JLG 601S Service And Maintenance Manual
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JLG 601S Service And Maintenance Manual

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Service and Maintenance Manual
Model
601S
P/N - 3120746
November 22, 2016

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  • Page 1 Service and Maintenance Manual Model 601S P/N - 3120746 November 22, 2016...
  • Page 3 59319, 59352, 59358, 59361, 59769, 60253, 60254, 60286, and 60242 A Machine that incorporates the ADE (Advanced Design Elec- tronics) system can be out- wardly identified by the analyzer connection at the base of the platform control box as shown by the arrow. – JLG Lift –...
  • Page 4 THIS PAGE LEFT BLANK INTENTIONALLY – JLG Lift –...

  • Page 5: 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 3120746 – JLG Lift –...
  • Page 6 INTRODUCTION REVISON LOG Original Issue March, 1998 Revised February 1, 1999 Revised February 14, 2001 Revised August 24, 2001 Revised April 18, 2002 Revised August 6, 2003 Revised February 26, 2014 Revised November 22, 2016 – JLG Lift – 3120746...

  • Page 7: Table Of Contents

    Service and Guidelines ............2-2 3120746 – JLG Lift –...
  • Page 8 Welding on JLG Equipment ............2-6 Do the Following When Welding on JLG Equipment ......2-6 Do NOT Do the Following When Welding on JLG Equipment .
  • Page 9 Troubleshooting............3-61 3.19 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61306) ....3-63 3120746 – JLG Lift –...
  • Page 10 Disassembly............. . 5-2 – JLG Lift –...
  • Page 11 To Connect the JLG Control System Analyzer ........
  • Page 12 Addco Adjustments - Deutz ............3-64 – JLG Lift –...
  • Page 13 Analyzer Flow Chart - Sheet 3 of 3 ..........6-11 3120746 – JLG Lift –...
  • Page 14 Hydraulic Schematic - Sheet 4 of 4..........7-19 viii – JLG Lift – 3120746...
  • Page 15 Diagnostic Menu Descriptions ........... .6-47 3120746 – JLG Lift –...
  • Page 16 TABLE OF CONTENTS (Continued) This page left blank intentionally. – JLG Lift – 3120746...

  • Page 17: Section 1. Specifications

    Alternator - 40 Amp, Belt Drive. Toe-in, adjust for 1/4" (6.35 mm) overall. Battery - 85 Amphour, 550 Cold Cranking Amps, 12 VDC. Fuel Consumption. Low RPM - 3.45 GPH (13.06 lph). High RPM - 4.60 GPH (17.41 lph). 3120746 – JLG Lift –...

  • Page 18: Swing System

    Articulating Jib: Platform level and centered with the Boom Elevation boom. Start with the Jib down. Jib Up, Record Time. Jib +60 ft. 2 13/16 in. (18.36 m) -6 ft. 1 11/16 in. (1.87 m). Down, Record Time. – JLG Lift – 3120746...

  • Page 19: Test Notes

    37-45 value. Drive Forward & Reverse (4WD) 43-136 Drive Above Horizontal - Forward & Reverse (2WD & 4WD) *Max 10% Difference Between Left & Right **Max 15% Difference Between Left & Right 4150130 - E 3120746 – JLG Lift –...

  • Page 20: Lubrication

    *Not recommended for severe service, including high RPM operation NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C or have properties of API classification CC/CD grades. NOTE: Crankcase oil must be high quality detergent type meeting API service classification SF, SH, SG. – JLG Lift – 3120746...

  • Page 21: Hydraulic Oil

    -20° F 6,200 Viscosity Index NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Indus- tries for proper recommendations.

  • Page 22: Cylinder Specifications

    Turntable Complete (including engine) 7315 3318 Chassis Complete (w/pneumatic tires) 10400 4718 Chassis Complete (w/foam-filled tires) 11680 5300 Machine Complete (GVW) - 2WD w/pneumatic tires 22000 9979 Machine Complete (GVW) - 4WD w/pneumatic tires 22510 10211 – JLG Lift – 3120746...

  • Page 23: Serial Number Locations

    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 1-1. Serial Number Locations 3120746 – JLG Lift –...

  • Page 24: Lubrication Diagram

    NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION. IN USA MADE 9, 12 THRU 17 ENGINE LOCATED ON OPPOSITE SIDE OF MACHINE FROM VIEW SHOWN. 8, 10 1, 6 2, 4 Figure 1-2. Lubrication Diagram – JLG Lift – 3120746...

  • Page 25: Lubrication Chart

    (approximately 221 degrees F) cooler will fill up Multi-Purpose Grease within minutes; shut down and wait for approximately two minutes. Check oil level, fill oil to max marking on the dipstick. 3120746 – JLG Lift –...
  • Page 26 SECTION 1 - SPECIFICATIONS 1-10 – JLG Lift – 3120746...

  • Page 27: 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 28: 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 29: Component Disassembly And Reassembly

    If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 3120746 – JLG Lift –...

  • Page 30: Lubrication And Information

    1. Refer to Section 1 for recommendations for viscosity key designations appearing in the Lubrication Chart. ranges. 2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below -15 degrees F (-26 degrees C) is not recom- mended.

  • Page 31: Cylinder Drift Test

    If the cylinder passes this test, it is acceptable. burrs, nicks, and scratches which would dam- age the bearing during installation and opera- NOTE: This information is based on 6 drops per minute cyl- tion. inder leakage. 3120746 – JLG Lift –...

  • Page 32: Welding On Jlg Equipment

    Silicone Dielectric Compound must be used on all electri- machine on an external structure, or component, cal connections for the following reasons: Do the Following When Welding on JLG • To prevent oxidation at the mechanical joint between Equipment male and female pins.

