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SECTION 2 - GENERAL

3121619

2-5

2.4

CYLINDER DRIFT

Theory

When a hydraulic cylinder is supporting a load, cylinder drift
may occur as a result of any of the circumstances below:

• Normal leakage of load holding valves or malfunction of

load holding valves. See Cylinder Leakage Test and Table 2-
2, Cylinder Drift below for evaluation.

• Damaged or worn piston seals.

• Normal thermal expansion or contraction of the hydraulic

oil within cylinders (See Cylinder Thermal Drift below).

The first two circumstances may result in cylinder movement
due to oil leaking out of the cylinder externally or by leaking
back to tank or due to oil leaking internally from one cylinder
chamber to the other.

Thermal expansion or contraction of oil in hydraulic cylinders
is a normal occurrence and does not result in oil leaking out of
the cylinder or leaking internally from one cylinder chamber
to the other. Thermal expansion or contraction is the tendency
for materials to change size in response to a change in temper-
ature.

Cylinder Leakage Test

Cylinder oil must be at stabilized ambient temperature
before beginning this test.

Measure drift at cylinder rod with a calibrated dial indicator.

In an area free of obstructions, cylinder must have load
applied and appropriately positioned to detect drift.

Cylinder leakage is acceptable if it passes this test.

Cylinder Thermal Drift

The oil in all hydraulic cylinders will expand or contract due to
thermal effects over time and may result in changes to the
boom and/or platform position while the machine is station-
ary. These effects occur as the cylinder oil changes tempera-
ture, usually from a higher oil temperature as it cools and
approaches the ambient air temperature. Results of these
effects are related to several factors including cylinder length
and change in temperature over the time the cylinder remains
stationary.

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

Max. Acceptable Drift

in 10 Minutes

inches

mm

inches

mm

3

76.2

0.026

0.66

3.5

89

0.019

0.48

4

101.6

0.015

0.38

5

127

0.009

0.22

6

152.4

0.006

0.15

7

177.8

0.005

0.13

8

203.2

0.004

0.10

9

228.6

0.003

0.08

NOTE:

This information is based on 6 drops per minute cylinder
leakage.

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Summary of Contents for 1850SJ

Page 1: ...Service and Maintenance Manual Model 1850SJ 3121619 June 29 2018 Rev J AS NZS...

Page 2: ......

Page 3: ...ic systems oper ate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system Do not use...

Page 4: ...ue A June 18 2014 Revised B September 25 2014 Revised C May 15 2015 Revised D November 5 2015 Revised E January 27 2016 Revised F June 8 2016 Revised G November 8 2016 Revised H May 23 2017 Revised I...

Page 5: ...2 2 General 2 2 Safety and Workmanship 2 2 Cleanliness 2 2 Components Removal and Installation 2 2 Component Disassembly and Reassembly 2 3 Pressure Fit Parts 2 3 Bearings 2 3 Gaskets 2 3 Bolt Usage a...

Page 6: ...3 15 Swing Control System 3 47 3 16 Chassis Tilt Indicator System 3 47 3 17 Auxiliary Power System 3 47 3 18 Water in Fuel Sensing System Optional 3 48 3 19 Deutz Turbocharger Operation 3 48 Operating...

Page 7: ...nal Replacement Criteria 4 57 4 12 Wire Rope Tensioning Adjustment 4 58 Boom Preparation for Section Repositioning 4 58 Wire Rope Tensioning Procedure 4 64 Confirm Proper Boom Deployment Function 4 66...

Page 8: ...placement 5 49 5 3 Hydraulic Cylinders 5 59 Axle Extend Cylinder 5 59 Jib Level Slave Cylinder 5 64 Platform Level Cylinder 5 70 Boom Lift Cylinder 5 76 Jib Lift Cylinder 5 82 Jib Lock Cylinder 5 88 S...

Page 9: ...Level Angle Sensor 1 6 47 Sensor 7 Jib Lock Pin Proximity Sensor 1 6 47 Sensor 8 Jib Stow Angle Sensor 1 6 49 Sensor 9 Jib Lift Angle Sensor 1 6 49 Sensor 10 Dual Capacity Jib Transport Length Switch...

Page 10: ...ement 7 1 Resistance Measurement 7 2 Continuity Measurement 7 2 Current Measurement 7 3 7 3 Applying Silicone Dielectric Compound to Electrical Connections 7 3 Installation of Dielectric Grease 7 4 De...

Page 11: ...t Sheet 2 of 2 3 10 3 9 Turntable Hydraulic System 3 11 3 10 Drive Assembly 3 12 3 11 Drive Hub 3 13 3 12 Disengaging Drive Hubs 3 21 3 13 Gear Hub Oil Fill and Drain 3 21 3 14 Drive Motor 3 22 3 15 D...

Page 12: ...Sheet 7 of8 3 58 3 53 Diesel Exhaust Fluid DEF System Sheet 6 of 7 3 59 3 54 Engine Electrical Circuit 3 60 3 55 Mixing Petroleum With Summer Diesel Fuel 3 61 4 1 Boom Hydraulic System 4 7 4 2 Boom As...

Page 13: ...ertrack Shimming Instructions 4 72 4 45 Powertrack Locations for Threadlocker Application and Torque Sheet 1 of 4 4 73 4 46 Powertrack Locations for Threadlocker Application and Torque Sheet 2 of 4 4...

Page 14: ...ing Installation 5 63 5 33 Seating the Tapered Bearing 5 63 5 34 Rod Assembly Installation 5 63 5 35 Cylinder Barrel Support 5 64 5 36 Capscrew Removal 5 64 5 37 Cylinder Rod Support 5 64 5 38 Jib Lev...

Page 15: ...ensor Removal 5 82 5 78 Capscrew Removal 5 82 5 79 Jib Lift Cylinder Assembly 5 83 5 80 Cylinder Rod Support 5 84 5 81 Tapered Bushing Removal 5 84 5 82 Piston Disassembly 5 84 5 83 Cylinder Head Disa...

Page 16: ...5 124 Main Valve Identification Sheet 1 of 2 5 110 5 125 Main Valve Identification Sheet 2 of 2 5 111 5 126 Main Valve Torque Values Sheet 1 of 2 5 112 5 127 Main Valve Torque Values Sheet 2 of 2 5 1...

Page 17: ...are Version 7 X Sheet 4 of 4 6 35 6 18 Ground Control Module Sheet 1 of 3 6 36 6 19 Ground Control Module Sheet 2 of 3 6 37 6 20 Ground Control Module Sheet 3 of 3 6 38 6 21 Chassis Control Module 6 3...

Page 18: ...3 7 28 Jib Valve Wiring Harness Sheet 1 of 3 7 24 7 29 Jib Valve Wiring Harness Sheet 2 of 3 7 25 7 30 Jib Valve Wiring Harness Sheet 3 of 3 7 26 7 31 BLAM Module Wiring Harness Sheet 1 of 2 7 27 7 32...

Page 19: ...T4F Engine Harness Sheet 4 of 14 7 69 7 74 T4F Engine Harness Sheet 5 of 14 7 70 7 75 T4F Engine Harness Sheet 6 of 14 7 71 7 76 T4F Engine Harness Sheet 7 of 14 7 72 7 77 T4F Engine Harness Sheet 8 o...

Page 20: ...et 7 of 21 7 103 7 108 Electrical Schematic Sheet 8 of 21 7 104 7 109 Electrical Schematic Sheet 9 of 21 7 105 7 110 Electrical Schematic Sheet 10 of 21 7 106 7 111 Electrical Schematic Sheet 11 of 21...

Page 21: ...3121619 xvii LIST OF FIGURES FIGURE NO TITLE PAGE NO Thispageleftblankintentionally...

Page 22: ...e SAE Steel 5 12 5 6 45 Flare SAE Aluminum Brass 5 12 5 7 O ring Face Seal ORFS Steel 5 13 5 8 O ring Face Seal ORFS Aluminum Brass 5 14 5 9 DIN 24 Cone MBTL MBTS 5 16 5 10 Bulkhead Fittings BH INCH 5...

Page 23: ...er Size and Torque Chart 5 148 5 42 Plug Size and Torque Chart 5 148 5 43 Troubleshooting 5 169 6 1 Analyzer Abbreviations 6 8 6 2 Machine Configuration Programming Information 6 10 6 3 Machine Config...

Page 24: ...xx 3121619 LIST OF TABLES TABLE NO TITLE PAGE NO Thispageleftblankintentionally...

Page 25: ...ht stowed 10ft 0 5in 3 06m MachineLength stowed 47ft 9 5in 14 57m PlatformHeight 500lb 230kg capacity 185ft 7in 56 56m PlatformHeight 1000lb 450kg capacity 165ft 2in 50 34m HorizontalReachfromcenterli...

Page 26: ...procedures Table 1 6 Critical Stability Weights Components LBS KG Tire Wheel 1025 465 DriveHub Motor 337 153 SwingDrive 223 101 2 EngineAssembly 822 373 CompleteBoom includingjib platform 23 600 1070...

Page 27: ...theticBiodegradable ISOViscosityGrade 46 SpecificGravity 910 PourPoint 44 F 42 C FlashPoint 500 F 260 C OperatingTemp 0to180 F 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 45cSt at100...

Page 28: ...SECTION 1 SPECIFICATIONS 1 4 3121619 11 10 13 15 12 18 14 6 3 3 3 3 1 7 9 2 5 8 16 17 4 Figure 1 1 Maintenance and Lubrication Diagram...

Page 29: ...bearing is completely lubricated 2 Swing Gearbox Lube Point s Fill Plug Capacity 3 qt 2 8 L Lube GL 5 Interval Check level every 150 hrs Change every 1200 hours of operation Fill to cover ring gear 3...

Page 30: ...every 6 months or 300 hrs thereafter Comments Remove wing nut and cover to replace Under certain conditions it may be necessary to replace on a more frequent basis 6 Hydraulic Charge Filter Lube Poin...

Page 31: ...y 2 years or 1200 hours of operation 9 Main Valve Filter Lube Point s Replaceable Element Interval Change after first 50 hours and every 6 months or 300 hours thereafter 10 Oil Change w Filter Deutz L...

Page 32: ...ilter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator Comments Check dust valve for dirt daily 14 Boom Lube Point s Apply...

Page 33: ...oint Fill Cap Lube DEF Capacity 5 7 gal 21 5 L 17 DEF Supply Module Filter If Equipped Interval 500 hours or 2 years whichever comes first 18 Optional Fuel Filter Water Separator Lube Point s Replacea...

Page 34: ...SECTION 1 SPECIFICATIONS 1 10 3121619 Figure 1 2 Torque Chart Sheet 1 of 5 SAE Fasteners Torq ue To rqu e Torq ue To rqu e Torq ue Torq ue...

Page 35: ...SECTION 1 SPECIFICATIONS 3121619 1 11 Figure 1 3 Torque Chart Sheet 2 of 5 SAE Fasteners Torq ue Tor que Torq ue Torqu e To rqu e...

Page 36: ...SECTION 1 SPECIFICATIONS 1 12 3121619 Figure 1 4 Torque Chart Sheet 3 of 5 SAE Fasteners Cl amp L oa d To rque To rqu e Torq ue Torqu e Tor que Torq ue...

Page 37: ...SECTION 1 SPECIFICATIONS 3121619 1 13 Figure 1 5 Torque Chart Sheet 4 of 5 METRIC Fasteners To rqu e To rqu e Torq u e To rq ue To rqu e To rq ue...

Page 38: ...SECTION 1 SPECIFICATIONS 1 14 3121619 Figure 1 6 Torque Chart Sheet 5 of 5 METRIC Fasteners Torq ue To rqu e Tor qu e To rqu e To rqu e To rq ue...

Page 39: ...ery The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours whichever comes first out of service for a period of more than 3 months or when purchased used T...

Page 40: ...containers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc sho...

Page 41: ...ssary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usag...

Page 42: ...ned flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mi...

Page 43: ...temper ature Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature before beginning this test Measure drift at cylinder rod with a calibrated dial indicator In an area free of o...

Page 44: ...wound bearing are a dry joint and should not be lubricated unless otherwise instructed i e sheave pins c Pins should be inspected to ensure it is free of burrs nicks and scratches which would damage...

Page 45: ...1 2 Extend RetractChainorCableSystems 1 2 3 1 2 3 PlatformAssembly Platform 1 2 Railing 1 1 2 Gate 1 5 1 5 Floor 1 1 2 Rotator 5 9 15 LanyardAnchoragePoint 1 2 10 1 2 10 TurntableAssembly SwingBearin...

Page 46: ...ndBreather 1 2 5 1 5 Hydraulic ElectricSystem HydraulicPumps 1 2 9 HydraulicCylinders 1 2 7 9 1 2 9 CylinderAttachmentPinsandPinRetainers 1 2 9 1 2 HydraulicHoses Lines andFittings 1 2 9 12 1 2 9 12 H...

Page 47: ...roperandsecureinstallation 2 Visualinspectionfordamage cracks distortionorexcessivewear 3 Checkforproperadjustment 4 Checkforcrackedorbrokenwelds 5 OperatesProperly 6 Returnstoneutralor off positionwh...

Page 48: ...SECTION 2 GENERAL 2 10 3121619 Figure 2 1 Engine Operating Temperature Specifications Deutz 1001159163 A...

Page 49: ...ity at 40 C cSt Typical Viscosity Index Mineral Oils Vegetable Oils Synthetic Synthetic Polyol Esters Readily Biodegradable Virtually Non toxic Fire Resistant Mobilfluid424 55 145 X MobilDTE10Excel32...

Page 50: ...SECTION 2 GENERAL 2 12 3121619 NOTES...

Page 51: ...width center piece location larger or smaller diameter etc without written factory recommendations may result in an unsafe condition regarding stability Wheel Installation It is extremely important to...

Page 52: ...the transport position The steering angle will be automatically limited to 20 degrees anytime the axles are not fully extended If the wheel angle is more than 20 degrees when the axle retract command...

Page 53: ...Axle Extension System for interaction with the axle extension system If a wheel cannot achieve its com manded angle within a specified time it is considered jammed When a wheel is considered jammed d...

Page 54: ...e tighter the turn the slower the allowable drive speed As crab steer does not steer on a radius full drive speed is maintained regardless of steer angle 3 6 TRACTION CONTROL SYSTEM The traction contr...

Page 55: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 5 This page left blank intentionally...

Page 56: ...SECTION 3 CHASSIS TURNTABLE 3 6 3121619 Figure 3 4 Axle Hose Routing Sheet 1 of 2...

Page 57: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 7 Figure 3 5 Axle Hose Routing Sheet 2 of 2...

Page 58: ...SECTION 3 CHASSIS TURNTABLE 3 8 3121619 Figure 3 6 Steering Axle Hydraulic Circuit...

Page 59: ...WIVEL PORT 3 A1 B1 BR B2 A2 TS A6 A4 B4 RIGHT R IGH T RE AR H U B DR IVE M OTOR A B X X A B X X REAR LEFT LEFT R EAR H UB D R IV E MOTOR A B X X FRONT LEFT FR ONT H UB D R IV E MOTOR A B X X FR ON T V...

Page 60: ...R L EFT RIGHT TO SWIVEL PORT 7 X X X X X X X X LEFT FRONT HUB DRIVE MOTOR X RIGHT REAR HUB DRIVE MOTOR X X1 L1 RIGHT FRONT HUB DRIVE MOTOR X L1 BR X1 LEFT REAR HUB DRIVE MOTOR X CASE DRAIN MANIFOLD T...

Page 61: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 11 Figure 3 9 Turntable Hydraulic System...

Page 62: ...SECTION 3 CHASSIS TURNTABLE 3 12 3121619 3 7 DRIVE ASSEMBLY Figure 3 10 Drive Assembly 1 2 3 4 5 6 7 1 DriveHub 2 O Ring 3 Drivemotor 4 Washer 5 Bolt 6 Washer 7 Bolt...

Page 63: ...lange 26 O Ring 27 RingNut 28 SetScrew 29 Bearing 30 HubSupport 31 O Ring 32 Bearing 33 Seal 34 Coupling 35 Spring 36 RetainingRing 37 Bearing 38 Axle 39 Plug 40 Plug 41 PlasticPlug 42 InputShaft 43 I...

Page 64: ...screws 56 motor flange 55 and O Ring 54 Do not damage O Ring 3 Remove two screws 2 cover 3 and pin 4 4 Remove Ring 1 Cover 6 O Ring 7 Spacer 8 and O Ring 10 Do not damage O Rings Check and remove Gask...

Page 65: ...tary Ring 18 and O Ring 26 Do not damage O Ring 7 Remove Coupling 34 and Spring 35 8 Remove three snap rings 22 and planetary gears 24 from spindles on Flange 25 9 Remove two Set Screws 28 from Ring N...

Page 66: ...le 38 12 Remove Snap Ring 53 Spacer 52 Seal 48 O Ring 49 and Brake Piston 50 from Axle 38 Remove five Brake Springs 51 from Brake Piston 50 Use com pressed air to remove Brake Piston from Axle 13 Remo...

Page 67: ...nd Bearing Secure with Split Ring 36 3 Install Seal 46 O Ring 47 Seal 48 and O Ring 49 in Axle 38 Starting with Brake Disk 43 alternate with Iron Disk 44 until a total of eight Brake Disks and nine Ir...

Page 68: ...with convex part facing bearing 7 Install Ring Nut 27 on Flange 25 Prevent Flange from turning and torque Ring Nut to 295 ft lb 400 Nm Tighten and back off two times to completely seat bear ings Tight...

Page 69: ...11 Install Gear Reduction Assembly 16 Gear Reduction Assembly 13 and Pinion 11 in Planetary Housing Lubricate all bearings 12 Install O Ring 7 and O Ring 10 in Cover 6 Liberally coat Spacer 8 with gr...

Page 70: ...completed Drive Hub assembly rotates freely 15 Install Pin 4 and Cover 3 Secure with two Screws 2 Torque to 7 ft lb 10 Nm FAILURE TO PROPERLY FILL DRIVE HUB WITH OIL BEFORE OPERATION WILL RESULT IN E...

Page 71: ...OIL SERVICE Check Oil Level 1 Position hub as shown in Figure 3 13 2 Remove Level Plug 3 and check oil is level with plug opening Add oil as needed 3 Reinstall plug Change Gear Hub Oil NOTE Change oi...

Page 72: ...tingPin 4 O Ring 5 Plug 6 DowelPin 7 NeedleBearing 8 ValvePlate 9 SnapRing 10 SpringRetainer 11 Spring 12 Washer 13 CylinderBlock 14 SlipperPin 15 Guide 16 SlipperRetainer 17 CylinderPiston 18 PistonR...

Page 73: ...Minimum and maximum displacement can be set with fixed internal stops The large diameter servo piston allows smooth acceleration and deceleration with relatively large circuit orificing Figure 3 15 Dr...

Page 74: ...ench remove plug 3 3 Remove O rings 4 5 and 6 4 Using pliers remove centering springs 7 8 and 9 5 Remove spring retaining washers 10 and 11 6 Remove shift spool 12 7 Remove orifice poppet 13 INSPECTIO...

Page 75: ...Description Action Checkoillevelinreservoirandoil supplytopump Insufficientamountofhydraulicfluidwillnotmeetsystemcooling demands Fillreservoirtoproperlevel Inspectheatexchanger if equipped Ifheatexch...

Page 76: ...ny O rings on fit tings 9 Using an 11 16 inch hex wrench loosen speed sensor lock nut 14 if equipped Remove speed sensor using a Vi inch hex wrench Units without speed sensor have an O ring plug 15 in...

Page 77: ...Remove valve plate 25 and timing pin 26 from end cap Each displacement has a unique valve plate For identification the last two digits of the valve plate part number are stamped on its surface 16 Rem...

Page 78: ...ID DAMAGING SHAFT DURING SEAL REMOVAL INSTALL A LARGE SHEET METAL SCREW IN CHUCK OF SLIDE HAMMER DRIVE SCREW INTO SEAL SURFACE AND USE SLIDE HAMMER TO PULL SEAL 19 Turn housing over and remove snap ri...

Page 79: ...Turn housing over and remove swashplate 39 by lifting on end opposite servo lever 23 Remove servo piston 40 Remove piston seal 41 and O ring 42 from servo piston Discard seal and O ring 24 Remove jou...

Page 80: ...ully release pressure and remove outer block spring washer 50 block spring 52 and inner block spring washer 53 from cylinder block Inspection After disassembly wash all parts including end cap and hou...

Page 81: ...ll not reduce thick ness below minimum specification SWASHPLATE AND JOURNAL BEARINGS Inspect running face servo ball joint and swashplate journal surfaces for damage or excessive wear Some material tr...

Page 82: ...and servo pis ton ball socket for damage or excessive wear Replace as required LOOP FLUSHING SPOOL Inspect loop flushing spool for cracks or damage Replace as required Assembly 1 Install new O ring 1...

Page 83: ...nsure concave sur face of retainer seats on ball guide If reusing pistons install them in original block bores Lubricate pistons slippers retainer and ball guide before assembly Set cylinder kit aside...

Page 84: ...d bearings are properly seated Install cylinder kit 19 on shaft Install with slippers fac ing swashplate Rock the shaft to align block splines and slide cylinder kit into place Orient motor with shaft...

Page 85: ...n place during installation 15 Install endcap 25 on housing with endcap screws 26 Ensure endcap will properly seat to housing without interference Improper assembly of internal compo nents may prevent...

