Jlg E300 Service Manual- Manuals

3121253 – JLG Lift – iii TABLE OF CONTENTS SECTION NO. TITLE PAGE NO . 3.11 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . ...

iv – JLG Lift – 3121253 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 6 - JLG CONTROL SYSTEM 6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

3121253 – JLG Lift – v LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . ....

viii – JLG Lift – 3121253 LIST OF TABLES TABLE NO. TITLE PAGE NO. 1-1 Operating specifications - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2 Operating specifications - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

SECTION 1 - SPECIFICATIONS 3121253 – JLG Lift – 1-1 SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-1. Operating specifications - E300AJ Capacity: Unrestricted: 500 lbs. (227 kg) Maximum Travel Grade, stowed Position (Gradeability) 25% Maximum Travel Grade, stowed...

SECTION 1 - SPECIFICATIONS 1-2 – JLG Lift – 3121253 1.3 CAPACITIES 1.4 TIRES 1.5 HYDRAULIC OIL NOTE: Refer to Figure 1-1., Hydraulic Oil Specifications. NOTE: Hydraulic oils require anti-wear qualities at least APIService Classification GL-3, and sufficient chemicalstability for mobile hydraulic sys...

SECTION 1 - SPECIFICATIONS 3121253 – JLG Lift – 1-3 MO BI L DTE 1 1 M MOB IL DT E 10 EXCEL 15 MO BILF LU ID 4 2 4 QUINT O L U BRIC 888- 46 M O B IL E A L E N V IR O N S Y N H 3 2 MOBIL EAL 224 H U N IVI S HVI 26 HYDRAULIC FLUID OPERATION CHART ° C ° F AIR TEMPERATURE 49 120 110 100 90 80 70 60 50 40...

SECTION 1 - SPECIFICATIONS 1-4 – JLG Lift – 3121253 1.7 FUNCTION SPEEDS Test Notes 1. Stop watch should be started with the function, not with the controller or switch. 2. Drive test results reflect standard size tires. 3. All speed tests are run from the platform. These speeds do not reflect the gr...

SECTION 1 - SPECIFICATIONS 1-6 – JLG Lift – 3121253 1.8 OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Fig-ure 1-2., Operator Maintenance and LubricationDiagram. LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATIONUNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPE...

SECTION 1 - SPECIFICATIONS 3121253 – JLG Lift – 1-7 3. Hydraulic Tank Lube Point(s) - Fill CapCapacity - 2.9 Gal. (11 L), 2.1 Gal. ( 8 L) to Full MarkLube - HOInterval - Check Level daily; Change every 2 years or1200 hours of operation.Comments - On new machines, those recently over-hauled, or after...

SECTION 1 - SPECIFICATIONS 1-8 – JLG Lift – 3121253 Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7) REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N Loctite® P/N ND Industries P/N Description 0100011 242 TM Vibra-TITE TM 121 Medium Strength (Blue) 0100019 271 TM Vibra-TITE TM 140 High ...

SECTION 1 - SPECIFICATIONS 1-10 – JLG Lift – 3121253 Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7) Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 32 0....

SECTION 2 - GENERAL 3121253 – JLG Lift – 2-1 SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information neededby those personnel that are responsible to place themachine in operation readiness and maintain its safeoperating conditi...

SECTION 2 - GENERAL 2-2 – JLG Lift – 3121253 2.2 SERVICE AND GUIDELINES General The following information is provided to assist you in theuse and application of servicing and maintenance proce-dures contained in this book. Safety and Workmanship Your safety, and that of others, is the first consider...

SECTION 2 - GENERAL 2-4 – JLG Lift – 3121253 2. The design and manufacturing tolerances of thecomponent working parts are very close, therefore,even the smallest amount of dirt or foreign matterentering a system can cause wear or damage to thecomponents and generally results in faulty opera-tion. Ev...

SECTION 2 - GENERAL 3121253 – JLG Lift – 2-5 Cylinder Drift Drift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil must be at ambient temper-ature and temperature stabilized. The cylinder must have the normal load, which is the nor-mal platform load applied. If...

