JLG M600 Service Manual

Download

Page 1

Service and Maintenance Manual

Model

E600

E600J

E600JP

M600

M600J

M600JP

P/N - 3121117

December 18, 2012

Page 2

Page 3

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

AGENERAL

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.

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

B HYDRAULIC SYSTEM SAFETY

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

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

CMAINTENANCE

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

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

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3121117 – JLG Lift – A-1

Page 4

INTRODUCTION

REVISON LOG

Original Issue - July 25, 2000 Revised - October 17, 2000 Revised - April 15, 2003 Revised - February 11, 2008 Revised - December 18, 2012

A-2 – JLG Lift – 3121117

Page 5

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

SECTION 1 - SPECIFICATIONS

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

1.2 Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.5 Drive/Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.7 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.8 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

1.10 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.11 Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.12 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.13 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SECTION 2 - GENERAL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3121117 – JLG Lift – i

Page 6

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

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

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

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

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

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

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

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

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

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 Drive Hub -REAR (Prior to S/N 0300112585) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Disengaging for Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Engaging after Towing is Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

Disassembly of Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

Initial Start-Up and After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

3.3 Drive Hub (S/N 115723 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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

Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Planet Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Hub-Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Cover Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.4 Drive Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.5 Speed Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Speed Sensor Installation Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Verification w/ Analyzer Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.6 Oscillating Axle Lockout Test (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3.7 Oscillation Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Bleeding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Checking Oscillation Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

ii – JLG Lift – 3121117

Page 7

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

3.8 Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Roll, Leak and Brake Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Hub-shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Hub-Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Motor-Brake Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Motor-Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Tube Fitting Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Procedure for Setting Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.9 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Replacement of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Swing Bearing Torque Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Swing Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Setting Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3.10 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

Battery Maintenance, Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

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

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

Removing the Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3.11 Generator (Prior to S/N 88375) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52

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

To Connect the JLG Control System Analyzer to the Generator . . . . . . . . . . . . . . . . . . . . . 3-55

Alarms and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Output Current and Voltage Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Priming the Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3.12 Generator (S/N 88375 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-59

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Dynamo and Dynamo Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Dynamo Output Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Control Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Start Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

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

Start Control Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Fuel Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Glow Plug Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Fuel Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Engine Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Engine Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Alternator Output Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

RBS Engine/Generator Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

3121117 – JLG Lift – iii

Page 8

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

Warnings and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

System Status and Performance Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

System Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

RBS Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

RBS shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

RBS Alarms and Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Resetting the RBS Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

APU Engine Start Battery Boosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

3.13 Supplementary fuse for Engine Generator Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Tools And Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70

SECTION 4 - BOOM & PLATFORM

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

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

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

4.2 Load Cell Calibration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4.3 Platform Rotator (Prior to S/N 0300130810) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Assembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.4 Platform Rotator (S/N 0300130810 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4.5 Jib Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Testing the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

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

Lift, Telescope, Slave, Master, Oscillation (if equipped), Jib (if equipped), and Steer . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

iv – JLG Lift – 3121117

Page 9

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

5.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.5 Pressure settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

Proportional Main Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Lift Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Flow Control / Bang Bang Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Platform Level Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Platform Level Up Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Jib Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

SECTION 6 - JLG CONTROL SYSTEM

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

6.2 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.3 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

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

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

6.6 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6.7 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6.8 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6.9 Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

Help Descriptions and Fault Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.10 Analyzer Diagnostics Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6.11 System Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29

3121117 – JLG Lift – v

Page 10

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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

7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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

Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3 Checking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

Basic Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .7-4

7.5 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 7-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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

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

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

7.6 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

vi – JLG Lift – 3121117

Page 11

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

2-1. Operating Temperature Specifications - Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

3-1. Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-2. Main Disassembly Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-3. Main Disassembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3-4. Output Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-5. Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-6. Input Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-7. Hub Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-8. Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-9. Hub Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

3-10. Hub Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3-11. Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-12. Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-13. Drive Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-14. Speed Sensor Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-15. Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-16. Oscillating Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-17. Axle Oscillation Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-18. Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-19. Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-20. Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-21. Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-22. Hub Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-23. Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-24. Setting Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-25. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3-26. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3-27. Swing Drive and Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

3-28. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-29. Battery Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

3-30. Batteries and Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

3-31. Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

3-32. Battery Charger Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

3-33. Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53

3-34. Generator System Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56

3-35. Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

4-1. Boom Assembly - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-2. Boom Assembly - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-3. Boom Assembly - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-4. Boom Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-5. Transport Limit Switch (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-6. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-7. Load Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-8. Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-9. Platform Rotator Assembly - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-10. Rotary Actuator - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-11. Rotary Actuator - Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4-12. Operating Principle - Jib Rotator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

3121117 – JLG Lift – vii

Page 12

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

4-12. Jib Rotator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

4-13. Tool for Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

4-14. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-2. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-4. Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-5. Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-6. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-7. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-8. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-9. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-10. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-11. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-12. Gar-Max Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-13. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-14. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-15. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-16. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-17. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-18. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-19. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-20. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-21. Hydraulic Tank and Pump (Prior to S/N 51941) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

5-22. Hydraulic Tank and Pump (S/N 51941 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

5-23. Hydraulic Control Valve - Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

5-24. Hydraulic Control Valve - Platform Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

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

6-2. Analyzer Flow Chart - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

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

6-4. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

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

7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

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

7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7-7. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-8. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-9. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

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

7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-18. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7-19. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7-20. Electrical Schematic - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

7-21. Electrical Schematic - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

7-22. Electrical Schematic - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

7-23. Electrical Schematic - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17

7-24. Hydraulic Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-25. Hydraulic Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

viii – JLG Lift – 3121117

Page 13

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

This page left blank intentionally.

3121117 – JLG Lift – ix

Page 14

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-3 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-4 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-5 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-6 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-7 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-8 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-9 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-10 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-11 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-12 Mobil DTE 11M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

1-14 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-15 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

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

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

2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

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

3-2 Drive Brake Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

3-3 RBS Prestart Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

3-4 RBS Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

3-5 RBS Shutdown Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

3-6 Generator System Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3-7 Controller Interface Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64

3-8 RBS Alarms and Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

3-9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

5-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

6-1 Machine Setup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-2 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6-3 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-4 JLG Control System Flash Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-5 Help Descriptions and Fault Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-6 ADJUSTMENTS - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-7 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-8 Calibration Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27

6-9 Calibration Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

6-10 System Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29

6-11 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

x – JLG Lift – 3121117

Page 15

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Table 1-1. Capacities

Generator Fuel Tank (M Models Only) 13 gallons (49.2 liters)

Hydraulic Tank Prior to S/N 51941 S/N 51941 to Present

Drive Hub 0.4 gal. (1.5 liters)

15 gallons (57 liters)

15.9 gal.(60.2 L)

12.4 gal. (46.9 L) to full mark

1.2 OPERATING SPECIFICATIONS

Table 1-2. Operating Specifications

Maximum Work Load (Capacity) U n re s tr i ct e d: 5 00 l b (2 3 0 k g )

Maximum Travel Grade (Gradeability) with Boom retracted and approximately horizontal. Tower Boom fully lowered.

Maximum Travel Grade (Side Slope) with Boom retracted and approximately horizontal. Tower Boom fully lowered. 5°

Tilt Alarm Setting (See Section 3) A NS I , CS A CE E/M600 & E/M600J C E E / M 60 0 JP

Maximum Vert ical Platform Height: 60 ft. (18.29 m)

Maximum Horizontal Platform Reach E 60 0 E 60 0 J

Machine Width 2 WD 4 WD

Machine Length E /M 6 0 0 E /M 6 0 0J E /M 6 0 0J P

Tur ning Radius (outside) 15 ft. 3 in. (4.65 m)

Tur ning Radius (inside) 4 ft. (1.23 m)

Maximum Tire Load: 7700 lbs. (3500 kg)

Maximum Ground Bearin g Pres sure E600J/M600J E600JP/M600JP

Maximum Drive Speed: 3.0 mph (1.3 m/s)

Electrical System Voltage 48 volts

Maximum Hydraulic System Pressure 3200 psi (221 Bar)

Maximum Wind Speed 28 mph (12.5 m/s)

43 ft. (13. 11 m)

42 ft. 9 in. ( 13.11 m)

7 ft. 11 7/16 in. (2.42 m)

7 ft. 11 3/8 in. (2.42 m)

30 ft. 11 5/16 in. (9.43 m) 30 ft. 8 15 /16 in. (9.37 m)

33 ft. 3 3/4 in. (10.15 m)

52 psi (3.7 kg/cm 51 psi (3.6 kg/cm

30%

Table 1-2. Operating Specifications

Maximum Manual Force 400N

Gross Machine Weight (Platfor m Empty) E600J/M600J E600JP/M600JP

16,300 lb. (7,393 kg) 16,800 lb. (7,620 kg)

1.3 GENERATOR

Table 1-3. Generator

Alternator Output 58 volts @ 45 Amps

RPM’s under max. load 3100

Start B atter y 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

1.4 BATTERY CHARGER

Table 1-4. Battery Charger

5° 4° 3°

AC Input 120V - 240V Auto Seeking

AC Draw 17 amps at start of charging

DC Output 48 volts, 23 amps

1.5 DRIVE/STEER SYSTEM

Table 1-5. Drive System

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

tinuous, rotation - reversible

Drive Brake spring-applied, hydraulically released

1.6 TIRES

Table 1-6. Tires

Size Type Pressure

36/14 LL-22.5 pneumatic 55 psi (4.0 Bar)

36/14 LL-22.5 f oam filled N/A

3121117 – JLG Lift – 1-1

Page 16

SECTION 1 - SPECIFICATIONS

1.7 FUNCTION SPEEDS

Table 1-7. Function Speeds

Lift Up 55-61

Lift Down 55-61

Swing Right & Left 72-84

Telescope Out 46-50

Telescope In 46-50

Platform Rotate Left & Right 24-26

Jib Up 25-27

Jib Down 21-23

Jib Swing 30-40

High Drive (200 ft.) 42-46 (3.0 mph)

Drive above Horizontal (50 ft.) 65-71 (0.5 mph)

Machine Orientation When Doing Speed Tests

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

Swing: Boom at Full Elevation. Telescope Retracted. Swing the Turntable to the end stop. Swing the Opposite Direction, Record Time.

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

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

Drive (Above Horizontal): Test should be done on a smooth level surface. The Platform Speed Knob should be selected out of the 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.

