JLG 740A Service And Maintenance Manual
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JLG 740A Service And Maintenance Manual

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Table of Contents

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Service and Maintenance Manual
Models
740A
740AJ
P/N - 3121160
January 8, 2013

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Summary of Contents for JLG 740A

  • Page 1 Service and Maintenance Manual Models 740A 740AJ P/N - 3121160 January 8, 2013...

  • Page 3: Bhydraulic System Safety

    Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be discon- nected with minimal fluid loss. 3121160 – JLG Lift –...
  • Page 4 INTRODUCTION REVISON LOG Original Issue - November 4, 2002 Revised - September 8, 2003 Revised - March 10, 2006 Revised - September 28, 2007 Revised - June 3, 2008 Revised - January 8, 2013 – JLG Lift – 3121160...

  • Page 5: Table Of Contents

    Lubrication and Servicing ........... 2-3 3121160 – JLG Lift –...
  • Page 6 Welding on JLG Equipment ............2-5 Do the Following When Welding on JLG Equipment ......2-5 Do NOT Do the Following When Welding on JLG Equipment .
  • Page 7 Deutz EMR 2 (S/N 85331 to Present) ..........3-113 3121160 – JLG Lift –...
  • Page 8 Cooler Core Cleaning (Exterior) ..........3-160 – JLG Lift –...
  • Page 9 Theory of Operation............4-29 3121160 – JLG Lift –...
  • Page 10 Spray Method ............5-2 – JLG Lift –...
  • Page 11 To Connect the JLG Control System Analyzer ........
  • Page 12 HD30/HDP20 Series Disassembly..........7-9 viii – JLG Lift – 3121160...
  • Page 13 Loop Flushing Spool ............3-42 3121160 – JLG Lift –...
  • Page 14 Air Fuel Mixer..............3-130 – JLG Lift –...
  • Page 15 Wiper Seal Installation............5-7 3121160 – JLG Lift – xiii...
  • Page 16 HD/HDP Unlocking Contacts ........... . .7-9 – JLG Lift –...
  • Page 17 Hydraulic Schematic - Sheet 6 of 6..........7-31 3121160 – JLG Lift –...
  • Page 18 Air Compressor Troubleshooting ..........3-162 – JLG Lift –...
  • Page 19 Diagnostic Menu Descriptions ........... .6-56 3121160 – JLG Lift – xvii...
  • Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally. xviii – JLG Lift – 3121160...

  • Page 21: Section 1 - Specifications

    2.50 GPH (9.46 lph) Cooling System 16 Quarts (15.14 L) Battery 1000 Cold Cranking Amps, 210 Spark Plug AWSF-52-C minutes Reserve Capacity, 12 VDC Spark Plug Gap 0.044 in. (1.117 mm) Horsepower 64 @ 2600 RPM, full load 3121160 – JLG Lift –...

  • Page 22: Tires

    2.1cu. in. (34.4 cm ) Max. Pump Output 15.5 GPM (59 lpm) @ 1800 RPM Stand By Pressure 400 PSI.(27.5 Bar) @ 1800 RPM High Pressure Relief High Pressure Relief - 2700 PSI.(186 Bar) Rotation Clockwise – JLG Lift – 3121160...

  • Page 23: Auxiliary Power Pump

    14 ft.- 6 in. (4.42 m) BAR) Turning Radius (Inside) 11 ft.- 0 in. (2.13 m) Pump Displacement 0.305 cu. in. (5 cm Boom Elevation - 740A Above Grade +80 ft.-3 in. (24.46 m) Valving Non-Adj. Unloader Preset to 230 psi Below Grade -15 ft.-7 in.

  • Page 24: Function Speeds

    Tower Lift Down 44 - 53 Drive (2WD) Forward & Reverse 33-45 Drive (4WD) Forward & Reverse 33-45 Drive Above Elevation 2WD Forward & Reverse Min 61 Drive Above Elevation 4WD Forward & Reverse Min 122 4150241-D – JLG Lift – 3121160...

  • Page 25: Torque Requirements

    29.5-40 ft. lbs. At Installation mends the use of Mobil DTE13. Engine) (40-54 Nm) Aside from JLG recommendations, it is not advisable to Megajector Mounting 60 in. lbs. As required mix oils of different brands or types, as they may not con-...

  • Page 26: Cylinder Specifications

    Specific Gravity 1.082 Pour Point, Max -58°F (-50°C) Viscosity at 0° C (32° F) 340 cSt (1600SUS) at 40° C (104° F) 46 cSt (215SUS) at 65° C (150° F) 22 cSt (106SUS) Viscosity Index – JLG Lift – 3121160...

  • Page 27: Major Component Weights

    Table 1-28. Critical Stability Weights COMPONENTS LBS. 18 X 19.5 Tire & Wheel Engine Ford Deutz GM w/pumps 1030 Counterweight Turntable 4805 2180 Wheel Hubs Front & Rear Platform 6 FT. (1.83 M) 8 FT. (2.44 M) 3121160 – JLG Lift –...

  • Page 28: Operator Maintenance

    Comments - Remote Access LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI- SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON- MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. – JLG Lift – 3121160...
  • Page 29 Lube Point(s) - Fill Cap Capacity - 40 gallons (151 L) Tank; 77 gallons (291.4 L) System Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 3121160 – JLG Lift –...

  • Page 30: Deutz Engine Dipstick

    MAXIMUM LEVEL, OIL COLD NOTE: Hot oil checks should not be made until the engine has been shut down for a period of 5 minutes. Figure 1-2. Deutz Engine Dipstick 1-10 – JLG Lift – 3121160...
  • Page 31 16.Fuel Filter (Propane) - GM Engine Interval - 3 Months or 150 hours of operation Lube Point(s) - Replaceable Element Comments - Replace filter. Refer to Propane Fuel Interval - Every Year or 600 hours of operation Filter Replacement 3121160 – JLG Lift – 1-11...

  • Page 32: Draining Oil Build Up From The Propane Regulator

    4. Push in the Emergency Switch once the engine stops. 10. Dispose of any drained oil in a safe and proper fash- ion. 5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. 1-12 – JLG Lift – 3121160...

  • Page 33: Propane Fuel Filter Replacement

    8. Tighten the filter retaining bolt to 106 in lbs (12 Nm). 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 3121160 – JLG Lift – 1-13...

  • Page 34: Propane Fuel System Pressure Relief

    2.Start and run the vehicle until the engine stalls. 3.Turn the ignition switch OFF. RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE. 1-14 – JLG Lift – 3121160...

  • Page 35: Torque Chart (Sae Fasteners - Sheet 1 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3) 3121160 – JLG Lift – 1-15...

  • Page 36: Torque Chart (Sae Fasteners - Sheet 2 Of 3))

    SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3)) 1-16 – JLG Lift – 3121160...

  • Page 37: Torque Chart (Sae Fasteners - Sheet 3 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 3) 3121160 – JLG Lift – 1-17...

  • Page 38: Torque Chart (Metric Fasteners - Sheet 1 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3) 1-18 – JLG Lift – 3121160...

  • Page 39: Torque Chart (Metric Fasteners - Sheet 2 Of 3))

    SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 2 of 3)) 3121160 – JLG Lift – 1-19...

  • Page 40: Torque Chart (Metric Fasteners - Sheet 3 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3) 1-20 – JLG Lift – 3121160...

  • Page 41: Section 2 - General

    JLG Service It is important to establish and conform to a comprehen- Training School for the subject JLG product model. Refer- sive inspection and preventive maintenance program. The ence the machine Service and Maintenance Manual and...

  • Page 42: Service And Guidelines

    Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance Inspection rental delivery. Mechanic Manual and applicable JLG inspection form. Frequent Inspec- In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance tion ever comes first;...

  • Page 43: Component Disassembly And Reassembly

    (See Hydraulic system filters should be checked, Torque Chart Section 1.) cleaned, and/or replaced as necessary, at the speci- 3121160 – JLG Lift –...

  • Page 44: Hydraulic Oil

    Lubrication Chart. ranges. 2.4 CYLINDER DRIFT TEST 2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity Maximum acceptable cylinder drift is to be measured index of 152.

  • Page 45: Pins And Composite Bearing Repair Guidelines

    The cylinder must have the normal load, which is the nor- machine on an external structure, or component, mal platform load applied. Do the Following When Welding on JLG If the cylinder passes this test, it is acceptable. Equipment NOTE: This information is based on 6 drops per minute cyl- •...

  • Page 46: Inspection And Preventive Maintenance Schedule

    1,2,5 Hood, Hood Props, Hood Latches Chassis Assembly 16,17 16,17,18 16,17,18 Tires Wheel Nuts/Bolts 14,24 Wheel Bearings Oscillating Axle/Lockout Cylinder Systems Outrigger or Extendable Axle Systems Steer Components Drive Motors Torque Hubs Functions/Controls Platform Controls – JLG Lift – 3121160...
  • Page 47 7,11 7,11 Hydraulic Fluid Electrical Connections 5,23 Instruments, Gauges, Switches, Lights, Horn General Operators and Safety Manuals in Storage Box ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible 3121160 – JLG Lift –...
  • Page 48 21, 22 Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to use each day; or at each Operator change Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...

  • Page 49: Engine Operating Temperature Specifications - Deutz

    -10° F (-23° C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIF IED COLD WEATHER -20° F (-29° C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ET HER INJECTION OR KEROSENE -30°...

  • Page 50: Engine Operating Temperature Specifications - Ford

    SECTION 2 - GENERAL 4150548 E Figure 2-2. Engine Operating Temperature Specifications - Ford 2-10 – JLG Lift – 3121160...

  • Page 51: Engine Operating Temperature Specifications - Gm

    SECTION 2 - GENERAL 4150548 E Figure 2-3. Engine Operating Temperature Specifications - GM 3121160 – JLG Lift – 2-11...
  • Page 52 SECTION 2 - GENERAL NOTES: 2-12 – JLG Lift – 3121160...

  • Page 53: Section 3. Chassis & Turntable

    The air pressure for pneumatic tires must be equal to Wheel Replacement the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational The rims installed on each product model have been characteristics.

  • Page 54: Oscillating Axle Bleeding Procedure And Lockout Test

    NOTE: Bleeding of the oscillating axles is an infrequent operation performed after hydraulic line failure and or lock-out cylinder repair. Figure 3-1. Oscillating Valve Adjustment. NOTE: To oscillate the axle, the lock-out valve plunger must be depressed. – JLG Lift – 3121160...

  • Page 55: Oscillating Axle Lockout Test

    14. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed posi- tion, lockout cylinders should release and allow 3121160 – JLG Lift –...

  • Page 56: Torque Hub, Drive

    Turn cover over and push disconnect rod into corrosion, or excessive wear. If necessary, replace cover cap. Rod will be held in place by friction bearings as a complete set ensuring that they from o-ring. remain covered until use. – JLG Lift – 3121160...
  • Page 57 Place spacer into opposite side of cluster gear Ensure chamfered side of hole in planet shaft is and against needle rollers. lined up with pin hole in carrier. 3121160 – JLG Lift –...

