Jlg M600 Service Manual Instrukcja Użytkownika

Service and Maintenance ManualModelE600E600JE600JPM600M600JM600JPP/N - 3121813December 18, 2012

vi – JLG Lift – 3121813TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121813Fuel Control RelayThe fuel control relay energizes the hold coil of the fuelsolenoid.The

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-63Fuel PumpThe fuel pump runs in parallel with the fuel solenoid holdcoil which is run by th

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3121813engine. The signal is also used in determining if the airglow plug should be energized.The

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-65Warnings and Safety PrecautionsTHE RBS MAY START WITHOUT WARNING.MORE THAN ONE LIVE CIRCUI

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121813RBS Start RBS shutdownCall to start Manual 48V DC applied to the inputAutomatic 1 Low

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-67RBS Alarms and Flash CodesIn the event of an RBS alarm, a flash code will be issuedand an

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 3121813TroubleshootingTable 3-9. TroubleshootingFlash Code Problem Solution- Unit Off / Disabled

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-69APU Engine Start Battery BoostingAlways connect the POSITIVE (+) of the booster batteryto

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 31218133.13 SUPPLEMENTARY FUSE FOR ENGINE GENERATOR CONTROLLERThe purpose of this section is to d

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-71conductors of the harness.5. Cut wire 106 going to the Engine/Generator Control-ler after

3121813 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3121813NOTES:

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOMRemoval1. Raise the boom to horizontal and make sure tha

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121813Figure 4-1. Boom Assembly - Sheet 1 of 3

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-3Figure 4-2. Boom Assembly - Sheet 2 of 3

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121813Figure 4-3. Boom Assembly - Sheet 3 of 3

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-513. Remove the upper master cylinder pivot pin.14. Remove the boom pivot pin.15. Remove the boo

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121813Figure 4-4. Boom Limit Switch Adjustment

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-7SWITCH TO ACTIVATE WHEN BOOMIS EXTENDED 18 ± 1” (46 ± 2.5 CM)Figure 4-5. Transport Limit Switc

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31218134.2 LOAD CELL CALIBRATION PROCEDURE1. Place the machine in the stowed position.2. Activate both

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-9Figure 4-7. Load Sensor

viii – JLG Lift – 3121813LIST OF FIGURES FIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 31218134.3 PLATFORM ROTATOR (PRIOR TO S/N 0300130810)Theory of Operation See Figure 4-9., Platform Ro

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-111. Housing & Ring Gear2A. Shaft2B. Flange2C. Bearing Tube3. Piston Sleeve4. Piston5.

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3121813If the actuator is not equipped with grease fittings, thethrust bearings (20) are coated with

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-13Required ToolsUpon assembly and disassembly of the actuator there arebasic tools required. The

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3121813PARTS1. Housing 2. Sha ft 3. Piston Sleeve4. End Ca pHARDWARE103.1. Screw1

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-15PARTS1. Housing 2. Sha ft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3121813Disassembly1. Remove the capscrews (113) over end cap lock pins(109). 2. Using a 1/8” (3.18mm)

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-176. Remove the end cap (4) and set aside for laterinspection. 7. Remove the stop tube if includ

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 312181310. Remove the shaft (2). It may be necessary to strikethe threaded end of the shaft with a ru

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-1916. To remove the main pressure seals (205), it is easi-est to cut them using a sharp razor bl

3121813 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3121813Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-212. Install the thrust washer (304) onto shaft (2) and endcap (4). 3. Install the wiper seal (3

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3121813Each T-seal has 2 back-up rings (see drawing for ori-entation). Beginning with the inner seal

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-239. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 312181314. Coat the threads on the end of the shaft with anti-seize grease to prevent galling. 15. In

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-254.5 JIB ROTATOROperating Principle Helac’s helical hydraulic rotary actuators use our slidings

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121813turning in a counterclockwise direction as shownbelow. A considerable amount oftorque may be r

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-271. Housing2. Sha ft3. Piston Sleeve4. End Ca p5. Loc kring102. Socket He

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 31218136. With the shaft removed, note the orientation of thetiming marks on the piston sleeve and