SECTION 2 - GENERAL 2-6 – JLG Lift – 3121253 Table 2-3. Inspection and Preventive Maintenance Schedule AREA INTERVAL Pre-Start 1 Inspection Weekly Preventive Maintenance Monthly Preventive Maintenance Pre- Delivery 2 or Frequent 3 Inspection Annual 4 (Yearly) Inspection Every 2 Years Boom Assembly 9...

SECTION 2 - GENERAL 3121253 – JLG Lift – 2-7 Functions/Controls 9 Platform Controls 5 5 6 6 Ground Controls 5 5 6 6 Function Control Locks, Guards, or Detents 1,5 1,5 5 5 Footswitch 1,5 5 5 Emergency Stop Switches (Ground & Platform) 5 5 5 Function Limit or Cutout Switch Systems 5 5 5 Capacity I...

SECTION 2 - GENERAL 2-8 – JLG Lift – 3121253 All Decals/Placards Installed, Secure, Legible 21 21 21 Walk-Around Inspection Performed 21 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 General Structural Condition ...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-1 SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES AND WHEELS Tire Wear and Damage Inspect tires daily for wear or damage. Tires with wornedges or distorted profiles require replacement. Tires withsignificant damage in the tread area or side wal...

SECTION 3 - CHASSIS & TURNTABLE 3-4 – JLG Lift – 3121253 3.2 SPINDLE Setting Wheel Bearing End Play BE SURE NOT TO OVER-TIGHTEN THE SPINDLE NUT. 1. Tighten the spindle nut to assure the bearings areproperly seated. 2. Loosen the spindle nut completely until the nut canbe turned by hand. 3. Tight...

SECTION 3 - CHASSIS & TURNTABLE 3-6 – JLG Lift – 3121253 3.3 DRIVE HUB Roll and Leak Testing Torque-Hub units should always be roll and leak testedbefore disassembly and after assembly to make surethat the unit’s gears, bearings and seals are workingproperly. The following information briefly ou...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-9 Output Carrier Disassembly 1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into the Planet Shaft (4E) until it bottoms against theCarrier (3A). 2. Using a soft face hammer, tap the Planet Shaft (4E)out of the Carrier (4A). 3. Us...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-11 Input Carrier Disassembly 1. Using a 1/8" diameter punch, drive the Roll Pin (4G)into the Planet Shaft (3E) until it bottoms against theCarrier (3A). 2. Using a soft face hammer, tap the Planet Shaft (3E)out of the Carrier (3A). 3. Us...

SECTION 3 - CHASSIS & TURNTABLE 3-12 – JLG Lift – 3121253 Hub-Spindle Disassembly 1. Place unit on bench with Spindle (1 A) end down. 2. Remove Retaining Ring (1J) with appropriate tool. 3. Remove Spacer (1N). 4. Remove Bearing Cone (1C) from Bearing Cup (1D)in Hub (1G). 5. Lift Hub (1G) off of ...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-13 Cover Disassembly 1. Remove O-Ring (17) from groove in Cover (6A). 2. Remove Thrust Washer (2) from Cover (6A) pockets. 3. Unscrew two Hex Head Bolts (6C) and remove Dis-engage Cap (6B) from Cover (6A). 4. Pull Disengage Rod (6D) out from...

SECTION 3 - CHASSIS & TURNTABLE 3-14 – JLG Lift – 3121253 Input Carrier Assembly (Refer to Figure 3-8., Input Carrier) 1. Apply a liberal coat of grease to the bore of oneInput Planet Gear (3F). 2. Line the inside of the Planet Gear (3F) with 14 Nee-dle Rollers (3C). NOTE: The last roller instal...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-15 Output Carrier Assembly (Refer to Figure 3-6., Output Carrier) 1. Place Thrust Washer (4H) into counterbore of Carrier(4A). BE SURE the small diameter side of Washer(4H) facing planet gear side. 2. Place Planet Gear Sub-assembly (4) into ...

SECTION 3 - CHASSIS & TURNTABLE 3-18 – JLG Lift – 3121253 Cover Subassembly (Refer to Figure 3-10., Cover Assembly) 1. Grease O-Ring (6E) and insert into internal groove inCover (6A). 2. Assemble Disengage Cap (6B) onto Cover (6A)using two Hex Head Bolts (6C). Torque bolts to 70-80 in-lbs. 3. In...