  • Page 33: 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 2-3.). from it. Figure 2-2. AMP Connector 3120746 – JLG Lift –...
  • Page 34 (See Figure 2-5.). Release the locking latches by squeezing them inward (See Figure 2-4.). Figure 2-5. Connector Assembly Figure 4 Figure 2-4. Connector Assembly Figure 3 – JLG Lift – 3120746...

  • Page 35: Disassembly

    The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. 3120746 – JLG Lift –...

  • Page 36: Connector Installation

    SECTION 2 - GENERAL Figure 2-7. Connector Installation 2-10 – JLG Lift – 3120746...

  • Page 37: Inspection And Preventive Maintenance Schedule

    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 3120746 – JLG Lift – 2-11...
  • Page 38 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 2-12 – JLG Lift – 3120746...
  • Page 39 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 40 SECTION 2 - GENERAL This page left blank intentionally. 2-14 – JLG Lift – 3120746...

  • Page 41: Section 3. Chassis & Turntable

    Place disconnect cap over cover cap with nipple 2. Inspect bearing cups and cones for damage, pitting, facing out and secure with two bolts. Torque corrosion, or excessive wear. If necessary, replace bolts to 70-80 in. lbs. (7.9-9.0 Nm). 3120746 – JLG Lift –...
  • Page 42 Clean and inspect all parts in accordance with Cleaning and Inspection procedures. Replace parts as necessary. h. Apply a coat of grease or petroleum jelly to clus- ter gear bore. k. Place second set of sixteen needle rollers into cluster gear. – JLG Lift – 3120746...
  • Page 43 Line up cluster gear and thrust washers with in that order, onto input shaft. hole in carrier and slide planet shaft through. Ensure chamfered side of hole in planet shaft is lined up with pin hole in carrier. 3120746 – JLG Lift –...

  • Page 44: Assembly

    5), with large inside diameters facing out, into hub (7) counter bores. 5. Place bearing cone (6) over end of spindle and into bearing cup. 2. Place bearing cone (4) into bearing cup (3) in small end of hub. – JLG Lift – 3120746...
  • Page 45 Ensure retaining ring is entirely in groove. 11. Place input shaft assembly (35) into spindle bore with unsplined end facing out. 8. Place internal gear (12) onto end of spindle. 3120746 – JLG Lift –...
  • Page 46 Ensure punch marks remain in correct location dur- ing ring gear installation. 14. Place o-ring (22) into hub counter bore. Use petro- leum or grease to hold o-ring in place. Slight stretch- ing of o-ring may be necessary to insure proper seating. – JLG Lift – 3120746...
  • Page 47 18. Install input gear (37) into carrier, meshing with large diameter cluster gears (18). Counter bore in bore of input gear must be to outside of carrier assembly. 3120746 – JLG Lift –...
  • Page 48 26. Fill hub one-half full of EPGL 90 lubricant before operation. 23. Locate four shoulder bolts (42), 90 degrees apart into counter bored holes in hub marked in step (13). Torque shoulder bolts to 47 ft. lbs. (64 Nm). – JLG Lift – 3120746...

  • Page 49: Torque Hub, Drive (Fairfield)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-1. Torque Hub, Drive (Fairfield) 3120746 – JLG Lift –...

  • Page 50: Torque Hub, Drive (Auburn Gear)

    Assemble the twelve bolts (25) and flat bearing cups (7 & 10) and cones (6 & 11) be washer (26). Torque bolts to 61 - 67 Nm (45 - 50 ft. replaced in sets. lbs.). 3-10 – JLG Lift – 3120746...

  • Page 51: Torque Hub, Drive (Auburn Gear)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-2. Torque Hub, Drive (Auburn Gear) 3120746 – JLG Lift – 3-11...

  • Page 52: Drive Brake - Ausco

    BRAKE REQUIRES. CHECK THE PARTS LIST CAREFULLY FOR THE EXACT QUANTITY. IN THE CASE OF SPRINGS, SPACE THE SPRINGS AS SHOWN IN THE FIGURE. 1. Worn o-rings and damaged or worn Teflon backup rings must be replaced prior to assembly. 3-12 – JLG Lift – 3120746...

  • Page 53: Drive Brake Assembly (Ausco)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-3. Drive Brake Assembly (Ausco) 3120746 – JLG Lift – 3-13...

  • Page 54: Drive Brake - Mico

    Note direction of seal. IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE MUST NOT EXCEED 3. Press bearing (18) into position until it bottoms out on borestep. 134.5 BAR (500 PSI). 3-14 – JLG Lift – 3120746...

  • Page 55: 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 3-4. Drive Brake - Mico 3120746 – JLG Lift – 3-15...

  • Page 56: Bleeding

    Discs frozen These brakes are designed for only lim- Replace disc stack. ited dynamic braking. A severe emer- gency stop or prolonged reduced release pressure operation may result in this type of damage. 3-16 – JLG Lift – 3120746...

  • Page 57: Drive Motor (Prior To S/N 85132)

    Same sealing kit like shown above only seal material 3.5 DRIVE MOTOR (PRIOR TO S/N 85132) changed to Viton Spare Parts Kits Sealing kit, existing spare parts: shaft sealing ring, 6 differ- ent O-rings and a circlip (sealing mat.: perbunan) Drive shaft 3120746 – JLG Lift – 3-17...

  • Page 58: Replacing The Drive Shaft Seal

    Parts of the control device: control piston, piston rod, plug, spring stopper max hex. nut, and hex. head nut flow 3. Be careful while you seal the drive shaft, use an adhesive tape to protect the splines. 3-18 – JLG Lift – 3120746...

