JLG 600SJ Service And Maintenance Manual
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JLG 600SJ Service And Maintenance Manual

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Service and Maintenance Manual
Models
600S
600SJ
660SJ
S/N 0300080000
to 0300171769
P/N - 3121202
February 26, 2014

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Summary of Contents for JLG 600SJ

  • Page 1 Service and Maintenance Manual Models 600S 600SJ 660SJ S/N 0300080000 to 0300171769 P/N - 3121202 February 26, 2014...

  • Page 3: Bhydraulic System Safety

    Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be discon- nected with minimal fluid loss. 3121202 – JLG Lift –...
  • Page 4 Original Issue - October 15, 2004 Revised - May 23, 2005 Revised - October 11, 2005 Revised - March 2, 2006 Revised - March 12, 2008 Revised - November 20, 2012 Revised - February 26, 2014 – JLG Lift – 3121202...

  • Page 5: Table Of Contents

    Battery ..............2-3 3121202 – JLG Lift –...
  • Page 6 Welding on JLG Equipment ............2-5 Do the Following When Welding on JLG Equipment ......2-5 Do NOT Do the Following When Welding on JLG Equipment .
  • Page 7 Coolant Fill Procedure - Dual Fuel Engine ........3-97 3121202 – JLG Lift –...
  • Page 8 Assembly ..............4-16 – JLG Lift –...
  • Page 9 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication......5-35 3121202 – JLG Lift –...
  • Page 10 To Connect the JLG Control System Analyzer ........
  • Page 11 Swash Plate and Journal Bearing ..........3-29 3121202 – JLG Lift –...
  • Page 12 Deutz Sensors for JLG Control System ........
  • Page 13 Platform Support Torque Values...........4-38 3121202 – JLG Lift –...
  • Page 14 Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4 .......6-16 – JLG Lift –...
  • Page 15 Hydraulic Schematic - Sheet 6 of 6..........7-25 3121202 – JLG Lift –...
  • Page 16 Major Component Weights - 600SJ ........

  • Page 17: Section 1 - Specifications

    0.044 in. (1.117 mm) Aspiration turbocharged Compression ratio 19:1 Displacement 203 in (3.33 L) Firing Order 1-3-4-2 Rotation (viewed from flywheel) Counterclockwise Oil Capacity (w/filter) 10.6 quarts (10 L) Cooling System (Engine Only) 5.8 quarts (5.5 L) 3121202 – JLG Lift –...

  • Page 18: Drive System

    Hydraulic Strainers (In Tank) 30 Microns Size Load Range Ply Rating Pressure 15 x 19.5 95 PSI (6.5 Bar) 15 x 19.5 Foam-Filled 18 x 625 60 PSI (4 Bar) 41/18LL x 22.5 70 PSI (5 Bar) – JLG Lift – 3121202...

  • Page 19: Performance Data

    4.5 MPH (7.25 Km/hr.) Machine Length (Stowed) 4 MPH (6.44 Km/hr.) 600S Over Drive Axle 27 ft. 11.125 in. (8.51 m) 600SJ Over Drive Axle 32 ft. 11.75 in. (10.05 m) Gradeability 660SJ Over Drive Axle 35 ft. 2.875 in. (11.40 m)

  • Page 20: Function Speeds

    Start with the Jib down. Jib Up, Record Time. Jib Reverse 58-68 Down, Record Time. Drive Above Horizontal - Forward & Reverse 46-54 (4WD) *Max 10% Difference Between Left & Right **Max 15% Difference Between Left & Right 4150501 - B – JLG Lift – 3121202...

  • Page 21: Torque Requirements

    NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C Above +32°F. (+0°C.) or have properties of API classification CC/CD Above +50°F. (+10°C.) grades. Multi-Viscosity Oil. (SF, SF-SE, SF-CC, SF-CD) *Not recommended for severe service, including high RPM operation 3121202 – JLG Lift –...

  • Page 22: Hydraulic Oil

    152. Aside from JLG recommendations, it is not advisable to NOTE: When temperatures remain below 20° F (-7° C), JLG mix oils of different brands or types, as they may not con- Industries recommends the use of Mobil DTE 13M.

  • Page 23: Cylinder Specifications

    (88.9) (331.8) (38.1) (76.2) (215.9) (38.1) Lift (Articulating 25.5 Jib Boom) (76.2) (647.7) (38.1) Table 1-22. Cylinder Specifications - 600SJ 1.9 MAJOR COMPONENT WEIGHTS DESCRIPTION BORE STROKE ROD DIA. Lift 6.00 44.6875 (152.4) (1135.1) (76.2) Table 1-24. Major Component Weights - 600S Telescope 143.1875...

  • Page 24: Critical Stability Weights

    SECTION 1 - SPECIFICATIONS Table 1-27. Critical Stability Weights - 600S Table 1-25. Major Component Weights - 600SJ Tire and Wheel (Ballasted Only) Size (15 - 19.5) Platform Control Console Engine Ford Platform Level Cylinder Deutz Main Boom (Includes Lift Cyl., Rotator, and Support)

  • Page 25: Lubrication And Operator Maintenance

    Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/ MIL-L-2104C. Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Remote Access 3121202 – JLG Lift –...
  • Page 26 2 years or 1200 hours of operation 6. Hydraulic Charge Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. 1-10 – JLG Lift – 3121202...
  • Page 27 11. Oil Change w/Filter - Caterpillar Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10.6 Quarts Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accor- dance with engine manual. 3121202 – JLG Lift – 1-11...
  • Page 28 Lube Point(s) - Replaceable Element Interval - Every Year or 1200 hours of operation Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 1-12 – JLG Lift – 3121202...

  • Page 29: Draining Oil Build Up From The Propane Regulator

    5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Propane Fuel Fil- ter Replacement 3121202 – JLG Lift – 1-13...

  • Page 30: Propane Fuel Filter Replacement

    6. Remove the filter from the housing. 7. Remove and discard the housing seal. 8. Remove and discard the retaining bolt seal. 9. Remove and discard mounting plate to lock off O- ring seal. 1-14 – JLG Lift – 3121202...

  • Page 31: Propane Fuel System Pressure Relief

    A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame. Figure 1-3. Serial Number Locations 3121202 – JLG Lift – 1-15...

  • Page 32: Torque Chart (Sae Fasteners - Sheet 1 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3) 1-16 – JLG Lift – 3121202...

  • Page 33: Torque Chart (Sae Fasteners - Sheet 2 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3) 3121202 – JLG Lift – 1-17...

  • Page 34: Torque Chart (Sae Fasteners - Sheet 3 Of 3)

    SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 3) 1-18 – JLG Lift – 3121202...

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

    SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3) 3121202 – JLG Lift – 1-19...

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

    SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 2 of 3) 1-20 – JLG Lift – 3121202...

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

    SECTION 1 - SPECIFICATIONS Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3) 3121202 – JLG Lift – 1-21...
  • Page 38 SECTION 1 - SPECIFICATIONS NOTES: 1-22 – JLG Lift – 3121202...

  • Page 39: Section 2 - General

    (13) months from the maintenance have been completed before placing the date of the prior Annual Machine Inspection. JLG Indus- machine into service. tries recommends this task be performed by a Factory- Trained Service Technician.

  • Page 40: Service And Guidelines

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

  • Page 41: Component Disassembly And Reassembly

    If a bolt is too short, tion) lines. there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 3121202 – JLG Lift –...

  • Page 42: Hydraulic Oil

    (if equipped) slightly elevated, main boom fully extended with the rated load in the platform and power off. Maximum allowable drift is 2 inches (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following. – JLG Lift – 3121202...

  • Page 43: Cylinder Drift

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

  • Page 44: Inspection And Preventive Maintenance Schedule

    1,2,5 Hood, Hood Props, Hood Latches Chassis Assembly 16,17 16,17,18 16,17,18 Tires Wheel Nuts/Bolts 14,24 Wheel Bearings Oscillating Axle/Lockout Cylinder Systems Outrigger or Extendable Axle Systems Steer Components Drive Motors Torque Hubs Functions/Controls Platform Controls – JLG Lift – 3121202...
  • Page 45 7,11 7,11 Hydraulic Fluid Electrical Connections 5,23 Instruments, Gauges, Switches, Lights, Horn General Operators and Safety Manuals in Storage Box ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible 3121202 – JLG Lift –...
  • Page 46 21, 22 Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to use each day; or at each Operator change Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...

  • Page 47: Engine Operating Temperature Specifications - Deutz

    SECTION 2 - GENERAL 4150548 E Figure 2-1. Engine Operating Temperature Specifications - Deutz 3121202 – JLG Lift –...

  • Page 48: Engine Operating Temperature Specifications - Ford

    SECTION 2 - GENERAL 4150548 E Figure 2-2. Engine Operating Temperature Specifications - Ford 2-10 – JLG Lift – 3121202...

  • Page 49: Engine Operating Temperature Specifications - Caterpillar

    SECTION 2 - GENERAL 4150548 E Figure 2-3. Engine Operating Temperature Specifications - Caterpillar 3121202 – JLG Lift – 2-11...