SECTION 3 - CHASSIS & TURNTABLE 3-20 – JLG Lift – 3121253 3.4 DRIVE BRAKE - MICO Disassembly 1. Remove pressure plate (3) from cover (21) byremoving the capscrews (1) and washers (2). PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXI-MATELY 1500 LBS (680 KGF). THE FOUR CAP SCREWS SHOULDBE LOOSEN...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-23 3.5 SPEED SENSOR ADJUSTMENT FOR PROPER DRIVE OPERATION, THE SPEED SENSORS (2)MUST BE PROPERLY INSTALLED AND ADJUSTED. THE SENSOROPERATES ON A LEADING PULSE TO SHOW DIRECTION. IFINSTALLED INCORRECTLY, THE SENSOR WILL NOT BE ABLE TOSENSE TH...

SECTION 3 - CHASSIS & TURNTABLE 3-24 – JLG Lift – 3121253 Verification w/ Analyzer Procedure The motor controller averages the readings from the rightand left speed sensors and therefore, it can be difficult todetect if the speed sensors are adjusted properly. Oftenoperators report that posi-tra...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-25 18. While watching the analyzer display select drive for-ward. Be ready to remove your foot from the foot-switch if the machine lunges forward. 19. The analyzer display should ready the following ifthe left speed sensor is adjusted proper...

SECTION 3 - CHASSIS & TURNTABLE 3-32 – JLG Lift – 3121253 Preparation Before Disassembly • Before you disassemble the motor unit or any of its components read this entire section. It provides impor-tant information on parts and procedures you will needto know to service the motor. • Thoroughly c...

SECTION 3 - CHASSIS & TURNTABLE 3-38 – JLG Lift – 3121253 21. If the bearings, bushing or thrust washers must bereplaced use a suitable size bearing puller toremove bearing/bushings (19) and (13) from hous-ing (18) without damaging the housing. Removethrust washers (14) and thrust bearing (15) i...

SECTION 3 - CHASSIS & TURNTABLE 3-44 – JLG Lift – 3121253 cover and other components into place with a finaltorque of 25-30 ft. lbs. (34-41 N m). One Piece Stator Construction A disassembled rotor stator and vanes that cannot bereadily assembled by hand can be assembled by the fol-lowing procedu...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-45 4. Assemble six vanes, or as many vanes that will read-ily assemble into the stator vane pockets. EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTOPLACE COULD SHEAR OFF THE COATING APPLIED TO THE STA-TOR VANE POCKETS. 5. Grasp the output ...

SECTION 3 - CHASSIS & TURNTABLE 3-46 – JLG Lift – 3121253 8. Assemble six vanes, or as many vanes that will read-ily assemble into the stator vane pockets. 9. Grasp the output end of coupling shaft (12)with locking pliers or other appropriate turningdevice and rotate coupling shaft, drive link a...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-49 11. Install the worm cap (21) using proper shims (28) toachieve 0.000 to 0.001" (0.000 to 0.025 mm) endplay. Apply LocTite 242 to end of 1/2-13 x 1.25"grade 5 bolts (5) and LocTite #515 sealant to shims.Torque the bolts to 75 lbs-...

SECTION 3 - CHASSIS & TURNTABLE 3-50 – JLG Lift – 3121253 c. Lower the main boom to horizontal and fullyextend the boom. d. At the position indicated on Figure 3-24., SwingBearing Tolerance Boom Placement try andinsert the.0015” feeler gauge between the bolthead and hardened washer at the arrow ...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-51 JIB ELEVATED90 DEGREES MAIN BOOM FULLY ELEVATEDAND FULLY RETRACTED MEASURING POINT NOTE : LOWER BOOMFULLY ELEVATED AJP Models PLATFORM ROTATED90 DEGREES Figure 3-24. Swing Bearing Tolerance Boom Placement

SECTION 3 - CHASSIS & TURNTABLE 3-52 – JLG Lift – 3121253 MAIN BOOMFULLY EXTENDED MAIN BOOMHORIZONTAL LOWER BOOMFULLY ELEVATED MEASURING POINT NOTE : Figure 3-25. Swing Bearing Tolerance Boom Placement

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-53 Replacement of Swing Bearing 1. Removal. a. Attach an adequate support sling to the boomand draw all slack from sling. Prop or block theboom if feasible. b. Tag and disconnect hydraulic lines runningthrough center of turntable and frame. ...