  • Page 58: Assembly

    Cleaning and Inspection procedures. Replace parts as necessary. d. Place washer (31), spring (32), and washer (31), in that order, onto input shaft. 2. Place bearing cone (4) into bearing cup (3) in small end of hub. – JLG Lift – 3121160...
  • Page 59 7. Install new retaining ring (9) completely into spindle groove and against bearing shim. Ensure retaining ring is entirely in groove. 5. Place bearing cone (6) over end of spindle and into bearing cup. 8. Place internal gear (12) onto end of spindle. 3121160 – JLG Lift –...
  • Page 60 14. Place o-ring (22) into hub counter bore. Use petro- leum or grease to hold o-ring in place. Slight stretch- ing of o-ring may be necessary to insure proper seating. 11. Place input shaft assembly (35) into spindle bore with unsplined end facing out. – JLG Lift – 3121160...
  • Page 61 ‘X’ over one of counter bored holes in hub. NOTE: If gears do not mesh easily or carrier assembly does not rotate freely, then remove carrier and ring gear and check cluster gear timing. 3121160 – JLG Lift –...
  • Page 62 23. Locate four shoulder bolts (42), 90 degrees apart into counter bored holes in hub marked in step (13). Torque shoulder bolts to 47 ft. lbs. (64 Nm). 26. Fill hub one-half full of EPGL 90 lubricant before operation. 3-10 – JLG Lift – 3121160...

  • Page 63: Torque Hub Drive (Fairfield)

    34. Retaining Ring 35. Input Shaft 36. Thrust Spacer 37. Input Gear 38. Not Used 39. Thrust Washer 40. Thrust Bearing 41. Bolt 42. Shoulder Bolt 43. Coupling Figure 3-3. Torque Hub Drive (Fairfield) 3121160 – JLG Lift – 3-11...

  • Page 64: Drive Brake - Ausco (Prior To S/N 56875)

    7. Install bolts (24) with washers (23) in the power plate they are inspection, they are found to be in good (21. Tighten sequentially, one turn at a time, until the condition. power plate is properly seated. Torque 105-115 Ft. Lbs.(142.4-155.9 Nm) 3-12 – JLG Lift – 3121160...

  • Page 65: Drive Brake, Ausco

    11. Primary Disc 17. O-ring 23. Washer 5. Retaining Ring 12. Rotating Disc 18. Backup Ring 24. Bolt 6. Seal 13. Not Used 19. O-ring 25. Gasket 7. Spring Retainer Figure 3-4. Drive Brake, Ausco 3121160 – JLG Lift – 3-13...

  • Page 66: Drive Brake - Mico (S/N 56875 To 83332)

    BRAKE ASSEMBLY, RELEASE PRESSURE MUST NOT EXCEED 1.Use an alkaline wash to clean parts before assembly. 134.5 BAR (500 PSI). 2. Press oil seal (17) into cover plate (16) until it is flush with bearing shoulder. Note direction of seal. 3-14 – JLG Lift – 3121160...

  • Page 67: Drive Brake - Mico (S/N 56875 To 83332)

    11. Stator Disc 18. Bearing 5. O-ring 12. Rotor Disc 19. Retaining Ring 6. Backup Ring 13. Return Plate 20. Retaining Ring 7. Piston 14. Springs Figure 3-5. Drive Brake - Mico (S/N 56875 to 83332) 3121160 – JLG Lift – 3-15...

  • Page 68: Bleeding

    Discs frozen These brakes are designed for only lim- Replace disc stack. ited dynamic braking. A severe emer- gency stop or prolonged reduced release pressure operation may result in this type of damage. 3-16 – JLG Lift – 3121160...

  • Page 69: Drive Brake (S/N 83332 To Present)

    4. Examine compression springs (22 & 23) for damage or fatigue. 5. Check ball bearing (10) for axial float or wear. 6. Examine O-ring seals (15 & 17) and backing rings (16 & 18) for damage. 3121160 – JLG Lift – 3-17...

  • Page 70: Drive Brake (S/N 83332 To Present)

    13. Capscrew 18. Backup Ring 23. Spring (Blue) 4. Pressure Plate 9. Piston 14. Lockwasher 19. Dowel Pin 5. Gasket 10. Ball Bearing 15. O-ring 20. Plug Figure 3-6. Drive Brake (S/N 83332 to Present) 3-18 – JLG Lift – 3121160...

  • Page 71: Drive Motor (Prior To S/N 83332)

    Viton Parts of the control device: control piston, piston rod, plug, spring stopper max hex. nut, and hex. head nut flow Drive shaft Spare parts kit DFR pilot valve Bearing set/miscellaneous parts 3121160 – JLG Lift – 3-19...

  • Page 72: Replacing The Drive Shaft Seal

    Figure 3-7. 600S Drive Motor Cutaway 2. Change the shaft seal and check its sliding surface (drive shaft) and housing, grease the sealing ring. Replacing the Drive Shaft Seal 1. Remove the snap ring 3-20 – JLG Lift – 3121160...

  • Page 73: Disassembly And Assembly

    5. Assemble the snap ring. 3. Remove the port plate together with the valve plate (hold the valve plate so that the plate can’t fall down). 6. Assemble the snap ring in the correct position. 3121160 – JLG Lift – 3-21...
  • Page 74 9. Turn in the stopper max flow to get swivel angle zero. 6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position. 7. Unscrew the cap nut and remove it. 11. Disassemble the stopper - max. flow. 3-22 – JLG Lift – 3121160...
  • Page 75 18. Remove both bearing shells. 14. Disassemble the control piston while moving the swash plate. 19. Remove the drive shaft. 15. The swash plate must be lifted a little bit to disas- semble the piston rod. 3121160 – JLG Lift – 3-23...
  • Page 76 22. The external front bearing ring is pulled out of the pump housing. 25. The spring has additional pretension while you dis- assemble the three pressure pins inside the cylinder. 3-24 – JLG Lift – 3121160...

  • Page 77: Assembly Notes

    (Note spare parts exist as cw and ccw valve plates.) Taper Roller Bearing Initial Tension Cast iron pump housing must have initial tension of the bearings: 0..0,05 mm, grind Pos. 12 if necessary. 3121160 – JLG Lift – 3-25...

  • Page 78: Flow Control Pilot Valves

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Differential volume if you are rotating the threaded pin - each rotation is appr. 3,1 cm3. Figure 3-8. Flow Control Pilot Valves 3-26 – JLG Lift – 3121160...

  • Page 79: Testing And Setup

    4. Tighten jam nut, install cap nut. NOTE: The “o” ring must be seated in groove in cap nut. inches cu. in. /rev 0.433 4-W D 1.000 Figure 3-9. Drive Motor Adjustment (Prior to S/N 83332) 3121160 – JLG Lift – 3-27...

  • Page 80: Drive Motor (S/N 83332 To Present)

    2. Install a new shaft seal with the cupped side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal. 3. Install seal support washer. 4. Install snap ring. 5. Remove the installation sleeve. 3-28 – JLG Lift – 3121160...

  • Page 81: Loop Flushing Valve

    3. Remove O-rings (4, 5, and 6). 4. Using pliers, remove centering springs (7, 8, and 9). 5. Remove spring retaining washers (10 and 11). 6. Remove shift spool (12). 7. Remove orifice poppet (13). 3121160 – JLG Lift – 3-29...

  • Page 82: Troubleshooting

    The smaller the orifice, the longer the time it takes to shift the and verify that they are not obstructed. Clean or replace as erly installed, and are not motor. Obstruction will also increase shift times. necessary. obstructed. 3-30 – JLG Lift – 3121160...

  • Page 83: Disassembly

    11. Using a 5/16 inch internal hex wrench, remove drain 7. Remove orifice poppet (13). plugs (19, 20). Discard O-rings. 12. Using a 9/16 inch internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings. 3121160 – JLG Lift – 3-31...

  • Page 84: End Cap

    The grease will force the bearing out. Use caution not to drive the bearing past the rear shaft journal as the bearing may become trapped on the shaft and damaged. 3-32 – JLG Lift – 3121160...

  • Page 85: Cylinder Kit

    20. Turn the housing over and remove the snap ring (32) retaining the shaft seal and support washer. Remove the support washer (33) and carefully pry out the shaft seal (34). Discard the seal. 3121160 – JLG Lift – 3-33...

  • Page 86: Swash Plate & Servo Piston

    A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON- ABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED. 3-34 – JLG Lift – 3121160...

  • Page 87: Inspection

    Table 3-8. Cylinder Block Measurements Measurement 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14) Minimum Cylinder Block Height (A) 0.002 0.002 0.002 0.002 0.002 Cylinder Block Surface Flatness (0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079) 3121160 – JLG Lift – 3-35...
  • Page 88 Measure the swashplate thickness from sealing surfaces. the journals to the running face. Replace swashplate if damaged or worn beyond minimum specification. 3-36 – JLG Lift – 3121160...

  • Page 89: Assembly

    3. Servo Piston Figure 3-22. Servo Piston 2. After piston seal has relaxed, lubricate and install servo piston into the housing bore. Align the piston with the ball socket facing the inside of the housing. 3121160 – JLG Lift – 3-37...

  • Page 90: Cylinder Kit Assembly

    12. Slipper Retainer 8. Retaining Ring Figure 3-23. Cylinder Kit Assembly 4. Turn the block over and install the retaining ring (8), hold-down pins (9), and ball guide (10) to the cylin- der block. 3-38 – JLG Lift – 3121160...

  • Page 91: Shaft And Front Bearing

    Install the install shaft/bearing assembly into housing from the flange end. Install the snap-ring (18). 20. Servo Spring 21. Minimum Angle Stop Figure 3-27. Servo Spring and Minimum Angle Stop 3121160 – JLG Lift – 3-39...

  • Page 92: Valve Plate And Rear Bearing

    Apply a liberal coat of assembly the specified maximum force, disassemble and grease to the endcap side of the valve plate to keep check the unit. it in place during installation. 3-40 – JLG Lift – 3121160...

  • Page 93: Shaft Seal

    1.5 to 2.5 ft.lbs. (2.03 to 3.39 Nm) 28. Seal Support Washer 29. Snap Ring Figure 3-30. Shaft Seal 1/4 in 33 ft.lbs. (45 Nm) 5/16in 63 ft.lbs. (85 Nm) Figure 3-31. Plugs and Fittings Installation 3121160 – JLG Lift – 3-41...

  • Page 94: Initial Start-Up Procedures

    9. Shut down the prime mover and remove the pres- sure gauge. Replace plug at the charge pressure gauge port. 10. Check the fluid level in the reservoir; add clean fil- tered fluid if necessary. The motor is now ready for operation. 3-42 – JLG Lift – 3121160...

  • Page 95: Swing Hub Installation

    5. Position swing drive to approx. location of bearing gear max. eccentric tooth. (high spot) 6. With bearing free to slide, shim between pinion gear and the bearing teeth to +.008" / +.012" (+.20mm/ +.30mm)backlash. 3121160 – JLG Lift – 3-43...

  • Page 96: Swing Bearing

    NOTE: This check is designed to replace the existing bear- checked in all quadrants. ing bolt torque checks on JLG Lifts in service. This 2. Check the turntable to bearing Attach bolts as fol- check must be performed after the first 50 hours of...

  • Page 97: Swing Bearing Tolerance Boom Placement. (Sheet 1 Of 2)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-34. Swing Bearing Tolerance Boom Placement. (Sheet 1 of 2) 3121160 – JLG Lift – 3-45...
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 3-46 – JLG Lift – 3121160...

  • Page 99: Wear Tolerance

    ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE plete turntable assembly from the bearing. OF THIS, PROPER MAINTENANCE OF THE SWING BEARING Ensure that no damage occurs to the turntable, BOLTS IS A MUST FOR SAFE OPERATION. bearing or frame-mounted components. 3121160 – JLG Lift – 3-47...

  • Page 100: Swing Bearing Torque Sequence

    Figure 3-38. Swing Bearing Torque Sequence. h. Carefully place the turntable on a suitably sup- ported trestle. JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING i. Use a suitable tool to scribe a line on the outer BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE race of the swing bearing and the frame.

  • Page 101: Swing Bearing Torque Values

    8. Remove Bearing Shim (1H) from the Output Shaft (1A). 9. The Output Shaft (1A) may now be pressed out of the Hub (1G). 3121160 – JLG Lift – 3-49...

