JLG 340AJ PVC 2001 Service & Maintenance Manual (31215004) – PDF DOWNLOAD
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JLG 340AJ PVC 2001 Service & Maintenance Manual (31215004) – PDF DOWNLOADJLG 340AJ PVC 2001 Service & Maintenance Manual (31215004) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 340AJ PVC 2001 Service & Maintenance Manual (31215004) – PDF DOWNLOAD
31215004 _A_Review_340 AJ_JLG_Service Manual_English................................................................................................................................................................................................................................. 1
Section A. Introduction - Maintenance Safety Precaitions......................................................................................................................................................................................................................... 3
A General.................................................................................................................................................................................................................................................................... 3
B Hydraulic System Safety.................................................................................................................................................................................................................................................... 3
C Maintenance................................................................................................................................................................................................................................................................ 3
Table of Contents................................................................................................................................................................................................................................................................ 5
List of Figures.................................................................................................................................................................................................................................................................. 11
List of Tables................................................................................................................................................................................................................................................................... 15
Section 1. Specifications........................................................................................................................................................................................................................................................ 17
1.1 Operating Specifications................................................................................................................................................................................................................................................. 17
1.2 Dimensional Data......................................................................................................................................................................................................................................................... 17
1.3 Capacities............................................................................................................................................................................................................................................................... 17
1.4 Tires.................................................................................................................................................................................................................................................................... 17
1.5 Engine Data.............................................................................................................................................................................................................................................................. 18
1.6 Hydraulic Oil............................................................................................................................................................................................................................................................ 18
Major Component Weights.................................................................................................................................................................................................................................................. 19
1.7 Operator Maintenance..................................................................................................................................................................................................................................................... 21
1. Swing Bearing......................................................................................................................................................................................................................................................... 21
2. Swing Bearing/Worm Gear Teeth......................................................................................................................................................................................................................................... 21
3. Hydraulic Tank........................................................................................................................................................................................................................................................ 22
4. Hydraulic Tank Return Filter and Breather............................................................................................................................................................................................................................. 22
5. Wheel Drive Hub....................................................................................................................................................................................................................................................... 22
6. Oil Change with Filter - Kubota....................................................................................................................................................................................................................................... 22
7. Fuel Filter/Water Separator - Kubota.................................................................................................................................................................................................................................. 23
8. Oil Change with Filter - GM........................................................................................................................................................................................................................................... 23
9. Charge Filter......................................................................................................................................................................................................................................................... 23
1.8 Threadlocking Compound................................................................................................................................................................................................................................................... 24
1.9 Torque Charts............................................................................................................................................................................................................................................................ 25
SAE Fastener Torque Chart................................................................................................................................................................................................................................................ 25
SAE Fastener Torque Chart (Continued).................................................................................................................................................................................................................................... 26
SAE Fastener Torque Chart (Continued).................................................................................................................................................................................................................................... 27
SAE Fastener Torque Chart (Continued).................................................................................................................................................................................................................................... 28
SAE Fastener Torque Chart (Continued).................................................................................................................................................................................................................................... 29
SAE Fastener Torque Chart (Continued).................................................................................................................................................................................................................................... 30
Metric Fastener Torque Chart............................................................................................................................................................................................................................................. 31
Metric Fastener Torque Chart (Continued)................................................................................................................................................................................................................................. 32
Metric Fastener Torque Chart (Continued)................................................................................................................................................................................................................................. 33
Metric Fastener Torque Chart (Continued)................................................................................................................................................................................................................................. 34
Section 2. General............................................................................................................................................................................................................................................................... 35
2.1 Machine Preparation, Inspection, and Maintenance......................................................................................................................................................................................................................... 35
General.................................................................................................................................................................................................................................................................. 35
Preparation, Inspection, and Maintenance................................................................................................................................................................................................................................. 35
Pre-Start Inspection..................................................................................................................................................................................................................................................... 35
Pre-Delivery Inspection and Frequent Inspection.......................................................................................................................................................................................................................... 35
Annual Machine Inspection................................................................................................................................................................................................................................................ 35
Preventive Maintenance................................................................................................................................................................................................................................................... 35
2.2 Service and Guidelines................................................................................................................................................................................................................................................... 36
General.................................................................................................................................................................................................................................................................. 36
Safety and Workmanship................................................................................................................................................................................................................................................... 36
Cleanliness.............................................................................................................................................................................................................................................................. 36
1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provi........... 36
2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter..................... 36
3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their co........... 36
Components Removal and Installation...................................................................................................................................................................................................................................... 36
1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted..................................... 36
2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees................................... 36
3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering..................................................................................................... 36
Component Disassembly and Reassembly..................................................................................................................................................................................................................................... 37
Pressure-Fit Parts....................................................................................................................................................................................................................................................... 37
Bearings................................................................................................................................................................................................................................................................. 37
1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing................................................................. 37
2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned................................................................................................................................................................................ 37
3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install....................................................................................... 37
4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race................................. 37
Gaskets.................................................................................................................................................................................................................................................................. 37
Bolt Usage and Torque Application........................................................................................................................................................................................................................................ 37
1. Always use new replacement hardware when installing locking fasteners. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area........... 37
2. Unless specific torque requirements are given within the text, standard torque values should be used on heat- treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.).................................. 37
Hydraulic Lines and Electrical Wiring.................................................................................................................................................................................................................................... 37
Hydraulic System......................................................................................................................................................................................................................................................... 37
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.............................................................................................................................. 37
2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly............................................................................................. 37
Lubrication.............................................................................................................................................................................................................................................................. 38
Battery.................................................................................................................................................................................................................................................................. 38
Lubrication and Servicing................................................................................................................................................................................................................................................ 38
Hydraulic System......................................................................................................................................................................................................................................................... 38
1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenanc........... 38
2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera........... 38
3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil........................................................ 38
4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is........... 38
Hydraulic Oil............................................................................................................................................................................................................................................................ 38
1. Refer to Section 1 for recommendations for viscosity ranges....................................................................................................................................................................................................... 38
Changing Hydraulic Oil................................................................................................................................................................................................................................................... 38
1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this ........... 38
2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replac........... 38
3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.................. 38
Lubrication Specifications............................................................................................................................................................................................................................................... 38
2.3 Cylinder Drift........................................................................................................................................................................................................................................................... 39
Theory................................................................................................................................................................................................................................................................... 39
Cylinder Leakage Test.................................................................................................................................................................................................................................................... 39
Cylinder Thermal Drift................................................................................................................................................................................................................................................... 39
2.4 Pins and Composite Bearing Repair Guidelines............................................................................................................................................................................................................................. 40
1. Pinned joints should be disassembled and inspected if the following occurs:........................................................................................................................................................................................... 40
a. Excessive sloppiness in joints.................................................................................................................................................................................................................................... 40
b. Noise originating from the joint during operation................................................................................................................................................................................................................. 40
2. Filament wound bearings should be replaced if any of the following is observed:....................................................................................................................................................................................... 40
a. Frayed or separated fibers on the liner surface................................................................................................................................................................................................................... 40
b. Cracked or damaged liner backing.................................................................................................................................................................................................................................. 40
c. Bearings that have moved or spun in their housing................................................................................................................................................................................................................. 40
d. Debris embedded in liner surface.................................................................................................................................................................................................................................. 40
3. Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection):..................................................................................................................................................... 40
a. Detectable wear in the bearing area............................................................................................................................................................................................................................... 40
b. Flaking, pealing, scoring, or scratches on the pin surface........................................................................................................................................................................................................ 40
c. Rusting of the pin in the bearing area............................................................................................................................................................................................................................ 40
4. Re-assembly of pinned joints using filament wound bearings............................................................................................................................................................................................................ 40
a. Housing should be blown out to remove all dirt and debris. Bearings and bearing housings must be free of all contamination........................................................................................................................................ 40
b. Bearing / pins should be cleaned with a solvent to remove all grease and oil. Filament wound bearing are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave pins).................................................................. 40
c. Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would damage the bearing during installation and operation..................................................................................................................... 40
2.5 Welding on JLG Equipment................................................................................................................................................................................................................................................. 40
Do the Following When Welding on JLG Equipment........................................................................................................................................................................................................................... 40
Do Not Do the Following When Welding on JLG Equipment.................................................................................................................................................................................................................... 40
Section 3. Chassis & Turntable................................................................................................................................................................................................................................................... 47
3.1 Tires and Wheels......................................................................................................................................................................................................................................................... 47
Tire Replacement......................................................................................................................................................................................................................................................... 47
Wheel and Tire Replacement............................................................................................................................................................................................................................................... 47
Wheel Installation....................................................................................................................................................................................................................................................... 47
1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts...................................................................................................................................................................... 47
2. Tighten nuts in the following sequence............................................................................................................................................................................................................................ 47
3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque............................................................................................................................................ 47
4. Wheel nuts should be torqued after each wheel removal. Check and torque every 3 months or 150 hours of operation.................................................................................................................................................. 47
3.2 Drive Orientation System................................................................................................................................................................................................................................................. 48
3.3 Beyond Transport Position - Drive Speed Cutback System................................................................................................................................................................................................................... 48
3.4 Drive/Steer - Boom Function Interlock System (CE ONLY)................................................................................................................................................................................................................... 48
3.5 Drive System............................................................................................................................................................................................................................................................. 48
3.6 Drive Motor.............................................................................................................................................................................................................................................................. 49
Disassembly.............................................................................................................................................................................................................................................................. 49
1. Remove the drain plug (13) and washer (14)........................................................................................................................................................................................................................ 49
2. Carefully place the motor in a vise and remove the two seal plugs (33) from the end cover (32).................................................................................................................................................................... 49
3. Remove the four bolts (34) from the assembly...................................................................................................................................................................................................................... 49
4. Lifting from below the port plate (23), carefully lift the components from the port plate (23) up from the motor assembly as a unit............................................................................................................................... 49
5. Separate the port plate (23) from the other components............................................................................................................................................................................................................ 49
6. Remove the o-ring (19)............................................................................................................................................................................................................................................ 49
7. Remove the stop ring (24)......................................................................................................................................................................................................................................... 49
8. Remove the disc valve (25)........................................................................................................................................................................................................................................ 49
9. Remove the spacer (30)............................................................................................................................................................................................................................................ 49
10. Pour oil into the spacer hole and use a 0.56 in. (14.25 mm) mandrel as a piston to press up the pressure plate(26)............................................................................................................................................... 49
11. Remove the guide pin (27)........................................................................................................................................................................................................................................ 49
12. Remove the o-rings (28 & 29)..................................................................................................................................................................................................................................... 49
13. Remove the crinkle washer (31)................................................................................................................................................................................................................................... 49
14. Remove the valve drive (22)...................................................................................................................................................................................................................................... 49
15. Carefully lifting from under the gear set (20) to prevent parts from dropping out, remove the gear set (20)...................................................................................................................................................... 49
16. Remove the o-ring (19)........................................................................................................................................................................................................................................... 49
17. Remove the cardan shaft (18)..................................................................................................................................................................................................................................... 49
Assembly................................................................................................................................................................................................................................................................. 49
1. Carefully lift from under the gear set to prevent parts from falling out. Lay the gearwheel set so the o-ring groove is upwards. Mark the wheel of the gearwheel set at the point where the bottom of an internal tooth is opposite the bottom of an ex........... 49
2. Mark the tip of a spline tooth on the end of the valve drive (22) with the widest splines. Line up the mark on the rotor and valve drive (22). The end with the widest splines must point upwards................................................................. 49
3. Grease the o-ring (19) with petroleum jelly. Install it in the gearwheel (20) and channel plate groove............................................................................................................................................................ 49
4. Fit the channel plate (23) so the o-ring groove is upwards and the check valve holes line up with the through hole in the gear set................................................................................................................................ 49
5. Install the balls (35)............................................................................................................................................................................................................................................ 49
6. Align the mark on the valve drive (22) with a hole in the outer rim. Turn the disc valve (25) counterclockwise until the splines in the two parts engage.......................................................................................................... 50
7. Place the crinkle washer in the end cover (32).................................................................................................................................................................................................................... 50
8. Grease the two o-rings (28 & 29) with petroleum jelly and install them in the balance plate grooves............................................................................................................................................................... 50
9. Install the guide pin (27) in the end cover (32).................................................................................................................................................................................................................. 50
10. Install the balance plate in the end cover (32).................................................................................................................................................................................................................. 50
11. Grease the spacer (30) with petroleum jelly to prevent it from dropping out...................................................................................................................................................................................... 50
12. Install the valve housing (32) on the motor assembly. The ports should face in the dame direction as the drain port.............................................................................................................................................. 50
13. Secure the assembly together by installing the bolts (34) and torquing 55 to 59 ft.lbs. (75 to 80 Nm)............................................................................................................................................................ 50
13. Drain Plug....................................................................................................................................................................................................................................................... 51
14. Washer........................................................................................................................................................................................................................................................... 51
15. Not Used......................................................................................................................................................................................................................................................... 51
16. Mounting Flange.................................................................................................................................................................................................................................................. 51
17. O-ring........................................................................................................................................................................................................................................................... 51
18. Cardan Shaft..................................................................................................................................................................................................................................................... 51
19. O-ring........................................................................................................................................................................................................................................................... 51
20. Gear Set......................................................................................................................................................................................................................................................... 51
21. Not Used......................................................................................................................................................................................................................................................... 51
22. Valve Drive...................................................................................................................................................................................................................................................... 51
23. Pressure Plate................................................................................................................................................................................................................................................... 51
24. Guide Pin........................................................................................................................................................................................................................................................ 51
25. Channel Plate.................................................................................................................................................................................................................................................... 51
26. Stop Ring........................................................................................................................................................................................................................................................ 51
27. Disc Valve....................................................................................................................................................................................................................................................... 51
28. O-ring........................................................................................................................................................................................................................................................... 51
29. O-ring........................................................................................................................................................................................................................................................... 51
30. Spacer........................................................................................................................................................................................................................................................... 51
31. Crinkle Washer................................................................................................................................................................................................................................................... 51
32. End Cover........................................................................................................................................................................................................................................................ 51
33. Seal Plug........................................................................................................................................................................................................................................................ 51
34. Bolt............................................................................................................................................................................................................................................................. 51
35. Ball............................................................................................................................................................................................................................................................. 51
3.7 Drive Hub................................................................................................................................................................................................................................................................ 56
Roll, Leak and Brake Testing............................................................................................................................................................................................................................................. 56
THE ROLL TEST........................................................................................................................................................................................................................................................ 56
THE LEAK TEST (MAIN UNIT)............................................................................................................................................................................................................................................ 56
THE BRAKE TEST....................................................................................................................................................................................................................................................... 56
Tightening and Torquing Bolts............................................................................................................................................................................................................................................ 56
1. Tighten (but do not torque) bolt "A" until snug................................................................................................................................................................................................................... 56
2. Go to the opposite side of the bolt circle and tighten bolt "B" until equally snug................................................................................................................................................................................ 56
3. Crisscross around the bolt circle and tighten remaining bolts..................................................................................................................................................................................................... 56
4. Now use a torque wrench to apply the specified torque to bolt "A"................................................................................................................................................................................................. 56
5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts....................................................................................................................................................... 56
Measuring Rolling Torque................................................................................................................................................................................................................................................. 57
1. Screw one bolt down into the housing and rotate the housing so that the bolt is at twelve o’clock................................................................................................................................................................. 57
2. Position the torque wrench so that it is perpendicular to the vertical centerline as shown........................................................................................................................................................................ 57
3. The correct reading can only be made if the torque wrench is pulled slowly (approximately 3.5 rpm) and smoothly towards you....................................................................................................................................... 57
Main Disassembly......................................................................................................................................................................................................................................................... 57
1. Perform Roll Check, Leak Check and Brake Check if applicable prior to disassembling the unit...................................................................................................................................................................... 57
2. Drain oil from unit. Note the condition and volume of the oil..................................................................................................................................................................................................... 57
3. Remove Retaining Ring (6G) by prying the open end of retaining ring out of the groove in the Ring Gear (1E) with a screwdriver, then grasp the loose end with pliers and pull the retaining ring completely out of the groove..................................... 57
4. Remove the Cover Subassembly (6) from the unit. The unit can be carefully pressurized with air to pop the cover subassembly out of the unit....................................................................................................................... 57
5. Remove O-Ring (17) from groove in Cover Subassembly (6)........................................................................................................................................................................................................... 57
6. Remove the Sun Gear (11).......................................................................................................................................................................................................................................... 57
7. Loosen and remove the three Flat Head Bolts (19) that retain the Ring Gear (1E) to the Housing (1D)............................................................................................................................................................... 57
8. Lift the Ring Gear (1E) off of the Housing (1D)................................................................................................................................................................................................................... 57
9. Remove the O-Ring (18) from between the Housing (1D) and the Ring Gear (1E)....................................................................................................................................................................................... 57
10. Using a 1/8" diameter punch, drive the Roll Pin (4G) into the Planet Shaft (4E) until it bottoms against the Spindle (1 A)....................................................................................................................................... 57
11. Grasp the Roll Pin (4G) using needle nosed pliers or some sort of hooked tool, and pull the Planet Shaft (4E) out of the Spindle (1A)............................................................................................................................ 57
12. Using a 1/8" diameter punch, drive the Roll Pin (4G) out of the Planet Shaft (4E)................................................................................................................................................................................ 57
13. Slide the Planet Gear Subassembly (4F) out of the Spindle (1A) being careful to not drop the Needle Bearings (4C) in the process................................................................................................................................. 57
14. Remove the Thrust Washers (4B), all the Needle Rollers (4C) and the Thrust Spacer (4D) from the Planet Gear (4F)................................................................................................................................................. 57
15. Repeat Steps 12 though 14 for the remaining two Planet Gears Subassemblies (4F).................................................................................................................................................................................. 59
16. Remove the Thrust Washer (4H) from the counterbore in the Spindle (1 A).......................................................................................................................................................................................... 59
17. Remove the Input Shaft (9)....................................................................................................................................................................................................................................... 59
Housing-Spindle Disassembly.............................................................................................................................................................................................................................................. 59
1. Secure the unit in a fixture with Spindle (1 A) flange end down................................................................................................................................................................................................... 59
2. Remove the Set Screws (1G) from Bearing Nut (1F). Then loosen the Bearing Nut (1F) using the Bearing Nut Wrench. It may be necessary to heat the Bearing Nut (1F) to break down the threadlocking compound that was used to secure the bearing nut on t........... 59
3. While supporting the unit on Housing (1D) flange, press Spindle (1 A) out of housing.............................................................................................................................................................................. 59
4. Lift Housing (1D) off of Spindle (1 A)............................................................................................................................................................................................................................ 59
5. If necessary, press Studs (1H) out of Housing (1D)................................................................................................................................................................................................................ 59
6. Remove Lip Seal (1B) from Housing (1D)............................................................................................................................................................................................................................ 59
7. Using a soft steel rod, carefully knock both Ball Bearings (1C) out of Housing (1D)............................................................................................................................................................................... 59
Spindle-Brake Subassembly Disassembly.................................................................................................................................................................................................................................... 61
1. Place Spindle (1 A) with the flange side up. Remove the Bolts (21) in an X pattern by backing each bolt half way out, and then finish backing them out. Remove Motor Adaptor (1N). If necessary, remove Retaining Ring (8C), knock Ball Bearing (8B) ou........... 61
2. Remove Compression Springs (8L) and (8M) from Brake Piston (8A)................................................................................................................................................................................................... 62
3. Using an air hose, slowly and carefully pressurize the brake port in the Spindle (1 A) until the Brake Piston (8A) comes out of brake piston bore of Spindle (1 A), then pull the Brake Piston (8A) out of the Spindle (1A) by hand............................... 62
4. Remove Backup Ring (8H) and O-Ring (8F) from grooves in Spindle (1A) and Brake Piston (8A)........................................................................................................................................................................ 62
5. Remove Coupling (7) from brake cavity in Spindle (1A)............................................................................................................................................................................................................. 62
6. Remove Backup Ring (8E) and O-Ring (8D) from grooves in Spindle (1A).............................................................................................................................................................................................. 62
