

Inspection

Every 2

Years

2-8 – JLG Lift – 3121827

SECTION 2 - GENERAL

-40 F(-40 C)

-30 F(-34 C)

-20 F(-29 C)

-10 F(-23 C)

0 F(-18 C)

10 F(-12 C)

20 F(-7 C)

30 F(-1 C)

40 F(4 C)

50 F(10 C)

60 F(16 C)

70 F(21 C)

80 F(27 C)

90 F(32 C)

100 F(38 C)

110 F(43 C)

120 F(49 C)

ENGINE SPECIFICATIONS

ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.

AMBIENT AIR

TEMPERATURE

SAE 30

SAE 20SAE 5W-30

SAE 10W-30

SAE 10

NO OPERATION BELOW THIS AMBIENT TEMPERATUR E

NO OPERATION ABOVE THIS AMBIENT TEMPERATUR E

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS

EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC

OIL COOLER (CONSULT JLG SERVICE

180° F(82° C)

PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100°F(38°C) OR ABOVE.

EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180°F (82° C) OR ABOVE.

NO OPERATION BELOW THIS AMBIENT TEMPERATURE

MOBIL 424 10W-30

HYDRAULIC SPECIFICATIONS

NO OPERATION ABOVE THIS AMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM

WITHOUT HEATING AIDS WITH MOBILE 424

HYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM

WITHOUT HEATING AIDS AND COLD WEATHER

HYDRAULIC OIL BELOW THIS TEMPERATURE

EXXON UNIVIS HVI 26

MOBIL DTE 13

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES

CONSISTANTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

Figure 2-1. Engine Operating Temperature Specifications - Kubota

4150548 E

3121827 – JLG Lift – 2-9

SECTION 2 - GENERAL

NOTES:

2-10 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Tire Inflation

The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics.

Tire Damage

For pneumatic tires, JLG Industries, Inc. recommends that when any cut, rip, or tear is discovered that exposes sidewall or tread area cords in the tire, measures must be taken to remove the JLG product from service immediately. Arrangements must be made for replacement of the tire or tire assembly.

For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly.

• a smooth, even cut through the cord plies which exceeds 3 inches (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plies which exceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

• any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria.

Tire Replacement

JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics:

Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

Wheel Replacement

The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability.

Wheel Installation

It is extremely important to apply and maintain proper wheel mounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.

Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. If you do not have a torque wrench, tighten the fasteners with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper torque. Over-tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels. The proper procedure for attaching wheels is as follows:

1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to the original

• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load)

3121827 – JLG Lift – 3-1

SECTION 3 - CHASSIS & TURNTABLE

2. Tighten nuts in the following sequence:

3. The tightening of the nuts should be done in stages.

Following the recommended sequence, tighten nuts per wheel torque chart.

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

40 ft. lbs.

(55 Nm)

4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation.

100 ft. lbs.

(130 Nm)

170 ft. lbs.

(255 Nm)

3.2 SPINDLE

5. Check the unit for end play by moving the hub up & down parallel along the centerline of the spindle. If you can feel excessive end play (over the 0.010" [0.25 mm] specification), recheck the nut to see what is causing the excessive end play. Keep in mind that there can be some movement and still be within the 0.010" (0.25 mm) maximum specification. If there is no way of getting the excessive end play out by using your fingers, a socket or wrench may have to be used to set the end play.

6. The units should be checked visually to make sure the cotter pins are installed and that the correct components have been used. Each unit must also be checked for the proper feel to make sure there isn’t excessive end play and the hubs turn freely.

7. Insert the dust cap and check to make sure the cotter pin is not going to interfere. Cap must be pressed all the way down. The unit should be checked again to assure it spins freely after the dust cap is installed.

Specifications

The end play specification is 0.001”/0.010" (0.025 / 0.254 mm) for all units.

Checking

The end play is checked by clamping the spindle in a fixture or vise and moving the hub parallel to the spindle centerline without rocking the hub. If the end play is set properly the following should apply:

1. Hub should rotate freely when spun by hand.

2. The hub should not be noticeably loose when

moved parallel with spindle centerline.

Setting Wheel Bearing End Play

BE SURE NOT TO OVER-TIGHTEN THE SPINDLE NUT.

1. Tighten the spindle nut to assure the bearings are properly seated.

2. Loosen the spindle nut completely until the nut can be turned by hand.

3. Tighten the spindle nut by hand using a socket without rotating the hub.

4. If the cotter pin can be assembled with the spindle nut finger tight, insert cotter pin without backing the nut off. If the cotter pin cannot be assembled with the spindle nut hand tight, tighten the spindle nut to the nearest available slot and insert cotter pin. If more than ½ of the cotter pin hole in the spindle can be seen in a slot, back nut off to nearest slot and insert pin.

Greasing Requirements

Hub assemblies shall have grease packed in the bearings via an appropriate greasing spindle or by hand. In either method, the bearing must be greased so the grease is forced thru the entire bearing cavity and thru the rollers of both inner and outer bearings.

Dust or grease caps used shall have grease applied to the inside of the cap.

The bearing cavity shall be filled 50 - 80% full of grease on all applications.

Dust or grease caps shall also be filled 10-20% full of grease on all applications prior to final assembly.

Visually verify that grease has flowed thru all rollers of the inner and outer bearings.

3-2 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

1. Dust Cap

2. Cotter Pin

3. Spindle Nut

4. Spindle Washer

5. Stud Nut

6. Bearing Cone

7. Hub

8. Bearing Cone

9. Seal

10. Spindle

Figure 3-3. Spindle Assembly

3121827 – JLG Lift – 3-3

SECTION 3 - CHASSIS & TURNTABLE

3.3 DRIVE HUB (PART NO. 2780236)

The final drive consists of two planetary stages with an integrated disconnect mechanism. Each stage incorporates a set of matched planetary gears, which provide an equal load distribution. All torque transmitting components are made of forged quenched and tempered highalloy steels. External gears are carburized. Precision roller bearings support the sprocket or wheel loads. A shaft seal protects the unit against contamination.

Dissembling

1. Position drive so that one of the fill holes is at the bottom of the end cover and drain the oil.

2. Remove all bolts holding the motor and Remove motor from drive.

3. Compress the disc (59) using a simple fixture or other suitable device.

4. Remove snap ring (66) and release pressure on disc until loose. Remove tool and disc.

5. Remove the spring (55) from the input shaft (44).

6. Turn unit so that cover (8) is in the up position.

7. Remove the screw plugs (22) and seal rings (21).

8. Remove snap rings (34), and remove the cover unit

(8) from drive.

9. Remove “o” ring (33).

10. Remove the first stage planetary assembly (7).

15. Inspect the planetary stage assemblies as complete

units. Thoroughly clean and check both the gearing and the bearings for damage and apply new oil. If the gears or bearings need replacing, they must be replaced as complete sets.

16. The first stage planetary gears (2) must be changed

in sets of three pieces.

