JLG 260MRT Service And Maintenance Manual
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JLG 260MRT Service And Maintenance Manual

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Service & Maintenance Manual
Model
260MRT
3121801
July 23, 2018 - Rev K

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  • Page 1 Service & Maintenance Manual Model 260MRT 3121801 July 23, 2018 - Rev K...
  • Page 3 INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC- aerial platform. It is of utmost importance that mainte- TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR nance personnel pay strict attention to these warnings DEATH AND IS A SAFETY VIOLATION.

  • Page 4: Table Of Contents

    INTRODUCTION REVISION LOG Original Issue A - April 13, 2000 Revised B - Jan 24, 2002 Revised C - April 22, 2004 Revised D - July 3, 2006 Revised E - Aug 30, 2006 Revised F - Oct 11, 2007 Revised G - April 28, 2008 Revised...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION 1 - SPECIFICATIONS Operating Specifications ................1-1 Capacities .

  • Page 6: Table Of Contents

    Joystick Controller - (JLG P/N 1600308) ........

  • Page 7: Table Of Contents

    TABLE OF CONTENTS 3-13. DT/DTP Contact Removal................3-10 3-14.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Capacities .

  • Page 9: Operating Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 CAPACITIES Table 1-2. Capacities Table 1-1. Operating Specifications Fuel Tank 27.2 L (7.2 gal) Machine Weight 3701 kg (8160 lbs) Hydraulic Oil Tank 56.8 L (15 gal) Machine Height: Hydraulic System (including tank) 68.1 L (18 gal) Fully Elevated...

  • Page 10: Lubrication

    28 cm³/rev 1.4 cm³/rev (1.7 in³/rev) (0.36 in.³/rev) NOTE: Aside from JLG recommendations, 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 viscosi- ties.

  • Page 11: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS 1.6 CYLINDER SPECIFICATIONS 1.9 MAJOR COMPONENT WEIGHTS Table 1-10. Cylinder Specifications Table 1-12. Major Component Weights Description Bore Stroke Rod Dia. Component Weight 10.2 cm 119.4 cm 6.4 cm Platform 295 kg Lift Cylinder (4 in.) (47 in.) (2.5 in.) (650 lbs)

  • Page 12: Serial Number Locations

    SECTION 1 - SPECIFICATIONS 1.11 SERIAL NUMBER LOCATIONS For machine identification, a serial number plate is affixed to the machine. The plate is located on the rear center of the machine frame, just below the middle step of the ladder. In addition, if the serial number plate is damaged or missing, the machine serial number is stamped on the right front frame rail, adjacent to the sizzor arms.

  • Page 13: Lubrication Diagram

    SECTION 1 - SPECIFICATIONS Figure 1-2. Lubrication Diagram Table 1-14. Lubrication Chart INTERVAL INDEX NO COMPONENT NUMBER/TYPE LUBE POINTS LUBE METHOD HOURS Hydraulic Oil Reservoir Fill Cap/Drain Plug HO - Check HO Level 10/500 HO - Change HO Hydraulic Filter Element Initial Change - 50 Hours Engine Crankcase, Fill Cap/Drain Plug,...

  • Page 14: Operating Temperature Specifications - Kubota

    SECTION 1 - SPECIFICATIONS 4150548_E Figure 1-3. Operating Temperature Specifications - Kubota 3121801...

  • Page 15: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.12 TORQUE CHARTS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 5) 3121801...

  • Page 16: Torque Chart (Sae Fasteners - Sheet 2 Of 5))

    SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 5)) 3121801...

  • Page 17: Torque Chart (Sae Fasteners - Sheet 3 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 5) 3121801...

  • Page 18: Torque Chart (Sae Fasteners - Sheet 4 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (SAE Fasteners - Sheet 4 of 5) 1-10 3121801...

  • Page 19: Torque Chart (Metric Fasteners - Sheet 5 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 5) 3121801 1-11...
  • Page 20 SECTION 1 - SPECIFICATIONS NOTES: 1-12 3121801...

  • Page 21: General

    Components Removal and Installation components and systems. With proper care, maintenance and inspections performed per JLG's recommendations with any and all discrepancies corrected, this product will be fit for con- 1. Use adjustable lifting devices, whenever possible, if tinued use.

