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Service & Maintenance Manual

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2. NOISH3A 408 ANY 3NIHOVI 3 18V IIVAV 38 LON AYN SN33HDS 4105 3 LON 2 39 JLG Lift 3121801 SECTION 2 PROCEDURES 2 21 MACHINE MODEL ADJUSTMENT Table 2 11 Machine Model Adjustment 2 40 Adjustment Adjustment range Default Values Gas Default Values Diesel DRIVE ACCEL 1 0t05 0 sec 4 4 DECEL 1 0t05 0 sec 2 2 FWD MIN 010 100 21 21 FWD 010 100 52 52 FWDELEV 010 35 30 30 REV MIN 010 100 21 21 REV 010 100 52 52 REV ELEV 010 35 30 30 LO 3510 65 50 50 ENGINE SPD 280010 3800 RPM 3600 3000 GAIN 010 999 180 50 DROOP 010999 200 250 STABILITY 010 999 170 80 LIFT ACCEL 0 2T05 0 3 3 DECEL 0 2T05 0 0 5 0 5 UP MIN ENG 1400 TO 2200 RPM 2000 1800 UP MAX ENG 2600 to 3600 RPM 3600 3000 LO MAX 35 to 55 50 50 GAIN 010 999 150 5 DROOP 010 999 220 200 STABILITY 010 999 125 90 ENGINE SPEED 1200 1500 1500 1500 GAIN 010 999 150 10 DROOP 010 999 250 90 STABILITY 010 999 100 130 0 100 19 18 MAXACT L D 0 TO 10096 60 100 MAX ACT IDLE 0 TO 100 55 55 CUT ACT 200 To 2800 RPM 500 500 GEN ENG SPD 2000 To 3600 RPM 3000 3000 4150335
3. 3121801 JLG Lift 3 29 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Figure 3 24 Electrical Componants Installation Prior to S N 141689 Sheet 1 3 30 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 Figure 3 25 Electrical Componants Installation Prior to S N 141689 Sheet 2 3121801 JLG Lift 3 31 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 32 5 PLATFORM WORK LIGHTS PISTON 2 PUMP Figure 3 26 Electrical Componants Installation S N 141689 to Present Sheet 1 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 GROUND CONTROL SENDER BEACON TO ELEVATION PROXIMITY SWITCH SWITCH f ANALYZER p e P C KA C P A B 26 GROUND d SPLICE tt emm 2 4 9 LEVELING Z SWITCHES Figure 3 27 Electrical Componants Installation S N 141689 to Present Sheet 2 3121801 JLG Lift 3 33 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
4. Table 2 4 Joystick Specifications Table 2 5 Joystick Plug Loading Chart Input Voltage 4 3V 0 1V Terminal Color Function Centered Output Voltage 2 2V x 0 1V 1 Yellow Steer Right Full Positive Rev Deflection Output Voltage 4 0V x0 1V 2 Green Steer Left Full Negative Fwd Output Voltage 0 4V x 0 1V 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 7 Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot 2 24 JLG Lift 3121801 SECTION 2 PROCEDURES 49 9 ohm 75 0 3 GGER SUPPLY GGER SWITCH TRIGGER SWITCHES 5 LEFT V SUPPLY STEER ROCKER STEER RIGHT SWITCHES Figure 2 23 Joystick Controller JLG P N 1600403 Table 2 6 Joystick Specifications Table 2 7 Joystick Plug Loading Chart Input Voltage 5V Terminal Color Function Centered Output Voltage 4 25V to 2 60V 1 Yellow Steer Right Reverse Voltage 4 60V to 4 80V 2 Green Steer Left Forward Voltage 0 40V to 0 60V 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 4 T Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot 3121801 JLG Lift 2 25 SECTION 2 PROCEDURES 2 17 SENSOR Tilt Sensor JLG P N 4000006
5. 2 41 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 1 Generals o ue 3 1 3 2 Multimeter Basics u L T be M yah vL em pae EE 3 1 3 3 Applying Silicone Dielectric Compound Amp 3 5 3 4 Working With Deutsch 3 10 3 5 SWItChES uoc eee Se ad lbi PME RR DEA 3 12 3 6 Troubleshooting zip ei Remy dE EP E RE ER RE EE RIA 3 13 3121801 JLG Lift TABLE CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Number Location a y petite oe Gk aasma g h ah 1 4 1 2 Lubrication Dlagrarm eh e au Xu e MODA ua ein 1 5 1 3 Operating Temperature Specifications Kubota 1 6 1 4 Torque Chart In Lb Ft Lb For ASTM Fasteners 1 7 1 5 Torque Chart Metric Conversion For ASTM 1 8 1 6 Torque Chart N m For Metric Class 1 9 2 1 Arms and Platform Positioning and Support Cylinder 2 6 2 2 Lift Oylinder 2 eee RM 2 7 2 3 Cylinder Barrel
6. WHT YEL 48 4 BLU ORN 52 1 WHT YEL 48 1 WHT YEL 48 10 WHT YEL 48 2 55 2 ORANGE 55 1 AAAAA e feo f lt gt foo fo 2 fel fe fel fel fel IK OHM 5 5 5 5 53555855 525 i5 s W 150 OHM uu Z 8 822 gp Hia 5 Z 2 Sas Z 5 5 5 amp 4 5V OUTPUT 2 CENTER i PLATFORM DISPLAY up law tol E 1 has M E BS RR E Me per R LIET ENGINE GLOW 8 989289995 RTP 2913 335 YELLOW 10 1 SELECT SELECT SPEED START HORN 55 LP GAS CHOKE 1 SEDET FUEL SELECT SELECT L J OPTION PAK AAA P Aree 5 5 5 5 5 5 ORN RED 49 3 T V V V V V YEL RED 2 1 WHT RED 51 2 4i WHT RFD 51 3 BLU ORN 52 4 251813 WHT RED 51 4 Y lt a a e ge 8 g a h 5 THIS SYMBOL 15 WIRE CABLE CONTINUATION TO ANOTHER LOCATION GENERATOR x ala al ala H WIN N RENT STE BLU ORN 52 48 55 zz LETTER NUMBER a 5 l BLU ORN 52 4 GENERATOR ATA AA A A A A A A AAAAAAAA LOCATION I TP VALVE 89888898565 gt 5 5 5 5 55555 5 5 5555 55 5 s A lt s CS E ik ae M LUE 858 ss S S e 5208226 g 255555 E E mr oen am CHOKE 55 5 o 9 o 5 25 2 B RELAY 81 TILTY gt 5 30 gt TILT SENSOR GND BL
7. 2 22 2 21 Joystick Controller JLG P N 1600308 2 23 2 22 Joystick Controller JLG P N 1600403 2 24 2 23 liltSensor Location 22 nd pem pa 2 25 2 24 Tilt Sensor Removal 6 2 25 2 25 Tilt Sensor Location D Q Me ue E id ee mae pb OR E ER s eR 2 26 2 26 Tilt Sensor Removal 2 26 2 27 Hand Held Analyzer secs errre eds bi be Gur ea le ade oes 2 29 2 28 Analyzer Flow Chart Sheet 1 4 1 2 35 2 29 Analyzer Flow Chart Sheet 2 4 2 36 2 30 Analyzer Flow Chart Sheet 3 4 2 37 2 34 Analyzer Flow Chart Sheet 4 4 1 2 38 3 1 Voltage Measurement 3 2 3 2 Resistance Measurement 3 2 3 3 Continuity 3 3 3 4 Current Measurement 2 3 3 3 5 AMP GOnHROCIOL oco ae setts ener
8. 1 Ground Control Box 2 Tilt Sensor JLG P N 4000006 Figure 2 24 Tilt Sensor Location Tilt Sensor Removal NOTE Refer to Figure 2 24 Tilt Sensor Removal for num bers in parenthesis 1 Disconnect the batteries 2 Open the Ground Control Box to gain access to the Tilt Sensor Assembly 3 Remove the four Screws 2 and Lockwashers 3 to remove the Tilt Sensor 1 from the Ground Control Box NOTE Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 2 18 Calibrations 1 Tilt Sensor JLG P N 4000006 2 Screw 6 32 x 3 4 3 Lockwasher Figure 2 24 Tilt Sensor Removal Table 2 8 Tilt Sensor Harness Chart Wire Color Function Connector Pin Red VCC 1 Black Ground 4 Blue PWMX 2 Yellow PWMY 3 3121801 2 26 JLG Lift SECTION 2 PROCEDURES Tilt Sensor JLG P N 4000021 4 Ground Control Box 5 Tilt Sensor Assembly JLG P N 1810140 Figure 2 25 Tilt Sensor Location Tilt Sensor Removal NOTE NOTE 3121801 Refer to Figure 2 26 Tilt Sensor Removal for num bers in parenthesis Disconnect the batteries Open the Ground Control Box to gain access to the Tilt Sensor Assembly Remove the four Screws 3 Lockwashers 4 Standoff Insulato
9. Component Weight Tire and Wheel Assembly Std each i E Tire and Wheel Assembly each S Kubota Gas DF Engine Dry Kubota Diesel Engine Dry b E JLG Lift SECTION 1 SPECIFICATIONS 1 11 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is located on the rear center of the machine frame just below the middle step of the lad der In addition if the serial number plate is damaged or missing the machine serial number is stamped on the right front frame rail adjacent to the sizzor arms SERIAL NUMBER PLATE Figure 1 1 Serial Number Location 1 4 JLG Lift 3121801 SECTION 1 SPECIFICATIONS Figure 1 2 Lubrication Diagram Table 1 14 Lubrication Chart INDEX NO COMPONENT NUMBER TYPE LUBE POIN
10. 2 8 2 4 Gapbscrew Removal y u ante esci en eee e gae pa i obe 2 8 2 5 Cylinder Rod SUppott core etuer reU S uen En hee Pa PAD 2 8 2 6 Tapered Bushing 1 4 1 2 9 2 7 Rod Seal 22 2222222 2 10 2 8 Wiper Seal Installations u ee cai eda BAe ee Ley ee a Cha 2 10 2 9 Installation of Head Seal Kit 2 10 2 10 Piston Seal Kit Installation 0 20 1 2 11 2 11 Tapered Bushing Installation 4 1 2 11 2 12 Seating the Tapered Bearing 2 11 2 13 Poly Pak Piston Seal 2 2 12 2 14 Rod Assembly Installation 0 cece 2 12 2 15 Steer 2 16 2 16 Leveling Jack Assembly Prior to S N 105371 2 17 2 17 Leveling Jack Assembly S N 105371to S N 141689 2 18 2 18 Leveling Jack Assembly S N 141689 to 2 19 219 Valve Components ic been ebd ee eee uhuy beer 2 20 2 20 Automatic Choke Adjustment 750
11. 3 2a 5 7 a m 5 P N H mL 7 JO e 5 vd a Ow lt idi I gt gt 21 o EY m we 3 lt z 9 RIGHT FRONT LEFT FRONT Figure 3 31 Hydraulic Diagram Leveling Jacks 3121801 JLG Lift 3 37 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS NOTES 3 38 JLG Lift 3121801 3121801 An Oshkosh Corporation Company Corporate Office Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 pia B JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 811111 612 65 810122 JLG Latino Americana Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 USA 717 485 5161 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 1
12. Dea UE OVE IDE TOME enm 3 5 3 6 Connector Assembly 1 4 3 6 9 7 Connector Assembly 2014 2 3 6 3 8 Connector Assembly 3 of 4 4 3 7 3 9 Connector Assembly 4014 1 3 7 3 10 Connector Disassembly 3 8 3 11 Connector 3 9 3 12 Contact Installation 3 10 3 13 Contact 1 3 10 3 14 HD HDP Contact 3 10 3 15 HD HDP Locking Contacts Into Position 3 11 3 16 HD HDP Contact Removal 2 3 11 3 17 HD HDP Unlocking Contacts 3 11 JLG Lift 3121801 TABLE CONTENTS 3 18 3 19 3 20 3 21 3 22 3 23 3 24 3 25 3 26 3 27 3 28 3 29 3 30 3 31 TABLE NO 3121801 Electrical Schematic Sheet 1 Of 3 3 22 Electrical Schematic Sheet 2
13. I DS 1 1 1 3 Component Bala ESSERE ER ra Lebe 1 1 1 4 L briCatlor 2 Eget 1 2 1 5 Lubrication 1 2 1 6 Cylinder Specifications escis ru I Cane UE HEUS MORI EROR 1 3 1 7 Pressure Settings whe need dee eI ERES 1 3 1 8 Eimit SWitehes 53d os p eR RR mt e e E SE Ep MN PC eet Rei ea 1 3 1 9 Major Component 1 3 1 10 Critical Stability Weights 1 3 1 11 Serial Number 1 4 SECTION 2 PROCEDURES 2 1 General zs eee etd dette uad t das du e q wag TM Beaten as 2 1 2 2 Servicing and Maintenance Guidelines 2 1 2 8 L btication Information 25 Chi PRECII RR ER RR Eat P MR 2 2 24 Cylinders Theory of Operation 2 3 2 5 Valves Theory 2 4 2 3 2 6 Component Functional Description 2 4 2 7 Wear Pads 2 usus sup mapa
14. Table 2 2 Holding Valve Torque Specifications Description Torque Value 30 35ftlbs Sun 7 8hexM20x1 5thds 41 48 Nm 45 50 1165 Sun 1 1 8 hex 1 14 UNS thds 61 68 Nm 150 153 ftlbs Sun 1 1 4 hex M36 x 2 thds 204 207 Nm 50 55ftlbs Racine 1 1 8 hex 1 1 16 12 thds 68 75 Nm 75 80ftlbs Racine 1 3 8 hex 1 3 16 121045 102 109 Nm 100 110ftlbs Racine 1 7 8 hex 1 5 8 12 thds 136 149 Nm 3121801 SECTION 2 PROCEDURES 2 11 STEER CYLINDER REPAIR Removal Before beginning this procedure ensure that the parking brake is engaged and the rear wheels are chocked 1 Tag and disconnect the hydraulic lines to the steer cylinder then cap the steer cylinder hydraulic lines and ports 2 Ateach steer spindle remove the bolt and lock nut securing the steer cylinder to the spindle 3 When the steer cylinder is disconnected from the steer spindles turn each wheel by hand to give clearance to remove the steer cylinder from the front axle 4 Carefully lift the steer cylinder until the cylinder mounting block clears the mounting slot in the bot tom of the axle then slowly remove the cylinder from the axle and place it in a suitable work area Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Place the cylinder barrel into a suitable holding fix ture 2 Using a sui
15. 4 2 2 25 Tilt Sensor Harness sss oun edie DS RR DURER LER GERE LED UQ Qa 2 26 Help Messages and Flash Codes Software 1 2 33 Machine Model Adjustment 2 2 2 39 Machine Configuration Programming 2 40 Preventive Maintenance and Safety Inspection 2 42 Elevation System Troubleshooting 3 14 Chassis Troubleshooting 3 16 Hydraulic System Troubleshooting 3 19 Electrical System 0 222222 22 3 20 JLG Lift iii TABLE CONTENTS This page left blank intentionally JLG Lift 3121801 SECTION 1 SPECIFICATIONS 1 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 2 CAPACITIES Table 1 1 Operating Specifications Table 1 2 Capacities Fuel Tank 27 2L 7 2 gal Hydraulic Oil Tank 56 81 15 gal Hydraulic System including tank 68 1L 18 gal Engine Crankcase Gasoline Engine Diesel Engine 3 25 L 3 4 qts 4L 4 2 qts Engine Coolant Machine Weight 3701 kg 8160 Ibs Machine Height Fully Elevated 8m 26ft Stowed 2 3m 7 5ft Machine Width 1 8m 5 9ft Machine Length 2 7 m 8 9ft Platf
16. Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound 2 2 JLG Lift 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 system warm up or leaks in the pump supply suc tion lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty 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 and the Preventive Maintenance and Inspection Chart in this section Always examine fil ters for evidence of metal particles 3 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
17. YEL RED 2 2 AAA AAAA SA A YEL RED 2 4 metr c Ee F 663 5 5 5 5 5 5 5 5 5 5 5565 b LIFT ES UP DOWN ew S x rz E ES lt CHOKE 8B8BBBBZrPe2222 zrg S 2 z 0805 2 vou de n BLACK 1 3 lt GND 5 TAN 4 1 ONG Y TAN 3 1 Q TP lt AT GROUND LOT 6196 YEL RED 2 1 L_ lt GETD lt STRE H N lt 4 15 lt 1 6NDE 15 AMP RED 1 2 RED 1 1 B B STRS WHT YEL 48 8 A WHT YEL 48 7 GLOW GLOW CLOSED WHEN ELEV PLUG ELEVATION CAM LOCATED PLATFORM 15 ON RELAY 87 FULLY ee DIESEL ENGINE FLEVATION 2 29 lt 6N PROX SW L J OPTION LOW 55 2 E PLUGS ich s gt eus 2 25 Z 5 5 me xn on S e Re SSE e 5s E STROBE M 2 AAAA IGN CONNECTOR lt amp je E al fest EM np ri YELIRED 2 5 C CHASSIS 9 QUSS HARNESS TO V VY Y V V Y V M 5 1 0 MODULE RED 1 1 25 RS nz LBRN WHT 41 6 A 52 a 4 5 BLACK Ht 9 8 1 4 BLACK 44 219 25 4 ENGINE LOW OIL PRESSURE 2974 3 9 3 SWITCH 8251 5778 8 z START gom 25 RELAY 874 A 4 NOTE 1 g po HOUR METER NV d A nie Ej D 000
18. 3 35 Figure 3 29 Hydraulic Schematic S N 141689 to Present JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS _ sels 6 ee oc i lt eo x o onnl lt 4 gt lt lt 2 gt m T c 88 L See a gt lt r N 4 Vl 5 L 2792448 1 Figure 3 30 Hydraulic Diagram Generator 3 36 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 2792686 C a 2 5 5 E E o 5 lt o ta e Q Q x
19. 4 It is not advisable to mix oils of different brands or types except as recommended as they may not contain the same required additives or be of compa rable viscosities Good grade mineral oils with vis cosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil 1 Refer to 1 for recommendations for viscosity ranges 2 JLG recommends Mobilfluid 424 which has an SAE viscosity of 10W 30 and a viscosity index of 152 NOTE Start up of hydraulic system with oil temperatures below 26 C 15 F is not recommended If it is necessary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low 3121801 SECTION 2 PROCEDURES 3121801 density 100VAC heater to a minimum temperature of 26 C 15 F 3 The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent This will allow start up at temperatures down to 29 C 20 F However use of this oil will give poor perfor mance at temperatures above 49 C 120 F Sys tems using DTE 11 oil should not be operated at temperatures above 94 C 200 F under any condi tion Changing Hydraulic Oil 1 Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the
