Manual de Servicio JLG E600 M600 Pat-08 PDF
Manual de Servicio JLG E600 M600 Pat-08 PDF
Model
E600
E600J
E600JP
M600
M600J
M600JP
P/N - 3121813
A GENERAL C MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
sonnel pay strict attention to these warnings and precau- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
tions to avoid possible injury to themselves or others, or NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate. • ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS
OR COMPONENTS.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM • NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE ING ELECTRICAL STORMS. ENSURE THAT FUEL
MANUFACTURER. CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.
The specific precautions to be observed during mainte- • REMOVE ALL RINGS, WATCHES AND JEWELRY
nance are inserted at the appropriate point in the manual. WHEN PERFORMING ANY MAINTENANCE.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
parts. LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
Your safety, and that of others, is the first consideration IN EQUIPMENT.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy • OBSERVE AND OBEY ALL WARNINGS AND CAU-
parts without the aid of a mechanical device. Do not allow TIONS ON MACHINE AND IN SERVICEMANUAL.
heavy objects to rest in an unstable position. When raising • KEEP OIL, GREASE, WATER, ETC. WIPED FROM
a portion of the equipment, ensure that adequate support STANDING SURFACES AND HAND HOLDS.
is provided.
• USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
B HYDRAULIC SYSTEM SAFETY PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pres- • BATTERY SHOULD ALWAYS BE DISCONNECTED-
sures. Every effort should be made to relieve any system DURING REPLACEMENT OF ELECTRICAL COMPO-
pressure prior to disconnecting or removing any portion of NENTS.
the system. • KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
Relieve system pressure by cycling the applicable control MENTS STOWED IN THEIR PROPER PLACE.
several times with the engine stopped and ignition on, to • USE ONLY APPROVED, NONFLAMMABLE CLEANING
direct any line pressure back into the reservoir. Pressure SOLVENTS.
feed lines to system components can then be discon-
nected with minimal fluid loss.
REVISON LOG
SECTION 1. SPECIFICATIONS
Maximum Tire Load: 7700 lbs. (3500 kg) Size Type Pressure
Maximum Ground Bearing Pressure 36/14 LL-22.5 pneumatic 55 psi (4.0 Bar)
E600J/M600J 52 psi (3.7 kg/cm2) 36/14 LL-22.5 foam filled N/A
E600JP/M600JP 51 psi (3.6 kg/cm2)
Maximum Drive Speed: 3.0 mph (1.3 m/s)
Electrical System Voltage 48 volts
Maximum Hydraulic System Pressure 3200 psi (221 Bar)
Maximum Wind Speed 28 mph (12.5 m/s)
*Check swing bearing bolts for security after first 50 hours of opera-
tion and every 600 hours thereafter. (See Swing Bearing in Section 3.)
SERIAL NUMBER
NOTE: When maintenance becomes necessary or a fas- PLATE
tener has loosened, refer to the Torque Chart to
determine proper torque value.
6
2
1
5
3,4
DRAIN
Torque
Torque (Loctite®
Tensile Torque
Clamp Torque (Loctite® 262TM 242TM or 271TM
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)
Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
Size PITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18
Torque
Torque
Torque (Lub OR Loctite®
Tensile (Loctite® 262TM
Clamp Load (Dry or Loctite® 242TM or 271TM
Size PITCH Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
General areas of this manual for servicing and maintenance proce-
This section provides the necessary information needed dures.
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe Annual Machine Inspection
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and The Annual Machine Inspection must be performed by a
maintenance have been completed before placing the Factory-Certified Service Technician on an annual basis,
machine into service. no later than thirteen (13) months from the date of the
prior Annual Machine Inspection. JLG Industries, Inc. rec-
ognizes a Factory-Certified Service Technician as a per-
Preparation, Inspection, and Maintenance son who has successfully completed the JLG Service
It is important to establish and conform to a comprehen- Training School for the subject JLG product model. Refer-
sive inspection and preventive maintenance program. The ence the machine Service and Maintenance Manual and
following table outlines the periodic machine inspections appropriate JLG inspection form for performance of this
and maintenance recommended by JLG Industries, Inc. inspection.
Consult your national, regional, or local regulations for fur-
ther requirements for aerial work platforms. The frequency Reference the JLG Annual Machine Inspection Form and
of inspections and maintenance must be increased as the Inspection and Preventative Maintenance Schedule for
environment, severity and frequency of usage requires. items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this man-
Pre-Start Inspection ual for servicing and maintenance procedures.
It is the User’s or Operator’s primary responsibility to per-
For the purpose of receiving safety-related bulletins, it is
form a Pre-Start Inspection of the machine prior to use
important that JLG Industries, Inc. has updated ownership
daily or at each change of operator. Reference the Opera-
information for each machine. When performing each
tor’s and Safety Manual for completion procedures for the
Annual Machine Inspection, notify JLG Industries, Inc. of
Pre-Start Inspection. The Operator and Safety Manual
the current machine ownership.
must be read in its entirety and understood prior to per-
forming the Pre-Start Inspection.
Preventative Maintenance
Pre-Delivery Inspection and Frequent In conjunction with the specified inspections, mainte-
Inspection nance shall be performed by a qualified JLG equipment
The Pre-Delivery Inspection and Frequent Inspection shall mechanic. JLG Industries, Inc. recognizes a qualified JLG
be performed by a qualified JLG equipment mechanic. equipment mechanic as a person who, by possession of a
JLG Industries, Inc. recognizes a qualified JLG equipment recognized degree, certificate, extensive knowledge, train-
mechanic as a person who, by possession of a recog- ing, or experience, has successfully demonstrated the
nized degree, certificate, extensive knowledge, training, or ability and proficiency to service, repair, and maintain the
experience, has successfully demonstrated the ability and subject JLG product model.
proficiency to service, repair, and maintain the subject
Reference the Preventative Maintenance Schedule and
JLG product model.
the appropriate areas of this manual for servicing and
The Pre-Delivery Inspection and Frequent Inspection pro- maintenance procedures. The frequency of service and
cedures are performed in the same manner, but at differ- maintenance must be increased as environment, severity
ent times. The Pre-Delivery Inspection shall be performed and frequency of usage requires.
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser-
vice for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
increased as environment, severity and frequency of
usage requires.
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operator and Safety Manual
At each Operator change.
Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance
Inspection rental delivery. Mechanic Manual and applicable JLG
inspection form.
Frequent Inspection In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance
ever comes first; or Mechanic Manual and applicable JLG
Out of service for a period of more than 3 inspection form.
months; or
Purchased used.
Annual Machine Annually, no later than 13 months from the Owner, Dealer, or User Factory-Certified Service and Maintenance
Inspection date of the prior inspection. Service Technician Manual and applicable JLG
inspection form.
Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance Maintenance Manual. Mechanic Manual
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo-
General nent is disconnected, cap or cover all openings to
The following information is provided to assist you in the prevent entry of foreign matter.
use and application of servicing and maintenance proce-
dures contained in this book. 3. Clean and inspect all parts during servicing or main-
tenance, and assure that all passages and openings
Safety and Workmanship are unobstructed. Cover all parts to keep them
Your safety, and that of others, is the first consideration clean. Be sure all parts are clean before they are
when engaging in the maintenance of equipment. Always installed. New parts should remain in their contain-
be conscious of weight. Never attempt to move heavy ers until they are ready to be used.
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
Components Removal and Installation
is provided.
1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
Cleanliness cables, etc.) should be parallel to each other and as
1. The most important single item in preserving the near perpendicular as possible to top of part being
long service life of a machine is to keep dirt and for- lifted.
eign materials out of the vital components. Precau-
tions have been taken to safeguard against this. 2. Should it be necessary to remove a component on
Shields, covers, seals, and filters are provided to an angle, keep in mind that the capacity of an eye-
keep air, fuel, and oil supplies clean; however, these bolt or similar bracket lessens, as the angle between
items must be maintained on a scheduled basis in the supporting structure and the component
order to function properly. becomes less than 90 degrees.
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within
the text, standard torque values should be used on
When disassembling or reassembling a component, com-
heat-treated bolts, studs, and steel nuts, in accor-
plete the procedural steps in sequence. Do not partially
dance with recommended shop practices. (See
disassemble or assemble one part, then start on another.
Torque Chart Section 1.)
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval. Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
Pressure-Fit Parts them from the unit. This will assure that they are correctly
When assembling pressure-fit parts, use an anti-seize or reinstalled.
molybdenum disulfide base compound to lubricate the
mating surface.
Hydraulic System
Bearings 1. Keep the system clean. If evidence of metal or rub-
ber particles are found in the hydraulic system, drain
1. When a bearing is removed, cover it to keep out dirt and flush the entire system.
and abrasives. Clean bearings in nonflammable
2. Disassemble and reassemble parts on clean work
cleaning solvent and allow to drip dry. Compressed
surface. Clean all metal parts with non-flammable
air can be used but do not spin the bearing.
cleaning solvent. Lubricate components, as
2. Discard bearings if the races and balls (or rollers) required, to aid assembly.
are pitted, scored, or burned.
Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
2.4 CYLINDER DRIFT TEST 2.5 PINS AND COMPOSITE BEARING REPAIR
Maximum acceptable cylinder drift is to be measured GUIDELINES
using the following methods. Filament wound bearings.
1. Pinned joints should be disassembled and
Platform Drift inspected if the following occurs:
Measure the drift of the platform to the ground. Lower a. Excessive sloppiness in joints.
booms (if equipped) slightly elevated, upper boom fully
b. Noise originating from the joint during operation.
extended with the rated load in the platform and power off.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes. 2. Filament wound bearings should be replaced if any
If the machine does not pass this test, proceed with the of the following is observed:
following.
a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
Cylinder Drift
c. Bearings that have moved or spun in their hous-
Table 2-2. Cylinder Drift ing.
d. Debris embedded in liner surface.
Max. Acceptable Drift
Cylinder Bore Diameter
in 10 Minutes 3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inches mm inches mm
inspection):
3 76.2 0.026 0.66
a. Detectable wear in the bearing area.
3.5 89 0.019 0.48
b. Flaking, pealing, scoring, or scratches on the pin
4 101.6 0.015 0.38 surface.
5 127 0.009 0.22 c. Rusting of the pin in the bearing area.
6 152.4 0.006 0.15
4. Re-assembly of pinned joints using filament wound
7 177.8 0.005 0.13 bearings.
8 203.2 0.0038 0.10
a. Housing should be blown out to remove all dirt
9 228.6 0.0030 0.08 and debris...bearings and bearing housings
must be free of all contamination.
Drift is to be measured at the cylinder rod with a calibrated b. Bearing / pins should be cleaned with a solvent
dial indicator. The cylinder oil must be at ambient temper- to remove all grease and oil...filament wound
ature and temperature stabilized. bearing are a dry joint and should not be lubri-
cated.
The cylinder must have the normal load, which is the nor-
c. Pins should be inspected to ensure it is free of
mal platform load applied.
burrs, nicks, and scratches which would dam-
age the bearing during installation and opera-
If the cylinder passes this test, it is acceptable.
tion.
NOTE: This information is based on 6 drops per minute cyl-
inder leakage.
• Disconnect the moment pin connection (where fitted) • To prevent electrical malfunction caused by low level
conductivity between pins when wet.
• Ground only to structure being welded.
Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors. This procedure
Do NOT Do the Following When Welding on applies to all plug connections not enclosed in a box. Sili-
JLG Equipment cone grease should not be applied to connectors with
• Ground on frame and weld on any other area than the external seals.
chassis. 1. To prevent oxidation, silicone grease must be
• Ground on turntable and weld on any other area than packed completely around male and female pins on
the turntable. the inside of the connector prior to assembly. This is
most easily achieved by using a syringe.
• Ground on the platform/support and weld on any other
area than the platform/support. NOTE: Over a period of time, oxidation increases electrical
• Ground on a specific boom section and weld on any resistance at the connection, eventually causing cir-
other area than that specific boom section. cuit failure.
• Allow pins, wear pads, wire ropes, bearings, gearing, 2. To prevent shorting, silicone grease must be packed
seals, valves, electrical wiring, or hoses to be between around each wire where they enter the outside of the
the grounding position and the welded area. connector housing. Also, silicone grease must be
applied at the joint where the male and female con-
nectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the con-
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY
nector should also be sealed.
RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.) NOTE: This condition is especially common when machines
are pressure washed since the washing solution is
much more conductive than water.
INTERVAL
Boom Assembly 9
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Platform Assembly 9
Platform 1,2 1,2
Railing 1,2 1 1,2
Gate 5 1 1,5
Floor 1,2 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 2 1,2,10 1,2,10
Turntable Assembly 9
Swing Bearing 1,2,14 1,2,3,13,14
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly 9
Tires 1 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 1 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Steer Components
Drive Motors
Drive Hubs 11 11
Functions/Controls 9
Platform Controls 5 5 6 6
Ground Controls 5 5 6 6
Function Control Locks, Guards, or Detents 1,5 1,5 5 5
Footswitch 1,5 5 5
INTERVAL
INTERVAL
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
4150548 D
3.1 TIRES & WHEELS pneumatic tire. When selecting and installing a replace-
ment tire, ensure that all tires are inflated to the pressure
recommended by JLG. Due to size variations between
Tire Inflation tire brands, both tires on the same axle should be the
The air pressure for pneumatic tires must be equal to the same.
air pressure that is stenciled on the side of the JLG prod-
uct or rim decal for safe and proper operational character- Wheel Replacement
istics.
The rims installed on each product model have been
designed for stability requirements which consist of track
Tire Damage width, tire pressure, and load capacity. Size changes such
For pneumatic tires, JLG Industries, Inc. recommends that as rim width, center piece location, larger or smaller diam-
when any cut, rip, or tear is discovered that exposes side- eter, etc., without written factory recommendations, may
wall or tread area cords in the tire, measures must be result in an unsafe condition regarding stability.
taken to remove the JLG product from service immedi-
ately. Arrangements must be made for replacement of the Wheel Installation
tire or tire assembly.
