Home

Service 3121325 03-24-11 ANSI English

1. J1 Connector 42 1 1 24V to Console 2 Drive Height LS 2 Deck Extension 3 Lower 3 Ignition 4 Ground 4 Start 5 Lift 5 Horn 6 Joystick Analog Signal 6 Not Used 7 Pump 1 7 Not Used 8 Max Height L S 8 Differential Lock 9 Steer Right 9 Trigger Switch 10 Steer Left 10 Ground 11 Tilt Switch 11 Not Used 12 Fast Drive 12 Steer Right 13 Fast Drive L S 13 Lift Select 14 Not Used 14 Steer Left 15 Ignition 15 Fast Drive 16 Pump 2 16 Joystick Analog Signal 17 Start 18 Diff Lock Table 5 2 Key 19 Platform In Output Signal 20 Not Used Input Signal 21 Ground Not Used 22 Platform Out 23 Horn 24 24V Power Table 5 3 J3 Connector J3 Connector Table 5 1 Key 1 NotUsed Ouiput Signal 2 FastDrive LED Input Signal 3 Max Height LED NotUsed 4 Drive Height LED 5 Not Used 6 Ground Table 5 3 Key Output Signal Input Signal Not Used 3121325 Lift 5 3 SECTION 5 CONTROL SYSTEM Table 5 4 Complex 2 Circuit Board JLG Lift 3 8 5 2 5308 5 65 8 2 18 2 8 5 2 9 Io 8 2 85 5 2 5 5 2 8
2. o s ISNV 105 Jodumf pued Ionuoo Figure 6 31 Electrical Schematic Sheet 14 of 15 6 25 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS CI 98 4 TS 9 TS 08 1514 pIeog Xnp OoAIN 7 OLLIVINHHOS XII II III oa ssa 6sa 516 0IL 19 od Crd u 18 10014 ppa ysy 34874 Epad Usi Et Peet A X TIOS 1289 0 yams Xn OAIN Xo du10 SoA EA Sunjr pue oinssoid 11216 peusrur ssoooud uoo13 c xot q c po1 umnpuoq A 0 C X956I9 094 umnpuaq x ZZONd
3. 9 SEXA HATHIG OE SA SA OE NAOG INYOA LV Td sf lt lt TE TX CI0M800 Waa fe v9 TX X1ddhs 9 syoe THNVd NO s1e331no Figure 6 24 Electrical Schematic Sheet 7 15 3121325 Lift 6 18 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 8 715 9 IS 08 98911 IV I X ST 19 Vox 9 I X 81 08 101 ATXV DNIIVTIIOSO SHATVA 91 11 XW IdINOO VIX HATSIQ X 4 195 c UTE X8 IdIWOO SUIX Ie q 19S 91 1 X 9 TX GAINO U I XT IdINOO CUTX IVORLLOQT TH OLLVINHHOS X YLLATI ee u TIXV ONILVTIOSO dIN 1d lt IVIIHS lt 6 L A Iddf1S B c dung AV TAA Figure 6 25 Electrical Schematic Sheet 8 of 15 6 19 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATI
4. 1 Ground Control Panel 3 Bolt M6 x 20mm 5 Flatwashers M6 2 Electrical Compartment 4 Nut M6 Figure 3 23 Ground Control Panel Removal Removal DISCONNECT GROUND CONTROL PANEL 1 FROM BATTERY BEFORE REMOVING AND OR SERVICING 1 Disconnect all plugs and wires from the back of the control panel 2 Remove the panel from the the Electrical Compart ment 2 by removing the six Bolts 3 Nuts 4 and twelve Flatwashers 5 NOTE When removing the control panel take care not to damage any plug receptacles and switches Installation 1 Attach the Ground Control Panel to the Electrical Compartment with the Bolts Flatwashers and Nuts 2 Carefully attach all wires and reconnect to battery 3 Make certain all LED s and switches work properly 3121325 JLG Lift 3 25 3 5515 amp 5 55 5 3 10 BATTERY REMOVAL 1 Batteries 2 Battery Cable Battery to Battery 3 Battery Cable Battery to Battery Disconnector 4 Battery Cable Battery to Engine 5 Bolts M8 x 35mm 6 Lockwashers M8 7 Battery Hold Clamp NOTE Items 5 6 and 7 are also located on the back side of t
5. 516 42 C2 C2 J1B X1 C2 J2A 121314 2 5 munawan 123456167 7I 819 II 213 3 4 5 617 8 9202 I 212263242 526272 82930313232333 343536373839404 I 4I 4243444546474849505 525354555657585960 A 0CCCCCCCCCCCCCCCXL 41 1121314 C2 J2B E 10A FUSE 55 5 1 TERMINAL BOX CIRCUIT BOARDS 5 1 Figure 5 1 Main Terminal Box JLG Lift 3121325 SECTION 5 JLG CONTROL SYSTEM 5 2 CONTROL CARD COMPLEX 2 abita NN 280 gt Jumper Plug 52 Figure 5 2 Control Card Complex 2 Board General Description of Components and Functions The Complex 2 Control circuit board is an electronic printed circuit board which processes the input signals from the control console and the joystick trigger switch circu
6. 6 10 HD HDP Locking Contacts Into Position 1 6 11 Removal iri sorsoran ee eee ae LA 6 11 HD HDP Unlocking Contacts 6 11 Electrical Schematic Sheet 1 15 6 12 JLG Lift 3121325 5 6 19 6 20 6 21 6 22 6 23 6 24 6 25 6 26 6 27 6 28 6 29 6 30 6 31 6 32 6 33 6 34 6 35 6 36 6 37 3121325 Electrical Schematic Sheet 20115 6 13 Electrical Schematic Sheet 30115 6 14 Electrical Schematic Sheet 40115 6 15 Electrical Schematic Sheet 5 0115 6 16 Electrical Schematic Sheet 60115 6 17 Electrical Schematic Sheet 70115 6 18 Electrical Schematic Sheet 80115 6 19 Electrical Schematic Sheet 90115 6 20 Electrical Schematic Sheet 10 15 6 21 Electrical Schematic Sheet 11 15
7. De YAMOT T E a LAVLS TI TANVd THNVd HE TANVd HHLNVIS Hc 14 1 4 MOTD TANVd eum CATA 4 XIYIOAIN Wad JNd30 2 1 1 Hc f Figure 6 23 Electrical Schematic Sheet 6 15 6 17 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 715 19 IS 08 19599 HOLIAS HHODnLILOO uo s1933uno uonisod T V IL 9 559 S T T 2 97 dol 7 X IVORLLOT IH OLLVINHHOS 1olp uuoo qT1 XII II III p X SHATVA LATI X4 9 LHOTA INOW Xo 22 ES 21 6 C AST ASI 0 1 9 cst T Sf TILI 6 LL 8 8 KO KO 9 LILT 9 17 9 ELE OT Xn OAIN 8VIII9 9 I
8. 1 6 10 HD30 HDP20 Series 6 10 HD30 HDP20 Series 1 6 11 JLG Lift 3121325 5 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Limit Switch Locations Baad Bent ya wide ME IND pU eee 1 3 1 2 Engine Operating Temperature 1 5 1 3 Torque Chart Metric Conversion For ASTM 1 6 1 4 Torque Chart In Lb Ft Lb For ASTM Fasteners 1 7 1 5 Torque Chart Nm For Metric Class 1 8 2 1 Lubrication Diagram SERE WORRY rr E 2 5 3 1 Torque WUD INI 3 2 3 2 Wheel Assembly 3 4 3 3 Hub Torque Values oda ep Pg RR ER 3 5 3 4 Torgus H b Assembly penada eae ak ede ees Rp c RR ec pal er Bo 3 6 3 5 Drive Motor 100 3 7 3 6 Steering Assembly
9. 4 17 Valve Compartment 4 17 Pressure Switch Drive Enable 4 17 uw upa 5 4 18 sauku cia esa us Cus huayu 4 19 Mair Valve Bloek ur ro o ee tue t Sree quate ek as abe Je nae S Sus 4 20 Pump Engage Disengage 4 21 Hand Pump eua cete vL ea te a reel dep ed 4 22 Load Holding Valve 25 REA EISE EE E 4 23 Lift Eower Valve Block irigas ee ae nemen d ee ob RU UR e e Br cR 4 24 Platform Lower Flow Valve 454 1 4 24 Outrigger Safety Valves 2 4 25 SECTION 5 JLG CONTROL SYSTEM 5 1 Main Terminal Box Circuit Boards 5 1 5 2 Control Complex 2 issuer deem ne Rx RR Red p Edo eg e rr Ed 5 2 General Description of Components and 5 2 5 3 Nivolux Automatic Self Leveling System 5 5 Introductorio arte aAa E teeta ald 5 5 x ei Vk Sie inier 5 5 Operation os ntt e s e eae fold 5
10. SA X SA vL C II 5 M ANVd 7 0 XVNS fL IS IX DL 6021 HL 9 8 XNTOAIN LAI 19 LAX LAIT 1 49 TANVd 65 IX ITLS 1 XL IC Y IC IHOIHH XVI S HADIG Hv dc SAX SA TISE u XNTOAIN TIXV M TIIOSO cS 9 IX HA 199591990 S S119 10 Figure 6 20 Electrical Schematic Sheet 3 15 3121325 Lift 6 14 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Ad 715 19 715 08 198911 IVOBILLOT TH OLLVINHHOS ST 9 101 XII II III ST 08 401 4I90 L 09 1X OVd WHS XI XI CI IX 8C IX S
11. 2 1 4 13 Axle Locking Cylinder 4 14 Extension Cylinder 4 15 Arms and Platform Positioning and 4 16 Valve Hydraulic 1 4 4 2 4 17 Pressure Switch 4 17 Brake usut u e EDEN IRE VR IA oe 4 18 Brake Valve Adjustment 2 2 2 4 18 4 19 Main Valve er DM ese sasa 4 20 Pressure Test pr pepe Eu aeri ee 4 21 Proportional Valve Pressure Adjustment 4 21 Pump Engage Disengage 4 4 21 Hand P mp Assembly erii 4 22 Hand Pump Valve 4 4 23 Load Holding sla 4 23 Lift Lower Valve ne edn Sood cae BERG ae Rote o ict 4 24 Platfor
12. OLLVINHHOS HNIDNH TASHA ST 08 10 X YLLATI HL 5 e TI TANVd Vol lt gix X YIOAIN 7 24016 814 AV TS 431315 4 55 4 Blow 0I CX _ T H 0C onuoo awn usoq o vX TANVd ANNONO NOLIV LS Amas 1 c IHNVd IOX INOO 8 jou 07912 OW onuob ZLON3d 205 99 A e 966 OW 8 qo S lt HL vst XNTOAIN CIONA TOS 9 _ 9
13. Hose Fitting Fuel Line Hose 7 5mm Clamp 4 Hose Fitting Fuel Tank Strap Nut M8 uoo 20 N Lockwasher M8 Figure 3 22 Fuel Tank Removal Removal NOTE Drain Fuel Tank 1 before removing Store diesel fuel in approved receptacle 1 Disconnect the Fuel Line Hoses 2 5 from the fuel tank by loosening the Clamps 3 6 Pull hose from Hose Fittings 4 7 2 Remove the Fuel Tank 1 by removing the four Nuts 9 and Lockwashers 10 on the two fuel Tank Straps 8 3 24 JLG Lift Installation 1 Place Fuel Tank onto the chassis Secure tank with Fuel Tank Strap Fasten with Bolts and Lockwashers 2 Secure Hose Fittings to Hoses with Clamps 3 Refuel Tank with diesel fuel NOTE Empty fuel tank weighs approximately 36 6 Ibs 16 6 kg 3121325 3 5515 amp 5 55 5 3 9 GROUND CONTROL PANEL
14. dumg 57 dung 9 cf 1011900 19881 11015 pued H9 1I9 JoNUOD apoy 959ICI 5 Vct 101000 193311 G9uoniu8 uo pued x lduroO SA oued II foy 8 pued punog 19 poued VOD cd 1 81 19 s oued NI VOD 24 Figure 6 27 Electrical Schematic Sheet 10 of 15 6 21 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 11 o8eg IS 19 715 08 959ICI ST 19 10 8 uonoouuo IVOBLILOT TH OLLVIWHHOS XII II III 2V OIM 2IXV Sun IonuoO 1010IVI cv 11 1 dung 7 uuope d ZZONd SA q dung ZZONd IX 1 Ionuoo 19331 19 XNJOAIN TVI IX T 19456 DOT 12219 5 WT SUIP OH Aroneg punosis
15. 6 22 Electrical Schematic Sheet 12 0115 6 23 Electrical Schematic Sheet 13 15 6 24 Electrical Schematic Sheet 14 15 6 25 Electrical Schematic Sheet 15 0115 6 26 Electrical Diagram 1 2 2 6 38 Electrical Diagram Page 2 2 6 39 Hydraulic Components H900067 RevE Page 1 of 2 6 40 Hydraulic Components 900067 RevD Sheet 2012 6 41 Hydraulic Schematic 1001091321 6 42 JLG Lift vii LIST TABLES TABLE NO TITLE PAGE NO 1 1 Operating Specifications Mane ee Pal LU ee 1 1 1 2 Dimensional Datar uu puru RU AN ee et Vere 1 1 1 3 02850252 8 ELS ua hata cce 1 1 1 4 Engine SpecificationS 20 sas Waa ed 1 2 1 5 Engine Battery 1 2 1 6 Tire OS re oe dads ch GEO a aer ec ee 1 2
16. tem 1 2 1 5 WIE 1 2 1 6 Torque Requirements pl bua pir a E 1 2 1 7 Sensors icone RE A 1 2 Platform Stowed Jacks Retract Limit 1 1 2 High Drive Speed Cutout Limit Switch 1 2 Maximum Drive Height Maximum Height without Outriggers Limit Switch 1 2 Maximum Height Limit 41 1 2 4 A nd Qus t eo et a uya acie o ud sd tied 1 2 Outrigger Sensors oer c RR pun DIM PUE da eo 1 2 Oscillating Axle Limit Switch Re 1 2 1 8 Pressure Setting 1 4 1 9 Major Component Weights 4 1 4 1 10 Critical Stability Weights 0 1 4 1 11 au uu ga pastes sys he eae ey de Says cate eave h a 1 4 SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance 2 1 General CH REL 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection Lee e ue eri 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine
17. 3 7 Motor Disassembly 3 8 22 2 ade dace aa 3 8 3 4 Steering Assembly ee ix ede ees 3 9 3 5 Rear AKC 3 10 Lirrit SWItChes 1s DA Qo ES e Doa ge ari TR eat 3 10 3 6 Outrigger Cylinder 1 2 3 11 3 7 Engine Conipartmient le ed Sa ee ee 3 13 Hood Assembly 22 Saat 3 13 D utz Engine u u re sete ete f B ity e de 3 14 Engine Tray Slide Preeti a Ere 3 15 Glow PlUQS need mahu Roca ede ede cea eae ae quse 3 16 Engine Solenoid Fuse 2 22 ad ie pu UE eee eed ede aa oe 3 16 Hydraulic Pump Assembly 2 3 17 Hydraulic PUMP Se ee ue web qe ee he 3 18 Exhaust Pipe Assembly 2 5 22 2 3 19 Air Filter Assembly e eee hee idonee RT us eA een 3 20 M 3 21 Hydraulic Tank uu c eder ov e r
18. I Surpjog proT MOT poued 11 19407 d 16 TE OL mdu 19407 c I I IZ WPH 9MIC Xe Ic WL S II II x lduoo IV IX LAO ULL td SAM 1 17 J S XN 8 8 S x lduroO C 8f X0I0 IM 5 C7 I I Xojduro S c Hc z dung 91 1 x duroO Dc pom LNO Held yoo pued APA LNO Dc NI Ald NI Pld Srourg S NI pued punog epomed T 39071 Z AEA 3007 dc 3207 8 1 x lduroO 1V 3L 6 1 f ATA 14814 19916 01 1 x lduroO ATLA 1191 19915 ca 194195 2 4 195 21 11 X9I 9 11 Soyeuy aapea SAL t ab NI A 8A dk S 1f Ig 8 101000 193811 9
19. XC IX kas FL 1213 oum ATT IHOIHH LHOISH 557 1 1 1 16 CND MOLLSAOL XC OL 3 _ jndino Sojeuy ndur ITOLA MOILSAOL WYOALV Td 6 jndino 19881 101000 198811 jndur 1988111 6 ze MOILSAOLS 11 C VVX Oc VvX T 3 005 1 0 54055105 Figure 6 19 Electrical Schematic Sheet 2 15 6 13 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS IS 19 15 08 1959 IVORLLOH TH OLLVIWHHOS XII II III ST 105 Aquo XVW 104 SunjrT e 6021 gt M HOLIAS 1997195 399595I91 0 sec JL AATVA qo Idd LOOHLIA 1 XVII S F Ic DNIIVTIIOSO
20. amp 5 55 5 Glow Plugs 1 30 Fuses 2 Timer Relay N6 3 Relay K3 Engine Solenoid Fuse 1 Solenoid 2 30 Fuse Figure 3 14 Engine Solenoid 3 16 JLG Lift 3121325 3 5515 amp 5 55 5 Hydraulic Pump Assembly Hydraulic Pump Bolt M12 x 30mm Lockwasher M12 Flange Capscrew M10 x 25mm Lockwasher M10 Coupling Hex Head Screw M8 x 25mm see installation note below Lockwasher M10 Figure 3 15 Hydraulic Pump Assembly REMOVAL 1 3121325 Disconnect any hoses and or wires on the Hydraulic Pump 1 Remove the two Bolts 2 and Lockwashers 3 necting the pump to the Flange 4 Carefully remove the pump To remove the Flange unscrew and remove the twelve Capscrews 5 and Lockwashers 6 Remove the Coupling 7 by unscrewing and remov ing the six bolts 8 and Lockwashers 9 INSTALLATION 1 NOTE JLG Lift Follow the Removal Procedures in reverse order when installing the hydraulic pump assembly Torque item 5 Capscrews and lockwasher to 50Nm 37 Ib ft DRY Do not reuse the lockwashers item 10 when reas sembling item 8 Hexhead Screws Apply Loctite 242 to the treads of item 8 Coupling Plate Screws M8 x 25mm upon reassembly and torque to 25Nm 18 5 Ib ft 3 17 3 5515 amp 5 55
21. 1 1 2 2 1 Preventative 1 2 1 2 2 Service and 2 2 General so Tor TL 2 2 Safety and Workmanship 1 2 2 2 2 Components Removal and 2 2 Component Disassembly and Reassembly 2 3 Pressure Fit Parts 2er eripe MERE REPE EE Yd 2 3 __ 2 3 2 3 Bolt Usage and Torque Application 1 2 3 Hydraulic Lines and Electrical 0 2 3 Hydraulic System RR RR e 2 3 eo Nga Oel ip 2 3 tau piqa kisi uru ee ae ctos e sa 2 3 Lubrication and Servicing 2 3 2 3 Lubrication and Information 1 2 4 Hydraulic 2 4 2 4 Changing Hydraulic II 22
22. t 1 81210 25 FOR REFERENCE ONLY t 1 y is RL B2 bottom side NOTE FOR SL210 25 AND SL245 25 MODELS ONLY D3 5 el 6 x T 52 CLEE N i gt 5 D4 g 2 5 A 6 C4 59 po 918 V 8 Es 82 Br B1 bottom side g 8 RR lt Figure 6 35 Hydraulic Components H900067 Page 1 of 2 6 40 Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS v 7 v d FL ate DEUTZ 4 CYL f e B3 front side ja lange 2 8 c2
23. Bushing Limit Switch Capscrews M5 x 50mm Plate Bolt M12 x 80mm 11 Lockwasher M12 12 Bushing 13 Bushing oco PF O DN 14 M20 x 80mm 15 Hardened Washer 20mm 16 Nut M20 Figure 3 7 Oscillating Axle Limit Switches NOTE Limit switches are located on the front side of the rear axle Follow the below procedures when removing and or replacing limit switches Removal 1 3 10 Disconnect battery by turning the handle on the ground control panel Remove the Limit Switch Cover 2 and Bushings 6 by unscrewing and removing the two Bolts 3 Flat washers 4 and Lockwashers 5 The Limit Switches 7 can now be removed Unscrew the four Capscrews 8 at each corner of the limit switch Disconnect any electrical wires Remove limit switch from Plate 9 The Plate can be removed from the Axle 1 by unscrewing and removing the two Bolts 10 Lock washers 11 and Bushings 12 and 13 Installation 1 Follow the removal steps in reverse order when installing the limit switches and or any of the compo nents Limit Switch Adjustment a Adjust limit switches to trip when axle is oscil lated 1 Axle Removal T 2 JLG Lift Secure the machine and the axle Remove the eight Capscrews 14 Hardened Wash ers 15 and Nuts 16 Carefully remove the axle from the chassis When installing the axle torque the Capscre
24. 5 Hydraulic Pump 1 Drain Port tighten to 177 Ib ft 240 Nm 2 Pressure Port tighten to 30 Ib ft 40 Nm 3 Inlet Port tighten to 66 Ib ft 90 Nm Figure 3 16 Variable Displacement Axial Piston Pump NOTICE Pump Flow Flow from the pump to the control valve is protected by a full flow and a load sensing dump valve both nor mally open to tank ports To generate hydraulic power to the control valve both dump valves need to be acti vated THIS PUMP IS FACTORY SET FOR FLOW PRESSURE AND HORSEPOWER CONTROL AND SHOULD NOT BE ADJUSTED CONTACT THE JLG SERVICE DEPARTMENT FOR INFORMATION Table 3 5 Variable Displacement Axial Piston Pump Specs Displacement 45 cc rev Max Speed 2300 rpm Power 40Kw Delta P 203 psi at 3046 psi 14 bar at 210 bar Max Torque 146 Ib ft 200 Nm Torque 53 Ib ft 72 Nm Filling Volume 0 26 gal 1 0L Nominal Pressure 4000 psi 280 bar Max Pressure 5100 psi 350 bar Weight dry 46 3105 21 kg 3 18 JLG Lift 3121325 3 5515 amp 5 55 5 Exhaust Pipe Assembly 1 Muffler 2 Exhaust Clamp 3 Exhaust Elbow 4 Exhaust Clamp 5 Exhaust Flex Pipe 6 Exhaust Clamp Tailpipe 8 Bolt M10 x 20mm 9 Lockwasher M10 Figure 3 17 Exhaust Pipe Assembly NOTE In the event any or all exhaust piping needs repaired or replaced f
25. 2 S P 2 s 15 8 58 5 8 5 2 la 13 3 2 8 00 S 5 19 5 5 N lo co e OUTPUT SIGNAL 88885 5 53 5333885558 Ignition signal diesel and relais J1 15 1 Starter J1 17 Drive Signal during Drive 1 1413 13 Drive Signal during Steering J1 1 1 1 1 1 Analog J1 6 1 Lift J1 5 V d X y d 1 Lower 1 3 Right Steer J1 9 1 1 1 LeftSteer J1 10 1 1 1 SER PAR J1 12 1 13 3 1 Differential Lock J1 18 1 1 Platform In J149 1 1 Platform Out 41 22 1 1 d Pump 1 amp RPM Liftor Lower Platform J1 7 1191 X 1 1 1 1 Pump 1 amp RPM Drive J1 7 1 1 1 1 Pump 1 8 RPM Steer J1 7 1 1 1 1 1 Pump 1 amp RPM Ext Retract PItf J1 7 1 1 1 1 1 Pump 2 Drive Mode if applicable J1 16 1 1 1 Pump 2 Lift Mode if applicable J1 16 1 1 1 I 1 LED 58 18 21 Drive Available J3 4 1 1 LED Max Height Lift Available J3 3 1 1 LED 2 5 Fast Drive Available J3 2 1 1 Horn J1 23 1 1 Board Power Linked to J1 21 on Diesel units Ground 414 Or Signals 1 1 Jumper Closed Power 24V Vs J1 24 3121325 SECTION 5 CONTROL SYSTEM 5 3 NIVOLUX AUTOMATIC SELF LEVELING SYSTEM Potentiometer TP 1 lateral axis Potentiometer TP 2 lateral axis Measuring Point Soll X Y Measuring Point Ist Y Me
26. GGN 104 LIYYJZ5X1 UL 2 5m SWITCH ader 1 X1 34A 2 ader 2 X1 26 1 ader 3 X1 35 2 ader 4 X1 36 3 GGN 3121325 JLG Lift 6 31 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description Position 1 Position 2 Label External Harness 105 LIYYJZ4X1 UL PLATFORM VALVE ader 1 1 22 1 1 2 1 21 1 2 3 1 2 GGN 106 LIYYJZAX1 UL LIFT VALVE ader 1 KL 14 1 ader 2 X1 32B 3 2 ader 3 1 1 GGN 107 LIYYJZ4X1 UL DRIVE VALVE ader 1 X1 13B 1 1 ader 2 1 14 1 2 3 1 041 GGN 108 LIYYJZ4X1 UL STEERING VALVE ader 1 X1 18 1 2 1 17 1 1 3 1 1 2 GGN 109 LIYYJZ12X0 75UL OUTRIGGER VALVES ader 1 1 OUTRIGGER 1 VALVE ader 2 J7 2 2 3 47 3 4 7 4 1 OUTRIGGER 2 VALVE ader 5 47 5 2 ader 6 J7 6 PE 7 7 7 1 OUTRIGGER 3 VALVE ader 8 J7 8 2 ader 9 J7 9 PE ader 10 J7 10 1 OUTRIGGER 4 VALVE ader 11 7 11 2 GGN 7 2 126 LIYYJZ25X0 75UL GROUND PANEL ader 1 1 1 1 ader 2 1 2 1 ader 3 X1 3 1 PC ader 4 X1 4 2 PD ader 5 X1 5 2 PE ader 6 X1 6A 2 PF ader 7 1 7 2 PG ader 8 X1 9 2 PH 6 32 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal B
27. Ajunoog YOUMS 188914 9I Surreoq punodr ur 4 Figure 6 32 Electrical Schematic Sheet 15 of 15 3121325 Lift 6 26 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description IV08 Position 1 Position 2 Label External Harness 1 UL1569 180R X1 12 3 PNP5 J1 1 2 UL1569 18R X1 6A 3 PNP5 J1 2 3 UL1569 18GR X1 16 4 PNP5 J1 3 4 UL1569 18BR X1 13A 4 PNP5 J1 5 5 UL1569 18P X1 15 3 PNP5 J1 4 6 UL1569 18P ELCO 5 1 4 7 1 1569 18 ELCO 5 J2 1 8 UL1569 18BL X1 C 4 5 J2 1 9 UL1569 18G X1 23 3 PNP5 J2 2 10 UL1569 18GN X1 26 3 5 J2 4 11 UL1569 18W X1 24 4 5 J2 5 12 UL1569 18ZW X1 41B 3 5 J2 6 13 UL1569 18GR 1 33 2 5 1 14 111569 1808 X1 G 4 KVS A2 15 UL1569 18GR X1 6B 3 KVS 13 16 UL1569 18GR KVS 23 KVS 13 17 UL1569 18GR X1 34 A 4 KVS 14 18 UL1569 18GR X1 28 3 KVS 24 20 UL1569 18GR X1 11 3 D20 A 136 UL1569 18GR KTC 11 D20 K 135 UL1569 18GR trig contr J2 4 KTC 14 21 UL1569 18GR X1 16 3 KD2 A1 22 UL1569 18GR X1 A 3 KD2 A2 23 UL1569 18GR X1 14 3 KD2 21 24 111569 1808 1 138 3 KD2 11 25 UL1569 18GR X1 56 3 KT 24 26 UL1569 18GR X1 7A 1 KT 21 27 UL1569 18GR
28. Figure 4 21 Rod Installation 14 Continue pushing the rod into the barrel until the inder head can be inserted into the barrel cylinder 3121325 Cylinder Rod lt Cylinder Head Figure 4 22 Rod Assembly Installation 15 Using a spanner wrench tighten the cylinder head onto the barrel NOTE Steps 16 applies only the Lift and Axle Lockout Cyl inders 16 If applicable after the cylinder has been reassem bled the rod should be pushed all the way in fully retracted prior to the reinstallation of any valve block load check valve or safety valve Cylinder Barrel Setscrews NOTE Lift Cylinder only Figure 4 23 Valve Block Installation JLG Lift 4 9 SECTION 4 HYDRAULICS Load Check Valve oA e 2 NOTE Axle Lockout Cylinder only Figure 4 24 Load Check Valve Installation 4 10 JLG Lift on gt Limit Switch Safety Valve Outrigger Cylinder NOTE Outrigger Cylinders only Figure 4 25 Safety Valve and Limit Switch Installation NOTE Refer to Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 3 to Figure 1 8 Torque Chart METRIC Fasteners Sheet 3 of 3 for setscrew torques 3121325 SECTION 4 HYDRAULICS 3121325 Piston Rod 2 3 4 5 6 Bushing Piston Piston Seal O Ring Setscrew 7 Cylinder Head 13 Solenoid Valve 8 Wiper 14 Che