SECTION 3 - CHASSIS & TURNTABLE 3-54 – JLG Lift – 3121253 f. Following the torque sequence diagram showni n F i g u r e 3 - 2 6 . , S w i n g B e a r i n g To r q u eSequence, tighten the bolts to an initial torque of140 ft. lbs. (190 Nm). Then following the samesequence, tighten to a final torq...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-55 3.10 BATTERY MAINTENANCE AND CHARGING TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE ORALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC-ING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SER-VICING BATTERIES. Battery Maintenance, Quarterly ...

SECTION 3 - CHASSIS & TURNTABLE 3-56 – JLG Lift – 3121253 3.11 BATTERY CHARGER LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGENGAS DURING NORMAL OPERATION. KEEP SPARKS, FLAMES,AND SMOKING MATERIALS AWAY FROM BATTERIES. PROVIDEADEQUATE VENTILATION DURING CHARGING. NEVER CHARGE AFROZEN BATTE R ...

SECTION 3 - CHASSIS & TURNTABLE 3-58 – JLG Lift – 3121253 NO LIGHTS AT ALL No Lights at all indicate that AC power to the charger isnot connected or that the AC voltage is too low. It couldalso indicate an internal failure in the charger. 1. Check the connections to AC power. Check for AC voltag...

SECTION 3 - CHASSIS & TURNTABLE 3-60 – JLG Lift – 3121253 Checking/Changing the Battery Charger Algorithm The charger is pre-loaded with programming algorithmsfor the specific batteries detailed in Table 3-4, BatteryAlgorithms. NOTE: Contact JLG if your specific battery model is notlisted. Each ...

SECTION 3 - CHASSIS & TURNTABLE 3121253 – JLG Lift – 3-61 3.13 DRIVE ORIENTATION SYSTEM The Drive Orientation System (DOS) is intended to indi-cate to the operator conditions that could make the direc-t i o n o f m o v e m e n t o f t h e c h a s s i s d i f f e r e n t t h a n t h edirection of...

SECTION 3 - CHASSIS & TURNTABLE 3-62 – JLG Lift – 3121253 UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ARE IN INCHES. DRIVE TARGET CAM PROXIMITY SWITCH SWITCH MOUNTING BRACKET CLEARANCE FORSWITCH TO TARGETWITH HORIZONTALSLOTS IN ITEM #14 .25 +.00-.13 WHEN BOOM IS OUTSIDE THIS 56° WINDOW OVER REAR ...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-1 SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE Removal of the Main Boom HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON-TAMINANTS INTO SYSTEM. 1. Raise the boom to a horizontal posit...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-3 NOTE: The telescope cylinder weighs approximately 53 lbs.(24 kg). 6. Using a suitable lifting device, remove telescope cyl-inder from the rear of the boom sections. 7. Remove hardware securing the front wear pads onbase boom section, remove we...

SECTION 4 - BOOM & PLATFORM 4-4 – JLG Lift – 3121253 Installation of the Main Boom NOTE: The main boom assembly weighs approximately 475lbs. (216 kg). 1. Using suitable lifting equipment, position boomassembly into the upper upright so the boom pivotholes in both the boom and upright are aligned...

SECTION 4 - BOOM & PLATFORM 4-6 – JLG Lift – 3121253 13. Using JLG P/N 0100011 thread locking compoundor equivalent, install the retaining bolt, keeper, andpin that secures the level cylinder to the jib. Torquethe retaining bolt to 35 ft.lbs. (48 Nm). 14. Route the hydraulic hoses on top of the ...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-7 Use JLG P/N 0100011 Thread Locking Compound or equivalent * * * * * * * Figure 4-2. Boom Thread Locking Compound Location

SECTION 4 - BOOM & PLATFORM 4-10 – JLG Lift – 3121253 Use JLG P/N 0100011 Thread Locking Compound or equivalent * * * * * * * * * * * Figure 4-5. Lower Boom Thread Locking Compound Location

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-15 4.2 POWERTRACK MAINTENANCE Removing a Link NOTE: Hoses shown in the powertrack are for example only.Actual hose and cable arrangements will be differ-ent. 1. Clamp the bar and poly roller tightly so they do notspin when removing the screw. Wi...