Test No tes

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

2. Drive test results reflect 36/14LL-22.5 tires.

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

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

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

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

4150273-N

1.8 PRESSURE SETTINGS

Table 1-8. Pressure Settings

SETTING PSI BAR

Proportional Main Relief 3200 220

Bang Bang Main Relief 3000 207

Lift Up 2500 172

Lift Down 1100 76

Swing 2500 172

Swing Brake 320 22

Steer 1800 124

Platform Level Up 2500 172

Platform Level Down 1500 103

Jib Up 2300 158.5

Jib Down 2300 158.5

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

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

1-2 – JLG Lift – 3121117

Page 17

SECTION 1 - SPECIFICATIONS

Figure 1-1. Serial Number Location

SERIAL NUMBER

PLATE

SERIAL NUMBER

STAMPED ON FRAME

1.9 TORQUE REQUIREMENTS

Table 1-9. Torque Requirements

Description Tor qu e Value (Dry) Interval Hours

Wheel Lugs 170 ft. lbs.(238 Nm) 150

T/T Counterweight Bolts

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

*Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter. (See Swing Bearing in Section 3.)

NOTE: When maintenance becomes necessary or a fas-

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

400 ft.lbs.(560 Nm) A/R

1.10 MAJOR COMPONENT WEIGHTS

Table 1-10. Component Weights

Component Pounds Kilograms

Frame (bare) 1381 626

T/T (bare) 2093 950

Boom Assembly (E/M 600) 4464 2025

Boom Assembly (E/M 600J) 4464 2025

Tire & Wheel 226 1 02.5

Swing Drive 70 32

Swing Bearing 100 45.4

Platform Console 25 11

Side Entry Platform - 30x72 (bare) 175 80

Side Entry Platform - 30x48 (bare) 144 66

Counterweight 2560 1161

Foam Fill (Filled Tires) 441 200

1.11 SERIAL NUMBER LOCATION

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

3121117 – JLG Lift – 1-3

Page 18

SECTION 1 - SPECIFICATIONS

Table 1-11. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F (-18° to +83° C)

10W

+0° to + 210° F (-18° to +99° C)

10W-20, 10W30

+50° to + 210° F (+10° to +99° C

20W-20

Table 1-13. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Viscosity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

Table 1-14. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)

Flash Point 500°F (260°C)

Operating Temp. 0 to 180°F (-17 to 16 2°C)

Weight 7.64 lb. per g al.

(0.9 kg per liter)

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

1.12 HYDRAULIC OIL

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

to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service.

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

Table 1-12. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Point, M ax -4 0°F (-4 0°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

1-4 – JLG Lift – 3121117

Page 19

SECTION 1 - SPECIFICATIONS

Figure 1-2. Operator Maintenance and Lubrication Diagram

3,4

Table 1-15. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of

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

EPGL Extreme Pressure Gear Lube (oil) meeting API Service

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

HO Hydraulic Oil. Mobil DTE-11M

O G* Op e n G e ar L u be - Tr ib o l M o lub-Alloy 936 Open Gear Com-

pound. (JLG Part No. 3020027)

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

460.

LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG

Part No. 3020022)

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

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

1.13 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Fig-

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

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

3121117 – JLG Lift – 1-5

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.

NOTE: It is recommended as a good practice to replace all

filters at the same time.

1. Swing Bearing - Internal Ball Bearing

Lube Point(s) - 1 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

Page 20

SECTION 1 - SPECIFICATIONS

FILL

DRAIN

2. Generator Engine (If Equipped)

4. Hydraulic Filter

Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. Comments - Under certain conditions, it may be necessary to replace the filter on a more frequent basis.

5. Swing Drive Hub (S/N 58845 to Present)

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.

3. Hydraulic Tank

Lube Point(s) - Fill Cap Capacity Prior to S/N 51941 - 15 gal. tank (56.7 L) S/N 51941 to present - 15.9 gal. system (56.7L)

12.4 gal. (46.9 L) to Full Mark Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation.

Lube Point(s) - Level/Fill Plug Capacity - 24 oz. (0.7 L) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation

1-6 – JLG Lift – 3121117

Page 21

6. Wheel Drive Hub

Lube Point(s) - Level/Fill Plug Capacity - 0.4 gal. (1.5 L) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation

SECTION 1 - SPECIFICATIONS

3121117 – JLG Lift – 1-7

Page 22

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)

1-8 – JLG Lift – 3121117

Page 23

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

3121117 – JLG Lift – 1-9

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

Page 24

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 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 AP PLY TO CADMIUM PLATED FASTENERS

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

1-10 – JLG Lift – 3121117

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

Page 25

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 TORQU E 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

SECTION 1 - SPECIFICATIONS

3121117 – JLG Lift – 1-11

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

Page 26

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 KN [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)

1-12 – JLG Lift – 3121117

Page 27

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 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

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

3121117 – JLG Lift – 1-13

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

Page 28

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 HAR DEN ED WASHER OR FASTENER IS PLAC ED AGAINST PLATED STEEL OR RAW ALUMINUM

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

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

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

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

1-14 – JLG Lift – 3121117

Page 29

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 Preventative Maintenance Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

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 Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.

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

Preventative Maintenance

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

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

3121117 – JLG Lift – 2-1

Page 30

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type 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

Preventative 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 a nd Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qu alified JLG

Owner, Dealer, or User Factory-Certified

Owner, Dealer, or User Qu alified 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

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 – 3121117

Page 31

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

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

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

Hydraulic Lines and Electrical Wiring

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

Hydraulic System

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

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

Lubrication

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

Battery

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

Lubrication and Servicing

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

Bolt Usage and Torque Application

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

3121117 – JLG Lift – 2-3

Page 32

SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION

Hydraulic System

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

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

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

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

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

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.

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-11M hydraulic oil for this machine.

NOTE: Start-up of hydraulic system with oil temperatures

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

2-4 – JLG Lift – 3121117

Page 33

SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST

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

Platform Drift

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

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

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

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

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

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

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

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

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

ing.

d. Debris embedded in liner surface.

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

a. Detectable wear in the bearing area.

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

surface.

c. Rusting of the pin in the bearing area.

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

a. Housing should be blown out to remove all dirt

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

b. Bearing / pins should be cleaned with a solvent

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

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

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

3121117 – JLG Lift – 2-5

Page 34

SECTION 2 - GENERAL

2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to

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

Do the Following When Welding on JLG Equipment

• Disconnect the battery.

• Disconnect the moment pin connection (where fitted)

• Ground only to structure being welded.

Do NOT Do the Following When Welding on JLG Equipment

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

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

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

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

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

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

2.7 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS

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

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

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

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

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

NOTE: Over a period of time, oxidation increases electrical

resistance at the connection, eventually causing circuit failure.

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

NOTE: This condition is especially common when machines

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

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

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

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

2-6 – JLG Lift – 3121117

Page 35

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Boom Assembly

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

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

Pivot Pins and Pin Retainers 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pads 1,2 1,2

Covers or Shields 1,2 1,2

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

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 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 1,2,14 1,2,3,13,14

Swing Drive System 11 11

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

Steer Components

Drive Motors

Drive Hubs 11 11

Functions/Controls

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

Pre-Start

Inspection

Preventive

Maintenance

Weekly

Monthly

Preventive

Maintenance

Pre-Delivery or Frequent

Inspection

Annual

(Yearly)

Inspection

Every 2

Years

3121117 – JLG Lift – 2-7

Page 36

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

Emergency Stop Switches (Ground & Platform) 555

Function Limit or Cutout Switch Systems 555

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 33

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

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 11,9 2 1,5 1,5

Hydraulic/Electric System

Hydraulic Pumps 1,9 1,2,9

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

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

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

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

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 12020

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

General

Operators and Safety Manuals in Sto rage Box 21 21 21

ANSI and EMI Manuals/Handbooks Installed 21

Capacity Decals Installed, Secure, Legible 21 21 21

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

Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

Annual

(Yearly)

Inspection

Every 2

Years

2-8 – JLG Lift – 3121117

Page 37

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

Preventive

Maintenance

Weekly

Monthly

Preventive

Maintenance

Pre-Delivery or Frequent

Inspection

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

Annual

(Yearly)

Inspection

Every 2

Years

3121117 – JLG Lift – 2-9

Page 38

SECTION 2 - GENERAL

Figure 2-1. Operating Temperature Specifications - Kubota

4150548 D

2-10 – JLG Lift – 3121117

Page 39

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:

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)

Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a

3121117 – JLG Lift – 3-1

Page 40

SECTION 3 - CHASSIS & TURNTABLE

2. Tighten nuts in the following sequence:

ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL.

THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE. THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY.

ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION. ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE.

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 DRIVE HUB -REAR (PRIOR TO S/N

0300112585)

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.

1. Remove the two hex head bolts from the cover.

2. Remove the cover.

Disengaging for Towing

PRIOR TO OPERATING THE DISCONNECT THE MACHINE HAS TO BE ON LEVEL GROUND AND COMPLETELY SECURED FROM ANY MOVEMENT, I.E. VIA TOW BAR TO PULLING VEHICLE. THE MACHINE SHOULD NOT BE MOVED UNLESS IT IS SECURED TO THE TOWING VEHICLE TO PREVENT RUNAWAY.

3-2 – JLG Lift – 3121117

Page 41

3. Rotate the cover to show the inside diameter

SECTION 3 - CHASSIS & TURNTABLE

THE GEAR DRIVE TEMPERATURE SHOULD BE CHECKED PRIOR TO ANY WORK BEING DONE. THIS IS IMPORTANT IF THE GEAR DRIVE HAS RECENTLY BEEN OPERATED SINCE IT MAY BE HOT AND CAUSE INJURY.

ENSURE THE AREA SURROUNDING THE DISCONNECT IS CLEANED PRIOR TO OPERATION. ENSURE THAT DIRT OR OTHER CONTAMINANTS DO NOT ENTER THE GEAR DRIVE.

THE COVER IS UNDER SPRING FORCE

1. Remove the 2 hex head bolts securing the cover evenly and remove the cover.

4. Press the cover sufficiently against the shift rod to insert the bolts at least 2 to 3 threads into the cover. This will subject the shift rod to spring force.

5. Install the bolts and torque 6.3 ft. lbs. (8.8 Nm) until they are flush with the cover.

6. The sun gear shaft and input shaft are now disconnected and the machine is ready to be towed.

BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHICLE, EITHER THE GEAR DRIVE HAS TO BE REENGAGED OR SUITABLE MEASURES MUST BE TAKEN TO SECURE THE MACHINE FROM MOVEMENT.