  • Page 59: Disassembly And Assembly

    6. Assemble the snap ring in the correct position. 3. Remove the port plate together with the valve plate (hold the valve plate so that the plate can’t fall down). 3120746 – JLG Lift – 3-19...
  • Page 60 9. Turn in the stopper max flow to get swivel angle zero. 6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position. 7. Unscrew the cap nut and remove it. 11. Disassemble the stopper - max. flow. 3-20 – JLG Lift – 3120746...
  • Page 61 18. Remove both bearing shells. 14. Disassemble the control piston while moving the swash plate. 19. Remove the drive shaft. 15. The swash plate must be lifted a little bit to disas- semble the piston rod. 3120746 – JLG Lift – 3-21...
  • Page 62 22. The external front bearing ring is pulled out of the pump housing. 25. The spring has additional pretension while you dis- assemble the three pressure pins inside the cylinder. 3-22 – JLG Lift – 3120746...

  • Page 63: Assembly Notes

    (Note spare parts exist as cw and ccw valve plates.) Taper Roller Bearing Initial Tension Cast iron pump housing must have initial tension of the bearings: 0..0,05 mm, grind Pos. 12 if necessary. 3120746 – JLG Lift – 3-23...

  • Page 64: 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 3-5. Flow Control Pilot Valves 3-24 – JLG Lift – 3120746...

  • Page 65: Testing And Setup

    (if it’s DFR design then open the adjustable orifice and increase force of the spring - FR -). FR: If swivel angle is in the mid position adjust differential pressure 14 bar adjustable orifice is partly closed). 3120746 – JLG Lift – 3-25...

  • Page 66: Drive Motor Adjustment Procedure (Prior To S/N 85132)

    3. Measure from top of jam nut to the end of adjust- ment screw. (See Figure 3-6., Drive Motor Adjust- ment.) 4. Tighten jam nut, install cap nut. NOTE: The “o” ring must be seated in groove in cap nut. 3-26 – JLG Lift – 3120746...

  • Page 67: Drive Motor (S/N 85132 To Present)

    2. Install a new shaft seal with the cupped side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal. 3. Install seal support washer. 4. Install snap ring. 5. Remove the installation sleeve. 3120746 – JLG Lift – 3-27...

  • Page 68: 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). 3-28 – JLG Lift – 3120746...

  • Page 69: 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. 3120746 – JLG Lift – 3-29...

  • Page 70: 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. 3-30 – JLG Lift – 3120746...

  • Page 71: Valve Plate & Rear Shaft Bearing

    Use caution not to drive the bearing past the rear shaft journal as the bearing may become trapped on the shaft and damaged. 18. Remove minimum angle stop (29) and servo spring (30) from the housing. 3120746 – JLG Lift – 3-31...

  • Page 72: Shaft Seal

    Pull the bearing (37) off of the shaft (38). 32. Snap Ring 33. Support Washer 34. Shaft Seal Figure 3-15. Shaft Seal 20. Turn the housing over and remove the snap ring (32) retaining the shaft seal and support washer. Remove 3-32 – JLG Lift – 3120746...

  • Page 73: 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. 3120746 – JLG Lift – 3-33...

  • Page 74: Inspection

    Table 3-7. 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) 3-34 – JLG Lift – 3120746...
  • Page 75 Measure the swashplate thickness from sealing surfaces. the journals to the running face. Replace swashplate if damaged or worn beyond minimum specification. 3120746 – JLG Lift – 3-35...

  • Page 76: 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 3-36 – JLG Lift – 3120746...

  • Page 77: Swash Plate And Journal Bearing

    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. 3120746 – JLG Lift – 3-37...

  • Page 78: 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 3-24. Servo Spring and Minimum Angle Stop 3-38 – JLG Lift – 3120746...

  • Page 79: 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. 3120746 – JLG Lift – 3-39...

  • Page 80: Shaft Seal

    1.5 to 2.5 ft.lbs. (2.03 to 3.39 Nm) 28. Seal Support Washer 29. Snap Ring Figure 3-27. Shaft Seal 1/4 in 33 ft.lbs. (45 Nm) 5/16in 63 ft.lbs. (85 Nm) Figure 3-28. Plugs and Fittings Installation 3-40 – JLG Lift – 3120746...

  • Page 81: Initial Start-Up Procedures

    The motor is now ready for operation. 3.8 FREE WHEELING OPTION To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. 1. Chock wheels securely if not on flat level surface. 3120746 – JLG Lift – 3-41...

  • Page 82: To Engage Drive Motors And Brakes (Normal Operation)

    2. Connect both drive hubs by inverting disconnect cap in center of hub. 3. Remove chocks from wheels as required. DISCONNECT Drive Hub Engaged DRIVE DISCONNECT (REVERSED) DRIVE Drive Hub Disconnected Figure 3-30. Disconnecting the Drive Hubs 3-42 – JLG Lift – 3120746...

  • Page 83: Oscillating Axle Bleeding Procedure And Lockout Test

    5. Carefully activate SWING control lever and position Figure 3-32. Brake Valve Wiring Connection boom over right side of machine. 3120746 – JLG Lift – 3-43...

  • Page 84: Steer Adjustments

    DRIVE to release cylinders. 15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation. Figure 3-34. Steer Adjustments 3-44 – JLG Lift – 3120746...

  • Page 85: Swing Hub

    NOTE: This check is designed to replace the existing bear- position. ing bolt torque checks on JLG Lifts in service. This 3. Lower the boom to horizontal and fully extend the check must be performed after the first 50 hours of boom.

  • Page 86: Wear Tolerance

    Use a suitable container to retain any residual hydrau- d. Rough rotation. lic fluid. Immediately cap lines and ports. 5. If bearing inspection shows no defects, reassemble and return to service. 3-46 – JLG Lift – 3120746...
  • Page 87 Using all applicable safety precautions, activate THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICA- the hydraulic system and check the swing sys- TIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOM- tem for proper and safe operation. MENDED. b. Apply a light coating of Loctite #271 to the new...
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 3-48 – JLG Lift – 3120746...