It is extremely important to apply and maintain proper
For polyurethane foam filled tires, JLG Industries, Inc. rec- wheel mounting torque.
ommends that when any of the following are discovered,
measures must be taken to remove the JLG product from
service immediately and arrangements must be made for
replacement of the tire or tire assembly. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE
PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS,
• a smooth, even cut through the cord plies which AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE
exceeds 3 inches (7.5 cm) in total length AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE
• any tears or rips (ragged edges) in the cord plies which ANGLE OF THE WHEEL.
exceeds 1 inch (2.5 cm) in any direction
Tighten the lug nuts to the proper torque to prevent
• any punctures which exceed 1 inch in diameter wheels from coming loose. Use a torque wrench to tighten
• any damage to the bead area cords of the tire the fasteners. If you do not have a torque wrench, tighten
the fasteners with a lug wrench, then immediately have a
If a tire is damaged but is within the above noted criteria,
service garage or dealer tighten the lug nuts to the proper
the tire must be inspected on a daily basis to insure the
torque. Over-tightening will result in breaking the studs or
damage has not propagated beyond the allowable crite-
permanently deforming the mounting stud holes in the
ria.
wheels. The proper procedure for attaching wheels is as
follows:
Tire Replacement
1. Start all nuts by hand to prevent cross threading. DO
JLG recommends a replacement tire be the same size, ply NOT use a lubricant on threads or nuts.
and brand as originally installed on the machine. Please
refer to the JLG Parts Manual for the part number of the
approved tires for a particular machine model. If not using
a JLG approved replacement tire, we recommend that
replacement tires have the following characteristics:
3. The tightening of the nuts should be done in stages. 1. Remove the two hex head bolts from the cover.
Following the recommended sequence, tighten nuts
per wheel torque chart.
TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
40 ft. lbs. 100 ft. lbs. 170 ft. lbs.
(55 Nm) (130 Nm) (255 Nm)
1. Planet Gear 13. Not Used 24. Ball 45 to 48. Not Used 60. Spindle
2. Planet Gear 14. Retaining Ring 25. Expander 49. Thrust Washer 61. Not Used
3. Sun Gear 15. Retaining Ring 26. to 28. Not Used 50. Not Used 62. Coupler
4. Shaft Nut 16. Retaining Ring 29. Housing Washer 51. Cover 63 to 65. Not Used
5. Planet Bolt 17. Support Disk 29. Ring Gear 52. Disk 66. Snap Ring
6. Support Ring 18. Not Used 31. & 32. Not Used 53. Bolt 67 to 80. Not Used
7. Planet Carrier 19. O-ring 33. O-ring 54. O-ring 81. Ball Bearing
8. Cover 20. Ring Seal 34. Retaining Ring 55. Pressure Spring 82. Snap Ring
9. Not Used 21. Plug 35 to 42. Not Used 56. Shaft Rod 83. Snap Ring
10. Roller Bearing 22. Ring Seal 43. Sun Gear Shaft 57 & 58. Not Used 84 to 87. Not Used
11. Roller Bearing 23. Bolt 44. Input Shaft 59. Disk Rotor 88. Wheel Stud
12. Roller Bearing
Assembly of end cover unit (8) Initial Start-Up and After Repairs
Before operating the machine, make sure that the drive is
1. Press sleeve (52) into cover (8).
filled with clean oil, approximately 0.2 us gallons (0.8 L).
2. Install "o" ring (54) into groove of cover (8). An accurate oil level is determined by the oil level plug,
which should be removed before oil fill.
3. Install shift rod (56) into cover (8).
4. Install the cover (51) into cover (8) and fix cover (51) With the gear case filled to their proper levels, start the
with hex bolts (53). Tighten bolts with torque wrench machine and allow sufficient time for run-in at moderate
to 6.3 ft. lbs. (8.5 Nm). pressure and speed before running at full speed. After 4
hours of operation, recheck oil level.Maintenance
Final Assembly Daily: - Check for oil leakage
1. Install thrust washer (29) in spindle (60). Weekly: - Check oil level
2. Install "o" ring (19) into groove of support ring (6). Monthly: - Check mounting bolt torque
3. Install planet gears (1) onto planet pins which are
part of spindle (60). Oil Change Interval-Gear Drive
4. Install snap rings (15) on planet pins of spindle (60) 1. Perform the first oil change after approximately 150
in order to fix the planet gears (1). hours.
5. Put ring gear (30) onto support ring (6) and fix ring 2. Subsequent changes, every 1500 hours or annually,
gear (30) with hex head bolts (23). Tighten bolts with whichever occurs first.
torque wrench to 15.5 ft. lbs.(21.1 Nm).
NOTE: Flush the drive before filling with new oil.
6. Insert the first stage planetary assembly (7) into
drive.
3.3 DRIVE HUB (S/N 115723 TO PRESENT)
7. Install “o” ring (33) in groove of ring gear (30).
8. Install end the cover unit (8) on shoulder ring gear Roll and Leak Testing
(30) and fix with snap ring (34). Torque-Hub units should always be roll and leak tested
9. Install seal rings (21) and screw plugs (22). before disassembly and after assembly to make sure
that the unit’s gears, bearings and seals are working
10. Before installation of motor, CHECK THAT THERE IS properly. The following information briefly outlines what
1-2mm OF CLEARANCE BETWEEN THE MOTOR to look for when performing these tests.
SPLINE SHAFT SHOULDER AND THE COUPLER
(62). THE ROLL TEST
11. Install the motor and reconnect hydraulic lines. The purpose of the roll test is to determine if the unit’s
gears are rotating freely and properly. You should be
12. Roll motor so that one fill plug is at 12 o’clock posi- able to rotate the gears in your unit by applying con-
tion, and the other is at 3 o’clock. Fill to bottom of 3 stant force to the roll checker. If you feel more drag in
o’ clock plug with gear oil. reinstall plugs the gears only at certain points, then the gears are not
rolling freely and should be examined for improper
installation or defects. Some gear packages roll with
more difficulty than others. Do not be concerned if the
gears in your unit seem to roll hard as long as they roll
with consistency.
THE LEAK TEST (MAIN UNIT)
The purpose of a leak test is to make sure the unit is air
tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to
fall after the unit has been pressurized and allowed to
equalize. Leaks will most likely occur at the pipe plugs,
the main seal or wherever o-rings or gaskets are
located. The exact location of a leak can usually be
detected by brushing a soap and water solution
around the main seal and where the o-rings or gaskets
meet on the exterior of the unit, then checking for air Main Disassembly
bubbles. If a leak is detected in a seal, o-ring or gasket,
the part must be replaced, and the unit rechecked. 1. Perform Roll Check and Leak Check if applicable
Leak test at 10 psi for 20 minutes. prior to disassembling the unit.
Tightening and Torquing Bolts 2. Drain oil from unit. Note the condition and volume of
the oil.
If an air impact wrench is used to tighten bolts, extreme
care should be taken to ensure that the bolts are not 3. Remove Coupling (7) from Spindle End first.
tightened beyond their specified torque. 4. Remove Retaining Ring (6G) by prying the open end
The following steps describe how to tighten and torque of Retaining Ring out of the groove in the Ring Gear
bolts or socket head cap screws in a bolt circle. (1F) with a screwdriver, then grasp the loose end
with pliers and pull the Retaining Ring completely
1. Tighten (but do not torque) bolt "A" until snug. out of the groove.
2. Go to the opposite side of the bolt circle and tighten 5. Remove the Cover Subassembly (6) from the unit.
bolt "B" until equally snug. The unit can be carefully pressurized with air to pop
the cover out of the unit. Washer (2) may have to be
3. Crisscross around the bolt circle and tighten remain-
removed separately because of the loose attach-
ing bolts.
ment.
4. Now use a torque wrench to apply the specified
6. Remove the First Stage Sun Gear (10) if applicable.
torque to bolt "A".
5. Using the same sequence, crisscross around the NOTE: On units with ratios greater than 36:1 numerically,
bolt circle and apply an equal torque to the remain- there will not be a separate First Stage Sun Gear
ing bolts. (10), as the gear teeth will be integral to the Input
Shaft (9).
NOTE: On units with a ratio 48:1, the Sun Gear (11) and the
Input Shaft (9) will need to be removed together.
Output Carrier Disassembly 3. Using a 1/8" diameter punch, drive the Roll Pin (4G)
out of the Planet Shaft (4E). NOTE: The Roll Pins
1. Using a 1/8" diameter punch, drive the Roll Pin (4G) (4G) should not be reused when reassembling the
into the Planet Shaft (4E) until it bottoms against the unit.
Carrier (3A).
4. Slide the Planet Gear Sub-assembly (4) out of the
2. Using a soft face hammer, tap the Planet Shaft (4E) Output Carrier (4A) being careful to not drop the
out of the Carrier (4A). Needle Bearings (4C) in the process.
5. Remove 4 Thrust Washers (4B), 28 Needle Rollers 6. Repeat Steps 1 though 5 for the remaining two
(4C) and the Thrust Spacer (4D) from the Second Planet Gears (4F).
Stage Planet Gear (4F).
7. Remove the Thrust Washer (4H) from the counter-
bore in the Output Carrier (4A).
1F Output Carrier
4B Thrust Washer
4C Needle Bearing
4D Thrust Spacer
4F Planet Gear
Figure 3-5. Planet Gear
Input Carrier Disassembly (4G) should not be reused when reassembling the
unit.
1. Using a 1/8" diameter punch, drive the Roll Pin (4G)
4. Slide the Planet Gear (3F) and the two Thrust Wash-
into the Planet Shaft (3E) until it bottoms against the
ers (3B) out of the Carrier (3A).
Carrier (3A).
5. Remove the 14 needle Bearings (3C) from the bore
2. Using a soft face hammer, tap the Planet Shaft (3E)
of the Planet Gear (3F).
out of the Carrier (3A).
6. Repeat steps 1 through 5 for each of the two remain-
3. Using a 1/8" diameter punch, drive the Roll Pin (4G)
ing planet gears.
out of the Planet Shaft (3E). NOTE: The Roll Pins
3A Carrier
3B Thrust Washer
3C Needle Bearing
3E Planet Shaft
3F Planet Gear
4G Roll Pin
1A Spindle 1H Stud
1D Tapered Bearing Cup 1J Retaining Ring Ext.
1E Tapered Bearing Cone 1N Spacer
1G Hub (Housing) 1Q Seal Boot
Figure 3-7. Hub Spindle
Cover Disassembly 4. Pull Disengage Rod (6D) out from Cover (6A).
5. Use appropriate tool to remove O-ring (6E) from
1. Remove O-Ring (17) from groove in Cover (6A).
internal groove in Cover (6A).
2. Remove Thrust Washer (2) from Cover (6A) pockets.
6. Remove two O-Ring Pipe Plugs (6F) from Cover
3. Unscrew two Hex Head Bolts (6C) and remove Dis- (6A).
engage Cap (6B) from Cover (6A).
2 Thrust Spacer
3A Input Carrier
6A Cover
6B Disengage Cap
6C Bolt, Hex
6D Dowel Pin
6E O-ring
6F Pipe Plug
17 O-ring
1. Apply a liberal coat of grease to the bore of one 1. Apply a liberal coat of grease to the bore of one Out-
Input Planet Gear (3F). put Planet Gear (4F).
2. Line the inside of the Planet Gear (3F) with 14 Nee- 2. Line the inside of the Planet Gear (4F) with 14 Nee-
dle Rollers (3C). dle Rollers (4C).
NOTE: The last roller installed must be installed end wise. NOTE: The last roller installed must be installed end wise.
That is, the end of the last roller must be placed in That is, the end of the last roller must be placed in
between the ends of the two rollers which form the between the ends of the two rollers which form the
space, and then slid, parallel to the other rollers, into space, and then slid, parallel to the other rollers, into
place. place.
3. Set Carrier (3A) in an upright position. 3. Place Spacer (4D) into the bore of the Output Planet
(4F).
4. Insert a Planet Shaft (3E) into the planet shaft hole in
the end of the Carrier (3A) opposite the splined end. 4. Repeat Step 2 to put in second roll of Needle Rollers
The end of the planet shaft that does NOT have the (4C).
roll pin hole should be inserted into the carrier
5. Apply grease to hold two Thrust Washers (4B)
FIRST.
together and onto Output Planet Gear (4F) counter-
5. Place one Thrust Washer (3B) onto the end of Planet bore. Do the same to the other side.
Shaft (3E). Make sure the flat faces towards the
6. Repeat Steps 1 -5 to finish the assembly of the two
inside of the carrier and make sure the button fits in
remaining Output Planet Gears (4F).
the pocket on the inside of the Carrier (3A) towards
the OD.
6. Following the thrust washer, place Planet Gear (3F)
with needle rollers, onto Planet Shaft (3E).
7. Following the planet gear, place one more Thrust
Washer (3B) onto Planet Shaft (3E). Align the Thrust
Washer (3B) in the same manner described in Step
5.
8. Now insert Planet Shaft (3E) through the opposite
planet shaft hole on Carrier (3A). Use an alignment
punch or similar tool to align the roll pin holes on
Carrier (3A) and Planet Shaft (3E).
NOTE: Be sure not to hit the Planet Gears (3F) when driving
in the Roll Pins (4G).
9. Drive Roll Pin (4G) down into the aligned roll pin
holes. Pin should be flush with the flat of carrier.
10. Repeat Steps 1-9 for the installation of the two
remaining Planet Gears (3F).
1. Place Thrust Washer (4H) into counterbore of Carrier NOTE: Spray a light film of oil on all component parts during
(4A). BE SURE the small diameter side of Washer assembly.
(4H) facing planet gear side.
1. Place Hub (1G) into pressing base. Press nine Studs
2. Place Planet Gear Sub-assembly (4) into Carrier (1H) into Hub.
(4A). Visually align the planet gear bore with one of
the planet shaft holes on the Carrier (4A). NOTE: Use enough pressure to press in studs. Don’t use
excessively high pressure to press in studs or hub
3. Insert a Planet Shaft (4E) into the planet shaft hole may crack.
described in Step 2 on Carrier (4A). The end of the
planet shaft that does NOT have the roll pin hole NOTE: Spray a generous amount of oil on bearings during
should be inserted into the Carrier (4A) FIRST. installation.