29. 1 4 JLG Lift 3121325 SECTION 1 SPECIFICATIONS 4150548 27 120 F 49 C AMBIENT NO OPERATION BELOW THIS AMBIENT TEMPERATURE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 OR ABOVE 180 F 82 HYD OIL TANK TEMP TEMPERATURE a 3121325 120 F 49 C 110 F 43 C IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER CONSULT JLG SERVICE AMBIENT TEMPERATURE NO OPERATION ABOVE THIS PROLONGED OPERATION AMBIENT AIR TEMPERATURES 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C MOBIL 424 10W 30 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C O F 18 C 10 F 23 C a MOBIL DTE 13 OF 100 F 38 C OR ABOVE HYDRAULIC SPECIFICATIONS DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE 20 F 29 C 30 F 34 C EXXON UNIVIS 26 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS
30. With 24V on Coils 3 and 4 oil is forced through the flow dividers as it enters the A1 and A2 ports of the mani fold splitting 5096 of the oil to each axle resulting in Dif ferential Lock Tractor Drive 4 19 SECTION 4 HYDRAULICS Main Valve Block d 5 5 55 2 5 8 205 LNOUS 9 c 5 e ot ONIT3A31 2222 12010220 S S 5 5 5 0 C 5 LNOtid Ha 54 d dw 3 o G SNII3ATI 1431 ONIT3A31 5007 gt lt 1 HV3H O RA ONIT3A31 GIS ROLES 5 ONIH33IS SES 45 OU RELI 4 S gt 8 53 2 WHO4A1V1d AN Q JLG Lift 3121325 Figure 4 37 Main Valve Block 4 20 SECTION 4 HYDRAULICS Adjust main pressure on top of the Main Pressure Block remove the cap and attach a pressure gauge to pres sure test port see Figure 4 38 remove rubber plug from adjustment port pressure should be set to maximum of 210 bar 3045 8 psi Adjust the setting screw fully in clockwise direc tion see Figure 4 39 22 Figure 4 39 Proportional Valve Pressure Adjustment Figure 4 38 Pressure Test Port Pump Engage Disengage Valve 1 Torque to 5 ft Ibs 6 8 Nm 2 Torque to 25 ft 16 33 9 Nm Operating Pressure 3000 psi 207 bar Voltage 24VDC Figure 4 40 Pump Engage Disengage Valve 3121325 JLG Lift 4 21 SECTION 4 HYD
31. 1 1 2 7004276 CYLINDER 2 7002826 lt HEAD Figure 4 15 Cylinder Head Seal Installation 4 Carefully install the cylinder head on the rod ensur ing that the wiper o ring and rod seals are not dam aged or dislodged Push the head along the rod to the rod end as applicable Cylinder Figure 4 14 Rod Seal Installation Head EM WHEN INSTALLING PISTON SEALS ENSURE SEALS ARE Cylinder INSTALLED PROPERLY IMPROPER SEAL INSTALLATION COULD Rod RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER WHEN INSTALLING THE WIPER SEAL APPLY LOCTITE 609 THE WIPER SEAL IN THREE EVENLY SPACED PLACES TO AID IN RETENTION OF THE SEAL 2 Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove Install a new rod seal into the applicable cylinder head gland groove 3 Install a new head seal new o rings if applica Figure 4 16 Cylinder Head Installation ble a new backup ring in the appropriate outside diameter groove of the cylinder head 3121325 JLG Lift 4 7 SECTION 4 HYDRAULICS 5 Carefully slide the piston spacer onto the cylinder rod Cylinder Rod Figure 4 17 Spacer Installation 6 If applicable correctly install new o ring and snap ring in the inner piston diameter groove 7 applicable correctly place new seals in the outer piston diameter groove s A tube with an inner diameter slightly larger t
32. 22 12 0000 2 47 XCCICCC eiete lt 0000000009 loc a 5 J8 NIVOLUX 2 e zeg s lt lt 0 9 0 000 0000 0 00 ool SECTION 5 JLG CONTROL SYSTEM 2 N2J10 lt lok s 0000 eo KTC KT KD2 KL a CCCCCCCCVC b 2 w la ez ez 2 6 Al 13 23 KVS 1 CCCCCCCCCCCCCCCCC XC m lt 13 23 SECTION 5 JLG CONTROL SYSTEM TRIGGER OC K3 Bra C 00000000000000000 66660800000000 009 CL CONTROL loc 2 5o 1 2 3 4 5 6 7 8 910 11 12 Drama ar K1 lt
33. SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPON SIBILITY OF THE OWNER OPERATOR B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system 3121325 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 C MAINTENANCE A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS SAFETY VIOLATION NO SMOKING IS MANDATORY NEVER REFUEL DUR ING 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 CAU TIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UNDER A
34. zi 5 12 6 1 Main Terminal Box Wiring 2 6 27 viii JLG Lift 3121325 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 14 OPERATING SPECIFICATIONS Table 1 1 Operating Specifications 12 DIMENSIONAL DATA Table 1 2 Dimensional Data 3121325 JLG Lift Parameter 8051 8051 Maximum Working Height with outriggers deployed 87 ft 26 5 m Machine Height 13 91 with outriggers stowed 728 22 m rails up 4 24m Maximum Platform Height Machine Height 10 4ft with outriggers deployed 80 ft 24 5 rails down 3 16m with outriggers stowed 65 ft 19 8 Turning Radius Machine Width 2 Inside 14 5 ft 4 4m 2 53 m Outside 20 3 ft 6 1 498 Wheelbase 12 8 ft 3 9 m Machine Length 5 78m Maximum Work Load Capacity 1650 Ibs Main Platform Platform Extension 750 kg mensions extension Maximum Occupants 4 1300165 Platform dimensions extension 8 2x25 6ft Tools and Equipment 590 kg extended 2 5x7 8m 200 Ib force Transport Dimensions 19x8 3x10 4 ft Maximum Horizontal Manual Side Force 890 N 5 78x2 5x3 16 m Tilt Sensor Setting 3 Maximum Operating Wind Speed 28 mph 1
35. 6 9 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 4 WORKING WITH DEUTSCH CONNECTORS DT DTP Series Assembly Figure 6 12 DT DTP Contact Installation 1 Grasp crimped contact about 25mm behind the contact barrel 2 Hold connector with rear grommet facing you 3 Push contact straight into connector grommet until a click is felt A slight tug will confirm that it is properly locked in place 4 Once all contacts are in place insert wedgelock with arrow pointing toward exterior locking mechanism The wedge lock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly Figure 6 13 DT DTP Contact Removal 5 Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out 6 To remove the contacts gently pull wire backwards while at the same time releasing the locking finger by moving it away from the contact with a screwdriver 7 Hold the rear seal in place as removing the contact may displace the seal HD30 HDP20 Series Assembly Figure 6 14 HD HDP Contact Installation 8 Grasp contact about 25mm behind the contact crimp barrel 9 Hold connector with rear grommet facing you 6 10 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 10 Push contact straight into connector grommet until a positive stop is felt
36. When this switch is activated the drive speed is limited 2 to slow speed Self Leveling system valve outputs OUTPUT S S KK S 5 cut and the tilt switch circuit controls the lift function a SOP phe which is cut out Trigger Switch J2 3 1 1 1 Start 426 0 1 Maximum Drive Height Maximum Height without Outrig gers Limit Switch Drive Height Drive 42 8 1 1 Spare 4011 1 1 This limit switch is mounted the chassis and is acti vated by a cam mounted on the pivot of the scissor pack When the platform is below the maximum permitted drive Board Power height this switch is closed and 24V output is available 24V Vs J2 1 The Control System Complex Board uses this signal Ground 92 12 to enable the drive function 1 Trigger Input Pump Lower input within 6 seconds When this switch is activated the drive function is cut When elevating without outriggers deployed this switch will also prevent lifting above the drive cutout height Maximum Height Limit Switch S Max Height This limit switch is mounted on the chassis and is acti vated by mounted on the pivot of the scissor pack 3121325 Lift 5 9 SECTION 5 CONTROL SYSTEM When the platform is below the maximum height this switch is closed One contact passes a 24V signal to the Control System Complex 2 Board to enable lift up The other contact passes 24V from Relay KT cont
37. 3 9 3 7 Oscillating Axle Limit 1 3 10 3 8 Outrigger Cylinder Removal Sheet 1 2 3 11 3 9 Outrigger Cylinder Removal Sheet 2 2 3 12 3 10 Hood Assembly ccs et ee eek ee RR 3 13 3 11 Deutz F4b 2011 reer e ieee xe ET YT BE ee ee els ee c g 3 14 3 12 Engine Tray Slide asain snes elie Mes DAD naa ite ve AVE E PARURE 3 3 15 3 13 r GIOW PIUGgS Cth elt Oa diesel bee binned iden se ME deis us 3 16 3 14 Engine Solenoid Ra n URP edie 3 16 3 15 Hydraulic Pump ell mu 3 17 3 16 Variable Displacement Axial Piston 3 18 3 17 Exhaust Pipe 2 3 19 3 18 AirFilter Assembly a ete bee nU ue PSP Wer rd euren 3 20 3 19 Engine Removal 2 uyu a te SE ERU RU Merced A WES 3 21 3 20 Hydraulic Tank 1 1 4 4 3 22 3 21 Pressure Filter Removal 2 3 23 3 22 Fuel Tank Removal Be ACRI DER De ee ee s 2 3 24
38. 8 1 Diesel Engine 3 Air Intake 2 Air Filter 4 Hydraulic Oil Tank Figure 3 11 Deutz F4L 2011 Table 3 4 Engine Technical Data Description Deutz F4L 2011 Deutz D2011 L04 i of cylinders 4 Cylinder Arrangement Vertical In Line Bore 94 mm Stroke 112mm Total Displacement 3108 cm Working Cycle 4 Stroke Diesel Engine Specific Fuel Consumption 214 g kWh Engine Speed High 2300 l min Low 850 l min Voltage 24V Starter Battery qty 2 12V 88 Alternator 14V 60Ah Weight 256 kg 3 14 JLG Lift 3121325 3 5515 amp 5 55 5 Engine Tray Slide 1 Capscrew M16 30mm 2 Lockwasher M16 3 Capscrew M16 x 60mm Figure 3 12 Engine Tray Slide The engine tray can slide outward approximately 5 9 in 15 cm when servicing components inside the engine compartment 1 Remove the two Capscrews 1 and Lockwashers 2 on the front of the engine tray 2 Loosen the two top Capscrews 3 at both ends of the engine compartment Slide engine tray outward 3 Be sure to return engine tray to stowed position when finished servicing Secure engine tray with the two front Capsrews 1 and Lockwashers 2 and two top Capscrews 3 3121325 JLG Lift 3 15 3 5515
39. o2 9 T Y II 2 b d M 17 x lt gt lt gt Lr MV V lt re y 4 17 C1 bd 3 v M Br 1 v i le 7 9 nd 1 01 t Br B4 front side FR 4 8 B ES J x gt 9 9 gt om 24 2 E 5 5 5 5 2 5 5 amp Figure 6 36 Hydraulic Components H900067 RevF Sheet 2 of 2 3121325 JLG Lift 6 41 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS F4L 2011 NOTE FOR SL210 25 SL245 25 MODELS ONLY NOTE 51210 25 MODEL HAS 1 EXTENSION CYLINDER Figure 6 37 Hydraulic Schematic 1001091321 RevD 3121325 Lift 6 42 An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA g 717 485 5161 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia F 612 65 811111 61 2 65 810122 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany FE 49 0 421 69 350 20 49 0 421 69 350 45 JLG Polska UI Krolewska
40. 00 060 Warsawa Poland FE 48 0 914 320 245 48 0 914 358 200 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 EL 852 2639 5797 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland 44 0 141 781 6700 44 0 141 773 1907 amp 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 28 44 0 161 654 1000 44 0 161 654 1001 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 34 93 771 1762 www jlg com 3121325 JLG France SAS 2 1 de Baulieu 47400 Fauillet France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 Oshkosh JLG Singapore T E P Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 65 6591 9030 65 6591 9031 JLG Sverige Enkopingsv
41. 1868 KTC 11 D20 K 137 UL 1569 18GR KTC 11 D17 K 138 UL 1569 1868 C2 J2B 1 D19 A 139 UL 1569 18GR D13 A C2J1A 3 140 UL 1569 1868 D14 A 2 141 UL 1569 1868 D15 A C2 J1B 7 142 UL 1569 18GR 016 C2J1B 10 143 UL 1569 1868 KL 24 C2 LED GROEN 144 UL 1569 18GR X1 D 3 KL A2 145 UL 1569 1868 X1 38 1 KL 11 146 UL 1569 18GR D24 K KL A1 147 UL 1569 18GR D25 K KL A1 148 LIYY JZ2X1 ader 1 Splice8 L 52 11 ader 2 Splice7 R 2 12 D1 DIO BY550 X1 7A 3 X1 8 3 D2 398 ANSI DIO X1 8 4 X1 33 3 D3 398 ANSI DIO 1 11 4 1 41 4 04 398 ANSI DIO 1 11 4 1 40 3 05 398 51 010 1 25 3 X1 B 3 D6 398 ANSI DIO X1 32B 4 X1 B 4 D7 398 ANSI DIO X1 41B 2 X1 21B 2 D8 398 ANSI DIO X1 20 3 1 3 09 398 ANSI DIO KVS A1 KVS A2 D10 398 ANSI DIO REL 12 REL 21 011 398 ANSI DIO X41 A 2 X1 22 3 D12 398 ANSI DIO KD2 A1 KD2 A2 D18 DIO BY550 KTC A2 1 021 398 ANSI DIO X1 51 3 X1 30 3 D22 398 ANSI DIO X1 56 2 X1 30 2 D23 DIO BY550 KL A2 KL A1 51 CSS 1001 2x 2 CSS 1001 4x 3 CSS 1009 3121325 JLG Lift 6 35 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description ee Type Position 1 Position 2 Label External Harness 54 CSS 1009 5 CSS 1003 7x 56 6551003 57 CSS 1002 58 655 1003 2 59 55 1005 510 CSS 1007 900066 NOTE Position 1 Termination point the Terminal Box There 4 connections at each terminal posit
42. 47 2 KG 3 36 JLG Lift 3121325 3 5515 amp 5 55 5 3 13 BEACON INSTALLATION OPTION Front and Rear 1 Beacon amp Protective Cage Mounting Bracket Screw 6mm x 16mm m Washer 6mm Rear Beacon Front Beacon Harness Position W11 0000000 OOO Opooeo e MTB Underside 5 Bolt x 25mm 6 Nut M4 7 Washer 8 Guiding Rods Figure 3 35 Beacon Installation Removal NOTE Procedures apply to both the Front and Rear Bea cons Disconnect electrical supply 2 Disconnect beacon harness from beacon and MTB if needed 3 Remove Bolts 5 Nuts 6 and Washers 7 to remove the Beacon and Protective Cage 1 4 The Mounting Bracket 2 can be removed from the chassis by removing the two Screws 3 and Wash ers 4 5 Repair Replace if necessary Installation 1 3121325 Follow Removal Procedures in reverse order 2 Route Front Beacon Cable behind the Guiding Rods 8 to avoid contact with the tie bar Follow route of the signal cable for Outrigger 1 Fix with tie straps Route Rear Beacon Cable together with signal cable for Outrigger 3 Fix with tie straps Route Harness through Position W11 on the under side of the M
43. 59700 740 1005 796 1079 1100 1491 11 8 7 1 1250 0 7630 68700 960 1302 1030 1396 1400 118981 1 1250 0 8560 1155 1607 1575 2135 1 2500 0 9690 1360 1844 1453 1970 2000 2712 1 2500 1 0730 96600 1500 2034 1610 2183 2200 129851 1 3750 1 1550 1907 _ 2586 2625 35591 12 6 2 1 3750 1 3150 118100 2040 2765 2165 12935 3000 4067 1 5000 1 4050 126500 2360 152001 2530 13430 3475 punt 142200 2660 _ 3606 2844 13856 3925 153221 5000029 LI NOTE THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS SAE GRADE 5 SAE GRADE 8 Figure 1 5 Torque Chart SAE Fasteners Sheet 3 of 3 1 8 JLG Lift 3121325 SECTION 1 SPECIFICATIONS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS TORQUE tw TE LOCTITE 28 4 XII 1 4 2 3 3 4 6 8 12 19 28 55 97 154 241 331 469 639 811 1130 1530 2560 1920 2690 4090 3070 4290 _ 5000029_H NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS METRIC CLASS 8 8 METRIC CLASS 10 9 Figure 1 6 Torque Chart METRIC Fasteners Sheet 1 of 3 3121325 JLG Lift 1 9 SECTION 1 SPECIFICATIONS VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY TENSILE TORQUE STRESS DRY OR LOCTITE 263 AREA CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS
44. 75 75 35 40 1940 2630 1460 1979 1755 2379 2025 2746 2200 2983 1640 2224 1974 26761 2300 3118 NOTE THESE TORQUE VALUES DO APPLY TO CADMIUM PLATED FASTENERS Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 3 JLG Lift 5000029 H SAE GRADE 5 SAE GRADE 8 3121325 SECTION 1 SPECIFICATIONS 3121325 SIZE BOLT DIA TENSILE STRESS AREA 0 00604 0 00661 48 0 1120 32 0 1380 0 00909 VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY SAE GRADE 8 BOLTS amp GRADE 8 NUTS amp SOCKET HEAD CAP SCREWS 6 THRU 1 4 TORQUE DRY OR LOCTITE 263 TORQUE LOCTITE 262 TORQUE LOCTITE 242 OR 271 0 1380 0 01015 920 32 0 1640 0 01400 36 0 1640 0 01474 10 0 1900 0 01750 0 0318 0 0364 LB IN LB IM IN LB IN LB N m 540 12 4 1 0 60 13 1 5 9 II 820 23 2 61 11 91 25 12 8 19 12 21 41145 31135 sd 1320 4 5 32 4 1 1580 6017 45 5 3 0 190 0000 180 18 14116 108 12 168 19 120 14 185 1201 20 0 2500 28 0 2500 18 0 3125 0054 16 0 3750 7000 45 61 35 471 40 54 1681 M 0 4375 0 1063 20 0 5000 0 1599 12 0505 0 180 EBMI ON m 0 6250 0 2260 2 2 0 7500 0 3340 30100 380 515 280 _ 380 301 14081 4 569 4 0 7500 0 3730 0 8750 0 4620 0 8750 0 5090 45800 6
45. A slight tug will confirm that it is properly locked in place LOCKING FINGERS CONTACT UNLOCKED POSITION CONTACT LOCKED IN POSITION Figure 6 15 HD HDP Locking Contacts Into Position NOTE For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly P Figure 6 16 HD HDP Contact Removal 11 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 12 Slide tool along into the insert cavity until it engages contact and resistance is felt 13 Pull contact wire assembly out of connector TOOL INSERTED TO TOOL AND CONTACT UNLOCK CONTACT REMOVED Figure 6 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121325 JLG Lift 6 11 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS e8eq vTM L 715 19 IS 08 9891 poued 103005 IVORLLOT IH OLLVINHHOS X YLLATI SI VYX I2 VVX KIN PX 5 S VVX 0I VVX 9I VVX 6I VVX1 VI VVXI I VVX IHOIHH 1 MOOT CND MOLLSAOL MOILSAOL WdaOALV Id 8 3 5 TIY 54055105 MOILSAOLS 6UV VXI 0CVVVXI SUVTXI OL VtX 91 CI VVX vUvvX S vr
46. 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 comprehen sive inspection and preventive maintenance program The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult your national regional or local regulations for fur ther requirements for aerial work platforms The frequency of inspections and maintenance must be increased as environment severity and frequency of usage requires Pre Start Inspection It is the User s or Operator s primary responsibility to per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor s and Safety Manual for completion procedures for the Pre Start Inspection The Operator and Safety Manual must be read in its entirety and understood prior to per forming the Pre Start Inspection Pre Delivery Inspection and Frequent Inspection The Pre Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recog
47. Cylinder from the arm stack by 1 is still attached to the chassis and the arm stack removing the Bolt 3 and Lockwasher 4 Pull out will pivot about the Pin 2 When sufficient clear the Pin 2 ance is achieved between the lift cylinder and frame secure the cylinder NEVER EXTEND THE LIFT CYLINDER WHEN THERE IS NO LOAD ON THE CYLINDER THE CYLINDER IS SINGLE ACTING AND WILL HAVE NO MEANS OF RETRACTING 5 STRAP _ 1 Lift Cylinder 3 Bolt M20 x 35mm 2 Pin 4 Lockwasher M20 13 The arm stack can now be moved away from the NOTE Follow the removal steps in reverse order when machine Place the arm stack in a holding device or installing the arm assembly on secure blocks 3121325 JLG Lift 3 41 3 5515 amp 5 55 5 Lift Cylinder Removal A WARNING USE CAUTION WHEN REMOVING AND MOVING THE LIFT CYLIN DER THE LIFT CYLINDER ASSEMBLY WEIGHS APPROXIMATELY 992 LBS 450 KG USE APPROPRIATE LIFTING DEVICES 1 Follow the procedures on the previous pages to remove the platform and scissor arm assemblies 2 Shutoff flow of hydraulic fluid by closing the shutoff levers on the hydraulic tank see Figure 3 20 Remove all hoses and or wires from the Lift Cylinder 1 MAKE SURE THE FITTING ON THE LEAK OIL LINE IS CLOSED TO PREVENT EXTENSION OF THE CYLINDER WHILE LIFTING FROM THE MACHINE 3
48. Machine Stabilization The arm stack can be supported by using an overhead crane Figure 4 31 If an overhead crane is not available the stack may also be lifted by using a forktruck using the following instructions 1 With the forks on the forktruck slid close together enter from the front of the machine and place the forks on the cross tube of the second arm weldment below the platform Slowly lift the arm stack with the forktruck while the manual descent valve is being engaged this allows the oil to drain back into the tank Place machine on safety prop and leave the fork truck in place If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and plat form removal 3 34 NOTE Procedures apply to both left and right sides Removal 1 JLG Lift Disconnect all wiring and hydraulic lines attached to the platform or plattorm components Cap hydraulic lines to prevent leakage Support the platform along the sides with the fork truck forks or use suitable straps or chains at the four corners of the platform Remove the two Bolts 2 and Lockwashers 3 attaching the two Platform Pivot Pins 1 to the Plat form Continue on to the rear of the machine See next page 3121325 3 5515 amp 5 55 5 1 Platform Retaining Bracket 2 Bolt M10 x 16mm 3 Lockwasher M10 NOTE Illustra