  • Page 50: Engine Operating Temperature Specifications - Gm

    SECTION 2 - GENERAL 4150548 E Figure 2-4. Engine Operating Temperature Specifications - GM 2-12 – JLG Lift – 3121202...

  • Page 51: Section 3 - Chassis & Turntable

    The air pressure for pneumatic tires must be equal to the The rims installed on each product model have been air pressure that is stenciled on the side of the JLG prod- designed for stability requirements which consist of track uct or rim decal for safe and proper operational character- width, tire pressure, and load capacity.

  • Page 52: Drive Torque Hub

    If a leak is detected in a seal, o- ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi for 20 minutes. THE BRAKE TEST – JLG Lift – 3121202...

  • Page 53: Tightening And Torquing Bolts

    4. Remove the Cover Subassembly (6) from the unit. ing bolts. The unit can be carefully pressurized with air to pop 4. Now use a torque wrench to apply the specified the cover out of the unit. torque to bolt "A". 3121202 – JLG Lift –...

  • Page 54: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE 6. Cover 6G. Retaining Ring 15. ID Plate Figure 3-1. Main Disassembly – JLG Lift – 3121202...

  • Page 55: Input Carrier

    Input Shaft (9) will need to be removed together. sembling the unit. 9. Loosen and remove the three Flat Head Bolts (19) that retain the Ring Gear (1E) to the Housing (1G). 10. Lift the Ring Gear (1E) off of the Housing (1D). 3121202 – JLG Lift –...

  • Page 56: Planet Gear Sub Assembly

    Spindle (1A). (4C) and the Thrust Spacer (4D) from the Second Stage Planet Gear (4F). 4B. Thrust Washer 4D. Thrust Spacer 4C. Needle Roller 4F. Planet Gear Figure 3-3. Planet Gear Sub Assembly – JLG Lift – 3121202...

  • Page 57: Input Carrier Disassembly

    (3B) out of the Carrier (3A). 5. Remove the 14 needle Bearings (3C) from the bore of the Planet Gear (3F). 6. Repeat steps 1 through 5 for each of the two remain- ing planet gears. 3121202 – JLG Lift –...

  • Page 58: Hub-Spindle Disassembly

    4. While supporting the unit on Hub (1D) flange, press (1C) out of Hub (1D). Spindle (1A) out of Hub (1D). 5. Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q) from Hub (1D) if applicable. – JLG Lift – 3121202...

  • Page 59: Spindle-Brake Disassembly

    8J. Rotor 12. Plastic Plug 7. Coupling Subassembly 8D. O-Ring 8K. Stator 21. Pipe Plug 8A. Piston 8E. Backup Ring 8L. Compression 22. Flat Head Capscrew 8B. Pressure Plate 8F. O-Ring Spring Figure 3-7. Spindle Brake 3121202 – JLG Lift –...

  • Page 60: Coupling Subassembly

    Retaining Ring (8C). NOTE: Flat Head Cap Screws (22) are removed prior to shipping new units since they are for transit and ser- vice only. They are included in most brake repair kits. 3-10 – JLG Lift – 3121202...

  • Page 61: Cover Disassembly

    6. Remove two O-Ring Pipe Plugs (6F) from Cover (6A). 3. Unscrew two Hex Head Bolts (6C) and remove Dis- engage Cap (6B) from Cover (6A). 4. Pull Disengage Rod (6D) out from Cover (6A). 3121202 – JLG Lift – 3-11...

  • Page 62: Input Carrier Sub-Assembly

    Piston (8A). Make sure the O-Ring is seated on the bottom of the groove. NOTE: Some grease may need to be applied to the Thrust Washers (3B) to hold them in place while installing the planet gears. 3-12 – JLG Lift – 3121202...

  • Page 63: Hub-Spindle Sub-Assembly

    6. Set Spindle assembly (1A) on the bench with the flange down. Turn Hub (1D) over and lower onto Spindle (5). Install boot (21) if applicable. 3121202 – JLG Lift – 3-13...

  • Page 64: Cover Sub-Assembly

    9. Place Input Carrier Sub-Assembly (3A) onto Output Sun Gear (11) splines. Drop Input Sun (10) into mesh with planet gears for specific ratios, if required. (No timing required). 10. Grease O-Ring (17) and insert into groove in Cover Sub-Assembly (6). 3-14 – JLG Lift – 3121202...

  • Page 65: Hub Assembly

    6A. Cover 8B. Pressure Plate 9. Input Shaft 20. Retaining Ring 1K. Retaining Ring 4B. Thrust Washer 6B. Disengage Cap 8C. Retaining Ring 10. Sun Gear 21. O-Ring Plug 1L. Spring Figure 3-10. Hub Assembly 3121202 – JLG Lift – 3-15...

  • Page 66: Bearing Cup Pressing Tool

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-11. Bearing Cup Pressing Tool Figure 3-12. Seal Pressing Tool 3-16 – JLG Lift – 3121202...

  • Page 67: Bearing Cup Pressing Tool

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-13. Bearing Cup Pressing Tool Figure 3-14. Drift Pin for Lining Up Thrust Washers with Output Planet Gear 3121202 – JLG Lift – 3-17...

  • Page 68: Free Wheeling Option

    Shaft Cylinder Block DISCONNECT Shaft Seal Piston Bearing Endcap Slipper Valve plate Figure 3-16. Drive Motor Cross Section Drive Hub Engaged DRIVE DISCONNECT (REVERSED) DRIVE Drive Hub Disconnected Figure 3-15. Disconnecting the Drive Hubs 3-18 – JLG Lift – 3121202...

  • Page 69: Shaft Seal Replacement

    To avoid damaging the shaft during removal, install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal. 4. Discard the seal. 3121202 – JLG Lift – 3-19...

  • Page 70: Loop Flushing Valve

    3. Remove O-rings (4, 5, and 6). 4. Using pliers, remove centering springs (7, 8, and 9). 5. Remove spring retaining washers (10 and 11). 6. Remove shift spool (12). 7. Remove orifice poppet (13). 3-20 – JLG Lift – 3121202...

  • Page 71: Troubleshooting

    Clean or motor. The smaller the orifice, the longer the time it takes to properly installed, and are replace as necessary. shift the motor. Obstruction will also increase shift times. not obstructed. 3121202 – JLG Lift – 3-21...

  • Page 72: Disassembly

    11. Using a 5/16 inch internal hex wrench, remove drain plugs (19, 20). Discard O-rings. 12. Using a 9/16 inch internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings. 3-22 – JLG Lift – 3121202...

  • Page 73: End Cap

    The grease will force the bearing out. Use caution not to drive the bearing past the rear shaft journal as the bearing may become trapped on the shaft and damaged. 3121202 – JLG Lift – 3-23...

  • Page 74: Cylinder Kit

    22. Remove the snap-ring (36) retaining the shaft front bearing. Pull the bearing (37) off of the shaft (38). 32. Snap Ring 33. Support Washer 34. Shaft Seal Figure 3-24. Shaft Seal 3-24 – JLG Lift – 3121202...

  • Page 75: Swash Plate & Servo Piston

    A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON- ABLE EFFOR T. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED. 3121202 – JLG Lift – 3-25...

  • Page 76: Inspection

    Table 3-8. Cylinder Block Measurements Measurement Minimum Cylinder Block Height 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14) 0.002 0.002 0.002 0.002 0.002 Cylinder Block Surface Flatness (0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079) 3-26 – JLG Lift – 3121202...
  • Page 77 Measure the swashplate thickness from sealing surfaces. the journals to the running face. Replace swashplate if damaged or worn beyond minimum specification. 3121202 – JLG Lift – 3-27...

  • Page 78: Assembly

    ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED. 3. Install the inner block spring washer (4), block spring (5), and outer washer (6) into the cylinder 3-28 – JLG Lift – 3121202...

  • Page 79: Cylinder Kit Assembly

    If you're reusing the pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder kit aside on a clean sur- face until needed. 3121202 – JLG Lift – 3-29...

  • Page 80: Shaft And Front Bearing

    Install the install shaft/bearing assembly into housing from the flange end. Install the snap-ring (18). 20. Servo Spring 21. Minimum Angle Stop Figure 3-33. Servo Spring and Minimum Angle Stop 3-30 – JLG Lift – 3121202...

  • Page 81: Valve Plate And Rear Bearing

    Apply a liberal coat of assembly check the unit. grease to the endcap side of the valve plate to keep it in place during installation. 3121202 – JLG Lift – 3-31...

  • Page 82: Shaft Seal

    1.5 to 2.5 ft.lbs. (2.03 to 3.39 Nm) 28. Seal Support Washer 29. Snap Ring Figure 3-36. Shaft Seal 1/4 in 33 ft.lbs. (45 Nm) 5/16in 63 ft.lbs. (85 Nm) Figure 3-37. Plugs and Fittings Installation 3-32 – JLG Lift – 3121202...

  • Page 83: Initial Start-Up Procedures

    9. Shut down the prime mover and remove the pres- sure gauge. Replace plug at the charge pressure gauge port. 10. Check the fluid level in the reservoir; add clean fil- tered fluid if necessary. The motor is now ready for operation. 3121202 – JLG Lift – 3-33...