4. Now insert Planet Shaft (4E) through the first set of 2. Press Bearing Cup (1D), position "A", into Hub (1G)
Thrust Washers (4B), Planet gear, then the second using appropriate pressing tool.
set of Thrust Washers (4B). Use an alignment punch
3. Turn hub over and press Bearing Cup (1D), position
or similar tool to align roll pin holes on Carrier (4A)
"B", into hub using appropriate pressing tool.
and Planet Shaft (4E).
4. Place Bearing Cone (1E), into Bearing Cup (1D),
NOTE: Be sure not to hit the Planet Gears (4F) when driving position "B".
in Roll Pins (4G).
5. Grease Seal (1B) lip and press seal into Hub (1G)
5. Drive Roll Pin (4G) down into the aligned roll pin using appropriate tool until seal is flush with end of
holes. Pin should be flush with OD of Carrier (4A). hub.
6. Repeat Steps 1-5 for the installation of the two 6. Press Seal Boot (1Q) onto Hub (1G) if required. Turn
remaining Planet Gears (4F). Hub (1G) over and lower onto Spindle (1A).
7. Install Bearing Cone (1C) into Bearing Cup (1D),
position "A".
8. Place Bearing Spacer (1N) on top of Bearing Cone
(1C).
9. Using appropriate tool, install Retaining Ring (1J)
into Spindle (1A) groove. Make sure ring is com-
pletely seated in groove.
5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The 5. Place Output Carrier Sub-Assembly (4) into mesh
plugs should be hand tight according to SAE stan- with Spindle (1A) splines.
dard.
6. Place External Retaining Ring (5) over 13T spline to
the retaining groove on Input Shaft (9).
NOTE: For ratio 48:1, assemble Output Sun Gear (11) over
Input Shaft (9) first, then install External Retaining
Ring (5).
3.4 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in
cover (21).
IF THE SENSOR RING (12) IS DAMAGED OR NEEDS REPLACED, 10. Install new case seal (4) in cover (21).
THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT. THE SEN- 11. Position pressure plate (3) on cover (21) aligning
SOR RING IS NOT AVAILABLE AS A SERVICE PART. dowel pins (20) with holes in pressure plate.
5. Remove stack assembly, consisting of stator disc NOTE: A hydraulic press will simplify installation of pressure
(11), sensor ring (12), rotor disc (13), and plate (14) plate on cover. Clamp pressure plate in position
from cover (21). while tightening the cap screws.
6. Remove dowel pins (20), springs (15) and spring
12. Install capscrews (1) and washers (2) and tighten
retainer (16) from cover (21).
evenly to draw pressure plate (3) to cover (21).
NOTE: Note number and pattern of springs for reassembly Torque capscrews to 55 ft.lbs. (74.6 Nm).
purposes.
7. Remove retaining ring (17) from cover (21). IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
8. Remove shaft (10) by pressing or using a soft mallet BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED
on male end of the shaft. 2000 PSI (137.9 BAR) UNLESS TWO ADDITIONAL BOLTS ARE
USED FOR SUPPLEMENTAL CLAMPING.
9. Remove retaining ring (19) and bearing (18) from
shaft (10).
Bleeding
10. Press rotary oil seal (20) from cover (18). I
1. Clean all parts thoroughly before assembly. 3. Apply sufficient pressure to release brake and check
for proper operation in system.
2. Press new rotary seal (22) into cover (21). Note
direction of seal
3. Install new bearing (18) and retaining ring (19) on
shaft (10).
23
22
19
21
18
17
16
20
15
14
13
12
11
10
9
8
7
6
5
4
2
1
23
Corrective
Problem Cause Explanation
Action
Brake slips Excessive pressure In hydraulic If there is back pressure in the actuation line of the Check filters. hose size, restrictions
system brake, holding torque will be reduced. in other hydraulic components.
Oil In brake if designed for dry Wet linings generate 67% of the dry torque rating. If Replace oil seal in brake. Check
use the brake has oil In it, check the type of oil hydraulic motor seal. Check piston seals.
or gearbox. Note: Internal components will
1. Gearbox oil need to be inspected, cleaned, and
2. Hydraulic oil replaced as required.
Disc plates worn The thickness of the disc stack sets the torque level. Check disc thickness.
A thin stack reduces torque.
Springs broken or have taken a Broken or set springs can cause reduced torque - Check release pressure.
permanent set rare occurrence. (See spring replacement)
Brake drags or runs Low actuation pressure The brake should be pressurized to minimum of Place pressure gauge in bleed port
hot 1.38 bar (20 psi) over the full release pressure under & check pressure with system on.
normal operating conditions. Lower pressures will
cause the brake to drag thus generating heat.
Bearing failure If the bearing should fall. a large amount of drag can Replace bearing.
be generated.
Brake will not release Stuck or clogged valve Brakes are designed to come on when system pres- Place pressure gauge in bleed port
sure drops below stated release pressure. If pres- - check for adequate pressure.
sure cannot get to brake, the brake will not release. Replace defective line or compo-
nent.
Bad O-rings f release piston will not hold pressure, brake will not Replace o-rings.
release.
Discs frozen These brakes are designed for only limited dynamic Replace disc stack.
braking. A severe emergency stop or prolonged
reduced release pressure operation may result in
this type of damage.
Adjustment Procedure
1. Back off the locking nut and o-ring.
2. Thread the sensor in until it bottoms out (don’t use
excessive force).
For proper drive operation, the speed sensors must be
properly installed and adjusted. The sensor operates on a 3. Back-off 1-2 turns and align the notch with the axis
leading pulse to show direction. If installed wrong, the of the brake. Refer to Figure 3-14., Speed Sensor
sensor will not be able to sense the proper direction. Orientation.
4. Use a 1/2" wrench to hold the sensor and a 11/16"
wrench to snug the lock nut to the brake.
6. Use the right and left cursor keys to display ’SPEED 16. Use the right and left cursor keys on the analyzer to
0%" on the analyzer. highlight drive and press enter.
7. While watching the analyzer display, select drive for- 17. Use the right and left cursor keys to display "speed
ward. Be ready to remove your foot from the foot- 0%" ON THE ANALYZER.
switch if the machine lunges forward.
18. while watching the analyzer display, select drive for-
8. The analyzer display should read the following if the ward. Be ready to remove your foot from the foot-
RIGHT speed sensor is adjusted properly: "SPEED switch if the machine lunges forward.
20% FWD".
19. The analyzer display should read the following if the
9. If the speed sensor is adjusted improperly, the ana- left speed sensor is adjusted properly: "SPEED 20%
lyzer will display "SPEED 20%REV" and the machine FWD".
will lunge forward.
20. If the left speed sensor is adjusted improperly, the
10. Adjust the right speed sensor using the preceding analyzer will display "SPEED 20% REV", and the
Adjustment Procedure until the analyzer displays machine will lunge forward.
"SPEED 20% FWD" when forward is selected at the
21. Adjust the left speed sensor using the preceding
platform. The percentage displayed is not critical,
Adjustment Procedure until the analyzer displays
just the direction.
"SPEED 20% FWD" when forward is selected in the
11. After obtaining the display in step 10, operate the platform. The percentage displayed is not critical,
machine in both forward and reverse directions. The just the direction.
machine should be controllable in both directions
22. After obtaining the display in step 10, operate the
and will only drive at a maximum of creep speed.
machine in both the forward and reverse directions.
The display on the analyzer should match the direc-
The machine should be controllable in both direc-
tion selected.
tions and will only drive at a maximum of creep
12. After completing adjustment of the right sensor, plug speed. The display on the analyzer should match
the left sensor into the posi-tilt module. the direction selected.
13. Unplug the right sensor from the power module. 23. Plug in the right sensor to the power module.
14. Power up the machine in platform mode and plug in 24. Test the machine. The machine should now have
the analyzer in the platform. maximum drive speed available in both directions
and should be controllable in both directions. The
15. Use the right left cursor keys on the analyzer to high-
analyzer display should match the direction
light diagnostics and press enter.
selected.
3.6 OSCILLATING AXLE LOCKOUT TEST (IF 13. If lockout cylinders do not function properly, have
qualified personnel correct the malfunction prior to
EQUIPPED) any further operation.
ROLL TEST
The purpose of the roll test is to determine if the unit’s
gears are rotating freely and properly. You should be able
to rotate the gears in your unit by applying constant force
to the roll checker. If you feel more drag in the gears only
at certain points, then the gears are not rolling freely and
should be examined for improper installation or defects.
Some gear packages roll with more difficulty than others.
Do not be concerned if the gears in your unit seem to roll
hard as long as they roll with consistency.
LEAK TEST (MAIN UNIT) 1. Tighten (but do not torque) bolt “A" until snug.
The purpose of a leak test is to make sure the unit is air 2. Go to the opposite side of the bolt circle and tighten
tight. You can tell if your unit has a leak if the pressure bolt "B" until equally snug.
gauge reading on your air checker starts to fall after the
3. Crisscross around the bolt circle and tighten remain-
unit has been pressurized and allowed to equalize. Leaks
ing bolts.
will most likely occur at the pipe plugs, the main seal or
wherever o-rings or gaskets are located. The exact loca- 4. Now use a torque wrench to apply the specified
tion of a leak can usually be detected by brushing a soap torque to bolt "A".
and water solution around the main seal and where the o-
5. Using the same sequence, crisscross around the
rings or gaskets meet on the exterior of the unit, then
bolt circle and apply an equal torque to the remain-
checking for air bubbles. If a leak is detected in a seal, o-
ing bolts.
ring or gasket, the part must be replaced, and the unit
rechecked. Leak test at 10 psi for 20 minutes.
Motor Control Valve Disassembly
BRAKE TEST
1. Place unit on bench with the motor end up.
The brake test should be performed prior to disassembly
and after reassembly to ensure that the brake functions 2. Remove Hydraulic Tubing Assembly (20) by loosen-
properly and does not leak. The brake test procedure can ing Fittings (18) on both ends of tube with a wrench.
be found in the Motor-Brake Subassembly section of this
manual. NOTE: Items (18) & (19) are included on Item (20) when
ordering a replacement Tubing Assembly.
NOTE: Failure to perform this test may result in damaged or
ineffective brake parts. 3. Using a wrench, loosen jam nut on Elbow Fitting
(17) and remove fitting from Motor Control Valve
Tightening and Torquing Bolts (31).
If an air impact wrench is used to tighten bolts, extreme
care should be taken to ensure that the bolts are not tight- 4. Using a wrench, remove Fitting (21) from Brake
ened beyond their specified torque. Housing.
The following steps describe how to tighten and torque 5. Remove Motor Control Valve (31) from Motor (10) by
bolts or socket head cap screws in a bolt circle. removing the four Bolts (34) and washers (33).
5A. O-ring
11. Thrust Washer
12. Hex Bolts
1. With unit resting on bench with Motor (10) end up, 3. Remove Thrust Washer (11) from between Brake/
loosen Hex Bolts (12) and remove Brake/Motor Sub- Motor Subassembly and Carrier.
assembly from the Housing (1G) (See assembly
4. Remove one O-Ring Plug (13) from Motor (10) and
drawing).
one O-Ring Plug (13) from Brake Housing (6).
2. Remove O-Ring (5A) from between Brake/Motor
5. Remove O-Ring Plug (4) from Brake Housing (6).
Subassembly and Housing (1G) (See assembly
drawing).
6. Remove Motor (10) from Brake Housing (6) by 9. Remove Brake Piston (8-2) from Brake Housing (6)
removing four Bolts (15) incrementally until spring by slowly pressurizing brake port in Brake Housing
pressure is relieved. (6) with air.
7. Remove O-Ring (26) from between Motor (10) and 10. Remove O-Rings (8-1A) & (8-1C) and Backup Rings
Brake Housing (6). (8-1B) & (8-1D) from Brake Piston (8-2).
8. Remove Springs (8-6) & (8-7) from Brake Piston (8- 11. Remove Sun Gear (9).
2).
12. Remove Outer Plates (8-3) and Inner Plates (8-4)
from the Brake Housing (6).
13. Remove the Thrust Spacer (8-5).
WEAR EYE PROTECTION DURING THE NEXT STEP OF THIS PRO-
CEDURE.
Main Disassembly 3. Remove O-ring (5) from between Ring Gear (2) and
Housing Subassembly.
1. With the unit resting on the Output Shaft (Pinion)
4. Remove four Dowel Pins (14) from Housing Subas-
(1A), remove the Carrier Subassembly.
sembly.
2. Remove Ring Gear (2) from Housing Subassembly.
2. Ring Gear
5. O-Ring
14. Dowel Pins
28. Input Spacer
Hub-shaft Disassembly 4. Remove the Bearing Cone (1D) from the Housing
(1G).
1. Using retaining ring pliers, remove Retaining Ring
5. Invert the Housing (1G) and remove the Lip Seal
(1I) from groove in Output Shaft (1A) and discard.
(1B) if not already removed when Output Shaft (1A)
was pressed out of Housing (1G).
6. Using a bearing puller, remove the Bearing Cone
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
(1F) from the Output Shaft (1A).
2. Remove Thrust Washer (1H). 7. Bearing Cups (1C & 1E) will remain in Housing (1G).
3. While supporting the Housing (1G) on the Output NOTE: If bearing replacement is necessary, the Bearing
Shaft (1A) end, press the Output Shaft (1A) out of Cups (1C & 1E) can be removed with a slide ham-
the Housing (1G). mer puller or driven out with a punch.
NOTE: The Lip Seal (1B) may or may not be pressed out of
the Housing (1G) by the Bearing Cone (1D) during
this step.
Carrier Disassembly 3. Slide the Planet Gear (3F) and the two Thrust Wash-
ers (3B) out of the Carrier (3A).
1. Using a 1/4" punch, drive the Roll Pin (3G) which
4. Remove both rows of Needle Bearings (3C) and the
holds the Planet Shaft (3E) in the Carrier (3A) down
Spacer (3D) from the bore of the Planet Gear (3F).
into the Planet Shaft (3E) until it bottoms.
5. Using a 1/4" punch, drive the Roll Pin (3G) out of the
NOTE: Make sure that the Roll Pin has bottomed. Other-
Planet Shaft (3E).
wise, damage to the carrier could occur when the
Planet Shaft is removed. 6. Repeat Steps 1 through 5 for the remaining two
Planet Gears (3F).