49. Number 1 000 000 Example 1 2 1200 Example 50 mA 0 05 A 3121325 JLG Lift 6 1 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Voltage Measurement Resistance Measurement Figure 6 1 Voltage Measurement DC Figure 6 2 Resistance Measurement If meter is not auto ranging set it to the correct range First test meter and leads by touching leads together See multimeter s operation manual Resistance should read a short circuit very low resis Use firm contact with meter leads tance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing If meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads 6 2 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Current Measurement 1 7 Tu Figure 6 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity Figure 6 4 Current Measurement DC Set up th
50. Place a strap attached to an overhead lifting device through the top portion of the lift cylinder to secure the cylinder 4 Put cylinder into a vertical position with the over head lifting device 5 Remove the Bolt 2 and Lockwasher 3 Pull the Pin 4 out of the machine 3 42 6 Carefully raise the Lift Cylinder 1 from the chassis using an overhead crane or other suitable lifting device 1 Lift Cylinder 3 Lockwasher M20 2 Bolt M20 x 35mm 4 Pin Figure 3 37 Lift Cylinder Removal NOTE Follow the removal procedures in reverse order when installing the lift cylinder JLG Lift 3121325 SECTION 3 CHASSIS PLATFORM amp SCISSOR ARMS Scissor Arms Disassembly A CAUTION INDIVIDUAL SCISSOR ARMS ARE HEAVY USE CAUTION WHEN REMOVING USE APPROPRIATE LIFTING DEVICES 1 NOTE Disconnect battery and shutoff flow of hydraulic fluid by closing the shutoff levers on the hydraulic tank see Figure 3 20 Remove Platform see Figure 3 32 Platform Removal 1 of 2 Front of Platform and Figure 3 33 Platform Removal 2 of 2 Rear of Platform Hydraulic lines and electrical lines run through the insides of the scissor arms These hoses and wires must be removed before removing the arm compo nents Brace the Scissor Arm Assembly as well as the indi vidual Scissor Arm s being removed The below steps apply to each scissor arm pin On the left si
51. SPECIFICATIONS 1 12 TORQUE CHARTS BOLT DIA TENSILE STRESS AREA 50 VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY SAE GRADE 5 BOLTS amp GRADE 2 NUTS TORQUE DRY OR LOCTITE 263 IN LB N m TORQUE LOCTITE LOCTITE 262 du OR IN LB 0 00604 L 9 7 0 00661 1 0 8 0 00909 0 01015 1 8 2 0 1 4 1 5 0 01400 3 5 2 5 0 01474 4 2 6 0 01750 5 3 5 0 02000 5 5 4 0 0318 11 9 105 12 0 0364 120 14 10 155115 SQ IN 2 7 2 6 2 6 2 1 1250 0 8560 3340 3700 4940 5600 6800 7550 9050 10700 12950 14400 16300 21300 23800 29400 32400 38600 42200 42300 47500 53800 59600 64100 73000 78000 87700 FT LB N m 17 23 19 26 30 41 35 47 50 68 55 75 75 102 90 122 110 120 150 170 260 149 163 203 230 353 300 407 430 583 470 637 640 868 700 949 800 1085 880 1193 1120 1240 1460 1680 1518 1681 1979 2278 FT LB N m 55 60 85 FT LB N m FT LB N m 1 2 3 8 9 2 2 3 5 6 200 12711 3251 285 386 30 140 6 7 8 2 5 0 8 8 40 68 86 258 386 447 644 705 350 475 480 651 530 7191 425 579 576 785 633 _ 858 600 813 714 968 660 895 85 30
52. Service Training School for the subject JLG product model Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for perfor mance of this inspection Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection Reference the appropriate areas of this man ual for servicing and maintenance procedures For the purpose of receiving safety related bulletins it is important that JLG Industries Inc has updated ownership information for each machine When performing each Annual Machine Inspection notify JLG Industries Inc of the current machine ownership Preventative Maintenance In conjunction with the specified inspections mainte nance shall be performed by a qualified JLG equipment mechanic JLG Industries Inc recognizes a qualified equipment mechanic as a person who by possession of a recognized degree certificate extensive knowledge train ing or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environment severity and frequency of usage requires 3121325 JLG Lift 2 1 SECTION 2 GEN
53. TS 19 15 08 1951 THNVd OLLVINHHOS ATI XC wtb 0 THNVd YOLOANNOD V d THUD 9 SILX TANVd YOLOANNOD gil 9 CX TANVd YOLOANNOD 4 d NOLLVLS 9 NHINVLS 22 TANVd YOLOANNOD 4 4 TANVd GNNOUD YOLOANNOD H 4 9 IX IHNVd YOLOUNNOD 9 4 X IHNVd YOLOANNOD 9 24018 S 76 I IHNVd Q I THNVd YOLIANNOD O 4 N nd TANVd YOLOANNOD N d IV IX TANVd 210 LDHNNOO N 4 SE TX TANVd YO LOANNOD d 4 5 TANVd S 8 TANVd YOLOANNOD Y d TANVd YOLOANNOD N d XI ie Cx THNVd TANVd YOLOANNOD Y d THNVd CM 095 YOLOANNOD 1 4 TANVd YOLOANNOD O 4 Vd GNNOYD YOLOANNOD f 8 XII II III Figure 6 29 Electrical Schematic Sheet 12 of 15 6 23 JLG Lift 3121
54. 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 equal ize Leaks will most likely occur at the pipe plugs the main seal or wherever o rings 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 meet on the exterior of the unit then checking for air bubbles If leak is detected a seal o ring or gas ket the part must be replaced and the unit rechecked Leak test at 10 psi for 20 minutes NOTE Due to the small air volume inside this Torque Hub it will pressurize to 10 psi very quickly If the pressure becomes excessive in the unit the seals will be destroyed Lubricant The torque hub unit is shipped with 90W gear oil It is designed to utilize the same oil throughout its service life However should it need to be serviced the oil will need to be drained and replaced In the event of servicing fill the unit with Arco 120 Drum or Exxon GX 80W 90 3 2 JLG Lift III III 1 Drive Hub 2 Screw 3 Circlip 4 Pin Figure 3 1 Torque Hub Hub Disengaging and Oil Checking Procedure 1 Loosen the two Screws 2 securing the Circlip 3 2 Slide the Circlip 3 in the direction of th
55. Valve Pac Outrigger Oylinder Figure 4 3 Safety Valve and Limit Switch Removal 3121325 DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 5 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 6 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power Source 7 Adequately support the cylinder rod if applicable 8 Place the cylinder barrel into a suitable holding fix ture BARREL CLAMP 5 PROTECTED ROD CLAMP SUPPORT TABLE Figure 4 4 Cylinder Barrel Support JLG Lift 4 3 SECTION 4 HYDRAULICS 9 Using a spanner wrench loosen and remove the 11 cylinder head from the barrel Cylinder Rod Using suitable protection clamp the cylinder rod a vise or similar holding fixture as close to the piston as possible If applicable loosen and remove the setscrew which attaches the piston to the rod and remove the pis ton N Oylinder Barrel Pistons ds 2 Nb Setscrews Figure 4 5 Cylinder Head Removal EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL 13 INDER ROD HEAD AND PISTON AVOID PULLING THE R
56. all hose clamps the hose clamps Once the hose clamps are loos ened the tubes and pipes can be removed for main tenance or replacement 2 remove the Air Filter 1 unscrew and remove the 2 Bolts 2 four Flatwashers 4 and two Locknuts 3 Remove the air cleaner from the bracket 3 20 JLG Lift 3121325 SECTION 3 CHASSIS PLATFORM amp SCISSOR ARMS Engine Removal 1 Bolt M12 x 110mm Flatwasher M12 Locknut M12 Oil Drain Port e 3 19 NOTE Refer Figure 3 19 when removing engine from engine compartment A WARNING ENGINE REMOVAL REQUIRES HEAVY LIFTING DEVICES USE EXTREME CAUTION WHEN REMOVING THE ENGINE 1 Disconnect electrical supply 2 Disconnect all electrical wires hoses pipes etc attached to the engine assembly 3 Secure engine with appropriate lifting device Refer to Deutz Operation Manual included with the machine 4 Unscrew and remove 4 Nuts 8 and Flatwashers 2 from the underside of the engine tray 3121325 5 JLG Lift Remove all 4 Bolts 1 and second set of Flatwash ers Carefully lift engine from engine compartment with appropriate lifting device When installing the engine follow the steps in reverse order The machine comes with an engine oil drain hose located in the plastic bag in the valve compartment to use when draining the oil
57. along with the components that make up that system are listed The INTERVAL portion of the table is 15 Check for proper inflation divided into five columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked 14 Check for condition of element replace as neces sary The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine 2 10 JLG Lift 3121325 SECTION 2 GENERAL Table 2 3 Preventive Maintenance and Safety Inspection AREA INTERVAL Daily Weekly 100 Hours 3 Months 200 Hours 6 Months 400 Hours 1 year PLATFORM 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 1 2 4 Control Tags 1 2 5 Hoses and Cables 48 6 Wear Pads 7 Handrails and Chains CHASSIS 1 Battery 2 Hydraulic Pump 3 Valves 4 Hydraulic Filter ANNUAL 5 Hydraulic Hoses and Tubing 6 Hydraulic Oil Tank 3 4 8 Lift Cylinder 1 12 5 6 13 9 Limit Switch 1 7 10 Tilt Alarm Switch 4 1 Placa
58. amp TIMER Figure 6 33 Electrical Diagram Page 1 of 2 6 38 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SCISSOR LOWERING ARMS LIMIT SWITCHES BATTERIES 1 h h B ye 7 e 9 e 91 5 91 6 l 6 Tal x STARTER DISCONNECT SWITCH PLATFORM CONSOLE gt C 8 0 9 Figure6 34 Electrical Diagram Page 2 of 2 3121325 JLG Lift 6 39 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SL245 25 FOR REFERENCE ONLY
59. be necessary to heat the oil with a low density electrical heater to a minimum temperature of 15 F 26 C Changing Hydraulic Oil 1 Use of of the recommended crankcase hydraulic oils eliminates the need for changing the oil on a regular basis However filter elements must be changed annually unless operating in extreme conditions If it is necessary to change the oil use only those oils meeting or exceeding the specifica tions appearing in this manual If unable to obtain the same type of oil supplied with the machine con sult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends chang ing the hydraulic oil annually Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always replace the filter and clean magnet any time the system oil is changed While the unit is shut down a good preventive main tenance 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 var
60. be removed Installation NOTE Place the rail s on the platform in their stowed posi tion when installing 1 Follow the removal instructions in reverse order 3121325 3 5515 amp 5 55 5 Platform Extension Rail Extension End Rail 2 Cotter Pin 3 Pin 4 Hinge Bracket 5 Bolt M10 x 120mm 6 Locknut M10 7 Flatwasher M10 8 Chain Assembly Mounting Plate 9 Tube Figure 3 31 Extension End Rail Removal Removal Installation 1 If applicable detach the end 1 from the side 1 Follow the Removal instructions in reverse order rails see removal instructions for side rails on previ when installing the platform extension end rail ous page 2 Remove Cotter Pins 2 from Pins 3 3 Pull Pins out of Hinge Brackets 4 4 Carefully lower rail to its stowed position 5 Secure rail 6 Remove the Bolts 5 Locknuts 6 Flatwashers 7 and Chain Assembly Mounting Plate 8 N Carefully remove the rail 8 Remove the Tube 9 from the rail 3121325 JLG Lift 3 33 3 5515 amp 5 55 5 Platform Removal NOTE Illustration shows scissor arm assembly connection point to Liz gt underside of platform at the front of the platform 1 Platform Pivot Pin 2 Bolt M12 x 25mm 3 Lockwasher M12 Figure 3 32 Platform Removal 1 of 2 Front of Platform
61. from the engine Remove the cover on the Oil Drain Port 4 Attach the drain hose to the Port The valve on the hose releases the valve on the Port to drain the oil Run the hose through the opening on the bottom of the engine tray 3 21 3 5515 amp 5 55 5 Hydraulic Tank 1 Hydraulic Tank 2 3 4 5 6 Capscrew M10 x 25mm Flatwasher M10 2 per capscrew Nut M10 Shutoff Valve Lever Filler Figure 3 20 Hydraulic Tank Removal Removal 1 NOTE 3 22 Close shutoff valve lever 5 to turn off flow of hydraulic fluld Drain hydraulic fluid by opening the drain port on the underside of the Hydraulic Tank 1 Store fluid in appropriate receptacle Disconnect all hoses Remove hydraulic tank by removing the four Cap screws 2 Nuts 4 and eight Flatwashers 3 Carefully remove the tank from the engine compart ment If required remove and replace Filter see Figure 3 21 Close hydraulic shutoff valve lever when servicing the hydraulic system and components Make certain to open lever when finished to return flow of hydrau lic fluid JLG Lift Installation 1 Place tank into engine compartment lining up the bolt holes Replace Capscrews Flatwashers and Nuts into their respectable holes Tighten Replace all hydraulic hoses Ensure the drain port is closed If require
62. in each direction gently pull the wire until the contact is removed gt Figure 6 10 Connector Disassembly NOTE The wedge lock should never be removed from the housing for insertion or removal of the contacts Wedge Lock The wedge lock has slotted openings in the forward or mating end These slots accommodate circuit testing in the field by using a flat probe such as a pocket knife DO NOT use a sharp point such as an ice pick 6 8 Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Service Voltage Reading A CAUTION DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands This nullifies the effectiveness of the connector seals and could result in system failure WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA CUTOFF TAB MUST BE VISIBLE SCREWDRIVER SLOT LOCKING LATCH MUST BE TO LIFT LATCH FOR SECURELY FASTENED UNMATING FOR MATING PLUG AND HEADER MUST BE OF IDENTICAL COLOR IN ORDER FOR THEM TO MATE Figure 6 11 Connector Installation 3121325 JLG Lift
63. metal or rub ber 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 JLG Lift 2 3 SECTION 2 GENERAL 2 3 LUBRICATION AND INFORMATION Hydraulic System 1 The primary enemy of a hydraulic system is contam ination 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 quantity of oil in supply tube The design and manufacturing tolerances of the component working parts are very close there
64. of these valves is 15 psi 1 bar for the rear and 116 psi 8 bar for the front Steer Cylinder Steering is controlled by a double acting cylinder con nected to the 4 section of the main control valve 4 2 VALVES THEORY OF OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three position solenoid valves of the sliding spool design When a circuit is acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Relief Valves Main relief valves are installed at various points within the hydraulic system to protect as
65. output at X2 8 fuel solenoid 005559 this input also powers up the glow plug relays at X2 23 Initially all 6 LEDs will flash 3 times to test the system and the LEDs After this startup check only the OK LED should flash An additional 7 seconds later the sys tem monitoring system is activated and the circuit recognizes fault input signals 2 start input on 1 2 50e creates an output at X2 7 start relay This input is ignored by the system after 10 sec to protect against short circuit or switch contact stuck closed situations The output is also dependant on the alternator input signal 3 The alternator input X2 10 W is monitored in the following way a When a start signal is applied to X1 2 50e the input on X2 10 needs to be less than 4Hz to enable an output at X2 7 50f Start lockout fea ture when engine is running b When X2 10 reaches 150Hz the X2 7 output is cut engine is sensed to be running and start signal is cut NOTE An input frequency of 80Hz can be achieved when the engine is cranking but not started If this occurs increase the sensing trip point in the E prom on the circuit board to 150Hz This ensures the engine is running before cutting the start signal 3121325 JLG Lift Motorcheck MC 716 G wibelectronics Ident Nr 043021 23 45 12 24 EO Vertragshandler Teilnummer 9999 1297 60 Glow Start 100
66. sight window on hydraulic tank If oil is not visible add oil until oil is visible in both ADD and FULL sight windows on tank Do not overfill tank Figure 2 1 Lubrication Diagram 3121325 Lift a 2 gt N 5 Outrigger Cylinders Engine Compartment Tie Rod End Spindles Oscillating Axle Lift Cylinder Fuel Tank Opposite Side Deck Arm Pivot Pin Upper Slide Pads Lower Slide Pads SECTION 2 GENERAL NOTE The following numbers correspond with those in 3 Engine Compartment a Engine Oil Check Fill Figure 2 1 Lubrication Diagram 1 Arm Pins Lube Points 41 Grease Fittings Capacity As Required Lube MPG Interval As Required 2 Outrigger Cylinders Lube Points Fill Cap amp Dip Stick Capacity See Engine Manual Lube EO SAE 20W20 Interval Every 3 months or 150 hours of operation Oil Drain Plug 1 Lube Points 4 Grease Fittings Capacity As Required Lube MPG Interval As Required 2 6 JLG Lift 3121325 SECTION 2 GENERAL b Oil Filter d Air Filter Maintenance Replaceable Element JLG P N 7016331 Maintenance Replaceable Element Interval Change every 500 hours or 6 months which JLG P N H005232 amp 70000054 ever comes first Change filter every time engine oil is changed Interval Every 6 months 300 hours of opera
67. speed time delay th 1 peration is performed with the engine at NOTE After the initial lift movement a short e high engine speed solenoid is ener gized to deliver the required oil capacity for normal lift ing operation Above the Fast Speed Cutout Height limit switch S 2 5m the NIVOLUX Board cuts all output to the outrig 2 ger valves This ensures that no leveling function can be performed with a raised platform 3 To retract the outriggers it is necessary to maintain the lowering function via the controller joystick after the 4 platform is in the fully lowered position This position is sensed the limit switch Platform Down and the NIVOLUX system automatically increases the engine speed from low idle and powers up the 4 outrigger retract valves When all outriggers are retracted the hydraulic system pressure increases to the relief setting This pressure is 5 sensed at approximately 2683 psi 185 pressure switch and signals the NIVOLUX system to re enable the drive function 6 This completes a full lifting cycle NIVOLUX Board LED s LED Meaning 7 Elevating the MEWP with outriggers selected Red LED N 59 Level OK Red LED N 60 Leveling Finished Red LED N 58 Ground Bearing Pressure Reached Red LED 61 Ground Bearing Pressure OK and Start Lifting After retracting the outriggers GreenLEDN 66 All Outriggers Retracted Elevating
68. the right and 0 1V represents an inclination of approximately 1 to the left Turn off the ignition switch and close the MTB 3121325 SECTION 5 JLG CONTROL SYSTEM Table 5 5 NIVOLUX Circuit Board 29 2 SiS 2 201 255 E S ale 5 XM AE 3 9 I MES 85 28 8 2 5 E 5 5 E 8 55 6 eS Output signal 8 8 2882 88 8 RPM to Deutz box 8 PNP Lift wth NIVOLUX J8 4 1 1 RPM to Deutz box amp PNP Lift wthout NIVOLUX J8 4 1 1 1 1 RPM to Deutz box amp PNP Lowering J8 4 1 1 Lift Valve J8 7 1 Drive OK with NIVOLUX J8 10 0 1 1 0 1 Drive OK without NIVOUX J8 10 1 1 1 Front Left J7h 1 1 0 Front Left OUT during leveling 47 2 1 1 1 1 0 FrontLeft OUT establishing ground pressure J7 2 1 1 amp amp amp amp 0 0 Front Right IN J7 4 1 1 0 Front Right OUT during leveling J7 5 1 1 1 1 0 Front Right OUT establishing ground pressure J7 5 1 1 amp amp amp amp 0 0 Rear Right IN J7 7 1 1 0 Rear Right OUT during leveling J7 8 1 1 1 1 0 Rear Right OUT establishing ground pressure J7 8 1 1 amp amp amp amp 0 0 Rear Left IN 4710 1 1 0 Rear Left OUT during leveling J7 11 1 1 1 1 0 Rear Left OUT establishing ground pressure J7 11 1 1 amp amp
69. with a pneumatic tire When selecting and installing a replacement tire ensure that all tires are inflated to the pressure recom mended by JLG Due to size variations between tire brands both tires on the same axle should be the same NOTE Tires are foam filled to 108 8 psi 7 5 bar 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 diam eter etc without written factory recommendations may result in an unsafe condition regarding stability 3121325 Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque A WARNING 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 fo
70. 1 2 93 LIYYJZ4X0 75 UL TILT SWITCH ader 1 X1 28 1 ader 2 X1 29 1 ader3 X1 B 2 GGN 94 LIYYJZ4X0 75 UL DRIVE2 VALVE ader 1 KD2 12 1 ader2 KD2 22 2 ader3 X1 F 3 PE GGN 95 LIYYJZ2X1 UL PRESSURE NIVO SWITCH ader 1 X1 53 1 1 ader 2 1 54 1 2 96 LIYYJZ2X1 UL HORN ader 1 1 25 1 ader 2 X1 G 2 119 LIYYJZ2X1 UL S 8M ader 1 X1 36 1 ader 2 X1 37 1 97 LIYYJZ5X1 UL MAX HEIGHT SWITCH ader 1 X1 36 1 6 30 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description ee Type Position 1 Position 2 Label External Harness ader 2 X1 37 1 ader 3 X1 30 1 ader 4 D24 A GGN 98 LIYYJZ2X1 UL LOWERING VALVE ader 1 X1 32 1B Splice2 L ader 2 X1 A 2 Splice3 L 112 LIYYJZ2X1 UL ader 1 1 Splice2 R ader 2 2 Splice3 R 113 LIYYJZ2X1 UL ader 1 1 Splice2 R ader 2 2 Splice3 R 99 LIYYJZ2X1 UL SER PAR ader 1 1 16 1 1 ader 2 1 1 2 111 LIYYJZ2X1 UL DIFF LOCK VALVE 1 ader 1 X1 20 2 1 ader 2 1 0 2 2 100 LIYYJZ2X1 UL DIFF LOCK VALVE 2 ader 1 X1 20 1 1 ader 2 X1 D 2 2 101 LIYYJZ2X1 UL BRAKE VALVE ader 1 X1 13A 1 1 ader 2 1 1 2 102 LIYYJZ2X1 UL MAX HEIGHT SWITCH ader 1 X1 34A 1 ader 2 1 27 1 103 LIYYJZ7X1 UL ENGINE BOX ader 1 1 8 1 2 1 9 1 ader 3 1 41 1 ader 4 X1 58 3 5