Engaging after Towing is Complete

2. Rotate the cover 180 degrees and secure with the two hex head bolts.

3. Torque the hex head bolts 6.3 ft.lbs. (8.8 Nm).

PULL VERY SLOWLY WITH THE TOWING VEHICLE CONNECTED TO THE MACHINE TO ALLOW THE SPLINE OF THE SUN GEAR SHAFT TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT.

DO NOT OPERATE THE MOTOR TO MAKE THE SUN GEAR SHAFT TO ENGAGE WITH THE SPLINE OF THE INPUT SHAFT.

4. Check to ensure all bolts are tight and all components are returned to their original positions.

5. The gear drive should now be reengaged and the machine can be disconnected from the towing vehicle.

ENSURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL.

3121117 – JLG Lift – 3-3

Page 42

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. Roller Bearing

13. Not Used

14. Retaining Ring

15. Retaining Ring

16. Retaining Ring

17. Suppo rt Disk

18. Not Used

19. O-ring

20. Rin g Seal

21. Plug

22. Rin g Seal

23. Bo lt

24. Ball

25. Expander

26. to 28. Not Used

29. Housing Washer

29. Ring Gear

31. & 32. Not Used

33. O-ring

34. Retaining Ring 35 to 42. Not Used

43. Sun Gear Shaf t

44. Input Shaft

45 to 48. Not Used

49. Thr ust Washer

50. Not Used

51. Cover

52. Disk

53. Bolt

54. O-ring

55. Pressure Spring

56. Shaft Rod 57 & 58. Not Used

59. Disk Rotor

60. Spindle

61. Not Used

62. Coupler 63 to 65. Not Used

66. Snap Ring

67 to 80. Not Used

81. Ball Bearing

82. Snap Ring

83. Snap Ring 84 to 87. Not Used

88. Wheel Stud

Figure 3-1. Torque Hub

3-4 – JLG Lift – 3121117

Page 43

SECTION 3 - CHASSIS & TURNTABLE

Disassembly

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).

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.

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.

Disassembly of Cover

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)

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 stay rings (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).

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.

3121117 – JLG Lift – 3-5

Page 44

SECTION 3 - CHASSIS & TURNTABLE

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).

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 (21) and screw plugs (22).

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 0.2 us gallons (0.8 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.

3.3 DRIVE HUB (S/N 115723 TO PRESENT)

Roll and Leak Testing

Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit’s gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests.

THE ROLL TEST

The purpose of the roll test is to determine if the unit’s gears are rotating freely and properly. You should be able to rotate the gears in your unit by applying constant force to the roll checker. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others. Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency.

THE LEAK TEST (MAIN UNIT)

The purpose of a leak test is to make sure the unit is air tight. You can tell if your unit has a leak if the pressure gauge reading on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main seal or wherever o-rings or gaskets are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o-rings or gaskets

3-6 – JLG Lift – 3121117

Page 45

SECTION 3 - CHASSIS & TURNTABLE

meet on the exterior of the unit, then checking for air bubbles. If a leak is detected in a seal, o-ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi for 20 minutes.

Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque.

The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle.

1. Tighten (but do not torque) bolt "A" until snug.

2. Go to the opposite side of the bolt circle and tighten

bolt "B" until equally snug.

3. Crisscross around the bolt circle and tighten remaining bolts.

4. Now use a torque wrench to apply the specified torque to bolt "A".

5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts.

Main Disassembly

1. Perform Roll Check and Leak Check if applicable prior to disassembling the unit.

2. Drain oil from unit. Note the condition and volume of the oil.

3. Remove Coupling (7) from Spindle End first.

4. Remove Retaining Ring (6G) by prying the open end

of Retaining Ring out of the groove in the Ring Gear (1F) with a screwdriver, then grasp the loose end with pliers and pull the Retaining Ring completely out of the groove.

5. Remove the Cover Subassembly (6) from the unit. The unit can be carefully pressurized with air to pop the cover out of the unit. Washer (2) may have to be removed separately because of the loose attachment.

6. Remove the First Stage Sun Gear (10) if applicable.

NOTE: On units with ratios greater than 36:1 numerically,

there will not be a separate First Stage Sun Gear (10), as the gear teeth will be integral to the Input Shaft (9).

7. Remove the Input Carrier Sub-assembly (3). Continued on next page.

8. Remove the Second Stage Sun Gear (11).

9. Remove the Input Shaft (9).

NOTE: On units with a ratio 48:1, the Sun Gear (11) and the

Input Shaft (9) will need to be removed together.

10. Remove the Output Stage Carrier Sub-assembly (4)

11. Loosen and remove the three Flat Head Bolts (19)

that retain the Ring Gear (1F) to the Housing (1G).

12. Lift the Ring Gear (1F) off of the Housing (1G).

13. Remove the O-ring (18) from between the Housing

(1G) and the Ring Gear (1F).

3121117 – JLG Lift – 3-7

Page 46

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-2. Main Disassembly Drawing 1

1F. Ring Gear 1G. Housing

2. Washer

3. Input Carrier Subassembly

4. Output Carrier Subassembly

6. Cover Assembly 6G. Retaining Ring

7. Coupling

9. Input Shaft

10. First Stage Sun Gear

11. Second Stage Sun Gear

15. I.D. Plate

18. O-ring

19. Flat Head Bolts

3-8 – JLG Lift – 3121117

Page 47

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-3. Main Disassembly Drawing 2

1F. Ring Gear 1G. Housing

4. Output Carrier Subassembly

5. Retaining Ring

6. Cover Assembly 6G. Retaining Ring

9. Input Shaft

10. First Stage Sun Gear

11. Second Stage Sun Gear

18. O-ring

19. Flat Head Bolts

20. Retaining Ring

3121117 – JLG Lift – 3-9

Page 48

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-4. Output Carrier

4 A O ut p ut C ar ri e r 4 B T hr u st Wa s he r 4C Needle Bearing 4 D T hr u st S pa ce r

4E Planet Shaft 4F Planet Gear 4 G R ol l Pi n 4 H T hr u st Wa s he r

Output Carrier Disassembly

1. Using a 1/8" diameter punch, drive the Roll Pin (4G) into the Planet Shaft (4E) until it bottoms against the Carrier (3A).

2. Using a soft face hammer, tap the Planet Shaft (4E) out of the Carrier (4A).

3. Using a 1/8" diameter punch, drive the Roll Pin (4G) out of the Planet Shaft (4E). NOTE: The Roll Pins (4G) should not be reused when reassembling the unit.

4. Slide the Planet Gear Sub-assembly (4) out of the Output Carrier (4A) being careful to not drop the Needle Bearings (4C) in the process.

3-10 – JLG Lift – 3121117

Page 49

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-5. Planet Gear

1 F O ut p ut Ca r ri e r 4 B T hr u st Wa s he r 4C Needle Bearing 4D Thrust Spacer 4F Planet Gear

5. Remove 4 Thrust Washers (4B), 28 Needle Rollers (4C) and the Thrust Spacer (4D) from the Second Stage Planet Gear (4F).

6. Repeat Steps 1 though 5 for the remaining two Planet Gears (4F).

7. Remove the Thrust Washer (4H) from the counterbore in the Output Carrier (4A).

3121117 – JLG Lift – 3-11

Page 50

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-6. Input Carrier

3 A C ar r ie r 3 B T hr u st Wa s he r 3C Needle Bearing 3E Planet Shaft 3F Planet Gear 4 G Ro l l P i n

Input Carrier Disassembly

1. Using a 1/8" diameter punch, drive the Roll Pin (4G) into the Planet Shaft (3E) until it bottoms against the Carrier (3A).

2. Using a soft face hammer, tap the Planet Shaft (3E) out of the Carrier (3A).

3. Using a 1/8" diameter punch, drive the Roll Pin (4G) out of the Planet Shaft (3E). NOTE: The Roll Pins

(4G) should not be reused when reassembling the unit.

4. Slide the Planet Gear (3F) and the two Thrust Washers (3B) out of the Carrier (3A).

5. Remove the 14 needle Bearings (3C) from the bore of the Planet Gear (3F).

6. Repeat steps 1 through 5 for each of the two remaining planet gears.

3-12 – JLG Lift – 3121117

Page 51

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-7. Hub Spindle

1 A S pi n dl e 1D Tapered Bearing Cup 1E Tapered Bearing Cone 1G Hub (Housing)

1 H S tu d 1J Retaining Ring Ext. 1N Spacer 1Q Seal Boot

Hub-Spindle Disassembly

1. Place unit on bench with Spindle (1 A) end down.

2. Remove Retaining Ring (1J) with appropriate tool.

3. Remove Spacer (1N).

4. Remove "A" position Bearing Cone (1C) from Bear-

ing Cup (1D) in Hub (1G).

5. Lift Hub (1G) off of Spindle (1 A). Remove Boot Seal (1Q) from Hub (1G) if applicable.

6. If necessary, press 9 Studs (1H) out of Hub (1G). Locate Hub (1G) on Seal (1B) end.

7. Remove Seal (1B) from Hub (1G).

NOTE: The Seal (1B) should NOT be reused when reassem-

bling the unit.

8. Remove "B" position Bearing Cone (1E) from Hub (1G).

9. Using a soft steel rod, knock both Bearing Cups (1D) out of Hub (1G).

3121117 – JLG Lift – 3-13

Page 52

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-8. Cover Assembly

2 T h ru s t S pa c er 3 A I np u t C a rr ie r 6 A C ov e r 6B Disengage Cap 6 C B ol t , H e x 6D Dowel Pin 6E O-ring 6F Pipe Plug 1 7 O -r i ng

Cover Disassembly

1. Remove O-Ring (17) from groove in Cover (6A).

2. Remove Thrust Washer (2) from Cover (6A) pockets.

3. Unscrew two Hex Head Bolts (6C) and remove Dis-

engage Cap (6B) from Cover (6A).

4. Pull Disengage Rod (6D) out from Cover (6A).

5. Use appropriate tool to remove O-ring (6E) from

internal groove in Cover (6A).

6. Remove two O-Ring Pipe Plugs (6F) from Cover (6A).

3-14 – JLG Lift – 3121117

Page 53

SECTION 3 - CHASSIS & TURNTABLE

Input Carrier Assembly

(Refer to Figure 3-6., Input Carrier)

1. Apply a liberal coat of grease to the bore of one Input Planet Gear (3F).

2. Line the inside of the Planet Gear (3F) with 14 Needle Rollers (3C).

NOTE: The last roller installed must be installed end wise.

