JLG t350 Service And Maintenance Manual
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JLG t350 Service And Maintenance Manual

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Service and Maintenance Manual
Models
T350
P/N - 3121198
January 9, 2013

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  • Page 1 Service and Maintenance Manual Models T350 P/N - 3121198 January 9, 2013...

  • Page 3: Ageneral

    Every effort should be made to relieve any system • KEEP ALL SUPPORT EQUIPMENT AND ATTACH- pressure prior to disconnecting or removing any portion of MENTS STOWED IN THEIR PROPER PLACE. the system. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS. 3121198 – JLG Lift –...
  • Page 4 Revised - July 15, 2005 Revised - August 26, 2005 Revised - December 12, 2005 Revised - February 24, 2006 Revised - May 1, 2007 Revised - September 28, 2011 Revised - January 9, 2013 – JLG Lift – 3121198...

  • Page 5: Table Of Contents

    Lubrication Specifications ........... 2-4 3121198 – JLG Lift –...
  • Page 6 Welding on JLG Equipment ............2-6 Do the Following When Welding on JLG Equipment ......2-6 Do NOT Do the Following When Welding on JLG Equipment .
  • Page 7 Swing Drive Checks............3-55 3121198 – JLG Lift –...
  • Page 8 Battery Charger Fault Codes..........3-96 – JLG Lift –...
  • Page 9 Hydraulic Filter and Breather ........... . .5-12 3121198 – JLG Lift –...
  • Page 10 To Connect the JLG Control System Analyzer ........
  • Page 11 System Test Flow Chart - Ground Station Tests........6-13 3121198 – JLG Lift –...
  • Page 12 Hydraulic Schematic - Drive Option (Electric) - Sheet 2 of 2 ......7-31 viii – JLG Lift – 3121198...
  • Page 13 Connector Identification ............7-15 3121198 – JLG Lift –...

  • Page 14: Table No

    LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally. – JLG Lift – 3121198...

  • Page 15: Section 1 - Specifications

    3748 lbs. (1700 kg) CE Machines Speed Category DO NOT exceed axle rating or GVW rating. Inflation Pressure 50 psi (345 kPa) Wheel Nut Torque 90-120 ft. lbs. 66 ft. lbs. (122-164 Nm) (90 Nm) 3121198 – JLG Lift –...

  • Page 16: Engine

    Overall Width (outriggers down - CE) 11 ft 3 in (3.4 m) Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- tain the same required additives or be of comparable vis- cosities.

  • Page 17: Major Component Weights

    SECTION 1 - SPECIFICATIONS MAJOR COMPONENT WEIGHTS PRESSURE SETTINGS Cold temperatures have a significant impact on pressure Table 1-9. Component Weights readings. JLG Industries Inc. recommends operating the machine until the hydraulic system has warmed to normal Component Pounds Kilograms operating temperatures prior to checking pressures.

  • Page 18: Operator Maintenance & Lubrication

    Hydraulic Oil. API Service Classification GL-3, SAE 10W-20, Viscosity Index 152, e.g. Mobil- fluid 424. Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L- 2104B/MIL-L-2104C. Open Gear Lubricant - Mobiltac 375 or equiva- lent. – JLG Lift – 3121198...
  • Page 19 Interval - As Required DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN BLOWING OUTER SEALS IN HOUSING. Interval - 100 hours Comments - Change after the first 20 hours, then every 100 hours of operation. 3121198 – JLG Lift –...
  • Page 20 12. Jockey Wheel Bearing (Drive and Set Option Only) GREASE Capacity - As necessary Lube - MPG & EO Lube Point(s) - 1 Grease Fittings Interval - As necessary Capacity - As Required Lube - MPG Interval - As Required – JLG Lift – 3121198...

  • Page 21: Torque Chart (Sae Fasteners - Sheet 1 Of 7)

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N Loctite® P/N...

  • Page 22: Torque Chart (Sae Fasteners - Sheet 2 Of 7)

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7) – JLG Lift – 3121198...

  • Page 23: Torque Chart (Sae Fasteners - Sheet 3 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7) 3121198 – JLG Lift –...

  • Page 24: Torque Chart (Sae Fasteners - Sheet 4 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7) 1-10 – JLG Lift – 3121198...

  • Page 25: Torque Chart (Metric Fasteners - Sheet 5 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7) 3121198 – JLG Lift – 1-11...

  • Page 26: Torque Chart (Metric Fasteners - Sheet 6 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 1-12 – JLG Lift – 3121198...

  • Page 27: Torque Chart (Metric Fasteners - Sheet 7 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 3121198 – JLG Lift – 1-13...
  • Page 28 SECTION 1 - SPECIFICATIONS NOTES: 1-14 – JLG Lift – 3121198...

  • Page 29: 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 30: 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 Inspection In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance ever comes first;...

  • Page 31: Component Disassembly And Reassembly

    If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 3121198 – JLG Lift –...

  • Page 32: Lubrication And Information

    2. The design and manufacturing tolerances of the for assistance in selecting the proper equivalent. component working parts are very close, therefore, Avoid mixing petroleum and synthetic base oils. JLG even the smallest amount of dirt or foreign matter Industries recommends changing the hydraulic oil entering a system can cause wear or damage to the annually.

  • Page 33: Cylinder Drift Test

    If the cylinder passes this test, it is acceptable. tion. NOTE: This information is based on 6 drops per minute cyl- inder leakage. 3121198 – JLG Lift –...

  • Page 34: Welding On Jlg Equipment

    • Ground on turntable and weld on any other area than Do the Following When Welding on JLG the turntable. Equipment • Ground on the platform/support and weld on any other area than the platform/support.

  • Page 35: Maintenance Schedule

    NOTE: 1 = Retighten when new and at the first 10, 25 and 50 miles 2 = Adjust after first 200 miles, 3000 mile intervals or as use requires. 3 = 1000 miles or 1 month when used in hot and dry environment. 3121198 – JLG Lift –...
  • Page 36 SECTION 2 - GENERAL NOTES: – JLG Lift – 3121198...

  • Page 37: Section 3 - Chassis & Turntable

    If you do not have these Manually Adjusting Brake Shoes instructions, call your dealer or JLG to obtain a copy. A hard stop is used to: The manually adjusted brakes should be adjusted in the following manner: •...

