JLG 600AJ Service And Maintenance Manual
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JLG 600AJ Service And Maintenance Manual

Mobile elevating work platform (mewp)
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Service and Maintenance Manual
Model
600AJ
PVC 2001
31215031
October 10, 2019 - Rev A
AS/NZS

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Summary of Contents for JLG 600AJ

  • Page 1 Service and Maintenance Manual Model 600AJ PVC 2001 31215031 October 10, 2019 - Rev A AS/NZS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: Bhydraulic System Safety

    ARE APPROVED BY JLG. TO BE CONSIDERED APPROVED, R E P L A C E M E N T PA R T S O R CO M P O N E N T S M U S T B E IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - October 10, 2019 31215031...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 DO NOT Do the Following When Welding on JLG Equipment: .......
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.14 Swing Drive..................3-42 Roll, Leak And Brake Testing .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Rotator and Slave Cylinder................4-5 Removal .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Lubricating O-rings In The Hydraulic System ............5-1 Cup and Brush .
  • Page 10 JLG Control System Analyzer Kit Instructions ........
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Applying Silicone Dielectric Compound Electrical Connections ........7-3 Dielectric Grease Application .
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Operator Maintenance and Lubrication Diagram - Deutz D2011........1-6 1-2.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-53. Carrier ................... . . 3-47 3-54.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-15. Foot Switch Adjustment ................4-38 4-16.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-56. Cylinder Barrel Support................5-31 5-57.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-112. 4-Wheel Steer (4WS) Hydraulic Schematic 2 of 2 ........... . . 5-71 5-113.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-37. Deutz TD2.9L4 (T4F) Engine harness ..............7-34 7-38.
  • Page 18 LIST OF TABLES TABLE NO. TITLE PAGE NO. Deutz TD 2.9L Specifications ............... . 1-2 Deutz D2011L04.
  • Page 19 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 20: Specifications

    Maximum Tire Load: 12,500 lb (5670 kg) Ground Bearing Pressure  600AJ 77 psi (5.5 kg/cm 600AJ - 7 ft Chassis 94 psi (6.6 kg/cm Maximum Drive Speed 4.25 MPH (6.84 KM/hr.) Gross Machine Weight (Approximate) 2WS 22,240 lb (10,088 kg) 4WS...

  • Page 21: Capacities

    SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES Table 1-3. Ford DF 2.5L, MSG 425 Fuel Tank 30 Gallons (113.6 L) Fuel Gasoline/LP Gas Hydraulic Oil Tank 30.6 Gallons (115.8 L) Oil Capacity 7 qt (6.6 L) Hydraulic System (Including Tank) 40 Gallons (151.4 L) Coolant Capacity 0.63 Gallon (2.4 L) 20 ounces (0.6L)

  • Page 22: Tires

    SECTION 1 - SPECIFICATIONS 1.5 TIRES 1.6 TORQUE REQUIREMENTS Size IN355/55D 625 36x14-20FA Interval Description Torque Value (Dry) Load Range Hours Ply Rating Bearing To Chassis 190 ft-lb (260 Nm) 50/600* Tire Pressure Foam-Filled Solid-Boss Bearing To Turntable 190 ft-lb (260 Nm) 50/600* * Load Capacity - 11,800 lb (4404 kg) - Static Wire Rope...

  • Page 23: Hydraulic Oil

    6,200 index of 152. Viscosity Index NOTE: When temperatures remain below 20° F (-7° C), JLG Indus- tries recommends the use of Premium Hydraulic Fluid. Table 1-6. Quintolubric 888-46 Specs NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types.

  • Page 24: Critical Stability Weights

    1222 Viscosity at 40° C 48.8 cSt Engine Deutz TD2.9L 1250 at 100° C 7.8 cSt Ford Viscosity Index 600AJ 6100 2767 Counterweight Table 1-9. Mobil EAL 46 Specs Narrow Frame 8050 3651 Type Synthetic Biodegradable 30x48 ISO Viscosity Grade...
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-1. Operator Maintenance and Lubrication Diagram - Deutz D2011 31215031...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-2. Operator Maintenance and Lubrication Diagram - Deutz TD2.9 31215031...
  • Page 27 SECTION 1 - SPECIFICATIONS Figure 1-3. Operator Maintenance and Lubrication Diagram - Ford MSG 425 31215031...

  • Page 28: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.9 OPERATOR MAINTENANCE Wheel Bearings (If equipped) NOTE: The following numbers correspond to those in Figure 1-1., Figure 1-2. and Figure 1-3. Table 1-11. Lubrication Specifications. SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 29 SECTION 1 - SPECIFICATIONS Wheel Drive Hub Hydraulic Charge Filter • Interval - Change after first 50 hrs. and every 6 months or • Lube Point(s) - Level/Fill Plug 300 hrs. thereafter, or as shown by Condition Indicator. • Capacity - 20 oz. (0.6 L) Hydraulic Tank Lube Point(s) - Fill Cap •...
  • Page 30 SECTION 1 - SPECIFICATIONS A. Oil Change w/Filter - Deutz 2011 B. Oil Change w/Filter - Deutz D2.9 • Lube Point(s) - Fill Cap/Spin-on Element • Lube Point(s) - Fill Cap/Spin-on Element • Capacity - 11 Quarts Crankcase; 5 Quarts Cooler •...
  • Page 31 SECTION 1 - SPECIFICATIONS Oil Change w/Filter - Ford (On Engine) B. Fuel Filter - Deutz TD2.9 (On Turntable) • Lube Point(s) - Replaceable Element • Interval - Change in accordance with engine manual C. Fuel Filter - Deutz TD2.9 (On Engine) MAE18190 •...
  • Page 32 SECTION 1 - SPECIFICATIONS  A. Fuel Filter - Ford (On Engine) B. Air Filter - Deutz D2.9 FUEL FILTER • Lube Point(s) - Replaceable Element • Interval - Every 6 months or 300 hours of operation or as shown by condition indicator. C.

  • Page 33: Thread Locking Compound

    SECTION 1 - SPECIFICATIONS 1.10 THREAD LOCKING COMPOUND ® JLG PN ND Industries Description Loctite ™ ™ 0100011 Medium Strength (Blue) Vibra-TITE ™ ™ 1001095650 Medium Strength (Blue) Vibra-TITE ™ ™ 0100019 High Strength (Red) Vibra-TITE ™ ™ 0100071 Medium - High Strength (Red) Vibra-TITE ®...

  • Page 34: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.11 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque ™ Torque (Loctite® 242 Tensile Clamp Torque Torque ™ ™ Size Bolt Dia Stress (Loctite®...
  • Page 35 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque ™ ™ ™ Tensile Clamp (Loctite® 242 or 271 (Loctite® 262 Size Bolt Dia (Dry or Loctite®...
  • Page 36 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque ™ ™ ™ Tensile Clamp (Loctite® 242 or 271 (Loctite® 262 Size Bolt Dia (Dry) Stress Area Load...
  • Page 37 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque ™ ™ ™ Tensile Clamp (Loctite® 242 or 271 (Loctite® 262 Size Bolt Dia (Dry or Loctite®...
  • Page 38 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAP SCREWS Torque Torque Clamp ™ ™ ™ Tensile Torque (Loctite® 242 or 271 (Loctite® 262 Size Bolt Dia Load See Stress Area (Dry) K=0.17 ™...
  • Page 39 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAP SCREWS Torque Torque Clamp ™ ™ ™ Tensile Torque (Loctite® 242 or 271 (Loctite® 262 Size Bolt Dia Load See Stress Area (Dry) K=0.17 ™...

  • Page 40: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque ™ Torque (Loctite® 242 Clamp ™ (Loctite® 262 Tensile (Dry or Loctite® ™...
  • Page 41 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Torque Torque ™ Torque (Lube or Loctite®...
  • Page 42 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque ™ ™ Torque (Lube or Loctite® 242 (Loctite® 262 Tensile Clamp Load ™...
  • Page 43 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Torque Torque ™ Torque (Lube or Loctite® 242 Clamp ™...

  • Page 44: General

    Service Technician as a person who has successfully com- pleted before placing the machine into service. With proper pleted the JLG Service Training School for the subject JLG care, maintenance, and inspections performed per JLG's rec- product model. Reference the machine Service and Mainte-...

  • Page 45: Service And Guidelines

    Service and Maintenance Manual Owner, Dealer, or User Qualified JLG Mechanic Inspection rental delivery. and applicable JLG inspection form. In service for 3 months or 150 hours, whichever Frequent comes first; or Service and Maintenance Manual Owner, Dealer, or User...

  • Page 46: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Unless specific torque requirements are given within the text, use standard torque values on heat-treated bolts, studs, and steel nuts, in accordance with recommended When disassembling or reassembling a component, complete shop practices. (See Section 1.11,Torque Charts) the procedural steps in sequence.

  • Page 47: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION Inspect all hydraulic components, lines, fittings, etc. while unit is shut down. Perform a functional check of each system before placing machine back in service. Hydraulic System Lubrication Specifications The primary enemy of a hydraulic system is contamina- Specified lubricants, as recommended by component manu- tion.

  • Page 48: Cylinder Thermal Drift

    These effects occur as the cylinder oil changes tempera- DO NOT Do the Following When Welding on JLG ture, usually from a higher oil temperature as it cools and approaches the ambient air temperature. Results of these...
  • Page 49 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields Extend/Retract Chain or Cable Systems...
  • Page 50 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Functions/Controls Platform Controls 5, 6 Ground Controls 5, 6 Function Control Locks, Guards, or Detents 1, 5 Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Drive Brakes Swing Brakes...
  • Page 51 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: 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 52 SECTION 2 - GENERAL 4150548-E Figure 2-1. Engine and Hydraulic Operating Temperature Specifications - Deutz 31215031...
  • Page 53 SECTION 2 - GENERAL 4150548-E Figure 2-2. Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425 2-10 31215031...
  • Page 54 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 55: Chassis & Turntable

    JLG recommends a replacement tire be the same size, ply, and brand as originally installed on the machine. Please refer to the JLG Parts Manual for part number of approved tires for a par- ticular machine model. If not using a JLG approved replace-...

  • Page 56: Oscillating Axle Bleeding Procedure And Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE 3.2 OSCILLATING AXLE BLEEDING PROCEDURE AND From platform control station, start engine. LOCKOUT TEST Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left Lockout Cylinder Bleeding front wheel is on top of block.
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE 8FT/2.4M WIDE MACHINES OSCILLATING FIXED 7FT/2.1M WIDE MACHINES OSCILLATING FIXED MAE1260 Figure 3-2. Axle Installation - Sheet 1 of 2 31215031...
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 10. Thrust washer 19. Bearing 2. Bolt 11. Shim 20. Axle Lockout Cylinder Assembly 3. Bearing 12. Stop Plate 21. Pin 4. Axle Lockout Cylinder Assembly 13. Capscrew 22. Keeper Pin 5. Pin 14.
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE MAE1920 Figure 3-4. Steering Installation (8ft/2.4m Wide Machines Without Tow Package) - Sheet 1 of 2 31215031...
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 14. Spindle 27. Pin 40. Cup Bearing 2. Steer Cylinder Assembly 15. Thurstwasher 28. Keeper Pin 41. Bolt 3. Bolt 16. Thurstwasher 29. Keeper Pin 42. Hub Cap 4. Bushing 17. Thurstwasher 30.
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE MAE1930 Figure 3-6. Steering Installation (8ft/2.4m Wide Machines With Tow Package) - Sheet 1 of 2 31215031...
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 18. Keeper Pin 35. Bushing 51. Pin 2. Bolt 19. Keeper Pin 36. Bushing 52. Cotter Pin 3. Screw 20. Tie-Rod 37. Bushing 53. Keeper Pin 4. Bushing 21. Shim 38. Bushing 54.
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE FRONT AXLE WITHOUT TOW REAR AXLE MAE2070 Figure 3-8. Steering Installation (7ft/2.1m Wide Machines) - Sheet 1 of 3 3-10 31215031...
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE FRONT AXLE WITH TOW MAE2130 Figure 3-9. Steering Installation (7ft/2.1m Wide Machines) - Sheet 2 of 3 31215031 3-11...
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 1. Cup Bearing 19. Cotter Pin 38. Cone Bearing 56. Pin 2. Cone Bearing 20. Keeper Pin 39. Thurstwasher 57. Pin 3. Thurstwasher 21. Tie-Rod 40. Bolt 58. Pin 4. Bolt 22. Seal 41. Bolt 59.

  • Page 66: Torque Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.3 TORQUE HUB Tightening and Torquing Bolts Oil Information USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN TYPE – EP90  BOLTS BEYOND THEIR TORQUE SPECIFICATION. NEVER USE AN IMPACT Use EP90 for normal applications.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1L. Spring 4C. Needle Bearing 6C. Bolt 8D. O-Ring 12. Plug 1B. Seal 1M. Thrustwasher 4D. Thrust Spacer 6D. Dowel Pin 8E. Backup Ring 15. I.D. Plate 1C. Bearing 2. Thrustwasher 4E. Planet Shaft 6E.