20. 5 BLACK 2 8 5 85 5 gt 44 E gi Z ENGINE LOW OIL PRESSURE 5 5954 START T ES E SWITCH 8951 25778 RELAY 2 BES Z a7 8 amp PGYS gt e NOTE 1 ni ae m 00000 OIL G 2 5 ENGINE VALVE HOUR METER PRESSUR S HIGH LOCATED ON 4 SWITCH B e M E ENGINE Ve 8 s ole el d VALVE IGN ENGINE e 3 8 r Z CEN a gt FUEL TON 8 a PUMP SYSTI 24 5 b BATT LAMP I ee CHARGE O VT YEL RED 2 5 PRESSURE N o 70 S TEMPERATURE BLACK amp SWITCH Mu GN ALTERNATOR ZTN de NOTE 1 lt PGN2 1 LAMP C PGN8 Figure 3 21 Electrical Schematic w Generator Sheet 1 of 3 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ORN WHT 55 3
21. 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 3 5 AMP Connector 3121801 JLG Lift 3 5 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Assembly Check to be sure the wedge lock is in the open or as shipped position See Figure 3 6 Connector Assembly 1 of 4 Pro ceed as follows CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Figure 3 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 3 7 Connector Assem
22. e EA 01041NVR NIWA m A SSY 7438 2 2 2 2 z C35 19 99 11 91 S 4 03S Ge T YE ETE TTE Ge 338 01 6 8 1 s v eu 2 x U H SYOLOW JLG Lift 3121801 Figure 3 28 Hydraulic Schematic Prior to S N 141689 3 34 2792717 D NOI1ORS v gt SYOLOW J3JAIY0 1H918 AT SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 42018 JA VA 430lAIQ 1540021 Fl 4703 A NIVW 01 ey 8 LP of ort SYOLOW 3 1 80 uv3iu 195910 410006 599 91009 03395 3 19 3 3315 1411
23. ee RA aus 2 4 2 8 Cylinder Checking 2 4 2 9 Lift Cylinder Removal and 2 5 2 10 Cylinder Repail o Pe PERE a SIE 2 8 2 11 Steer Cylinder Repair 2 13 2 12 Limit Switcki Adjustmornt gt penu REF arb e euo Sau pasce a y 2 15 2 13 Pressure Setting Procedures 1 2 15 2 14 Drive Pump Start up 2 21 2 15 Automatic Choke Field Adjustment 750 2 22 2 16 Joystick Controller aile tte E ow Eos 2 23 2 17 Tilt Sensor scm Re SS oe ies wa tes AR e tto b D ed e caen 2 25 2 18 Calibrations cem ata ween e 2 27 2 19 Electronic Control 4 2 29 2 20 Flash Codes and Descriptions 2 33 2 21 Machine Model Adjustment 14 2 39 2 22 Machine Configuration Programming 2 40 2 23 Preventive Maintenance and Inspection
24. 3 23 Electrical Schematic Sheet 3 3 24 Electrical Schematic w Generator Sheet 1 of 8 3 26 Electrical Schematic w Generator Sheet 2013 3 27 Electrical Schematic w Generator Sheet 3 3 28 Electrical Componants Installation Prior to S N 141689 1 3 30 Electrical Componants Installation Prior to S N 141689 2 3 31 Electrical Componants Installation S N 141689 to Present Sheet 1 3 32 Electrical Componants Installation S N 141689 to Present Sheet 2 3 33 Hydraulic Schematic Prior to S N 141689 3 34 Hydraulic Schematic S N 141689 to 3 35 Hydraulic Diagram 3 36 Hydraulic Diagram Leveling 3 37 LIST OF TABLES TITLE PAGE NO eas dede eq 1 1 Capacities merias EROR Ua EM 1 1 WG750 B Kubota 2 1 1 D905 B Kubota Dies
25. To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS ACTIVATE TESTS ACCESS LEVEL PERSONALITIES MACHINE SETUP LEVEL VEHICLE If you press ENTER at the HELP PRESS ENTER display and a fault is present during power up the analyzer dis play will scroll the fault across the screen If there was no fault detected during power up the display will read HELP EVERYTHING OK 3121801 If ENTER is pressed again the display moves to the fol lowing display V P LOGGED HELP 1 STARTUP 2 1 At this point the analyzer will display the current fault if any are present You may scroll through the fault logs to view what the last 15 faults were Use the right and left arrow keys to scroll through the fault logs To return to the beginning press ESC two times When a top level menu is selected a new set of menu items may be offered for example PLATFORM DRIVE LIFT SEL SPEED SEL HORN ENGINE START FUEL GLOW STEER LEFT STEER RIGHT JOYSTICK Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the
26. 15 THE PROPERTY OF JLG INDUSTRIES INC AND CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION OF JLG IT MAY NOT BE COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT JLG S WRITTEN CONSENT AND IS PROVIDED FOR THE LIMITED PURPOSE OF REVIEW AND EVALUATION Figure 3 20 Electrical Schematic Sheet 3 of 3 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 NOTES 3121801 JLG Lift 3 25 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 12VDC 3 26 1001109561 B Sheet 1 ORN WHT 55 3 BATTERY W
27. 650 Ibs 5 1cm 20cm 2 8cm 454 kg Steer Cylinder 2 in 7 84in 1 12in Platform and Extension 1000165 159 kg Manual Platform Extension 350 Ibs 1 7 PRESSURE SETTINGS Arm Assembly Includes Lift Cylinder 925 kg 2040 Ibs Table 1 11 Pressure Settings Chassis w Standard Tires 1869 kg Main Relief 3 4 bar 50 psi 227 5 bar 3300 psi 4120 Ibs Steer Relief Left 158 8 bar 2300 psi Steer Relief Right 117 2 bar 1700 psi Lift Up Relief 158 8 bar 2300 psi 1 10 CRITICAL STABILITY WEIGHTS Leveling Jack Relief 207 bar 2500 psi 1 8 LIMIT SWITCHES A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS ENGINES AXLES OR TIRES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY The machine is equipped with the following limit switches Tilt Alarm Illuminates light on the platform and sounds an alarm when the machine is 3 out of level side to side or 5 fore and aft Platform Overload When platform becomes overloaded the LED on the platform controller illuminates and the lift up and drive functions are cut out Platform is overloaded with 652 kg 1437 5 165 High Drive Cut Out High drive speed is cut out when the platform is raised above the stowed position Max Drive Height The drive function is cut out when the platform is raised by 2 3 2 4 m 7 5 8 ft 3121801 Table 1 13 Critical Stability Weights
28. ACTIVE PLATFORM OVERLOAD ELEV PROX PERMANENTLY CLOSED CHECK PROX amp CAM SWITCH ADJUSTMENT LEVEL PREVENTED CHASSIS TILTED EXCESSIVELY 2 6 FRONT LEFT LEVELING JACK SHORT TO GROUND FRONT RIGHT LEVELING JACK SHORT TO GROUND REARLEFT LEVELING JACK SHORT TO GROUND REAR RIGHT LEVELING JACK SHORT TO GROUND FRONT LEFT LEVELING JACK SHORT TO BATTERY FRONT RIGHT LEVELING JACK SHORT TO BATTERY REARLEFT LEVELING JACK SHORT TO BATTERY REAR RIGHT LEVELING JACK SHORT TO BATTERY 3 3 OUTPUT ENERGIZED EXTERNALLY CHECK WIRING OUTPUT SHORTED CHECK WIRING 4 4 BATTERY VOLTAGE TOO LOW Battery voltage below 8 0V Check battery and alternator BATTERY VOLTAGE TOO HIGH Battery voltage above 16V Check battery and alternator 5 5 ENGINE SHUTDOWN OVERSPEED The engine speed exceeded 4500 RPM for more than 2 seconds Check throttle actuator for debris or interference which prevents free movement of actuator Recycle power to clear the fault and restart ENGINE SHUTDOWN OIL PRES COOLANT TEMP The engine oil pressure was too low or the engine coolant temperature was too high for more than 10 seconds Check engine fluid levels Recycle power to clear fault and restart 6 6 COMMUNICATION FAILURE MODULE 3121801 JLG Lift 2 35 SECTION 2 PROCEDURES t JO 1995 sezAjeuy 82 2 4
29. Figure 3 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 wed gelock 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 3 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 3 14 HD HDP Contact Installation 8 Grasp contact about 25mm behind the contact crimp barrel 9 Hold connector with rear grommet facing you 3 10 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 10 Push contact straight into connector grommet until a positive stop is felt A slight tug will confirm that it is properly locked in place LOCKING FINGERS cm CONTACT INSERTION UNLOCKED POSI
30. Resistance Measurement Figure 3 1 Voltage Measurement DC Figure 3 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 3 2 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Current Measurement 2 Su Figure 3 3 Continuity Measurement e Some meters require a separate button press to enable audible continuity testing e 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 3 4 Current Measurement DC e Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected If meter is not auto
31. 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 k kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed Number 1 000 000 Example 1 2 1200 Q Example 50 mA 0 05 3121801 JLG Lift 3 1 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Voltage Measurement
32. in rotation to the specified torque value See Table 2 1 Cylinder Component Torque Specifications After the screws have been torqued tap the tapered bushing with a hammer 16 to 24 oz and brass shaft approximately 3 4 in diameter as follows a Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews b Tap each space once this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews PISTON TAPERED BUSHING BRASS SHAFT Figure 2 12 Seating the Tapered Bearing Retorque the capscrews evenly and progressively in rotation to the specified torque value SeeTable 2 1 Cylinder Component Torque Specifications Remove the cylinder rod from the holding fixture 2 11 SECTION 2 PROCEDURES 16 Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston See Figure 2 10 Piston Seal Kit Installation PISTON REF Figure 2 13 Poly Pak Piston Seal Installation 17 Position the cylinder barrel in a suitable holding fix ture 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 18 With barrel clamped securely and while adequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and se
33. 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 3 8 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 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 3 11 Connector Installation 3121801 JLG Lift 3 9 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 4 WORKING WITH DEUTSCH CONNECTORS DT DTP Series Assembly
34. personality settings for selected menus JLG Lift 2 31 SECTION 2 PROCEDURES while access level 2 Remember always cel a selected menu item by pressing the ESC key The access level should display the following if the pass word was entered correctly Changing the Access Level of the Hand Held f N Analyzer When the analyzer is first connected you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a pass word to advance to a lower level This ensures that a set ting cannot be accidentally altered To change the access level the correct password must be entered To enter the ESC ENTER password scroll to the ACCESS LEVEL menu For exam ple gt S S fF LEVEL 2 Sy f MENU ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key position the cursor to the right one space to enter the second digit of the pass word Use the UP or DOWN arrow key to enter the second digit of the password which is 3 Repeat this process until you have entered all five digit
35. pressure If necessary adjust Steer pressure to 110 bar 1600 psi Remove the pressure gauge from gauge port MP Leveling Jack Relief Adjustment 1 2 JLG Lift Refer to Figure 2 19 Main Valve Block Install a pressure gauge 345 bar 5000 psi or higher at port MP on the main valve block Start the engine and activate jack retract When all jacks are retracted the gauge should read 172 bar 2500 psi Adjust the relief valve located on the leveling jack directional valve refer to Figure 2 20 clockwise to increase counter clockwise to decrease The relief valve is on the same face as the solenoid valves Remove the pressure gauge from gauge port MP 2 19 SECTION 2 PROCEDURES Main Valve Components 2 0 MAIN MANIFOLD set 2300psi Ca STEERS rh aD 1 Tow Brake Release Acuator 5 Lift Relief 9 Steer Solenoid Right 2 Valve Knob 6 Steer Relief Right 10 Lift Solenoid 3 Brake Solenoid 7 Main Relief 11 Steer Solenoid Left 4 Dump Valve 8 Steer Relief Left 12 MP Figure 2 19 Valve Components 2 20 JLG Lift 3121801 SECTION 2 PROCEDURES Leveling Jacks Directio
36. properly Repair or replace cylinder Hydraulic pump not functioning properly Repair or replace pump Platform will not raise Joystick not activated within three sec onds after lift switch is activated Activate lift switch then activate joystick within three seconds Enable circuit notfunctioning properly Replace enable circuit card Load capacity exceeded Personnel and or equipment on platform Reduce load Referto capacity placard Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve Lift cylinder not functioning properly Repair or replace lift cylinder Engine does notrespond when lift control Switch is moved to up position Referto Electrical System Troubleshoot ing Noresponseto control switch Noelectrical signal being sentto lift up control valve cartridge Referto Electrical System Troubleshooting No response to control switch Platform will not lower Joystick not activated within three sec after lift switch is activated Depress lift switch then activate control ler within three seconds Enable circuit not functioning properly Replace enable circuit card No electrical signal sent to lift down con trol valve cartridge Refer to Electrical System Trou
37. 00 OIL NS gr f PRESSURE E 52 LL LOCATED ON 844 448 SWITCH GAS uu E ENGINE Nat 15344 NOTE 1 4 VALVE ENGINE a gt 8444 awe 4 IGN TEMP 3 3 FUEL i 452358558 E PUMP Li be BATT LAMP voe T9 3 VEN CHARGE O i EL RED 2 5 _ ERE PRESSURE IN N O 10 TEMPERATURE ALAC 5 SWITCH START D gt MOTOR IGN ALTERNATOR PSA 7 NOTE 1 E nu NOTE 1 LAMP Figure 3 18 Electrical Schematic Sheet 1 of 3 3 22 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 ORN WHT 55 3 WHT YEL 48 10 WHI YEL 48 4 BIU ORN 52 1 WHT YEL 48 1 WHT YFI 48 2 IAN 55 2 ORANGE 55 1 AAAA bi OHM POT 8 5 E 5 5 5 5 W 150 OHM CURRENT LIMITING RESISTORS 252 5 5 228
38. 001400 90 30 34 22 25 1 _ 01640 001474 940 31 35 26 T j 51900 001750 __ a 48 32 35 1 EN 2 0 1900 0 02000 1285 49 5 5 36 4 E oz eese 39 308 ef 02500 0 0364 2320 120 135 w 195 s o ooo m sam im Fre rip iNm 03125 00580 3700 19 34 39 2 1 L 39 37 23 0 4375 0 1063 6800 50 68 35 47 55 75 45 61 04375 0 187 7550 s 75 54 60 52 5 6 0 5000 0 1599 10700 90 122 65 88 100 136 80 108 0 5625 0 1820 11600 mo 49 so 18 120 163 98 133 0 6250 0 2260 14400 150 203 110 149 165 224 135 183 0 7500 0 3730 23800 300 407 220 298 330 449 268 363 1 0000 0 6060 38600 640 868 480 651 675 918 579 785 1 1250 0 8560 47500 880 1193 660 895 925 1258 802 1087 1 3750 1 1550 64100 1460 1979 1100 1491 1525 2074 1322 1792 1 5000 1 5800 87700 2200 2983 1640 2224 2300 3128 1974 2676 NO 5000059 REV J 6 8 3 7 16 40 8 20 14 2 1 2 1 1 1 1 3 0 74 8 2 8 4 1 1 8 1 5 7 1 11 A oo NOTES 1 TORQUE VALUES DO APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HAR