2. Remove the Planet Shaft (3E) from the Carrier (3A).
1. Press Bearing Cup (1E) into Motor end of Housing 1. Apply a liberal coat of grease to the bore of Planet
(1G) using an appropriate pressing tool. Gear (3F). This will enable the Needle Rollers (3C) to
be held in place during assembly.
2. Invert Housing (1G) and press Bearing Cup (1C) into
Housing (1G) using an appropriate pressing tool.Set 2. Install the first row of 16 Needle Rollers (3C) into the
Bearing Cone (1F) onto Bearing Cup (1E). bore of Planet Gear (3F).
3. Using an appropriate pressing tool, press Seal (1B) 3. Insert Spacer (3D) into bore of Planet Gear (3F) on
into Housing (1G) until it is flush with the end of the top of the Needle Rollers (3C).
Housing (1G).
4. Place second row of Needle Rollers (3C) into bore of
4. Apply liberal amount of grease to lip of Seal (1B). Planet Gear (3F) against Spacer (3D) and remove
Planet Shaft (3E).
5. Invert Housing (1G) and lower onto Output Shaft
(1A). 5. Place Carrier (3A) on bench so that one of the Roll
Pin (3G) holes is straight up.
NOTE: Be careful not to damage seal while lowering Hous-
ing onto Output Shaft. 6. Paying attention to the location of the Roll Pin (3G)
hole in the Planet Shaft (3E), start Planet Shaft (3E)
6. Press Bearing Cone (1D) onto Output Shaft (1A) through the hole in Carrier (3A). Using ample grease
until it seats against the bearing shoulder. to hold it in position, slide one Thrust Washer (3B)
over the Planet Shaft (3E) with the tang resting in the
7. Place Thrust Washer (1H) onto Bearing Cone (1D). cast slot of the Carrier (3A).
7. Place the Planet Gear (3F) into position in Carrier
(3A) and push Planet Shaft (3E) through the Planet
EYE PROTECTION SHOULD BE WORN DURING THE NEXT STEP Gear (3F) without going all the way through.
OF THIS PROCEDURE.
8. Slide the second Thrust Washer (3B) between the
NOTE: Retaining Ring (1I) should never be reused in a Planet Gear (3F) and the Carrier (3A) with the tang of
repair or rebuild. the washer located in the cast slot of the Carrier
(3A). Finish sliding the Planet Shaft (3E) through the
8. Using retaining ring pliers, install Retaining Ring (1I) Thrust Washer (3B) and into the Carrier (3A).
into groove in Output Shaft (1A). If Retaining Ring
9. Position the non-chamfered side on the Planet Shaft
(1I) will not seat completely into groove, use an
(3E) roll pin hole so that it is in line with the hole in
appropriate pressing tool to press down on Bearing
the Carrier (3A) using a 1/8 inch diameter punch.
Cone (1D) while rotating Housing (1G). Reinstall
Thrust Washer (1H) and Retaining Ring according to NOTE: If Planet Shaft (3E) has a flat on the end, position the
preceding procedures. Tap the Retaining Ring (1I) flat toward the center of the Carrier (3A).
with a soft metal punch to ensure that the Retaining
Ring (1I) is completely seated in the groove of the 10. After using a 1/4" punch to align the Roll Pin (3G)
Output Shaft (1A). holes in the Carrier (3A) and the Planet Shaft (3E),
drive the Roll Pin (3G) through Carrier (3A) and into
9. Using a soft face hammer, hit the end of the Shaft
the Planet Shaft (3E) until the Roll Pin (3G) is flush
(1A) to remove the bearing preload.
with the bottom of the cast tang slot in the Carrier
10. Install O-ring Plug (1J) and torque to 23 to 24 ft-lbs. (3A). Use a 1/4" pin punch to make sure the Roll Pin
(3G) is flush in the slot.
Main Assembly NOTE: Be sure that Backup Rings (8-1B) & (8-1D) are
located as tightly into the grooves in the Piston (8-2)
(See Figure 3-21., Main Disassembly)
as possible to prevent them from being “shaved”
when Piston (8-2) is installed into Brake Housing (6).
1. With the Housing-Shaft Subassembly resting on the
Shaft (1A) install one Dowel Pin (14) into each of the
5. Apply grease sparingly to Piston (8-2) O.D. and the
four counter-bored holes in the Housing (1G) (See
cylinder bore of Brake Housing (6). Insert Piston (8-
assembly drawing) until they bottom out. Also at this
2) into cylinder of Brake Housing (6), be sure not to
time, mark the four Dowel Pin (14) holes on the O.D.
cut the O Rings (8-1A) & (8-1C) or Backup Rings (8-
of the Housing (1G) (See assembly drawing). This is
1B) & (8-1D).
for identification later in the assembly.
6. Install Compression Springs (8-6) into spring pock-
2. Install Thrust Spacer (28) into counter-bore in
ets in Piston (8-2).
splined end of the Output Shaft (1A).
7. Install Compression Springs (8-7) into Compression
3. Place O-Ring (5) into Housing (1G) counter-bore.
Springs (8-6) in spring pockets in Piston (8-2).
Use grease to hold O-ring in place.
8. Grease O-Ring (26) and install into counter-bore in
Brake Housing (6).
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE 9. Assemble Test Cover (See Tools at back of manual
SEATING THIS O-RING. for drawing) to Brake Housing (6) using four Bolts
(15) evenly tightening Bolts (15) to 80-100 ft-lbs.
4. Install Carrier Subassembly with splined end down
so that the spline of the Carrier Subassembly is in 10. Check the brake for release. Apply pressure to
mesh with the spline of the Housing-Shaft Subas- brake port in side of Brake Housing (6) while trying
sembly. Rotate carrier in assembly to check for free- to rotate Sun Gear (9) by hand. The brake should
dom of rotation. release between 200-255psi. Remove Test Cover.
5. With large shoulder side of Ring Gear (2) facing 11. Assuming that Brake passed the Brake Test, place
down, place Ring Gear (2) onto Housing-Shaft Sub- Motor (10) into Brake Housing (6) with splines of
assembly with gear teeth in mesh with the Planet Motor (10) meshing with splines of Sun Gear (9).
Gears (3f) in the Carrier (3A). The side of the Ring 12. Attach Motor (10) to Brake Housing (6) with four
Gear (4) with an "X" or punch mark stamped on it Bolts (15) and torque to Bolts (15) to 80–100 ft-lbs.
should be up and the marked hole should be at a
Dowel Pin (14) location. 13. 13. Install O-Ring Plug (13) and torque to 13–15 ft-
lbs.
Motor-Brake Subassembly
(See Figure 3-19., Motor and Brake Disassembly)
Motor-Brake Assembly
(See Figure 3-19., Motor and Brake Disassembly)
1. Place Brake Housing (6) on bench with flange end
down. Either block Brake Housing (6) up or place 1. Grease Thrust Washer (11) and install into counter-
over hole in bench large enough for the shoulder of bore of Carrier Subassembly, which should already
the Sun Gear (9) to rest on the bottom of the Brake be installed into the Main Subassembly.
Housing (6). Then install Sun Gear (9) with gear end 2. Grease O-Ring (5A) and install into counter-bore of
down into Brake Housing (6). the Brake Housing (6) in the Motor-Brake Subas-
2. Place Spacer (8-5) into Brake Housing (6) in bottom sembly.
of small counter bore below splines. 3. Install Motor-Brake Subassembly onto Main Assem-
3. Install brake disks, starting with an Outer Plate (8-3), bly using twelve Bolts (12). Torque bolts to 23 – 27 ft-
then alternating Inner Plates (8-4) and Outer Plates lbs.
(8-3) into splined bore.
4. Grease the O Rings (8-1A) & (8-1C) and Backup
Rings (8-1B) & (8-1D), and place them in their
respective grooves in the Piston (8-2). Make sure the
backup-rings are correctly positioned as per the
assembly print.
1. Assemble nut onto tubing with threaded end toward Figure 3-24. Setting Gear Backlash
the assembled end of the tube.
2. Assemble ferrule onto tube with the large tapered NOTE: The bearing high spot will be marked with yellow
end into the nut. paint.
3. Place tube tight against the flared fitting in the
assembly. 1. Place a shim, JLG P/N 4071009, between the pinion
and bearing high spot.
4. Lubricate threads and fitting end with hydraulic oil.
5. Slide ferrule and nut against fitting and hand tighten
nut to the fitting.
6. Mark nut in relation to the fitting.
7. Hold tube tight against fitting and tighten nut 1-1/4
turns of the nut past the marked location.
5. Tighten the setscrew (3) until the pinion is com- 4. Assure that the 0.0015" feeler gauge will not pene-
pletely snug against the shim and bearing and then trate under the bolt head to the bolt shank.
back off the setscrew.
5. Swing the turntable 90 degrees, and check some
6. Torque the setscrew to 50 ft.lbs. (70 Nm). selected bolts at the new position.
7. Tighten the jam nut (4). 6. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
8. Torque the four 3/4 inch capscrews (2) to 420 ft.lbs.
all quadrants.
(588 Nm).
7. Lower the boom to horizontal and fully extend the
9. Remove and discard the shim.
boom.
8. Swing the turntable over the side.
3.9 SWING BEARING
9. On the frame, at the front of the turntable, try to
insert the 0.0015" feeler gauge between the bolt
Turntable Bearing Mounting Bolt Condition head and hardened washer at the indicated posi-
Check tion.
10. Assure that the 0.0015" feeler gauge will not pene-
NOTE: This check is designed to replace the existing bear-
trate under the bolt head to the bolt shank.
ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of 11. Swing the turntable 90 degrees, and check some
machine operation and every 600 hours of machine selected bolts at the new position.
operation thereafter. If during this check any bolts
12. Continue rotating the turntable at 90 degrees inter-
are found to be missing or loose, replace missing or
vals until a sampling of bolts have been checked in
loose bolts with new bolts and torque to the value
all quadrants.
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and Check the turntable to bearing. Attach bolts as follows:
retorquing bolt or bolts recheck all existing bolts for
looseness. 1. Elevate the fully retracted boom to full elevation and
rotate the platform 90o.
Check the frame to bearing. Attach bolts as follows: 2. Swing the turntable over the side.
1. Elevate the fully retracted boom to full elevation and 3. At turntable rear, try and insert the 0.0015" feeler
rotate platform 90o. gauge between the bolt head and hardened washer
2. Swing turntable over the side. at the arrow indicated position.
4. Assure that the 0.0015" feeler gauge will not pene- Wear Tolerance
trate under the bolt head to the bolt shank.
1. With the boom positioned over the side of the
5. Swing the turntable 90 degrees, and check some
machine, the Boom horizontal with telescope fully
selected bolts at the new position.
extended, using a magnetic base dial indicator,
6. Continue rotating the turntable at 90 degrees inter- measure and record the distance between the swing
vals until a sampling of bolts have been checked in bearing and turntable front.
all quadrants.
2. With the boom positioned over the side of the
.
machine, the Boom fully elevated, retracted, and
platform rotated 90o, using a magnetic base dial
indicator, measure and record the distance between
the swing bearing and turntable rear.
7. Lower the boom to horizontal and fully extend the Figure 3-26. Swing Bearing Tolerance Measuring Point
boom.
8. At turntable front, try and insert the 0.0015" feeler 3. If a difference greater than 0.057 in. (1.40 mm) is
gauge between the bolt head and hardened washer determined, the swing bearing should be replaced.
at the arrow indicated position.
4. If a difference less than 0.057 in. (1.40 mm) is deter-
9. Assure that the 0.0015" feeler gauge will not pene- mined, and any of the following conditions exist, the
trate under the bolt head to the bolt shank. bearing should be removed.
10. Swing the turntable 90 degrees, and check some a. Metal particles in the grease.
selected bolts at the new position. b. Increased drive power.
11. Continue rotating the turntable at 90 degrees inter- c. Noise.
vals until a sampling of bolts have been checked in d. Rough rotation.
all quadrants.
5. If bearing inspection shows no defects, reassemble
bearing and return to service.
Replacement of Swing Bearing NOTE: If Mobiltac 375NC is not available, Tribol Molub-Alloy
936 Open Gear Compound or Mobilith SHC Bearing
Removal of the swing bearing is as follows:
Grease or Multi-Purpose Grease (MPG) can be sub-
1. Attach an adequate support sling to the boom and stituted, however the service interval will be shorter.
draw all slack from sling. Prop or block the boom if
feasible. 4. Using suitable lifting equipment, install bearing/
assembly to frame with soft spot (red) 90 degree rel-
2. Tag and disconnect hydraulic lines running through
ative to load axis. If reusing old bearing, ensure that
center of turntable and frame. Use a suitable con-
scribed line of outer race of the bearing aligns with
tainer to retain any residual hydraulic fluid. Cap lines
the scribed mark on the frame.
and ports.
3. Attach suitable overhead lifting equipment to the
base of turntable weldment.
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8
4. Use a suitable tool to scribe a line on the inner race BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED
of the swing bearing and on the underside of the WITH NEW GRADE 8 NUTS AND BOLTS. SINCE THE SWING BEAR-
turntable. This will aid in aligning the bearing upon ING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND
installation. Remove bolts, nuts and washers which TURNTABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT
attach the turntable to the bearing inner race. Dis- HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG
card nuts and bolts. HARDWARE IS HIGHLY RECOMMENDED.
5. Use the lifting equipment to carefully lift the com- 5. Apply a light coating of Loctite 271 to the new bear-
plete turntable assembly from the bearing. Ensure ing bolts and loosely install the bolts and washers
that no damage occurs to the turntable, bearing or through the frame and outer race of bearing.
frame mounted components.
6. Carefully place the turntable on a suitably supported
trestle. IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT
NOTE: The bearing weighs approximately 100 lbs. (45 kg.). WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT
BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD
7. Use a suitable tool to scribe a line on the outer race BE CHECKED PRIOR TO USE.
of the swing bearing and the frame. This line will aid
in aligning the bearing upon installation. Remove the 6. Following the torque sequence diagram shown in
bolts and washers which attach the outer race of the Figure 3-28., Swing Bearing Torque Sequence,
bearing to the frame. Discard the bolts. Use suitable tighten the bolts to an initial torque of 130 ft. lbs.
lifting equipment to remove the bearing from the (175 Nm). Then following the same sequence,
frame; move to a clean, suitably supported work tighten to a final torque of 190 ft. lbs. (260 Nm).
area. 7. Remove lifting equipment from bearing.