  • Page 68: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly NOTE: Carefully pressurize unit with air to pop cover off. Perform Roll Check, Leak Check, and Brake Check if Remove Input Carrier Subassembly (3). applicable before disassembly. Remove Input Shaft (9). Drain oil from unit. Note condition and volume of oil. Remove Second Stage Sun Gear (11).

  • Page 69: Output Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Output Carrier Disassembly Slide Planet Gear Subassembly (4) out of Spindle (1A). Do not drop Needle Bearings (4C). Use a 1/8” diameter punch to drive Roll Pin (4G) in Planet Remove four Thrust Washers (4B), 28 Needle Rollers (4C), Shaft (4E) until it bottoms against Spindle (1A).

  • Page 70: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Spindle Disassembly Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q) from Hub (1D) if applicable. Place unit on bench with Spindle (1A) end down. If necessary, press nine Studs (1H) out of Hub (1D). Locate Hub (1D) on Seal (1B) end.

  • Page 71: Spindle-Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Spindle-Brake Disassembly Remove Flat Head Capscrews (22) and Pressure Plate (8B) from brake cavity in Spindle (1A). NOTE: Units with integral Input Brake (8) only. Remove Compression Springs (8L) from Piston (8A). Using an air hose, slowly and carefully pressurize brake port in Spindle (1A) until Piston (8A) comes out of piston COMPRESSED SPRINGS CAN FLY OUT AND CAUSE SEVERE EYE DAMAGE OR bore of Spindle (1A).

  • Page 72: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly Input Carrier Sub-Assembly Remove O-Ring (17) from groove in Cover (6A). Apply a liberal coat of grease to bore of one Input Planet Gear (3F). Remove Thrust Washer (2) from Cover (6A) pockets. Line inside of Planet Gear (3F) with 14 Needle Rollers Unscrew two Hex Head Bolts (6C) and remove Disen- (3C).

  • Page 73: Spindle - Brake Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Repeat Step 2 to put in second roll of Needle Rollers (4C). Hub-Spindle Sub-Assembly Apply grease to hold two Thrust Washers (4B) together NOTE: Spray a light film of oil on all component parts during and on Output Planet Gear (4F) counterbore.

  • Page 74: Cover Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Insert Planet Shaft (4E) through first set of Thrust Wash- Place Input Carrier Sub-Assembly (3A) on Output Sun ers (4B), Planet gear, then second set of Washers (4B). Gear (11) splines. Drop Input Sun (10) in mesh with Use an alignment punch or similar tool to align roll pin planet gears for specific ratios, if required.
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE 1A. Spindle 1M. Thrust Washer 4C. Needle Bearing 6C. Bolt 8D. O-Ring 11. Sun Gear 1B. Lip Seal 1Q. Seal Boot 4D. Thrust Spacer 6D. Dowel Pin 8E. Backup Ring 12. Plastic Plug 1C. Tapered Bearing 2.

  • Page 76: Bearing Cup Pressing Tool

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-20. Bearing Cup Pressing Tool Figure 3-21. Seal Pressing Tool 31215031 3-23...
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE Figure 3-22. Bearing Cup Pressing Tool Figure 3-23. Drift Pin for Lining Up Thrust Washers with Output Planet Gear 3-24 31215031...

  • Page 78: Free Wheeling Option

    SECTION 3 - CHASSIS & TURNTABLE 3.4 FREE WHEELING OPTION 3.5 DRIVE MOTOR Disengage Drive Motors and Brakes for Towing, etc. Description (Free Wheel) Drive motors are low to medium power, two-position axial pis- ton motors incorporating an integral servo piston. They are Chock wheels securely if not on flat level surface.

  • Page 79: Shaft Seal Replacement

    SECTION 3 - CHASSIS & TURNTABLE Shaft Seal Replacement INSPECTION Inspect new seal, motor housing seal bore, and sealing area on shaft for rust, wear, and contamination. Polish shaft and clean REMOVAL housing if necessary. Remove snap ring (1) retaining shaft seal, and support washer.

  • Page 80: Loop Flushing Valve

    SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve INSPECTION Inspect new O-rings and the sealing area for rust, wear, or con- tamination. Check springs and poppet for wear. REMOVAL Remove plug (1) and (2) using an 11/16 in internal hex INSTALLATION wrench.

  • Page 81: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-2. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill reservoir to proper level. Ensure oil supply to motor is adequate and supply to motor.

  • Page 82: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly  NOTE: Removal of endcap voids warranty.  Coat all moving parts with a film of clean hydraulic oil dur- ing assembly. This ensures parts will be lubricated during  start-up.   Replace all O-Rings and gaskets.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 23. End Cap 26. End Cap 24. O-ring 27. O-ring Figure 3-30. End Cap 28. O-ring 29. Bearing Using an 8 mm internal hex wrench, remove endcap- 30. Servo Spring screws (22).

  • Page 84: Cylinder Kit Assembly

    SECTION 3 - CHASSIS & TURNTABLE 31. Cylinder Kit Assembly 35. Inner Snap Ring Figure 3-32. Cylinder Kit 36. Snap Ring 37. Bearing Turn housing on its side and remove cylinder kit assem- 38. Shaft bly (31). Set assembly aside. Do not to scratch running Figure 3-34.

  • Page 85: Inspection

    SECTION 3 - CHASSIS & TURNTABLE Turn block over. Using a press, apply pressure on block spring washer (50) to compress the block spring. Com- press spring enough to safely remove the spiral retain- ing ring (51). While maintaining pressure, unwind the spiral retaining ring (51).
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE CYLINDER BLOCK Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface. Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing will not reduce block height below minimum specification.

  • Page 87: Assembly

    SECTION 3 - CHASSIS & TURNTABLE SHAFT BEARINGS Assembly Inspect bearings for excessive wear or contamination. Rotate Install new O-ring (1) and piston seal (2) to servo piston bearings while feeling for uneven movement. Bearings should (3). Install piston seal over O-ring. spin smoothly and freely.

  • Page 88: Swash Plate And Journal Bearing

    SECTION 3 - CHASSIS & TURNTABLE Install inner block spring washer (4), block spring (5), Install journal bearings (13) in housing seats. Use assem- and outer washer (6) in cylinder block. Using a press, bly grease to keep bearings seated during assembly. compress block spring enough to expose retaining ring Ensure locating nubs drop into seat cavities.

  • Page 89: Shaft And Front Bearing

    SECTION 3 - CHASSIS & TURNTABLE Press front shaft bearing (15) on shaft (16). Press bearing Verify swashplate and bearings are properly seated. on shaft with lettering facing out. Lubricate bearing roll- Install cylinder kit (19) on shaft. Install with slippers fac- ers.

  • Page 90: Valve Plate And Rear Bearing

    SECTION 3 - CHASSIS & TURNTABLE Press rear shaft bearing (22) in endcap. Install bearing Install endcap (25) on housing with endcap screws (26). with letters facing out. Press until bearing surface is 0.08 Ensure endcap will properly seat to housing without ±0.01 in (2 ±0.25 mm) above endcap surface.

  • Page 91: Initial Start-Up Procedures

    SECTION 3 - CHASSIS & TURNTABLE 11/16 in 27 ft.lbs. (37 Nm) 5/8 in 20 ft.lbs. (27 Nm) 11/16 in 27 ft.lbs. (37 Nm) 27. Shaft Seal 28. Seal Support Washer 29. Snap Ring Figure 3-45. Shaft Seal 30. Orifice Poppet 34.

  • Page 92: Steer Adjustments

    SECTION 3 - CHASSIS & TURNTABLE To ensure pump and motor stay filled with oil, install 3.6 STEER ADJUSTMENTS case drain lines in upper most case drain ports. NOTE: 2 Wheel Steering/2 Wheel Drive: Spindles do not stop on Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres- cylinder stroke.

  • Page 93: Chassis Tilt Indicator System

    4 degree, but it need to select between 4.0 degree, and 3.0 machine is in the "unsafe" condition and the switch arm is free degree by JLG hand held Analyzer. By factory default, the tilt while the machine is in the "safe" condition.

  • Page 94: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.12 OSCILLATING AXLE SYSTEM 3.13 DRIVE SYSTEM The oscillating front axle is attached to the frame by a pivot The drive system consists of one variable displacement closed pin, which allows all four wheels to remain on the ground loop pump, four variable displacement piston motors, gear when traveling on rough terrain.

  • Page 95: Swing Drive

    SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING DRIVE Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care Roll, Leak And Brake Testing should be taken to ensure that the bolts are not tightened beyond their specified torque.

  • Page 96: Motor Control Valve Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly Using a wrench, loosen jam nuts on Elbow Fittings (30) and remove fittings from Brake (6) and Motor Control Valve (32). NOTE: Refer to Figure 3-49. Remove O-ring Plugs (23) from Motor Control Valve (32). Place unit on bench with the motor end up.

  • Page 97: Motor And Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly Remove the Springs (8L) from the piston. Apply less than 50 psi (3.45 bar) air to the “brake port” to NOTE: Refer to Figure 3-50. remove Brake Piston (8A). With unit resting on bench with Motor (31) end up, loosen Hex Bolts (29) and remove Lift Lugs (28) from the Motor (31).

  • Page 98: Main Drive Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Drive Disassembly Remove Thrust Washer (11) from between Brake Hous- ing (6) and Carrier Subassembly. NOTE: Refer to Figure 3-51. Remove Ring Gear (4) from Housing (1G). Remove Sun Gear (8) with Retaining Ring (44) inside. Remove O-ring (5) from between Ring Gear (4) and Housing (1G).

  • Page 99: Hub-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly While supporting the Housing (1G) on the Output Shaft (1A) end, press the Output Shaft (1A) out of the Housing (1G). NOTE: Refer to Figure 3-52. NOTE: The Lip Seal (1B) will be pressed out of the Housing (1G) by Using retaining ring pliers remove Retaining Ring (1I) the Bearing Cone (1D) during this step.

  • Page 100: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly Remove the Planet Shaft (3E) from the Carrier (3A). Use a small punch to remove the Roll Pin (3D) from the Planet Shaft (3E). NOTE: Refer to Figure 3-53. Slide the Planet Gear (3F), the two Thrust Washers (3B) Using a 3/16”...

  • Page 101: Hub-Shaft Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Assembly Carrier Assembly NOTE: Refer to Figure 3-52. NOTE: Refer to Figure 3-53. Press Bearing Cup (1C) into Housing (1G) taking care to Apply a liberal Coat of grease to the bore of Cluster Gear insure cup starts square with the bore of Hub (1G).

  • Page 102: Main Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Drive Assembly NOTE: If gears do not mesh easily or Carrier Assembly does not rotate freely, then remove the Carrier and Ring Gear and check the Cluster Gear timing. NOTE: Refer to Figure 3-51. Install Thrust Washer (11) into the counterbore on the With the Hub Shaft Sub-Assembly resting on the Shaft face of the carrier.

  • Page 103: Motor And Brake Assembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly Motor Control Valve Assembly NOTE: Refer to Figure 3-50. NOTE: Refer to Figure 3-49. Alternate Stators (8K) (O.D. lobes) with Rotors (8J) (I.D. Lay assembly down with motor ports facing up. Remove splines) into bore of Brake Housing (6).
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE 1A. Output Shaft 1G. Housing 2. Internal Gear 5A. O-Ring 12. Bolt 1B. Lip Seal 1H. Thrust Washer 3. Carrier Assembly 6. Brake Housing 13. Dowel Pin 1C. Bearing 1I. Retaining Ring 4. Ring Gear 8.
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE 6. Brake Housing 8L. Spring 35. Tube 108. Rotor Set 117. Backup Washer 8A. Piston 21. Bolt 101. Bolt 109. Wear Plate 118. Housing 8D. O-Ring 22. Lockwasher 102. End Cover 110. Drive Link 119.

  • Page 106: Swing Hub Removal

    SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING HUB REMOVAL 3.16 SWING HUB INSTALLATION Ensure mounting plate and mounting location of the base Disconnect all wiring harness terminals connected to plate are clean and painted with a uniform coating of mini- the swing motor.

  • Page 107: Swing Drive Lubrication

    SECTION 3 - CHASSIS & TURNTABLE Remove turntable lock pin. Torque mounting bolts to 340 ft. lbs. (Nm). Apply High Strength Threadlocking Compound and pre- torque swing drive mounting bolts to 30 ft. lbs. (40 Nm). Remove shim and discard. Tighten jack bolt until pinion is completely snug against shim and bearing then loosen jack bolt.

  • Page 108: Swing Bearing

    NOTE: This check is designed to replace existing bearing bolt bolt head and hardened washer at position shown torque checks on JLG Lifts in service. This check must be in  performed after first 50 hours of machine operation and Figure 3-56.

  • Page 109: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance From underside of the machine, at rear center, with the tower boom fully elevated and fully retracted, as shown in Figure 3-58. Swing Bearing Tolerance Measurement Location & Boom Placement A, using a magnetic base dial indicator, measure and record distance between swing bearing and turntable as shown in Figure 3-57.
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE MAF23640 31215031 3-57...