39. 0701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE i TM Tensile Dry or Loctite 2427 2717 Loctite 262 Size PITCH Stress OR Vibra TITE OR Vibra TITE i um or 140 M 15 678 78 8 78 36 60 115 12 5 18 0 22 8 36 1 52 5 as mm sen em m es NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 10 Torque Chart METRIC Fasteners Sheet 7 of 7 3121801 JLG Lift 1 13 SECTION 1 SPECIFICATIONS NOTES JLG Lift 3121801 SECTION 2 PROCEDURES SECTION 2 PROCEDURES 2 1 GENERAL This section provides information necessary to perform maintenance on the scissor lift Descriptions techniques and specific procedures are designed to provide the saf est and most efficient maintenance for use by personnel responsible for ensuring the correct installation and oper ation of machine components and s
40. 10 D N IA eg OL NOISH3A SAYVMLAOS ANV 3NIHOVIN 3 18V IIVAV LON AVI SN33HD8S 3INOS 3 LON 3121801 JLG Lift 2 36 SECTION 2 PROCEDURES NOISH3A 408 ANV 3NIHOVIA NOdfl SNIGN3d3Q 3 18V IIVAV LON AYN 5 939995 3INOS 31ON t 10 Z 1994S Jez jeuy 62 2 enDi4 2 37 JLG Lift 3121801 SECTION 2 PROCEDURES t JO 19945 06 2 10 01 3HVMIJOS ANY 3NIHOVIN 3 18V IIVAV 38 LON AYN SN33dOS 3INOS ALON 3121801 JLG Lift 2 38 SECTION 2 PROCEDURES JO t 19945 MEYO Jez jeuy 12 2 10
41. 125 0 0580 5220 3 8 16 0 3750 0 0775 7000 50 35 50 35 50 7116 1 2 9 16 5 8 34 78 08750 04600 4160 515 70 485 4660 45 620 1 8 1000 06060 5150 70 95 685 90 645 875 1178 12 114 7 12 13 8 6 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH SECTION 1 SPECIFICATIONS HEAD SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Loctite amp 242 or 271 Torque Biba o Semp eee Ed Loctite 262 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 859 K 0 15 12 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 PI K 0 18 o ose e me mm oe mm os 4 40 0120 0064 j 01 jJ T 6 32 01380 00090 j _ 40 0130 000015 j j j j 9 8 32 060 00400 J T T j O 16 01640 00474 j j AJ j 10 24 0190 0070 A j j j j O _ 32 0
42. 1900 J j j j j O U 1 4 20 0250 0 0318 _ 2860 143 16 129 15 C 1 28 0250 0 0364 3280 164 19 148 J 17 LT 24 03125 0 0580 520 25 3 25 35 2 25 1 24 0350 00878 700 5 70 45 3 50 716 14 0435 0 1063 950 70 95 6 9 50 70 1 20 0437 0 1187 1070 80 no 70 95 6 1 20 05000 01599 1400 120 165 10 9 120 118 0 5625 02030 1850 170 230 155 20 130 175 5 8 1 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 215 290 180 245 3 4 10 0 7500 0 3340 340 460 380 16 0 7500 0 3730 380 515 430 14 0 8750 0 5090 45800 670 910 600 815 500 680 112 100 0630 5900 95 1355 895 1215 745 1015 112 11250 0 8560 7700 1445 1965 1300 170 1085 1475 112 12500 1 0730 59600 2015 2740 1810 240 1510 2055 112 1370 13150 118100 2705 3680 2435 3310 2030 2760 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITI
43. 325 215 245 375 510 340 380 420 570 380 430 i 0 5090 45800 670 910 600 815 500 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000059 J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER Figure 1 5 Torque Chart SAE Fasteners Sheet 2 of 7 Lift 3121801 SECTION 1 SPECIFICATIONS HEAD SCREWS Magni Coating Ref 4150701 NOTES 1 THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS 3121801 CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 6 Torque Chart SAE Fasteners Sheet 3 of 7 JLG Lift Torque Si TPI Bolt Di Tensile Clamp Load Torque Loctite 2627 07778 Stress Area See Note 4 Dry K 17 ORVibra TITE 111 or or Vibra TITE 131 140 OR Precoat 859 4 0120 00064 1 46 ooo J T T T j e 32 01380 00099 7 117 s ER 8 32 0 1640 0 01400 10 24 0 1900 0 01750 32 01900 oo00 T T j 14 20 02500 00318 260 122 4 33 7 28 02050 0 0364 3280 139 16 131 75 T 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3
44. 5 C 5 F less then 21 C 70 F Top View Top Cover Screw Vacuum Connection Vacuum Pull off Positive Connection Side View Horizontal Adjusting 7 4 Screws Air Han tB Auto choke Assembly omen Bronze Coupling Figure 2 21 Automatic Choke Adjustment DF 750 Reassembly Reassemble the air horn making sure the choke is not binding test to insure that none of the settings have moved and the choke is not binding The vacuum pull off should be set such that when vacuum is applied to the choke system the choke butterfly is full open NOTE If the machine starts and stalls immediately or if it is extremely cold limiting the choke pull off to 75 to 90 may improve the performance of the machine No adjustment is normally required Diesel Engine NOTE Never run the fuel tank dry Diesel engines cannot be restarted after running out of fuel until the fuel sys tem has been air vented or bled of air See the Kubota Instruction Manual for the proper procedure JLG Lift 2 23 SECTION 2 PROCEDURES 2 16 JOYSTICK CONTROLLER 150 ohm 2W PO POT 150 ohm 2W CENTER TAP TRIGGER SUPPLY TRIGGER SWITCH STEER LEFT V SUPPLY STEER STEER RIGHT Figure 2 22 Joystick Controller JLG P N 1600308 TRIGGER SWITCHES ROCKER SWITCHES
45. 5 5 PL ISPLAY T 0 CENTER ee RS E QW 9 Wash mite Sea mina d uam LP E2032 DRIVE PILIFT ENGINE HORN GLOW CHOKE UJ ZU judo du me Se YELLOW 10 1 5888588 RTP SELECT select spego START LUGS P Gas SELECT FUEL SELECT s TT gt QRN RED 49 3 BLAC A ARM YEL RED 2 12 WIT RED 51 2 WHT RED 51 3 e g am 144 41 a od WHIJRED 51 4 ae 9 9 9 848 A AAA 0 THIS SYMBOL 15 p eed ee zz 8 A WIRE CABLE z 8 SIE z CONTINUATION TO gg alg ANOTHER LOCATION A AAAAAAAA ON THE DRAWING 158 365 a A m m m m m g Al s del lea lest fect lea LETTER NUMBER gt OUOUG OO 095 INDICATES OTHER LOCATION J Sao a hse Serre RIT MES He 8 8808 8S 2 S E g Z g g ur Sap 55 5 5 5 5 5 Stix BLUE DANS CHOKE WHT YEL 20 AMP TILTY gt YELLOW TILT SENSOR LOCATED re STA BLACK GAS ie ENGINE aed d 30 QC m CHOKE GND m WHT YEL_ 48 11 x I E WHITE er DNS 2 187 M UPS OGD IAN 3 RVS ORANGE 8 1 FWS ORANGF 1 1 BRS ORANGF 55 7 RTS YELLOW 10 2 YELLOW 9 2 RED WET 50 1 2 DUMP STEER STEER BRAKE DRIVE oRIVE LIFT LIFT g VALVE LEFT RIGHT FOR REV UP DOWN e a ESR ESS Z z 13 3 3 390040040040 Log xol dm im Sim OE E E SAARA s 5 55555 SS S FUEL Y Y
46. 61 654 1001 JLG France SAS 2 1 de Baulieu 47400 Fauillet France FF 33 0 5 53 88 31 70 33 0 5 53 88 31 79 A JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 2 49 0 421 69 350 20 EL 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI y 39 029 359 5210 39 029 359 5845 JLG Singapore E P Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 48 65 6591 9030 65 6591 9031 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 34 93 771 1762 A JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 A www jlg com
47. ACK p LOCATED N GA m ENGINE CHOKE md WHT YEL 48 11 tel YEL RED 2 58 WHITE UPS TAN 3 2 RVS ORANGE 8 1 FWS ORANGF 1 1 BRS ORANGF 55 7 RTS YELLOW 10 2 LTS YELLOW 9 2 DPS RED WHT 50 1 2 FUEL 2 22 gt DUMP STEER STEER BRAKE DRIVE DRIVE LIFT LIFT 5 VALVE LEFT RIGHT FOR REV DOWN 6ND gt 2 1 gt S amp FESSao 5 5 amp lt lt gS sh E 5 GND 202 207 gt 5 12 t3 t2 Fl fe ie 5 E F n e fe SE mcs S 5 B ist is 5 S SE ACTUATOR FUE BLACK 4 V V V V V V N V V V V AMME 4 2 BLACK 11 BLACK fe ME 5 T ENGINE LOW OIL PRESSURE 5 SWITCH 8951 1 gt PGYS NOTE zd Pers pore NE SPEED UNLESS OTHERWISE SPECIFIED ALL ENS ENGINE a m Pick UP DIMENSIONS ARE IN INCHES E E HIGH TEMP 2 SWITCH z 48 GAS S 79 4 VALVE THIS PRINT 15 THE PROPERTY OF JLG INDUSTRIES INC 5 FAPTE 4 T AND CONTAINS PROPRIETARY AND CONFIDENTIAL E INFORMATION OF JLG IT MAY NOT BE COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT JLG S z 8 3 PUMP SYSTEM WRITTEN CONSENT AND IS PROVIDED FOR THE ag ES LIMITED PURPOSE OF REVIEW AND EVALUATION X YEL RED 2 5 TEMPERATURE BLACK 8 SWITCH D X 1001109561 B Shee
48. ARNING 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 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 ISA 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 AN ELEVATE
49. B Lift 3121801 SECTION 2 PROCEDURES 2 22 MACHINE CONFIGURATION PROGRAMMING INFORMATION NOTE When configuring scissors machine the cause the personality settings to return to default val any personality settings can be changed Changing the personality settings first and then changing the model number of the machine configuration will machine configuration must be completed before ues Table 2 12 Machine Configuration Programming Information Configuration Digit Number Description Default Number 1 0 260 0 2 0 750 Dual Fuel 0 Engine Type 1 905 Diesel 0 CEW OCUT Defalutsettingfor CE machines Tiltanleis 3 degree side to side 5 degree front to back 3 1 DOM CSA W CUT Cutout lift up and drive iftilted and elevated Required for CSA market Tilt Configuration Tiltangleis 3 degree side to side and frontto back 0 9 2 LIFTUP amp DRIVE Cutout lift up and drive if tilted and elevated Required for AUS and BRZ markets Optional for DOM and CE markets Tiltangle is 3 degree side to side 5 degree front to back 4 0 No drive cutout switch installed Drive Cutout 1 Cuts out drive when deckis elevated above a predetermined elevation 0 Notavailable on 260MRT 5 0 FWD amp LIFT up 0 Control Direction 1 FWD amp LIFT dn for future use 6 0 No 0 Leveling Jacks 1 Yes 7 0 DOM amp FIXED Axle Type 1 DOMESTIC OSC 0 2 CE OS
50. CAP SCREWS M5 Torque m Torque Lub OR Loctite amp Torque Dry or Loctite 24277 or 2711 OR Loctite 262 OR Size PITCH Stress TM TM Area 263 Vibra TITE 111 Vibra TITE 131 K 0 20 140 K 0 15 K 0 18 3 os 593 s13 ECCE EE T a oz ez sa o spo p 0 8 25 2 22 7 18 9 1 25 36 5 32 8 7 NN ERE de 2 wm ze 200 1 150 16 2 17 978 ss ET NETTO WARE F CNN DRE RN 20 25 245 1525 io sso 460 24 3 220 1065 960 800 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s n ewo ses s 4395 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED NJO Figure 1 9 Torque Chart METRIC Fasteners Sheet 6 of 7 1 12 JLG Lift 3121801 SECTION 1 SPECIFICATIONS Magni Coating Ref 415
51. CEDURES 1 special tool is used to install a new rod seal into 3 Place a new o ring and back up seal in the applica the applicable cylinder head gland groove ble outside diameter groove of the cylinder head ROD SEAL CYLINDER HEAD SEAL TOOL O RING BACKUP RING CYLINDER Figure 2 9 Installation of Head Seal Kit HEAD 4 Install washer ring onto rod carefully install the head gland on the rod ensuring that the wiper and rod Figure 2 7 Rod Seal Installation seals are not damaged or dislodged Push the head along the rod to the rod end as applicable 5 Carefully slide the piston spacer on the rod WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS 6 If applicable correctly place new o ring in the inner ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLA piston diameter groove The backup ring side fac TION FOR CORRECT SEAL ORIENTATION IMPROPER SEAL ing the O ring is grooved INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 2 Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable cylinder head gland groove WIPER EAL CYLINDER MALLET HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head Figure 2 8 Wiper Seal Installation 2 10 JLG Lift 3121801 SECTION 2 PROCEDURE
52. CILLATING 8 0 NONE Function Cutout DRV amp LFTUR 0 2 ALL FUNCTIONS 9 0 NOTINSTALLED Load 1 CUTOUTPLT 0 2 CUTOUTALL 4150336_E 3121801 JLG Lift 2 41 SECTION 2 PROCEDURES 2 23 PREVENTIVE MAINTENANCE AND The inspection and maintenance code numbers are as fol INSPECTION SCHEDULE lows 1 The preventive maintenance and inspection checks are listed and defined in the following table This table is and the INTERVA at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that 2 divided into two basic parts the AREA to be inspected 3 4 system are listed The INTERVAL portion of the table is 5 divided into five columns representing the various inspec tion time periods The numbers listed within the interval 6 column represent the applicable inspection code for which that component is to be checked 7 The checks and services listed in this schedule are not intended to replace any local or regional regulations that 8 may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times 9 may occur due to climate and or conditions and depend 10 ing on the location and use of the machine JLG Industries requires that a complete annual inspection performed accordance with the Annual Machine Inspection Report form Forms are supplied with each 12 n
53. D BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DUR ING REPLACEMENT OF ELECTRICAL COMPONENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS REVISION LOG 3121801 JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS Original Issue April 18 2000 Revised January 24 2002 Revised April 22 2004 Revised July 3 2006 Revised August 30 2006 Revised October 11 2007 Revised April 28 2008 Revised December 19 2008 Revised October 20 2011 Revised April 19 2013 JLG Lift 3121801 TABLE CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION INTRODUCTION SAFETY PRECAUTIONS A A creer es IX ae as 1 a A B Hydraulic System 1 a A C Maintenarice e Se ree t cire gne Coe dot c 1 a SECTION 1 SPECIFICATIONS 1 1 i fte ot ete t ERE Gas E tdi Opa ars eR oe d ad 1 1 1 2
54. DENED WASHER REFERENCE ANEROBIC THREAD LOCKING COMPOUND 0100011 242 Vibra TITE 121 Medium Strength Blue Vibra TITE 140 High Strength Red Vibra TITE 131 Medium High Strength Red Figure 1 4 Torque Chart SAE Fasteners Sheet 1 of 7 24 0100019 0100071 3121801 JLG Lift 1 7 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque orque se ma cam e Clamp e aede 202 estes Vibra Stress Area OR Vibra TITE 111 or TITE 131 140 K 18 K 0 15 In Sq In LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 0 1120 0 00661 a ____ ________________ 0 1380 0 00909 0 1380 0 01015 m 03640 001400 __ L T L 0 1640 001474 13 0 43 5 _ __ 24 0190 00170 1580 0 7 0 1900 0 02000 1800 68 oco x1 14 20 02500 00318 2860 0 2500 0 0364 3280 eus m i 25 25 3 8 16 0370 0 0775 700 45 60 40 55 35 50 50 70 20 0435 0 1187 10700 80 10 70 95 60 80 12 13 110 120 155 8999 ees iro ae ps 288 EE 175 210 285 190 220 240
55. E An Oshkosh Corporation Company Service amp Maintenance Manual Model 260MRT 3121801 April 19 2013 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 W
56. ESTRAINED FROM MOVEMENT WITH SAFETY PROPS BLOCKING OR OVERHEAD SLING o STRAP SAFETY PROP 2 6 JLG Lift 3121801 SECTION 2 PROCEDURES 1 Barrel 6 Restrictor Check Valve 11 O Ring 16 Seal 2 Rod 7 Locknut 12 Spacer 17 O Ring 3 Solenoid Valve 8 Wear Ring 13 O Ring 18 Head 4 Cotter Pin 9 Seal 14 Back Up Ring 19 Wiper 5 Cable Adaptor 10 Piston 15 Wear Ring 20 Bushing Figure 2 2 Lift Cylinder 3121801 JLG Lift 2 7 SECTION 2 PROCEDURES 2 10 CYLINDER REPAIR Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting NOTICE DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if nec essary 3 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture BARREL CLAMP SUPPORT TABLE Figure 2 3 Cylinder Barrel Support 5 Mark cylinder he