17. The first stage planetary gears (2) must be changed as a complete set of three and JLG recommends changing the sun gear shaft (43) along with this set of planets.

18. The second stage planetary bearings (11) must be replaced in sets of four pieces.

19. The second stage planetary gears (1) must be changed as a complete set of four and JLG recommends changing the sun gear (3) along with this set of planets.

11. Remove hex bolts (23).

12. Remove ring gear (30) and “o” ring (19).

13. Remove snap rings (15).

14. Pull off planet gears (1) together with cylindrical

roller bearings (11) from spindle (60).

NOTE: Further disassembly of the hub is discouraged. rein-

stallation of the shaft nut (4) requires a special tool and a torque of 626 ft./ lbs. (876 Nm) for proper reassembly. These components Will Fail if not properly reassembled.

3-4 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

Disassembly

1. Loosen and remove hex head bolts (53) to remove cover (51).

2. Remove shaft rod (56) and “o” ring (54).

3. Remove sleeve (52).

Disassembly of the first stage planetary assembly (7)

1. Push sun gear shaft (43) out of the first stage.

2. Remove snap rings (14).

3. Press planet pins (5) out of the planet gears (2).

4. Pull cylindrical roller bearing (10) out of the planet

gears (2).

5. Remove snap ring (16) from sun gear (3) and Remove planet carrier (7) from sun gear (3).

6. Remove thrust washer (49).

Disassembly of second stage planet gears (1)

1. Press cylindrical roller bearings out of planet gears (1).

Assembly of first stage planetary assembly (7)

1. Pre-freeze planet pins (5) and install into planet carrier (7).

2. Install planet carrier (7) together with planet pins (5) on sun gear (3), and install snap ring (16).

3. Pre-heat thrust washer (49) and Install onto sun gear shaft (43).

4. Put sun gear shaft (43) into sun gear (3).

5. Pre-heat support disk (17) and install onto planet

pins (5).

6. Pre-heat cylindrical roller bearings (10) and install onto planet pins (5) and fix bearings with snap rings (14).

Assembly of end cover unit (8)

1. Press sleeve (52) into cover (8).

2. Install “o” ring (54) into groove of cover (8).

3. Install shift rod (56) into cover (8).

4. Install the cover (51) into cover (8) and fix cover (51)

with hex bolts (53). Tighten bolts with torque wrench to 6.3 ft. lbs. (8.5 Nm).

3121827 – JLG Lift – 3-5

SECTION 3 - CHASSIS & TURNTABLE

Final Assembly

1. Install thrust washer (29) in spindle (60).

2. Install “o” ring (19) into groove of support ring (6).

3. Install planet gears (1) onto planet pins which are

part of spindle (60).

4. Install snap rings (15) on planet pins of spindle (60) in order to fix the planet gears (1).

5. Put ring gear (30) onto support ring (6) and fix ring gear (30) with hex head bolts (23). Tighten bolts with torque wrench to 15.5 ft. lbs.(21.1 Nm).

6. Insert the first stage planetary assembly (7) into drive.

7. Install “o” ring (33) in groove of ring gear (30).

8. Install end the cover unit (8) on shoulder ring gear

(30) and fix with snap ring (34).

9. Install seal rings (22) and screw plugs (21).

10. Before installation of motor, CHECK THAT THERE IS

1-2mm OF CLEARANCE BETWEEN THE MOTOR SPLINE SHAFT SHOULDER AND THE COUPLER (62).

11. Install the motor and reconnect hydraulic lines.

12. Roll motor so that one fill plug is at 12 o’clock posi-

tion, and the other is at 3 o’clock. Fill to bottom of 3 o’ clock plug with gear oil. reinstall plugs

Initial Start-up And After Repairs

Before operating the machine, make sure that the drive is filled with clean oil, approximately.2 us gallons(.8 L). An accurate oil level is determined by the oil level plug, which should be removed before oil fill.

With the gear case filled to their proper levels, start the machine and allow sufficient time for run-in at moderate pressure and speed before running at full speed. After 4 hours of operation, recheck oil level.

Maintenance

Daily: - Check for oil leakage

Weekly: - Check oil level

Monthly: - Check mounting bolt torque

Oil Change Interval-Gear Drive

1. Perform the first oil change after approximately 150 hours.

2. Subsequent changes, every 1500 hours or annually, whichever occurs first.

NOTE: flush the drive before filling with new oil.

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 626 ft. lbs. (850 Nm).

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) 0.04 to 0.05 inches (1.1 to 1.3 mm) into the spindle thread. Then set ball (24) in position by punching in expander (25).

3-6 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

1. Planet Gear

2. Planet Gear

3. Sun Gear

4. Shaft Nut

5. Planet Bolt

6. Support Ring

7. Planet Carrier

8. Cover

9. (Not Used)

10. Roller Bearing

11. Roller Bearing

12. Tapered Roller Bearing

13. (Not Used)

14. Retaining Ring

15. Retaining Ring

16. Retaining Ring

17. Support Disc

18. (Not Used)

19. O Ring

20. Ring Seal

21. Screw Plug

22. Seal Ring

23. Bolt

24. Ball

25. Expander

26. thru 28. (Not Used)

29. Washer

30. Ring Gear

31. thru 32. (Not Used)

33. O Ring

34. Spring

35. thru 42. (Not Used)

43. Sun Gear Shaft

44. Input Shaft

45. thru 48. (Not Used)

49. Washer

50. (Not Used)

51. Cover

52. Disc

53. Bolt

54. O Ring

55. Pressure Spring

56. Shaft Rod

57. thru 58. (Not Used)

59. Rotor Disc

60. Spindle

61. (Not Used)

62. Coupler

63. thru 65.(Not Used)

66. Retaining Ring

67. thru 80. (Not Used)

81. Ball Bearing

82. Retaining Ring

83. Retaining Ring

84. thru 87. (Not Used)

88. Wheel Stud

Figure 3-1. Drive Hub - Cutaway

3121827 – JLG Lift – 3-7

SECTION 3 - CHASSIS & TURNTABLE

3.4 DRIVE BRAKE - MICO

Disassembly

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

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

IF THE SENSOR RING (12) IS DAMAGED OR NEEDS REPLACED, THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT. THE SENSOR RING IS NOT AVAILABLE AS A SERVICE PART.

5. Remove stack assembly, consisting of stator disc (11), sensor ring (12), rotor disc (13), and plate (14) from cover (21).

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

NOTE: Note number and pattern of springs for reassembly

purposes.

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

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

spring pattern as recorded during disassembly. This should be five red springs evenly spaced.

5. Install dowel pins (20), spring retainer (16) and springs (5) in cover plate (21).

6. Position plate (14) on springs (15). NOTE: Disc (13 &11) and plate (14) must remain dry during installation. No oil residue must be allowed to contaminate disc surfaces.