  • Page 89: Swing Bearing Torque Value

    Using an appropriate tool, pry the seal (6) out from the inside of the brake. Take care not to damage the bore. Remove the retaining ring (5). Tap the bearing (4) out with a plastic mallet. 3120746 – JLG Lift – 3-49...

  • Page 90: Inspection

    IS CRITICAL. THE SURFACE OF THE PISTON AT THE CUTOUTS MUST BE FLUSH TO 0.120 IN BELOW THE SURFACE OF THE POWER PLATE. DO NOT EXCEED THE 0.120 DEPTH OR THE PIS- TON WILL COCK RESULTING IN A COMPLETE LOSS OF BRAK- ING. 3-50 – JLG Lift – 3120746...

  • Page 91: Swing Brake Assembly (Ausco)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-40. Swing Brake Assembly (Ausco) 3120746 – JLG Lift – 3-51...

  • Page 92: Swing Motor

    THESE SCREWS WERE LOCTITED DURING ASSEMBLY. DO NOT EXCEED 500 IN. LBS (56 NM) OF REMOVAL TORQUE Seal Seal Spacer Plate End Cap Seal Capscrew Geroler Drive Figure 3-41. End Cap Removal 3-52 – JLG Lift – 3120746...

  • Page 93: Reassembly

    4. Lubricate and install the back - up ring and pressure. rounding the end of a small blade screwdriver. Use a seal installation tool to press the pressure seal into place. DO NOT DAMAGE THE MOUNTING FLANGE WHERE THE SHAFT PASSES THROUGH IT. 3120746 – JLG Lift – 3-53...

  • Page 94: Motor Timing

    BE SURE THE SLOTS IN THE SPACER PLATE PROVIDE PAS- SAGE FOR HYDRAULIC FLUID AS WELL AS THE CAP SCREWS. IF THE SPACER PLATE IS FLIPPED THE MOTOR WILL NOT OPERATE. 3-54 – JLG Lift – 3120746...

  • Page 95: Swing Motor

    Mounting Flange 13. Drive Backup Ring 14. Spacer Plate Pressure Seal 15. Seal Seal 16. Geroler Bearing Race 17. Seal Needle Thrust Bearing 18. End Cap 19. Capscrew Output Shaft Figure 3-42. Swing Motor 3120746 – JLG Lift – 3-55...

  • Page 96: Tilt Alarm Switch (Machines With External Tilt Sensor)

    “stumble” from lack of gasoline. Figure 3-43. Tilt Switch Adjustment 4. As the engine begins to “stumble”, place the switch to the LPG position, allowing the LP fuel to be sent to the fuel regulator. 3-56 – JLG Lift – 3120746...

  • Page 97: Changing From Lp Gas To Gasoline

    (See diagram on page 43 E-331 Electronics - achieve this. This can usually be done, and is usually Adjustment Locations.) worth the effort! Below are some workable installations, 3120746 – JLG Lift – 3-57...

  • Page 98: Mounting-Controller

    Move the linkage slowly through its travel, and look for any binding or unexplained forces. Correct any before going further. 3-58 – JLG Lift – 3120746...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 3120746 – JLG Lift – 3-59...

  • Page 100: Check-Out And Initial Start-Up Procedures

    High Engine pot, or have lost track of where you are, turn the pot 25-30 turns CCW, then back 10-12 turns CW to get back into the range of normal adjustment. 3-60 – JLG Lift – 3120746...

  • Page 101: Troubleshooting

    Bad voltage regulator. speed adjustment pot. The overspeed is simply to shut down an over revving engine. e. Bad ground connection. f. Corroded terminals. g. Undersized wiring. 3120746 – JLG Lift – 3-61...
  • Page 102 Governor output arm and control engine manually. b. Start engine, hold at a low speed, Governor arm should move to full-fuel position. c. Increase engine speed carefully. At some engine speed, Governor arm should move to low-fuel position. 3-62 – JLG Lift – 3120746...

  • Page 103: Throttle Checks And Adjustments - Deutz Engine (Prior To S/N 61306)

    1 - POSITION 1 CW=RETRACT 2 - POSITION 2 CW=RETRACT E - EXTEND INDICATOR (AMBER) 3 - POSITION 3 CW=RETRACT C - CLUTCH INDICATOR (GREEN) 4 - POSITION 4 CW=RETRACT F - FAILURE INDICATOR (RED) 3120746 – JLG Lift – 3-63...

  • Page 104: Procedure

    2. The input voltage must be greater than 10.5 Vdc. 3. Check wiring for any damage and correct. 4. Disconnect engine harness and actuator connnec- tions. 5. If problem reoccurs return unit. Clutch engaged actuator extending 3-64 – JLG Lift – 3120746...

  • Page 105: Automatic Choke Adjustment - Ford Engine

    2. Examine throttle linkage for any damage or bent components and correct. 3. With linkage disconnected, check each potentiome- ter for operation. 4. Reconnect linkage and reset each potentiometer for correct operation. 5. If failure continues to occur, replace unit. 3120746 – JLG Lift – 3-65...

  • Page 106: Cold Weather Starting Difficulty

    2. Engine Not Receiving Fuel - If after cranking the engine for a period of time, and there is no white smoke coming out of the exhaust tube, follow the procedures under Checking the Fuel. 3-66 – JLG Lift – 3120746...

  • Page 107: Checking The Ignition

    2-4lbs. 3. Check Fuel Filter: a. Loosen jam nut NOTE: Some JLG machines have a fuel return line between b. Screw the adjustment screw all the way in, then the fuel pump and carburetor, if this return line is back out 1/2 turn.

  • Page 108: Ford Efi Engine (Machines After S/N 58209)

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

  • Page 109: Engine Module And Sensors

    The crankshaft position (CKP) sensor provides a signal used by the Engine Module to calculate the ignition sequence. The CKP sensor initiates the reference pulses which the Engine Module uses to calculate RPM and crankshaft position. 3120746 – JLG Lift – 3-69...