  • Page 111: Swing Bearing Replacement

    NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY JLG INDUSTRIES RECOMMENDS ALL REMOVED BEARING BOLTS BE DISCARDED PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCK- AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY ING.

  • Page 112: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-59. Swin Using suitable lifting equipment, carefully position the Using all applicable safety precautions, activate the turntable assembly above the machine frame. hydraulic system and check the swing system for proper and safe operation. Carefully lower the turntable onto the swing bearing, ensuring that the scribed line of the inner race of the Swing Bearing Torque Values...
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE MAF21470 Figure 3-60. Swing Bearing Removal 3-60 31215031...

  • Page 114: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.18 ROTARY COUPLING Assemble lip seals (14) in direction shown in Figure 3-62. Rotary Coupling - Sheet 2 of 2. Use the following procedure to install the seal kit. Reassemble O-ring (18). If not already removed, remove axle oscillation valve Heat cap seals (17) in hydraulic oil for 5 minutes at 300°...
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE DETAIL A 1. O-ring 6. Spring 11. Housing 16. Bearing 2. Plug 7. Valve Block Plunger 12. Retaining Ring 17. Cap Seal 3. Check Valve 8. Valve Block 13. Ring 18. O-ring 4. Screw 9.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE Figure 3-63. Rotary Coupling Port Location - 2WS 31215031 3-63...
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 1,5,9 Figure 3-64. Rotary Coupling Port Location - 4WS 3-64 31215031...

  • Page 118: Generator

    SECTION 3 - CHASSIS & TURNTABLE Table 3-9. Coupling Port Information Table - 2WS 3.19 GENERATOR Operating Proof Port Out- Port Every 250 hours Description Pressure Pressure Size PSI (Bar) PSI (Bar) Check drive belt tension every 250 hours of operation,. Brake 450 (31) 675 (47)

  • Page 119: Overload Protection

    SECTION 3 - CHASSIS & TURNTABLE Overload Protection Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings Refer to Figure 3-69. Inspecting Generator Brushes, Replacing STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER. Brushes, and Cleaning Slip Rings. The circuit breaker protects generator windings from overload. INSPECTING BRUSH POSITION Generator output stops if circuit breaker opens.
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings Acceptable Unacceptable Brushes must ride completely on slip rings 1/4 in (6 mm) Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New 1. Brush Holder Assembly 2.

  • Page 121: Deutz D2.9 L4 (T4F) Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.20 DEUTZ D2.9 L4 (T4F) ENGINE 1. Fan 11. Spark Arrester 21. Gear Pump Assembly 31. Oil Fill Cap 2. Adapter 12. Pressure Sensor 22. Oil Drain Hose 32. Oil Cooler 3. Drive Belt 13.
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE 1. Coolant Recovery Tank 4. Coolant Overflow Hose 7. Fuel Pre-Filter 10. Relay 13. Engine Tray 2. Radiator Assembly 5. Coolant Level Sensor 8. Battery 11. Lanyard 14. Air Filter Assembly 3. Air Filter Service Indicator 6.

  • Page 123: Check Oil Level

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed operat- Change Engine Oil ing and maintenance instructions. Allow engine to warm up. Engine oil should reach Check Oil Level approximately 176° F (80° C). Make sure machine and engine are level and switch Make sure machine and engine are level and switch off engine OFF before checking oil level.

  • Page 124: Change Oil Filter

    SECTION 3 - CHASSIS & TURNTABLE Change Oil Filter Change Fuel Filters Wipe area around filter to clean any dirt from area. Using a suitable oil filter removal tool, loosen lube oil fil- FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE ter cartridge and spin off.

  • Page 125: Deutz D2011 (T4I) Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.21 DEUTZ D2011 (T4I) ENGINE MAF06180 1. Radiator Mounting Plate 10. Right Rear Engine Mounting Plate 19. Left Front Engine/Generator Support 2. Fan 11. Exhaust Pipe 20. Starter 3. Dipstick 12. Coupling 21. Muffler 4.
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE MAE4090 1. Battery 7. Engine Tray 13. Temperature Sensor 2. Battery Hold-Down 8. Filler Cap 14. Oil Pressure Sensor 3. J-Bolt 9. Oil Lube Pump 15. Speed Sensor 4. Battery Hold-Down Plate 10. Oil Filter 16.

  • Page 127: Checking Oil Level

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed operat- Changing Engine Oil ing and maintenance instructions. Allow engine to warm up. Engine oil should reach Checking Oil Level approximately 176° F (80° C). Make sure machine and engine are level and switch Make sure machine and engine are level and switch off engine OFF before checking oil level.

  • Page 128: Changing Oil Filter

    SECTION 3 - CHASSIS & TURNTABLE Changing Oil Filter Check oil filter cartridge for leaks. Replace Fuel Filter Wipe area around filter to clean any dirt from area. Using a suitable oil filter removal tool, loosen lube oil fil- ter cartridge and spin off. FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY.

  • Page 129: Spark Arrester Cleaning Instructions

    3.22 SPARK ARRESTER CLEANING INSTRUCTIONS 3.23 GLOW PLUGS If the glow plug option is enabled in the JLG Control System, Remove the cleanout plug in the bottom of spark the glow plug and indicator lamp will be energized when the arrester (muffler).

  • Page 130: Deutz Emr 2

    The EMR2 consists of the sensors, the control unit and the (Limp home) functions. actuator. Engine-side controls as well as the JLG Control Sys- In order to switch the engine off, the EMR2 is switched in a de- tem are connected by means of separate cable harnesses to energized fashion over the ignition switch.
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE 3-78 31215031...
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE 31215031 3-79...
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE 3-80 31215031...
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE 31215031 3-81...
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE Figure 3-83. EMR 2 Engine Plug Pin Identification 3-82 31215031...
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Figure 3-84. EMR 2 Vehicle Plug Pin Identification 31215031 3-83...
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE 3-84 31215031...
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE 31215031 3-85...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 3-86 31215031...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE 31215031 3-87...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE 3-88 31215031...
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 1-2-6 Hand throttle idle validation switch; short Sensor defect. If the signal is below the applicatable threshold circuit to battery.
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 1227 5-9-4 EGR-Valve (2.9;3.6) or Throttle-Valve Short-Circuit to battery on component wiring. Threshold for error detection is an internal ECU (4.1;6.1;7.8);...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 2-1-6 Sensor error low fuel pressure, signal range Cable break or short circuit, sensor defective or Check cabling.
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 2-2-3 Charged air pressure above warning thresh- Charged air cooler pressure above threshold. Check waste gate system if necessary replace old.
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 1-3-6 Air filter differential pressure; air filter Pressure loss above target range, air filter Check air filter and if necessary clean or renew it, clogged.
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 1181 3-1-8 Physical range check low for battery voltage. Battery voltage below limit. Check alternator, cabling, contact resistance, safety fuses, too high load in energy system, check battery and if necessary replace...
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 2-8-1 Access error EEPROM memory (delete). Sections could not be erased. Threshold for error detection is an internal ECU threshold.
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code Injector 3 (in firing order): Short circuit. Injector cylinder 3: Check wiring harness, injectors and if necessary Wiring harness, cable break or short circuit.
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 5-1-2 Starter relay power stage over temperature. Temperature over limit. Threshold for error detection is an internal ECU threshold.
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 1080 2-8-2 Failure of sensor supply voltage 2. Suspected components EDC17cv52 Check cabling of external components, check Pin K16: second foot pedal working voltage and if necessary correct Pin K18: Pressure DS DPF...
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 523354 Injector power stage output defect. Defective power stage in ECU. If error is not removable, change ECU. Threshold for error detection is an internal ECU threshold.
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 523601 2-8-2 Failure of sensor supply voltage 3. Suspected components EDC17cv52 Check cabling of external components, check Pin A18: Delta Press Venturi / Position intake working voltage and if necessary correct throttle flap...
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 523612 ECU reported internal software error. Error in the check of the shut-off path test of the Threshold for error detection is an internal ECU under- voltage detection (ECU internal threshold.
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 523613 1-3-4 Rail pressure metering unit, Rail pressure Leakage is detected based on fuel quantity bal- Threshold for error detection is an internal ECU disrupted.
  • Page 156 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 523776 1-1-9 Timeout error of CAN-Receive-Frame TSC1TE Timeout error (missing CAN-Bus message). Threshold for error detection is an internal ECU - active.
  • Page 157 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. Engine Fault Codes (Deutz Engine) Deutz Blink Error Description Possible Reasons For Error Take Action For Repair (TAFR) Code Code 524107 1678 9-3-1 Timeout error of CAN-Receive-Frame Not used. Not used. ComRxEGRMsFlw2 (EGR actuator). 524108 1669 9-3-2...

  • Page 158: Bio Fuel In Deutz Engines

    SECTION 3 - CHASSIS & TURNTABLE 3.25 BIO FUEL IN DEUTZ ENGINES Bio Fuel General PERMITTED BIO-DIESEL FUELS as a bio-diesel fuel in Europe but fatty acid methylester (FAME) Use of bio fuels is permitted for the compact engines made by based on other oils have come onto the market increasingly in DEUTZ.

  • Page 159: Biological Contamination In Fuels

    SECTION 3 - CHASSIS & TURNTABLE APPROVED ENGINES Biological Contamination In Fuels The 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and 513 series are approved for bio-diesel from year of manufac- SYMPTOMS ture 1993 under compliance with the basic conditions speci- The following symptoms may indicate that a fuel tank is con- fied below.

  • Page 160: Ford Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.26 FORD ENGINE  NOTE: Detailed Engine service instructions are provided in the following publications: Service Manual 3128849. MAE13920 Figure 3-90. Ford Engine Installation Sheet 1 of 4 31215031 3-107...
  • Page 161 SECTION 3 - CHASSIS & TURNTABLE MAE13930 Figure 3-91. Ford Engine Installation Sheet 2 of 4 3-108 31215031...
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE MAE13940 Figure 3-92. Ford Engine Installation Sheet 3 of 4 31215031 3-109...
  • Page 163 SECTION 3 - CHASSIS & TURNTABLE 1. Lock-Off Valve 18. O-Ring 35. Radiator Hose 2. LP Mixer 19. Gear Pump and Fitting Assembly 36. Motor Mount 3. Governor 20. Rear Engine Mount 37. Tray 4. Rubber Isolator 21. Oil Filter 38.
  • Page 164 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Fault Code Cross Reference List (Ford Engine) Original DTC Corresponding Fault Name Number DTC (Current) Intake cam / distributor position Exhaust cam position CL high LPG 1151 EGO open/lazy pre-cat 1 EGO open/lazy pre-cat 2/post-cat 1 EGO open/lazy post-cat 1 EGO open/lazy post-cat 2 CL high gasoline bank1...
  • Page 165 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Fault Code Cross Reference List (Ford Engine) Original DTC Corresponding Fault Name Number DTC (Current) AUX DIG3 high 1555 AUX DIG3 low 1556 IAT high voltage IAT low voltage IAT higher than expected 1 IAT higher than expected 2 Oil pressure low ECT/CHT High Voltage...
  • Page 166 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Fault Code Cross Reference List (Ford Engine) Original DTC Corresponding Fault Name Number DTC (Current) Emissions/catalyst damaging misfire Injector Loop Open or Low-side short to Ground Injector Coil Shorted Injector Loop Open or Low-side short to Ground Injector Coil Shorted Injector Loop Open or Low-side short to Ground Injector Coil Shorted...
  • Page 167 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Fault Code Cross Reference List (Ford Engine) Original DTC Corresponding Fault Name Number DTC (Current) Primary Loop Open or Low-side Short to Ground 2315 Primary Coil Shorted 2316 Primary Loop Open or Low-side Short to Ground 2318 Primary Coil Shorted 2319...
  • Page 168 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Fault Code Cross Reference List (Ford Engine) Original DTC Corresponding Fault Name Number DTC (Current) Spark rev limit 1112 COP failure Invalid interrupt 1616 A/D loss 1615 RTI 1 loss 1612 Flash checksum invalid RAM failure 5VE1 low voltage 5VE1 high voltage...
  • Page 169 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Fault Code Cross Reference List (Ford Engine) Original DTC Corresponding Fault Name Number DTC (Current) PWM5 short to power 1640 MIL control ground short 1644 MIL open MIL control short to power 1645 Tach output ground short 2618...
  • Page 170 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. CAN to DTC Cross Reference (Ford Engine) DTC and Description MAP pressure high MAP voltage low ECT voltage high ECT voltage low ECT higher than expected stage 1 IAT voltage high IAT voltage low 2229 BP pressure high BP pressure low...
  • Page 171 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. CAN to DTC Cross Reference (Ford Engine) DTC and Description 1161 Adaptive-learn LPG high 4237 1162 Adaptive-learn LPG low 4237 1163 Adaptive-learn NG high 4237 1164 Adaptive-learn NG low 4237 Injector 1 open or short to ground Injector 2 open or short to ground Injector 3 open or short to ground Injector 4 open or short to ground...
  • Page 172 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. CAN to DTC Cross Reference (Ford Engine) DTC and Description 2328 Spark coil 10 primary shorted 1277 ECT higher than expected stage 2 IAT higher than expected stage 1 IAT higher than expected stage 2 Knock1 sensor open or not present 2112 Unable to reach higher TPS...
  • Page 173 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. CAN to DTC Cross Reference (Ford Engine) DTC and Description FP high voltage FP low voltage Catalyst inactive on gasoline (Bank 1) 3050 1165 Catalyst inactive on LPG 3050 1166 Catalyst inactive on NG 3050 1171 MegaJector delivery pressure higher than expected...
  • Page 174 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. CAN to DTC Cross Reference (Ford Engine) DTC and Description MIL open 1213 1645 MIL control short to power 1213 2618 Tach output ground short 2619 Tach output short to power 2130 IVS stuck at-idle, FPP1/2 match 2131 IVS stuck off-idle, FPP1/2 match...
  • Page 175 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. CAN to DTC Cross Reference (Ford Engine) DTC and Description 1556 AUX digital 3 low voltage Gaseous fuel temperature sender high voltage 3468 Gaseous fuel temperature sender low voltage 3468 1629 J1939 TSC1 message receipt loss Fuel run-out longer than expected 1630 J1939 ETC message receipt loss...
  • Page 176 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. CAN to DTC Cross Reference (Ford Engine) DTC and Description 8917 UEGO pump cell impedance high 3225 8918 UEGO pump cell impedance low 3225 1311 Cylinder 1 misfire detected 1323 1312 Cylinder 2 misfire detected 1324 1313 Cylinder 3 misfire detected...