  • Page 84: Oscillating Axle Bleeding Procedure And Lockout Test

    5. Carefully activate SWING control lever and position boom over right side of machine. 6. With boom over right side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp. 3-34 – JLG Lift – 3121202...

  • Page 85: Steer Adjustments

    #2 to contact axle. (2WS/2WD) Spindles do not stop on cylinder stroke. Adjust steer- ing stops as follows: Adjust item #1 to achieve 39° inside turn angles. Steer full left and adjust RH item 3121202 – JLG Lift – 3-35...

  • Page 86: Swing Hub

    6. Lift out the internal gear (2) and thrust washer (11). 13. The needle rollers (3C) and spacer (3D) are now The thrust washer (11) may stick to the under side of the carrier (3). removed from the cluster gear (3F). 3-36 – JLG Lift – 3121202...

  • Page 87: Main Assembly Procedure

    (3F) and locate at 12 0’clock (straight-up) from each planet pin. Marked tooth will be located just under the car- rier (3A) on upper two gears (3F). 3121202 – JLG Lift – 3-37...
  • Page 88 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. 11. Place O-ring (5) into cover (6) counterbore. Use petroleum jelly to hold O-ring in place. 3-38 – JLG Lift – 3121202...
  • Page 89 EP 90 lubricant before operation if the unit is mounted horizontally, and completely filled if mounted vertically. In vertical mounting application case oil circula- tion is recommended. 13. Install regular grade 8 bolts (12) into remaining holes. 3121202 – JLG Lift – 3-39...

  • Page 90: Hub Shaft Sub-Assembly

    3. Invert hub (1G) and press bearing cup (1E) into inter counterbore of hub (1G). 6. The bearing cone (1F) is an interference fit and has to be pressed or tapped on. 3-40 – JLG Lift – 3121202...
  • Page 91 EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. This completes the hub shaft sub-assembly —items (1A) through (1J). If this assembly is not going to be used right away, it should be oiled and covered to help prevent rust- ing, 3121202 – JLG Lift – 3-41...

  • Page 92: Carrier Sub-Assembly

    NOTE: Some old style carriers will not have slots and tangs should be located inside boss relief. 3. Place spacer washer into opposite side of cluster gear and against needle rollers. 3-42 – JLG Lift – 3121202...
  • Page 93 7. Line up cluster gear and thrust washer with hole in carrier and slide planet shaft through. Line up cham- fered side of hole in planet shaft with pin hole in car- rier. 3121202 – JLG Lift – 3-43...
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 3-44 – JLG Lift – 3121202...

  • Page 95: Swing Bearing

    Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bear- ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 3-46 – JLG Lift – 3121202...

  • Page 97: Swing Bearing Replacement

    NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING. JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN b.

  • Page 98: Swing Bearing Torque Values

    Sequence, tighten the bolts to a torque of 190 ft. lbs. (258 Nm) w/Loctite. i. Remove the lifting equipment. j. Install the rotary coupling retaining yoke brack- ets, apply a light coating of Loctite #242 to the 3-48 – JLG Lift – 3121202...

  • Page 99: Swing Brake - Mico

    3. Discard seals and o-rings. 4. Closely inspect bearings and bearing contact sur- faces. Replace as necessary. NOTE: Bearings may be reused if, after thorough inspection, they are found to be in good condition. 3121202 – JLG Lift – 3-49...

  • Page 100: Swing Brake Assembly (Mico)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-46. Swing Brake Assembly (Mico) 3-50 – JLG Lift – 3121202...

  • Page 101: Rotary Coupling

    8. Heat cap seals (17) in hydraulic oil for 5 minutes at 300° F (149° C). 9. Assemble cap seals over O-rings 10. Reinsert center body into housing (lube with hydrau- lic oil). 11. Replace thrust ring and snap ring. 3121202 – JLG Lift – 3-51...

  • Page 102: Rotary Coupling - Sheet 1 Of 2

    SECTION 3 - CHASSIS & TURNTABLE 1. Rotary Coupling 5. Bolt 2. Torque Lug 6. Nut 3. Locknut 7. Bracket 4. Flatwasher Figure 3-47. Rotary Coupling - Sheet 1 of 2 3-52 – JLG Lift – 3121202...

  • Page 103: Rotary Coupling - Sheet 2 Of 2

    3. Check Valve 13. Ring 17. Cap Seal 8. Valve Block 4. Screw 14. Oil Seal 18. O-ring 9. O-ring 5. Plug 15. O-ring 10. Body Figure 3-48. Rotary Coupling - Sheet 2 of 2 3121202 – JLG Lift – 3-53...

  • Page 104: Rotary Coupling Port Location - 2Ws

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-49. Rotary Coupling Port Location - 2WS 3-54 – JLG Lift – 3121202...

  • Page 105: Rotary Coupling Port Location - 4Ws

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-50. Rotary Coupling Port Location - 4WS 3121202 – JLG Lift – 3-55...

  • Page 106: Generator

    250 (17) 375 (26) Steer 2500 (172) 3750 (259) Steer 2500 (172) 3750 (259) Every 500 hours of service, blow out the inside of the gen- erator. If operating in a hostile environment, clean monthly. 3-56 – JLG Lift – 3121202...

  • Page 107: Overload Protection

    Clean the rings with 220 grit emery paper. Remove as little material as possible. If the rings are deeply pitted and do not clean up, consult generator factory service. Reinstall the belt, brush holder assembly, and end panel. 3121202 – JLG Lift – 3-57...

  • Page 108: Inspecting Generator Brushes, Replacing Brushes, And Cleaning Slip Rings

    Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New 1. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-51. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3-58 – JLG Lift – 3121202...

  • Page 109: Spark Arrester Cleaning Instructions

    If no matching symptom is available, analyze the com- If the glow plug option is enabled in the JLG Control Sys- plaint and develop a plan for diagnostics utilizing the wir- tem, the glow plug and indicator lamp will be energized ing diagrams, technical assistance, and repair history.

  • Page 110: Ecm/Epm And Sensors

    • Inspect intake air system and air filter for restrictions. • Inspect battery condition and starter current draw. If no evidence of a problem is found after visual/physical engine check has been performed, proceed to MIL DTC retrieval procedure. 3-60 – JLG Lift – 3121202...
  • Page 111 If the ECM is replaced, the new ECM will need to be pro- grammed. An IBM-compatible computer and software containing the correct program and calibration for the application are required to program the ECM. 3121202 – JLG Lift – 3-61...
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE 3-62 – JLG Lift – 3121202...
  • Page 113 • Engine vacuum level for engine control purposes. the ground or the power feed circuit through transistors or • Barometric pressure (BARO) other solid state devices. 3121202 – JLG Lift – 3-63...
  • Page 114 ECM circuit and result in component damage. For volt- apply voltage to any of the ECM/EPM's circuits unless age measurements, use only a digital voltmeter with an instructed to do so. input impedance of at least 10 megohms. 3-64 – JLG Lift – 3121202...

  • Page 115: Fuel System

    The fuel is injected under pressure in a conical spray pat- tern at the opening of the intake valve. Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank. 3121202 – JLG Lift – 3-65...

  • Page 116: Typical Fuel System

    1 part of gasoline by weight, which provides the most efficient combustion. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injec- tion system is called a "closed loop" system. 3-66 – JLG Lift – 3121202...
  • Page 117 (MAP) with throttle position. When the ECM/EPM detects a change in engine load, it can adjust idle speed by changing the PWM signal to the governor. 3121202 – JLG Lift – 3-67...
  • Page 118 • Remote mounting capability ter on the power stroke. • No mechanical load on the engine • More coil cooldown time between firing events • Elimination of mechanical timing adjustments • Increased available ignition coil saturation time 3-68 – JLG Lift – 3121202...
  • Page 119 • Intake air temperature (IAT) sensor The primary coils in the coil pack are triggered by the • Throttle position sensor "Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals from the ECM/EPM. • Crankshaft position sensor 3121202 – JLG Lift – 3-69...

  • Page 120: Ford Lpg System

    O depending on the speed and load of the engine. The megajector must be mounted per the 2.5L 2004 Emission Installation Instructions. Torque mounting bolts to a maxi- mum of 60 in.lbs. (7 Nm). 3-70 – JLG Lift – 3121202...

  • Page 121: Ford Lpg System

    SECTION 3 - CHASSIS & TURNTABLE Megajector Mixer Regulator Lockoff Solenoid Figure 3-54. Ford LPG System 3121202 – JLG Lift – 3-71...

  • Page 122: Megajector Diagnostic Code Descriptions

    -4.00 inches (10.1 cm) of Control System senses a fault dealing with the megajec- tor. Refer to Section 6 - JLG Control System for more infor- a. Fuel Supply - Check fuel supply pressure at the mation concerning the Control System.

  • Page 123: Changing From Gasoline To Lp Gas

    Megajector - Megajector has an internal failure. BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO Contact JLG Industries for further assistance. LP GAS. DTC 364 - Megajector Internal Circuitry Fault Detection. 3. While the engine is operating, place the three posi- a.

  • Page 124: Deutz Sensors For Jlg Control System

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-55. Deutz Sensors for JLG Control System 3-74 – JLG Lift – 3121202...