7. Remove Brake Rotors (8J) and Brake Stators (8K) from brake cavity in Spindle (1A)................................................................................................................................................................................. 62
8. Remove Retaining Ring (5) out of the internal groove of Coupling (7) using Truarc #0100 or equivalent pliers...................................................................................................................................................... 62
9. Remove the Thrust Washer (1M) and Spring (1L) out of the bore of Coupling (7)..................................................................................................................................................................................... 62
10. Knock Ball Bearing (8B) out of Spindle (1A) counterbore if needed................................................................................................................................................................................................ 62
11. Remove Pressure Plug (22) and Pipe Plug (12) from Spindle (1 A) if applicable. This completes the Spindle-Brake Subassembly Disassembly.......................................................................................................................... 62
Cover Disassembly........................................................................................................................................................................................................................................................ 62
1. Remove Thrust Washer (2) from pocket side of the Cover (6A), if necessary......................................................................................................................................................................................... 62
2. Unscrew Hex Head Bolts (6C) and remove Disengage Cap (6B) from Cover (6A)......................................................................................................................................................................................... 62
3. Pull Disengage Rod (6D) out from Cover (6A)....................................................................................................................................................................................................................... 62
4. Use appropriate tool to remove O-Ring (6E) from internal groove in Cover (6A)..................................................................................................................................................................................... 62
5. Remove O-Ring Pipe Plugs (6F) from Cover (6A)..................................................................................................................................................................................................................... 62
Planet Gear Subassembly.................................................................................................................................................................................................................................................. 64
1. Apply a liberal coat of grease to the bore of one of Planet Gears (4F)............................................................................................................................................................................................ 64
2. Line the inside of the Planet Gear (4F) with Needle Rollers (4C).................................................................................................................................................................................................. 64
3. Place Spacer (4D) into the bore of the Planet Gear (4F)........................................................................................................................................................................................................... 64
4. Repeat Step 2 to put in second roll of Needle Rollers (4C)........................................................................................................................................................................................................ 64
5. Apply grease to hold Thrust Washers (4B) together and onto Planet Gear (4F) counterbore. Do the same to the other side............................................................................................................................................ 64
6. Repeat Steps 1-5 to finish the assembly of the two remaining Planet Gears Subassemblies (4F)...................................................................................................................................................................... 64
Spindle-Brake Subassembly................................................................................................................................................................................................................................................ 65
1. Place Spindle (1 A) with the flange side up. Press Ball Bearing (8B) into the small counterbore of the spindle.................................................................................................................................................... 65
2. Place Brake Stator (8K) into the Spindle (1A) aligning with the scallop cuts...................................................................................................................................................................................... 65
3. Place Brake Rotor (8J) on top of Brake Stator (8K)................................................................................................................................................................................................................ 65
4. Repeat steps 2 and 3 until there are a total of nine Brake Stators (8K) and eight Brake Rotors (8J) installed..................................................................................................................................................... 65
5. Place Spring (1L) into counterbore of the Coupling (7), then place Thrust Washer (1M) on top of the spring........................................................................................................................................................ 65
6. Use Truarc #0100 or equivalent pliers to install Retaining Ring (5) into the retaining ring groove in the counterbore the Coupling (7)............................................................................................................................ 66
7. Insert Coupling Subassembly (7) through Brake Rotors (8J)......................................................................................................................................................................................................... 66
8. Grease the O-Rings (8F) and (8D) and the Backup Rings (8H) and (8E)............................................................................................................................................................................................... 66
9. Install small O-Ring (8D) into the o-ring groove of Spindle (1A).................................................................................................................................................................................................. 66
10. Install small Backup Ring (8E) into the o-ring groove of Spindle (1A), on bottom of the small O-Ring (8D)........................................................................................................................................................ 66
11. Set the Brake Piston (8A) so that the large diameter end is down. Install large Backup Ring (8H) in the large diameter groove at the bottom of the Brake Piston (8A)............................................................................................. 66
12. Install large O-Ring (8F) in the large-diameter groove at the bottom of the Brake Piston (8A), on top of the large Backup Ring (8H).............................................................................................................................. 66
13. Use appropriate tool to insert Brake Piston (8A) with backup ring and o-ring into Spindle (1A) until it contacts Brake Stator (8K)............................................................................................................................... 66
14. Insert twelve Springs (8L) into Brake Piston (8A) holes and then install the smaller twelve Springs (8M) into the Springs (8L) already installed into the brake piston........................................................................................... 66
15. Press Ball Bearing (8B) in the Mounting Adaptor (1N) and then install Retaining Ring (8C) into the retaining ring groove of the mounting adaptor................................................................................................................. 66
16. Before installing the Quad Seal (1K) into groove of Mounting Adaptor (1N) grease internal diameter of the quad seal.............................................................................................................................................. 66
17. Install O-Ring (8F) into the outside o-ring groove of the Mounting Adaptor (1N).................................................................................................................................................................................. 66
18. Insert the Adaptor Subassembly onto Spindle (1A) with the o-ring port on the spindle flange centered between the two motor mounting holes on the Mounting Adaptor (1N)........................................................................................... 66
19. Secure the Mounting Adaptor (1N) to the Spindle (1 A) with 8 bolts (21). Torque the bolts to 36-38 ft-lbs in X pattern........................................................................................................................................... 66
20. Use the Integral Brake Check Procedure to leak check the brake, record initial release pressure.................................................................................................................................................................. 66
21. Disconnect Brake Tester and install O-Ring Plug (12) and tighten according to DIN standard if applicable......................................................................................................................................................... 66
Housing-Spindle Subassembly.............................................................................................................................................................................................................................................. 67
1. With housing flange side up and press outbound Ball Bearing (1C) into Housing (1D) using Bearing Pressing Tool.................................................................................................................................................... 67
2. Turn housing over and press inbound Ball Bearing (1C) into Housing (1D) using Bearing Pressing Tool............................................................................................................................................................... 67
3. Grease Lip Seal (1B) and then press lip seal into Housing (1D) using Seal Pressing Tool until seal is flush with end of housing................................................................................................................................... 67
4. Secure Housing (1D) and press Studs (1H) into housing............................................................................................................................................................................................................. 67
5. Secure Spindle-Brake Subassembly with the flange down and then lower the Housing (1D) onto Spindle (1A)........................................................................................................................................................... 67
6. Apply High Strength ThreadLocking Compound on Bearing Nut (1F) threads. Install the Bearing Nut (1F) onto Spindle (1 A) with a nut torque of 100-110 in-lbs. Make sure the bearings have 0.001 - 0.005 inches end play with a dial indicator sitting on........... 67
7. Install Set Screws (1G) into Bearing Nut (1F) threaded holes. Make sure Set Screw (1G) is driven into the spindle threads. Tighten the set screws to damage the threads and stake the edge of the nut around the Set Screws (1G) so the nut will not lo........... 67
Housing-Ring Gear Subassembly............................................................................................................................................................................................................................................ 68
1. Insert Input Shaft (9) into mesh with Coupling’s (7) internal splines and place the Thrust Washer (4H) into counterbore of Spindle (1A)........................................................................................................................... 68
2. Place one of the Planet Gear Subassemblies (4F) into Spindle (1 A) through gap between two Studs (1H). Align the planet gear bore with one of the planet shaft holes on the Spindle-Brake Subassembly using the Drift Pin Assembly Tool........................... 68
3. Insert Planet Shaft (4E) into the planet shaft hole described in Step (2) on Spindle (1A). The end of the planet shaft that does NOT have the roll pin hole should be inserted into the spindle FIRST............................................................. 68
4. Now insert Planet Shaft (4E) through the first set of Thrust Washers (4B), Planet gear, then the second set of Thrust Washers (4B). Use an alignment punch or similar tool to align roll pin holes on Spindle (1A) and Planet Shaft (4E).......................... 68
5. Drive Roll Pin (4G) down into the aligned roll pin holes. Pin should be flush with OD of spindle.................................................................................................................................................................. 68
6. Repeat Steps (2-6) for the installation of the two remaining Planet Gears (4F).................................................................................................................................................................................... 69
7. Grease O-Ring (18) and place it into groove of Housing (1D)....................................................................................................................................................................................................... 69
8. Place Ring Gear (1E) onto Housing (1D). Align the three shipping capscrew holes on Housing (1D) and Ring Gear (1E)................................................................................................................................................ 69
9. Install three Shipping capscrews (19) into Ring Gear (1E) and Housing (1G). Torque them to15-20 ft-lbs............................................................................................................................................................ 69
10. With the non-toothed end facing up, place the Sun Gear (11) into mesh with the planet gears from the Housing- Spindle Subassembly................................................................................................................................ 69
Cover Subassembly........................................................................................................................................................................................................................................................ 69
1. Grease O-Ring (6E) and insert into internal groove in Cover (6A).................................................................................................................................................................................................. 69
2. Assemble Disengage Cap (6B) onto Cover (6A) using two Hex Head Bolts (6C). Torque bolts to 70-80 in-lbs........................................................................................................................................................... 70
3. Insert Disengage Rod (6D) into hole in Cover (6A) until it touches the inside of the Disengage Cap (6B)........................................................................................................................................................... 70
4. Grease face of Thrust Washer (2) that mates with pocket side of the Cover (6A), making sure that tangs on washer seats into pockets............................................................................................................................... 70
5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The plugs should be hand tight. The Cover Subassembly is now complete............................................................................................................................................. 70
Main Assembly............................................................................................................................................................................................................................................................ 70
1. Grease O-Ring (17) and insert into groove in Cover Subassembly (6)................................................................................................................................................................................................ 70
2. Install Cover Subassembly (6) into Ring Gear (1E) counterbore and install Retaining Ring (6G) into groove in Ring Gear (1E)....................................................................................................................................... 70
3. Attach ID Plate (15) onto unit using Drive Screws (16) if needed.................................................................................................................................................................................................. 70
4. Check disconnect, roll and air check unit. The Main Assembly is now complete...................................................................................................................................................................................... 70
Integral Brake Check Procedure........................................................................................................................................................................................................................................... 71
1. Using appropriate fittings to connect hydraulic line from hand pump to the brake port............................................................................................................................................................................. 71
2. Check to see that brake is set by trying to rotate Input Shaft (9). This can be accomplished by installing an appropriate tool (any tool that can locate on the splines of the Input Coupling (7), such as a mating splined shaft) into Input Coupling (7)........ 71
3. Bleed brake. Increase hydraulic pressure gradually while trying to rotate the input until brake just starts to release. Note this pressure. Make sure the pressure falls into the appropriate range below......................................................... 71
4. Increase pressure to 3,625 psi and hold for 60 seconds to check for leaks. Repair leaks if necessary.............................................................................................................................................................. 71
3.8 Oscillating Axle System.................................................................................................................................................................................................................................................. 76
Oscillating Axle Bleeding Procedure...................................................................................................................................................................................................................................... 76
1. Start the engine.................................................................................................................................................................................................................................................. 76
2. Position the turntable to the normal stowed position.............................................................................................................................................................................................................. 76
3. Position a small container suitable for containing hydraulic oil in front of the lockout cylinder bleeder......................................................................................................................................................... 76
4. Using a 3/8" wrench, loosen the bleeder by slowly turning counterclockwise........................................................................................................................................................................................ 76
5. Bleed approximately 2 cups (0.2 L) of fluid from the bleeder in the cylinder. Tighten the bleeder while the machine is running.................................................................................................................................... 76
6. Locate the bleeder on the opposite lockout cylinder and repeat steps 3 thru 5..................................................................................................................................................................................... 76
3.9 Chassis Tilt Indicator System............................................................................................................................................................................................................................................ 78
3.10 Swing Motor............................................................................................................................................................................................................................................................. 78
1. Hose fittings loose, worn or damaged.................................................................................................................................................................................................................................. 79
2. Oil seal rings (4) deteriorated by excess heat........................................................................................................................................................................................................................ 79
3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing area deteriorated by corrosion................................................................................................................................................................................... 79
4. Internal shaft seal (16) worn or damaged.............................................................................................................................................................................................................................. 79
5. Worn coupling shaft (12) and internal seal (16)....................................................................................................................................................................................................................... 79
1. Lack of sufficient oil supply......................................................................................................................................................................................................................................... 79
2. High internal motor leakage........................................................................................................................................................................................................................................... 79
3. Severely worn or damaged internal splines............................................................................................................................................................................................................................. 79
4. Excessive heat........................................................................................................................................................................................................................................................ 79
1. Line blockage......................................................................................................................................................................................................................................................... 79
2. Internal interference................................................................................................................................................................................................................................................. 79
3. Lack of pumping pressure.............................................................................................................................................................................................................................................. 79
4. Excessive binding or loading in system external to motor unit......................................................................................................................................................................................................... 79
Removal.................................................................................................................................................................................................................................................................. 80
1. Thoroughly clean the area around the swing motor to prevent any dirt from entering the system..................................................................................................................................................................... 80
2. Tag and disconnect the hydraulic lines running to the swing motor. Cap or plug all openings....................................................................................................................................................................... 80
3. Secure the worm gear shaft so it does not pull out any when removing the swing motor. Failure to do so could damage the worm gear seals........................................................................................................................... 80
4. Remove the bolts securing the swing motor to the swing drive assembly............................................................................................................................................................................................. 80
5. Carefully pull the swing motor from the swing drive............................................................................................................................................................................................................... 80
Preparation Before Disassembly........................................................................................................................................................................................................................................... 80
Disassembly and Inspection............................................................................................................................................................................................................................................... 81
1. Place the motor in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port O-Rings if applicable......................................... 81
2. Scribe an alignment mark down and across the motor components from end cover (2) to housing (18) to facilitate reassembly orientation where required.............................................................................................................. 81
3. Remove the special ring head bolts (1) using an appropriate 1/2 or 9/16 inch size socket. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts......................................................................... 81
1. Bolt.............................................................................................................................................................................................................................................................. 82
2. End Cover......................................................................................................................................................................................................................................................... 82
3. Seal Ring......................................................................................................................................................................................................................................................... 82
4. Seal Ring......................................................................................................................................................................................................................................................... 82
5. Commutator........................................................................................................................................................................................................................................................ 82
6. Commutator Ring................................................................................................................................................................................................................................................... 82
7. Manifold.......................................................................................................................................................................................................................................................... 82
8. Rotor Set 8A. Rotor 8B. Stator Half............................................................................................................................................................................................................................... 82
9. Wear Plate........................................................................................................................................................................................................................................................ 82
10. Drive Link....................................................................................................................................................................................................................................................... 82
11. Thrust Bearing................................................................................................................................................................................................................................................... 82
12. Coupling Shaft................................................................................................................................................................................................................................................... 82
13. Inner Bushing.................................................................................................................................................................................................................................................... 82
14. Thrust Washer.................................................................................................................................................................................................................................................... 82
15. Thrust Bearing................................................................................................................................................................................................................................................... 82
16. Seal............................................................................................................................................................................................................................................................. 82
17. Backup Ring...................................................................................................................................................................................................................................................... 82
18. Housing.......................................................................................................................................................................................................................................................... 82
19. Outer Bushing.................................................................................................................................................................................................................................................... 82
20. Dirt & Water Seal................................................................................................................................................................................................................................................ 82
21. Not Used......................................................................................................................................................................................................................................................... 82
22. Not Used......................................................................................................................................................................................................................................................... 82
23. Not Used......................................................................................................................................................................................................................................................... 82
24. Not Used......................................................................................................................................................................................................................................................... 82
25. Backup Washer.................................................................................................................................................................................................................................................... 82
4. Remove end cover assembly (2) and seal ring (4). Discard seal ring............................................................................................................................................................................................ 83
5. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary.... 83
6. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs...................................................................................................................................................................................... 83
7. Remove commutator (5) and seal ring (3) Remove seal ring from commutator, using an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or burrs, wear, scoring, spalling or brinel....... 83
8. Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. A polished pattern on the ground surface from commutator or rotor rotation is normal. Remove and discard the sea....... 84
9. Remove rotor set (8) and wearplate (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane to stator contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wear....... 84
10. Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes (180 degrees apart) and a roller vane centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a....... 85
11. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted between mating spline parts. Remove and dis....... 85
12. Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion and a full complement of retained rollers................................................................................................................ 85
13. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used....................................... 85
14. Remove coupling shaft (12), by pushing on the output end of shaft. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external spline....... 86
15. Remove and discard seal ring (4) from housing (18)........................................................................................................................................................................................................... 86
16. Remove thrust bearing (15) and thrust washer (14). Inspect for wear, brinelling, corrosion and a full complement of retained rollers......................................................................................................................... 86
17. Remove seal (16) and backup ring (17) from housing (18) and backup washer (25). Discard both................................................................................................................................................................. 86
18. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required................................................................................................................................... 86
19. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is de....... 87
20. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be ....... 87
21. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they wer....... 88
Assembly................................................................................................................................................................................................................................................................. 88
1. If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease recommended in the material section. Press the new bearing/bushing into the counte........... 88
2. The inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 inch (0.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer ........... 89
3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The dirt and water seal (20) must be pressed in until its’ flange is flush against the housing.............................................................................. 89
4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange........................................................................................................................................ 89
5. Assemble a new backup ring (17), new backup washer (25) and new seal (16) with the seal lip facing toward the inside of the motor, into their respective counterbores in housing (18)............................................................................. 89
6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the motor.............................................................................................................................................................................. 90
7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal............................................................................................................................................................................... 90
8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15).............................. 90
9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove.................................................................................................................................................. 91
10. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines....................................................................................................... 91
11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18)....................................................................................................................................................................... 91
12. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator............................................................................................................. 91
13. Install the assembled rotor set (8) onto wear plate (9) with rotor counterbore and seal ring side down and the splines into mesh with the drive link splines..................................................................................................... 91
14. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7).................................................................................................................................. 92
15. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set..................................................................................................... 92
16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold................................................................................................................................................................ 92
17. Assemble the commutator ring (6) over alignment studs onto the manifold.......................................................................................................................................................................................... 92
18. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up.................................................................................................. 93
19. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18). The........... 93
20. Assemble the bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with........... 94
One Piece Stator Construction............................................................................................................................................................................................................................................ 94
1. Place stator onto wear plate (9) with seal ring (4) side down, after following assembly procedures 1 through 13. Be sure the seal ring is in place................................................................................................................ 94
2. If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing bolt holes and turn two bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain stator and wear plate stationary................. 94
3. Assemble the rotor, counterbore down if applicable, into stator, and onto wear plate (9) with rotor splines into mesh with drive link (10) splines................................................................................................................ 94
4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets...................................................................................................................................................................... 95
5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes into stator, creating the necessary clearance to assemble........... 95
6. Remove the two assembled bolts (1) if used to retain stator and wear plate. Go to assembly procedure #15, to continue assembly.................................................................................................................................... 95
Two Piece Stator Construction............................................................................................................................................................................................................................................ 95
1. Place stator half onto wear plate (9) with seal ring (4) side down, after following motor assembly procedures 1 through 13. Be sure the seal ring is in place..................................................................................................... 95
2. Align stator bolt holes with wear plate and housing bolts and turn two alignment studs finger tight into bolt holes approximately 180 degrees apart to retain stator half and wear plate stationary............................................................... 95
3. Assemble rotor, counterbore down if applicable, into stator half, and onto wear plate (9) with rotor splines into mesh with drive link (10) splines............................................................................................................... 95
4. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets...................................................................................................................................................................... 95
5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator half, creating the necessary clearance t........... 95
6. Place second stator half on a flat surface with seal ring groove up. Apply a small amount of grease to a new seal ring (4) and assemble it into stator half ring groove........................................................................................... 95
7. Assemble the second stator half over the two alignment studs and rotor with seal ring side down onto the first stator half aligning any timing marks applied for this purpose..................................................................................... 95
8. Assemble six vanes, or as many vanes that will readily assemble into the stator vane pockets...................................................................................................................................................................... 96
9. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes into stator, creating the necessary clearance to assemble........... 96
Final Checks............................................................................................................................................................................................................................................................. 96
1. Pressurize the motor with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for external leaks...................................................................................................................................................... 96
2. Check motor for rotation. Torque required to rotate coupling shaft should not be more than 50 ft. lbs. (68 N m)................................................................................................................................................... 96
3. Pressure port with "A" cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with "B" cast under it is for counterclockwise coupling shaft rotation............................... 96
4. Use test stand if available, to check operation of the motor...................................................................................................................................................................................................... 96
Installation............................................................................................................................................................................................................................................................. 96
1. Carefully insert the swing motor into the swing drive, making sure the swing motor shaft key is aligned correctly................................................................................................................................................. 96
2. Secure the swing motor to the swing drive assembly with the retaining bolts. Apply High Strength Threadlocking Compound to the threads of the retaining bolts and torque to 85 ft.lbs. (115 Nm)................................................................... 96
3. Connect the hydraulic lines running to the swing motor as tagged during removal................................................................................................................................................................................... 96
4. Operate the swing function in both directions to ensure proper operation. Inspect the hose connections for any leakage............................................................................................................................................ 96
3.11 Swing Drive............................................................................................................................................................................................................................................................. 96
Removal.................................................................................................................................................................................................................................................................. 96
1. Remove the hardware securing the battery cover and remove the battery cover....................................................................................................................................................................................... 96
2. Disconnect the negative terminal on the battery................................................................................................................................................................................................................... 96
3. Install eyebolts as specified in Figure 3-33., Eyebolt for Counterweight in the counterweight..................................................................................................................................................................... 97
4. Securely strap the booms together to prevent any movement during the lifting process.............................................................................................................................................................................. 97
5. If equipped, remove the LP fuel tank on the side of the frame. It may also be desirable to remove the tank retaining brackets to gain additional clearance to work................................................................................................ 98
6. Remove the access covers on either side of the frame to gain entry to the flow divider valve...................................................................................................................................................................... 98
7. Pull out the engine tray as far as it will go. Unbolt the charge filter bracket so it can be moved aside for more operating surface............................................................................................................................... 98
8. Loosen and remove all but a few of the bolts securing the turntable to the swing bearing..........................................................................................................................................................................100
9. Place a drain pan under the flow divider valve to catch any escaping hydraulic oil. Tag and disconnect the hoses from the flow divider valve that go up through the turntable. Cap or plug all openings so no dirt enters the system..............................100
10. Remove the drive orientation and lockout switches so they don’t get broken during the removal procedure..........................................................................................................................................................100
11. Swing the engine tray back into position and secure it in place with the retaining bolt..........................................................................................................................................................................100
12. Attach chains and slings to support the upperstructure. Begin with the chain at the approximate lengths as shown below and adjust as necessary to maintain the turntable in a level position during lifiting.....................................................100
13. Remove the remaining turntable bolts that were left in place earlier in the procedure............................................................................................................................................................................100
14. Lift the turntable off of the bearing and place it out of the way on adequate blocking...........................................................................................................................................................................100
15. Remove the bolts securing the bearing to the frame. It may be necessary to disconnect more hoses on the flow divider valve. If so, tag and disconnect all hoses and cap or plug all openings to prevent dirt from entering the hydraulic system..................101
16. Remove the bearing assembly from the frame.......................................................................................................................................................................................................................101
Installation.............................................................................................................................................................................................................................................................101
1. Using an adequate lifting device, place the bearing assembly onto the frame.......................................................................................................................................................................................101
2. Install the bearing in the position shown in Figure 3-36., Bearing Placement. Coat the bearing bolts with High Strength Threadlocking Compound and secure the bearing assembly to the frame with the bolts. Following the torque sequence diagram in Fi...........101
3. If any hydraulic hoses were disconnected to remove the swing bearing assembly, reconnect them as tagged during removal............................................................................................................................................101
4. Using an adequate lifting device, lift the turntable assembly from the blocking it is resting on and lower it down onto the swing bearing assembly. Refer to the removal instructions for chain placement.........................................................101
5. Install several bearing bolts snuggly to secure the turntable’s position on the swing bearing assembly, but do not torque them at this time and keep the lifting device in place to support the weight of the turntable...........................................101
6. Coat the bearing bolts with High Strength Threadlocking Compound and install the remaining bolts securing the turntable to the swing bearing. Tighten the bolts snugly but do not torque them at this time. Remove the bolts installed to secure the tu...........101
7. Following the torque sequence diagram in Figure 3-37., Swing Bearing Torque Sequence, tighten the bolts to an initial torque of 95 ft.lbs. (130 Nm). Next, following the same sequence, tighten to a final torque of 133 ft.lbs. (180 Nm).........................101
8. Install the drive orientation and lockout switches................................................................................................................................................................................................................101
9. Route the hydraulic hoses down through the turntable and reconnect them as they were tagged during removal........................................................................................................................................................101
10. Secure the charge filter bracket.................................................................................................................................................................................................................................101
11. Install the access covers on the side of the frame...............................................................................................................................................................................................................101
12. If removed, install the LP tank retaining brackets and LP fuel tank..............................................................................................................................................................................................101
13. Remove the lifting device from the machine.......................................................................................................................................................................................................................101
14. Remove any straps that had been on the boom to prevent movement of the boom sections.............................................................................................................................................................................101