  • Page 102: Assembly

    Shaft (1A) install Internal Gear (2). The Spline of the Internal Gear (2) bore will mesh with the Spline of the Output Shaft (1A). 2. Thrust Washer (11) is installed on the face of the Output Shaft (1A). Sufficient Grease or Petroleum 3-50 – JLG Lift – 3121160...
  • Page 103 Ring Gear over (into mesh with) large gears. Be sure that punch marks remain in correct location during Ring Gear installation. The side of the Ring Gear with an X stamped on it should be up. 3121160 – JLG Lift – 3-51...
  • Page 104 BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS O-RING. 14. Pipe Plugs (20) are to be installed into Cover (6) using a lubricant seal of some sort. 3-52 – JLG Lift – 3121160...

  • Page 105: Hub Shaft Sub-Assembly

    2. Press Bearing Cup (1C) into Hub (1G) taking care to rectly installed (smooth face UP and located just insure cup start square with the bore of Hub (1G). flush with the counterbore face). 3121160 – JLG Lift – 3-53...
  • Page 106 Shaft (1A) and locates on Bearing Cone (1F). 11. Upon completion of Step 10, rap the internal end of the Output Shaft (1A) twice with a piece of soft metal rod. This will release the preload which was on the Bearings. 3-54 – JLG Lift – 3121160...

  • Page 107: Carrier Sub-Assembly

    2. Place sixteen Needle Rollers into Cluster Gear bore. bosses in Carrier with washer tang fitting into slot in Carrier outside diameter. NOTE: Some old style Carriers will not have slots and tangs should be located inside boss relief. 3121160 – JLG Lift – 3-55...
  • Page 108 7. Line up Cluster Gear and thrust Washers with hole in to complete Carrier Sub Assembly. Carrier and slide Planet Shaft through. Line up chamfered side of hole in Planet Shaft with pin hole in Carrier. 3-56 – JLG Lift – 3121160...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-57...

  • Page 110: Swing Brake - Ausco (Prior To S/N 0300068040)

    7. Install bolts (24) with washers (23) in the power plate (21. Tighten sequentially, one turn at a time, until the power plate is properly seated. Torque 105 to 115 Ft. Lbs. (147 to 161 Nm) 3-58 – JLG Lift – 3121160...

  • Page 111: Swing Brake Assembly (Ausco) (Prior To S/N 0300068040)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-40. Swing Brake Assembly (Ausco) (Prior to S/N 0300068040) 3121160 – JLG Lift – 3-59...

  • Page 112: Swing Motor (Eaton) (Prior To S/N 0300068040)

    Apply heat to where the screw threads into the motor Seal Seal Spacer Plate End Cap Seal Capscrew Geroler Drive Figure 3-41. End Cap Removal 3-60 – JLG Lift – 3121160...

  • Page 113: Reassembly

    4. Lubricate and install the back - up ring and pressure. Use a seal installation tool to press the pressure seal DO NOT DAMAGE THE MOUNTING FLANGE WHERE THE SHAFT into place. PASSES THROUGH IT. 3121160 – JLG Lift – 3-61...

  • Page 114: Motor Timing

    BE SURE THE SLOTS IN THE SPACER PLATE PROVIDE PASSAGE FOR HYDRAULIC FLUID AS WELL AS THE CAP SCREWS. IF THE SPACER PLATE IS FLIPPED THE MOTOR WILL NOT OPERATE. 3-62 – JLG Lift – 3121160...

  • Page 115: Swing Motor (Prior To S/N 0300068040)

    5. Pressure Seal 15. Seal 6. Seal 16. Geroler 7. Bearing Race 17. Seal 8. Needle Thrust Bearing 18. End Cap 9. Key 19. Capscrew 10. Output Shaft Figure 3-42. Swing Motor (Prior to S/N 0300068040) 3121160 – JLG Lift – 3-63...

  • Page 116: Swing Hub (S/N 0300068040 To Present)

    12. The cluster gear (3F) can now be removed from the carrier (3A). THe thrust washers (3B) will be removed with the cluster gear (3F). 13. The needle rollers (3C) and spacer (3D) are now removed from the cluster gear (3F). 3-64 – JLG Lift – 3121160...
  • Page 117 Marked tooth will be located just under the car- rier (3A) on upper two gears (3F). 6. With shoulder side of ring gear (4) facing down, place ring gear over (into mesh with) large gears. Be 3121160 – JLG Lift – 3-65...
  • Page 118 10. Thrust washer (11) is installed into the counterbore of the carrier (3). 13. Install regular grade 8 bolts (12) into remaining holes. 11. Place O-ring (5) into cover (6) counterbore. Use petroleum jelly to hold O-ring in place. 3-66 – JLG Lift – 3121160...

  • Page 119: Hub Shaft Sub-Assembly

    (1A) is carefully installed mounted horizontally, and completely filled if mounted into the hub (1G). vertically. In vertical mounting application case oil circula- tion is recommended. Hub Shaft Sub-Assembly 1. Press bearing cone (1D) onto shaft (1A). 3121160 – JLG Lift – 3-67...
  • Page 120 6. The bearing cone (1F) is an interference fit and has to be pressed or tapped on. EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 7. Pipe plugs (1J & 1K) should be checked and/ or installed at this time in the assembly. 3-68 – JLG Lift – 3121160...

  • Page 121: Carrier Sub-Assembly

    This completes the hub shaft sub-assembly —items (1A) through (1J). If this assembly is not going to be used right away, it should be oiled and covered to help prevent rust- ing, 3121160 – JLG Lift – 3-69...
  • Page 122 6. While keeping thrust washers in place, slide cluster gear into carrier with the larger gear on the side with the small pin hole. 3-70 – JLG Lift – 3121160...
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-71...

  • Page 124: Swing Brake (S/N 0300068040 To Present)

    4. Install retaining ring (20) in cover (16). 5. Press shaft (9) into bearing (18) until it bottoms on the shoulder. Bearing (18) inner race must be sup- ported during this operation. 3-72 – JLG Lift – 3121160...

  • Page 125: Swing Brake (S/N 0300068040 To Present)

    15. Dowel Pin 6. Piston 16. Cover 7. O-rings 17. Oil Seal 8. Backup Rings 18. Bearing 9. Shaft 19. Retaining Ring 10. Stator Disc 20. Retaining Ring Figure 3-44. Swing Brake (S/N 0300068040 to Present) 3121160 – JLG Lift – 3-73...

  • Page 126: Swing Motor (S/N 0300068040 To Present)

    12. Remove needle thrust bearing from shaft or hous- ing. of hard rubber or board. 2. remove cap screws and seal washers. 3. Remove end cap. 3-74 – JLG Lift – 3121160...
  • Page 127 8 to 10 seconds. As soon as screw breaks loose, remove heat from hous- ing. Continue turning screw until it is completely removed. BE CAREFUL NOT TO SCRATCH SEAL CAVITY O.D. THIS COULD CREATE A LEAK PATH. 3121160 – JLG Lift – 3-75...

  • Page 128: Inspection And Cleaning

    Clean all metal parts in clean solvent. Blow dry with air. Do not wipe parts with cloth or paper towel because lint or other matter could get into the hydraulic system and cause damage. 3-76 – JLG Lift – 3121160...
  • Page 129 Do not apply Loctite to threads more than 15 min- utes before installing screws. If housing stands for more than 15 minutes, repeat application. No addi- tional cleaning or removal of previously applied Loc- tite is necessary. 3121160 – JLG Lift – 3-77...

  • Page 130: Timing Procedure

    22 mm (0.875 in.) under head length. See parts book for correct part number. GEROTOR END 1. Reposition motor with gerotor end up, then clamp across ports. Do not clamp on side of housing. 3-78 – JLG Lift – 3121160...
  • Page 131 2. Install drive spacer if applicable. 3. Install 73 mm (2.875 in.) seal in end cap. Carefully place end cap on gerotor. 3121160 – JLG Lift – 3-79...

  • Page 132: Swing Motor

    10. Seal Washer (When Applicable) 24. Plug/O-ring S/A (End Ported Motors) 11. Capscrew 25. O-ring 12. Plug/O-ring S/A 26. O-ring 13. End Cap 27. Optional - Base Block Mounting Kit 14. Seal 28. Capscrew Figure 3-45. Swing Motor 3-80 – JLG Lift – 3121160...

  • Page 133: Rotary Coupling

    10. Reinsert center body into housing (lube with hydrau- 2. Remove snap ring (7) from end. lic oil). 3. Remove thrust ring (3) from the same end. 11. Replace thrust ring and snap ring. Figure 3-46. Rotary Coupling Seal Installation 3121160 – JLG Lift – 3-81...

  • Page 134: Rotary Coupling Cutaway

    SECTION 3 - CHASSIS & TURNTABLE 1. Center Body 5. Seal 2. Seal 6. Thrust Ring 3. Housing 7. Snap Ring 4. O-ring 8. Valve Block (Axle Oscillation) Figure 3-47. Rotary Coupling Cutaway 3-82 – JLG Lift – 3121160...

  • Page 135: Rotary Coupling Port Location

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-48. Rotary Coupling Port Location 3121160 – JLG Lift – 3-83...

  • Page 136: Rotary Coupling Installation

    3. Bolt 8. Retaining Ring 13. O-ring 18. Check Valve 4. Bolt 9. Plug 14. Bearing 19. Case 5. Bracket 10. Torque Lug 15. Cap Seal 20. Plunger Valve Figure 3-49. Rotary Coupling Installation 3-84 – JLG Lift – 3121160...

  • Page 137: Tilt Alarm Switch (Prior To S/N 0300062045)

    If the switch does not trip in all three tests, the flange nuts have been tightened too far. Loosen the “X” nut and repeat steps (2) through (4) LIMIT SWITCHES ADJUSTMENTS. 3121160 – JLG Lift – 3-85...

  • Page 138: Auxiliary Pump - Sheet 1 Of 2

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-51. Auxiliary Pump - Sheet 1 of 2 3-86 – JLG Lift – 3121160...

  • Page 139: Auxiliary Pump - Sheet 2 Of 2

    B. Torque 114 to 150 inch-pounds (13 to 17 Nm) C. Torque 144 to 180 inch-pounds (16 to 20 Nm) D. Torque to 84 inch-pounds (9.5 Nm) Figure 3-52. Auxiliary Pump - Sheet 2 of 2 3121160 – JLG Lift – 3-87...

  • Page 140: Generator

    Reinstall the belt, brush holder assembly, and end panel. STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT BREAKER. The circuit breaker protects the generator windings from overload. If the circuit breaker opens, generator output 3-88 – JLG Lift – 3121160...

  • Page 141: Inspecting Generator Brushes, Replacing Brushes, And Cleaning Slip Rings

    Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New 1. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-53. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3121160 – JLG Lift – 3-89...

  • Page 142: Dual Fuel System

    4. If a diagnostic trouble code (DTC) is stored, contact engine check has been performed, proceed to MIL DTC a JLG distributor to make an effective repair. retrieval procedure. 5. If no DTC is stored, select the symptom from the symptom tables and follow the diagnostic path or suggestions to complete the repair.

  • Page 143: Engine Module And Sensors

    As long as the fault is present, the engine can be restarted. It will run in the previously established injection sequence. 3121160 – JLG Lift – 3-91...

  • Page 144: Ecm Diagnostic Trouble Codes

    Camshaft Position Sensor (CMP) Sensor Illegal Pattern Engine Control Module (ECM) Fault Illegal Operation Engine Control Module (ECM) Fault Illegal Interruption Engine Control Module (ECM) Fault COP (Computer Operating Properly) Failure System Voltage Low System Voltage High 3-92 – JLG Lift – 3121160...