  • Page 177: Counterweight

    SECTION 3 - CHASSIS & TURNTABLE 3.27 COUNTERWEIGHT If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-94. Counterweight Bolt Torque. MAE18160 * Torque to 260 ft.lbs. (353 Nm) Figure 3-94.
  • Page 178 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 179: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM Each function has its own personality settings allowing the 4.1 PLATFORM CONTROL ENABLE SYSTEM characteristics of each function to be modified using the stan- The platform controls make use of a time dependent enable dard analyzer.

  • Page 180: Platform

    SECTION 4 - BOOM & PLATFORM 4.6 PLATFORM Remove the bolts and locknuts securing the support to the rotator. Support Removal ROTATOR PLATFORM SUPPORT BOLT 1001167596-M MAF15830M 1001167596-M MAF15820M Using a suitable brass drift and hammer, remove the Figure 4-1. Location of Components Platform Support rotator shaft, then remove the support from the rotator.

  • Page 181: Support Installation

    SECTION 4 - BOOM & PLATFORM Support Installation Position the platform on the platform support and install the bolts securing the platform to the platform Using a suitable lifting device, support the platform sup- support. port and position it on the rotator. ...
  • Page 182 SECTION 4 - BOOM & PLATFORM A,B,D NOTE: If any rotator bolts are replaced, all bolts on the rotator should be torqued. 1001167596-M MAF15860M A Torque to 40 ft. lbs. (55 Nm) B Medium Strength Threadlocking Compound C Torque to 586 ft. lbs. (795 Nm) Check torque every 150 hours of operation Torque 71.5 ft.

  • Page 183: Rotator And Slave Cylinder

    SECTION 4 - BOOM & PLATFORM 4.7 ROTATOR AND SLAVE CYLINDER Installation Support the slave cylinder. Using a suitable brass drift Removal and hammer, install pin #3 to the fly boom. Support the rotator. Using a suitable brass drift and Tag and disconnect hydraulic lines from the rotator.

  • Page 184: Main Boom Powertrack

    SECTION 4 - BOOM & PLATFORM 4.8 MAIN BOOM POWERTRACK Installation Using suitable lifting equipment, adequately support Removal the powertrack weight along entire length. Disconnect wiring harness connectors located in tower With powertrack supported and using all applicable upright. safety precautions, install bolts #3 securing rail to the base boom.

  • Page 185: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.9 POWERTRACK MAINTENANCE Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack. Remove Link NOTE: Hoses shown in powertrack are for example only. Actual hose and cable arrangements are different. Clamp bar and poly roller tightly so they do not spin when removing screw.
  • Page 186 SECTION 4 - BOOM & PLATFORM To remove a link, rivets holding links together must be After grinding it may be necessary to use a center punch removed. Use a right-angle pneumatic die grinder with with a hammer to remove rivet. a ¼”...
  • Page 187 SECTION 4 - BOOM & PLATFORM Insert flat head screwdriver between links. Twist and pull Remove link from other section of powertrack using links apart. screwdriver. 31215031...

  • Page 188: Install New Link

    SECTION 4 - BOOM & PLATFORM Install New Link Spread half-shear (female) end of new link and slide cut- out end of track section into it. Use screwdriver if neces- Squeeze cut-out end of new link into half-shear (female) sary. end of track section.
  • Page 189 SECTION 4 - BOOM & PLATFORM Pull moving end over track so new connection is posi- Push pin through center hole. Slide washer on pin. tioned in curve of powertrack. Round half-shears will rotate into cut-outs. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed.
  • Page 190 SECTION 4 - BOOM & PLATFORM NOTE: Make sure snap rings are seated in pin groove and closed Pull up on other end of round bar. Slide new poly roller properly. on bar. Incorrect Correct Install new 8-32 x 0.500 self-threading Torx head screw in end of new aluminum round bar.

  • Page 191: Replace Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM Install new 8-32 x 0.500 self threading screw on other Replace Fixed End Brackets side. Torque to 18-20 in-lb (2-2.25 Nm). REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. Remove rivets as shown in link removal instructions. NOTE: When tightening screws make sure screw head is seated against link with no space in between link and underside of screw head.

  • Page 192: Replace Moving End Brackets

    SECTION 4 - BOOM & PLATFORM Take new bracket and install bracket center pin and Replace Moving End Brackets snap ring. Repeat on other bracket if replacing it. NOTE: Ensure snap rings are seated in pin groove and closed properly. REPOSITION CABLES AND HOSES.
  • Page 193 SECTION 4 - BOOM & PLATFORM Install center pin with snap ring in new bracket. NOTE: Ensure snap rings are seated in pin groove and closed properly. Incorrect Correct Make sure both brackets rotate correctly. Install radius pins and snap rings in original locations. Repeat with other moving end if replaced.

  • Page 194: Main Boom Assembly

    SECTION 4 - BOOM & PLATFORM 4.10 MAIN BOOM ASSEMBLY Remove lift cylinder pin from base boom using a suit- able brass drift and hammer. Refer to Figure 4-5., Main Boom Assembly Components. Remove hardware securing master cylinder rod end to base boom section.

  • Page 195: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly Inspection Remove hardware securing telescope cylinder to aft end NOTE: Replace worn or damage components as needed. of main boom section. Inspect main boom pivot pin for wear, scoring, tapering Remove hardware and wear pads from top, sides, and and ovality, or other damage.

  • Page 196: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly Installation Use a suitable lifting device to position boom assembly NOTE: When installing fly section wear pads, install same number on upright. Align pivot holes in boom and upright. and thickness of shims as were removed during disassem- bly.

  • Page 197: Upright

    SECTION 4 - BOOM & PLATFORM 4.11 UPRIGHT Installation Removal Using suitable lifting device, position upright on tower boom assembly so pivot holes in upright and tower boom are aligned. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- Install upright pivot pin (11) into the tower boom CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

  • Page 198: Tower Boom Assembly

    SECTION 4 - BOOM & PLATFORM 4.12 TOWER BOOM ASSEMBLY Mark all hoses and wiring harnesses at bracket on rear end of tower base boom section for future assembly. Remove hoses and wiring harness from tower boom Removal powertrack. Remove mounting hardware which secures the push tubes to the tower fly boom section.

  • Page 199: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection Align tower telescope cylinder with attach holes in tower fly boom. Install cylinder pin in tower fly boom NOTE: Replace worn or damage components as needed. using a soft head mallet. Secure with mounting hard- ware.

  • Page 200: Installation

    SECTION 4 - BOOM & PLATFORM Installation 4.13 JIB ASSEMBLY Refer to Figure 4-11., Jib Assembly. Position tower boom assembly on turntable using a suit- able lifting device. Align pivot holes in boom and turnta- Removal ble. Install tower boom pivot pin #1. Ensure location of hole NOTE: Support the jib using a suitable lifting device.

  • Page 201: Inspection

    SECTION 4 - BOOM & PLATFORM Remove mounting hardware from lift cylinder pin #7. Assembly Using a suitable brass drift and hammer, remove the cyl- inder pin from articulating jib boom. Align lift cylinder with attach holes in jib assembly. Using a soft head mallet, install cylinder pin #7 into jib and secure with mounting hardware.

  • Page 202: Boom Cleanliness Guidelines

    Make sure that all debris is removed, that no “puddling” of water has JLG recommends the use of the JLG Hostile Environment occurred, and that the boom internal components are Package if available to keep the internal portions of a dry prior to operating the machine.

  • Page 203: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.15 ROTARY ACTUATOR Required Tools Theory of Operation The L20 Series rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation. Each actuator is composed of a housing with integrated gear teeth (1) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (2), and the annular piston sleeve (3).
  • Page 204 SECTION 4 - BOOM & PLATFORM MAF19010 1. Housing 5. O-Ring 9. Cap Seal 13. Cap Bearing 2. Shaft 6. Shaft Bearing 10. Backup Ring 14. Capscrew 3. Piston 7. Thrustwasher 11. Rod Seal 15. Bolt 4. End Cap 8. Bearing Packing 12.

  • Page 205: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly Remove end cap (4) using tools provided with Helac seal kit. Remove capscrews (113) over end cap lock pins (109). Using a metal bar or similar tool, unscrew end cap (4) by Using a 1/8” (3.18mm) drill bit, drill a hole in center of turning it counterclockwise.
  • Page 206 SECTION 4 - BOOM & PLATFORM Remove stop tube if installed. Before removing shaft, (2), use a felt marker to clearly indicate timing marks between shaft and piston. This simplifies timing during assembly. Actuator has timing marks for proper engagement. Remove shaft (2).
  • Page 207 SECTION 4 - BOOM & PLATFORM Before removing piston (3), mark housing (1) ring gear in At the point when piston gear teeth come out of relation to piston O.D. gear. There should be timing engagement with housing gear teeth, mark piston and marks on housing (1) ring gear, piston (3), and shaft (2).
  • Page 208 SECTION 4 - BOOM & PLATFORM Remove wear guides (302) from end cap (4) and shaft Remove thrust washers (304) from end cap (4) and shaft (2). (2). Remove wiper seal (304.1) from end cap (4) and shaft (2). To remove main pressure seals (205), cut them with a sharp razor blade.

  • Page 209: Inspection

    SECTION 4 - BOOM & PLATFORM Remove piston I.D. seal (200). Inspect thrust washers (304) for rough or worn edges and surfaces. Measure thickness is within specifications (Not less than 0.092” or 2.34 mm). Inspection Inspect wear guide condition and measure thickness Clean all parts in a solvent tank and dry with com- (not less than 0.123”...

  • Page 210: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly Install wiper seal (304.1/green 0-ring) in groove on shaft (2) and end cap (4) - around outside edge of thrust Gather all components and tools to one location. Use washer (304). cut away drawing to reference seal orientations. Use a seal tool install main pressure seal (205) on shaft Install thrust washer (304) on shaft (2) and end cap (4).
  • Page 211 SECTION 4 - BOOM & PLATFORM Install inner T-seal (200) in piston (3) using a circular Insert piston (3) in housing (1) as shown, until outer pis- motion. Install outer T-seal (202) by stretching it around ton seal (202) touches inside housing bore. the groove in a circular motion.
  • Page 212 SECTION 4 - BOOM & PLATFORM Looking from opposite end of housing (1) when timing Install 2 bolts in threaded holes in flange. Using a bar, marks line up, tap piston (3) in until gear teeth mesh rotate shaft clockwise until wear guides are seated in together.
  • Page 213 SECTION 4 - BOOM & PLATFORM Install 0-ring (204) and backup ring (207) in inner seal Place lock pins (109) provided in Helac seal kit in holes groove on end cap (4). with dimple side up. Using a punch, tap lock pins to bot- tom of hole.

  • Page 214: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve Bolts that come with valve are Grade 8 bolts. Install new bolts with a new valve. Apply Medium Strength Thread- Refer to Figure 4-13., Rotator Counterbalance Valve. locking Compound to shanks of the three bolts at time Make sure surface of actuator is clean and free of any of installation.

  • Page 215: Testing Actuator

    SECTION 4 - BOOM & PLATFORM Testing Actuator Connect a 3/16" inside diameter x 5/16" outside diame- ter x 5 foot clear, vinyl drain tube to each of the two If equipment is available, test actuator on a hydraulic test bleed nipples.

  • Page 216: Troubleshooting

    SECTION 4 - BOOM & PLATFORM Troubleshooting Table 4-1. Troubleshooting Problem Cause Solution 1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not exceed OEM’s  pressure specifications. Load may be above maximum ...