  • Page 125: Deutz Engine Installation - Sheet 1 Of 2

    3. Gear Pump 7. Motor Mount 11. Rear Engine Mounting Plate 15. Restriction Indicator 4. Piston Pump 8. Muffler 12. Radiator 16. Oil Drain Valve Figure 3-56. Deutz Engine Installation - Sheet 1 of 2 3121202 – JLG Lift – 3-75...

  • Page 126: Deutz Engine Installation - Sheet 2 Of 2

    19. Hayes Coupling 24. Oil Filter 28. Alternator 32. Speed Sensor 20. Pump Adapter Plate 25. Injector Pump 29. Starter 33. Throttle Actuator 21. Dipstick Figure 3-57. Deutz Engine Installation - Sheet 2 of 2 3-76 – JLG Lift – 3121202...

  • Page 127: Caterpillar Engine Installation - Sheet 1 Of 2

    4. Coolant Overflow Container 11. Glow Plug Relay 5. Pump Coupling 12. Aux Power Relay 6. Fan 13. Restriction Indicator 7. Engine Mount 14. Oil Drain Valve Figure 3-58. Caterpillar Engine Installation - Sheet 1 of 2 3121202 – JLG Lift – 3-77...

  • Page 128: Caterpillar Engine Installation - Sheet 2 Of 2

    24. Engine Temperature Sender 18. Fuel Filter 25. Throttle Actuator 19. Alternator 26. Fuel Supply Pump 20. Oil Pressure Switch 27. Water Pump 21. Oil Filter Figure 3-59. Caterpillar Engine Installation - Sheet 2 of 2 3-78 – JLG Lift – 3121202...

  • Page 129: Ford Engine Installation - Sheet 1 Of 2

    14. Fuel Filter 3. Piston Pump 7. Engine Mount 11. Oil Drain Valve 15. Starter 4. Load-Sensing Pump 8. Radiator 12. Engine Tray 16. Alternator w/Regulator Figure 3-60. Ford Engine Installation - Sheet 1 of 2 3121202 – JLG Lift – 3-79...

  • Page 130: Ford Engine Installation - Sheet 2 Of 2

    26. EPM Module 30. Overflow Bottle 19. MAP Sensor 23. Oil Filter 27. Muffler 31. Starter 20. EGR Sensor 24. Pump Coupling 28. LP Regulator Figure 3-61. Ford Engine Installation - Sheet 2 of 2 3-80 – JLG Lift – 3121202...

  • Page 131: Deutz Emr 2 (S/N 84827 To Present)

    (Limp home) functions. The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control In order to switch the engine off, the EMR2 is switched in a System are connected by means of separate cable har- de-energized fashion over the ignition switch.

  • Page 132: Emr 2 Engine Side Equipment

    SENSOR JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYS- TEM USES THIS TO CONTROL THE ENGINE & OIL PRESSURE FAULT REPORTING.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE 3121202 – JLG Lift – 3-83...
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE 3-84 – JLG Lift – 3121202...
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE 3121202 – JLG Lift – 3-85...
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE 3-86 – JLG Lift – 3121202...

  • Page 137: Emr 2 Engine Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-67. EMR 2 Engine Plug Pin Identification 3121202 – JLG Lift – 3-87...

  • Page 138: Emr 2 Vehicle Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-68. EMR 2 Vehicle Plug Pin Identification 3-88 – JLG Lift – 3121202...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 3121202 – JLG Lift – 3-89...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE 3-90 – JLG Lift – 3121202...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE 3121202 – JLG Lift – 3-91...
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE 3-92 – JLG Lift – 3121202...
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE 3121202 – JLG Lift – 3-93...

  • Page 144: Bio Fuel In Deutz Engines

    EN 590 and ASTM D 975. No emission values are guaranteed with the other fuels described. It is the obligation of the owner to check the permission for use of the fuels in accordance with regional regulations. 3-94 – JLG Lift – 3121202...

  • Page 145: Biological Contamination In Fuels

    The use of fuel additives is not permitted. The flow improv- of various manufacturers is not allowed and leads to loss ers mentioned above are an exception. Use of unsuitable of warranty rights. additives will result in loss of warranty. 3121202 – JLG Lift – 3-95...

  • Page 146: Gm Engine General Maintenance

    • Check the entire engine wire harness for rubbing chaf- ing, cuts or damaged connections, repair if necessary Figure 3-74. Engine Oil Dip Stick • Check all wire harness connectors to insure they are fully seated and locked 3-96 – JLG Lift – 3121202...

  • Page 147: Changing The Engine Oil

    8. Start the engine and check for oil leaks. 9. Stop the engine and check the oil level to insure the oil level is at "FULL". 10. Dispose of the oil and filter in a safe manner. 3121202 – JLG Lift – 3-97...

  • Page 148: Gm Engine Dual Fuel System

    170° F (77° C), which can be checked switch in the operator's platform. When the operator using the JLG handheld analyzer. places the selector switch in the gasoline mode the gaso- line fuel pump is energized. While in the gasoline mode the LPG fuel lock-off is isolated and will not energize.

  • Page 149: Fuel Filter

    (ECM). 1. Pressure Regulator Section 4. Primary Test Port 2. Fuel Inlet 5. Secondary Test Port 3. Coolant Passage 6. Voice Coil Section Figure 3-75. Electric Fuel Lock Off Figure 3-76. EPR Assembly 3121202 – JLG Lift – 3-99...

  • Page 150: Low Pressure Regulator (Lpr)

    SIONS CONTROL DEVICE AND CANNOT BE REBUILT. IF THE COIL ASSEMBLY FAILS TO OPERATE PROPERLY, REPLACE IT WITH AN OEM REPLACEMENT PART ONLY. Figure 3-78. Air Fuel Mixer Figure 3-77. Low Pressure Regulators 3-100 – JLG Lift – 3121202...

  • Page 151: Electronic Throttle Control (Etc)

    Figure 3-79. ETC throttle control device Figure 3-80. LPG Engine Control Unit (ECM) Figure 3-81. ECM Assembly 3121202 – JLG Lift – 3-101...

  • Page 152: Heated Exhaust Gas Oxygen Sensor

    The primary components of the Gasoline Multi Point Fuel Injection (MPFI) fuel system are the fuel tank, electric fuel Figure 3-83. Gasoline Fuel Pressure and Temperature pump, fuel pressure and temperature sensor manifold, Manifold Assembly fuel filter and fuel rail. 3-102 – JLG Lift – 3121202...

  • Page 153: Fuel Filter

    Use a commercially available liquid leak detector or an electronic leak detec- tor. When using both methods, use the electronic leak detector first to avoid contamination by the liquid leak detector. 3121202 – JLG Lift – 3-103...

  • Page 154: Propane Fuel Filter Replacement

    NOTE: Residual vapor pressure will be present in the fuel 1. Install the mounting plate to lock off O-ring seal. system. 2. Install the retaining bolt seal. 4.Disconnect the electrical connector to the Electric Lock 3. Install the housing seal. off. 3-104 – JLG Lift – 3121202...

  • Page 155: Pressure Regulator Section

    6. Install the electric lock off into the regulator inlet and tighten into proper location, connect the electrical connector. 7. Connect the fuel supply line and tighten until fully seated. 3121202 – JLG Lift – 3-105...

  • Page 156: Temperature Manifold Absolute Pressure (Tmap) Sensor

    NOTE: Apply a small amount of O-ring lubricant before installation. 1. Install in the TMAP . 2. Tighten retaining bolts to 62 lb-in (7 Nm). 3. Start the vehicle and check for proper operation. 3-106 – JLG Lift – 3121202...

  • Page 157: Mixer Replacement

    4 retaining screws. Tighten 80 lb-in (9 Nm) 3. Install Throttle body. Refer to Electronic Throttle Control Device Replacement. 4. Start the engine and leak check all fittings and con- nections. 3121202 – JLG Lift – 3-107...

  • Page 158: Coolant Hose Replacement

    4. Unplug controller and remove. INSTALLATION INSTALLATION NOTE: Use hose material and lengths specified by JLG. 1. Install the hose clamps to each hose and set the clamp back on each hose to make installation eas- THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY ier.

  • Page 159: Gm Engine Lpg Fuel System Diagnosis

    This vacuum signal is most commonly referred to as air valve vacuum. In the mixer, the fuel mixes with the air entering the engine. This air/ fuel mixture is then drawn into the engine for combustion. 3121202 – JLG Lift – 3-109...

  • Page 160: Lpf Fuel System Diagnosis

    (LPR). 2. Crank the engine and observe the pressure reading for the LPR primary 1- 3 PSI Go to Step 22 Go to Step 13 pressure. Is the fuel pressure ABOVE the specified value? 3-110 – JLG Lift – 3121202...
  • Page 161 Is the action complete? Replace the lock-off. Refer to Lock-off Replacement. Go to Step 26 Is the action complete? Replace the mixer assembly. Refer to Fuel Mixer Replacement. Go to Step 26 Is the action complete? 3121202 – JLG Lift – 3-111...
  • Page 162 1. Disconnect all test equipment 2. Install the primary and secondary test port plugs. 3. Start the engine. System OK 4. Using SNOOP or equivalent, leak check the test port plugs. Is the action complete? 3-112 – JLG Lift – 3121202...