Installation of the swing bearing is as follows: 8. Use suitable lifting equipment to carefully position
the turntable assembly above the machine frame.
1. Install bearing to turntable with two capscrews, so
the grease hose is on the forward side of the frame 9. Carefully lower the turntable onto the swing bearing.
as close to the centerline of the turntable as the bolt Ensure that the scribed line of the inner race of the
pattern will allow. Do not tighten capscrews. bearing aligns with the scribed mark on the turnta-
ble. If a new swing bearing is used, ensure that the
2. Line up high spot (marked with yellow paint) of bear- filler plug fitting is at 90 degrees from the fore and aft
ing with center tooth of bull gear. Set backlash to centerline of the turntable.
0.008 - 0.012 inch (0.20 - 0.30 mm). Refer to Swing
Drive Installation. Tighten capscrews as shown in 10. Apply a light coating of Loctite 271 to the new bear-
Figure 3-28., Swing Bearing Torque Sequence ing bolts and install through the turntable and inner
race of bearing.
3. Grease bearing with Mobilith SHC Bearing Grease.
Grease fitting is on inside wall of inner race of bear-
ing.
11. Following the torque sequence shown in Figure 3- Swing Drive Installation
28., Swing Bearing Torque Sequence tighten the
bolts to an initial torque of 130 ft. lbs. (175 Nm). 1. Coat the threads of the socket head bolts securing
Then following the same sequence, tighten the bolts the swing drive to the mounting plate with Loctite
to 190 ft. lbs (260 Nm). #271 and torque to 120 ft.lbs. (168 Nm).
12. Remove the lifting equipment. 2. Position swing drive to location of bearing gear max
eccentric tooth. High spot is marked with yellow
13. Route hydraulic lines through center of turntable and
paint in tooth.
frame and connect as tagged prior to removal.
3. With the mounting plate pivoting about the shoulder
14. Using all applicable safety precautions, activate the
bolt, adjust backlash between the pinion and bear-
hydraulic system and functionally check swing sys-
ing gear teeth to 0.008 to 0.012 inch backlash
tem for proper and safe operation
(0.20mm to 0.30mm).
.
Setting Backlash
1. Place a shim (JLG P/N 4071009) between pinion
and bearing on high spot of bearing.
2. After applying Loctite #271 to the shoulder bolt,
torque to 420 foot-pounds (588 Nm).
3. Remove the lock pin on the turntable.
4. After applying Loctite #271, torque the four ¾"
socket head bolts to 120 foot-pounds (168 Nm).
5. Tighten the setscrew until the pinion is snug against
the shim and bearing.
Figure 3-28. Swing Bearing Torque Sequence 6. Torque the setscrew to 50 foot-pounds (70 Nm).
7. Tighten the jam nut.
Swing Bearing Torque Value 8. Torque the four ¾" socket head bolts to 420 foot-
Install with Loctite - 190 ft. lbs. (260 Nm). pounds (588 Nm).
9. Recover the shim and throw it away.
Removing the Battery Box NOTE: The battery box and batteries complete weigh
approximately 668 pounds (303 kg).
To remove the battery box, perform the following steps.
3. Using a forklift, lift the battery box up enough to
1. Pull the pull ring to disconnect the batteries at the
clear the notch on the battery box rails and remove
battery disconnect beside the box.
the battery box from the machine.
2. Remove the two attachment bolts that secure the
battery box to the turntable.
15
12
19
7
13 14
20
18
1
2
3
1
17
8
10
6
9
11
INTERLOCK CONNECTOR
SCR
HEATSINK
WHITE
YELL
YELL
ORG
ORG
BLK
BE COVERED WITH VARFLEX
10 11 15 6 16 17
*OPTIONAL* CAPACITORS REQUIRED IN CE CHARGERS 8 WHT BLUE
8 1
7 GRN GRN
7 7 5
WHT
9 9 CIRCUIT
BOARD 4
HARNESS
13 WHT
13
12 BLK
12 3
12
LIGHT BOARD
WHT
14 * IN SOME CHARGERS
14 4 3 2 1 2 THIS MAY BE AN
1
REMOTE
BLACK
1 1 BLK AUTOMOTIVE FUSE.
2 2
WHITE WHT
2 GRN
3 GREEN TO 4POS CONN CONNECTORS ARE SAME.
4 3 RED
3 RED OF MAIN BOARD
4 4 J-2
PIN 1 RED
CONNECTOR
PIN 2 GRN
PIN 3 WHT
PIN 4 BLK
TDPH, if enabled, occurs after TDES has elapsed Crank Time -> Rest Time
and the engine temperature is below the factory set (Until Engine Start or # of
engine preheat temperature setting. The engine pre- Crank Cycles)
heater will be energized for the factory set preheat TDBP Bypass
delay period.
Normal Running Operation
Table 3-3. RBS Prestart Sequence
• RBS Shutdown Sequence
CTS (Call to Start)
Once all CTS conditions have been removed, the RBS will
TDES (Engine Start)
begin the shutdown sequence. If a CTS condition is initi-
Preheat Delay ated during the shutdown sequence, the RBS will return to
RBS Startup Sequence normal running operation until the CTS is removed.
1. Time Delay Engine Run (TDER)
• RBS Startup Sequence
3. Crank Time Once the CTS condition is removed, the TDER
period begins. This period ensures that no further
The RBS will crank for a period up to the crank time CTS conditions occur prior to the cooldown period.
or until the engine starts. 2. Time Delay Cooldown (TDC)
4. Rest Time
Once the TDER period ends, the alternator output is
If the engine does not successfully start, the RBS will reduced to a minimal level in order to allow the
wait for the rest time before attempting to crank the engine to cool down for the TDC period. If a CTS is
engine again. received during the TDC period, the CTS must last
for at least the TDES period for the RBS to return to
5. Crank Cycles normal running operation.
The RBS will attempt to start the engine up until the Table 3-5. RBS Shutdown Sequence
number of crank cycles is reached. If the RBS does
not start, an Overcrank fault is indicated. Remove CTS
TDER Engine Run
TDC Cooldown
Engine Stop
To Connect the JLG Control System Analyzer Alarms and Fault Flash Codes
to the Generator In the event of an RBS alarm, a flash code will be issued
and an alarm indicated on the analyzer.
The JLG Control System Analyzer can be used to monitor
generator settings and conditions. Connect the analyzer NOTE: Alarms must be reset once the fault has been cor-
as follows: rected.
Priming the Fuel Line 5. Clean up any spilled fuel and try to start the genera-
tor engine.
The following procedure is for re-priming the fuel line on
the generator engine in the event fuel system components 6. If the engine still doesn’t start, remove the steel line
have been replaced or the unit has been run dry of fuel. from the fuel injector pump.
1. Make sure the fuel line isn’t blocked or kinked. 7. Once fuel starts to flow, re-connect the fuel line to
the fuel injector pump.
2. Make sure fuel tank has fuel.
8. Clean up any spilled fuel and try to start the genera-
3. Disconnect the rubber fuel line at the fuel injector
tor engine.
pump.
9. If no fuel flows there are some possibilities:
a. There is no fuel getting to the injector pump. No
fuel in tank, or obstruction in fuel line, or clogged
inline fuel filter.
b. The engine/camshaft rotation is not opening the
injection fuel pump. Using the recoil starter,
rotate the engine 1/3 of a turn and fuel should
spill from the fuel injector pump.
10. Engine might run rough for 20 seconds or so, but it
will clean out.
3.12 GENERATOR (S/N 88375 TO PRESENT) Dynamo and Dynamo Voltage Regulator
NOTE: Throughout the Generator section, the abbreviation
RBS is used. RBS stands for Rotary Battery System,
which is the generator system.
Engine
Peak rating:
Continuous rating:
6.2 HP The engine is equipped with a dynamo and dynamo volt-
0.6 HP at 3600 RPM age regulator.
Refer to the Engine Manual for a complete description of Dynamo output: 12V
the engine. 7A DC
Refer to the Engine Manual for a complete description of
Alternator the dynamo and dynamo voltage regulator.
13
10
12
11
8 9
10 5
1. Glow Plug Relay 8. Temperature Sensor 12
2. Fuel Control Relay 9. Voltage Regulator
3. Start Control Relay 10. Alternator
13
4. Fuel Solenoid 11. Starter
5. Fuel Filter 12. Starter Solenoid
6. Low Oil Pressure Switch 13. Oil Filter
7. Glow Plug
3
2 6
4
1
Engine Starter
The fuel control relay energizes the hold coil of the fuel The glow plug control relay energizes the glow plug. It is
solenoid. energized by the engine/generator controller, pin J2-27.
The fuel control relay is energized by the engine/ The glow plug control relay is located on the fuel solenoid
generator controller from pin J2-3. bracket on the right side of the engine.
The fuel control relay is located on the fuel solenoid
bracket on the right side of the engine. Glow Plug
The glow plug is a resistive heating element located in the
combustion chamber. It is used during starting at temper-
atures below 32°F (0°C).
The heater is energized by the glow plug control relay.
The fuel pump runs in parallel with the fuel solenoid hold
coil which is run by the fuel control relay.
The pump runs whenever the engine runs, and keeps the
fuel filter filled. Excess fuel flows through the return line
back to the fuel tank.
The engine is equipped with a low oil pressure switch.
The fuel pump is located on the right side of the engine. This switch is closed when the oil pressure is below 7psi.
It is mounted on the side cover.
Fuel Solenoid
Engine Oil Temperature Sensor
engine. The signal is also used in determining if the air RBS Engine/Generator Controller
glow plug should be energized.
The control system enclosure houses the RBS engine/
The engine oil temperature sensor is connected to the
generator controller, which performs all control tasks
engine/generator controller at pins J2-8 and J2-19.
associated with the RBS.
The engine oil temperature sensor is located on the left
The engine/generator controller interface is via a J2 35-pin
side of the engine.
connector.
Alternator Output Current Sensor Table 3-7. Controller Interface Pin Assignments
The alternator output current sensor provides a signal pro-
portional to the output current of the alternator to the PIN FUNCTION
engine/generator controller. The output current is regu- 1 System 48VDC
lated at 45ADC. 2 System 0V DC
The alternator output current sensor is connected to the 3 Fuel solenoid
engine/generator controller at pins J2-21, J2-31 and J2-
4 Starter Solenoid
32.
5 Manual call to start
The alternator output current sensor is located inside the
rear cover of the alternator. 6 Low oil pressure
7 Not used
Engine Speed Sensor 8 Engine oil temperature
9 Speed sensing input
10 RS-232 +12V
11 RXD
12 TXD
13 LED Driver GND
14 LED Driver +48V
15 Speed sensor GND
16 Not used
17 Not used
18 - Output voltage
The engine speed sensor provides a signal proportional 19 Engine oil temperature/ambient temp. + 8V
to the rotational speed of the engine to the engine/genera- 20 Speed Sensing + 8V
tor controller. This signal is used by the engine/generator 21 Output current sensor (GND)
controller to determine starter cut-out, overspeed fault and
22 Not used
underspeed fault. If the signal is not present at the engine/
generator controller, the unit will fault with a loss of speed 23 RS-232 GND
signal indication. 24 - Field drive
The engine speed sensor is connected to the engine/gen- 25 + Start battery
erator controller at pins J2-9, J2-15 and J2-20. 26 - Start battery
The engine speed sensor is located inside the recoil 27 Pre-heat
starter cover at the front of the engine.
28 Inhibit run
29 Engine temp. switch
30 + Output voltage
31 Speed sensing + 5V
32 Output current sense
33 Not used
34 Not used
35 Field Drive
THE RBS MAY START WITHOUT WARNING. Low battery voltage call to start level 48.0 VDC
Low battery voltage remove call to start level 54.0 VDC
Low temperature call to start level 5°C
Low temperature remove call to start level 8°C
MORE THAN ONE LIVE CIRCUIT IS USED INSIDE THE RBS CON-
TROL PANEL. EXERCISE CAUTION WHEN THE CONTROL PANEL Low start battery voltage call to start level 12.2 V
IS OPEN, EVEN WHEN THE RBS IS NOT RUNNING. Low start battery voltage remove call to start level 12.9 V
CRANK SETTINGS
Crank time 15s
Reset time 15s
Crank cycles 3
Alarms must be reset once the fault has been corrected Maintenance Schedule
(see below).
Check oil level every 24 hours
Resetting the RBS Controller Change engine oil and filter every 150 hours
The RBS can be reset using the analyzer or by disabling
and re-enabling the RBS controller. This will clear any cur-
rent fault condition with the controller.
Troubleshooting
Check the warning LED. Remedy fault if present and restart the RBS.
Check that the ambient temperature is within the design limits of the engine.
Ensure there is an adequate supply of combustion air to the engine. Check air
cleaner.
Verify setting of governor lever. Readjust if required.
If the engine exhaust contains white smoke then fuel is entering the engine but
the engine is not firing. Refer to the Kubota OC60 Engine Manual for further
checks.
If the ambient temperature is low, verify that the heater and/or glow plug are
operating.
1-5 No Speed Signal Check wiring connections.
2-1 Overvoltage Check alternator output voltage.
3.13 SUPPLEMENTARY FUSE FOR ENGINE 2. Find where the harness attaches to the rear cover of
the generator and the connection point for the new
GENERATOR CONTROLLER inline fuse.
The purpose of this section is to describe the procedure to
add a supplementary fuse for the Engine Generator Con-
troller for the APU.
conductors of the harness. 6. Re-install the harness with the new fuse in place.
NOTES:
11. Position the jib to the pivot points and install the jib
pivot pin and the slave cylinder pivot pin.
12. Connect the hydraulic lines running to the jib cylin-
der as tagged during removal. If equipped with a
side swing jib, connect the hydraulic lines running to
the jib rotator.
13. Install the platform support and platform.
13. Remove the upper master cylinder pivot pin. 14. Install the hydraulic lines to the platform valve and
14. Remove the boom pivot pin. rotator as tagged during removal.
15. Remove the boom link pivot pin. 15. Reconnect the electrical leads at the platform and
platform valve as tagged during disassembly.