  • Page 217: Foot Switch Adjustment

    ING INSTALLATION OR MAINTENANCE. alarm will sound at the standard JLG duty cycle of 5sec on / 2sec off and all platform controls (except emergency descent) NOTE: For models with two switches, both switches can be inde- will be disabled.

  • Page 218: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.18 SKYGUARD Function Test Operation SKYGUARD ONLY Perform this function test if SkyGuard only is selected in SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-4). When the SkyGuard sensor is activated, functions in use at the time of actuation will reverse or cutout.

  • Page 219: Diagnostics & Troubleshooting

    SECTION 4 - BOOM & PLATFORM In Ground Mode: Engage the SkyGuard sensor and observe the Analyzer to determine if the switch/relay closes. Operation is allowed regardless of SkyGuard activation. If the status of the switch/relay remains OPEN while the Sky- SOFT TOUCH ONLY Guard sensor is actively engaged, it is possible the sensor has If Soft Touch only is selected in machine setup (refer to ...

  • Page 220: Bolt-On External Fall Arrest

    SECTION 4 - BOOM & PLATFORM 4.19 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion. The Bolt-On External Fall Arrest system is designed to provide GAP SHOWING: a lanyard attach point while allowing the operator to access GAP SHOWING: INCORRECT INCORRECT...

  • Page 221: Installation

    SECTION 4 - BOOM & PLATFORM Installation Without twisting the fall arrest cable, pull it thru the left hand bracket and mark the top of the swaged cable end. Install the retaining hardware (bolts, nuts, and washers) Install the fall arrest cable through the left hand bracket and secure the brackets to the platform rail.
  • Page 222 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 223: Basic Hydraulics Information & Schematics

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SECTION 5. BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.

  • Page 224: Dip Method

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- Hold the fitting over suitable catch can.

  • Page 225: Cylinders - Theory Of Operation

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.2 CYLINDERS - THEORY OF OPERATION Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder Systems With Double Acting Cylinders Using all applicable safety precautions, activate engine and fully extend cylinder to be checked. Shut down Systems with double acting cylinders are the Slave Level, Mas- engine.

  • Page 226: Cylinders With Single Counterbalance Valve

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Cylinders With Single Counterbalance Valve Cylinders With Dual Counterbalance Valves (Main Lift Cylinder) (Articulating Jib Boom Lift, and Slave), Slave Level, Lower Lift, Upright level, Main Telescope and Tower Telescope) OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

  • Page 227: Hydraulic Cylinders

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.4 HYDRAULIC CYLINDERS Cylinder Locations Item Cylinder Item Cylinder Tower Boom Lift Tower Boom Telescope Upright Level Platform Level Slave Master Jib Lift Main Boom Lift Steer Main Boom Telescope Axle Lockout Figure 5-2.

  • Page 228: Main Boom Telescope Cylinder Removal

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Removal Main Boom Telescope Cylinder Installation Attach hydraulic power supply to telescope cylinder Place machine on flat and level surface with main boom ports. Using suitable supports or lifting devices at each horizontal.

  • Page 229: Main Boom Lift Cylinder Removal

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Main Boom Lift Cylinder Removal Main Boom Lift Cylinder Installation Place machine on flat and level surface. Start engine and Install lift cylinder in place using suitable slings or sup- place main boom horizontal. Shut down engine and ports.

  • Page 230: Upright Level Cylinder Removal

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Upright Level Cylinder Removal Drive barrel end attach pin (1) through mounting holes in upright and leveling cylinder using a suitable drift. With aid of an assistant, manually override Plunger Valve Remove mounting hardware from upright to tower with a pry bar.

  • Page 231: Tower Boom Lift Cylinder Removal

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Tower Boom Lift Cylinder Removal Remove mounting hardware securing cylinder rod pin to tower boom. Drive out cylinder rod attach pin using a Refer to Figure 5-6. Boom Positioning and Support, Cylinder suitable brass drift.

  • Page 232: Tower Lift Cylinder Installation

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Tower Lift Cylinder Installation Tower Telescope Cylinder Installation With boom positioned as in Figure 5-3. Telescope and With main boom and tower boom positioned and sup- Lift Cylinder Installation, slide telescope cylinder into ported as in Figure 5-1.

  • Page 233: Hydraulic Cylinder Repair

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.5 HYDRAULIC CYLINDER REPAIR Tower Boom Lift Cylinder DISASSEMBLY NOTE: Refer to Figure 5-8. Tower Boom Lift Cylinder NOTE: SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION. 1001261003-A MAF23530A Figure 5-8. Tower Boom Lift Cylinder 31215031 5-11...

  • Page 234: Upright Level Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Upright Level Cylinder Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews DISASSEMBLY from cylinder barrel. NOTE: Refer to Figure 5-12.
  • Page 235 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 20** 11 14 *Torque to 50 - 55 ft-lb (68 - 75 Nm) **Torque to 30 ft-lb (41 Nm) 1001228042-D MAF06200D 1. Barrel 5. Tapered Bushing 11. Lock Ring 17. Backup Ring 1a.
  • Page 236 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Using suitable protection, clamp cylinder rod in a vise or Remove and discard two lock rings (11) and seals (12) similar holding fixture as close to piston as possible. from outside grooves of piston. Remove capscrews attaching tapered bushing to piston.

  • Page 237: Cleaning And Inspection

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Cleaning and Inspection Inspect rod and barrel bearings for signs of excessive wear or damage. Replace as necessary. Clean parts thoroughly with approved cleaning solvent. a. Thoroughly clean hole, (steel bushing) of burrs, dirt Inspect cylinder rod for scoring, tapering, ovality, or etc.

  • Page 238: Assembly

    Install two seals (12) and lock rings (11) in outside diam- NOTE: Use proper cylinder seal kit for cylinder assembly. See your eter piston grooves.  JLG Parts Manual.  Apply a light film of hydraulic oil to all components before assembly.
  • Page 239 Clamp barrel (1) securely and support rod (2). Insert pis- ton in cylinder. Do not damage or dislodge piston load- Insert tapered bushing loosely in the piston. Install JLG ing O-ring and seal ring. capscrews (not vendor capscrews) through drilled holes in the bushing and tapped holes in piston.

  • Page 240: Master Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Master Cylinder DISASSEMBLY NOTE: Refer to Figure 5-24. Master Cylinder Assembly NOTE: SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION. 1001251052-A MAF23540A Figure 5-24. Master Cylinder Assembly 5-18 31215031...

  • Page 241: Main Boom Lift Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Main Boom Lift Cylinder Mark cylinder head (3) and barrel (1) with center punch marks for later realignment. Remove cylinder head cap- screws (9). DISASSEMBLY NOTE: Refer to Figure 5-28. Main Boom Lift Cylinder Assembly CONTAMINATION MAY DAMAGE EQUIPMENT.
  • Page 242 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 21*** *Torque to 30 - 35 ft-lb (41 - 48 Nm) **Torque to 50 - 55.3 ft-lb (68 - 75 Nm) ***Torque to 9.5 ft-lb (13 Nm) 1001228004-B MAF06220B 1. Barrel 4. Piston 9.
  • Page 243 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Using suitable protection, clamp cylinder rod in a vise or Remove and discard two lock rings (19) and seals (20) similar holding fixture as close to piston as possible. from outside grooves of piston. Remove capscrews attaching tapered bushing to piston.

  • Page 244: Cleaning And Inspection

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Cleaning and Inspection Inspect rod and barrel bearings for signs of excessive wear or damage. Replace as necessary. Clean parts thoroughly with approved cleaning solvent. a. Thoroughly clean hole, (steel bushing) of burrs, dirt Inspect cylinder rod for scoring, tapering, ovality, or etc.

  • Page 245: Assembly

    Use proper cylinder seal kit for cylinder assembly. See your Install two seals (20) and lock rings (19) in outside diam-  JLG Parts Manual. eter piston grooves.  Apply a light film of hydraulic oil to all components before assembly.
  • Page 246 Clamp barrel (1) securely and support rod (2). Insert pis- ton in cylinder. Do not damage or dislodge piston load- Insert tapered bushing loosely in the piston. Install JLG ing O-ring and seal ring. capscrews (not vendor capscrews) through drilled holes in the bushing and tapped holes in piston.

  • Page 247: Main Boom Telescope Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Main Boom Telescope Cylinder Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews DISASSEMBLY from cylinder barrel. NOTE: Refer to Figure 5-28.
  • Page 248 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 11** 22**** 10*** * Torque to 10 ft-lb (14 Nm) ** Torque to 9.5 ft-lb (13 Nm) *** Torque to 18.4 ft-lb (25 Nm) **** Torque to 30 ft-lb (41 Nm) 1001228007-D MAE32120D 1.
  • Page 249 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Using suitable protection, clamp cylinder rod in a vise or Remove and discard backup ring (21), O-ring (14), similar holding fixture as close to piston as possible. backup ring (21) from inside grooves of piston (3). Remove capscrews attaching tapered bushing to piston.

  • Page 250: Cleaning And Inspection

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Cleaning and Inspection Inspect rod and barrel bearings for signs of excessive wear or damage. Replace as necessary. Clean parts thoroughly with approved cleaning solvent. a. Thoroughly clean hole, (steel bushing) of burrs, dirt etc.

  • Page 251: Assembly

    NOTE: Use proper cylinder seal kit for cylinder assembly. See your Install backup ring (21), O-ring (14) and backup ring (21) JLG Parts Manual. in piston (3). NOTE: Apply a light film of hydraulic oil to all components before Install seal (13) and two lock rings (12) in outside diame- assembly.
  • Page 252 Clamp barrel (1) securely and support rod (2). Insert pis- ton (3) in cylinder. Do not damage or dislodge piston Insert tapered bushing loosely in the piston. Install JLG loading O-ring and seal ring. capscrews (not vendor capscrews) through drilled holes in the bushing and tapped holes in piston.

  • Page 253: Tower Boom Telescope Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Tower Boom Telescope Cylinder Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews DISASSEMBLY from cylinder barrel. NOTE: Refer to Figure 5-28.
  • Page 254 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 21** 20*** *Torque to 50 - 55 ft-lb (68 - 75 Nm) **Torque to 30 - 35 ft-lb (41 - 47 Nm ) ***Torque to 9.5 ft-lb (13 Nm) 1001228006-B MAF06230B 1. Barrel 6.
  • Page 255 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Using suitable protection, clamp cylinder rod in a vise or Remove and discard two lock rings (11) and seal (12) similar holding fixture as close to piston as possible. from outside grooves of piston. Remove capscrews attaching tapered bushing to piston.

  • Page 256: Cleaning And Inspection

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Cleaning and Inspection Inspect rod and barrel bearings for signs of excessive wear or damage. Replace as necessary. Clean parts thoroughly with approved cleaning solvent. a. Thoroughly clean hole, (steel bushing) of burrs, dirt Inspect cylinder rod for scoring, tapering, ovality, or etc.

  • Page 257: Assembly

    NOTE: Use proper cylinder seal kit for cylinder assembly. See your Install two seal (12) and two lock rings (11) in outside JLG Parts Manual. diameter piston grooves. NOTE: Apply a light film of hydraulic oil to all components before assembly.
  • Page 258 Clamp barrel (1) securely and support rod (2). Insert pis- ton in cylinder. Do not damage or dislodge piston load- Insert tapered bushing loosely in the piston. Install JLG ing O-ring and seal ring. capscrews (not vendor capscrews) through drilled holes in the bushing and tapped holes in piston.

  • Page 259: Platform Level (Slave) Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Platform Level (Slave) Cylinder DISASSEMBLY NOTE: Refer to Figure 5-71. Platform Level (Slave) Cylinder NOTE: SERVICE INFORMATION NOT AVAILABLE AT TIME OF PUBLICATION. 1001251051-A MAF23550A Figure 5-71. Platform Level (Slave) Cylinder 31215031 5-37...

  • Page 260: Jib Lift Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Jib Lift Cylinder Mark cylinder head and barrel with a center punch for easy realignment. Using an allen wrench, loosen the cyl- inder head retainer capscrews and remove capscrews DISASSEMBLY from cylinder barrel. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK BARREL SURFACE IN A DIRT FREE WORK AREA.
  • Page 261 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 20** 20** 16*** *Torque to 5 ft. lbs. (7 Nm) **Torque to 50-55 ft. lbs. (68-75 Nm) ***Torque to 18 ft. lbs. (25 Nm) 1001248012-B MAE33410B 1. Barrel 7. O-ring 13. Backup Ring 19.
  • Page 262 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION vise or similar holding fixture as close to the piston as Clean all parts thoroughly in an approved cleaning sol- possible.
  • Page 263 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.
  • Page 264 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Use a soft mallet to tap a new wiper seal into the appli- Assemble the tapered bushing loosely into the piston cable cylinder head gland groove. Install a new wear and insert capscrews through the drilled holes in the ring into the applicable cylinder head gland groove.
  • Page 265 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Rotate the capscrews evenly and progressively in rota- tion to 5 ft. lbs. (7 Nm). EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, Remove the cylinder rod from the holding fixture. HEAD, AND PISTON.