  • Page 38: Electric Brakes

    This movement in turn actuates the secondary the magnet to grip the armature surface of the brake drum shoe through the adjuster link assembly. Braking in more firmly. This results in increasing the pressure against – JLG Lift – 3121198...

  • Page 39: Self Adjusting Mechanism

    1. Jack up trailer and secure on adequate capacity jack stands. check that the wheel and drum rotate freely. 2. Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate. 3121198 – JLG Lift –...

  • Page 40: Hubs, Drums, Wheel Bearings

    0.015 in. (0.38 mm), then the drum cup is seated all the way up against the retaining surface should be re-machined. If scoring or other shoulder in the hub. wear is greater than 0.090 in. (2.28 mm) on the – JLG Lift – 3121198...

  • Page 41: Bearing Lubrication

    If there is any question of condition, replace the seal. 5. Bend over the cotter pin legs to secure the nut. To replace the seal: NOTE: The nut should be free to move with the only restraint being the cotter pin. 3121198 – JLG Lift –...

  • Page 42: Hub And Brake Assembly

    6. Wheel Stud 10. Spindle Nut 14. Hub 3. Inner Bearing Cup 7. Outer Bearing Cup 11. Cotter Pin 4. Brake Assembly 8. Outer Bearing Cone 12. Grease Cap Figure 3-3. Hub and Brake Assembly – JLG Lift – 3121198...

  • Page 43: Tires & Wheels

    Please drum smooth only if under maximum diameter. Replace refer to the JLG Parts Manual for the part number of the as necessary. approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that TIRES &...

  • Page 44: Wheel Installation

    25 AND 50 MILES OF DRIVING. METAL CREEP BETWEEN THE WHEEL RIM AND LUG NUTS WILL RESULT IN A WHEEL COMING OFF, LEADING TO DEATH OR SERI- OUS INJURY. TIGHTEN LUG NUTS BEFORE EACH TOW. – JLG Lift – 3121198...

  • Page 45: Spare Tire (Optional)

    THE TWO SLOTS IN THE MOUNTING PLATE AND INSERT CARRIAGE BOLTS THROUGH FROM THE BACK SIDE. ASSEMBLE WHEEL NUTS TO THIS SIDE INSERT CARRIAGE BOLTS SO THAT THE SQUARE NECKS ARE IN SLOTS ON THIS SIDE AS SHOWN Figure 3-4. Spare Tire (Optional) 3121198 – JLG Lift –...

  • Page 46: Hydraulic Brake Coupler

    Replace actuator Worn brake shoe(s) Replace brake shoe(s) Towing Vehicle Shaking Back and Forth Worn vehicle suspension Replace shock absorber Hitch not secure Tighten all bolts and nuts Under-sized hitch ball Replace with proper size 3-10 – JLG Lift – 3121198...

  • Page 47: Bleeding The Brake System

    1/2" (13 mm) from the top of the reservoir. 6. When no air bubbles are visible, close the bleeder valve securely and remove the bleeder hose. 7. Repeat steps 1 thru 6 for the remaining brake. 3121198 – JLG Lift – 3-11...

  • Page 48: Backing Up

    DO NOT USE THE BREAKAWAY CABLE AS A PARKING BRAKE. CHECK THE LOCATION OF THE BREAKAWAY CABLE PERIODI- CALLY DURING EACH TRIP. THE INDICATOR SHOULD REST AGAINST THE SPRING STOP. ACCIDENTAL APPLICATION WILL CAUSE BRAKES TO DRAG AND HEAT UP. 3-12 – JLG Lift – 3121198...

  • Page 49: Maintenance

    2. Check for leaks in the brake system. Periodic checks should be made on all hoses and fittings to guard against cuts and worn hoses which may cause failure (leaks, rupturing under pressure, and collapsing). Replace defective hoses. 3121198 – JLG Lift – 3-13...

  • Page 50: Combination Coupler

    To adjust the brakes, release the emergency lever from the locked position, set each wheel’s brake adjust- ment up 2 or 3 notches. 9. Repeat the test procedure as necessary. 3-14 – JLG Lift – 3121198...

  • Page 51: Hydraulic Brake Coupler

    34. Piston 11. Locknut 5. Release Handle 17. S-Hook 23. Flatwasher 29. Flatwasher 35. Housing 12. Not Used 6. Master Cylinder 18. Bolt 24. Locknut 30. Bracket 36. Hitch Figure 3-5. Hydraulic Brake Coupler 3121198 – JLG Lift – 3-15...

  • Page 52: Combination Coupler

    55. Channel Centered 5. Not Used 12. Emergency Lever 18. Push Rod & Piston Guide Slider 6. Damper Shock Spring Plate Assembly 24. Boot 13. Bolt 19. Nut 25. Pin Outer Case Figure 3-6. Combination Coupler 3-16 – JLG Lift – 3121198...

  • Page 53: Hitch Coupler & Axle (Ce Only)

    Maintenance, repairs, and replacement of wearing parts for the chassis and the braking system may only performed by a qualified garage. Only original JLG parts may be used in order to: • ensure proper functioning and safety • preserve all rights under warranty •...
  • Page 54 If it takes longer than approxi- mately 30 seconds to return, the over-run hitch must be checked at a qualified workshop. 3-18 – JLG Lift – 3121198...

  • Page 55: Coupling Head Maintenance

    DO NOT re-use the old nuts as this is safety must be replaced by carefully following the replace- critical. On a T350, torque to 85 ft. lbs. (115 Nm), on ment instructions above. a T500J, torque to 214 ft. lbs. (290 Nm). Fit the plas- tic nut covers.

  • Page 56: Damper Maintenance

    Undo the self locking nut from the front bolt, extract the bolt and remove the head. b. Replace both bolts in the draw tube and finger tighten the bolts. 3-20 – JLG Lift – 3121198...

  • Page 57: Brake Maintenance

    CLEAN THE DRUM. CAREFULLY REMOVE THE DUST USING A SMALL BRUSH. 4. Follow the procedure under ADJUSTMENT. 6. Check the condition of the brake drum. Replace the brake drum if deep score marks are visible. 3121198 – JLG Lift – 3-21...