  • Page 110: Ecm Diagnostic Trouble Codes

    Camshaft Position Sensor (CMP) Sensor Illegal Pattern Engine Control Module (ECM) Fault Illegal Operation Engine Control Module (ECM) Fault Illegal Interruption Engine Control Module (ECM) Fault COP (Computer Operating Properly) Failure System Voltage Low System Voltage High 3-70 – JLG Lift – 3120746...

  • Page 111: Epm Diagnostic Trouble Codes

    Adaptive Learn High (LPG) This fault will set if the adaptive multiplier exceeds the limits of normal operation. Adaptive Learn Low (LPG) This fault will set if the adaptive multiplier exceeds the limits of normal operation. 3120746 – JLG Lift – 3-71...
  • Page 112 TPS, and RPM. When the fault is set, the Adaptive Learn will be disabled for the remainder of the key on cycle and the MIL will be on. The engine will operate on a default MAP during this active fault. 3-72 – JLG Lift – 3120746...
  • Page 113 Injector Driver #3 Shorted (2.5L) This fault will set if the EPM detects low feedback voltage on the inter- nal injector while the injector drive circuit is in the off-state and battery voltage is greater than 9 volts. 3120746 – JLG Lift – 3-73...
  • Page 114 If the active fault is no longer present, the MIL light will flash at 2 Hz for the remainder of the key-on cycle. This is a reminder that the Low Rev Limit is still enforced. 3-74 – JLG Lift – 3120746...
  • Page 115 TPS2 (Signal Voltage) Low This fault will set if voltage is below 0.2 volts at any operating condi- tion while the engine is cranking or running. The engine will not start or run during this active fault. 3120746 – JLG Lift – 3-75...
  • Page 116 It will not self- erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. 3-76 – JLG Lift – 3120746...
  • Page 117 It will not self- erase. During this active fault, Power Derate (level 2) will be enforced. When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. 3120746 – JLG Lift – 3-77...
  • Page 118 If the Engine Module is replaced, the new Engine Module will need to be programmed. An IBM-compatible com- puter and software containing the correct program and calibration for the application are required to program the Engine Module. 3-78 – JLG Lift – 3120746...
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE 3120746 – JLG Lift – 3-79...
  • Page 120 The Engine Module controls output circuits such as the fuel injectors, electronic gover- nor, etc., by control ling the ground or the power feed cir- cuit through transistors or other solid state devices. 3-80 – JLG Lift – 3120746...
  • Page 121 • Do not employ any non-standard practices such as charging the battery with an arc welder. • Take proper precautions to avoid static damage to the Engine Module. Refer to "Electrostatic Discharge Dam- age" for more information. 3120746 – JLG Lift – 3-81...

  • Page 122: Ecm/Epm Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-47. ECM/EPM Identification 3-82 – JLG Lift – 3120746...

  • Page 123: 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. 3120746 – JLG Lift – 3-83...

  • Page 124: Typical Fuel System

    14.7 parts of air to 1 part of gasoline by weight, which provides the most efficient combustion. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a "closed loop" system. 3-84 – JLG Lift – 3120746...
  • Page 125 The width of the "on" pulse determines the amount of throttle opening. The Engine Module sends a signal with the appropriate pulse width to the governor based on the operator's choice of switch settings. 3120746 – JLG Lift – 3-85...
  • Page 126 CAMSHAFT POSITION (CMP) SENSOR The CMP sensor uses a variable reactor sensor to detect camshaft position. The CMP signal is created as piston #1 is a predetermined number of degrees after top dead cen- 3-86 – JLG Lift – 3120746...
  • Page 127 "waste spark." The primary coils in the coil pack are triggered by the "Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals from the Engine Module. 3120746 – JLG Lift – 3-87...
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3-88 – JLG Lift – 3120746...

  • Page 129: Section 4. Boom & Platform

    Supporting the slave, cylinder remove the hard- ware from pin #3. Using a suitable brass drift and hammer remove pin #3 from the fly boom. f. Tag and disconnect hydraulic lines to the slave leveling cylinder. Use a suitable container to 3120746 – JLG Lift –...

  • Page 130: Disassembly Boom Sections

    Remove hardware securing the boom pivot pin to the turntable upright. j. Using a suitable brass drift and hammer, remove the pivot pin from the turntable upright. – JLG Lift – 3120746...

  • Page 131: Disassembly Of Sheave Assembly

    11. Remove hardware which secures the wear pads to the aft end of mid boom section; remove the wear pads from the top, sides and bottom of the mid boom section. 3120746 – JLG Lift –...

  • Page 132: Boom Assembly Cutaway - Sheet 1 Of 2

    SECTION 4 - BOOM & PLATFORM Figure 4-5. Boom Assembly Cutaway - Sheet 1 of 2 – JLG Lift – 3120746...

  • Page 133: Boom Assembly Cutaway - Sheet 2 Of 2

    SECTION 4 - BOOM & PLATFORM Figure 4-6. Boom Assembly Cutaway - Sheet 2 of 2 3120746 – JLG Lift –...

  • Page 134: Inspection

    5. Inspect boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as nec- essary. 6. Inspect telescope cylinder attach point for scoring, tapering and ovality. Replace pins as necessary. Figure 4-7. Disassembly Wire Rope Routing Pro- cedure – JLG Lift – 3120746...

  • Page 135: Assembly

    9. Properly position the retraction wire rope sheaves assemblies at the aft end of the mid boom section; ensure all sheave-to-mounting block attachment holes align. Install the sheave pins and secure them with mounting hardware. Position retract wire ropes onto the sheaves. 3120746 – JLG Lift –...
  • Page 136 20. Align holes in aft end of the fly boom section with holes in wire rope mounting block, then secure with mounting hardware. 21. Align holes in aft end of the mid boom section with holes in wire rope mounting block, then secure with mounting hardware. – JLG Lift – 3120746...