NOTE: The standard boom assembly weighs approximately
16. Cycle test the boom from the ground station to
1993 lbs. (904 kg).
ensure all functions operate properly.
16. Using an adequate lifting device, remove the boom 17. After verifying that all functions operate properly
from the machine. from the ground station, cycle test the boom from
the platform station to ensure all functions operate
Installation properly from the platform station as well.
4.2 LOAD CELL CALIBRATION PROCEDURE 13. Remove the weight from the basket.
14. Adjust P2 until the load = 0%.
1. Place the machine in the stowed position.
15. Place 500 lbs. (230kg) in the center of the basket.
2. Activate both emergency stop switches and turn the
key switch to the platform position. 16. Adjust P1 until the load = 95%.
3. Remove all loads from the basket including the 17. Add 55lbs. (25kg) in center of the basket.
operator.
18. Verify that the overload lamp lights continuously and
4. Turn P1 clockwise (in) until the potentiometer begins the alarm sounds continuously during an overload
to click. condition.
5. Plug the analyzer into the port in the platform. 19. Remove weight from the basket.
6. Enter the password 33271. 20. Seal Potentiometers with fingernail polish.
7. Select Machine Set-Up/Load Cell/ 1=Warn Only. 21. When an overload condition is reached, the
machine will give an indication by activating the tilt
8. Select Diagnostics/System/Load Cell on the Ana-
alarm, lighting the overload light, put all platform
lyzer.
functions into creep, cutout lift up and telescope out
9. Adjust P2 until the load = 0%. at platform and ground.
The horn will be activated when MTB ground control
10. Place 455 lbs. in the center of the basket.
switch is selected to ground and overload condition
11. Adjust P1 until the load = 100%. is reached.
12. Verify that the overload lamp lights continuously and
the alarm sounds continuously during an overload
condition.
C,D
1. Housing & Ring Gear 5. End Cap 15. O-ring 21. O-ring
2A. Shaft 6. Locknut 16. Exclusion Seals 22. O-ring
2B. Flange 7. Capscrew 17. Piston Bearing P1 Pressure Port
2C. Bearing Tube 9. Piston Seal 18. Radial Bearing P2 Pressure Port
3. Piston Sleeve 11. Piston Seal 19. Radial Bearing
4. Piston 14. O-ring 20. Thrust Bearing
Figure 4-9. Platform Rotator Assembly - Cutaway
If the actuator is not equipped with grease fittings, the preventing piston movement and locking the shaft in posi-
thrust bearings (20) are coated with good grease before tion.
sliding on the shaft and end cap. The shaft is installed by
again aligning the proper punched timing marks. Tempo-
rarily taping the threaded portion of the shaft will help
installation past the shaft seals (masking tape works well).
Apply anti-seize to threaded and surrounding areas of the
end caps. Also, depending on the size of the actuator
(60K and larger), the end cap may need to be installed
with the actuator in a vertical position.
The end cap (5) is torqued to 60-400 ft-lb (84-560 Nm)
depending on the actuator size, such that the actuator
begins rotation at approximately 100 psi (6.9 bar) pres-
sure. The shaft flange cannot be rotated by hand; the
combined backdrive efficiency and friction prevent man-
ual rotation. If the end cap is torqued too high, the actua-
tor may require as much as 300 psi (20.7 bar) to rotate. If
the end cap is not torqued high enough, shaft axial motion
and radial backlash will result. The end cap must be
secured against the shaft by tightening cap screws (7), or
by installing axial setscrews, depending on the
model. Apply hydraulic pressure and check for breakaway
pressure and shaft axial motion.
To test for leakage, pressurize Port P2 to 3000 psi (206.8 Bars indicate starting posi- As fluid pressure is applied,
tio ns of pisto n and shaft. the piston is displaced axially
bar). No oil should seep from Port P1 or from around end
Arrows indicate direction they while the helical gearing
cap (5). Repeat test by pressurizing Port P1 and check for
will rotate. The housing with causes the piston and shaft to
leakage out of Port P2, around shaft flange (2B), and from integral ring gear remains sta- rotate simultaneously. The
ring gear pin welds. tionary. double helix design com-
pounds rotation: shaft rota-
4.4 PLATFORM ROTATOR (S/N tion is about twice that of the
piston.
0300130810 TO PRESENT)
Theory of Operation The shaft is supported radially by the large upper radial
bearing and the lower radial bearing. Axially, the shaft is
The L20 Series rotary actuator is a simple mechanism that separated from the housing by the upper and lower thrust
uses the sliding spline operating concept to convert linear washers. The end cap is adjusted for axial clearance and
piston motion into powerful shaft rotation. Each actuator is locked in position by set screws or pins.
composed of a housing with integrated gear teeth (01)
and only two moving parts: the central shaft with inte-
grated bearing tube and mounting flange (02), and the
annular piston sleeve (03). Helical spline teeth machined
on the shaft engage matching splines on the in- side
diameter of the piston. The outside diameter of the piston
carries a second set of splines, of opposite hand, which
engage with matching splines in the housing. As hydraulic
pressure is applied, the piston is displaced axially within
the housing - similar to the operation of a hydraulic cylin-
der - while the splines cause the shaft to rotate. When the
control valve is closed, oil is trapped inside the actuator,
Required Tools 6. Pry bar - removal of end cap and manual rotation of
shaft.
Upon assembly and disassembly of the actuator there are
basic tools required. The tools and their intended func- 7. Rubber mallet- removal and installation of shaft and
tions are as follows: piston sleeve assembly.
8. Nylon drift - installation of piston sleeve
9. End cap dowel pins - removal and installation of end
cap (sold with Helac seal kit).
The seal tool is merely a customized standard flat head
screwdriver. To make this tool you will need to heat the flat
end with a torch. Secure the heated end of the screwdriver
in a vice and physically bend the heated end to a slight
radius. Once the radius is achieved round off all sharp
edges of the heated end by using a grinder. There may be
some slight modifications for your own personal prefer-
ence.
If the pin will not come out with the ”Easy Out”, use
6. Remove the end cap (4) and set aside for later 8. Every actuator has timing marks for proper engage-
inspection. ment.
10. Remove the shaft (2). It may be necessary to strike 13. At the point when the piston gear teeth come out of
the threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the
piston and housing with a marker as shown.
11. Before removing the piston (3), mark the housing (1)
ring gear in relation to the piston O.D. gear. There 14. Remove the o-ring (204) and backup ring (207) from
should now be timing marks on the housing (1) ring end cap (4) and set aside for inspection.
gear, the piston (3) and the shaft (2).
15. Remove the wear guides (302) from the end cap (4)
12. To remove the piston (3) use a rubber mallet and a and shaft (2).
plastic mandrel so the piston is not damaged.
16. To remove the main pressure seals (205), it is easi- 19. Remove the piston O.D. seal (202).
est to cut them using a sharp razor blade being
careful not to damage the seal groove.
20. Remove the piston I.D. seal (200). You may now pro-
ceed to the inspection process.
17. Remove the thrust washers (304), from the end cap
(4) and shaft (2).
18. Remove the wiper seal (304.1) from its groove in the
end cap (4) and shaft (2).
Assembly
1. Gather all the components and tools into one loca-
tion prior to re-assembly. Use the cut away drawing
to reference the seal orientations.
2. Inspect the thrust washers (304) for rough or worn
edges and surfaces. Measure it’s thickness to make
sure it is within specifications (Not less than 0.092”
or 2.34 mm).
2. Install the thrust washer (304) onto shaft (2) and end 4. Using a seal tool install the main pressure seal (205)
cap (4). onto shaft (2) and end cap (4). Use the seal tool in a
circular motion.
3. Install the wiper seal (304.1/green 0-ring) into it’s 5. Install the wear guide (302) on the end cap (4) and
groove on the shaft (2) and end cap (4) around the shaft (2).
outside edge of the thrust washer (304).
6. Install the inner T-seal (200) into the piston (3) using
a circular motion.
Each T-seal has 2 back-up rings (see drawing for ori- 7. Insert the piston (3) into the housing (1) as shown,
entation). until the outer piston seal (202) is touching inside
the housing bore.
9. Looking from the opposite end of the housing (1) 11. Looking from the view shown, use the existing tim-
you can see if your timing marks are lining up. When ing marks to line up the gear teeth on the shaft (2)
they do, tap the piston (3) in until the gear teeth with the gear teeth on the inside of the piston (3).
mesh together. Tap the piston into the housing the Now tap the flange end of the shaft with a rubber
rest of the way until it bottoms out. mallet until the gear teeth engage.
10. Install the shaft (2) into the piston (3). Be careful not 12. Install 2 bolts in the threaded holes in the flange.
to damage the seals. Do not engage the piston gear Using a bar, rotate the shaft in a clockwise direction
teeth yet. until the wear guides are seated inside the housing
bore.
13. Install the stop tube onto the shaft end. Stop tube is
an available option to limit the rotation of an actua-
tor.
14. Coat the threads on the end of the shaft with anti- 17. Tighten the end cap (4). In most cases the original
seize grease to prevent galling. holes for the lock pins will line up.
18. Place the lock pins (109) provided in the Helac seal
15. Install the 0-ring (204) and back-up ring (207) into
kit in the holes with the dimple side up. Then, using
the inner seal groove on the end cap (4).
a punch, tap the lock pins to the bottom of the hole.
16. Thread the end cap (4) onto the shaft (2) end. Make
sure the wear guide stays in place on the end cap as 19. Insert the set screws (113) over the lock pins.
it is threaded into the housing (1). Tighten them to 25 in. lbs. (2.825 Nm).
turning in a counterclockwise direction as shown and the root of a spline tooth on the shaft gearing
below. indicate timing as seen below.
6. With the shaft removed, note the orientation of the ing using the handle of a rubber mallet as shown
timing marks on the piston sleeve and ring gear in below.
the housing as below.
washer comes to a stop against the housing thrust 11. Apply a generous amount of anti-seize to the splines
surface. at the end of the shaft. Locate the correct position of
the locknut to align its bolt circle with that of the end
cap. If the bolt circles do not align, unthread the end
cap no more than a half a pitch of the shaft splines.
Insert the cap screws and torque to 108 IN-LB (147
N.m).
12. Grease the thrust washers. Pump a high quality
NLGI-2 lithium based grease into the grease fittings
at both ends of the housing until it begins to ooze
from the grease reliefs. If possible, rotate the shaft
during greasing to ensure even distribution on the
thrust surfaces.
Installing Counterbalance Valve 3. The bolts that come with the valve are grade 8 bolts.
New bolts should be installed with a new valve. Loc-
Refer to Figure 4-14., Rotator Counterbalance Valve. tite #242 should be applied to the shank of the three
bolts at the time of installation.
1. Make sure the surface of the actuator is clean, free
of any contamination and foreign debris including 4. Torque the 1/4-inch bolts 110 to 120 inch pounds
old Loctite. (12.4 to 13.5 Nm). Do not torque over 125 inch
pounds (14.1 Nm). Torque the 5/16-inch bolts 140
2. Make sure the new valve has the O-rings in the
inch pounds (15.8 Nm). Do not torque over 145 inch
counterbores of the valve to seal it to the actuator
pounds (16.3 Nm).
housing.
Testing the Actuator collect the purged oil. The oil can be returned to the
reservoir after this procedure is completed.
If the equipment is available, the actuator should be tested
on a hydraulic test bench. The breakaway pressure — the
pressure at which the shaft begins to rotate — should be
approximately 400 psi (28 bar). Cycle the actuator at least
25 times at 3000 psi (210 bar) pressure. After the 25 rota-
tions, increase the pressure to 4500 psi (315 bar) to check
for leaks and cracks. Perform the test again at the end of
the rotation in the opposite direction.
Installation and Bleeding 2. With an operator in the platform, open both bleed
nipples 1/4 turn. Hydraulically rotate the platform to
After installation of the actuator on the equipment, it is the end of rotation (either clockwise or counterclock-
important that all safety devices such as tie rods or safety wise), and maintain hydraulic pressure. Oil with
cables are properly reattached. small air bubbles will be seen flowing through the
To purge air from the hydraulic lines, connect them tubes. Allow a 1/2 gallon of fluid to be purged from
together to create a closed loop and pump hydraulic fluid the actuator.
through them. Review the hydraulic schematic to deter- 3. Keep the fittings open and rotate the platform in the
mine which hydraulic lines to connect. The linear feet and opposite direction to the end position. Maintain
inside diameter of the hydraulic supply lines together with hydraulic pressure until an additional 1/4 gallon of
pump capacity will determine the amount of pumping time fluid is pumped into the container.
required to fully purge the hydraulic system.
4. Repeat steps 2 & 3. After the last 1/2 gallon is
Bleeding may be necessary if excessive backlash is exhib- purged, close both bleed nipples before rotating
ited after the actuator is connected to the hydraulic sys- away from the end position.
tem. The following steps are recommended when a
minimum of two gallons (8 liters) is purged.
1. Connect a 3/16" inside diameter x 5/16" outside
diameter x 5 foot clear, vinyl drain tube to each of the
two bleed nipples. Secure them with hose clamps.
Place the vinyl tubes in a clean 5-gallon container to
Troubleshooting
Table 4-1. Troubleshooting
b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic
lines for restrictions and leaks.
c. Control or counterbalance valve has internal c. Disconnect hydraulic lines and bypass valve.
leak Leave valve ports open and operate the actuator
through housing ports (do not exceed OEM’s
operating pressure). The valve must be replaced if
a steady flow of fluid is seen coming from the valve
ports.
d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in
the Testing section on page 24 of this manual.
e. Corrosion build-up on the thrust surfaces e. Re-build the actuator. Remove all rust then pol-
ish. Replacement parts may be needed.
f. Swollen seals and composite bearings caused f. Re-build the actuator. Use fluid that is compati-
by incompatible hydraulic fluid ble with seals and bearings.
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. See bleeding proce-
dures.
3. Shaft will not fully rotate a. Twisted or chipped gear teeth a. Check for gear binding. Actuator may not be
able to be re-built and may need to be replaced.