  • Page 22: Lubrication Information

    Clean batteries, using a non-metallic brush and a solution of 2. JLG recommends Mobilfluid 424, which has an SAE vis- baking soda and water. Rinse with clean water. After cleaning, cosity of 10W-30 and a viscosity index of 152.

  • Page 23: Cylinders - Theory Of Operation

    VALVES - THEORY OF OPERATION plier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil every Solenoid Control Valves (Bang-Bang) two years.

  • Page 24: Component Functional Description

    SECTION 2 - PROCEDURES Relief Valves CYLINDER CHECKING PROCEDURES Main relief valves are installed at various points within the NOTE: Cylinder checks must be performed any time a cylinder hydraulic system to protect associated systems and compo- component is replaced or when improper system opera- nents against excessive pressure.

  • Page 25: Lift Cylinder Removal And Installation

    SECTION 2 - PROCEDURES Cylinders w/Single Counterbalance Valves - Lift 2. Using a suitable lifting device capable of lifting 160 lb. (73 kg), place a strap/sling around the lift cylinder barrel Cylinder to support it when the upper and lower attach pins are removed in the following steps.

  • Page 26: Arms And Platform Positioning And Support, Cylinder Repair

    SECTION 2 - PROCEDURES Figure 2-1. Arms and Platform Positioning and Support, Cylinder Repair 3121801...

  • Page 27: Lift Cylinder Removal - Cylinder Support

    SECTION 2 - PROCEDURES 1. Lift Cylinder 3. Lower Attach Pin, Bolt and Locking Nut 2. Upper Attach Pin, Bolt and Locking Nut 4. Overhead Lifting Hook with Sling/Strap Figure 2-2. Lift Cylinder Removal - Cylinder Support 3121801...

  • Page 28: Lift Cylinder

    SECTION 2 - PROCEDURES 1. Barrel 6. Restrictor/Check Valve 11. O-Ring 16. Seal 2. Rod 7. Locknut 12. Spacer 17. O-Ring 3. Solenoid Valve 8. Wear Ring 13. O-Ring 18. Head 4. Cotter Pin 9. Seal 14. Back-Up Ring 19. Wiper 5.

  • Page 29: Cylinder Repair

    SECTION 2 - PROCEDURES 2.10 CYLINDER REPAIR Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting. DO NOT FULLY EXTEND CYLINDER TO END OF STROKE.

  • Page 30: Tapered Bushing Removal

    SECTION 2 - PROCEDURES 11. Insert the cap screw(s) in the threaded holes in the outer 8. Inspect seal and o-ring grooves in piston for burrs and piece of the tapered bushing. Progressively tighten the sharp edges. Dress applicable surfaces as necessary. cap screw(s) until the bushing is loose on the piston.

  • Page 31: Rod Seal Installation

    NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly.

  • Page 32: Piston Seal Kit Installation

    NOTE: When installing the tapered bushing, piston and mating end of rod must be free of oil. 11. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) Figure 2-13. Seating the Tapered Bearing 14. Retorque the capscrews evenly and progressively in rotation to the specified torque value.

  • Page 33: Poly-Pak Piston Seal Installation

    SECTION 2 - PROCEDURES 16. Place new guide locks and seals in the applicable out- side diameter grooves of the cylinder piston. (See Figure IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE, 2-11., Piston Seal Kit Installation ) EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED.

  • Page 34: Steer Cylinder Repair

    SECTION 2 - PROCEDURES 2.11 STEER CYLINDER REPAIR 9. Carefully remove the piston from the cylinder rod. Remove and discard the T-seal and o-ring. Removal 10. Remove the cylinder rod from the holding fixture. Before beginning this procedure, ensure that the parking Cleaning and Inspection brake is engaged and the rear wheels are chocked.
  • Page 35 SECTION 2 - PROCEDURES Assembly Installation 1. Carefully install the steer cylinder assembly into the NOTE: Prior to cylinder assembly, ensure that the proper cylinder front axle. Align the cylinder mounting block on the bar- seal kit is used. rel with the mounting slot in the bottom of the axle and lower the steer cylinder until the mounting block rests in Apply a light film of hydraulic oil to all components prior to the slot.