Page 86: ...Install shift spool 31 22 Install spring retaining washers on springs 32 and 33 23 Carefully install centering springs 34 35 and 36 24 Install new O rings 37 38 and 39 25 Using a 5 8 in wrench torque...

Page 87: ...tor system pressure during start up 6 Watching pressure gauge and run engine at lowest pos sible speed until system pressure builds to normal levels minimum 160 psi 11 bar Once system pressure is esta...

Page 88: ...SE OF THIS PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION NOTE This check is designed to replace the existing bearing bolt torque checks on JLG Lifts in service This check...

Page 89: ...o insert the 0 0015 feeler gauge between the bolt head and hardened washer at the arrow indicated position c Lower the boom to horizontal and fully extend the boom d At the position indicated on Posit...

Page 90: ...1 3 3 36 2 2 4 1 5 4 6 5 7 11 8 10 18 26 32 29 21 9 9 10 8 11 12 7 13 6 14 17 15 16 16 15 17 14 18 23 19 34 24 30 20 25 35 31 21 22 22 23 24 25 26 27 28 29 30 31 32 33 34 35 13 19 27 33 28 20 12 Figu...

Page 91: ...Check dial indicator accuracy once positioned using a feeler gauge and ensure the dial indicator reading is the same as the feeler gauge thickness 5 Position the machine as follows and as seen in Fig...

Page 92: ...SECTION 3 CHASSIS TURNTABLE 3 42 3121619 Figure 3 39 Swing Bearing Wear Tolerance...

Page 93: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 43 CEN TER OF GRAVITY 31 7 8 0 cm Upperstructure 39 000 lbs 17 690 kg Figure 3 40 Swing Bearing Removal Sheet 1 of 4...

Page 94: ...SECTION 3 CHASSIS TURNTABLE 3 44 3121619 Figure 3 41 Swing Bearing Removal Sheet 2 of 4...

Page 95: ...SECTION 3 CHASSIS TURNTABLE 3121619 3 45 Main Boo m Pivot CENTER OF GRAVITY B oom Assembly 21 650 lbs 9 82 0 kg Figure 3 42 Swing Bearing Removal Sheet 3 of 4...

Page 96: ...N 3 CHASSIS TURNTABLE 3 46 3121619 Note Attach Lifting Device to Turntable Cutouts Closest to This Side of Turntable Turntable 15 350 lbs 6 963 kg 83 3 212 cm Figure 3 43 Swing Bearing Removal Sheet 4...

Page 97: ...tilt setting is used in conjunction with the main boom length and when exceeded imposes the same func tionality as the 5 0 omni directional setting plus prevents boom telescope out The side tilt setti...

Page 98: ...ng the engine or turbocharger ensure the turbo charger is pre lubed by adding clean engine oil into the turbo charger oil inlet until full After pre lubing crank the engine without firing engine fuel...

Page 99: ...uced to 2 months NOTE DEF freezes at 12 F 11 C Cleaning and Flushing the Tank If contaminated fluid or foreign material is found in the tank the tank must be cleaned Use the following procedure for cl...

Page 100: ...SECTION 3 CHASSIS TURNTABLE 3 50 3121619 Figure 3 44 Diesel Exhaust Fluid DEF Tank Sheet 1 of 2...

Page 101: ...lTube 3 DEFFilter 4 Tie Wrap 5 RubberBushing 6 FloatAssembly 7 SuctionTube 8 SuctionStrengtheningPlate 9 ReturnTube 10 ReturnStrengtheningPlate 11 Connector 12 RubberHeader 13 Header 14 MetallicFlange...

Page 102: ...A DRIVE PUMP FUNCTION PUMP GEAR PUMP SEE DETAIL B AIR FILTER SURGE TANK DOC SCR TANK VENT PORT FUEL RETURN FROM ENGINE SUPPLY FUEL LINE TANK TO PRE FILTER SEE DETAIL C FUEL SUPPLY PORT Figure 3 46 Eng...

Page 103: ...AND RETURN FUEL LINE EMR4 HARNESS 140 AMP BATTERY ISOLATOR DETAIL B SUPPLY FUEL LINE INBOARD RETURN FUEL LINE OUTBOARD ENGINE HARNESS FUEL PUMP SUPPLY FUEL LINE FROM TANK DETAIL C Figure 3 47 Engine...

Page 104: ...54 3121619 1001192266 F F SUPPLY PREFILTER TO FUEL PUMP DEF SUPPLY OUTLET TO DOSING MODULE DEF SUPPLY MODULE INLET FROM DEF TANK BACKFLOW TO DEF TANK Figure 3 48 Engine Installation and Diesel Exhaust...

Page 105: ...1001192266 F COOLANT RETURN FROM DOSING MODULE COOLANT RETURN PORT COOLANT SUPPLY PORT COOLANT RETURN FROM DEF TANK COOLANT SUPPLY TO TEE FITTING UNDER ENGINE Figure 3 49 Engine Installation and Dies...

Page 106: ...RNTABLE 3 56 3121619 1001192266 F L L L L SUPPLY FUEL LINE RETURN FUEL LINE DEF COOLANT SUPPLY LINE DEF COOLANT RETURN LINE DEF FLUID SUPPLY Figure 3 50 Engine Installation and Diesel Exhaust Fluid DE...

Page 107: ...INE FROM DEF COOLANT VALVE INSTALL FUEL PUMP SUPPLIED WITH ENGINE SUPPLY FUEL LINE TO SECONDARY FUEL FILTER ON ENGINE TANK VENT HOSE DEF SUPPLY FROM OUTLET PORT ON SUPPLY MODULE DEF DOSING MODULE J J...

Page 108: ...PPLY PORT DOSING MODULE VALVE TO BE ORIENTED WITH THE FLOW FACING THE FRONT CCW END OF THE MACHINE DEF COOLANT SUPPLY VALVE DEF COOLANT RETURN LINE COOLANT SUPPLY TO DEF COOLANT SUPPLY VALVE COOLANT S...

Page 109: ...1 G PRESSURE SENSOR MIXING PIPE EXH GAS TEMP CONNECTION NOx SENSOR AFTER SCR O2 SENSOR O2 SENSOR STARTER CONNECTION ENGINE ECU CONNECTION PRE SCR NOx SENSOR DOC TEMP SENSOR GLOW PLUG CONNECTION Figure...

Page 110: ...SECTION 3 CHASSIS TURNTABLE 3 60 3121619 Figure 3 54 Engine Electrical Circuit...

Page 111: ...ulphur content may not be used in engines with exhaust gas after treatment Fuels with a sulphur content 1 0 m m are not permissible due to high corrosion and considerable shortening of the engine life...

Page 112: ...NOx using ammonia as a reductant within a catalyst system The chemi cal reaction is known as reduction where the DEF is the reducing agent that reacts with NOx to convert the pollutants into nitrogen...

Page 113: ...ing will be stopped immediately if The Platform Ground Select switch is switched from Ground to Platform mode Function switch is enabled to perform a boom function The Engine is powered down If Mainte...

Page 114: ...eepandDTC active 3 ShutOff Level 1125 Blinking 3Hz IdleLock Boom FunctionsLocked OutandTrappedin Transport ContactDeutzDealer Table 3 9 Cleaning When Crystallization is Detected During SCR Crystalliza...

Page 115: ...nsA01 K74 K91and orreflashECU Iferrorisstillpresent exchangeECU 43 731 523925 4 Shortcircuittogroundactuatorrelais3 OverloadatPinsO_V_RH3x A88 K57 Suspectedcomponents 1 PinA88 Preheatrelay Exhaustflap...

Page 116: ...tioncableandif necessaryrepairorreplaceit checkresistancein CANlines 120Ohm 88 223 102 2 Chargeairpressuremessuredbysensoris abovetheshutoffthreshold Chargedaircoolerpressurebelowthreshold Checkwasteg...

Page 117: ...CAN BUS 130 597 3224 9 TimeoutErrorofCAN Receive Frame AT1IG1Vol NOXsensor SCR system upstreamcat DPF systemdownstreamcat FailureoftheCANBusmessage NOXsensorandsensorconnectioncheck 133 766 523938 9 T...

Page 118: ...ANBusmessage Checkwiringharnessandcustomerdevices 179 527 523240 9 TimeoutCAN messageFunModCtl Func tionModeControl TimeoutError MissingCANBusmessage CheckCANBuscabling Bussheduling polarity shortcirc...

Page 119: ...nginespeedcalculated byECUisabovethetargetrange theECU activatesasystemreaction Overspeedmonitoringduring1levelofFOC Failureoverruncondition ifenginespeed wasoverLimit checkpowertrainsettingsregarding...

Page 120: ...ensordefect Checkofwiringandwaterinfuelsensor Checkcabling ifchargeWaterinFuelsensoris notworking checksensorandif necessaryreplaceit checkconnectioncableandifnecessaryrepair orreplaceit 465 228 97 4...

Page 121: ...trisationofinjector adjustmentcyl 3 ThresholdforerrordetectionisaninternalECU threshold Checkcorrectinjectoradjustmentvalue IMA 562 1 5 8 523898 13 Missingorwronginjectoradjustmentvalue programming IM...

Page 122: ...ectorcylinder1 wiringharness cablebreakorshortcircuit sen sordefective connectioncable damaged ThresholdforerrordetectionisaninternalECU threshold Checkwiringharness injectorsandifnecessary repair rep...

Page 123: ...old Checkwiringharnessandmeteringunitifnec essaryrepair replaceit 597 135 523615 4 Fuelmeteringunit thecurrentdrainmea suredbyECUisabovethetargetrange shortcircuittogroundlowside Thresholdforerrordete...

Page 124: ...3612 12 Internalhardwaremonitoring theCPUof theECUisresetandthecauseisloggedinter nally noitemwillbecreatedinerrormem ory Errorinthecheckoftheshut offpathtestofthe undervoltagedetection ECUinternal er...

Page 125: ...g timewithmaximumpermittedenergising time Diagnosticfaultchecktoreporttheerror duetoOver Run ThresholdforerrordetectionisaninternalECU threshold Iferrorisstillpresent exchangeECU 638 555 523612 12 Err...

Page 126: ...e shortcircuittobatteryorcablebreak checkbatteryandwiring Checkcabling Ifsensornotworking checksen sorandifnecessaryreplaceit checkconnectioncableandifnecessaryrepair orreplaceit 733 224 100 4 Oilpres...

Page 127: ...isoutofthetarget range TheSensorVoltageisabovetheThreshold Checkcabling ifchargeairpressure tempera turesensorisnotworking checksensor andifnecessaryreplaceit checkconnection cableandifnecessaryrepair...

Page 128: ...laceit 825 253 523009 9 Thepressurereliefvalve PRV hasreached thenumberofallowedactivations Railpressurehasexceededthetriggerthresh oldofthepressurelimitingvalve Replacepressurereliefvalve PRV andrese...

Page 129: ...einrailcalcu latedbyECUisbelowthetargetrangewhich isdependantontheenginespeed Pressuregovernordeviationexceedsthelimit ingvaluebasedontheenginespeed ThresholdforerrordetectionisaninternalECU threshold...

Page 130: ...suredbyECUisoutofthetargetrange Checkcabling checkrailpressuresensorandif necessaryreplaceit checkconnectioncableandifnecessaryrepair orreplaceit Checkcabling checkrailpressuresensorandif necessaryrep...

Page 131: ...l Thesignalexceedstheapplicatablethreshold signalrangeviolation Ifthesignalisbelowtheapplicatablethreshold APP_uRawSRCHiHTLIS_C thesignal rangeviolationisreset afterthehealingdebouncing IncasewhentheC...

Page 132: ...movable changeECU 947 282 1080 13 Internalhardwaremonitoring theECU detectsadeviationofthetargetrangeofthe powersupplyvoltageofsensoroutput2 SuspectedcomponentsEDC17cv52 PinK16 secondfootpedal PinA20...

Page 133: ...edbyECUisabovethetar getrange ShortcutLowSide Outputtoground ThresholdforerrordetectionisaninternalECU threshold Checkcablingandstartrelayandifnecessary replaceit checkconnectioncableofterminal50andif...

Page 134: ...sensorrawsignalAir_uRawTCACDs volt age isbelowAir_SRCTCACDs uMin_C CheckCAC sensorandifnecessaryreplaceit checkconnectioncableandif necessaryrepairorreplaceit 996 233 105 0 Chargeairtemperaturedownstr...

Page 135: ...ordetection deviationfrom setpoint 7 TroubleshootingwithSERDIA2010UseCase EGRDiagnostic 1022 5 9 4 5763 6 ActuatorerrorEGR Valve signalrangecheck high measuredcurrentbyECUisovertarget Shortcircuittoba...

Page 136: ...sitionupstreamDOC not upstreamSCRordownstreamDOC CheckTupstreamDOCsensor CheckotherT sensorswithinEAT system Exh_tOxiCatDs UCatUsT_tFlt_mpshow plausiblevalues Noerrorsonthem 1039 683 4765 0 Theexhaust...

Page 137: ...eraturesensor thevoltageofsensormeasuredbyECUisout ofthetargetrange VoltageoftemperaturesensorupstreamSCR catalyst minimumlimit Shortcircuittoground Checksensor Checkwiring ReplaceUCatUsT sensor 1075...

Page 138: ...tcuttogroundorbrokenwiring broken heatingelementinpressureline ThresholdforerrordetectionisaninternalECU threshold Checkwiring Checkheatingelement 1098 676 523718 5 Ureaheaterrelay thecurrentdrainmea...

Page 139: ...Uisabovethetargetrange Shortcuttobattery Ifthiserrordetectedduringtheheatingphaseis aresulterror KWP1089 Brokenwiring Ureatankheatingvalvedefect ThresholdforerrordetectionisaninternalECU threshold Che...

Page 140: ...essuresensor the currentdrainmeasuredbyECUisabovethe targetrange Shortcuttobattery Brokenwiring Pressuresensorinureasupplymoduledefect Checkwiring Checkpressuresensorinureasupplymodule 1128 665 523632...

Page 141: ...nvT_t About 40 C IfyesErrorcouldbeplausible CheckureatanktemperatureSCR_tSensUTnkT CheckwiringofanalogDEFT Levelsensor CheckanalogDEFT Levelsensor 1137 6 6 9 4365 2 SignalerrorincaseofUreatanktemperat...

Page 142: ...se 1226 594 5763 3 ActuatorEGR valve shortcuttobatteryis detected Short Circuittobatteryoncomponentwiring ThresholdforerrordetectionisaninternalECU threshold Checkwiring component ECU CheckrepairwithS...

Page 143: ...togroundoncylinder bank0 Short Circuittogroundoncomponentwiring Checkwiring component ECU Note affectedinjectorhastobeevaluated accordingtofiringorder 1340 566 2798 4 Injectortest Shortcuttogroundoncy...

Page 144: ...2 Lowfuelpressure thelowfuelpressurecal culatedbyECUisunderneaththetarget range theECUactivatesasystemreaction Fuelpressurebelowwarningthreshold ThresholdforerrordetectionisaninternalECU threshold Ch...

Page 145: ...mounting Ifwaterinside replacesen sor Checkmountingpositionofsensorandjudgeit regardingcondensewaterformation agglomeration Checkwiringharness Exchangesensor 1537 255 524078 9 LambdavalueofNOx Sensord...

Page 146: ...heckLambdavaluesofNOx sensorupstream SCRcatalystatatidleconditions ComRxSCR_rCanLamUs_mp Threshold ComparetoComRxSCR_rCanLamDs_mp Must bealmostidentical CheckCANBusofNOx sensorupstreamSCRcat alyst Che...

Page 147: ...1 SCRHtr_rUHtrMeasRatio_mp Threshold 2 Short Circuittobatteryonwiringtocomponent Checkwiring component 1559 869 524063 4 Connectionbetweenheatingvalve Y31 on thecontrolunitPinA 92and LoadsideSCRheater...

Page 148: ...ken ExchangeSCR Cat alyst 1566 892 524065 1 Therelativpressurevalueoftheexhaustgas fromtheureacatupstreamsensorisless thananapplicableminimumpressure threshold sensedpresureupstreamSCRcatalyst physi c...

Page 149: ...leminimum heatertemperaturethresholdofthesupply module ThetemperatureisreadoutviathePWMsig naloftheureapump Thatisonlypossiblein statusinitoftheSCR systemshortafterigni tionwasswitchedon Whenthatstate...

Page 150: ...aldefectatthefloatgauge Checklevelsensorandfloatgauge 1594 129 1761 1 TheDEFtanklevelsensordetectsavalue lowerthantheminimumallowedthreshold Suspectedcomponents UreaQualitySensordefect mechanicaldefec...

Page 151: ...pressuresensor Atignitiononand SCRsystemstate 0 Initcheck SCR_pAbsAdapUPmpPshallbeidenticalto EnvP_p Fulfilled Sensorokay Checkrevertingvalve see DFC_SCRCoRevVlvBlk Checkpumpfilter dirtinside Suspecte...

Page 152: ...sage PGN65348 Themessageisnotreceived ThresholdforerrordetectionisaninternalECU threshold CheckCANBUSEATControlReceiveMessage PGN65348 CM1ModuleCustomerRecieveMessage 1683 9 4 5 524121 9 Timeouterroro...

Page 153: ...ratureabovethresh old overheatingofEGRactuator LetEGRactuatorcooldown checkheataccu mulationduringworstcaseoperation 1763 415 2791 0 Internalactuatortemperatureisabove threshold OverheatingofEGRactuat...

Page 154: ...Status_mp 1 Thiserrorshowsup ifnoproperureapresure couldbebuildupwithintheSCRsystem state FillLines SCRCo_stStatus_mp 1 3casescanleadtotheerror CaseA increasingpressureisdetectedwithin 15sthecheckhasp...

Page 155: ...tails Erroratdynamicplausibilitycheck temperaturedifferenceofsensedtempera tureupstreamSCRcatalystandambient temperature asdynamicplausibilitylimit dynamiccheckisblockedifstaticplausibility checkisalr...

Page 156: ...ensordefect Supplymoduletemperaturesensordefect ProblematSupplymoduleunit broken exchangesupplymodule 1868 894 524067 2 absolutediferenceofsensedtemperatureof supplymoduletemperatureandambient tempera...

Page 157: ...eand atcorrectpositions CheckthepositionofthesensorupstreamSCR whichmightbephysicallymountedin thewrongposition Ifcoldstartconditioncanbemadesure engine wasoffforatleast8h compare valuesofEnvT_t EngDa...

Page 158: ...eachrequiredtem peraturelevel Checkengineairpath IntakeTrottle EGR Valve andturbochargerokay Anyleakageinengineairintakesytemor exhaustgassystem Checktemperaturesensorswithinexhaustsys tem upstreamDOC...

Page 159: ...fference 10Kafter25min stand stillmainphase 590 Cdownstream DOCarenotreached exchangeDOC Verybigdifference 100Kafter25minstand stillmainphase 590 Cdownstream DOCexceeded checkinjectionsystemof engine...

Page 160: ...tanktemperature fillinggradeandDEF qualityanditisalsoanCANsensor no PIN Wrongdiagnosticoftheshortcircuitslogic insidethetemperaturesensoroftheUQS CANCommunicationcorrupted Checkthewiringtothesuctionu...

Page 161: ...orcrystallisation DoestheNOx Sensorsworkproperly Compare ComRxSCR_rNOxUsto ComRxSCR_rNOxDs when ComRxSCR_stNOxRdyUs 1 ComRxSCR_stNOxRdyDs 1 Warmengine andEAT system SCRT_tCatAvrgExhGs_mp 250 C SCR_stS...

Page 162: ...s DEFqualitysensor DEF CheckDEFqualityand orDEFqualitysensor 1908 277 3519 13 TemperatureatUQSoutofrangethespeci fiedthresholds invalidqualityofthetem perature SuspectedComponents Tankheater DEFsensor...

Page 163: ...aining sensor or switch In addition for a failure of either jib transport length switch jib length will be determined by the remaining switch This system is used to control the following systems Beyon...

Page 164: ...sult in reduced function speeds BCS warning light illumination and restriction of functions The platform alarm will sound and the BCS light will flash with attempts to operate restricted functions The...

Page 165: ...racking function ality can be turned off using the manual position of the boom control select switch Slow Down System When the main boom approaches the edges of the working envelope all functions exce...

Page 166: ...All functions will default to creep speed if in platform mode and the boom is out of the transport position To reset the fault the emergency stop switch should be recy cled Boom Control Select The bo...

Page 167: ...ground module loses CAN communication with both the Jib Control Module and the Platform module in the case of a sev ered boom cable for example This mode allows the boom to be lifted down and telesco...

Page 168: ...bled to recover the boom After the boom is brought down it will be trapped into transport Reset or turning it off is achieved by escaping out of the service mode by cycling power to the machine or re...

Page 169: ...SECTION 4 BOOM PLATFORM 3121619 4 7 Figure 4 1 Boom Hydraulic System...

Page 170: ...pin Lower the lift cylinder down until it rests on the boom rest 7 Use an overhead crane or similar lifting device to sup port the rear of the boom 8 Remove the boom pivot pin 9 Carefully lift the bo...

Page 171: ...m Sec tion 5 is the fly NOTE During Assembly Super Lube lubricant JLG p n 3020042 is to be moderately applied to all four inner surfaces of both ends of each boom section to a minimum depth of three t...

Page 172: ...with JLG threadlocking com pound P N 0100011 and secure the wear pads with the bolts and washers Torque the bolts to 40 5 ft lbs 55 Nm 4 Install the section 5 retract ropes to into the holes in the si...