71. 1 7 Pressure Settings epee eed b a Rey aa E 1 4 1 8 Major Component 4 4 1 4 1 9 Critical Stability 1 4 1 10 reu 1 4 1 11 Mobil Hydraulic 1 4 1 4 2 1 Inspection and 2 2 2 2 Lubrication 2 4 2 3 Preventive Maintenance and Safety 2 11 3 1 Torque Hub Technical 3 3 3 2 Dtive Motor SDecs oes S RE DURAS T ey 3 7 3 3 Tightening Torques ecl Ree oe 3 8 3 4 Engine Technical Data ski RR s as MRNA ERE IRURE AR RE 3 14 3 5 Variable Displacement Axial Piston Pump 3 18 3 6 Joystick Specifications 2454 ERE ER er Tux pa E ce OR Es 3 28 3 7 Plug Loading Chart SM RE 3 28 3 8 Beacon Harness Connections 3 37 4
72. 1 SdNd lt TIX oAuq Ionuoo 1988111 67 1 LITE mdur aAA 1 21 19 9 ampon STIX Jc occ 8I IX IHOA RECEN gc Jc Figure 6 21 Electrical Schematic Sheet 4 of 15 6 15 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS V AS 19 TS 08 8911 TWORLLOATA OLLVINHHOS XII II III ET SOOT CM5 IX fp S A PA 244 0 WYOALV Td X 1 s T 02 IX Wct SdNd 9 ct SdNd SInPON IHNVd 19 INO 9 MOOT Dc Jc JLG Lift 3121325 Figure 6 22 Electrical Schematic Sheet 5 of 15 6 16 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 1 9384 194 715 19 IS 08 195 psaq
73. 1 steer Cylinder Specs u Re Gates 4 12 4 2 Outrigger Cylinder 4 13 4 3 Axle Locking Cylinder Specs 4 14 4 4 Deck Extension Cylinder 4 15 5 1 _ _ ___ _____ _ _ lt 3 lt _ _ _ 4 _ _ 5 3 5 2 J2 GOnnectorz ebbe Re OS ae ar sero e Re ve he ee CR Epod es 5 3 5 3 43 0 6 PORE TRA 5 3 5 4 Complex 2 Circuit 5 4 5 5 NIVOLUX Circuit Board cdm Ro Ren I Benda doe pa ey 5 7 5 6 PNP Circuit Board tee Eq ate eran teed 5 8 5 7 El Ue RR ERE RT RR ds 5 8 5 8 ge lae 5 8 5 9 Connector Sede UE ict es 5 9 5 10 Trigger Control Circuit Board 5 9 5 11 Limit Switches bor ak ll whe tee aoc sie Dee tas ee ne 5 10 5 12 Deutz Engine Control 5 12 5 13 Deutz
74. 1094781 When start signal is applied to X1 2 50 and the input on X2 10 remains zero after 1 second of cranking the output X2 7 is cut and the G LED turns on no input from alternator NOTE The field current strength during initial start in cold temperatures from the W input 600 can be insufficient to generate a sensed signal If this occurs increase the field current sensed to 1A by reducing the exciter resistor to 23 5 Ohm from 39 Ohm This ensures sufficient initial start signal strength in cold weather d If X2 10 goes to zero when the engine is run ning the output to X2 8 is cut and the G LED turns on lost input from alternator There is a 6 second time delay between start attempts The 6 seconds starts when there is zero input on X2 10 The main use of the additional push button Start Assist is to prime the fuel line When this button is operated simultaneously with the start button the start cut out control feature is ignored This condi tion continues for 3 minutes during which only one start attempt can be made When there is an imput to X2 11 the Glow Time LED lamp on H005559 is turned on The duration of the time on is controlled by the glow relays When there is an air intake filter clogged input ground on X2 4 Air the fault LED on the panel is illuminated This is an indication warning only It does not cut the engine This warning signal 5 11 SECTION 5 CONTROL SYSTE
75. 114 UL1569 18ZW 2 2 115 111569 1868 trig contr J2 3 D19 A 138 UL1569 18GR C2 J2B 1 D19 A 130 UL1569 18GR KTC 24 C2 J2B 8 131 UL1569 18GR X1 31 1 D17 A 137 UL1569 18GR KTC 11 D17 K 132 UL1569 18GR KTC A2 X1 4 133 UL1569 18GR KTC A1 trig contr J2 3 143 UL1569 18GR KL 24 C2 LED GROEN 144 UL1569 18GR X1 D 3 KL A2 145 UL1569 18GR X1 38 1 146 111569 1868 024 1 147 111569 1868 025 1 84 LIYYJZ5X0 5 UL OUTRIGGER 4 SWITCH ader 1 1 46 1 2 1 47 1 ader 3 X1 50 1 ader 4 1 51 1 GGN 85 LIYYJZ5X0 5 UL OUTRIGGER 3 SWITCH ader 1 X1 45 1 ader 2 X1 46 2 ader 3 1 49 1 4 1 50 2 GGN 86 LIYYJZ5X0 5 UL OUTRIGGER 2 SWITCH ader 1 1 44 1 2 1 45 2 3121325 JLG Lift 6 29 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description ee Type Position 1 Position 2 Label External Harness ader 3 X1 48 1 ader 4 X1 49 2 GGN 87 LIYYJZ5X0 5 UL OUTRIGGER 1 SWITCH ader 1 X1 39 1 ader 2 1 44 2 ader 3 X1 43 2 ader 4 1 48 2 GGN 88 LIYYJZ2X1 UL DOWN SWITCH ader 1 X1 32A 2 2 1 55 1 89 LIYYJZ2X1 UL OSCILLATING AXLE ader 1 X1 36 2 Splice6 L ader 2 X1 35 1 Splice7 L 91 LIYYJZ2X1 UL PUMP 1 VALVE ader 1 1 11 1 1 ader2 X1 G 1 2 92 LIYYJZ2X1 UL PUMP 2 ader 1 X1 11 2 1 ader2 X1 H
76. 12 9 SOCKET HEAD CAP SCREWS 3 5 TORQUE LOCTITE 262 TORQUE LOCTITE 242 OR 271 NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS METRIC CLASS 8 8 5000029 METRIC CLASS 10 9 Figure 1 7 Torque Chart METRIC Fasteners Sheet 2 of 3 JLG Lift 3121325 SECTION 1 SPECIFICATIONS JLG SPECIFICATION 4150701 MAGNA 565 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE SIZE PITCH TENSILE TORQUE LOCTITE gt a so 15 2 4 7 878 1 55 48 a 8 142 71 27 e 1 201 125 2 17 8 125 see 228 27 29 4 to 15 seo 361 54 8 79 12 175 525 95 13 2 ns 71 0 150 160 20 16 2 157 97 8 235 20 54 18 25 192 119 5 323 34 475 27 286 0 1160 1240 160 I p on op NOTE THESE TORQUE VALUES DO NOT 5000029 H APPLY TO CADMIUM PLATED FASTENERS METRIC CLASS 88 CLASS 10 9 Figure 1 8 Torque Chart METRIC Fasteners Sheet 3 of 3 3121325 JLG Lift 1 11 SECTION 1 SPECIFICATIONS 27 NOTES JLG Lift 3121325 SECTION 2 GENERAL SECTION 2 GENERAL 2 1 MACHINE PREPARATION INSPECTION
77. 121 LIYYJZ2X1 UL S OSCILLATING AXLE ader 1 PNP5 J2 3 Splice4 L ader 2 1 2 Splice5 L 122 LIYYJZ2X1 UL ader 1 Splice4 R ader 2 Splice5 R 123 LIYYJZ2X1 UL ader 1 Splice4 R 2 Splice5 R 124 UL1569 18ZW 1 125 UL1569 18ZW 2 126 LIYYJZ25X0 75 UL GROUND PANEL ader 1 1 1 1 ader 2 1 2 1 ader 3 X1 3 1 PC ader4 X1 4 2 PD ader 5 X1 5 2 PE ader 6 X1 6A 2 PF ader 7 X1 7A 2 PG ader 8 X1 9 3 PH ader 9 X1 21B 2 PJ ader 10 X1 22 2 PK ader 11 X1 56 2 PL ader 12 X1 38 4 PM ader 13 X1 41A 4 PN ader 14 X1 32A 1 PO ader 15 X1 30 2 PP ader 16 X1 42 1 PQ ader 17 1 43 1 18 1 58 2 5 19 1 1 5 ader 20 025 ader 21 X1 34B 1 PU ader 22 PV ader 23 PW ader 24 PX GGN 128 LIYYJZ2X1 UL ader 1 Splice6 R 51 11 2 Splice8 R 1 12 129 UL 1569188 KVS Y1 KVS Y2 6 34 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description Position 1 Position 2 Label External Harness 130 UL 1569 1868 KTC 24 C2 J2B 8 131 UL 1569 18GR X1 31 1 D17 A 132 UL 1569 18R DIODE 6 K X1 60 2 132 UL 1569 18GR KTC A2 X1 1 4 133 UL 1569 18BR DIODE6 A X1 38 2 133 UL 1569 18GR KTC A1 TRIG CONTR J2 3 134 UL 1569 18GR X1 60 3 BUZ 1 135 UL 1569 1868 TRIG CONTR 2 4 KTC 14 136 UL 1569
78. 24VDC Figure 4 34 Brake Valve Brake Valve Adjustment To achieve smooth deceleration when the joystick is returned quickly from the max forward or backward position to the neutral position completely close the valve knob shown to the left then open the knob 1 2 of a revolution Figure 4 35 Brake Valve Adjustment 4 18 JLG Lift 3121325 SECTION 4 HYDRAULICS Drive Valve SCHEMATIC D3 C2 Drive 2 Drive 1 2 9 2 Valve Parallel 4 Wheel Drive A Fast 2 Wheel Drive Drive 2 Drive 1 8 Q 3 Valve Drive 1 Valve Active Active Posi trac 4 Wheel Drive Figure 4 36 Drive Valve With no power activating the Valve Coils 1 thru 4 the machine is in 4 wheel drive low speed A2 and A1 receive flow from both drive sections of the Main Valve Block With 24V on Coils 1 and 2 all oil from the pump will give maximum oil flow through A1 section of the valve to the front wheels resulting in High Speed 2 Wheel Drive 3121325 JLG Lift
79. 3 6 14 6 15 6 16 6 17 6 18 Spacer Removal o LE bu bb ia et E ec P s ED 4 5 Cylinder Head Removal 4 5 Cylinder Head Seals ree 4 5 Bushing a eo E 4 6 Rod Seal Installation 4 7 Cylinder Head Seal 1 4 7 Cylinder Head 1 4 7 Spacer Installation ee i eee ee ek aera eg ad 4 8 Piston Seal Installations dace tee iba endo yaa Oat Hee bea aces Oa ee 4 8 Piston Installation 5 o dae 4 8 Piston Setscrew Installation 2 4 8 Rodilnstallation eens e Is eae eid et eee Pa 4 9 Rod Assembly ttt teas 4 9 Valve Block Installation ee 4 9 Load Check Valve Installation 4 10 Safety Valve and Limit Switch Installation 4 10 Lifting Cylinder 4 11 Steering Cylinder Assembly 4 12 Outrigger Cylinder
80. 3 23 Ground Control Panel Removal 3 25 3 24 Battery Removal isn isai voee ea poe er o mpi pt e dg e pet edt 3 26 9 25 Platf rm Gontrol oe ey Ah ae EUR SERE URGET en NEP mene 3 27 9 26 4 cce ER Ibm Ea E oes wet queres s aea ee iugis 3 28 3 27 Platform Receptacle Box 0 3 29 3 28 Side Rails Removal esce Saeed ae et A d dd e 3 30 3 29 End Rail Removal eie ue Ori EA EA uel 3 31 3 30 Extension Side Rails 3 32 3 31 Extension End Rail 4 3 33 3 32 Platform Removal 1 of 2 Front of 3 34 3 33 Platform Removal 2 of 2 Rear of Platform 3 35 3 34 Ladder Installation a mee ERR UE ERE 3 36 3 35 Beacon Installation ra erem act hud a ary 3 37 3 36 Limit Switch 4 3 38 3 37 Lift Cylinder Removal 14 41 1 3 42 3 38 Scissor Arm Remova
81. 3 CAPACITIES 12 5 m s 36 960 Ibs Table 1 3 Capacities Gross Machine Weight Approximate 16 765 kg 0 4 mph 0 6 ft sec Fuel Tank 23 8 gal Drive Speed slow 0 2 m s 90L 1 9 mph 68 7 gal Drive Speed fast 0 86 m s Hydraulic Tank 2601 Sideslope Machine Stowed 5 Gradeability MachineStowed 25 o 191051 Lift Speed load 125 sec without Filter 10 6 gt 101 Lowering Speed 80 sec 3046 psi Maximum Operating Hydraulic Pressure 210 bar Power Supply Diesel Engine Maximum Ground Bearing Pressure Outriggers 128 psi 9 kg cm Tires 85 psi 6 kg cm 17 020 Ibs Maximum Outrigger Pad Load 7720 kg 14 595 Ibs Maximum Tire Load Rating 6620 Electrical System Voltage 24V 10 8in Ground Clearance 27 4cm SECTION 1 SPECIFICATIONS 1 4 ENGINE Table 1 4 Engine Specifications Type Deutz FAL 2011 Deutz 020111041 Displacement 3108 cm 94 Stroke 112mm Power 42kW Fuel Type Diesel Engine High Speed 2300 l min Engine Low Speed 850 l min Voltage 24 Volt Table 1 5 Engine Battery Specifications Voltage 12V Amp Hour 100 Amp 880 1 5 TIRES Table 1 6 Tire Specifications Size 315 80R 22 5 Foam Filled Pressure 101 5 psi 7 0 bar Wheel Lug Nut Torque Front Axle Rear Axle 480 Nm 354 ft Ibs 480 Nm 354 ft Ibs Bolt Size M18x1 5 1 6 TORQUE REQU
82. 325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS T 84 194 TS 19 TS 08 1959111 91480 TqVOTXLOG Td OLLVINHHOS XII LLHI I ST 19 01 ST 08 193 AXL 8 XNJOAIN 81121250 S 19905 21920 51058125 POT 100W Wim V esse SS TPAS ST 08 10 Kioneg 82110 WAL 5 YT Yuri 19 z dung dung ST aiid XNTOAIN XH IdNOO Lift 3121325 Figure 6 30 Electrical Schematic Sheet 13 of 15 6 24 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 98 4 194 715 19 715 08 19591 OLLVIWHHOS X YLLATI HH 100 HIL S 15 584 Xe 09815 S SALI GND black 100 dung 2 18
83. 4 HYDRAULICS Cleaning and Inspection 1 10 11 12 13 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary If applicable inspect threaded portion of piston for damage Dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect rod and barrel bushings for signs of excessive wear or damage Replace as nec es
84. 4 HYDRAULICS 4 1 CYLINDERS THEORY OF OPERATION Deck Extension Cylinder The deck is extended and retracted by means of a double acting cylinder controlled by the first section in the main control valve see Figure 4 37 Main Valve Block The service line relief valve in the control valve is set at 1160 psi 80 bar for extend and 3046 psi 210 bar for retract Lift Cylinder The lift cylinder is a single acting cylinder incorporating dual solenoid holding valves and a pilot operated check valve for emergency lowering The lifting function is con trolled by the 3 section of the main control valve Lift speed is limited by flow from section 1 in the pump Lowering is operated by energizing the 2 solenoid holding valves together with the 39 section of the main control valve Descent speed is controlled by an adjustable line mounted flow control valve To enable lowering at full speed when the engine is stopped i e there is no hydraulic power available to act as a pilot supply for the electrical actuator a pilot line is connected to the auxiliary port M on the control valve via a check valve This provides the hydraulic power neces sary to shift the lower valve section Outrigger Cylinders The automatic self leveling system is controlled by 4 dou ble acting cylinders mounted at each corner of the machine chassis These cylinders incorporate pilot oper ated holding valves on the piston side The cracking pres sure
85. 49 Reduction Gear Kit 11 Pin 24 Circlip 37 Blocking Ring 12 Thrust Washer 25 Circlip 38 O Ring 13 Spacer 26 Disc 39 Blocking Ring Figure 3 4 Torque Hub Assembly 3 6 JLG Lift 3121325 3 5515 amp 5 55 5 3 3 DRIVE MOTOR 1 Dust Seal 6 Output Shaft 11 End Cover 2 Motor Housing 7 Shaft 12 Washer 3 Shaft Seal 8 O Ring 13 Screw 4 Bearing Race 9 Distributor Plate 5 Axel Needle Bearing 10 Gear Wheel Set Figure 3 5 Drive Motor OMR 100 Table 3 2 Drive Motor Specs Displacement 99 8 cm Max Speed 600 rpm 177 Ibft Max Torque 240 Nm Max Power 13kw 15 9 gal min Max 0il Flow 60 L min 3121325 JLG Lift 3 7 3 5515 amp 5 55 5 Motor Disassembly NOTE For numbers refer to Figure 3 5 Drive Motor OMR 100 Place the Motor Housing 2 in a holding tool with the flange upwards 2 Use 13 spanner socket to remove the screws 13 and washers 12 3 Remove the End Cover 11 sideways 4 When removing the Gear Wheel Set 10 and two O Rings 8 keep fingers under the the gear wheel set to prevent the parts from falling out 5 Remove the Cardan Shaft 7 6 Remove the Distributor Plate 9 and O Ring 8 7 To remove the Output Shaft 6 place the mo
86. 5 NIVOLUX Board LED S Re 5 6 Setting and Adjustment of the NIVOLUX Board 5 6 5 4 PNPS Gircuit Board eese Oe ie se ae A ee 5 8 Ge a PA RE COR RP RACE 5 8 Operation C 5 8 Adjustment ss occ RIS IG te EDI ad a bau he ete 5 8 5 5 Trigger Control Circuit Card 2 2 5 8 Relay Kl eil eee ce asas ela aan 5 8 Relay Ke Lae Ee Qe OP hand tta cuales teda 5 8 Relay uet e ease a eee ed 5 9 5 6 Limit Switch amp Sensor Operation 5 9 Height Limit Switches 5 9 _33 __ _ _ _ _3__ ___33_ _ _ _ _ __ 33_ _ 5 10 Oscillating Axle Limit Switches 1 5 10 Outrigger Limit 1 5 10 Pressure SWIICh eek eed Wapa 5 10 5 7 Engine Control System 5 11 Functional Description bares Dba Each qn 5 11 SECTION 6 GENERAL ELECTRICAL INFORMATION a
87. 52520 G s ua eben EAR 2 4 Lubrication Specifications 2 4 2 4 Operator Maintenance 2 5 3121325 JLG Lift 2 5 Cylinder Drift Test de REIR ELEME RW ee ER 2 10 Plattorm Ae 2 10 2 6 Preventive Maintenance and Inspection Schedule 2 10 SECTION 3 CHASSIS PLATFORM amp SCISSOR ARMS 3 1 Operating 3 1 Leveling RR ass Per Pe 3 1 3 2 eO ERE ee deg Y noh RR etn 3 1 Drive System zc sedo tea m p RC Ur eh S te au 3 1 Drive Hub reete Ier pa oe Dip POUR 3 2 Roll Test s et E te de bre 3 2 Leak IN 3 2 Lubricant aus k E a a p Rn 3 2 Tire Replacement M 3 3 Wheel Replacement fcc ce ge tele e 3 3 Wheel 3 3 3 3 Drive MOtOr rz EUR
88. 60 895 500 678 534 724 983 1 0000 0 6060 1 0000 0 6630 11 8 0 7650 7 1 2500 0 9690 12 1250 109 1 3 8 1 3750 1 1550 1 3750 1 3150 11 2 1 5000 1 4050 4720 FT LB N m 25 34 N m 18 24 FT LB N m 22 30 FT LB 5220 25 34 20 27 25 34 41 41 30 30 50 80 90 50 I681 3 471 45 61 9550 70 19 55 75 63 _ 85 108 10700 80 11081 60181 70 19 1122 10 149 80 108 96 130 14400 120 163 90 12 108 146 135 183 16400 150 2031 10 19 139 188 185 224 170 230 130 176 154 12091 20350 220 298 2301 180 244 23000 240 15251 420 569 600 813 180 244 320 460 434 624 204 277 336 485 456 658 325 359 40 65 20 75 90 900 1220 680 922 687 _ 931 59700 1000 1356 740 1003 796 1079 1100 1491 68700 1280 1735 960 1302 1030 11396 1400 1898 140 1952 1080 1464 1155 1607 87200 1820 2468 1360 1844 1453 1970 2000 127121 96600 2000 2712 1500 120541 1610 2183 2200 129831 2380 13277 1780 _ 2413 1907 2586 2720 3688 2040 2765 2165 129351 3160 4284 2360 _ 3200 2530 3430 3560 4827 2660 156061 2844 3856 NOTE THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS JLG Lift 5000029 H 69 SAE GRADE 5 Figure 1 4 Torque Ch
89. C2 J1A 3 57 11569 1868 C2J1A 4 1 4 58 011569 1868 02 4 C2 J1B 9 59 UL1569 18GR D14 K X1 39 4 140 111569 1868 D14 A C2 5 60 UL1569 18GR C2 J1A 6 X1 14 4 61 UL1569 18GR 02 1 40 4 62 011569 1868 02 8 1 27 4 63 011569 1868 C2J1A 9 X1 18 4 64 UL1569 18GR C2 1 10 1 17 4 65 11569 1868 2 1 1 29 4 66 111569 1868 02 12 1 15 4 67 011569 1868 C2 1 26 4 68 11569 1868 C2 J1B 3 X1 33 4 69 UL1569 18GR C2 J1B 4 X1 23 4 70 UL1569 18GR C2 J1B 5 trig contr J2 5 118 111569 1868 trig contr J2 6 X1 9 4 71 UL1569 18GR C2 J1B 6 X1 19 4 72 UL1569 1868 D15 K X1 21B 4 141 111569 18GR D15 A C2 J1B 7 73 011569 1868 016 1 22 4 6 28 Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description Position 1 Position 2 Label External Harness 142 UL1569 18GR 016 C2 J1B 10 74 111569 1868 C2 J1B 11 X1 25 4 75 UL1569 18GR C2 J1B 12 X1 6B 4 76 UL1569 18GR X1 FUSE B X1 2 4 77 111569 1808 X1 FUSE T 1 3 4 78 011569 1868 48 1 1 3 3 79 11569 1868 48 9 1 348 4 80 111569 1868 48 2 1 26 2 81 111569 1868 48 6 1 39 3 82 11569 1868 48 3 1 40 2 83 011569 1868 48 4 X1 41A 3 128 UL1569 18ZW 51 oscillating 12 52 oscillating 11 124 UL1569 18ZW 1 125 UL1569 18ZW 2
90. CONNECT BATTERY SUPPLY ON GROUND CONTROL PANEL BEFORE REMOVING RECEPTACLE BOX 6 The Platform Control Box Outlet 6 can be removed by removing the four Bolts 7 eight Flatwashers 8 and four Nuts 9 1 Remove front platform floor panel to expose the bolts connecting the Receptacle Box 1 to the plat form Installation 1 Follow Removal steps reverse order 2 Disconnect all wires connected to the 110V Recep 5 and Platform Control Box Outlet 6 3 Remove the four Bolts 2 eight Flatwashers 3 and four Nuts 4 4 Lift box from platform 3121325 JLG Lift 3 29 3 5515 amp 5 55 5 Main Platform Side Rails 1 Side Rail 7 Locknut M12 2 Cotter Pin 8 Pin 3 Pin 9 Cotter Pin 4 Bar 10 Pin 5 Pin 11 Hinge Bracket 6 Bolt M12 x 40mm 12 Bolt M10 x 120mm 13 Chain Assembly Mounting Plate 14 Flatwasher M10 15 Locknut M10 16 Tube Figure 3 28 Side Rails Removal NOTE Before rails can be lowered loosen the bolt on the 2 Remove the Cotter Pins 9 from the Pins 10 on all plastic rail guide rollers and lower the roller so that it three Hinge Brackets 11 Pull the Pin out of the is not hindering the lowering of the rails side rail Carefully fold rail down to the stowed posi tion NOTICE 3 Side rail can now be removed from the platform by SIDE RAILS WEIGH APPROXIMATELY 72 3 LBS 32 8 KG EACH remo
91. ERAL Table 2 1 Inspection and Maintenance Type Frequenc Primary 300106 Reference 4 Responsibility Qualification Pre start Priortouse each day or User or Operator User or Operator Operator and Safety Manual Inspection Ateach Operator change Pre Delivery Prior to each sale lease Qualified JLG 59IV0080 Owner Dealer User Manual and applicable JLG nspection rental delivery Mechanic inspection form In service for 3 months or 150 hours which ever comes first or Qualified JLG Service and Maintenance que Outof service for a period of more than 3 Owner Dealer or User Manual and applicable JLG nspection Mechanic 4 months or inspection form Purchased used Annual Machine Annually no later than 13 months from the Factory Certified Service and Maintenance n Owner Dealer or User Service Technician Manual and applicable JLG nspection date of the prior inspection recommended inspection form Preventative Atintervals as specified in the Service and Qualified JLG Service and Maintenance Owner Dealer or User Maintenance Maintenance Manual Mechanic Manual 2 2 SERVICE AND GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this book Safety and Workmanship Your safety and that of others is the first considerati