  • Page 36: Steer Cylinder Assembly

    SECTION 2 - PROCEDURES 1. Barrel 2. Rod 3. Locknut 4. Seal 5. Piston 6. O-Ring 7. Back-Up Ring 8. Wear Ring 9. Guide 10. Wiper 11. O-Ring 12. Retaining Ring Figure 2-16. Steer Cylinder Assembly 2-16 3121801...

  • Page 37: Leveling Jack Assembly - (Prior To S/N 105371)

    SECTION 2 - PROCEDURES 1. Barrel 7. Flatwasher, 1 1/4" Narrow 13. O-Ring 19. Rod 2. Counter Balance Valve 8. Guidelock 14. Wear Ring 20. Plate 3. Check Valve 9. Polyseal 15. Head 21. Trailer Ball 4. Plug 10. Piston 16.

  • Page 38: Leveling Jack Assembly - (S/N 105371To S/N 141689)

    SECTION 2 - PROCEDURES 1. Barrel 7. Flatwasher, 1 1/4" Narrow 13. Wear Ring 19. Plate 2. Check Valve 8. Guidelock 14. Head 20. Screw, 1/2" 3. Counter Balance Valve 9. Polyseal 15. Hydrolock 21. Jack Pad 4. Plug 10. Piston 16.

  • Page 39: Leveling Jack Assembly - (S/N 141689 To Present)

    SECTION 2 - PROCEDURES 1. Barrel 5. Wear Ring 9. Polyseal 13. Retaining Ring 2. Rod 6. O-Ring 10. Wiper Seal 14. Plate 3. Wear Ring 7. Back-Up Ring 11. Washer Ring 15. Screw, 1/2" 4. Seal 8. Head 12. Screw, 5/16" 16.

  • Page 40: Limit Switch Adjustment

    SECTION 2 - PROCEDURES 2.12 LIMIT SWITCH ADJUSTMENT Steer Relief Adjustment 1. Install a pressure gauge at gauge port MP, located on Platform Limit Switch the lower right side of the valve body. The port is identi- fied by a stamping on the valve body. The platform limit switch is located on the left side of the frame of the machine.

  • Page 41: Valve Components

    SECTION 2 - PROCEDURES Main Valve Components 1. Tow Brake Release Acuator 5. Lift Relief 9. Steer Solenoid (Right) 2. Valve Knob 6. Steer Relief (Right) 10. Lift Solenoid 3. Brake Solenoid 7. Main Relief 11. Steer Solenoid (Left) 4. Dump Valve 8.

  • Page 42: Leveling Jacks Directional Valve

    SECTION 2 - PROCEDURES Leveling Jacks Directional Valve Leveling Jacks - Pressure Relief Valve Location P A 2 P B1 P A 1 P B3 P A 3 P B2 P B4 P A 4 Figure 2-21. Leveling Jacks Directional Valve Table 2-3.

  • Page 43: Drive Pump Start-Up Procedure

    SECTION 2 - PROCEDURES 2.14 DRIVE PUMP START-UP PROCEDURE It is recommended that the external control input signal elec- trical connections be disconnected at the pump control until after initial start-up. This will allow the pump to remain in its neutral position.

  • Page 44: Automatic Choke - Field Adjustment (Df-750)

    SECTION 2 - PROCEDURES 2.15 AUTOMATIC CHOKE - FIELD ADJUSTMENT (DF-750) Inspection NOTE: All automatic choke assemblies have been pre-set to oper- ate between -7°C and 38°C (20°F and 100°F) with little or no adjustment. If the machine will be operated for prolong use outside these temperature ranges, adjustments could be made to improve performance of the engine.

  • Page 45: Joystick Controller

    SECTION 2 - PROCEDURES 2.16 JOYSTICK CONTROLLER Figure 2-23. Joystick Controller - (JLG P/N 1600308) Table 2-4. Joystick Specifications Table 2-5. Joystick Plug Loading Chart Input Voltage 4.3V (±0.1V) Terminal Color Function Centered Output Voltage 2.2V (±0.1V) Yellow Steer Right Full Positive (Rev) Deflection Output Voltage 4.0V (±0.1V)

  • Page 46: Joystick Controller - (Jlg P/N 1600403)

    SECTION 2 - PROCEDURES Figure 2-24. Joystick Controller - (JLG P/N 1600403) Table 2-6. Joystick Specifications Table 2-7. Joystick Plug Loading Chart Input Voltage Terminal Color Function Centered Output Voltage 4.25V to 2.60V Yellow Steer Right Reverse Voltage 4.60V to 4.80V...