  • Page 163: Symptom Diagnosis

    If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the Operational Test problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit. 3121202 – JLG Lift – 3-113...
  • Page 164 ² Check for the following: - Vacuum leaks - Improper valve timing Engine Mechanical Checks - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. 3-114 – JLG Lift – 3121202...
  • Page 165 - Improper valve timing Engine Mechanical Checks - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. ² Check the intake and exhaust manifolds for casting flash. 3121202 – JLG Lift – 3-115...
  • Page 166 ² A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present. ² If the problem exists, check the routing of the secondary wires and the ground circuit. 3-116 – JLG Lift – 3121202...
  • Page 167 Sticking or leaking valves Exhaust system leakage ² Check the intake and exhaust system for casting flash or other restrictions. Fuel System Checks ² Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis. 3121202 – JLG Lift – 3-117...
  • Page 168 ² Suggest that a different operator use the equipment and record the results. ² Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis. Fuel System Checks ² Check the fuel system for leakage. Sensor Checks ² Check the Temperature Manifold Absolute Pressure (TMAP) sensor. 3-118 – JLG Lift – 3121202...
  • Page 169 ²Check the ECM grounds for being clean, tight, and in their proper locations. ²Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality. 3121202 – JLG Lift – 3-119...
  • Page 170 ² Check the ECM grounds for being clean, tight, and in their proper locations. ² Check the generator output voltage. Additional Check ² Check the vacuum hoses for kinks or leaks. ² Check Transmission 3-120 – JLG Lift – 3121202...

  • Page 171: Dtc To Spn/Fmi Cross Reference Chart

    Injector Driver 3 Open Injector Driver 3 Shorted Injector Driver 4 Open Injector Driver 4 Shorted Crank Sync Noise Crank Loss Cam Sync Noise Cam Sensor Loss Gasoline Cat Monitor 520211 Oil Pressure Low 3121202 – JLG Lift – 3-121...
  • Page 172 CAN Rx Failure 1627 CAN Address Conflict Failure 1628 Loss of TSC 1 1629 Unable to Reach Lower TPS 2111 Unable to Reach Higher TPS 2112 TPS 1/2 Simultaneous Voltages 2135 BP Pressure High 2229 3-122 – JLG Lift – 3121202...

  • Page 173: Section 4 - Boom & Platform

    Check the boom for proper function. Figure 4-2. Clamping Wire Ropes 3. Install adjusting nuts (or remove nylon collar lock- nuts if re-adjusting) to both retract and extend wire ropes. 3121202 – JLG Lift –...

  • Page 174: Wear Pads

    When adding shims, longer bolts must be used to ensure proper thread engagement in insert. b. When shims are removed, shorter bolts must be used so bolt does not protrude from insert and come into contact with boom surface. – JLG Lift – 3121202...

  • Page 175: Three Month Inspection

    6. Ropes with 6 total broken wires in one rope lay, 3 in one strand in one rope lay, 1 valley break, or 1 break f. Tag and disconnect hydraulic lines to the slave at any end termination. leveling cylinder. Use a suitable container to 3121202 – JLG Lift –...

  • Page 176: Location Of Components - Boom Powertrack

    Using a suitable brass drift and hammer, remove e. Using a suitable lifting equipment, adequately the master cylinder pin from the base boom. support powertrack weight along entire length. f. Remove bolts #1 securing the push tube on the fly boom section. – JLG Lift – 3121202...

  • Page 177: Disassembly Of Boom Sections

    8. Pull the telescope cylinder and wire ropes partially from aft end of the base boom section; secure the cylinder with a suitable sling and lifting device at approximately the center of gravity. 3121202 – JLG Lift –...

  • Page 178: Boom Assembly Cutaway - Sheet 1 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-8. Boom Assembly Cutaway - Sheet 1 of 3 – JLG Lift – 3121202...

  • Page 179: Boom Assembly Cutaway - Sheet 2 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-9. Boom Assembly Cutaway - Sheet 2 of 3 3121202 – JLG Lift –...

  • Page 180: Boom Assembly Cutaway - Sheet 3 Of 3

    Remove hardware from the wear pads; remove wear pads from cylinder. b. Remove hardware from the wire rope guard; remove guard from cylinder. Figure 4-11. Disassembly of Sheave Assembly – JLG Lift – 3121202...

  • Page 181: Inspection

    NOTE: When inspecting pins and bearings Refer to the guidelines established in Section 2 - General. 1. Inspect all sheaves (extend and retract wire ropes and telescope cylinder) for excessive groove wear, burrs or other damage. Replace sheaves as neces- sary. 3121202 – JLG Lift –...

  • Page 182: Dimension Of Sheaves When New

    4. Inspect telescope cylinder sheave pin for scoring, tapering and ovality. Replace pins as necessary. 5. Inspect boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as nec- essary. 4-10 – JLG Lift – 3121202...

  • Page 183: Assembly

    SLIDING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS, TOOLS, AND OTHER OBSTRUCTIONS. 6. Shim the insides of the boom sections for a total of 1/16 inch (0.062) clearance (if the action is centered, there will be 1/32 clearance on each side). 3121202 – JLG Lift – 4-11...

  • Page 184: Boom Powertrack Installation

    SECTION 4 - BOOM & PLATFORM Figure 4-15. Boom Powertrack Installation 4-12 – JLG Lift – 3121202...

  • Page 185: Installing The Proximity Switch

    SLOWLY INTO POSITION. DAMAGE TO COMPONENTS MAY 15. Align the telescope cylinder barrel-to-sheave attach- ment point. Install extend sheave pin through the RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES. Figure 4-16. Installing the Proximity Switch 3121202 – JLG Lift – 4-13...

  • Page 186: Installation

    7. Connect all hydraulic lines running along side of through the powertrack rail, powertrack and boom assembly. push tube. Tighten or install all clamping or securing apparatus to the hoses or cables, as necessary. 4-14 – JLG Lift – 3121202...

  • Page 187: Articulating Jib Boom

    Figure 4-18. Location of Components - Articulating Jib Boom 4. Remove mounting hardware from articulating jib boom pivot pin #2. Using a suitable brass drift and hammer, remove the pivot pin from boom assembly. 3121202 – JLG Lift – 4-15...

  • Page 188: Assembly

    Components - Articulating Jib Boom. ments. 1. JLG recommends the use of the JLG Hostile Envi- 1. Align lift cylinder with attach holes in articulating jib ronment Package to keep the internal portions of a boom.

  • Page 189: Horizontal Limit And Dual Capacity Limit Switches Adjustments

    SECTION 4 - BOOM & PLATFORM Figure 4-19. Horizontal Limit and Dual Capacity Limit Switches Adjustments 3121202 – JLG Lift – 4-17...

  • Page 190: Transport Switch Adjustments - Ce Machines Only

    SECTION 4 - BOOM & PLATFORM Figure 4-20. Transport Switch Adjustments - CE Machines Only 4-18 – JLG Lift – 3121202...

  • Page 191: Platform

    Figure 4-24. Heating Setscrew 0300130779) 5. Remove the two (2) setscrew (4) from bottom of actuator (1). Discard setscrew. Disassembly 1. Place actuator on a clean workbench. 2. Remove all hydraulic fittings. Figure 4-25. Removing Setscrew 3121202 – JLG Lift – 4-19...

  • Page 192: Rotator Assembly (Helac)

    SECTION 4 - BOOM & PLATFORM Figure 4-22. Rotator Assembly (Helac) 4-20 – JLG Lift – 3121202...

  • Page 193: Inspection

    2. Install new seal (8), thrust ring (10) and bearing (9) on shaft (2). NOTE: Apply a coat of grease to the thrust ring before slid- ing onto the end cap. 3121202 – JLG Lift – 4-21...

  • Page 194: Rotary Actuator (S/N 0300130779 To Present)

    The shaft is supported radially by the large upper radial bearing and the lower radial bearing. Axially, the shaft is separated from the housing by the upper and lower thrust 4-22 – JLG Lift – 3121202...

  • Page 195: Required Tools

    Once the radius is achieved round off all sharp edges of the heated end by using a grinder. There may be 3121202 – JLG Lift – 4-23...

  • Page 196: Rotary Actuator - Exploded View

    204. O-ring 420.2 Bushing 4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing 109 . Lock Pin 207. Backup Ring 113. Capscrew 304.1. Wiper Seal Figure 4-30. Rotary Actuator - Exploded View 4-24 – JLG Lift – 3121202...

  • Page 197: Rotary Actuator - Assembly Drawing

    204. O-ring 420.2 Bushing 4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing 109 . Lock Pin 207. Backup Ring 113. Capscrew 304.1. Wiper Seal Figure 4-31. Rotary Actuator - Assembly Drawing 3121202 – JLG Lift – 4-25...