15. Remove the eyebolts from the counterweight.......................................................................................................................................................................................................................101
16. Connect the negative terminal on the battery.....................................................................................................................................................................................................................101
17. Install the battery cover........................................................................................................................................................................................................................................101
18. Push the engine tray back into place and secure it...............................................................................................................................................................................................................101
19. Start the machine and run it through several operating cycles. Swing the machine in both directions..............................................................................................................................................................101
20. Check for any leaks and that all functions are operating properly. Top off the hydraulic oil level if necessary..................................................................................................................................................101
Turntable Bearing Mounting Bolt Condition Check..........................................................................................................................................................................................................................102
1. Elevate the fully retracted boom to 70 degrees (full elevation)...................................................................................................................................................................................................102
2. At the positions indicated on the figure titled Swing Bearing Tolerance Boom Placement. Try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.........................................................102
3. Assure that the 0.0015" feeler gauge will not penetrate under the bolt head to the bolt shank.....................................................................................................................................................................102
4. Swing the turntable 90 degrees, and check some selected bolts at the new position.................................................................................................................................................................................102
5. Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants..............................................................................................................................................102
1. Elevate the fully retracted boom to 70 degrees (full elevation)...................................................................................................................................................................................................102
2. At the positions indicated in the figure below, try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.................................................................................................102
3. Lower the boom to horizontal and fully extend the boom............................................................................................................................................................................................................102
4. At the position indicated on Figure 3-30., Swing Motor - Cutawayre. try and insert the 0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.............................................................................102
Wear Tolerance...........................................................................................................................................................................................................................................................102
1. With the boom positioned over the side of the machine, the Upper Boom horizontal with telescope fully extended and Mid/Lower Boom stowed, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turntable...........102
2. At the same point, with the boom positioned over the side of the machine, the Upper Boom fully elevated and the Mid/Lower Boom fully elevated, using a magnetic base dial indicator, measure and record the distance between the swing bearing and turn...........102
3. If a difference greater than 0.057 in. (1.40 mm) is determined, the swing bearing should be replaced..............................................................................................................................................................102
4. If a difference less than 0.057 in. (1.40 mm) is determined, and any of the following conditions exist, the bearing should be removed.............................................................................................................................102
a. Metal particles in the grease.................................................................................................................................................................................................................................102
b. Increased drive power.........................................................................................................................................................................................................................................102
c. Noise.........................................................................................................................................................................................................................................................102
d. Rough rotation................................................................................................................................................................................................................................................102
5. If bearing inspection shows no defects, reassemble bearing and return to service..................................................................................................................................................................................102
Swing Bearing Torque Value...............................................................................................................................................................................................................................................102
Disassembly..............................................................................................................................................................................................................................................................104
1. Remove the swing bearing assembly from the machine................................................................................................................................................................................................................104
2. To remove the slew ring (14), remove two 1/4" (5) bolts and washers (1) that hold the slew ring to the housing....................................................................................................................................................104
3. Remove four #6 machine screws (13) that are located on the cover plate (19) immediately in front of the Pinion (21)...............................................................................................................................................104
4. Remove eight 5/16" 12 point capscrews (4) from gear/ pinion cap (18). Pry cap from housing. Cover plate (19) will come off with cap. Note where sealant is on Cover and plate so when assembling can put sealant in same place. Note number and color o...........104
5. Remove Pinion and Gear assembly (15, 16, 17, 21, 23, 24, and 31) from housing. These lift directly upward from the housing........................................................................................................................................104
6. Disassemble pinion and gear assembly using a press. Support worm gear (31) on press with pinion (21) down allowing room for pinion to be pressed out of gear. Press pinion out of bearing (17) spacer (24) and worm gear (31) Pressing on end of pinion...........104
1. Washer............................................................................................................................................................................................................................................................105
2. Bearing...........................................................................................................................................................................................................................................................105
3. Oil Seal..........................................................................................................................................................................................................................................................105
4. Capscrew..........................................................................................................................................................................................................................................................105
5. Bolt..............................................................................................................................................................................................................................................................105
6. Bolt..............................................................................................................................................................................................................................................................105
7. Bolt..............................................................................................................................................................................................................................................................105
8. Pressure Vent.....................................................................................................................................................................................................................................................105
9. Oil Seal..........................................................................................................................................................................................................................................................105
10. Pipe Plug........................................................................................................................................................................................................................................................105
11. Grease Fitting...................................................................................................................................................................................................................................................105
12. Grease Fitting...................................................................................................................................................................................................................................................105
13. Grease Fitting...................................................................................................................................................................................................................................................105
14. Slew Ring........................................................................................................................................................................................................................................................105
15. Bearing..........................................................................................................................................................................................................................................................105
16. Grease Ring......................................................................................................................................................................................................................................................105
17. Bearing..........................................................................................................................................................................................................................................................105
18. Gear Cap.........................................................................................................................................................................................................................................................105
19. Cover Plate......................................................................................................................................................................................................................................................105
20. Worm Cap.........................................................................................................................................................................................................................................................105
21. Output Pinion....................................................................................................................................................................................................................................................105
22. Motor Adapter....................................................................................................................................................................................................................................................105
23. Face Seal........................................................................................................................................................................................................................................................105
24. Washer Spacer....................................................................................................................................................................................................................................................105
25. Housing..........................................................................................................................................................................................................................................................105
26. Cap Shim.........................................................................................................................................................................................................................................................105
27. Cover Shim.......................................................................................................................................................................................................................................................105
28. Gasket...........................................................................................................................................................................................................................................................105
29. Gasket...........................................................................................................................................................................................................................................................105
30. Screw............................................................................................................................................................................................................................................................105
31. Worm Gear........................................................................................................................................................................................................................................................105
32. Worm.............................................................................................................................................................................................................................................................105
7. Remove bearing (15) and Nilos Ring (16) from pinion (21) using external bearing puller or press...............................................................................................................................................................106
8. Remove motor and motor adapter (22) and shims (28)............................................................................................................................................................................................................106
9. Remove ¾" bolts (7) from Worm Cap (20) using ¾" socket. Remove shim (29) and seal (9) and discard.............................................................................................................................................................106
10. Remove worm (32) from housing (25) by pushing worm from motor end using steel rod and hammer. Bearing cup (3) on hex end of worm will be forced out of housing. Once the bearing cup (2) has come out of housing use soft hammer to tap worm on hex en.......106
11. Remove both bearings (2) from worm (32) from worm using external bearing puller or press.....................................................................................................................................................................106
12. Bearing cup (17) can be removed from housing (25) by lifting out (this is not a press fit just a close slip fit).............................................................................................................................................106
13. Bearing cup (15) can be removed from cap (18) using small pry bar. Or by welding a small bead of weld on internal diameter of cup, this is a press fit.......................................................................................................106
Assembly.................................................................................................................................................................................................................................................................106
1. Press bearing cup (15) into cap (18)..............................................................................................................................................................................................................................106
2. Place bearing cup (17) into housing (25)..........................................................................................................................................................................................................................106
3. Put face seal (23) on to hub of worm gear (31) with flap of seal pointing away from gear..........................................................................................................................................................................106
4. Place worm gear (31) on press with face seal up and press pinion (21) into worm gear. Place Nilos Ring (16) on to pinion so that cup shape is up and press bearing (15) on to pinion tight to Nilos Ring..........................................................106
5. Turn assembly over and place spacer (24) on pinion against gear hub so that large chamfer on I.D. of spacer is against Bronze gear. Press Bearing (17) on to pinion tight to spacer and gear......................................................................106
6. Place pinion/gear assembly into housing. Place gear cap (18) and shims (26) over gear/pinion assembly to achieve a slight preload on pinion bearings. Remove cap and shims and set shims aside. Install new cover plate (19) on to cap using 6 screws (...........106
7. Install bearing (2) on bore end of worm (32) only. This is almost a slip fit, may have to be lightly tapped with soft hammer......................................................................................................................................106
8. Install worm (32) into housing (25), hex end first................................................................................................................................................................................................................106
9. On bore end of worm, install bearing cup (2) into worm bore of housing. Also on bore end of worm (32) install motor adapter (22) and 1 shim (28 yellow) to housing using ¾-13 x 1" bolts (6) and sealant. Torque to 75 ft-lbs. (3.1 Nm) (these bolts w............106
10. Install bearing cone (2) on hex end of worm (32). Place bearing cup (2) over bearing and lightly tap cup into bore using soft hammer.............................................................................................................................106
11. Install worm cap (20) using proper shims (29) to achieve 0.000 to 0.001" (0.0000 to 0.0254 mm) end play. Apply Medium Strength Threadlocking Compound to end of ¾-13 x 1.25" grade 5 bolts (7) and Threadlocking Compound sealant to shims. Torque bo............106
12. Place pinion/gear assembly into housing so gear teeth mesh with worm gear teeth. May have to turn worm or gear set by hand to achieve this.......................................................................................................................106
13. Apply Threadlocking Compound to surfaces of housing where cap assembly will touch. This includes the vertical surfaces...........................................................................................................................................106
14. Place gear cap assembly and shims set aside in step 6, over pinion assembly......................................................................................................................................................................................106
15. Apply Medium Strength Threadlocking Compound to end of eight 5/16" 12 point screws (4) and torque to 20 ft-lbs. (0.84 Nm)........................................................................................................................................106
16. Install 4 small screws (30) through cover plate (18) and into housing (25) tighten screws take care not the twist these screws off...............................................................................................................................106
17. Install seal (9) in worm cap at hex end of worm..................................................................................................................................................................................................................106
18. Install slew ring (14) using two 1/4" bolts (5) and washer (1). Adjust backlash with pinion to 0.008/0.012" (0.203/ 0.305 mm) and torque bolts to 10 ft-lbs. (0.42 Nm)...........................................................................................106
19. Fill unit with SHC 007 grease and grease pinion bearing (15) thru fitting (11) with Mobil SHC 460 grease.........................................................................................................................................................106
3.12 Engine Operating States.................................................................................................................................................................................................................................................116
3.13 Engine Start Conditions.................................................................................................................................................................................................................................................117
1. The Start Switch is selected..........................................................................................................................................................................................................................................117
a. Ground Mode is active with Ground Module input J4-4 energized or..................................................................................................................................................................................................117
b. Platform Mode is active with Platform Module input J1-14 energized................................................................................................................................................................................................117
2. The selected Operating Station must have all of its control switches in the neutral position since power up and remain in the neutral position prior to selecting the Start Switch....................................................................................117
3. If operating from the Platform Station, the footswitch must not be depressed (Ground Module J7-15 deenergized; Platform Module J7-8 energized) before selecting the Start Switch......................................................................................117
4. If operating from the platform, the Auxiliary Power Switch must not be selected before selecting the Start Switch.....................................................................................................................................................117
5. If operating from the ground station, the Function Enable Switch must not be selected before selecting the Start Switch...............................................................................................................................................117
6. If the Engine Starter was disengaged because the Start Switch was released, more than 3 seconds must pass with the Start Switch in the released position..............................................................................................................117
7. If the Engine Starter has been cranking without the engine starting for the Engine Starter Engaged Time Limit, the control system deenergizes the Engine Starter for the Engine Restart Wait Period. The Start Switch must be in the deselected positio...............117
8. The engine must be in the Engine Stopped or Engine Cranking state.....................................................................................................................................................................................................117
9. The Engine Shutdown switch must not be activated......................................................................................................................................................................................................................117
10. The Start Switch has been in the deselected position after the Engine State changes to Engine Stopped from Engine Running or Engine Starting.........................................................................................................................117
3.14 Engine RPM Levels.......................................................................................................................................................................................................................................................117
Engine Stop RPM..........................................................................................................................................................................................................................................................117
Idle RPM.................................................................................................................................................................................................................................................................117
1. The Engine State is Engine Running, Engine Cranking, or Engine Starting...........................................................................................................................................................................................117
2. The operator is not shutting down the engine......................................................................................................................................................................................................................117
3. The control system is not commanding a higher engine RPM (Mid-Engine, Multi-function, or High Engine).............................................................................................................................................................117
4. The control system is not calling for Generator RPM...............................................................................................................................................................................................................117
Mid Engine RPM...........................................................................................................................................................................................................................................................117
1. The Engine State is Engine Running................................................................................................................................................................................................................................117
2. The operator is not shutting down the engine......................................................................................................................................................................................................................117
3. The control system is not commanding a higher engine RPM (Multi-function or High Engine)..........................................................................................................................................................................117
4. The control system is not calling for Generator RPM...............................................................................................................................................................................................................117
5. Platform mode is active with the controls enabled or Ground mode is active with any function enabled except for Lift Down, Tower Lift Down, or Jib Lift Down......................................................................................................117
Multi-Function RPM.......................................................................................................................................................................................................................................................118
1. The Engine State is Engine Running................................................................................................................................................................................................................................118
2. The operator is not shutting down the engine......................................................................................................................................................................................................................118
3. High Engine RPM is not being commanded............................................................................................................................................................................................................................118
4. The control system is not calling for Generator RPM...............................................................................................................................................................................................................118
5. One of the following conditions exist;............................................................................................................................................................................................................................118
a. Two of the following functions are being operated: Lift Up, Tower Lift Up, Swing..............................................................................................................................................................................118
b. Telescope is functioning at the same time as one of the following functions: Jib Lift Up, Platform Rotate, Platform Level.....................................................................................................................................118
High Engine RPM..........................................................................................................................................................................................................................................................118
1. The Engine State is Engine Running................................................................................................................................................................................................................................118
2. The operator is not shutting down the engine......................................................................................................................................................................................................................118
3. The control system is not calling for Generator RPM...............................................................................................................................................................................................................118
4. The operator is operating the Drive function at Max Torque or Max Speed...........................................................................................................................................................................................118
5. Drive Forward or Drive Reverse is being operated..................................................................................................................................................................................................................118
Generator RPM............................................................................................................................................................................................................................................................118
1. The Engine State is Engine Running................................................................................................................................................................................................................................118
2. The operator is not shutting down the engine......................................................................................................................................................................................................................118
3. The Control System is configured for a generator..................................................................................................................................................................................................................118
4. The Platform Generator Switch is Enabled and Selected.............................................................................................................................................................................................................118
3.15 Engine Controls.........................................................................................................................................................................................................................................................118
Ambient Air Temperature Sensor...........................................................................................................................................................................................................................................118
Fuel Level Sensor........................................................................................................................................................................................................................................................118
3.16 Engine Startup Procedure (Kubota).......................................................................................................................................................................................................................................119
1. With the engine off, disconnect the fuel line connection at the engine’s fuel injection pump. This is a short hose between the mechanical lift pump and the injection pump............................................................................................119
2. Actuate the priming lever on the mechanical lift pump until fuel comes out of the disconnected side of the fuel hose..................................................................................................................................................119
3. Attach the fuel hose and secure it in place with the existing hose clamp..............................................................................................................................................................................................119
4. Start the engine and ensure it runs properly and the fuel line does not leak..........................................................................................................................................................................................119
3.17 Kubota Engine...........................................................................................................................................................................................................................................................120
Engine Oil Pressure Switch...............................................................................................................................................................................................................................................120
Engine Speed Sensor......................................................................................................................................................................................................................................................120
Coolant Sensor...........................................................................................................................................................................................................................................................121
Glow Plugs...............................................................................................................................................................................................................................................................121
Engine Speed Actuators...................................................................................................................................................................................................................................................122
Engine throttle actuator.............................................................................................................................................................................................................................................122
Proportional Fuel Rack Actuator......................................................................................................................................................................................................................................123
Engine Start.............................................................................................................................................................................................................................................................123
Alternator Excitation....................................................................................................................................................................................................................................................123
Fuel Pump................................................................................................................................................................................................................................................................123
Shutdown.................................................................................................................................................................................................................................................................123
1. Remove power and prevent power from flowing to the Proportional Fuel Rack Actuator by turning off output terminal J1-1............................................................................................................................................123
2. Remove power and prevent power from flowing to the Engine Throttle Actuator by turning off output terminal J1-2...................................................................................................................................................123
1. Fuel Tank.........................................................................................................................................................................................................................................................124
2. Coolant Recovery Tank.............................................................................................................................................................................................................................................124
3. Alternator........................................................................................................................................................................................................................................................124
4. Oil Filter........................................................................................................................................................................................................................................................124
5. Starter...........................................................................................................................................................................................................................................................124
6. Main Pump.........................................................................................................................................................................................................................................................124
7. Gear Pump.........................................................................................................................................................................................................................................................124
8. Battery...........................................................................................................................................................................................................................................................124
9. Air Filter........................................................................................................................................................................................................................................................124
10. Muffler..........................................................................................................................................................................................................................................................124
11. Starter Relay....................................................................................................................................................................................................................................................124
12. Full Speed Relay.................................................................................................................................................................................................................................................124
13. Glow Plug Relay..................................................................................................................................................................................................................................................124
1. Coolant Recovery Tank.............................................................................................................................................................................................................................................125
2. Muffler...........................................................................................................................................................................................................................................................125
3. Main Pump.........................................................................................................................................................................................................................................................125
4. Gear Pump.........................................................................................................................................................................................................................................................125
5. Air Filter........................................................................................................................................................................................................................................................125
6. Fuel Filter/ Water Separator......................................................................................................................................................................................................................................125
7. Fuel Pump.........................................................................................................................................................................................................................................................125
8. Fuel Level Sending Unit...........................................................................................................................................................................................................................................125
9. Fuel Tank.........................................................................................................................................................................................................................................................125
10. Radiator.........................................................................................................................................................................................................................................................125
11. Pressure Cap.....................................................................................................................................................................................................................................................125
1. Radiator..........................................................................................................................................................................................................................................................126
2. Radiator Mount....................................................................................................................................................................................................................................................126
3. Engine Oil Filter.................................................................................................................................................................................................................................................126
4. Mid Engine Harness................................................................................................................................................................................................................................................126
5. Engine Harness....................................................................................................................................................................................................................................................126
6. Starter Relay.....................................................................................................................................................................................................................................................126
7. Full Speed Relay..................................................................................................................................................................................................................................................126
8. Glow Plug Relay...................................................................................................................................................................................................................................................126
9. Starter...........................................................................................................................................................................................................................................................126
10. Gear Pump........................................................................................................................................................................................................................................................126
11. Main Pump........................................................................................................................................................................................................................................................126
12. Muffler..........................................................................................................................................................................................................................................................126
13. Coolant Recovery Tank............................................................................................................................................................................................................................................126
1. Muffler...........................................................................................................................................................................................................................................................127
2. Main Pump.........................................................................................................................................................................................................................................................127
3. Gear Pump.........................................................................................................................................................................................................................................................127
4. Negative Battery Terminal.........................................................................................................................................................................................................................................127
5. Negative Battery Post.............................................................................................................................................................................................................................................127
6. Battery...........................................................................................................................................................................................................................................................127
7. Positive Battery Terminal.........................................................................................................................................................................................................................................127
8. Positive Battery Post.............................................................................................................................................................................................................................................127
9. Fuel Supply Line..................................................................................................................................................................................................................................................127
10. Fuel Return Line.................................................................................................................................................................................................................................................127
11. Radiator.........................................................................................................................................................................................................................................................127
12. Fuel Tank........................................................................................................................................................................................................................................................127
13. Fuel Level Sensor................................................................................................................................................................................................................................................127
3.18 GM Dual Fuel Engine.....................................................................................................................................................................................................................................................128
Communications with the JLG Control System...............................................................................................................................................................................................................................128
Engine Start.............................................................................................................................................................................................................................................................128
Oil Pressure.............................................................................................................................................................................................................................................................128
Engine Speed.............................................................................................................................................................................................................................................................128
Coolant Temperature......................................................................................................................................................................................................................................................128
Fuel Select..............................................................................................................................................................................................................................................................128
