JLG 600A Service And Maintenance Manual
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JLG 600A Service And Maintenance Manual

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Service and Maintenance Manual
Models
600A
600AJ
S/N 0300080000
to Present
P/N - 3121201
December 10, 2012

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  • Page 1 Service and Maintenance Manual Models 600A 600AJ S/N 0300080000 to Present P/N - 3121201 December 10, 2012...

  • Page 3: Ageneral

    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. 3121201 – JLG Lift –...
  • Page 4 Original Issue - October 15, 2004 Revised - June 10, 2005 Revised - October 6, 2005 Revised - March 2, 2006 Revised - December 4, 2007 Revised - April 1, 2008 Revised - December 10, 2012 – JLG Lift – 3121201...

  • Page 5: Table Of Contents

    Lubrication and Servicing ........... 2-3 3121201 – 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 ........3-100 3121201 – JLG Lift –...
  • Page 8 Limit Switches and Cam Valve Adjustment ......... .4-11 – JLG Lift –...
  • Page 9 Relief Valves............. . 5-37 3121201 – JLG Lift –...
  • Page 10 To Connect the JLG Control System Analyzer ........
  • Page 11 Swash Plate and Journal Bearing ..........3-41 3121201 – JLG Lift –...
  • Page 12 Deutz Sensors for JLG Control System ........
  • Page 13 Tower Telescope Cylinder Removal ..........5-15 3121201 – JLG Lift –...
  • Page 14 HD/HDP Unlocking Contacts ........... . .7-9 – JLG Lift –...
  • Page 15 Hydraulic Schematic - Sheet 6 of 6..........7-25 3121201 – JLG Lift –...
  • Page 16 Major Component Weights - 600A ........

  • Page 17: Section 1 - Specifications

    Table 1-3. Ford LRG-425 Specifications 600A 77 psi (5.4 kg/cm Fuel Gasoline 600AJ 75 psi (5.3 kg/cm 600A - narrow chassis 94 psi (6.6 kg/cm Crankcase Capacity 4.5 Quarts (4.25 L) w/Filter 600AJ - narrow chassis 94 psi (6.6 kg/cm Idle RPM...

  • Page 18: Deutz F4M2011 Specifications

    18 psi (1.2 Bar) @ 2000 rpm Low RPM 1.90 GPH (7.19 lph) Compression Ratio 9.2:1 High RPM 2.50 GPH (9.46 lph) Firing Order 1-3-4-2 Horsepower 49 @ 2500 RPM, full load Max. RPM 2800 – JLG Lift – 3121201...

  • Page 19: Tires

    Static Machine Height (Stowed) 8 ft. 3.75 in. (2.53 m) Machine Length (Stowed) Drive System 600A Over Drive Axle 26 ft. 5 in. (8.05 m) 600AJ Over Drive Axle 28 ft. 11.4375 in. (8.82 m) Table 1-9. Drive System Machine Width Standard 8 ft.

  • Page 20: Function Speeds

    4. Function speeds may vary due to cold, thick hydrau- fastener has loosened, refer to the Torque Chart lic oil. Test should be run with the oil temperature to determine proper torque value. above 100° F (38° C). – JLG Lift – 3121201...

  • Page 21: Lubrication

    Hydraulic Oil cosities. If use of hydraulic oil other than Kendall Hyken 052 or Mobilfluid 424 is desired, contact JLG Industries for Table 1-16. Hydraulic Oil proper recommendations. HYDRAULIC SYSTEM OPERATING SAE VISCOSITY 1.7 PRESSURE SETTINGS...

  • Page 22: Major Component Weights

    SECTION 1 - SPECIFICATIONS 1.9 MAJOR COMPONENT WEIGHTS Table 1-21. Cylinder Specifications - 600AJ Table 1-22. Major Component Weights - 600A DESRIPTON BORE STROKE ROD DIA. Lower Lift 34.0625 (165.1) (865.2) (63.5) Platform Control Console Tower Tele- 63.75 Platform Level Cylinder scope (76.2)

  • Page 23: Critical Stability Weights

    OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTERWEIGHT, ENGINE & PLAT- FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABIL- ITY. Table 1-24. Critical Stability Weights - 600A Tire and Wheel (Ballasted Size (14-17.5) Only)

  • Page 24: Lubrication & Maintenance

    Comments - Remote Access 2104C. LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI- SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON- MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. – JLG Lift – 3121201...
  • Page 25 Interval - Check level every 3 months or 150 hrs of Interval - Change after first 50 hrs. and every 6 operation; change every 2 years or 1200 hours of months or 300 hrs. thereafter or as indicated by operation Condition Indicator. 3121201 – JLG Lift –...
  • Page 26 Interval - Check Level daily; Change every 2 years or Capacity - 4.5 Quarts 1200 hours of operation. Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accor- dance with engine manual. 1-10 – JLG Lift – 3121201...

  • Page 27: Deutz Engine Dipstick

    Interval - Every Year or 1200 hours of operation MAXIMUM LEVEL, OIL COLD NOTE: Hot oil checks should not be made until the engine has been shut down for a period of 5 minutes. Figure 1-3. Deutz Engine Dipstick 3121201 – JLG Lift – 1-11...

  • Page 28: Draining Oil Build Up From The Propane Regulator

    FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM- PERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO BE LIQUID AND FLOW FREELY FROM THE REGULATOR. 1. Move the equipment to a well ventilated area. Ensure there are no external ignition sources. 1-12 – JLG Lift – 3121201...

  • Page 29: Propane Fuel Filter Replacement

    LPG fuel temperature sensor and reconnect the electrical connector. 8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil in a safe and proper fash- ion. 3121201 – JLG Lift – 1-13...

  • Page 30: Propane Fuel System Pressure Relief

    8. Tighten the filter retaining bolt to 106 in lbs (12 Nm). 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 1-14 – JLG Lift – 3121201...

  • Page 31: Torque Chart (Sae Fasteners - Sheet 1 Of 7)

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

  • Page 32: Torque Chart (Sae Fasteners - Sheet 2 Of 7)

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER Figure 1-6. Torque Chart (SAE Fasteners - Sheet 2 of 7) 1-16 – JLG Lift – 3121201...

  • Page 33: Torque Chart (Sae Fasteners - Sheet 3 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-7. Torque Chart (SAE Fasteners - Sheet 3 of 7) 3121201 – JLG Lift – 1-17...