That is, the end of the last roller must be placed in between the ends of the two rollers which form the space, and then slid, parallel to the other rollers, into place.

3. Set Carrier (3A) in an upright position.

4. Insert a Planet Shaft (3E) into the planet shaft hole in

the end of the Carrier (3A) opposite the splined end. The end of the planet shaft that does NOT have the roll pin hole should be inserted into the carrier FIRST.

5. Place one Thrust Washer (3B) onto the end of Planet Shaft (3E). Make sure the flat faces towards the inside of the carrier and make sure the button fits in the pocket on the inside of the Carrier (3A) towards the OD.

6. Following the thrust washer, place Planet Gear (3F) with needle rollers, onto Planet Shaft (3E).

Output Planet Gear Assembly

(Refer to Figure 3-5., Planet Gear)

1. Apply a liberal coat of grease to the bore of one Output Planet Gear (4F).

2. Line the inside of the Planet Gear (4F) with 14 Needle Rollers (4C).

NOTE: The last roller installed must be installed end wise.

That is, the end of the last roller must be placed in between the ends of the two rollers which form the space, and then slid, parallel to the other rollers, into place.

3. Place Spacer (4D) into the bore of the Output Planet (4F).

4. Repeat Step 2 to put in second roll of Needle Rollers (4C).

5. Apply grease to hold two Thrust Washers (4B) together and onto Output Planet Gear (4F) counterbore. Do the same to the other side.

6. Repeat Steps 1 -5 to finish the assembly of the two remaining Output Planet Gears (4F).

7. Following the planet gear, place one more Thrust Washer (3B) onto Planet Shaft (3E). Align the Thrust Washer (3B) in the same manner described in Step

8. Now insert Planet Shaft (3E) through the opposite planet shaft hole on Carrier (3A). Use an alignment punch or similar tool to align the roll pin holes on Carrier (3A) and Planet Shaft (3E).

NOTE: Be sure not to hit the Planet Gears (3F) when driving

in the Roll Pins (4G).

9. Drive Roll Pin (4G) down into the aligned roll pin holes. Pin should be flush with the flat of carrier.

10. Repeat Steps 1-9 for the installation of the two remaining Planet Gears (3F).

NOTE: Some grease may need to be applied to the Thrust

Washers (3B) to hold them in place while installing the planet gears.

3121117 – JLG Lift – 3-15

Page 54

SECTION 3 - CHASSIS & TURNTABLE

Output Carrier Assembly

(Refer to Figure 3-4., Output Carrier)

1. Place Thrust Washer (4H) into counterbore of Carrier (4A). BE SURE the small diameter side of Washer (4H) facing planet gear side.

2. Place Planet Gear Sub-assembly (4) into Carrier (4A). Visually align the planet gear bore with one of the planet shaft holes on the Carrier (4A).

3. Insert a Planet Shaft (4E) into the planet shaft hole described in Step 2 on Carrier (4A). The end of the planet shaft that does NOT have the roll pin hole should be inserted into the Carrier (4A) FIRST.

4. Now insert Planet Shaft (4E) through the first set of Thrust Washers (4B), Planet gear, then the second set of Thrust Washers (4B). Use an alignment punch or similar tool to align roll pin holes on Carrier (4A) and Planet Shaft (4E).

NOTE: Be sure not to hit the Planet Gears (4F) when driving

in Roll Pins (4G).

5. Drive Roll Pin (4G) down into the aligned roll pin holes. Pin should be flush with OD of Carrier (4A).

6. Repeat Steps 1-5 for the installation of the two remaining Planet Gears (4F).

Hub-Spindle Assembly

(Refer to Figure 3-7., Hub Spindle)

NOTE: Spray a light film of oil on all component parts during

assembly.

1. Place Hub (1G) into pressing base. Press nine Studs (1H) into Hub.

NOTE: Use enough pressure to press in studs. Don’t use

excessively high pressure to press in studs or hub may crack.

NOTE: Spray a generous amount of oil on bearings during

installation.

2. Press Bearing Cup (1D), position "A", into Hub (1G) using appropriate pressing tool.

3. Turn hub over and press Bearing Cup (1D), position "B", into hub using appropriate pressing tool.

4. Place Bearing Cone (1E), into Bearing Cup (1D), position "B".

5. Grease Seal (1B) lip and press seal into Hub (1G) using appropriate tool until seal is flush with end of hub.

6. Press Seal Boot (1Q) onto Hub (1G) if required. Turn Hub (1G) over and lower onto Spindle (1A).

7. Install Bearing Cone (1C) into Bearing Cup (1D), position "A".

8. Place Bearing Spacer (1N) on top of Bearing Cone (1C).

9. Using appropriate tool, install Retaining Ring (1J) into Spindle (1A) groove. Make sure ring is completely seated in groove.

NOTE: Extra bearing pre-load caused by using tool in Step

#9 must be removed. This should be done by placing a tool (NOT THE SAME TOOL USED IN STEP #9) on the end of the spindle, and then striking the tool with a piece of barstock. This should be adequate to remove any additional bearing pre-load.

3-16 – JLG Lift – 3121117

Page 55

SECTION 3 - CHASSIS & TURNTABLE

Cover Subassembly

(Refer to Figure 3-8., Cover Assembly)

1. Grease O-Ring (6E) and insert into internal groove in Cover (6A).

2. Assemble Disengage Cap (6B) onto Cover (6A) using two Hex Head Bolts (6C). Torque bolts to 7080 in-lbs.

3. Insert Disengage Rod (6D) into hole in Cover (6A) until it touches the inside of the Disengage Cap (6B).

NOTE: The Disengage Rod can be inserted either end first.

4. Grease Face of Thrust Washer (2) and place in Cover (6A) making sure that tangs on washer seat into pockets in cover.

5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The plugs should be hand tight according to SAE standard.

Main Assembly

(Refer to Figure 3-2., Main Disassembly Drawing 1 and Figure 3-3., Main Disassembly Drawing 2)

NOTE: All components should receive a generous amount

of lubricant oil as they are being assembled.

1. Place Hub-Spindle Sub-Assembly on the bench.

2. Grease O-Ring (18) and place it into groove of Hub

(1G).

3. Place Ring Gear (1F) onto Hub (1G). Align the three shipping Cap Screw Holes on Hub (1G) and Ring Gear (1F).

4. Install three shipping Cap Screws (19) into ring gear and hub. Torque them to 15-20 ft-lbs.

5. Place Output Carrier Sub-Assembly (4) into mesh with Spindle (1A) splines.

6. Place External Retaining Ring (5) over 13T spline to the retaining groove on Input Shaft (9).

NOTE: For ratio 48:1, assemble Output Sun Gear (11) over

Input Shaft (9) first, then install External Retaining Ring (5).

7. Using appropriate tool to install Retaining Ring (20) into groove on Output Sun (11)

8. Place Input Shaft (9) spline end into mesh with Internal Coupling (7) splines.

9. With the modified spline end facing up, place the Output Sun Gear (11) into mesh with the output planet gears.

10. Place Input Carrier Sub-Assembly (3) onto Output Sun Gear (11) splines. Drop Input Sun (10) into mesh with planet gears for specific ratios, if required. (No timing required)

11. Grease O-Ring (17) and insert into groove in Cover Sub-Assembly (6).

12. Install Cover Sub-Assembly (6) into Ring Gear (1F) counterbore and install Retaining Ring (6G) into groove in Ring Gear (1F).

13. Attach ID Tag (15) onto unit using Drive Screws (16).

14. Check disconnect, roll and air check unit, leak check

brake, and record release pressure. 14. Insert Plastic Plug (12) into place if applicable.

3121117 – JLG Lift – 3-17

Page 56

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-9. Hub Assembly - Sheet 1 of 2

3-18 – JLG Lift – 3121117

Page 57

SECTION 3 - CHASSIS & TURNTABLE

1A Spindle 1B Lip Seal 1C Taper ed Bearing Cone 1D Taper ed Bearing Cup 1E Tapered Bearing Cone 1 F R in g Ge a r 1G Hub (Housing) 1 H S tu d 1 J R et a in i ng Ri n g E x t. 1K Retaining Ring Int. 1 L S pr i ng ( 1. 46 0 ,1 . 50 0) 1 M T hr u st Wa s he r 1Q Seal Boot 2 T h ru s t S pa c er 3A Input Carrier

3 B T hr u st Wa s he r 3C Needle Bearing 3E Planet Shaft 3F Planet Gear 4A Output Carrier 4 B T hr u st Wa s he r 4C Needle Bearing 4D Thrust Spacer 4E Planet Shaft 4F Planet Gear 4 G Ro l l P i n 4H Thrust Washer 5 Retaining Ring - Ext 6 A C ov e r 6B Disengage Cap

6C Bolt, Hex (.250-20 Unc, .500 Gr5) 6D Dowel Pin 6E O-ring 6F Pipe Plug 6G Retaining Ring - Int 7.086 7 C o up l in g 9 I n pu t Sh af t 10 Input Sun Gear 11 Output Sun Gear 1 5 I D P l at e 1 6 D ri v e S c re w 1 7 O -r i ng 1 8 O -r i ng 19 Bolt, Flat Head - Hex Skt (.375-16) 2 0 R et a in i ng Ri n g - E xt .

Figure 3-10. Hub Assembly - Sheet 1 of 2

3121117 – JLG Lift – 3-19

Page 58

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-11. Cup Pressing Tool

Figure 3-12. Cup Pressing Tool

3-20 – JLG Lift – 3121117

Page 59

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.

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.

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. Press the speed sensor ring (12) onto the rotor disc

(13).

8. Place a new rotor disc (13) on the shaft (10) until it contacts the plate (14). Install stator disc (11).

9. 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.

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

11. Position pressure plate (3) on cover (21) aligning

dowel pins (20) with holes in pressure plate.

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.

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).

NOTE: A hydraulic press will simplify installation of pressure

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

12. 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).

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.

3121117 – JLG Lift – 3-21

Page 60

SECTION 3 - CHASSIS & TURNTABLE

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 3-13. Drive Brake

3-22 – JLG Lift – 3121117

Page 61

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

Disc plates worn The thickness of the disc stack sets the torque level.

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 The brake should be pressurized to minimum of

Bearing failure If the bearing should fall. a large amount of drag can

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

A thin stack reduces torque.

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 .

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.

Check disc thickness.

Check release pressure. (See spring replacement)

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

Replace bearing.

