JLG 660SJ Service And Maintenance Manual
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JLG 660SJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
600S
660SJ
From S/N 0300171769
to S/N 0300235167
P/N - 3121298
August 09, 2017
AS/NZS

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Summary of Contents for JLG 660SJ

  • Page 1 Service and Maintenance Manual Model 600S 660SJ From S/N 0300171769 to S/N 0300235167 P/N - 3121298 August 09, 2017 AS/NZS...

  • Page 3: Bhydraulic System Safety

    REPLACEMENT OF ELECTRICAL COMPONENTS. • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL- VENTS. 3121298 – JLG Lift –...
  • Page 4 INTRODUCTION REVISON LOG - August 07, 2013 Original Issue Revised - October 10, 2013 Revised - November 25, 2013 Revised - February 26, 2014 - November 08, 2016 Revised - August 09, 2017 Revised – JLG Lift – 3121298...

  • Page 5: Table Of Contents

    Do NOT Do the Following When Welding on JLG Equipment: .......
  • Page 6 Motor Control Valve Assembly ..............3-43 – JLG Lift –...
  • Page 7 Temperature Manifold Absolute Pressure (TMAP) Sensor ........3-88 3121298 – JLG Lift –...
  • Page 8 Replace Moving End Brackets ..............4-41 – JLG Lift –...
  • Page 9 Hydraulic Component Start-Up ..............5-52 3121298 – JLG Lift –...
  • Page 10 Connect JLG Control System Analyzer ........
  • Page 11 Swing Drive Shim Placement ............... 3-36 3121298 – JLG Lift –...
  • Page 12 Filter Lock Assembly................3-86 viii – JLG Lift – 3121298...
  • Page 13 Head Seal Kit Installation ................5-16 3121298 – JLG Lift –...
  • Page 14 Screw Adjustable Charge Relief Valve Components ..........5-49 – JLG Lift –...
  • Page 15 Platform and Ground Control Electrical Schematic - 2 of 2 ......... . . 7-13 3121298 – JLG Lift –...
  • Page 16 Hydraulic Schematic 4-Wheel Drive - 2 of 2 ............7-25 – JLG Lift –...
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3121298 – JLG Lift – xiii...
  • Page 18 Fault Code List ..................6-39 – JLG Lift –...

  • Page 19: Specifications

    600S - 2WS 21,425 lbs. (9718 kg) Wheelbase 8 ft. 1 in. (2.46 m) 600S - 4WS 21,800 lbs. (9888 kg) 660SJ - 2WD 26,275 lbs. (11918 kg) Ground Clearance 12 in. (0.3 m) 660SJ - 4WS 25,910 lbs. (12088 kg)

  • Page 20: Capacities

    Tire & Wheel Weight 724 lb (329 kg) 18 psi (1.2 Bar) @ 2000 rpm Max Tire Load 15,500 lb @ 70 psi/5 bar Compression Ratio 9.2:1 Firing Order 1-3-4-2 Max. RPM 2800 Fuel Consumption – JLG Lift – 3121298...

  • Page 21: Function Speeds

    Select Platform Speed Knob out of creep speed. This verifies switches are working when boom is above horizontal. Results should be recorded for a 50 ft course. Drive forward, record time. Drive reverse, record time. 3121298 – JLG Lift –...

  • Page 22: Hydraulic Oil

    They may not contain required additives or be of comparable viscosities. If Specific Gravity 1.082 hydraulic oil other than Mobil 424 is desired, contact JLG Pour Point, Max -58°F (-50°C) Industries for proper recommendations.

  • Page 23: Major Component Weights

    Engine - Deutz at 40° C 25.8 cSt Counterweight 4650 2109 at 100° C 9.3 cSt Viscosity Index Platform - 6 ft. (1.83 M) NOTE: ExxonMobil recommends checking oil viscosity Platform - 8 ft. (2.44 M) yearly. 3121298 – JLG Lift –...

  • Page 24: Operator Maintenance

    90 degree intervals until bearing is completely LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR- lubricated. MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. – JLG Lift – 3121298...
  • Page 25 Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as shown by Condition Indica- tor. 3121298 – JLG Lift –...
  • Page 26 NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION Capacity - 26 gal. Tank; 40 gal. System Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation – JLG Lift – 3121298...
  • Page 27 Comments - Check level daily/Change in accordance Lube Point(s) - Replaceable Element with engine manual.. Interval - Every 6 months or 300 hours of operation or as shown by condition indicator MINIMUM OIL LEVEL MAXIMUM OIL LEVEL 3121298 – JLG Lift –...
  • Page 28 17. Fuel Filter (Propane) - GM Engine Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation Interval - 3 Months or 150 hours of operation Comments - Replace filter. 1-10 – JLG Lift – 3121298...

  • Page 29: 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 30: Torque Chart (Sae Fasteners - Sheet 2 Of 7)

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7) 1-12 – JLG Lift – 3121298...

  • Page 31: Torque Chart (Sae Fasteners - Sheet 3 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7) 3121298 – JLG Lift – 1-13...

  • Page 32: Torque Chart (Sae Fasteners - Sheet 4 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7) 1-14 – JLG Lift – 3121298...

  • Page 33: Torque Chart (Metric Fasteners - Sheet 5 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7) 3121298 – JLG Lift – 1-15...

  • Page 34: Torque Chart (Metric Fasteners - Sheet 6 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 1-16 – JLG Lift – 3121298...

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

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 3121298 – JLG Lift – 1-17...
  • Page 36 SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3121298...

  • Page 37: General

    Service Technician as a person who has successfully com- maintain its safe operating condition. For maximum service pleted the JLG Service Training School for the subject JLG life and safe operation, ensure all necessary inspections and product model. Reference the machine Service and Mainte-...

  • Page 38: Service And Guidelines

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

  • Page 39: 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. 3121298 – JLG Lift –...

  • Page 40: Lubrication And Information

    3. While the unit is shut down, a good preventive mainte- nance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a – JLG Lift – 3121298...