  • Page 58: Brake Assembly

    19. Drawbar Eye 4. Dust Cap 10. Tension Spring (Top) 15. Adjusting Bolt 20. Protective Sleeve 5. Flanged Nut 11. Tension Spring (Bottom) 16. Bolt 21. Brake Cable 6. Bearing Figure 3-7. Brake Assembly 3-22 – JLG Lift – 3121198...
  • Page 59 8. The brake adjustment should be rechecked after a 20. Install the hub cap. short journey. 21. Repeat the procedure on the other drum. 22. Install the tires and wheels. THE DRUMS MAY BE HOT. 23. Follow the procedure under ADJUSTMENT. 3121198 – JLG Lift – 3-23...

  • Page 60: Adjustment And Readjustment Of The Overrun Braking System

    They should be at right angles to the direction of 5. Drawbar & Bellows towing. Figure 3-8. Overrun Brake System c. If necessary, adjust the position of the balance (10) and control cables (11). 3-24 – JLG Lift – 3121198...
  • Page 61 The main purpose of readjusting the braking system is compensate for brake lining wear. To readjust the wheel brakes, follow the instructions under ADJUSTING THE BRAKING SYSTEM. Check the play in the linkage and readjust if necessary. 3121198 – JLG Lift – 3-25...

  • Page 62: Troubleshooting

    50 mm in diameter when new and it must be Ø 49.5 mm. If the ball diameter decreases to less than 49.0 mm, the ball has to be replaced. The ball must be perfectly spherical. 3-26 – JLG Lift – 3121198...

  • Page 63: Coupler Assembly (S/N 0030002099 To Present)

    Damaged parts must IN LINE WITH FRONT OF be replaced. If there is any damage to the lanyard itself ACCESS HOLE) the entire pushrod assembly will need to be replaced. 3121198 – JLG Lift – 3-27...

  • Page 64: Coupler Assembly - S/N 0030002099 To Present

    4. Cap 10. Bottom Slide 16. Locknut 22. Spacer 5. Capscrew 11. Damper Shock 17. Locknut 23. Lever 6. Capscrew 12. Spacer 18. Bracket 24. Fitting Figure 3-9. Coupler Assembly - S/N 0030002099 to Present 3-28 – JLG Lift – 3121198...

  • Page 65: Actuator Maintenance

    4. Grease pivot hinge with automotive grease. 3121198 – JLG Lift – 3-29...

  • Page 66: Trailer Jack (Solid Wheels)

    To place the jack into the horizontal position, allow about 2" (5 cm) of ground clear- ance beneath the wheels. Pull the plunger pin out of the opening and swivel the jack. Rotate either left or right until 3-30 – JLG Lift – 3121198...

  • Page 67: Assembly

    The wheel must spin freely. 3. Loosen and remove the bolts holding the motor assembly together. 4. Remove the end cover. 5. Remove the body seal and discard the seal. 3121198 – JLG Lift – 3-31...

  • Page 68: Assembly

    6. Place the seal carrier onto the shaft (large end down) and carefully press the seal carrier down onto the seal assembly using an arbor press and sleeve to compress the seals into the carrier. 3-32 – JLG Lift – 3121198...

  • Page 69: Shaft Timing Procedure

    5. Turn the housing over so the pilot of the housing faces down and secure the housing in a vise. 6. Without disturbing the seal carrier assembly or drive link, carefully lower the shaft assembly into the housing. 3121198 – JLG Lift – 3-33...

  • Page 70: Installation

    15. Using alignment marks as a guide, place the end 120 ft.lbs. (163 Nm). cover onto the motor making sure the end of the drive link pin is in the hole in the center of the end cover. 3-34 – JLG Lift – 3121198...

  • Page 71: Swing Motor

    3. Backup Shim 8. Thrust Bearing 13. Housing 18. Shaft 4. Housing Seal 9. Wear Plate 14. Drive Link 19. Key 5. Body Seal 10. End Cover 15. Rotor Set Figure 3-13. Swing Motor 3121198 – JLG Lift – 3-35...

  • Page 72: Swing Motor (S/N 0030001050 To Present)

    Inspect bolts for damaged threads, or seal- port O-Rings (18A) if applicable. ing rings, under the bolt head. Replace damaged bolts. IFTHETORQLINK™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED DURINGTHE SERVICE PROCEDURES, CAUSING INJURY. 3-36 – JLG Lift – 3121198...

  • Page 73: Swing Drive Motor

    4. Remove end cover assembly (2) and seal ring (4). NOTE: Refer to the appropriate “alternate cover construc- Discard seal ring. tion” on the exploded view to determine the end cover construction being serviced. 3121198 – JLG Lift – 3-37...
  • Page 74 (5) is normal. Discolor- ation would indicate excess fluid temperature, ther- mal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set. 3-38 – JLG Lift – 3121198...
  • Page 75 Marking the sur- ends of rotor. face of the rotor and stator that is facing UP, with etching ink or grease pencil before removal from Torqlink™ will ensure correct reassembly of rotor 3121198 – JLG Lift – 3-39...
  • Page 76 NOTE: A slight “polish” is permissible in the shaft bearing seal and bearing. Crocus cloth or fine emery paper areas. Anything more would require coupling shaft may be used. replacement. 16. 16. Remove and discard seal ring (4) from housing (18). 3-40 – JLG Lift – 3121198...
  • Page 77 Small Frame, housing (18). Discard both. rosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assem- bly. 3121198 – JLG Lift – 3-41...
  • Page 78 (19) and (13) from hous- ing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13). 3-42 – JLG Lift – 3121198...

  • Page 79: Assembly

    Torqlink™ housings require the use of bearing man- drel to press bearing/ bushing (19) into the housing to a required depth of 0.151/0.161 inches (3.84/4.09 mm) from the end of the bearing counterbore. 3121198 – JLG Lift – 3-43...
  • Page 80 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing. 3-44 – JLG Lift – 3121198...
  • Page 81 ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16). 3121198 – JLG Lift – 3-45...
  • Page 82 11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). 9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. 3-46 – JLG Lift – 3121198...
  • Page 83 (9). 3121198 – JLG Lift – 3-47...
  • Page 84 If the end cover has only 5 position. bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The correct 5 3-48 – JLG Lift – 3121198...

  • Page 85: One Piece Stator Construction

    (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required. 3121198 – JLG Lift – 3-49...

  • Page 86: Installation

    Torque the bolts to the rotor and the assembled vanes (8C) into stator 120 ft.lbs. (163 Nm). (8B), creating the necessary clearance to assemble 3-50 – JLG Lift – 3121198...