  • Page 47: Tilt Sensor

    SECTION 2 - PROCEDURES 2.17 TILT SENSOR Tilt Sensor, JLG P/N 4000006: 1. Ground Control Box 2. Tilt Sensor (JLG P/N 4000006) Figure 2-25. Tilt Sensor Location TILT SENSOR REMOVAL: NOTE: Refer to Figure 2-26., Tilt Sensor Removal for numbers in parenthesis.

  • Page 48: Tilt Sensor Location

    SECTION 2 - PROCEDURES Tilt Sensor, JLG P/N 4000021: 1. Ground Control Box 2. Tilt Sensor Assembly (JLG P/N 1810140) Figure 2-27. Tilt Sensor Location TILT SENSOR REMOVAL: NOTE: Refer to Figure 2-28., Tilt Sensor Removal for numbers in parenthesis.

  • Page 49: Calibrations

    SECTION 2 - PROCEDURES 2.18 CALIBRATIONS b. Tilt sensor mounting on machine or wedged crooked in control box: Refer “Changing the Access Level of the Hand Held Analyzer” If the machine mounting/grade appears acceptable, to go to access level 1. open the Ground Control box carefully.
  • Page 50 SECTION 2 - PROCEDURES For the following troubleshooting steps, a bubble level Joystick Calibration (smaller is better) will be needed and the machine must be on (Software 1.5 and Higher and Higher) a level surface: Using the Analyzer, in Access Level 1, go to MENU: CALIBRA- 1.

  • Page 51: Electronic Control System

    SECTION 2 - PROCEDURES 2.19 ELECTRONIC CONTROL SYSTEM Hand Held Analyzer m en u: Analyzer Display HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, Sub Level, To return home or access previ- and item menus ous menu Left &...
  • Page 52 SECTION 2 - PROCEDURES Using the Analyzer If ENTER is pressed again, the display moves to the following display: With the machine power on and the analyzer connected prop- erly, the analyzer will display the following: l og: ( 211) M ENU: HELP:PRESS ENTER LOGGED HELP...
  • Page 53 SECTION 2 - PROCEDURES Remember, you may always cancel a selected menu item by The access level should display the following, if the password pressing the ESC key. was entered correctly: Changing the Access Level of the Hand Held Analyzer When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings M ENU:...
  • Page 54 NOTE: Refer to the appropriate Machine Personality Settings ensure efficient operation. The Value will not increase if the UP Table, and the Machine Setup Table in the JLG Service Man- arrow is pressed when at the maximum value nor will the ual for the recommended factory settings.

  • Page 55: Flash Codes And Descriptions

    SECTION 2 - PROCEDURES 2.20 FLASH CODES AND DESCRIPTIONS Table 2-10. Help Messages and Flash Codes - Software P1.X FLASH CODE HELP MESSAGES AND FLASH CODES No Flash Code EVERYTHING OK GROUND MODE OK ALARM SOUNDING - TILTED & ABOVE ELEVATION Platform is elevated and the chassis is not level.
  • Page 56 SECTION 2 - PROCEDURES Table 2-10. Help Messages and Flash Codes - Software P1.X FLASH CODE HELP MESSAGES AND FLASH CODES FUNCTION PROBLEM - TRIGGER PERMANENTLY CLOSED Trigger switch in the platform control box closed at start up. Release switch to clear fault. TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL Trigger switch in the platform control box closed for more than ten seconds while the joystick is in the neutral position.
  • Page 57 SECTION 2 - PROCEDURES 3121801 2-37...
  • Page 58 SECTION 2 - PROCEDURES 2-38 3121801...
  • Page 59 SECTION 2 - PROCEDURES 3121801 2-39...
  • Page 60 SECTION 2 - PROCEDURES 2-40 3121801...
  • Page 61 SECTION 2 - PROCEDURES 3121801 2-41...

  • Page 62: Machine Model Adjustment

    SECTION 2 - PROCEDURES 2.21 MACHINE MODEL ADJUSTMENT Table 2-11. Machine Model Adjustment Adjustment Adjustment range Default Values - Gas Default Values - Diesel DRIVE Accel 1.0 to 5.0 sec Decel 1.0 to 5.0 sec FWD MIN 0 to 100% FWD MAX 0 to 100% FWD ELEV...