  • Page 41: Pins And Composite Bearing Repair Guidelines

    2. Filament wound bearings should be replaced if any of • Ground only to structure being welded. the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing.
  • Page 42 Turntable Lock 1,2,5 1,2,5 Hood, Hood Props, Hood Latches 1,2,5 Chassis Assembly Tires 16,17 16,17,18 16,17,18 Wheel Nuts/Bolts Wheel Bearings 14,24 Oscillating Axle/Lockout Cylinder Systems Extendable Axle Systems Steer Components Spindle Thrust Bearing/Washers Drive Hubs – JLG Lift – 3121298...
  • Page 43 Electrical Connections Instruments, Gauges, Switches, Lights, Horn 5,23 General Operation and Safety Manuals in Storage Box ANSI and AEM Manuals/Handbooks Installed (ANSI Mar- kets Only) Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible 3121298 – JLG Lift –...
  • Page 44 Function Test of All Systems 21, 22 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 45: Deutz Engine And Hydraulic Operating Temperature Specifications

    SECTION 2 - GENERAL 4150548 E Figure 2-1. Deutz Engine and Hydraulic Operating Temperature Specifications 3121298 – JLG Lift –...

  • Page 46: Gm Engine And Hydraulic Operating Temperature Specifications

    SECTION 2 - GENERAL 4150548 E Figure 2-2. GM Engine and Hydraulic Operating Temperature Specifications 2-10 – JLG Lift – 3121298...

  • Page 47: Chassis & Turntable

    Due to size variations between tire brands, both tires on the Pneumatic tire air pressure must be equal to air pressure sten- same axle should be identical. ciled on side of JLG product or rim decal for safe and proper machine operation. Wheel Replacement...

  • Page 48: Torque Hub

    Figure 3-2. Bolt Tightening Sequence Some gear packages roll with more difficulty than others. Do not be concerned if gears seem to roll hard as long as they roll with consistency. – JLG Lift – 3121298...

  • Page 49: Torque Hub

    1H. Wheel Stud 3F. Planet Gear 6A. Cover Plate 8B. Pressure Plate 9. Input Shaft 21. Plug 1K. Retaining Ring 4B. Thrustwasher 6B. Disengage Cap 8C. Retaining Ring 11. Sun Gear Figure 3-3. Torque Hub 3121298 – JLG Lift –...

  • Page 50: Main Disassembly

    Grasp loose end with pliers and pull out Retaining Ring. 9. Lift Ring Gear (1E) off Housing (1D). 4. Remove Cover Subassembly (6). 10. Remove O-ring (18) from Housing (1D. Figure 3-4. Torque Hub Main Disassembly – JLG Lift – 3121298...

  • Page 51: Output Carrier Disassembly

    4. Slide Planet Gear (3F) and two Thrust Washers (3B) out of Carrier (3A). 5. Remove 14 needle Bearings (3C) from bore of Planet Gear (3F). 6. Repeat steps 1 through 5 for remaining planet gears. Figure 3-6. Input Carrier Disassembly 3121298 – JLG Lift –...

  • Page 52: Hub-Spindle Disassembly

    10. Using a soft steel rod, knock both Bearing Cups (1C) out Cup (1C) in Hub (1D). of Hub (1D). 4. While supporting unit on Hub (1D) flange, press Spindle (1A) out of Hub (1D). Figure 3-7. Hub Spindle Disassembly – JLG Lift – 3121298...

  • Page 53: Spindle-Brake Disassembly

    3. Back Flat Head Cap Screws (22) incrementally out of Pis- 11. Remove Plastic Plug (12) and Pipe Plug (21) from Spindle ton (8A) until spring force is relieved from Pressure Plate (1A) if applicable. Figure 3-8. Spindle Brake Disassembly 3121298 – JLG Lift –...

  • Page 54: Cover Disassembly

    4. Grease face of Thrust Washer (2) and place in Cover (6A). Make sure tangs on washer seat into pockets in cover. 5. Install O-Ring Pipe Plugs (6F) in Cover (6A). Plugs should be hand tight. Figure 3-9. Torque Hub Cover – JLG Lift – 3121298...

  • Page 55: Input Carrier Assembly

    Planet Shaft (3E). 7. Following the planet gear, place one more Thrust Washer (3B) onto Planet Shaft (3E). Align Thrust Washer (3B) in same manner described in Step 5. Figure 3-10. Input Carrier Assembly 3121298 – JLG Lift –...

  • Page 56: Spindle - Brake Assembly

    9. Install small Backup Ring (8H) in small-diameter groove 17. Install Pipe Plug (21) if applicable. near top of Piston (8A), on top of small O-Ring (8F). Figure 3-11. Spindle-Brake Assembly 3-10 – JLG Lift – 3121298...

  • Page 57: Hub-Spindle Assembly

    5. Place Hub (1D) into pressing base. Press nine Studs (1H) Tighten set screws to damage thread and stake edge of in Hub. nut around Set Screws (1G) so nut will not loosen. Figure 3-12. Hub Spindle Assembly 3121298 – JLG Lift – 3-11...

  • Page 58: Output Planet Gear Assembly

    11. Drive new Roll Pin (4G) in aligned roll pin holes. Pin 7. Place Thrust Washer (4H) in counterbore of Spindle (1A). should be flush with OD of spindle. 12. Repeat Steps (11-14) for remaining Planet Gears (4F). Figure 3-13. Output Planet Gear Assembly 3-12 – JLG Lift – 3121298...

  • Page 59: Main Assembly

    Table 3-2. NOTE: Make sure brake re-engages when pressure is released. NOTE: When done, make sure Input Coupling (7) is centered in Spindle (1A) to make installation of motor possible without release of brake. 3121298 – JLG Lift – 3-13...

  • Page 60: 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 3-15. Hub Assembly 3-14 – JLG Lift – 3121298...

  • Page 61: Bearing Cup Pressing Tool

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-16. Bearing Cup Pressing Tool Figure 3-17. Seal Pressing Tool 3121298 – JLG Lift – 3-15...

  • Page 62: Bearing Cup Pressing Tool

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-18. Bearing Cup Pressing Tool Figure 3-19. Drift Pin for Lining Up Thrust Washers with Output Planet Gear 3-16 – JLG Lift – 3121298...

  • Page 63: Free Wheeling Option

    3. Swashplate 7. Slipper 11. Cylinder Block 4. Output Shaft 8. Piston 12. Minimum Angle Stop DISCONNECT CAP (REVERSED) Figure 3-21. Drive Motor Cross Section DRIVE Drive Hub Disengaged Figure 3-20. Disengaging Drive Hubs 3121298 – JLG Lift – 3-17...

  • Page 64: Shaft Seal Replacement

    NOTE: To avoid damaging shaft during removal, install a large sheet metal screw in chuck of a slide hammer. Drive screw in seal surface and use slide hammer to pull seal. 4. Discard seal. 3-18 – JLG Lift – 3121298...