1. Fuel Tank.........................................................................................................................................................................................................................................................129
2. Coolant Recovery Tank.............................................................................................................................................................................................................................................129
3. Radiator..........................................................................................................................................................................................................................................................129
4. Oil Filter........................................................................................................................................................................................................................................................129
5. Starter...........................................................................................................................................................................................................................................................129
6. Main Pump.........................................................................................................................................................................................................................................................129
7. Gear Pump.........................................................................................................................................................................................................................................................129
8. Battery...........................................................................................................................................................................................................................................................129
9. Muffler...........................................................................................................................................................................................................................................................129
10. Fuel Mixer.......................................................................................................................................................................................................................................................129
1. Coolant Recovery Tank.............................................................................................................................................................................................................................................130
2. Fuel Tank.........................................................................................................................................................................................................................................................130
3. Radiator..........................................................................................................................................................................................................................................................130
4. Oil Filter........................................................................................................................................................................................................................................................130
5. Negative/Ground Terminal..........................................................................................................................................................................................................................................130
6. Positive Terminal.................................................................................................................................................................................................................................................130
7. Main Pump.........................................................................................................................................................................................................................................................130
8. Gear Pump.........................................................................................................................................................................................................................................................130
9. Battery...........................................................................................................................................................................................................................................................130
10. Muffler..........................................................................................................................................................................................................................................................130
1. Alternator........................................................................................................................................................................................................................................................131
2. Supply Fuel Hose..................................................................................................................................................................................................................................................131
3. Return Fuel Hose..................................................................................................................................................................................................................................................131
4. Main Pump.........................................................................................................................................................................................................................................................131
5. Fuel Pump Harness.................................................................................................................................................................................................................................................131
6. Air/Fuel Mixer....................................................................................................................................................................................................................................................131
7. Gear Pump.........................................................................................................................................................................................................................................................131
8. Muffler...........................................................................................................................................................................................................................................................131
9. Fuel Level Sensor.................................................................................................................................................................................................................................................131
10. Radiator.........................................................................................................................................................................................................................................................131
11. Carbon Cannister.................................................................................................................................................................................................................................................131
1. Dipstick..........................................................................................................................................................................................................................................................132
2. Relays............................................................................................................................................................................................................................................................132
3. Muffler...........................................................................................................................................................................................................................................................132
4. Main Pump.........................................................................................................................................................................................................................................................132
5. Gear Pump.........................................................................................................................................................................................................................................................132
6. Negative Battery Cable............................................................................................................................................................................................................................................132
7. Negative Battery Post.............................................................................................................................................................................................................................................132
8. Battery...........................................................................................................................................................................................................................................................132
9. Positive Battery Cable............................................................................................................................................................................................................................................132
10. Positive Battery Post............................................................................................................................................................................................................................................132
11. Air/Fuel Mixer...................................................................................................................................................................................................................................................132
12. Air Filter.......................................................................................................................................................................................................................................................132
13. Fuel Pump........................................................................................................................................................................................................................................................132
14. Fuel Mixer.......................................................................................................................................................................................................................................................132
15. Fuel Level Sensor................................................................................................................................................................................................................................................132
16. Fuel Tank........................................................................................................................................................................................................................................................132
17. Fuel Lock-off Valve..............................................................................................................................................................................................................................................132
18. Engine Oil Fill Cap..............................................................................................................................................................................................................................................132
1. Fuel Level Sensor.................................................................................................................................................................................................................................................133
2. Fuel Lock-off Valve...............................................................................................................................................................................................................................................133
3. Muffler...........................................................................................................................................................................................................................................................133
4. Air Mixer Valve...................................................................................................................................................................................................................................................133
5. Gear Pump.........................................................................................................................................................................................................................................................133
6. Fuel Pump Harness.................................................................................................................................................................................................................................................133
7. Fuel Filter.......................................................................................................................................................................................................................................................133
8. Fuel Pump.........................................................................................................................................................................................................................................................133
9. Return Port.......................................................................................................................................................................................................................................................133
10. Supply Port......................................................................................................................................................................................................................................................133
1. Air Mixer Valve...................................................................................................................................................................................................................................................134
2. Muffler...........................................................................................................................................................................................................................................................134
3. Gear Pump.........................................................................................................................................................................................................................................................134
4. Battery...........................................................................................................................................................................................................................................................134
5. Alternator........................................................................................................................................................................................................................................................134
6. Fuel Level Sensor.................................................................................................................................................................................................................................................134
7. Fuel Tank.........................................................................................................................................................................................................................................................134
8. Carbon Cannister..................................................................................................................................................................................................................................................134
9. Coolant Recovery Tank.............................................................................................................................................................................................................................................134
10. Engine Oil Filler Cap............................................................................................................................................................................................................................................134
11. Fuel Mixer.......................................................................................................................................................................................................................................................134
12. Fuel Lock-off Valve..............................................................................................................................................................................................................................................134
13. Relays...........................................................................................................................................................................................................................................................134
3.19 Fuel Reserve / Cut-Out System...........................................................................................................................................................................................................................................142
3.20 Cold Start System (Diesel Engine).......................................................................................................................................................................................................................................142
3.21 Generator...............................................................................................................................................................................................................................................................142
3.22 Counterweight...........................................................................................................................................................................................................................................................143
Section 4. Boom & Platform.......................................................................................................................................................................................................................................................145
4.1 Platform Control Enable System...........................................................................................................................................................................................................................................145
4.2 Platform Load Sensing System (CE & AUS)..................................................................................................................................................................................................................................145
4.3 Ground Control Keyswitch System..........................................................................................................................................................................................................................................145
4.4 Function Speed Control System............................................................................................................................................................................................................................................145
4.5 Jib Lift End Of Stroke Dampening.........................................................................................................................................................................................................................................145
4.6 Emergency Decent System..................................................................................................................................................................................................................................................145
4.7 Transport Position Sensing System........................................................................................................................................................................................................................................145
4.8 Platform.................................................................................................................................................................................................................................................................146
Platform/Support Removal.................................................................................................................................................................................................................................................146
1. Disconnect electrical cable from control console..................................................................................................................................................................................................................146
2. Tag and disconnect the hydraulic lines from the rotator. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports.............................................................................................................146
3. Remove the bolts securing the platform to the platform support, then remove the platform..........................................................................................................................................................................146
4. Using a suitable device, support the platform support.............................................................................................................................................................................................................146
5. Remove the bolts and washers securing the platform support cover to the platform support. Remove platform support cover...........................................................................................................................................146
6. Remove the bolts and washers securing the support to the rotator..................................................................................................................................................................................................146
7. Using a suitable brass drift and hammer, remove the center bolt and locknut.......................................................................................................................................................................................146
8. Remove the platform support from rotator..........................................................................................................................................................................................................................146
Support Installation.....................................................................................................................................................................................................................................................147
1. Using a suitable device, support the platform support and position it on the rotator..............................................................................................................................................................................147
2. Install the rotator center bolt and locknut.......................................................................................................................................................................................................................147
3. Apply Medium Strength Threadlocking Compound to the eight bolts securing the support to the rotator and install the bolts.........................................................................................................................................147
4. Torque the nut on the rotator center bolt and the retaining bolts. See Figure 4-2.................................................................................................................................................................................147
5. Apply Medium Strength Threadlocking Compound to the bolts and washers securing platform support cover to the platform support.....................................................................................................................................147
6. Position the platform on the platform support and install the bolts securing the platform to the platform support. See Figure 4-2.................................................................................................................................147
7. Remove tag and reconnect the hydraulic lines to the rotator.......................................................................................................................................................................................................147
8. Connect the electrical harness to the platform control console....................................................................................................................................................................................................147
4.9 Main Boom Powertrack.....................................................................................................................................................................................................................................................149
Removal..................................................................................................................................................................................................................................................................149
1. Disconnect wiring harness connectors located in turntable.........................................................................................................................................................................................................149
2. Tag and disconnect hydraulic lines from connectors at boom assembly. Use suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports.................................................................................................149
3. Remove hydraulic lines and electrical cables from Powertrack......................................................................................................................................................................................................149
4. Using suitable lifting device, adequately support Powertrack weight along entire length...........................................................................................................................................................................149
5. Remove hardware #1 securing the powertrack on the tube carrier....................................................................................................................................................................................................149
6. Remove bolt #2 securing the powertrack on the base boom section. Remove the powertrack assembly...................................................................................................................................................................149
Installation.............................................................................................................................................................................................................................................................149
1. Using suitable lifting device, adequately support the powertrack weight along entire length.......................................................................................................................................................................149
2. With powertrack supported and using all applicable safety precautions, install hardware #2 securing rail to the base boom.........................................................................................................................................149
3. Install hardware #1 to tube carrier...............................................................................................................................................................................................................................149
4. Remove tag and reconnect all hydraulic lines and electrical cable from powertrack.................................................................................................................................................................................149
5. Remove tag and reconnect hydraulic lines from connectors at boom assembly.........................................................................................................................................................................................149
4.10 Powertrack Maintenance..................................................................................................................................................................................................................................................150
Remove Link..............................................................................................................................................................................................................................................................150
1. Clamp bar and poly roller tightly so they do not spin when removing screw. With a small 1/4 in. ratchet and a T-20 torx bit, remove 8-32 x 0.500 screw from one side..............................................................................................150
2. Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack...................................................................................................................................................................150
3. To remove a link, rivets holding links together must be removed. Use a right-angle pneumatic die grinder with a 1/4 in. ball double cut bur attachment............................................................................................................151
4. Insert tool into rolled over end of rivet. Grind out middle of rivet until rolled over part of rivet falls off. Repeat for all rivets to be removed...............................................................................................................151
5. After grinding it may be necessary to use a center punch with a hammer to remove rivet............................................................................................................................................................................151
6. Insert flat head screwdriver between links. Twist and pull links apart............................................................................................................................................................................................152
7. Remove link from other section of powertrack using screwdriver....................................................................................................................................................................................................152
Install New Link.........................................................................................................................................................................................................................................................153
1. Squeeze cut-out end of new link into half-shear (female) end of track section.....................................................................................................................................................................................153
2. Spread half-shear (female) end of new link and slide cut- out end of track section into it. Use a screwdriver if necessary........................................................................................................................................153
3. After new link is installed round half-shears do not fit properly in cut-outs.....................................................................................................................................................................................153
4. Pull moving end over track so new connection is positioned in curve of powertrack. Round half-shears will rotate into cut-outs....................................................................................................................................154
5. Parts shown below connect new link to powertrack..................................................................................................................................................................................................................154
6. Push pin through center hole then slide washer on pin.............................................................................................................................................................................................................154
7. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed........................................................................................................................................................154
8. Install new 8-32 x 0.500 self-threading torx head screw in end of new aluminum round bar. Torque to 18-20 in. lbs. (2-2.25 Nm)....................................................................................................................................155
9. Pull up on other end of round bar and slide new poly roller on bar................................................................................................................................................................................................155
10. Install new 8-32 x 0.500 self threading screw on other side. Torque to 18-20 in. lbs. (2-2.25 Nm)................................................................................................................................................................156
Replace Fixed End Brackets...............................................................................................................................................................................................................................................156
1. Remove rivets as shown in link removal instructions on page 4-7...................................................................................................................................................................................................156
2. Parts used: Bracket Center Pin and Center Pin Snap Ring...........................................................................................................................................................................................................157
3. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it............................................................................................................................................................157
Replace Moving End Brackets..............................................................................................................................................................................................................................................157
1. Remove existing pins and center rivet. Remove rivet as shown in link removal instructions on page 4-2. Repeat on other bracket if replacing it....................................................................................................................157
2. Install center pin with snap ring in new bracket..................................................................................................................................................................................................................158
3. Install radius pins and snap rings in original locations. Repeat with other moving end if replacing it............................................................................................................................................................158
4. Make sure both brackets rotate correctly..........................................................................................................................................................................................................................158
4.11 Boom Maintenance........................................................................................................................................................................................................................................................159
Disassembly of the Main Boom.............................................................................................................................................................................................................................................159
1. Loosen the wear pad retaining bolts at the rear of fly boom section and remove the shims and wear pads noting the location and amount of shims to aid in reassembly...............................................................................................159
2. Using a portable power source, attach hose to telescope cylinder port block. Using all applicable safety precautions, activate hydraulic system and extend cylinder to gain access to cylinder rod retaining pin. Shut down the portable power source.............159
3. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After initial discharge, there should be no further leakage from the retract port. Cap...........159
4. Remove the retaining ring and pin securing the telescope cylinder rod end to the fly boom section.................................................................................................................................................................159
5. Remove the bolts and washers securing telescope cylinder to the rear of the base boom section.....................................................................................................................................................................159
6. Using a suitable lifting device, remove telescope cylinder from the rear of the boom sections.....................................................................................................................................................................160
7. Remove hardware securing the front wear pads on base boom section, remove wear pads and shims, noting the location and amount of shims to aid in reassembly.......................................................................................................160
8. Using a suitable lifting device, remove fly boom from boom section................................................................................................................................................................................................160
Inspection...............................................................................................................................................................................................................................................................160
1. Inspect all boom pivot pins for wear, scoring or other damage, and for tapering or ovality. Replace pins as necessary.............................................................................................................................................160
2. Inspect lift cylinder pins for wear, scoring or other damage, and for tapering or ovality. Ensure pin surfaces are protected prior to installation. Replace pins as necessary.....................................................................................160
3. Inspect telescope cylinder rod attach pin for wear, scoring or other damage. Replace pin as necessary.............................................................................................................................................................160
4. Inspect inner diameter of boom pivot bushings for scoring, distortion, wear or other damage. Replace bushings as necessary........................................................................................................................................160
5. Inspect wear pads for wear........................................................................................................................................................................................................................................160
6. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary..............................................................................................................................................160
7. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary.........................................................................................................................160
Assembly of the Main Boom................................................................................................................................................................................................................................................160
1. Using Medium Strength Threadlocking Compound or equivalent, install the bottom wear pads and shims as noted during disassembly on the rear of the fly section. Torque the retaining bolts to 40 ft.lbs. (55 Nm). Install the rest of the wear pads on t...........160
2. Using an adequate lifting device, slide the fly boom section into the base boom section. Install the remaining shims on the rear of the fly section as noted during disassembly and torque the retaining bolts to 40 ft.lbs. (55 Nm). Pull the fly sect...........160
3. Using Medium Strength Threadlocking Compound or equivalent, install the front wear pads and shims as noted during disassembly on the base boom section. Torque the retaining bolts to 40 ft.lbs. (55 Nm)..........................................................161
4. Using an adequate lifting device, install the telescope cylinder into the boom assembly. It will aid assembly if the cylinder is extended to enable connection to the fly boom section............................................................................161
5. Align the telescope cylinder rod end with the corresponding hole in the fly boom section. If necessary, attach a portable power supply to the cylinder to extend or retract the cylinder for alignment. Install the retaining pin and secure it in plac...........161
6. Using Medium Strength Threadlocking Compound or equivalent, secure the rear of the telescope cylinder to the base boom section with the attaching bolts and washers. Torque the bolts 95 ft.lbs. (129 Nm).........................................................161
1. Master Cylinder...................................................................................................................................................................................................................................................162
2. Upper Lift Cylinder...............................................................................................................................................................................................................................................162
3. Jib...............................................................................................................................................................................................................................................................162
4. Main Boom.........................................................................................................................................................................................................................................................162
5. Level Cylinder....................................................................................................................................................................................................................................................162
6. Upper Upright.....................................................................................................................................................................................................................................................162
7. Mid Boom Link.....................................................................................................................................................................................................................................................162
8. Mid Boom..........................................................................................................................................................................................................................................................162
9. Jib Cylinder......................................................................................................................................................................................................................................................162
1. Rotator...........................................................................................................................................................................................................................................................163
2. Jib Cylinder......................................................................................................................................................................................................................................................163
3. Jib Pivot.........................................................................................................................................................................................................................................................163
4. Platform Support..................................................................................................................................................................................................................................................163
5. Hose Carrier......................................................................................................................................................................................................................................................163
6. Lower Jib Link....................................................................................................................................................................................................................................................163
7. Upper Jib Link....................................................................................................................................................................................................................................................163
4.12 Boom Cleanliness Guidelines.............................................................................................................................................................................................................................................164
1. JLG recommends the use of the JLG Hostile Environment Package if available to keep the internal portions of a boom cleaner and to help prevent dirt and debris from entering the boom. This package reduces the amount of contamination which can enter...............164
2. JLG recommends that you follow all guidelines for servicing your equipment in accordance with the instructions outlined in the JLG Service & Maintenance Manual for your machine. Periodic maintenance and inspection is vital to the proper operation ...............164
3. Debris and foreign matter inside of the boom can cause premature failure of components and should be removed. Methods to remove debris should always be done using all applicable safety precautions outlined in the JLG Service & Maintenance Manuals................164
4. The first attempt to remove debris from inside the boom must be to utilize pressurized air to blow the debris toward the nearest exiting point from the boom. Make sure that all debris is removed before operating the machine.......................................164
5. If pressurized air cannot dislodge the debris, then water with mild solvents applied via a pressure washer can be used. Again the method is to wash the debris toward the nearest exiting point from the boom. Make sure that all debris is removed, th...............164
6. If neither pressurized air nor washing of the boom dislodges and removes the debris, then disassemble the boom in accordance to the instructions outlined in the JLG Service & Maintenance Manual to remove the debris................................................164
4.13 Rotary Actuator.........................................................................................................................................................................................................................................................167
Theory of Operation......................................................................................................................................................................................................................................................167
Tools Required...........................................................................................................................................................................................................................................................168
1. PIPE VISE.........................................................................................................................................................................................................................................................168
2. HEXWRENCH Removal and replacement of port plugs and set screws....................................................................................................................................................................................................168
3. ASSORTED SCREWS...................................................................................................................................................................................................................................................168
4. SAFETY GLASSES....................................................................................................................................................................................................................................................168
5. END CAP REMOVAL TOOLS (provided with seal kit)....................................................................................................................................................................................................................168
6. DRILL.............................................................................................................................................................................................................................................................168
7. FLASHLIGHT Helps in locating and examining timing marks, component failure and overall condition..................................................................................................................................................................168
8. RUBBER MALLET Removal and installation of shaft and piston sleeve assembly........................................................................................................................................................................................168
9. PLASTIC MANDREL...................................................................................................................................................................................................................................................168
10. PRY BAR Removal of end cap and manual rotation of shaft..........................................................................................................................................................................................................168
11. FELT MARKER Highlights timing marks and outlines troubled areas. Permanent ink is recommended....................................................................................................................................................................168
12. T-HANDLE SCREW EXTRACTOR.........................................................................................................................................................................................................................................168
13. HEX WRENCH SET Removal and replacement of port plugs and set screws (106,110)....................................................................................................................................................................................168
14. SEAL TOOLS Removal and installation of seals and wear guides.....................................................................................................................................................................................................168
15. PUNCH............................................................................................................................................................................................................................................................168
16. DOWEL PINS Removal and installation of end cap...................................................................................................................................................................................................................168
Disassembly..............................................................................................................................................................................................................................................................169
1. Remove port plugs (106.1) (106.2) and drain oil. Inspect oil for signs of contamination, i.e. water, metal shavings...............................................................................................................................................169
2. Remove the capscrews (113) that cover the end cap lock pins (109).................................................................................................................................................................................................169
3. Using a 1/8" (3 mm) drill bit, drill a hole in the center of each lock pin to a depth of approximately 3/16" (5 mm)...............................................................................................................................................169
4. Remove the lock pins using a screw extracting tool such as an "Easy Out" (a size #2 is shown). If the pin cannot be removed with the screw extractor, use a 5/16" bit to drill out the entire pin. Do not drill deeper than 1/2" (12.7 mm)........................169
5. Install the end cap removal tools provided with the seal kit. (1/4-20)............................................................................................................................................................................................169
6. Using a metal bar or similar tool, unthread the end cap (4) by turning it counterclockwise........................................................................................................................................................................169