  • Page 137: Installation

    10. Adjust retract and extend cables to the proper torque. Refer to Section 4.2, Boom Rope Torquing Procedures. 11. Using all applicable safety precautions, operate machine systems and raise and extend boom fully, noting the performance of the extension cycle. 3120746 – JLG Lift –...

  • Page 138: Wear Pads

    4.3 WEAR PADS come into contact with boom surface. Main Boom 1. Shim up wear pads to within 1/32 inch (.79 mm) tol- erance between wear pad and adjacent surface. 4-10 – JLG Lift – 3120746...

  • Page 139: Wire Rope

    5. Sheaves failing wearout gage 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 at any end termination. 3120746 – JLG Lift – 4-11...

  • Page 140: Limit Switches And Cam Valve Adjustment

    SECTION 4 - BOOM & PLATFORM 4.5 LIMIT SWITCHES AND CAM VALVE ADJUSTMENT Adjust switches and cam valve as shown in Limit Switches Adjustment. Figure 4-14. Limit Switches Adjustments 4-12 – JLG Lift – 3120746...

  • Page 141: Limit Switch Functional Check

    45 degrees to 50 degrees when lifting least 5° slope. Check the out of level indicator, with down. the machine on the ramp. If the light does not illu- 3120746 – JLG Lift – 4-13...

  • Page 142: Rotator - Helac

    (5). Remove the end cap from actuator (1). Figure 4-15. Removing Portion of End Cap 4. Using a torch, apply heat to the setscrews on the bottom of actuator. Figure 4-18. Removing End Cap Figure 4-16. Heating Setscrew 4-14 – JLG Lift – 3120746...

  • Page 143: Inspection

    4. Inspect the cylinder bore for wear and scratches. Figure 4-19. Removing Shaft from Housing 8. Remove piston sleeve (3) from housing (1). Figure 4-20. Removing Sleeve from Housing 9. Remove all seals and bearings from grooves. Dis- card seals. 3120746 – JLG Lift – 4-15...

  • Page 144: Assembly

    NOTE: The timing marks (the small punch marks on the face of each gear), must be aligned for proper shaft orientation. (See Actuator Timing.) 5. Install the shaft (2) into housing (1) by aligning the proper punched timing marks. (See Actuator Tim- ing.) 4-16 – JLG Lift – 3120746...

  • Page 145: Rotator Assembly (Helac)

    SECTION 4 - BOOM & PLATFORM Figure 4-22. Rotator Assembly (Helac) 3120746 – JLG Lift – 4-17...

  • Page 146: Drive Card Setup Procedures

    1. This sets the minimum current setting for the card. 2. Install test harness JLG P/N 4922012. Rotate the input potentiometer to its extreme posi- tion and operate the telescope function. Turn P3 3.

  • Page 147: Foot Switch Adjustment

    4.8 FOOT SWITCH ADJUSTMENT Adjust so that functions will operate when pedal is at cen- ter of travel. If switch operates within last 1/4 in. (6.35 mm) of travel, top or bottom, it should be adjusted. 3120746 – JLG Lift – 4-19...
  • Page 148 SECTION 4 - BOOM & PLATFORM This page left blank intentionally. 4-20 – JLG Lift – 3120746...

  • Page 149: Section 5. Hydraulics

    Relief valves are installed at various points within the made. hydraulic system to protect associated systems and com- ponents against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of 3120746 – JLG Lift –...

  • Page 150: Cylinders With Dual Counterbalance Valves

    5. Mark cylinder head and barrel with a center punch check for leaks. for easy realignment. Using an allen wrench, loosen the eight (8) cylinder head retainer cap screws, and remove cap screws from cylinder barrel. – JLG Lift – 3120746...

  • Page 151: Cap Screw Removal

    13. Insert the cap screw(s) in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the cap screw(s) until the bushing is loose on the piston. 14. Remove the bushing from the piston. 3120746 – JLG Lift –...

  • Page 152: Cleaning And Inspection

    7. Inspect threaded portion of piston for damage. damage. Replace as necessary. Dress threads as necessary. 8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as nec- essary. – JLG Lift – 3120746...

  • Page 153: Assembly

    SECTION 5 - HYDRAULICS Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.

  • Page 154: Piston Seal Kit Installation

    13. Continue pushing the rod into the barrel until the cyl- inder head gland can be inserted into the barrel cyl- inder. 14. Secure the cylinder head gland using the washer ring and socket head bolts. (Table 5-1, Cylinder – JLG Lift – 3120746...

  • Page 155: Rod Assembly Installation

    (9 Nm) Telescope 50 ft. lbs. 9 ft. lbs. Cylinder (68 Nm) (12 Nm) Lockout Cylinder 80 ft. lbs. (109 Nm) Steer Cylinder Piston Nut Torque Specifications LBS. Steer Cylinder 150 ft. lbs 204 Nm 3120746 – JLG Lift –...

  • Page 156: Cylinder Removal And Installation

    7. Using a suitable brass drift, carefully drive the push twist or cross the cables. bar pins from the telescope cylinder rod and turnta- ble. 8. Remove hardware securing cable adjustment block to aft end of the base boom section and remove block. – JLG Lift – 3120746...

  • Page 157: Boom Lift Cylinder Removal

    5. Remove barrel end attach pin retaining hardware. Using a suitable brass drift drive out the barrel end attach pin from the turntable. 6. Remove the cylinder from the turntable and place in a suitable work area. 3120746 – JLG Lift –...

  • Page 158: 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 5-13. Troubleshooting - Neutral Difficult or Impossible to Find 5-10 – JLG Lift – 3120746...