  • Page 266: Steer Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Steer Cylinder Unscrew Spanner Nut (13) with hook spanner. DISASSEMBLY Refer to Figure 5-89. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.
  • Page 267 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 13** *150-180 ft-lb (203-244 Nm) **57-63 ft-lb (77-85 Nm) 1001097242-B MAF23520B 1. Piston 5. Barrel 9. Backup Ring 12. Wiper 2. Seal 6. Rod 10. Seal 13. Spanner Nut 3. O-Ring 7. Head 11.

  • Page 268: Cleaning And Inspection

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Remove two Seals (2) and O-Ring (3) from Piston (1). Cleaning and Inspection Loosen two Setscrews (4) in Piston (1). Unscrew and Clean all parts in an approved cleaning solvent. remove Piston (1) from Rod (6) with strap wrench. Inspect cylinder rod for scoring, tapering, ovality, or other damage.

  • Page 269: Assembly

    INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. USE EXTREME CARE INSTALLING CYLINDER ROD AND PISTON. Insert rod assembly in barrel. Apply locking primer (JLG PN 0100038) and Medium Strength Threadlocking Compound to spanner nut threads (3). Tighten spanner nut with hook spanner to 57-63 ft-lb Figure 5-93.

  • Page 270: Axle Lockout Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS ASSEMBLY Axle Lockout Cylinder Install two new wear rings (5) and rod seal (7) in piston NOTE: Refer to Figure 5-96. bore grooves. Make sure they are not twisted. DISASSEMBLY Install new wiper (6) in housing. Lubricate piston bore with clean hydraulic fluid.
  • Page 271 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS FALLING PARTS CAN CAUSE INJURY AND EQUIPMENT DAMAGE. CYLINDER ROD CAN FALL OUT WHEN BLEEDER VALVE IS OPENED. *Torque to 25 - 27 ft-lb (33 - 36 Nm) 1684465 F 1. Barrel 4.

  • Page 272: Hydraulic Pump (Gear)

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.6 HYDRAULIC PUMP (GEAR) Remove pump from vise and place on clean work bench. Remove four hex head bolts and spacers if applicable. Disassembly NOTE: The following general instructions also apply to multiple section gear pumps.
  • Page 273 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Remove rear bearing block from drive and idler shafts. Remove front bearing block. Remove idler shaft from bearing block. Turn mounting flange over, with shaft seal up. Remove retaining ring with snap ring pliers. Remove drive shaft from mounting flange.

  • Page 274: Inspect Parts For Wear

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Inspect Parts For Wear Inspect gear face for scoring or excessive wear. If face edge of gear teeth are sharp, they will mill into the bear- Clean and dry all parts thoroughly before inspection. It ing blocks.

  • Page 275: General Information

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS General Information Install retaining ring in groove in seal bore of mounting flange. FAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT WITH LITTLE OR NO FLOW AT RATED PRESSURE. RELATIONSHIP OF MOUNTING FLANGE, BEAR- ING BLOCKS, AND GEAR HOUSING MUST BE CORRECT.
  • Page 276 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Place mounting flange, with shaft seal side down, on a Place rear bearing block over drive and idler gear shafts clean flat surface. with seal side up and open end of E-seal facing intake side of pump.
  • Page 277 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Gently slide gear housing over rear bearing block Install four spacers (if applicable) and hex head bolts assembly. Slide housing down until it engages dowel through bolt holes in end cover. Hand tighten. pins.

  • Page 278: Placing Pump Back Into Service

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Placing Pump Back Into Service 5.7 VARIABLE PUMP Ports and Pressure Gauges If shop test stand is available, use the following proce- dure for testing rebuilt pumps: Proper servicing of pumps and motors requires pressure mea- a.

  • Page 279: Remove And Install Fnr And Nfpe Modules

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Remove and Install FNR and NFPE Modules SHIM ADJUSTABLE STYLE Clean pump and module housings. Remove four screws retaining module to pump housing (4 mm Int. Hex). Remove module from housing. Remove O-rings from the control ports. Examine ports for cleanliness.
  • Page 280 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS System Pressure Gauge Port M2 Case Drain Port L2 System Pressure Port B Servo Pressure Gauge Port L4 System Pressure Port A Case Drain Port L1 System Pressure Gauge Port M1 Case Drain Port L1 (non-feedback) Servo Pressure Gauge Port M5 Charge Pressure Gauge Case Drain Port L2 (non-feedback)
  • Page 281 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Torque Plug/ Fitting lb. ft. Servo Gauge Port M4 11/16 20-35 27-47 9/16 70-100 95-135 Case Drain Port L1 Charge Pressure Gauge M3 Charge Pump Inlet Port S Case Drain Port L2 Port N System Gauge M1 &...

  • Page 282: Shaft Seal And Shaft Replacement

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Install new O-ring on valve plug. Reinstall poppet, Shaft Seal and Shaft Replacement spring, and plug (with shims and O-ring) into pump housing. Torque to 40-100 ft-lb (55-135 Nm). SCREW ADJUSTABLE STYLE 1.

  • Page 283: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Position pump with shaft facing up. NOTE: If unit is positioned horizontally when shaft is removed, cyl- inder block could move out of place, making shaft installa- tion difficult. Remove retaining ring from housing. Pull out seal carrier assembly.

  • Page 284: Charge Pump

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Charge Pump NOTE: Disassemble charge pump to inspect and clean, or change auxiliary shaft drive coupling. Remove auxiliary pump if necessary. Remove screws retaining charge pump cover to pump housing (Torx T). Seven screws are used with “no pad” or SAE “A”...

  • Page 285: Hydraulic Component Start-Up

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.8 HYDRAULIC COMPONENT START-UP NOTE: Oil used to fill component housing must be clean. Store fill container properly to prevent contamination. The goal at hydrostatic system start up is to preserve the Install 1000 psi (60 bar) pressure gauge in charge pressure designed life span of the system.

  • Page 286: Main Valve Block Pressure Settings

    Turn adjuster clockwise to HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES increase pressure or counterclockwise to decrease pres- BEFORE CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CALI- sure. BRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF WITHIN +/- 5% OF SPECIFIED PRESSURES.
  • Page 287 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS * 25-30 ft.lbs. (33.8-40.6 Nm) * * 13 ft.lbs. (17.6 Nm) Front Steer Left Tower Lift Down Direct Control Dump Valve Front Steer Right Test Port MP Tower Telescope Out Swing Right Front Steer Pressure Relief Main Upper Boom Pressure Relief Main Lift Down...
  • Page 288 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 12** 24*** Rear Steer Left (4-Wheel Steer Only) Tower Lift Down Direct Control Dump Valve Front Steer Left Rear Steer Pressure Relief (4-Wheel Steer Only) Tower Telescope Out Front Steer Right Rear Steer Right (4-Wheel Steer Only) Main Upper Boom Pressure Relief Swing Right Rear Steer Pressure Relief (4-Wheel Steer Only)
  • Page 289 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 13** 8*** 11*** 9*** *20 ft-lb (27 Nm) **13 ft-lb (17.6 Nm) ***5 ft-lb (7 Nm) MAF19020 Level Up Relief Valve (RV2) Flow Relief Valve (FR1) Jib Up Solenoid Test Port M1 Rotate Left Solenoid Jib Down Solenoid Level Down Relief Valve (RV1...

  • Page 290: Hydraulic Schematics

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.11 HYDRAULIC SCHEMATICS SHEET 1 Figure 5-108. 2-Wheel Steer (2WS) Hydraulic Schematic 1 of 2 5-68 31215031...
  • Page 291 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Figure 5-109. 2-Wheel Steer (2WS) Hydraulic Schematic 2 of 2 31215031 5-69...
  • Page 292 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 2 Figure 5-110. 4-Wheel Steer (4WS) Hydraulic Schematic 1 of 2 5-70 31215031...
  • Page 293 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 1 Figure 5-111. 4-Wheel Steer (4WS) Hydraulic Schematic 2 of 2 31215031 5-71...
  • Page 294 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 3 Figure 5-112. 2-Wheel Drive (2WD) Hydraulic Schematic 1 of 2 5-72 31215031...
  • Page 295 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 3 Figure 5-113. 2-Wheel Drive (2WD) Hydraulic Schematic 2 of 2 31215031 5-73...
  • Page 296 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 4 Figure 5-114. 4-Wheel Drive (4WD) Hydraulic Schematic 1 of 2 5-74 31215031...
  • Page 297 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SHEET 4 Figure 5-115. 4-Wheel Drive (4WD) Hydraulic Schematic 2 of 2 31215031 5-75...
  • Page 298 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 299: Jlg Control System

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH The JLG Control System controller has a built in LED to indicate AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- any faults. The system stores recent faults which may be TRIES, INC.

  • Page 300: Connect Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Connect JLG Control System Analyzer Using the Analyzer Connect four pin end of cable supplied with hand-held With the machine power on and the analyzer connected prop- or wireless analyzer to controller module on platform erly, the analyzer will display the following.

  • Page 301: 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 302: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Analyzer Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

  • Page 303: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press UP DOWN arrow keys to adjust its value, for example: CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFOR- MANCE OF YOUR MACHINE.
  • Page 304 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING ACCEL ACCELERATE GROUND ACTIVE GREEN ANALOG DIGITAL CONVERTER COUNT GROUND MODULE AMB. AMBIENT HOURS ANGLE HARDWARE AUXILIARY HWFS HARDWARE FAILSAFE BOOM CONTROL SYSTEM...
  • Page 305 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP...
  • Page 306 SECTION 6 - JLG CONTROL SYSTEM Function Switch Inputs Function Speed Knob Platform Module Lift/Swing Lamp Inputs Joystick Drive/Steer Valve Inputs Joystick Analyzer Connection Option Switch Inputs Load Cell Input Boom Cable Valve Inputs Ground Module Tilt Limit Switch Lamp Inputs...
  • Page 307 SECTION 6 - JLG CONTROL SYSTEM MENU : HELP : (001 ) HELP :PRESS ENTER EVERYTHING OK LOG : (xxx) x : xxxxxxxxxxx MENU : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS DRIVE /STEER BOOM FUNCTIONS ENGINE JOYSTICK LIFT :...
  • Page 308 SECTION 6 - JLG CONTROL SYSTEM From DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : ENGINE SYSTEM FEATURES BOOM FUNCTIONS LOAD START SEQUENCE CHASSIS TILT GROUND MODULE : FEATURES : SKYGUARD INPUTS : NOT ACTIVE BATTERY : XX.XV SKYGUARD ANGLE : XX.X...
  • Page 309 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : DIAGNOSTICS : LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS CAPACITY LENGTH CAN STATISTICS CALIBRATION DATA DATALOG : GROUND MODULE SWITCH : CLOSED LOAD ZERO :...
  • Page 310 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : DIAGNOSTICS MENU : SYSTEM TEST : SYSTEM TEST ACTIVATE ? MENU : ACCESS LEVEL ACCESS LEVEL X CODE XXXXXX PERSONALITIES : MENU : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES :...
  • Page 311 SECTION 6 - JLG CONTROL SYSTEM FROM PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE RIGHT TRACK MAIN LIFT : SWING : TOWER LIFT : MAIN TELESCOPE TOWER TELESCOPE ACCEL X .XS...
  • Page 312 SECTION 6 - JLG CONTROL SYSTEM FROM MENU : PERSONALITIES MENU : MODEL NUMBER : MARKET : ENGINE : FLYWHEEL TEETH GLOW PLUG : STARTER LOCKOUT : MACHINE SETUP 600AJ ANSI USA PERKINS ECM 133 TEETH IN-CYLINDER DISABLED FUEL CUTOUT :...
  • Page 313 SECTION 6 - JLG CONTROL SYSTEM FROM CALIBRATIONS : CALIBRATIONS : CALIBRATIONS : CALIBRATIONS : CALIBRATIONS : CALIBRATIONS : PLAT . LEVELING LEVEL UP CRKPT LEVEL DOWN CRKPT PROP MODULE MSSO DEUTZ SETUP MSSO RESET PLAT . LEVELING : LEVEL UP CRPT :...