  • Page 65: 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). 3121298 – JLG Lift – 3-19...

  • Page 66: Troubleshooting

    Ensure proper control orifices are installed in motor and not obstructed. fices are properly installed and not the longer the time it takes to shift the motor. Obstruction also increases Clean or replace as necessary. obstructed. shift times. 3-20 – JLG Lift – 3121298...

  • Page 67: Disassembly

    6. Remove shift spool (12). plugs (19, 20). Discard O-rings. 7. Remove orifice poppet (13). 12. Using a 9/16 inch internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O- rings. 3121298 – JLG Lift – 3-21...

  • Page 68: End Cap

    After shaft is removed, insert it into bear- ing cavity and tap splined end lightly with a soft mallet. Grease will force the bearing out. Remove minimum angle stop (29) and servo spring (30) from housing. 3-22 – JLG Lift – 3121298...

  • Page 69: Cylinder Kit

    1. Turn housing over and remove snap ring (32) retaining # of Grooves Frame L Frame K shaft seal and support washer. Remove support washer (33) and carefully pry out shaft seal (34). Discard seal. 3121298 – JLG Lift – 3-23...

  • Page 70: Shaft & Front Bearing

    5. Remove servo piston (40). Remove piston seal (41) and O-ring (42) from servo piston. Discard seal and O-ring. 6. Remove journal bearings (43) from housing. Note loca- tion and orientation of each bearing for reassembly. 3-24 – JLG Lift – 3121298...

  • Page 71: Inspection

    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. 3121298 – JLG Lift – 3-25...
  • Page 72 0.025 mm (0.001 in) 0.0076 mm (0.00030 in) Convex Max Inspect journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively worn. Polymer wear layer must be smooth and intact. 3-26 – JLG Lift – 3121298...

  • Page 73: Assembly

    Inspect loop flushing spool for cracks or damage. Replace as Figure 3-33. Servo Piston required. 2. After piston seal has relaxed, lubricate and install servo piston in housing bore. Align piston with ball socket fac- ing inside of housing. 3121298 – JLG Lift – 3-27...

  • Page 74: Swash Plate And Journal Bearing

    If reusing pistons, install them in original block bores. Lubricate pistons, slippers, retainer, and ball guide before assembly. Set cylinder kit aside on a clean surface until needed. 3-28 – JLG Lift – 3121298...

  • Page 75: Shaft And Front Bearing

    20. Servo Spring 21. Minimum Angle Stop Figure 3-37. Servo Spring and Minimum Angle Stop 19. Cylinder Kit Figure 3-36. Cylinder Kit Installation 3121298 – JLG Lift – 3-29...

  • Page 76: Valve Plate And Rear Bearing

    17. Before installing shaft seal, ensure shaft turns smoothly with less than 120 in-lb (13.5 Nm) of force. If shaft does not turn smoothly within specified maximum force, dis- assemble and check unit. 3-30 – JLG Lift – 3121298...

  • Page 77: Shaft Seal

    9/16 in 125 ft-lb (170 Nm) 3 mm 1.5 - 2.5 ft-lb (2 - 3 Nm) 1/4 in 33 ft-lb (45 Nm) 5/16 in 63 ft-lb (85 Nm) Figure 3-41. Plugs and Fittings Installation 3121298 – JLG Lift – 3-31...

  • Page 78: Initial Start-Up Procedures

    Figure 3-43. Bleeder Valve Location 8. Close bleeder valve when no more air in hydraulic oil. 9. Repeat on opposite lockout cylinder. 10. Shut down engine. 11. Reconnect hose and tee fitting to Port 11 on flow divider. 3-32 – JLG Lift – 3121298...

  • Page 79: Oscillating Axle Lockout Test

    (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground. It may be necessary activate DRIVE to release cylinders. Figure 3-44. Steer Adjustments 3121298 – JLG Lift – 3-33...

  • Page 80: Swing Drive

    13. Dowel Pin 1C. Bearing 1I. Retaining Ring 4. Ring Gear 8. Sun Gear 20. Pipe Plug 1E. Bearing 1J. Pipe Plug 5. O-Ring 11. Thrust Washer 44. Internal Retaining Ring Figure 3-45. Swing Drive Assembly 3-34 – JLG Lift – 3121298...

  • Page 81: Swing Motor And Brake Assembly

    105. Commutator and Ring Assy 114. Thrust Washer 8J. Rotor Disc 29. Bolt 106. Ring 115. Thrust Bearing 8K. Stator Disc 30. Elbow 107. Manifold 116. Inner Seal Figure 3-46. Swing Motor and Brake Assembly 3121298 – JLG Lift – 3-35...

  • Page 82: Gear Backlash

    Set backlash to .010 - .015 in (0.254 to 0.381mm). bearing, then loosen jack bolt. 1. Insert shim (JLG P/N 4071009) between pinion and bear- 7. Apply JLG Thread locking compound P/N 0100019 to ing on the bearing high spot. The bearing high spot jack bolt threads.

  • Page 83: Motor Control Valve Disassembly

    5. Apply less than 50 psi air to brake port to remove Brake Piston (8A). O-Ring 6. Remove Rotors (8J) and Stators (8K) from Brake Housing Figure 3-51. Main Control Valve Disassembly Figure 3-52. Motor and Brake Disassembly 3121298 – JLG Lift – 3-37...

  • Page 84: Main Disassembly

    10. Remove Internal Gear (2). NOTE: If bearing replacement is necessary, Bearing Cups (1C & 1F) can be removed with a slide hammer puller or driven out with a punch. Figure 3-54. Hub-Shaft Disassembly Figure 3-53. Main Disassembly 3-38 – JLG Lift – 3121298...

  • Page 85: Carrier Disassembly

    Carrier (3A). 4. Remove both rows of Needle Bearings (3C) and Spacer (3D) from bore of Planet Gear (3F). 5. Repeat Steps 1 thru 4 for remaining Cluster Gears (3F). Figure 3-55. Carrier Disassembly 3121298 – JLG Lift – 3-39...

  • Page 86: Hub-Shaft Subassembly

    11. Tap Retaining Ring (1I) with a soft metal punch to ensure Reinstall Drain Plug if not already installed (1P from Fig. it is completely seated in groove of Output Shaft (1A). 3-45). Torque to 23 - 24 ft-lb (31 - 32 Nm). 3-40 – JLG Lift – 3121298...