  • Page 145: Epm Diagnostic Trouble Codes

    Adaptive Learn High (LPG) This fault will set if the adaptive multiplier exceeds the limits of normal operation. Adaptive Learn Low (LPG) This fault will set if the adaptive multiplier exceeds the limits of normal operation. 3121160 – JLG Lift – 3-93...
  • Page 146 TPS, and RPM. When the fault is set, the Adaptive Learn will be disabled for the remainder of the key on cycle and the MIL will be on. The engine will operate on a default MAP during this active fault. 3-94 – JLG Lift – 3121160...
  • Page 147 Injector Driver #3 Shorted (2.5L) This fault will set if the EPM detects low feedback voltage on the inter- nal injector while the injector drive circuit is in the off-state and battery voltage is greater than 9 volts. 3121160 – JLG Lift – 3-95...
  • Page 148 If the active fault is no longer present, the MIL light will flash at 2 Hz for the remainder of the key-on cycle. This is a reminder that the Low Rev Limit is still enforced. 3-96 – JLG Lift – 3121160...
  • Page 149 TPS2 (Signal Voltage) Low This fault will set if voltage is below 0.2 volts at any operating condi- tion while the engine is cranking or running. The engine will not start or run during this active fault. 3121160 – JLG Lift – 3-97...
  • Page 150 It will not self- erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. 3-98 – JLG Lift – 3121160...
  • Page 151 It will not self- erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. 3121160 – JLG Lift – 3-99...
  • Page 152 A constant voltage below 200 mV for 10 consecutive sec- onds will set OTC 32. A constant voltage above 650 mV for 10 consecutive seconds will set OTC 42. 3-100 – JLG Lift – 3121160...
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-101...
  • Page 154 The Engine Module controls the systems that affect engine performance. The Engine Mod- ule performs the diagnostic function of the system. It can recognize operational problems, alert the operator through the Malfunction Indicator Lamp (MIL), and store 3-102 – JLG Lift – 3121160...
  • Page 155 5-Volt reference or signal circuits for greater than 2 consecutive seconds will set either a DTC 12 or DTC 22. A hard failure with the TP sensor ground circuit for more than two consecutive seconds may set DTC 22. If either 3121160 – JLG Lift – 3-103...

  • Page 156: Ecm/Epm Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-55. ECM/EPM Identification 3-104 – JLG Lift – 3121160...

  • Page 157: Fuel System

    The fuel is injected under pressure in a conical spray pat- tern at the opening of the intake valve. Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank. 3121160 – JLG Lift – 3-105...

  • Page 158: Typical Fuel System

    14.7 parts of air to 1 part of gasoline by weight, which provides the most efficient combustion. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a "closed loop" system. 3-106 – JLG Lift – 3121160...
  • Page 159 The width of the "on" pulse determines the amount of throttle opening. The Engine Module sends a signal with the appropriate pulse width to the governor based on the operator's choice of switch settings. 3121160 – JLG Lift – 3-107...
  • Page 160 CAMSHAFT POSITION (CMP) SENSOR The CMP sensor uses a variable reactor sensor to detect camshaft position. The CMP signal is created as piston #1 is a predetermined number of degrees after top dead cen- 3-108 – JLG Lift – 3121160...
  • Page 161 "waste spark." The primary coils in the coil pack are triggered by the "Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals from the Engine Module. 3121160 – JLG Lift – 3-109...

  • Page 162: Ford Lpg System (S/N 0300077500 To Present)

    The mixer accepts LPG vapor at the megajector outlet pressure (-1.00 to -5.00 inches [-2.5 to -12.7 cm] of H and mixes it with clean air. This mixture is then sucked into the engine via the actuator. 3-110 – JLG Lift – 3121160...

  • Page 163: Lpg System Components (S/N 0300077500 To Present)

    SECTION 3 - CHASSIS & TURNTABLE Megajector Mixer Regulator Lockoff Solenoid Figure 3-57. LPG System Components (S/N 0300077500 to Present) 3121160 – JLG Lift – 3-111...

  • Page 164: Lockoff Solenoid

    Control System senses a fault dealing with the megajec- completely, it could cause low fuel pressure. tor. Refer to Section 6 - JLG Control System for more infor- mation concerning the Control System. d. Reference Line - Make sure the reference line is...

  • Page 165: Deutz Emr 2 (S/N 85331 To Present)

    The EMR2 consists of the sensors, the control unit and the the battery is less than 9.5 volts: actuator. Engine-side controls as well as the JLG Control The battery is faulty System are connected by means of separate cable har- nesses to the EMR control unit.

  • Page 166: Emr 2 Engine Side Equipment

    SENSOR JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYS- TEM USES THIS TO CONTROL THE ENGINE & OIL PRESSURE FAULT REPORTING.
  • Page 167 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-115...
  • Page 168 SECTION 3 - CHASSIS & TURNTABLE 3-116 – JLG Lift – 3121160...
  • Page 169 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-117...
  • Page 170 SECTION 3 - CHASSIS & TURNTABLE 3-118 – JLG Lift – 3121160...

  • Page 171: Emr 2 Engine Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-63. EMR 2 Engine Plug Pin Identification 3121160 – JLG Lift – 3-119...

  • Page 172: Emr 2 Vehicle Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-64. EMR 2 Vehicle Plug Pin Identification 3-120 – JLG Lift – 3121160...
  • Page 173 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-121...
  • Page 174 SECTION 3 - CHASSIS & TURNTABLE 3-122 – JLG Lift – 3121160...
  • Page 175 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-123...
  • Page 176 SECTION 3 - CHASSIS & TURNTABLE 3-124 – JLG Lift – 3121160...
  • Page 177 SECTION 3 - CHASSIS & TURNTABLE 3121160 – JLG Lift – 3-125...

  • Page 178: Gm Engine General Maintenance

    • Check the entire engine wire harness for rubbing chaf- ing, cuts or damaged connections, repair if necessary Figure 3-70. Engine Oil Dip Stick • Check all wire harness connectors to insure they are fully seated and locked 3-126 – JLG Lift – 3121160...

  • Page 179: Changing The Engine Oil

    8. Start the engine and check for oil leaks. 9. Stop the engine and check the oil level to insure the oil level is at "FULL". 10. Dispose of the oil and filter in a safe manner. 3121160 – JLG Lift – 3-127...
  • Page 180 The thermostat opens at 170° F (77° C), which can be checked using the JLG handheld analyzer. WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRES- ENT COMING FROM THE RADIATOR. THIS IS NORMAL.

  • Page 181: Gm Engine Dual Fuel System

    1. Pressure Regulator Section 4. Primary Test Port 2. Fuel Inlet 5. Secondary Test Port 3. Coolant Passage 6. Voice Coil Section Figure 3-72. EPR Assembly 3121160 – JLG Lift – 3-129...

  • Page 182: Low Pressure Regulator (Lpr)

    SIONS CONTROL DEVICE AND CANNOT BE REBUILT. IF THE COIL ASSEMBLY FAILS TO OPERATE PROPERLY, REPLACE IT WITH AN OEM REPLACEMENT PART ONLY. Figure 3-73. Low Pressure Regulators Figure 3-74. Air Fuel Mixer 3-130 – JLG Lift – 3121160...

  • Page 183: Electronic Throttle Control (Etc)

    Figure 3-76. LPG Engine Control Unit (ECM) Figure 3-75. ETC throttle control device Figure 3-77. ECM Assembly 3121160 – JLG Lift – 3-131...

  • Page 184: Heated Exhaust Gas Oxygen Sensor

    The primary components of the Gasoline Multi Point Fuel Injection (MPFI) fuel system are the fuel tank, electric fuel pump, fuel pressure and temperature sensor manifold, Figure 3-79. Gasoline Fuel Pressure and Temperature fuel filter and fuel rail. Manifold Assembly 3-132 – JLG Lift – 3121160...

  • Page 185: Fuel Filter

    Use a commercially available liquid leak detector or an electronic leak detec- tor. When using both methods, use the electronic leak detector first to avoid contamination by the liquid leak detector. 3121160 – JLG Lift – 3-133...

  • Page 186: Propane Fuel Filter Replacement

    8. Tighten the filter bowl retainer to 106 in lbs (12 Nm). 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 3-134 – JLG Lift – 3121160...

  • Page 187: Electronic Pressure Regulator (Epr) Assembly Replacement

    8. Using a clamp pliers pinch off the hoses on the cool- ant lines to the regulator 9. Remove the lock pin from both the water fittings on the regulator housing and remove the fittings and hoses and retain the pin 3121160 – JLG Lift – 3-135...

  • Page 188: Temperature Manifold Absolute Pressure (Tmap) Sensor

    (6) retaining screws and tighten 70 in lbs (8 Nm). 2. Tighten retaining bolts to 62 lb-in (7 Nm). 2. Install the EPR refer to EPR Installation. 3. Start the vehicle and check for proper operation. 3-136 – JLG Lift – 3121160...

  • Page 189: Electronic Throttle Control Replacement

    Notice the orientation of the air inlet and throttle body cover. LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO ADAPTER O-RINGS. 1. Install the O-ring on throttle body. Press it down to the bottom of the surface. 3121160 – JLG Lift – 3-137...

  • Page 190: Mixer Replacement

    3. Remove the hose from each of the fittings. INSTALLATION NOTE: Use hose material and lengths specified by JLG. 1. Install the hose clamps to each hose and set the clamp back on each hose to make installation eas- ier.

  • Page 191: Engine Control Module Replacement

    3. Check for any DTC codes and clear. with the air entering the engine. This air/ fuel mixture is 4. Verify engine is in closed loop and no warning lights then drawn into the engine for combustion. are illuminated. 3121160 – JLG Lift – 3-139...

  • Page 192: Diagnostic Aids

    10. This step determines if the Mixer requires replacement Diagnostic Scan Tool 14. This step determines if the Lock Off requires replace- • Diagnostic Display tool. ment 17. This step determines if the Fuel Filter requires replace- ment. 3-140 – JLG Lift – 3121160...

  • Page 193: Lpf Fuel System Diagnosis

    1- 3 PSI Go to Step 22 Go to Step 13 (LPR). 2. Crank the engine and observe the pressure reading for the LPR primary pres- sure. Is the fuel pressure ABOVE the specified value? 3121160 – JLG Lift – 3-141...
  • Page 194 Is the action complete? Replace the lock-off. Refer to Lock-off Replacement. Go to Step 26 Is the action complete? Replace the mixer assembly. Refer to Fuel Mixer Replacement. Go to Step 26 Is the action complete? 3-142 – JLG Lift – 3121160...
  • Page 195 1. Disconnect all test equipment System OK 2. Install the primary and secondary test port plugs. 3. Start the engine. 4. Using SNOOP or equivalent, leak check the test port plugs. Is the action complete? 3121160 – JLG Lift – 3-143...

  • Page 196: Symptom Diagnosis

    If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the prob- lem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit. 3-144 – JLG Lift – 3121160...
  • Page 197 Check for the following: - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. 3121160 – JLG Lift – 3-145...
  • Page 198 - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. Check the intake and exhaust manifolds for casting flash. 3-146 – JLG Lift – 3121160...
  • Page 199 Monitoring the engine RPM with a scan tool can detect an EMI. A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present. If the problem exists, check the routing of the secondary wires and the ground circuit. 3121160 – JLG Lift – 3-147...
  • Page 200 Intake manifold gaskets Sticking or leaking valves Exhaust system leakage Check the intake and exhaust system for casting flash or other restrictions. Fuel System Checks Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis. 3-148 – JLG Lift – 3121160...
  • Page 201 Suggest that a different operator use the equipment and record the results. Fuel System Checks Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis. Check the fuel system for leakage. Sensor Checks Check the Temperature Manifold Absolute Pressure (TMAP) sensor. 3121160 – JLG Lift – 3-149...
  • Page 202 Check the ECM grounds for being clean, tight, and in their proper locations. Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality. 3-150 – JLG Lift – 3121160...
  • Page 203 - Check the Crankshaft Position (CKP) sensor. Additional Check Check the ECM grounds for being clean, tight, and in their proper locations. Check the generator output voltage. Check the vacuum hoses for kinks or leaks. Check Transmission 3121160 – JLG Lift – 3-151...