Page 173: ...SECTION 4 BOOM PLATFORM 3121619 4 11 Figure 4 2 Boom Assembly Sheet 1 of 9...

Page 174: ...SECTION 4 BOOM PLATFORM 4 12 3121619 Figure 4 3 Boom Assembly Sheet 2 of 9...

Page 175: ...SECTION 4 BOOM PLATFORM 3121619 4 13 Figure 4 4 Boom Assembly Sheet 3 of 9...

Page 176: ...SECTION 4 BOOM PLATFORM 4 14 3121619 Figure 4 5 Boom Assembly Sheet 4 of 9...

Page 177: ...SECTION 4 BOOM PLATFORM 3121619 4 15 Figure 4 6 Boom Assembly Sheet 5 of 9...

Page 178: ...SECTION 4 BOOM PLATFORM 4 16 3121619 Figure 4 7 Boom Assembly Sheet 6 of 9...

Page 179: ...SECTION 4 BOOM PLATFORM 3121619 4 17 Figure 4 8 Boom Assembly Sheet 7 of 9...

Page 180: ...SECTION 4 BOOM PLATFORM 4 18 3121619 Figure 4 9 Boom Assembly Sheet 8 of 9...

Page 181: ...SECTION 4 BOOM PLATFORM 3121619 4 19 Figure 4 10 Boom Assembly Sheet 9 of 9...

Page 182: ...SECTION 4 BOOM PLATFORM 4 20 3121619 Figure 4 11 Locations for Threadlocker Application Sheet 1 of 5...

Page 183: ...SECTION 4 BOOM PLATFORM 3121619 4 21 Figure 4 12 Locations for Threadlocker Application Sheet 2 of 5...

Page 184: ...SECTION 4 BOOM PLATFORM 4 22 3121619 Figure 4 13 Locations for Threadlocker Application Sheet 3 of 5...

Page 185: ...SECTION 4 BOOM PLATFORM 3121619 4 23 Figure 4 14 Locations for Threadlocker Application Sheet 4 of 5...

Page 186: ...SECTION 4 BOOM PLATFORM 4 24 3121619 Figure 4 15 Locations for Threadlocker Application Sheet 5 of 5...

Page 187: ...SECTION 4 BOOM PLATFORM 3121619 4 25 Figure 4 16 Boom Assembly Torque Values Sheet 1 of 4...

Page 188: ...SECTION 4 BOOM PLATFORM 4 26 3121619 Figure 4 17 Boom Assembly Torque Values Sheet 2 of 4...

Page 189: ...SECTION 4 BOOM PLATFORM 3121619 4 27 Figure 4 18 Boom Assembly Torque Values Sheet 3 of 4...

Page 190: ...SECTION 4 BOOM PLATFORM 4 28 3121619 Figure 4 19 Boom Assembly Torque Values Sheet 4 of 4...

Page 191: ...ds and shims to section 4 Coat the retaining bolts with JLG threadlocking com pound P N 0100011 and secure the wear pads with the bolts and washers Torque the bolts to 28 ft lbs 38 Nm 13 Install the f...

Page 192: ...ave retaining bolts to 178 ft lbs 241 Nm Torque the sheave plate retainer block bolts to 40 5 ft lbs 55 Nm 22 Install the section 4 extend ropes to section 4 NOTE Boom section 3 weighs approximately 2...

Page 193: ...ts with JLG Threadlocker P N 0100011 and install the section 5 retract ropes to section 3 using the nuts keeper plates bolts and washers 27 Coat the bolts with JLG Threadlocker P N 0100011 and install...

Page 194: ...with JLG Threadlocker P N 0100011 Install the rope retaining blocks to the front of section 3 using washers bolts and nuts 31 Coat the bolts with JLG Threadlocker P N 0100011 Install the front side we...

Page 195: ...r Lube lubricant JLG p n 3020042 to all 4 sides of the boom approximately 3 to 4 feet on both ends Apply Super Lube to section 3 on the end that will go into section 2 only Apply super lube to all out...

Page 196: ...r wear pads after they are installed Slide sections 2 3 4 and 5 as an assembly into section 1 using proper lifting procedures NOTE Position the deflectors so the surface is 3 4 mm from the section 2 b...

Page 197: ...ng the telescope cyl inder barrel trunnion blocks to boom section 2 and remove the trunnion blocks 4 Remove the bolts securing the adjustment mount and disconnect the adjustment mount from boom sectio...

Page 198: ...e bottom wear pad s on Section 5 boom as specified on the boom assembly drawing 4 Install the top wear pad s on Section 5 boom and shim as required to obtain the total dimension 0 to1 16 under the cor...

Page 199: ...ness for machines that are used in excessively dirty environments 1 JLG recommends the use of the JLG Hostile Environment Package if available to keep the internal portions of a boom cleaner and to he...

Page 200: ...and cables until they are resting against the flat bars on the outside radius of the power track Force additional hydraulic hose slack into the power track by pushing the hoses from the Location E Ti...

Page 201: ...SECTION 4 BOOM PLATFORM 3121619 4 39 Figure 4 20 Hose Adjustment...

Page 202: ...SECTION 4 BOOM PLATFORM 4 40 3121619 Figure 4 21 Section 3 Boom Cables...

Page 203: ...SECTION 4 BOOM PLATFORM 3121619 4 41 Figure 4 22 Section 4 Boom Cables...

Page 204: ...SECTION 4 BOOM PLATFORM 4 42 3121619 Figure 4 23 Section 5 Boom Cables...

Page 205: ...SECTION 4 BOOM PLATFORM 3121619 4 43 Figure 4 24 Jib Hydraulics Sheet 1 of 7...

Page 206: ...V1 T V2 JIB STOW ROTATOR P L2 L1 T2 R1 R2 S1 S2 T1 FRONT VIEW OF PLATF ORM CONT ROL VALVE JIB LOC K CYLINDER V1 V2 JIB LEVEL CYLINDER V1 V2 JIB LIF T CYLINDER V1 V2 JIB TELESCOPE CYLIND ER V1 V2 PLAT...

Page 207: ...SECTION 4 BOOM PLATFORM 3121619 4 45 PLATFORM LEVEL CYLINDER PL ATFOR M VALVE JIB LOCK C YL INDER JIB CONTR OL VALVE JIB TELE CYLIND ER PORT BLOCK 10011 57243 C Figure 4 26 Jib Hydraulics Sheet 3 of 7...

Page 208: ...SECTION 4 BOOM PLATFORM 4 46 3121619 PLATFORM VALVE JIB LOCK CYLINDER JIB CONTROL VALVE Figure 4 27 Jib Hydraulics Sheet 4 of 7...

Page 209: ...SECTION 4 BOOM PLATFORM 3121619 4 47 PLATFORM VALVE 10 0115 7243 C Figure 4 28 Jib Hydraulics Sheet 5 of 7...

Page 210: ...CTION 4 BOOM PLATFORM 4 48 3121619 0 75 AIR LINE 0 815 GEN CABLE 0 7 CONTROL CABLE 0 75 AIR LINE 0 81 5 GEN C ABLE 25 POWER CABLE 2 5 POWER CABL E 1001 1572 43 C Figure 4 29 Jib Hydraulics Sheet 6 of...

Page 211: ...319 195 271 313 382 423 324 362 382 300 MAINTAIN H OSE LOOP AT THIS DIMENSION 1600 PULLED LENGTH OF H OSES STRETCH H OSE OUT AN D MEASURE IN A STRAIGHT LINE NOTE AL L DIMEN SIONS IN MM 379 389 459 401...

Page 212: ...the hydrau lic hoses that run from the boom to the jib control valve It may be necessary to disconnect additional lines to gain access to certain fittings Cap or plug all openings 5 Unbolt the valve f...

Page 213: ...in place with the keeper pin and bolt Torque the bolt to 165 ft lbs 224 Nm 5 Place the mounting bracket on the jib valve and bolt the jib valve to the fly boom section 6 Install the wiring harnesses a...

Page 214: ...N 0100019 HOSE CLAMP RUBBER PAD RUBBER PAD BOLT KEEPER PIN TORQUE 120 FT LBS 163 Nm BOLT KEEPER PIN BOLT KEEPER PIN SCREW COVER BOLT KEEPER PIN TORQUE 60 FT LBS 82 Nm TORQUE 25 FT LBS 34 Nm PLATFORM L...

Page 215: ...adlocker PN 0100011 JLGThreadlocker PN 0100019 BOLT BOLT BOLT SHIMS JIB PIVOT JIB LIFT CYLINDER JIB ROTATE ACTUATOR TORQUE 190 FT LBS 260 Nm TORQUE 340 FT LBS 460 Nm BOLT KEEPER PIN TORQUE 120 FT LBS...

Page 216: ...ESS FIT JIB ROTATOR BEARING HOUSING JIB PIVOT BEARING HOUSING JIB PIVOT BEARING HOUSING SECTION A A ALIGN CUTOUT IN CAP LOCK PIN CYLINDER CAP AS SHOWN Loctite RC 609Threadlocker TORQUE 180 FT LBS 245...

Page 217: ...Threadlocker ORIENT PORT ON LOCK CYLAS SHOWN JIB PIVOT BEARING BEARING BEARING PIVOT PAD MOUNT JIB ROTATOR BOTTOM PLATE TORQUE BOLTS TO 20 FT LBS BOLT SHIMS WEAR PADS JIB ROTATE ACTUATOR GUIDE BLOCK B...

Page 218: ...between the wear pad and pivot pad mount 3 Add shims as required to fill the gap between the wear pad and the edge of the side plate of the jib rotator 4 Shim until the distance between the jib and t...

Page 219: ...vement NOTE Delayed movement of the fly boom indicates loose wire ropes 12 Year or 7000 Hour Replacement 1 Mandatory wire rope and sheave replacement Additional inspection required if a Machine is exp...

Page 220: ...4 followed by section 5 Use the Boom Telescope function to position the boom sec tions Using the wire rope adjustment nuts to position the boom sections will cause damage to the wire rope adjust ers 1...

Page 221: ...SECTION 4 BOOM PLATFORM 3121619 4 59 Figure 4 37 Initial Exposed Thread Length for Wire Rope Adjustment...

Page 222: ...e equal to what the section needs to move to be within tolerance for example if the section must move 0 5 inches to fall within the dimension shown tighten the nut so it moves 0 5 inches further from...

Page 223: ...ion 4 Repositioning BOOM SECTION 4 REPOSITIONING 1 If Boom Section 4 falls within the dimension and toler ance shown in Figure 4 36 with the boom fully retracted proceed to Boom Section 5 Repositionin...

Page 224: ...exposed end of the adjustment stud e Retract the boom assembly such that the platform moves 2 to 3 feet 0 6m 0 9m from the previous extended position in step c f Tighten the Section 4 Extend Adjustmen...

Page 225: ...the Section 5 Retract Adjustment Nuts shown below moving them a distance equal to what the section needs to move to be within toler ance E g If the section must move to fall within the dimension show...

Page 226: ...ions and tolerances shown in Figure 4 36 If the boom sections have been properly positioned but there is not enough adjustment travel remaining on a wire rope to achieve proper torque the service life...

Page 227: ...the two ropes until both maintain the required torque 10 Using tool JLG p n 1001162216 torque Section 4 Extend Adjustment Nuts to 17 ft lb 23 Newton meters alternating between the two ropes until both...

Page 228: ...t Function Exercise the boom telescope function When wire ropes are properly torqued all traveling sections will move simultane ously when extending and retracting Re Assembly 1 Install nylon collar l...

Page 229: ...esponsibility of the operator to take immediate action To avoid damaging the proximity switch install and adjust after assembling the switch block compression spring and torquing the wire ropes Adjust...

Page 230: ...SECTION 4 BOOM PLATFORM 4 68 3121619 1 Powertrack 2 Powertrack 3 Clamp Plate 4 Rubber Pad 5 Powertrack 6 Clamp Plate 7 Rubber Pad Figure 4 40 Powertrack Installation Sheet 1 of 4...

Page 231: ...SECTION 4 BOOM PLATFORM 3121619 4 69 1 Clamp Plate 2 Rubber Pad 3 Clamp Plate 4 Rubber Pad 5 Clamp Plate 6 Rubber Pad Figure 4 41 Powertrack Installation Sheet 2 of 4...

Page 232: ...pport 5 Track Support Cover 6 Spacer Tube 7 Power Track Support 8 Track Support Cover 9 Power Track Support 10 Track Support Cover 11 Support Bracket 12 Support Bracket 13 Support Bracket 14 Hose Cove...

Page 233: ...ush Tube Pad 3 Push Tube Pad 4 Upper Push Tube Assembly 5 Adjusting Shims 6 Mounting Plate 7 Adjusting Shims 8 Lower Push Tube Assembly 9 Adjusting Shims 10 Mounting Plate 11 Adjusting Shims 12 Suppor...

Page 234: ...SECTION 4 BOOM PLATFORM 4 72 3121619 Figure 4 44 Powertrack Shimming Instructions...

Page 235: ...SECTION 4 BOOM PLATFORM 3121619 4 73 Figure 4 45 Powertrack Locations for Threadlocker Application and Torque Sheet 1 of 4...

Page 236: ...SECTION 4 BOOM PLATFORM 4 74 3121619 Figure 4 46 Powertrack Locations for Threadlocker Application and Torque Sheet 2 of 4...

Page 237: ...SECTION 4 BOOM PLATFORM 3121619 4 75 Figure 4 47 Powertrack Locations for Threadlocker Application and Torque Sheet 3 of 4...

Page 238: ...SECTION 4 BOOM PLATFORM 4 76 3121619 Figure 4 48 Powertrack Locations for Threadlocker Application and Torque Sheet 4 of 4...

Page 239: ...SECTION 4 BOOM PLATFORM 3121619 4 77 Figure 4 49 Powertrack Hose Installation Sheet 1 of 4...

Page 240: ...SECTION 4 BOOM PLATFORM 4 78 3121619 Figure 4 50 Powertrack Hose Installation Sheet 2 of 4...

Page 241: ...SECTION 4 BOOM PLATFORM 3121619 4 79 Figure 4 51 Powertrack Hose Installation Sheet 3 of 4...

Page 242: ...SECTION 4 BOOM PLATFORM 4 80 3121619 Figure 4 52 Powertrack Hose Installation Sheet 4 of 4...

Page 243: ...ntenance 1 Place the powertrack on a workbench 2 Remove the screws from the bars on one side of the powertrack on the first link 3 Remove the screws from the flat bar on the other side of the powertra...

Page 244: ...1619 5 Slide the poly roller off of the round bar 6 Hold the round bar to remove the other screw 7 Slide the flat bar out 8 Remove the snap ring from one side of the bracket 9 Remove the snap ring fro...

Page 245: ...and slide the bracket side up and over the extrusion on the link 11 Repeat the previous step on the other side 12 Slide the bracket off of the powertrack Two Piece Bracket Maintenance 1 Loosen the scr...

Page 246: ...snap rings and pins 6 Remove the screws from the bar Remove the snap ring and pin 7 Slide the link out Snap Rings and Screws WHEN PERFORMING MAINTENANCE ON THE POWERTRACK MAKE SURE TO DISCARD AND REP...

Page 247: ...p ring is shown below A snap ring that is not seated is shown below A seated and closed snap ring is shown below 10 24 x 0 812 button torx socket head with blue locking patch Tighten to 45 50 in lbs 5...

Page 248: ...N 4 BOOM PLATFORM 4 86 3121619 C D E A B C D E Torqueto40ft lbs 55Nm Loctite 242 Torqueto586ft lbs 795Nm Checktorqueevery150hoursofoperation Torqueto85ft lbs 116Nm Figure 4 53 Platform Support Torque...

Page 249: ...FORE RETURNING TO SERVICE REFER TO THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTIFICATION THE ANNUAL INSPECTION AND...

Page 250: ...belleville washers washer retain ing nut and jam nuts Orient the hardware as shown below and with the belleville washers so the gap is pres ent at the outside diameter of the washers install the nuts...

Page 251: ...ION 4 BOOM PLATFORM 3121619 4 89 I 8 7 1 2 3 4 6 9 5 Figure 4 55 Bolt On External Fall Arrest System 1 BellevilleWasher 2 Washer 3 HexNut 4 JamNut 5 LHBracket 6 AttachmentRing 7 Cable 8 RHBracket 9 De...

Page 252: ...SECTION 4 BOOM PLATFORM 4 90 3121619 NOTES...

Page 253: ...prior to assembly Cup and Brush The following is needed to correctly oil the o ring in this man ner A small container for hydraulic oil Small paint brush 1 Hold the fitting in one hand while using the...

Page 254: ...d drip from the bottom of the fitting This should signify an even coating of oil on the fitting 3 O ring Boss type fittings will require more pressure in able to immerse more of the fitting into the s...

Page 255: ...nnections JIC 37 flare per SAE J514 SAE 45 flare per SAE J512 ORFS o ring face seal per SAE J1453 MBTL metric flareless bite type fitting pressure rating L medium per ISO 8434 DIN 2353 MBTS metric fla...

Page 256: ...will no longer thread onto the mating part when tightened by hand or fin gers Finger Tight is relative to user strength and will have some variance The average torque applied by this method is 3 ft l...

Page 257: ...owever care should be taken not to introduce sealant into the system d Avoid applying sealant to the area of the threads where the sealant will be forced into the system This is generally the first tw...

Page 258: ...ber of turns per Table 5 1 NPTF Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 5 1 NPTF Pipe Thread are applicable for the following material...

Page 259: ...fitting the number of turns per Table 5 2 BSPT Pipe Thread See FFWR and TFFT Methods for TFFT procedure requirements NOTE TFFT values provided in Table 5 2 BSPT Pipe Thread are applicable for the fol...

Page 260: ...D THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE 3 Torque assembly to value listed in Table Table 5 3 37 Flare JIC Thread Steel or Table 5 4 37 Flare JIC Thread Aluminum...

Page 261: ...11 60 0 50 12 70 14 15 15 19 20 21 1 to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 22 23 24 30 31 33 1 to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 42 44 46 57 60 63 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0 87 22 20...

Page 262: ...1 2 20 0 46 11 60 0 50 12 70 9 10 10 12 13 14 1 to1 1 2 6 9 16 18 0 51 13 00 0 56 14 30 14 15 16 19 20 21 1 to1 1 2 8 3 4 16 0 69 17 60 0 75 19 10 27 29 30 37 39 41 1 1 2to1 3 4 10 7 8 14 0 81 20 50 0...

Page 263: ...ICATION OR SEALANT IS REQUIRED THE LUBRICATION WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE Torque fitting to value listed in Table 5 5 45 Flare SAE Steel and Table 5 6 45 Flare SAE A...

Page 264: ...25 00 1 06 27 00 84 88 92 114 119 125 Aand Bthreaddimensionsforreferenceonly SeeFFWRandTFFTMethodsforFFWRprocedurerequirements Table 5 6 45 Flare SAE Aluminum Brass TYPE FITTING IDENTIFICATION Torque...

Page 265: ...ig uration of the connection ALUMINUM BRASS FITTINGS OR ALUMINUM BRASS MATING COMPONENTS indicate either the following material configu rations STEEL fittings with ALUMINUM or BRASS mating compo nents...

Page 266: ...3 4 6 11 16 16 0 63 15 90 0 69 17 50 20 21 22 27 28 30 1 4to1 2 1 2to3 4 8 13 16 16 0 75 19 10 0 81 20 60 26 28 29 35 38 39 1 4to1 2 1 2to3 4 10 1 14 0 94 23 80 1 00 25 40 39 41 43 53 56 58 1 4to1 2 1...

Page 267: ...are If necessary replace fitting or tube 2 Lubricate thread and cone of fitting body or hardened pre assembly tool as well as the progressive ring and nut threads 3 Slip nut and progressive ring over...

Page 268: ...1 5to1 75 22 M30x2 27 90 30 00 7 50 22 20 1 5to1 75 28 M36x2 33 90 36 00 7 50 28 20 1 5to1 75 35 M45x2 42 90 45 00 10 50 35 30 1 5to1 75 42 M52x2 49 90 52 00 11 00 42 30 1 5to1 75 TYPE Tube O D Thread...

Page 269: ...splatter splits burrs or other foreign material If necessary replace fitting or adapter 2 Remove the locknut from the bulkhead assembly 3 Insert the bulkhead side of the fitting into the panel or bulk...

Page 270: ...5 142 149 183 193 202 14 15 16 12 170 179 187 230 243 254 16 17 16 12 200 210 220 271 285 298 20 111 16 12 245 258 270 332 350 366 24 2 12 270 284 297 366 385 403 TYPE Dash Size Thread Size Torque Ft...

Page 271: ...39 47 50 53 15 M22x1 5 44 47 50 60 64 68 18 M26x1 5 70 75 80 95 102 108 22 M30x2 115 120 125 156 163 169 28 M36x2 150 157 164 203 213 222 35 M45x2 155 162 169 210 220 229 42 M52x2 220 230 240 298 312...

Page 272: ...fer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 12 thru Table 5 17 while using the Double Wrench Method a The table headings identify the...

Page 273: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HEX TYPE PLUGS STUD ENDS with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thr...

Page 274: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION STUD ENDS with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Size A Torque...

Page 275: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with 37 JIC or L series DIN MBTL opposite end MATERIAL Dash Size Thread...

Page 276: ...87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION ADJUSTABLE STUD END with ORFS or S series DIN MBTS opposite end MATERIAL Dash Size Thread Siz...