  • Page 63: Machine Configuration Programming Information

    5 Deg F-R NOTE: This machine requires periodic safety and maintenance 6 Deg F-R Spl inspections be a JLG Dealer. A decal located on the frame affords a place to record (stamp) inspection dates. Notify Tilt Cutout dealer if inspection is overdue.
  • Page 64 SECTION 2 - PROCEDURES Table 2-13. Preventive Maintenance and Safety Inspection AREA Inspections Pre-Delivery Annual (Yearly) or Frequent Inspection Inspection (Quarterly) Scissor Arms Scissor Arms Safety Prop Nuts, Bolts, Shafts, Shields, Bearings and Locking Devices Cylinder/pivot Pins and Attaching Hardware Platform Assembly Platform Mandrill Chain/Gate, Bar and Latches...

  • Page 65: Preventive Maintenance And Safety Inspection

    Paint and Overall Appearance Operation And Safety Manual General Structural Condition and Welds Grease and Lubrication Specification Function Test of All System Notify JLG Change In Machine Ownership ANSI and AEM Handbook Capacity Decals All Decals/Placards Annual Machine Inspection Safety Publication...
  • Page 66 SECTION 2 - PROCEDURES Table 2-13. Preventive Maintenance and Safety Inspection AREA Inspections Pre-Delivery Annual (Yearly) or Frequent Inspection Inspection (Quarterly) Footnotes: Prior to each sale, lease, or delivery In service for 3 months; Out of service for 3 months or more; Purchased used Annually, no later than 13 months from the date of the prior inspection, Includes all daily and quarterly inspections, mandated by regulating body Indicates a 50 hour interval required to perform task after initial use of machine.
  • Page 67 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 3. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3.1 GENERAL or negative side of the signal and the lead on the other port goes to the positive side of the signal. This section contains schematics to be used for locating and Scale correcting most of the operating problems which may develop.

  • Page 68: Voltage Measurement (Dc)

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 3-1. Voltage Measurement (DC) Figure 3-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together. (See multimeter’s operation manual) Resistance should read a short circuit (very low resis- tance)

  • Page 69: Continuity Measurement

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 3-3. Continuity Measurement Figure 3-4. Current Measurement (DC) • Some meters require a separate button press to enable • Set up the meter for the expected current range audible continuity testing •...
  • Page 70 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, lon- ger than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness.

  • Page 71: Applying Silicone Dielectric Compound To Amp Connectors

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3.3 APPLYING SILICONE DIELECTRIC COMPOUND TO male and female pins on the inside of the connector after the mating of the housing to the header. This is AMP CONNECTORS easily achieved by using a syringe to fill the header with silicone dielectric compound, to a point just above the Silicone Dielectric Compound must be used on the AMP top of the male pins inside the header.

  • Page 72: Connector Assembly (1 Of 4)

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 3-6. Connector Assembly (1 of 4)). Proceed as follows: Figure 3-6. Connector Assembly (1 of 4) 3.

  • Page 73: Connector Assembly (3 Of 4)

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 3-8. Connector Assembly (3 of 4) Figure 3-9. Connector Assembly (4 of 4) 3121801...

  • Page 74: Connector Disassembly

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 6. Pry open the wedge lock to the open position. 7. While rotating the wire back and forth over a half turn 5. Insert a 4.8 mm (3/16”) wide screwdriver blade between (1/4 turn in each direction), gently pull the wire until the the mating seal and one of the red wedge lock tabs.

  • Page 75: Connector Installation

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to tem. The resulting pinholes in the insulation will allow mois- probe wires by piercing the insulation with a sharp point.

  • Page 76: Working With Deutsch Connectors

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3.4 WORKING WITH DEUTSCH CONNECTORS HD30/HDP20 Series Assembly DT/DTP Series Assembly Figure 3-12. DT/DTP Contact Installation Figure 3-14. HD/HDP Contact Installation 1. Grasp crimped contact about 25mm behind the contact 8. Grasp contact about 25mm behind the contact crimp barrel.
  • Page 77 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTE: Do Not twist or insert tool at an angle. 3121801 3-11...