57. HT YEL 48 4 BLU ORN 52 1 WHT YEL 48 1 WHI YEL 48 10 WHT YEL 48 2 YEL RED 2 3R IAN 55 2 ORANGE 55 1 AAAAAA AAA 7 fel fel fe fe 2 I gt 080 gt EUER UE CE STE M S SBS Ses 4 5V OUTPUT ae BULK BULK 2 GROUND HEAD ENGINE GROUND HEAD ENGINE PLATFORM DISPLAY HARNESS DUAL HARNESS HARNESS DUAL _ HARNESS 5 GND SL NS up OW 9 1 ig Bs PLUG SOCKET PLUG PLUG SOCKET PLUG 5 aif S Sus ta ae are S gt PGWI k PEW4 qoe Mee iE ie S PGW2 PEW3 2 lt gt E aa fe 5 A fo TILT ras k PEW2 P6Y3 PEE PEY2 4 45 3 E E S g iu EUR th ARM 125 Tof PGY4 2 2 PEYI 8 34 VV VV V PGWS gt PEW8 PGY5 lt PEY8 eo WHT RED 51 2 PGW6 2 25 PEYT mm YEL RED 2 13 ATTE PGWT NC NC PEWS 6 ITCH lt gt lt gt PGW8 PEE PEWS 8 254 PEY5 A M 254 v WHT RED 51 4 44 GROUND ENGINE HARNESS GROUND ENGINE HARNESS 484 WHITE CONNECTORS YELLOW CONNECTORS a 3 3 NOTE 1 ALL PGWX AND PGYX TERMINALS SHOWN ON THIS DRAWING ARE REFERENCED FROM THE A A A A GROUND HARNESS PLUG AND ACTUALLY REPRESENT THE CONNECTION BETWEEN THE GROUND HARNESS PLUG AND THE ASSOCIATED ENGINE HARNESS PLUG VIA A FEMALE TO FEMALE BULKHEAD SOCKET THIS CONFIGURATION DOES NOT ALLOW A ONE TO ONE TERMINAL CONNECTION BE
58. N ABOVE THIS AMBIENT TEMPERATURE PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE F 27C MOBIL 424 10W 30 MOBIL DTE 13 a 5 5 x 5 HYDRAUL IC SPECIFICA TIONS DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE NO OPERATION BELOW THIS AMBIENT TEMPERATURE NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 3 WITH COLD WEATHER PKG GASOLINE COLD START POSSIBLE 57 157 Figure 1 3 Operating Temperature Specifications Kubota JLG Lift 3121801 SECTION 1 SPECIFICATIONS 1 12 TORQUE CHARTS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque Tensile Torque Loctite amp 242 271 Bolt Dia Load Loctite amp 262 Vibra D Lubricated OR Vibra TITE 111 or Stress Area TITE 131 140 0 00604 6 07 8 09 6 4 0 1120 0 00661 420 9 1 0 7 0 8 0 1380 0 00909 580 16 1 8 12 14 Torque 4 01380 0 01015 61 18 20 13 15 L TL TT 51640
59. NECTOR ON GND 21 4 00000 12 11 ORNIWHT 55 20 VALVE RR LJ CHASSIS HARNESS SZ 168 21 5 220001 42 12 ORN WHT 55 21 fx 120 VALVE LJ EXTEND RCE 12 5 ON CANH 1 6 230002 15 1 ORN WHT 55 2 2 VALVE LJ EXTEND 2 SUD BOARD ol ik 71 7 Sipoo3 15 2 ORNIMHT 55 23 22 VALVE LJ RETRACT gt 24 gt 6 CAN SHIELD JI 8 0004 25 3 55 24 4 Y28 VALVE 0005 J5 4 ORN WHT 55 25 0006 25 5 DIOO SFDTH 12 4 IGN J4 1 0105 42 9 GND 4 2 2 10 CAN H J4 3 DIO J2 5 CAN L J4 4 0102 J2 6 CAN SHIELD 24 5 0103 J2 7 SPARE J4 6 0007 25 6 0008 25 1 0009 25 8 YEL RED 2 20 m 0104 22 8 RECEPTACLE RX J5 10 525 X 15 11 FNT LFT STOWED GND J5 12 BLACK SWITCH WHITE J3 RECEPTACLE s26 FNT STOWED BLACK SWITCH WHITE 9 527 REAR LFT STOWED BLACK SWITCH WHITE OSS 28 REAR STOWED BLACK SWITCH WHITE nS E d Waite 22 FOR CODE UPGRADE ONLY 133 E E REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT PRESSURE PRESSURE PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER TRANSDUCER 1001109660 B Sheet 2 3 24 ALL TRAI SHIELDE SHOULD WIRE AT NOTE ALL COMPONENTS SHOWN ON THIS PAGE ARE FITTED FOR THE LEVELING JACK OPTION ONLY NSDUCERS ARE WIRED USING A 3 CONDUCTOR D CABLE THE SHIELD FOR EACH CABLE BE TERMINATED WITH THE RESPECTIVE BLACK ALL DIMENSIONS IN L J ARE IN mm THIS PRINT
60. NG ON THE LIFT CYLINDER RAISE THE PLAT FORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Raise platform completely then retract cylinder slightly to avoid trapping pressure Place a suitable overhead lifting device approximately 2 5 cm 1 in below the platform 3 Shut down hydraulic system and allow machine to sit for 10 15 minutes Carefully remove hydraulic hoses from cylinder port block 4 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the counterbalance valve is defective and must be replaced 5 f no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 6 Remove lifting device from platform activate hydrau lic system and run cylinder through one complete cycle to check for leaks 3121801 2 9 LIFT CYLINDER REMOVAL AND INSTALLATION Removal 1 Place the machine on a flat and level surface Start the motor and raise the platform Shut down the engine and attach a suitable lifting device to the plat form 2 Remove the bolt and locknut securing the cylinder rod attach pin to the upper inner arm assembly Using a su
61. ONAL TESTING IS REQUIRED Figure 1 7 Torque Chart SAE Fasteners Sheet 4 of 7 JLG Lift 3121801 SECTION 1 SPECIFICATIONS Tensile Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite amp Loctite 262 242 or 271 OR Vibra OR Vibra TITE 131 TITE 111 or 140 561 3 694 302 0 1990 1490 2090 14 23 0 7 8 78 3 82 34 6 8 6 2 874 n 79 12 19 125 3660 15 9 28 55 12 175 8430 367 88 66 97 154 241 331 469 22 303 639 24 353 811 27 459 1130 30 1530 33 36 42 5 4 817 355 5 2560 1920 2690 5 42 4 1120 487 0 4090 3070 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED 3121801 Figure 1 8 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD
62. ORED A function i e Drive Lift etc is active and the operator has selected another function The system has ignored the new selection DRIVING AT CUTBACK ABOVE ELEVATION Platformis elevated and the machine is in the drive mode of operation FUNCTION SELECTED BUT TRIGGER SWITCH OPEN Afunction i e Drive Lift etc has been selected by the operator butthe trigger switch is not active closed JOYSTICK MOVED BUT NO FUNCTION SELECTED The joystick was moved out ofthe center position before a function was selected DRIVE PREVENTED ABOVE DRIVE CUTOUT HEIGHT Machinis elevated above the drive cutout height 2 1 STARTUP Anew system power up has occurred since the last help message 2 2 FUNCTIONS LOCKED OUT SHORT TO PLATFORM ROW INPUT DETECTED Battery power has been detected on a row input pins J1 8 J1 9 or J1 13 FUNCTION PROBLEM DRIVE PERMANENTLY SELECTED Drive select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM LIFT PERMANENTLY SELECTED Lift select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM O R or L J PERMANENTLY SELECTED Anoutrigger select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM START PERMANENTLY SELECTED Start switch in the pl
63. ORY OF OPERATION Oylinders are of the double acting type The Lift and Steer systems incorporate double acting cylinders A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite direction and the inder rod will retract A holding valve is used in the Lift circuit to prevent retrac tion of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve 2 5 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
64. OWED GND 05 12 BLACK SWITCH WHITE 13 RECEPTACLE 5 9 225225255255 526 258755755758 ENT RUT STOWED BLACK WHITE cele iau ue e bel 527 REAR LFT STOWED BLACK SWITCH WHITE e 28 REAR STOWED BLACK SWITCH WHITE UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE IN INCHES ae d Sd ded ddd z TOR CODE UPGRADE ONLY THIS PRINT 15 THE PROPERTY OF JLG INDUSTRIES INC 54 858 4 4 498 4 8 AND CONTAINS PROPRIETARY AND CONFIDENTIAL as gs 28 845 INFORMATION OF JLG IT MAY NOT BE COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT 165 WRITTEN CONSENT AND 15 PROVIDED FOR TUE 3 28 REAR RIGHT PRESSURE TRANSDUCER REAR LEFT FRONT RIGHT PRESSURE PRESSURE TRANSDUCER TRANSDUCER FRONT LEFT PRESSURE TRANSDUCER SHIELDED CABLE THE SHIELD FOR EACH CABLE SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK WIRE AT J3 ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR NOT LIMITED PURPOSE OF REVIEW AND EVALUATION E ALL COMPONENTS SHOWN ON THIS PAGE ARE FITTED FOR THE LEVELING JACK OPTION ONLY 1001109561_B Sheet 2 Figure 3 23 Electrical Schematic w Generator Sheet 3 of 3 Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 NOTES
65. RAL ELECTRICAL INFORMATION amp SCHEMATICS 3 1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop Ifa 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 3 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 796 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 sealed 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
66. Remove prox switch from its mount 2 Reconnect harness if it was disconnected for step a and turn on machine 3 Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer See vehicle or control system documentation on how to do this 4 Place sensing face of switch on the object to be sensed by the switch If that is not available use a piece of ferrous metal physically similar to it The switch state in the control system diagnostics should change 5 When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the switch and object sensed Automatic Switches If the switch is actuated automatically by temperature or pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pressure for example to the switch These switches may need to be ener gized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe switch state in control system with the Analyzer See vehicle or control system documentation on how to do this 3 12 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 3 Operate system such that the switch actuates This could be going over a certain pressure or temperature for exam ple The state indicated in the control system should change Switch Wiring Low Side High S
67. S 7 f applicable correctly place new seals and guide lock rings in the outer piston diameter groove A tube with 1 0 slightly larger than the O D of the pis ton is recommended to install the solid seal NOTE The backup rings for the solid seal have a radius on one side This side faces the solid seal See magni fied insert in Figure 2 10 The split of seals and backup rings are to be positioned so as not to be in alignment with each other 3121801 PISTON BACKUP SPLIT SEAL RINGS T RING Backup RNG SPLIT SEAL Figure 2 10 Piston Installation 8 Using suitable protection clamp the cylinder rod a vise or similar holding fixture as close to piston as possible 9 Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged 10 Thread piston onto rod until it abuts the spacer end and install the tapered bushing NOTE When installing the tapered bushing piston and mat ing end of rod must be free of oil 11 Assemble the tapered bushing loosely into the pis ton and insert JLG capscrews not vendor cap 12 13 14 15 JLG Lift screws through the drilled holes in the bushing and into the tapped holes in the piston PISTON TAPERED BUSHING CAP SCREWS Figure 2 11 Tapered Bushing Installation Tighten the capscrews evenly and progressively
68. S N 105371 JLG Lift O Ring Wear Ring Head Hydrolock Wiper Seal Cap 19 20 21 22 23 24 Rod Plate Trailer Ball Jack Pad Retainer Ring Bolt 3121801 SECTION 2 PROCEDURES o N 3121801 Barrel 7 Flatwasher 1 1 4 Narrow 13 Wear Ring 19 Plate Check Valve 8 Guidelock 14 Head 20 Screw 1 2 Counter Balance Valve 9 Polyseal 15 Hydrolock 21 Jack Pad Plug 10 Piston 16 Wiper Seal Rod 11 O Ring 17 Cap Nut 12 O Ring 18 Retaining Ring Figure 2 17 Leveling Jack Assembly S N 105371to S N 141689 Lift 2 17 SECTION 2 PROCEDURES 1 Barrel 5 Wear Ring 9 Polyseal 13 Retaining Ring 2 Rod 6 O Ring 10 Wiper Seal 14 Plate 3 Wear Ring 7 Back Up Ring 11 Washer Ring 15 Screw 1 2 4 Seal 8 Head 12 Screw 5 16 16 Jack Pad Figure 2 18 Leveling Jack Assembly S N 141689 to Present 2 18 JLG Lift 3121801 SECTION 2 PROCEDURES 2 12 LIMIT SWITCH ADJUSTMENT Platform Limit Switch The platform limit switch is located on the left side of the frame of the machine When activated the switch cuts out the High Drive function Adjust the switch to activate when the platform is raised above the stowed position 2 13 PRESSURE SETTING PROCEDURES NOTE Make all pressure adjustments with the engine oper ating and the hydraulic oil at normal operating tem perature In addition all functions must be operated from the
69. Should this occur attempt to dissect the three areas of error to find the primary contributor a Machine mounting and or grade With a digital level measure the top of the Ground Control box for levelness If unable to get a good reading check the box s mounting surface for levelness 1 Ground Control Box 2 Tilt Sensor c Tilt sensor has developed an offset shift Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and Ground Control box electrically connected Level one axis of the tilt sensor and observe the raw read ing should be within 2 0 Do the same for the 2 Digital Level other axis If either axis is greater than 2 0 replace the tilt sensor 1 Ground Control Box Some possible reasons that the tilt sensor will not cali brate are a The surface the machine is sitting on is off level by a few degrees flat doesn t imply level park ing lots are often not level b The tilt sensor has failed one or both of the channels X axis and Y axis c Tilt sensor has moisture intrusion that has shifted its output d Water and or corrosion in the box has corrupted electrical connections or caused a tilt sensor or ground control board failure observe any cracks in the box 2 28 JLG Lift 3121801 SECTION 2 PROCEDURES Ground Control Box as mounted the machine does not all
70. TION CONTACT LOCKED IN POSITION Figure 3 15 HD HDP Locking Contacts Into Position NOTE For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly T Figure 3 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 3 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121801 Lift SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 5 SWITCHES Basic check The following check determines if the switch is functioning properly not the circuit in which the switch is placed A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected 1 De energize the circuit 2 Isolate the switch from the rest of the circuit if possible If not possible keep in mind it may affect readings 3 Access the terminals to the switch 4 lf the switch has two terminals a Measure resistance across the terminals b Change the switch position Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it
71. TRAPPING PRES SURE 1 Using all applicable safety precautions activate motor and fully extend cylinder to be checked Shut down motor 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port 3 Activate motor and activate cylinder extend function Check retract port for leakage 4 cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder 5 With cylinder fully retracted shut down motor and carefully disconnect hydraulic hose from cylinder extend port 6 Activate motor and activate cylinder retract function Check extend port for leakage 7 cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If extend port leakage is less than 6 8 drops per min ute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks 3121801 SECTION 2 PROCEDURES Cylinders w Single Counterbalance Valves Lift Cylinder OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKI