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-29Inspection Inspect all parts for wear, damage, cracks, etc. HOUSING Inspect the cylinder bore

x – JLG Lift – 3121813LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3121813washer comes to a stop against the housing thrustsurface. 8. Remove the masking tape and apply

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-31Installing Counterbalance ValveRefer to Figure 4-14., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 3121813Testing the ActuatorIf the equipment is available, the actuator should be testedon a hydraulic

SECTION 4 - BOOM & PLATFORM3121813 – JLG Lift – 4-33TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 3121813NOTES:

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121813Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-35.2 CYLINDERS - THEORY OF OPERATIONLift, Telescope, Slave, Master, Oscillation (if equipped), Jib (if eq

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3121813Cylinders With Dual Counterbalance ValveTelescope and Slave CylindersOPERATE ALL FUNCTIONS FROM GROUND C

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-51. Barrel2. Not Used3. Wear Ring4. T-Seal5. Wear Ring6. O-ring7. Backup Ring8. Wiper Ring9. Seal10. Rod1

SECTION 1 - SPECIFICATIONS3121813 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 OPERATING SPECIFICATIONS1.3 GENERATOR1.4 BATTERY CHARGER

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31218131. Loctite #242 (Not Shown)2. Locking Primer3. Loctite #RC609 (Not Shown)4. Bolt5. Tapered Bushing6. Bus

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-71. Loctite #242 (Not Shown)2. Not Used3. Locking Primer (Not Shown)4. Loctite #RC609 (Not Shown)5. Bolt6

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31218131. Loctite #242 (Not Shown)2. Locking Primer (Not Shown)3. Loctite (Not Shown)4. Bolt5. Tapered Bushing6

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-91. Locknut2. O-ring3. Wear Ring4. Piston5. Piston Seal6. O-ring7. Spacer8. Barrel8A. Bushing9. Rod 9A

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31218131. Loctite #242 (Not Shown)2. Locking Primer (Not Shown)3. Loctite (Not Shown)4. Rod5. Barrel6. Head7.

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-111. Loctite #242 (Not Shown)2. Locking Primer (Not Shown)3. Loctite (Not Shown)4. Bolt5. Bolt6. Tapered

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3121813NOTE: Steps 6 applies only to the telescope cylinders.6. Using a spanner wrench, loosen the end cap orh

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-139. Inspect cylinder head inside diameter for scoring orother damage and for ovality and tapering. Repla

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31218133. Place a new o-ring and back-up seal in the applica-ble outside diameter groove of the cylinder head.

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-15screws) through the drilled holes in the bushing andinto the tapped holes in the piston. 12. Tighten th

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31218131.7 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsLift: Boom Retracted. Telescope Retract

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 312181317. Position the cylinder barrel in a suitable holding fix-ture.EXTREME CARE SHOULD BE TAKEN WHEN INSTA

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-171. Hydraulic Tank2. Filter & Pressure Switch3. Suction Strainer4. Magnetic Plug5. Sight Gauge6. Fil

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31218131. Hydraulic Tank2. Filter & Pressure Switch3. Suction Strainer4. Magnetic Plug5. Sight Gauge6. Fil

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-195.5 PRESSURE SETTINGSProportional Main Relief - 3200 psi (220 Bar)Bang Bang Main Relief - 3000 psi (207

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 3121813Figure 5-23. Hydraulic Control Valve - Main ValveNOTE: Torque all cartridges to 20 ft. lbs.(28 Nm)

SECTION 5 - HYDRAULICS3121813 – JLG Lift – 5-21Figure 5-24. Hydraulic Control Valve - Platform ValveNOTE: Torque all cartridges to 20 ft. lbs.(28 Nm)

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121813NOTES:

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING A NEW POWER MODULE CONTROLLER ONTH

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121813Figure 6-2. Analyzer Flow Chart - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-3Figure 6-3. Analyzer Flow Chart - Sheet 2 of 2

SECTION 1 - SPECIFICATIONS3121813 – JLG Lift – 1-31.9 TORQUE REQUIREMENTS1.10 MAJOR COMPONENT WEIGHTS1.11 SERIAL NUMBER LOCATIONA serial number plate

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121813Figure 6-4. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-56.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the four pin end of the cable supplied

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121813Pressing ENTER with any of the above displayed menus,will display additional sub-menus within th