  • Page 78: Switches

    A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping Another type of limit switch used by JLG is the inductive current flow. This voltage can be seen if the measurement proximity switch, also referred to as a "prox switch".

  • Page 79: Troubleshooting

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3.6 TROUBLESHOOTING General This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.

  • Page 80: Elevation System Troubleshooting

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-1. Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform Elevation System No Response to LIft Control Lift not performed within three seconds after lift function Reselect lift function switch, then activate joystick within switch is selected.
  • Page 81 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-1. Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform raises and lowers erratically Hydraulic system oil low. Replenish oil as necessary. Restricted or broken hydraulic line or fitting. Clean, repair or replace line. Counterbalance valve on lift cyl.

  • Page 82: Chassis Troubleshooting

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-2. Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Drive System No response to drive controller Joystick not activated within three seconds after drive select Activate drive select switch, then activate joystick within switch is activated.
  • Page 83 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-2. Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY High-Speed Drive function does not operate Loose or damaged wiring between drive controller and High Ensure proper connection of wires. Using suitable test meter, Speed switch.
  • Page 84 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-2. Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Steering inoperative Steer switch on controller not functioning properly. Repair or replace switch. Hydraulic system pressure too low. Adjust pressure. Loose or damaged wiring on control switch or solenoid valve. Ensure proper connection of wires at control switch or sole- noid valve.

  • Page 85: Hydraulic System Troubleshooting

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-3. Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hydraulic System - General Hydraulic Pump Noisy Air bubbles in oil. (Reservoir too low.) Replenish oil as necessary. Oil filter dirty. Clean and/or replace filter as necessary. Pump cavitating.

  • Page 86: Electrical System Troubleshooting

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-4. Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hand Controller Valve will not function when handle is moved in either direction. Enable switch not activated. Activate enable switch. Controller not activated within three seconds after enable Activate enable switch, then activate controller within three switch is activated.
  • Page 87 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 3-4. Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY No voltage present at applicable control valve coil. Check applicable wire for proper connection at terminal strip, valve harness plug pin, valve harness receptacle pin and engine start relay.

  • Page 88: Electrical Schematics

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3.7 ELECTRICAL SCHEMATICS ORN/WHT 55-3 WHT/YEL 48-10 WHT/YEL 48-4 BLU/ORN 52-1 WHT/YEL 48-1 WHT/YEL 48-2 YEL/RED 2-3B TAN 55-2 ORANGE 55-1 BLACK 8 J3-5 4.5V OUTPUT J3-1 BULK- BULK- PLATFORM DISPLAY HEAD GROUND GROUND HEAD...

  • Page 89: Electrical Schematic - Sheet 2 Of 4

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ORN/WHT 55-3 WHT/YEL 48-10 WHT/YEL 48-4 BLU/ORN 52-1 WHT/YEL 48-1 WHT/YEL 48-2 TAN 55-2 ORANGE 55-1 1K OHM POT W/ 150 OHM CURRENT LIMITING RESISTORS BLACK 8 J3-5 4.5V OUTPUT J3-1 2.3V @ CENTER PLATFORM DISPLAY YELLOW 9-1 J3-2...

  • Page 90: Electrical Schematic - Sheet 3 Of 4

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SERIAL DATA IN YEL/BLK J2-30 SERIAL DATA CLOCK WHT/RED J2-29 R 01 R 02 R 03 SERIAL DATA OUT J2-40 J1 RECEPTACLE PFDTH (J2-1) PFDTH (J1-1) PFDTH1 (J2-2) FL LJ VALVE PFDTH1 (J1-2) IGN (J5-9) FR LJ BLK/YEL...

  • Page 91: Electrical Schematic - Sheet 4 Of 4

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS FL LJ VALVE FR LJ BLACK Y 18 VALVE RL LJ ORN/WHT 55-20 Y 19 VALVE RR LJ ORN/WHT 55-21 Y 20 VALVE LJ EXTEND 1 ORN/WHT 55-22 Y 21 VALVE LJ EXTEND 2 ORN/WHT 55-23 Y 22 VALVE...

  • Page 92: Electrical Schematic - (W/ Generator) - Sheet 1 Of 4

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ORN/WHT 55-3 WHT/YEL 48-4 BLU/ORN 52-1 WHT/YEL 48-1 WHT/YEL 48-10 WHT/YEL 48-2 YEL/RED 2-3B TAN 55-2 ORANGE 55-1 BLACK 8 J3-5 4.5V OUTPUT J3-1 BULK- BULK- HEAD GROUND GROUND HEAD ENGINE ENGINE PLATFORM DISPLAY YELLOW 9-1 DUAL...