  • Page 34: Torque Chart (Sae Fasteners - Sheet 4 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-8. Torque Chart (SAE Fasteners - Sheet 4 of 7) 1-18 – JLG Lift – 3121201...

  • Page 35: Torque Chart (Metric Fasteners - Sheet 5 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 7) 3121201 – JLG Lift – 1-19...

  • Page 36: Torque Chart (Metric Fasteners - Sheet 6 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 1-20 – JLG Lift – 3121201...

  • Page 37: Torque Chart (Metric Fasteners - Sheet 7 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-11. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 3121201 – JLG Lift – 1-21...
  • Page 38 SECTION 1 - SPECIFICATIONS NOTES: 1-22 – JLG Lift – 3121201...

  • Page 39: Section 2 - General

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

  • Page 40: Service And Guidelines

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

  • Page 41: Component Disassembly And Reassembly

    (See Hydraulic system filters should be checked, Torque Chart Section 1.) cleaned, and/or replaced as necessary, at the speci- 3121201 – JLG Lift –...

  • Page 42: Hydraulic Oil

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

  • Page 43: Cylinder Drift

    The cylinder must have the normal load, which is the nor- Do the Following When Welding on JLG mal platform load applied. Equipment If the cylinder passes this test, it is acceptable.

  • 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 – 3121201...
  • 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 3121201 – 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

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)

  • Page 48: Engine Operating Temperature Specifications - Ford

    WITH THE RECOMMENDED FLUIDS AND A FU LLY CHARGED BATTERY. 0 F(-18 C) -10 F(-23 C) A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

  • Page 49: Engine Operating Temperature Specifications - Caterpillar

    0°F(-18°C) ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND -30 F(-34 C) °...

  • Page 50: Engine Operating Temperature Specifications - Gm

    -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

  • Page 51: Section 3 - Chassis & Turntable

    The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE characteristics.

  • 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. – JLG Lift – 3121201...

  • Page 53: Tightening And Torquing Bolts

    3. Crisscross around the bolt circle and tighten remain- The unit can be carefully pressurized with air to pop ing bolts. the cover out of the unit. 4. Now use a torque wrench to apply the specified torque to bolt "A". 3121201 – 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 – 3121201...

  • 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). 3121201 – 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 – 3121201...

  • Page 57: Input Carrier Disassembly

    5. Remove the 14 needle Bearings (3C) from the bore 3F. Planet Gear of the Planet Gear (3F). Figure 3-5. Planet Gear Subassembly 6. Repeat steps 1 through 5 for each of the two remain- ing planet gears. 3121201 – 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 – 3121201...

  • Page 59: Spindle-Brake Disassembly

    12. Plastic Plug 7. Coupling Subassembly 8D. O-Ring 8J. Rotor 21. Pipe Plug 8A. Piston 8E. Backup Ring 8K. Stator 22. Flat Head Capscrew 8B. Pressure Plate 8F. O-Ring 8L. Compression Spring Figure 3-7. Spindle Brake 3121201 – JLG Lift –...

  • Page 60: Coupling Subassembly

    They are included in most brake repair kits. 2. Using retaining ring pliers, remove Retaining Ring (8C) from the groove in the Spindle (1A). 3-10 – JLG Lift – 3121201...

  • 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). 3121201 – 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 – 3121201...

  • 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. 3121201 – 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 – 3121201...

  • 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 3121201 – 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 – 3121201...

  • 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 3121201 – JLG Lift – 3-17...

  • Page 68: Drive Brake - Mico (S/N 56718 To 81836)

    IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE 2. Press oil seal (17) into cover plate (16) until it is flush BRAKE ASSEMBLY, RELEASE PRESSURE MUST NOT EXCEED with bearing shoulder. Note direction of seal. 134.5 BAR (500 PSI). 3-18 – JLG Lift – 3121201...

  • Page 69: Drive Brake - Mico

    4. Case Seal 11. Stator Disc 18. Bearing 5. O-ring 12. Rotor Disc 19. Retaining Ring 6. Backup Ring 13. Return Plate 20. Retaining Ring 7. Piston 14. Springs Figure 3-15. Drive Brake - Mico 3121201 – JLG Lift – 3-19...

  • Page 70: Bleeding

    Discs frozen These brakes are designed for only lim- Replace disc stack. ited dynamic braking. A severe emer- gency stop or prolonged reduced release pressure operation may result in this type of damage. 3-20 – JLG Lift – 3121201...

  • Page 71: Free Wheeling Option

    Viton cap in center of hub. 3. Remove chocks from wheels as required. DISCONNECT Drive shaft Drive Hub Engaged DRIVE DISCONNECT (REVERSED) DRIVE Drive Hub Disconnected Figure 3-16. Disconnecting the Drive Hubs 3121201 – JLG Lift – 3-21...
  • Page 72 Rotary group complete 9 pistons, cylinder sub-assembly, Spare parts kit DFR pilot valve valve plate (cw or ccw corresponding to the order) retain- ing plate and retaining ball. Swash Plate 3-22 – JLG Lift – 3121201...

  • Page 73: Replacing The Drive Shaft Seal

    (drive shaft) and housing, grease the sealing ring. 6. Assemble the snap ring in the correct position. 3. Be careful while you seal the drive shaft, use an adhesive tape to protect the splines. 3121201 – JLG Lift – 3-23...

  • Page 74: Disassembly And Assembly

    6. Remove the adjustment shim. 3. Remove the port plate together with the valve plate (hold the valve plate so that the plate can’t fall down). 7. Unscrew the cap nut and remove it. 3-24 – JLG Lift – 3121201...
  • Page 75 14. Disassemble the control piston while moving the swash plate. 10. Disassemble the rotary group in horizontal position. 15. The swash plate must be lifted a little bit to disas- semble the piston rod. 11. Disassemble the stopper - max. flow. 3121201 – JLG Lift – 3-25...
  • Page 76 20. Remove the snap ring. 17. Remove the spring. 21. Disassemble the sealing ring. 18. Remove both bearing shells. 22. The external front bearing ring is pulled out of the pump housing. 19. Remove the drive shaft. 3-26 – JLG Lift – 3121201...