7. Place a new rotor disc (13), including speed sensor

ring (12), on the shaft (10) until it contacts the 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 and backup rings. Insert piston (7) into pressure plate (3). Be careful not to shear orings 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.

NOTE: A hydraulic press will simplify installation of pressure

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

11. Install capscrews (1) and washers (2) and tighten evenly to draw pressure plate (3) to cover (21). Torque capscrews to 55 ft.lbs. (74.6 Nm).

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

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

on male end of the shaft.

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

10. Press rotary oil seal (20) from cover (18).

Assembly

NOTE: Lubricate all rubber components from the repair kit

with clean type fluid used in the 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).

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 2000 PSI (137.9 BAR) 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 pressur-

izing side inlet port and allowing air to escape from top port. Pressure should not exceed 100 psi (6.9 bar) during bleeding.

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

3-8 – JLG Lift – 3121827

13142

1. Capscrew

2. Washer

3. Pressure Plate

4. Case Seal

5. O-ring

6. Backup Ring

7. Piston

8. O-ring

9. Backup Ring

10. Shaft

11. Stator Disc

12. Sensor Ring

13. Rotor Disc

14. Plate

15. Spring

16. Spring Retainer

17. Retaining Ring

18. Bearing

19. Retaining Ring

20. Dowel Pin

21. Cover

22. Rotary Oil Seal

23. Gasket

Figure 3-2. Drive Brake

NOTE: The speed sensor port in the cover (21)

should be 180° from the brake release port in the pressure plate (3).

SECTION 3 - CHASSIS & TURNTABLE

3121827 – JLG Lift – 3-9

SECTION 3 - CHASSIS & TURNTABLE

Table 3-2. Drive Brake Diagnosis

Problem Cause Explanation

Brake slips Excessive pressure In hydraulic

system

Oil In brake if designed for dry use

Springs broken or have taken a permanent set

Brake drags or runs hot

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

Low actuation pressure T he brake should be pressurized to minimum of

Bearing failure If the bearing should fall. a large amount of drag can

Bad o-rings Release piston will not hold pressure, brake will not

If there is back pressure in the actuation line of the brake, holding torque will be reduced.

Wet linings generate 67% of the dry torque rating. If the brake has oil In it, check the type of oil hydraulic or gearbox.

1. Gearbox oil

2. Hydraulic oil

Broken or set springs can cause reduced torque rare occurrence.

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

be generated.

sure drops below stated release pressu re. If pressure cannot get to brake, the brake will not release .

release.

Corrective

Action

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

Replace oil seal in brake. Check motor seal. Check piston seals. Note: Internal components will need to be inspected, cleaned, and replaced as required.

See spring replacement

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

Replace bearing.

Place pressure gauge in bleed por t

- check for adequate pressure. Replace defective line or component.

Replace o-rings.

Discs frozen These brakes are designed for only limi ted dynamic

braking. A severe emergency stop or prolonged reduced release pressure operation may result in this type of damage.

Replace disc stack.

3-10 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

3.5 SPEED SENSOR ADJUSTMENT

For proper drive operation, the speed 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 WILL NOT STOP UNLESS THE FOOTSWITCH IS RELEASED OR THE EMS IS PUSHED IN.

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 3-3., 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.

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.

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Figure 3-3. Speed Sensor Orientation

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Figure 3-4. Frame Mounted Electrical Components - Sheet 1 of 2

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Figure 3-5. Frame Mounted Electrical Components - Sheet 2 of 2

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Should read 0-7 Volts. Anything o

r 7

volts should flash Err

Code 7-7, Open Pump Circuit. If

the voltage is

high,

check for

corrosion, a dirty pump motor, or

brushes

The drive system should show 48 volts w ith

the main contactor closed and 35 volts with

the main contactor open.

These voltage checks should be performed

w ith th e ma ch in e p owe r e d u p a n d th e ma in

contactor o pen .

Figure 3-6. Voltage Checks

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Speed Sensor Installation Verification

The motor controller averages the readings from the right and left speed sensors and therefor, it can be difficult to detect if the speed sensors are adjusted properly. When the positrac keeps coming in and out while on level surfaces, this is a sure indication that one of the speed sensors is not adjusted properly.

The worse case condition of speed sensor installation occurs when both sensors are installed in a manner that allows them to indicate the exact opposite direction that the machine is traveling. This situation causes the controller to believe that the machine is rolling in opposite direction than that selected by the operator. The controllers reaction to this situation is to put more power into the drive motors to attempt to overcome the fact that it believes the machine is rolling backwards. This presents itself as uncontrolled movement in the direction selected by the operator until the controller recognizes that it is placing maximum power in the motors and the controller and the speed sensors are still reporting movement in the opposite direction. The controller responds by shutting down drive and reporting flash code 5/5- Vehicle Runaway Check Speed Encoders.

If either speed sensor is disconnected or faulty, the controller will recognize this condition and immediately report flash code 5/5 - Left or Right speed Encoder Faulty.

Verification w/ Analyzer Procedure

Below is a procedure using the Analyzer that will verify that the speed sensors are installed correctly.

THIS PROCEDURE REQUIRES A LARGE SPACE CLEAR OF OBSTRUCTIONS. THE OPERATOR SHOULD BE FAMILIAR WITH JLG EQUIPMENT AND BE PREPARED TO USE THE FOOTSWITCH TO STOP THE MACHINE. READ AND UNDERSTAND THIS ENTIRE PROCEDURE PRIOR TO BEGINNING.

1. Before beginning this procedure, insure that there is at least 10 ft. (3m)in front and back of machine. Be sure that all other personnel stand clear of the machine during this procedure.

2. Unplug the left speed sensor from the posi-trac tilt module.

3. Power up the machine in platform mode and plug in the Analyzer in the platform.

4. Use the right and left cursor keys on the analyzer to highlight “DIAGNOSTICS” and press enter.

5. Use the right and left cursor keys on the analyzer to highlight “DRIVE” and press enter.

6. Use the right and left cursor keys to display ’SPEED 0%” on the analyzer.

7. While watching the analyzer display, select drive forward. Be ready to remove your foot from the foot switch if the machine lunges forward.

8. The analyzer display should read the following if the RIGHT speed sensor is adjusted properly: “SPEED 20% FWD”.

9. If the speed sensor is adjusted improperly, the analyzer will display “SPEED 20% REV” and the machine will lunge forward.

10. Adjust the right speed sensor using the preceding Adjustment Procedure until the analyzer displays

“SPEED 20% FWD” when forward is selected at the platform. The percentage displayed is not critical, just the direction.

11. After obtaining the display in step 10, operate the machine in both forward and reverse directions. The machine should be controllable in both directions and will only drive at a maximum of creep speed. The display on the analyzer should match the direction selected.

12. After completing adjustment of the right sensor, plug the left sensor into the posi-tilt module.

13. Unplug the right sensor from the power module.

14. Power up the machine in platform mode and plug in

the analyzer in the platform.