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-76.5 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZEROnce you have gained access to level 1, and

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121813There is a setting that JLG strongly recommends that youdo not change. This setting is so noted

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-96.7 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within theadjustment

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121813TELEscope ACCELeration 0.5 to 5.0 0.7DECELeration 0.1 to 3.0 0.5MINimum IN speed 0 to 20 20MAXi

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-11GR OUN D MO DE L IF T UP speed 0 to 1 00 8 5LIFT DOWN speed 0 to 100 63SWING speed 0 to 100 4T

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 31218136.8 MACHINE CONFIGURATION PROGRAMMING INFORMATIONTable 6-3. Machine Configuration Programming I

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-137PLATFORM ALARM01 Sounds continuously when above elevation and tilted only.Sounds continuously

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31218131.12 HYDRAULIC OILNOTE: Hydraulic oils must have anti-wear qualities at leastto API Service Classifi

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 31218136.9 LEVEL VEHICLE DESCRIPTIONA NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THETIME UNTIL

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-15Table 6-5. Help Descriptions and Fault Flash CodesFlash Code DescriptionNo flash code is indica

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 31218132/2 Flash code 2/2 indicates problems with drive & steer selection.DRIVE JOYSTICK FAULTYThe

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-172/5 Flash code 2/5 indicates that a function is prevented due to a cutout.BOOM PREVENTED - DRIV

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 31218133/3 Flash code 3/3 indicates that a contactor coil is short-circuit.OVERLOADED VALVE SUPPLY-CHE

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-195/5 Flash code 5/5 indicates problems with vehicle speed or the encoder.NO VEHICLE MOVEMENT DET

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 31218137/7 Flash code 7/7 indicates problems with a motor.CAPACITOR BANK FAULT - CHECK POWER/MOTOR WIR

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-219/9 Flash code 9/9 indicates problems with the controller.POWER MODULE FAILURE: CONTACTOR DRIVE

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 31218136.10 ANALYZER DIAGNOSTICS MENU STRUCTURE In the following structure descriptions, an intended i

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-23CREEP LEFT … Displays/adjusts maximum swing left speedNOTE: used when creep switch on pump pot

SECTION 1 - SPECIFICATIONS3121813 – JLG Lift – 1-51.13 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1-2., Operator M

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121813MAX DOWN … Displays/adjusts maximum jib down speedMIN LEFT … Displays/adjusts minimum jib left

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-25Table 6-7. Diagnostic Menu DescriptionsDRIVEDRIVE … Displays drive joystick direction & dem

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121813FSW1 … Displays footswitch statusNOTE: FSW1 is wired to the power moduleFSW2 … Displays footswi

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-27Table 6-8. Calibration DescriptionsCALIBRATIONS Not available at password level 2; can be viewe

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121813Table 6-9. Calibration Ranges/DefaultsCalibration Range DefaultsE600 M600BRAKE 0 to 100 25PUMP@

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-296.11 SYSTEM SELF TESTThe system self test is utilized to locate typical problems.See Table 6-10

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121813Table 6-11. System Test MessagesRUNNING Initial display when system test is run; certain “criti

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-31TESTING VALVES Indicates that the valve test is beginning.Each valve is alternately energized a

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121813CHECKING INPUTS Indicates that the inputs test is beginning.Every input is checked to ensure th

SECTION 6 - JLG CONTROL SYSTEM3121813 – JLG Lift – 6-33TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system t

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31218132. Generator Engine (If Equipped)Lube Point(s) - Fill CapCapacity - Refer to Engine ManualLube - EOI

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121813NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.6 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121813Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 3121813Automatic SwitchesIf the switch is actuated automatically, by tempera

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-57.10 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connec

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 31218133. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-7Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 3121813Figure 7-11. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-97.11 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 1 - SPECIFICATIONS3121813 – JLG Lift – 1-76. Wheel Drive HubLube Point(s) - Level/Fill PlugCapacity - 0.4 gal. (1.5 L)Lube - EPGLInterval - Ch

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121813HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the con

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-11This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121813Figure 7-18. Electrical Components Installation - Sheet 1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-13Figure 7-19. Electrical Components Installation - Sheet 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121813Figure 7-20. Electrical Schematic - Sheet 1 of 4