92. IREMENTS NOTE JLG recommends that once any locknut is removed from the machine it is discarded and replaced with a new one When maintenance becomes necessary or a fastener has loosened refer to Figure 1 3 Torque Chart SAE Fasteners Sheet 1 of 3 to Figure 1 8 Torque Chart METRIC Fasteners Sheet 3 of 3 to determine proper torque value JLG Lift 1 7 SENSORS Platform Stowed Jacks Retract Limit Switch Switch that senses when the platform is lowered to 10 5 ft 3 2 m Cuts out lowering function enables drive function when tilted and enables outriggers retract when outrig gers are deployed High Drive Speed Cutout Limit Switch When the platform reaches and exceeds a height of 12 1 ft 8 7 m the fast drive speed will be cut back to the slow drive speed Once the platform is completely lowered the high drive speed is possible The warning LED will be out when this limit is exceeded Maximum Drive Height Maximum Height without Outriggers Limit Switch The drive function will be disabled once the platform reaches a height of 65 ft 19 8 m The platform must be lowered below the limit to enable the drive function The lift function is also disabled once the platform reaches a height of 65 ft 19 8 m when the outriggers are not deployed Maximum Height Limit Switch Once the platform has reached it s maximum height of 80 ft 24 5 m the lifting function will be cut off by the maxi mum height limit switch Whe
93. JG An Oshkosh Corporation Company Service amp Maintenance Manual Model SOSL 3121325 March 24 2011 MG An Oshkosh Corporation Company INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that main tenance personnel pay strict attention to these warn ings 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 A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consider ation when engaging in the maintenance of equip ment 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 pro vided A WARNING
94. M remains even if the switch resets until the igni tion input X1 1 15 is recycled The monitoring system will shut the engine down Table 5 13 Deutz Engine ouput to X1 7 is cut if one of the following fault gt Coma ysi input signals is present for 3 seconds Ignition xi a No frequency on W X2 10 SH Al b Input on Oil X2 1 RPM XIN c Input on Temp X2 3 h 2 when there Is output 501 the engine Oil Pressure Switch Ground X2h speed is increased by energizing the throttle sole noid The circuit card generates this output from a Alternator D 2 2 24 input 1 3 Aux2 Temperature Switch Ground X2 3 Air Filter Switch Ground X2 4 Table 5 12 Deutz Engine Control Board Power 24V 25 Ground X2 6 Start X2 7 Fuel Solenoid 2 8 6 RPM Solenoid X2 9 E Alternator W X2 10 E 5 Glow Plug Ground Vee Belt Ground gt E Through Line Connector 9 9 9 24 Power direct to battery Ignition 1 1 1 24V Power Alternator B Start 1 2 1 Input RPM X1 3 Output Oil Pressure Switch Ground X2 1 0 Alternator D X2 2 Temperature Switch Ground X2 3 0 Air Filter Switch Ground X2 4 0 Alternator W X2 10 0 Glow Time Ground o
95. N Hood Gas Spring Bolt M8 x 30mm Nut M8 Cabinet Top Panel Left Cabinet Panel Right Special Bolt Flatwasher M12 Air Intake Pipe Bolt M8 x 25 Flatwasher M8 Locknut M8 Bolt M10 x 30mm Nut M10 Flatwasher M10 Nut M10 NOTE Removing the hoods will allow for easier access to NOTE Step 4 applies only to the Engine Side Compart the components inside the engine compartment and ment valve compartment 4 Remove the Air Intake Pipe 9 by removing the four 1 Open and secure Hood 1 Bolts 10 Flatwashers 11 and Locknuts 12 2 Remove Bolt 3 and Nut 4 on both Gas Springs 5 Remove the Cabinet Top Panel 5 amp 6 by removing 2 Return Hood to closed position the 4 Bolts 13 eight Flatwashers 14 and four 3 Remove both Bolts 7 and Flatwashers 8 connect Nuts 16 ing hoods to the Cabinet Top Panel 5 amp 6 3121325 JLG Lift NOTE Follow the steps in reverse order to re attach the hood and top panel 3 13 3 5515 amp 5 55 5 Deutz Engine
96. N ELEVATED SIZZOR UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DUR ING REPLACEMENT OF ELECTRICAL COMPONENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue February 6 2007 Revised March 5 2007 Revised June 7 2007 Revised November 20 2007 Revised March 10 2008 Revised July 26 2010 Revised March 24 2011 JLG Lift 3121325 5 TABLE CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A u IX RENI RU C ra a ass ale 1 Hydraulic System 1 Maintenance eel oh Gente eo Eger Ren 1 SECTION 1 SPECIFICATIONS 1 1 Operating Specifications Dae AN GRE Qy S 1 1 1 2 Dimensional Data EE 1 1 1 3 Capacitles Loco irai dh 1 1 1 4
97. NG PROCEDURE NOTE Cylinder check must be performed anytime a system component is replaced or when improper system operation is suspected 1 Using all applicable safety precautions activate engine and fully extend cylinder to be checked Shut down engine 2 Carefully disconnect hydraulic hoses from retract port of cylinder There will be some initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further drainage from the retract port Activate engine and extend cylinder 4 I cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to port and retract cylinder If leakage continues at a rate of 6 8 drops per minute or more cylinder repair must be made 5 With cylinder fully retracted shut down engine and carefully disconnect hydraulic hose from cylinder extend port 6 Activate engine and retract cylinder Check extend port for leakage 7 f extend port leakage is less than 6 8 drops minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made 4 2 JLG Lift 4 4 CYLINDER REPAIR NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that apply to a specific cylinder will be so noted Refer to Figur
98. OD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 10 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel SUPPORT TABLE Figure 4 6 Cylinder Rod Support 4 4 JLG Lift Figure 4 7 Piston Setscrew Removal If applicable unscrew the piston counter clock wise by hand and remove the piston from the cylinder rod ES Cylinder Rod Figure 4 8 Piston Removal 3121325 SECTION 4 HYDRAULICS 14 Remove discard the piston o rings seal rings and if applicable the snap ring Snap Ring Outrigger Cylinder Only Piston a 4 2 SS Piston Seal Figure 4 9 Piston Seals 15 If applicable remove the spacer from the Spacer Cylinder Rod Figure 4 10 Spacer Removal 16 Remove the rod from the holding fixture 3121325 17 Remove the cylinder head from the cylinder rod Cylinder Head EN Cylinder Rod 18 JLG Lift Figure 4 11 Cylinder Head Removal If applicable remove and discard the cylinder head seal rod seal wiper o ring s back up ring and snap ring Snap Ring Outrigger Cylinder Only 1 1 Outrigger and Axle Head Lockout Cylinders Only Figure 4 12 Cylinder Head Seals SECTION
99. ON amp SCHEMATICS 11112 DWNOUTP N M gt 104110 DO IVNV DWNINP TVNDISdINNd DRVOUTP amp XI GND DRVINP 52 STARTOUTP STARTINP 5 Diesel 80 SL 67 SL 314151617819 DEADOUTP DEADINP SUPPLY e Trigger Control 2 WD lt TT I LOdNI DIVLS 15 11410 vis C 0 I 1 SCHEMATIC ELECTRICAL 2 gt xladns Trigger Control LIFTLUX Figure 6 26 Electrical Schematic Sheet 9 of 15 6 20 Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 01 o8eq IS 9 IS 08 TVORLLOHT IH OLLVWAHOS XII II III 6 8 s oued TCVI SAM 21 usc 8 I 8 XN Sipe SA 5 x lduoo 155910 d IV SAM
100. RAULICS 3 9 25 13 Assembly 17 29 Valve 2378 Assembly gt 20 0 26 31 24 Pump Assembly 12 Ball Valve Assembly 28 Spring 1 Valve Suction 13 Ring 18 Body 29 Nut M10 2 Plug 14 Washer 19 Ball 30 Seal 3 Plug 15 Ring Internal Retaining 20 Ring 31 Setscrew 4 Body 16 Seal 21 Bolt M8 x 8mm 32 Relief Valve 5 Rod connecting 17 Spring 22 Spinner Not Shown 33 Pin Ball Driving 6 Lever 23 Spring 34 Plate Seal 7 Piston 24 Plug 35 Valve 8 Seal 25 Screw 36 Knob Assembly 9 Seal 26 Fitting Straight 37 Valve Body 10 Pin 27 Seal 11 Ring Retaining Figure 4 41 Hand Pump Assembly prior to S N 1200021263 4 22 JLG Lift 3121325 SECTION 4 HYDRAULICS VALVE SCHEMATIC B 5 Figure 4 42 Hand Pump Valve Schematic Load Holding Valve 1 Torque to 5 ft lbs 6 8 Nm 2 Torque to 20 ft Ibs 27 1 Nm Operating Pressure 3000 psi 207 bar Voltage 24VDC Axle Lockout Cylinder Figure 4 43 Load Holding Valve 3121325 JLG Lift 4 23 SECTION 4 HYDRAULICS Lift Lower Valve Block Solenoid Valves Qty 2 1 Torque to 5 ft Ibs 6 8 Nm 2 Torque to 60 ft lbs 44 25 Nm Lift Lower Valve Block Operating Pressure 3500 psi 240 bar Check Valve 3 Torque to 20 f
101. TEMPERATURE 40 F 40 OPERATION BELOW THIS AMBIENT TEMPERATURE NO OPERATION ABOVE THIS 5 110 F 43 C 100 F 38 C 90 F 32 C I rake 1 II 80 F 27 CMCIMC GRADE 21 23 fes 70 F 21 FUEL 8 8 8 7 X SPECIFICATIONS 60 16 2 2 2 2 2 2 4 50 10 40 F 4 C 30 F 1 C WINTER 20 7 C ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE TEMPERATURE WITH THE RECOMMENDED FLUIDS FUEL 10 F 12 C FULLY CHARGED BATTERY O F 18 WINTER ENGINE WILL START AND OPERATE AT THIS TEMPERATURE GRADE 10 F 23 C WITH THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY FUEL 2 AND THE AID COMPLETE JLG SPECIFIED COLD WEATHER WITH 20 F 29 C PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR GLOW KEROSENE P 5 PLUGS BATTERY WARMER AND HYDRAULIC OIL TANK HEATER ADDED 1 1 30 34 40 F 4020 AMBIENT TEMPERATURE p NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL F c DE SUMMER GRADE FUEL 14 10 lt 5 15 22 88 WINTER GRADE FUEL 43 25 22 30 0 10 20 30 40 50 60 OF ADDED KEROSENE Figure 1 2 Engine Operating Temperature Specifications JLG Lift SECTION 1
102. X1 F 2 trig contr J2 12 28 UL1569 18GR trig contr J2 1 X1 8 2 29 UL1569 18GR X1 28 2 12 30 011569 1868 1 59 2 11 31 011569 1868 1 4 2 32 011569 1868 1 29 3 1 33 011569 188 DIODE3 K X1 60 1 34 UL1569 18BR DIODE3 A X1 32B 2 35 UL1569 18BL X1 D 4 BUZ 2 36 UL1569 18R DIODE4 K X1 60 4 37 UL1569 18BR DIODE4 A X1 13B 4 132 UL1569 18R DIODE6 K X1 60 2 133 UL1569 18BR DIODE6 A X1 38 2 134 UL1569 18GR X1 60 3 BUZ 1 3121325 JLG Lift 6 27 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description TRAP Type Position 1 Position 2 Label External Harness 38 UL1569 18R K1 Y1 K1 Y2 129 UL1569 18R KVS Y1 KVS Y2 39 UL1569 18BL X1 54 3 K1 24 40 UL1569 18P X1 53 3 K1 23 41 11569 18W 1 38 3 1 13 42 11569 18 1 1 DIODE5 K 43 UL1569 18BL K1 A2 DIODE5 A 44 UL1569 18R K1 A1 X1 52 2 45 UL1569 18GR K1 A2 N2J1 3 46 UL1569 18GR K1 14 J8 7 47 UL1569 18GR 48 11 X1 E 4 48 UL1569 18GR J8 8 X1 55 4 49 UL1569 18GR N2J1 2 X1 54 4 50 UL1569 18GR N2J1 1 X1 53 4 51 UL1569 1868 N2J10 1 X1 42 4 52 UL1569 18GR N2J10 2 X1 43 4 53 UL1569 18GR J8 10 X1 35 4 54 UL1569 18GR C2 trig contr J2 7 117 111569 1868 trig contr J2 8 X1 12 4 55 UL1569 18GR C2 J1A 2 X1 37 4 56 UL1569 18GR D13 K X1 31 4 139 UL1569 18GR D13 A
103. acts to the Ground control Lift Up Switch When this switch is activated the lift function is cut Tilt Switch S Tilt Switch The scissor lift is equiped with a chassis inclination sensor set to trip at 3 The value of the incline will be monitored by a tilt switch which will cut off lifting driving and steer ing once the platform is raised above High Drive Speed Cutout Limit Switch S 2 5m and the set angle is reached The lowering function remains available to bring the platform below the High Drive Speed Cutout Limit Switch S 2 5m height This permits the drive function to enable the MEWP to be repositioned on a level surface This multi axis tilt switch is mounted in the valve compart ment to sense the angle of the chassis The Control Sys tem Complex 2 Board uses the input signal from the High Drive Speed Cutout Limit Switch S 2 5m to bypass this tilt switch When the chassis is within the set point angle limits there is a constant output of 24V The Control System Complex 2 Board uses this signal to permit the lift up drive and steering functions when the machine is ele vated S 2 5m is cut When tilted beyond 3 there is zero output and a red LED on the console is turned on by means of relay KT Also when S 2 5m Limit Switch is activated the functions of lift drive and steer are also cut Adjustment Place the machine on a flat level surface Using a digital level ensure the chassis is
104. agen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534
105. ain Terminal Box MTB Table 3 8 Beacon Harness MTB Connections Side Wire Color Signal Termiinal Position Brown X1 34B 1 Front Blue GND X1 1 3 Brown X1 34B 2 Rear Blue GND X1 1 4 JLG Lift 3 37 3 5515 amp 5 55 5 3 14 SCISSOR ARMS Limit Switches 1 Platform Stowed Jacks Retract Limit Switch 5 1 2 High Drive Speed Cutout Limit Switch 6 Cam2 3 Max Drive Height Max Height without Outriggers Limit Switch 7 Cam3 4 Max Height Limit Switch 8 Cam4 Figure 3 36 Limit Switch Adjustment Cam Adjustment 3 Adjust Cam 3 7 to activate Max Drive Height Max Height without Outriggers Limit Switch 3 when 1 Adjust Cam 1 5 to activate Platform Stowed Jacks platform is at a height of 65 ft 20 m Retract Limit Switch 1 when platform is completely stowed 4 Adjust Cam 4 8 to activate Max Height Limit Switch latf height of 68 9 ft 21 m 2 Adjust Cam 2 6 to activate High Drive Speed Cut 68 9 211 out Limit Switch 2 when platform is at a height of NOTE The limit switch plate can be removed by removing 12 1 ft 3 7 m the bolts washers and nuts at each end of the mounting plate 3 38 JLG Lift 3121325 SECTION 3 CHASSIS PLATFORM amp SCISSOR ARMS Scissor Arm Assembly Removal 3 Secure scissor arm assembly with two lifting straps attached to an overhead lifting
106. amp amp 0 0 XSupply 15V J5 1 15V Output with Board Power On Y Supply 15V J6 1 15VOutputwith Board Power On 24V to P Switch and K1 23 24 contacts 24V Output with Board Power On 24V to Jack Select Switch with NIVOLUX J10 1 18 1 0 24V to Jack Select Switch without NIVOLUX J10 1 1 1 LED LeftHigh D42 1 1 0 LED Right High D43 1 1 0 LED Front High D44 1 1 0 LED Rear High D45 1 1 0 LED No Drive 054 1 0 Board Power Ground J8 11 Vs 24V 48 1 This input is only necessary to establish output on J1 2 after the output J1 2 is established input J8 8 is not a necessity J1 10 output is cut with a momentary lift input and reset with a J1 2 input or recycling power amp 7 5V signal which is level input from sensors 1 This input is only necessary to establish this output after the output is established the input is not necessary 3121325 JLG Lift 5 7 SECTION 5 CONTROL SYSTEM 5 4 PNP5 CIRCUIT BOARD System The 5 circuit board is an electronic printed circuit board mounted on the Din rail situated in the MTB refer to Figure 5 1 Main Terminal Box Operation The circuit acts on the control system in the following ways 1 Amplifies signals to activate the drive and series par allel hydraulic valves 2 Activates the oscillating axle hydraulic valves when the platform is not elevated and the drive function is operated 3 Enables the output to activat
107. art SAE Fasteners Sheet 2 of 3 SAE GRADE 8 SECTION 1 SPECIFICATIONS JLG SPECIFICATION 4150701 MAGNA 565 SOCKET HEAD CAP SCREWS 5 16 amp ABOVE TORQUE TORQUE LOCTITE LOCTITE 262 242 08 211 N m N m IN LB N m SIZE BOLT DIA TENSILE STRESS AREA LB 0 1120 0 00604 0 1120 0 00661 0 1380 0 00909 __ 2 0 1580 0 01015 0 1640 0 01400 0 1640 0 01474 0 1900 0 01750 4 FT LB N m FT LB N m FT LB N m 2 130 9 4 0 0 3125 0 0524 18 0 3125 0 0580 25 BH 30 41 0 3750 0 0775 7000 35 147 40 54 50 68 5 5 0 2 5 16 __ 5 to 24 _ 0 2500 0 0318 2860 MERE 0 2500 0 0364 TPI 4 40 48 6 3 40 8 32 36 10 24 32 0 1900 0 02000 1 4 20 28 18 24 3 8 16 24 4 1201 0 3750 0 0878 1 16 1 0 4375 0 1063 950 8 08 20 0 4375 0 1187 0 5000 0 1419 80 108 0 5000 0 1599 0 5625 0 1820 18 0 5625 0 2030 130 176 154 209 190 258 58 M 0 6250 0 2260 20350 170 1230 180 244 240 325 1181 0 6250 0 2560 34 10 0 7500 0 3340 2 380 301 408 400 569 16 0 7500 0 3730 33600 3 434 336 14561 465 630 0 8750 0 4620 4 14 0 8750 0 5090 1 1 8 51500 12 8 2 6 0 6781 534 724 725 19851 0 0 0 6241 0 0 5 6 1 0000 0 6060 8 922 687 _ 931 990 1342 1 0000 0 6630
108. asuring Point Ist X 2 33 SRA Plug J6 Xpendulum Figure 5 3 Nivolux Control Board Introduction Normally the operation of leveling the chassis on a Mobile Elevating Work Platform MEWP is very time consuming The Liftlux NIVOLUX automatic self leveling system elimi nates this additional time as it is a feature when selected of the normal lift and lowering operation The estimated time saved over conventional systems can be in excess of 60 The System A pair of angle sensors located inside the Main Terminal MTB senses the chassis angle of the MEWP As indi cated on the MTB decal the inclination of the longitudinal axis is designated Y and the lateral axis is designated X The leveling function is achieved by hydraulic outrig ger cylinders mounted at each corner of the chassis Switches mounted on the top of each outrigger cylinder sense outrigger ground contact The system is controlled by an electronic circuit board mounted in the MTB The NIVOLUX automatic self leveling system on JLG MEWPs is a selectable system Deployment of the outriggers is necessary to achieve the maximum platform height 3121325 JLG Lift The system is intended for use when the machine is positioned on uneven ground The system when selected operates automatically in conjunction with the control console when connected to either the platform or chassis position It does not operate in
109. ck Valve 9 Rod Seal 15 Capscrew M8 x 120mm 10 O Ring 16 Hydraulic Block 11 Cylinder Barrel 17 Pressure Sensor 12 Lift Lower Valve 18 O Ring Figure 4 26 Lifting Cylinder Assembly JLG Lift 4 11 SECTION 4 HYDRAULICS 10 N a 1 CY C gt Z 1 Barrel 2 Bushing 7 SZ 2 3 Piston 4 4 Piston 5 Setscrew VE 2 NN 6 Spacer m 7 N G 2 7 8 Head Seal 11 8 3 9 Rod Seal 2 4 10 Wiper 11 O Ring 5 12 22 6 2 3 Z gt we 7 4 2 Figure 4 27 Steering Cylinder Assembly Table 4 1 Steer Cylinder Specs Max Working Pressure Piston Head Torque Apply Loctite 242 before tightening 1 6 ft sec Max Speed 0 5 m sec Max Operating Temperature 201 4 12 JLG Lift 3121325 SECTION 4 HYDRAULICS Barrel O Ring Cap Mounting Flange Stop Piston WY Snap Ring SS Piston Seal gt 11 12 Back up Ring 13 Head 14 Rod Seal 15 Wiper 16 Snap Ring 17 O Ring 18 Rod Assembly Figure 4 28 Outrigger Cylinder Assembly Table 4 2 Outrigger Cylinder Specs 2683 1 p
110. code numbers are as fol lows 3 Wipe cylinder rod clean and place a mark on the rod 1 Check for proper and secure installation 50mm from the cylinder head Check for visible damage and legibility 2 4 Wait 15 minutes 3 Check for proper fluid level 4 5 Measure distance of mark from head Check for any structural damage cracked or broken welds bent or warped surfaces 6 Difference cylinder drift must not exceed 3mm 5 Check for leakage NOTE If cylinder drift exceeds 3mm repeat test If still 6 Check for presence of excessive dirt or foreign greater than 3mm check holding valve refer to Fig material ure 4 44 Lift Lower Valve Block If still greater than 3mm replace cylinder seals refer to Section 4 4 7 Check for proper operation and freedom of move ment Cylinder Repair 8 Check for excessive wear or damage 9 Check for proper tightness and adjustment 10 Drain clean and refill 2 6 PREVENTIVE MAINTENANCE AND 11 Check for proper operation while pump motor is INSPECTION SCHEDULE pamp The preventive maintenance and inspection checks are 12 Check for proper lubrication listed and defined in the following table This table is 13 Check for evidence of scratches nicks or rust and divided into two basic parts the to be inspected for straightness of rod and the INTERVAL at which the inspection is to take place Under the portion of the table the various systems
111. conjunction with the ground control station Operation The activation of the NIVOLUX self leveling system is part of the lifting process The system starts the level ing function when the lifting function is operated and the outrigger mode is selected By activating the lifting function via the controller joystick the automatic measuring system is powered up the drive function is blocked and the control LED s on the MTB indicate the chassis tilt attitude The leveling process starts by powering the lowest out rigger until the difference of the measured angle to set point is less than 0 5 The next lowest outrigger is then powered to level one axis within 0 5 This process continues until both axes are within 0 5 i e the chassis is level 5 5 SECTION 5 CONTROL SYSTEM When the system completes the leveling process sensed angle is within 0 5 of set point in both axis the NIVOLUX system checks that all 4 outriggers have ground contact and then powers up the lift valve NOTE If ground contact is lost on any one of the 4 outrig gers the lift function will be cut In this event the platform should be fully lowered and the ground con Setting and Adjustment of the NIVOLUX Board Located on the circuit board is a potentiometer for each axis Y longitudinal and X lateral to set a zero ditions checked before attempting to re level the chassis All the above o low idle