SECTION 4 - BOOM & PLATFORM 4-18 – JLG Lift – 3121253 7. Remove the link from the other section of the pow-ertrack using a screwdriver. Installing a New Link 1. Squeeze the peanut cut out end of the new link intothe half-shear (female) end of the track section.

SECTION 4 - BOOM & PLATFORM 4-20 – JLG Lift – 3121253 4. Pull the moving end out over the track so that thenew connection is positioned in the curve of thepowertrack. In this position the round half-shears willrotate into the peanut cut outs. 5. The parts shown below will be used to connect then...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-21 NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. 8. Hold new aluminum round bar tightly, then installnew 8-32 x 0.500 self-threading torx head screw intoone end. NOTE: Maximum tightening torque is ...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-23 Replacing Fixed End Brackets 1. Remove the rivets the same way as shown under thelink removal instructions. M O V E T H E C A B L E S / H O S E S O U T O F T H E W A Y D U R I N G T H EGRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND CABL...

SECTION 4 - BOOM & PLATFORM 4-24 – JLG Lift – 3121253 3. Take the new bracket and install bracket center pinand snap ring. Repeat on the other bracket if replac-ing it as well. NOTE: When installing snap rings make sure they areseated in pin groove and closed properly. Replacing Moving End Brack...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-27 4.3 BOOM CLEANLINESS GUIDELINES The following are guidelines for internal boom cleanlinessfor machines that are used in excessively dirty environ-ments. 1. JLG recommends the use of the JLG Hostile Envi-ronment Package if available to keep th...

SECTION 4 - BOOM & PLATFORM 4-28 – JLG Lift – 3121253 4.7 ROTARY ACTUATOR Theory of Operation The rotary actuator is a simple mechanism that uses thesliding spline operating concept to convert linear pistonmotion into powerful shaft rotation. Each actuator is com-posed of a housing with integrat...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-29 PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End Cap HARDWARE103.1. Screw103.2 . Washer106.1. Port Plug106.2. Port Plug109 . Lock Pin113. Capscrew SEALS200. T-Seal202. T-Seal204. O-ring205. Cup Seal207. Backup Ring304.1. Wiper Seal BEARINGS302...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-31 Disassembly 1. Remove the capscrews (113) over end cap lock pins(109). 2. Using a 1/8” (3.18mm) drill bit, drill a hole in the cen-ter of each lock pin to a depth of approximately 3/16” (4.76mm). 3. Remove the lock pins using an ”Easy Out” (a...

SECTION 4 - BOOM & PLATFORM 4-34 – JLG Lift – 3121253 16. To remove the main pressure seals (205), it is easi-est to cut them using a sharp razor blade beingcareful not to damage the seal groove. 17. Remove the thrust washers (304), from the end cap(4) and shaft (2). 18. Remove the wiper seal (3...

SECTION 4 - BOOM & PLATFORM 4-40 – JLG Lift – 3121253 Installing Counterbalance Valve Refer to Figure 4-12., Rotator Counterbalance Valve. 1. Make sure the surface of the actuator is clean, freeof any contamination and foreign debris includingold Loctite. 2. Make sure the new valve has the O-rin...

SECTION 4 - BOOM & PLATFORM 4-42 – JLG Lift – 3121253 Installation and Bleeding After installation of the actuator on the equipment, it isimportant that all safety devices such as tie rods or safetycables are properly reattached. To pur ge a ir f rom th e hydr aulic lines, connect themtogether t...

SECTION 4 - BOOM & PLATFORM 3121253 – JLG Lift – 4-43 Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output b. Low rate of fluid flow c. Control or counterbalance valve has internal leak d. Piston and/or shaft seal l...

SECTION 5 - HYDRAULICS 3121253 – JLG Lift – 5-1 SECTION 5. HYDRAULICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEM When assembling connectors in the hydraulic that use o-ring fittings, it is necessary to lubricate all fittings withhydraulic oil prior to assembly. To lubricate the fittings, useone...