Page 277: ...1 87 47 60 305 321 336 415 435 456 32 21 2 12 2 50 63 50 375 394 413 510 534 560 TYPE FITTING IDENTIFICATION HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque UNF in mm Min Nom Max Min Nom Max...

Page 278: ...1 33 30 20 15 8 12 1 63 41 30 24 17 8 12 1 87 47 60 32 21 2 12 2 50 63 50 TYPE FITTING IDENTIFICATION ZERO LEAK GOLD HOLLOW HEX PLUGS MATERIAL Dash Size Thread Size A Torque UNF in mm Min Nom Max Min...

Page 279: ...ings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 18 Table 5 19 Table 5 20 Table 5 21 Table 5 22 or Table 5 23 while using the Doubl...

Page 280: ...3 65 69 72 103 108 113 140 146 153 M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209 M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374 M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550...

Page 281: ...25 132 137 66 70 73 90 95 99 M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198 M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341 M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495...

Page 282: ...66 70 73 90 95 99 M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149 M33x2 28 266 280 293 360 380 397 166 175 183 225 237 248 M42x2 35 398 418 438 540 567 594 266 280 293...

Page 283: ...5 69 72 125 132 138 170 179 187 M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297 M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450 M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594 M48...

Page 284: ...37 M22x1 5 18 100 105 110 135 142 149 100 105 110 135 142 149 M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198 M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342 M42x2 35 332 349 365 450...

Page 285: ...110 115 121 92 97 101 125 132 137 59 62 65 80 84 88 M22x1 5 18 89 94 98 120 127 133 100 105 110 135 142 149 M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 M33x2 28 266 280 293 360 380 397 M...

Page 286: ...read the fitting by hand until contact 5 For Adjustable fittings refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 24 while using the Dou...

Page 287: ...10x1 6 11 12 12 15 16 16 15 16 17 20 22 23 M12x1 5 8 18 19 20 25 26 27 26 28 29 35 38 39 M14x1 5 10 26 28 29 35 38 39 33 35 36 45 47 49 M16x1 5 12 30 32 33 40 43 45 41 43 45 55 58 61 M18x1 5 15 33 35...

Page 288: ...2 22 48 51 53 65 69 72 81 86 90 110 117 122 M30x2 62 65 68 84 88 92 114 120 125 155 163 169 M33x2 25 78 82 86 106 111 117 150 157 164 203 213 222 M38x2 88 93 97 119 126 132 153 161 168 207 218 228 M42...

Page 289: ...ngs refer to Adjustable Stud End Assembly for proper assembly 6 Torque the fitting or nut to value listed in Table 5 25 Table 5 26 Table 5 27 Table 5 28 Table 5 29 or Table 5 30 while using the Double...

Page 290: ...95 99 133 140 146 180 190 198 G1A 28 111 117 122 150 159 165 243 255 267 330 346 362 G1 1 4A 35 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 42 214 225 235 290 305 319 465 489 512 630 663...

Page 291: ...140 146 180 190 198 133 140 146 180 190 198 G1A 28 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 35 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 42 398 418 438 540 567 594 398 41...

Page 292: ...7 230 243 254 103 108 113 140 146 153 G1A 28 236 248 260 320 336 353 148 156 163 200 212 221 G1 1 4A 35 398 418 438 540 567 594 295 313 5 332 400 425 450 G1 1 2A 42 516 542 568 700 735 770 332 349 365...

Page 293: ...199 209 219 270 283 297 G1A 25 111 117 122 150 159 165 251 264 276 340 358 374 G1 1 4A 30 177 186 195 240 252 264 398 418 438 540 567 594 G1 1 2A 38 214 225 235 290 305 319 516 542 568 700 735 770 MA...

Page 294: ...A 20 133 140 146 180 190 198 133 140 146 180 190 198 G1A 25 229 241 252 310 327 342 229 241 252 310 327 342 G1 1 4A 30 332 349 365 450 473 495 332 349 365 450 473 495 G1 1 2A 38 398 418 438 540 567 59...

Page 295: ...73 90 95 99 89 94 98 120 127 133 G3 4A 20 92 97 101 125 132 137 170 179 187 230 243 254 G1A 25 236 248 260 320 336 353 G1 1 4A 30 398 418 438 540 567 594 G1 1 2A 38 516 542 568 700 735 770 MATERIAL B...

Page 296: ...lits scratches dirt foreign matter or burrs 2 See Figure for O ring installation instructions 3 Pre lubricate the O ring with Hydraulic Oil 4 Position flange and clamp halves 5 Place lock washers on b...

Page 297: ...110 116 111 116 122 150 158 165 40 2 50 64 3 50 88 90 1 2 13 77 81 85 105 110 116 111 116 122 150 158 165 48 3 00 76 4 19 106 43 5 8 11 155 163 170 210 221 231 218 228 239 295 310 325 56 3 50 89 4 75...

Page 298: ...01 68 71 75 92 97 101 40 2 50 64 3 50 88 90 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 48 3 00 76 4 19 106 43 M12x1 75 68 71 75 92 97 101 68 71 75 92 97 101 56 3 50 89 4 75 120 65 M16x2 155 163 17...

Page 299: ...up wrench If two wrenches are not used inadvertent component rotation may occur which absorbs torque and causes improper joint load and leads to leaks For hose connections the layline printed on the...

Page 300: ...connection has been properly tightened mark a straight line across the connecting parts not covering the dots to indicate the connection has been properly tightened Adjustable Stud End Assembly For Ad...

Page 301: ...cks If any are found replace O ring 2 Ensure proper O ring to be installed Many O rings look the same but are of different material different hard ness or are slightly different diameters or widths 3...

Page 302: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 50 3121619 Figure 5 15 Turntable Hydraulic System...

Page 303: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 51 Figure 5 16 Hydraulic Hose Installation Sheet 1 of 8...

Page 304: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 52 3121619 Figure 5 17 Hydraulic Hose Installation Sheet 2 of 8...

Page 305: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 53 Figure 5 18 Hydraulic Hose Installation Sheet 3 of 8...

Page 306: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 54 3121619 Figure 5 19 Hydraulic Hose Installation Sheet 4 of 8...

Page 307: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 55 Figure 5 20 Hydraulic Hose Installation Sheet 5 of 8...

Page 308: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 56 3121619 Figure 5 21 Hydraulic Hose Installation Sheet 6 of 8...

Page 309: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 57 Figure 5 22 Hydraulic Hose Installation Sheet 7 of 8...

Page 310: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 58 3121619 Figure 5 23 Hydraulic Hose Installation Sheet 8 of 8...

Page 311: ...er barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking compound 5 Mark cylinder head and barrel with center punch marks for...

Page 312: ...ing 2 Barrel 3 CounterbalanceValve 4 Capscrew 5 WasherRing 6 WiperSeal 7 Seal 8 CylinderHead 9 BackupRing 10 O Ring 11 WearRing 12 Spacer 13 BackupRing 14 O Ring 15 Piston 16 LockRing 17 Seal 18 Taper...

Page 313: ...reads as necessary 4 Inspect inner surface of cylinder barrel tube for scoring or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect threaded portion of barrel f...

Page 314: ...film of hydraulic oil to all components before assembly 1 Install backup ring and o ring in outside diameter grooves of cylinder head 3 Install rod seal wiper ring and wear rings in cylinder head as...

Page 315: ...aces between the capscrews b Tap each space once this means the tapered bush ing is tapped 3 times as there are 3 spaces between the capscrews 13 Retorque the capscrews evenly and progressively in rot...

Page 316: ...m cylinder port block Discard O rings 4 Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking compound 5 Mark...

Page 317: ...Torque to 50 55 ft lb 67 75 Nm Torque to 30 ft lb 41 Nm 1 Bushing 2 Barrel 3 CounterbalanceValve 4 Capscrew 5 WasherRing 6 WiperSeal 7 RodSeal 8 CylinderHead 9 WearRing 10 BackupRing 11 O Ring 12 Spa...

Page 318: ...SE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 12 Remove and discard backup ring 13 O ring 14 and backup ring 13 from inside grooves of p...

Page 319: ...aded portion of head for damage Dress threads as necessary 11 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 12 Inspect cylinder head outside...

Page 320: ...Do not damage or dislodge wiper and rod seals Push cylinder head to rod end 4 Install spacer 12 on rod 21 5 Install backup ring 13 O ring 14 and backup ring 13 in inside grooves of piston 15 6 Instal...

Page 321: ...as there are 3 spaces between the capscrews 13 Re torque capscrews evenly and progressively in rota tion to 30 ft lb 41 Nm INSERTING ROD OFF CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES USE...

Page 322: ...ove cartridge type counterbalance valve and fit tings from cylinder port block Discard O rings 5 If neccessary remove eight capscrews 8 and retainer cap 7 Remove O Ring plug 12 and setscrew 11 Remove...

Page 323: ...e to 9 ft lb 12 Nm Torque to 200 ft lb 271 Nm 1 Screw 2 CounterbalanceValve 3 Barrel 4 Bushing 5 SpacerSleeve 6 LengthSensor 7 RetainerCap 8 Capscrew 9 RetainingRing 10 SensorMagnet 11 Setscrew 12 Plu...

Page 324: ...iston 13 Screw piston counter clockwise by hand and remove from cylinder rod REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY DO NOT USE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATI...

Page 325: ...damage ovality and tapering Replace as necessary 13 Inspect cylinder length sensor components for damage Replace as needed 14 Inspect rod and barrel bearings for signs of excessive wear or damage Rep...

Page 326: ...P N 0100011 or equivalent to tapered bushing capscrews and assemble the tapered bushing loosely into the piston Insert capscrews through the drilled holes in the bushing and into the tapped holes in...

Page 327: ...and support rod NOTE Apply locking primer and JLG Threadlocker01 P N 0100011 to cylinder head threads 16 Insert piston end into barrel cylinder Do not damage or dislodge piston loading O ring and seal...

Page 328: ...nd fittings from cylinder port block Discard O rings 4 Place cylinder barrel in a suitable holding fixture Tap around outside of cylinder head retainer with a suitable hammer to break thread locking c...

Page 329: ...e 3 CounterbalanceValve 4 CounterbalanceValve 5 Barrel 6 Capscrew 7 WasherRing 8 WearRing 9 BackupRing 10 O Ring 11 WiperSeal 12 RodSeal 13 Head 14 BackupRing 15 O Ring 16 BackupRing 17 Piston 18 Lock...

Page 330: ...AND INSPECTION 1 Clean parts thoroughly with approved cleaning solvent 2 Inspect cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replac...

Page 331: ...ubrication is not required with nickel plated pins and bearings Install pin in composite bushing dry d Press bushing into barrel or rod bushing with cor rect size arbor 14 Inspect port block fittings...

Page 332: ...ushing loosely into the piston and insert capscrews through the drilled holes in the bushing and into the tapped holes in the piston 7 Tighten the capscrews evenly and progressively in rota tion to 60...

Page 333: ...amp barrel 5 securely and support rod 24 Insert piston 17 end in barrel Do not damage or dislodge pis ton O rings or seal rings 13 Continue pushing rod in barrel until cylinder head 13 can be inserted...

Page 334: ...rce Adequately support cylinder rod if applicable 3 Place cylinder barrel in a suitable holding fixture 4 Remove cartridge type counterbalance valve and fit tings from cylinder port block Discard O ri...

Page 335: ...ue to 9 ft lb 12 Nm 1 Barrel 2 CounterbalanceValve 3 Bushing 4 Setscrew 5 O RingPlug 6 Spacer 7 SensorMagnet 8 InternalRetainingRing 9 CylinderLengthSensor 10 RetainerCap 11 Capscrew 12 Bolt 13 Tapere...

Page 336: ...er clockwise by hand and remove from cylinder rod REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY DO NOT USE A KNIFE SHARP OBJECT OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROP...

Page 337: ...coring damage ovality and tapering Replace as necessary 13 Inspect cylinder length sensor components for damage Replace as needed 14 Inspect rod and barrel bearings for signs of excessive wear or dama...

Page 338: ...ll tapered bushing NOTE When installing the tapered bushing piston and mating end of rod must be free of oil 9 Apply JLG Threadlocker P N 0100011 to tapered bush ing bolts Assemble the tapered bushing...

Page 339: ...iston loading O ring and seal ring 14 Continue pushing rod into barrel until cylinder head gland can be inserted into barrel cylinder NOTE Apply JLG Threadlocker P N 0100011 or equivalent to capscrews...

Page 340: ...4 Mark cylinder head and barrel with a center punch for realignment Unscrew cylinder head with pin face span ner wrench PULLING ROD OFF CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES USE EXTRE...

Page 341: ...C INFORMATION HYDRAULIC SCHEMATICS 3121619 5 89 1 8 4 3 2 6 5 7 9 11 10 1001119313 1 Rod 2 Seal 3 WearRing 4 Barrel 5 O Ring 6 BackupRing 7 O Ring 8 Head 9 WearRing 10 Seal 11 RodWiper Figure 5 91 Jib...

Page 342: ...y and tapering Replace as necessary 11 Inspect oil ports for blockage or presence of dirt or other foreign material Repair as necessary ASSEMBLY NOTE Use proper cylinder seal kit for cylinder assembly...

Page 343: ...d 5 and barrel 2 5 Unscrew cylinder head with pin face spanner wrench PULLING ROD OFF CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES USE EXTREME CARE WHEN REMOVING CYLINDER ROD HEAD AND PISTON...

Page 344: ...AULIC SCHEMATICS 5 92 3121619 1001155986 1 Bushing 2 Barrel 3 WiperSeal 4 Seal 5 Head 6 O Ring 7 BackupRing 8 O Ring 9 Screw 10 WearRing 11 O Ring 12 Piston 13 Setscrew 14 WearRing 15 Seal 16 Bushing...

Page 345: ...s threads as necessary 11 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 12 Inspect cylinder head outside diameter for scoring damage ovality...

Page 346: ...fixture and support rod Insert piston end into barrel cylinder Do not dam age or dislodge piston O rings or seal rings 12 Apply ant seize compound to cylinder head threads 13 Continue pushing rod int...

Page 347: ...ght socket head screws 6 and two pad sup ports 7 from cylinder head 12 Reinstall one socket head screw finger tight 6 Remove three cartridge valves from valve block 7 Tap around outside of cylinder he...

Page 348: ...ft lb 27 Nm Torque to 25 30 ft lb 33 40 Nm Torque to 100 ft lb 135 Nm 1 ShuttleValve 2 CounterbalanceValve 3 Barrel 4 Bolt 5 Washer 6 WearPad 7 Capscrew 8 SupportPad 9 Washer 10 Nut 11 Wiper 12 Seal 1...

Page 349: ...ck inside diameter for tapering or ovality Replace if necessary 4 Inspect piston surface for damage scoring or distortion Dress piston surface or replace piston as necessary 5 Inspect threaded portion...

Page 350: ...eal 22 and two wear rings in outer grooves of piston 8 Using suitable protection clamp cylinder rod in a vise or similar holding fixture as close to piston as possible 9 Apply medium strength locking...

Page 351: ...0 ft lb 27 Nm following sequence shown in Figure 5 107 16 Install each wear pad 5 with two bolts 3 four washers 4 and two bolts 9 17 Install shuttle valve 1 with new O ring in valve block Torque to 20...

Page 352: ...ngs Remove four capscrews 1 and valve block from rod 7 Discard O rings 5 6 5 Mark cylinder head 23 and barrel 28 with center punch marks for later realignment Remove two cap screws 27 and bracket 26 6...

Page 353: ...CheckCartridge 4 CounterbalanceValve 5 O Ring 6 O Ring 7 Rod 8 Bolt 9 TaperedBushing 10 Piston 11 WearRing 12 Seal 13 BackupRing 14 WasherRing 15 Capscrew 16 Spacer 17 WearRing 18 O Ring 19 Back UpRi...

Page 354: ...OR SCREW DRIVER MAKE NOTE OF SEAL ORIENTATION BEFORE REMOVING FOR PROPER INSTALLATION 13 Remove and discard two backup rings 13 washer ring 14 two wear rings 11 and seal 12 from piston 10 14 Remove c...

Page 355: ...sary 10 Inspect seal and O ring grooves in head for burrs and sharp edges Dress applicable surfaces as necessary 11 Inspect cylinder head outside diameter for scoring damage ovality and tapering Repla...

Page 356: ...and mating end of rod must be free of oil when installing tapered bushing 10 Thread piston on rod until it aligns with spacer end and install tapered bushing 11 Apply JLG Threadlocker P N 0100011 to...

Page 357: ...nd support rod Insert piston end into barrel Do not damage or dislodge pis ton O ring and seal ring 18 Push rod in barrel until cylinder head can be inserted 19 Install cylinder head 23 in barrel 28 a...

Page 358: ...lbs 84 kg and the platform level cylinder weighs approximately 76 lbs 34 kg 2 Support the weight of the jib cylinder and remove the bolt and keeper pin that secure the cylinder barrel retaining pin R...

Page 359: ...ULIC SCHEMATICS 3121619 5 107 7 Using an allen wrench remove the bolts securing the retaining cap and remove the cap 8 Pull sensor out of the cylinder DO NOT use the wiring harness to pull the sensor...

Page 360: ...the sensor bore DO NOT tap on the wiring harness 2 Install the cap and secure in place with the retaining bolts 3 Apply lubricant JLG P N 3020039 to the setscrew and install the setscrew Torque the se...

Page 361: ...lect switch to the ground controls and start the engine 3 Locate the oil sampling valve on the front of the main control valve 4 Unscrew the knurled end which is attached to the chain 5 Place a drip p...

Page 362: ...AIN DUMP MP4 MP5 MAIN TELE OUT MAIN LIFT UP SWING RIGHT LIFT DOWN AUX LIFT PILOT SWING LEFT RELIEF LIFT UP RELIEF PORT 5 PORT 4 TELE OUT RELIEF PORT 8 PORT 7 M8 PRESSURE REDUCING VALVE REDUCED PRESSUR...

Page 363: ...19 5 111 MP CHASSIS ENABLE WARM UP TELE CNTL M7 LIFT CNTL M4 TELE OUT RELIEF SWING CNTL LIFT DOWN RELIEF MS2 M5 SWING RIGHT RELIEF MS3 LIFT DOWN AUX LIFT PILOT SWING LEFT MAIN LIFT DOWN MAIN TELE IN M...

Page 364: ...SCHEMATICS 5 112 3121619 Figure 5 126 Main Valve Torque Values Sheet 1 of 2 Item Ft Lbs Nm 1 60 70 81 95 2 25 30 34 40 5 3 40 49 54 66 4 2 2 3 3 4 5 30 35 40 5 47 6 122 133 165 180 7 3 7 5 2 5 7 8 28...

Page 365: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 113 Figure 5 127 Main Valve Torque Values Sheet 2 of 2...

Page 366: ...the main valve block 2 Remove the Deutsch connector from the lift down coil 3 Activate lift down The gauge should read 4000 psi 275 bar 4 To make an adjustment to this pressure go back to the engine c...

Page 367: ...or from lift down coil 3 Turn adjustment screws on the pressure reducing valve located at 3 o clock adjacent to port P4 and the relief valve located at 5 o clock adjacent to port P4 fully clock wise E...

Page 368: ...ten locknuts LIFT UP 1 Install a high pressure gauge at the M5 port of the main valve block 2 Plug and cap the hose on port 5 Activate lift up The gauge should read 3700 psi 255 bar 3 The adjustment c...

Page 369: ...ld read 2850 psi 196 bar The adjustment car tridge is located to the left of the M4 gauge port Turn clockwise to increase counterclockwise to decrease SWING 1 Install a high pressure gauge at port MS2...

Page 370: ...pres sure TELESCOPE OUT NOTE NEVER increase telescope out pressure to achieve desired telescope length 1 Install a high pressure gauge at the M8 port of the main valve bank 2 Plug the telescope out ho...

Page 371: ...port of the main valve block 2 Plug the telescope in hose either at the valve bank port 7 or at the inlet of the telescope cylinder V2 3 Activate telescope in The gauge should read 3300 psi 227 bar Th...

Page 372: ...AR 1 To extend the axles drive the machine back and forth until extended A machine that cannot be driven must be jacked up 2 On both the front and rear frame valve banks install a high pressure gauge...

Page 373: ...ear valves Each relief valve is located next to its own gauge port Turn clockwise to increase counterclockwise to decrease 4 Adjustments Made at the Platform Valve Bank PLATFORM LEVEL UP 1 Install a h...

Page 374: ...extend This is the bottom relief valve on the platform valve Turn CW to increase and CCW to decrease pressure 5 Adjustments Made at Jib Valve JIB LEVEL UP NOTE To check or adjust the jib level up pres...

Page 375: ...zer should read JIB SWING Press ENTER 8 Enter code 58237 and Press ENTER The screen should read SERVICE MODE JIB SWING AND JIB LEVEL 9 Press ENTER again The screen will read JIB LEVEL OVERRIDE OFF Use...

Page 376: ...r pressure is set and cycle machine power JIB LEVEL DOWN 1 Install high pressure gauge at MLA 2 Connect the analyzer to the ground control connector 3 Position the main boom on the boom rest and the j...

Page 377: ...is will activate the Jib Level Down function 11 When the cylinder is completely retracted the pressure should be 1500 psi 104bar CW increases and CCW decreases setting Jib level down adjustment is adj...

Page 378: ...erride to off after pressure is set and cycle machine power Operate the main boom to verify jib level is working properly JIB TELESCOPE OUT 1 Install high pressure gauge at MTB 2 Extend jib telescope...