  • Page 87: 3.14 Swing Bearing

    Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bear- ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.

  • Page 88: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 1. Inner Race Bolt 2. Outer Race Bolt 3. Inner Bearing Cup 4. Swing Motor 5. Bearing 6. Swing Arm Figure 3-16. Swing Bearing 3-52 – JLG Lift – 3121198...

  • Page 89: Wear Tolerance

    Discard the bolts. Use suitable lifting equipment to remove the bearing from the frame, then move the bearing to a clean, suitably supported work area. Figure 3-17. Swing Bearing Tolerance Measuring Point 3121198 – JLG Lift – 3-53...

  • Page 90: Swing Bearing Installation

    JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN...

  • Page 91: Swing Bearing Torque Values

    Swing Bearing Torque Values 1. Outer Race - 130 ft.lbs. (180 Nm) 2. Inner Race - 130 ft.lbs. (180 Nm) 3. See Swing Bearing Torquing Sequence. 3121198 – JLG Lift – 3-55...

  • Page 92: Swing Bearing Torque Sequence

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races. Figure 3-19. Swing Bearing Torque Sequence 3-56 – JLG Lift – 3121198...

  • Page 93: 3.15 Engine

    Checking RPM Level 1. Connect the JLG Analyzer to the ground control NOTE: Refer to the engine manufacturer’s manual for box. Refer to Section 6.2, To Connect the JLG Con- detailed operating and maintenance instructions. trol System Analyzer. Throttle & Choke Adjustment 2.

  • Page 94: Choke Actuator

    6. Fully seat the dipstick and remove again. 7. Check the oil level, and if necessary, top the oil level with an approved grade and type of oil as outlined in the engine manufacturer’s operator’s manual. 3-58 – JLG Lift – 3121198...

  • Page 95: Engine Assembly

    18. Oil Fill Plug 3. Heat Shield 7. Muffler 11. Choke Relay 15. Choke Solenoid Actuator 19. Battery 4. Starter 8. Dipstick 12. Engine Stop Relay 16. Pump 20. Battery Hold-Down Figure 3-20. Engine Assembly 3121198 – JLG Lift – 3-59...

  • Page 96: Outrigger Cylinder And Stabilizer

    4. Lift the outrigger cylinder slightly up out of the frame to gain better access to the hydraulic lines running to the cylinder. Tag and disconnect the lines from the cylinder and cap or plug all openings. 3-60 – JLG Lift – 3121198...

  • Page 97: Installation

    7. Function the outriggers several times to check for proper operation and any leakage. 3. Install the bolt and keeper securing the pin at the pad end of the stabilizer and install the pin. 3121198 – JLG Lift – 3-61...

  • Page 98: Outrigger Assembly

    SECTION 3 - CHASSIS & TURNTABLE 1. Outrigger Pad 7. Keeper 2. Stabilizer 8. Pin 3. Cylinder Cover 9. Outrigger Pin 4. Cylinder 10. Retaining Cup 5. Pad Rod 11. Outrigger Cam Pin 6. Bolt Figure 3-21. Outrigger Assembly 3-62 – JLG Lift – 3121198...

  • Page 99: 3.17 Outrigger Limit Switches

    2. Utilizing the service outrigger retract harness (JLG functions will be cut back in the event two outriggers are P/N 4923341), locate the wire labeled outrigger...

  • Page 100: 3.19 Leveling, Tilt Sensor Calibration

    PUMP HANDLE 8. Disconnect the service outrigger harness from the four outriggers and control valve. Reconnect the wir- ing connectors to each cylinder’s solenoid and the solenoid on the control valve. 3-64 – JLG Lift – 3121198...

  • Page 101: Setup When Machine Is Not On Firm Level Surface And Adjustment Procedure

    1.0° analyzer: Use the right arrow key to reach DIAGNOSTICS, down arrow key once , right arrow key to scroll over to SYSTEM, then the down arrow key to reach Tilt 3121198 – JLG Lift – 3-65...

  • Page 102: 3.20 Drive & Set

    Ground Control Module through the CANBUS system. The Drive Enable Valve sends oil to either the Main Valve Bank for boom functions or the Drive Directional Valve. A 3-66 – JLG Lift – 3121198...

  • Page 103: Drive & Set Interlocks

    4. Pull the Enable trigger Mechanical switch on the lift cylinder that can sense main boom above horizontal 5. Joystick must be moved within 7 seconds (after 7 seconds, begin with trigger switch again) 3121198 – JLG Lift – 3-67...

  • Page 104: Drive And Set - Sheet 1 Of 2

    3. Proximity Sensor 9. Drive Directional Valve 4. Propulsion Module 10. Drive Motor 5. Drive Engagement Release Valve 11. Proximity Sensor 6. Brake Release Cylinder Figure 3-22. Drive and Set - Sheet 1 of 2 3-68 – JLG Lift – 3121198...

  • Page 105: Drive And Set - Sheet 2 Of 2

    Adjust the switch mounting so the cylinder barrel moves forward completely off the target zone of the limit switch when the parking brake is engaged. Figure 3-23. Drive and Set - Sheet 2 of 2 3121198 – JLG Lift – 3-69...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 3-70 – JLG Lift – 3121198...

  • Page 107: 3.21 Drive Motor

    16 or 3/8 inch Allen wrench or 1 inch hex socket Discard seal ring. required. NOTE: Refer to the appropriate “alternate cover construc- tion” on the exploded view to determine the end cover construction being serviced. 3121198 – JLG Lift – 3-71...
  • Page 108 CAVITY WHEN THE PLUGS ARE REMOVED. NOTE: The insert and if included the orifice plug in the end cover (2) must not be removed as they are serviced as an integral part of the end cover. 3-72 – JLG Lift – 3121198...
  • Page 109 A polished pattern on the ground surface from commutator or rotor rota- tion is normal. Remove and discard the seal rings (4) that are on both sides of the manifold. 3121198 – JLG Lift – 3-73...

  • Page 110: Assembly

    NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets of seven vanes (8C & 8E) as shown in the alternate construction TG rotor set assembly view, check the rotor lobe to roller vane clearance at both ends of rotor. 3-74 – JLG Lift – 3121198...
  • Page 111 NOTE: A slight “polish” is permissible in the shaft bearing seal and bearing. Crocus cloth or fine emery paper areas. Anything more would require coupling shaft may be used. replacement. 16. 16. Remove and discard seal ring (4) from housing (18). 3121198 – JLG Lift – 3-75...
  • Page 112 Small Frame, housing (18). Discard both. rosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assem- bly. 3-76 – JLG Lift – 3121198...
  • Page 113 (19) and (13) from hous- ing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13). 3121198 – JLG Lift – 3-77...