15. Use the right left cursor keys on the analyzer to highlight diagnostics and press enter.

16. Use the right and left cursor keys on the analyzer to highlight drive and press enter.

17. Use the right and left cursor keys to display “speed 0%” ON THE ANALYZER.

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18. While watching the analyzer display, select drive forward. Be ready to remove your foot from the foot switch if the machine lunges forward.

19. The analyzer display should read the following if the left speed sensor is adjusted properly: “SPEED 20% FWD”.

20. If the left speed sensor is adjusted improperly, the analyzer will display “SPEED 20% REV”, and the machine will lunge forward.

21. Adjust the left speed sensor using the preceding Adjustment Procedure until the analyzer displays

“SPEED 20% FWD” when forward is selected in the platform. The percentage displayed is not critical, just the direction.

22. After obtaining the display in step 10, operate the machine in both the forward and reverse directions. The machine should be controllable in both directions and will only drive at a maximum of creep speed. The display on the analyzer should match the direction selected.

23. Plug in the right sensor to the power module.

24. Test the machine. The machine should now have

maximum drive speed available in both directions and should be controllable in both directions. The analyzer display should match the direction selected.

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Figure 3-7. Steering Components and Spindles

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Figure 3-8. Drive Components

3.6 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 JLG Control System Analyzer Kit instructions. Use a standard 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.

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 BE LEVEL WHEN INSTALLING AND CALIBRATING A NEW POSITRAC/TILT MODULE.

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Figure 3-9. Tilt Sensor Location

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3.7 SWING MOTOR - S/N 0300135649 TO

Figure 3-10. Swing Motor - Cutaway

PRESENT

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IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING ABILITY.

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Table 3-3. Swing Motor Troubleshooting

Trouble Cause Remedy

Oil Leakage 1. Hose fittings loose, worn or damaged.

Check & replace damaged fittings or "O" Rings. Torque to manufacturers specifications.

2. Oil seal rings (4) deteriorated by excess heat.

3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing area deteriorated by corrosion.

4. Internal shaft seal (16) worn or damaged.

5. Worn coupling shaft (12) and internal seal (16).

Significant loss of speed under load 1. Lack of sufficient oil supply

2. High internal motor leakage

3. Severely worn or damaged internal splines.

4. Excessive heat.

Low mechanical efficiency or undue high pressure required to operate unit

1. Line blockage

2. Internal interference

Replace oil seal rings by disassembling unit.

(a) Loosen then tighten single bolt to torque specification. (b) Replace bolt.

Replace seal. Disassembly of motor unit necessary.

Replace coupling shaft and seal by disassembling unit.

(a) Check for faulty relief valve and adjust or replace as required. (b) Check for and repair worn pump. (c) Check for and use correct oil for temperature of operation.

Replace worn rotor set by disassembling unit.

Replace rotor set, drive link and coupling shaft by disassembling unit.

Locate excessive heat source (usually a restriction) in the system and correct the condition.

Locate blockage source and repair or replace.

Disassemble unit, identify and remedy cause and repair, replacing parts as necessary.

3. Lack of pumping pressure

4. Excessive binding or loading in system external to motor unit.

Check for and repair worn pump.

Locate source and eliminate cause.

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123

1. Bolt

2. End Cover

3. Seal Ring

4. Seal Ring

5. Commutator

6. Commutator Ring

7. Manifold

8. Rotor Set 8A. Rotor 8B. Stator Half

8C. Stator Vane 8D. Stator Half

9. Wear Plate

10. Drive Link

11. Thrust Bearing

12. Coupling Shaft

13. Inner Bushing

14. Thrust Washer

15. Thrust Bearing

16. Seal

17. Backup Ring

18. Housing

19. Outer Bushing

20. Dirt & Water Seal

21. Not Used

22. Not Used

23. Not Used

24. Not Used

25. Backup Washer

Figure 3-11. Swing Motor - Exploded View

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Preparation Before Disassembly

• Before you disassemble the motor unit or any of its components read this entire section. It provides important information on parts and procedures you will need to know to service the motor.

• Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnecting and removing the motor. Remove rust or corrosion from coupling shaft.

• Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines.

• Remove the motor from system, drain it of fluid and take it to a clean work surface.

• Clean and dry the motor before you start to disassemble the unit.

• As you disassemble the motor clean all parts, except seals, in clean petroleum-based solvent, and blow them dry.

PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.

WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

NEVER STEAM OR HIGH PRESSURE WASH HYDRAULIC COMPONENTS. DO NOT FORCE OR ABUSE CLOSELY FITTED PARTS.

Disassembly and Inspection

1. Place the motor in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port ORings if applicable.

IF THE MOTOR IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED DURING THE SERVICE PROCEDURES, CAUSING INJURY.

2. Scribe an alignment mark down and across the motor components from end cover (2) to housing (18) to facilitate reassembly orientation where required.

• Keep parts separate to avoid nicks and burrs.

• Discard all seals and seal rings as they are removed from the motor. Replace all seals, seal rings and any damaged or worn parts with OEM approved service parts.

3-24 – JLG Lift – 3121827

3. Remove the special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.

SECTION 3 - CHASSIS & TURNTABLE

5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.

NOTE: A polished pattern (not scratches) on the cover from

rotation of the commutator (5) is normal. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set.

4. Remove end cover assembly (2) and seal ring (4). Discard seal ring.

6. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs.

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7. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set.

8. Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard the seal rings (4) that are on both sides of the manifold.

NOTE: The manifold is constructed of plates bonded

together to form an integral component not subject to further disassembly for service. Compare configuration of both sides of the manifold to ensure that same surface is reassembled against the rotor set.

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SECTION 3 - CHASSIS & TURNTABLE

9. Remove rotor set (8) and wearplate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane to stator contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wearplate. You may have to shift the rotor set on the wearplate to work the drive link out of the rotor and wearplate. Inspect the rotor set in its assembled form for nicks, scoring, or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the wearplate for cracks, brinelling, or scoring. Discard seal ring (4) that is between the rotor set and wearplate.

10. Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 degrees apart) and a roller vane centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline. If there is more than

0.005 inches (0.13 mm) of clearance, replace rotor set.

NOTE: If rotor set (8) has two stator halves and two sets of

seven vanes as shown, check the rotor lobe to roller vane clearance at both ends of rotor.

NOTE: The rotor set (8) components may become disas-

sembled during service procedures. Marking the surface of the rotor and stator that is facing UP, with etching ink or grease pencil before removal will ensure correct reassembly of rotor into stator and rotor set into motor. Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maximum wear life and performance of rotor set and motor.

11. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and discard seal ring (4) from housing (18).

NOTE: A polished pattern on the wear plate from rotor rota-

tion is normal.

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12. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used.

13. Remove coupling shaft (12), by pushing on the output end of shaft. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or

keyway. Replace coupling shaft if any of these conditions exist.

NOTE: Minor shaft wear in seal area is permissible. If wear

exceeds 0.020 inches (0.51 mm) diametrically, replace coupling shaft.