  • Page 77: Assembly Notes

    4 degrees out of center in the same direction de-centered like drive direction. (Note spare parts exist as cw and ccw valve plates.) 25. The spring has additional pretension while you dis- assemble the three pressure pins inside the cylinder. 3121201 – JLG Lift – 3-27...

  • Page 78: Flow Control Pilot Valves

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Differential volume if you are rotating the threaded pin - each rotation is appr. 3,1 cm3. Figure 3-17. Flow Control Pilot Valves 3-28 – JLG Lift – 3121201...

  • Page 79: Taper Roller Bearing Initial Tension

    Vg max to 50% of Vg max. Taper Roller Bearing Initial Tension Cast iron pump housing must have initial tension of the bearings: 0..0,05 mm, grind Pos. 12 if necessary. 3121201 – JLG Lift – 3-29...

  • Page 80: Drive Motor - 2Wd (Prior To S/N 81836)

    Slide the new seal over the shaft and press it into the housing bore. Be careful not to damage seal. A seal installer tool can be made to aid in installing the seal. Reinstall the seal retaining ring. 3-30 – JLG Lift – 3121201...

  • Page 81: 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. 3121201 – JLG Lift – 3-31...

  • Page 82: 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. 3-32 – JLG Lift – 3121201...

  • Page 83: 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). 3121201 – JLG Lift – 3-33...

  • Page 84: Disassembly

    (19, 20). Discard O-rings. 12. Using a 9/16 inch internal hex wrench, remove work 6. Remove shift spool (12). port plugs (21, if equipped with axial ports). Discard 7. Remove orifice poppet (13). O-rings. 3-34 – JLG Lift – 3121201...

  • Page 85: 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. 3121201 – JLG Lift – 3-35...

  • Page 86: 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 3-26. Shaft Seal 3-36 – JLG Lift – 3121201...

  • Page 87: Swash Plate & Servo Piston

    REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED. 3121201 – JLG Lift – 3-37...

  • Page 88: 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) 3-38 – JLG Lift – 3121201...
  • Page 89 SERVO PISTON AND MINIMUM ANGLE STOP Replace if necessary. Inspect the minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. 3121201 – JLG Lift – 3-39...

  • Page 90: Assembly

    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 block. Using a press, compress the block spring 3-40 – JLG Lift – 3121201...

  • Page 91: 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. 3121201 – JLG Lift – 3-41...

  • Page 92: 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 3-35. Servo Spring and Minimum Angle Stop 3-42 – JLG Lift – 3121201...

  • Page 93: 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. 3121201 – JLG Lift – 3-43...

  • Page 94: Shaft Seal

    1.5 to 2.5 ft.lbs. (2.03 to 3.39 Nm) 28. Seal Support Washer 29. Snap Ring Figure 3-38. Shaft Seal 1/4 in 33 ft.lbs. (45 Nm) 5/16in 63 ft.lbs. (85 Nm) Figure 3-39. Plugs and Fittings Installation 3-44 – JLG Lift – 3121201...

  • Page 95: 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. 3121201 – JLG Lift – 3-45...

  • Page 96: Oscillating Axle Bleeding Procedure And Lockout Test

    2. From platform control station, activate machine hydraulic system. 3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/TORQUE SELECT control switches to their respective LOW positions. 3-46 – JLG Lift – 3121201...

  • Page 97: Swing Hub

    13. Have an assistant check to see that right front wheel remains locked in position off of ground. 14. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed posi- 3121201 – JLG Lift – 3-47...

  • Page 98: Disassembly

    13. The needle rollers (3C) and spacer (3D) are now removed from the cluster gear (3F). WHEN REBUILDING OR REPAIRING THE UNIT, THE RETAINING RING (1I), O-RINGS (5) AND SEAL (1B) SHOULD ALWAYS BE REPLACED. 3-48 – JLG Lift – 3121201...
  • Page 99 12 0’clock (straight-up) from each planet not rotate freely, then remove the carrier and ring pin. Marked tooth will be located just under the car- gear and check the cluster gear timing. rier (3A) on upper two gears (3F). 3121201 – JLG Lift – 3-49...
  • Page 100 10. Thrust washer (11) is installed into the counterbore of the carrier (3). 13. Install regular grade 8 bolts (12) into remaining holes. 11. Place O-ring (5) into cover (6) counterbore. Use petroleum jelly to hold O-ring in place. 3-50 – JLG Lift – 3121201...

  • Page 101: Hub Shaft Sub-Assembly

    (1A) is carefully installed mounted horizontally, and completely filled if mounted into the hub (1G). vertically. In vertical mounting application case oil circula- tion is recommended. Hub Shaft Sub-Assembly 1. Press bearing cone (1D) onto shaft (1A). 3121201 – JLG Lift – 3-51...
  • Page 102 6. The bearing cone (1F) is an interference fit and has to be pressed or tapped on. EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 7. Pipe plugs (1J & 1K) should be checked and/ or installed at this time in the assembly. 3-52 – JLG Lift – 3121201...

  • Page 103: Carrier Sub-Assembly

    This completes the hub shaft sub-assembly —items (1A) through (1J). If this assembly is not going to be used right away, it should be oiled and covered to help prevent rust- ing, 3121201 – JLG Lift – 3-53...
  • Page 104 NOTE: Some old style carriers will not have slots and tangs should be located inside boss relief. 6. While keeping thrust washers in place, slide cluster gear into carrier with the larger gear on the side with the small pin hole. 3-54 – JLG Lift – 3121201...
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE 3121201 – JLG Lift – 3-55...

  • Page 106: 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 107 SECTION 3 - CHASSIS & TURNTABLE 3121201 – JLG Lift – 3-57...

  • Page 108: Swing Bearing Replacement

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

  • Page 109: Swing Bearing Torque Values

    Sequence, tighten the bolts to a torque of 190 ft. lbs. (260 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 3121201 – JLG Lift – 3-59...

  • Page 110: 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. 3-60 – JLG Lift – 3121201...

  • Page 111: Swing Brake Assembly (Mico)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-47. Swing Brake Assembly (Mico) 3121201 – JLG Lift – 3-61...

  • Page 112: Rotary Coupling - S/N 81836 To Present

    10. Reinsert center body into housing (lube with hydrau- lic oil). -8, -6 Case Drain 250 (17) 375 (26) Steer 2500 (172) 3750 (259) 11. Replace thrust ring and snap ring. Steer 2500 (172) 3750 (259) 3-62 – JLG Lift – 3121201...