Place pressure gauge in bleed por t

- check for adequate pressure. Replace defective line or component.

Bad O-rings f release piston will not hold pressure, brake will not

release.

Discs frozen These brakes are designed for only limited dynamic

braking. A severe emergency stop or prolonged reduced release pressure operation may result in this type of damage.

Replace o-rings.

Replace disc stack.

3121117 – JLG Lift – 3-23

Page 62

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.

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

Adjustment Procedure

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

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

excessive force).

3. Back-off 1-2 turns and align the notch with the axis of the brake. Refer to Figure 3-14., 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.

3-24 – JLG Lift – 3121117

Page 63

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-14. Speed Sensor Orientation

3121117 – JLG Lift – 3-25

Page 64

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-15. Drive Components

3-26 – JLG Lift – 3121117

Page 65

SECTION 3 - CHASSIS & TURNTABLE

Speed Sensor Installation Verification

The motor controller averages the readings from the right and left speed sensors and therefore, 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 misadjustment 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.

3121117 – JLG Lift – 3-27

Page 66

SECTION 3 - CHASSIS & TURNTABLE

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 footswitch 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.

18. while watching the analyzer display, select drive forward. Be ready to remove your foot from the footswitch 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.

3-28 – JLG Lift – 3121117

Page 67

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-16. Oscillating Axle

3121117 – JLG Lift – 3-29

Page 68

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-17. Axle Oscillation Lockout Valve

3-30 – JLG Lift – 3121117

Page 69

SECTION 3 - CHASSIS & TURNTABLE

3.6 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and cen-

tered between drive wheels prior to beginning lockout cylinder test.

1. Place a 6 inches (15.2 cm) high block with ascension ramp in front of left front wheel.

2. From platform control station, start engine

3. Place the Drive control lever to the forward position

and carefully drive machine up ascension ramp until left front wheel is on top of block.

4. Carefully activate Swing control lever and position boom over right side of machine.

5. With boom over right side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

6. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground.

7. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate Drive to release cylinders.

8. Place the 6 inches (15.2 cm) high block with ascension ramp in front of right front wheel.

9. Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block.

10. With boom over left side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

11. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground.

13. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

3.7 OSCILLATION CYLINDER BLEEDING

NOTE: The oscillating axle must be checked daily for proper

operation.

Bleeding Procedure

1. Run one side wheel onto a ramp or block of wood. On the other side, the lockout cylinder should be extended.

2. Block the rear wheels and disconnect the drive hubs.

NOTE: Step three is only for models with all wheel drive.

3. Next, unplug the 4 wheel assist valve under the frame.

4. Have an assistant activate drive forward and telescope in from the platform. Open up the bleeder screws on the extended side lockout cylinder. Let the hydraulic oil run out until all the air bubbles are out of the cylinder. Then close the bleeder screws.

Checking Oscillation Cylinders

After bleeding the lockout cylinders, check to see that they are holding their position when oscillated.

1. Reconnect the drive hubs and 4-wheel assist valve.

2. Run one wheel onto a ramp or a block of wood,

mark the retracted cylinder with a marker, swing the turntable off of the cam valve.

3. Back the unit off of the ramp, check the retracted cylinder for drive no more than ½" (12.7 mm).

4. Repeat this procedure for the other side. If the lockout cylinders do not hold, repeat the bleeding procedure or check for the following:

a. Air in lockout system.

b. Bad cylinder seals.

c. Bad holding valves.

12. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate Drive to release cylinders.

3121117 – JLG Lift – 3-31

Page 70

SECTION 3 - CHASSIS & TURNTABLE

3.8 SWING DRIVE

Roll, Leak and Brake Testing

NOTE: The brake must be released and hydraulic lines to

motor removed before performing the roll test.

ROLL TEST

The purpose of the roll test is to determine if the unit’s gears are rotating freely and properly. You should be able to rotate the gears in your unit by applying constant to the roll checker. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others. Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency

LEAK TEST (MAIN UNIT)

The purpose of a leak test is to make sure the unit is air tight. You can tell if your unit has a leak if the pressure gauge reading on your air checker starts to fall after the unit has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main seal or wherever o-rings or gaskets are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the orings or gaskets meet on the exterior of the unit, then checking for air bubbles. If a leak is detected in a seal, oring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi for 20 minutes.

BRAKE TEST

The brake test should be performed prior to disassembly and after reassembly to ensure that the brake functions properly and does not leak. The brake test procedure can be found in the Motor-Brake Subassembly section of this manual.

NOTE: Failure to perform this test may result in damaged or

ineffective brake parts.

force

Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque.

The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle.

1. Tighten (but do not torque) bolt “A" until snug.

2. Go to the opposite side of the bolt circle and tighten

bolt "B" until equally snug.

3. Crisscross around the bolt circle and tighten remaining bolts.

4. Now use a torque wrench to apply the specified torque to bolt "A".

5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts.

Motor Control Valve Disassembly

1. Place unit on bench with the motor end up.

2. Remove Hydraulic Tubing Assembly (20) by loosen-

ing Fittings (18) on both ends of tube with a wrench.

NOTE: Items (18) & (19) are included on Item (20) when

ordering a replacement Tubing Assembly.

3. Using a wrench, loosen jam nut on Elbow Fitting (17) and remove fitting from Motor Control Valve (31).

4. Using a wrench, remove Fitting (21) from Brake Housing.

5. Remove Motor Control Valve (31) from Motor (10) by removing the four Bolts (34) and washers (33).

3-32 – JLG Lift – 3121117

Page 71

SECTION 3 - CHASSIS & TURNTABLE

17. Elbow Fitting

18. Fittings

19. Ferrule

20. Tubing Assembly

21. Fitting

29. Plug

31. Motor Control Valve

33. Washers

34. Bolts

Figure 3-18. Motor Control Valve Disassembly

3121117 – JLG Lift – 3-33

Page 72

SECTION 3 - CHASSIS & TURNTABLE

5A. O-ring

11. Thrust Washer

12. Hex Bolts

Figure 3-19. Motor and Brake Disassembly

Motor and Brake Disassembly

1. With unit resting on bench with Motor (10) end up, loosen Hex Bolts (12) and remove Brake/Motor Subassembly from the Housing (1G) (See assembly drawing).

2. Remove O-Ring (5A) from between Brake/Motor Subassembly and Housing (1G) (See assembly drawing).

3. Remove Thrust Washer (11) from between Brake/ Motor Subassembly and Carrier.

4. Remove one O-Ring Plug (13) from Motor (10) and one O-Ring Plug (13) from Brake Housing (6).

5. Remove O-Ring Plug (4) from Brake Housing (6).

3-34 – JLG Lift – 3121117

Page 73

SECTION 3 - CHASSIS & TURNTABLE

4 . O -r i ng Pl u g

6. Brake Housing 8-1A. O-ring 8-1B. Backup Ring 8-1C. O-ring 8-1D. Backup Ring

8-2. Brake Piston 8-3. Outer Plates 8-4. Inner Plates

8.5. Thrust Spacer 8-6. Spring

8.7. Spring

9. Sun Gear

10. Motor

13. O-ring Plug

15. Bolts

26. O-ring

Figure 3-20. Brake Disassembly

6. Remove Motor (10) from Brake Housing (6) by

removing four Bolts (15) incrementally until spring pressure is relieved.

7. Remove O-Ring (26) from between Motor (10) and Brake Housing (6).

8. Remove Springs (8-6) & (8-7) from Brake Piston (8-

2).

WEAR EYE PROTECTION DURING THE NEXT STEP OF THIS PROCEDURE.

9. Remove Brake Piston (8-2) from Brake Housing (6) by slowly pressurizing brake port in Brake Housing (6) with air.

10. Remove O-Rings (8-1A) & (8-1C) and Backup Rings (8-1B) & (8-1D) from Brake Piston (8-2).

11. Remove Sun Gear (9).

12. Remove Outer Plates (8-3) and Inner Plates (8-4)

from the Brake Housing (6).

13. Remove the Thrust Spacer (8-5).

3121117 – JLG Lift – 3-35

Page 74

SECTION 3 - CHASSIS & TURNTABLE

2. Ring Gear

5. O-Ring

14. Dowel Pins

28. Input Spacer

Figure 3-21. Main Disassembly

Main Disassembly

1. With the unit resting on the Output Shaft (Pinion) (1A), remove the Carrier Subassembly.

2. Remove Ring Gear (2) from Housing Subassembly.

3. Remove O-ring (5) from between Ring Gear (2) and

Housing Subassembly.

4. Remove four Dowel Pins (14) from Housing Subassembly.

3-36 – JLG Lift – 3121117

Page 75

SECTION 3 - CHASSIS & TURNTABLE

1A. Output Shaft 1B. Lip Seal 1C. Bearing Cup 1D. Bearing Cone 1E. Bearing Cup

1F. Bearing Cone 1G. Housing 1H. Thrust Washer 1l. Retaining Ring

Figure 3-22. Hub Shaft Disassembly

Hub-shaft Disassembly

1. Using retaining ring pliers, remove Retaining Ring (1I) from groove in Output Shaft (1A) and discard.

EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.

2. Remove Thrust Washer (1H).

3. While supporting the Housing (1G) on the Output

Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G).

NOTE: The Lip Seal (1B) may or may not be pressed out of

the Housing (1G) by the Bearing Cone (1D) during this step.

4. Remove the Bearing Cone (1D) from the Housing (1G).

5. Invert the Housing (1G) and remove the Lip Seal (1B) if not already removed when Output Shaft (1A) was pressed out of Housing (1G).

6. Using a bearing puller, remove the Bearing Cone (1F) from the Output Shaft (1A).

7. Bearing Cups (1C & 1E) will remain in Housing (1G).

NOTE: If bearing replacement is necessary, the Bearing

Cups (1C & 1E) can be removed with a slide hammer puller or driven out with a punch.

3121117 – JLG Lift – 3-37

Page 76

SECTION 3 - CHASSIS & TURNTABLE

3A. Carrier 3B. Thrust Washers 3C. Needle Bearings 3D. Spacer

3E. Planet Shaft 3F. Planet Gear 3G. Roll Pin

Figure 3-23. Carrier Disassembly

Carrier Disassembly

1. Using a 1/4" punch, drive the Roll Pin (3G) which holds the Planet Shaft (3E) in the Carrier (3A) down into the Planet Shaft (3E) until it bottoms.