NOTE: A slight "polish" is permissible in the shaft bearing

areas. Anything more would require coupling shaft replacement.

14. Remove and discard seal ring (4) from housing (18).

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15. Remove thrust bearing (15) and thrust washer (14). Inspect for wear, brinelling, corrosion and a full complement of retained rollers.

16. Remove seal (16) and back up ring (17) from housing (18) and backup washer (25). Discard both.

18. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assembly.

19. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. The bushing (19) or (13) to coupling shaft diameter clearance must not exceed

0.010 inch (0.025 mm). A bearing, bushing, or thrust washer that does not pass inspection must be

17. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required.

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SECTION 3 - CHASSIS & TURNTABLE

replaced. If the housing has passed this inspection the disassembly of the motor is completed.

20. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13).

NOTE: The depth or location of bearing/bushing (13) in rela-

tion to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/ bushings. This will facilitate the correct reassembly of new bearings/bushings.

Assembly

Replace all seals and seal rings with new ones each time you reassemble the motor unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

NOTE: Unless otherwise indicated, do not oil or grease

parts before assembly.

Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.

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SECTION 3 - CHASSIS & TURNTABLE

SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH.

WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

1. If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease recommended in the material section. Press the new bearing/bushing into the counterbore at the mounting flange end of the housing, using the appropriate sized bearing mandrel as described which will control the bearing/ bushing depth.

The housing requires the use of bearing mandrel to press bearing/ bushing (19) into the housing to a required depth of 0.151/0.161 inches (3.84/4.09 mm) from the end of the bearing counterbore.

IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADEQUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COMPONENTS WHEN ASSEMBLED.

BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE REUSED.

NOTE: Bearing mandrel must be pressed against the let-

tered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/ bushing is not cocked when pressing a bearing/bushing into the housing.

2. The inner housing bearing/bushing (13) can now be pressed into its counter-bore in housing (18) flush to

0.03 inch (0.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/ bushing (19).

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3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The dirt and water seal (20) must be pressed in until its’ flange is flush against the housing.

4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange.

6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the motor.

NOTE: The motor requires one thrust washer (14) with

thrust bearing (15). The coupling shaft will be seated directly against the thrust bearing.

7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal.

5. Assemble a new backup ring (17), new backup washer (25) and new seal (16) with the seal lip facing toward the inside of the motor, into their respective counterbores in housing (18).

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SECTION 3 - CHASSIS & TURNTABLE

8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15).

THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED GREASE.

NOTE: The coupling shaft (12) will be flush or just below the

housing wear surface when properly seated while the coupling shaft (12). The coupling shaft must rotate smoothly on the thrust bearing package.

9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove.

NOTE: One or two alignment studs screwed finger tight into

housing (18) bolt holes, approximately 180 degrees apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as required that are over 0.5 inch (12.7 mm) longer than the bolts (1) used in the motor.

10. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines.

NOTE: Use any alignment marks put on the coupling shaft

and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines.

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11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18).

12. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator.

NOTE: It may be necessary to turn one alignment stud out

of the housing (18) temporarily to assemble rotor set (8) or manifold (7) over the drive link.

NOTE: If necessary, go to the appropriate, "Rotor Set Com-

ponent Assembly Procedure."

NOTE: The rotor set rotor counterbore side must be down

against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to determine which side was down. The rotor set seal ring groove faces toward the wear plate (9).

14. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7).

NOTE: The manifold (7) is made up of several plates

13. Install the assembled rotor set (8) onto wear plate (9) with rotor counterbore and seal ring side down and the splines into mesh with the drive link splines.

bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has it’s series of irregular shaped cavities on the largest circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.

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15. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set.

16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold.

18. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up.

17. Assemble the commutator ring (6) over alignment studs onto the manifold.

19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The correct 5 bolt end cover bolt hole relationship to housing port bosses is shown below.

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SECTION 3 - CHASSIS & TURNTABLE

20. Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 25-30 ft. lbs. (34-41 N m).

NOTE: If the end cover has a valve (24) or has five bolt

holes, use the line you previously scribed on the cover to radially align the end cover into its original position.

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SECTION 3 - CHASSIS & TURNTABLE

One Piece Stator Construction

A disassembled rotor stator and vanes that cannot be readily assembled by hand can be assembled by the following procedures.

1. Place stator onto wear plate (9) with seal ring (4) side down, after following assembly procedures 1 through 13. Be sure the seal ring is in place.

2. If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary.

3. Assemble the rotor, counterbore down if applicable, into stator, and onto wear plate (9) with rotor splines into mesh with drive link (10) splines.

4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets.

EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.

5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes into stator, creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

6. Remove the two assembled bolts (1) if used to retain stator and wear plate.

Go to assembly procedure #15, to continue assembly.

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SECTION 3 - CHASSIS & TURNTABLE

Two Piece Stator Construction

A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be assembled by the following procedures.

1. Place stator half onto wear plate (9) with seal ring (4) side down, after following motor assembly procedures 1 through 13. Be sure the seal ring is in place.

2. Align stator bolt holes with wear plate and housing bolts and turn two alignment studs finger tight into bolt holes approximately 180 degrees apart to retain stator half and wear plate stationary.

3. Assemble rotor, counterbore down if applicable, into stator half, and onto wear plate (9) with rotor splines into mesh with drive link (10) splines.

NOTE: Use any marking you applied to rotor set compo-

nents to reassemble the components in their original relationship to ensure ultimate wear life and performance.

4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets.

8. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets.

9. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes into stator, creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

Go to assembly procedure #15, to continue assembly.

Final Checks

1. Pressurize the motor with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for external leaks.

2. Check motor for rotation. Torque required to rotate coupling shaft should not be more than 50 ft. lbs. (68 N m)

3. Pressure port with "A" cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with "B" cast under it is for counter clockwise coupling shaft rotation.

EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.

5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator half, creating the necessary clearance to assemble the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force.

6. Place second stator half on a fl at surface with seal ring groove up. Apply a small amount of grease to a new seal ring (4) and assemble it into stator half ring groove.

7. Assemble the second stator half over the two alignment studs and rotor with seal ring side down onto the first stator half aligning any timing marks applied for this purpose.

IF THE STATOR HALF (8B) IS A DIFFERENT HEIGHT (THICKNESS) THAN STATOR HALF (8D) THE STATOR VANES (8C) OR (8E)OF THE SAME LENGTH (HEIGHT) AS THE STATOR HALF MUST BE REASSEMBLED IN THEIR RESPECTIVE STATOR HALF FOR THE ROTOR SET TO FUNCTION PROPERLY.