  • Page 204: Dtc To Spn/Fmi Cross Reference Chart

    Injector Driver 3 Open Injector Driver 3 Shorted Injector Driver 4 Open Injector Driver 4 Shorted Crank Sync Noise Crank Loss Cam Sync Noise Cam Sensor Loss Gasoline Cat Monitor 520211 Oil Pressure Low 3-152 – JLG Lift – 3121160...
  • Page 205 CAN Rx Failure 1628 CAN Address Conflict Failure 1629 Loss of TSC 1 2111 Unable to Reach Lower TPS 2112 Unable to Reach Higher TPS 2135 TPS 1/2 Simultaneous Voltages 2229 BP Pressure High 3121160 – JLG Lift – 3-153...

  • Page 206: Air Compressor

    (ie. air being used) will re-activate the inlet valve and the compressor again starts to load and pro- duce air. The discharge air pressure switch will typically be set with a 30 psi (2.0 bar) differential pressure. 3-154 – JLG Lift – 3121160...

  • Page 207: Air Compressor

    SECTION 3 - CHASSIS & TURNTABLE 1. Compressor Assembly 2. Air Filter Element 3. Coalescer Spin-On Element 4. Oil Filter Element Figure 3-86. Air Compressor 3121160 – JLG Lift – 3-155...

  • Page 208: Minimum Pressure Valve/Check Valve Assembly

    OK The hydraulic motor powers the compressor through a 13. Close service valve then switch instrument switch to belt drive system. OFF. 14. Disengage hydraulic system. 3-156 – JLG Lift – 3121160...

  • Page 209: Normal Startup Procedure

    5. Check all fittings and fastenings. sure. 6. Test shutdown system. 2. Check for leaks. EVERY 1000 HOURS (OR 1 YEAR) 1. Check safety circuit switches. 2. Check sump safety valve. 3. Replace spin-on coalescer (sooner if required). 3121160 – JLG Lift – 3-157...

  • Page 210: Lubrication Guide

    If this condition persists, consider changing to a different type of lubricant 2. Screw new element on, clockwise by hand until seal (consult supplier). contacts filter head, then turn an additional 3/4 turn (by hand). 3-158 – JLG Lift – 3121160...

  • Page 211: Coalescer (Air/Oil Separator) Replacement

    2. Fit new element inside housing. 3. Replace lid and tighten wing nut on top of air filter assembly. 4. Test run and functional test. 3121160 – JLG Lift – 3-159...

  • Page 212: Cooler Core Cleaning (Exterior)

    INCREASING AIR PRESSURE WILL INCREASE THE REQUIRED COMPRESSOR H.P. BE SURE THE HYDRAULIC POWER SUPPLY IS CAPABLE (HYDRAULIC PRESSURE) OTHERWISE THE COMPRES- SOR MAY STALL OUT DURING OPERATION DUE TO INCREASED POWER REQUIREMENT. 3-160 – JLG Lift – 3121160...

  • Page 213: Intake Control

    Compressor Thermal Valve HAS COOLED DOWN. Controls compressor oil temperature and permits for rapid compressor oil warm up. Commences to pass oil through cooler at 160°F (71°C) and is fully open at 185°F (85°C). 3121160 – JLG Lift – 3-161...

  • Page 214: Air Compressor Troubleshooting

    Dirt or ice, clean/free up f. Sol. valve not energized/faulty f. Check for power/replace g. Faulty gauge g. Check with shop air/replace h. Defective safety valve h. Replace i. Plugged coalescer i. Replace 3-162 – JLG Lift – 3121160...
  • Page 215 Clean f. Pressure set too high f. Readjust g. Contaminated cooler core g. Remove and clean h. Running too fast h. Check hydraulic flow & pressure i. Thermal Valve – element faulty i. Replace 3121160 – JLG Lift – 3-163...
  • Page 216 Adjust pressure switch to reduce air system pressure. f. Leak in solenoid valve cartridge f. Remove & check seals or fit new valve (directional flow control valve) on mani- cartridge. fold g. Check over-pressure or over-temper- ature 3-164 – JLG Lift – 3121160...

  • Page 217: Section 4 - Boom & Platform

    2. Remove the eight (8) bolts securing the platform to the platform support, then remove the platform. 3. Using an overhead crane or suitable lifting device, strap support the platform support. 3121160 – JLG Lift –...

  • Page 218: Support Installation

    6. Connect the electrical harness to the platform con- trol console. 3. Apply Loctite #242 to the eight (8) bolts and lock- nuts securing the support to the rotator and install the bolts and locknuts. – JLG Lift – 3121160...

  • Page 219: Rotator And Slave Cylinder

    #2. Using a suitable brass drift and hammer, remove pin #2 from the fly boom and remove the rotator. 4. Telescope the fly section out approximately 20 inches (50.8 cm) to gain access to the slave leveling cylinder. 3121160 – JLG Lift –...

  • Page 220: Main Boom Powertrack

    7. With powertrack supported and using all applicable safety precautions, remove bolts #3, #4 and #5 securing rail to the base boom section. Remove powertrack from boom section. Figure 4-4. Boom Power Track Components – JLG Lift – 3121160...

  • Page 221: Round Bar/Poly Bar Removal

    1. Use a small ¼” ratchet with a T-25 Torx bit. Remove the 10-24 x 0.812 screw. (If the bar spins then grip the bar and poly tightly with a vise-grip). 2. Lift up one end of the bar and slide the poly roller off. 3121160 – JLG Lift –...

  • Page 222: Removing And Installing Links

    2. Insert the tool into the rolled over end of the rivet as shown. Grind out the middle of the rivet until the rolled over part of the rivet falls off. Repeat this step for all rivets that must be removed. – JLG Lift – 3121160...
  • Page 223 Install the snap ring into the tion point is in the curved part of the track. This will groove in the pin. allow the round half-shears to be rotated in a way they will fit into the peanut-shaped cut-outs. 3121160 – JLG Lift –...
  • Page 224 NOTE: When installing snap rings make sure they are 6. Install more pins, washers, and snap rings into all seated in the pin groove and closed properly. the links where a rivet was removed. CLOSED SNAP RING SNAP RING NOT CLOSED PROPERLY – JLG Lift – 3121160...

  • Page 225: Installing A New Flat Bar

    Installing a New Round Bar/Poly Roller 1. While tightly holding the round bar, install the new 10-24 x 0.812 self threading torx screw. Next lift up NOTE: Maximum tightening torque for the 10-24 screw is 45-50 in-lbs (5-5.6 Nm). 3121160 – JLG Lift –...

  • Page 226: Replacing A Fixed End Bracket

    After the pins, washers, and new snap rings. After install- installing the new bracket make sure that it rotates ing a new bracket make sure that it rotates correctly. correctly. 4-10 – JLG Lift – 3121160...

  • Page 227: Replacing A One Piece Bracket

    1. Remove all pins, washers, and snap rings and slide rings. After installing the new bracket make sure that the bracket off of the links. it rotates correctly. 3121160 – JLG Lift – 4-11...

  • Page 228: Main Boom Assembly

    Cap hydraulic lines and ports. c. Remove the bolt and keeper pin securing the master cylinder barrel end pin to the base boom section. Next, install a 3/8-16 UNC threaded lift- 4-12 – JLG Lift – 3121160...

  • Page 229: Disassembly

    Replace pins as necessary. 4. Inspect inner diameter of boom pivot bearing for scoring, distortion, wear, or other damage. Replace bearing as necessary. (See Section 5, Cylinder Repair for bearing replacement). 3121160 – JLG Lift – 4-13...

  • Page 230: Upright

    Figure 4-5. Location of Components - Upright 6. Remove mounting hardware from the Upright Pivot Pin using a suitable brass drift and hammer. Remove pin # 4 from tower boom assembly. 4-14 – JLG Lift – 3121160...

  • Page 231: Inspection

    Using a soft head mallet, install the cylinder pin into tower fly boom and secure with mounting hardware. 4. Secure the sling and lifting device at the tower fly boom assembly’s approximate center of gravity. 3121160 – JLG Lift – 4-15...

  • Page 232: Tower Out Of Sync

    Replace the cartridge. They are pre-set. 5. The packing on either the upright or lower cylinder can cause this. Do cylinder tests to determine if either cylinder needs new packing. 4-16 – JLG Lift – 3121160...
  • Page 233 There could be a leak path 4. The packing on the lower lift cylinder can cause this. Do a cylinder test to check this out. Refer to Section 2.4, Cylinder Drift Test. 3121160 – JLG Lift – 4-17...

  • Page 234: Articulating Jib Boom

    #7. Using a suitable brass drift and hammer, remove welds, or other damage. Replace boom sections as the cylinder pin from articulating jib boom. necessary. Figure 4-6. Location of Components-Articulating Jib 4-18 – JLG Lift – 3121160...

  • Page 235: Assembly

    7. Align the slave leveling cylinder with attach holes in articulating jib boom pivot weldment. Using a soft head mallet, install slave leveling cylinder pin #1 into articulating jib boom pivot weldment and secure with mounting hardware. 3121160 – JLG Lift – 4-19...

  • Page 236: Boom Valve And Limit Switches Location

    SECTION 4 - BOOM & PLATFORM 0271989-A Figure 4-7. Boom Valve and Limit Switches Location 4-20 – JLG Lift – 3121160...

  • Page 237: Transportation Switch Installation. (Ce Only)

    SECTION 4 - BOOM & PLATFORM 0258384-A Figure 4-8. Transportation Switch Installation. (CE Only) 3121160 – JLG Lift – 4-21...
  • Page 238 SECTION 4 - BOOM & PLATFORM 4-22 – JLG Lift – 3121160...
  • Page 239 SECTION 4 - BOOM & PLATFORM 3121160 – JLG Lift – 4-23...

  • Page 240: Platform

    When adding shims, longer bolts must be used to ensure proper thread engagement in insert. b. When shims are removed, shorter bolts must be used so bolt does not protrude from insert and come into contact with boom surface. 4-24 – JLG Lift – 3121160...

  • Page 241: Main Boom

    When shims are removed, shorter bolts must be used so bolt does not protrude from insert and Sheaves and wire rope must be replaced as sets. Removing Portion Of End Cap 3121160 – JLG Lift – 4-25...

  • Page 242: Inspection

    3. Check the ring gear for wear and weld damage to the pins. 7. Remove the shaft (2) from piston sleeve (3) and the actuator housing (1). 4. Inspect the cylinder bore for wear and scratches. 4-26 – JLG Lift – 3121160...

  • Page 243: Assembly

    7. The end cap (5) is torqued to 40 - 50 ft. lbs. (54 - 68 Nm), such that the actuator begins rotation at approximately 100 psi (6.895 Bar) pressure. 8. The end cap must be secured against the shaft by installing axial set screws (4). 3121160 – JLG Lift – 4-27...

  • Page 244: Rotator Assembly (Helac)

    SECTION 4 - BOOM & PLATFORM Figure 4-14. Rotator Assembly (HELAC) 4-28 – JLG Lift – 3121160...

  • Page 245: Rotator Assembly (S/N 0300130881 To Present)

    - pounds rotation: shaft rota- tion is about twice that of the piston. 3121160 – JLG Lift – 4-29...