Page 379: ...or cap port JB 3 Set pressure to 2800 psi 193bar Clockwise increases and Counterclockwise decreases setting Adjustment is on the boom side of MJB JIB LIFT DOWN 1 Install high pressure gauge at port MJ...

Page 380: ...Adjust the charge relief valve to obtain reading of 400psi 28bar The charge relief is located on the turntable side of the pump above M3 Clockwise increases pressure Counterclockwise decreases pressur...

Page 381: ...Swashplate Cylinder block Swashplate bearing Swashplate bearing Front shaft bearing Center shaf t bearings Rear shaft bearin g Figure 5 128 Piston Pump Cross Sectional View Table 5 33 Port information...

Page 382: ...1 1 5 16 12 System port B ISO 11926 1 1 5 16 12 Servo gauge port M4 ISO 11926 1 7 16 20 Charge inlet port E ISO 11926 1 1 5 16 12 Servo gauge port M5 ISO 11926 1 7 16 20 Case drain port L3 ISO 11926 1...

Page 383: ...ge port MB ISO 11926 1 9 16 18 Brake gage port X7 ISO 11926 1 9 16 18 Charge constr port M3 ISO 11926 1 9 16 18 Se rvo gauge port M4 ISO 11926 1 7 16 20 Servo gauge port M5 ISO 11926 1 7 16 20 Case dr...

Page 384: ...r for several seconds Do not to exceed the engine manufacturer s recommenda tion Wait 30 seconds and then crank the engine a sec ond time as stated above This operation helps remove air from the syste...

Page 385: ...ndseeifpumpcomesbacktoneutral IfYes controlneu tralimproperlyset Ifno balanceswashplate seeMechanical neutraladjustment Ifyoustillcannotsetneutral replacecon trol Table 5 36 System operating hot Item...

Page 386: ...ck HPRVs Inputtocontrol Inputtocontrolmoduleisoperatingimproperly Repairorreplacecontrol Optionalcontrolcutoffvalve Controlcutoffvalvecoilnotenergized EnsurechargepressuretocontrolviaportX7 If none co...

Page 387: ...ed Chargeandcontrolpressures Incorrectpressureswillaffectsystemperfor mance Measureandadjustchargeandcontrolpres sures Airinsystem Airinsystemwillproducesluggishsystem response Filltanktoproperlevel C...

Page 388: ...valve set tings refer to model code located on serial number plate These pressures assume 1800 min 1 rpm pump speed and a reservoir temperature of 50 C 120 F and are referenced to case pressure NOTE L...

Page 389: ...turn adjusting screw to reduce any pressure differential NOTE Adjustment of the EDC is very sensitive Be sure to hold the hex wrench steady while loosening the locknut Total adjustment is less than 12...

Page 390: ...for both the front and rear sections Alternate M4 M5 and MA MB to zero out forward and reverse directions of the front unit then move the gauges to M4 M5 of the rear unit and MC MD system gauge ports...

Page 391: ...ear servo gauge port M5 ISO 11926 1 7 16 20 System port MD ISO 11926 1 9 16 18 System gauge port MA ISO 11926 1 9 16 18 System gauge port MC ISO 11926 1 9 16 18 System gauge port MB ISO 11926 1 9 16 1...

Page 392: ...1 6 on the rear pump Remember that the rear pump is a mirror image of the front pump and therefore the locations of the servo gauge ports M4 M5 and the control sole noids C1 C2 are opposite 13 Remove...

Page 393: ...ed in the center of the con trol module when installing control REASSEMBLY NOTE Ensure you install dowel pins D300 in housing before installing control 1 Install a new gasket D150 2 If you removed scr...

Page 394: ...onnect electrical connections and test the pump for proper operation Shaft Seal and Bearing The front pump input shaft assembly is serviceable without disassembling the pump the rear shaft is not Orie...

Page 395: ...tion pump with front shaft pointing downward Attach securely to a proper work stand If an auxiliary pump is attached remove auxiliary pump before servicing charge pump REMOVAL 1 Remove screws K351 and...

Page 396: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 144 3121619 Figure 5 136 Charge Pump...

Page 397: ...g in the table Charge Check HPRV The high pressure relief and charge check valve assembly may be removed for cleaning and replacement of the O rings These valves are factory set and are not field adju...

Page 398: ...or a 1 in V10 2 wrench remove the charge pressure relief valve Discard the O rings V10A INSPECTION 1 Inspect the sealing surfaces of the pump and charge pressure relief valve for nicks or scratches r...

Page 399: ...wrench to remove the control cutoff valve G10 Remove and discard the O rings and backup rings G10A INSPECTION 1 Inspect the sealing surfaces of the pump and control cutoff valve for nicks or scratche...

Page 400: ...3Nm 9 5lbft E350 Servocylinderlockingscrew 10mmhex 14 5Nm 11lbft G10 Controlcutoffvalve 11 16inhex 45Nm 33lbft G10B Controlcutoffvalvecoilnut 24mmhex 9Nm 7lbft K007 Chargecheck HPRV 8mminternalhex 80N...

Page 401: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 3121619 5 149 Figure 5 141 Fastener and Plug Locations...

Page 402: ...6 Remove the bearing cup B010 bearing cone B020 and housing O ring K060 Discard the O ring 7 Tilt the housing on its side to allow fluid to drain 8 Remove the cylinder block kit while holding onto th...

Page 403: ...ly pry out the shaft seal K020 If you are unable to pull the shaft seal out try to push the seal out by going through the inside of the housing 21 Remove the 4 plugs C103 C104 C105 C106 and their O ri...

Page 404: ...n solvent and allow to air dry Blow out oil passages in the housing and endcap with com pressed air Conduct inspection in a clean area and keep all parts free from contamination Clean and dry parts ag...

Page 405: ...ar and replace if necessary Check the spool s outside diameter for scratches and or burrs Clean and coat all spools bores and seals with a light coating of hydraulic oil INPUT SHAFT Check to see that...

Page 406: ...s these may decrease pump flow Lap or replace if grooves or nicks are present Inspect the mating sur faces of the endcap and valve plate for any possible contami nation even a few thousandths of an in...

Page 407: ...a solvent and lubricate with hydraulic fluid NOTE Replace the bearing if the problem is not remedied by cleaning Inspect for uneven wear If abnormal wear is found replace the bearing kit Assembly 1 Co...

Page 408: ...ock 8 Install the pistons K050 to the slipper retainer K049 Install the piston retainer assembly into the cylinder block Ensure the concave surface of the retainer seats on the ball guide If you re re...

Page 409: ...he housing just far enough to clear the retaining ring groove Install seal with the cupped side toward the shaft bearing Do not damage the seal dur ing installation Using the appropriate snap ring pli...

Page 410: ...housing Install and tighten set screw C102 at 7 5 to 10 8 Nm 5 5 to 8 0 lbft Also install the plugs C105 C106 with new O rings Torque the plugs at 10 8 to 13 5 Nm 8 to 10 lbft NOTE PC and LS spools n...

Page 411: ...y bearings gears and body faces Do not touch or score them with metal tools or cutting edges MARKING THE PARTS Mark the parts before completely disassembling a pump The marks allow components to be re...

Page 412: ...onding screws on the rear flange 4 Remove front flange Place the pump on the table and slowly remove the front flange Be careful not to damage the shaft seal when removing the flange Avoid contact of...

Page 413: ...henever there are burrs evidence of extrusion or marks caused by overheating If the seals need to be replaced carefully remove them from the flange cover beginning with the backup ring and then the pr...

Page 414: ...he seals Have the entire seal kit available Lightly coat all seals with seal grease The grease is needed to adhere the seals to their grooves Do not install dry seals 2 Install shaft seal into front f...

Page 415: ...on backup ring Ensure that the seals are located in the grooves as shown 5 Prepare the body Clean the body Inspect the internal and mating surfaces Ensure the sur faces are free of burrs and scratches...

Page 416: ...and bottom of the gears Ensure these surfaces are free from burrs or scratches If scratches or burrs are found clean them with a flat stone and or very fine emery paper Rewash the gears after this ope...

Page 417: ...using as before dis assembly Ensure that the relative position of the gear mesh is maintained as before disassembly Misalign ment of the gear teeth may increase operating noise 10 Install the gear blo...

Page 418: ...may drop inside the pump during assem bly 13 Clean the mating surfaces Remove any excess lubrication and grease from the mat ing surfaces of the front flange and rear cover Ensure that these surfaces...

Page 419: ...by the shaft splines keyway during front flange assembly Install the flange onto the body then remove the pro tective sleeve Ensure that the seals remain seated in their grooves dur ing this operation...

Page 420: ...to flange pilot 19 Testing After pump has been disassembled and reassembled it is suggested that the pump be run in and tested on an appropriate test stand This is done to verify the volu metric effi...

Page 421: ...tem Description Action 1 Checkoillevelinreservoir Excessiveairwillcausecavitationsound Fillreservoirtoproperlevel 2 Checkinletlineforleaks Excessiveairwillcausecavitationsound Repairinletline 3 Checkp...

Page 422: ...he machine is accomplished by a flow divider combiner car tridge installed in the Traction Control Manifold There is a flow divider combiner for each side Each flow divider combiner also has a bleed o...

Page 423: ...cated on the Traction Manifold This disables the machine s ability to release the brakes Stroke the transmission pumps slightly less than 20 and check the setting of the high pressure cross port relie...

Page 424: ...BORE 5 5 IN ROD 4 5 IN STROKE 333 15 BORE 8 0 IN ROD 7 0 IN STROKE 84 9 B10 1000 43 PSI 3BAR BYPASS P1 P2 LS T3 T1 8 EXH MAIN DUMP 4000PSI 275 9BAR 500PSI 34 5BAR 2800PSI 193BAR 5A 4 5 7 9BAR 1 03BAR...

Page 425: ...T 2 P TO JIB VALVE SWING BRAKES B10 1000 43 PSI 3BAR BYPASS P4 2 2A 3 3A SWING SWING 2000PSI 138BAR 245 BAR 2000PSI 138BAR P T A B b a A B A B MS2 MS3 SWING DRIVES MP4 MP5 MAIN CONTROL VALVE SWING FLO...

Page 426: ...16 49 SQ IN STROKE 14 24 IN STEERING CYLINDERS BORE 4 75 IN 17 72 SQ IN ROD 1 75 IN 2 4 SQ IN ANNULAR 15 32 SQ IN STROKE 9 8 IN LEFT VALVE MS2 MS1 MS4 MS3 A 3 A 1 S 1 S 3 S 4 P T S 2 MA1 p t a b a p...

Page 427: ...1 V 2 V 1 SWIVEL PORT 2 RIGHT VALVE M A 2 P T M A 1 A 3 A 1 A 2 S 1 M S 1 M S 2 S 2 S 3 M S 3 M S 4 S 4 a p t b b p t a b p t a 2 0 0 0 p s i 2 6 0 0 p s i 2 0 0 0 p s i 2 6 0 0 p s i 2 5 0 0 p s i 2...

Page 428: ...VALVE PAGE 1 TO PORT T4 MAIN CONTROL VALVE PAGE 1 SWIVEL PORTS D MP 300 PSI 20 7 BAR TRACTION MANIFOLD BRAKE 2 SPEED A3 B3 A5 B1 D C A B 8 7 6 5 5 6 7 8 C1 F00A F00B CW M3 MB MC PORT 7 PORT 6 PORT 5 R...

Page 429: ...001149709 D A B C D 1 2 3 4 CW L3 FCOA FCOB C2 C1 M14 CHARGE PUMP 1 025 IN3 CHARGE PUMP FILTER B6 200 BYPASS 50PSI REAR DRIVE PUMP OIL COOLER OPTION PORT L3 OF THE PUMP TO THE INLET OF THE COOLER COOL...

Page 430: ...8 2 8 B A R 1 9 3 1 B A R V 1 JIB LIFT CYLINDER BORE 5 ROD 2 5 STROKE 25 15 V 2 JIB TELESCOPE CYLINDER BORE 2 5 ROD 1 5 STROKE 84 06 D C A B 8 7 6 5 5 6 7 8 V 1 V 2 P 1 P 2 T 1 T 2 T 3 M L A L A 1 5 0...

Page 431: ...V 1 T PLATFORM LEVEL CYLINDER BORE 3 55 ROD 1 5 STROKE 14 79 M L 2 0 2 G P M R 1 4 3 2 2 3 4 S 2 V 2 JIB LOCK CYLINDER BORE 2 5 ROD 1 75 STROKE 13 375 PLATFORM ROTATOR SPRING 3000 PSI P A G E 4 J I B...

Page 432: ...SECTION 5 BASIC HYDRAULIC INFORMATION HYDRAULIC SCHEMATICS 5 180 3121619 NOTES...

Page 433: ...ing func tions The main lift swing and drive are controlled by individual joy sticks with steering being controlled by a rocker switch built into the top the drive joystick To activate Drive Lift and...

Page 434: ...connected backwards 2 Power up the Control System by turning the lower key to the platform or ground position and pulling both emer gency stop buttons on Using the Analyzer With the machine power on a...

Page 435: ...TARTUP 2 1 indicates a power up When a top level menu is selected a new set of menu items may be offered for example DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed m...

Page 436: ...e above steps if the correct access level is not dis played or you can not adjust the personality settings Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1 and...

Page 437: ...l 1 which will permit you to change all machine personality settings There is a setting that JLG strongly recommends that you do not change This setting is so noted below ELEVATION CUTBACK CHANGING TH...

Page 438: ...e the splash screen will show for 3 sec onds and then launch the Diagnostics Screen The indicator lamp will light when there is an active DTC in the Fault Log The Diagnostic Screen will show active an...

Page 439: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 7 h Figure 6 5 Ground Control Console Display Gauge INDICATORLAMP ENGINEHOURS FUELLEVEL NAVIGATEFORWARDARROW NAVIGATIONBUTTONS NAVIGATEBACKARROW...

Page 440: ...LEVATED TILTED ELEV ELEVATION ENG ENGINE EXT EXTEND F FRONT FL FLOW FNT FRONT FOR FORWARD FWD FORWARD FSW FOOTSWITCH FUNC FUNCTION G GROUND GND GROUND GRN GREEN GM GROUNDMODULE H HOURS HW HARDWARE HWF...

Page 441: ...ER SPD SPEED STOW STOWED STOWD STOWED SW SWITCHorSOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ TORQUE TRN TRANSPORT T T TURNTABLE T TOWER TURNTBL TURNTABLE TWR TOWER U UPPERorUP V VOLT VER VERSION VLV...

Page 442: ...ault The items marked in BOLD bold text on this sheet represent a new board that has never been configured MODELNUMBER 1 0 1 2 NoModel 1500SJ 1850SJ 0 ENVELOPEHEIGHT 2 0 1 1500SJ 150 MAX 1850SJ 185 MA...

Page 443: ...degreesandaboveelevation alsocutsoutdrive 4DEGREES DRVCUT Reducesthemaximumspeedofallboomfunctionstocreepwhentiltedmore than4degreesandaboveelevation alsocutsoutdrive 3DEGREES DRVCUT Reducesthemaximum...

Page 444: ...SKYGUARD Skyguardonlyinstalled BOTH CUTOUT SofttouchandSkyguardinstalled 0 GENSET WELDER 14 0 1 2 NO Nogeneratorinstalled BELTDRIVE Beltdrivensetup HYDRAULICDRIVE Hydraulicdrivensetup 1 GENSETCUTOUT 1...

Page 445: ...oveelevation DRIVECUTE T Drivecutoutaboveelevationandtilted 0 Onlyvisibleundercertainmarketselections Certainmarketselectionswilllimitfunctioncutoutoptionsoralterdefaultsetting GROUNDALARM 19 0 1 2 3...

Page 446: ...ON 25 0 1 OFFFORCREEP 20FPSFORCREEP 0 LANGUAGE 26 0 1 2 3 4 5 6 7 8 9 10 ENGLISH SPANISH EUROPORTUGUESE BRAZILIANPORTUGUESE FRENCH GERMAN DUTCH ITALIAN SIMPLIFIEDCHINESE JAPANESE KOREAN 0 LANGUAGE 27...

Page 447: ...2 4WheelSteer 0 0 0 0 0 0 1 1 1 1 1 1 DriveType 0 0 0 0 0 0 1 1 1 1 1 1 SoftTouch Skyguard 0 0 0 0 0 0 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 GenSet Welder 0 0 0 0 0 0 1 1 1 1 1 1 2 2 2 2 2 2 GenSetCutou...

Page 448: ...10 10 10 10 10 PlatformCutout 0 0 0 0 0 0 1 1 1 1 1 1 TempCutout X 0 X 0 X X X 1 X 1 X X BOLDTEXTindicatesthedefaultsetting Plaintextindicatesanotheravailableselec tion ITALICTEXTindicatesthedefaultw...

Page 449: ...Displays adjustsmaximumreversedrivespeed 0to100 100 ELEV MAXXX Displays adjustsmaximumdrivespeed NOTE usedwhenelevationcutoutswitchesare limitingmaximumspeed 0to50 25 110 112 seeorientation CREEPMAXXX...

Page 450: ...1 MININXX Displays adjustsminimummaintelescopein speed SameasCreepspeed 0to65 15 MAXINXXX Displays adjustsmaximummaintelescopein speed 0to100 65 45 65 seeorientation MINOUTXX Displays adjustsminimumm...

Page 451: ...ximumjibdownspeed 0to100 76 65 100 JIBSWING ACCELX Xs Displays adjustsjibswingacceleration 0 1to5 0sec 1 5 DECELX Xs Displays adjustsjibswingdeceleration 0 1to3 0sec 0 5 MINLEFTXX Displays adjustsmini...

Page 452: ...ys adjustsfixedswingspeed 0to100 60 PLATFORMLVLXXX Displays adjustsfixedbasketlevelspeed 0to100 75 PLATFORMROTXXX Displays adjustsfixedbasketrotatespeed 0to100 75 MAINTELEXXX Displays adjustsfixedmain...

Page 453: ...horizontal 500 lb capacity selected DRIVE FORWARD Max high speed low torque setting drive 200 ft front wheels to front wheels Timed after machine has obtained maximum speed DRIVE REVERSE Max high spee...

Page 454: ...e stored into the ground module i e Personalities or Calibrations Interlocks Any device that sends an electrical input For an example a limit switch proximity switch etc Platform Level The GROUND MODU...

Page 455: ...Can Lo SN129 Load Pin MS158 1 MS15 8 2 MS158 3 A B C Shield GRN Can Lo YELCan High B A C B A C MS261 1 MS26 2 3 A B C Shi eld GRN C an Lo YEL Ca n Hig h 3 4 5 SN260 Jib Lift Cylinder Angle Sensor 1 2...

Page 456: ...MS999 3 TeeConnector under drive pumps MS999 2 Shield GRN Can Lo YEL Can High A B C MS1001 2 A B C MS1001 1 A B C 120 OHM MS1001 3 Deutz ECM J1 Connector 54 76 Tee Connector underDeutz ECM 1 2 3 G H...

Page 457: ...ion Instructions Calibration Procedure ReasonsforRe calibration SteeringCalibration Groundmodulereplacement Chassismodulereplacement Steersensorremovalorreplacement Persistentwheelmisalignment DriveCa...

Page 458: ...r See Figure 6 10 See Figure 6 11 See Figure 6 12 See Figure 6 14 or See Figure 6 15 or See Figure 6 16 or See Figure 6 17 NOTE The layout shown includes all possible analyzer screens Please note that...

Page 459: ...9 6 27 Figure 6 9 Analyzer Flow Chart Personalities Sheet 1 of 2 Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available de...

Page 460: ...121619 Figure 6 10 Analyzer Flow Chart Personalities Sheet 2 of 2 Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available d...

Page 461: ...3121619 6 29 Figure 6 11 Analyzer Flow Chart Machine Setup Software Version 7 X NOTE The layout shown includes all possible ana lyzer screens Please note that some screens may not be available dependi...

Page 462: ...6 30 3121619 Figure 6 12 Analyzer Flow Chart Calibrations Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available dependin...

Page 463: ...3121619 6 31 Figure 6 13 Analyzer Flow Chart Service Mode Software Version 7 X NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available dependin...

Page 464: ...SECTION 6 JLG CONTROL SYSTEM 6 32 3121619 Figure 6 14 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 1 of 4...

Page 465: ...19 6 33 Figure 6 15 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 2 of 4 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available de...

Page 466: ...121619 Figure 6 16 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 3 of 4 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available dep...

Page 467: ...19 6 35 Figure 6 17 Analyzer Flow Chart Diagnostics Software Version 7 X Sheet 4 of 4 NOTE The layout shown includes all possible analyzer screens Please note that some screens may not be available de...

Page 468: ...5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT 6 GROUND GROUND INPUT 7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT 8 TOWER TELESCOPE POWER DIGITAL OUTPUT 9 TELESCOPE FLOW CONTROL DIGITAL OUTPUT 10 LIFT PILO...

Page 469: ...GROUND INPUT 19 SPARE PIN GROUND INPUT 20 SPARE ANALOG INPUT 1 ANALOG INPUT 21 PUSH TO TEST DIGITAL INPUT 22 TOWER BOOM TRANSPORT ANGLE DIGITAL INPUT 23 GROUND CONTROL ENABLE DIGITAL INPUT 24 CAN LO...