112. d replace Filter Remove Filler cap 6 fill tank with hydraulic fluid to its designated capacity 68 7 gal 260 L Open shutoff valve lever to turn on flow of hydraulic fluid 3121325 3 5515 amp 5 55 5 Pressure Filter Sa w 1 Pressure Filter 2 Capscrew M10 x 20mm 3 Lockwasher M10 Figure 3 21 Pressure Filter Removal Removal Installation 1 Disconnect hose s from the Pressure Filter 1 1 Align the pressure filter so that the screw holes itch ith th w holes on the holdin 2 Loosen and remove the four Capscrews 2 and 9 bracket Lockwashers 3 3 Remove the Pressure Filter NOTE Be sure arrow on top of filter points towards the hydraulic tank NOTE Replace filter every 250 hours of operation 2 Insert the four Lockwashers and Capscrews into the holes and tighten 3 Reconnect hose s disconnected during removal 3121325 Lift 3 23 3 5515 amp 5 55 5 3 8 FUEL TANK hee 10 7 10 1 a Fuel Line Hose 5 5 mm 9
113. de of the machine remove the Nut 2 with a spanner wrench Next remove the Retaining Washer 3 and Washer and Pin 4 Arm Pin 75mm 90mm 110mm 130mm Nut 80mm or 100mm Retaining Washer 60mm 80mm or 100mm Washer amp Pin Figure 3 38 Scissor Arm Removal Left Side 3121325 6 Move to the right side of the machine The Arm Pin 1 can now be pulled out of the scissor arm stack Remove the four Bushings 2 two Ball Thrust Bear ings 3 and two Bushings 4 Arm Pin 75mm 90mm 110mm or 130mm Bushing 75 x 60mm 90 x 60mm 110 x 60mm 130 x 60mm Ball Thrust Bearing Bushing 75 x 80mm 90 x 100mm 110 x 110mm or 130 x 100mm Figure 3 39 Scissor Arm Removal Right Side JLG Lift Repeat steps 4 and 5 at each Arm Pin in order to remove the individual scissor arm Carefully lift the arm from the assembly Follow the removal steps in reverse order when installing the scissor arms Tighten the Lock Nuts until there is zero clearance between the arms and the bearings Back off one quarter of a revolution Bend the lip on the corre sponding Retaining Washer into the notch on the lock nuts 3 43 3 5515 amp 5 55 5 27 NOTES 3 44 JLG Lift 3121325 SECTION 4 HYDRAULICS SECTION
114. device A WARNING NOTE Scissor arm assembly weighs approximately 15 653 168 7100 kg Straps and lifting device must be EXTREME CAUTION MUST BE USED WHILE REMOVING ANY capable of lifting the scissor assembly LARGE COMPONENTS THESE COMPONENTS ARE EXTREMELY HEAVY AND CAN CAUSE SERIOUS INJURY OR DEATH IF NOT REMOVED CAUTIOUSLY NOTE It is recommended to remove the scissor arm assembly as a whole unit 1 Remove the platform from the scissor arm assembly refer to Figure 3 32 Platform Removal 1 of 2 Front of Platform and Figure 3 33 Platform Removal 2 of 2 Rear of Platform 2 Disconnect all hoses and wires connecting the scis sor assembly to the chassis and platform 3121325 JLG Lift 3 39 3 5515 amp 5 55 5 Remove one from the steering linkage to access to the scissor arms pin behind the wheel see Section 3 6 Steering Assembly Remove the cable from the ground control socket in the valve compartment Remove the hydraulic hoses for the platform extension Refer to Figure 4 37 Main Valve Block Cap the fittings and secure the cable and hoses to the arm stack with ta
115. e 2nd pump if fitted and selected when the platform is not elevated Also delays this output until the engine speed and torque are sufficient This delay is adjustable by means of a potentiometer on the board Adjustment With the platform stowed position the drive speed select switch to High Speed Operate the drive func tion and adjust the potentiometer to produce a 2 sec ond time delay pump 2 output signal on J2 2 following the engine speed increase Table 5 6 PNP Circuit Board I O oj 5 2 2 Lo wo IN SR E QUE ES Drive J1 1 1 1 Series Parallel J1 4 1 Pump2 J2 2 1 2 5m Limit Switch J2 4 1 High Engine RPM J2 6 1 24V Vs 41 2 Ground J2 1 Adjust Potentiometer to delay Pump 2 output after RPM input allows engine to begin torque before adding load 5 8 JLG Lift Table 5 7 Connector J1 Drive In J1 1 Power 24V J1 2 Series Parallel Out J1 3 Series Parallel In J1 4 Drive Out J1 5 Table 5 8 Connector J2 Ground J2 1 Pump 2 In J2 2 Oscillating Axle 2 3 2 5 12 4 Pump 2 Out 42 5 42 6 5 5 TRIGGER CONTROL CIRCUIT CARD Relay 1 NOTE Refer to Table 5 9 for numbers 1 Energized when there is a trigger input at 2 2 When astart input signal is applied to 5 and there is no input from the tr
116. e 6 6 Connector Assembly 1 of 4 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 6 7 Connector Assembly 2 of 4 2 Pull back on the contact wire with a force of 1 or 2 Ibs to be sure the retention fingers are holding the contact See Fig ure 6 7 Connector Assembly 2 of 4 3 After all required contacts have been inserted the wedge lock must be closed to its locked position Release the lock ing latches by squeezing them inward See Figure 6 8 Connector Assembly 3 of 4 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 6 9 Connector Assembly 4 of 4 PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT Figure 6 7 Connector Assembly 2 of 4 6 6 Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 6 8 Connector Assembly 3 of 4 WEDGE LOCK FLUSH WITH A SESE Figure 6 9 Connector Assembly 4 4 3121325 JLG Lift 6 7 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Disassembly 5 Insert a 4 8 mm 3 16 wide screwdriver blade between the mating seal and one of the red wedge lock tabs 6 Pry open the wedge lock to the open position 7 While rotating the wire back and forth over a half turn 1 4 turn
117. e arrow 3 Remove the Pin 4 4 The proper gear oil level should be to the base of the opening Add gear oil if needed 5 Turn the Pin 4 around and place back onto Hub 1 NOTE Side of Pin that was facing outside should now be facing the inside of the hub 6 Slide Circlip 3 in opposite direction of arrow to secure the Pin Tighten Screws 2 to secure the Cir clip in place 3121325 3 5515 amp 5 55 5 Table 3 1 Torque Hub Technical Specifications Max Torque 55 Max Speed 4000 rpm 101 41bs Weight 46kg Brake 147 568 Static Torque 200 Nm 174 217 5 psi Releasing Pressure 12 15 bar 1450 3 psi Max Pressure 100 bar 147 5 lb ft Max Input Torque 200 Nm 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 and model If not using a JLG approved replacement tire it is recom mended that replacement tires have the following charac teristics 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 Unless specifically approved by JLG Industries Inc do not replace a foam filled tire assembly
118. e meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected f meter is not auto ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire longer than the reach of standard instrument leads is possible to perform the check without excessively long leads Using the other wires in the harness one can determine the condition of a particular wire in the harness Requirements Harness with at least three separate wires including the wire under test These wires must be able to be isolated from other wires etc Jumper or method to connect contacts on one side of harness Meter that can measure resistance or continuity Procedure Test multimeter leads resistance Subtract this value from the measured resistance of the wires to get a more accurate mea surement Consult the circuit schematic to determine which wires to use in addition to wire under test here called wire 1 and wire 2 and how to isolate these wires These wires should appear in the same connectors as the wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two addi
119. e valves is 15 psi 1 bar for the rear and116 psi 8 bar for the front 1 Activate the leveling jack switch located on the ground control console 2 Extend the jacks by moving the joystick on the plat form control box forward NOTE The jacks deploy at idle engine speed Once all four jacks make contact with the ground the system will go from set mode into level mode Once level engine rpm s will increase and lift is allowed 3 The tilt indicator LED s on the Main Terminal Box will go out once the machine is level NOTE There are limit switches mounted at each jack cyli inder These sense when the jack makes ground contract and enable the lift function All four switches must have contact lift indicator LED on the platform will light to enable lift When elevated if a contact signal is lost jack loses ground contact wire cut etc the lift function is stopped and only lowering is permitted The jacks are operational extend or retract if the machine is in the stowed position The minimum height limit switch must sense the machine is stowed A failure of the limit switch will prevent the jacks from being activated NOTE Refer to Section 5 3 Nivolux Automatic Self Level ing System for detailed information regarding the automatic leveling system 3 2 WHEEL ASSEMBLY Drive System Wheel drive is achieved by orbital type 100cc rev hydraulic motors driving a wheel type gearbox 29 8 1 reduction through a s
120. ent chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity index of 152 When temperatures remain below 20 F 7 C JLG Industries recommends the use of Mobil DTE13M Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Indus tries for proper recommendations 1 10 CRITICAL STABILITY WEIGHTS Table 1 11 Mobil Hydraulic Oil Specs ud Mobil Mobil EAL 46 NOTICE Mondes 13M Envirosyn H 46 DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS ISO Viscosity Grade 10W 30 32 46 BATTERIES OR SOLID TIRES WITH ITEMS DIFFERENT T WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY Specific Gravity 29 0 0 877 0 922 AFFECT STABILITY Pour Point Max 46 C 40 C 39 C 7 12 43 F 40 F 38 2 F Table 1 9 Critical Stability Weights Flash Point Min 2286 166 C 310 C Component 80SL 442 F 330 F 590 F 573105 Viscosity Wheel and Tire bl 260 at 40 C 1049 556 3369 47 cSt 675105 at 100 C 212 F 9 3 cSt 6 5 cSt 951 Wheel Tire and Drive Assembly each 306 kg Viscosity Index 152 140 176 Batteries Standard each
121. es 4 26 thru 4 30 for specific cylinder assembly breakdowns and for specific parts references Refer to JLG Parts Manual 3121326 for seal kits and part numbers Disassembly A WARNING BEFORE REMOVING CYLINDERS FROM THE MACHINE BE SURE TO SUPPORT THE MACHINE AND SCISSOR ARMS PLATFORM WITH SAFETY PROPS FORKLIFTS OR OVERHEAD CRANE TO PREVENT RELEVANT COMPONENTS FROM COLLAPSING AND CAUSING SERIOUS INJURY OR DEATH SEE FIGURE 4 31 NOTICE DISCONNECT THE BATTERIES BEFORE REMOVING ANY COM PONENTS FROM THE CYLINDER ASSEMBLY 1 Remove cylinder s from the machine by first dis connecting all hoses and or wires and any valves Next unscrew bolts connecting cylinder s to the machine If applicable remove any pins connecting the cylinders to the machine NOTE Step 2 applies only to the Lift Cylinder 2 To prevent damage remove the valve block from the lift cylinder barrel by unscrewing the 4 set screws Oylinder Barrel etscrews Figure 4 1 Lift Cylinder Valve Block Removal 3121325 SECTION 4 HYDRAULICS NOTE Step 3 applies only Axle Lockout Cylinder 3 To prevent damage remove the load check valve from the barrel Load Check Valve DA Cylind Figure 4 2 Load Check Valve Romoval NOTE Step 4 applies only to the Outrigger Cylinders 4 To prevent damage remove the safety valve and limit switch from the top of the outrigger cylinders Limit Switch Safety
122. eta bod 3 22 Pressure eoe ode este gd vr ia de Pret 3 23 3 8 0I 5 3 24 3 9 Ground Control Panel Seg pp Sake puer 3 25 3 10 Battery Removal 2 GR EEG RR UE pag s 3 26 3 11 3 27 Platform Gontrol x s u E a en eR Ht 3 27 Joystick Controller 3 28 5 L Gu aa Ce 3 29 Main Platform Side 3 30 Main Platform End Rails 3 31 Platform Extension Side 1 3 32 Platform Extension End 3 33 Plattorm Removal kus Cre aad adis ea re dta 3 34 3 12 Ladder Installation Soe 5 3 36 3 13 Beacon Installation Option 14 3 37 3 14 SCISSORAIMNS x oe eee re uet ease rt dere Agi dient ei e a edes 3 38 Limit SwitChes gt Sec tan pue p eR Er ee em ROOR ETUR ERR S 3 38 Scis
123. for all jacks then enable lift up by energizing relay K1 Outriggers Jacks Not Selected Switch input to X1 43 and N O contacts wired in series to sense all jacks retracted and enable lift up by energizing relay K1 S Platform Down N C contacts sense when platform is fully lowered Enables jacks retract select by resetting lift switch when fully lowered and continue to lower and re enable drive function Only when jacks are selected N C contacts sense at 12 ft 3 7 platform height and interlock fast drive speed Interlock drive 5250 and lift if tilted tilt switch tripped Also indicates lift available LED at console contacts sense max permitted drive height of the platform and interlocks drive function Senses max lift height when outriggers are not deployed Also indicates lift available LED at console S Max Height N C contacts sense max platform height and interlocks lift up Also indicates lift available LED at con sole 5 10 JLG Lift 3121325 SECTION 5 CONTROL SYSTEM 5 7 ENGINE CONTROL SYSTEM Motorcheck MC 716 G Berectronics 6 Vertragshandler O 9999 1297 V Belt Alt 90 9 005559 Functional Description NOTE desciptions refer to Figure 6 23 Electrical Schematic Sheet 6 of 15 1 An ignition input on X1 1 15 creates an
124. fore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary at the speci fied intervals required in the Lubrication Chart in Section 1 Always examine filters for evidence of metal particles Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is oper ating are recommended for use Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil 1 NOTE 2 4 Refer to Section 1 for recommendations for viscosity ranges JLG recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 Start up of hydraulic system with oil temperatures below 15 F 26 C is not recommended If it is nec essary to start the system in a sub zero environ ment it will
125. han the outer diameter of the piston is recommended to install the solid seal Snap Ring Outrigger Cylinder Only Piston 2 Figure 4 18 Piston Seal Installation 8 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 4 8 JLG Lift 9 applicable carefully thread the piston clock wise on the cylinder rod hand tight until it abuts the spacer ensuring that the o ring snap ring and pis ton seals are not damaged or dislodged h Spacer 2 Cylinder Figure 4 19 Piston Installation 10 If applicable insert the setscrews on the piston and tighten to lock piston in place on cylinder rod Pistons Setscrews Figure 4 20 Piston Setscrew Installation 11 Remove the cylinder rod from the holding fixture 12 Position the cylinder barrel in a suitable holding fix ture 3121325 SECTION 4 HYDRAULICS EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 13 With the barrel clamped securely and while ade quately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged Cylinder Head Cylinder Rod Piston _____ Cylinder Barrel
126. he battery not shown ENGINE STARTER A CHECK BOX ENGINE A Battery Schematic A BATTERY LI _ DISCONNECTOR BATTERIES Figure 3 24 Battery Removal Installation Removal 1 3 26 Disconnect and remove the Battery Cables 2 3 4 from the battery terminals Loosen the bolt on the terminal clamps to remove the cables Remove the Bolts 5 Flatwashers 6 securing the both the front shown and rear not shown Battery Hold Clamp 7 to the electrical compartment Remove the Battery Hold Clamp Remove Batteries 1 JLG Lift 1 2 3 4 Place Batteries into electrical compartment Align Battery Hold Clamps with bolt holes on floor Secure Clamps with Bolts and Lockwashers Reconnect Battery Cables to the battery terminals Tighten bolt on the terminal clamps 3121325 3 5515 amp 5 55 5 3 11 PLATFORM Platform Control Box 1 Control Box Lid 2 Control Box 3 Screw M4 x 30 Figure 3 25 Platform Control Box For access to the inside of the platform control box follow NOTE When assembling the platform control box be care these steps ful not to pinch wires when replacing the lid back x 1 Disconnect platform control box connector from the machine 2 Remove the six Screws 3 securing the Control Box Lid 1 t
127. iety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart Table 2 2 Lubrication Specifications KEY SPECIFICATIONS Multipurpose Grease having a minimum dripping point MPG of 350 F 177 C 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 EO 2104 Diesel API CC CD class MIL L 2104B MIL L Engine crankcase Oil Gas API SF SG class MIL L 2104C HO Hydraulic Oil API service classification GL 3 e g Mobil 424 JLG Lift 3121325 SECTION 2 GENERAL 2 4 OPERATOR MAINTENANCE TO AVOID PERSONAL INJURY USE SAFETY PROPS FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED NOTE Be sure to lubricate like items on each side NOTE Recommended lubricating intervals are based on machine operations under normal conditions For machines used in multi shift operations and or exposed to hostile environments or conditions lubrication frequencies must be increased accordingly Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank Oil should be visible in ADD
128. igger switch no input on 2 the start ouput signal passes through the N C contacts on relays K1 and 2 to 6 3 When a trigger input signal is present at 2 there is a 6 second window to receive a pump lower input sig nal at 4 to keep energized This trigger input passes through the N O contacts to produce a trig ger output on 3 4 If there is no pump lower input within this time e g the trigger switch is taped closed K1 is de ener gized and the trigger output at 3 is cut Relay K2 1 Energized when there is a trigger input at 2 2 This input passes through the N O contacts to pro duce a drive output on 8 3 When this trigger input is removed there is a 3 sec ond time delay before K2 is de energized and the drive output on 8 is cut Anti bounce function for the drive function 3121325 SECTION 5 CONTROL SYSTEM Relay 1 Energized when there is trigger output at 3 5 6 LIMIT SWITCH amp SENSOR OPERATION NOTE Refer to Figure 1 1 Limit Switch Locations for loca tions of limit switches 2 The analogue input signal 4 passes through a set of N O contacts to produce an analogue output on 11 Height Limi itch 3 The pump input signal 10 or lower input signal 9 619 t Limit Switches passes through set of contacts This ouptu Platform Stowed Jacks Retract Limit Sw
129. ion These are designated as 1 Top Top 2 Tob Bottom 3 Bottom Top and 4 Bottom Bottom Refer to Figure 5 1 Main Terminal Box Position 2 The position on the end item if not specified in the table it can be located on the electrical schematic 6 36 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 2 NOTES 3121325 JLG Lift 6 37 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS OSCILLATING AXLE TILT GROUND OUTRIGGER LIMIT SWITCHES SWITCH CONTROL VALVES LIMIT DIRECTIONAL SWITCHES CONTROL 56 Jd VALVE 8 lel II LF 1 2 ge OSCILLATING AXLE M CYLINDER SOLENOIDS 9 pi LR 4 RR 3 STROBE LIGHTS PUMP ENGAGE DISENGAGE VALVE HORN MAIN TERMINAL BOX BOTTOM VIEW ENGINE CONTROL BOX PRESSURE SWITCH GLOW PLUG RELAY
130. iq IL 19024 oum GAT CHT I Vr X poued oueg spouy t LX 8 8 S ZZONd vC IX XNJOAIN 91188814 Slys ZZONd IX IN 1 9 188914 Se ZZONd I V IX spouy 1 LS 615 1 PLS VI 215 I 615 VI 115 I CLS C2 718 TU ELS Ic LS cc cLs 12 ELSIS TU 115 Ic LS COLL X I0MM I ILS syor 17011 Xn OAIN s oued epomed 9 ead poep tad PIRE XNTOAIN Wadd 10005 WANY Id 8f Xh OAIN 9 8f X0I0 VX 1 11868 ZZONd 1 IX Ug c 1f x lduuoO 348 I S 1 ean 01 8 9IXV 841811250 4 Figure 6 28 Electrical Schematic Sheet 11 of 15 3121325 Lift 6 22 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ZI 13 8 4 94
131. it board and enables outputs to the rest of the machine control system The circuit board is located on the lid of the Main Terminal Box TP1 amp TP2 There are 2 potentiometers installed on the circuit card indentified as TP1 and TP2 which adjust the creep speed and the drive on off ramp TP1 This is used to adjust the elevated creep speed by modifying the analogue output voltage to the drive control valve section With the platform in an elevated position fast drive speed limit switch tripped and operating the machine with the console in the platform 5 2 JLG Lift position adjust the TP1 potentiometer to obtain the correct creep drive speed of 0 5 km h TP2 This is used to adjust the ramp time to engage and disengage the drive control valve section With the platform in the lowered position and operating the machine with the console in the platform position adjust the TP2 potentiometer to obtain a drive acceler ation and deceleration to ensure smooth operation nominal setting should be 2 seconds S1 The connection S1 has not effect on the machine It s purpose when removed is to apply the ramp settings from TP2 to the pump output signal S2 The connection S2 must be closed with a jumper plug to enable the Lift and Lower output signals 3121325 SECTION 5 JLG CONTROL SYSTEM Table 5 1 41 Connector Table 5 2 J2 Connector