  • Page 114: Assembly

    Torqlink™ housings require the use of bearing man- drel to press bearing/ bushing (19) into the housing to a required depth of 0.151/0.161 inches (3.84/4.09 mm) from the end of the bearing counterbore. 3-78 – JLG Lift – 3121198...
  • Page 115 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore. The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing. 3121198 – JLG Lift – 3-79...
  • Page 116 ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16). 3-80 – JLG Lift – 3121198...
  • Page 117 11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). 9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. 3121198 – JLG Lift – 3-81...
  • Page 118 (9). 3-82 – JLG Lift – 3121198...
  • Page 119 If the end cover has only 5 position. bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The correct 5 3121198 – JLG Lift – 3-83...

  • Page 120: One Piece Stator Construction

    (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly. Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required. 3-84 – JLG Lift – 3121198...
  • Page 121 5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B), creating the necessary clearance to assemble 3121198 – JLG Lift – 3-85...

  • Page 122: Batteries (Electric Machines)

    5. When all cables and terminal posts have been weighs 59 lbs. (26.8 kg). Do not use batteries that cleaned, ensure all cables are properly positioned are not approved by JLG. and do not get pinched. Close battery compartment cover.
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE 1. Contactor Assembly 2. Fuse 3. Clamping Bar 4. Relay 5. Battery 6. Battery Pad 7. Tie Down Strap 8. Rubber Tape Figure 3-26. Battery and Contactor Installation - Sheet 1 of 2 3121198 – JLG Lift – 3-87...
  • Page 124 Torque nuts on fuse to 120 in.lbs. (13.5 Nm) Torque contactor nuts to 45 in.lbs. (5 Nm) 9. Sevcon Controller 10. Relay 11. Ground Control Module Figure 3-26. Battery and Contactor Installation - Sheet 2 of 2 3-88 – JLG Lift – 3121198...

  • Page 125: Battery Cable Routing

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-26. Battery Cable Routing 3121198 – JLG Lift – 3-89...

  • Page 126: 3.23 Battery Charger

    The VP Series battery charger allows for replacement of the following internal components. Consult your Illustrated Parts Manual for part numbers of these components which are available from the JLG Parts Department: • Transformer • Printed Circuit Board • Shunt Assembly •...

  • Page 127: Printed Circuit Board Replacement

    Also make note of the position of each washer, nut and wire connector when removing for later assembly. 3. Remove the SCR Rectifier. 3121198 – JLG Lift – 3-91...

  • Page 128: Ac Circuit Breaker Replacement

    LOCKING TABS 3. Remove the breaker from the chassis. 3-92 – JLG Lift – 3121198...

  • Page 129: Battery Charger

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-27. Battery Charger Schematic 3121198 – JLG Lift – 3-93...
  • Page 130 1. Selector Switch 6. DC Harness 2. AC Circuit Breaker 7. DC Circuit Breaker 3. Interlock Relay 8. SCR Rectifier 4. Varistor 9. Transformer 5. Shunt Assembly 10. Circuit Card Figure 3-28. Battery Charger 3-94 – JLG Lift – 3121198...

  • Page 131: 3.24 Battery Charger

    The charger may now be unplugged from AC power. If left plugged in, the charger will automatically restart a complete charge cycle if battery voltage drops below a mini- mum voltage or 30 days have elapsed. 3121198 – JLG Lift – 3-95...
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-96 – JLG Lift – 3121198...

  • Page 133: Section 4 - Boom & Platform

    5. Using an adequate lifting device, position straps 5. Operate all boom functions and check for proper around the boom and cylinders assembly, taking operation or any leakage. care to ensure the weight of the assembly is evenly distributed. 3121198 – JLG Lift –...

  • Page 134: Main Boom

    5. Remove the bolt, nut, and pivot pin securing the top of the timing link to the boom. 6. Remove the bolt, keeper pin, and pivot pin securing the boom to the turntable. Lift the boom away from – JLG Lift – 3121198...
  • Page 135 NOTE: The pivot weighs approximately 19 lbs. (9 kg). 4. Remove the slave cylinder. Refer to Section 4.4, 7. Pull the telescope cylinder out from the rear of the Slave Cylinder. boom. 3121198 – JLG Lift –...

  • Page 136: Assembly

    10. If necessary, remove the wear pads from the rear of 3. If removed, install the wear pads into the front of the the fly section. boom base section. Apply loctite #242 to the bolts and torque to 35 ft.lbs. (47 Nm). – JLG Lift – 3121198...
  • Page 137 Cylinder. 5. Install the retaining rings and attach pins securing the telescope cylinder to the boom fly section. 8. Position the pivot onto the boom assembly. NOTE: The pivot weighs approximately 19 lbs. (9 kg). 3121198 – JLG Lift –...

  • Page 138: Installation

    5. Install the master cylinder. Refer to Section 4.3, Mas- ter Cylinder. 6. Operate the boom through all functions and check for proper operation or any leakage. – JLG Lift – 3121198...

  • Page 139: Master Cylinder

    3. Connect the hydraulic hoses to the master cylinder as tagged during removal. 4. Cycle the master cylinder several times to check for proper operation and any leakage. NOTE: The master cylinder weighs approximately 18 lbs. (8 kg). 3121198 – JLG Lift –...

  • Page 140: Slave Cylinder

    3. Connect the hoses running to the slave cylinder as tagged during removal. 4. Function the slave cylinder through several cycles and check for proper operation and any leakage. NOTE: The slave cylinder weighs approximately 23 lbs. (10 kg). – JLG Lift – 3121198...

  • Page 141: Boom And Cylinders Assembly

    12. Upright 3. Retaining Pin 8. Tower Boom 13. Timing Link 4. Pivot Pin 9. Tower Boom Link 14. Powertrack 5. Boom Rest 10. Master Cylinder 15. Slave Cylinder Figure 4-1. Boom and Cylinders Assembly 3121198 – JLG Lift –...