72. TRICAL INFORMATION amp SCHEMATICS Table 3 3 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hydraulic System General Hydraulic Pump Noisy Air bubbles in oil Reservoir too low Replenish oil as necessary Oil filter dirty Clean and or replace filter as necessary Pump cavitating Vacuum in pump due to oil starvation reservoir low Replenish oil as necessary Restricted reservoir air vent Clean vent Oil viscosity too high Drain system and replace with recom mended oil Referto Hydraulic Oil System overheating Oil viscosity too high Drain system and replace with recom mended oil Referto Hydraulic Oil Main relief valve settoo high Adjust relief valve to proper pressure Hydraulic system oil low Replenish oil as necessary Pump not delivering oil Defective pump Repair or replace pump System pressure too low Main relief valve settoo low Reset valve as required Hydraulic pump not functioning properly Repair or replace pump Leak in component line or fitting Repair or replace component line or fit ting Scored valve spool scored cylinder Replace valve replace cylinder System s operate erratically Sticking or binding valve cartridge piston rod etc Clean repair or replace components as necessary Hydraulic oil no
73. TS LUBE METHOD S HO Check HO Level 1 Hydraulic Oil Reservoir Fill Cap Drain Plug Change HO 10 500 2 Hydraulic Filter Element N A Initial Change 50 Hours 250 Engine Crankcase Fill Cap Drain Plug Check Engine Oil Level 10 100 3 Engine Oil Filter Filter Element Initial Change 50 Hours 200 Engine Fuel Filter Filter Element Check amp Clean every 100 hrs 400 Engine Fuel Filter Kubota DF752 Filter Element Check amp Clean every 100 hrs Yearly 4 Rail Slides N A MPG Brush 100 KEY TO LUBRICANTS MPG Multi purpose Grease EPGL Extreme Pressure Gear Lube HO Hydraulic Oil Mobil 424 NOTE A WARNING TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED NOTE Be sure to lubricate like items on each side Recommended lubricating intervals are based on machine operations under normal conditions For 3121801 JLG Lift machines used in multi shift operations and or exposed to hostile environments or conditions lubrication frequencies must be increased accord ingly Operate hydraulic functions through one complete cycle before checking hydraulic oil level in tank Oil should be visible in ADD 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 Any time the pump coupling is removed coat splines of coupling with Texaco Code 1912
74. TWEEN THE TW PLUGS ACTUAL TERMINAL INTERFACE CONNECTIONS ARE SHOWN ABOVE NO CONNECTION FOR PGW4 PGW7 AND PGYI alele EIS ELE Ez lt 5 al 5 2 5 2 5 sl E 5 5 YEL RED 2 2 A A A A A YEL RED 2 4 m afa JEBBBHBEE 2 m 16 63 START gt o gt 555 85885 Ss B Sess z e LIFT e up DOWN Bo SES ART ss oe o 23 X 9 5 CHOKE ass 8dgddidddgbiBsE og BEES 5 z 888 s es E 2 222 8 8 95 n g PLUGS BLACK a TAN 4 1 ESTOP 3 1 GROUND CONTROL YEL RED 2 1 15 AMP RED 1 2 6 RED 1 1 in B B WHT YEL 48 8 A NOTE 1 WHT YEL 48 7 GLOW e L J S lt PGY3 Q2 2p lt 5 5 3 PLUG CLOSED MHEN po P ELEVATTO CAN EEEN 8 z FULLY LOWERED SWITCH 85 114 ELEVATION 329 fo ROX SW L J OPTION 2 LOCATED PROX 5 ON S a ORN RED 49 8 55 2 do manon a m FS T ELJRED 2 5 222 215 222232565 Z s 2 us NAZ optional 9 5 d o lt 4 5 9 9 REIS PLUGS STROBE A AAA AAR A 5 IGN CONNECTOR s m e e E m S s 2 3 ON CHASSIS 55555 6 Ss 5 PUELURED 2 540 VON CHASSIS V VU V V 5 1 0 MODULE 5 RED 1 1 Di Z BRN MHT 41 6 F LIT EN a T 25 J 1 422 445 25
75. Y SENDER Dx FITTED 34 i BLACK LI i BLACK 2 7 58 ul ENGINE LOW OIL PRESSURE J Z SWITCH 8951 45 84 d NOTE SPEED d nm gt P gt PICK UP ENGINE we HIGH TEMP ES 31448 SWITCH as gt ALL DIMENSIONS IN 1 ARE IN mm g NOTE 1 0 6 SCPE e 4 THIS PRINT 15 THE PROPERTY OF JLG INDUSTRIES INC AND CONTAINS 43835 J PROPRIETARY AND CONFIDENTIAL INFORMATION OF JLG IT MAY NOT 3333 8 FUEL TN COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT 21675 WRITTEN 3485 PUMP SYSTEM CONSENT AND 15 PROVIDED FOR THE LIMITED PURPOSE OF REVIEW AND E i i EVALUATION YEL RED 2 5 N O 10 TX BLACK 8 SEQUENCE NO SWITCH AN QUANTITY 1001106560_B Sheet 1 3121801 Figure 3 19 Electrical Schematic Sheet 2 of 3 JLG Lift 3 23 SECTION 3 GENERAL ELECTRICAL INFORMATION 5 5 SERIAL DATA IN ir YEL BLK 02 30 SERIAL Dat Loc ROI R02 3000 lt 300 Q 03 300 Q SERIAL DATA OUT 32 197 JI RECEPTACLE 2 22 1 PFDTH J 2 2 UNT PFDTHI Ji 2 16 5 9 FR LJ FROM IGN ELS SFOTH Ji 3 ZOND J2 3 BLACK yis VALVE RL LJ CON
76. ad and barrel with a center punch for easy realignment Using an allen wrench loosen the cylinder head retainer cap screws and remove cap screws from cylinder barrel 2 8 JLG Lift CAPSCREWS WASHER Figure 2 4 Capscrew Removal 6 Using a spanner wrench loosen the end cap or head retainer and remove from cylinder barrel 7 Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 8 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel ROD SUPPORT SUPPORT TABLE Figure 2 5 Cylinder Rod Support 9 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 10 Loosen and remove the cap screw s if applicable which attach the tapered bushing to the piston 3121801 SECTION 2 PROCEDURES 11 12 13 14 15 16 Insert the cap screw s the threaded holes in the outer piece of the tapered bushing Progressively tighten the cap screw s until the bushing is loose on the piston Remove the bushing from the piston PISTON TAPERED BUSHING CAP SCREWS Figure 2 6 Tapered Bush
77. al ring are not damaged or dislodged 19 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder 20 Secure the cylinder head gland using the washer ring and socket head bolts SPACER HEAD ASSY CYLINDER BARREL PISTON ASSY WASHER lt RING Figure 2 14 Rod Assembly Installation 21 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves 22 lf applicable install the cartridge type holding valve and fittings in the rod port block using new o rings as applicable See Table 2 1 Cylinder Component Torque Specifications 2 12 JLG Lift A CAUTION IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED USE EITHER A TRAVELING OVERHEAD HOIST FORK LIFT OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD 23 If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable SeeTable 2 2 Holding Valve Torque Specifications Table 2 1 Cylinder Component Torque Specifications Torque Value Component w Loctite u m 80 ftlbs Tapered Bushing Retaining Screws Lift Cylinder 108 Nm 9ftlbs Head Retaining Screws Lift Cylinder 12 Nm
78. assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scored or burned 3 Ifa bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install JLG Lift 2 1 SECTION 2 PROCEDURES 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 Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Section 1 2 3 LUBRICATION INFORMATION Hydraulic System 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 bla
79. atform control box closed at start up Release switch to clear fault FUNCTION PROBLEM GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM STEER LEFT PERMANENTLY SELECTED Steer left switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED Steer right switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM HORN PERMANENTLY SELECTED Horn switch in platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM JOYSTICK CALIBRATIONFAULTY The Personalities for theJoystick are improperly adjusted or a joystick calibration attempt failed Re adjust or recalibrate JOYSTICK FAULTY WIPER OUT OF RANGE The joystick wiper signal inputis outside the acceptable voltage range The wiper wire being off the wiper wire shorted to battery power or the wiper wire shorted to battery negative could cause this JOYSTICK FAULTY STEER SWITCHES ACTIVE TOGETHER Both the steer left and steer right inputs are closed at the same time A shortin the steer switch wiring or a failed steer switch can cause this FUNCTIONLOCKED OUT JOYSTICK NOT CENTERED Selected function is not allowed because the joystick is not centered Return joystick to center and reselect function FUNCTION PROBLEM JOYSTICK CALIBRATION FAULTY Th
80. be made to improve per formance of the engine The machine will take time to warm up and you may experience low power or rough running for the first few minutes of operation or until the engine warms up LET THE ENGINE WARM UP Make sure that the choke shaft operates freely and does not bind this can be done without removing the air horn by rotating the bronze coupling with an eraser on a pencil or by removing the vacuum pull off line at the manifold and supply a small amount of vacuum to the hose the choke rod should move freely using either method Adjustments NOTE If the choke rod is binding make sure the support bracket is straight 1 There are two adjustments Vertical loosening the air horn nuts and Horizontal loosening the bracket to adaptor screws These two adjustments should resolve any binding problem 2 To adjust the choke at 21 C 70 F ambient remove the air horn and reinstall the nut that holds the choke and support bracket securely making sure the choke moves freely 3 Loosen the 3 top cover screws and rotate the top cover till the choke butterfly is closed with 1 32 in space between the plate and the wall of the carbure tor 4 lf the ambient temperature is less then 21 C 70 F the top cover counter should be rotated CCW 1 mark for every 15 C 5 F less then 21 C 70 F 5 Ifthe ambient temperature is more then 21 C 70 F the top cover counter should be rotated CW 1 mark for every 1
81. bleshoot ing No response to control switch Lift down control valve cartridge not functioning properly Repair or replace lift down control valve cartridge Lift cylinder not functioning properly Repair or replace lift cylinder Engine does not respond when lift switch is moved to down position Referto Electrical System Troubleshoot ing No response to control switch No electrical signal being sentto lift down control valve Referto Electrical System Troubleshoot ing No response to control switch 3 14 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 3 1 Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform raises and lowers erratically Hydraulic system oillow Replenish oilas necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line Counterbalance valve on lift cyl rely adjusted or notfunctioning properly Replace valve Control valve not functioning properly Repair or replace valve Worn seals in lift cylinder Replace seals Lift cylinder not functioning properly Repair or replace lift cylinder Platform drifts down Manual lowering valve notfunctioning properly Repair or replace valve Worn seals in lift cylinder Replace seals Holding valve on lift cylinder not function i
82. bly 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 3 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 3 8 Connector Assembly 3 of 4 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 3 9 Connector Assembly 4 of 4 PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT Figure 3 7 Connector Assembly 2 of 4 3 6 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 3 8 Connector Assembly 3 of 4 WEDGE LOCK FLUSH WITH 22422222222 SS MENT E gt gt Figure 3 9 Connector Assembly 4 of 4 3121801 JLG Lift 3 7 SECTION 3 GENERAL ELECTRICAL INFORMATION 5 5 Disassembly 5 Inserta 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 in each direction gently pull the wire until the contact is removed Figure 3 10 Connector Disassembly NOTE The wedge lock should
83. ceptacle pin and electric motor start relay Using suit abletest meter perform continuity test on wire Repair or replace wire as necessary Defective electric motor start relay Replace electric motor start relay No voltage supplied to motorfrom start Check battery cable from relay to motor relay for proper connection or damage Repair or replace wire as necessary Defective motor pump assembly Replace motor pump assembly 3121801 JLG Lift 3 21 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ORN WHT 55 3 WHT YEL 48 10 1001106560 B Sheet 1 THEMEN BLU ORN 52 1 WHT YEL 48 1 WHI YE 48 YEL RED 2 38 IAN 55 2 ORANGE 551 A A A A E AAAA 5 3 fA 4 5 fo fo fe fo e H lest sl 1 le le e
84. cosity of 10W 30 and a viscosity index of 152 Table 1 8 Hydraulic Oil Pedes SAE VISCOSITY GRADE ae 10W 20 10W 30 GUES ma NOTE Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Indus tries for proper recommendations 1 5 LUBRICATION SPECIFICATIONS Table 1 9 Lubrication Specifications KEY SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350 degrees Excellent water resistance and adhesive qualities and being of extreme pres sure type Timken OK 40 pounds minimum MPG Extreme Pressure Gear Lube oil meeting API ser EPGL vice classification GL 5 or MIL Spec MIL L 2105 Engine crankcase Oil Gas API SF SG class EO MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C Hydraulic Oil API service classification GL 3 e g 19 Mobil 424 3121801 SECTION 1 SPECIFICATIONS 1 6 CYLINDER SPECIFICATIONS Table 1 10 Cylinder Specifications 1 9 MAJOR COMPONENT WEIGHTS Table 1 12 Major Component Weights Description Bore Stroke Rod Dia Component Weight 10 2cm 119 4cm 6 4cm 295 kg Ain 47 in 2 5in
85. e Personalities for theJoystick are improperly adjusted or a joystick calibration attempt failed Re adjust or recalibrate 2 34 Lift 3121801 SECTION 2 PROCEDURES Table 2 10 Help Messages and Flash Codes Software 1 FLASH CODE HELP MESSAGES AND FLASH CODES 2 2 FUNCTION PROBLEM TRIGGER PERMANENTLY CLOSED Trigger switch in the platform control box closed at start up Release switch to clear fault TRIGGER CLOSED TOOLONG WHILE IN NEUTRAL Trigger switch inthe platform control box closed for more than ten seconds while the joystick is in the neutral position Release Switch to clear fault 2 3 FUNCTION PROBLEM LIFT PERMANENTLY SELECTED Lift switch up or down in the ground control box closed at start up Release switch to clear fault FUNCTION PROBLEM START PERMANENTLY SELECTED Start switch in the ground control box closed at start up Release switch to clear fault FUNCTION PROBLEM GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the ground control box closed at start up Release switch to clear fault NO DATA FROM TILT SENSOR NOT CONNECTED OR FAULTY No signal from the tilt switch Check wiring and plug connections at the level sensor and at the ground control board 2 5 DRIVE amp LIFTUP PREVENTED OSC AXLE NOT SET DRIVE amp LIFTUP PREVENTED FUNCTION CUTOUT ACTIVE ALL FUNCTIONS PREVENTED FUNCTION CUTOUT