Page 470: ...EVEL UP DIGITAL INPUT 18 BASKET ROTATE RIGHT DIGITAL INPUT 19 JIB UP DIGITAL INPUT 20 JIB RIGHT DIGITAL INPUT 21 TOWER DOWN DIGITAL INPUT 22 MAIN BOOM TRANSPORT ANGLE CLOSED DIGITAL INPUT 23 UPPER LIF...

Page 471: ...r Feed Thru to J1 2 Ground Front Axles Limit Switch Rear Axles Limit Switch Drive Orientation Switch Oscillating Axle Pres Sw Turntable Angle Sensor 1 Turntable Angle Sensor 2 Spare Analog Front Rear...

Page 472: ...8 Main Boom Ang 1 Gravity Digital Input 9 Main Boom Ang 2 Gravity Digital Input 10 Spare Analog Analog Input 11 Right Drive Pump Forward Digital Output 12 Right Drive Pump Reverse Digital Output Conn...

Page 473: ...ster Ground Connect Power Input 5 Master Ignition Connect Power Input 6 CANbus High Serial I O 7 CANbus Low Serial I O 8 CANbus Shield Serial I O 9 CANbus Terminator Serial I O 10 CANbus Terminator Se...

Page 474: ...SECTION 6 JLG CONTROL SYSTEM 6 42 3121619 Figure 6 24 Analyzer Connecting Points PLATFORMCONNECTION GROUNDCONTROLCONNECTION...

Page 475: ...ble with a load cell pin This pin is fixed to the Turntable so as to allow mea surement of the force exerted by the cylinder regardless of the cylinder orientation Sensor 2 Main Boom Angle Sensors 2 S...

Page 476: ...IN DESC SENSOR HARNESS PIN 1 POWER RED RED PIN 2 OUTPUT WHITE BLUE PIN 3 GROUND BLACK BLACK ANGLE SENSOR 2 LEFT PIN DESC SENSOR HARNESS PIN 1 POWER RED ORANGE PIN 2 OUTPUT WHITE YELLOW PIN 3 GROUND BL...

Page 477: ...al body with electrically opposing signals Sensor 5 Main Boom Transport Length Switch 1 See See Figure 6 27 This switch is used to indicate Main Boom retracted position for transport This is a mechani...

Page 478: ...LIMIT SWITCH WIRING TORQUE BOLT TO 55 NM SECTION E E LIMIT SWITCH ADJUSTMENT TOP OF SENSOR LIMIT SWITCH COVER LIMIT SWITCH LIMIT SWITCH CABLE T orque 25ft lbs 34 Nm BOLT WASHER THREADLOCKER P N 010001...

Page 479: ...the sensor arm 3 Install the sensor subassembly onto the boom 4 Connect the sensor wiring Sensor 7 Jib Lock Pin Proximity Sensor 1 This sensor is used to indicate the Jib Lock Pin is fully engaged Thi...

Page 480: ...L BETWEEN LINKAND ARM TORQUEUNTIL SNUG 5 NM MAX BOLT SPACER ANGLE SENSOR ANGLE SENSOR SENSOR MOUNT SENSOR LINK SENSOR COVER WASHER NUT SCREW NUT SCREW THREADLOCKER P N 0100011 BOLT WASHER THREADLOCKER...

Page 481: ...with elec trically opposing signals Sensor 9 Jib Lift Angle Sensor 1 This sensor s function is to measure the Jib angle relative to the Main Boom Pivot weldment A linear position sensor is located ins...

Page 482: ...posing signals ADJUSTMENT Adjust the Proximity Sensors so the front sensing face is flush to 0 75 mm below the surface of the mounting face Sensor 11 Platform Level Angle Sensor 1 This sensor is used...

Page 483: ...measures the tilted angle of the turntable relative to gravity It is mounted on a bracket on the left side of the turntable adjacent to the UGM and BLAM module It is a dual axis output sensor in a si...

Page 484: ...Platform Ground select switch to the Plat form position 2 Pull out the Emergency Stop switch at the Ground Con trol Station 3 Plug the analyzer into the connector at the base of the platform control...

Page 485: ...gain to activate 8 Follow the flow path in Figure 6 33 System Test Flow Chart Platform Tests Sheet 1 of 2 and Figure 6 34 Sys tem Test Flow Chart Platform Tests Sheet 2 of 2 and go through the compone...

Page 486: ...SECTION 6 JLG CONTROL SYSTEM 6 54 3121619 Figure 6 33 System Test Flow Chart Platform Tests Sheet 1 of 2...

Page 487: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 55 Figure 6 34 System Test Flow Chart Platform Tests Sheet 2 of 2...

Page 488: ...to reach SYSTEM TEST Hit Enter The analyzer will prompt you asking if you want to acti vate the system test hit Enter again to activate 6 Follow the flow path in Figure 6 35 System Test Flow Chart Gr...

Page 489: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 57 Figure 6 35 System Test Flow Chart Ground Station Tests...

Page 490: ...itsEEPROMstoredpersonalitysettingsatswitchon Checkand ifnecessarycorrect allpersonalitysettings OPENFSW Inplatformmode thefootswitchmustbeopenatthestartofthetest CLOSEFSW Inplatformmode thefootswitchm...

Page 491: ...witch wiring CHECKXXXXXXXJOY Thenamedjoystickappearstobefaulty Checkjoystick TESTINGLAMPS Indicatesthatthelampstestisbeginning Eachlampisenergizedinturn apromptasksforcon firmationthatthelampislit ENT...

Page 492: ...tsdisplayedduringtheoperatorinputtestbelowmessages CLOSEXXXXXXX Thenamedswitchshouldbeclosed OPENXXXXXXX Thenamedswitchshouldbeopened XXXXXXXXXXXXXXTOMAX Thenamedjoystickshouldbepushedtoitsfullextenti...

Page 493: ...m is clean Ensure the jib is horizontal Ensure the jib swing is centered if Jib swing is configured Ensure the platform is level Ensure the platform is not rotated Ensure the turntable is centered bet...

Page 494: ...otate func tions and display CAL POSITION 2 on the first line 6 The controller shall display LIFT UP TO STOP After the operator presses the ENTER key the controller shall dis play CAL POSITION 3 and S...

Page 495: ...is cycled While the boom is in this state the telescope functions will be allowed to extend or retract the boom 1 0 at a time This can be repeated until the length reading deviates from the expected w...

Page 496: ...e performed on an individual basis 1 Position the Platform Ground select switch to the Ground position 2 Plug the analyzer into the connector inside the Ground control box 3 Pull out the Emergency Sto...

Page 497: ...e the arrow keys to reach the JIB SENSORS The screen should read 9 Press ENTER The screen should read 10 Press ENTER The screen should read as shown below When it does activate boom lift until the con...

Page 498: ...ed jib sensor calibration The available sensor calibrations are JIB LIFT JIB LEVEL JIB SWING PLATFORM LEVEL 12 If the operator presses enter at the jib lift sensor calibra tion prompt the screen shown...

Page 499: ...SC will take the system back to the initial jib lift calibration display NOTE At this point the left or right arrow key may be used to skip to any of the other jib sensor calibrations 16 Hitting the E...

Page 500: ...s at the mechanical stop the operator must hit ENTER again The screen will show 19 When the system completes this step the next screen will show 20 Press ENTER The screen should read 21 Operate jib li...

Page 501: ...low The control system will jib level down and stop the jib leveling command 24 When the system completes the previous step the screen will read 25 Hitting the escape key ESC will take the system back...

Page 502: ...alibration The screen will show 27 Press Enter The screen shown below will be displayed At this point use the platform rotate right function switch to swing the jib right 28 When the jib reaches the m...

Page 503: ...o swing the jib left 31 When the jib is at the mechanical stop press ENTER The screen will show 32 At the finish of the jib swing lift calibration the jib lock pin will be locked by the control system...

Page 504: ...ER key at this point will continue the cali bration sequence The screen will show 36 Press Enter The screen shown below will be displayed At this point use the platform level up function switch to lev...

Page 505: ...trol system will stop the platform level and the screen will show 41 Pressing ENTER will take you back to the beginning and escape ESC will take you to the initial screen Calibrating the Jib Level Up...

Page 506: ...again 10 You will hear engine go to 1800 rpm 11 Using UP ARROW increase the value until you see the jib level movement 12 Hit ENTER again CAL COMPLETE message should appear 13 Engine should again retu...

Page 507: ...rt and the analyzer will display ENVLP VIOLATION 1 Using the analyzer enter access level 1 Unlock Boom can be found under the Calibrations menu 2 Once the operator selects the UNLOCK BOOM option the s...

Page 508: ...e in and out functionality will be restored The ana lyzer menu will display Engage Tele Out until the control system cuts it out The system will cut out at 60 0 After the machine reaches the set point...

Page 509: ...een will remain until the boom check has com pleted the check fails or the routine is interrupted by an attempted command If the check is interrupted the analyzer will display CHECK FAILED PRESS ENTER...

Page 510: ...menu will advance If the machine does not move or moves in the wrong direction the menu CHECK FAILED WRONG TELE DIR will be displayed and the test will end The WRONG TELE RESPONSE fault will still be...

Page 511: ...THE ANALYZER TO THE CONNECTION PORT IN THE PLAT FORM DO NOT CONDUCT ANY CRACKPOINT SETTINGS FROM THE PLATFORM NOTE Cycle the boom functions 8 to 10 times 5 seconds in each direction prior to setting...

Page 512: ...ENTER 5 Scroll to LEVEL UP CRKPT and press ENTER 6 Press ENTER to calibrate Platform Level Up crack point NOTE Have an assistant help verify that movement occurs 7 Using the analyzer press and hold th...

Page 513: ...o return to the calibrations menu 9 Scroll to LEVEL DOWN CRKPT and press ENTER 10 Press ENTER to calibrate Platform Level Down crackpoint NOTE Have an assistant help verify that movement occurs 11 Usi...

Page 514: ...C to exit calibra tions 14 Push in Power Emergency stop switch to save the cali bration changes Jib Level Up and Down Crackpoints NOTE To set crackpoints for the Jib Level Up and Down a JLG analyzer i...

Page 515: ...s ENTER 5 Scroll to JIB LVL UP CRKPT and press ENTER 6 Press ENTER to calibrate Jib Level Up crackpoint NOTE Have an assistant help verify that movement occurs 7 Using the analyzer press and hold the...

Page 516: ...return to the calibrations menu 9 Scroll to JIB LVL DN CRKPT and press ENTER 10 Press ENTER to calibrate Jib Level Down crack point NOTE Have an assistant help verify that movement occurs 11 Using th...

Page 517: ...exit calibrations 14 Push in Power Emergency Stop switch to save the calibration changes Main Lift Up and Down Crackpoints NOTE To set crackpoints for the Main Lift Up and Down a JLG analyzer is need...

Page 518: ...SECTION 6 JLG CONTROL SYSTEM 6 86 3121619 4 Scroll to MENU CALIBRATIONS and press ENTER 5 Scroll to MAIN LIFT CRKPT and press ENTER 6 Press ENTER 7 Press ENTER to calibrate Main Lift Up crackpoint...

Page 519: ...ement occurs 8 At the Ground Controls press and hold the Lift Up toggle switch until the function starts moving then press ENTER Release the Lift Up toggle switch 9 This completes the Main Lift Up cra...

Page 520: ...occurs 11 At the Ground Controls press and hold the Lift Down toggle switch until the function starts moving then press ENTER Release the Lift Down toggle switch 12 This completes the Main Lift Down...

Page 521: ...dle speed lift should not be moving then press ENTER Release the Lift Up tog gle switch 15 At the Ground Controls press and hold the Lift Down toggle switch until the function starts moving then press...

Page 522: ...NG THE MAIN TELESCOPE OUT AND IN CRACKPOINT PROCEDURE NOTE To set crackpoints for the Main Telescope Out and In a JLG analyzer is needed Have an assistant on hand to help ver ify that movement occurs...

Page 523: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 91 5 Scroll to MAIN TELE CRKPT and press ENTER 6 Press ENTER 7 Press ENTER to calibrate Main Telescope Out crackpoint...

Page 524: ...s 8 At the Ground Controls press and hold the Telescope Out toggle switch until the func tion starts moving then press ENTER Release the Telescope Out toggle switch 9 This completes the Main Telescope...

Page 525: ...ls press and hold the Telescope In toggle switch until the func tion starts moving then press ENTER Release the Telescope In toggle switch 12 The crackpoint setting procedure for Main Telescope Out an...

Page 526: ...ent is permitted by a Removing the excess platform load until actual plat form load is less than Rated Load b Operation of the overriding emergency system Auxiliary Power Unit c By an authorized perso...

Page 527: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 95 Figure 6 36 LSS Installation Sheet 1 of 4...

Page 528: ...SECTION 6 JLG CONTROL SYSTEM 6 96 3121619 Figure 6 37 LSS Installation Sheet 2 of 4...

Page 529: ...SECTION 6 JLG CONTROL SYSTEM 3121619 6 97 Figure 6 38 LSS Installation Sheet 3 of 4...

Page 530: ...SECTION 6 JLG CONTROL SYSTEM 6 98 3121619 Figure 6 39 LSS Installation Sheet 4 of 4...

Page 531: ...7 Diagnostic Menu Descriptions Diagnostics Menu Displayed on Analyzer 1st Line Parameter Displayed on Analyzer 2nd Line Parameter Value Displayed on Analyzer 2nd Line Description PLATFORMLOAD STATE OK...

Page 532: ...roximately level for calibra tion Level the platform from ground control if neces sary to within 5 4 To access the Calibration Menu use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top...

Page 533: ...Accessory Weights Use the up and down analyzer keys to enter the accessory weight s in lbs When all the accessory weights are entered press ENTER The screen will read LOAD SENSI NG accessory xxxlbs T...

Page 534: ...than 575 lbs 261 kg If the platform weight is not within the allowed range the calibration attempt will be unsuccessful and the Analyzer will show the following 10 Press ENTER The control system will...

Page 535: ...y Reduc tions and Table 6 10 Pipe Rack Capacity Reductions Table 6 9 SkyGlazier Capacity Reductions Capacity PLATFORM OVRLD PLATFORM OVRLD RESTRICT 500lb 227kg 400lb 181kg n a 550lb 250kg 400lb 181kg...

Page 536: ...SECTION 6 JLG CONTROL SYSTEM 6 104 3121619 14 Press ENTER If calibration is successful the screen will read...

Page 537: ...load Visual Warning at the Ground Controls should flash and the Audible Warning at Platform and Ground should sound for 5 seconds On 2 seconds Off However the controls should remain functional when us...

Page 538: ...theywillleaveconductiveresidue Moistureshouldbeallowedtoevaporateor acceleratedwithaheat gun uselowheatandbecarefullytonotmeltconnectormaterials Moistureintrusionintothemoldedportionof theconnector ca...

Page 539: ...console NOTE If performing the procedure from the platform console the Emergency Stop switch on the ground console must also be pulled out 4 Pull out the Emergency Stop switch 5 The analyzer screen sh...

Page 540: ...CONTROL SYSTEM 6 108 3121619 12 Press Enter The screen will read 13 Press Enter The JLG Control System will reset an active 873 DTC and the MSSO System will be reset Press Escape to return to the CALI...

Page 541: ...ate normally Cycling the EMS will clear the fault and allow the operator to operate the machine as a new level set point is taken VALVE DRIVER ERRORS There are three possible level valve driver errors...

Page 542: ...e Lift swing drive and telescope will continue to operate In each of the cases above it will be necessary to re cycle the EMS to clear the fault Operable functions shall be in the creep mode except wh...

Page 543: ...EINITIALIZED 0 0 21 RUNNINGATCREEP PLATFORMSTOWED 0 0 30 FUELLEVELLOW ENGINESHUTDOWN 0 0 31 APUACTIVE 0 0 35 JIBUNLOCKEDOUTOFTRANSPORT HYDRAULICSSUSPENDED 0 0 37 SWINGENVELOPEENCROACHED HYDRAULICSSUSP...

Page 544: ...TIONCHECKPRESSURESENSOR LOW 2 3 23131 MODELCHANGED HYDRAULICSSUSPENDED CYCLEEMS 2 5 259 GENERATORMOTIONCUTOUTACTIVE 2 5 2513 BOOMPREVENTED DRIVESELECTED 2 5 2514 DRIVEPREVENTED BOOMSELECTED 2 5 2515 D...

Page 545: ...VEPUMP SHORTTOGROUND 3 3 3320 RIGHTREVERSEDRIVEPUMP OPENCIRCUIT 3 3 3321 RIGHTREVERSEDRIVEPUMP SHORTTOBATTERY 3 3 3322 LEFTFORWARDDRIVEPUMP SHORTTOGROUND 3 3 3324 LEFTFORWARDDRIVEPUMP OPENCIRCUIT 3 3...

Page 546: ...3 3 3377 HEADTAILLIGHT SHORTTOBATTERY 3 3 3378 HOURMETER SHORTTOGROUND 3 3 3379 HOURMETER OPENCIRCUIT 3 3 3380 HOURMETER SHORTTOBATTERY 3 3 3381 PLATFORMLEVELUPOVERRIDEVALVE SHORTTOGROUND 3 3 3385 PL...

Page 547: ...3134 PLATFORMCONTROLVALVE SHORTTOBATTERY 3 3 33135 MAINLIFTAPUVALVE SHORTTOGROUND 3 3 33136 MAINLIFTAPUVALVE OPENCIRCUIT 3 3 33137 MAINLIFTAPUVALVE SHORTTOBATTERY 3 3 33138 MAINLIFTPILOT PRESSUREFAILU...

Page 548: ...TERY 3 3 33169 RESTRICTEDTOTRANSPORT AXLELOCKOUTVALVE SHORTTOBATTERY OROPENCIRCUIT 3 3 33173 RESTRICTEDTOTRANSPORT BRAKE SHORTTOBATTERYOROPENCIR CUIT 3 3 33174 JIBROTATELEFTVALVE OPENCIRCUIT 3 3 33175...

Page 549: ...ACKREADINGTOOLOW 3 3 33414 SWING CURRENTFEEDBACKREADINGLOST 3 3 33418 JIBLIFTUPOVERRIDEVALVE SHORTTOGROUND 3 3 33429 JIBLIFTUPOVERRIDEVALVE OPENCIRCUIT 3 3 33430 JIBLIFTUPOVERRIDEVALVE SHORTTOBATTERY...

Page 550: ...LEVELUPVALVE SHORTTOGROUND 3 4 343 PLATFORMLEVELUPVALVE SHORTTOBATTERYOROPENCIRCUIT 3 4 344 PLATFORMLEVELDOWNVALVE SHORTTOGROUND 3 4 347 PLATFORMLEVELDOWNVALVE SHORTTOBATTERYOROPENCIRCUIT 3 4 348 JIBL...

Page 551: ...EADINGLOST 3 6 3612 REARAXLEEXTENDVALVE OPENCIRCUIT 3 6 3613 FRONTAXLEVALVE CURRENTFEEDBACKREADINGTOOLOW 3 6 3514 REARAXLERETRACTVALVE OPENCIRCUIT 3 6 3615 REARAXLEVALVE CURRENTFEEDBACKREADINGTOOLOW 3...

Page 552: ...AGE 4 5 455 TOWERTELESCOPEPVGVALVE HIGHVOLTAGE 4 5 456 MAINLIFTPVGVALVE LOWVOLTAGE 4 5 457 TOWERLIFTPVGVALVE LOWVOLTAGE 4 5 458 TOWERTELESCOPEPVGVALVE LOWVOLTAGE 4 5 459 MAINLIFTPVGVALVE STUCKNEUTRAL...

Page 553: ...TOWERTELESCOPEPVGVALVE PARAMETERSINCORRECT 4 5 4536 MAINLIFTPVGVALVE LOCATIONIMPROPER 4 5 4537 TOWERLIFTPVGVALVE LOCATIONIMPROPER 4 5 4538 TOWERTELESCOPEPVGVALVE LOCATIONIMPROPER 4 5 4539 MAINLIFTPVG...

Page 554: ...SSISTILTSENSORDISAGREEMENT 8 1 815 CHASSISTILTREADINGDISAGREEMENT 8 1 8111 LSSCELL 1ERROR 8 2 821 LSSCELL 2ERROR 8 2 822 LSSCELL 3ERROR 8 2 823 LSSCELL 4ERROR 8 2 824 LSSHASNOTBEENCALIBRATED 8 2 825 R...

Page 555: ...NOTCALIBRATED 8 3 8329 JIBSWINGSENSORS DISAGREEMENT 8 3 8330 JIBLOCKPINSENSOR DISAGREEMENT 8 3 8331 JIBTRANSPORTSENSOR 1 DISAGREEMENT 8 3 8332 JIBTRANSPORTSENSOR 2 DISAGREEMENT 8 3 8333 JIBLIFTANGLESE...

Page 556: ...WERLENGTHSENSOR 2 OUTOFRANGEHIGH 8 4 8426 TOWERLENGTHSENSOR 2 OUTOFRANGELOW 8 4 8427 TOWERANGLESENSOR 1 INVALIDANGLE 8 4 8428 TOWERANGLESENSOR 2 INVALIDANGLE 8 4 8429 TOWERANGLESENSOR 1 INVALIDMODEL 8...

Page 557: ...MULTIPLEFAILURESACTIVE 8 4 8487 MAINCYLINDERANGLESENSOR 2 OUTOFRANGELOW 8 4 8492 MAINCYLINDERANGLESENSOR 2 OUTOFRANGEHIGH 8 4 8493 MAINCYLINDERANGLESENSORS DISAGREEMENT 8 4 8494 TURNTABLESENSOR 1 FREQ...