7. Remove the end cap (4) and carefully set aside for later inspection...............................................................................................................................................................................................172
8. Remove the stop tube (400) if the actuator is equipped with one. The stop tube is an available option that limits the rotation of the actuator....................................................................................................................172
9. Every actuator has two sets of small punched timing marks that indicate timing between the gear sets. The location and appearance of the marks can vary slightly between models. One set indicates the timing between the piston sleeve (3) and the hou...........172
10. Prior to removing the shaft (2), use a felt marker to clearly indicate the timing between shaft and piston sleeve (3). This will greatly simplify timing when the actuator is reassembled........................................................................172
11. Remove the shaft (2) by rotating counterclockwise. As the shaft is rotated, it will disengage from the piston sleeve (3) and can be removed. It may be necessary to strike the threaded end of the shaft with a rubber mallet....................................173
12. As in step 9, before removing the piston (3), mark the housing (1) ring gear in relation to the piston outside diameter gear. There should now be timing marks on the housing (1) ring gear, the piston (3) and the shaft (2)....................................173
13. To remove the piston (3) use a rubber mallet and a plastic mandrel so the piston and housing bore are not damaged................................................................................................................................................173
14. At the point when the piston gear teeth come out of engagement with the housing gear teeth, mark the piston and housing with a marker as shown...................................................................................................................173
15. Remove the O-ring (204) and backup ring (207) from end cap (4)...................................................................................................................................................................................................173
16. Remove the wear guide (302) from the end cap (4) and shaft (2)...................................................................................................................................................................................................173
17. Remove the main pressure seal (205)..............................................................................................................................................................................................................................174
18. Remove the thrust washer (304) from the end cap (4) and shaft (2)................................................................................................................................................................................................174
19. Remove the O-ring (304.1) from its groove in the end cap (4) and shaft (2).......................................................................................................................................................................................174
20. Remove the outside diameter piston seal (202) from the piston....................................................................................................................................................................................................174
21. Remove the inside diameter piston seal (200).....................................................................................................................................................................................................................174
Inspection...............................................................................................................................................................................................................................................................174
1. Clean all parts in a solvent tank and dry with compressed air prior to inspecting.................................................................................................................................................................................174
2. Carefully inspect all critical areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, shaft surface, housing bore and gear teeth.............................................................................................174
Assembly.................................................................................................................................................................................................................................................................175
1. Gather all the components and tools into one location prior to re-assembly. Use the cut away drawing to reference the seal orientations...........................................................................................................................175
2. Coat the thrust washers (304) with a generous amount of Lithium grease. Install the thrust washer (304) onto shaft (2) and end cap (4)............................................................................................................................175
3. Install the exclusion seal (304.1) into the appropriate grooves on the shaft (2) and end cap (4) around the outside edge of the thrust washer (304)...............................................................................................................175
4. Using a seal tool install the main pressure seal (205) onto shaft (2) and end cap (4). Use the seal tool in a circular motion.....................................................................................................................................175
5. Install the wear guide (302) on the end cap (4) and shaft (2).....................................................................................................................................................................................................175
6. Install the O-ring (204) and backup ring (207) into the inner seal groove on the end cap (4)......................................................................................................................................................................175
7. Install the inner T-seal (200) into the appropriate groove in the piston (3). Use a circular motion to ensure the seal is correctly seated in the groove. Install the outer T-seal (202) by stretching it around the groove in a circular motion. Each ...........176
8. Insert the piston (3) into the housing (1) as shown, until the outer piston seal (202) contacts the inside housing bore...........................................................................................................................................176
9. Looking into the housing bore from the shaft flange end, rotate the piston (3) until the marks you put on the piston and the housing (1) during disassembly align as shown. Using a rubber mallet, tap the piston into the housing until the gear teeth...........176
10. Looking into the bore from the opposite end of the housing (1) be sure the timing marks align correctly. Rotate the piston as necessary until aligned, then gently tap the piston (3) into the housing until the gear teeth mesh together. Tap the pis...........177
11. Insert the shaft (2) into the piston (3). Be careful not to damage the piston seals. Do not engage the piston gear teeth yet.....................................................................................................................................177
12. Looking at the actuator from the end opposite the shaft flange, use the existing timing marks to align the gear teeth on the shaft (2) with the gear teeth on the inside of the piston (3). When the marks align, gently tap the flange end of the sha...........177
13. Install two bolts in the threaded holes in the flange. Using a metal bar, rotate the shaft in a clockwise direction until the wear guides are seated inside the housing bore.....................................................................................177
14. Install the stop tube (400) onto the shaft end if necessary. Stop tubes are an available option to limit the rotation of an actuator.............................................................................................................................178
15. Coat the threads on the end of the shaft with anti-seize grease to prevent galling...............................................................................................................................................................................178
16. Thread the end cap (4) onto the shaft (2). Make sure the wear guide remains in place on the end cap as it is threaded into the housing (1).......................................................................................................................178
17. Tighten the end cap (4) using a metal bar. In most cases the original holes for the lock pins will align.........................................................................................................................................................178
18. Insert the lock pins (109) provided with the Helac seal kit into the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole.............................................................................................178
19. Insert the set screws (113) over the lock pins. Tighten to 25 in-lbs. (2.8 Nm)...................................................................................................................................................................................178
Greasing Thrust Washers..................................................................................................................................................................................................................................................179
1. After the actuator is assembled but before it is put into service, the thrust washer area must be packed with Lithium grease. There are two grease ports located on both the shaft flange and the end cap. They are plugged with capscrews (113) or set...........179
Installing Counterbalance Valve..........................................................................................................................................................................................................................................179
1. Make sure the surface of the actuator is clean, free of any contamination and foreign debris including old ThreadLocking Compound.................................................................................................................................179
2. Make sure the new valve has the O-rings in the counterbores of the valve to seal it to the actuator housing.......................................................................................................................................................179
3. The bolts that come with the valve are grade 8 bolts. New bolts should be installed with a new valve. Medium Strength ThreadLocking Compound should be applied to the shank of the three bolts at the time of installation........................................179
4. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4 to 13.5 Nm). Do not torque over 125 inch pounds (14.1 Nm). Torque the 5/16-inch bolts 140 inch pounds (15.8 Nm). Do not torque over 145 inch pounds (16.3 Nm)..............................................179
Testing the Actuator.....................................................................................................................................................................................................................................................179
Testing the Actuator for Internal Leakage............................................................................................................................................................................................................................179
Installation and Bleeding................................................................................................................................................................................................................................................181
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 collect the purged oil. The oil can be...........181
2. With an operator in the platform, open both bleed nipples 1/4 turn. Hydraulically rotate the platform to the end of rotation (either clockwise or counterclockwise), and maintain hydraulic pressure. Oil with small air bubbles will be seen flowing t...........181
3. Keep the fittings open and rotate the platform in the opposite direction to the end position. Maintain hydraulic pressure until an additional 1/4 gallon of fluid is pumped into the container....................................................................181
4. Repeat steps 2 & 3. After the last 1/2 gallon is purged, close both bleed nipples before rotating away from the end position......................................................................................................................................181
Troubleshooting..........................................................................................................................................................................................................................................................182
1. Shaft rotates slowly or not at all................................................................................................................................................................................................................................182
2. Operation is erratic or not responsive............................................................................................................................................................................................................................182
3. Shaft will not fully rotate.......................................................................................................................................................................................................................................182
4. Selected position cannot be maintained............................................................................................................................................................................................................................182
4.14 Skyguard®...............................................................................................................................................................................................................................................................183
Operation................................................................................................................................................................................................................................................................183
Function Test............................................................................................................................................................................................................................................................183
SkyGuard Only........................................................................................................................................................................................................................................................183
1. Operate the telescope out function, then activate SkyGuard sensor.............................................................................................................................................................................................183
2. Once sensor has been activated, ensure telescope out function stops then telescope in function operates for a short duration. Additionally, verify Soft Touch/SkyGuard indicator light flashes and horn sounds. If machine is equipped with SkyGuard be.......183
3. With SkyGuard sensor still engaged, press and hold yellow Soft Touch/SkyGuard override button. Operate a function to verify operation can be resumed..........................................................................................................183
4. Disengage SkyGuard sensor, release controls, and recycle footswitch. Ensure normal operation available........................................................................................................................................................183
1. Operation is allowed regardless of SkyGuard activation........................................................................................................................................................................................................183
Soft touch only......................................................................................................................................................................................................................................................183
SkyGuard not selected in machine setup...............................................................................................................................................................................................................................183
Diagnostics & Troubleshooting............................................................................................................................................................................................................................................184
Fault Codes..........................................................................................................................................................................................................................................................184
Section 5. Basic Hydraulic Information & Schematics..............................................................................................................................................................................................................................185
5.1 Lubricating O-Rings in the Hydraulic system..............................................................................................................................................................................................................................185
Cup and Brush............................................................................................................................................................................................................................................................185
1. Hold the fitting in one hand while using the brush with the other hand to dip into the container. Remove excess hydraulic oil from the brush so an even film of oil is applied on the o-ring......................................................................185
2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the fitting, making sure the entire o-ring is completely saturated....................................................................................185
3. Turn the o-ring on the other side of the fitting and repeat the previous step, ensuring the entire o-ring is coated with hydraulic oil............................................................................................................................185
Dip Method...............................................................................................................................................................................................................................................................186
1. Place the sponge inside the container and add hydraulic oil to the sponge until it is fully saturated.............................................................................................................................................................186
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.......................................................186
3. O-ring Boss type fittings will require more pressure in able to immerse more of the fitting into the saturated sponge. This will also cause more oil to be dispersed from the sponge..............................................................................186
Spray Method.............................................................................................................................................................................................................................................................186
1. Fill the spray bottle with hydraulic oil..........................................................................................................................................................................................................................186
2. Hold the fitting over a suitable catch can........................................................................................................................................................................................................................186
3. Spray the entire o-ring surface with a medium coat of oil.........................................................................................................................................................................................................186
Brush-on Method..........................................................................................................................................................................................................................................................186
1. Fill the bottle with hydraulic oil................................................................................................................................................................................................................................186
2. Using slight pressure to the body of the spray bottle, invert the bottle so the brush end is in the downward position.............................................................................................................................................186
3. Brush hydraulic oil on the entire o-ring, applying an even coat of oil............................................................................................................................................................................................186
5.2 Hydraulic Cylinders......................................................................................................................................................................................................................................................187
Disassembly and Assembly Instructions....................................................................................................................................................................................................................................187
1. Make sure the work surface is large enough for the entire cylinder and clean and free of dirt. Ensure the cylinder can be secured firmly in place during disassembly..............................................................................................187
2. Prepare all the necessary tools and replacement parts. Refer to Table 5-1, Required Tools.........................................................................................................................................................................187
General Information......................................................................................................................................................................................................................................................187
1. Clean any burrs or contamination from the surface of the cylinder before disassembly..............................................................................................................................................................................187
2. Handle every part with care. Each part is precision made and hitting parts together or letting them fall could damage the machined surfaces.......................................................................................................................187
3. Do not twist or strike parts to get them apart. This will damage the part and/or threads, resulting in leakage and poor function..................................................................................................................................187
4. Do not let the cylinder in a disassembled condition for a long period of time. It only takes a short period of time for the parts to rust.........................................................................................................................187
Standard of Maintenance..................................................................................................................................................................................................................................................187
1. Bushings - 1/4 of the bushing is worn off.........................................................................................................................................................................................................................187
2. Seal and Slide Ring - Replace during disassembly..................................................................................................................................................................................................................187
3. Pin Bushing - When it is worn down................................................................................................................................................................................................................................187
4. Rod - Bent or warped more than 0.5mm/1m...........................................................................................................................................................................................................................187
Inspection After Assembly................................................................................................................................................................................................................................................187
Disassembly Procedure....................................................................................................................................................................................................................................................190
1. Remove the oil from the cylinder..................................................................................................................................................................................................................................190
2. Fix the cylinder in a vertical or horizontal position. Vertical position is convenient for disassembly and assembly. Fix the base by inserting the pin not to be rotated. Remove any hoses, valves, or fittings that may be in the way............................190
3. Unscrew the cylinder Head Glands that are threaded into the barrel are locked in place with caulking. Using a spanner wrench, unscrew the gland from the barrel. (It is easier to do this with rod pulled out 5cm from the gland). If there is no caulk...........190
4. Remove the Rod assembly...........................................................................................................................................................................................................................................190
a. Check if the cap or plug has been removed from the cylinder ports.............................................................................................................................................................................................190
b. Place a suitable container under the cylinder to catch any oil coming out of the cylinder.....................................................................................................................................................................190
c. After the Rod assembly is pulled from the barrel, unscrew the head using a spanner wrench.....................................................................................................................................................................191
d. After disassembling the rod assembly, place it on a support...................................................................................................................................................................................................191
5. Place the Rod assembly on blocking as shown below. Use the pin hole to keep it from rotating......................................................................................................................................................................191
6. Unscrew the Piston Nut............................................................................................................................................................................................................................................191
a. Unscrew the set screw. Caulking is used to lock the setscrew so grind the caulking area and then unscrew the set screw........................................................................................................................................191
b. Remove the steel ball.........................................................................................................................................................................................................................................191
c. Unscrew the piston nut. The piston nut is secured with a torque specified in Table 5-3, Piston Nut Torque. 1.5 x this torque is needed to remove the nut. If the stronger torque is needed, use a power wrench operated by a hydraulic unit...................191
7. Remove the PISTON NUT, PISTON and GLAND in sequence...............................................................................................................................................................................................................191
8. Piston nut, piston, gland disassembly.............................................................................................................................................................................................................................192
a. Unscrew the Piston Nut........................................................................................................................................................................................................................................192
b. Take the piston apart by sliding off the rod in the direction of the rod threads..............................................................................................................................................................................192
c. Take the gland apart by sliding off the rod in the direction of the rod threads...............................................................................................................................................................................192
9. Take apart piston seals...........................................................................................................................................................................................................................................192
a. The wear ring is easily taken apart by hand...................................................................................................................................................................................................................192
b. The piston seal is a two piece seal; the ring at the outer side is easily removed. Remove the ring inside of the piston seal..................................................................................................................................192
c. Remove the o-ring.............................................................................................................................................................................................................................................192
10. Remove the gland seal............................................................................................................................................................................................................................................192
a. Remove the rod seal and backup ring...........................................................................................................................................................................................................................192
b. Remove the retaining ring with a flat-head screwdriver prior to removing the dust wiper and remove the dust wiper.............................................................................................................................................192
c. Remove the o-ring and backup ring.............................................................................................................................................................................................................................192
d. The du bushing is pressed in and must be removed by using a tool as shown below...............................................................................................................................................................................192
11. MRP BEARING DISASSEMBLY To remove the MRP bearing, break it into pieces..........................................................................................................................................................................................192
12. WASHING AND STORAGE All removed parts should be washed with cleaning solution and then coated with light oil to prevent rust. If the cylinder is not to be reassembled right away, store the parts and put a covering over them..................................192
Assembly.................................................................................................................................................................................................................................................................193
1. Pin bushing assembly Coat the opening with oil to aid in assembly and press the bushing into the rod as shown below...............................................................................................................................................193
2. Gland seal assemblies.............................................................................................................................................................................................................................................193
a. Coat the opening with oil to aid in assembly and press the bushing into place with the proper tool............................................................................................................................................................193
b. Rod seal assembly (Keep the right direction and do not make damage to seal)...................................................................................................................................................................................193
c. Install du bushing assembly and dust wiper assembly as shown below............................................................................................................................................................................................194
d. Assemble backup ring, o-ring (Check the sequence of backup ring, o-ring.).....................................................................................................................................................................................194
3. Piston Seal Assembly..............................................................................................................................................................................................................................................194
a. Assembly the seal assembly....................................................................................................................................................................................................................................194
b. Install the o-ring into the groove............................................................................................................................................................................................................................194
c. Using a proper tool, press the piston seal onto the piston. When installing the piston seal, it is stretched while passing over the head......................................................................................................................194
d. Install the wear ring assembly by spreading it apart..........................................................................................................................................................................................................194
4. Rod assembly......................................................................................................................................................................................................................................................194
a. Secure the rod assembly.......................................................................................................................................................................................................................................194
b. Install the Head onto the rod assembly. Take care as not to damage the lip of the dust wiper and rod seal.....................................................................................................................................................194
c. Assemble Piston...............................................................................................................................................................................................................................................194
d. Torque the Piston nut as specified in Table 5-3, Piston Nut Torque. Lack of the torque can result in internal leakage, the piston coming unscrewed, and thread damage. If overtorqued, the piston surface which meets the rod will be damaged.................195
5. Assemble the rod assembly.........................................................................................................................................................................................................................................195
a. Secure the barrel at a vertical or horizontal position........................................................................................................................................................................................................195
b. Insert the assembly into the barrel...........................................................................................................................................................................................................................195
c. When piston is inserted to the barrel take care as to not damage the seal rings...............................................................................................................................................................................195
6. Gland assembly. Install the gland using a spanner wrench as shown below...........................................................................................................................................................................................195
7. Caulking. Caulk at the machined area of the cylinder barrel end so that it locks the cylinder head in place and it does not unscrew from the barrel. If there is no caulking hole, caulking is not necessary......................................................195
8. Test operation....................................................................................................................................................................................................................................................195
a. Install the cylinder on a machine. Fill the cylinder with oil and then have the cylinder slowly operated a minimum of 8 cycles. If it is operated too fast in the beginning, cavitation will result. It is important to make sure all air is cycled fro.......195
b. Grease the end of the pin.....................................................................................................................................................................................................................................195
1. Tube..............................................................................................................................................................................................................................................................196
2. Rod...............................................................................................................................................................................................................................................................196
3. Gland.............................................................................................................................................................................................................................................................196
4. Dust Wiper........................................................................................................................................................................................................................................................196
5. Retaining Ring....................................................................................................................................................................................................................................................196
6. Rod Seal..........................................................................................................................................................................................................................................................196
7. Backup Ring.......................................................................................................................................................................................................................................................196
8. Dry Bearing.......................................................................................................................................................................................................................................................196
9. O-ring............................................................................................................................................................................................................................................................196
10. Backup Ring......................................................................................................................................................................................................................................................196
11. O-ring...........................................................................................................................................................................................................................................................196
12. Piston...........................................................................................................................................................................................................................................................196
13. Piston Seal......................................................................................................................................................................................................................................................196
14. Wear Ring........................................................................................................................................................................................................................................................196
15. O-ring...........................................................................................................................................................................................................................................................196
16. Nut..............................................................................................................................................................................................................................................................196
17. Poppet Valve.....................................................................................................................................................................................................................................................196
18. Check Valve......................................................................................................................................................................................................................................................196
19. Plug.............................................................................................................................................................................................................................................................196
20. O-ring...........................................................................................................................................................................................................................................................196
21. Orifice..........................................................................................................................................................................................................................................................196
22. MPR Bearing......................................................................................................................................................................................................................................................196
23. Plug.............................................................................................................................................................................................................................................................196
24. O-ring...........................................................................................................................................................................................................................................................196
1. Tube..............................................................................................................................................................................................................................................................197
2. Rod...............................................................................................................................................................................................................................................................197
3. Gland.............................................................................................................................................................................................................................................................197
4. Dust Wiper........................................................................................................................................................................................................................................................197
5. Retaining Ring....................................................................................................................................................................................................................................................197
6. Rod Seal..........................................................................................................................................................................................................................................................197
7. Backup Ring.......................................................................................................................................................................................................................................................197
8. Dry Bearing.......................................................................................................................................................................................................................................................197
9. O-ring............................................................................................................................................................................................................................................................197
10. Backup Ring......................................................................................................................................................................................................................................................197
11. O-ring...........................................................................................................................................................................................................................................................197
12. Piston...........................................................................................................................................................................................................................................................197
13. Piston Seal......................................................................................................................................................................................................................................................197
14. Wear Ring........................................................................................................................................................................................................................................................197
15. O-ring...........................................................................................................................................................................................................................................................197
16. Nut..............................................................................................................................................................................................................................................................197
17. Spacer...........................................................................................................................................................................................................................................................197
18. O-ring...........................................................................................................................................................................................................................................................197
19. Poppet Valve.....................................................................................................................................................................................................................................................197
20. Check Valve......................................................................................................................................................................................................................................................197
21. Plug.............................................................................................................................................................................................................................................................197
22. O-ring...........................................................................................................................................................................................................................................................197
23. Orifice..........................................................................................................................................................................................................................................................197
24. MPR Bearing......................................................................................................................................................................................................................................................197
25. Plug.............................................................................................................................................................................................................................................................197
26. O-ring...........................................................................................................................................................................................................................................................197
1. Tube..............................................................................................................................................................................................................................................................198
2. Rod...............................................................................................................................................................................................................................................................198
3. Gland.............................................................................................................................................................................................................................................................198
4. Dust Wiper........................................................................................................................................................................................................................................................198
5. Retaining Ring....................................................................................................................................................................................................................................................198
6. Rod Seal..........................................................................................................................................................................................................................................................198
7. Backup Ring.......................................................................................................................................................................................................................................................198
8. Dry Bearing.......................................................................................................................................................................................................................................................198
9. O-ring............................................................................................................................................................................................................................................................198
10. Backup Ring......................................................................................................................................................................................................................................................198
11. O-ring...........................................................................................................................................................................................................................................................198