132. itch S Platform signal maintains the Trigger input signal 2 which Down energizes relay K1 This limit switch is mounted on the chassis and is acti Table 5 9 Connector CON1 vated by a cam mounted on the pivot of the scissor pack 1 24V Supply When the platform is fully lowered this switch is closed 2 Trigger Switch Input and permits a platform lower signal from the Complex 3 Trigger Switch Output to enable the NIVOLUX board to retract the out 4 Analog Signal Input 55 5 Start Input When this switch is activated the outriggers can not be retracted 6 Start Output 7 Drive Input High Drive Speed Cutout Limit Switch S 2 5m 8 Drive Output This limit switch is mounted on the chassis and is acti 9 Lower Signal Input vated by a cam mounted on the pivot of the scissor pack 10 Pump Signal Output When the platform is within approximately 0 5m 1 6 ft of the fully lowered position this switch is closed 2 24V 11 Analogue Signal Output outputs are available 12 Ground The Control System Complex Board uses one of these signals to enable fast drive bypass the tilt Table 5 10 Trigger Control Circuit Board switch lift cutout feature The Self Leveling System NIVOLUX Board also uses this signal to enable the 5 2 outrigger outputs 9 2 5 The second bypasses the oscillating axle sensing 6 switches D 5 485 AME Ela o o
133. l Left Side 3 43 3 39 Scissor Arm Removal Right 4 3 43 4 1 Lift Cylinder Valve Block 4 2 4 2 Load Check Valve 40 2 4 3 4 3 Safety Valve and Limit Switch 4 3 4 4 Gylinder Barrel Support Saree ek edt eese ET ede hae Bande 4 3 4 5 Cylinder Head Removal 4 4 4 6 Cylinder Rod Support s ae 4 4 4 7 Piston 4 4 4 4 8 Piston Removal iio eme E Tue EUER A Ua heed ee sans 4 4 4 9 4 5 3121325 JLG Lift 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4 29 4 30 4 31 4 32 4 33 4 34 4 35 4 36 4 37 4 38 4 39 4 40 4 41 4 42 4 43 4 44 4 45 4 46 5 1 5 2 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 9 6 10 6 11 6 12 6 1
134. led type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the connec tor such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed con nector by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent conditions while alone For example you can read the voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the location of the signal and that the leads are connected to the device under test cor rectly Also check that the lead on the port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed
135. level Adjust the X and Y axis nuts to place the top mounted bubble level in the center Oscillating Axle Limit Switches A pair of switches are mounted on the oscillating axle and sense the angle of the axle with respect to the frame These are wired in series with the S8m Limit Switch The 2 5 Limit Switch signal bypasses both switches When the axle is within 1 5 of the frame the switches are closed and permit a 24V signal to the S8m Switch When either of the switches are activated and Limit Switch S2 5m is also activated the drive function is Cut Outrigger Limit Switches These 4 limit switches are mounted on the top barrel end of each outrigger cylinder and work in conjunction with the NIVOLUX Automatic Self Leveling System They are utilized to sense when the outrigger pad makes ground contact and are wired in series on both the normally open N O and normally closed N C contacts Refer to Section 5 3 Nivolux Automatic Self Leveling System for a description of the operation Pressure Switch A pressure switch is line mounted in the drive brake hydraulic line This pressure switch works in conjunction with the NIVOLUX Automatic Self Leveling System Refer to Section 5 3 Nivolux Automatic Self Leveling System for a description of the operation Table 5 11 Limit Switches Switch Purpose Jacks Selected No switch inputto X1 43 and N C contacts wired in series to sense ground contact
136. llows 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten nuts in the following sequence 3 The tightening of the nuts should be done in stages Following the recommended sequence tighten the nuts per wheel torque chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 150 190 lb ft 230 270 Ib ft 305 343 Ib ft 210 270 320 380 440 480 4 Wheel nuts should be torqued after the first 50 hours of operation and after each wheel removal Check torque every 3 months or 150 hours of operation JLG Lift 3 3 3 5515 amp 5 55 5 1 Wheel Nut 6 per tire 2 Drive Hub 3 Bolt M16 x 55mm 6 per wheel 4 Flatwasher M16 6 per wheel 5 Capscrew M16 x 35mm 2 per wheel 6 Double Shock Valve Rear Wheels Travel Brake Valve Front Wheels Not Shown 7 Capscrew M10 x 45mm Rear 4 per valve Capscrew M10 x 55mm Front Not Shown 4 per valve 8 Drive Motor Bolt M12 x 35mm 2 per motor 10 Lockwasher M12 2 per motor Figure 3 2 Wheel Assembly Removal 3 Disconnect all hoses wires from Drive Motor 5 WARNING SECURE MACHINE WITH JACKS AND CHALK BLOCKS WHEN ku REMOVING AND OR INSTALLING WHEELS 5 Remove two Bolts 6 and Lockwashers 7 attach NOTE Follow these steps whe
137. m Lower Flow 4 4 4 1 4 24 Outrigger ValVes oe ere edo d da das 4 25 Main Terminal BOX 2 ER ener em Ee deg 5 1 Control Card Complex 2 Board 5 2 Nivolux Control Board eee Pie ir eee rtu MSS 5 5 Voltage Measurement 6 2 Resistance Measurement le rr e m mh 6 2 Continuity 2 6 3 Current Measurement 6 3 AMP Sond cael e S ae es 6 5 Connector Assembly 1 4 2 6 6 Connector Assembly 2014 6 6 Connector Assembly 3 004 6 7 Connector Assembly 4 4 4 6 7 Connector Disassembly hmm 6 8 Connector 2 222222 2 21 4 6 9 DT DTP Contact Installation 2 2 6 10 DT DTP Contact 2 6 10 HD HDP Contact
138. move the rail 6 The Gate 3 can be detached from the right side End Rail 1 by removing the screws on the two Hinges 11 3121325 Lift tion when installing Follow the removal instructions in reverse order Attach End Rails to Side Rails via the pins in Figure 3 28 3 31 3 5515 amp 5 55 5 Platform Extension Side Rails 1 Extension Side Rail 7 Chain Assembly Mounting Plate 13 Locknut M12 2 Cotter Pin 8 Cotter Pin 14 Chain Assembly Mounting Plate 3 Pin 9 Pin 15 Bolt M10 x 25mm 4 Bolt M6 x 16mm 10 Extension Rail Bracket 16 Lockwasher M10 5 Lockwasher M6 11 Bolt M12 x 100mm 6 Flatwasher M6 12 Flatwasher M12 Figure 3 30 Extension Side Rails Removal THE EXTENSION SIDE RAILS WEIGH APPROXIMATELY 58 LBS 26 2 KG EACH USE CAUTION WHEN REMOVING ANY PLAT FORM RAIL NOTE All procedures apply to the opposite side Removal 1 Disconnect Side Rails 1 from end rail by removing Cotter Pin 2 from Pin 3 NOTE The Chain Assembly Pin Cotter Pin can be removed by removing the Bolt 4 Lockwasher 5 and Flat washer 6 3 32 JLG Lift 2 Remove the Cotter Pins 8 from the Pins 9 on each Bracket 10 Pull the pin out of the bracket 3 Carefully fold rails inward to the stowed position 4 Remove the Bolts 11 Locknuts 13 Flatwashers 12 and Chain Assembly Mounting Plates 14 The rail can now
139. mp SCHEMATICS 6 1 General oe EE dee ra 6 1 6 2 Multimeter Basics Bed hem Poche ad Reo dre 6 1 d PR PUE 6 1 3121325 JLG Lift Backprobing WU Re dE dak ans we Des Gee ee die Yd 6 1 i UE ue Sta Gude ERES 6 1 Polay uu ee ohne E Ru bee eee eration 6 1 56 r usa mre ahs 6 1 Continuity Measurement Over Long Distances 6 4 REQUIREMENTS oer A oi tae doge henge dG AUS meets Meese esas 6 4 Procedure L rover ee aud 6 4 6 3 Applying Silicone Dielectric Compound To Amp 6 5 Assembly rep De edd Dt Lacu ite bee e P a e 6 6 Disassembly xx I leni OS Rela eae 6 8 Wedge Lock aus se eae wee Ae RE ER EIS 6 8 Service Voltage 0 6 9 6 4 Working With Deutsch 6 10 DI DTIP Series Assembly a eb P 6 10 DT DTP Series
140. n maximum height is reached the Lift Cutout Indicator LED on the platform control console will no longer be illuminated Tilt Sensor The tilt switch cuts out lifting driving and steering once the platform reaches a tilt angle slope beyond 3 and the platform height exceeds 12 1 ft 3 7 m At this point the warning LED on the platform control console will illumi nate and lowering is the only function possible Outrigger Sensors Outriggers Selected Limit switch senses ground contact for all outriggers to enable platform to be raised Outriggers Not Selected Limit switch senses when all outriggers are retracted to enable platform to be raised and machine to be driven Oscillating Axle Limit Switch When the platform is raised above 12 8 ft 3 9 m and the axle inclination is gt 1 the drive function is cutout by a limit switch When the platform is below 12 8 ft the inclina tion of the axle is ignored and driving is possible 3121325 SECTION 1 SPECIFICATIONS 1 Platform Stowed Jacks Retract Limit Switch 5 Tilt Sensor 2 High Dri
141. n servicing replacing the ing the Drive Motor to the Drive Hub Carefully wheel tire assembly remove the Drive Motor 6 Remove the eight Bolts 3 and Flatwashers 4 Removal attaching the Drive Hub to the Spindle 8 Carefully 1 Elevate machine with jacks or other suitable device remove the Drive Hub and secure Installation 1 Remove 6 Wheelnuts 1 0 Follow the removal steps reverse order when install 2 Carefully remove tire from Drive Hub 2 ing the wheel assembly 3 4 JLG Lift 3121325 3 5515 amp 5 55 5 Drive Motor Side I 3 2 1 Torque to 354 Ib ft Dry 480 Nm 2 Torque to 230 9 Ib ft Dry 313 Nm 3 Torque to 230 9 Ib ft Dry 313 Nm Figure 3 3 Hub Torque Values 3121325 JLG Lift 3 5 3 5515 amp 5 55 5 1 14 Sun Pinion 27 Circlip 40 Screw 2 Hub 15 Piston 28 Plug 41 Screw 3 Gear Ring 16 Spring 29 O Ring 42 Screw 4 Cover 17 Disc 30 O Ring 43 Plug 5 Flange 18 Disc 31 O Ring 44 Washer 6 Coupling 19 Lock Nut 32 O Ring 45 Plug 7 Thrust Washer 20 Bearing 33 O Ring 46 Disc 8 Thrust Washer 21 Bearing 34 Oil Seal 47 Threaded Stud 9 Circlip 22 Bearing 35 Gasket 48 O Ring 10 Planetary Gear 23 Bearing 36 O Ring
142. nizes a qualified JLG equipment mechanic as a person who by possession of a recog nized degree certificate extensive knowledge training or experience has successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model The Pre Delivery Inspection and Frequent Inspection pro cedures are performed in the same manner but at differ ent times The Pre Delivery Inspection shall be performed prior to each sale lease or rental delivery The Frequent Inspection shall be accomplished for each machine in ser vice for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used The frequency of this inspection must be increased as environment severity and frequency of usage requires Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection JLG recommends that the Annual Machine Inspection be performed by Factory Certified Service Technician on annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Indus tries Inc recognizes a Factory Certified Service Techni cian as a person who has successfully completed the JLG
143. o each other and as near perpendicular as possible to top of part being lifted Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 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 3121325 SECTION 2 GENERAL Component Disassembly and Reassembly When disassembling or reassembling a component com plete 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 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 I 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 un
144. o the Control Box 2 3 Carefully lift the lid from the box 4 At this point wires plugs and other parts may be disconnected for repair replacement 3121325 JLG Lift 3 27 3 5515 amp 5 55 5 Joystick Controller Table 3 6 Joystick Specifications TOP DIRECTION FT RIGHT FRONT MM N C R2 1 0 Figure 3 26 Joystick 019 JO Table 3 7 Plug Loading Chart Input Voltage 24V 0 05V Terminal Color Function Centered Output Voltage 12V 0 25V 1 Green Steer Left Reverse Voltage 5 5 6 5V 2 Yellow Steer Right Forward Voltage 17 5 18 5V 3 Brown Pot Out 4 N C 5 N C 6 N C 7 24 8 Red Enable 24V Out 9 White Black Ground 3 28 JLG Lift 3121325 3 5515 amp 5 55 5 5 1 Receptacle 4 6 Bolt M5 x 16 2 Bolt M6 x 20mm 5 110V Receptacle 8 Flatwasher M5 qty 2 3 Flatwasher 6 qty 2 6 Platform Control Box Outlet 9 Nut M5 Figure 3 27 Platform Receptacle Box Removal 5 The 110V Receptacle 5 can be removed from the A WARNING box by removing the four screws on the backside DIS
145. ollow the below steps Refer to Figure 3 17 Exhaust Pipe Assembly 1 Loosen the Exhaust Clamp 2 located on the muf fler 2 2 Slide the Exhaust Elbow 3 out of the muffler 3 Loosen the Exhaust Clamp 4 4 The exhaust elbow can now be removed 3121325 5 JLG Lift Remove the Exhaust Flex Pipe 5 by loosening the Exhaust Clamp 6 Slide the pipe out of the Tailpipe 7 The tail pipe can be removed by unscrewing and removing the two Bolts 8 and Lockwashers 9 connecting the pipe to the engine tray Follow the previous steps in reverse order to install the exhaust system Be sure to securely tighten the exhaust clamps 3 19 SECTION 3 CHASSIS PLATFORM amp SCISSOR ARMS Air Filter Assembly 1 Air Filter 2 Bolt M8 x 45mm 3 Flatwasher M8 4 Locknut M8 5 Hose Clamp Clip 6 Air Intake Hose 7 Hose Clamp Clip 8 Reducing Sleeve 9 Clamp 10 Air Intake Elbow 11 Clamp 12 Intake Hose 13 Clamp Figure 3 18 Air Filter Assembly NOTE Refer to Figure 3 18 when dismantling the Air Filter 3 Liftthe latches on the end of the Air Filter for access for service and or replacements Follow the steps to the safety element not shown below when removing installing any components HR NOTE When assembling the air filler system take care to securely fit all tubing and piping together and to 1 Removing the pipes and tubes requires loosening securely tighten
146. on when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Cleanliness 1 2 2 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions 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 JLG Lift At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel t
147. ox Wiring Description Position 1 Position 2 Label External Harness ader 9 X1 21B 2 PJ ader 10 X1 22 2 PK ader 11 X1 56 2 PL ader 12 X1 38 4 PM ader 13 X1 41B 1 PN ader 14 X1 32A 1 PO ader 15 X1 30 2 PP ader 16 X1 42 1 PQ ader 17 1 43 1 18 1 58 2 5 19 20 D25 A PU ader 21 X1 B34 1 PV ader 22 PW ader 23 PX ader 24 GGN 110 LIYYJZ25X1 UL SCISSORS CABLE SOCKET ader 1 2 1 C2 J2A 1 ader 2 2 2 C2 J2A 2 ader3 X2 3 C2 J2A 3 ader4 X2 4 C2 J2A 4 ader5 X2 5 C2 J2A 5 ader 6 X2 6 NC ader 7 X2 7 NC ader 8 X2 8 C2 J2A 8 ader 9 X2 9 trig contr J2 2 ader 10 X2 10 C2 J2B 2 ader 11 X2 11 NC ader 12 X2 12 C2 J2B 4 ader 13 2 13 C2 J2B 5 ader 14 X2 14 C2 J2B 6 ader 15 X2 15 C2 J2B 7 ader 16 X2 16 KTC 21 ader 17 2 17 1 59 1 18 2 18 C2 LED GEEL ader 19 X2 19 KL 21 ader 20 X2 20 C2 LED BLAUW ader 21 2 21 NC ader 22 X2 22 C2 LED ZWART ader 23 X2 23 X1 58 1 ader 24 X2 24 NC 3121325 JLG Lift 6 33 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 6 1 Main Terminal Box Wiring Description Position 1 Position 2 Label External Harness GGN NC NC
148. pe As soon as possible brace the lift cylinder so that when it is disconnected from the arm stack it will be secured and will not fall Remove the Bolts 1 Flatwashers 2 and Lockn nuts 4 on the bottom arm pin at the rear of the machine Bolt M16 140mm Flatwasher M16 Spacer N Locknut M16 shown Slightly lift the scissor stack up with the overhead crane so that the rear sliding blocks in the chassis are free 1 2 Lockwasher M6 10 Remove the Coverplates 3 from both sides of the machine by removing the two Bolts 1 and Lock washers 2 Once the coverplates are removed the Pin 4 can be pushed out Bolt M6 x 10mm 3 Coverplate 4 Pin Remove the plate with the limit switches attached refer to Figure 3 36 Limit Switch Adjustment Remove the bottom arm Pin 3 at the front of the machine by removing the Bolt 1 and Lockwasher 2 Pull the Pin out and secure it to the chassis Z Y JLG Lift 1 Bolt M20 x 3amm 2 Lockwasher M20 3 Pin 3121325 3 5515 amp 5 55 5 11 Lift the arm stack up and to the front The lift cylinder 12 Disconnect the Lift
149. ply Loctite 242 to Piston Thread before tightening 147 510 200 Setscrew Torque 14 8101 20 Max Speed 0 5 m sec Max Operating Temperature 22 F to 176 F 30 C to 80 C 3121325 JLG Lift 4 15 SECTION 4 HYDRAULICS amp WARNING REMOVE ANY LOAD FROM PLATFORM NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS BLOCKING OR OVERHEAD SLING 7 52 0 STRAP STRAP lt N ARM SAFETY Q 9 y 2 Figure 4 31 Arms and Platform Positioning and Support 4 16 JLG Lift 3121325 SECTION 4 HYDRAULICS 4 5 VALVES Valve Compartment 1 Pressure Switch Drive Enable amp Brake Valve 2 Drive Valve 3 Main Valve Block 4 Hand Pump Figure 4 32 Valve Hydraulic Compartment Pressure Switch Drive Enable Operate the lower function to retract the jacks and adjust the switch screw on the top of the switch to trip at 2683 psi 185 bar Figure 4 33 Pressure Switch Adjustment 3121325 JLG Lift 4 17 SECTION 4 HYDRAULICS Brake Valve VALVE SCHEMATIC 1 Torque to 5 ft Ibs 6 8 Nm A 2 Torque to 20 ft Ibs 27 1 Nm Operating Pressure 3000 psi 207 2 Voltage
150. pring applied brake The brake is released by actuating a 3 way solenoid valve This valve provides hydraulic power from the pump directly to the brakes The brake resets by deactivating the valve and restricting flow to the tank through an orifice to smooth out hard stops Drive is controlled by 2 proportional solenoid valve sec tions within the main control valve Flow to the drive motors passes through a 4 section solenoid drive valve manifold 2 for differential lock and 2 for fast drive There are three modes for drive selected by the drive speed select switch on the platform control console 1 Normal Drive 4 wheel drive 2 Differential Lock 4 wheel drive with flow dividers 3 Fast Drive 2 wheel drive Normal Drive Flow passes from section 9 to the front drive section of the drive valve ports A1 amp B1 and from section 2 to the rear section of the drive valve ports A2 amp B2 All 4 solenoids on the drive valve are in the passive non energized mode Flow from A B1 passes directly to the front drive motor ports C D1 amp C D2 and from A B2 to the rear drive motors C D3 amp C D4 Differential Lock As in normal drive flow passes from section 9 to the front drive section of the drive valve ports A1 amp B1 and from section 2 to the rear section of the drive valve ports A2 amp B2 The 2 differential lock solenoids are energized which directs the flow through 2 flow dividers in the drive valve The
151. r Vee Belt Ground Power 24V X2 5 Ground X2 6 0 Zero frequency 5 12 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop problem should develop which is not presented in this section or which is not corrected by listed corrective actions tech nically qualified guidance should be obtained before proceeding with any maintenance 6 2 MULTIMETER BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 7 is recommended for the measurements in these procedures This section shows dia grams of a common digital VOM configured for several different circuit measurements Instructions for your VOM may vary Please consult the meter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the voltage source Backprobing To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the connector is the sea
152. rds and Decals 1 2 4 2 Wheel and Tire Assemblies 8 9 4 3 Drive Motors 1 5 6 14 Drive Brakes 1 6 15 Drive Torque Hubs 1 3 5 6 16 Steer Cylinder 5 6 13 4 7 Steer Components 46 4 8 Wheel Bearings 19 Scissor Arms 1 4 20 Safety Props 1 4 21 Sliding Wear Pads 8 12 22 Pivot Pins Bolts 1 4 7 8 23 Switches Ground Control 1 11 24 Control Tags 1 2 25 Frame including doubler plate gussets and surrounding area 3121325 JLG Lift 2 11 SECTION 2 GENERAL 27 NOTES 2 12 JLG Lift 3121325 3 5515 amp 5 55 5 SECTION 3 CHASSIS PLATFORM 4 SCISSOR ARMS 31 OPERATING CHARACTERISTICS ANYTIME SERVICING OF ELECTRICAL OR HYDRAULIC COMPO NENTS IS REQUIRED DISCONNECT BATTERY VIA THE DISCON NECT SWITCH ON THE GROUND CONTROL PANEL AND SHUT VALVE LEVERS AT THE BASE OF THE HYDRAULIC TANK TO STOP FLOW OF HYDRAULIC FLUID Leveling Jacks The machine is equipped with auto leveling jacks The automatic self leveling system is controlled by 4 double acting cylinders mounted at each corner of the machine chassis These cylinders incorporate pilot operated hold ing valves on the piston side The cracking pressure of thes
153. rical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors 1 To prevent oxidation and low level conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole plug into this and or any unused wire seal that has silicone dielectric compound escaping from it PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY RETENTION LEG WEDGE LOCK HOUSING Figure 6 5 AMP Connector 3121325 JLG Lift 6 5 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Assembly Check to be sure the wedge lock is in the open or as shipped position See Figure 6 6 Connector Assembly 1 of 4 Pro ceed as follows CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Figur