  • Page 87: Carrier Subassembly

    Thrust Washer (3B) into Carrier (3A). 9. Position non-chamfered side on Planet Shaft (3E) Roll Figure 3-57. Carrier Subassembly Pin hole in line with hole in Carrier (3A) using a 1/8 inch diameter punch. 3121298 – JLG Lift – 3-41...

  • Page 88: Main Assembly

    9. Install Thrust Washer (11) in counter bore on face of car- rier. Use grease to hold in place. 10. Place O-ring (5A) into counter bore of Brake Housing (6). Use grease to hold O-Ring in place. Figure 3-58. Main Assembly 3-42 – JLG Lift – 3121298...

  • Page 89: Motor And Brake Assembly

    Brake (6) against Motor flange. Torque to 80-100 ft-lb ing O-ring Plug (23) in Motor Control Valve (32). Torque (108-135 Nm). to 30-31 ft-lb (40-42 Nm). O-Ring Brake Port Figure 3-60. Motor Control Valve Assembly Figure 3-59. Motor and Brake Assembly 3121298 – JLG Lift – 3-43...

  • Page 90: Swing Bearing

    NOTE: This check is designed to replace existing bearing bolt IS HERE STRESSES OF LIFTING ARE CONCENTRATED, AT CENTER OF ROTATION. torque checks on JLG Lifts in service. This check must be BECAUSE OF THIS, PROPER MAINTENANCE OF SWING BEARING BOLTS IS A performed after first 50 hours of machine operation and MUST FOR SAFE OPERATION.
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 3121298 – JLG Lift – 3-45...

  • Page 92: Swing Bearing Replacement

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

  • Page 93: Swing Bearing Torque Values

    2. Inner Race - 190 ft-lb (258 Nm) w/Loctite. 8. Install rotary coupling retaining yoke brackets. Apply a 3. See Figure 3-64. Swing Bearing Torque Sequence. light coating of Thread Locking Compound, JLG P/N 0100011 to attaching bolts. Secure yoke to turntable with mounting hardware.

  • Page 94: Rotary Coupling

    5. Cut off old seals (14,15,17,18). Detail A 1. Rotary Coupling 3. Locknut 5. Bolt 2. Torque Lug 4. Flat Washer 6. Nut 7. Bracket Figure 3-65. Rotary Coupling - Sheet 1 of 2 3-48 – JLG Lift – 3121298...

  • Page 95: 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 3-66. Rotary Coupling - Sheet 2 of 2 3121298 – JLG Lift – 3-49...

  • Page 96: Rotary Coupling Port Location - 2Ws

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-67. Rotary Coupling Port Location - 2WS 3-50 – JLG Lift – 3121298...

  • Page 97: Rotary Coupling Port Location - 4Ws

    SECTION 3 - CHASSIS & TURNTABLE 1,5,9 Figure 3-68. Rotary Coupling Port Location - 4WS 3121298 – JLG Lift – 3-51...

  • Page 98: Generator

    Steer 2500 (172) 3750 (259) Figure 3-70. Generator Brushes and Slip Rings Blow out inside of generator every 500 hours of service. If operating in a hostile environment, clean monthly. Figure 3-71. Generator Cleaning 3-52 – JLG Lift – 3121298...

  • Page 99: Overload Protection

    3. Clean rings with 220 grit emery paper. Remove as little material as possible. If rings are deeply pitted and do not clean up, consult generator factory service. Figure 3-72. Generator Circuit Breaker Location 4. Reinstall belt, brush holder assembly, and end panel. 3121298 – JLG Lift – 3-53...

  • Page 100: Inspecting Generator Brushes, Replacing Brushes, And Cleaning Slip Rings

    Less - Replace 7/16 in - 1/2 in (11 - 12 mm ) New 1. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-73. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3-54 – JLG Lift – 3121298...

  • Page 101: Deutz D2.9 L4 Engine

    15. Shuttle Valve 23. Oil Drain Valve 31. Oil Fill Cap 8. Temperature Sender 16. Catalytic Converter/Muffler 24. Pump Coupler 32. Oil Cooler Figure 3-74. Deutz D2.9 L4 Engine Installation - Sheet 1 of 2 3121298 – JLG Lift – 3-55...

  • Page 102: Deutz D2.9 L4 Engine Installation - Sheet 2 Of 2

    14. Air Filter Assembly 3. Air Filter Service Indicator 6. Fuel Pump 9. Power Module Relay 12. Hitch Pin 15. Engine Control Unit (ECU) Figure 3-75. Deutz D2.9 L4 Engine Installation - Sheet 2 of 2 3-56 – JLG Lift – 3121298...

  • Page 103: Check Oil Level

    6. Pour in new engine oil. Refer to Section 1 for capacity and Figure 3-81., Engine Oil Viscosity. MAXIMUM OIL LEVEL Figure 3-76. Deutz 2.9 T4F Dipstick Markings 5. Replace dipstick until fully seated. Figure 3-77. Engine Oil Viscosity 3121298 – JLG Lift – 3-57...

  • Page 104: Change Oil Filter

    8. Check oil level. 9. Check oil pressure. Check oil filter cartridge for leaks. 7. Connect water sensor connector (Pre-filter Only). 8. Open fuel shut-off valve. 9. Check for leaks. 3-58 – JLG Lift – 3121298...

  • Page 105: Deutz D2011 Engine

    5. Control Module 11. Exhaust Pipe 17. Engine Mount 23. Radiator Hose 6. Fuel Injector 12. Coupling 18. Left Front Engine Support 24. Radiator Figure 3-78. Deutz D2011 Engine Installation - Sheet 1 of 2 3121298 – JLG Lift – 3-59...

  • Page 106: Deutz D2011 Engine Installation - Sheet 2 Of 2

    3. J-Bolt 7. Fuel Filter 11. Starter 15. Relay 18. Engine Tray 4. Battery Hold-Down Plate 8. Oil Pressure Sensor 12. Oil Lube Pump Figure 3-79. Deutz D2011 Engine Installation - Sheet 2 of 2 3-60 – JLG Lift – 3121298...

  • Page 107: Checking Oil Level

    6. Pour in new engine oil. Refer to Section 1 for capacity and Figure 3-81., Engine Oil Viscosity. Figure 3-80. Deutz Dipstick Markings 5. Replace dipstick until fully seated. Figure 3-81. Engine Oil Viscosity 3121298 – JLG Lift – 3-61...