NOTE: Make sure that the Roll Pin has bottomed. Other-

wise, damage to the carrier could occur when the Planet Shaft is removed.

2. Remove the Planet Shaft (3E) from the Carrier (3A).

3. Slide the Planet Gear (3F) and the two Thrust Wash-

ers (3B) out of the Carrier (3A).

4. Remove both rows of Needle Bearings (3C) and the Spacer (3D) from the bore of the Planet Gear (3F).

5. Using a 1/4" punch, drive the Roll Pin (3G) out of the Planet Shaft (3E).

6. Repeat Steps 1 through 5 for the remaining two Planet Gears (3F).

3-38 – JLG Lift – 3121117

Page 77

SECTION 3 - CHASSIS & TURNTABLE

Hub-Shaft Sub-Assembly

(See Figure 3-22., Hub Shaft Disassembly)

1. Press Bearing Cup (1E) into Motor end of Housing (1G) using an appropriate pressing tool.

2. Invert Housing (1G) and press Bearing Cup (1C) into Housing (1G) using an appropriate pressing tool.Set Bearing Cone (1F) onto Bearing Cup (1E).

3. Using an appropriate pressing tool, press Seal (1B) into Housing (1G) until it is flush with the end of the Housing (1G).

4. Apply liberal amount of grease to lip of Seal (1B).

5. Invert Housing (1G) and lower onto Output Shaft

(1A).

NOTE: Be careful not to damage seal while lowering Hous-

ing onto Output Shaft.

6. Press Bearing Cone (1D) onto Output Shaft (1A) until it seats against the bearing shoulder.

7. Place Thrust Washer (1H) onto Bearing Cone (1D).

EYE PROTECTION SHOULD BE WORN DURING THE NEXT STEP OF THIS PROCEDURE.

NOTE: Retaining Ring (1I) should never be reused in a

repair or rebuild.

8. Using retaining ring pliers, install Retaining Ring (1I) into groove in Output Shaft (1A). If Retaining Ring (1I) will not seat completely into groove, use an appropriate pressing tool to press down on Bearing Cone (1D) while rotating Housing (1G). Reinstall Thrust Washer (1H) and Retaining Ring according to preceding procedures. Tap the Retaining Ring (1I) with a soft metal punch to ensure that the Retaining Ring (1I) is completely seated in the groove of the Output Shaft (1A).

9. Using a soft face hammer, hit the end of the Shaft (1A) to remove the bearing preload.

10. Install O-ring Plug (1J) and torque to 23 to 24 ft-lbs.

Carrier Sub-Assembly

(See Figure 3-23., Carrier Disassembly)

1. Apply a liberal coat of grease to the bore of Planet Gear (3F). This will enable the Needle Rollers (3C) to be held in place during assembly.

2. Install the first row of 16 Needle Rollers (3C) into the bore of Planet Gear (3F).

3. Insert Spacer (3D) into bore of Planet Gear (3F) on top of the Needle Rollers (3C).

4. Place second row of Needle Rollers (3C) into bore of Planet Gear (3F) against Spacer (3D) and remove Planet Shaft (3E).

5. Place Carrier (3A) on bench so that one of the Roll Pin (3G) holes is straight up.

6. Paying attention to the location of the Roll Pin (3G) hole in the Planet Shaft (3E), start Planet Shaft (3E) through the hole in Carrier (3A). Using ample grease to hold it in position, slide one Thrust Washer (3B) over the Planet Shaft (3E) with the tang resting in the cast slot of the Carrier (3A).

7. Place the Planet Gear (3F) into position in Carrier (3A) and push Planet Shaft (3E) through the Planet Gear (3F) without going all the way through.

8. Slide the second Thrust Washer (3B) between the Planet Gear (3F) and the Carrier (3A) with the tang of the washer located in the cast slot of the Carrier (3A). Finish sliding the Planet Shaft (3E) through the Thrust Washer (3B) and into the Carrier (3A).

9. Position the non-chamfered side on the Planet Shaft (3E) roll pin hole so that it is in line with the hole in the Carrier (3A) using a 1/8 inch diameter punch.

NOTE: If Planet Shaft (3E) has a flat on the end, position the

flat toward the center of the Carrier (3A).

10. After using a 1/4" punch to align the Roll Pin (3G) holes in the Carrier (3A) and the Planet Shaft (3E), drive the Roll Pin (3G) through Carrier (3A) and into the Planet Shaft (3E) until the Roll Pin (3G) is flush with the bottom of the cast tang slot in the Carrier (3A). Use a 1/4" pin punch to make sure the Roll Pin (3G) is flush in the slot.

NOTE: On 6:1 Ratios of S1C"s, the pin must be 0.125”

below the surface of the outside diameter.

11. Repeat Steps 1 through 10 for the remaining two Planet Gears (3F).

3121117 – JLG Lift – 3-39

Page 78

SECTION 3 - CHASSIS & TURNTABLE

Main Assembly

(See Figure 3-21., Main Disassembly)

1. With the Housing-Shaft Subassembly resting on the Shaft (1A) install one Dowel Pin (14) into each of the four counter-bored holes in the Housing (1G) (See assembly drawing) until they bottom out. Also at this time, mark the four Dowel Pin (14) holes on the O.D. of the Housing (1G) (See assembly drawing). This is for identification later in the assembly.

2. Install Thrust Spacer (28) into counter-bore in splined end of the Output Shaft (1A).

3. Place O-Ring (5) into Housing (1G) counter-bore. Use grease to hold O-ring in place.

BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE SEATING THIS O-RING.

4. Install Carrier Subassembly with splined end down so that the spline of the Carrier Subassembly is in mesh with the spline of the Housing-Shaft Subassembly. Rotate carrier in assembly to check for freedom of rotation.

5. With large shoulder side of Ring Gear (2) facing down, place Ring Gear (2) onto Housing-Shaft Subassembly with gear teeth in mesh with the Planet Gears (3f) in the Carrier (3A). The side of the Ring Gear (4) with an "X" or punch mark stamped on it should be up and the marked hole should be at a Dowel Pin (14) location.

Motor-Brake Subassembly

(See Figure 3-19., Motor and Brake Disassembly)

1. Place Brake Housing (6) on bench with flange end down. Either block Brake Housing (6) up or place over hole in bench large enough for the shoulder of the Sun Gear (9) to rest on the bottom of the Brake Housing (6). Then install Sun Gear (9) with gear end down into Brake Housing (6).

2. Place Spacer (8-5) into Brake Housing (6) in bottom of small counter bore below splines.

3. Install brake disks, starting with an Outer Plate (8-3), then alternating Inner Plates (8-4) and Outer Plates (8-3) into splined bore.

4. Grease the O Rings (8-1A) & (8-1C) and Backup Rings (8-1B) & (8-1D), and place them in their respective grooves in the Piston (8-2). Make sure the backup-rings are correctly positioned as per the assembly print.

NOTE: Be sure that Backup Rings (8-1B) & (8-1D) are

located as tightly into the grooves in the Piston (8-2) as possible to prevent them from being “shaved” when Piston (8-2) is installed into Brake Housing (6).

5. Apply grease sparingly to Piston (8-2) O.D. and the cylinder bore of Brake Housing (6). Insert Piston (8-

2) into cylinder of Brake Housing (6), be sure not to cut the O Rings (8-1A) & (8-1C) or Backup Rings (81B) & (8-1D).

6. Install Compression Springs (8-6) into spring pockets in Piston (8-2).

7. Install Compression Springs (8-7) into Compression Springs (8-6) in spring pockets in Piston (8-2).

8. Grease O-Ring (26) and install into counter-bore in Brake Housing (6).

9. Assemble Test Cover (See Tools at back of manual for drawing) to Brake Housing (6) using four Bolts (15) evenly tightening Bolts (15) to 80-100 ft-lbs.

10. Check the brake for release. Apply pressure to brake port in side of Brake Housing (6) while trying to rotate Sun Gear (9) by hand. The brake should release between 200-255psi. Remove Test Cover.

11. Assuming that Brake passed the Brake Test, place Motor (10) into Brake Housing (6) with splines of Motor (10) meshing with splines of Sun Gear (9).

12. Attach Motor (10) to Brake Housing (6) with four Bolts (15) and torque to Bolts (15) to 80–100 ft-lbs.

13. 13. Install O-Ring Plug (13) and torque to 13–15 ftlbs.

Motor-Brake Assembly

(See Figure 3-19., Motor and Brake Disassembly)

1. Grease Thrust Washer (11) and install into counterbore of Carrier Subassembly, which should already be installed into the Main Subassembly.

2. Grease O-Ring (5A) and install into counter-bore of the Brake Housing (6) in the Motor-Brake Subassembly.

3. Install Motor-Brake Subassembly onto Main Assembly using twelve Bolts (12). Torque bolts to 23 – 27 ftlbs.

3-40 – JLG Lift – 3121117

Page 79

SECTION 3 - CHASSIS & TURNTABLE

1. Shoulder Screw

2. Capscrew

3. Setscrew 4 . J am N ut

Figure 3-24. Setting Gear Backlash

Motor Control Valve Assembly

(See Figure 3-18., Motor Control Valve Disassembly)

1. Lay assembly down with motor ports facing up. Remove the two plastic plugs in the motor ports on new motors, being careful not to loose the O ring in each port. Assemble the Motor control Valve (31) onto the Motor (10) with Bolts (34) and Washers (33). Torque Bolts (34) to 23-27 ft-lbs.

NOTE: Be sure to align the holes in the control valve with

the motor ports and make sure o-ring is in hole.

2. Install Straight Fitting (21) into Brake Housing (6) and torque to 13-15 ft-lbs.

3. Install Elbow Fitting (17) into Motor Control Valve (31) with chamfered end of fitting pointing towards straight Fitting (21). Thread fitting all the way in until in the correct position, then torque jam nut to 13-15 ft-lbs.

4. Assemble Tubing (20) Nuts (18) and Ferrules (19) per the procedures below.

Tube Fitting Assembly Procedures

NOTE: Be sure the tube is inline with the fitting. If required,

gently modify the tube bends to be inline.

Procedure for Setting Gear Backlash

1. Assemble nut onto tubing with threaded end toward the assembled end of the tube.

2. Assemble ferrule onto tube with the large tapered end into the nut.

3. Place tube tight against the flared fitting in the assembly.

4. Lubricate threads and fitting end with hydraulic oil.

5. Slide ferrule and nut against fitting and hand tighten

nut to the fitting.