12. Piston...........................................................................................................................................................................................................................................................198
13. Piston Seal......................................................................................................................................................................................................................................................198
14. Wear Ring........................................................................................................................................................................................................................................................198
15. O-ring...........................................................................................................................................................................................................................................................198
16. Nut..............................................................................................................................................................................................................................................................198
17. MRP Bearing......................................................................................................................................................................................................................................................198
18. Plug.............................................................................................................................................................................................................................................................198
1. Barrel............................................................................................................................................................................................................................................................199
2. Rod...............................................................................................................................................................................................................................................................199
3. Cylinder Head.....................................................................................................................................................................................................................................................199
4. Wiper Seal........................................................................................................................................................................................................................................................199
5. Retaining Ring....................................................................................................................................................................................................................................................199
6. Rod Seal..........................................................................................................................................................................................................................................................199
7. Backup Ring.......................................................................................................................................................................................................................................................199
8. Bearing...........................................................................................................................................................................................................................................................199
9. O-Ring............................................................................................................................................................................................................................................................199
10. Backup Ring......................................................................................................................................................................................................................................................199
11. O-Ring...........................................................................................................................................................................................................................................................199
12. Piston...........................................................................................................................................................................................................................................................199
13. Piston Seal......................................................................................................................................................................................................................................................199
14. Wear Ring........................................................................................................................................................................................................................................................199
15. Wear Ring........................................................................................................................................................................................................................................................199
16. Nut..............................................................................................................................................................................................................................................................199
17. Bushing..........................................................................................................................................................................................................................................................199
18. Cartridge Valve..................................................................................................................................................................................................................................................199
19. Cartridge Valve..................................................................................................................................................................................................................................................199
20. Plug.............................................................................................................................................................................................................................................................199
21. Valve Seat.......................................................................................................................................................................................................................................................199
22. O-Ring...........................................................................................................................................................................................................................................................199
23. Steel Ball.......................................................................................................................................................................................................................................................199
1. Tube..............................................................................................................................................................................................................................................................200
2. Rod...............................................................................................................................................................................................................................................................200
3. Gland.............................................................................................................................................................................................................................................................200
4. Dust Wiper........................................................................................................................................................................................................................................................200
5. Retaining Ring....................................................................................................................................................................................................................................................200
6. Rod Seal..........................................................................................................................................................................................................................................................200
7. Backup Ring.......................................................................................................................................................................................................................................................200
8. Dry Bearing.......................................................................................................................................................................................................................................................200
9. O-ring............................................................................................................................................................................................................................................................200
10. Backup Ring......................................................................................................................................................................................................................................................200
11. O-ring...........................................................................................................................................................................................................................................................200
12. Piston...........................................................................................................................................................................................................................................................200
13. Piston Seal......................................................................................................................................................................................................................................................200
14. Wear Ring........................................................................................................................................................................................................................................................200
15. O-ring...........................................................................................................................................................................................................................................................200
16. Piston Ring......................................................................................................................................................................................................................................................200
17. Hex Nut..........................................................................................................................................................................................................................................................200
18. MRP Bearing......................................................................................................................................................................................................................................................200
19. MRP Bearing......................................................................................................................................................................................................................................................200
20. Poppet Valve.....................................................................................................................................................................................................................................................200
21. Check Valve......................................................................................................................................................................................................................................................200
22. Counterbalance Valve.............................................................................................................................................................................................................................................200
23. Plug.............................................................................................................................................................................................................................................................200
24. O-ring...........................................................................................................................................................................................................................................................200
25. Orifice..........................................................................................................................................................................................................................................................200
26. Plug.............................................................................................................................................................................................................................................................200
27. O-ring...........................................................................................................................................................................................................................................................200
1. Tube..............................................................................................................................................................................................................................................................201
2. Rod...............................................................................................................................................................................................................................................................201
3. Piston............................................................................................................................................................................................................................................................201
4. Gland.............................................................................................................................................................................................................................................................201
5. Dust Wiper........................................................................................................................................................................................................................................................201
6. Rod Seal..........................................................................................................................................................................................................................................................201
7. Dry Bearing.......................................................................................................................................................................................................................................................201
8. O-ring............................................................................................................................................................................................................................................................201
9. Backup Ring.......................................................................................................................................................................................................................................................201
10. O-ring...........................................................................................................................................................................................................................................................201
11. Wear Ring........................................................................................................................................................................................................................................................201
12. Piston Seal......................................................................................................................................................................................................................................................201
13. MRP Bearing......................................................................................................................................................................................................................................................201
1. Tube Assembly.....................................................................................................................................................................................................................................................202
2. Rod...............................................................................................................................................................................................................................................................202
3. Gland.............................................................................................................................................................................................................................................................202
4. Dust Wiper........................................................................................................................................................................................................................................................202
5. Retaining Ring....................................................................................................................................................................................................................................................202
6. Rod Seal..........................................................................................................................................................................................................................................................202
7. Backup Ring.......................................................................................................................................................................................................................................................202
8. Dry Bearing.......................................................................................................................................................................................................................................................202
9. O-ring............................................................................................................................................................................................................................................................202
10. Backup Ring......................................................................................................................................................................................................................................................202
11. O-ring...........................................................................................................................................................................................................................................................202
12. Piston...........................................................................................................................................................................................................................................................202
13. Piston Seal......................................................................................................................................................................................................................................................202
14. Wear Ring........................................................................................................................................................................................................................................................202
15. O-ring...........................................................................................................................................................................................................................................................202
16. Hex Nut..........................................................................................................................................................................................................................................................202
17. Spacer...........................................................................................................................................................................................................................................................202
18. O-ring...........................................................................................................................................................................................................................................................202
19. Counterbalance Valve.............................................................................................................................................................................................................................................202
20. Counterbalance Valve.............................................................................................................................................................................................................................................202
21. Load Shuttle Valve...............................................................................................................................................................................................................................................202
22. Plug.............................................................................................................................................................................................................................................................202
23. Plug.............................................................................................................................................................................................................................................................202
24. Plug.............................................................................................................................................................................................................................................................202
25. MRP Bearing......................................................................................................................................................................................................................................................202
1. Body..............................................................................................................................................................................................................................................................203
2. Rod...............................................................................................................................................................................................................................................................203
3. Dust Wiper........................................................................................................................................................................................................................................................203
4. Rod Seal..........................................................................................................................................................................................................................................................203
5. Backup Ring.......................................................................................................................................................................................................................................................203
6. Wear Ring.........................................................................................................................................................................................................................................................203
7. Counterbalance Valve..............................................................................................................................................................................................................................................203
8. Bleeder...........................................................................................................................................................................................................................................................203
9. Plug..............................................................................................................................................................................................................................................................203
10. O-ring...........................................................................................................................................................................................................................................................203
11. Plug.............................................................................................................................................................................................................................................................203
12. O-ring...........................................................................................................................................................................................................................................................203
13. Not Used.........................................................................................................................................................................................................................................................203
14. Not Used.........................................................................................................................................................................................................................................................203
15. Plug.............................................................................................................................................................................................................................................................203
16. O-ring...........................................................................................................................................................................................................................................................203
17. Plug.............................................................................................................................................................................................................................................................203
18. O-ring...........................................................................................................................................................................................................................................................203
1. Return Filter.....................................................................................................................................................................................................................................................204
2. Breather..........................................................................................................................................................................................................................................................204
3. Fill Cap..........................................................................................................................................................................................................................................................204
4. Internal Baffle...................................................................................................................................................................................................................................................204
5. Drain Plug........................................................................................................................................................................................................................................................204
6. Oil Level Gauge...................................................................................................................................................................................................................................................204
5.3 Drive Pump...............................................................................................................................................................................................................................................................218
Description..............................................................................................................................................................................................................................................................218
The System Circuit.......................................................................................................................................................................................................................................................219
the basic closed circuit.............................................................................................................................................................................................................................................219
Case drain and heat exchanger........................................................................................................................................................................................................................................219
High Pressure Relief Valve (HPRV) and Charge Check.......................................................................................................................................................................................................................219
Charge Pressure Relief Valve.............................................................................................................................................................................................................................................220
Electrical Displacement Control (EDC)....................................................................................................................................................................................................................................221
eDC Principle........................................................................................................................................................................................................................................................221
EDC Operation........................................................................................................................................................................................................................................................221
Disassembly..............................................................................................................................................................................................................................................................223
SHAFT SEAL REMOVAL...................................................................................................................................................................................................................................................223
1. Orient pump with the shaft pointing up........................................................................................................................................................................................................................223
2. Remove the spiral ring (J300) from the front housing to release the shaft seal carrier (J275).................................................................................................................................................................223
3. Pry on the lip of the seal carrier to remove it from the pump.................................................................................................................................................................................................223
4. Remove and discard the O-ring (J260) and seal (J250) from the seal carrier....................................................................................................................................................................................223
INPUT SHAFT..........................................................................................................................................................................................................................................................223
1. Pull the shaft with bearing out of the pump. If necessary, tap lightly on the shaft to dislodge it from the internal pump components..........................................................................................................................223
2. Remove the snap ring (J200) using snap ring pliers............................................................................................................................................................................................................223
3. Use an adequate press to remove the bearing from the shaft....................................................................................................................................................................................................223
EDC CONTROL REMOVAL..................................................................................................................................................................................................................................................223
1. Remove control screws (D250) using a 5 mm internal hex wrench. Remove the control from the pump...............................................................................................................................................................223
2. Remove and discard the gasket (D150)..........................................................................................................................................................................................................................223
3. Using a 13 mm deep well socket wrench, remove feedback pin (D200) from top of swash plate.....................................................................................................................................................................223
4. If necessary, remove the screen (D084)........................................................................................................................................................................................................................223
5. If necessary, remove orifices (F100) using a 3 mm internal hex wrench.........................................................................................................................................................................................223
EDC CONTROL DISASSEMBLY..............................................................................................................................................................................................................................................224
1. Use a 4 mm internal hex wrench to remove capscrews (D050).....................................................................................................................................................................................................224
2. Remove solenoids (D025). Remove and discard O-rings (D025A)...................................................................................................................................................................................................224
AUXILIARY PAD OR END COVER REMOVAL...................................................................................................................................................................................................................................224
1. Position pump so end cover (K100) or auxiliary pad is on top..................................................................................................................................................................................................224
2. Remove end cover/auxiliary pad screws (K400) using an 8 mm internal hex wrench................................................................................................................................................................................224
3. Remove and discard gasket (K150)..............................................................................................................................................................................................................................225
4. Remove thrust washer (K500). Note thrust washer orientation...................................................................................................................................................................................................225
5. Remove pressure balance plate (S200) and seal (S300). Note plate orientation. Discard seal (S300).............................................................................................................................................................225
6. Remove coupling (K200)........................................................................................................................................................................................................................................225
CHARGE PUMP REMOVAL..................................................................................................................................................................................................................................................225
1. Remove charge pump outer ring (S150),and gearset(S100)........................................................................................................................................................................................................225
2. Remove valve plate (S250) with seal (S300). Discard seal (S300)...............................................................................................................................................................................................225
PRESSURE LIMITER REMOVAL.............................................................................................................................................................................................................................................225
1. Using a 14 mm wrench, remove pressure limiter cartridges (L300) and (L400)....................................................................................................................................................................................225
2. Remove and discard O-ring (L022)..............................................................................................................................................................................................................................225
CHARGE PRESSURE RELIEF VALVE REMOVAL.................................................................................................................................................................................................................................225
HIGH PRESSURE RELIEF VALVE REMOVAL...................................................................................................................................................................................................................................225
ENDCAP REMOVAL.......................................................................................................................................................................................................................................................226
1. Remove two endcap screws (G400) using a 10 mm internal hex wrench.............................................................................................................................................................................................226
2. Remove four endcap screws (G350) using a 10 mm internal hex wrench............................................................................................................................................................................................226
3. Carefully remove the endcap (G100) and valveplate (C025). Valveplate may be stuck to endcap. Alignment pin (C020) may remain in endcap........................................................................................................................226
4. Place the endcap and valve plate in a clean area, protecting them from contamination..........................................................................................................................................................................226
5. Remove and discard gasket (G150)..............................................................................................................................................................................................................................226
6. If necessary, remove bushing (G550) using a suitable puller...................................................................................................................................................................................................226
7. Remove locating pins (B010)...................................................................................................................................................................................................................................226
CYLINDER BLOCK KIT REMOVAL...........................................................................................................................................................................................................................................226
1. Remove cylinder block assembly (C010).........................................................................................................................................................................................................................226
2. Set cylinder block and components on a clean dry surface......................................................................................................................................................................................................226
SERVO SLEEVE REMOVAL.................................................................................................................................................................................................................................................226
1. If equipped, remove and discard locking nut (E550) and remove displacement limiter screw (E450)...............................................................................................................................................................226
2. Remove the locking screws (E350) with a 10 mm hex wrench. Remove the locking plates (E300)....................................................................................................................................................................227
3. Using a 3/4 in.deep socket, unthread the servo sleeves (E600) from each side of the pump. Servo piston will be loose after servo cylinders are removed. Discard O-rings (E250)................................................................................227
SERVO PISTON REMOVAL.................................................................................................................................................................................................................................................227
SWASHPLATE AND SWASHPLATE BEARING REMOVAL............................................................................................................................................................................................................................227
1. Lift the swashplate (D070) out by grasping the swashplate pin. Swashplate bearings (D075) will remain on the swash plate......................................................................................................................................227
2. Remove bearings (D075) by sliding them from the swashplate and discard them...................................................................................................................................................................................227
SERVO PISTON DISASSEMBLY.............................................................................................................................................................................................................................................227
1. Remove and discard seals (E025)...............................................................................................................................................................................................................................227
2. Remove slider block (EO 15)...................................................................................................................................................................................................................................227
CYLINDER KIT.........................................................................................................................................................................................................................................................228
1. Pull to remove the slipper retainer (C20) with the pistons (C10) from the cylinder kit........................................................................................................................................................................228
2. Remove the ball guide (C15)...................................................................................................................................................................................................................................228
3. Remove the three pins (C25)...................................................................................................................................................................................................................................228
Block spring removal.................................................................................................................................................................................................................................................228
1. Turn the block over. Using a press, apply pressure on the block spring washer (C35) to compress the block spring (C30). Compress the spring enough to safely remove the spiral retaining ring (C45).While maintaining pressure, unwind the spiral retai.......228
Inspection...............................................................................................................................................................................................................................................................228
OVERVIEW.............................................................................................................................................................................................................................................................228
PISTONS AND SLIPPERS.................................................................................................................................................................................................................................................228
BALL GUIDE, SLIPPER RETAINER, AND HOLD-DOWN PINS.....................................................................................................................................................................................................................229
BLOCK SPRING, AND WASHERS............................................................................................................................................................................................................................................229
CYLINDER BLOCK.......................................................................................................................................................................................................................................................229
SHAFT................................................................................................................................................................................................................................................................229
SHAFT BEARING........................................................................................................................................................................................................................................................229
SWASHPLATE...........................................................................................................................................................................................................................................................229
VALVE PLATE..........................................................................................................................................................................................................................................................229
ENDCAP...............................................................................................................................................................................................................................................................230
HOUSING..............................................................................................................................................................................................................................................................230
PRESSURE LIMITER.....................................................................................................................................................................................................................................................230
HPRV VALVE...........................................................................................................................................................................................................................................................231
OPTIONAL DISPLACEMENT LIMITER........................................................................................................................................................................................................................................231
CHARGE PRESSURE RELIEF VALVE.........................................................................................................................................................................................................................................231
SERVO PISTON ASSEMBLY................................................................................................................................................................................................................................................231
CONTROL..............................................................................................................................................................................................................................................................231
Assembly.................................................................................................................................................................................................................................................................232
SHAFT AND SEAL INSTALLATION..........................................................................................................................................................................................................................................232
1. Orient pump with the mounting flange pointing up..............................................................................................................................................................................................................232
2. Using an adequate press, press the bearing (J150) onto the shaft (J100) and install the retaining ring (J200). Ensure the retaining ring diameter is less than 38.84 mm [1.53 in] once installed on the shaft.................................................232
3. Lubricate and install a new O-ring (J260) onto seal carrier (J275). Press a new seal (J250) into the seal carrier so the solid side of the seal is against the shoulder of the seal carrier...................................................................232
4. Install the shaft assembly into the front housing. Cover the shaft with an installation sleeve to protect it during installation of the seal carrier..........................................................................................................232
5. Hand press the seal carrier (J275) into the housing. Ensure the seal carrier clears the spiral ring groove in the housing. Remove protective cover from shaft end.............................................................................................232
6. Install the spiral ring (J300) into the housing. The inside diameter of the ring must be at least 68 mm [2.677 in] after installation.........................................................................................................................232
SWASHPLATE BEARINGS AND SWASHPLATE INSTALLATION......................................................................................................................................................................................................................232
1. Position housing with front flange pointing down..............................................................................................................................................................................................................232