  • Page 113: 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 3-48. Rotary Coupling - Sheet 1 of 2 3121201 – JLG Lift – 3-63...

  • Page 114: Rotary Coupling - Sheet 2 Of 2

    17. Cap Seal 3. Check Valve 8. Valve Block 13. Ring 18. O-ring 4. Screw 9. O-ring 14. Oil Seal 5. Plug 10. Body 15. O-ring Figure 3-49. Rotary Coupling - Sheet 2 of 2 3-64 – JLG Lift – 3121201...

  • Page 115: Rotary Coupling Port Location - 2Ws

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-50. Rotary Coupling Port Location - 2WS 3121201 – JLG Lift – 3-65...

  • Page 116: Rotary Coupling Port Location - 4Ws

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-51. Rotary Coupling Port Location - 4WS 3-66 – JLG Lift – 3121201...

  • Page 117: Generator

    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. 3121201 – JLG Lift – 3-67...

  • Page 118: 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 3-52. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3-68 – JLG Lift – 3121201...

  • Page 119: Spark Arrester Cleaning Instructions

    MUST BE FOLLOWED. 4. If a diagnostic trouble code (DTC) is stored, contact a JLG distributor to make an effective repair. Changing from Gasoline to LP Gas 5. If no DTC is stored, select the symptom from the 1.

  • Page 120: Ecm 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. 3-70 – JLG Lift – 3121201...

  • Page 121: Ecm Diagnostic Trouble Codes

    Camshaft Position Sensor (CMP) Sensor Illegal Pattern Engine Control Module (ECM) Fault Illegal Operation Engine Control Module (ECM) Fault Illegal Interruption Engine Control Module (ECM) Fault COP (Computer Operating Properly) Failure System Voltage Low System Voltage High 3121201 – JLG Lift – 3-71...
  • Page 122 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. 3-72 – JLG Lift – 3121201...
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE 3121201 – JLG Lift – 3-73...
  • Page 124 The MAP sensor is used to determine the following: injectors, electronic governor, etc., by control ling the ground or the power feed circuit through transistors or • Engine vacuum level for engine control purposes. other solid state devices. • Barometric pressure (BARO) 3-74 – JLG Lift – 3121201...
  • Page 125 ECM circuit and result in component damage. For volt- apply voltage to any of the ECM's circuits unless age measurements, use only a digital voltmeter with an instructed to do so. input impedance of at least 10 megohms. 3121201 – JLG Lift – 3-75...

  • Page 126: 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. 3-76 – JLG Lift – 3121201...

  • Page 127: Typical Fuel System

    14.7 parts of air to 1 part of gasoline by weight, which provides the most effi- cient combustion. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a "closed loop" system. 3121201 – JLG Lift – 3-77...
  • Page 128 When the ECM detects a change in engine load, it can adjust idle speed by changing the PWM signal to the governor. 3-78 – JLG Lift – 3121201...
  • Page 129 • 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 3121201 – JLG Lift – 3-79...
  • Page 130 • 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 • Crankshaft position sensor from the ECM. 3-80 – JLG Lift – 3121201...

  • Page 131: Ford Lpg System

    The mixer accepts LPG vapor at the megajector outlet pressure (-1.00 to -5.00 inches [-2.5 to -12.7 cm] of H and mixes it with clean air. This mixture is then sucked into the engine via the actuator. 3121201 – JLG Lift – 3-81...
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE Megajector Mixer Regulator Lockoff Solenoid 3-82 – JLG Lift – 3121201...

  • Page 133: Lockoff Solenoid

    Control System senses a fault dealing with the megajec- completely, it could cause low fuel pressure. tor. Refer to Section 6 - JLG Control System for more infor- mation concerning the Control System. d. Reference Line - Make sure the reference line is...
  • Page 134 Megajector - Megajector has an internal failure. If the CAN circuits are ok and all wiring connections are Contact JLG Industries for further assistance. good, the Megajector has an internal failure and must be DTC 364 - Megajector Internal Circuitry Fault Detection.

  • Page 135: Deutz Sensors For Jlg Control System

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-55. Deutz Sensors for JLG Control System 3121201 – JLG Lift – 3-85...

  • Page 136: Deutz Emr 2 (S/N 84711 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 137: 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 138 SECTION 3 - CHASSIS & TURNTABLE 3-88 – JLG Lift – 3121201...
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 3121201 – JLG Lift – 3-89...
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE 3-90 – JLG Lift – 3121201...
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE 3121201 – JLG Lift – 3-91...

  • Page 142: Emr 2 Engine Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-61. EMR 2 Engine Plug Pin Identification 3-92 – JLG Lift – 3121201...

  • Page 143: Emr 2 Vehicle Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-62. EMR 2 Vehicle Plug Pin Identification 3121201 – JLG Lift – 3-93...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE 3-94 – JLG Lift – 3121201...
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE 3121201 – JLG Lift – 3-95...
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE 3-96 – JLG Lift – 3121201...
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE 3121201 – JLG Lift – 3-97...
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE 3-98 – JLG Lift – 3121201...

  • Page 149: Gm Engine General Maintenance

    • Check the entire engine wire harness for rubbing chaf- ing, cuts or damaged connections, repair if necessary Figure 3-68. Engine Oil Dip Stick • Check all wire harness connectors to insure they are fully seated and locked 3121201 – JLG Lift – 3-99...

  • Page 150: 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. 3-100 – JLG Lift – 3121201...

  • Page 151: 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 152: 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 3-69. Electric Fuel Lock Off Figure 3-70. EPR Assembly 3-102 – JLG Lift – 3121201...

  • Page 153: 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 3-71. Low Pressure Regulators Figure 3-72. Air Fuel Mixer 3121201 – JLG Lift – 3-103...

  • Page 154: Electronic Throttle Control (Etc)

    Figure 3-73. ETC throttle control device Figure 3-74. LPG Engine Control Unit (ECM) Figure 3-75. ECM Assembly 3-104 – JLG Lift – 3121201...

  • Page 155: 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 3-77. Gasoline Fuel Pressure and Temperature pump, fuel pressure and temperature sensor manifold, Manifold Assembly fuel filter and fuel rail. 3121201 – JLG Lift – 3-105...