86. e above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving There are certain set tings allowed to install optional features or select the machine model When selecting the machine model to match the size of the machine the personality settings will return to default settings NOTE Refer to the appropriate Machine Personality Set tings Table and the Machine Setup Table in JLG Service Manual for the recommended factory set tings Password 33271 will give you access to level 1 which will permit you to change all machine person ality settings IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION JLG Lift 2 33 SECTION 2 PROCEDURES 2 20 FLASH CODES AND DESCRIPTIONS Table 2 10 Help Messages and Flash Codes Software P1 X FLASH CODE HELP MESSAGES AND FLASH CODES NoFlash Code EVERYTHING OK GROUND MODE OK ALARM SOUNDING TILTED amp ABOVE ELEVATION Platform is elevated and the chassis is not level DIFFERENT FUNCTION SELECTED amp IGN
87. el coepere qe Ea a uec P Ee RAD 1 1 D1005 K bot Diesel hr eI 1 1 Tire Specifications ooo Reda Pee 1 2 UL PM RUE As 1 2 Hydraulic Oil 52 ttp to eT REP Aden euet 1 2 Lubrication 1 2 Cylinder Specifications s Leger l dep TRIP ei ec ed ee eu 1 3 Pressure Settings ccr ve ER E ARR sup ee ee IPFE E EET 1 3 Major Component 1 3 Critical Stability Weights 4 1 3 Lubrication su eme d uma rwy duo e bod rU NT ND 1 5 Cylinder Component Torque 2 12 Holding Valve Torque Specifications 2 12 Joystick Specifications 2 2 23 Joystick Plug Loading 1 2 23 Joystick Specifications iaei iia e 2 24 Joystick Plug Loading 2 24 Tilt Sensor Harness
88. est 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 3 4 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 3 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 electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors
89. ew machine and are also available from JLG Customer Service Form must be completed and returned to JLG 19 Industries 14 NOTICE JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL 15 INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM 16 NOTE This machine requires periodic safety and mainte nance inspections be a JLG Dealer A decal located on the frame affords a place to record stamp inspection dates Notify dealer if inspection is over due 2 42 JLG Lift Check for proper and secure installation Check for visible damage and legibility Check for proper fluid level Check for any structural damage cracked or broken welds bent or warped surfaces Check for leakage Check for presence of excessive dirt or foreign material Check for proper operation and freedom of move ment Check for excessive wear or damage Check for proper tightness and adjustment Drain clean and refill Check for proper operation while pump motor is running Check for proper lubrication Check for evidence of scratches nicks or rust and for straightness of rod Check for condition of element replace as neces sary Check for proper inflation Check Inspection Decal for current inspection stamp 3121801 SECTION 2 PROCEDURES Table 2 13 Preventive Maintenance and Safety Inspection AREA INTERVAL 10Hours 50 Hours 200 Hours 500 Hours 1000 Hours Daily Weekly Mont
90. fore proceeding with any mainte nance Troubleshooting Information The troubleshooting procedures applicable to the aerial platform are listed and defined in following troubleshooting tables Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determi nation of the applicable remedial action The probable causes and the remedial action should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electri cal systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir cuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechani cally or electrically so that oil is available to the function valve
91. function properly 2 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 3121801 nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 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 4 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 5 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 6 If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or 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
92. grease prior to assembly SECTION 1 SPECIFICATIONS OPERATING TEMPERATURE SPECIFICATION HYD AMBIENT AIR TEMPERATURE 40 KUBOTA GAS amp DIESEL NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 180 F 82 C OIL TANK TEMP 120 F 49 C 110 F 43 C 100 F 38 C F 32 C F 21 C F 16 C F 10 C F 4 C F 1 C F 7 C F 12 C 18 C F 23 C F 29 C F 34 C F 40 C 4150548 NO OPERATION BELOW THIS AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURE 1 120 F 49 C 110 43 3 8 100 F 38 C 5 Je M 2 2 90 F 32 C 2 80 F 27 C T E 2 60 F 16 C 50 10 40 F C m 30 F 1 C er o 5 20 F 7 C 10 F 12 C 0 F 18 C 1 23 20F 299c 30 F 34 C 40 F 40 C EXTENDED DRIVING WITH gt HYDRAULIC OIL TANK TEMPERATURES OF 180 82 C OR ABOVE F EITHER OR BOTH CONDITIONS XIST JLG HIGHLY RECOMMENDS HE ADDITION OF A HYDRAULIC IL COOLER CONSULT JLG SERVICE NO OPERATIO
93. hly 8 Month 6 Month PLATFORM 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 12 4 Control Tags 1 2 5 Hoses and Cables 4 8 6 Wear Pads 8 7 Handrails and Chains 14 CHASSIS 1 Engine Oil 2 Battery 3 Air Cleaner wl 4 Exhaust System 5 Engine Mounts 1 6 Hydraulic Pump 1 7 Valves 1 8 Hydraulic Filter See Lubrication Chart 5 14 14 9 Hydraulic Hoses and Tubing 1 10 Hydraulic Oil 3 5 4 11 Hydraulic Tank Breather 6 14 12 Fuel Tank 3 5 13 Lift Cylinder 1 12 5 6 13 14 Limit Switch 1 7 15 Tilt Alarm Switch 1 7 4 6 Placards Decals 1 2 7 Wheel and Tire Assemblies 1 8 9 18 Drive Motors 1 5 6 19 Drive Brakes 1 6 8 20 Drive Torque Hubs 1 3 5 6 21 Steer Cylinder 1 5 6 13 22 Steer Components 1 4 6 23 Wheel Bearings 2 Wheel Drive 8 12 24 Sizzor Arms 14 25 Safety Props 14 26 Sliding Wear Pads 8 27 Pivot Pins Bolts 14 7 8 28 Switches Ground Control 1 1 29 Control Tags 1 2 Inspection and Maintenance code 1010 be performed annually 4 3121801 JLG Lift 2 43 SECTION 2 PROCEDURES BS NOTES 2 44 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 SECTION 3 GENE
94. id cooled Power 23 5 horsepower 3000 rpm Bore x Stroke 76 0mmx73 6 mm Displacement 61 08 in Low Idle 800 rpm High Idle 3800 rpm Alternator 12V 30 Amp Starter 12V 1 0 Amp 3121801 JLG Lift 14 SECTION 1 SPECIFICATIONS 1 4 LUBRICATION Hydraulic Oil Tires Table 1 6 Tire Specifications Description Standard Non Marking Size 26x12 15 Load Range 8Ply Pressure 55psi Pumps Table 1 7 Pump Specifications Description Drive Pump Lift Steer Pump Type Piston Gear 83 3 lpm 22 18 Ipm 4 75 3000 rpm 3000 rpm Displae ment 28 cm rev 1 4 cm rev p 1 7 inS rev 0 36 in 3 rev Steer Drive System Tire Pneumatic or foam filled 26 x 12 15 lug NOTE Inflate pneumatic tire to 3 1 bar 45 psi Toe In Adjust to 12 7 mm 1 2 inch overall Drive Motor Rexroth Hydraulic Filter Inline Full flow paper filter Cartridge type Torque Requirement All wheel lug nuts should be torqued to 142 Nm 105 ft Ib every 150 hours NOTE When maintenance becomes necessary or a fas tener has loosened refer to the Torque Chart in this section to determine proper torque value 1 2 JLG Lift NOTE Hyaraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE vis
95. ide When controlling a load a switch can be wired between the positive side of the power source and the load This switch is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle What is actually being measured is the voltage drop across the switch This could mislead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load measure voltage across the load s power terminals Also the technician can mea sure the voltage at both power terminals with respect to battery ground The difference between those two measure ments is the voltage applied to the load 3 6 TROUBLESHOOTING General This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained be
96. igh pressure gauge ports A WARNING DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL POSITION 0 DEGREES SWASHPLATE ANGLE TAKE PRECAU TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START UP Once charge pressure has been established increase speed to normal operating RPM Charge pressure should be approximately 20 7 bar 300 psi minimum If charge pressure is incorrect shut down and determine cause for improper pressure A WARNING INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA TOR S ABILITY TO CONTROL THE MACHINE Shut down prime mover and connect external control input signal start prime mover checking to be certain pump remains in neutral with prime mover at normal operating speed slowly check for forward and reverse machine operation Charge pressure should remain at 20 7 bar to 22 1 bar 300 psi to 320 psi minimum during forward or reverse operation Continue to cycle slowly between forward and reverse for at least five minutes Shut down prime mover remove gauges and plug ports Check reservoir level and add fluid if necessary 3121801 SECTION 2 PROCEDURES 3121801 2 15 AUTOMATIC CHOKE FIELD ADJUSTMENT DF 750 Inspection NOTE All automatic choke assemblies have been pre set to operate between 7 C 38 C 20 F and 100 F with little or no adjustment If the machine will be operated for prolong use outside these temperature ranges adjustments could
97. in a vise or similar holding fixture Place a new o ring into the cylinder rod piston groove Place a new T seal on the piston then carefully install the piston the cylinder rod ensuring that the o ring in the rod groove is not damaged or dis lodged Secure the piston in place with two new retaining rings Carefully slide the spacers onto the cylinder rod Place a new wiper rod seal o ring and wear ring on each of the two cylinder heads Set the heads aside for later installation on the cylinder rod Remove the cylinder rod assembly from the holding fixture Position the cylinder barrel in a suitable holding fix ture NOTICE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD PISTON AND HEADS AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 8 10 11 12 2 14 With the barrel clamped securely and while ade quately supporting the cylinder rod assembly insert the cylinder rod assembly into the cylinder barrel Ensure that the piston T seal and o ring are not dam aged or dislodged Continue pushing the rod assembly into the cylinder barrel until the cylinder rod is approximately cen tered in the barrel Carefully install one of the cylinder heads on one end of the cylinder rod and push the head onto the rod until it is snug against the end of the cylinder barrel Install one of the cylinder head retainers on the end of the cylinde
98. ing Removal Screw the piston CCW by hand and remove the piston from cylinder rod Remove and discard the piston o rings seal rings and backup rings Remove piston spacer if applicable from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer plate if applica ble Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 3121801 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 Inspect threaded portion of piston for damage Dress threads as necessary 10 11 12 13 14 15 16 17 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
99. ir or replace switch Hydraulic system pressure too low Adjust pressure Loose or damaged wiring on control switch or solenoid valve Ensure proper connection of wires at con trol switch or solenoid valve Using suit abletest meter perform continuity test on wires Repair or replace wires as neces sary Solenoid valve notfunctioning properly Repair or replace valve Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair or replace line Relief valve improperly set or notfunction ing properly Reset repair or replace valve as neces sary Steer cylinder not functioning properly Repair or replace cylinder Machine will not steer left or right Steer switch on controller not functioning properly Replace controller Wiring on steer control switch is dam aged Repair or replace wiring Wiring on solenoid valve damaged Repair or replace wiring Coilin solenoid damaged Replace coil Bent cylinder rod Repair or replace cylinder Damaged steer linkage Repair or replace steer linkage Machine wanders steering not firm Crossover relief valve settoo low or not functioning properly Reset repair or replace valve as neces sary Steer linkage loose Tighten linkage Spindle bushings badly worn Replace bushings 3 18 JLG Lift 3121801 SECTION 3 GENERAL ELEC
100. itable brass drift drive out the rod end attach pin from the arm assembly 3 Retract the lift cylinder rod completely 4 disconnect the hydraulic lines then cap the lift cylinder hydraulic lines and ports 5 Remove the bolt and locknut securing the barrel end attach pin to the lower arm assembly Using a suit able brass drift drive out the barrel end attach pin from the arm assembly 6 Carefully remove the cylinder from the scissor lift and place in a suitable work area Installation 1 Install lift cylinder in place using suitable slings aligning barrel end attach pin mounting holes on lower arm assembly 2 Using a suitable drift drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly Secure in place with the bolt and locknut 3 Remove oylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports 4 Extend the cylinder rod until the attach pin hole aligns with those in the upper arm assembly Using a suitable drift drive the cylinder rod attach pin through the aligned holes taking care to align the pin retaining hole with the hole in arm assembly Secure the pin in place with the bolt and locknut 5 Lower platform to stowed position and shut down motor Check hydraulic fluid level and adjust accord ingly JLG Lift 2 5 SECTION 2 PROCEDURES NEVER WORK UNDER ELEVATED PLATFORM UNTIL IT HAS BEEN R
101. ivated Activate drive switch then activate joy stick within three seconds Enable circuit not functioning properly Replace enable circuit card Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve Drive motor notfunctioning properly Repair or replace motor Brake notfunctioning properly Repair or replace brake Engine will not respond when enable Switch is activated and drive controller is activated Referto Electrical System Troubleshoot ing No response to control switch No electrical signal being sentto the drive valve cartridge Referto Electrical System Troubleshoot ing No response to control switch Machine will not travel in reverse See Machine will nottravel forward 3 16 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY High Speed Drive function does not operate Loose or damaged wiring between drive controller and High Speed switch Ensure proper connection of wires Using suitabletestmeter perform continuitytest on wiring between switches Repair or replace wires as necessary Defective high speed control switch Replace high s