  • Page 198: Disassembly

    (4) by turning it counter clockwise. 16” (4.76mm). 3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). If the pin will not come out with the ”Easy Out”, use 4-26 – JLG Lift – 3121202...
  • Page 199 9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assem- bly. 3121202 – JLG Lift – 4-27...
  • Page 200 15. Remove the wear guides (302) from the end cap (4) 12. To remove the piston (3) use a rubber mallet and a and shaft (2). plastic mandrel so the piston is not damaged. 4-28 – JLG Lift – 3121202...
  • Page 201 17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2). 3121202 – JLG Lift – 4-29...

  • Page 202: Inspection

    2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within specifications (Not less than 0.092” or 2.34 mm). 4-30 – JLG Lift – 3121202...
  • Page 203 (304). 6. Install the inner T-seal (200) into the piston (3) using a circular motion. Install the outer T-seal (202) by stretching it around the groove in a circular motion. 3121202 – JLG Lift – 4-31...
  • Page 204 (1) during disassembly line up as shown. Using Repeat this step for the outer seal (202). a rubber mallet, tap the piston into the housing up to the point where the gear teeth meet. 4-32 – JLG Lift – 3121202...
  • Page 205 13. Install the stop tube onto the shaft end. Stop tube is an available option to limit the rotation of an actua- tor. 3121202 – JLG Lift – 4-33...
  • Page 206 19. Insert the set screws (113) over the lock pins. it is threaded into the housing (1). Tighten them to 25 in. lbs. (2.825 Nm). 4-34 – JLG Lift – 3121202...

  • Page 207: Installing Counterbalance Valve

    (15.8 Nm). Do not torque over 145 inch 2. Make sure the new valve has the O-rings in the pounds (16.3 Nm). counterbores of the valve to seal it to the actuator housing. Figure 4-32. Rotator Counterbalance Valve 3121202 – JLG Lift – 4-35...

  • Page 208: Testing The Actuator

    1. Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the two bleed nipples. Secure them with hose clamps. Place the vinyl tubes in a clean 5-gallon container to 4-36 – JLG Lift – 3121202...

  • Page 209: Troubleshooting

    Operate the actuator through the housing ports. Conduct the internal leakage test as described in the Testing section on page 24 of this manual. c. Air in actuator c. Purge air from actuator. See bleeding proce- dures 3121202 – JLG Lift – 4-37...

  • Page 210: Foot Switch Adjustment

    Torque to 50 ft.lbs. (68 Nm) Loctite #242 Torque to 480 ft. lbs. (650 Nm) Check torque every 150 hours of operation Torque to 85 ft. lbs. (115 Nm) Figure 4-33. Platform Support Torque Values 4-38 – JLG Lift – 3121202...

  • Page 211: Section 5 - Hydraulics

    After the initial discharge, there should be no further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the counterbalance valve is defective and must be replaced. 3121202 – JLG Lift –...

  • Page 212: Cylinders With Dual Counterbalance Valves

    Note: Do not clamp on threads. Remove jam nuts and loosen adjustment nuts so there is slack in the cables. (See Section 4 - Boom & Platform). 6. Remove the hardware securing push bar to turnta- ble and telescope cylinder. – JLG Lift – 3121202...

  • Page 213: Main Boom Telescope Cylinder Installation

    Loosely install nuts and jam nuts 9. Remove cylinder port plugs and hydraulic line caps onto the threaded end of cables. and correctly attach lines to cylinder ports. Figure 5-1. Boom Positioning and Support, Cylinder Repair 3121202 – JLG Lift –...

  • Page 214: Main Boom Lift Cylinder Removal

    5. Remove boom prop and overhead crane. Activate hydraulic system. 6. Using all applicable safety precautions, operate the boom functions. Check for correct operation and hydraulic leaks. Secure as necessary. – JLG Lift – 3121202...

  • Page 215: Cylinder Barrel Support

    Pull the ring out of the groove toward the wall mouth. Once one end of the retaining ring is free from the groove, the remainder can be easily pried free using ones fingers or pliers. 3121202 – JLG Lift –...

  • Page 216: Cleaning And Inspection

    Repair as necessary. 7. Inspect threaded portion of piston for damage. 17. If applicable, inspect piston rings for cracks or other Dress threads as necessary. damage. Replace as necessary. – JLG Lift – 3121202...

  • Page 217: Assembly

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

  • Page 218: Piston Seal Kit Installation

    11. Assemble the tapered bushing loosely into the pis- one side. This side faces the solid seal.(See magni- ton and insert JLG capscrews (not vendor cap- fied insert in Figure 5-11.)The split of seals and screws) through the drilled holes in the bushing and backup rings are to be positioned so as not to be in into the tapped holes in the piston.

  • Page 219: Seating The Tapered Bearing

    CYLINDER BARREL SURFACES. 18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged. 3121202 – JLG Lift –...

  • Page 220: Holding Valve Torque Specifications

    TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING Articulating 50 ft. lbs. 9 ft. lbs. ROD. Master Cylinder (68 Nm) (12 Nm) Steer Cylinder Piston Nut Torque Specifications Steer Cylinder LBS. 150 ft. lbs 204 Nm 5-10 – JLG Lift – 3121202...

  • Page 221: Axle Lockout Cylinder

    THE CYLINDER IF THE BLEEDER SCREW IS LOOSENED. 1. Barrel 4. Wear Ring 7. Bleeder 2. Rod 5. Wiper Ring 8. Cartridge Valve 3. Not Used 6. Rod Seal Figure 5-15. Axle Lockout Cylinder 3121202 – JLG Lift – 5-11...

  • Page 222: Level Cylinder

    13. Seal 22. Not Used 5. Tapered Bushing 14. Lock Ring 23. Valve Cartridge 6. Spacer 15. O-Ring 24. O-Ring Plug 7. Cartridge Valve 16. Back-Up Ring 25. Socket Head Screw Figure 5-16. Level Cylinder 5-12 – JLG Lift – 3121202...

  • Page 223: Lift Cylinder

    17. Back-Up Ring 24. Socket Head Screw 4. Piston 11. Lock Ring 18. Rod Seal 25. O-Ring Plug 5. Tapered Bushing 12. Hydrolock Seal 19. Wiper 26. Loctite #609 (Not Shown) Figure 5-17. Lift Cylinder 3121202 – JLG Lift – 5-13...

  • Page 224: Jib Lift Cylinder

    24. Wiper 4. Head 11. O-Ring Plug 18. O-Ring 25. Loctite #609 (Not Shown) 5. Tapered Bushing 12. O-Ring Plug 19. Back-Up Ring 26. Socket Head Capscrew 6. Spacer Figure 5-18. Jib Lift Cylinder 5-14 – JLG Lift – 3121202...

  • Page 225: Master Cylinder

    23. Not Used 3. Piston 10. Locking Primer (Not Shown) 17. Back-Up Ring 24. Plug Fitting 4. Head 11. Seal 18. Rod Seal 5. Tapered Bushing 12. Lock Ring 19. Wiper Figure 5-19. Master Cylinder 3121202 – JLG Lift – 5-15...

  • Page 226: Steer Cylinder

    6. Rod 11. Lip Seal 2. Piston 7. Capscrew 12. Spanner Nut 3. Seal 8. O-Ring 13. Wiper 4. O-Ring 9. Back-Up Ring 14. Bushing 5. Barrel 10. Retainer Ring Figure 5-20. Steer Cylinder 5-16 – JLG Lift – 3121202...

  • Page 227: Telescope Cylinder

    16. Back-Up Ring 22. Loctite #242 (Not Shown) 5. Tapered Bushing 11. Capscrew 17. Wear Ring 23. Locking Primer (Not Shown) 6. Spacer 12. Capscrew 18. O-Ring 24. Not Used Figure 5-21. Telescope Cylinder 3121202 – JLG Lift – 5-17...

  • Page 228: Variable Displacement Pump (M46 Series)

    Tee into Charge Pump Inlet Line return lines, oil cooler, and return filter. Servo Pressure 1000 PSI or 60 Bar Gauge 9/16-18 O-ring Fitting Servo Pressure 1000 PSI or 60 Bar Gauge 9/16-18 O-ring Fitting 5-18 – JLG Lift – 3121202...

  • Page 229: Troubleshooting - Neutral Difficult Or Impossible To Find

    SECTION 5 - HYDRAULICS Figure 5-22. Troubleshooting - Neutral Difficult or Impossible to Find Figure 5-23. Troubleshooting - System Operating Hot 3121202 – JLG Lift – 5-19...

  • Page 230: Troubleshooting - Transmission Operates In One Direction Only

    SECTION 5 - HYDRAULICS Figure 5-24. Troubleshooting - Transmission Operates in One Direction Only 5-20 – JLG Lift – 3121202...

  • Page 231: Troubleshooting - System Response Is Sluggish

    SECTION 5 - HYDRAULICS Figure 5-25. Troubleshooting - System Response is Sluggish 3121202 – JLG Lift – 5-21...