154. s Required 11 Lower Slide Pads 4 Lube Points 2 Grease Fittings Capacity As Required 7 Lube MPG Interval As Required Lube Points 2 Grease Fittings Capacity As Required Lube MPG Interval As Required 3121325 JLG Lift 2 9 SECTION 2 GENERAL 2 5 CYLINDER DRIFT TEST JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM Maximum acceptable cylinder drift is to be measured using the following method Platform Drift Forms are supplied with each new machine and are also available from JLG Customer Service Forms must be NOTE Test cylinder drift with machine oil at ambient tem completed and ret rned to JLG Industries perature NOTE This machine requires periodic safety and mainte nance inspections by a JLG Dealer A decal located 1 Place maximum work load onto platform Refer to on the frame affords a place to record stamp Table 1 1 Operating Specifications inspection dates Notify dealer if inspection is over i due 2 Extend lift cylinder to achieve a platform height 3 to 5 meters from fully stowed The inspection and maintenance
155. sary a Thoroughly clean bushing housing of burrs dirt etc to facilitate bearing installation b Inspect bushing housing for wear or other dam age If the bushing housing is worn or damaged rod barrel must be replaced c Lubricate inside of bushing housing with WD40 prior to bushing installation d Using an arbor of the correct size carefully press the bushing s into bushing housing on the cylinder rod and cylinder barrel if applica ble Bushing Housing Bushing 9 0 Figure 4 13 Bushing Installation NOTE Step 14 applies only to the Lift Cylinder and Axle Lockout Cylinder 14 Inspect lift lower valve and load check valve Replace as necessary 15 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 16 If applicable inspect piston rings for cracks or other damage Replace as necessary JLG Lift 3121325 SECTION 4 HYDRAULICS Assembly Ri Snap Ring NOTE Prior to cylinder assembly ensure that the proper Outrigger Cylinder Only cylinder seal kit is used See your JLG Parts Manual 3121326 Always replace seals when servicing cylin ders C gt Apply a light film of hydraulic oil to all components prior to Backup Ring assembly ae Cylinder Outrigger and Axle Head Lockout Cylinders Only 1 special tool is used to install a new rod seal into the applicable cylinder head gland groove SEAL TOOL 1 7004275
156. se split the flow to the left and right front motors 1 amp 2 and to the rear motors 3 amp 4 Fast Drive Valve section 2 is not used in fast drive Flow from section 9 passes to the front section of the drive valve The 2 fast drive solenoids are energized which connect the ports of the rear drive motors C3 to D3 and C4 to D4 This allows the rear drive motors to free wheel 3121325 JLG Lift 3 1 3 5515 amp 5 55 5 Drive Hub DRIVE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT S GEARS AND SEALANTS ARE WORKING PROPERLY The following information briefly outlines what to look for when performing these tests A WARNING IF THE MACHINE IS ON ANY INCLINE THE WHEELS MUST BE ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING THE BRAKES FAILURE TO DO SO MAY RESULT IN INJURY OR EVEN DEATH 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 wheel or hub of the gearbox by hand 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
157. sher 31 Bolt M12 x 20mm 5 Grease Fitting 14 Grease Fitting 23 Washer 32 Lockwasher M12 6 Bolt M12 x 30mm 15 Bolt M12 x 20mm 24 Flatwasher M12 33 Pin 7 Lockwasher M12 16 Lockwasher M12 25 Nut M12 8 O Ring 17 Bushing 26 Pin 9 Ring 18 Tie Bar 27 Grease Fitting Cap NOTE not used on later machines Figure 3 6 Steering Assembly Remove wheel and tire assemblies before attempt ing to service the steering assembly Disconnect electrical supply and any wires and or hoses Secure machine with proper stabilizing devices Removal 1 3121325 Remove Steer Oylinder 19 by removing Bolts 20 31 Washers 21 22 23 32 Nuts 25 and Pins 26 33 Disconnect Tie Bar 18 from both Spindles 1 2 by removing Bolts 15 Lockwashers 16 Pins 12 and Bushings 17 Remove Tie Bar Spindles can now be removed from the chassis Secure Spindle Remove Grease Cap 4 and Fitting b Remove Bolts 6 Lockwashers 7 Cap 3 O Ring 8 Ring 9 and Bushings 10 The Spindle can now be removed for repair replacement Installation JLG Lift Follow the Removal Steps in reverse order when assembling the steering system 3 5515 amp 5 55 5 3 5 Limit Switches Limit Switch Cover Bolt M12 x 70mm Flatwasher M12 Lockwasher M12
158. si Max Working Pressure 185 bar 737 668 Piston Head Torque Apply Loctite 243 prior to tightening torque with Rod End 1000 Nm 958 8 Ib ft Cap Torque Apply Circlip behind Piston Head prior 1300 Nm Max Speed 0 5 m sec 22 F to 212 F Max Operating Temperature 30 C to 100 C 3121325 JLG Lift 4 13 SECTION 4 HYDRAULICS k Barrel Bushing Load Check Valve Piston Piston Seal Setscrew Head Seal Backup Ring O Ring Head Rod Seal 20 MI 2 E Wiper Rod O Ring n 2 Figure 4 29 Axle Locking Cylinder Assembly Table 4 3 Axle Locking Cylinder Specs Max Working Pressure Piston Head Torque Apply Loctite 242 to Piston Head before tightening Speed 0 5 Max Operating Temperature 4 14 JLG Lift 3121325 SECTION 4 HYDRAULICS Figure 4 30 Extension Cylinder Assembly Table 4 4 Deck Extension Cylinder Specs Barrel Piston Spacer Head O Ring Wiper O Ring SO BN i Wiper n Bushing Setscrew Piston Seal Head Seal Max Working Pressure 3045 7 psi 210 bar Full Bore Relief Pressure 1160 3 psi 80 bar Piston Torque Ap
159. sociated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing rupture of the cylinder hydraulic line or fitting Complete failure of the system pump is also avoided by relieving cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual integral relief s are provided for each side of the circuit Proportional Valve Flow is proportional to the amount of voltage supplied to the valve coil Voltage is gained by the machine controller and determined by the position of the joystick 3121325 JLG Lift 4 1 SECTION 4 HYDRAULICS 4 3 CYLINDER CHECKI
160. sor Arm Assembly 1 3 39 Lift Cylinder 4 0 3 42 Scissor Arms Disassembly 4 3 43 SECTION 4 HYDRAULICS 4 1 Cylinders Theory of Operation 4 1 ii JLG Lift 3121325 5 Deck Extension Cylinder 0 54 1 4 1 Lift Cylinder P LE 4 1 Outrigger Cylinders eee qe ek Eee He ee 4 1 4 1 4 2 Valves Theory 4 1 Solenoid Control Valves Bang Bang 4 1 Relief uu be eng ee aed 4 1 Crossover Relief 4 1 Proportional Valve s hae whee een 6 se tree ee 4 1 4 3 Cylinder Checking 4 4 2 4 4 Cylinder Repair bie Ee bab eot ag 4 2 DISASSCMBIY u uyta si te ee decet er ode eR ose eus 4 2 Cleaning and 4 6 Assembly OW aE E 4 7 4 5
161. t 16 27 1 Nm 1 Solenoid Valves Operating Pressure 3500 psi 240 bar Figure 4 44 Lift Lower Valve Block Platform Lower Flow Valve with the rated load on the platform see Table 1 1 adjust the knob shown to the left to obtain the lowering speed as specified in Table 1 1 Figure 4 45 Platform Lower Flow Valve 4 24 JLG Lift 3121325 SECTION 4 HYDRAULICS Outrigger Safety Valves Front Outriggers Operating Pressure 116 psi 8 bar Outrigger Safety Valve Cylinder Rear Outriggers Operating Pressure 14 5 psi 1 bar Figure 4 46 Outrigger Valves 3121325 JLG Lift 4 25 SECTION 4 HYDRAULICS 27 NOTES 4 26 JLG Lift 3121325 u S a 4 7 2 IG C S LEVEL lt SENSOR 2 J6 N2J1 819 C lt lt
162. the MEWP with outriggers OFF GreenLEDN 66 All Outriggers Retracted 5 6 JLG Lift point There are three measuring points to accommo date a conventional voltmeter To Check and Set Adjustment Place the MEWP on an even flat and level surface Ensure the MEWP is level to within 0 5 of 0 The MEWP can be manually leveled by using the outrigger handles on the main valve block refer to Figure 4 33 Main Valve Block Lower outriggers by engaging the handles until the machine is level to within 20 59 of 0 from front to back and right to left Check with a digital level gauge Ensure the Battery Disconnect is ON Turn the select switch to Platform and switch outriggers select to Outriggers ON Power up the NIVOLUX board by switching the igni tion switch on the console to ON Open the MTB and measure the voltage between the measuring points SOLL X Y supposed value and IST Y actual value which are the upper and center measuring points A voltage of 0 1V 100mV represents about 1 of inclination nose up A value of 0 1V represents about 1 of inclina tion nose down Adjust TP2 see Figure 5 3 with small screwdriver until your voltmeter shows zero Turning counter clockwise reduces the value Measure the voltage between the measuring points SOLL X Y supposed value and IST X actual value and follow the same steps as in step 5 0 1V represents an inclination of approximately 1 to
163. the motor housing In case of different splines lengths turn the cardan shaft to ensure the long splines end is fitted in the output shaft Transfer marking from output shaft to cardan shaft Place the two O Rings 8 greased in the O ring grooves of the Gearwheel In gearwheels with non through splines place the gearwheel with the recess in the spline hole facing down towards the housing Place the Gear Wheel Set 10 on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel are vertically above the mark on the car dan shaft Turn the gearwheel set counterclockwise until the cardan shaft and the gearwheel start to mesh 15 Turn the gearwheel rim so that the holes made for the screws line up Turn the End Cover 11 so that the holes line up Place the Washers 12 onto the Screws 13 Usea 18mm spanner socket to tighten the screws Table 3 3 Tightening Torques Item Torque Screws item 13 in Figure 3 5 270 3151bfin 8 0 3 5daNm Plug ifapplicable not shown 445 620 Ibf in 5 7 daNm JLG Lift 3121325 3 5515 amp 5 55 5 3 4 STEERING ASSEMBLY 1 Right Spindle 10 Bushing 19 Steer Cylinder 28 Grease Fitting 2 Left Spindle 11 Ring 20 Bolt M12 x 150mm 29 Grease Fitting Cap 3 Cap 12 Pin 21 Flatwasher M12 30 Grease Fitting 4 Grease Fitting Cap 13 Grease Fitting Cap 22 Wa
164. til they are ready to install 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage 3121325 Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance 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 evidence of
165. tion c Fuel Filter e Hydraulic Oil Check Fill Maintenance Replaceable Element JLG P N 7020023 Interval Change every year or 600 hours of operation whichever comes first Lube Points Fill amp Site Gauge Capacity 68 7 gal 260 1 Lube HO Interval Check oil daily change every 1200 hours of operation 3121325 JLG Lift 2 7 SECTION 2 GENERAL 4 Rod Ends 6 Oscillating Axle Lube Points 2 Grease Fittings Capacity As Required Lube MPG Lube Points 3 Grease Fittings Capacity As Required Lube MPG Interval As Required Interval As Required 5 Spindles 7 Lift Cylinder Lube Points 2 Grease Fittings Lube Points 2 Grease Fittings Capacity As Required Lube MPG Interval As Required Capacity As Required Lube MPG Interval As Required 2 8 JLG Lift 3121325 SECTION 2 GENERAL 8 Fuel Tank Opposite Engine Compartment 10 Upper Slide Pads Capacity 23 8 gal 90 L Lube Diesel Fuel Lube Points 2 Grease Fittings Interval Check fuel periodically during each shift Capacity As Required Lube MPG 9 Deck Arm Pivot Pin Interval A
166. tion shows scissor arm assembly connection point to underside of platform at the rear of the platform Figure 3 33 Platform Removal 2 of 2 Rear of Platform Platform Removal Installation NOTE Procedures apply to both left and right sides 1 The removal steps should be followed in reverse order when installing the platform 1 Support the platform along the sides with the fork truck forks or use suitable straps or chains at the four corners of the platform 2 Remove the fourteen Bolts 2 and Lockwashers 3 attaching both Platform Retaining Brackets 1 to the Platform 3 Liftthe platform from the armstack 3121325 JLG Lift 3 35 3 5515 amp 5 55 5 3 12 LADDER INSTALLATION Y Ladder Bolt M10 x 25mm Spring Lockwasher M10 Flatwasher M10 if applicable MA Figure 3 34 Ladder Installation Removal Installation 1 The ladder can easily be removed from the chassis 1 Lift ladder so that the four mounting brackets align by removing the four Bolts 2 Spring Lockwashers with the bolt holes on the chassis 3 and Flatwashers 4 2 Secure ladder to the chassis with the four Bolts 2 CAUTION Spring Lockwashers 3 and Flatwashers 4 USE CAUTION WHEN REMOVING THE LADDER THE LADDER WEIGHS APPROXIMATELY 104 LBS
167. tional wires If harness is not com pletely isolated disconnect battery terminals also as a precaution 2 Measure continuity between all three wires the wire under test wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 side jumper from contact of wire 1 and wire 2 4 Measure continuity between wire 1 and wire 2 If there is continuity both wires are good and can be used for this test If there is not continuity either wire could be bad Check connections and measurement setup Redo measure ment If still no continuity repair wires or consult schematic for other wires to use for test 5 Jumper from wire under test to wire 1 6 Measure continuity If there is continuity the wire under test is good Resistance of a wire increases as the length increases and as the diameter decreases One can find the continuity of two wires here 1 and 2 at once by following steps 1 through 4 If there is a problem the third wire is used to troubleshoot the other wires To find the problem start at step 1 and use the entire procedure 6 4 JLG Lift 3121325 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 6 3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent elect
168. tor housing 2 on a work bench and press the shaft out of the motor housing 8 Remove the Bearing Race 4 from the motor hous ing 2 9 Remove the Axel Needle Bearing 5 10 With a mandrel and plastic hammer carefully knock out the Shaft Seal 3 and Dust Seal Ring 1 NOTE When cleaning parts clean parts carefully with low aromatic kerosine Check all parts carefully and replace if necessary Before assembly lubricate all parts with hydraulic oil and grease rubber parts with vaseline Motor Assembly 1 Place the Motor Housing 2 in a holding tool with the flange upwards 2 Lubricate the Shaft Seal 3 on the outside with hydraulic oil Fit the shaft seal correctly onto the mandrel and carefully press the shaft seal into posi tion into the motor housing 3 Place the Dust Seal Ring 1 in the spigot flange and knock it into position with a plastic hammer and appropriate mandrel 4 Fit the Bearing Race 4 onto the shaft and mount together with the shaft 5 Place the Axel Needle Bearing 5 back onto shaft 6 Output Shaft 6 Grease the journals with hydraulic oil The rear shaft end must be marked before fitted The mark must be positioned vertically above a 3 8 10 11 12 commutation slot leading up to the front annular channel Grease the O Ring 8 and put it in the O ring groove of the housing Turn the Distributor Plate 9 so that the holes iine up Guide the Cardan Shaft 7 down into
169. ttaching the cylin der to the frame Carefully lower the Cylinder out of the frame 3 5515 amp 5 55 5 10 Bolt M6 16mm 11 Lockwasher M6 12 Plate 13 Gasket 14 Bolt M12 x 70mm 15 Lockwasher M12 16 Outrigger Cylinder Figure 3 9 Outrigger Cylinder Removal Sheet 2 of 2 Installation 5 1 Carefully insert Outrigger Cylinder 16 back into the frame and secure with the four Bolts 14 and Lock washers 15 6 2 Replace Gasket 13 and Plate 12 Secure with four Bolts 10 and Lockwashers 11 NOTE At this point the frame may be lowered 3 Place Valve Assembly 7 Limit Switch Bracket 8 and Limit Switch 9 back onto the top of the cylinder and secure with the four Bolts 5 and Lockwashers 6 4 Reconnect all hydraulic lines and electrical wires 3 12 JLG Lift Return flow of hydraulic oil and ensure there is no leakage Operate cylinder to ensure it works prop erly Replace Cover 1 and secure with four Bolts 2 and Lockwashers 3 3121325 3 5515 amp 5 55 5 3 7 ENGINE COMPARTMENT Hood Assembly 2 4 13 2 1423 PS Sr x 1871 po Ye jer ENGINE SIDE 7 16 AS Figure 3 10 Hood Assembly k gt p N s
170. ve Speed Cutout Limit Switch 6 Outrigger Sensor all 4 outriggers 3 Maximum Drive Height Maximum Height without 7 Oscillating Axle Limit Switches rear axle Outriggers Limit Switch 4 Maximum Height Limit Switch Figure 1 1 Limit Switch Locations 3121325 JLG Lift 1 3 SECTION 1 SPECIFICATIONS 18 PRESSURE SETTING Cold temperatures have a significant impact on pressure readings JLG Industries Inc recommends setting the pressures with the operating temperature between 59 68 F 15 20 C JLG Industries Inc also recommends the use of a calibrated gauge The pressures may be set with 1 11 LUBRICATION Hydraulic Oil Table 1 10 Hydraulic Oil HYDRAULIC SYSTEM OPERATING SAE VISCOSITY GRADE tolerence of 43 5 psi 3 bar Table 1 7 Pressure Settings TEMPERATURE RANGE 0980 23 F 18 10 5 C 10 Main Pressure Relief 43 5 psi 3 bar quias Pump Charge Pressure 43 5 psi 3 bar 19 MAJOR COMPONENT WEIGHTS Table 1 8 Major Component Weights 0 to 210 eee 10W 20 10W 30 50 to 210 F 10 to 100 C 8051 Platform Assembly including extension 065 Platform Extension 12 787 108 Chassis ok 15 653 Ibs Arm Assembly 7100 ka Lift Cylinder NOTE Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and suffici
171. ving the Bolts 12 Chain Assembly Mounting USE CAUTION WHEN REMOVING ANY PLATFORM RAIL Plates 13 Flatwashers 14 and Locknuts 15 on all three rail legs NOTE All procedures apply to the opposite side 4 Remove the Tubes 16 once the rail is removed Removal Installation NOTE The below procedures apply to both right and left side rails NOTE The below procedures apply to both the right and left 1 Disconnect side rail 1 from the end rail by pulling the Cotter Pin 2 from the Pin 3 Remove the Pin from the Bar 4 and Pin 5 located on the end rail 3 30 JLG Lift 1 side rails Follow the removal procedures in reverse order when installing the side rails 3121325 3 5515 amp 5 55 5 Main Platform End Rails 1 Rail right side 5 Cotter Pin 9 Chain Assembly Mounting Plate 2 End Rail left side 6 Pin 10 Locknut M10 3 Gate 7 Bolt M10x 120mm 11 Hinge 4 Platform 8 Flatwasher M10 Figure 3 29 End Rail Removal Removal Installation 1 If applicable disconnect end rails 1 2 3 from side NOTE Place the rail s on the platform in their stowed posi rails see removal instructions for side rails on pre vious page 2 Remove Cotter Pins 5 from Pins 6 on rail legs 3 Fold rails down to the stowed position 4 Remove Bolts 7 Flatwashers 8 Locknuts 10 and Chain Assembly Mounting Plates 9 5 Carefully re
172. ws 14 to 450 Ib ft 610 Nm dry 3121325 3 5515 amp 5 55 5 3 6 OUTRIGGER CYLINDER REMOVAL Cover Bolt M8 x 160mm Lockwasher M8 Outrigger Cylinder Bolt M8 x 50mm Lockwasher M8 Valve Assembly Limit Switch Bracket Limit Switch Figure 3 8 Outrigger Cylinder Removal Sheet 1 of 2 NOTE Refer to Figure 3 8 Outrigger Cylinder Removal Sheet 1 of 2 and Figure 3 9 Outrigger Cylinder Removal Sheet 2 of 2 Shut off flow of hydraulic oil before attempting to remove any outrigger cylinder Removal A 1 3121325 Remove the Cover 1 by removing the four Bolts 2 and Lockwashers 3 Disconnect all hydraulic hoses and wires attached to the Valve Assembly 7 and Limit Switch 9 Remove the Valve Assembly Limit Switch Bracket 8 and Limit Switch from the top of Outrigger Cylin der 4 by removing the four Bolts 5 and Lockwash ers 6 NOTE Support cylinder rod to prevent rod extension and JLG Lift consequential oil spillage After Removal Step 3 the frame must be elevated greater than the length of the stowed outrigger cylin der to remove the cylinder Remove the Plate 12 and Gasket 13 by removing the four Bolts 10 and Lockwashers 11 Secure the Outrigger Cylinder 16 Remove the four Bolts 14 and Lockwashers 15 a
173. x NI jum MOTD AD 14 10 11 5 44 2 88915 z z lt gt LIAN SAOLLSAOL 5 THNVd IOX LNOO LAIT 4015 I9V L s Figure 6 18 Electrical Schematic Sheet 1 of 15 3121325 JLG Lift 6 12 SECTION 6 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 08 a y oum o D gt 89 UALAVLS 9c 1X II OL IS 19 15 lt S IHOIHH JAMAA 08 9 Xd IdINOO amour 15 gt I INO NI W amp OdLV Td TUTIX MOOT 011615 Onuoo JOMOT UI 4 445 81 1X IVORLLOHT IH OLLVINHHOS 96 9 DO IVNV 96 I XII II III 96 nuog ODL 8t 198841 19 8CTX SA SA 1 Mes 195910 LX SAM S

Service 3121325 03-24-11 ANSI English

Contents

Download Pdf Manuals

Related Search

Related Contents