  • Page 108: Changing Oil Filter

    4. Apply light film of oil or diesel fuel to rubber gasket of new filter cartridge. 5. Screw in new filter by hand until gasket is flush. Hand- tighten filter another half-turn. 6. Open fuel shut-off valve. 7. Check for leaks. 3-62 – JLG Lift – 3121298...

  • Page 109: Clean Fuel Strainer

    4. Install cleanout plug. 3.14 GLOW PLUGS If glow plug option is enabled in the JLG Control System, glow plug and indicator lamp will be energized when Power/Emer- gency Stop switch is pulled on if ambient air temperature is less than 50°...

  • Page 110: Deutz Emr 2

    The EMR2 consists of sensors, control unit, and actuator. home) functions. In order to switch the engine off, the EMR2 is Engine-side controls and the JLG Control System are con- switched in a de-energized fashion over the ignition switch. A nected by separate cable harnesses to the EMR control unit.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE 3121298 – JLG Lift – 3-65...
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE 3-66 – JLG Lift – 3121298...
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE 3121298 – JLG Lift – 3-67...
  • Page 114 SECTION 3 - CHASSIS & TURNTABLE 3-68 – JLG Lift – 3121298...

  • Page 115: Emr 2 Engine Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-87. EMR 2 Engine Plug Pin Identification 3121298 – JLG Lift – 3-69...

  • Page 116: Emr 2 Vehicle Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-88. EMR 2 Vehicle Plug Pin Identification 3-70 – JLG Lift – 3121298...
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 3121298 – JLG Lift – 3-71...
  • Page 118 SECTION 3 - CHASSIS & TURNTABLE 3-72 – JLG Lift – 3121298...
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE 3121298 – JLG Lift – 3-73...
  • Page 120 SECTION 3 - CHASSIS & TURNTABLE 3-74 – JLG Lift – 3121298...
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE 3121298 – JLG Lift – 3-75...

  • Page 122: Bio Fuel In Deutz Engines

    The use of US bio-diesel based on soy oil methylester is only permissible in mixtures with diesel fuel with a bio-diesel part of a max. 20 weight-%. The US bio-diesel used for the mixture must comply with the ASTM D6751-07a (B100) standard. 3-76 – JLG Lift – 3121298...

  • Page 123: Biological Contamination In Fuels

    Use of unsuitable additives watery phase, at phase boundary to the fuel phase, from which will result in loss of warranty. they draw their nutrition. There is an increased risk especially with bio-diesel (FAME). 3121298 – JLG Lift – 3-77...

  • Page 124: Gm Engine General Maintenance

    • Replace spark plugs at the proper intervals as prescribed in the engine manufacturer’s manual • Make sure all electrical components are fitted securely. • Check ground and platform control stations to ensure all warning indicator lights are functioning. 3-78 – JLG Lift – 3121298...

  • Page 125: Changing Engine Oil

    170° F (77° C), which can be TO HAVE FROST FORMING ON IT IS A SIGN THE ENGINE COOLING SYSTEM CON- checked using the JLG handheld analyzer. TAINS AIR. APPEARANCE AND TEMPERATURE OF THE EPR SHOULD BE MONI- TORED DURING COOLANT FILL OPERATION.

  • Page 126: Gm Engine Dual Fuel System

    Filter maintenance is critical to proper operation of the fuel system and should be replaced as listed in Section 1. More frequent replacement of the filter may be necessary in severe operating conditions. 3-80 – JLG Lift – 3121298...

  • Page 127: Gm 3.0 Dual Fuel System Components

    SECTION 3 - CHASSIS & TURNTABLE 1. T-MAP Sensor 3. Mixer 5. Regulator 7. Throttle Body 2. Lock-Off Valve 4. Adapter 6. Direct Electronic Pressure Regulator (DEPR) 8. Intake Manifold Figure 3-95. GM 3.0 Dual Fuel System Components 3121298 – JLG Lift – 3-81...

  • Page 128: Direct Electronic Pressure Regulator (Depr)

    ECM can communicated from the mixer venturi to the IEPR via the fuel be further adjusted using closed loop feedback. supply hose. Figure 3-96. Direct Electronic Pressure Regulator Figure 3-97. Air Fuel Mixer 3-82 – JLG Lift – 3121298...

  • Page 129: Electronic Throttle Control (Etc)

    Engine Control Module (ECM). stores information about the malfunction in its memory. Figure 3-101. ECM Input-Output Diagram Figure 3-99. Electric Lock Off Assembly 3121298 – JLG Lift – 3-83...

  • Page 130: Heated Exhaust Gas Oxygen Sensor

    The primary components of the Gasoline Multi Point Fuel Injection (MPFI) fuel system are the fuel tank, electric fuel pump, fuel pressure and temperature sensor manifold, fuel fil- ter, and fuel rail. Figure 3-103. Gasoline Fuel Pressure and Temperature Manifold Assembly 3-84 – JLG Lift – 3121298...

  • Page 131: Fuel Filter

    Check for leaks at fittings of the serviced or replaced component. Use a commercially available liquid leak detector or an electronic leak detector. When using both methods, use electronic leak detector first to avoid contamination by liquid leak detector. 3121298 – JLG Lift – 3-85...

  • Page 132: Propane Fuel Filter Replacement

    7. Remove and discard housing seal. 5. Check DEPR for external damage. 8. Remove and discard retaining bolt seal. 6. Check DEPR electrical connections are seated and 9. Remove and discard mounting plate to lock off O-ring locked. seal. 3-86 – JLG Lift – 3121298...

  • Page 133: Check/Drain Oil Build-Up In 2-Stage Vaporizer

    10. Inspect secondary chamber for any large dried particles and remove. 11. Remove receptacle and reinstall regulator retaining bolts. Torque to specifications. 12. Reinstall fuel hoses. Reconnect any other hoses removed during this procedure. 13. Slowly open manual service valve. 3121298 – JLG Lift – 3-87...

  • Page 134: Exhaust System And Catalytic Converter Inspection And Maintenance

    2. Torque retaining bolt to 62 in-lb (7 Nm). 3. Reinstall Air Intake Hose. 3. Start vehicle and check for proper operation. 4. Start engine and leak check all fittings and connections. 3-88 – JLG Lift – 3121298...