2. Coat swashplate bearings (D075) with hydraulic fluid and install them onto the swashplate (D070). The inner race of the swashplate bearing clips onto the swashplate..........................................................................................232
3. Install the swashplate and bearings into the housing. Ensure swashplate is in neutral position................................................................................................................................................................233
4. If removed, install new filter screens (B040) into housing. Install screens in same orientation as when removed...............................................................................................................................................233
SERVO PISTON REASSEMBLY..............................................................................................................................................................................................................................................233
1. Lubricate and install new piston seals and O-rings (E025). Stretch O-rings onto servo piston, then install piston seals outboard of the O-rings. Allow seals to relax before installing servo piston. Use the servo cylinder to resize the seals before.......233
2. Lubricate and install slider block (EOT 5)....................................................................................................................................................................................................................233
SERVO PISTON INSTALLATION............................................................................................................................................................................................................................................233
SERVO CYLINDER INSTALLATION..........................................................................................................................................................................................................................................233
1. Lubricate new O-rings (E250) and install on each servo cylinder...............................................................................................................................................................................................233
2. While holding the servo piston in place, thread servo cylinders into housing using a 3/4 in socket. Thread cylinders equal distance in each side of pump until each cylinder contacts servo cylinder. Do not compress servo piston spring.....................233
3. Install locking plates (E300). Using a 10 mm wrench, install locking plate screws (E350). Torque screws to 13.2-16.1 Nm [9.7-11.9 Ib.ft.].....................................................................................................................233
CYLINDER KIT REASSEMBLY..............................................................................................................................................................................................................................................234
1. Coat all parts with hydraulic fluid prior to reassembly.......................................................................................................................................................................................................234
2. Install the inner block spring washer (C40), block spring (C30), and outer washer (C35) into the cylinder block. Using a press, compress the block spring enough to expose the retaining ring groove. Wind the spiral retaining ring (C45) into the gro.......234
3. Turn the block over and install the hold-down pins (C25) and ball guide (C15) into the cylinder block.........................................................................................................................................................234
4. Insert the pistons (C10) into the slipper retainer (C20). Install the piston/retainer assembly into the cylinder block. Ensure the concave surface of the retainer seats on the ball guide. If you are reusing the pistons, install them to the origina.......234
CYLINDER KIT INSTALLATION............................................................................................................................................................................................................................................234
1. Position pump with shaft pointing down........................................................................................................................................................................................................................234
2. Insert the cylinder block kit onto the shaft. While holding the shaft, slightly rotate the cylinder block kit to help start the shaft splines over the ball guide and align it with the block splines.........................................................234
TIMING PIN AND ENDCAP BUSHING INSTALLATION...........................................................................................................................................................................................................................235
1. Install timing pin (C020) in endcap as shown. Orient slot away from valve plate. Install the alignment pins (B010) in housing. Measure pin insertion depth to verify proper pin insertion.....................................................................235
2. Orient endcap bushing slots towards top or bottom of endcap. Lubricate and press the bushings (G550) into the end cap to depth shown below....................................................................................................................235
VALVE PLATE AND ENDCAP INSTALLATION..................................................................................................................................................................................................................................235
1. Install the alignment pins (B010) in housing..................................................................................................................................................................................................................235
2. Clean the valve plate (C025) and endcap(G100).................................................................................................................................................................................................................235
3. Apply a liberal amount of assembly grease to the backside of the valve plate surface to hold it in place and position on endcap in original position..........................................................................................................235
4. Install new gasket (G150).....................................................................................................................................................................................................................................236
5. Using a 10 mm internal hex wrench install endcap with capscrews (G350) and (G400).............................................................................................................................................................................236
6. Torque capscrews (G350) and (G400) to 110 Nm [81 Ib.ft.]......................................................................................................................................................................................................236
7. Use torque sequence shown below...............................................................................................................................................................................................................................236
CHARGE PUMP INSTALLATION.............................................................................................................................................................................................................................................236
1. Install new seal (S300) to valve plate (S250). Lubricate valve plate (S250) and install in same orientation as when it was removed............................................................................................................................236
2. Lubricate and install outer ring (S150) and charge pump gear set (S100). Lubricate and install coupling (K200)................................................................................................................................................236
3. Lubricate and install pressure-balance plate (S200) in same orientation as when it was removed. Install new outer seal (S300).................................................................................................................................236
4. Lubricate and install thrust washer (K500) in same orientation as when it was removed.........................................................................................................................................................................236
END COVER INSTALLATION...............................................................................................................................................................................................................................................237
1. Install alignment pins (G450). Install gasket (K150)..........................................................................................................................................................................................................237
2. Install end cover with capscrews (K400) using an 10 mm internal hex wrench. Torque to 92 Nm [68 Ib.ft.]. Follow torque sequence below.........................................................................................................................237
CHARGE PRESSURE RELIEF VALVE INSTALLATION............................................................................................................................................................................................................................237
1. Install new O-ring (V024).....................................................................................................................................................................................................................................237
2. Using a 22 mm wrench, install the charge pressure relief valve (VI0)..........................................................................................................................................................................................237
3. Torque to 52 Nm [38 Ib.ft.]...................................................................................................................................................................................................................................237
PRESSURE LIMITER INSTALLATION........................................................................................................................................................................................................................................237
1. Lubricate and install O-rings (L022)..........................................................................................................................................................................................................................237
2. Using a 14 mm wrench, install pressure limiter cartridges (L300) and (L400)...................................................................................................................................................................................237
3. Torque to 30 Nm [22 Ib.ft.]...................................................................................................................................................................................................................................237
HPRV VALVE INSTALLATION..............................................................................................................................................................................................................................................237
1. Replace and lubricate O-rings (L060) and backup rings (L068) before reassembly................................................................................................................................................................................237
2. Using a 22 mm wrench, install HPRV valves (L100) and (L200)...................................................................................................................................................................................................237
3. Torque to 70 Nm [52 Ib.ft.]...................................................................................................................................................................................................................................237
OPTIONAL DISPLACEMENT LIMITER INSTALLATION...........................................................................................................................................................................................................................238
1. Thread displacement limiter adjusting screw (E450) into servo sleeve..........................................................................................................................................................................................238
2. Thread a new locking nut onto adjustment screw.Torque to 23 Nm [17 ft.lbs.] using a 13mm hex wrench...........................................................................................................................................................238
EDC CONTROL ASSEMBLY.................................................................................................................................................................................................................................................238
1. Install new O-rings (D025A) into solenoids (D025), and attach solenoids with capscrews (D050) using 4 mm internal hex wrench. Torque to 8 Nm [6 ft.lbs.]......................................................................................................238
2. Replace screen (D084) if removed. Drawing shows proper screen orientation.....................................................................................................................................................................................238
EDC CONTROL INSTALLATION.............................................................................................................................................................................................................................................239
1. Use a 13 mm deep well socket to install feedback pin in swashplate. Torque to 23-28 Nm [17-20 ft.lbs.]. Do not overtorque.....................................................................................................................................239
2. Install dowel pins (D300).....................................................................................................................................................................................................................................239
3. Install new gasket (D150).....................................................................................................................................................................................................................................239
4. Position control on pump housing. Remove plug on top of control to visually ensure that feedback pin on swashplate is engaged properly in control arms........................................................................................................239
5. Using a 5 mm internal hex wrench, fasten control to pump with hex screws (D250). Torque screws to 13 Nm [10 ft.lbs.]. Follow torque sequence shown............................................................................................................239
Port Locations and Gauge Installation....................................................................................................................................................................................................................................240
PORT LOCATIONS AND GAUGE INSTALLATION................................................................................................................................................................................................................................240
Fastener Size and Torque Chart...........................................................................................................................................................................................................................................241
Plug Size and Torque Chart...............................................................................................................................................................................................................................................241
Initial Startup Procedures...............................................................................................................................................................................................................................................244
geneRaL..............................................................................................................................................................................................................................................................244
PRE-FILL PRoCeDuRe...................................................................................................................................................................................................................................................244
1. Fill the hydraulic reservoir..................................................................................................................................................................................................................................244
2. Locate the L2 case port on the pump. It is located on the back side facing the turntable side plate. Using a 9/16" allen wrench, remove the O-ring plug.......................................................................................................244
3. When hydraulic oil starts to flow out of this port for approximately 30 to 40 seconds, install the O-ring plug................................................................................................................................................244
staRt-uP PRoCeDuRe...................................................................................................................................................................................................................................................244
1. Ensure that the machine hydraulic oil and system components (reservoir, hoses, valves, fittings, and heat exchanger) are clean and free of any foreign material...............................................................................................244
2. Install new system filter element(s) if necessary. Check that inlet line fittings are properly tightened and there are no air leaks...........................................................................................................................244
3. Install the pump. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M3......................................................................................................................................................................244
4. Fill the housing by adding filtered oil in the upper case drain port. If the control is installed on top, open the construction plug in the top of the control to assist in air bleed.........................................................................244
5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a 10-micron filler filter. Fill inlet line from reservoir to pump. Ensure construction plug in control is closed after filling.............................................244
6. Disconnect the pump from all control input signals............................................................................................................................................................................................................244
7. Close construction plug removed in step 4.....................................................................................................................................................................................................................244
8. Use a common method to disable the engine to prevent it from starting. Crank the starter for several seconds. Do not to exceed the engine manufacturer's recommendation. Wait 30 seconds and then crank the engine a second time as stated above. This .......244
9. When the gauge begins to register charge pressure, enable, and start engine. Let the engine run for a minimum of 30 seconds at low idle to allow the air to work itself out of the system. Check for leaks at all line connections and listen for cavit.......244
10. When adequate charge pressure is established (as shown in model code), increase engine speed to normal operating rpm to further purge residual air from the system...........................................................................................244
11. Shut off engine. Connect pump control signal. Start engine, checking to be certain pump remains in neutral. Run engine at normal operating speed and carefully check for forward and reverse control operation...............................................244
12. Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminants out of loop...........................................................................................................................244
13. Check that the reservoir is full. Remove charge pressure gauge.The pump is now ready for operation...........................................................................................................................................................244
Troubleshooting..........................................................................................................................................................................................................................................................245
PReCautions..........................................................................................................................................................................................................................................................245
Pump Adjustment..........................................................................................................................................................................................................................................................248
1. With the prime mover off, thoroughly clean the outside of the pump................................................................................................................................................................................................248
2. If removing the pump, tag each hydraulic line. When you disconnect hydraulic lines, cap them and plug each open port to prevent contamination.....................................................................................................................248
3. Ensure the surrounding area is clean and free of contaminants like dirt and grime.................................................................................................................................................................................248
4. Inspect the system for contamination..............................................................................................................................................................................................................................248
5. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil, sludge, or metal particles..............................................................................................................................................248
6. If there are signs of contamination in the hydraulic fluid, replace all filters and drain the hydraulic system. Flush the lines and refill the reservoir with the correct filtered hydraulic fluid................................................................248
7. Before re-installing the pump, test for leaks.....................................................................................................................................................................................................................248
Charge Pressure Relief Valve Adjustment..............................................................................................................................................................................................................................248
1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3. Install a 10 bar [100 psi] gauge at case pressure port L1, L2, or L3. Operate the system with the pump in neutral (zero displacement) when measuring charge pressure.............248
2. The table shows the acceptable pump charge pressure range for some nominal charge relief valve settings (refer to model code located on serial number plate). These pressures assume 1800 min-1 (rpm) pump speed and a reservoir temperature of 50°C [........248
3. Rotate the adjusting screw clockwise to increase the setting; counterclockwise to decrease it. Subtract the case pressure reading to compute the actual charge pressure.......................................................................................248
4. While holding the adjusting screw, torque locknut to 17 Nm [13 lb.ft.]........................................................................................................................................................................................248
5. When you achieve the desired charge pressure setting, remove the gauges and plug the ports....................................................................................................................................................................248
Pressure Limiter Adjustment..........................................................................................................................................................................................................................................249
1. Install 600 bar [10,000 psi] pressure gauges in the high pressure gauge ports (MA and MB). Install a 50 bar [1000 psi] pressure gauge in the charge pressure gauge port (M3)..................................................................................249
2. Start the prime mover and operate at normal speed.............................................................................................................................................................................................................249
3. Use a 17mm wrench to loosen the locking nut (L024)............................................................................................................................................................................................................249
4. Activate the control input until pressure in the high side of the system loop stops rising. This pressure is the PL setting...................................................................................................................................249
5. Return the pump to neutral and adjust the PL setting using an internal hex wrench. Wrench size is in the diagram on the previous page. Turn the adjusting screw clockwise to increase the PL setting, counterclockwise to decrease it.The adjustment is.......249
6. Repeat steps four and five until you reach the desired PL setting. After adjustment, torque the locknut (L024) to 12 Nm [9 ft.lbs.]. Do not over torque.......................................................................................................250
7. Shut down the prime mover. Remove gauges and replace plugs....................................................................................................................................................................................................250
Displacement Limiter Adjustment..........................................................................................................................................................................................................................................251
1. Loosen the locking nut............................................................................................................................................................................................................................................251
2. Rotate the adjusting screw to achieve the desired maximum displacement. Set the adjusting screw against the servo piston by feel before counting turns. Refer to the table below for change per turn. Clockwise rotation decreases displacement, counte...........251
3. After establishing the desired maximum displacement setting, hold the adjusting screw while torquing the locknut to the value in the table below..................................................................................................................251
4. Test operation of the vehicle/ machine to verify proper maximum speed of vehicle/work function....................................................................................................................................................................251
Control Neutral Adjustment...............................................................................................................................................................................................................................................252
1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4and M5). Disconnect the external control input (electrical connections) from the control. Start the prime mover and operate at normal speed.............................................252
2. Use a 4mm internal hex wrench to hold the neutral adjusting screw (D015) stationary while loosening the locknut (D060) with a 13mm wrench.........................................................................................................................252
3. Observe pressure gauges. If necessary, turn adjusting screw (D015) to reduce any pressure differential............................................................................................................................................................252
4. Rotate the neutral adjusting screw (D015) clockwise until the pressure increases on the gauge. Note the angular position of the wrench. Then rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the...........252
5. Rotate the neutral adjusting screw clockwise half the distance between the wrench positions noted above. The gauges should read the same pressure, indicating that the control is in its neutral position.........................................................252
6. Hold the neutral adjusting screw stationary and tighten the lock nut (D060).Torque to 10 Nm [7 lb.ft.]. Do not over torque the nut................................................................................................................................252
7. When the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the external control input.................................................................................................................252
Mechanical Neutral Adjustment............................................................................................................................................................................................................................................253
servo adjustment.....................................................................................................................................................................................................................................................253
1. Run prime mover at 1800 min rpm...............................................................................................................................................................................................................................253
2. If using a PWM signal, ensure the signal is off. Check the servo pressure gauges. Ensure the differential between M4 and M5 is less than 1.5 bar [22 psi].....................................................................................................253
3. Using a 3/4 in hex deep socket, unthread both servo cylinders 2-3 turns.This step ensures the servo cylinders have no contact with the servo piston...........................................................................................................253
4. Stroke the pump by turning the control eccentric screw (or supplying current to solenoid C1) until the servo pressure at port M4 is 1 to 2 bar [14- 29 psi] greater than at port M5 and the system pressure gauges indicate displacement. Pressure shou.......253
5. Slowly thread the servo cylinder on the M5 side in until the system pressure differential starts to decrease. Maintain servo pressure differential between 1-2 bar [14-29 psi] during this step. Continue turning the servo cylinder in until the syste.......253
6. To complete setting neutral, repeat steps 1-5 but stroke the pump in the opposite direction by turning the eccentric screw in the opposite direction, or by supplying current to solenoid C2. Reverse gauge locations (M4 for M5, MB for MA) from those.......253
7. Remove all gauges and replace gauge port plugs. You can find wrench sizes and plug torques in the Plug size and torque chart..................................................................................................................................253
Servo Adjustment Side M4.............................................................................................................................................................................................................................................253
1. Run prime mover at 1800 rpm...................................................................................................................................................................................................................................253
2. If using a PWM signal to set mechanical neutral, start with the electronic control testing tool off (no current to either solenoid). Check to be sure the servo pressure differential is less than 1.5 bar [22 psi]. Reference Control Neutral Adjustment.....253
3. Turn neutral adjust excenter screw (or supply current to solenoid C2) until the servo pressure at port M5 is 1 - 2 bar [14- 29 psi] greater than at port M4...................................................................................................253
4. The system pressure differential must be greater than zero and the pressure at port A (B for clockwise rotation) must be greater than the pressure at port B (A for clockwise rotation). This step ensures the servo is in contact with the servo cylin.......253
5. Slowly turn in the servo cylinder on the M4 side until the system pressure differential starts to decrease. The servo pressure differential must be maintained between 1-2 bar [14-29 psi] during this step. Continue turning in the servo cylinder unt.......253
Verify neutral setting...............................................................................................................................................................................................................................................253
1. If using a PWM signal to set mechanical neutral, check that servo pressure differential is less than 1.5 bar [22 psi]. Refer to Control Neutral Adjustment....................................................................................................253
2. To verify mechanical neutral, provide current to solenoid C1,or turn neutral adjust excenter screw, until the servo pressure differential is 3 bar [43 psi]. The system pressure differential must be below 1.5 bar [22 psi]. Repeat test on solenoid C.......253
3. The current required to set the servo pressure differential to 3 bar [43 psi] should be the same for each solenoid. Refer to TS-392...........................................................................................................................253
4. If using neutral adjust excenter screw to set mechanical neutral, reset control neutral.......................................................................................................................................................................253
Removing the Pump........................................................................................................................................................................................................................................................254
Disassembly, Inspection, Assembly....................................................................................................................................................................................................................................254
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the pump....................................................................................................................................................................254
2. Tag, disconnect, and cap each hydraulic line connected to the pump. As hydraulic lines are disconnected, plug each open port, to ensure that dirt and contamination do not get into the pump..................................................................254
3. Remove the pump and its auxiliary pump (if applicable) as a single unit.......................................................................................................................................................................................254
4. Ensure the work surface and surrounding area are clean and free of contaminants such as dirt and grime........................................................................................................................................................254
5. Inspect the system for contamination..........................................................................................................................................................................................................................254
6. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam in the oil, sludge, or metal particles.................................................................................................................................254
7. Before replacing the pump, replace all filters and drain the hydraulic system. Flush the system lines and fill the reservoir with the correct, filtered hydraulic fluid.......................................................................................254
8. Fill the pump with clean, filtered hydraulic fluid............................................................................................................................................................................................................254
9. Attach the pump to the prime mover. Torque mounting screws according to the manufacturers recommendation......................................................................................................................................................254
10. Replace all hydraulic lines. Ensure the charge inlet line is filled with fluid...............................................................................................................................................................................254
Electric Control Module..................................................................................................................................................................................................................................................254
Removal, Inspection, Reassembly......................................................................................................................................................................................................................................254
1. Using a 5 mm internal hex wrench, remove the six capscrews (D250).............................................................................................................................................................................................254
2. Remove the control module and gasket (D150). Discard the gasket...............................................................................................................................................................................................254
3. If necessary, remove orifices (F100) using a 3 mm internal hex wrench. Tag and number them for reinstallation.................................................................................................................................................254
4. Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches, replace the component...................................................................................................................................254
5. Install a new gasket (D150)...................................................................................................................................................................................................................................254
6. If you removed screen (D084), install a new one. Install with the mesh facing outward (see drawing)...........................................................................................................................................................254
7. If previously removed, install orifices (F100) using a 3 mm internal hex wrench. Torque to 2.5 Nm [1.8 lb.ft.]................................................................................................................................................254
8. Install the control module and six capscrews (D250)...........................................................................................................................................................................................................254
9. Using a 5 mm internal hex wrench, torque the capscrews (D250) to 13.5 Nm [10 lb.ft.]..........................................................................................................................................................................254
Control Solenoids........................................................................................................................................................................................................................................................255
Removal, Inspection, Reassembly......................................................................................................................................................................................................................................255
1. Disconnect electrical connection and remove the three capscrews (D050) using a 4 mm internal hex wrench.......................................................................................................................................................255
2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring.............................................................................................................................................................................................255
3. If necessary, remove the coil using a 12 point 26 mm socket...................................................................................................................................................................................................255
4. Inspect the machined surface on the control. If you find any nicks or scratches, replace the component........................................................................................................................................................255
5. Lubricate new O-ring (D025A) using petroleum jelly and install................................................................................................................................................................................................255
6. Install solenoid with three capscrews (D050) using a 4 mm internal hex wrench. Torque screws to 5 Nm [4 lb.ft.]...............................................................................................................................................255
7. Install coil using a 12 point 26 mm socket. Torque coil nut to 5 Nm [3.7 ft.lbs.].............................................................................................................................................................................255
8. Reconnect electrical connections and test the pump for proper operation.......................................................................................................................................................................................255
Shaft Seal, Roller Bearing and Shaft Replacement.........................................................................................................................................................................................................................255
Removal, Inspection, Assembly........................................................................................................................................................................................................................................255
1. Unwind the spiral ring (J300) from the housing to release the shaft/seal/bearing subassembly..................................................................................................................................................................255
2. Pry on the lip of the seal carrier (J275) to dislodge it from the pump. Remove the seal carrier. Remove and discard O-ring (J260). Press the seal (J250) out of the carrier and discard.......................................................................255
3. Pull the shaft (J100) with bearing (J150) out of the pump. If necessary, tap lightly on the shaft to dislodge it from the cylinder block. C...................................................................................................................256
4. Remove the retaining ring (J200) using retaining ring pliers. Press the bearing off the shaft.................................................................................................................................................................256
5. Inspect the shaft journals for wear, scratching, and pits. Check the splines for fretting; replace if damaged. Rotate the bearing, if it does not rotate smoothly, replace it.................................................................................256
6. Press the bearing (J150) onto the shaft (J100) and replace the retaining ring (J200). Ensure the retaining ring diameter is less than 38.84 mm [1.53 in] when installed on the shaft..........................................................................256
7. Install the shaft/bearing assembly into the pump..............................................................................................................................................................................................................256
8. Lubricate and install a new O-ring (J260) onto seal carrier (J275). Press a new seal (J250) into the seal carrier. Press the seal until it is flush within +0.12mm [0.005 in] or -0.72 mm [0.0028 in] of the inside lip of the carrier as shown below.........256
9. Cover the shaft with a protective sleeve while installing the seal carrier. Hand press the seal carrier into the housing. Ensure the seal carrier clears the spiral ring groove in the housing. Remove the protective sleeve..................................256
10. Wind the spiral ring into the housing. Ensure the inside diameter of the spiral ring is greater than 68 mm [2.677 in] after installation.....................................................................................................................256
Charge Check / HPRV......................................................................................................................................................................................................................................................257
Removal, Inspection, Assembly........................................................................................................................................................................................................................................257
1. Using a hex wrench shown in the table below, remove the HPRVs (L1 50). Remove and discard the O-rings (L060) and backup rings (L068)..........................................................................................................................257
2. Inspect the sealing surfaces in the pump for nicks or scratches. Check the valves for damage. Replace any damaged components..................................................................................................................................257
3. Lubricate and install new backup rings (L068) and O- rings (L060).............................................................................................................................................................................................257
4. Install HPRVs. Torque to the value in the table below.........................................................................................................................................................................................................257
5. Operate the vehicle/machine through full range of controls to ensure proper operation. Check for leaks........................................................................................................................................................257
Charge Pressure Relief Valve.............................................................................................................................................................................................................................................257
Removal, Inspection, Assembly........................................................................................................................................................................................................................................257
1. Using a 22 mm wrench, remove the charge pressure relief valve (V010). Discard seal (V024).....................................................................................................................................................................257
2. Inspect the sealing surfaces of the pump for nicks or scratches...............................................................................................................................................................................................257
3. Lubricate and install new seal (V024).........................................................................................................................................................................................................................257
4. Install the charge pressure relief valve. Torque to 52 Nm [38 lb.ft.].........................................................................................................................................................................................257
5. Operate vehicle/machine through full range of controls to ensure proper operation.............................................................................................................................................................................257
Pressure Limiter Valve Replacement.......................................................................................................................................................................................................................................258
Removal, Inspection, Assembly........................................................................................................................................................................................................................................258
1. Using a 14 mm wrench, remove the pressure limiter valve (L100). Discard O-ring................................................................................................................................................................................258
2. Inspect the sealing surfaces of the pump for nicks or scratches...............................................................................................................................................................................................258
3. Install new O-ring. Lubricate O-ring with petroleum jelly.....................................................................................................................................................................................................258
4. Replace pressure limiter valve. Torque to 30 Nm [22 lb.ft.]...................................................................................................................................................................................................258
5. Operate pump at full range of controls to ensure proper machine operation. Pressure limiter is available as complete unit only. O-ring is available separately................................................................................................258
5.4 Gear Pump................................................................................................................................................................................................................................................................258
Disassembly..............................................................................................................................................................................................................................................................258
Cleanliness..........................................................................................................................................................................................................................................................258
Lubrication of Moving Parts..........................................................................................................................................................................................................................................258
Care of Surface Treatment............................................................................................................................................................................................................................................258
Marking the Parts....................................................................................................................................................................................................................................................259
Procedure............................................................................................................................................................................................................................................................259
1. Clamp the unit. Clamp the unit in a vice from the flange side. Make sure the vice jaws are clean and have smooth surfaces to prevent damage to the pump. Clamping the pump on the body is not recommended because serious damage to the surfaces, on wh.......259
2. Remove capscrews. Use a 17 mm socket wrench and loosen the four capscrews on the cover. Next completely unscrew the capscrews and remove them. Inspect the threads of the capscrews for damage................................................................259
3. Remove socket head capscrews. Using a 4 mm internal hex wrench, loosen and remove the two small socket screws placed in the center of the cover. Repeat the same operation for the corresponding screws on the rear flange....................................259
4. Remove front flange. Place the pump on the table and slowly remove the front flange. Be careful not to damage the shaft seal when removing the flange. Avoid contact of the shaft seal lips with keyway edges (in tapered and parallel shafts) or splin.......261
5. Remove rear cover. Clean with shop solvent, dry, and set aside. Visually inspect rear cover and seal area.....................................................................................................................................................261
6. Remove bearing blocks and gears. Place the pump on its side and carefully remove the bearing block and gear set. To accomplish this, hold the pump body and push with your fingers on the rear bearing block. Mark the relative positions of the gear m.......261