  • Page 246: Rotator - Exploded View (S/N 0300067538 To Present)

    420.2 Bushing 4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing 109 . Lock Pin 207. Backup Ring 113. Capscrew 304.1. Wiper Seal Figure 4-15. Rotator - Exploded View (S/N 0300067538 to Present) 4-30 – JLG Lift – 3121160...

  • Page 247: Rotator- Assembly Drawing (S/N 030013250 To Present)

    420.2 Bushing 4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing 109 . Lock Pin 207. Backup Ring 113. Capscrew 304.1. Wiper Seal Figure 4-16. Rotator- Assembly Drawing (S/N 030013250 to Present) 3121160 – JLG Lift – 4-31...

  • Page 248: Disassembly

    (4) by turning it counter clockwise. 3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). If the pin will not come out with the ”Easy Out”, use 4-32 – JLG Lift – 3121160...
  • Page 249 9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assem- bly. 3121160 – JLG Lift – 4-33...
  • Page 250 15. Remove the wear guides (302) from the end cap (4) 12. To remove the piston (3) use a rubber mallet and a and shaft (2). plastic mandrel so the piston is not damaged. 4-34 – JLG Lift – 3121160...
  • Page 251 17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2). 3121160 – JLG Lift – 4-35...

  • Page 252: Inspection

    2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within specifications (Not less than 0.092” or 2.34 mm). 4-36 – JLG Lift – 3121160...
  • Page 253 3. Install the wiper seal (304.1/green 0-ring) into it’s 5. Install the wear guide (302) on the end cap (4) and groove on the shaft (2) and end cap (4) around the shaft (2). outside edge of the thrust washer (304). 3121160 – JLG Lift – 4-37...
  • Page 254 Beginning with the inner seal (200) insert one end of b/u ring in the lower groove and feed the rest in using a circular motion. Make sure the wedged ends overlap correctly. Repeat this step for the outer seal (202). 4-38 – JLG Lift – 3121160...
  • Page 255 13. Install the stop tube onto the shaft end. Stop tube is an available option to limit the rotation of an actua- tor. 3121160 – JLG Lift – 4-39...
  • Page 256 19. Insert the set screws (113) over the lock pins. it is threaded into the housing (1). Tighten them to 25 in. lbs. (2.825 Nm). 4-40 – JLG Lift – 3121160...

  • Page 257: Installing Counterbalance Valve

    2. Make sure the new valve has the O-rings in the inch pounds (15.8 Nm). Do not torque over 145 inch counterbores of the valve to seal it to the actuator pounds (16.3 Nm). housing. Figure 4-17. Rotator Counterbalance Valve 3121160 – JLG Lift – 4-41...

  • Page 258: Testing The Actuator

    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 4-42 – JLG Lift – 3121160...

  • Page 259: Troubleshooting

    Operate the actuator through the housing ports. Conduct the internal leakage test as described in the Testing section on page 24 of this manual. c. Air in actuator c. Purge air from actuator. See bleeding proce- dures 3121160 – JLG Lift – 4-43...

  • Page 260: Drive Card Setup Procedures

    Turn P3 coun- ter clockwise until the adjustment pot starts clicking. 6. Install test harness JLG P/N 4922012. Place a current meter in series with the “A” output. 7. Set the minimum and maximum currents. The input...

  • Page 261: Foot Switch Adjustment

    Ramp Down Time = 2:30 sec. Ramp Up Time = 4:30 sec. Drive Reverse Ramp Down Time = 2:00 sec. Ramp Up Time =3:00 sec. Flow Control Figure 4-19. Releveling Valve Ramp Down Time =0.00 sec. 3121160 – JLG Lift – 4-45...
  • Page 262 SECTION 4 - BOOM & PLATFORM 4-46 – JLG Lift – 3121160...

  • Page 263: Calibration - Pre Ade Machines

    NOTE: Repeat step #4 if the correct access level is not dis- played. 5. Calibrate the Upright Monitoring System (UMS) sen- sors by the following procedure: THE UPRIGHT SENSOR AND TURNTABLE SENSOR WILL BE CALI- BRATED SIMULTANEOUSLY THROUGH THIS STEP. 3121160 – JLG Lift – 4-47...
  • Page 264 Start the machine and fully elevate the main boom. After the main boom has been fully ele- d. Press "ENTER" and the screen will display the following: vated, press "ENTER" . The analyzer will display the following: 4-48 – JLG Lift – 3121160...
  • Page 265 Continue to hold the tower boom down function for an additional twenty (20) seconds WITHOUT RELEASING THE FUNCTION SWITCH. The calibration must recognize continuous activation of the tower down function switch for the required time. 3121160 – JLG Lift – 4-49...
  • Page 266 DO NOT RAISE THE TOWER BOOM AGAIN DURING CALIBRA- TION. j. To correctly complete the calibration process, fully retract and fully lower the boom. Once the machine is in the stowed position, turn off the machine and disconnect the analyzer. 4-50 – JLG Lift – 3121160...

  • Page 267: Calibration - Ade Equipped Machines

    Calibration - ADE Equipped Machines b. After pressing 'ENTER" one of the following 1. Connect the JLG Hand-held analyzer to the original screens will be displayed: analyzer connection in the ground box. DO NOT CONNECT TO THE ANALYZER CONNECTION PORT INSTALLED WITH THE UPRIGHT MONITORING SYSTEM MODULE.
  • Page 268 NOTE: By pressing the left or right arrow keys in this screen, "ENTER" . The screen will display the fol- you may view the output of the sensor. lowing, asking you to fully elevate the main boom: 4-52 – JLG Lift – 3121160...
  • Page 269 (6) feet or two (2) meters. After elevating the t o w e r t h e r e q u i r e d d i s t a n c e , p r e s s "ENTER" 3121160 – JLG Lift – 4-53...
  • Page 270 (20) seconds WITHOUT RELEASING THE FUNCTION SWITCH. The calibration must recognize continuous activation of the tower down function switch for the required time. 4-54 – JLG Lift – 3121160...

  • Page 271: Calibration Faults

    DO NOT RAISE THE TOWER BOOM AGAIN DURING CALIBRA- TION. k. To correctly complete the calibration process, fully retract and fully lower the main boom. Once the machine is in the stowed position, turn off the machine and disconnect the analyzer. 3121160 – JLG Lift – 4-55...

  • Page 272: Function Check

    Using the arrows on the keypad, enter the password "33271" and press "ENTER" 5. Scroll left to right through the above menu items until "TEST UMS?" sub menu appears on the bottom line of the analyzer display. Press the "ENTER" key. 4-56 – JLG Lift – 3121160...

  • Page 273: Service Mode/Tower Boom Retrieval

    Upon the function test, the system will acti- vate the Upright Monitoring System, warning lights, and alarm. Verify that the alarm sounds, the boom malfunction indicator lights (platform and ground) are illuminated. 3121160 – JLG Lift – 4-57...
  • Page 274 Press the MODE appears. Press "ENTER" to select this menu item. After pressing "ENTER" one of the follow- ing screens will be displayed: "ENTER" key. 6. The controller will now display the following: 4-58 – JLG Lift – 3121160...
  • Page 275 Upon loss of power (pressing the EMS) to the sys- tem, the upright monitoring system will reset and all functionality will be restored to the machine. The flashing and scrolling messages will repeat until the "ENTER" key is pressed. 3121160 – JLG Lift – 4-59...

  • Page 276: Ums Sensor Location

    SECTION 4 - BOOM & PLATFORM THIS SENSOR ON NON ADE MACHINES ONLY Figure 4-21. UMS Sensor Location 4-60 – JLG Lift – 3121160...

  • Page 277: Ums Module Location

    SECTION 4 - BOOM & PLATFORM NON-ADE MACHINES MACHINES Figure 4-22. UMS Module Location 3121160 – JLG Lift – 4-61...

  • Page 278: Ums Module Pin Identification

    DIGITAL OUTPUT 2 (PWM, IF) CANBUS HIGH DIGITAL OUTPUT 3 (PWM, IF) CANBUS LOW DIGITAL OUTPUT 4 (PWM) ANALYZER TRANSMIT DIGITAL OUTPUT 5 (PWM) ANALYZER RECEIVE GRAY BLACK Figure 4-23. UMS Module Pin Identification 4-62 – JLG Lift – 3121160...

  • Page 279: Tower Lift Down Permanently Closed

    • Inspect harness, looking closely for possible short cir- cuits. • Inspect machine hydraulics. Battery voltage > 16.0 Volts 4/4 SYSTEM VOLTS HIGH Battery voltage is above 16V. Solution: • Inspect battery and alternator output. 3121160 – JLG Lift – 4-63...

  • Page 280: Ums Sensor Not Calibrated Message

    If the control system detects that either angle sensor has • Inspect harness and valve. not been calibrated, the ground boom malfunction lamp will flash at a 3 Hz rate until the system is calibrated or dis- abled. Solution: • Calibrate sensor. 4-64 – JLG Lift – 3121160...

  • Page 281: Turntable Sensor Faulted

    If the UMS detects a valid ground module software version Solution: but digital input 2 is not tied high the UMS module shall • Contact JLG if message is reoccurring. report a fault. 4.18 UMS TROUBLESHOOTING AND FAULT Solution: MESSAGES - ADE MACHINES •...

  • Page 282: Out Of Usable Range Message

    100Hz +/- 5Hz range or the duty cycle is outside 50% +/- 21% range the control system shall report a fault. Solution: • Inspect wire harness going to the sensor and UMS module. • Inspect sensor mounting. • Replace sensor. 4-66 – JLG Lift – 3121160...

  • Page 283: Use And Care Of Fall Arrest System

    Prior to use inspection should include a visual inspection of the following items: Cable: Proper tension, broken strands, corrosion. Fittings: Loose fittings and fractures, damage to hanger Transfastener: Damage, free and proper sliding Attaching Hardware: Loose, missing, properly tightened 3121160 – JLG Lift – 4-67...

  • Page 284: Annual Inspection And Certification

    If inspection services are required, contact: in place. Flexible Lifeline Systems 14325 West Hardy Rd. Houston, TX 77060 Phone: 281-448-8821 4-68 – JLG Lift – 3121160...

  • Page 285: Fall Arrest System

    SECTION 4 - BOOM & PLATFORM Transfastener Bracket Cable Swage/Slip Indicator Turnbuckle Line Tenser Figure 4-24. Fall Arrest System 3121160 – JLG Lift – 4-69...
  • Page 286 SECTION 4 - BOOM & PLATFORM NOTES: 4-70 – JLG Lift – 3121160...

  • Page 287: Section 5 - Hydraulics

    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. 3121160 – JLG Lift –...

  • Page 288: Dip Method

    3. O-ring Boss type fittings will require more pressure in able to immerse more of the fitting into the satu- rated sponge. This will also cause more oil to be dis- persed from the sponge. – JLG Lift – 3121160...

  • Page 289: Valves - Theory Of Operation

    4. If cylinder retract port leakage is less than 6-8 drops per minute, carefully reconnect hose to port and retract cylinder. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repair must be made. 3121160 – JLG Lift –...

  • Page 290: Cylinders With Single Counterbalance Valve

    This is done to relieve pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block. – JLG Lift – 3121160...

  • Page 291: Cylinder Repair

    TER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND ture. CYLINDER BARREL SURFACES. 8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel. 3121160 – JLG Lift –...

  • Page 292: Cleaning And Inspection

    16. Remove piston spacer, if applicable, from the rod. d. Using an arbor of the correct size, carefully press the bearing into steel bushing. 17. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer plate, if applica- – JLG Lift – 3121160...

  • Page 293: Assembly

    Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. NOTE: Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.

  • Page 294: Installation Of Head Seal Kit

    9. Thread piston onto rod until it abuts the spacer end and install the tapered bushing. NOTE: When installing the tapered bushing, piston and mat- ing end of rod must be free of oil. – JLG Lift – 3121160...