4. Use test stand if available, to check operation of the motor.

3-38 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-12. Swing Bearing Feeler Gauge Check

3.8 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

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

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

1. Check the frame to bearing attach bolts as follows:

a. Elevate the fully retracted boom to 70 degrees

(full elevation).

b. At the positions indicated on Figure 3-12. try and

insert the 0.0015” feeler gauge between the bolt head and hardened washer at the arrow indicated position.

c. Assure that the 0.0015" feeler gauge will not

penetrate 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 follows:

a. Elevate the fully retracted boom to 70 degrees

(full elevation).

b. At the positions indicated on Figure 3-13. try and

insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

c. Lower the boom to horizontal and fully extend

the boom.

d. At the position indicated on Figure 3-12. try and

insert the 0.0015” feeler gauge between the bolt head and hardened washer at the arrow indicated position.

3121827 – JLG Lift – 3-39

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-13. Swing Bearing Tolerance Boom Placement

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 3-13.), using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable. (See Figure 3-14.

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 3-13.) using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable (See Figure 3-14.).

3-40 – JLG Lift – 3121827

3. If a difference greater than 0.057 in. (1.40 mm) is

Figure 3-14. Swing Bearing Tolerance Measuring Point

determined, the swing bearing should be replaced.

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

a. Metal particles in the grease.

b. Increased drive power.

c. Noise.

d. Rough rotation.

5. If bearing inspection shows no defects, reassemble

bearing and return to service.

SECTION 3 - CHASSIS & TURNTABLE

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

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 0.008 -

0.010 inch (0.20 - 0.25 mm). Tighten capscrews as shown in Figure 3-15., Swing Bearing 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.

Replacement of Swing Bearing

1. Removal.

a. Attach an adequate support sling to the boom

and draw all slack from sling. Prop or 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 assembly from the bearing. Ensure that no damage occurs to the turntable, bearing or frame mounted components.

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.

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

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

bearing bolts and loosely install the bolts and washers through the frame and outer race of bearing.

3121827 – JLG Lift – 3-41

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-15. Swing Bearing Torquing Sequence

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

g. Following the torque sequence diagram shown

in Figure 3-15., tighten the bolts to an initial torque of 130 ft. lbs. (175 Nm). Then following the same sequence, tighten to a final torque of 190 ft. lbs. (260 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 bolts and install through the turntable and inner race of bearing.

3. Following the torque sequence shown in Figure 3-

15., tighten the bolts to an initial torque of 130 ft. lbs. (175 Nm). Then following the same sequence, tighten the bolts to 190 ft. lbs (260 Nm).

a. Remove the lifting equipment.

b. Route hydraulic lines through center of turntable

and frame and connect as tagged prior to removal.

c. Using all applicable safety precautions, activate

the hydraulic system and functionally check swing system for proper and safe operation.

3-42 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

Allowable Tolerance

.001 to .005

()

Fig 2 Adjusting End Play.

END PLATE

SHIMS

Swing Bearing Torque Value

Install bolts with Loctite - 190 ft. lbs. (260 Nm).

Checking Worm Gear End Play

NOTE: JLG Industries requires that a annual 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.

2. If tolerance exceeds 0.010", reduce end play to less than 0.005". Refer to Adjusting End Play

Adjusting End Play

1. Remove end plate.

2. Measure and record total thickness of existing shim

pack.

3. Determine thickness of shim pack required to obtain

0.001" - 0.005" end play.

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

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

6. Recheck end play.

3121827 – JLG Lift – 3-43

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-16. Swing Components

3-44 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-17. Remote LED Card

3.9 BATTERY MAINTENANCE AND CHARGING

Battery Maintenance, Quarterly

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, non-metallic

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 3/8”(1 cm) above separators.

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.

Charging Sequence of Remote LED Card

1. Plug in charger.

2. All three LED’s (light emitting diode) flash three

times.

3. In sequence.

a. Green LED flashes once.

b. Yellow LED flashes once.

c. Red LED flashes once.

4. All Three LED flash three times.

5. Yellow LED comes on indicates charger is charging.

6. Yellow LED will stay on until fully charged and green

LED will illuminate.

7. If Red LED remains on, this indicates a fault.

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 required.

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.

3121827 – JLG Lift – 3-45

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-18. Battery Cable Connections

3-46 – JLG Lift – 3121827

Battery Charging (On Board Charger)

Figure 3-19. Batteries and Battery Charger (Prior to S/N 0300059350)

SECTION 3 - CHASSIS & TURNTABLE

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.

Optional On Board Generator

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

WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE 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 ALSO AUTOMATICALLY START IF THE GENERATOR START BATTERY IS LOW.

NOTE: The engine will automatically shut down under the

following conditions:

High Engine Oil Temperature Low Engine Oil Pressure Engine Overspeed Generator Over voltage Batteries fully charged Engine underspeed

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.

3121827 – JLG Lift – 3-47

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-20. On Board Generator

3-48 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

3.10 BATTERY CHARGER (S/N 0300059350 TO PRESENT)

LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION. KEEP SPARKS, FLAMES, AND SMOKING MATERIALS AWAY FROM BATTERIES. PROVIDE ADEQUATE VENTILATION DURING CHARGING. NEVER CHARGE A FROZEN BATTERY. STUDY ALL BATTERY MANUFACTURERS' SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE AND REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.

RISK OF ELECTRIC SHOCK. CONNECT CHARGER POWER CORD TO AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES. A GROUNDED OUTLET IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK - DO NOT USE GROUND ADAPTERS OR MODIFY PLUG. DO NOT TOUCH UNINSULATED PORTION OF OUTPUT CONNECTOR OR UNINSULATED BATTERY TERMINAL. DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY WHILE CHARGING. DO NOT OPEN OR DISASSEMBLE CHARGER. DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE DAMAGED IN ANY WAY - REFER ALL REPAIR WORK TO QUALIFIED PERSONNEL. NOT FOR USE BY CHILDREN.

Operating Instructions

ALWAYS USE A GROUNDED OUTLET. WHEN USING AN EXTENSION CORD, AVOID EXCESSIVE VOLTAGE DROPS BY USING A GROUNDED 3-WIRE 12 AWG CORD.

1. The charger will automatically turn on and go through a short self-test. All LED’s will flash in an updown sequence for two seconds. The yellow "Charging" LED will turn on and a trickle current will be applied until a minimum voltage is reached.

2. Once a minimum battery voltage of 2 volts per cell is detected, the charger will enter the constant-current charging stage and the yellow LED will remain on. The length of charge time will vary by input voltage and ambient temperature.

3. When the green "Charged" LED turns on, the batteries are completely charged. The charger may now be unplugged from AC power. If left plugged in, the charger will automatically restart a complete charge cycle if battery voltage drops below a minimum voltage or 30 days have elapsed.

4. If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error.

Maintenance Instructions

1. For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instructions recommended by the battery manufacturer.

2. Make sure charger connections to battery terminals are tight and clean.

3. Do not expose charger to oil or to direct heavy water spraying when cleaning vehicle.

Battery Charger Fault Codes

If a fault occurred during charging, the red "Fault" LED will flash with a code corresponding to the error. Refer to the table following for the flash codes and their removal.