  • Page 159: Troubleshooting - System Operating Hot

    SECTION 5 - HYDRAULICS Figure 5-14. Troubleshooting - System Operating Hot Figure 5-15. Troubleshooting - Transmission Operates in One Direction Only 3120746 – JLG Lift – 5-11...

  • Page 160: Troubleshooting - System Response Is Sluggish

    SECTION 5 - HYDRAULICS Figure 5-16. Troubleshooting - System Response is Sluggish 5-12 – JLG Lift – 3120746...

  • Page 161: 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. 3120746 – JLG Lift – 5-13...
  • Page 162 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). 5-14 – JLG Lift – 3120746...
  • Page 163 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. 3120746 – JLG Lift – 5-15...

  • Page 164: 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. 5-16 – JLG Lift – 3120746...
  • Page 165 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). 3120746 – JLG Lift – 5-17...
  • Page 166 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. 5-18 – JLG Lift – 3120746...
  • Page 167 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 3120746 – JLG Lift – 5-19...

  • Page 168: Pressure Setting Procedures

    2500 COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRES- PSI (172.4 Bar). This pressure only affects the SURE READINGS. JLG INDUSTRIES, INC. RECOMMENDS OPER- front axle. ATING THE MACHINE UNTIL THE HYDRAULIC SYSTEM HAS d.

  • Page 169: Main Control Valve - Sheet 1 Of 2

    Swing Left & Right Platform Level Relief Up Front Steering Right Tele Out Swing Right Platform Rotate Right Lift Down 10. Platform Level Down Figure 5-19. Main Control Valve - Sheet 1 of 2 3120746 – JLG Lift – 5-21...

  • Page 170: Main Control Valve - Sheet 2 Of 2

    Tele In Swing Left Platform Rotate Left Upper Lift Down Relief 10. Platform Level Down Relief Main Relief 11. Platform Level Up Lift Up Figure 5-20. Main Control Valve - Sheet 2 of 2 5-22 – JLG Lift – 3120746...

  • Page 171: Main Control Valve Torque Values

    SECTION 5 - HYDRAULICS 18-20 ft.lbs. (24.5-27.2 Nm) 25-27 ft.lbs. (34-36.7 Nm) * Torque Valve Bolts to 60 in. lbs. (7 Nm) Figure 5-21. Main Control Valve Torque Values 3120746 – JLG Lift – 5-23...

  • Page 172: Directional Control Valve

    The use of pump control until after initial start-up. This will ensure that contaminated fluid will cause damage to the components, the pump remains in its neutral position. which may result in unexpected vehicle/machine move- ment. 5-24 – JLG Lift – 3120746...
  • Page 173 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. 3120746 – JLG Lift – 5-25...
  • Page 174 SECTION 5 - HYDRAULICS This page left blank intentionally. 5-26 – JLG Lift – 3120746...

  • Page 175: Section 6. Jlg Control System (Ade)

    THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- system. TROLLER FOR THE PROPER MACHINE CONFIGURATION, The JLG Control System controller has a built in LED to INCLUDING OPTIONS. indicate any faults. The system stores recent faults which may be accessed for troubleshooting. Optional equip- ment includes a soft touch system, head and tail lights, and ground alarm.

  • Page 176: Epbcs Block Diagram

    SECTION 6 - JLG CONTROL SYSTEM (ADE) Figure 6-1. EPBCS Block Diagram – JLG Lift – 3120746...

  • Page 177: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM (ADE) The top level menus are as follows: 6.2 TO CONNECT THE JLG CONTROL 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 178: Analyzer Connecting Points

    SECTION 6 - JLG CONTROL SYSTEM (ADE) PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-2. Analyzer Connecting Points – JLG Lift – 3120746...

  • Page 179: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 180: Control Module And Fault Code Indicator Location

    SECTION 6 - JLG CONTROL SYSTEM (ADE) Figure 6-3. Control Module and Fault Code Indicator Location – JLG Lift – 3120746...

  • Page 181: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM (ADE) Once the correct password is displayed, press ENTER. 6.5 ADJUSTING PARAMETERS USING THE 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 182: 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 183 SECTION 6 - JLG CONTROL SYSTEM (ADE) 3120746 – JLG Lift –...
  • Page 184 SECTION 6 - JLG CONTROL SYSTEM (ADE) 6-10 – JLG Lift – 3120746...
  • Page 185 SECTION 6 - JLG CONTROL SYSTEM (ADE) 3120746 – JLG Lift – 6-11...

  • Page 186: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM (ADE) NOTE: Personality settings can be adjusted within the 6.8 MACHINE PERSONALITY SETTINGS adjustment range in order to achieve optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE Accel 0.1s to 5.0s Decel 0.1s to 3.0s...
  • Page 187 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS TELESCOPE Engine RPM 800 to 2900 1800 Engine RPM 800 to 2900 1500 BASKET LEVEL Engine RPM 800 to 2900 1500 BASKET ROTATE 0 to 100...

  • Page 188: Help Fault Codes, Displayed Faults, And Descriptions - Prior To S/N 66939

    SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66939 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 189 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66939 Flash code 2/3 indicates problems with boom function selection. LIFT/SWING JOYSTICK FAULTY The lift or swing joystick center tap is out of valid range, or the wiper is wire-off.
  • Page 190 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66939 Flash code 3/2 indicates that a contactor did not open when energized. NOT REQUIRED Flash code 3/3 indicates that a driver is short-circuit.
  • Page 191 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66939 Flash code 9/9 indicates problems with the controller. PLATFORM MODULE FAILURE: Platform module V(Low) FET has failed hwfs CODE 1...