Page 558: ...864 AXLERETRACTVALVE SHORTTOGROUND 8 6 865 RIGHTFRONTSTEERRIGHTVALVE SHORTTOBATTERYOROPENCIRCUIT 8 6 866 RIGHTFRONTSTEERRIGHTVALVE SHORTTOGROUND 8 6 867 RIGHTFRONTSTEERLEFTVALVE SHORTTOBATTERYOROPENC...

Page 559: ...ENGINESHUTDOWN AXLELOCKOUTVALVEFAULT 8 6 8651 RIGHTFRONTSTEERRIGHTVALVE OPENCIRCUIT 8 6 8670 RIGHTFRONTSTEERRIGHTVALVE SHORTTOBATTERY 8 6 8671 RIGHTFRONTSTEERLEFTVALVE OPENCIRCUIT 8 6 8672 RIGHTFRONT...

Page 560: ...DSENSORREFVOLTAGEOUTOFRANGE 9 9 9919 PLATFORMSENSORREFVOLTAGEOUTOFRANGE 9 9 9920 GROUNDMODULEFAILURE HIGHSIDEDRIVERCUTOUTFAULTY 9 9 9921 PLATFORMMODULEFAILURE HWFSCODE1 9 9 9922 GROUNDMODULEFAILURE HW...

Page 561: ...SUMINCORRECT 9 9 9945 LOADPINNOTCALIBRATED 9 9 9975 LSSCORRUPTEEPROM 9 9 9977 FUNCTIONSLOCKEDOUT GROUNDMODULESOFTWAREVERSION IMPROPER 9 9 9979 JIBCONTROLMODULE HIGHRESOLUTIONA2DFAILURE 9 9 99155 JIBCO...

Page 562: ...treportedduringpower up 0015 0 15 LOADSENSORREADINGUNDERWEIGHT LSShasbeencalibratedandtheUGMhas determinedthattheloadsensingsystem readingislessthan 50lbsfor2seconds If theloadsensingsystemdeterminest...

Page 563: ...lt ageis 8 1V Resistivejoysticks Ifthereferencevoltageis 7 7Vthenthereference voltageisoutoftoleranceofashorttobatteryhas occurred 2220 2 2 L SJOY CENTERTAPBAD TheL SJoystickcentertapvolt ageis 3 08Vo...

Page 564: ...CTED Drivingisnotpossiblewhilethevehicle aboveelevationANDisconfiguredtopre ventdrivewhileaboveelevation 2516 2 5 DRIVEPREVENTED ABOVEELEVATION DrivingisnotpossiblewhileBoomfunc tionsareselectedANDisc...

Page 565: ...theBrake Valve 332 3 3 BRAKE OPENCIRCUIT ThereisanOpenCircuittotheBrakeValve 3311 3 3 GROUNDALARM SHORTTOBATTERY ThereisaShorttoBatterytotheGround Alarm GroundAlarmequippedvehiclesonly 3316 3 3 RIGHTF...

Page 566: ...LDSTARTADVANCESOLENOID OPEN CIRCUIT ThereisanOpenCircuittothe ColdStartAdvanceSolenoid CATenginesonly 3345 3 3 COLDSTARTADVANCESOLENOID SHORT TOBATTERY ThereisaShorttoBatterytothe ColdStartAdvanceSole...

Page 567: ...3 3 PLATFORMLEVELUPOVERRIDEVALVE SHORTTOGROUND ThereisaShorttoGroundtothePlatform LevelUpOverrideValve Electroniclevelingsystemequippedvehiclesonly 3386 3 3 PLATFORMLEVELUPOVERRIDEVALVE OPENCIRCUIT Th...

Page 568: ...ehiclesonly 33152 3 3 LIFTPILOTVALVE SHORTTOBATTERY ThereisaShorttoBatterytotheLiftPilot Valve GravityLiftDownequippedvehiclesonly 33153 3 3 LIFTDOWNAUXVALVE SHORTTOGROUND ThereisaShorttoGroundtotheLi...

Page 569: ...heMainTele scopeFlowControlValve 33311 3 3 MAINLIFTFLOWCONTROLVALVE SHORT TOGROUND ThereisaShorttoGroundtothe MainLiftFlowControlValve 33312 3 3 MAINLIFTFLOWCONTROLVALVE OPEN CIRCUIT ThereisanOpenCirc...

Page 570: ...BATTERY ShorttoBatterydetected Checkwiring 33563 3 3 LIFTENABLEVALVE STUCKOPEN Liftpilotvalveisenergized duringauxil iaryorgravitysequence and1degof motionisdetectedpriortotheenablevalve beingenergiz...

Page 571: ...5 JIBLIFTUPVALVE SHORTTOBATTERYOR OPENCIRCUIT 357 3 5 JIBLIFTDOWNVALVE SHORTTOGROUND 358 3 5 JIBLIFTDOWNVALVE SHORTTOBATTERY OROPENCIRCUIT 359 3 5 JIBROTATELEFTVALVE SHORTTOGROUND 3510 3 5 JIBROTATELE...

Page 572: ...XLEVALVE CURRENTFEEDBACK READINGTOOLOW Currentfeedbackintocontrollerisbelow thresholdvalue Checkwiringandcoil 3615 3 6 REARAXLERETRACTVALVE OPENCIRCUIT OpenCircuitdetected Checkwiring 3616 3 6 REARAXL...

Page 573: ...TED SCRCleaningwasrequestedbunotiniti ated 4365 4 3 RUNNINGATCREEP ENGINEPOWER REDUCTION Triggeredby524190 14 enginecon trolled 4366 4 3 SCRCLEANINGREQUIRED SOOTDETECTED SCRCrystallizationhasbeendetec...

Page 574: ...TAGE NOTCALIBRATED TheshearbeamisreportingaSensorSup plyVoltagecalibrationerror Themachinewillassumetheplatformis overloaded Thisfault onceannunciatedislatched withinagivenkeycycle Possiblesensorhardw...

Page 575: ...dwareandwiring 815 8 1 CHASSISTILTSENSORDISAGREEMENT X 8111 8 1 CHASSISTILTREADINGDISAGREEMENT Disagreementbetweeninternal UGM and externalchassistiltsensors Checkexternal internalsensorhardwareandins...

Page 576: ...mhasdeterminedthatthe straingauge1readingintheloadsensoris stagnant notchanging Iftheplatformisnotconsideredtobeover loadedboomfunctionswillberestrictedto creep IfDTC8223isactiveincombinationwith DTC8...

Page 577: ...nunciatedislatched withinagivenkeycycle Possiblesensorhardwareissue 8226 8 2 LSSSTRAINGAUGE1 OUTOFRANGEHIGH Theshearbeamisreportinganoutofrange highissuewiththestraingauge1reading Iftheplatformisnotov...

Page 578: ...unciatedislatched withinagivenkeycycle Possiblesensorhardwareissue 8230 8 2 LSSSTRAINGAUGE1 NOTCALIBRATED Theshearbeamisreportingacalibration issuewiththestraingauge1sensor Iftheplatformisnotoverloade...

Page 579: ...anotinstalled issuewiththestraingauge1sensor Iftheplatformisnotoverloadedthe machinewillbeplacedintocreep IfDTC8235isalsoactivethemachinewill assumetheplatformisoverloaded Thisfault onceannunciatedisl...

Page 580: ...8 2 RUNNINGATCREEP PLATFORMOVER LOADED Allfunctionsatcreep theLoadSensingSys temindicatesthePlatformisoverloaded ANDisconfiguredtowarnonlywhilethe Platformisoverloaded 827 8 2 DRIVE BOOMPREVENTED PLAT...

Page 581: ...5 1 volts Electroniclevelingsystemequippedvehiclesonly 8315 8 3 PLATFORMLEVELINGSENSOR DISAGREE MENT TheControlSystemreadsthesensorvalues atpower up Thefaultistriggeredwhen thereisa 5degreedifferencef...

Page 582: ...ENSOR VALUEOUTOF RANGEHIGH BoomLengthoutofrangehigh EnvelopeControlequippedvehiclesonly 848 8 4 BOOMLENGTHSENSOR VALUEOUTOF RANGELOW BoomLengthoutofrangelow EnvelopeControlequippedvehiclesonly 849 8 4...

Page 583: ...ANDDRIVE ORIENTATIONSWITCH DIS AGREEMENT 84101 8 4 CHASSISTURNTABLESENSORS NOTCALI BRATED 84102 8 4 MAINCYLINDERANGLESENSOR NOT DETECTINGCHANGE 84103 8 4 JIBLEVELANGLESENSOR NOTDETECTING CHANGE 84104...

Page 584: ...heditsthreshold Thisvalueis storedinEEPROMinordertotrackthehis toryoftheissue AsuccessfulBoomSensor Calibrationwillresetthiscounter thisis reflectedintheboomsensorcalibration document TwrLenSnsr 1 2 F...

Page 585: ...heditsthreshold Thisvalueis storedinEEPROMinordertotrackthehis toryoftheissue AsuccessfulBoomSensor Calibrationwillresetthiscounter thisis reflectedintheboomsensorcalibration document TwrLenSnsr 1 2 F...

Page 586: ...ditsthreshold Thisvalueis storedinEEPROMinordertotrackthehis toryoftheissue AsuccessfulBoomSensor Calibrationwillresetthiscounter thisis reflectedintheboomsensorcalibration document BmLenSnsr 1 2 Faul...

Page 587: ...sensorcalibration document BmLenSnsr 1 2 FaultCounter_EEPROM 3 c Thefaultcounterbelowshallbeincre mentedeverytimethetriggercondition describedinsection a isobservedduring certainstepsduringBoomSensorC...

Page 588: ...penCircuit totheLeftFrontSteerRightValve 8611 8 6 LEFTFRONTSTEERRIGHTVALVE SHORTTO GROUND ThereisaShorttoGroundtothe LeftFrontSteerRightValve 8612 8 6 LEFTFRONTSTEERLEFTVALVE SHORTTO BATTERYOROPENCIRC...

Page 589: ...ghtSteerSensor 8631 8 6 FRONTRIGHTSTEERSENSOR SHORTTO BATTERY ThereisaShorttoBatterytothe FrontRightSteerSensor 8632 8 6 FRONTLEFTSTEERSENSOR SHORTTO GROUNDOROPENCIRCUIT ThereisaShorttoGroundoranOpenC...

Page 590: ...IT OpenCircuitdetected 8681 8 6 RIGHTREARSTEERLEFTVALVE SHORTTO BATTERY ShorttoBatterydetected 8682 8 6 LEFTREARSTEERRIGHTVALVE OPENCIR CUIT OpenCircuitdetected 8683 8 6 LEFTREARSTEERRIGHTVALVE SHORTT...

Page 591: ...ringpower up 9920 9 9 PLATFORMSENSORREFVOLTAGEOUTOF RANGE ThePlatformModulehasreportedthatits sensorreferencevoltageisoutsideaccept ablerange Notreportedduringpower up 9921 9 9 GROUNDMODULEFAILURE HIG...

Page 592: ...SUPPLYOUTOFRANGELOW TheBoomAngleSensorssupplyvoltageis low BLAMequippedvehiclesonly 9937 9 9 LENGTHSENSORREFVOLTAGEHIGH TheBoomLengthSensorssupplyvoltageis high 9938 9 9 LENGTHSENSORREFVOLTAGELOW TheB...

Page 593: ...amaging the seal around the wire It is best to use probes or probe tips specifically designed for this technique especially on sealed connectors Whenever possible insert probes into the side of the co...

Page 594: ...uto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Continuity Measurement Some meters require a separate button press to enable audible continu...

Page 595: ...e and female pins To prevent electrical malfunction caused by low level con ductivity between pins when wet Use the following procedure to apply Silicone Dielectric Com pound to the electrical connect...

Page 596: ...yringe for small connectors 2 Apply dielectric grease to the female contact fill it approximately full see example below 3 Leave a thin layer of dielectric grease on the face of the connector 4 Assemb...

Page 597: ...IN Connectors This connector is typically used on hydraulic valves Follow the installation instructions Exclusions A limited number of connectors do not benefit from dielectric grease or may be perman...

Page 598: ...ractical way to remove the dielectric grease replacement of female contacts required The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 con nector sys...

Page 599: ...ipped position See Figure 7 7 Proceed as follows 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 7 9 2 Pull back on the contact wire with a f...

Page 600: ...edge lock must be closed to its locked position Release the locking latches by squeezing them inward See Figure 7 10 4 Slide the wedge lock into the housing until it is flush with the housing See Figu...

Page 601: ...e 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 Service Voltage Reading DO NOT PI...

Page 602: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 10 3121619 Figure 7 13 Connector Installation...

Page 603: ...ward exterior locking mechanism The wedgelock 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 Seri...

Page 604: ...wire cavities insert sealing plugs for full envi ronmental sealing HD30 HDP20 Series Disassembly 1 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be remo...

Page 605: ...eFuelUsed Totalamountoffuelusedduringvehicleoperationduringidleconditions Liters TotalIdleHours Totaltimeofengineoperationduringidleconditions Seconds TotalEngineHours Totaltimeofengineoperation Secon...

Page 606: ...RICAL INFORMATION ELECTRICAL SCHEMATICS 7 14 3121619 MS1619 3 MS1619 1 MS1619 2 X1609 MS1620 1 S1614 S1615 MS1618 2 MS1620 3 MS1620 2 MS1618 3 CO1613 J2 CO1613 J1 X1606 Figure 7 20 Telematics Gateway...

Page 607: ...RN CANL2 18 AWG GXL MS1619 2 B 10 YEL CANH2 18 AWG GXL MS1619 2 A MS1619 3 CAN T 2 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO A YEL CANH2 18 AWG GXL MS1620 2 A B GRN CANL2 18 AWG GXL MS1620 2 B MS...

Page 608: ...18 AWG 155 GXL X1609 10 MS1619 2 A CAN H2 YEL 18 AWG 233 GXL MS1620 3 A CO1613 J2 10 CAN H1 YEL 18 AWG 157 GXL MS1618 2 A CO1613 J1 10 CAN H2 YEL 18 AWG 1150 GXL MS1619 3 A MS1620 2 A CAN H1 YEL 18 A...

Page 609: ...o the table below followed by a unique sequential number An optional suffix letters numbers may be added when multiple terminations occur at one device Terminals that are not loaded into connectors ar...

Page 610: ...tch SW Sensor Angle SN Fuel Length Limit Load Pressure Proximity Speed Temperature Terminals Pins T Sockets MaleBlades FemaleBlades Rings Forks ToggleSwitch DPDT SW DPST SPDT SPST Special Valves Simpl...

Page 611: ...SW 22 2 SW2 3 M AIN BO OM T ELE SW 21 JIB L IF T SW 19 JIB SWI NG SW1 4 J IB T EL E SW 13 PLT FM R OTAT E X38 8 X38 5 X39 0 X3 8A X38 7 X39 9 X39 1 X3 84 X3 98 AH 30 AH 30 X32 CO 01 J2 CO0 1 J1 X3 3A...

Page 612: ...GD04 J4 4 13 WHT 54 2 1000LBMODE 18 AWG GXL GD04 J3 4 14 WHT 39 1 AXL SET 18 AWG GXL GD04 J3 2 15 WHT 52 1 GEN 18 AWG GXL GD04 J4 2 16 WHT 49 21 SFTCH LT 18 AWG GXL LB12 1 17 WHT 48 1 ENG PREHEAT 18...

Page 613: ...J7 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 5 18 AWG GXL X33A 11 2 RED 1 4 3 PLTF MODE 18 AWG GXL SW35 1A 1A 3 YEL 2 4 18 AWG GXL X33A 4 4 BRN 49 11 X43 PWR 20 AWG CABLE X43A 1 5 WHT 23...

Page 614: ...ELECTRICAL SCHEMATICS 7 22 3121619 SN273 MS437 X36B HV281 PLTFM ENABLE HV275 P LVL UP HV278 P ROT RHT HV277 P ROT LFT HV276 P LVL DN HV342 JLOCK IN HV343 JLOCK OUT X365B Figure 7 26 Platform Valve Wi...

Page 615: ...E COLOR WIRE LABEL GAUGE JACKET TO 1 ORG CABLE 18 AWG CABLE X36B 15 2 YEL CABLE 18 AWG CABLE X36B 16 3 BLK CABLE 18 AWG CABLE X36B 17 HV281 PLTFM ENABLE CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO...

Page 616: ...2 JIB DN 18 AWG GXL HV253 1 S383 CONN P OS WIRE COLOR WIRE LABEL GAUGE J ACK ET TO 1 BLK 0 27 18 AWG GX L MS380 12 2 BLK 0 27 1 18 AWG GX L SN259 3 2 BLK 0 47 16 AWG GX L HV248 2 X230A X228B SN260 CO...

Page 617: ...245 J2 6 HV256 JIB LVL UP CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 55 20 JLVL UP 18 AWG GXL CO245 J2 11 2 BLK 0 25 1 18 AWG GXL MS347 8 HV250 JIB SWG RHT CONN POS WIRE COLOR WIRE LABEL GAU...

Page 618: ...26 18 AWG GXL MS347 12 CO245 J2 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 27 3 1 JIB DN O R 18 AWG GXL S265 1 2 WHT 27 6 1 J UP O R 18 AWG GXL S264 1 3 BLK 0 25 18 AWG GXL MS347 11 4 WHT 4...

Page 619: ...SIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 27 C O1 28 J5 CO128 J3 X411 SN13 0 CO12 8 J1 CO1 28 J2 X4 06A MS1 48 1 X421 X4 13 X2 22B Figure 7 31 BLAM Module Wiring Harness Sheet 1 of 2...

Page 620: ...1 18 AWG GXL X406A 2 9 WHT 49 61 GRVTY SEN2 18 AWG GXL X406A 6 10 11 WHT 7 1 RDRV PFWD 18 AWG GXL X222B 1 12 WHT 7 2 RDRV PREV 18 AWG GXL X222B 2 X406A CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1...

Page 621: ...JACKET A RED B PWR SUP 22 PVC B BLK B GND SUP 22 PVC C D GRN CAN HI 22 PVC E WHT CAN LO 22 PVC F CO128 J4 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 RED B PWR SUP 22 PVC 2 BLK B GND SUP 22 PVC 3 G...

Page 622: ...UE 1 ANGLE SIG 18 AWG CABLE C BLACK 1 ANGLE GND 18 AWG CABLE X406B CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 RED 1 ANGLE PWR 18 AWG CABLE 2 BLUE 1 ANGLE SIG 18 AWG CABLE 3 BLACK 1 ANGLE GND 18 AWG...

Page 623: ...G CABLE 6 ORANGE BRKN CBL SIG 18 AWG CABLE 7 BROWN BRKN CBL GND 18 AWG CABLE 8 SHIELD CABLESHIELD 18 AWG CABLE X404A CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 RED BLNTH PWR 18 AWG CABLE 2 BLUE BLN...

Page 624: ...G CABLE SN131 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET A RED BLNTHPWR 18 AWG CABLE C BLUE BLNTHSIG 18 AWG CABLE B BLACK BLNTHGND 18 AWG CABLE SN401 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1 BRO...

Page 625: ...EMATICS 3121619 7 33 X407B A C B 1 4 3 2 1 4 3 2 SN221 SN401 SN131 S40 9 S4 10 BRKN CBL PWR BRKN CBL SIG BRKN CBL GND BRKN CBL GND 1 BRKN CBL GND 2 BRKN CBL PWR 1 BRKN CBL SIG 1 B LNTH PWR B LNTH SIG...

Page 626: ...HT BECON PWR 16 AWG CABLE BEACON SIDE CONNECTION 2 BLK BECON GND 16 AWG CABLE BEACON SIDE CONNECTION BEACON SIDE CONNECTION CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT BEACON PWR 16 AWG CABLE...

Page 627: ...2 BL K 14 8 5 7 WT R F UL RTN 1 6 AW G GXL X9 4 2 2 X94 2 CONN POS WIRE COLOR WI R E L ABEL G AUGE JACKET TO 1 BLK 1 4 8 6 4 WTR FUL SW 1 6 AWG GXL SN95 9 1 2 BLK 1 4 8 5 7 WT R F UL RTN 1 6 AWG GXL S...

Page 628: ...DIODE DETAILS RL360 85 RL360 86 R L127 86 RL234 85 RL234 86 IP91 IP90 X378 X373 X376 X362 X418 X377 X375 X237 RL235 Y X353 RL235 R RL236 Y RL236 R X147A X149A X217A X218A S372 S239 S371 X159B RL127 85...

Page 629: ...18 AWG GXL IP90 1 IP91 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 RED 1 4 2 1 18 AWG GXL RL234 86 1 2 RED 1 4 2 18 AWG GXL X327B 4 IP90 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 4 2...

Page 630: ...AWG GXL X81 12 X353 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 12 18 AWG GXL X327B 5 1 YEL 2 17 18 AWG GXL LB417 1 RL235 R CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 1 99 IGNIT...

Page 631: ...1 YEL 2 1 99 IGNITION 18 AWG GXL S372 2 2 BLK 0 17 16 AWG GXL CO02 J1 8 3 WHT 52 9 GEN 18 AWG GXL CO02 J1 22 4 WHT 48 7 GLOW 18 AWG GXL CO02 J1 12 5 YEL 2 13 16 AWG GXL RL235 R 1 6 BLK 0 18 18 AWG GX...