  • Page 142: Boom Sensors

    BOOM ELEVATION LIMIT SWITCH 1. Set the limit switch to trip at 3.8° above horizontal (Main Boom Position). 2. Set the switch to reset at 1° below horizontal (Main Boom Position). 4-10 – JLG Lift – 3121198...

  • Page 143: 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. 3121198 – JLG Lift –...

  • Page 144: Dip Method

    3. O-ring Boss type fittings will require more pressure even coat of oil. 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 – 3121198...

  • Page 145: Cylinder Repair

    Remove the pis- ton assembly either by unthreading the locknut with a socket wrench or the piston itself from the rod using a spanner wrench depending on the cylinder model. 3121198 – JLG Lift –...

  • Page 146: Level Cylinder

    13. Bushing 2. Cylinder Rod 6. O-ring 10. Wear Ring 14. Cartridge 3. Piston 11. Piston Seal 15. Cartridge 7. Rod Seal 8. Backup Ring 4. Barrel 12. Locknut 16. Plug Figure 5-1. Level Cylinder – JLG Lift – 3121198...

  • Page 147: Lift Cylinder

    17. Relief Cartridge 7. Rod Seal 8. Backup Ring 3. Piston 13. Bushing 18. Plug 9. Wiper 4. Barrel 14. Cartridge 19. Spacer 10. Wear Ring 5. O-ring 15. Check Cartridge Figure 5-2. Lift Cylinder 3121198 – JLG Lift –...

  • Page 148: Master Cylinder

    1. Cylinder Head 5. O-ring 8. Backup Ring 11. Piston Seal 2. Cylinder Rod 6. O-ring 9. Wiper 12. Locknut 3. Piston 10. Wear Ring 13. Bushing Rod Seal 4. Barrel Figure 5-3. Master Cylinder – JLG Lift – 3121198...

  • Page 149: Outrigger Cylinder

    12. Rod Seal 17. Bushing 7. Not Used 8. T-Seal 3. Barrel 13. Wear Ring 18. Cartridge 9. Wear Ring 4. Piston 14. Wiper 19. Plug 10. O-ring 5. Locknut 15. O-ring Figure 5-4. Outrigger Cylinder 3121198 – JLG Lift –...

  • Page 150: Telescope Cylinder

    20. Bolt 3. Piston 8. Rod Seal 13. Piston Seal 17. Counterbalance Cartridge 21. Locknut 4. Barrel 9. Backup Ring 14. Locknut 18. Shuttle Cartridge 22. Spacer 5. O-ring 10. Wiper Figure 5-5. Telescope Cylinder – JLG Lift – 3121198...

  • Page 151: Assembly

    2. Slide stop tube (if equipped) onto rod. Do not scratch rod chrome. Slave 1050 3. For JLG p/n 1684402 piston with threaded ID, apply Loctite #7471 (Primer-T) to piston and rod threads. Master 1050 Allow primer to evaporate then apply two beads of...

  • Page 152: 5.3 Pressure Setting Procedure

    Cold temperatures have a significant impact on pressure 1. Install a pressure gauge at the port marked "GA" readings. JLG Industries Inc. recommends operating the located on the left side of the block right next to the machine until the hydraulic system has warmed to normal telescope directional valve.

  • Page 153: Hydraulic Test Ports

    SECTION 5 - HYDRAULICS Figure 5-6. Hydraulic Test Ports 3121198 – JLG Lift – 5-11...

  • Page 154: Outrigger Up

    14. Telescope the boom out to full stroke. 15. Telescope the boom in to the end of stroke. 16. Swing the turn-table1/8th turn in both directions. 17. Retract the outriggers. 18. Refill the tank to the full mark on the dipstick. 5-12 – JLG Lift – 3121198...

  • Page 155: Control Valve Torque Values - Sheet 1 Of 2

    Ft-Lbs. Ft-Lbs. Ft-Lbs. 23-24 31-32.5 17-19 23-26 5.5-6.75 43-48 58-65 12.5 13-15 17.5-20 24-26 32.5-35.25 25-28 34-38 28-33 38-45 18.5-22 25-30 154-170 209-230.5 Figure 5-7. Control Valve Torque Values - Sheet 1 of 2 3121198 – JLG Lift – 5-13...

  • Page 156: Control Valve Torque Values - Sheet 2 Of 2

    Ft-Lbs. Ft-Lbs. Ft-Lbs. 23-24 31-32.5 17-19 23-26 5.5-6.75 43-48 58-65 12.5 13-15 17.5-20 24-26 32.5-35.25 25-28 34-38 28-33 38-45 18.5-22 25-30 154-170 209-230.5 Figure 5-7. Control Valve Torque Values - Sheet 2 of 2 5-14 – JLG Lift – 3121198...

  • Page 157: Drive Directional Valve Identification - Drive & Set Option

    2. Shuttle Valve (LS2) 7. Shuttle Valve (LS1) 3. Right Drive Valve 8. Shuttle Valve (LS3) 4. EP2 9. Counterbalance Valves 5. EP1 Figure 5-7. Drive Directional Valve Identification - Drive & Set Option 3121198 – JLG Lift – 5-15...

  • Page 158: Drive Directional Valve Torque Values - Drive & Set Option

    SECTION 5 - HYDRAULICS Ft-Lbs. 18-20 24-27 30-35 41-47 35-40 47-54 Figure 5-8. Drive Directional Valve Torque Values - Drive & Set Option 5-16 – JLG Lift – 3121198...

  • Page 159: Drive Enable Valve Identification - Drive & Set Option

    1. Pressure Regulator (PR1) 2. Check Valve (CV1) 3. Relief Valve (RV1) 4. Relief Valve (RV2) 5. Solenoid Valve (SV1) 6. Filter (F1) Figure 5-9. Drive Enable Valve Identification - Drive & Set Option 3121198 – JLG Lift – 5-17...

  • Page 160: Hydraulic Diagram

    SECTION 5 - HYDRAULICS Figure 5-10. Hydraulic Diagram 5-18 – JLG Lift – 3121198...

  • Page 161: Section 6 - Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 INTRODUCTION The JLG designed Control System is a 12 volt based con- trol unit installed on the boom lift. The JLG Control System has reduced the need for...

  • Page 162: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM 6.2 TO CONNECT THE JLG CONTROL 6.3 USING THE ANALYZER SYSTEM ANALYZER With the machine power on and the analyzer connected properly, the analyzer will display the following: 1. Connect the cable supplied with the analyzer, to the...