  • Page 192: Help Fault Codes, Displayed Faults, And Descriptions - S/N 66939 To Present

    SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present 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 193 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present 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 194 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present 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 195 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault HOUR METER SHORT TO BATTERY HORN SHORT TO GROUND...
  • Page 196 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault STEER DUMP OPEN CIRCUIT STEER DUMP SHORT TO BATTERY...
  • Page 197 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present 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 198 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault TOWER DOWN OPEN CIR- CUIT TOWER DOWN SHORT TO...
  • Page 199 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present 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.
  • Page 200 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault JIB LEFT OPEN CIRCUIT JIB RIGHT SHORT TO BAT-...
  • Page 201 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present 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 202 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to Present 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 203: Machine Configuration Programming Information Prior To Software Version P5.3

    SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-4. 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 204 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-4. 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 205 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-4. 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 206 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-4. 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 207: Machine Configuration Programming Information Software Version P5.3 To Present

    SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to Present Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA...
  • Page 208 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-5. Machine Configuration Programming Information Software Version P5.3 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 209 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to Present 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 210 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to Present 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 211 SECTION 6 - JLG CONTROL SYSTEM (ADE) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to Present 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 212: Fault Code Listing

    SECTION 6 - JLG CONTROL SYSTEM (ADE) ‘ 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...
  • Page 213 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 214 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 215 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 216 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 217 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 218: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM (ADE) the next outer level. The LEFT/RIGHT arrow keys move 6.9 ANALYZER DIAGNOSTICS MENU 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 219 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 220 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 221: Diagnostic Menu Descriptions

    SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 222 SECTION 6 - JLG CONTROL SYSTEM (ADE) 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 223: Section 7 - Schematics

    For arising in the machine will be centered in the hydraulic aid in troubleshooting, refer to the Illustrated Parts Manual and electrical systems. for hydraulic diagrams of the various circuits. 3120746 – JLG Lift –...

  • Page 224: Electrical Components Installation (Prior To S/N 62137) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-1. Electrical Components Installation (Prior to S/N 62137) - Sheet 1 of 2 – JLG Lift – 3120746...

  • Page 225: Electrical Components Installation (Prior To S/N 62137)- Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-2. Electrical Components Installation (Prior to S/N 62137)- Sheet 2 of 2 3120746 – JLG Lift –...

  • Page 226: Electrical Components Installation (S/N 62137 To Present)-Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-3. Electrical Components Installation (S/N 62137 to Present)-Sheet 1 of 2 – JLG Lift – 3120746...

  • Page 227: Electrical Components Installation (S/N 62137 To Present)-Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-4. Electrical Components Installation (S/N 62137 to Present)-Sheet 2 of 2 3120746 – JLG Lift –...

  • Page 228: Electrical Schematic - Deutz Engine - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-5. Electrical Schematic - Deutz Engine - Sheet 1 of 2 – JLG Lift – 3120746...

  • Page 229: Electrical Schematic - Deutz Engine - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS 1870074-C Figure 7-6. Electrical Schematic - Deutz Engine - Sheet 2 of 2 3120746 – JLG Lift –...

  • Page 230: Electrical Schematic - Ford Dual Fuel Engine - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-7. Electrical Schematic - Ford Dual Fuel Engine - Sheet 1 of 2 – JLG Lift – 3120746...

  • Page 231: Electrical Schematic - Ford Dual Fuel Engine - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS 1870077-A Figure 7-8. Electrical Schematic - Ford Dual Fuel Engine - Sheet 2 of 2 3120746 – JLG Lift –...

  • Page 232: Electrical Schematic - Ford Efi Engine - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-9. Electrical Schematic - Ford EFI Engine - Sheet 1 of 2 7-10 – JLG Lift – 3120746...

  • Page 233: Electrical Schematic - Ford Efi Engine - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS 1870127-A Figure 7-10. Electrical Schematic - Ford EFI Engine - Sheet 2 of 2 3120746 – JLG Lift – 7-11...

  • Page 234: Electrical Schematic - Ade Machines - Sheet 1 Of 4

    SECTION 7 - SCHEMATICS Figure 7-11. Electrical Schematic - ADE Machines - Sheet 1 of 4 7-12 – JLG Lift – 3120746...

  • Page 235: Electrical Schematic - Ade Machines - Sheet 2 Of 4

    SECTION 7 - SCHEMATICS 1870132-G Figure 7-12. Electrical Schematic - ADE Machines - Sheet 2 of 4 3120746 – JLG Lift – 7-13...

  • Page 236: Electrical Schematic - Ade Machines - Sheet 3 Of 4

    SECTION 7 - SCHEMATICS Figure 7-13. Electrical Schematic - ADE Machines - Sheet 3 of 4 7-14 – JLG Lift – 3120746...

  • Page 237: Electrical Schematic - Ade Machines - Sheet 4 Of 4

    SECTION 7 - SCHEMATICS 1870132-G Figure 7-14. Electrical Schematic - ADE Machines - Sheet 4 of 4 3120746 – JLG Lift – 7-15...

  • Page 238: Hydraulic Schematic - Sheet 1 Of 4

    SECTION 7 - SCHEMATICS Figure 7-15. Hydraulic Schematic - Sheet 1 of 4 7-16 – JLG Lift – 3120746...

  • Page 239: Hydraulic Schematic - Sheet 2 Of 4

    SECTION 7 - SCHEMATICS 2792338-A Figure 7-16. Hydraulic Schematic - Sheet 2 of 4 3120746 – JLG Lift – 7-17...

  • Page 240: Hydraulic Schematic - Sheet 3 Of 4

    SECTION 7 - SCHEMATICS Figure 7-17. Hydraulic Schematic - Sheet 3 of 4 7-18 – JLG Lift – 3120746...

  • Page 241: Hydraulic Schematic - Sheet 4 Of 4

    SECTION 7 - SCHEMATICS 2792338-A Figure 7-18. Hydraulic Schematic - Sheet 4 of 4 3120746 – JLG Lift – 7-19...
  • Page 242 SECTION 7 - SCHEMATICS This page left blank intentionally. 7-20 – JLG Lift – 3120746...
  • Page 244 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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