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-15Figure 7-21. Electrical Schematic - Sheet 2 of 41870226 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121813Figure 7-22. Electrical Schematic - Sheet 3 of 4

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-17Figure 7-23. Electrical Schematic - Sheet 4 of 41870226 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121813Figure 7-24. Hydraulic Schematic - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121813 – JLG Lift – 7-19Figure 7-25. Hydraulic Schematic - Sheet 2 of 22792459 A

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3121813Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPOU

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121813NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

SECTION 1 - SPECIFICATIONS3121813 – JLG Lift – 1-9Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121813Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121813 – JLG Lift – 1-11Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121813Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3121813 – JLG Lift – 1-13Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121813Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 2 - GENERAL3121813 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

INTRODUCTION3121813 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 2 - GENERAL2-2 – JLG Lift – 31218132.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121813 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 31218132.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3121813 – JLG Lift – 2-52.4 CYLINDER DRIFT TESTMaximum acceptable cylinder drift is to be measuredusing the following methods.Platf

SECTION 2 - GENERAL2-6 – JLG Lift – 31218132.6 WELDING ON JLG EQUIPMENTNOTE: This instruction applies to repairs, or modifications tothe machine and t

SECTION 2 - GENERAL3121813 – JLG Lift – 2-7Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL2-8 – JLG Lift – 3121813Emergency Stop Switches (Ground & Platform) 555Function Limit or Cutout Switch Systems 555Capacity Indi

SECTION 2 - GENERAL3121813 – JLG Lift – 2-9All Relevant Safety Publications Incorporated 21 21General Structural Condition and Welds 2,4 2,4All Fasten

SECTION 2 - GENERAL2-10 – JLG Lift – 3121813Figure 2-1. Operating Temperature Specifications - Kubota4150548 D

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

INTRODUCTIONA-2 – JLG Lift – 3121813REVISON LOGOriginal Issue - August 10, 2000Revised - November 22, 2000Revised - April 15, 2003Revised - February 1

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31218132. Tighten nuts in the following sequence:3. The tightening of the nuts should be done in s

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-33. Rotate the cover to show the inside diameter4. Press the cover sufficiently against the

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31218131. Planet Gear2. Planet Gear3. Sun Gear4. Shaft Nut5. Planet Bolt6. Support Ring7. Planet C

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-5Disassembly1. Position drive so that one of the fill holes is at thebottom of the end cover

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121813Assembly of end cover unit (8)1. Press sleeve (52) into cover (8).2. Install "o"

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-7meet on the exterior of the unit, then checking for airbubbles. If a leak is detected in a

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121813Figure 3-2. Main Disassembly Drawing 11F. Ring Gear1G. Housing2. Washer3. Input

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-9Figure 3-3. Main Disassembly Drawing 21F. Ring Gear1G. Housing4. Output Carrier Sub

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121813Output Carrier Disassembly1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-115. Remove 4 Thrust Washers (4B), 28 Needle Rollers(4C) and the Thrust Spacer (4D) from the

3121813 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121813Input Carrier Disassembly1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-13Hub-Spindle Disassembly1. Place unit on bench with Spindle (1 A) end down.2. Remove Retain

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121813Cover Disassembly1. Remove O-Ring (17) from groove in Cover (6A).2. Remove Thrust Washer (

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-15Input Carrier Assembly(Refer to Figure 3-6., Input Carrier)1. Apply a liberal coat of grea

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121813Output Carrier Assembly(Refer to Figure 3-4., Output Carrier)1. Place Thrust Washer (4H) i

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-17Cover Subassembly(Refer to Figure 3-8., Cover Assembly)1. Grease O-Ring (6E) and insert in

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121813Figure 3-9. Hub Assembly - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-191A Spindle1B Lip Seal1C Tapered Bearing Cone1D Tapered Bearing Cup1E T

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121813Figure 3-11. Cup Pressing ToolFigure 3-12. Cup Pressing Tool

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-213.4 DRIVE BRAKE - MICODisassembly1. Remove pressure plate (3) from cover (21) byremoving t

ii – JLG Lift – 3121813TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31218132322192118171615201211109876542331131421. Capscrew2. Washer3. Pressure Plate4. Case Seal5.