  • Page 93: Electrical Schematic - (W/ Generator) - Sheet 2 Of 4

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ORN/WHT 55-3 WHT/YEL 48-4 BLU/ORN 52-1 WHT/YEL 48-1 WHT/YEL 48-10 WHT/YEL 48-2 TAN 55-2 ORANGE 55-1 1K OHM POT W/ 150 OHM CURRENT LIMITING RESISTORS BLACK 8 J3-5 4.5V OUTPUT J3-1 2.3V @ CENTER GENERATOR PLATFORM DISPLAY YELLOW 9-1...

  • Page 94: Electrical Schematic - (W/ Generator) - Sheet 3 Of 4

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SERIAL DATA IN YEL/BLK J2-30 SERIAL DATA CLOCK WHT/RED J2-29 R 01 R 02 R 03 SERIAL DATA OUT J2-40 J1 RECEPTACLE PFDTH (J2-1) PFDTH1 (J2-2) PFDTH (J1-1) FL LJ PFDTH1 (J1-2) IGN (J5-9) VALVE FR LJ...

  • Page 95: Electrical Schematic - (W/ Generator) - Sheet 4 Of 4

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS FL LJ VALVE FR LJ BLACK Y 18 VALVE RL LJ ORN/WHT 55-20 Y 19 VALVE RR LJ ORN/WHT 55-21 Y 20 VALVE LJ EXTEND 1 ORN/WHT 55-22 Y 21 VALVE LJ EXTEND 2 ORN/WHT 55-23 Y 22 VALVE...

  • Page 96: Electrical Componants Installation - Prior To S/N 141689 - Sheet 1

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS M AIN VAL VE HIGH PRESSURE FIL TER O VERLOAD ENGINE COM PONENTS PLA TFORM CONTROL BO X PLA TFORM W ORK LIGHTS PISTON PUM P LEVELING JACK VAL VES LIFT CYLINDER RECEPTACLE A T PLA TFORM GENERATOR...

  • Page 97: Electrical Componants Installation - Prior To S/N 141689 - Sheet 2

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS GROUND CONTROL BO X FUEL GAUGE SENDER BEACON LIGHT HORN ELEVA TION SW ITCH ALARM LEVELING JACK SW ITCHES Figure 3-27. Electrical Componants Installation - Prior to S/N 141689 - Sheet 2 3121801 3-31...

  • Page 98: Electrical Componants Installation - S/N 141689 To Present - Sheet 1

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS MA IN V AL VE ENGINE COMPONENTS PLA TFORM PLA TFORM CONTROL W ORK LIGHTS OV ERL OA D PISTON PUMP LIFT CYLINDER RECEPT A CLE A T PLA TFORM (DESIGN MA Y V A RY ) CIRCUIT BREA KER (CE SPEC ONL Y )

  • Page 99: Electrical Componants Installation - S/N 141689 To Present - Sheet 2

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS GROUND CONTROL FUEL GA UGE SENDER BEA CON LIGHT HORN/ A LA RM ELEV A TION SW ITCH PROXIMITY SW ITCH A NA L Y ZER CONTROLLER MODULE RESISTOR GROUND DIRECTIONA L SPLICE V A L VE IGN.

  • Page 100: Hydraulic Schematic - Prior To S/N 141689

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 2792402 T Figure 3-30. Hydraulic Schematic - Prior to S/N 141689 3-34 3121801...

  • Page 101: Hydraulic Schematic - S/N 141689 To Present

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 2792717 D Figure 3-31. Hydraulic Schematic - S/N 141689 to Present 3121801 3-35...

  • Page 102: Hydraulic Diagram (Generator)

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 2792448 B Figure 3-32. Hydraulic Diagram (Generator) 3-36 3121801...

  • Page 103: Hydraulic Diagram (Leveling Jacks)

    SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 2792686 C Figure 3-33. Hydraulic Diagram (Leveling Jacks) 3121801 3-37...
  • Page 104 SECTION 3 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3-38 3121801...
  • Page 106 3121801 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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