102. n control switch or solenoid valve Ensure proper connection of wires at con trol switch or solenoid valve Using suit abletest meter perform continuity test on wires Repair or replace wires as neces sary Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair or replace line Control valve not functioning properly Repair or replace valve Steer cylinder not functioning properly Repair or replace cylinder Machine hard to steer or steering is erratic Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting 3121801 JLG Lift SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine hard to steer or steering is erratic cont Lack of lubrication on steer components Lubricate steer components in accor dance with Lubrication Chart Restricted crossover relief valve Clean or replace valve Steer system pressure low Adjust pressure Bent steering linkage Repair or replace linkage as required Hydraulic pump not functioning properly Repair or replace valve Steer cylinder not functioning properly Repair or replace cylinder Steering inoperative Steer switch on controller not functioning properly Repa
103. nal Valve Leveling Jacks Pressure Relief Valve Location 02580952 B vendor info Figure 2 20 Leveling Jacks Directional Valve Table 2 3 Leveling Jacks Directional Valve Torque Specs Item Torque PA4 54 Nm 40 lb ft PB4 31 Nm 23 lb ft T 54 Nm 40 Ib ft 3121801 JLG Lift 2 21 SECTION 2 PROCEDURES 2 14 DRIVE PUMP START UP PROCEDURE THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND DRIVE FUNCTION DISCONNECTED ETC WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY TO TECHNICIAN AND OTHER PERSONNEL TAKE NECESSARY SAFETY PRECAU TIONS BEFORE MOVING THE MACHINE Prio
104. nd control box not positioned properly Place power selector switch to platform or ground as required Circuit breaker open Determine and correct cause Reset cir cuit breaker No voltage present at emergency stop switch Check battery cable from battery to emergency stop switch for proper con nection or damage Repair or replace cable as necessary EMERGENCY STOP switch not function ing properly Replace switch No voltage supplied to engine start relay from emergency stop switch Check battery cable from emergency stop switch to start relay for proper con nection or damage Repair or replace cable as necessary No voltage input at terminal strip Check wire from battery to terminal strip for proper connection or damage Repair or replace wire as necessary No voltage present at circuit breaker Check wire from terminal strip to circuit breaker for proper connection or dam age Repair or replace wire as necessary Defective circuit breaker Replace circuit breaker No voltage present at function control Switch Check wiring from emergency stop Switch to function control switch for proper connection or damage Repair or replace wiring as necessary Defective function control switch Replace function control switch 3 20 JLG Lift 3121801 SECTION 3 GENERAL ELECTRICAL INFORMATION amp 5 5 Table 3 4 Electrical Sys
105. ng properly Repair or replace valve High Drive does not operate below horizontal Damaged wiring on limit switch Repair or replace wiring Damaged limit switch Replace limit switch 3121801 JLG Lift 3 15 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Drive System Noresponseto drive controller Joystick not activated within three sec onds after drive select switch is activated Activate drive select switch then activate joystick withinthree seconds Enable circuit not functioning properly Replace enable circuit card Hydraulic system oil low Replenish oil as necessary Hydraulic pump not functioning properly Repair or replace pump Restricted or broken pump supply line Clean repair or replace line Drive motor notfunctioning properly Repair or replace motor Damaged wiring on drive controller Repair or replace wiring Drive controller notfunctioning properly Repair or replace controller Drive brake not releasing Determine cause and repair or replace brake Machine drives erratically Microcircuit on controller improperly adjusted Adjust microswitch on controller for proper operation Machine will nottravel forward Joystick not activated within three sec onds after drive switch is act
106. nk gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles is 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
107. nstalled at various points within the hydraulic system to protect associated 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 reliefs are provided for each side of the circuit 2 6 COMPONENT FUNCTIONAL DESCRIPTION Hydraulic Pump The machine is equipped with two hydraulic pumps a function pump and a drive pump The function pump is a single section gear pump that con
108. oil on a regular basis However filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifications appearing in this man ual If unable to obtain the same type of oil supplied with the machine consult local supplier for assis tance in selecting the proper equivalent Avoid mix ing petroleum and synthetic base oils JLG Industries recommends changing the hydraulic oil every two years 2 Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive 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 variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion 2 4 CYLINDERS THE
109. orm Railing Height 1 1m 43 5in Gasoline Engine Diesel Engine 4 7 L 1 25 gal 5 7 L 1 5 gal Platform Dimensions 2 59 1 65 m 8 5x5 4ft Platform Capacity 570 kg 1250 Ibs 1 3 COMPONENT DATA Platform Extension Capacit 140 kg 300 Ibs pacity g Engine Max Travel Speed 4 5 kmh 2 8 mph Table 1 3 WG750 B Kubota Gasoline LP Max Travel Grade 35 Max Slope Type 3 cylinder liquid cooled Sideto Side 3 24 5 horsepower 3600 rpm Fore amp Aft 5 Idle 1500 rpm Turning Radius High Engine 3600 rpm Inside 2 1 m 6 9ft Alternator 40 Amp Outside 4 4m 14 4 ft Fuel Consumption Lift Speed Low RPM 4 9 Lph 1 3 gph Up 32 34 sec High RPM 9 Lph 2 4 gph Down 21 27 secs Max Tire Load 921 kg 3300 165 Table 1 4 D905 B Kubota Diesel Max Ground Bearing Pressure 3 2 kg cm 33 psi Type 3 cylinder liquid cooled Max Hydraulic system Pressure 20 68 Mpa 3000 psi Power 26 horsepower 3000 rpm Electrical System Voltage 12 Volt Low Idle 800 rpm Wheelbase 2m 78in High Engine 3800 rpm Ground Clearance 20 3cm 8in Alternator 40 Amp Fuel Consumption Max Windspeed 12 5 m s 28 mph Low RPM 2 6 Lph 0 68 gph Max Horizontal Manual Side Force 400 N 90 Ibf High RPM 5 5Lph 1 48 gph Number of Persons 2 Table 1 5 D1005 Kubota Diesel Type 3 cylinder liqu
110. ow the tilt sensor to be level For the following troubleshooting steps a bubble level smaller is better will be needed and the machine must be on a level surface 1 3121801 On the Analyzer go to Diagnostics System and read the tilt angle If either angle reports 20 0 there is an electrical electronic failure tilt sensor control board electrical connections a Open the Ground Control Box b Disconnect the sensor and clean any corrosion off of the tilt sensor and control board connec tions c Reassemble and test If fault persists replace tilt sensor If the Analyzer displays angles other than 20 0 attempt to calibrate If machine will not calibrate note the reason displayed on Analyzer a SENSOR FAILURE tilt sensor internal fre quency is out of range replace sensor b NOT LEVEL tilt sensor has either developed an offset or it is to unlevel as mounted on the machine Joystick Calibration Software 1 5 and Higher and Higher Using the Analyzer in Access Level 1 go to MENU CALI BRATION JOYSTICK and press ENTER 1 JLG Lift Following the analyzer screen prompts a Move the Joystick FORWARD and press ENTER b Allow Joystick to be in CENTER position and press ENTER c Move the Joytstick REVERSE and press ENTER CAL COMPLETE or CAL FAILED will display on the analyzer Possible reasons if calibration failed a The forward position must be a lower voltage than
111. peed control switch Loose or damaged wiring in control box wire harness Ensure proper connection of wires atthe control switch Using suitable test meter perform continuity test on wires Repair or replace harness as necessary Loose or damaged wiring between plat form and high speed solenoid Ensure proper connection of wires atthe platform and atthe high speed solenoid Using suitable test meter perform conti nuity test on wires Repair or replace Wires as necessary High speed solenoid not functioning properly Replace solenoid Loose or damaged wiring between high speedrelay and high speed limit switch Ensure proper connection of wires between high speed relay and high speed limit switch Using suitable test meter per form continuity test on wires Repair or replace wires as necessary High speed limit switch not functioning properly Repair or replace limit switch Loose or damaged wiring in valve wiring harness Ensure proper connection of wires at ter minal strip Using suitable test meter per form continuity test on wires Repair or replace wires as necessary Steering System Noresponseto steer control switch on controller Steer switch on controller not functioning properly Repair or replace switch Hydraulic system oil low Replenish oil as necessary Hydraulic system pressure too low Adjust pressure Loose or damaged wiring o
112. platform control station in order to achieve full pump speed It may be necessary to use an assistant to adjust the pressure settings while oper ating the functions from the platform control station Pressure Adjustment Install a pressure gauge at gauge port located on the front upper right side of the valve body The port is identified by a stamping on the valve body Disconnect lift up solenoid connector From the Ground control panel activate the lift up function Bottom out the Lift Up function and adjust the main pressure to 228 bar 3300 psi Reconnect lift up solenoid connector Lift Relief Adjustments 1 4 3121801 Install a pressure gauge at gauge port MP located on the front upper right side of the valve body The port is identified by a stamping on the valve body From the platform control station activate the Lift Up function by selecting the lift control switch and posi tioning the joystick to the up position Bottom out the Lift Up function and adjust the Lift Up relief to 193 bar 2800 psi Remove the pressure gauge from gauge port MP Steer Relief Adjustment 1 4 Install a pressure gauge at gauge port located on the lower right side of the valve body The port is identified by a stamping on the valve body Activate the Steer Right function and check Steer pressure If necessary adjust Steer pressure to 159 bar 2300 psi Activate the Steer Left function and check Steer
113. 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 bearings for signs of correct excessive wear or damage Replace as necessary a Thoroughly clean hole steel bushing of burrs dirt etc to facilitate bearing installation b Inspect steel bushing for wear or other damage If steel bushing is worn or damaged rod barrel must be replaced c Lubricate inside of the steel bushing with WD40 prior to bearing installation d Using an arbor of the correct size carefully press the bearing into steel bushing Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper JLG Lift cylinder seal kit is used See your JLG Parts Manual Apply a light film of hydraulic oil to all components prior to assembly 2 9 SECTION 2 PRO
114. r barrel and tighten with a suitable chain wrench Carefully install the remaining cylinder head on the opposite end of the cylinder rod and push the head onto the rod until it is snug against the end of the cylinder barrel 13 Install the remaining cylinder head retainer on the end of the cylinder barrel and tighten with a suitable chain wrench Installation 1 JLG Lift Carefully install the steer cylinder assembly into the front axle Align the cylinder mounting block on the barrel with the mounting slot in the bottom of the axle and lower the steer cylinder until the mounting block rests in the slot Turn the steer wheels to line up the mounting holes in the steer spindles and the steer cylinder ends Secure each end of the steer cylinder with a bolt and lock nut Reconnect the hydraulic hoses to the applicable cyl inder ports 3121801 SECTION 2 PROCEDURES Rod Locknut Seal Piston O Ring Back Up Ring Wear Ring Guide 10 Wiper 11 O Ring o FO 12 Retaining Ring Figure 2 15 Steer Cylinder Assembly 3121801 JLG Lift 2 15 SECTION 2 PROCEDURES 1 Barrel 7 2 Counter Balance Valve 8 3 Check Valve 4 Plug 10 5 Nut 11 6 Locking Screw 12 Figure 2 16 2 16 Flatwasher 1 1 4 Narrow 13 Guidelock 14 Polyseal 15 Piston 16 O Ring 17 Spacer Tube 18 Leveling Jack Assembly Prior to
115. r to installing pump and or motor inspect unit s for damage incurred during shipping and handling Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with hydraulic fluid Fill reservoir with recommended hydraulic fluid which should be passed through a 10 micron nominal no bypass filter prior to entering the reservoir The use of contaminated fluid will cause damage to components which may result in unexpected machine movement The inlet line leading from the reservoir to the pump should be filled prior to start up Check inlet line for prop erly tightened fittings and make sure it is free of restric tions and air leaks Be certain to fill pump and or motor housing with clean hydraulic fluid prior to start up Fill housing by pouring fil tered oil into upper case drain port Install a O to 35 bar 0 to 500 psi pressure gauge in the charge pressure gauge port to monitor charge pressure during start up 2 22 JLG Lift It is recommended that the external control input signal electrical connections be disconnected at the pump con trol until after initial start up This will allow the pump to remain in its neutral position or slowly rotate prime mover until charge pressure starts to rise Start prime mover and run at the lowest pos sible RPM until charge pressure has been established Excess air may be bled from high pressure lines through h
116. ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads JLG Lift 3121801 SECTION 3 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 additional 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 t