  • Page 135: Electronic Pressure Regulator (Epr) Replacement

    VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED FOR THIS EQUIPMENT. DO 2. Remove hoses from regulator. NOT USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED PARTS. 3. Remove regulator from engine. 1. Install hose clamps and set back on each hose.

  • Page 136: Engine Control Module Replacement

    4. Verify engine is in closed loop and no warning lights are illuminated. 4. Reconnect the battery cable. 5. Start engine. 6. Check and clear any DTC codes. 7. Verify engine is in closed loop and no warning lights are illuminated. 3-90 – JLG Lift – 3121298...

  • Page 137: Gm Engine Lpg Fuel System Diagnosis

    17. This step determines if the Fuel Filter requires replacement. uum. Once in the mixer, fuel is combined with air and drawn into the engine for combustion. 3121298 – JLG Lift – 3-91...
  • Page 138 Does the test light illuminate? Using a DVOM, check the resistance of the low pressure lock-off (LPL). 12W - 16W Go to Step 15 Go to Step 23 Is the resistance within the specified range? 3-92 – JLG Lift – 3121298...
  • Page 139 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? 3121298 – JLG Lift – 3-93...
  • Page 140 If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit. 3-94 – JLG Lift – 3121298...
  • Page 141 ² Check for the following: - Vacuum leaks - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. 3121298 – JLG Lift – 3-95...
  • Page 142 - Inspect the muffler for signs of heat distress or for possible internal failure. ² Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in the GM Base Engine Service Manual 3-96 – JLG Lift – 3121298...
  • Page 143 ² Check the Manifold Absolute Pressure (MAP) sensor response and accuracy. ² Check LPL electrical connection ² Check the mixer air valve for sticking or binding. ² Check the mixer module assembly for proper installation and leakage. ² Check the EPR electrical connections. 3121298 – JLG Lift – 3-97...
  • Page 144 LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics ² Remove the air filter and check for dirt or restriction. ² Check the vehicle transmission Refer to the OEM transmission diagnostics. 3-98 – JLG Lift – 3121298...
  • Page 145 ² Check the ignition wires for the following items: - Cracking - Hardness - Proper connections Cooling System Checks ² Check the engine thermostat for always being open or for the wrong heat range 3121298 – JLG Lift – 3-99...
  • Page 146 DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal. Preliminary Checks Refer to Important Preliminary Checks. Sensor Checks ² Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance. 3-100 – JLG Lift – 3121298...
  • Page 147 Additional Check ² Check the ECM grounds for being clean, tight, and in their proper locations. ² Check the generator output voltage. ² Check the vacuum hoses for kinks or leaks. ² Check Transmission 3121298 – JLG Lift – 3-101...
  • Page 148 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 3-102 – JLG Lift – 3121298...
  • Page 149 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 3121298 – JLG Lift – 3-103...
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-104 – JLG Lift – 3121298...

  • Page 151: Boom & Platform

    Support platform (slave) level cylinder. Remove section. hardware from pin #3. Remove pin #3 from fly g. Remove bolts #2 securing push tube on mid boom boom with a suitable brass drift and hammer. section. 3121298 – JLG Lift –...

  • Page 152: Wear Pads

    Using a suitable brass drift and hammer, remove pivot pin from turntable upright. k. Using all applicable safety precautions, carefully lift boom assembly clear of turntable and lower to ground or suitably supported work surface. – JLG Lift – 3121298...

  • Page 153: Boom Disassembly/Assembly & Cable Replacement

    Remove bolts securing wire rope attach bar to top of fly boom section. Pull telescope cylinder and wire ropes partially from aft end of base boom section. Secure cylinder with a suit- able sling and lifting device at center of gravity. 3121298 – JLG Lift –...

  • Page 154: Wire Rope

    Ropes with 6 total broken wires in one rope lay, 3 in one Inspect sheaves with a groove wearout gauge for exces- strand in one rope lay, 1 valley break, or 1 break at any sive wear. end termination. – JLG Lift – 3121298...

  • Page 155: Wire Rope Tensioning Adjustment

    DO NOT CLAMP ON THREADS OR THREADS MAY BE DAMAGED. DO NOT ALLOW WIRE ROPE TO ROTATE OR WIRE ROPE MAY BE DAMAGED. CLAMP THREADED ENDS OF WIRE ROPE TO PREVENT ROTATION. Figure 4-11. Clamping Wire Ropes 3121298 – JLG Lift –...

  • Page 156: Boom Assembly Cutaway - Sheet 1 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-12. Boom Assembly Cutaway - Sheet 1 of 3 – JLG Lift – 3121298...

  • Page 157: Boom Assembly Cutaway - Sheet 2 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-13. Boom Assembly Cutaway - Sheet 2 of 3 3121298 – JLG Lift –...

  • Page 158: Boom Assembly Cutaway - Sheet 3 Of 3

    Remove sheave assemblies from mid boom section. Remove hardware which secures wear pads to front of mid boom section. Remove wear pads from top, sides, and bottom of the mid boom section. – JLG Lift – 3121298...

  • Page 159: Inspection

    When removing wire rope from fly boom section, push drawing. cable into fly boom. Route wire rope back through holes in side of fly boom section. Figure 4-17. Dimension of Sheaves When New Figure 4-16. Wire Rope Routing Disassembly 3121298 – JLG Lift –...

  • Page 160: Assembly

    ARE CLEAR OF CHAINS, TOOLS, AND OTHER OBSTRUCTIONS. Shim insides of boom sections for a total of 1/16 inch (0.062) clearance (if action is centered, there will be 1/32 inch clearance on each side). 4-10 – JLG Lift – 3121298...

  • Page 161: Boom Powertrack Installation

    SECTION 4 - BOOM & PLATFORM Figure 4-19. Boom Powertrack Installation 3121298 – JLG Lift – 4-11...

  • Page 162: Proximity Switch Installation

    Align holes in aft end of fly boom section with holes in der barrel and sheave assembly; secure pin with mount- wire rope mounting block. Secure with mounting hard- ing hardware. ware. Figure 4-20. Proximity Switch Installation 4-12 – JLG Lift – 3121298...

  • Page 163: Installation

    Tighten or install all clamping or securing apparatus to hoses or cables, as necessary. h. Install powertrack cover and push tube rods with mounting hardware. Figure 4-21. Boom Powertrack Assembly 3121298 – JLG Lift – 4-13...

  • Page 164: Articulating Jib Boom

    Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary. Inspect structural units of articulating jib boom assem- bly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary. 4-14 – JLG Lift – 3121298...