  • Page 156: 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. 3-106 – JLG Lift – 3121201...

  • Page 157: 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 3. Install the housing seal. Lock off . 3121201 – JLG Lift – 3-107...

  • Page 158: 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. 3-108 – JLG Lift – 3121201...

  • Page 159: 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. 3121201 – JLG Lift – 3-109...

  • Page 160: 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. 3-110 – JLG Lift – 3121201...

  • Page 161: 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 162: Lp Gas Fitting Inspection

    1/4” NPT X 1/4” SPT X 90 well-ventilated area free from any heat sources. degree elbow (JLG P/N 70001307). 2. Lower the platform to the stowed position. 8. Properly clean all old thread sealant from the LP gas fittings.

  • Page 163: 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. 3121201 – JLG Lift – 3-113...

  • Page 164: Lpf Fuel System Diagnosis

    1- 3 PSI Go to Step 22 Go to Step 13 (LPR). 2. Crank the engine and observe the pressure reading for the LPR primary pres- sure. Is the fuel pressure ABOVE the specified value? 3-114 – JLG Lift – 3121201...
  • Page 165 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? 3121201 – JLG Lift – 3-115...
  • Page 166 1. Disconnect all test equipment System OK 2. Install the primary and secondary test port plugs. 3. Start the engine. 4. Using SNOOP or equivalent, leak check the test port plugs. Is the action complete? 3-116 – JLG Lift – 3121201...

  • Page 167: Symptom Diagnosis

    If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the prob- lem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit. 3121201 – JLG Lift – 3-117...
  • Page 168 Check for the following: - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. 3-118 – JLG Lift – 3121201...
  • Page 169 - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. Check the intake and exhaust manifolds for casting flash. 3121201 – JLG Lift – 3-119...
  • Page 170 Monitoring the engine RPM with a scan tool can detect an EMI. A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present. If the problem exists, check the routing of the secondary wires and the ground circuit. 3-120 – JLG Lift – 3121201...
  • Page 171 Intake manifold gaskets Sticking or leaking valves Exhaust system leakage Check the intake and exhaust system for casting flash or other restrictions. Fuel System Checks Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis. 3121201 – JLG Lift – 3-121...
  • Page 172 Suggest that a different operator use the equipment and record the results. Fuel System Checks Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis. Check the fuel system for leakage. Sensor Checks Check the Temperature Manifold Absolute Pressure (TMAP) sensor. 3-122 – JLG Lift – 3121201...
  • Page 173 Check the ECM grounds for being clean, tight, and in their proper locations. Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality. 3121201 – JLG Lift – 3-123...
  • Page 174 - Check the Crankshaft Position (CKP) sensor. Additional Check Check the ECM grounds for being clean, tight, and in their proper locations. Check the generator output voltage. Check the vacuum hoses for kinks or leaks. Check Transmission 3-124 – JLG Lift – 3121201...

  • Page 175: 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 3121201 – JLG Lift – 3-125...
  • Page 176 CAN Rx Failure 1628 CAN Address Conflict Failure 1629 Loss of TSC 1 2111 Unable to Reach Lower TPS 2112 Unable to Reach Higher TPS 2135 TPS 1/2 Simultaneous Voltages 2229 BP Pressure High 3-126 – JLG Lift – 3121201...

  • Page 177: Section 4 - Boom & Platform

    When shims are removed, shorter bolts must be used so bolt does not protrude from insert and come into contact with boom surface. Figure 4-1. Location and Thickness of Wear Pads 3121201 – JLG Lift –...

  • Page 178: Boom Powertrack Installation

    SECTION 4 - BOOM & PLATFORM Figure 4-2. Boom Powertrack Installation – JLG Lift – 3121201...

  • Page 179: Boom Maintenance

    Disconnect dual capacity indicator limit switch from side of boom section. d. Remove hydraulic lines and electrical cables from powertrack. e. Using suitable lifting equipment, adequately support powertrack weight along entire length. 3121201 – JLG Lift –...

  • Page 180: Disassembly Of Boom Sections

    Using all applicable safety precautions, carefully Replace boom sections as necessary. lift boom assembly clear of turntable and lower to ground or suitably supported work surface. – JLG Lift – 3121201...

  • Page 181: Assembly

    Shim boom, if necessary, for a total of 2/10 inch (0.20) clearance. 9. Align the cylinder with the slots at aft end of base boom section, then secure cylinder with mounting hardware. 3121201 – JLG Lift –...

  • Page 182: Tower Boom

    Using a suitable brass drift and hammer, hammer, remove pin #1 from the tower boom assembly. e. Remove mounting hardware from tower boom pivot pin. Using a suitable brass drift and ham- mer, remove pin #2 from the turntable assembly. – JLG Lift – 3121201...

  • Page 183: Disassembly

    Figure 4-7. Location of Components - Tower Boom tubes. Powertrack 5. Remove mounting hardware which secures the powertrack to the top of the tower base section, then remove powertrack. 6. Remove mounting hardware from tower boom tele- scope cylinder barrel end. 3121201 – JLG Lift –...

  • Page 184: Inspection

    Secure hoses and harnesses with ments of the inside of base boom section. hoses brackets. – JLG Lift – 3121201...

  • Page 185: Installation

    1. JLG recommends the use of the JLG Hostile Envi- 2. Install tower boom pivot pin, ensuring that location ronment Package to keep the internal portions of a...

  • Page 186: Articulating Jib Boom

    2. Align rotator support with attach hole in articulating the cylinder pin from articulating jib boom. jib boom. Using a soft head mallet, install rotator support pin #6 into articulating jib boom and secure with mounting hardware. 4-10 – JLG Lift – 3121201...

  • Page 187: Limit Switches And Cam Valve Adjustment

    #1 into articulating jib boom pivot weldment and secure with mounting hardware. 4.6 LIMIT SWITCHES AND CAM VALVE ADJUSTMENT Adjust switches and cam valve as shown in Figure 4-9., Boom Limit Switch Adjustments. 3121201 – JLG Lift – 4-11...

  • Page 188: Boom Limit Switch Adjustments

    PLUNGER VALVE TO ACTIVATE WHEN BOOM IS RAISED BETWEEN 76° - 79° NOTE: ADJUST SCREWS SO THAT PLUNGER ON VALVES HAS 0.25" (6.35 mm) TRAVEL REMAINING WHEN LOWER BOOM IS FULLY RAISED AND RETRACTED Figure 4-9. Boom Limit Switch Adjustments 4-12 – JLG Lift – 3121201...