Table 3-11. Battery Charger Fault Codes (Delta-Q)

Flash(s) Fault Fault Removal

Battery voltage

4 Check battery

6QuiQ fault

high

Battery voltage

low

Charge

time-out

Over-

temperature

Auto-recover - Indicates a high battery pack voltage

Auto-recover - Indicates either a battery pack failure, battery pack not connected to charger or battery volts per cell is less than 0.5 VDC. Check the battery pack and connections

Indicates the batteries did not charge in the allowed time. This could occur if the batteries are a larger capacity than the algorithm is intended for or if the batteries are damaged old or in poor condition.

Indicates the batteries could not be trickle charged up to the minimum voltage per cell level required for the charge to be started.

Auto-recover - Indicates charger has shut down due to high internal temperature

Indicates that the battery will not accept charge current, or an internal fault has been detected in the charger. This fault will nearly always be set within the first 30 seconds of operation. Once it has been determined that the batteries and connections are not faulty and fault 6 is again displayed after interr upting AC power for at least 10 seconds, the charger must be brought to a qualified service depot.

3121827 – JLG Lift – 3-49

SECTION 3 - CHASSIS & TURNTABLE

1. AC Voltage - Input Cable

2. Charger Interlock Cable

3. DC Power Cable to Batteries

4. LED Indicator Cable

Figure 3-21. Battery Charger ((S/N 0300059350 to Present)

3-50 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

NO LIGHTS AT ALL

No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low. It could also indicate an internal failure in the charger.

1. Check the connections to AC power. Check for AC voltage between 90 and 260 VAC at the charger.

2. If the AC voltage is verified to be correct at the connection to the charger, and the charger still displays no lights at all, return the charger for service.

FAULT LED FLASHING

The Fault LED flashes to indicate the microcontroller inside the battery charger has detected a fault. The fault detected is indicated by the number of flashes. Count the number of flashes to determine the fault.

With any battery system, the most common problem will be a faulty battery connection. Because of the high likelihood of a battery connection problem, it is always worthwhile to confirm that all connections are good before checking for any other problems.

[1 Flash] - High Battery Voltage

1. Indicates a high battery voltage. Check that the battery charger voltage is consistent with the battery pack voltage. The first two digits of the four digit model name indicate the battery voltage the charger supports.

2. Check for wiring errors.

3. This fault will automatically clear and the charger will restart charging when this problem is removed.

4. High battery voltage could also occur if there is another source charging the battery. Disconnect any other sources during charging.

5. If this problem does not clear after the battery voltage is confirmed to be less than 2.4V per cell, return the charger for service.

[2 Flashes] - Low Battery Voltage

1. Indicates either a battery failure, no battery connected, or a lower than expected battery voltage. Check the battery and battery connections.

2. Check the nominal battery voltage. The first two digits of the four digit model name indicate the battery voltage the charger supports. Confirm that a nominal battery voltage is the same as the charger voltage.

3. This fault will clear automatically when the low battery voltage problem is rectified.

4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per cell and all connections are good, return the charger for service.

[3 Flashes] - Charge Timeout

Indicates the battery failed to charge within the allowed time. This could occur if the battery is of larger capacity than the algorithm is intended for. In unusual cases it could mean charger output is reduced due to high ambient temperature. It can also occur if the battery is damaged, old, or in poor condition.

1. Check the battery for damage such as shorted cells and insufficient water. Try the charger on a good battery.

2. If the same fault occurs on a good battery, check the connections on the battery and connection to AC, and the AC voltage itself.

3. Confirm that the nominal battery pack voltage is the same as the battery charger voltage.

4. This fault must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.

5. If a charger displays this fault on a battery pack, and the pack is of questionable status, reset the charger by disconnecting AC for 30 seconds, and then reconnect the AC to start a new charge cycle. After a few charge cycles, this problem could stop occurring as the pack "recovers."

[4 Flashes] - Check Battery

This fault indicates the battery pack could not be trickle charged up to the minimum level required for the normal charge cycle to be started.

1. Check that none of the battery pack connections between modules are reversed or incorrectly connected.

2. Check that one or more cells in the battery are no shorted.

3. Confirm that the nominal battery pack voltage is the same as the battery charger voltage.

4. Try the charger on a good battery.

5. If this fault occurs, the battery is likely in poor condition. Try to recover the pack with a charger that can charge the individual cells - such as an automotive charger. Be sure to set this charger to the appropriate voltage - 6V per 6V battery, 12V per 12V string/ battery.

3121827 – JLG Lift – 3-51

SECTION 3 - CHASSIS & TURNTABLE

[5 Flashes] - Over Temperature

This fault indicates the charger has become too hot during operation. Though not damanging to the charger, charge time will be extended significantly.

1. This fault indication will not clear automatically, but the charger will restart charging automatically when the temperature drops. The fault indicaiton must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.

2. If possible, move the machine to a cooler location.

3. Confirm that dirt or mud is not blocking the cooling fins of the charger. Clean the charger. Rinse the charger with a low pressure hose if required. Do no use high pressure. Do not us a pressure washer.

[6 Flashes] - Over Load/Over Temperature

This fault indicates that the batteries will not accept charge current, or an internal fault has been detected in the charger. This fault will nearly always be set within the first 30 seconds of operation. If it occurs after the charger has started charging normally, be sure to make a note of it.

1. Remove excessive AC loads from inverter if installed.

2. Try to clear the fault by unplugging the AC, waiting 30 seconds and reconnecting the ac power.

3. Check all battery connections. Look for a high resistance connection.The most likely reason for this fault is a fault in the battery such as a bad battery connection, an open cell, or insufficient water.

4. This fault will occur if an internal fuse inside the charger blows. If the green wire is shorted to ground even momentarily, this fuse will blow. To check the fuse, measure with an ohmmeter between the green and red wires with the AC disconnected. If a short circuit is not measured, the fuse has blown. Return unit to a service depot to have this fuse replaced.

Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell

These symptoms indicate over-charging or high battery temperature. These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack. The most likely cause for this problem is incorrect charge algorithm setting and/or high ambient temperatures.

1. Confirm that the battery pack is not too small - usually > 50Ah.

2. Confirm that the nominal battery voltage matches the charger output voltage.

3. Confirm the correct battery charge algorithm. If the battery pack is new, the algorithm will need to be changed if the pack is not the same as the old one. for instructions on how to determine and change the battery charge algorithm see the following sub-section.

4. If the output voltage of the charger seems excessive, return the charger for service. Contact JLG to get the expected battery voltage settings for the charger in question. Be sure to have the charger’s serial number and charge algorithm setting available when calling.

5. If this fault occurs after battery charging has started, confirm that AC power was not interrupted and that all battery connections are good.

6. If all battery connections are good, an internal fault has been detected and the charger must be brought to a qualified service depot.