  • Page 295: Rod Assembly Installation

    Pressurize cylinder on retract to 80/100 psi to push rod guide firmly against the round retaining ring. (Apply 1 drop of loctite #242, 2 places, at 180° apart. Hand tighten nut, then tighten 1/4 turn with spanner wrench.) 3121160 – JLG Lift –...

  • Page 296: Cylinder Removal And Installation

    4. Remove the retaining rings that retain the telescope cylinder rod to the fly boom. 5. Using a suitable brass drift, carefully drive telescope cylinder rod pin from the fly boom. Figure 5-13. Components Main Boom and Tower Boom 5-10 – JLG Lift – 3121160...

  • Page 297: Main Boom Telescope Cylinder Installation

    Secure the pin in place with attaching hardware. 10. Remove boom prop and overhead crane. Activate hydraulic system. 3121160 – JLG Lift – 5-11...

  • Page 298: Upright Level Cylinder Removal

    10. Remove hydraulic line caps and correctly attach all the upright. tagged hydraulic and electrical lines. 11. Remove mounting hardware securing the upright 11. Remove overhead crane from upper boom. Activate level cylinder barrel end pin to the upright. hydraulic system. 5-12 – JLG Lift – 3121160...

  • Page 299: Tower Boom Lift Cylinder Removal

    6. Remove caps from cylinder hydraulic lines and cor- 6. Remove sling from the slave cylinder and support rectly install lines to cylinder as previously tagged. from platform. 3121160 – JLG Lift – 5-13...

  • Page 300: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication

    17 mm wrench. Using a 3 mm allen wrench adjust clockwise to increase, or counterclockwise to decrease. After adjusting the pressure, tighten the jam nut and replace the cover nut. Reconnect the wires on the upper lift coils. 5-14 – JLG Lift – 3121160...

  • Page 301: Main Control Valve Pressure Adjustments

    6. Platform Level Up 2. Upper Lift Down 7. Swing 3. Pressure Check Port 8. Steer Right 4. Platform Level Down 9. Pressure Check Port 5. Pressure CheckPort 10. Steer Figure 5-14. Main Control Valve Pressure Adjustments 3121160 – JLG Lift – 5-15...

  • Page 302: Location Of Components - Main Control Valve

    20. Control Valve (Main Lift) 27. Load Sensing Dump (Steer) 7. Relief Valve (Main Lift) 14. Relief Valve (Front Steer) 21. Cartridge Valve (Tower Tele) 28. Load Sensing Dump Figure 5-15. Location Of Components - Main Control Valve 5-16 – JLG Lift – 3121160...

  • Page 303: Cartridge Torque Values

    SECTION 5 - HYDRAULICS Table 5-3. Cartridge Torque Values Ft-Lbs. 18-20 24.5-27.2 12-14 16.3-19 25-27 34-36 33-37 44.9-50.3 5.4-6.8 60 in.lbs. 3121160 – JLG Lift – 5-17...

  • Page 304: Wheel Steer (If Equipped)

    Turn will give you 2000 PSI (138 Bar) at the cylinders. clockwise to increase, and counterclockwise to 8. Re-connect the front steer din connectors at the decrease. valve bank. 5-18 – JLG Lift – 3121160...

  • Page 305: Hydraulic Oil Change-Out Procedure

    (plug the port) and place into a container that will This procedure is written to change out JLG std. hydraulic hold approx. 10 gallons (38 L). Start the engine. Pull...

  • Page 306: Rexroth Variable Displacement Pump (Prior To S/N 0300121643)

    Failure to do so may cause considerable damage to the entire system. 5-20 – JLG Lift – 3121160...

  • Page 307: Variable Displacement Pump. (Rexroth)

    SECTION 5 - HYDRAULICS Figure 5-17. Variable Displacement Pump. (Rexroth) 3121160 – JLG Lift – 5-21...

  • Page 308: Sauer Piston Pump S/N 0300121643 To Present

    SAE J1926/1, 0.875-14 Outlet port B System gauge po rt M2 Inlet port S SAE J1926/1, 1.3125-12 SAE J1926/1, 0.4375-20 SAE J1926/1, 1.875-12 Case drain port L2 SAE J1926/1, 0.875-14 Figure 5-18. Gauge Port Locations 5-22 – JLG Lift – 3121160...

  • Page 309: Initial Start-Up Procedures

    Allow system to warm up before operation or use or low fluid temperature will not allow the pump to fluid with the appropriate viscosity grade for fill or control to operate properly. expected operating temperatures. 3121160 – JLG Lift – 5-23...

  • Page 310: Actuator Response Is Sluggish

    External relief valve setting must be above Pressure Compen- sator setting for proper operation. Check pump inlet pressure / vacuum. High inlet vacuum adds heat to system. Correct inlet pressure / vacuum conditions. 5-24 – JLG Lift – 3121160...

  • Page 311: Low Pump Output Flow

    Pressure Compen- sator setting for proper operation. Check external relief valve. Chattering external relief valve may cause unsta- Adjust or replace relief valve. ble feedback to pump control. 3121160 – JLG Lift – 5-25...

  • Page 312: System Pressure Not Reaching Pressure Compensator Setting

    Too many fittings, bends, or long piping will cause Eliminate fittings to make path more direct. high inlet vacuum. Hydraulic fluid viscosity above acceptable limits. High fluid viscosity causes high inlet vacuum. Select fluid with appropriate viscosity for expected operating temperature. 5-26 – JLG Lift – 3121160...

  • Page 313: Shaft Seal Replacement

    Install seal with the (C102), Pressure Compensator adjustment screw cupped side toward the shaft bearing. Do not dam- (C138),O-ring (C136), springs (C135, C134), and age the seal during installation. seat (C133). Discard the O-ring. 3121160 – JLG Lift – 5-27...
  • Page 314 (C300). Torque to 11-13 ft.lb. [15-18 Nm].Torque screws in a criss-cross pattern and re- torque the first screw to ensure proper torque reten- tion. 8. Check and adjust the control setting. See Adjust- ments. 5-28 – JLG Lift – 3121160...

  • Page 315: Plug And Fitting Sizes And Torques

    41-95 N•m 27-35 N•m [30-70 lbf•f t ] [20-26 lbf•f t ] K040 7/8 in J040 3/8 in (M14) 54-136 N•m [40-100 lbf•ft] 27-35 N•m [20-26 lbf•ft] Figure 5-20. Plug Locations, Sizes, and Torques 3121160 – JLG Lift – 5-29...
  • Page 316 SECTION 5 - HYDRAULICS NOTES: 5-30 – JLG Lift – 3121160...

  • Page 317: Section 6 - Jlg Control System

    WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC- The JLG Control System controller has a built in LED to OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A indicate any faults. The system stores recent faults which MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM...

  • Page 318: Analyzer Abbreviations

    SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING ACCEL ACCELERATE LENGTH ACTIVE LIMIT ANALOG DIGITAL CONVERTER COUNT LEVEL AMB. AMBIENT MINUTES ANGLE MINIMUM AUXILIARY MAXIMUM BOOM CONTROL SYSTEM MAIN BM or BLAM...

  • Page 319: Ade Block Diagram

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. ADE Block Diagram 3121160 – JLG Lift –...
  • Page 320 SECTION 6 - JLG CONTROL SYSTEM – JLG Lift – 3121160...
  • Page 321 SECTION 6 - JLG CONTROL SYSTEM 3121160 – JLG Lift –...
  • Page 322 SECTION 6 - JLG CONTROL SYSTEM – JLG Lift – 3121160...
  • Page 323 SECTION 6 - JLG CONTROL SYSTEM 3121160 – JLG Lift –...
  • Page 324 SECTION 6 - JLG CONTROL SYSTEM – JLG Lift – 3121160...
  • Page 325 SECTION 6 - JLG CONTROL SYSTEM 3121160 – JLG Lift –...
  • Page 326 SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3121160...
  • Page 327 SECTION 6 - JLG CONTROL SYSTEM 3121160 – JLG Lift – 6-11...

  • Page 328: Control Module Location

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-11. Control Module Location 6-12 – JLG Lift – 3121160...

  • Page 329: Analyzer Connecting Points

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-12. Analyzer Connecting Points 3121160 – JLG Lift – 6-13...

  • Page 330: Canbus Communications

    SECTION 6 - JLG CONTROL SYSTEM CANBUS COMMUNICATIONS USING THE ANALYZER CANbus: CAN (Control Area Network) is a two wire differ- With the machine power on and the analyzer connected ential serial link between the Platform Module and Ground properly, the analyzer will display the following: Module providing bi-directional communications.

  • Page 331: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DRIVE DIAGNOSTICS BOOM SYSTEM TEST SYSTEM ACCESS LEVEL...

  • Page 332: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM ADJUSTING PARAMETERS USING THE Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the pass- HAND HELD ANALYZER word. Once you have gained access to level 1, and a personality...

  • Page 333: Machine Setup

    To level machine chose: There is a setting that JLG strongly recommends that you CALIBRATION: do not change. This setting is so noted below: TILT SENSOR ELEVATION CUTBACK Press ENTER.

  • Page 334: Machine Configuration Programming Information Prior To Software Version P5.3

    SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 335 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;...
  • Page 336 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / MOTION CUTOUT: Motion cutout in platform mode only.
  • Page 337 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GROUND ALARM: NO: No ground alarm installed. DRIVE: Travel alarm sounds when the drive function is active (Option).

  • Page 338: Machine Configuration Programming Information Software Version P5.3 To P6.1

    SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 339 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
  • Page 340 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI.
  • Page 341 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / MOTION CUTOUT: Motion cutout in platform mode only.
  • Page 342 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number FUNCTION CUTOUT: NO: No drive cutout. * Only visible under certain BOOM CUTOUT: Boom function cutout while driving above elevation.

  • Page 343: Machine Configuration Programming Information Software Version P6.1 To Present

    SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 344 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
  • Page 345 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number STARTER LOCKOUT: DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
  • Page 346 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number GEN SET/WELDER: NO: No generator installed. BELT DRIVE: Belt driven setup. GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON.
  • Page 347 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LOAD SENSOR: 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform Module.
  • Page 348 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LEVELING MODE: ALL FUNCTIONS: Platform level with all functions. * Only visible on 800S LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
  • Page 349 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. Shaded cells indicate a hidden menu or selection.

  • Page 350: Machine Configuration Parameters

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Parameters Configuration Parameter Parameter Value Description Rang Definition Data Default Digit (Displayed on (Displayed on Analyzer Increment Value 2nd Line) Analyzer 1 Line) Model Number: 1=400 Displays/adjusts 2=450 machine model...
  • Page 351 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Parameters Tilt: 1=5Deg Displays/adjusts tilt 5 degree – reduces the maxi- 2=4Deg sensor function mum speed of all boom func- 3=3Deg tions to creep when tilted and above elevation. Reduces drive speed to creep when tilted ANSI (US);...
  • Page 352 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Parameters Head & Tail 0=NO Displays presence No Head and Tail Lights LIGHTS 1=YES of head and tail installed lights BROKEN Cable 0=NO Displays presence No Broken Cable Switch switch...
  • Page 353 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Parameters PLATFORM 0=NO Displays/adjusts Sounds Continuously When ALARM 1=FAULT CODE platform alarm Above Elevation And Tilted presence/functions Only. Sounds Continuously When Above Elevation And Tilted, And In Conjunction With Fault Code Flashes.

  • Page 354: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-6. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s...
  • Page 355 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS SWING ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed 0 to 65%...
  • Page 356 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS BASKET ROTATE ACCELeration 0.1 to 5.0 DECELeration 0.1 to 3.0 MlNimum LEFT speed 0 to 65 MAXimum LEFT speed 0 to 100 MINimum RIGHT speed 0 to 65...