Damage could be a result of overload or shock.
b. Port fittings are obstructing the piston b. Check thread length of port fittings. Fittings
should during stroke not reach inside the housing
bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal a. Disconnect hydraulic lines and bypass valve.
leak Leave valve ports open and operate the actuator
through housing ports (do not exceed OEM’s
operating pressure). The valve must be replaced if
a steady flow of fluid is seen coming from the valve
ports.
b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in
the Testing section on page 24 of this manual.
NOTES:
SECTION 5. HYDRAULICS
5.1 LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in
HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com-
When assembling connectors in the hydraulic that use o- pletely saturated.
ring fittings, it is necessary to lubricate all fittings with
hydraulic oil prior to assembly. To lubricate the fittings, use
one of the following procedures.
The following is needed to correctly oil the o-ring in this 2. Hold the fitting over a suitable catch can.
manner:
3. Spray the entire o-ring surface with a medium coat
of oil.
• A small leak proof container
• Sponge cut to fit inside the container
• A small amount of hydraulic oil to saturate the sponge.
1. Place the sponge inside the container and add
hydraulic oil to the sponge until it is fully saturated.
2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and
drip from the bottom of the fitting. This should signify
an even coating of oil on the fitting.
Brush-on Method
This method requires a sealed bottle brush.
5.2 CYLINDERS - THEORY OF OPERATION drops per minute or more, cylinder repairs must be
made.
Lift, Telescope, Slave, Master, Oscillation (if Cylinders With Single Counterbalance Valve
equipped), Jib (if equipped), and Steer Lift Cylinder and Oscillation Cylinder
A double acting cylinder is one that requires oil flow to
operate the cylinder rod in both directions. Directing oil
(by actuating the corresponding control valve to the pis-
ton side of the cylinder) forces the piston to travel toward OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION
the rod end of the barrel, extending the cylinder rod (pis- ONLY.
ton attached to rod). When the oil flow is stopped, move-
ment of the rod will stop. By directing oil to the rod side of 1. Using all applicable safety precautions, activate
the cylinder, the piston will be forced in the opposite direc- hydraulic system.
tion and the cylinder rod will retract.
Holding valves are used in the Lift circuits to prevent
retraction of the cylinder rod should a hydraulic line rup- WHEN WORKING ON THE UPPER BOOM LIFT CYLINDER RAISE
ture or leak develop between the cylinder and its related THE UPPER BOOM TO HORIZONTAL AND PLACE A BOOM PROP
control valve. APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. IF
WORKING ON LOWER BOOM LIFT CYLINDER, RAISE LOWER
BOOM HALFWAY, FULLY ELEVATE UPPER BOOM AND ATTACH
5.3 CYLINDER CHECKING PROCEDURES OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING
APPROXIMATELY 1 INCH (2.54 CM) OF SLACK IN CHAIN OR
NOTE: Cylinder checks must be performed any time a cylin- SLING FOR TEST PURPOSES.
der component is replaced or when improper system
operation is suspected. 2. After completing the above, shut down hydraulic
system and allow machine to sit for 10-15 minutes.
Cylinder Without Counterbalance Valves This is done to relieve pressure in the hydraulic
Steer Cylinder and Master Cylinder lines. Carefully remove hydraulic hoses from appro-
priate cylinder port block.
1. Using all applicable safety precautions, activate 3. There will be initial weeping of hydraulic fluid, which
hydraulic system and fully extend cylinder to be
can be caught in a suitable container. After the initial
checked. Shut down hydraulic system.
discharge, there should not be any further leakage
2. Carefully disconnect hydraulic hose from retract port from the ports. If leakage continues at a rate of 6-8
of cylinder. There will be initial weeping of hydraulic drops per minute or more, the following cylinder
fluid which can be caught in a suitable container. repairs must be made. If the retract port is leaking,
After initial discharge, there should be no further the piston is leaking, the piston seals are defective
leakage from the retract port. and must be replaced. If the extend port is leaking,
the counterbalance is defective and must be
3. Activate hydraulic system, and activate cylinder replaced.
extend function.
4. If no repairs are necessary or when repairs have
4. If cylinder retract port leakage is less than 6-8 drops been made, carefully reconnect hydraulic hoses to
per minute, carefully reconnect hose to retract port the appropriate ports.
and retract cylinder. If leakage continues at a rate of
6-8 drops per minute or more, cylinder repairs must 5. Remove boom prop/overhead crane, activate
be made. hydraulic system and run cylinder through complete
cycle to check for leaks and operation.
5. With cylinder fully retracted, shut down motor and
carefully disconnect hydraulic hose from cylinder
extend port.
6. Activate hydraulic system and activate cylinder
retract function. Check extend port for leakage.
7. If extend port leakage is less than 6-8 drops per min-
ute, carefully reconnect hose to extend port, then
activate cylinder through one complete cycle and
check for leaks. If leakage continues at a rate of 6-8
Cylinders With Dual Counterbalance Valve 1. Connect a suitable auxiliary hydraulic power source
to the cylinder port block fitting.
Telescope and Slave Cylinders
Disassembly
1. Loctite #242 (Not Shown) 7. Head 13. Piston 19. O-ring 25. T-Seal
2. Locking Primer 8. Rod 14. Wear Ring 20. O-ring 26. Spacer
3. Loctite #RC609 (Not Shown) 9. Barrel 15. Washer Ring 21. Setscrew 27. Counterbalance Valve
4. Bolt 10. O-ring Plug 16. Backup Ring 22. Bolt 28. Counterbalance Valve
5. Tapered Bushing 11. O-ring Plug 17. Wear Ring 23. Wiper
6. Bushing 12. Not Used 18. Backup Ring 24. Seal
1. Loctite #242 (Not Shown) 7. Bushing 13. O-ring Plug 18. Seal 23. Seal
2. Not Used 8. Bushing 14. Piston 19. Wear Ring 24. Wiper
3. Locking Primer (Not Shown) 9. Head 15. Not Used 20. Wear Ring 25. T-Seal
4. Loctite #RC609 (Not Shown) 10. Barrel 16. Backup Ring 21. O-ring 26. Bolt
5. Bolt 11. Rod 17. Backup Ring 22. O-ring 27. Counterbalance Valve
6. Tapered Bushing 12. Washer Ring
1. Loctite #242 (Not Shown) 7. Barrel 12. Piston 17. Wear Ring 22. Rod Seal
2. Locking Primer (Not Shown) 8. Rod 13. Backup Ring 18. O-ring 23. Wiper
3. Loctite (Not Shown) 9. Head 14. Backup Ring 19. O-ring 24. Check Valve
4. Bolt 10. O-ring Plug 15. Washer Ring 20. Capscrew 25. Counterbalance Valve
5. Tapered Bushing 11. Not Used 16. Wear Ring 21. Seal 26. Check Valve
6. Bushing
1. Loctite #242 (Not Shown) 7. Barrel 13. Piston 19. O-ring 24. Wiper
2. Locking Primer (Not Shown) 8. Rod 14. Support Plate 20. O-ring 25. Seal
3. Loctite (Not Shown) 9. Head 15. Wear Ring 21. Bolt 26. Rod Seal
4. Bolt 10. O-ring Plug 16. Backup Ring 22. Bolt 27. Spacer
5. Bolt 11. Not Used 17. Wear Ring 23. Backup Ring 28. Valve
6. Tapered Bushing 12. Support Pad 18. O-ring
NOTE: Steps 6 applies only to the telescope cylinders. 12. Remove the bushing from the piston.
3. Place a new o-ring and back-up seal in the applica- backup rings are to be positioned so as not to be in
ble outside diameter groove of the cylinder head. alignment with each other.
screws) through the drilled holes in the bushing and b. Tap each space once; this means the tapered
into the tapped holes in the piston. bushing is tapped 3 times as there are 3 spaces
between the capscrews.
Figure 5-17. Tapered Bushing Installation Figure 5-18. Seating the Tapered Bearing
12. Tighten the capscrews evenly and progressively in 14. Retorque the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 5-1, rotation to the specified torque value. (See Table 5-1,
Cylinder Head and Tapered Bushing Torque Specifi- Cylinder Head and Tapered Bushing Torque Specifi-
cations.) cations.)
13. After the screws have been torqued, tap the tapered 15. Remove the cylinder rod from the holding fixture.
bushing with a hammer (16 to 24 oz.) and brass
shaft (approximately 3/4" in diameter) as follows; 16. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
a. Place the shaft against the cylinder rod and in (See Figure 5-19., Poly-Pak Piston Seal Installation)
contact with the bushing in the spaces between
the capscrews.
17. Position the cylinder barrel in a suitable holding fix- Table 5-1.Cylinder Head and Tapered Bushing Torque
ture. Specifications
Figure 5-20. Rod Assembly Installation RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs.
(136-149 Nm)
21. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
22. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Table 5-2, Holding Valve Torque
Specifications).
Lift Down - 1100 psi (76 Bar) 2. Activate and bottom out telescope in. Adjust pres-
sure to 3000 psi (207 Bar).
Lift Up - 2500 (172 Bar)
Swing - 2500 psi (172 Bar) Steer
Flow Control - 3000 psi (207 Bar) 1. Connect the pressure gauge at the MP port on the
main valve.
Steer - 1800 (124 Bar)
2. Activate and bottom out steer right or left. Adjust
Platform Level Up - 2500 psi (172 Bar)
pressure to 1800 psi (124 Bar).
Platform Level Down - 1500 psi (103 Bar)
Jib Up - 2300 psi (158.5 Bar) Platform Level Down
Jib Down - 2300 psi (158.5 Bar) 1. Connect a pressure gauge to the M1 port on the
platform control valve bank.
NOTE: All functions must be activated from the platform
control station when adjusting pressures at the Plat- 2. Activate and bottom out Platform Level Down. Adjust
form Control and Main Valve Blocks. to 1500 psi (103 Bar).
Lift Up
1. Connect the pressure gauge at the MP port on the
main valve.
2. Activate lift up until end of lift cylinder stroke. Adjust
pressure to 2600 psi (179 Bar). If ceiling height will
not allow elevation, disconnect lift up hose (port #8
on valve bank) and cap the port to make the setting.
Swing
1. Connect the pressure gauge at the MP port on the
main valve.
2. Activate the swing function with the turntable lock
pin engaged. Adjust pressure to 2500 psi (172 Bar).
NOTES:
6.1 INTRODUCTION creep and max.-speed for all boom, drive, and steering
functions.
The motor controller will control current output, as pro-
WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON grammed for smooth operation and maximum cycle time.
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- Ground control speeds for all boom functions can also be
TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUD- programmed into the motor controller. The motor control-
ING OPTIONS. ler also features an adjustable time limit for positive trac-
tion.
The JLG Control System controller has a built in LED to
indicate any faults. The system stores recent faults which
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- may be accessed for troubleshooting. Optional equip-
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- ment includes an hour meter, beacon light, function cut-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- out, and ground alarm. These options may be added later
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC- but must be programmed into the motor controller when
OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A installed.
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO- The Control System may be accessed utilizing a custom
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE designed, hand held analyzer (Analyzer Kit, JLG part no.
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION. 2901443) which will display two lines of information at a
time, by scrolling through the program.
The JLG designed Control System is a 48 volt based
NOTE: Each module has a label with the JLG part number
motor control unit installed on the boom lift.
and a serial number which contains a date code.
The JLG Control System has reduced the need for
exposed terminal strips, diodes and trimpots and provides The following instructions are for using the hand held ana-
simplicity in viewing and adjusting the various personality lyzer.
settings for smooth control of: acceleration, deceleration,
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub
To return home or
Level, and item menus
access previous menu
6.2 TO CONNECT THE JLG CONTROL The top level menus are as follows:
LOGGED HELP
1: STARTUP ( 2/ 1)
HELP:
PRESS ENTER
LOGGED HELP
1: STARTUP (2/1)
HELP: At this point, the analyzer will display the last fault the sys-
PRESS ENTER tem has seen, if any are present. You may scroll through
At this point, using the RIGHT and LEFT arrow keys, you the fault logs to view what the last 25 faults were. Use the
can move between the top level menu items. To select a right and left arrow keys to scroll through the fault logs. To
displayed menu item, press ENTER. To cancel a selected return to the beginning, press ESC. two times. STARTUP
menu item, press ESC.; then you will be able to scroll (2/1) indicates a power up.
using the right and left arrow keys to select a different When a top level menu is selected, a new set of menu
menu item. items may be offered: for example:
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
Pressing ENTER with any of the above displayed menus, Once the correct password is displayed, press ENTER.
will display additional sub-menus within the selected The access level should display the following, if the pass-
menu. In some cases, such as DRIVE, the next level is the word was entered correctly:
parameter or information to be changed. Refer to the flow
chart for what menus are available within the top level
menus. You may only view the personality settings for
selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the MENU:
ESC. key. ACCESS LEVEL 1
MENU:
ACCESS LEVEL 2 MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings.
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the pass-
word.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
GROUND ALARM:
2=DRIVE
PERSONALITIES:
DRIVE ACCEL 1.0s
GROUND ALARM:
2 = DRIVE
PERSONALITIES:
The effect of the machine digit value is displayed along
DRIVE ACCEL 1.0s
with its value. The above display would be selected if the
There will be a minimum and maximum for the value to machine was equipped with a ground alarm and you
ensure efficient operation. The Value will not increase if wanted it to sound when driving. There are certain set-
the UP arrow is pressed when at the maximum value nor tings allowed to install optional features or select the
will the value decrease if the DOWN arrow is pressed and machine model.
the value is at the minimum value for any particular per-
sonality. If the value does not change when pressing the When selection the machine model to match the size of
up and won arrows, check the access level to ensure you the machine, the personality settings will all default to the
are at access level 1. factory recommended setting.
There is a setting that JLG strongly recommends that you Table 6-1. Machine Setup Descriptions
do not change. This setting is so noted below:
MODEL NUMBER... Displays/adjusts machine model NOTE:
ELEVATION CUTBACK all personalities reset to default when
model number is altered
CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER- DRIVE CUTOUT... Displays/adjusts drive cutout switch
presence/ function
FORMANCE OF YOUR MACHINE.