7. Remove pressure seals. Check the seal quality. Replacement is recommended whenever there are burrs, evidence of extrusion, or marks caused by overheating. If the seals need to be replaced, carefully remove them from the flange cover, beginning wit.......261
8. Remove Outer O-Ring Seal Check the quality of this seal. If necessary, replace it. Follow the same removal recommendations given in step 7.} After removal, discard the damaged seal..........................................................................262
9. Remove the snap ring. Place the flange on the work surface. Using internal snap ring pliers, remove the snap ring.............................................................................................................................................262
10. Remove the shaft seal. Check the shaft seal quality and remove if necessary. To remove, pry the bottom of the shaft seal and force it out while rotating the flange to lift it out evenly. Do not use the flange pilot to gain leverage, damage may re.......262
Assembly.............................................................................................................................................................................................................................................................262
1. Prepare the seals. Have the entire seal kit available. Lightly coat all seals with seal grease. The grease is needed to adhere the seals to their grooves.....................................................................................................262
2. Install shaft seal into front flange. Prepare the flange and shaft seal by lightly. lubricating with grease. Seat the seal in the flange by hand. Then, using the shaft seal installation tool (shown on page 52), press the seal until the tool stops .......263
3. Install snap ring. Install the snap ring using internal snap ring pliers. Ensure the snap ring fits securely in its groove. This is necessary to retain the shaft seal........................................................................................263
4. Install pressure seals. Prepare the pressure seals by lightly lubricating them with grease. Install pressure seals into the grooves on the front flange and rear cover. Then install the teflon backup ring. Ensure that the seals are located in the g.......263
5. Prepare the body. Clean the body. Inspect the internal and mating surfaces. Ensure the surfaces are free of burrs and scratches. Check both the bearing block mating surface and the cut-in path. The cut-in path should be no deeper than 0.1 mm (0.00.......263
6. Install outer seal. Prepare the outer seal by lightly lubricating with grease. Install outer seals in the grooves on both sides of the body...................................................................................................................264
7. Prepare the gears.............................................................................................................................................................................................................................................264
8. Prepare the bearing blocks. Clean the two bearing blocks. Inspect the flat surfaces of the bearing blocks for burrs or scratches on the edges. If necessary, remove burrs with very fine emery paper. Then rewash the bearings. Inspect the DU™ bushi.........264
9. Assemble the bearing blocks and gears. Lubricate the journals and the gear faces. Assemble the bearing blocks and gears. Ensure that the recessed bearing faces are installed adjacent to the gear faces. Align all assembly marks made during disassem.......264
10. Install the gear block assembly. Install the bearing block and gear assembly into the body cavity. Align the assembly marks to ensure that the gear block assembly is installed with the same orientation as before disassembly..............................265
11. Clean the mating surfaces. Remove any excess lubrication and grease from the mating surfaces of the pump body. Ensure that these surfaces are dry and free of contamination before moving on to the next step................................................265
12. Install the dowel pins. Install four 5 mm dowel pins into the proper cavities on both sides of the body (refer to the illustration below). Swab the pins with assembly grease or petroleum jelly to retain them during assembly. Do not install dowel .......265
13. Clean the mating surfaces. Remove any excess lubrication and grease from the mating surfaces of the front flange and rear cover. Ensure that these surfaces are dry and free of contamination before moving on to the next step..............................266
14. Install Rear Cover. Mount the cover on the body. Ensure the arrow on the back is oriented properly. The arrow should be:.....................................................................................................................................266
15. Prepare pump for front flange assembly. Place the pump with the rear cover downwards. Ensure that the assembly marks on the bearing block / body are properly aligned........................................................................................266
16. Install the front flange. Install a protective sleeve over the shaft. The sleeve is used to protect the shaft seal from damage by the shaft splines / keyway during front flange assembly. Install the flange onto the body, then remove the protectiv.......266
17. Torque sequence. Install capscrews. While observing the torque sequence shown, pre tighten the capscrews. Then, using a torque wrench, tighten them to the proper torque. Torque 44-54 Nm (32-40 ft.lbs.)....................................................267
18. Install socket head capscrews. Using a 4 mm internal hex wrench, install the socket head capscrews to the front flange and rear cover. Torque 2.5-3.4 Nm (22-30 ft.lbs.). If used, install new o-ring to flange pilot........................................267
Troubleshooting..........................................................................................................................................................................................................................................................268
1. Check oil level in reservoir......................................................................................................................................................................................................................................268
2. Check input spline condition......................................................................................................................................................................................................................................268
3. Check pressure at pump inlet. Recommended inlet pressure: 0.8 to 3.0 bar absolute. 0.6 Minimum at cold start......................................................................................................................................................268
4. Check condition of gear faces and bearing blocks..................................................................................................................................................................................................................268
5. Check bushings....................................................................................................................................................................................................................................................268
1. Check oil level in reservoir......................................................................................................................................................................................................................................268
2. Check inlet line for leaks........................................................................................................................................................................................................................................268
3. Check pressure at pump inlet......................................................................................................................................................................................................................................268
1. Check for pinched o-rings or backup ring seal.....................................................................................................................................................................................................................268
2. Check pressure seals..............................................................................................................................................................................................................................................268
5.5 Pressure Setting Procedure...............................................................................................................................................................................................................................................269
1. P1 Main relief valve This is a solenoid valve and relief valve all in one. The relief portion is pre-set and non adjustable. The cartridge is located on the “T” port face of the valve block. This cartridge is the solenoid valve located at the ...................269
2. P2 Main relief valve This is a solenoid valve and relief valve all in one. The relief portion is pre-set and non adjustable. The cartridge is located on the tank port face of the valve block. This cartridge is the solenoid valve located just above...............269
3. Swing relief valve The swing relief valve is adjustable and is located on the “T” port face of the valve block. The relief valve is located right next to the “T” port. To check, install a pressure gauge at port “MS”. Activate swing unt...........................269
4. Steer relief valve The steer relief valve is adjustable and is located on the “T” port face of the valve block. The steer relief valve is located right next to the swing relief valve. To check, install a pressure gauge at port “M2”. Activa.......................269
5. Platform level up relief valve This relief valve is adjustable and is located on the valve manifold inside the tower upright boom. Install a pressure gauge at port “M1” of this valve. Remove the hose from port L1 located on the bottom of the v...................269
6. Platform level down relief valve This relief valve is adjustable and is located on the valve manifold inside the tower upright boom. Install a pressure gauge at port “M2” of this valve. The relief valve is located above port “P2”. Activate.......................269
5.6 Oil Sampling.............................................................................................................................................................................................................................................................269
Procedure................................................................................................................................................................................................................................................................269
1. Function the machine for approximately 15 minutes operating all functions.........................................................................................................................................................................................269
2. Switch the select switch to the ground controls and start the engine..............................................................................................................................................................................................269
3. Locate the oil sampling valve on the front of the main control valve..............................................................................................................................................................................................269
4. Unscrew the knurled end which is attached to the chain............................................................................................................................................................................................................269
5. Place a drip pan under the spout and push in for approximately 10 seconds. This should flush out the valve........................................................................................................................................................269
6. Open and place the sample bottle under the spout..................................................................................................................................................................................................................269
7. Push in on the end of the valve and fill up the bottle............................................................................................................................................................................................................269
8. Cap the bottle immediately........................................................................................................................................................................................................................................269
9. Thread the knurled cap back onto the valve........................................................................................................................................................................................................................269
10. The sample is complete...........................................................................................................................................................................................................................................269
5.7 Hydraulic Schematic......................................................................................................................................................................................................................................................272
Section 6. JLG Control System....................................................................................................................................................................................................................................................275
6.1 JLG Control System Analyzer Kit Instructions.............................................................................................................................................................................................................................275
Introduction.............................................................................................................................................................................................................................................................275
6.2 Analyzer Menu Structure..................................................................................................................................................................................................................................................276
1. HELP: PRESS ENTER This is the default menu that appears at power up of the Analyzer. This menu displays the current Help (fault) message. This is intended to quickly guide the technician in the event of a fault in the JLG Control System. This menu...............276
2. DIAGNOSTICS This menu provides real-time status information about the control system as a diagnostic aid..............................................................................................................................................................276
3. SYSTEM TEST This menu is used to activate and then interact with the Control System’s self-test functionality. Starting the System Test will cause the functionality of each device to be tested. Outputs are energized to detect short or open circu.................276
4. ACCESS LEVEL This menu allows the technician to navigate between access levels; Operator Access or Service Access. To enter the Service access level, a five-digit code must be entered. Powering down returns the Analyzer to Operator Access........................276
5. PERSONALITIES This menu contains performance settings specific to the machine. These settings are necessary to maintain functions such as solenoid breakpoints and joystick engagement percentages and are organized in an outline format (see Figure 6...............276
6. MACHINE SETUP This menu contains machine configuration information for the JLG Control System. Selections in this menu can change interlock functionality and cause some Personality and Machine Setup entries to be visible or hidden. These settings ...............276
7. CALIBRATIONS This menu allows the operator to interact with the sensors on the machine. These settings can be modified in the Service access level....................................................................................................................276
6.3 Using the Hand Held Analyzer.............................................................................................................................................................................................................................................277
To Connect the JLG Control System Analyzer...............................................................................................................................................................................................................................277
1. Connect the four pin end of the cable supplied with the analyzer, to the motor controller module located in the platform box or at the power module and connect the remaining end of the cable to the analyzer....................................................277
2. Power up the Control System by turning the lower key to the platform or ground position and pulling both emergency stop buttons on................................................................................................................................277
Using the Analyzer.......................................................................................................................................................................................................................................................277
Changing the Access Level of the Hand Held Analyzer......................................................................................................................................................................................................................278
Adjusting Parameters Using the Hand Held Analyzer........................................................................................................................................................................................................................279
Machine Setup............................................................................................................................................................................................................................................................280
Level Vehicle Description................................................................................................................................................................................................................................................280
6.4 Operator Controls and Switches...........................................................................................................................................................................................................................................290
Ground Control Switches..................................................................................................................................................................................................................................................290
Platform Control Switches................................................................................................................................................................................................................................................290
Proportional Joysticks...............................................................................................................................................................................................................................................290
Toggle Switches......................................................................................................................................................................................................................................................290
6.5 Control System Startup Checks............................................................................................................................................................................................................................................291
6.6 Machine Orientation When Performing Test.................................................................................................................................................................................................................................305
Drive (Below Elevation):.................................................................................................................................................................................................................................................305
Drive (Above Elevation):.................................................................................................................................................................................................................................................305
Swing:...................................................................................................................................................................................................................................................................305
Tower Lift:..............................................................................................................................................................................................................................................................305
Main Lift:...............................................................................................................................................................................................................................................................305
Telescope:...............................................................................................................................................................................................................................................................305
JIB LIFT:................................................................................................................................................................................................................................................................305
Platform Rotate:.........................................................................................................................................................................................................................................................305
Test Notes...............................................................................................................................................................................................................................................................305
1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.........................................................................................................................................305
2. Stop watch should be started with the function movement, not with actuation of the joystick or switch.............................................................................................................................................................305
3. Drive speeds would be set to the values below regardless of the tire size.........................................................................................................................................................................................305
4. All speed tests are run from the platform, these speeds do not reflect the ground control operation...............................................................................................................................................................305
5. The Platform Speed Control knob must be at full speed (turned clockwise completely) unless noted..................................................................................................................................................................305
6. Some flow control functions may not work with the Platform Speed Control knob clicked into the creep position.....................................................................................................................................................305
7. Functional speeds may vary due to cold thick hydraulic oil. Test should be run with the oil temperature above 38° C (100° F)......................................................................................................................................305
6.7 LSS System...............................................................................................................................................................................................................................................................312
1. The Overload Visual Warning Indicator will flash at the selected control position (platform or ground)................................................................................................................................................................312
2. The Platform and Ground Alarms will sound 5 seconds On, and 2 seconds Off.............................................................................................................................................................................................312
3. All normal movement will be prevented from the platform control position (optional - ground control functions may be prevented).......................................................................................................................................312
4. Further movement is permitted by:.....................................................................................................................................................................................................................................312
a. Removing the excess platform load until actual platform load is less than Rated Load..............................................................................................................................................................................312
b. Operation of the overriding emergency system (Auxiliary Power Unit)...............................................................................................................................................................................................312
c. By an authorized person at the ground control position (optional - ground control functions may be prevented).....................................................................................................................................................312
a. LSS Sensor removal or replacement.................................................................................................................................................................................................................................312
b. Addition or removal of certain platform mounted accessories. (Refer to Calibration)...............................................................................................................................................................................312
c. Platform is removed, replaced, repaired or shows evidence of impact...............................................................................................................................................................................................312
6.8 MSSO (Machine Safety System Override)....................................................................................................................................................................................................................................312
Diagnostic Menu..........................................................................................................................................................................................................................................................313
Calibration Procedure....................................................................................................................................................................................................................................................314
1. Remove everything from the platform, except permanently fixed JLG Accessories, to allow the Load Sensing System to record its’ weight during calibration. This includes all tools, debris, and customer-installed devices.........................................314
2. Plug the JLG Analyzer into the Machine at the Ground Station and enter Service Access Password 33271..............................................................................................................................................................314
3. The platform should be approximately level for calibration. Level the platform from ground control (if necessary) to within +/- 5°................................................................................................................................314
4. To access the Calibration Menu, use the LEFT and RIGHT Arrow keys to select CALIBRATION from the Top Level Menu. The screen will read:............................................................................................................................314
5. Press the ENTER key to view the menu. Upon entry to the Calibration Menu, the JLG Control System will link to the Analyzer and the screen will read:..............................................................................................................314
6. Press Enter . The Screen will read:...............................................................................................................................................................................................................................314
7. Press ENTER . The analyzer screen will read:......................................................................................................................................................................................................................315
8. If the platform is empty, press ENTER . The screen will read:.....................................................................................................................................................................................................315
9. The control system will calculate the load cell readings and ensure it is greater than 130 lb (59 kg), but less than 575 lb (261 kg)..............................................................................................................................316
10. Press ENTER . The control system will ask for installed accessories. The screen will show the following:.........................................................................................................................................................316
11. Use the analyzer keys to select N for no or Y for yes. Press ENTER . The screen will read:.......................................................................................................................................................................316
12. Use the analyzer keys to select N for no or Y for yes. Press ENTER . The control system will default to an estimate of unrestricted capacity, which can be adjusted if necessary. Refer to Table 6-11, SkyGlazier Capacity Reductions and Table 6-12, ...........317
13. Press ENTER . The following screen will be displayed for restricted capacity, which can be adjusted if necessary. Refer to Table 6-11, SkyGlazier Capacity Reductions and Table 6-12, Pipe Rack Capacity Reductions..............................................317
14. Press ENTER . If calibration is successful, the screen will read:................................................................................................................................................................................................318
Testing & Evaluation.....................................................................................................................................................................................................................................................319
1. Connect the JLG Analyzer..........................................................................................................................................................................................................................................319
2. Level the Platform. The platform should be approximately level for analysis, or the guidelines below will not be applicable. Level the platform from Ground Control (if necessary) to within ±5 degrees...........................................................319
3. Observe the Empty Platform Weight. Proceed to the DIAGNOSTICS, PLTLOAD sub-menu and observe the measured platform load. All tools, debris, and customer- installed devices shall be removed during evaluation. Ideally, the PLTLOAD should be zero but ...........319
4. Use the Technician’s Weight to Evaluate. The technician should enter the platform and record the PLTLOAD reading while standing in the center of the platform.....................................................................................................319
5. Confirm Control System Warnings and Interlocks. Using the keyswitch, select Platform Mode and power-up. Start the vehicle’s engine and ensure that all controls are functional and the Load Sensing System’s Overload Visual and Audible Warnings a...............319
6. Confirm Control System Capacity Indication (optional for vehicles with Dual Capacity Ratings). For vehicles equipped with a Capacity Select switch on the Platform Console Box, it is necessary to examine an additional interface between the Load Sen...........319
7. Confirm Load Sensing System Performance with Calibrated Weights. Operate the vehicle from Ground Control and place the boom in the transport position (fully stowed) for safety. Plug the JLG Analyzer into the control system connection and proceed t...........319
Troubleshooting..........................................................................................................................................................................................................................................................320
6.9 Resetting The MSSO System................................................................................................................................................................................................................................................321
1. Use the following procedure to reset the MSSO system..................................................................................................................................................................................................................321
2. Position the Platform/Ground select switch to the desired position....................................................................................................................................................................................................321
3. Plug the analyzer into the connector coming from the ground control module or from the platform console...............................................................................................................................................................321
4. Pull out the Emergency Stop switch....................................................................................................................................................................................................................................321
5. The analyzer screen should read:......................................................................................................................................................................................................................................321
6. Use the arrow button to reach OPERATOR ACCESS. Press Enter ...........................................................................................................................................................................................................321
7. Enter the Access Code, 33271..........................................................................................................................................................................................................................................321
8. Use the right Arrow key to reach MENU: CALIBRATIONS. Press Enter .....................................................................................................................................................................................................321
9. Use the arrow keys to reach the LOAD SENSING menu. The screen should read:............................................................................................................................................................................................321
10. Press ENTER .........................................................................................................................................................................................................................................................321
11. Use the Down arrow to reach MSSO RESET...............................................................................................................................................................................................................................321
12. Press Enter . The screen will read:..................................................................................................................................................................................................................................322
13. Press Enter . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to return to the CALIBRATIONS menu.................................................................................................................322
6.10 System Fault Messages...................................................................................................................................................................................................................................................323
Section 7. Basic Electrical Information & Schematics.............................................................................................................................................................................................................................365
7.1 General..................................................................................................................................................................................................................................................................365
7.2 Multimeter Basics........................................................................................................................................................................................................................................................365
Grounding................................................................................................................................................................................................................................................................365
Backprobing..............................................................................................................................................................................................................................................................365
Min/Max..................................................................................................................................................................................................................................................................365
Polarity.................................................................................................................................................................................................................................................................365
Scale....................................................................................................................................................................................................................................................................365
Voltage Measurement......................................................................................................................................................................................................................................................365
Resistance Measurement...................................................................................................................................................................................................................................................366
Continuity Measurement...................................................................................................................................................................................................................................................366
Current Measurement......................................................................................................................................................................................................................................................367
7.3 Applying Silicone Dielectric Compound to Electrical Connections..........................................................................................................................................................................................................367
1. To prevent oxidation, silicone grease must be packed completely around male and female pins on the inside of the connector prior to assembly. This is most easily achieved by using a syringe.........................................................................367
2. To prevent shorting, silicone grease must be packed around each wire where they enter the outside of the connector housing. Also, silicone grease must be applied at the joint where the male and female connectors come together. Any other joints (ar...............367
3. Anderson connectors for the battery boxes and battery chargers should have silicone grease applied to the contacts only...............................................................................................................................................367
7.4 Dielectric Grease Application............................................................................................................................................................................................................................................368
Installation.............................................................................................................................................................................................................................................................368
AMP Mate-N-Lok...........................................................................................................................................................................................................................................................368
AMP Faston...............................................................................................................................................................................................................................................................368
AMP Micro-Fit............................................................................................................................................................................................................................................................368
AMP Mini Fit Jr..........................................................................................................................................................................................................................................................369
Mini Fit Sr..............................................................................................................................................................................................................................................................369
DIN Connectors...........................................................................................................................................................................................................................................................369
Exceptions...............................................................................................................................................................................................................................................................369
Enclosures...........................................................................................................................................................................................................................................................369
Carling Switch Connectors............................................................................................................................................................................................................................................369
7.5 AMP Connector............................................................................................................................................................................................................................................................370
Applying Silicone Dielectric Compound to AMP Connectors..................................................................................................................................................................................................................370
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by using a syri...........370
2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.........................................................................................................................................................................370
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it..................................................................................................................................................370
Assembly.................................................................................................................................................................................................................................................................370
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-7.)..................................................................................................................................................370
2. Pull back on the contact wire with a force of 1 or 2 lb to be sure the retention fingers are holding the contact (See Figure 7-7.)................................................................................................................................370
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8.)......................................................................................371
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9.)........................................................................................................................................................................371
Disassembly..............................................................................................................................................................................................................................................................372
5. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs.........................................................................................................................................................372
6. Pry open the wedge lock to the open position......................................................................................................................................................................................................................372
7. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed...........................................................................................................................372
Wedge Lock...............................................................................................................................................................................................................................................................372
Service - Voltage Reading................................................................................................................................................................................................................................................372
7.6 Deutsch Connectors.......................................................................................................................................................................................................................................................374
DT/DTP Series Assembly...................................................................................................................................................................................................................................................374
1. Grasp crimped contact about 25mm behind the contact barrel........................................................................................................................................................................................................374
2. Hold connector with rear grommet facing you.......................................................................................................................................................................................................................374
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.................................................................................................................................374
4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.........................................................374
DT/DTP Series Disassembly................................................................................................................................................................................................................................................374
5. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.........................................................................................................................................................................374
6. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver.....................................................................................................374
7. Hold the rear seal in place, as removing the contact may displace the seal........................................................................................................................................................................................374
HD30/HDP20 Series Assembly...............................................................................................................................................................................................................................................375
8. Grasp contact about 25mm behind the contact crimp barrel..........................................................................................................................................................................................................375
9. Hold connector with rear grommet facing you.......................................................................................................................................................................................................................375
10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place........................................................................................................................375
HD30/HDP20 Series Disassembly............................................................................................................................................................................................................................................375
11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.........................................................................................................................................................375
12. Slide tool along into the insert cavity until it engages contact and resistance is felt..........................................................................................................................................................................375
13. Pull contact-wire assembly out of connector......................................................................................................................................................................................................................375
7.7 Telematics Gateway.......................................................................................................................................................................................................................................................376
Telematics-Ready (TCU) Plug..............................................................................................................................................................................................................................................376
7.8 Electrical Schematics....................................................................................................................................................................................................................................................411
SHEET 2: Platform........................................................................................................................................................................................................................................................411
SHEET 3: PLATFORM AND BOOM COMPONENTS....................................................................................................................................................................................................................................411
SHEET 4: CHASSIS, TURN-TABLE, AND UGM....................................................................................................................................................................................................................................411
SHEET 5: GROUND USER INTERFACE ANd TELEMATICS INTERFACE..................................................................................................................................................................................................................411
SHEET 6: ENGINE (KUBOTA) AND GENERATOR...................................................................................................................................................................................................................................411
SHEET 7: ENGINE (GM) VENDOR SCHEMATIC....................................................................................................................................................................................................................................411
SHEET 8: MID ENGINE HARNESS SCHEMATIC....................................................................................................................................................................................................................................411
SHEET 9: OPTIONS.........................................................................................................................................................................................................................................................411
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