6. Mark nut in relation to the fitting.

7. Hold tube tight against fitting and tighten nut 1-1/4

turns of the nut past the marked location.

NOTE: Be sure to align the holes in the control valve with

the motor ports.

8. Pressure test brake, tube and control valve connections by applying 3000psi pressure to the brake bleed port and holding for 1 minute. Check for leaks at the control-valve-motor interface and the tube connections. Release pressure.

3121117 – JLG Lift – 3-41

NOTE: The bearing high spot will be marked with yellow

paint.

1. Place a shim, JLG P/N 4071009, between the pinion and bearing high spot.

2. Torque the shoulder screw (1) to 420 ft.lbs. (588 Nm) with Loctite #271.

3. Remove the turntable lock pin.

4. Pre-torque the 3/4 inch capscrews (2) to 120 ft.lbs.

(168 Nm) with Loctite #271.

Page 80

SECTION 3 - CHASSIS & TURNTABLE

5. Tighten the setscrew (3) until the pinion is completely snug against the shim and bearing and then back off the setscrew.

6. Torque the setscrew to 50 ft.lbs. (70 Nm).

7. Tighten the jam nut (4).

8. Torque the four 3/4 inch capscrews (2) to 420 ft.lbs.

(588 Nm).

9. Remove and discard the shim.

3.9 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

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

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

Check the frame to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to full elevation and

rotate platform 90

2. Swing turntable over the side.

3. On the frame, at the rear of the turntable, try to insert

the 0.0015" feeler gauge between the bolt head and hardened washer at the indicated position. (Figure 3-25., Swing Bearing Feeler Gauge Check)

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

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

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

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

8. Swing the turntable over the side.

9. On the frame, at the front of the turntable, try to

insert the 0.0015" feeler gauge between the bolt head and hardened washer at the indicated position.

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

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

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

Check the turntable to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to full elevation and

rotate the platform 90

2. Swing the turntable over the side.

3. At turntable rear, try and insert the 0.0015" feeler

gauge between the bolt head and hardened washer at the arrow indicated position.

3-42 – JLG Lift – 3121117

Page 81

SECTION 3 - CHASSIS & TURNTABLE

.0015" Feeler Gauge

Figure 3-25. Swing Bearing Feeler Gauge Check

Figure 3-26. Swing Bearing Tolerance Measuring Point

4. Assure that the 0.0015" feeler gauge will not pene-

trate under the bolt head to the bolt shank.

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

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

Wear Tolerance

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

2. With the boom positioned over the side of the machine, the Boom fully elevated, retracted, and

platform rotated 90 indicator, measure and record the distance between the swing bearing and turntable rear.

, using a magnetic base dial

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

8. At turntable front, try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

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

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

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

3. If a difference greater than 0.057 in. (1.40 mm) is 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.

3121117 – JLG Lift – 3-43

Page 82

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-27. Swing Drive and Bearing Installation

3-44 – JLG Lift – 3121117

Page 83

SECTION 3 - CHASSIS & TURNTABLE

Replacement of Swing Bearing

Removal of the swing bearing is as follows:

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

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

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

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

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

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

NOTE: The bearing weighs approximately 100 lbs. (45 kg.).

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

Installation of the swing bearing is as follows:

1. Install bearing to turntable with two capscrews, so the grease hose is on the forward side of the frame as close to the centerline of the turntable as the bolt pattern will allow. Do not tighten capscrews.

2. Line up high spot (marked with yellow paint) of bearing with center tooth of bull gear. Set backlash to

0.008 - 0.012 inch (0.20 - 0.30 mm). Refer to Swing Drive Installation. Tighten capscrews as shown in Figure 3-28., Swing Bearing Torque Sequence

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

NOTE: If Mobiltac 375NC is not available, Tribol Molub-Alloy

936 Open Gear Compound or Mobilith SHC Bearing Grease or Multi-Purpose Grease (MPG) can be substituted, however the service interval will be shorter.

4. Using suitable lifting equipment, install bearing/ 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 GRADE 8 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.

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

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

6. Following the torque sequence diagram shown in Figure 3-28., Swing Bearing Torque Sequence, 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).

7. Remove lifting equipment from bearing.

8. Use suitable lifting equipment to carefully position

the turntable assembly above the machine frame.

9. 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.

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

3121117 – JLG Lift – 3-45

Page 84

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-28. Swing Bearing Torque Sequence

11. Following the torque sequence shown in Figure 3-

28., Swing Bearing Torque Sequence 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).

12. Remove the lifting equipment.

13. Route hydraulic lines through center of turntable and

frame and connect as tagged prior to removal.

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

Swing Drive Installation

1. Coat the threads of the socket head bolts securing the swing drive to the mounting plate with Loctite #271 and torque to 120 ft.lbs. (168 Nm).

2. Position swing drive to location of bearing gear max eccentric tooth. High spot is marked with yellow paint in tooth.

3. With the mounting plate pivoting about the shoulder bolt, adjust backlash between the pinion and bearing gear teeth to 0.008 to 0.012 inch backlash (0.20mm to 0.30mm).

4. Tighten the adjusting bolt, jam nut, and shoulder bolt to prevent the swing drive from moving. Coat the threads of the shoulder bolt with Loctite #271 and torque to 420 ft.lbs. (588 Nm).

5. Coat the threads of the mounting plate bolts with Loctite #271 and torque to 420 ft.lbs. (588 Nm).

Setting Backlash

1. Place a shim (JLG P/N 4071009) between pinion and bearing on high spot of bearing.

2. After applying Loctite #271 to the shoulder bolt, torque to 420 foot-pounds (588 Nm).

3. Remove the lock pin on the turntable.

Swing Bearing Torque Value

Install with Loctite - 190 ft. lbs. (260 Nm).

4. After applying Loctite #271, torque the four ¾" socket head bolts to 120 foot-pounds (168 Nm).

5. Tighten the setscrew until the pinion is snug against the shim and bearing.

6. Torque the setscrew to 50 foot-pounds (70 Nm).

7. Tighten the jam nut.

8. Torque the four ¾" socket head bolts to 420 foot-

pounds (588 Nm).

9. Recover the shim and throw it away.

3-46 – JLG Lift – 3121117

Page 85

SECTION 3 - CHASSIS & TURNTABLE

3.10 BATTERY MAINTENANCE AND CHARGING

IF REPLACING A BATTERY, EACH NEW BATTERY MUST WEIGH AT LEAST 115 POUNDS (52 KG). FAILURE TO REPLACE THE BATTERY WITH ONE OF THE CORRECT WEIGHT WILL RESULT IN A TIPOVER HAZARD WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.

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" 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.

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.

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 IN ON (PULLED OUT), THE GENERATOR WILL START AUTOMATICALLY WHEN THE BATTERIES REACH A LOW-CHARGE STATE AUTOMATICALLY CHARGING THE BATTERIES.

NOTE: The engine will automatically shut down under the

following conditions:

Charged Batteries High Engine Oil Temperature Low Engine Oil Pressure Engine Overspeed Generator Overvoltage

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

Battery Charging (On Board Charger)

1. For maximum battery life:

a. Avoid completely discharging the batteries.

b. Fully charge the batteries each day the machine

is used.

c. Charge the batteries at available times between

charging.

d. Be sure the battery fluid covers the battery

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

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

3. The charge cycle is complete when the 100% LED is lit. Any other reading indicates the charge cycle is not complete.

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

Depleted batteries will take approximately 23 hours to charge.

3121117 – JLG Lift – 3-47

Page 86

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-29. Battery Cable Routing

Removing the Battery Box

To remove the battery box, perform the following steps.

1. Pull the pull ring to disconnect the batteries at the battery disconnect beside the box.

2. Remove the two attachment bolts that secure the battery box to the turntable.

NOTE: The battery box and batteries complete weigh

approximately 668 pounds (303 kg).

3. Using a forklift, lift the battery box up enough to clear the notch on the battery box rails and remove the battery box from the machine.

3-48 – JLG Lift – 3121117

Page 87

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-30. Batteries and Battery Charger

3121117 – JLG Lift – 3-49

Page 88

SECTION 3 - CHASSIS & TURNTABLE

1. 20 Amp Circuit Breaker

2. Connector

3. PC Board

4. DC Cord

5. Fuse Ho lder

6. 80 Amp DC Fuse

7. Harness

8. Harness

9. Fuse Ho lder

10. AC Inlet Plug

11. D C Plug

12. Rectifier

13. SCR

14. Relay

15. Shunt Assembly

16. St rain Relief

17. Transformer

18. Varistor

Figure 3-31. Battery Charger

NOTE: Charger Cover removed for clarity.

Item #5 Not Shown.

3-50 – JLG Lift – 3121117

Page 89

SECTION 3 - CHASSIS & TURNTABLE

N.C. N.O.

BLK

AC BLK

AC GRN OR

AC GRN OR BLUE

YLW/GRN

OR BRN

CON.

RELAY

VARISTOR

GROUND SCREW

TX PRI

12A

SCR

WHT

(SEE D13552-1 ASSY DWG)

SOLDER CONNECTION

.001 OHM SHUNT

DC NEG

DC POS

RED

BLACK

NUT & BOLT CONN

* DC FUSE OR CIRCUIT BREAKER

WHT

SCR

CAP CAP

HEATSINK

BLUE

GRN

WHT

BLK

WHT

GRN

WHT

BLK

J-2 CONNECTOR

RED

CIRCUIT BOARD HARNESS

10 11 15 16 176

NOTE: ON CE CHARGERS VARISTOR LEADS MUST BE COVERED WITH VARFLEX

*OPTIONAL* CAPACITORS REQUIRED IN CE CHARGERS

7 7

12 12

YELL

BLK

WHITE

ORG

INTERLOCK CONNECTOR

AC FUSE OR CIRCUIT BREAKER

BLACK BLK

PIN 1

4321

TO 4POS CONN OF MAIN BOARD

* IN SOME CHARGERS THIS MAY BE AN AUTOMOTIVE FUSE. CONNECTORS ARE SAME.

WHITE WHT

PIN 2

GREEN GRN

PIN 3

RED RED

PIN 4

REMOTE

LIGHT BOARD

Figure 3-32. Battery Charger Schematic

3121117 – JLG Lift – 3-51

Page 90

SECTION 3 - CHASSIS & TURNTABLE

3.11 GENERATOR (PRIOR TO S/N 88375)

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.

• Control Fuse

This fuse provides power to the engine/generator and the relays for start control, fuel control, and pre-heater. This fuse is rated at 15 Amps DC and is located on the right side of the engine.