  • Page 232: Inspections And Adjustments

    Inspect for foreign material holding the poppet open, and for scoring or wear on the poppet and seat in the housing. Adjustments of the charge pressure is accomplished by changing the shim thickness behind the spring. 5-22 – JLG Lift – 3121202...
  • Page 233 5. Remove spacer, re-install orifices, gaskets, and cov- ers. Torque grade 5 bolts 8 to 11 ft.lbs. (10.8 to 14.9 Nm) and grade 8 bolts 11 to 13 ft.lbs. (14.9 to 17.8 Nm). 3121202 – JLG Lift – 5-23...
  • Page 234 7. Stop the engine. Connect the control input. Remove amount of rotation noted above. the servo pressure gauges. Return the machine to normal operating condition. Restart the engine and assure that the hydrostatic system is in neutral. 5-24 – JLG Lift – 3121202...

  • Page 235: Minor Repair And Replacement

    Polish the sealing area on the shaft if necessary. 4. Wrap the spline or key end of the shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the inside diameter of the new seal with petroleum jelly. 3121202 – JLG Lift – 5-25...
  • Page 236 Do not attempt to mix ate Service Parts Manual for more information. different vintage parts. 2. Reinstall the bypass valve into the housing. Torque to 7 to 10 ft. lbs. (9.5 - 13.6 Nm). 5-26 – JLG Lift – 3121202...
  • Page 237 2. Remove the spring and poppet from the housing. Do not alter the shims or interchange parts with another valve. Inspect the poppet and mating seat in the end cap for damage or foreign material. 3121202 – JLG Lift – 5-27...
  • Page 238 Refer to the Service Parts Manual for plug part numbers. 6. Replace the O-ring on the bottom of the control housing.Lightly lubricate all O-rings with clean petro- leum jelly prior to assembly. The control spool and 5-28 – JLG Lift – 3121202...

  • Page 239: Valves - Theory Of Operation

    At the same time other ports would be blocked to flow. The spool is spring loaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit. 3121202 – JLG Lift – 5-29...

  • Page 240: Pressure Setting Procedures

    ATING THE MACHINE UNTIL THE HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES PRIOR TO 3. While monitoring pressure gauge, adjust platform CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CAL- level relief to 2800 PSI (193.06 Bar). IBRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF 4.

  • Page 241: Main Control Valve Pressure Adjustments - Sheet 1 Of 2

    SECTION 5 - HYDRAULICS NOTE: Torque all valve cartridges 18 to 20 ft.lbs. (24.5 to 27.2 Nm). Figure 5-29. Main Control Valve Pressure Adjustments - Sheet 1 of 2 3121202 – JLG Lift – 5-31...

  • Page 242: Main Control Valve Pressure Adjustments - Sheet 2 Of 2

    SECTION 5 - HYDRAULICS NOTE: Torque all valve cartridges 18 to 20 ft.lbs. (24.5 to 27.2 Nm). Figure 5-30. Main Control Valve Pressure Adjustments - Sheet 2 of 2 5-32 – JLG Lift – 3121202...

  • Page 243: Location Of Components - Main Control Valve

    SECTION 5 - HYDRAULICS Figure 5-31. Location of Components - Main Control Valve 3121202 – JLG Lift – 5-33...

  • Page 244: Wheel Steer (If Equipped)

    Make certain that all system com- fill container in such a way as to prevent it from ponents (reservoir, hoses, valves, fittings, heat exchanger, becoming contaminated. etc.) are clean prior to filling with fluid. 5-34 – JLG Lift – 3121202...
  • Page 245 Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code. If charge pres- sure is inadequate, shut down and determine the cause for improper pressure. 3121202 – JLG Lift – 5-35...
  • Page 246 SECTION 5 - HYDRAULICS NOTES: 5-36 – JLG Lift – 3121202...

  • Page 247: Section 6 - Jlg Control System

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

  • Page 248: Ade Block Diagram

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. ADE Block Diagram – JLG Lift – 3121202...

  • Page 249: Using The Analyzer

    SECTION 6 - JLG CONTROL SYSTEM 6.2 TO CONNECT THE JLG CONTROL The top level menus are as follows: SYSTEM ANALYZER HELP DIAGNOSTICS 1. Connect the four pin end of the cable supplied with SYSTEM TEST the analyzer, to the controller module located in the...

  • Page 250: Analyzer Connecting Points

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-3. Analyzer Connecting Points – JLG Lift – 3121202...

  • Page 251: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu.

  • Page 252: Control Module Location

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-4. Control Module Location – JLG Lift – 3121202...

  • Page 253: Adjusting Parameters Using The Hand Held Analyzer

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

  • Page 254: Machine Setup

    To level machine chose: There is a setting that JLG strongly recommends that you CALIBRATION: do not change. This setting is so noted below: TILT SENSOR ELEVATION CUTBACK Press ENTER.
  • Page 255 SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift –...
  • Page 256 SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3121202...
  • Page 257 SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift – 6-11...
  • Page 258 SECTION 6 - JLG CONTROL SYSTEM 6-12 – JLG Lift – 3121202...
  • Page 259 SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift – 6-13...
  • Page 260 SECTION 6 - JLG CONTROL SYSTEM 6-14 – JLG Lift – 3121202...
  • Page 261 SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift – 6-15...
  • Page 262 SECTION 6 - JLG CONTROL SYSTEM 6-16 – JLG Lift – 3121202...

  • Page 263: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM 6.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S DRIVE ACCELeration 0.1s to 5.0s DECELeration 0.1s to 3.0s...
  • Page 264 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S SWING ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed...
  • Page 265 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S BASKET ROTATE ACCELeration 0.1 to 5.0 DECELeration 0.1 to 3.0 MlNimum LEFT speed 0 to 65% MAXimum LEFT speed 0 to 100% MINimum RIGHT speed...

  • Page 266: Help Fault Codes, Displayed Faults, And Descriptions

    SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault None No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
  • Page 267 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault D/S JOY. OUT OF RANGE Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1 HIGH volts.
  • Page 268 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault l/s joy. center tap bad Resistive joysticks: These faults occur when the center tap voltage is not between 3.08 volts and 3.83 volts.
  • Page 269 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault HOUR METER SHORT TO BATTERY HORN SHORT TO GROUND HORN OPEN CIRCUIT HORN SHORT TO BATTERY...
  • Page 270 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault STEER DUMP OPEN CIRCUIT STEER DUMP SHORT TO BATTERY TWO SPEED SHORT TO GROUND TWO SPEED OPEN CIRCUIT...
  • Page 271 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BASKET DOWN SHORT TO BATTERY BASKET DOWN OVERRIDE Only occurs on machines with electronic leveling systems.
  • Page 272 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault TOWER DOWN OPEN CIR- CUIT TOWER DOWN SHORT TO BATTERY TOWER IN SHORT TO GROUND...
  • Page 273 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All driver faults are detected in a similar manner. Open cir- cuit faults are detected when the analog feedback reads too high and the output is commanded off.
  • Page 274 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault JIB LEFT OPEN CIRCUIT JIB RIGHT SHORT TO BAT- TERY JIB RIGHT SHORT TO GROUND...
  • Page 275 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second power-up.
  • Page 276 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault CHASSIS TILT SENSOR NOT Indicates that the chassis tilt sensor calibration information has been lost.

  • Page 277: Machine Configuration Programming Information Prior To Software Version P5.3

    SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 278 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;...
  • Page 279 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / MOTION CUTOUT: Motion cutout in platform mode only.
  • Page 280 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GROUND ALARM: NO: No ground alarm installed. DRIVE: Travel alarm sounds when the drive function is active (Option).

  • Page 281: Machine Configuration Programming Information Software Version P5.3 To P6.1

    SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 282 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
  • Page 283 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI.
  • Page 284 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / MOTION CUTOUT: Motion cutout in platform mode only.
  • Page 285 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number FUNCTION CUTOUT: NO: No drive cutout. * Only visible under certain BOOM CUTOUT: Boom function cutout while driving above elevation.

  • Page 286: Machine Configuration Programming Information Software Version P6.1 To Present

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 287 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
  • Page 288 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number STARTER LOCKOUT: DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
  • Page 289 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number GEN SET/WELDER: NO: No generator installed. BELT DRIVE: Belt driven setup. GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON.
  • Page 290 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LOAD SENSOR: 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform Module.
  • Page 291 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LEVELING MODE: ALL FUNCTIONS: Platform level with all functions. * Only visible on 800S LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
  • Page 292 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 600S ANSI USA 0 11 ANSI EXPORT...
  • Page 293 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined numbers indicate the default when the option is factory installed. 600SJ ANSI USA 0 11 0 ANSI EXPORT...
  • Page 294 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined numbers indicate the default when the option is factory installed. 660SJ ANSI USA 0 11 ANSI EXPORT 1 11...

  • Page 295: Fault Code Listing

    SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL CLEARS WHEN FAULT IS REMOVED DRIVING AT CREEP - TILTED CLEARS WHEN FAULT IS REMOVED FSW OPEN CLEARS WHEN FAULT IS REMOVED RUNNING AT CREEP - CREEP SWITCH OPEN...
  • Page 296 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL FORD ECM POWER SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT HORN SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
  • Page 297 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL ALARM SHORT TO BATTERY REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT GENERATOR SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
  • Page 298 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL TOWER UP SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT TOWER UP OPEN CIRCUIT REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
  • Page 299 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL FORD FAULT CODE 31 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 32 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 33 CLEARS WHEN FAULT IS REMOVED...
  • Page 300 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL NO ALTERNATOR OUTPUT CLEARS WHEN FAULT IS REMOVED OIL PRESSURE LOW CLEARS WHEN FAULT IS REMOVED 485 COMMUNICATIONS LOST CLEARS WHEN FAULT IS REMOVED...