  • Page 165: Assembly

    Align bottom tubes with attach holes in articulating jib the JLG Operation & Safety Manual and the JLG Service boom pivot weldment. Using a soft head mallet, install & Maintenance Manuals.

  • Page 166: Horizontal Limit And Dual Capacity Limit Switches Adjustments

    SECTION 4 - BOOM & PLATFORM Figure 4-23. Horizontal Limit and Dual Capacity Limit Switches Adjustments 4-16 – JLG Lift – 3121298...

  • Page 167: Transport Switch Adjustments - Ce Machines Only

    SECTION 4 - BOOM & PLATFORM Figure 4-24. Transport Switch Adjustments - CE Machines Only 3121298 – JLG Lift – 4-17...

  • Page 168: Rotary Actuator

    Axially, the shaft is separated from the housing by upper and lower thrust washers. End cap is adjusted for axial clearance and locked in position by set screws or pins. 4-18 – JLG Lift – 3121298...

  • Page 169: 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 4-25. Rotary Actuator - Exploded View 3121298 – JLG Lift – 4-19...

  • Page 170: 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 4-26. Rotary Actuator - Assembly Drawing 4-20 – JLG Lift – 3121298...

  • Page 171: Disassembly

    Remove lock pins using an ”Easy Out” (Size #2 shown. If pin will not come out, use 5/16" drill bit 1/2" (12.7mm) Remove end cap (4) and set aside for later inspection. deep to drill out entire pin. 3121298 – JLG Lift – 4-21...
  • Page 172 This simplifies timing during assembly. Actuator has timing marks for proper engagement. Remove shaft (2). It may be necessary to strike threaded end of shaft with a rubber mallet. 4-22 – JLG Lift – 3121298...
  • Page 173 To remove piston (3), use a rubber mallet and plastic Remove O-ring (204) and backup ring (207) from end mandrel so piston is not damaged. cap (4) and set aside for inspection. 3121298 – JLG Lift – 4-23...
  • Page 174 Remove wiper seal (304.1) from end cap (4) and shaft (2). To remove main pressure seals (205), cut them with a sharp razor blade. Do not to damage seal groove. Remove piston O.D. seal (202). 4-24 – JLG Lift – 3121298...

  • Page 175: Inspection

    (not less than 0.123” or 3.12 mm). pressed air before inspecting. Carefully inspect all criti- cal areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore, and gear teeth. 3121298 – JLG Lift – 4-25...

  • Page 176: Assembly

    Install thrust washer (304) on shaft (2) and end cap (4). (2) and end cap (4). Use seal tool in a circular motion. Install wear guide (302) on end cap (4) and shaft (2). 4-26 – JLG Lift – 3121298...
  • Page 177 Using a rubber mallet, tap piston in ring in lower groove and feed the rest in using a circular housing to point where gear teeth meet. motion. Make sure wedged ends overlap correctly. Repeat for outer seal (202). 3121298 – JLG Lift – 4-27...
  • Page 178 Looking from view shown, use existing timing marks to line up gear teeth on shaft (2) with gear teeth on inside of piston (3). Tap flange end of shaft with rubber mallet until gear teeth engage. 4-28 – JLG Lift – 3121298...
  • Page 179 (1). Insert set screws (113) over lock pins. Tighten to 25 in-lb (2.825 Nm). Tighten end cap (4). Ensure holes for lock pins line up. 3121298 – JLG Lift – 4-29...

  • Page 180: Installing Counterbalance Valve

    Make sure new valve has the O-rings in counterbores of bolts to 140 in-lb (15.8 Nm). Do not torque over 145 in-lb valve to seal it to the actuator housing. (16.3 Nm). Figure 4-27. Rotator Counterbalance Valve 4-30 – JLG Lift – 3121298...

  • Page 181: Testing Actuator

    (8L) is purged. Repeat steps 2 & 3. After last 1/2 gallon is purged, close both bleed nipples before rotating away from end posi- tion. 3121298 – JLG Lift – 4-31...

  • Page 182: Troubleshooting

    Piston and/or shaft seal leak b. Remove plug and housing’s valve ports. Operate actuator through housing ports. Conduct internal leakage test. c. Purge air from actuator. See bleeding procedures c. Air in actuator 4-32 – JLG Lift – 3121298...

  • Page 183: Foot Switch Adjustment

    Replace rivets with 1/4 x 20 NC x 2 “grade 5 bolts, flat washers, and locknuts when installing a new gate to platform. 3121298 – JLG Lift – 4-33...

  • Page 184: Powertrack Maintenance

    1. Clamp bar and poly roller tightly so they do not spin when removing screw. With a small ¼” ratchet and a T- 20 Torx bit, remove 8-32 x 0.500 screw from one side. 4-34 – JLG Lift – 3121298...
  • Page 185 ¼” ball double cut bur attachment. insert tool into rolled over end of rivet. Grind out middle of rivet until rolled over part of rivet falls off. Repeat for all rivets to be removed. 3121298 – JLG Lift – 4-35...
  • Page 186 SECTION 4 - BOOM & PLATFORM Insert flat head screwdriver between links. Twist and pull Remove link from other section of powertrack using links apart. screwdriver. 4-36 – JLG Lift – 3121298...

  • Page 187: Install New Link

    Use screwdriver if neces- 1. Squeeze cut-out end of new link into half-shear (female) sary. end of track section. Round half-shears will not fit properly in cut-outs after new link is installed . 3121298 – JLG Lift – 4-37...
  • Page 188 Round half-shears will rotate into cut-outs. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed. Parts shown below connect new link to powertrack. 4-38 – JLG Lift – 3121298...
  • Page 189 Pull up on other end of round bar. Slide new poly roller properly. on bar. Incorrect Correct Install new 8-32 x 0.500 self-threading Torx head screw in end of new aluminum round bar. Torque to 18-20 in- lb (2-2.25 Nm). 3121298 – JLG Lift – 4-39...

  • Page 190: Replace Fixed End Brackets

    REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 1. Remove rivets as shown in link removal instructions.. NOTE: When tightening screws make sure screw head is seated against link with no space in between link and underside of screw head. 4-40 – JLG Lift – 3121298...