  • Page 314: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range for optimum machine performance. Table 6-2. Personality Ranges/Defaults DEFAULTS FUNCTION PERSONALITY RANGE Drive Pump Drive Pimp M46-XXX 830XXXX DRIVE Acceleration 0.0s to 5.0s...
  • Page 315 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults DEFAULTS FUNCTION PERSONALITY RANGE Drive Pump Drive Pimp M46-XXX 830XXXX SWING Acceleration 0.0s to 5.0s Deceleration 0.0s to 3.0s Minimum Left Speed 1 to 50% Maximum Left Speed 1 to 100%...
  • Page 316 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults DEFAULTS FUNCTION PERSONALITY RANGE Drive Pump Drive Pimp M46-XXX 830XXXX PLATFORM ROTATE Acceleration 0.0s to 5.0s Deceleration 0.0s to 3.0s Minimum Left Speed 1 to 100% Maximum Left Speed 1 to 100%...
  • Page 317 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check EVERYTHING OK The normal help message in Platform No response required for this Mode. DTC. GROUND MODE OK...
  • Page 318 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 2212 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with Can be reported during Footswitch open.
  • Page 319 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM A boom function has both directions Disable whichever boom selected together.
  • Page 320 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 2518 DRIVE PREVENTED - BOOM SELECTED MACHINE SETUP > FUNCTION CUTOUT = The UGM shall prohibit Drive BOOM CUTOUT and Steer.
  • Page 321 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 3350 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the Check Harness for damage.
  • Page 322 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 3374 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the Generator Check Harness for damage.
  • Page 323 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 33106 TOWER LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the Tower Lift Check Harness for damage.
  • Page 324 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 33175 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Check Harness for damage.
  • Page 325 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 33316 FLOW CONTROL VALVE - SHORT TO GROUND There is short to Ground to the Flow Control Check Harness for damage.
  • Page 326 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 33417 LIFT - CURRENT FEEDBACK READING LOST Measured feedback current < 225mA The UGM shall suspend Lift while PWM output >...
  • Page 327 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 3416 JIB LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the JIB Lift Up Check Harness for damage.
  • Page 328 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 4310 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts for more Activate the No Charge indica- then 15 seconds after engine start.
  • Page 329 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 6623 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telematics=YES, No device heartbeat for 30 sec 6629 CANBUS FAILURE - TELEMATICS CANBUS LOADING...
  • Page 330 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 8641 FRONT LEFT STEER VALVE - SHORT TO GROUND There is a short to Ground to the Front Left Check Harness for damage.
  • Page 331 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Flash Code Sequence Fault Message Fault Description Check 9920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has reported that its Not reported during power- sensor reference voltage is outside accept- able range.
  • Page 332 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information (Software Version P6.30) Configuration Default Number Description Label/Digit Number MODEL NUMBER: 600A 740A 800A 601S H800A MARKET: ANSI USA ANSI EXPORT AUSTRALIA JAPAN * Certain model selections will limit market options.
  • Page 333 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information (Software Version P6.30) Configuration Default Number Description Label/Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
  • Page 334 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information (Software Version P6.30) Configuration Default Number Description Label/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 335 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information (Software Version P6.30) Configuration Default Number Description Label/Digit Number JIB: NO: No Jib installed. YES: Jib installed which has up and down movements only. * Only visible under certain model selections.
  • Page 336 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information (Software Version P6.30) Configuration Default Number Description Label/Digit Number FUNCTION CUTOUT: NO: No drive cutout. BOOM CUTOUT: Boom function cutout while driving above elevation. DRIVE CUTOUT: Drive & steer cutout above elevation.
  • Page 337 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information (Software Version P6.30) Configuration Default Number Description Label/Digit Number CRIBBING OPTION: NO: Cribbing Option is disabled. YES: Cribbing Option is enabled. * Only visible under certain model selections.
  • Page 338 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Settings Table 6-5. Machine Configuration Programming Settings (Software Version P6.30) (Software Version P6.30) 600AJ 600AJ Load System Model Number Market Engine Glow Plug Function Cutout Starter Lockout Ground Alarm...
  • Page 339 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Settings (Software Version P6.30) 600AJ DUAL CAPACITY BOLD BLUE text indicates the default setting. Plain text indicates another available selection. ITALIC TEXT indicates the default when option is factory installed. SHADED CELLS indicate hidden menu or selection.
  • Page 340 SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN SETTING MAIN TELESCOPE, main lift at full elevation, telescope retracted. FUNCTION SPEEDS Telescope Out, record time. Telescope In, record time. DRIVE (Below Elevation), test should perform on a smooth, Turn Platform Speed Control Knob fully counterclockwise to level surface.

  • Page 341: Test Notes

    SECTION 6 - JLG CONTROL SYSTEM Test Notes Table 6-6. Function Speeds (In Seconds) Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum Speed Function machine performance. (Seconds) Stop watch should be started with the function move-...

  • Page 342: Canbus Communications

    Platform overload fault is logged like any other fault, it remains Differential: Any electrical line noise can affect the high or the active and is displayed until it is removed using the JLG Ana- low wires but never both, so communications is not corrupted. ...

  • Page 343: Lss System

    SECTION 6 - JLG CONTROL SYSTEM 6.6 LSS SYSTEM The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE OF form load via a sensor mounted in the platform support struc- THE FOLLOWING CONDITIONS OCCUR: ture.

  • Page 344: Diagnostic Menu

    SECTION 6 - JLG CONTROL SYSTEM Diagnostic Menu Press the LEFT and RIGHT Arrow keys to view the displays and select the various sub-menus. To access a sub-menu, press the The Diagnostic Menu is another troubleshooting tool for the ENTER key. Once in a sub-menu, press the LEFT and RIGHT Load Sensing System.

  • Page 345: Calibration Procedure

    Upon entry Remove everything from the platform, except perma- to the Calibration Menu, the JLG Control System will link nently fixed JLG Accessories, to allow the Load Sensing to the Analyzer and the screen will read: System to record its’...
  • Page 346 80 lb (36 kg) Work Surface 20 lb (9 kg) NOTE: Not all Accessories are available on every JLG model. Some Accessory combinations are prohibited due to excessive weight and/or load restriction. If any installed JLG Accessories are labeled with weight decals but are not listed in the table above, include their weight when entering the ACC WEIGHT value.
  • Page 347 SECTION 6 - JLG CONTROL SYSTEM The control system will calculate the load cell readings Use the analyzer keys to select N for no or Y for yes. Press and ensure it is greater than 130 lbs. (59 kg), but less than 575 lbs.(261 kg).
  • Page 348 SECTION 6 - JLG CONTROL SYSTEM Use the analyzer keys to select N for no or Y for yes. Press Table 6-10. Pipe Rack Capacity Reductions PLATFORM OVRLD ENTER . The control system will default to an esti- Capacity PLATFORM OVRLD...
  • Page 349 SECTION 6 - JLG CONTROL SYSTEM Press ENTER . If calibration is successful, the screen will read: 31215031 6-51...

  • Page 350: Testing & Evaluation

    (fully functional and the Load Sensing System’s Overload stowed) for safety. Plug the JLG Analyzer into the control Visual and Audible Warnings are not active. Simulate an system connection and proceed to the DIAGNOSTICS, Overload by unplugging the Shear Beam Load Cell.

  • Page 351: Troubleshooting

    Rated Load, or when simulated by unplugging the 1. The Load Sensing System must be enabled within the Control System. Plug the JLG Analyzer into the Control System, enter the Access Load Cell. Controls remain functional at Plat- Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu.

  • Page 352: Resetting The Msso System

    SECTION 6 - JLG CONTROL SYSTEM 6.7 RESETTING THE MSSO SYSTEM Use the arrow keys to reach the LOAD SENSING menu. The screen should read: Use the following procedure to reset the MSSO system. Position the Platform/Ground select switch to the desired position.
  • Page 353 SECTION 6 - JLG CONTROL SYSTEM Press Enter . The screen will read: Press Enter . The JLG Control System will reset an active 873 DTC and the MSSO System will be reset. Press Escape to return to the CALIBRATIONS menu.
  • Page 354 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Fault Code List 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 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION...
  • Page 355 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Fault Code List Text 2514 BOOM PREVENTED - DRIVE SELECTED 2516 DRIVE PREVENTED - ABOVE ELEVATION 2517 DRIVE PREVENTED - TILTED & ABOVE ELEVATION 2518 DRIVE PREVENTED - BOOM SELECTED 2519 DRIVE PREVENTED - TILTED & EXTENDED OR HIGH ANGLE...
  • Page 356 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Fault Code List Text 3369 TWO SPEED VALVE - OPEN CIRCUIT 3370 TWO SPEED VALVE - SHORT TO BATTERY 3371 GROUND ALARM - SHORT TO GROUND 3372 GROUND ALARM - OPEN CIRCUIT...
  • Page 357 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Fault Code List Text 33117 TOWER TELESCOPE OUT VALVE - SHORT TO BATTERY 33118 SWING RIGHT VALVE - SHORT TO GROUND 33119 SWING RIGHT VALVE - OPEN CIRCUIT 33120 TELESCOPE IN VALVE - SHORT TO BATTERY...
  • Page 358 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Fault Code List Text 33321 DRIVE REVERSE VALVE - SHORT TO BATTERY 33322 DRIVE REVERSE VALVE - SHORT TO GROUND 33323 LIFT UP VALVE - OPEN CIRCUIT 33324 LIFT UP VALVE - SHORT TO BATTERY...
  • Page 359 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Fault Code List Text 3426 JIB ROTATE RIGHT VALVE - SHORT TO GROUND FUEL SENSOR - SHORT TO BATTERY OR OPEN CIRCUIT FUEL SENSOR - SHORT TO GROUND OIL PRESSURE - SHORT TO BATTERY...
  • Page 360 SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Fault Code List Text 8640 FRONT LEFT STEER VALVE - SHORT TO BATTERY 8641 FRONT LEFT STEER VALVE - SHORT TO GROUND 8642 FRONT RIGHT STEER VALVE - OPEN CIRCUIT 8643 FRONT RIGHT STEER VALVE - SHORT TO BATTERY...
  • Page 361 SECTION 6 - JLG CONTROL SYSTEM GROUND CONTROL MODULE PLATFORM CONTROL MODULE MAE8820 Figure 6-10. Control Module Locations 31215031 6-63...
  • Page 362 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-11. Analyzer Connecting Points 6-64 31215031...
  • Page 363 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type ENGINE THROTTLE ACTUATOR DIGITAL OUTPUT LP START ASSIST DIGITAL OUTPUT DRIVE LEFT TRACK FORWARD COIL DIGITAL OUTPUT GROUND GROUND INPUT GROUND GROUND INPUT DRIVE LEFT TRACK REVERSE COIL DIGITAL OUTPUT LP LOCK ELECTRIC FAN DRIVE...
  • Page 364 SECTION 6 - JLG CONTROL SYSTEM Connector Function Type Function PLATFORM EMS DIGITAL INPUT Connector Type PLATFORM MODE DIGITAL INPUT MODULE GROUND GROUND OUTPUT GROUND MODE DIGITAL INPUT MODULE POWER VBAT INPUT (Black) CAPACITY ANGLE SWITCH ANALOG INPUT GROUND TO PLATFORM MODULE...
  • Page 365 SECTION 6 - JLG CONTROL SYSTEM CONNECTOR ASSIGNMENT FUNCTION UNALLOCATED DIGITAL INPUT UNALLOCATED DIGITAL INPUT BATTERY VOLTAGE HS DIGITAL INPUT DRIVE ORIENTATION SYSTEM OVERRIDE SWITCH HS DIGITAL INPUT UNALLOCATED LAMP OUTPUT CHASSIS TILTED INDICATOR LAMP OUTPUT FUNCTION ENABLE INDICATOR LAMP OUTPUT...
  • Page 366 SECTION 6 - JLG CONTROL SYSTEM FUNCTION CONNECTOR ASSIGNMENT GROUND MODULE GROUND BATTERY VOLTAGE MODULE POWER CONNECTOR ASSIGNMENT FUNCTION LIFT SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE LIFT CENTER TAP INPUT LIFT SIGNAL INPUT SWING SIGNAL INPUT NATURAL SWING CENTER TAP...
  • Page 367 SECTION 6 - JLG CONTROL SYSTEM J2 - GRAY 35 PIN J5 - NATURAL 8 PIN J6 - BLACK 8 PIN J8 - POWER J1 - BLACK 35 PIN J1 - NATURAL 35 PIN 1001106355-E MAF17690-E Figure 6-16. Platform Control Module (China Market)
  • Page 368 SECTION 6 - JLG CONTROL SYSTEM Connector Pin Assignment Function Connector Pin Assignment Function TOWER LIFT UP DIGITAL INPUT UNALLOCATED DIGITAL INPUT TOWER LIFT DOWN DIGITAL INPUT UNALLOCATED DIGITAL INPUT TOWER TELESCOPE IN DIGITAL INPUT BATTERY VOLTAGE HS DIGITAL TOWER TELESCOPE OUT...
  • Page 369 SECTION 6 - JLG CONTROL SYSTEM Connector Pin Assignment Function Connector Pin Assignment Function GROUND MODE GROUND MODE LIFT / SWING JOYSTICK SUPPLY VOLTAGE SUPPLY VOLTAGE PLATFORM EMS PLATFORM EMS LIFT CENTER TAP INPUT PLATFORM EMS TO GROUND MODULE PLATFORM...
  • Page 370 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 371: Basic Electrical Information & Electrical Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENERAL Polarity Getting a negative Voltage or current reading when expecting This section contains basic electrical information and  a positive reading frequently means the leads are reversed. schematics for locating and correcting most electrical prob- Check what reading is expected, location of the signal and lems.

  • Page 372: Resistance Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing conti- nuity Figure 7-2.

  • Page 373: Current Measurement

    ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG PN 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- RIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connec- tions: •...

  • Page 374: Dielectric Grease Application

    Anderson connectors for the battery boxes and battery The following connector systems are specifically chargers should have silicone grease applied to the con- addressed because of their widespread use at JLG. How- tacts only. ever, this guidance may be applied to similar devices.