  • Page 163: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM 6.4 CHANGING THE ACCESS LEVEL OF THE If ENTER is pressed again, the display moves to the fol- lowing display: HAND HELD ANALYZER When the analyzer is first connected, you will be in access...

  • Page 164: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM 6.5 ADJUSTING PARAMETERS USING THE Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- HAND HELD ANALYZER word was entered correctly: Once you have gained access to level 1, and a personality...

  • Page 165: 6.6 Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM 6.6 MACHINE SETUP The effect of the machine digit value is displayed along with its value. The above display would be selected if the When a machine digit item is selected, press the UP or...
  • Page 166 SECTION 6 - JLG CONTROL SYSTEM – JLG Lift – 3121198...
  • Page 167 SECTION 6 - JLG CONTROL SYSTEM 3121198 – JLG Lift –...
  • Page 168 SECTION 6 - JLG CONTROL SYSTEM – JLG Lift – 3121198...

  • Page 169: 6.7 System Test

    SECTION 6 - JLG CONTROL SYSTEM 6.7 SYSTEM TEST 4. The analyzer screen should read: The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures. Platform Test 1.
  • Page 170 SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3121198...

  • Page 171: Ground Test

    SECTION 6 - JLG CONTROL SYSTEM Ground Test 5. Use the arrow button to reach SYSTEM TEST. Hit Enter. The analyzer will prompt you asking if you 1.Position the Platform/Ground select switch to the want to activate the system test; hit Enter again to Ground position.

  • Page 172: User Fault Codes

    Function Problem - Engine Start Permanently Selected outriggers, as required. If the problem still exists, troubleshoot with a JLG Function Problem - Jib Down Permanently Selected analyzer.
  • Page 173 SECTION 6 - JLG CONTROL SYSTEM 3121198 – JLG Lift – 6-13...

  • Page 174: Ground Module - Sheet 1 Of 5

    SECTION 6 - JLG CONTROL SYSTEM NATURAL 35 PIN Refer to Figure 6-8. BLACK 35 PIN Refer to Figure 6-11. GREY 35 PIN Refer to Figure 6-9. BLUE 35 PIN Refer to Figure 6-10. BLACK 14 PIN Refer to Figure 6-10.

  • Page 175: Ground Module - Sheet 2 Of 5

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-8. Ground Module - Sheet 2 of 5 3121198 – JLG Lift – 6-15...

  • Page 176: Ground Module - Sheet 3 Of 5

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-9. Ground Module - Sheet 3 of 5 6-16 – JLG Lift – 3121198...

  • Page 177: Ground Module - Sheet 4 Of 5

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-10. Ground Module - Sheet 4 of 5 3121198 – JLG Lift – 6-17...

  • Page 178: Ground Module - Sheet 5 Of 5

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-11. Ground Module - Sheet 5 of 5 6-18 – JLG Lift – 3121198...

  • Page 179: Machine Model Adjustments And Speeds - Ansi & Csa

    SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Model Adjustments and Speeds - ANSI & CSA MODEL DEFAULTS ADJUSTMENT MODEL TIME RANGE (SECONDS) FUNCTION T350 T500J T500J T350 T500J T350 Gas T350 Gas T500J Gas RANGES Electric Electric Electric...
  • Page 180 Note 6: With swing motor P/N 3160182 optimum performance is achieved with these settings: SWING, MAX (RT OR LT) : T350 electric = 21 - 25%, T350 gas = 66%, time = 65-80 seconds SWING, MAX (RT OR LT) : T500J electric = 18%, T500J gas = 61%, time = 85-105 seconds...

  • Page 181: Machine Model Adjustments And Speeds - Ce Only

    SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Model Adjustments and Speeds - CE Only MODEL DEFAULTS ADJUSTMENT MODEL TIME RANGE (SECONDS) FUNCTION T350 T500J T500J T350 T500J T350 Gas T350 Gas T500J Gas RANGES Electric Electric Electric Electric...
  • Page 182 Note 6: With swing motor P/N 3160182 optimum performance is achieved with these settings: SWING, MAX (RT OR LT) : T350 electric = 21 - 25%, T350 gas = 66%, time = 65-80 seconds SWING, MAX (RT OR LT) : T500J electric = 18%, T500J gas = 61%, time = 85-105 seconds...

  • Page 183: Machine Orientation When Setting Speeds

    SECTION 6 - JLG CONTROL SYSTEM MACHINE ORIENTATION WHEN Test Notes SETTING SPEEDS 1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve opti- LIFT: Telescope retracted, lift up, and record time. Lift mum machine performance.

  • Page 184: Machine Configuration Programming Information

    SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Configuration Setting Description Market Default Digit T350 - 35ft. T500 - 50ft. (MODEL#) Electric - 24V Battery Engine - Honda Gasoline (POWER) NO - Drive option not installed.
  • Page 185 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code RUNNING AT CREEP — None...

  • Page 186: Help Messages

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code JOYSTICK FAULTY -- Y-AXIS Lift Up, Lift Down, Jib Up, Jib Down,...
  • Page 187 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code FUNCTION PROBLEM — LIFT Lift Up, Lift Down...
  • Page 188 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code FUNCTION PROBLEM — LIFT Lift Up...
  • Page 189 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code MODEL CHANGED — Lift Up, Lift Down, Swing Left, Swing...
  • Page 190 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code SWING RIGHT SOLENOID - Swing Right...
  • Page 191 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code R-L L/J SOLENOID - OPEN...
  • Page 192 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code THROTTLE PULL RELAY - Engine Throttle Pull...
  • Page 193 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code DRIVE LEFT FWD SOLE- NOID - SHORT TO BATTERY...
  • Page 194 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code FUNCTIONS AT CUTBACK -- POWER MODULE CURRENT...
  • Page 195 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code ACCESSORY FAULT CHASSIS TILT SENSOR NOT...
  • Page 196 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Help Messages Service User Function Locked Out from Function Locked Out from Help Message Index Flash Flash Function in Creep Mode Ground Control Platform Control Code Code FUNCTIONS LOCKED OUT — Lift Up, Lift Down, Swing Left, Swing...

  • Page 197: 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 3121198 – JLG Lift –...

  • Page 198: Resistance Measurement

    Meter should produce an audible alarm, indicating tance 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 – 3121198...