  • Page 189: Fiberglass Bar Installation

    SECTION 4 - BOOM & PLATFORM SWITCH TO ACTIVATE WHEN BOOM IS 126 ± 1" (320 ± 2.5 CM) FROM BEING FULLY EXTENDED Figure 4-10. Fiberglass Bar Installation 3121201 – JLG Lift – 4-13...

  • Page 190: Platform

    Figure 4-14. Heating Setscrew 0300132474) 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 4-15. Removing Setscrew 4-14 – JLG Lift – 3121201...

  • Page 191: Rotator Assembly (Helac)

    SECTION 4 - BOOM & PLATFORM Figure 4-12. Rotator Assembly (Helac) 3121201 – JLG Lift – 4-15...

  • Page 192: 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. 4-16 – JLG Lift – 3121201...

  • Page 193: Rotary Actuator (S/N 0300132474 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 3121201 – JLG Lift – 4-17...

  • Page 194: Required Tools

    Once the radius is achieved round off all sharp edges of the heated end by using a grinder. There may be 4-18 – JLG Lift – 3121201...

  • Page 195: 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 4-20. Rotary Actuator - Exploded View 3121201 – JLG Lift – 4-19...

  • Page 196: 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 4-21. Rotary Actuator - Assembly Drawing 4-20 – JLG Lift – 3121201...

  • Page 197: 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 3121201 – JLG Lift – 4-21...
  • Page 198 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. 4-22 – JLG Lift – 3121201...
  • Page 199 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. 3121201 – JLG Lift – 4-23...
  • Page 200 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). 4-24 – JLG Lift – 3121201...

  • Page 201: 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). 3121201 – JLG Lift – 4-25...
  • Page 202 (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. 4-26 – JLG Lift – 3121201...
  • Page 203 (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. 3121201 – JLG Lift – 4-27...
  • Page 204 13. Install the stop tube onto the shaft end. Stop tube is an available option to limit the rotation of an actua- tor. 4-28 – JLG Lift – 3121201...
  • Page 205 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). 3121201 – JLG Lift – 4-29...

  • Page 206: 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 4-22. Rotator Counterbalance Valve 4-30 – JLG Lift – 3121201...

  • Page 207: 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 3121201 – JLG Lift – 4-31...

  • Page 208: 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 4-32 – JLG Lift – 3121201...

  • Page 209: 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 4-23. Platform Support Torque Values 3121201 – JLG Lift – 4-33...
  • Page 210 SECTION 4 - BOOM & PLATFORM NOTES: 4-34 – JLG Lift – 3121201...

  • Page 211: Section 5 - Hydraulics

    1. Hold the fitting in one hand while using the brush with the other hand to dip into the container. Remove excess hydraulic oil from the brush so an even film of oil is applied on the o-ring. 3121201 – JLG Lift –...

  • Page 212: Dip Method

    3. Brush hydraulic oil on the entire o-ring, applying an in able to immerse more of the fitting into the satu- even coat of oil. rated sponge. This will also cause more oil to be dis- persed from the sponge. – JLG Lift – 3121201...

  • Page 213: Cylinders - Theory Of Operation

    4. To check piston seals, carefully remove the counter- balance valve from the retract port. After initial dis- charge, there should be no further leakage from the 3121201 – JLG Lift –...

  • Page 214: Cylinders With Dual Counterbalance Valves

    This is done to relieve pressure in the hydraulic lines. Carefully 3. If applicable, remove the cartridge-type holding remove hydraulic hoses from appropriate cylinder valve and fittings from the cylinder port block. Dis- port block. card o-rings. – JLG Lift – 3121201...

  • 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. 3121201 – 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 – 3121201...

  • 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- NOTE: The backup rings for the solid seal have a radius on ton and insert JLG capscrews (not vendor cap- one side. This side faces the solid seal.(See magni- screws) through the drilled holes in the bushing and fied insert in Figure 5-10.)The split of seals and...

  • Page 219: Seating The Tapered Bearing

    RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs. (136-149 Nm) 19. Continue pushing the rod into the barrel until the cyl- inder head gland can be inserted into the barrel cyl- inder. 3121201 – JLG Lift –...

  • Page 220: Cylinder Removal And Installation

    3. Install the cylinder into the boom assembly. 4. Remove the lifting devices from the telescope cylin- der. 5. Carefully install telescope cylinder rod pin #1 through the fly boom and secure it with the retaining rings. 5-10 – JLG Lift – 3121201...

  • Page 221: Main Boom Lift Cylinder Removal

    10. Check fluid level of hydraulic tank and adjust as nec- ware. Using a suitable brass drift drive out the barrel essary. end attach pin from the upright. 6. Remove the cylinder from the boom and place in a suitable work area. 3121201 – JLG Lift – 5-11...

  • Page 222: Main Boom Lift Cylinder Installation

    7. Check fluid level of hydraulic tank and adjust as nec- essary. 3. Remove the mounting hardware from pin #1, secur- ing leveling cylinder to upright. Figure 5-15. Leveling Cylinder Removal 5-12 – JLG Lift – 3121201...

  • Page 223: Boom Positioning And Support, Cylinder Repair

    SECTION 5 - HYDRAULICS Figure 5-17. Boom Positioning and Support, Cylinder Repair 3121201 – JLG Lift – 5-13...

  • Page 224: Upright Level Cylinder Installation

    9. Check fluid level of hydraulic tank and adjust as nec- boom fly assembly. essary. 13. Using a suitable drift, drive leveling cylinder pin #3 through the mounting holes in the tower boom fly and leveling cylinder, then remove leveling cylinder. 5-14 – JLG Lift – 3121201...

  • Page 225: Tower Boom Lift Cylinder Removal

    Place in a suitable 3. Using slings restrain tower lift cylinder. work area. 8. If necessary, use an auxiliary power source and fully retract lift cylinder. Figure 5-18. Tower Telescope Cylinder Removal 3121201 – JLG Lift – 5-15...