Page 632: ...RMATION ELECTRICAL SCHEMATICS 7 40 3121619 X81 SN123 LB417 X84 X327B X412 CO02 J7 X88 CO02 J1 IP85 S89 X440B X420 S456 CO02 J12 CO02 J8 MS83 MS148 2 MS148 3 X468 S469 X395 X467 MS82 Figure 7 44 Turnta...

Page 633: ...18 AWG GXL CO02 J7 1 LB417 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 17 18 AWG GXL X353 1 2 BLK 0 16 18 AWG GXL X237 1 X420 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 BLK 0 50 1 16...

Page 634: ...20 AWG J1939 CABLE S469 2 7 SHLD CANSHLD 20 AWG J1939 CABLE MS148 3 C 8 9 GRN CANLO 20 AWG J1939 CABLE X81 2 10 GRN CANLO 20 AWG J1939 CABLE MS148 3 B 11 YEL CANHI 20 AWG J1939 CABLE X81 3 12 YEL CAN...

Page 635: ...WHT 49 77 PC PWR 20 AWG GXL X440B 2 27 WHT 49 64 TILT PWR 18 AWG GXL X395 1 28 29 WHT BLNTH CBL 18 AWG CABLE SN123 4 30 WHT JUMPER3 18 AWG GXL CO02 J7 23 31 32 RED CABLE 18 AWG CABLE X412 5 33 34 YEL...

Page 636: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 44 3121619 MS148 2 MS83 MS82 X395 Figure 7 48 Turntable Wiring Harness Sheet 9 of 9...

Page 637: ...T AUX SW 64 PLATF LVL LB 76 1000 CAP LB 6 8 AXLE SET LB 75 PLATF OVRLD LB 73 MOMNT CNTRL LB 71 LO OIL LB 72 NO ALT SW66 1 SW66 2 LB 70 HI TEMP LB 74 BOOM CNTRL LB 69 GL OW PLUG L B 67 5 00 CAP SW 63 P...

Page 638: ...N POS WIRE COLOR W IRE LABEL GAUGE JACKET TO 1 WHT 23 5 P ROTRHT 18 AWG GXL CO02 J4 18 2 YEL 2 9 6 18 AWG GXL SW62 2 2 YEL 2 9 8 18 AWG GXL SW64 2 3 WHT 23 6 P ROTLFT 18 AWG GXL CO02 J4 6 LB67 CONN PO...

Page 639: ...9 3 JIB IN 18 AWG GXL CO02 J4 11 2 YEL 2 9 4 18 AWG GXL SW66 1 1 2 YEL 2 9 5 18 AWG GXL SW62 2 3 WHT 29 4 JIB OUT 18 AWG GXL CO02 J4 22 SW60 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 13 5 T...

Page 640: ...S 244 HV 176 LE FT RE AR ST R RHT HV 172 LEF T FRONT S TR RHT HV 163 RE AR AX LE S WG EX T HV 164 RE AR AX LE S WG RET HV 173 LE FT FRONT S TR LFT HV 177 LE FT REA R ST R LFT S 204 S 202 S168 HV 175 R...

Page 641: ...L GAUGE JACKET T O 1 WHT 38 6 RAXS RET 18 AWG GXL CO03 J2 7 2 WHT 60 5 2 RAXS RTN 18 AWG GXL S168 2 HV173 LEFT FRONT STR LFT CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 9 3 LF RNT STRL 18 AWG...

Page 642: ...RHT FRNT STR 18 AWG CABLE CO03 J7 4 4 SHIELD SHLD 18 AWG SHLD S424 2 5 6 S167 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 60 4 FAXS RTN 18 AWG GXL CO03 J3 1 2 WHT 60 4 1 FAXS RTN 18 AWG GXL H...

Page 643: ...R STRR 18 AWG GXL HV176 1 10 11 WHT 9 4 RFRNT STRR 18 AWG GXL HV170 1 12 13 WHT 55 14 BRAKE 18 AWG GXL HV179 1 14 BLK 00 1 18 AWG GXL S181 1 15 16 WHT 38 3 FAXS RET 18 AWG GXL HV162 1 17 BLK 00 3 18 A...

Page 644: ...L S195 1 10 11 12 13 14 WHT 38 10 FAXS LFT 18 AWG GXL X449B 2 15 WHT 38 9 RAXS RHT 18 AWG GXL X448B 2 16 WHT 55 15 TTABLE ANG 18 AWG GXL SN243 C 17 18 BLK 00 14 18 AWG GXL SN243 A 19 20 21 22 23 24 25...

Page 645: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 53 Figure 7 57 Chassis Harness Sheet 6 of 6...

Page 646: ...FL OW CNTRL H V316 WARM UP VLV X158 AH 318 SN11 4 FUEL LEVEL C O0 2 J3 CO02 J2 S15 7 S1 56 S1 55 S154 S1 53 HV10 8 TEL E FLOW CN TR L SN 438 SN43 9 H V315 LIFT EN ABLE X440 A S45 5 H V103 MAIN TELE OU...

Page 647: ...2 19 2 WHT 60 1 LFCNTRL RTN 18 AWG GXL CO02 J3 1 HV348 SWG FLOW CNTRL CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 WHT 55 32 SWG F C 18 AWG GXL CO02 J2 35 2 WHT 60 3 SWG RTN 18 AWG GXL CO02 J3 4 X...

Page 648: ...10 FUL SEN 18 AWG GXL CO02 J2 25 2 BLK 0 14 3 18 AWG GXL S157 2 S153 CONNECTOR PART NUM BER SPLICE CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TERM INAL P N TO 1 BLK 0 30 18 AWG GXL N A CO02 J2 18 2...

Page 649: ...8 AWG GXL X222A 3 1 BLK 0 15 3 18 AWG GXL HV144 2 1 BLK 0 15 4 18 AWG GXL HV145 2 2 BLK 0 15 1 18 AWG GXL HV142 2 2 BLK 0 15 2 18 AWG GXL HV143 2 HV142 RHT DRV PUMP FWD CONN POS WIRE COLOR WIRE LABEL...

Page 650: ...58 3121619 SN939 RL930 T920 RL931 85 RL931 86 RL931 87 RL930 1 RL930 2 FC1003 FC1004 X 1006 X950 MS1002 2 S 1008 X1009 MS999 1 EC241 L X217B X941 X218B S1011 S945 S944 ECM J2 MS1001 1 E CM J1 MS 1000...

Page 651: ...75 mm FLRYW EIC 52 39 40 41 42 43 44 BLK 148 44EHXAUST GAS RECIRCULATION 0 75 mm FLRYW EIC 50 45 46 47 48 49 50 51 52 53 GRN CAN LOW 0 75 mm FLRYW MS1000 1 B 54 YEL CAN HIGH 0 75 mm FLRYW MS1001 1 A 5...

Page 652: ...4 27 BLK 248 29 OIL PRESSURE 0 75 mm FLRYW ECM J2 29 28 BLK 248 40 AIR INLET TEMP 0 75 mm FLRYW ECM J2 40 29 BLK 248 27 BOOST PRESSURE TEMP 0 75 mm FLRYW ECM J2 27 30 31 BLK 248 25 RAIL PRESSURE FUEL...

Page 653: ...LRYW EIC 25 27 BLK 248 27 BOOST PRESSURE TEMP 0 75 mm FLRYW EIC 29 28 BLK 248 28COOLING TEMPERATURE 0 75 mm FLRYW EIC 24 29 BLK 248 29 OIL PRESSURE 0 75 mm FLRYW EIC 27 30 31 32 BLK 248 32 INJECTOR 3...

Page 654: ...CAN LOW 20 AWG J1939 CABLE MS1001 2 B C SHLD SHIELD 20 AWG J1939 CABLE MS1001 2 C MS999 3 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO A YEL CAN HI 20 AWG J1939 CABLE X1005 1 B GRN CAN LOW 20 AWG J...

Page 655: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 63 MS1000 2 X1005 MS1002 1 MS999 3 MS999 2 Figure 7 67 CAN Engine Harness Sheet 2 of 2...

Page 656: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 64 3121619 Figure 7 68 Generator Enable Harness Sheet 1 of 2...

Page 657: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 65 Figure 7 69 Generator Enable Harness Sheet 1 of 2...

Page 658: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 66 3121619 Figure 7 70 T4F Engine Harness Sheet 1 of 14...

Page 659: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 67 Figure 7 71 T4F Engine Harness Sheet 2 of 14...

Page 660: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 68 3121619 Figure 7 72 T4F Engine Harness Sheet 3 of 14...

Page 661: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 69 Figure 7 73 T4F Engine Harness Sheet 4 of 14...

Page 662: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 70 3121619 Figure 7 74 T4F Engine Harness Sheet 5 of 14...

Page 663: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 71 Figure 7 75 T4F Engine Harness Sheet 6 of 14...

Page 664: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 72 3121619 Figure 7 76 T4F Engine Harness Sheet 7 of 14...

Page 665: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 73 Figure 7 77 T4F Engine Harness Sheet 8 of 14...

Page 666: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 74 3121619 Figure 7 78 T4F Engine Harness Sheet 9 of 14...

Page 667: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 75 Figure 7 79 T4F Engine Harness Sheet 10 of 14...

Page 668: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 76 3121619 Figure 7 80 T4F Engine Harness Sheet 11 of 14...

Page 669: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 77 Figure 7 81 T4F Engine Harness Sheet 12 of 14...

Page 670: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 78 3121619 Figure 7 82 T4F Engine Harness Sheet 13 of 14...

Page 671: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 79 Figure 7 83 T4F Engine Harness Sheet 14 of 14...

Page 672: ...NFORMATION ELECTRICAL SCHEMATICS 7 80 3121619 X436B TO ENG HARN X734B TO ENG HARN SN238 UREA QUTY LVL TEMP X253 UREA SUP MOD X251 THRTLE HTR X250 SUCTION HTR X252 PRS HTR Figure 7 84 Urea Tank Supply...

Page 673: ...238 1 X250 SUCTION HTR CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL 2 60 3 2 5 mm FLRYW X436B 8 2 WHT 102 2 STION HTR 2 5 mm FLRYW X436B 7 X252 PRS HTR CONN POS WIRE COLOR WIRE LABEL GAUGE JAC...

Page 674: ...AWG TFFN J7_24 1 2 YEL CANH_6 18 AWG TFFN J7_13 1 J7_13 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 YEL CANH_6 18 AWG TFFN MS377 1 2 J7_24 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 GRN CA...

Page 675: ...CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 RED 103 18 AWG TFFN X383 1 1 BLK 119_1 14 AWG TFFN IP914 1 2 RED 115 18 AWG TFFN SW374 1 SW374 CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 RED 11...

Page 676: ...MS148 3 MS148 2 MS148 1 CO128 J5 CO128 J3 CO128 J1 X81 CONNECTS TO MAIN BOOM CABLE X341A CONNECTS TO 16 4 MAIN BOOM CABLE SN123 CONNECTS TO TRANSPORT SWITCH CABLE X406A CONNECTS TO BASE BOOM ANGLE SEN...

Page 677: ...LV HV108 TELE FLOW CNTRL HV102 LIFT FLOW CNTRL HV348 SWG FLOW CNTRL HV104 MAIN DUMP HV109 MAIN TELE IN HV101 MAIN LIFT DN HV100 SWG LFT HV107 LIFT PILOT HV103 MAIN TELE OUT X159A HV105 LIFT DN AUX HV9...

Page 678: ...406A X395 CONNECTS TO TILT SENSOR X412 X411 X84 LB417 SN959 SN123 X341A MS82 MS83 RL234 86 RL127 85 RL234 85 RL236 R RL235 Y RL236 Y X353 RL235 R RL127 86 RL360 85 RL360 86 X237 X362 X373 X375 X376 X3...

Page 679: ...EMP LB69 GLOW PLUG LB68 AXLE SET LB67 500 CAP LB76 1000 CAP LB73 MOMNT CNTRL LB75 PLATF OVRLD LB74 BOOM CNTRL SW66 2 SW63 PLATF ROT SW64 PLATF LVL SW65 STRT AUX X77 M D I SW60 MAIN TELE SW61 JIB TELE...

Page 680: ...TRICAL SCHEMATICS 7 88 3121619 IP415 IP379 BATTERY AND RELAYS IP414 EMERGENCY STOP AND KEY SWITCH SW56 1 GND MODE SW56 B E STOP B SW56 3 PLATF MODE SW55 2B E STOP B t SW55 1B BAT B Figure 7 92 Electri...

Page 681: ...Y X338A CONNECTS TO STEER CABLE 2 OF 4 X340A CONNECTS TO STEER CABLE 1 OF 4 442A 448B 449B 445A X339A CONNECTS TO STEER CABLE 3 OF 4 X337A CONNECTS TO STEER CABLE 4 OF 4 X160 SN243 X147B HV179 HV178 S...

Page 682: ...HT FRONT STR RHT HV174 RIGHT REAR STR RHT SECTION D D HV164 REAR AXLE SWG RET HV173 LEFT FRONT STR LFT HV177 LEFT REAR STR LFT HV163 REAR AXLE SWG EXT HV172 LEFT FRONT STR RHT HV176 LEFT REAR STR RHT...

Page 683: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 91 Figure 7 95 Electrical Installation Sheet 8 of 10 1001156522 H...

Page 684: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 92 3121619 Figure 7 96 Electrical Installation Sheet 9 of 10 1001156216 H...

Page 685: ...SCHEMATICS 3121619 7 93 HV256 JIB LVL UP HV250 JIB SWG RHT HV248 JIB ENABLE HV254 JIB LIFT UP HV251 JIB TELE OUT HV255 JIB LVL DN HV253 JIB LIFT DN HV249 JIB SWG LFT HV252 JIB TELE IN Figure 7 97 Ele...

Page 686: ...94 3121619 Figure 7 98 Battery Jump Start Hookup THIS MACHINE UTILIZES A 12 VOLT ELECTRICAL SYSTEM TO PREVENT DAMAGE WHEN JUMP STARTING THE MACHINE CONNECT THE JUMP START EQUIPMENT ONLY TO THE BATTER...

Page 687: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 95 Figure 7 99 Battery Installation Sheet 1 of 2...

Page 688: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 96 3121619 Figure 7 100 Battery Installation Sheet 2 of 2...

Page 689: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 97 Figure 7 101 Electrical Schematic Sheet 1 of 21...

Page 690: ...NT WHT 39 1 AXL SET WHT 39 1 AXL SET WHT 49 4 BCS WHT 49 4 BCS BLK 0 2 BLK 0 2 WHT 47 5 LOW FUL WHT 47 5 LOW FUL YEL 2 2 ENABLE YEL 2 2 ENABLE WHT 49 5 CREEP WHT 49 5 CREEP WHT 47 4 FUL FULL WHT 47 4...

Page 691: ...OT BLK 0 3 BLK 0 3 WHT 49 15 SFT TOUCH WHT 49 15 SFT TOUCH WHT 27 1 JIB UP WHT 27 1 JIB UP WHT 27 2 JIB DN WHT 27 2 JIB DN WHT 52 3 HEAD TAIL LT WHT 52 3 HEAD TAIL LT WHT 13 1 MTELE IN WHT 13 1 MTELE...

Page 692: ...7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 X36B 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 21 20 19 18 17 16 GRN GRN 1001145974_2 7 D WHT 25 3 2 PLVL UP WHT 25 3 2 PLVL UP WHT 25 4 2 PLVL DN WHT 25 4 2 PLVL D...

Page 693: ...LK 0 26 5 BLK 0 26 4 BLK 0 26 3 BLK 0 26 2 BLK 0 26 1 WHT 55 19 JLVL DN WHT 55 19 JLVL DN WHT 55 20 JLVL UP WHT 55 20 JLVL UP BLK 0 25 S264 S265 BLK 0 25 2 BLK 0 25 1 WHT 27 3 1 JIB DN O R WHT 27 6 1...

Page 694: ...5 7 D BLK 0 45 BLK 1 0 RED 1 0 RED 1 0 RED 1 7 WK LT PWR 12 IP379 RED 1 7 1 WK LT PWR 16 1001145974_5 8 E RED 1 7 2 WK LT PWR 16 RED 1 7 2 WK LT PWR 16 1001145974_5 8 E PROXIMITY SENSOR 2 BROKEN CABLE...

Page 695: ...K 0 20 12 1001145974_5 5 B RED 1 15 1001145974_5 2 C RED 1 5 16 1001145974_5 1 E BLK 0 22 14 BLK 0 22 14 X353 1 YEL 2 17 YEL 2 17 BATTERY DISCONNECT SOLENOID RL360 87 1 RL360 30 1 RL360 86 1 RL360 85...

Page 696: ...LO RED 1 4 3 RED 1 4 3 2 E 4 A RED 1 4 3 YEL CAN HI YEL CAN HI 1001145974_4 4 E GRN CAN LO GRN CAN LO 1001145974_4 4 E SHLD CAN SHLD SHLD CAN SHLD 1001145974_4 4 E WHT B LNTH CBL WHT B LNTH CBL 100114...

Page 697: ...T 49 30 OVERLOAD WHT 49 30 OVERLOAD WHT 54 5 1000 WHT 54 5 1000 BLK 0 12 9 BLK 0 12 9 BLK 0 12 8 BLK 0 12 8 BLK 0 12 7 BLK 0 12 7 BLK 0 12 6 BLK 0 12 6 BLK 0 12 5 BLK 0 12 5 BLK 0 12 4 BLK 0 12 4 BLK...

Page 698: ...1 2 5 6 7 8 3 4 WHT 61 1 5 5V 6 C WHT 61 1 6 5V 6 C WHT 55 18 TTABLE ANG2 X309 1 2 3 4 5 6 7 8 9 10 11 12 X147A 1 2 3 4 5 6 7 8 9 10 11 12 X311 1 2 3 4 5 6 7 8 9 10 11 12 YEL GRN BLK ORG DRIVE ORIENTA...

Page 699: ...T 61 1 3 5V 5 H WHT 61 1 4 5V 6 C WHT 61 1 3 5V 7 C BLK 00 9 BLK 00 9 WHT 55 15 TTABLE ANG WHT 55 15 TTABLE ANG BLK 00 6 BLK 00 6 BLK 00 5 BLK 00 5 BLK 00 4 1 BLK 00 3 1 S202 BLK 00 4 BLK 00 4 S203 BL...

Page 700: ...7 1 LDRV PFWD WHT 7 1 LDRV PFWD WHT 7 2 LDRV PREV WHT 7 2 LDRV PREV BLK 0 15 BLK 0 15 ENABLE CHASSIS HV314 1 2 ENABLE LIFT HV315 1 2 VALVE WARM UP HV316 1 2 WHT 55 33 WARM UP WHT 60 6 WARM UP RTN WHT...

Page 701: ...55 31 CHS ENABLE WHT 55 30 LFT ENABLE BLK 0 36 BLK 0 36 MOTION ALARM HORN AH318 A B C WHT 52 8 ALRM PWR WHT 52 8 ALRM PWR BLK 0 30 BLK 0 30 WHT 60 7 LENABLE RTN WHT 60 7 LENABLE RTN FLOW CONTROL SWING...

Page 702: ...8 CLUTCH SWITCH 120 OHM RED EPDM 2 0AWG MS999 1 A B C MS999 2 A B C MS999 3 A B C SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 MS1000 1 A B C MS1000 2 A B C MS1000...

Page 703: ...A B C SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 SHLD SHIELD J1939 CABLE 20 MS1000 2 A B C MS1000 3 A B C MS1001 2 A B C MS1001 3 A B C MS1002 1 A B C MS1002 2 A...

Page 704: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 112 3121619 Figure 7 116 Electrical Schematic Sheet 16 of 21...

Page 705: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 3121619 7 113 Figure 7 117 Electrical Schematic Sheet 17 of 21...

Page 706: ...R RTN 1 5mm WHT 44 38 INJCTR 1 5mm WHT 23 61 INJCTR RTN 1 5mm WHT 87 42 INJCTR 1 5mm WHT 66 37 INJCTR RTN 1 5mm WHT 25 20 MPROP 1 5mm WHT 46 19 MPROP RTN 1 5mm BLK 99 13 CAM ENG SPD WHT 100 14 CAM ENG...

Page 707: ...RY ISOLATOR IGNITION START REQUEST CAN HIGH CHANNEL 2 CAN LOW CHANNEL 2 ALTERNATOR EXCITE CAN SHIELD EMR4 IGNITION GROUND GENERATOR ENABLE GLOW GENERATOR POWER GENERATOR GROUND PLUGGED PLUGGED GLOW PL...

Page 708: ...TER UREA QUALITY LEVEL AND TEMP N6 CONNECTION UREA PURGE VALVE UREA PUMP SUPPLY MODULE HEATER UREA PRESSURE AFTER PUMP ENGINE HARNESS SHEET 10 ZONE A 2 3 ENGINE HARNESS SHEET 10 ZONE A 4 5 UREA TANK S...

Page 709: ...ITION BLK GROUND BLK GROUND RED BATTERY RED BATTERY RED CAN HIGH RED CAN HIGH BLK CAN LOW BLK CAN LOW WHT CAN SHIELD WHT CAN SHIELD WHT IGNITION BLK GROUND WHT CAN SHIELD WHT CAN SHIELD BLK CAN LOW BL...

Page 710: ...SECTION 7 BASIC ELECTRICAL INFORMATION ELECTRICAL SCHEMATICS 7 118 3121619 NOTES...

Page 711: ......

Page 712: ...rporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 Corporate 877 554 5438 Customer Support 717 485 6417 Visit our website for JLG Worldwide Locations www jlg c...

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