•Start Battery

A 12 volt lead-acid battery is utilized to provide starting power for the generator and power for the generator controls. This battery is charged by the engine dynamo and dynamo regulator when the engine is running.

• Start Control Relay

The start control relay energizes the solenoid of the engine starter and the pull coil of the engine fuel solenoid. The start control relay is located on the fuel solenoid bracket on 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.

• 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 failsafe protection, if it is not present at the controller, the unit will fault with a loss of speed signal indication. The engine speed sensor is located inside the recoil starter cover at the front of the engine.

•Engine Starter

The engine is equipped with a 12 Volt DC starter. This starter provides mechanical 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.

• 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).

3-52 – JLG Lift – 3121117

Page 91

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-33. Generator Components

3121117 – JLG Lift – 3-53

Page 92

SECTION 3 - CHASSIS & TURNTABLE

Timing Sequences

• RBS Prestart 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.

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 3-3. 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

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 3-4. 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 cooldown period.

2. Time Delay Cooldown (TDC)

Once the TDER period ends, the alternator output is reduced to a minimal level in order to allow the engine to cool down for the TDC period. If a CTS is received during the TDC period, the CTS must last for at least the TDES period for the RBS to return to normal running operation.

The RBS will attempt to start the engine up until the number of crank cycles is reached. If the RBS does not start, an Overcrank fault is indicated.

Table 3-5. RBS Shutdown Sequence

Remove CTS

TDER Engine Run

TDC Cooldown

Engine Stop

3-54 – JLG Lift – 3121117

Page 93

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 3-34., 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 3-6. 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.

• Overspeed

If the engine speed exceeds the overspeed limit, the engine will stop immediately and an overspeed alarm will be indicated.

Low Oil Pressure Shutdown due to low engine

High Engine Temperature

Engine Overspeed Shutdown due to high engine

Engine Underspeed/Overcrank

No Speed Signal S h u tdo w n du e t o lo s s of

Overvoltage Shutdown due to high output

Engine Starting System fault

Not Used Not Used

Loss of Voltage Sense

Unit Disabled No Faults. RBS enabled and

Unit Disabled RBS off or disabled; Will not

oil pressure

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

3121117 – JLG Lift – 3-55

Page 94

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-34. Generator System Analyzer Flow Chart

3-56 – JLG Lift – 3121117

Page 95

SECTION 3 - CHASSIS & TURNTABLE

•Underspeed

Enabled once TDBP (time delay bypass) period has elapsed after engine startup. If the engine speed drops below the underspeed limit, the engine will stop immediately and an engine underspeed alarm will be indicated.

• Overcrank

If the engine fails to start after a set number of start attempts, the RBS will cease attempts to restart and an engine overcrank alarm will be indicated.

• No Speed Signal

In the event of a loss of speed signal, the RBS will shutdown and an engine no speed signal alarm will be indicated. This shutdown is delayed by a factory set period to ensure the fault was not momentary.

•Overvoltage

If the voltage measured at the alternator output exceeds the high voltage setting, the RBS will stop immediately and an RBS high output alarm will be indicated. This shutdown is delayed by a factory set period to ensure the fault was not caused by a transient condition. This feature protects the batteries and load from high DC voltages.

• Engine Starting System Fault

Indicates a problem with either the engine start battery, engine magneto, or magneto voltage regulator.

Output Current and Voltage Settings

• Normal/Extended Output Voltage

The normal/extended output voltage setting is the voltage at which the alternator changes under normal operating conditions.

• Current Limit

The current limit setting determines the maximum alternator output current.

•High Voltage Shutdown Level

This setting determines the alternator output voltage at which the high voltage shutdown occurs. This protects the load from abnormally high voltages.

• Finish Charging Current

The finish charging current determines the level of the current alternator output must drop below for a low battery voltage CTS to be removed. This ensures that the batteries have accepted sufficient charge prior to shutting down the RBS. This level is used along with the low battery voltage remove CTS level to determine when the RBS removes the CTS after a low battery voltage CTS. If the charging current falls below the finish charging current while another CTS is active, the RBS will continue to operate at the normal/extended output voltage until all CTS’s are removed.

•Loss Of Voltage Sense

If the voltage measured at the alternator output is less than half of the system nominal voltage, the RBS will stop immediately and an RBS loss of voltage sense alarm will be indicated. This feature protects the batteries and load from high DC voltages due to a loss of output control.

•Run Inhibited

The RBS unit is disabled by the run inhibited input.

3121117 – JLG Lift – 3-57

Page 96

SECTION 3 - CHASSIS & TURNTABLE

Priming the Fuel Line

The following procedure is for re-priming the fuel line on the generator engine in the event fuel system components have been replaced or the unit has been run dry of fuel.

1. Make sure the fuel line isn’t blocked or kinked.

2. Make sure fuel tank has fuel.

3. Disconnect the rubber fuel line at the fuel injector

pump.

5. Clean up any spilled fuel and try to start the generator engine.

6. If the engine still doesn’t start, remove the steel line from the fuel injector pump.

7. Once fuel starts to flow, re-connect the fuel line to the fuel injector pump.

8. Clean up any spilled fuel and try to start the generator engine.

9. If no fuel flows there are some possibilities:

a. There is no fuel getting to the injector pump. No

fuel in tank, or obstruction in fuel line, or clogged inline fuel filter.

b. The engine/camshaft rotation is not opening the

injection fuel pump. Using the recoil starter, rotate the engine 1/3 of a turn and fuel should spill from the fuel injector pump.

10. Engine might run rough for 20 seconds or so, but it will clean out.

4. When fuel starts to flow out of the rubber line, reconnect the fuel line to the fuel injector pump.

3-58 – JLG Lift – 3121117

Page 97

SECTION 3 - CHASSIS & TURNTABLE

3.12 GENERATOR (S/N 88375 TO PRESENT)

NOTE: Throughout the Generator section, the abbreviation

RBS is used. RBS stands for Rotary Battery System, which is the generator system.

The engine-driven generator is designed to produce a DC output directly without the need of a separate rectifier. Included in the RBS unit is the engine, generator, engine/ generator controller, harness and related components.

Engine

Peak rating:

Continuous rating:

6.2 HP

0.6 HP at 3600 RPM

Refer to the Engine Manual for a complete description of the engine.

Alternator

Dynamo and Dynamo Voltage Regulator

The engine is equipped with a dynamo and dynamo voltage regulator.

Dynamo output: 12V 7A DC

Refer to the Engine Manual for a complete description of the dynamo and dynamo voltage regulator.

Dynamo Output Fuse

This fuse protects the dynamo output; it is located on the The RBS is equipped with a brushless DC output alternator.

The 3-phase AC output of the alternator is full wave rectified and presented to the output terminals.

Output rating: 58.0V at 45A

Voltage regulation and current limiting is provided by the RBS Engine/Generator Controller.

The rectifier diodes and output current sensor are located in the alternator endbell.

left side of the engine.

Rating: 20ADC

Control Fuse

The control fuse provides power to the engine/generator

controller and the relays for start control, fuel control and

glow plug.

Rating: 15ADC

This fuse is located on the right side of the engine.

3121117 – JLG Lift – 3-59

Page 98

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-35. Generator

8. Temperature Sensor

9. Voltage Regulator

10. Alternator

11. Star ter

12. Star ter Solenoid

13. Oil Filter

1. Glow Plug Relay

2. Fuel Control Relay

3. Start Control Relay

4. Fuel Solenoid

5. Fuel Filter

6. Low Oil Pressure Switch

7. Glow Plug

3-60 – JLG Lift – 3121117

Page 99

SECTION 3 - CHASSIS & TURNTABLE

Start Battery

The RBS requires a 12V lead-acid start battery (not supplied with the system), which provides starting power and power for the RBS controls.

This battery is charged by the engine dynamo and dynamo regulator when the engine is running.

Engine Starter

Start Control Relay

The engine is equipped with a 12VDC starter, which provides the 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.

The start control relay energizes the solenoid of the

engine starter and the pull coil of the engine fuel solenoid.

The start control relay is energized by the engine/genera-

tor controller from pin J2-4.

The start control relay is located on the fuel solenoid

bracket on the right side of the engine.

3121117 – JLG Lift – 3-61

Page 100

SECTION 3 - CHASSIS & TURNTABLE

Fuel Control Relay

Glow Plug 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 from pin J2-3.

The fuel control relay is located on the fuel solenoid bracket on the right side of the engine.

The glow plug control relay energizes the glow plug. It is energized by the engine/generator controller, pin J2-27.

The glow plug control relay is located on the fuel solenoid bracket on the right side of the engine.

Glow Plug

The glow plug is a resistive heating element located in the combustion chamber. It is used during starting at temperatures below 32°F (0°C).

The heater is energized by the glow plug control relay.

3-62 – JLG Lift – 3121117

JLG M600 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

AGENERAL

B HYDRAULIC SYSTEM SAFETY

CMAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

1.2 OPERATING SPECIFICATIONS

1.3 GENERATOR

1.4 BATTERY CHARGER

1.5 DRIVE/STEER SYSTEM

1.6 TIRES

1.7 FUNCTION SPEEDS

Machine Orientation When Doing Speed Tests

Test No tes

1.8 PRESSURE SETTINGS

1.9 TORQUE REQUIREMENTS

1.10 MAJOR COMPONENT WEIGHTS

1.11 SERIAL NUMBER LOCATION

1.12 HYDRAULIC OIL

1.13 OPERATOR MAINTENANCE

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

Preparation, Inspection, and Maintenance

Pre-Start Inspection

Pre-Delivery Inspection and Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

2.2 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

Lubrication and Servicing

Bolt Usage and Torque Application

2.3 LUBRICATION AND INFORMATION

Hydraulic System

Changing Hydraulic Oil

Lubrication Specifications

Hydraulic Oil

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

2.7 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Tire Inflation

Tire Damage

Tire Replacement

Wheel Replacement

Wheel Installation

Disengaging for Towing

Engaging after Towing is Complete

Disassembly

Disassembly of Cover

Disassembly of the first stage planetary assembly (7)

Disassembly of second stage planet gears (1)

Assembly of first stage planetary assembly (7)

Assembly of end cover unit (8)

Final Assembly

Initial Start-Up and After Repairs

Oil Change Interval-Gear Drive

3.3 DRIVE HUB (S/N 115723 TO PRESENT)

Roll and Leak Testing