  • Page 226: Tower Lift Cylinder Installation

    6. Remove mounting hardware securing upper cylin- der pin to fly boom. Using a suitable brass drift, drive out the cylinder rod pin. 7. Remove mounting hardware attaching retaining plates to base boom and remove plate. 5-16 – JLG Lift – 3121201...

  • Page 227: 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 5-19. Axle Lockout Cylinder 3121201 – JLG Lift – 5-17...

  • Page 228: 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 5-20. Level Cylinder 5-18 – JLG Lift – 3121201...

  • Page 229: 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 5-21. Jib Lift Cylinder 3121201 – JLG Lift – 5-19...

  • Page 230: 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 5-22. Master Cylinder 5-20 – JLG Lift – 3121201...

  • Page 231: 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 5-23. Steer Cylinder 3121201 – JLG Lift – 5-21...

  • Page 232: Level (Upright) Cylinder

    20. Loctite #242 (Not Shown) 25. O-Ring Plug 3. Head 9. Socket Head Capscrew 15. Wear Ring 21. Locking Primer (Not 26. Loctite #609 4. Piston 10. O-Ring Plug 16. O-Ring Shown) Figure 5-24. Level (Upright) Cylinder 5-22 – JLG Lift – 3121201...

  • Page 233: Main Boom Lift Cylinder

    22. Locking Primer (Not Shown) 3. Head 10. Washer Ring 17. 17. O-Ring 23. Not Used 4. Piston 11. O-Ring Plug 18. Back-Up Ring 24. Bolt 5. Spacer 12. Wiper Figure 5-25. Main Boom Lift Cylinder 3121201 – JLG Lift – 5-23...

  • Page 234: Tower Boom Lift Cylinder

    24. Counterbalance Valve 4. Head 11. Loctite #242 (Not Shown) 18. O-Ring 25. Bolt 5. Tapered Bushing 12. Locking Primer (Not Shown) 19. Back-Up Ring 26. Loctite #609 Figure 5-26. Tower Boom Lift Cylinder 5-24 – JLG Lift – 3121201...

  • Page 235: Main Boom Telescope Cylinder

    5. Spacer 12. Wear Ring 19. Rod Seal 26. Flatwasher 6. Tapered Bushing 13. Seal 20. Wiper 27. Not Used 7. Plate 14. O-Ring 21. Back-Up Ring 28. Bolt Figure 5-27. Main Boom Telescope Cylinder 3121201 – JLG Lift – 5-25...

  • Page 236: Tower Boom Telescope Cylinder

    5. Washer Ring 12. T-Seal 19. Wiper 6. Tapered Bushing 13. O-Ring 20. Locking Primer (Not Shown) 7. Valve Cartridge 14. Back-Up Ring 21. Loctite #242 (Not Shown) Figure 5-28. Tower Boom Telescope Cylinder 5-26 – JLG Lift – 3121201...

  • Page 237: Variable Displacement Pump (M46 Series)

    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 Figure 5-29. Troubleshooting - Neutral Difficult or Impossible to Find 3121201 – JLG Lift – 5-27...

  • Page 238: Troubleshooting - System Operating Hot

    SECTION 5 - HYDRAULICS Figure 5-30. Troubleshooting - System Operating Hot Figure 5-31. Troubleshooting - Transmission Operates in One Direction Only 5-28 – JLG Lift – 3121201...

  • Page 239: Troubleshooting - System Response Is Sluggish

    SECTION 5 - HYDRAULICS Figure 5-32. Troubleshooting - System Response is Sluggish 3121201 – JLG Lift – 5-29...

  • Page 240: 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. 5-30 – JLG Lift – 3121201...
  • Page 241 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). 3121201 – JLG Lift – 5-31...
  • Page 242 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. 5-32 – JLG Lift – 3121201...

  • Page 243: 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. 3121201 – JLG Lift – 5-33...
  • Page 244 Refer to the appropri- ate Service Parts Manual for more information. 2. Reinstall the bypass valve into the housing. Torque to 7 to 10 ft. lbs. (9.5 - 13.6 Nm). 5-34 – JLG Lift – 3121201...
  • Page 245 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. 3121201 – JLG Lift – 5-35...
  • Page 246 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 5-36 – JLG Lift – 3121201...

  • Page 247: 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. 3121201 – JLG Lift – 5-37...

  • Page 248: 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 249: 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 5-36. Main Control Valve Pressure Adjustments - Sheet 1 of 2 3121201 – JLG Lift – 5-39...

  • Page 250: 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 5-37. Main Control Valve Pressure Adjustments - Sheet 2 of 2 5-40 – JLG Lift – 3121201...

  • Page 251: Location Of Components - Main Control Valve

    SECTION 5 - HYDRAULICS Figure 5-38. Location of Components - Main Control Valve 3121201 – JLG Lift – 5-41...

  • Page 252: 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. 5-42 – JLG Lift – 3121201...

  • Page 253: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication

    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. 3121201 – JLG Lift – 5-43...
  • Page 254 SECTION 5 - HYDRAULICS NOTES: 5-44 – JLG Lift – 3121201...

  • Page 255: Section 6 - Jlg Control System

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- system. 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 256: Ade Block Diagram

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. ADE Block Diagram – JLG Lift – 3121201...

  • Page 257: 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 258: Analyzer Connecting Points

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-3. Analyzer Connecting Points – JLG Lift – 3121201...

  • Page 259: 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 260: Control Module Location

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-4. Control Module Location – JLG Lift – 3121201...

  • Page 261: 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 262: 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 263 SECTION 6 - JLG CONTROL SYSTEM 3121201 – JLG Lift –...
  • Page 264 SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3121201...
  • Page 265 SECTION 6 - JLG CONTROL SYSTEM 3121201 – JLG Lift – 6-11...
  • Page 266 SECTION 6 - JLG CONTROL SYSTEM 6-12 – JLG Lift – 3121201...
  • Page 267 SECTION 6 - JLG CONTROL SYSTEM 3121201 – JLG Lift – 6-13...
  • Page 268 SECTION 6 - JLG CONTROL SYSTEM 6-14 – JLG Lift – 3121201...
  • Page 269 SECTION 6 - JLG CONTROL SYSTEM 3121201 – JLG Lift – 6-15...
  • Page 270 SECTION 6 - JLG CONTROL SYSTEM 6-16 – JLG Lift – 3121201...