  • Page 301: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM 6.9 ANALYZER DIAGNOSTICS MENU the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow STRUCTURE keys alter a value if allowed In the following structure descriptions, an intended item is selected by pressing ENTER;...
  • Page 302 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Adjustments - Personality Descriptions SWING ACCEL … Displays/adjusts swing acceleration DECEL … Displays/adjusts swing deceleration MIN LEFT … Displays/adjusts minimum swing left speed MAX LEFT … Displays/adjusts maximum swing left speed CREEP LEFT …...
  • Page 303 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Adjustments - Personality Descriptions JIB LIFT Not displayed if JIB = NO ACCEL … Displays/adjusts jib acceleration DECEL … Displays/adjusts jib deceleration MIN UP … Displays/adjusts minimum jib up speed MAX UP …...

  • Page 304: Diagnostic Menu Descriptions

    SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Menu Descriptions DRIVE DRIVE FOR … Displays drive joystick direction & demand STEER … Displays steer switch direction & demand NOTE: steer demand is inversely proportional to vehicle speed BRAKES …...
  • Page 305 SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Menu Descriptions PM BATTERY … Displays battery voltage at platform module TEMP ... Displays ground module temperature ELEV. CUTOUT … Displays elevation cutout switch status FUNC. CUTOUT … Displays function cutout switch status CREEP…...
  • Page 306 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-60 – JLG Lift – 3121202...

  • Page 307: Section 7 - Basic Electrical Information & Schematics

    Polarity Getting a negative Voltage or current reading when expecting a positive reading frequently means the leads 3121202 – JLG Lift –...

  • Page 308: Resistance Measurement

    • First test meter and leads by touching leads • If meter is not auto ranging, set it to the correct together. Meter should produce an audible alarm, range (See multimeter’s operation manual) indicating continuity – JLG Lift – 3121202...

  • Page 309: Current Measurement

    NOTE: Do NOT apply dielectric grease to the following con- nections: NOTE: Curing-type sealants might also be used to prevent • Main Boom Rotary sensor connections (on Celesco shorting and would be less messy, but would make Sensor), future pin removal more difficult. 3121202 – JLG Lift –...

  • Page 310: Amp Connector

    3. Install a hole plug into this and/or any unused wire lbs. to be sure the retention fingers are holding the seal that has silicone dielectric compound escaping contact (See Figure 7-7.). from it. Figure 7-6. AMP Connector – JLG Lift – 3121202...

  • Page 311: Connector Assembly Figure 2

    (See Figure 7-9.). Release the locking latches by squeezing them inward (See Figure 7-8.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8. Connector Assembly Figure 3 3121202 – JLG Lift –...

  • Page 312: Disassembly

    The wedge lock has slotted openings in the forward, or the wire strands. This nullifies the effectiveness of the con- mating end. These slots accommodate circuit testing in nector seals and could result in system failure. – JLG Lift – 3121202...

  • Page 313: Connector Installation

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11. Connector Installation 3121202 – JLG Lift –...

  • Page 314: Deutsch Connectors

    The wedgelock will snap into place. Rectangular 3. Hold the rear seal in place, as removing the contact wedges are not oriented. Thy may go in either way. may displace the seal. – JLG Lift – 3121202...

  • Page 315: Hd30/Hdp20 Series Assembly

    3. Pull contact-wire assembly out of connector. Figure 7-15. HD/HDP Locking Contacts Into Position Figure 7-17. HD/HDP Unlocking Contacts NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing NOTE: Do Not twist or insert tool at an angle. 3121202 – JLG Lift –...

  • Page 316: Electrical Harness - Prior To S/N 87000 - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18. Electrical Harness - Prior to S/N 87000 - Sheet 1 of 2 7-10 – JLG Lift – 3121202...

  • Page 317: Electrical Harness - Prior To S/N 87000 - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-19. Electrical Harness - Prior to S/N 87000 - Sheet 2 of 2 3121202 – JLG Lift – 7-11...

  • Page 318: Electrical Harness - S/N 87000 To Present - Sheet 1 Of 2

    LIMIT SWITCHES (ALL SPECS EXCEPT CE & LATIN AMERICA SPECS) PLATFORM CONTROL GROUND (DEUTZ & GM) CONTROL HEADLIGHTS DIAGNOSTIC TAILLIGHTS ANALYZER Figure 7-20. Electrical Harness - S/N 87000 to Present - Sheet 1 of 2 7-12 – JLG Lift – 3121202...

  • Page 319: Electrical Harness - S/N 87000 To Present - Sheet 2 Of 2

    HYDRAULIC START PLUG PUMPS RELAY STARTER RELAY STROBE LIGHT RELAY MAIN CONTROL VALVE HORN VALVE FUEL VALVE LEVEL SENSOR ALARM Figure 7-21. Electrical Harness - S/N 87000 to Present - Sheet 2 of 2 3121202 – JLG Lift – 7-13...

  • Page 320: Electrical Schematic - Ade - Sheet 1 Of 6

    800A/AJ UPRIGHT TILT SWITCH LOCATED IN UPRIGHT WHITE BLACK= GROUND BLACK GREEN= N.O. RELAY CONTACT RED= 12 VDC GREEN WHITE= N.C. RELAY CONTACT Figure 7-22. Electrical Schematic - ADE - Sheet 1 of 6 7-14 – JLG Lift – 3121202...

  • Page 321: Electrical Schematic - Ade - Sheet 2 Of 6

    CAT ENGINE ONLY BLUE WHT/YEL ORN/RED 49-84 BROWN TOWER TELE. ORN/RED 49-85 BLACK PROX. SWITCH (800 A/AJ ONLY} BLUE ORN/RED 49-93 1870215 B Figure 7-23. Electrical Schematic - ADE - Sheet 2 of 6 3121202 – JLG Lift – 7-15...

  • Page 322: Electrical Schematic - Ade - Sheet 3 Of 6

    SEE SHT 3 SWITCH BRN/WHT 47-8-2 AUXILIARY SOLENOID STARTER MOTOR SOL. SEE SHT 3 STARTER MOTOR FUEL IGN POWER PUMP CONNECTOR SEE SHT 1 Figure 7-24. Electrical Schematic - ADE - Sheet 3 of 6 7-16 – JLG Lift – 3121202...

  • Page 323: Electrical Schematic - Ade - Sheet 4 Of 6

    RackMeasRef 120 OHM RESISTOR 5 AMP 7500 W GENERATOR GENERATOR CONTROL 12 VDC DEUTZ BATTERY DIANOSTICS PLUG 86 85 86 85 1870215 B Figure 7-25. Electrical Schematic - ADE - Sheet 4 of 6 3121202 – JLG Lift – 7-17...

  • Page 324: Electrical Schematic - Ade - Sheet 5 Of 6

    THROTTLE BLK/LT GRN TAN/ORN BRN/LT BLU BRN/YEL BRN/WHT BRN/ LT GRN PNK/DR GRN 16 PNK/DR GRN 16 PNK/DR GRN 16 PNK/DR GRN 16 Figure 7-26. Electrical Schematic - ADE - Sheet 5 of 6 7-18 – JLG Lift – 3121202...

  • Page 325: Electrical Schematic - Ade - Sheet 6 Of 6

    BLU/PNK CAN + UNUSED UNUSED GROUND BLACK 16 VBAT RED/LT BLU 16 UNUSED EPR FUSE RED/LT BLU 16 PNK/DR GRN 16 1870215 B Figure 7-27. Electrical Schematic - ADE - Sheet 6 of 6 3121202 – JLG Lift – 7-19...

  • Page 326: Hydraulic Schematic - Sheet 1 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28. Hydraulic Schematic - Sheet 1 of 6 7-20 – JLG Lift – 3121202...

  • Page 327: Hydraulic Schematic - Sheet 2 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605 D Figure 7-29. Hydraulic Schematic - Sheet 2 of 6 3121202 – JLG Lift – 7-21...

  • Page 328: Hydraulic Schematic - Sheet 3 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-30. Hydraulic Schematic - Sheet 3 of 6 7-22 – JLG Lift – 3121202...

  • Page 329: Hydraulic Schematic - Sheet 4 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605 D Figure 7-31. Hydraulic Schematic - Sheet 4 of 6 3121202 – JLG Lift – 7-23...

  • Page 330: Hydraulic Schematic - Sheet 5 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32. Hydraulic Schematic - Sheet 5 of 6 7-24 – JLG Lift – 3121202...

  • Page 331: Hydraulic Schematic - Sheet 6 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605 D Figure 7-33. Hydraulic Schematic - Sheet 6 of 6 3121202 – JLG Lift – 7-25...
  • Page 332 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-26 – JLG Lift – 3121202...
  • Page 334 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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