SECTION 5 - HYDRAULICS 5-2 – JLG Lift – 3121253 Dip Method NOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types. The following is needed to correctly oil the o-ring in thismanner: • A small leak proof container • Sponge cut to fit inside the container • A sm...

SECTION 5 - HYDRAULICS 3121253 – JLG Lift – 5-3 5.2 HYDRAULIC CYLINDERS Disassembly NOTE: Disassembly of the cylinder should be performed ona clean work surface in a dirt free work area. 1. Drain the oil from the cylinder. 2. Place the cylinder in a suitable holding fixture. 3. Position the cylinder...

SECTION 5 - HYDRAULICS 5-12 – JLG Lift – 3121253 4. Withdraw the O-ring and back up ring carefully asnot to damage the seals. 5. It is impossible to disassemble the bushing becauseit is pressed on. Remove it by using a press. PISTON SEAL DISASSEMBLY 1. The piston seal is used in pairs and the ring a...

SECTION 5 - HYDRAULICS 3121253 – JLG Lift – 5-13 4. Push the piston to the rod assembly to the end ofthe thread and then install the piston nut. Wheninstalling the piston nut, gland and valve, refer toTable 5-1, Cylinder Assembly Torques. 5. Assemble the rod assembly equipped with gland,piston and p...

SECTION 5 - HYDRAULICS 5-14 – JLG Lift – 3121253 5.3 PRESSURE SETTING PROCEDURE Adjustments made at the Main Valve Bank MAIN PRESSURE RELIEF VALVE – 3000 PSI (207 BAR) 1. Install pressure gauge at port MP of Main ValveBank. 2. Actuate and hold Telescope In to “end of stroke” &take pressure readi...

SECTION 5 - HYDRAULICS 3121253 – JLG Lift – 5-17 PLATFORM LEVEL UP – 3000 PSI (207 BAR) 1. Refer to the Main Pressure Relief Valve procedureand temporarily set Main Pressure Relief Valve to3300 psi (227.5 Bar). 2. Disconnect, cap, & plug the platform level up hose &adapter either at the plat...

SECTION 5 - HYDRAULICS 5-18 – JLG Lift – 3121253 • at end of platform level up hose (do not use this loca- tion if port 15 was chosen in step 2.) 4. Activate Platform Level Up and hold. Take pressurereading. 5. After loosening relief valve jam nut, adjust valveclockwise to increase pressure or count...

SECTION 5 - HYDRAULICS 3121253 – JLG Lift – 5-19 4. After loosening relief valve jam nut, adjust valveclockwise to increase pressure or counterclockwiseto reduce pressure accordingly. 5. Tighten relief valve jam nut. Repeat step 3 and verifythe pressure setting. Option 2: 1. Disconnect, cap, and plu...

SECTION 5 - HYDRAULICS 3121253 – JLG Lift – 5-25 5.4 INITIAL HYDRAULIC PUMP START-UP PROCEDURE This procedure must be used when the hydraulic pump orpump/motor assembly is removed or replaced to ensurethere is no air trapped in the hydraulic system. Having airin the system can cause damage to the pu...

SECTION 6 - JLG CONTROL SYSTEM 3121253 – JLG Lift – 6-1 SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONS Introduction WHEN INSTALLING A NEW POWER MODULE CONTROLLER ONTHE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON-TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLU...

SECTION 6 - JLG CONTROL SYSTEM 6-2 – JLG Lift – 3121253 The JLG Control System controller has a built in LED toindicate any faults. The system stores recent faults whichmay be accessed for troubleshooting. Optional equip-ment includes an hour meter, beacon light, function cut-out, and ground alarm. ...

SECTION 6 - JLG CONTROL SYSTEM 3121253 – JLG Lift – 6-5 Machine Setup When a machine digit item is selected, press the UP orDOWN arrow keys to adjust its value, for example: GROUND ALARM:2 = DRIVE The effect of the machine digit value is displayed alongwith its value. The above display would be sele...