  • Page 375: Amp Mini Fit Jr

    This connector system is typically used on control mod- from dielectric grease, and some non waterproof con- ules at JLG. Follow the general guidance for installation. nectors do not benefit from dielectric grease. In the exceptions below, we have found dielectric grease is not needed for some applications, and in some cases can interfere with the intended connection.

  • Page 376: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.5 AMP CONNECTOR Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact  (See Figure 7-7.). Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-5.).
  • Page 377 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-7. Connector Assembly Figure 2 After all required contacts have been inserted, the Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-9.) Release the locking latches by squeezing them inward (See Figure 7-8.).

  • Page 378: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-10. Connector Disassembly Disassembly Service - Voltage Reading Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. Pry open the wedge lock to the open position.
  • Page 379 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-11. Connector Installation 31215031...

  • Page 380: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.6 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-13. DT/DTP Contact Removal Figure 7-12. DT/DTP Contact Installation Remove wedgelock using needlenose pliers or a hook Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.

  • Page 381: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal 8. Grasp contact about 25mm behind the contact crimp 11. With rear insert toward you, snap appropriate size barrel.

  • Page 382: Telematics Gateway

    DEF Tank Level (If Equipped) Percentage (%) • 100% = Full • 00 - No Machine Faults • 01 - Active Machine Fault JLG Machine Faults: Active / Not-Active • 10 - Error • 11 - Not available Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions.
  • Page 383 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 31215031 7-13...
  • Page 384 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1609 ( MS1620-3 (CAN-T 2) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET 1-0 BAT 16 AWG X1606 (B) CANH2 18 AWG CO1613-J2 (10) 0-0 GND 16 AWG S1615 (1)
  • Page 385 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS FROM REFERENCE WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE MS1620-2 CAN L2 18 AWG 1151 MS1619-3 CAN L2 18 AWG X1609 MS1619-2 CAN L1 18 AWG MS1618-2 CO1613-J1 CAN L2 18 AWG MS1620-3 CO1613-J2...

  • Page 386: Wiring Harness

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.8 WIRING HARNESS Table 7-1. Wiring Harness Connector Labels Component Category Label Connector Labels Audible Alarms Connectors between harnesses are identified by the prefix “X” Horns and a sequentially assigned number. An optional suffix (letters Battery Batteries &...
  • Page 387 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Table 7-1. Wiring Harness Connector Labels Component Category Label Other Switches Disconnect Foot HVAC Park brake Pump pot Push Shifter Turn signal Relay 5 Pin 4 Pin Contactor Power module Rocker Switch Sensor Angle Fuel...

  • Page 388: Wiring Harness Breakdown

    FLOODLIGHTS 7500W GENERATOR GENERATOR PLATFORM SWITCH PLATFORM WORK LIGHTS ELEVATION LIMIT SWITCH TOWER BOOM ELEVATION LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH (600AJ ANSI ANSI EXPORT BRAZILIAN & JAPANESE SPECS) BOOM LENGTH LIMIT SWITCH PLATFORM CONTROL PLATFORM VALVE GROUND CONTROL...
  • Page 389 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 2500W GENERATOR RELAY 2500W GENERATOR CONTROL BOX 2500W 7500W 7500W GENERATOR GENERATOR 7500W GENERATOR CONTROL BOX RELAYS SKYPOWER GENERATOR ENGINE CONTROL MODULE (DEUTZ D2011) ENGINE TO FUEL WATER IN CONTROL FUEL PUMP FUEL IND.
  • Page 390 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001243984-B MAF17830B 7-20 31215031...
  • Page 391 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001243984-B MAF17840B 31215031 7-21...
  • Page 392 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS MAE18180C 7-22 31215031...
  • Page 393 BLACK "G" "E" NOTE: ALL WIRES ARE GXL UNLES OTHERWISE SPECIFIED LEVEL ALL WIRE COLORS, PRINTING AND NUMBERING METHODS MUST COMPLY WITH JLG ENGINEERING DESIGN GUIDELINES NUMBER 4.00. "F" ROTATE DETAIL "A" RIGHT (FOR BREAKING OUT LOOM FROM MAIN LOOM) MAE19430A Figure 7-26.
  • Page 394 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-24 31215031...
  • Page 395 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 31215031 7-25...
  • Page 396 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-26 31215031...
  • Page 397 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 31215031 7-27...
  • Page 398 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-28 31215031...
  • Page 399 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 31215031 7-29...
  • Page 400 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 4923224-F MAF17700F Figure 7-33. Main Valve Harness (China Market) 7-30 31215031...
  • Page 401 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS "E" C RED BLACK C BLACK RED E SHIELD WIRE DETAIL "B" DETAIL "C" BLACK E SHIELD WIRE (FOR BREAKING OUT LOOM (FOR BREAKING OUT LOOM A BLACK BLACK FROM MAIN LOOM) FROM MAIN LOOM) A RED DETAIL "P"...
  • Page 402 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS "E" DETAIL "B" DETAIL "C" (FOR BREAKING OUT LOOM (FOR BREAKING OUT LOOM FROM MAIN LOOM) FROM MAIN LOOM) "B" STROBE LIGHT SEE DETAIL COVER THIS END OF COMPLETED "P","T" HARNESS TO AVOID DAMAGE TO TERMINALS DURING SHIPPING AND HANDLING.
  • Page 403 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS C RED BLACK C BLACK RED E SHIELD WIRE BLACK E SHIELD WIRE A BLACK BLACK A RED DETAIL "P" SONIC WELDS SONIC WELD YEL/RED 2-1-98 -S YEL/RED 2-1-99-1 (16) -E YEL/RED 2-1-99 (16) -A DETAIL "T"...
  • Page 404 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001191866-C MAE19290C Figure 7-37. Deutz TD2.9L4 (T4F) Engine harness 7-34 31215031...
  • Page 405 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001214507-E MAE3630E Figure 7-38. Ford Engine Harness 31215031 7-35...
  • Page 406 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001243263-B MAF17850B Figure 7-39. Ground Control Box Harness Deutz D2011 (T4i), Deutz TD 2.9L4 (T4F) and Ford DF 2.5L, MSG425 Engines - Sheet 1 of 2 7-36 31215031...
  • Page 407 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS RED-DD BLACK-DD SHIELD WIRE 1001243263-B MAF18530B Figure 7-40. Ground Control Box Harness Deutz D2011 (T4i), Deutz TD 2.9L4 (T4F) and Ford DF 2.5L, MSG425 Engines - Sheet 2 of 2 31215031 7-37...
  • Page 408 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.10 ELECTRICAL SCHEMATICS PLATFORM WORK LIGHTS OPTION #1 SHEET 1 ZONE B2 GREEN SHEET 1 RED 1-91 ZONE B2 BLACK RED 1-2(10) 10/3 5 AMP 30 AMP BLACK SEE SHT 9 ZONE F5 20 AMP BLUE 102-1 SEE ZONE A5...
  • Page 409 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SHEET 1 ZONE B2 SHEET 1 RED 1-91 ZONE B2 RED 1-2(10) 5 AMP 30 AMP GROUND CONTROL BOX 20 AMP SEE ZONE A5 BLUE 102-1 +12 VDC BLACK OUTPUT YEL/RED 2-40-9 WHEN ON BROWN 13-2 BLACK...
  • Page 410 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BATTERY + SHEET 1 ZONE C1 STARTER MOTOR SEE VENDOR SCHEMATIC DETAIL SHEET 4 GLOW ZONE E/G2 PLUGS 14 GA FUSE LINK SEE VENDOR SCHEMATIC DETAIL SHEET 2 ZONE G/E2 LOW TEMPERATURE CUTOUT OPTION P-J8A YEL/RED-7 CONNECT TO P8...
  • Page 411 5 AMP POWERMITE 2500 W GENERATOR GENERATOR BLU/ORN 52-5 86 85 GENERATOR PLUG GENERATOR 4000 W CONTROL GENERATOR BLU/ORN 52-5 GENERATOR PLUG JLG GENERATOR WIRING SHEET 2 1001251537-B MAF17510B Figure 7-44. Electrical Schematic - Sheet 4 of 18 31215031 7-41...
  • Page 412 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS RECTIFER FUSIBLE LINK STATOR T4i ENGINE HARNESS STARTER ALTERNATOR DEUTZ ENGINE MOTOR SOL. REGULATOR SENSING AND STARTER SWITCHING MOTOR CIRCUITS WHT/YEL 48-13 (8) IN HEAD GLOW PLUGS sol. sol. J1-22 SHEET 1 ZONE D3 BLU/ORN 52-5 GENERATOR...
  • Page 413 J1-22 SELECT SWITCH SHEET 1 SHEET 1, ZONE G5 SHEET 1 ZONE D3 ZONE D3 GENERATOR RECEPTACLE SHEET 1 ZONE E5 JLG SCHEMATIC GM/PSI ENGINE SHEET 4 1001251537-B MAF17530B Figure 7-46. Electrical Schematic - Sheet 6 of 18 31215031 7-43...
  • Page 414 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ECM-J2 BUSSMANN DIODE PACK BLK 248-33 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT) (BLUE) BLK 248-16 INJECTOR 1 1.5mm² YELLOW CONNECTOR GLOWPLUG SOLENOID BLK 248-48 INJECTOR 4 1.5mm² GENERIC 150 AMP BLK 248-18 INJECTOR 4 1.5mm²...
  • Page 415 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BUSSMANN DIODE PACK FUEL PUMP 20A (SW), ECM 30A (CONT) (BLUE) YELLOW CONNECTOR GLOWPLUG SOLENOID GLOWPLUGS T4F ENGINE HARNESS SCHEMATICS GENERIC 150 AMP RELAY, POWER MODULE GENERIC GENERIC ALTERNATOR BATTERY POSITIVE BUSBAR EC971-B+ EC971...
  • Page 416 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS PLATFORM SENSOR ORN/RED 49-69 PLATFORM SENSOR YEL/RED P1 ZONE D6 SHT 1 YEL/RED 2-63 ZONE E6 YEL/RED P8 YEL/RED P9 ZONE D6 ZONE E2 YEL/RED P2 FOR REF. ONLY SEE SHEET 9 SOFT TOUCH ZONE E5 SOFT TOUCH AND PLATFORM SENSOR...
  • Page 417 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS PLATFORM SENSOR YEL/RED P3 YEL/RED P3 SHT 1 ZONE H8 YEL/RED P9-1 ORN/RED P5 ORN/RED P5-1 4 PIN ORN/RED P4 PLATFORM SENSOR ORN/RED P4-1 ORN/RED P4 ORN/RED P5 BLK P6 SHT 1 YEL/RED P10 YEL/RED P2 ZONE D7...
  • Page 418 J1-22 SELECT SWITCH SHEET 1 SHEET 1, ZONE G5 SHEET 1 ZONE D3 ZONE D3 GENERATOR RECEPTACLE SHEET 1 ZONE E5 JLG SCHEMATIC FORD ENGINE SHEET 7 1001251537-B MAF17560B Figure 7-51. Electrical Schematic - Sheet 11 of 18 7-48 31215031...
  • Page 419 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SHEET 8 Figure 7-52. Electrical Schematic - Sheet 12 of 18 7-50 31215031...
  • Page 420 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SHEET 8 1001251537-B MAF17570B Figure 7-53. Electrical Schematic - Sheet 13 of 18 31215031 7-51...
  • Page 421 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS HARNESS,GEN 2 PLAT INTERFACE 4 PIN SKYGUARD PLTFM SNSR PLTFM SNSR PLTFM SNSR RELAY #1 RELAY #2 NOTE: 6 PIN CONNECTOR AND RELAYS LOCATED ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX. IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 6.
  • Page 422 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS MACHINE WITH SOFTTOUCH SOFTTOUCH LIMIT SWITCH YEL/RED 2-63 SEE SHT 10 ZONE E6 NOTE: 6 PIN CONNECTOR AND RELAYS LOCATED ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX. 5 AMP IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 6.
  • Page 423 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SKYGUARD (BAR) 6 PIN HARNESS PLTFM SNSR PLTFM SNSR PLTFM SNSR RELAY #1 RELAY #2 S191 NOTE: 6 PIN CONNECTOR AND RELAYS LOCATED S192 ON THE LEFT SIDE OF THE CONTROL PLATFORM BOX. IF SKYGUARD RELAYS ARE ON THE RIGHT SIDE, SEE SHEET 6.
  • Page 424 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS ECM-J2 BUSSMANN DIODE PACK BLK 248-33 INJECTOR 1 1.5mm² (BLUE) GLOWPLUG SOLENOID BLK 248-16 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT) BLK 248-48 INJECTOR 3 1.5mm² YELLOW CONNECTOR 150 AMP BLK 248-18 INJECTOR 3 1.5mm²...
  • Page 425 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BUSSMANN DIODE PACK BLK 248-33 INJECTOR 1 1.5mm² (BLUE) BLK 248-16 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT) GLOWPLUG SOLENOID BLK 248-48 INJECTOR 3 1.5mm² YELLOW CONNECTOR 150 AMP BLK 248-18 INJECTOR 3 1.5mm²...
  • Page 426 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

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