  • Page 271: 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 DRIVE ACCELeration 0.1s to 5.0s DECELeration 0.1s to 3.0s...
  • Page 272 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS SWING ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed 0 to 65%...
  • Page 273 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS BASKET ROTATE ACCELeration 0.1 to 5.0 DECELeration 0.1 to 3.0 MlNimum LEFT speed 0 to 65% MAXimum LEFT speed 0 to 100% MINimum RIGHT speed 0 to 65%...

  • Page 274: 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 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 D/S JOY. OUT OF RANGE Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1 HIGH volts.
  • 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 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 277 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 278 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 279 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 280 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 281 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 282 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 283 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 284 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 285: 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 286 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 287 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 288 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 289: 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 290 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 291 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 292 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 293 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 294: 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 295 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 296 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 297 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 298 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 299 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 300 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. 600A ANSI USA ANSI EXPORT AUSTRALIA JAPAN...
  • Page 301 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. 600AJ ANSI USA ANSI EXPORT AUSTRALIA JAPAN...

  • Page 302: Analyzer Fault Code Listing

    SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text EVERYTHING OK GROUND MODE OK 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0011 FSW OPEN 0012 RUNNING AT CREEP - CREEP SWITCH OPEN 0013...
  • Page 303 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text BRAKE - SHORT TO BATTERY BRAKE - OPEN CIRCUIT 3311 GROUND ALARM - SHORT TO BATTERY 3316 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND 3319...
  • Page 304 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text 3370 TWO SPEED VALVE - SHORT TO BATTERY 3371 GROUND ALARM - SHORT TO GROUND 3372 GROUND ALARM - OPEN CIRCUIT 3373 GEN SET/WELDER - SHORT TO GROUND...
  • Page 305 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text 33115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND 33116 TOWER TELESCOPE OUT VALVE - OPEN CIRCUIT 33117 TOWER TELESCOPE OUT VALVE - SHORT TO BATTERY...
  • Page 306 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text 33315 FLOW CONTROL VALVE - SHORT TO BATTERY 33316 FLOW CONTROL VALVE - SHORT TO GROUND 33317 DRIVE FORWARD VALVE - OPEN CIRCUIT 33318 DRIVE FORWARD VALVE - SHORT TO BATTERY...
  • Page 307 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text FUEL SENSOR - SHORT TO BATTERY FUEL SENSOR - SHORT TO GROUND OIL PRESSURE - SHORT TO BATTERY OIL PRESSURE - SHORT TO GROUND COOLANT TEMPERATURE - SHORT TO GROUND...
  • Page 308 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text 8311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY 8312 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT 8313 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE...
  • Page 309 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Analyzer Fault Code Listing Analyzer Text 9920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE 9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY 9922 PLATFORM MODULE FAILURE - HWFS CODE 1...

  • Page 310: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM 6.9 ANALYZER DIAGNOSTICS MENU In the following structure descriptions, an intended item is selected by pressing ENTER; pressing ESC steps back to STRUCTURE the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow keys alter a value if allowed Table 6-7.
  • Page 311 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 312 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 313: 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 314 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 315: Section 7 - Basic Electrical Information & Schematics

    Polarity Getting a negative Voltage or current reading when expecting a positive reading frequently means the leads 3121201 – JLG Lift –...

  • Page 316: 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 – 3121201...

  • Page 317: 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. 3121201 – JLG Lift –...

  • Page 318: 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 – 3121201...

  • Page 319: 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 3121201 – JLG Lift –...

  • Page 320: 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 – 3121201...

  • Page 321: Connector Installation

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-11. Connector Installation 3121201 – JLG Lift –...

  • Page 322: 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 – 3121201...

  • Page 323: 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. 3121201 – JLG Lift –...

  • Page 324: Electrical Harness - S/N 80000 To 87000 - Sheet 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18. Electrical Harness - S/N 80000 to 87000 - Sheet 1 of 2 7-10 – JLG Lift – 3121201...

  • Page 325: Electrical Harness - S/N 80000 To 87000 - Sheet 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-19. Electrical Harness - S/N 80000 to 87000 - Sheet 2 of 2 3121201 – JLG Lift – 7-11...

  • Page 326: Electrical Harness - S/N 87000 To Present - Sheet 1 Of 2

    FOOTSWITCH GENERATOR SWITCH PLATFORM WORK LIGHTS MAIN BOOM ELEVATION LIMIT SWITCH TOWER BOOM ELEVATION LIMIT SWITCH BOOM CAPACITY ANGLE LIMIT SWITCH (600A ANSI, ANSI EXPORT, BRAZILIAN & JAPANESE SPECS) BOOM LENGTH LIMIT SWITCH PLATFORM CONTROL (DEUTZ) GROUND CONTROL (DEUTZ/GM ONLY)

  • Page 327: 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 3121201 – JLG Lift – 7-13...

  • Page 328: 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 – 3121201...

  • Page 329: 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 3121201 – JLG Lift – 7-15...

  • Page 330: 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 – 3121201...

  • Page 331: Electrical Schematic - Ade - Sheet 4 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS RECTIFER FUSIBLE LINK STATOR CAT ENGINE 600A, 600S, 800A STARTER ALTERNATOR MOTOR SOL. REGULATOR ALTERNATOR WITH PLUG CONNECTOR STARTER SENSING AND FUSIBLE MOTOR SWITCHING LINK CIRCUITS STATOR WHT/YEL 48-13 (8) ALTERNATOR GLOW PLUGS...

  • Page 332: 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 – 3121201...

  • Page 333: 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 3121201 – JLG Lift – 7-19...

  • Page 334: 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 – 3121201...

  • Page 335: Hydraulic Schematic - Sheet 2 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792691A Figure 7-29. Hydraulic Schematic - Sheet 2 of 6 3121201 – JLG Lift – 7-21...

  • Page 336: 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 – 3121201...

  • Page 337: Hydraulic Schematic - Sheet 4 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792691A Figure 7-31. Hydraulic Schematic - Sheet 4 of 6 3121201 – JLG Lift – 7-23...

  • Page 338: 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 – 3121201...

  • Page 339: Hydraulic Schematic - Sheet 6 Of 6

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792691A Figure 7-33. Hydraulic Schematic - Sheet 6 of 6 3121201 – JLG Lift – 7-25...
  • Page 340 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-26 – JLG Lift – 3121201...
  • Page 342 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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