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-23Table 3-2. Drive Brake DiagnosisProblem Cause ExplanationCorrectiveActionBrake slips Exces

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 31218133.5 SPEED SENSOR ADJUSTMENTFor proper drive operation, the speed sensors must beproperly i

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-25Figure 3-14. Speed Sensor Orientation

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121813Figure 3-15. Drive Components

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-27Speed Sensor Installation VerificationThe motor controller averages the readings from the

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 31218136. Use the right and left cursor keys to display ’SPEED0%" on the analyzer.7. While w

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-29Figure 3-16. Oscillating Axle

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121813Figure 3-17. Axle Oscillation Lockout Valve

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-313.6 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)LOCKOUT SYSTEM TEST MUST BE PERFORMED QUART

3121813 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31218133.8 SWING DRIVERoll, Leak and Brake TestingTorque-Hub units should always be roll and leak

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-3317. Elbow Fitting18. Fittings19. Ferrule20. Tubing Assembly21. Fitting29. Plug31. Motor Co

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 3121813Motor and Brake Disassembly1. With unit resting on bench with Motor (10) end up,loosen Hex

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-356. Remove Motor (10) from Brake Housing (6) byremoving four Bolts (15) incrementally until

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121813Main Disassembly1. With the unit resting on the Output Shaft (Pinion)(1A), remove the Carr

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-37Hub-shaft Disassembly1. Using retaining ring pliers, remove Retaining Ring(1I) from groove

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121813Carrier Disassembly1. Using a 1/4" punch, drive the Roll Pin (3G) whichholds the Plan

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-39Hub-Shaft Sub-Assembly(See Figure 3-22., Hub Shaft Disassembly)1. Press Bearing Cup (1E) i

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121813Main Assembly(See Figure 3-21., Main Disassembly)1. With the Housing-Shaft Subassembly res

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-41Motor Control Valve Assembly(See Figure 3-18., Motor Control Valve Disassembly)1. Lay asse

iv – JLG Lift – 3121813TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 31218135. Tighten the setscrew (3) until the pinion is com-pletely snug against the shim and bear

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-434. Assure that the 0.0015" feeler gauge will not pene-trate under the bolt head to th

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121813Figure 3-27. Swing Drive and Bearing Installation

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-45Replacement of Swing BearingRemoval of the swing bearing is as follows:1. Attach an adequa

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 312181311. Following the torque sequence shown in Figure 3-28., Swing Bearing Torque Sequence tig

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-473.10 BATTERY MAINTENANCE AND CHARGINGIF REPLACING A BATTERY, EACH NEW BATTERY MUST WEIGHAT

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3121813Removing the Battery BoxTo remove the battery box, perform the following steps.1. Pull the

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-49Figure 3-30. Batteries and Battery Charger

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121813131519121420732118101196417181. 20 Amp Circuit Breaker2. Connector3. PC Board4. DC Cord5.

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-511N.C.N.O.BLKBLKAC BLKAC GRN ORAC GRN OR BLUEYLW/GRNOR BRNCON.RELAYVARISTORGROUNDSCREWTXPRI

3121813 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31218133.11 GENERATOR (PRIOR TO S/N 88375)NOTE: Throughout the Generator section, the abbreviatio

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-53Figure 3-33. Generator Components

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121813Timing Sequences• RBS Prestart Sequence1. Time Delay Engine Start (TDES)TDES is the period

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-55To Connect the JLG Control System Analyzer to the GeneratorThe JLG Control System Analyzer

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3121813Figure 3-34. Generator System Analyzer Flow Chart

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-57•UnderspeedEnabled once TDBP (time delay bypass) period haselapsed after engine startup. I

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121813Priming the Fuel LineThe following procedure is for re-priming the fuel line onthe generat

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-593.12 GENERATOR (S/N 88375 TO PRESENT)NOTE: Throughout the Generator section, the abbreviat

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3121813713101211897121051336214Figure 3-35. Generator8. Temperature Sensor9. Voltage Regulator10

SECTION 3 - CHASSIS & TURNTABLE3121813 – JLG Lift – 3-61Start BatteryThe RBS requires a 12V lead-acid start battery (not sup-plied with the system