SECTION 6 - JLG CONTROL SYSTEM 3121253 – JLG Lift – 6-15 ME NU : H E L P :P R E S S ENT E R H E LP: (001 ) S Y STEM OK LO G: ( X X X ) X X : X XXXX X XXXXXXX ME NU : DI AG N O S T I C S D I AGNOSTICS: D R IVE D R IVE: D R IVE 0% D R IVE: S P EED STOPPED 0 % D R IVE: P O SITRAC OFF D R IVE: S T EER 0...

SECTION 6 - JLG CONTROL SYSTEM 6-16 – JLG Lift – 3121253 MENU: A C TI V A TE TE S T S ACT IV A T E T EST S : YES: ENT E R ,NO :E S C MENU: ACCESS LE V E L 1 ACCESS LE V E L : CODE 00000 MENU: PERSO N A LI T IES PERS ONALI T IE S : DRIVE DRIVE : A C C E L 1. 5s 2 DRIVE : D E C E L 0. 5s 2 DRIVE : MIN...

SECTION 6 - JLG CONTROL SYSTEM 3121253 – JLG Lift – 6-17 ME NU : MA CH INE SE TU P MOD EL N U M BER : 1=3 00 2 TI LT: 1= 5De g 2 DRI VE CU TO UT : 0=C HAR GE R 2 S O F T T O U CH CUT OU T 0= NO 2 JI B: 1= YES 2 G R O U N D ALA RM: 0= NO 2 PL ATFO RM AL AR M: 0=N O 2 LO AD : 0= NO 2 L E V E L inhi bi...

SECTION 6 - JLG CONTROL SYSTEM 6-28 – JLG Lift – 3121253 System Self Test The system self test is utilized to locate typical problems.See Table 6-5, System Test Descriptions for informationconcerning the tests performed and available messagesin this mode. 1. When the key switch is in the platform po...

SECTION 6 - JLG CONTROL SYSTEM 3121253 – JLG Lift – 6-29 Table 6-6. System Test Messages RUNNING Initial display when system test is run; cer tain “critical” checks are made. Problems which can be reported include: ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BAD POWE...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121253 – JLG Lift – 7-1 SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL This section contains basic electrical information andschematics to be used for locating and correcting most ofthe operating problems which may deve...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-2 – JLG Lift – 3121253 Resistance Measurement • First test meter and leads by touching leads together. Resistance should read a short circuit(very low resistance) • Circuit power must be turned OFF before testing resistance • Disconnect com...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121253 – JLG Lift – 7-3 Current Measurement • Set up the meter for the expected current range • Be sure to connect the meter leads to the correct jacks for the current range you have selected • If meter is not auto ranging, set it to the cor...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-4 – JLG Lift – 3121253 3. Anderson connectors for the battery boxes and bat-tery chargers should have silicone grease applied tothe contacts only. NOTE: Curing-type sealants might also be used to preventshorting and would be less messy, but...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121253 – JLG Lift – 7-5 AMP Mate-N-Lok Follow the installation instructions. DIN Connectors This connector is typically used on hydraulic valves. Fol-low the installation instructions. Exclusions A limited number of connectors do not benefit...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-6 – JLG Lift – 3121253 BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gold contact material to resist corro-sion and an o-ring seal for moisture integrity. If dielectricgrease is mistakenly applied to this connector system, thelow-f...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121253 – JLG Lift – 7-9 Disassembly 5. Insert a 4.8 mm (3/16") wide screwdriver bladebetween the mating seal and one of the red wedgelock tabs. 6. Pry open the wedge lock to the open position. 7. While rotating the wire back and forth ov...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121253 – JLG Lift – 7-11 7.5 DEUTSCH CONNECTORS DT/DTP Series Assembly 1. Grasp crimped contact about 25mm behind the con-tact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until acli...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-12 – JLG Lift – 3121253 HD30/HDP20 Series Assembly 8. Grasp contact about 25mm behind the contactcrimp barrel. 9. Hold connector with rear grommet facing you. 10. Push contact straight into connector grommet until apositive stop is felt. A ...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121253 – JLG Lift – 7-13 This page left blank intentionally.

Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia +61 2 65 811111 +61 2 65 810122 JLG Latino Americana Ltda.Rua Eng. Carlo...