117. reverse position b The difference between center and forward amp center and reverse must be atleast 1V 2 29 SECTION 2 PROCEDURES 2 19 ELECTRONIC CONTROL SYSTEM Hand Held Analyzer menu Analyzer Display HELP PRESS ENTER Escape Key Enter Key Toreturnhomeoraccess gt Esc Stores and selects Top Level Sub previous menu Level anditem menus Left amp Right Arrow Keys Used to move between Top Level Sub Level and item menus Up amp Down Arrow Keys Value Selector Figure 2 27 Hand Held Analyzer To Connect the Hand Held Analyzer 1 Connect the four pin end of the cable supplied with the analyzer to the top connection of the motor con troller and connect the remaining end of the cable to the analyzer NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the Control System by turning the lower key to the platform position and pulling both emer gency stop buttons on 2 30 JLG Lift 3121801 SECTION 2 PROCEDURES Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following 2 5 ED IVENU HELP PRESS ENTER e PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER
118. rs 5 and Washers 6 to remove the Tilt Sensor 1 and Sensor Mount 2 from the Ground Control Box The Tilt Sensor 1 can be removed from the Sensor Mount 2 by removing the three Screws 7 Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 2 18 Calibrations 1 Tilt Sensor JLG P N 4000021 Sensor Mount Screw 6 32 x 1 Lockwasher Standoff Insulator Washer 0 313 x 0 250 Nylon Screw M3 5 x 0 6 x 10 9 gg d co Figure 2 26 Tilt Sensor Removal Table 2 9 Tilt Sensor Harness JLG Lift Wire Color Function Connector Pin Red VCC 1 Green PWMX 2 White PWMY 3 Black Ground 4 2 27 SECTION 2 PROCEDURES 2 18 CALIBRATIONS b Tilt sensor mounting on machine or wedged crooked in control box If the machine mounting grade appears accept able open the Ground Control box carefully 1 Drive the machine onto a measured level surface Observe whether the tilt sensor is properly x 0 5 for both x and y axis seated 2 Using the Analyzer go to MENU CALIBRATION TILT SENSOR Press Enter LEVEL VEHICLE will dis play Press Enter again to calibrate Tilt Sensor Calibration 3 Both axis raw angles need to be within 5 0 other wise the machine is to unlevel and the software will prohibit calibration
119. ry dress the rod with Scotch Brite or equivalent Replace the rod if neces sary 3 Inspect the threaded portion of the rod for excessive damage Dress the threads as necessary 4 Inspect the inner surface of the cylinder barrel tube for scoring or other damage Check the inside diam eter for tapering or ovality Replace the barrel if nec essary 5 Inspect the piston surface for damage scoring and distortion Dress the piston surface or replace the piston as necessary 6 Inspect the seal and o ring grooves in the piston for burrs and sharp edges Dress applicable surfaces as necessary 7 Inspect the inside diameter of the spacers and heads for scoring or other damage and for ovality and tapering Replace as necessary 8 Inspect the seal and o ring grooves in the heads for burrs and sharp edges Dress applicable surfaces as necessary 9 Inspect the outside diameter of the spacers and heads for scoring or other damage and ovality and tapering Replace as necessary 10 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 11 Inspect the cam follower for wear or damage Replace as necessary JLG Lift 2 13 SECTION 2 PROCEDURES Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used Apply a light film of hydraulic oil to all components prior to assembly Using suitable protection clamp the cylinder rod
120. s of the password which is 33271 Once the correct password is displayed press ENTER 2 32 JLG Lift 3121801 SECTION 2 PROCEDURES Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example aL ET PERSONALI TI ES DHIVE ACCEL 4 0s c PERSONALITIES DRIVE ACCEL 4 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular per sonality If the value does not change when pressing the up and down arrows check the access level to ensure you are at access level 1 Machine Setup When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example A WARNING FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU LAR MACHINE CAN RESULT IN IMPROPER OPERATION CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF THE MACHINE 3121801 N x Me leveling j acks 1 5 Sac LEVELING JACKS 1 YES The effect of the machine digit value is displayed along with its value Th
121. should read short 5 If the switch has more than two terminals consult the schematic or switch diagram to determine what terminals will be connected The test is similar to testing a switch with two terminals a Place one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch The meter should read short only when the switch connects the two terminals and open otherwise c If the switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit switches are just like manually oper ated switches except that the moving object operates the switch These switches can be tested the same way as a stan dard switch by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Inductive proximity switches are actuated only by ferrous metal metal that contains Iron such as steel near the switch They do not require contact and must be energized to actuate These types of switches can be used to detect boom or platform position for example These switches have a sensing face where the switch can detect ferrous metal close to it To find the sensing face take note how the switch is mounted and how the mechanisms meet the switch Test this type of switch as follows 1
122. t 12 e e S E e E s E s b 2558 zoe m omi Ud S BULK BULK 2 1 m qom HEAD neme FERD a PLATFORM DISPLAY 24 HARNESS HARNESS 5 a PLUG SOCKET PLUG PLUG SOCKET PLUG _ T s ion RTP mE PGW NC PEY4 ER ERE PGW2 PEW3 PGY2 PEY3 q 4 lt gt 6 5 4 3 3 Q fm e TILT 4 j PGW3 lt gt PEW2 PGY3 k PEY2 384 ERE ALARM PGY4 PEYI V V V lt gt lt YFL RED 2 12 PGW5 PEW8 PGY5 7 lt gt lt gt gt 221 PEWT PGY6 y PEYT YEL RED 2 3 MILIRED 312 YEL RED 2 13 No pews P6Y1 6 TRIGGERA o 2172 PEWS PGY8 lt 5 lt gt lt 4444 444449 GROUND ENGINE HARNESS GROUND ENGINE HARNESS Gas e894 WHITE CONNECTORS YELLOW CONNECTORS E 5343133133 aoa 9 a gq d NOTE ALL PGWX AND PGYX TERMINALS SHOWN ON THIS DRAWING ARE REFERENCED FROM THE GROUND HARNESS PLUG AND ACTUALLY REPRESENT THE CONNECTION BETWEEN THE GROUND A A A A HARNESS PLUG AND THE ASSOCIATED ENGINE HARNESS PLUG VIA A FEMALE TO FEMALE BULKHEAD SOCKET THIS CONFIGURATION DOES NOT ALLOW A ONE TO ONE TERMINAL CONNECTION BETWEEN gt THE TWO PLUGS ACTUAL TERMINAL INTERFACE CONNECTIONS ARE SHOWN ABOVE NO CONNECTION FOR PGW4 PGW7 AND PGYI ele 252 S
123. t 1 Figure 3 22 Electrical Schematic w Generator Sheet 2 of 3 3121801 JLG Lift 3 27 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SERIAL DATA IN YEL BLK 202 30 SERIAL DATA CLOCK WHT RED 12 75 gt ROI R02 300 300 R03 300 SERIAL DATA QUT JI RECEPTACLE 2 1 CONECTOR ON PFDTH JI 1 42 2 FL LJ CHASSIS HARNESS BLK YEL PFDTHI 41 2 E IGN J5 9 VALVE FR LJ SOURCE J2 5 ON SFOTH J 3 E GND J2 3 BLACK CE fx 18 VALVE RL LJ GROUND BOARD GND 041 4 S000 J2 11 ORN WHT 55 20 4 VALVE RR LJ gt IN 01 5 J2 12 i 4 Y20 VALVE LJ EXTEND CANH JI 6 90002 05 1 d VALVE LJ EXTEND 2 atiek CANL 21 7 20003 45 2 ORUNIT 55 23 122 VALVE LJ RETRACT CAN SHIELD 041 8 72 0004 05 3 Y B VALVE S 0005 15 4 ORN WHT 55 25 123 0006 25 5 DIOO SFDTH J2 4 IGN 44 1 0105 12 9 GND 4 2 2 10 CAN J4 3 DIO 12 5 CAN L J4 4 0102 12 6 CAN SHIELD J4 5 0103 02 1 SPARE 04 6 0007 15 6 0008 15 1 0009 15 8 XELLRED 2 20 m 0104 22 8 RECEPTACLE RX 45 10 525 5 11 FNT LFT ST
124. t at operating tempera ture Allow oil sufficienttime to warm up 3121801 JLG Lift 3 19 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 3 4 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hand Controller Valve will notfunction when handle ism ovedin either direction Enable switch not activated Activate enable switch Controller not activated within three sec onds after enable switch is activated Activate enable switch then activate con troller within three seconds Enable circuit not functioning properly Replace enable circuit card No electrical power to handle Check electrical input to hand controller 12 Volts No electrical power to valve Check electrical output of printed circuit board and electrical signal atthe valve Improper ground Check for proper grounding of handle Control Switches Noresponse to a function control switch Enable switch not activated Activate enable switch Control switch not activated within three seconds after enable switch is activated Activate enable switch then activate con trol switch within three seconds Enable circuit not functioning properly Replace enable circuit card Applicable emergency stop switch not positioned properly Place applicable emergency stop switch toon Power selector switch on grou
125. table chain wrench carefully remove the cylinder head retainer from one end of the cylinder barrel 3 Attach a suitable pulling device to one end of the cylinder rod NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD SPACER AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 4 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 5 Using a suitable chain wrench carefully remove the remaining cylinder head retainer from the opposite end of the cylinder barrel Remove the head and remove and discard the wiper rod seal O ring and wear ring 6 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture 3121801 7 Carefully remove the head from the cylinder rod and remove and discard the wiper rod seal o ring and wear ring 8 Carefully remove the spacers from the cylinder rod then remove the retaining rings securing the piston in place on the cylinder rod Discard the retaining rings 9 Carefully remove the piston from the cylinder rod Remove and discard the T seal and o ring 10 Remove the cylinder rod from the holding fixture Cleaning and Inspection 1 Clean all parts thoroughly in an approved cleaning solvent 2 Inspect the cylinder rod for scoring tapering ovality or other damage If necessa
126. tem Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Noresponseto a function control switch cont No voltage present at applicable control Check applicable wire for proper con valve coil nection atterminal strip valve harness plug pin valve harness receptacle pin and engine start relay Using suitable test meter perform continuity test on wire Repair or replace wire or harness as nec essary No voltage supplied from terminal strip to Check applicable wire for proper con engine start relay nection at terminal strip valve harness plug pin valve harness receptacle pin and engine start relay Using suitable test meter perform continuity test on wire Repair or replace wire or harness as nec essary Defective engine start relay Replace engine start relay No voltage supplied to engine from start Check battery cable from relay to engine relay for proper connection or damage Repair or replace cable as necessary No voltage present at applicable control Check applicable wirefor proper con valve coil nection atterminal strip valve harness plug pin valve harness receptacle pin and valve coil Using suitable test meter perform continuity check on wires Repair or replace harness as necessary NO TERMINAL STRIPS No voltage Check applicable wire for proper con supplied from terminal strip to electric nection at terminal strip valve harness motor start relay plug pin valve harness re
127. then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit Hydraulic Circuit Checks The first reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a systematic check of the circuit components beginning with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagrams of the various circuits 3121801 JLG Lift 3 13 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 3 1 Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform Elevation System No Response to LIft Control Lift not performed within three seconds after lift function switch is selected Reselect lift function switch then activate joystick within three seconds Enable circuit not functioning properly Replace enable circuit card Lift control switch inoperative Repair or replace control switch Hydraulic system oil low Replenish oil as necessary Restricted or broken supply line on valve bank or pump Clean repair or replace line Control valve not functioning properly Repair or replace valve Lift cylinder not functioning
128. trols the lift and steer functions and provides a maximum output of 18 lpm 4 75 gpm The drive pump is a single section piston pump that controls the drive function and provides an output of 83 3 Ipm 22 gpm Lift Cylinder Counterbalance Manual Descent Valve The lift cylinder counterbalance manual descent valve is located on top of the lift cylinder The counterbalance valve is used to hold the platform in place when raised A cable is connected to the valve which when pulled manu ally opens the lift down port and allows the platform to be lowered in the event hydraulic power is lost The lift cylinder counterbalance manual descent valve is located on top of the lift cylinder The counterbalance valve is used to hold the platform in place when raised A cable is connected to the valve which when pulled manu 2 4 JLG Lift ally opens the lift down port and allows the platform to be lowered in the event hydraulic power is lost 2 7 WEAR PADS Sliding Pads The original thickness of the sliding pads is 51 mm 2 in Replace sliding pads when worn to 48 mm 1 875 in 2 8 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylinder w o Counterbalance Valves Steer Cylinder OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID
129. 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 Proportional Control Valves The proportional control valves provide a power output matching that required by the load A small line connected to a load sensing port feeds load pressure back to a sequence valve The sequence valve senses the differ ence between the load and pump outlet pressure and varies the pump displacement to keep the difference con stant This differential pressure is applied across the valve s meter in spool with the effect that pump flow is determined by the degree of spool opening independent of load pressure Return lines are connected together simplifying routing of return flow and to help reduce cavi tation Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence JLG Lift 2 3 SECTION 2 PROCEDURES valve Integral actuator port relief valves anti cavitation check valves and load check valves are standard Relief Valves Main relief valves are i
130. ystems A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED The maintenance procedures included consist of servic ing and component removal and installation disassembly and assembly inspection lubrication and cleaning Infor mation on any special tools or test equipment is also pro vided where applicable 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never 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 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

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