  • Page 357: Help Fault Codes, Displayed Faults, And Descriptions - Prior To S/N 0300066931

    SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault None No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
  • Page 358 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 Flash code 2/3 indicates problems with boom function selection. LIFT/SWING JOYSTICK FAULTY The lift or swing joystick center tap is out of valid range, or the wiper is wire-off.
  • Page 359 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 Flash code 3/2 indicates that a contactor did not open when energized. NOT REQUIRED Flash code 3/3 indicates that a driver is short-circuit.
  • Page 360 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931 Flash code 9/9 indicates problems with the controller. PLATFORM MODULE FAILURE: Platform module V(Low) FET has failed hwfs CODE 1...

  • Page 361: Analyzer Fault Code Listing

    SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text EVERYTHING OK GROUND MODE OK 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0011 FSW OPEN 0012 RUNNING AT CREEP - CREEP SWITCH OPEN 0013...
  • Page 362 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text BRAKE - SHORT TO BATTERY BRAKE - OPEN CIRCUIT 3311 GROUND ALARM - SHORT TO BATTERY 3316 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND 3319...
  • Page 363 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text 3370 TWO SPEED VALVE - SHORT TO BATTERY 3371 GROUND ALARM - SHORT TO GROUND 3372 GROUND ALARM - OPEN CIRCUIT 3373 GEN SET/WELDER - SHORT TO GROUND...
  • Page 364 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text 33115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND 33116 TOWER TELESCOPE OUT VALVE - OPEN CIRCUIT 33117 TOWER TELESCOPE OUT VALVE - SHORT TO BATTERY...
  • Page 365 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text 33315 FLOW CONTROL VALVE - SHORT TO BATTERY 33316 FLOW CONTROL VALVE - SHORT TO GROUND 33317 DRIVE FORWARD VALVE - OPEN CIRCUIT 33318 DRIVE FORWARD VALVE - SHORT TO BATTERY...
  • Page 366 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text FUEL SENSOR - SHORT TO BATTERY FUEL SENSOR - SHORT TO GROUND OIL PRESSURE - SHORT TO BATTERY OIL PRESSURE - SHORT TO GROUND COOLANT TEMPERATURE - SHORT TO GROUND...
  • Page 367 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text 8311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY 8312 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT 8313 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE...
  • Page 368 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Analyzer Fault Code Listing Analyzer Text 9920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE 9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY 9922 PLATFORM MODULE FAILURE - HWFS CODE 1...

  • Page 369: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM Analyzer Diagnostics Menu Structure the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow In the following structure descriptions, an intended item is keys alter a value if allowed selected by pressing ENTER;...
  • Page 370 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. ADJUSTMENTS - Personality Descriptions SWING ACCEL … Displays/adjusts swing acceleration DECEL … Displays/adjusts swing deceleration MIN LEFT … Displays/adjusts minimum swing left speed MAX LEFT … Displays/adjusts maximum swing left speed CREEP LEFT …...
  • Page 371 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. ADJUSTMENTS - Personality Descriptions ACCEL … Displays/adjusts jib acceleration DECEL … Displays/adjusts jib deceleration MIN UP … Displays/adjusts minimum jib up speed MAX UP … Displays/adjusts maximum jib up speed MIN DOWN …...

  • Page 372: Diagnostic Menu Descriptions

    SECTION 6 - JLG CONTROL SYSTEM Table 6-10. Diagnostic Menu Descriptions DRIVE DRIVE FOR … Displays drive joystick direction & demand STEER … Displays steer switch direction & demand NOTE: steer demand is inversely proportional to vehicle speed BRAKES …...
  • Page 373 SECTION 6 - JLG CONTROL SYSTEM Table 6-10. Diagnostic Menu Descriptions PM BATTERY … Displays battery voltage at platform module TEMP ... Displays ground module temperature ELEV. CUTOUT … Displays elevation cutout switch status FUNC. CUTOUT … Displays function cutout switch status CREEP…...
  • Page 374 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-58 – JLG Lift – 3121160...

  • Page 375: Section 7 - Basic Electrical Information & Schematics

    Getting a negative Voltage or current reading when expecting a positive reading frequently means the leads are reversed. Check what reading is expected, the loca- tion of the signal and that the leads are connected to the 3121160 – JLG Lift –...

  • Page 376: Resistance Measurement

    Meter should produce an audible alarm, resistance indicating continuity • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads – JLG Lift – 3121160...

  • Page 377: Current Measurement

    NOTE: Do NOT apply dielectric grease to the following con- nections: • Main Boom Rotary sensor connections (on Celesco Sensor), • LSS Modules connections, • Deutz EMR 2 ECM connection. 3121160 – JLG Lift –...

  • Page 378: Amp Connector

    3. Install a hole plug into this and/or any unused wire lbs. to be sure the retention fingers are holding the seal that has silicone dielectric compound escaping contact (See Figure 7-7.). from it. Figure 7-6. AMP Connector – JLG Lift – 3121160...

  • Page 379: Connector Assembly Figure 2

    (See Figure 7-9.). Release the locking latches by squeezing them inward (See Figure 7-8.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8. Connector Assembly Figure 3 3121160 – JLG Lift –...

  • Page 380: Disassembly

    The wedge lock has slotted openings in the forward, or mat- ing end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. – JLG Lift – 3121160...

  • Page 381: Connector Installation

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11. Connector Installation 3121160 – JLG Lift –...

  • Page 382: Deutsch Connectors

    The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way. NOTE: The receptacle is shown - use the same procedure for plug. – JLG Lift – 3121160...

  • Page 383: Hd30/Hdp20 Series Assembly

    3. Pull contact-wire assembly out of connector. Figure 7-15. HD/HDP Locking Contacts Into Position Figure 7-17. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle. NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing 3121160 – JLG Lift –...

  • Page 384: Electrical Components Installation - Sheet 1 Of 2

    PRIOR TO S/N 0300112885 S/N 0300112885 TO PRESENT MAIN BOOM ELEVATION LIMIT SWITCH TOWER BOOM ELEVATION LIMIT SWITCH ANALYZER HEADLIGHTS GROUND CONTROL TAILLIGHTS DIAGNOSTIC ANALYZER Figure 7-18. Electrical Components Installation - Sheet 1 of 2 7-10 – JLG Lift – 3121160...

  • Page 385: Electrical Components Installation - Sheet 2 Of 2

    BATTERY VALVE DEUTZ) GLOW HYDRAULIC START PLUG PUMPS RELAY STARTER RELAY STROBE LIGHT RELAY MAIN CONTROL VALVE HORN VALVE FUEL VALVE LEVEL SENSOR ALARM Figure 7-19. Electrical Components Installation - Sheet 2 of 2 3121160 – JLG Lift – 7-11...

  • Page 386: Electrical Schematic - Deutz & Ford Engines - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20. Electrical Schematic - Deutz & Ford Engines - Sheet 1 of 2 7-12 – JLG Lift – 3121160...

  • Page 387: Electrical Schematic - Deutz & Ford Engines - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870163 D Figure 7-21. Electrical Schematic - Deutz & Ford Engines - Sheet 2 of 2 3121160 – JLG Lift – 7-13...

  • Page 388: Electrical Schematic - Deutz Emr2 & Gm Engines (Prior To S/N 99884) - Sheet 1 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-22. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to S/N 99884) - Sheet 1 of 6 7-14 – JLG Lift – 3121160...

  • Page 389: Electrical Schematic - Deutz Emr2 & Gm Engines (Prior To S/N 99884) - Sheet 2 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870199 F Figure 7-23. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to S/N 99884) - Sheet 2 of 6 3121160 – JLG Lift – 7-15...

  • Page 390: Electrical Schematic - Deutz Emr2 & Gm Engines (Prior To S/N 99884) - Sheet 3 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-24. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to S/N 99884) - Sheet 3 of 6 7-16 – JLG Lift – 3121160...

  • Page 391: Electrical Schematic - Deutz Emr2 & Gm Engines (Prior To S/N 99884) - Sheet 4 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870199 F Figure 7-25. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to S/N 99884) - Sheet 4 of 6 3121160 – JLG Lift – 7-17...

  • Page 392: Electrical Schematic - Deutz Emr2 & Gm Engines (Prior To S/N 99884) - Sheet 5 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to S/N 99884) - Sheet 5 of 6 7-18 – JLG Lift – 3121160...

  • Page 393: Electrical Schematic - Deutz Emr2 & Gm Engines (Prior To S/N 99884) - Sheet 6 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870199 F Figure 7-27. Electrical Schematic - Deutz EMR2 & GM Engines (Prior to S/N 99884) - Sheet 6 of 6 3121160 – JLG Lift – 7-19...

  • Page 394: Electrical Schematic - Deutz Emr2 & Gm Engines (S/N 99884 To Present) - Sheet 1 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28. Electrical Schematic - Deutz EMR2 & GM Engines (S/N 99884 to Present) - Sheet 1 of 6 7-20 – JLG Lift – 3121160...

  • Page 395: Electrical Schematic - Deutz Emr2 & Gm Engines (S/N 99884 To Present) - Sheet 2 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870220 C Figure 7-29. Electrical Schematic - Deutz EMR2 & GM Engines (S/N 99884 to Present) - Sheet 2 of 6 3121160 – JLG Lift – 7-21...

  • Page 396: Electrical Schematic - Deutz Emr2 & Gm Engines (S/N 99884 To Present) - Sheet 3 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-30. Electrical Schematic - Deutz EMR2 & GM Engines (S/N 99884 to Present) - Sheet 3 of 6 7-22 – JLG Lift – 3121160...

  • Page 397: Electrical Schematic - Deutz Emr2 & Gm Engines (S/N 99884 To Present) - Sheet 4 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870220 C Figure 7-31. Electrical Schematic - Deutz EMR2 & GM Engines (S/N 99884 to Present) - Sheet 4 of 6 3121160 – JLG Lift – 7-23...

  • Page 398: Electrical Schematic - Deutz Emr2 & Gm Engines (S/N 99884 To Present) - Sheet 5 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32. Electrical Schematic - Deutz EMR2 & GM Engines (S/N 99884 to Present) - Sheet 5 of 6 7-24 – JLG Lift – 3121160...

  • Page 399: Electrical Schematic - Deutz Emr2 & Gm Engines (S/N 99884 To Present) - Sheet 6 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870220 C Figure 7-33. Electrical Schematic - Deutz EMR2 & GM Engines (S/N 99884 to Present) - Sheet 6 of 6 3121160 – JLG Lift – 7-25...

  • Page 400: Hydraulic Schematic - Sheet 1 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-34. Hydraulic Schematic - Sheet 1 of 6 7-26 – JLG Lift – 3121160...

  • Page 401: Hydraulic Schematic - Sheet 2 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792535 B Figure 7-35. Hydraulic Schematic - Sheet 2 of 6 3121160 – JLG Lift – 7-27...

  • Page 402: Hydraulic Schematic - Sheet 3 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-36. Hydraulic Schematic - Sheet 3 of 6 7-28 – JLG Lift – 3121160...

  • Page 403: Hydraulic Schematic - Sheet 4 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792535 B Figure 7-37. Hydraulic Schematic - Sheet 4 of 6 3121160 – JLG Lift – 7-29...

  • Page 404: Hydraulic Schematic - Sheet 5 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-38. Hydraulic Schematic - Sheet 5 of 6 7-30 – JLG Lift – 3121160...

  • Page 405: Hydraulic Schematic - Sheet 6 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792535 B Figure 7-39. Hydraulic Schematic - Sheet 6 of 6 3121160 – JLG Lift – 7-31...
  • Page 406 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-32 – JLG Lift – 3121160...
  • Page 408 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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