  • Page 199: Current Measurement

    These switches can be tested the same way as a standard switch by manually operating the sensing arm. Another type of limit switch used by JLG is the inductive Figure 7-4. Current Measurement (DC) proximity switch, also referred to as a "prox switch". Induc- tive proximity switches are actuated only by ferrous metal •...

  • Page 200: Automatic Switches

    NOTE: Curing-type sealants might also be used to prevent shorting and would be less messy, but would make future pin removal more difficult. – JLG Lift – 3121198...

  • Page 201: 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 from it. contact (See Figure 7-7.). Figure 7-6. AMP Connector 3121198 – JLG Lift –...

  • Page 202: 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 – JLG Lift – 3121198...

  • Page 203: Disassembly

    The wedge lock has slotted openings in the forward, or mating 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. 3121198 – JLG Lift –...

  • Page 204: Connector Installation

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11. Connector Installation – JLG Lift – 3121198...

  • Page 205: 7.6 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. 3121198 – JLG Lift –...

  • Page 206: Hd30/Hdp20 Series Assembly

    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 7-10 – JLG Lift – 3121198...
  • Page 207 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally. 3121198 – JLG Lift – 7-11...

  • Page 208: Chassis Wiring Harness And Connectors - Sheet 1 Of 2

    SWITCH VALVE/MOTOR/TANK (TANK SIDE) O/R JACK O/R JACK JACK JACK LIMIT LIMIT BATTERY STARTER VALVE VALVE SWITCH SWITCH (ENGINE POWERED) (ENGINE POWERED) Figure 7-18. Chassis Wiring Harness and Connectors - Sheet 1 of 2 7-12 – JLG Lift – 3121198...

  • Page 209: Chassis Wiring Harness And Connectors - Sheet 2 Of 2

    BRAKES CHOKE PULL RELAY ON TOW VEHICLE CENTER ENGINE WITH BRAKE STOP LIGHT HYDRAULIC RELAY BRAKES RIGHT RIGHT SIDE TAILLIGHT MARKER LIGHT Figure 7-19. Chassis Wiring Harness and Connectors - Sheet 2 of 2 3121198 – JLG Lift – 7-13...

  • Page 210: Controller And Valve Body Connector Locations

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20. Controller and Valve Body Connector Locations 7-14 – JLG Lift – 3121198...

  • Page 211: Connector Identification

    R/R Jack Limit Sw X092 Engine Oil Level Switch X046 F/L Jack Valve Coil X093 Engine Choke Pull Relay X047 F/R Jack Valve Coil X094 Engine Oil Pressure Switch X048 R/L Jack Valve Coil 3121198 – JLG Lift – 7-15...
  • Page 212 6V Batt 2, Neg. X110 6V Batt 3, Pos. X111 6V Batt 3, Neg. X112 6V Batt 4, Pos. X113 6V Batt 4, Neg. X114 Electric Pump Pos. X115 Electric Pump Neg. X116 Battery Charger Power 7-16 – JLG Lift – 3121198...
  • Page 213 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally. 3121198 – JLG Lift – 7-17...

  • Page 214: Electrical Schematic (Boom Operations) - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21. Electrical Schematic (Boom Operations) - Sheet 1 of 2 7-18 – JLG Lift – 3121198...

  • Page 215: Electrical Schematic (Boom Operations) - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870172 I Figure 7-22. Electrical Schematic (Boom Operations) - Sheet 2 of 2 3121198 – JLG Lift – 7-19...

  • Page 216: Electrical Schematic (Trailer) - Sheet 1 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS CE SPECS WITH ELECTRIC BRAKES ANSI & ANSI EXPORT SPECS WITH ELECTRIC BRAKES 1870185 C Figure 7-23. Electrical Schematic (Trailer) - Sheet 1 of 3 7-20 – JLG Lift – 3121198...

  • Page 217: Electrical Schematic (Trailer) - Sheet 2 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS ANSI & ANSI EXPORT SPECS WITH HYDRAULIC BRAKES 1870185 C Figure 7-24. Electrical Schematic (Trailer) - Sheet 2 of 3 3121198 – JLG Lift – 7-21...

  • Page 218: Electrical Schematic (Trailer) - Sheet 3 Of 3

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AUSTRALIAN & SOUTH AFRICA SPECS WITH HYDRAULIC BRAKES AUSTRALIAN & SOUTH AFRICA SPECS WITH ELECTRIC BRAKES 1870185 C 1870185 C Figure 7-25. Electrical Schematic (Trailer) - Sheet 3 of 3 7-22 – JLG Lift – 3121198...
  • Page 219 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally. 3121198 – JLG Lift – 7-23...

  • Page 220: Hydraulic Schematic - Electric Machines - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26. Hydraulic Schematic - Electric Machines - Sheet 1 of 2 7-24 – JLG Lift – 3121198...

  • Page 221: Hydraulic Schematic - Electric Machines - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-27. Hydraulic Schematic - Electric Machines - Sheet 2 of 2 3121198 – JLG Lift – 7-25...

  • Page 222: Hydraulic Schematic - Gas Machines - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28. Hydraulic Schematic - Gas Machines - Sheet 1 of 2 7-26 – JLG Lift – 3121198...

  • Page 223: Hydraulic Schematic - Gas Machines - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-29. Hydraulic Schematic - Gas Machines - Sheet 2 of 2 3121198 – JLG Lift – 7-27...

  • Page 224: Hydraulic Schematic - Drive Option (Gas) - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-30. Hydraulic Schematic - Drive Option (Gas) - Sheet 1 of 2 7-28 – JLG Lift – 3121198...

  • Page 225: Hydraulic Schematic - Drive Option (Gas) - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-31. Hydraulic Schematic - Drive Option (Gas) - Sheet 2 of 2 3121198 – JLG Lift – 7-29...

  • Page 226: Hydraulic Schematic - Drive Option (Electric) - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32. Hydraulic Schematic - Drive Option (Electric) - Sheet 1 of 2 7-30 – JLG Lift – 3121198...

  • Page 227: Hydraulic Schematic - Drive Option (Electric) - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792642-G Figure 7-33. Hydraulic Schematic - Drive Option (Electric) - Sheet 2 of 2 3121198 – JLG Lift – 7-31...
  • Page 228 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-32 – JLG Lift – 3121198...
  • Page 230 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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