3-52 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

Checking/Changing the Battery Charger Algorithm

The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4, Battery Algorithms.

NOTE: Contact JLG if your specific battery model is not

listed.

Each time AC power is applied with the battery pack not connected, the charger enters an algorithm select/display mode for approximately 11 seconds. During this time, the current Algorithm # is indicated on the Yellow Charging LED. A single digit Algorithm # is indicated by the number of blinks separated by a pause. A two digit Algorithm # is indicated by the number of blinks for the first digit followed by a short pause, then the number of blinks for the second digit followed by a longer pause.

To check / change the charging algorithm:

1. Disconnect the charger positive connector from the battery pack. Apply AC power and after the LED test, the Algorithm # will display for 11 seconds.

2. To change the algorithm, touch the connector to the battery’s positive terminal for 3 seconds during the 11 second display period and then remove. The Algorithm # will advance after 3 seconds. Repeat this procedure until the desired Algorithm # is displayed. A 30 second timeout is extended for every increment. Incrementing beyond the last Algorithm will recycle back to the first Algorithm. When the desired Algorithm is displayed, touch the charger connector to the battery positive terminal until the output relay makes a clicking noise (approx. 10 seconds). The algorithm is now in the permanent memory.

3. Remove the AC power from the charger and reconnect the charger’s positive connector to the battery. It is recommended to check a newly changed algorithm by repeating the above steps 1 and 3.

Table 3-4. Battery Algorithms

Proper

Algorithm # JLG P/N Battery Type

173 1001114782 DISCOVER EV 305A-A 43

173 0400055 US BATT L16 173

Algorithm

Setting

3121827 – JLG Lift – 3-53

SECTION 3 - CHASSIS & TURNTABLE

3.12 GENERATOR (PRIOR TO S/N 88539)

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 for Call To Start, which is the electronic 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, DC output alternator. 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 45 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.

The start control relay is located on the fuel solenoid bracket on the right side of the engine. The start control 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 control relay is energized 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 the hold coil is energized by the fuel control relay.

Engine Oil Temperature Sensor

The engine oil temperature sensor is used to sense the 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 current sensor provides a signal proportional 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.

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.

Engine Starter

The engine is equipped with a 12 Volt DC starter. This starter provides mechanical power to crank the engine. Electrical power for the starter is provided by the start battery. The starter is energized by the start control relay.

Start Control Relay

The start control relay energizes the solenoid of the engine starter and the pull coil of the engine fuel solenoid.

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 controller to determine starter cut-out, overspeed fault, and underspeed fault. This signal has fail-safe 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 Low Oil Pressure Switch

The engine is equipped with a low oil pressure switch. The switch is closed when the oil pressure is below 14.2 psi (1 Bar)

Timing Sequences

• RBS Pre-start Sequence

1. Time Delay Engine Start (TDES)

TDES is the period which the RBS waits to verify that the CTS is valid rather than a transient condition.

3-54 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-22. Generator Components

3121827 – JLG Lift – 3-55

SECTION 3 - CHASSIS & TURNTABLE

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 3-5. RBS Prestart Sequence

CTS (Call to Start)

TDES (Engine Start)

Preheat Delay

RBS Startup Sequence

• RBS Startup Sequence

3. Crank Time

The RBS will crank for a period up to the crank time or until the engine starts.

4. Rest Time

If the engine does not successfully start, the RBS will wait for the rest time before attempting to crank the engine again.

5. Crank Cycles

The RBS will attempt to start the engine up until the number of crank cycles is reached. If the RBS does not start, an Over crank fault is indicated.

6. 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 3-6. 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 have been removed, the RBS will begin the shutdown sequence. If a CTS condition is 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 cool down period.

Time Delay Cool down (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.

Table 3-7. RBS Shutdown Sequence

Remove CTS

TDER Engine Run

TDC Cooldown

Engine Stop

3-56 – JLG Lift – 3121827

SECTION 3 - CHASSIS & TURNTABLE

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 ground control station and connect the remaining end of the cable to the analyzer.The ground control module contains the settings 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 Analyzer 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 3-23., Generator System Analyzer Flow Chart

Alarms and Fault Flash Codes

In the event of an RBS alarm, a flash code will be issued and an alarm indicated on the analyzer.

NOTE: Alarms must be reset once the fault has been cor-

rected.

Table 3-8. 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

oil pressure

High Engine Temperature

Engine Overspeed Shutdown due to high engine

Engine Underspeed/Overcrank

No Speed Signal S hut d o wn d u e to l oss o f

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 RBS off or disabled; Will not

Shutdown due to high engine oil temperature

speed

Shutdown due to engine overcrank or underspeed

speed signal

voltage

Alarm not a shutdown; Indicates problem with the engine starting system

Shutdown due to loss of voltage sensing

can respond to any CTS

respond to any CTS

3121827 – JLG Lift – 3-57

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-23. Generator System Analyzer Flow Chart

3-58 – JLG Lift – 3121827

JLG M400 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

C MAINTENANCE

B HYDRAULIC SYSTEM SAFETY

SECTION 1. SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

1.2 CAPACITIES

1.5 HYDRAULIC PUMP/ELECTRIC MOTOR ASSEMBLY

1.6 GENERATOR

1.7 TIRES

1.3 BATTERY CHARGER

1.4 DRIVE SYSTEM

1.8 DIMENSIONAL DATA 1.9 FUNCTION SPEEDS

Machine Orientation When Doing Function Tests

1.10 TORQUE SPECIFICATIONS

1.11 CYLINDER SPECIFICATIONS

1.12 MAJOR COMPONENT WEIGHTS

1.13 CRITICAL STABILITY WEIGHTS

1.14 PRESSURE SETTINGS

1.15 SERIAL NUMBER LOCATIONS

Lubrication Specifications

1.16 LUBRICATION

1.17 OPERATOR MAINTENANCE & LUBRICATION

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

Preparation, Inspection, and Maintenance

Pre-Start Inspection

Pre-Delivery Inspection and Frequent Inspection

Annual Machine Inspection

Preventive Maintenance

2.2 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

Lubrication and Servicing

Bolt Usage and Torque Application

2.3 LUBRICATION AND INFORMATION

Hydraulic System

Hydraulic Oil

Changing Hydraulic Oil

Lubrication Specifications

2.4 CYLINDER DRIFT TEST

Platform Drift

Cylinder Drift

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

2.6 WELDING ON JLG EQUIPMENT

Do the Following When Welding on JLG Equipment

Do NOT Do the Following When Welding on JLG Equipment

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Tire Inflation

Tire Damage

Tire Replacement

Wheel Replacement

Wheel Installation

3.2 SPINDLE

Specifications

Checking

Setting Wheel Bearing End Play

Greasing Requirements

3.3 DRIVE HUB (PART NO. 2780236)

Dissembling

Disassembly

Disassembly of the first stage planetary assembly (7)

Disassembly of second stage planet gears (1)

Assembly of first stage planetary assembly (7)