FUNCTION CUTOUT... Displays/adjusts function cutout switch
presence/function
ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- JIB. . . Displays/adjusts jib presence
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- GROUND ALARM... Displays/adjusts ground alarm presence/
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- function
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOM-
MENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A PLATFORM ALARM... Displays/adjusts platform alarm pres-
ence/ function
MINIMUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO- 4WD ASSIST... Displays/adjusts 4WD assist presence
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION. SOFT TOUCH Displays/adjusts soft-touch system
presence
6.7 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the
adjustment range in order to achieve optimum
machine performance.
MINimum IN speed 0 to 20 20
MINimum UP speed 0 to 20 3
MAXimum UP speed 0 to 50 22
MINimum UP speed 0 to 50 4
Default
Configuration Digit Number Description
Number
1 1 E600 1
MODEL #
2 M600
2 When tilted the tilt light is lit (continuously) and drive speed is reduced to the creep speed setting
TILT SENSOR
1 5 degree - reduces the maximum speed of all platform functions to creep when tilted and 1
above elevation. Reduces drive speed to creep when tilted. (Domestic/Japan)
2 4 degree - reduces the maximum speed of all platform functions to creep when tilted and above
elevation. Reduces drive speed to creep when tilted. (European/Australian)
3 4 degree - cuts out drive and reduces boom functions to creep speed when tilted and above ele-
vation. Reduces drive speed to creep when tilted only. (Option)
4 3 degree - reduces the maximum speed of all boom functions to creep when tilted and above
elevation. Reduces drive speed to creep when tilted. (CE and Australian E600JP, M600JP)
NOTE: Any of the selections above will light the tilt lamp when a tilted condition
occurs and will sound the platform alarm when the machine is tilted
and above elevation.
3 0 Battery Charger Cutout - cuts out drive when the battery charger is plugged in 0
DRIVE CUTOUT
1 Battery Charger Cutout and Simultaneous Drive and Boom functions disabled above elevation
(European/Australian)
2 Jib installed which has up and down movements and side to side movements
(Option)
6 0 No ground alarm installed 0
GROUND
ALARM 1 Travel Alarm - Sounds when the drive function is active (Option)
Default
Configuration Digit Number Description
Number
7 0 Sounds continuously when above elevation and tilted only. 0
PLATFORM
ALARM 1 Sounds continuously when above elevation and tilted, and in conjunction with
fault code flashes (Option)
8 0 0=No Soft Touch system installed 0
SOFT TOUCH
1 1= Soft Touch system installed (Option)
9 0 No Load Cell Installed 0
LOAD CELL
1 Warn Only
6.9 LEVEL VEHICLE DESCRIPTION Help Descriptions and Fault Flash Codes
Table 6-4. JLG Control System Flash Codes
Code Description
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE
TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. 2-1 Faulty Footswitch/EMS
2-2 Drive/Steer inputs/Footswitch Interlocks
2-3 Boom function inputs/Lift-Swing Joystick
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
2-5 Function Cutout/Drive Cutout
3-1 Contactors miswired/Motors miswired
3-2 Line contactor welded
LEVEL VEHICLE 3-3 Contactor short circuit or valve short circuit
YES:ENTER, NO:ESC
3-5 Brake pressure input
4-2 Controller Overtemperature
4-4 Battery voltage out of range
5-5 Speed Sensor input
6-6 CANbus inputs
7-7 Traction /Pump motor wiring or motor faulty
9-9 Power Module Failure
LEVEL VEHICLE
YES:ENTER, NO:ESC
EVERYTHING OK
The “normal” help message in platform mode
GROUND MODE OK
The “normal” help message in ground mode
BATTERY LOW
Battery voltage is below 40V. This is a warning – the controller does not shut down (the low battery lamp will light below 45V and flash
below 40V.
BRAKES RELEASED
Indicates manual brake release in ground mode
FSW OPEN
A drive or boom function has been selected but footswitch is open.
FSW FAULTY
The two footswitch signals do not agree.
EMS recycle required.
STARTUP
Neither EMS input is active - the system is just switching on or is discharging the capacitor bank.
A welded line contactor might also cause this.
2/2 Flash code 2/2 indicates problems with drive & steer selection.
2/3 Flash code 2/3 indicates problems with boom function selection.
2/5 Flash code 2/5 indicates that a function is prevented due to a cutout.
3/1 Flash code 3/1 indicates that a contactor did not close when energized.
3/2 Flash code 3/2 indicates that a contactor did not open when deenergized.
3/5 Flash code 3/5 indicates that there is a brake pressure problem.
4/4 Flash code 4/4 indicates problems with the battery supply.
BATTERY LOW
Battery voltage is below 40V. This is a warning - the controller does not shut down.
5/5 Flash code 5/5 indicates problems with vehicle speed or the encoder.
9/9 Flash code 9/9 indicates problems with the controller. (continued)
6.10 ANALYZER DIAGNOSTICS MENU the next outer level. The LEFT/RIGHT arrow keys move
between items in the same level. The UP/DOWN arrow
STRUCTURE keys alter a value if allowed
In the following structure descriptions, an intended item is
selected by pressing ENTER; pressing ESC steps back to
DRIVE
TRACTION … Displays/adjusts the amount of time traction control is enabled after each input activation
POSITRAC … Displays/adjusts the maximum traction motor current at which positrac will activate
LIFT
SWING
TELE
BASKET LEVEL
BASKET ROTATE
STEER
MIN SPEED … Displays/adjusts minimum steer speed, which applies when vehicle speed is at maximum
MAX SPEED … Displays/adjusts maximum steer speed, which applies when vehicle speed is at minimum
GROUND MODE
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
CALIBRATIONS Not available at password level 2; can be viewed but not changed at level 1
CONTROLLER CALS
TILTdelayIN … Displays/adjusts how long the tilt sensor must indicate a tilted condition before it is registered
The setting should be adjusted to optimize controller response to a sudden tilt, while minimizing spurious tilt indica-
tions during acceleration & deceleration
TILTdelayOUT … Displays/adjusts how long the tilt sensor must indicate a not-tilted condition before it is registered
The setting should be adjusted to optimize controller response to a sudden tilt, while minimizing spurious tilt indica-
tions during acceleration & deceleration
MACHINE CALS
SPEEDprop1 … Displays/adjusts speed control PID algorithm proportional term in traction mode
The setting should be adjusted to optimize speed control
SPEEDprop2 … Displays/adjusts speed control PID algorithm proportional term in plugging mode
The setting should be adjusted to optimize speed control
SPEEDint … Displays/adjusts speed control PID algorithm integral term in traction & plugging mode
The setting should be adjusted to optimize speed control
E600 M600
BRAKE 0 to 100 25
PUMP@0% 0 to 50 6
FLOW VALVE@0% 0 to 50 44
TEMPERATURE 0 to 100 50
SPEEDprop1 0 to 30 8
SPEEDprop2 0 to 30 16
PLUGmax 30 to 100 75
*NOTE: TiltdelayIN and TILTdelayOUT are adjusted in internal units, not in 0.1s increments.
6.11 SYSTEM SELF TEST switch has been closed, it will move on to the next
input, lower lift down LLD. If the switch is faulty or the
The system self test is utilized to locate typical problems. wiring is faulty, the controller will not move on to the
See Table 6-10, System Test Descriptions and Table 6-11, next input. The controller will continue to wait for the
System Test Messages for information concerning the closure of the input. If the operator knows the switch
tests performed and available messages in this mode. is faulty and wants to continue the tests he must
1. When the keyswitch is in the platform position and simply press the enter key on the analyzer to con-
the self test enabled, the self test function will test all tinue.
valves, contactors, platform inputs, indicator lamps,
and system alarms for various fault conditions. 3. After the controller has conducted the tests from the
chosen operator station, it will display "TESTS COM-
When the keyswitch is in the ground position, the PLETE". This indicates that the controller has
self test function will test all valves, the line contac- checked all inputs and outputs for that station.
tor, ground control inputs, and the ground alarm out-
put for various fault conditions.
2. In order to test the inputs on the machine, the con- IN ORDER FOR THE MACHINE TO FUNCTION AFTER THE SELF
troller will ask the service technician to perform vari- TEST IS COMPLETE, POWER MUST BE RECYCLED USING THE
ous tasks at the appropriate operator control station. EMS OR THE KEYSWITCH.
An example of this is "Close LLU Switch". The con-
troller expects the operator to close the lower lift up
switch. When the controller sees that the lower lift up
RUNNING Initial display when system test is run; certain “critical” checks are made. Problems which can be reported include:
ONLY 1 ANALYZER!
Do not connect two Analyzers while running the system test.
BAD POWER WIRING
The capacitor bank is not charged or pump point A is low or traction point A is high or low.
Check all power wiring.
LINE CONT WELDED
The capacitor bank is at battery voltage.
Check line contactor.
Check all power wiring.
BATTERY TOO LOW
The system test cannot run with battery voltage below minimum.
BATTERY TOO HIGH
The system test cannot run with battery voltage above maximum.
CHECK CAN WIRING
The system test can’t run in platform mode unless data is being received from the platform, ground & positrac/tilt
modules.
The system test cannot run in ground mode unless data is being received from the ground and positrac/tilt modules.
CHECK LEFT SPD.
There is an open- or short- circuit in the left speed encoder wiring.
Check left speed encoder.
CHECK RIGHT SPD.
There is an open- or short- circuit in the right speed encoder wiring.
Check right speed encoder.
CHECK SHUNT
The traction current measurement is open-circuit.
Check wiring between power module and contactor panel.
BAD PUMP WIRING
Pump point A is not high, probably caused by an open-circuit pump motor or wiring.
Check all power wiring. Check pump motor.
BAD POWER MODULE
An internal problem was detected in the power module.
BAD POWER WIRING
Traction point A is high, probably caused by incorrect traction motor wiring.
Check all power wiring. Check traction motor.
HIGH TILT ANGLE
The vehicle is very tilted, or the tilt sensor has been damaged.
Check tilt sensor.
HOT POWER MODULE
The heatsink temperature exceeds 75C; this is only a warning.
BAD I/O PORTS
The controller detected a problem with its internal circuits at switchon.
If other problems are also detected, the controller may need replacing.
SUSPECT EEPROM
The controller detected a problem with its EEPROM stored personality settings at switch on.
Check and, if necessary correct, all personality settings.
WAIT:CAPBANK HI
This message can be displayed if the system test is run shortly after the vehicle was used; after a short wait, it should
clear.
OPEN FSW
In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW
In platform mode, the footswitch must be closed when this message is displayed; the footswitch MUST BE KEPT
CLOSED during the valve & contactor tests.
BAD FSW
The two footswitch signals are not changing together, probably because one is open-circuit. One footswitch signal
(“FSW1”) is routed to the power module, the other (“FSW2”) is routed to the platform module. Check footswitch &
wiring.
NOTES:
Backprobing
To "backprobe" means to take the measurement by
accessing a connector’s contact on the same side as the
wires, the back of the connector. Readings can be done
while maintaining circuit continuity this way. If the connec-
tor is the sealed type, great care must be taken to avoid
damaging the seal around the wire. It is best to use
probes or probe tips specifically designed for this tech-
nique, especially on sealed connectors. Whenever possi-
ble insert probes into the side of the connector such that
the test also checks both terminals of the connection. It is
possible to inspect a connection within a closed connec-
tor by backprobing both sides of a connector terminal and
measuring resistance. Do this after giving each wire a
gentle pull to ensure the wires are still attached to the con-
Figure 7-1. Voltage Measurement (DC)
tact and contacts are seated in the connector.
• If meter is not auto ranging, set it to the correct
Min/Max range (See multimeter’s operation manual)
Use of the "Min/Max" recording feature of some meters • Use firm contact with meter leads
can help when taking measurements of intermittent condi-
tions while alone. For example, you can read the Voltage
applied to a solenoid when it is only operational while a
switch, far from the solenoid and meter, is held down.
Polarity
Getting a negative Voltage or current reading when
expecting a positive reading frequently means the leads
are reversed. Check what reading is expected, the loca-
Limit Switches
Limit switches are used to control movement or indicate
position. Mechanical limit switches are just like manually
operated switches except that the moving object operates
the switch. These switches can be tested the same way as
a standard switch by manually operating the sensing arm.
Another type of limit switch used by JLG is the inductive
Figure 7-4. Current Measurement (DC) proximity switch, also referred to as a "prox switch". Induc-
• Set up the meter for the expected current range tive proximity switches are actuated only by ferrous metal
(metal that contains Iron, such as steel) near the switch.
• Be sure to connect the meter leads to the correct They do not require contact, and must be energized to
jacks for the current range you have selected actuate. These types of switches can be used to detect
• If meter is not auto ranging, set it to the correct boom or platform position, for example. These switches
range (See multi meter’s operation manual) have a sensing face where the switch can detect ferrous
metal close to it. To find the sensing face, take note how
• Use firm contact with meter leads the switch is mounted and how the mechanisms meet the
switch. Test this type of switch as follows:
7.8 CHECKING SWITCHES
1. Remove prox switch from its mount.
Basic Check 2. Reconnect harness if it was disconnected for step a,
and turn on machine.
The following check determines if the switch is functioning
properly, not the circuit in which the switch is placed. A 3. Hold switch away from metal and observe switch
switch is functioning properly when there is continuity state in the control system diagnostics using the
between the correct terminals or contacts only when Analyzer. See vehicle or control system documenta-
selected. tion on how to do this.
3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-9.).
Release the locking latches by squeezing them
inward (See Figure 7-8.).
A B
A B
C
C D
Figure 7-12. DT/DTP Contact Installation Figure 7-13. DT/DTP Contact Removal
A B A B
C C
Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal
Figure 7-15. HD/HDP Locking Contacts Into Position Figure 7-17. HD/HDP Unlocking Contacts
NOTE: For unused wire cavities, insert sealing plugs for full NOTE: Do Not twist or insert tool at an angle.
environmental sealing
1870226 A
1870226 A
2792459 A
Figure 7-25. Hydraulic Schematic - Sheet 2 of 2
NOTES:
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI Ltd
Germany Sheung Shui N. T. Italy 29 Tuas Ave 4,
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Jurong Industrial Estate
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 Singapore, 639379
(852) 2639 5797 +65-6591 9030
+65-6591 9031
www.jlg.com