  • Page 191: Replace Moving End Brackets

    1. Remove existing pins and center rivet. Remove rivet as shown in link removal instructions on page 4-20. Repeat on other bracket if replaced. NOTE: Ensure snap rings are seated in pin groove and closed properly. Correct Incorrect 3121298 – JLG Lift – 4-41...
  • Page 192 Install center pin with snap ring in new bracket. properly. Incorrect Correct Make sure both brackets rotate correctly. Install radius pins and snap rings in original locations. Repeat with other moving end if replaced. 4-42 – JLG Lift – 3121298...

  • Page 193: Hydraulics

    Make sure entire O-ring is coated with hydraulic oil. 1. Hold fitting in one hand and dip brush into container with other hand. Remove excess hydraulic oil from brush so an even film of oil is applied to O-ring. 3121298 – JLG Lift –...

  • Page 194: Dip

    3. Brush an even coat of hydraulic oil on entire O-ring. oil. NOTE: O-ring boss-type fittings require more pressure to immerse more of fitting into saturated sponge. This also causes more oil to be dispersed from sponge. – JLG Lift – 3121298...

  • Page 195: Cylinders - Theory Of Operation

    If leakage continues at a rate of 6-8 drops per min- suspected. ute or more, repair cylinder. Figure 5-1. Boom Positioning and Support, Cylinder Repair 3121298 – JLG Lift –...

  • Page 196: Cylinders With Single Counterbalance Valve

    6. Remove lifting device from upright or remove prop from below main boom. Activate hydraulic system and run cylinder through one complete cycle to check for leaks. – JLG Lift – 3121298...

  • Page 197: Cylinder Removal And Installation

    11. Pull telescope cylinder and cables partially from aft end of base boom section. Secure cylinder with a suitable sling and lifting device at center of gravity. 12. Carefully remove telescope cylinder and sheave assem- bly. Place telescope cylinder on a suitable trestle. 3121298 – JLG Lift –...

  • Page 198: Main Boom Lift Cylinder Removal

    5. Remove boom prop and overhead crane. Activate hydraulic system. 6. Using all applicable safety precautions, operate boom functions. Check for correct operation and hydraulic leaks. Secure as necessary. 7. Check fluid level of hydraulic tank. Adjust as necessary. – JLG Lift – 3121298...

  • Page 199: Cylinder Locations

    SECTION 5 - HYDRAULICS Cylinder Locations Item Cylinder Main Lift Master Telescope Platform (Slave) Level Jib Lift Steer Axle Lockout Figure 5-2. Hydraulic Cylinder Locations 3121298 – JLG Lift –...

  • Page 200: Main Lift Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-3. Cylinder Barrel Support Figure 5-5. Cylinder Rod Support – JLG Lift – 3121298...

  • Page 201: Main Lift Cylinder Assembly

    8. O-Ring Plug 14. Back-Up Ring 20. Locking Compound 3. Head 9. 5/16"-11x2 Bolt 15. Wear Ring 21. Locking Primer 4. Piston 10. O-Ring Plug 16. O-Ring 22. Ring Washer Figure 5-6. Main Lift Cylinder Assembly 3121298 – JLG Lift –...

  • Page 202: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 5-10 – JLG Lift – 3121298...

  • Page 203: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. Figure 5-10. Poly-Pak Piston Seal Installation 3121298 – JLG Lift – 5-11...

  • Page 204: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, platform (slave) level, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-15. Rod Assembly Installation Figure 5-14. Tapered Bushing Installation 5-12 – JLG Lift – 3121298...

  • Page 205: Master Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-16. Cylinder Barrel Support Figure 5-18. Cylinder Rod Support 3121298 – JLG Lift – 5-13...

  • Page 206: Master Cylinder Assembly

    6. Spacer 11. Seal 16. O-Ring 21. Capscrew 2a. Composite Bushing 7. Capscrew 12. Lock Ring 17. Back-Up Ring 3. Piston 8. Ring Washer 13. O-Ring 18. Rod Seal Figure 5-19. Master Cylinder Assembly 5-14 – JLG Lift – 3121298...

  • Page 207: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 3121298 – JLG Lift – 5-15...

  • Page 208: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. Figure 5-23. Poly-Pak Piston Seal Installation 5-16 – JLG Lift – 3121298...

  • Page 209: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, platform (slave) level, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-28. Rod Assembly Installation Figure 5-27. Tapered Bushing Installation 3121298 – JLG Lift – 5-17...

  • Page 210: Telescope Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-29. Cylinder Barrel Support Figure 5-31. Cylinder Rod Support 5-18 – JLG Lift – 3121298...

  • Page 211: Telescope Cylinder Assembly

    18. O-Ring 23. Locking primer 4. Piston 9. Capscrew 14. Rod Seal 19. Back-Up Ring 24. Not Used 5. Tapered Bushing 10. Ring Washer 15. O-Ring 20. T-Seal 25. Bolt Figure 5-32. Telescope Cylinder Assembly 3121298 – JLG Lift – 5-19...

  • Page 212: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 5-20 – JLG Lift – 3121298...

  • Page 213: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. Figure 5-36. Poly-Pak Piston Seal Installation 3121298 – JLG Lift – 5-21...

  • Page 214: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, platform (slave) level, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-41. Rod Assembly Installation Figure 5-40. Tapered Bushing Installation 5-22 – JLG Lift – 3121298...

  • Page 215: Platform (Slave) Level Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-42. Cylinder Barrel Support Figure 5-44. Cylinder Rod Support 3121298 – JLG Lift – 5-23...

  • Page 216: Platform (Slave) Level Cylinder Assembly

    8. O-Ring Plug 14. Ring Lock 20. Rod Seal 25. Bolt 3. Piston 9. Capscrew 15. O-Ring 21. Wiper 4. Head 10. Ring Washer 16. Back-Up Ring Figure 5-45. Platform (Slave) Level Cylinder Assembly 5-24 – JLG Lift – 3121298...

  • Page 217: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 3121298 – JLG Lift – 5-25...

  • Page 218: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. Figure 5-49. Poly-Pak Piston Seal Installation 5-26 – JLG Lift – 3121298...

  • Page 219: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, platform (slave) level, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-54. Rod Assembly Installation Figure 5-53. Tapered Bushing Installation 3121298 – JLG Lift – 5-27...

  • Page 220: Jib Lift Cylinder (Sj Only)

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-55. Cylinder Barrel Support Figure 5-57. Cylinder Rod Support 5-28 – JLG Lift – 3121298...

  • Page 221: Jib Lift Cylinder Assembly(600Sj)

    3. Ring Washer 7. Not Used 12. Spacer 17. Back-Up Ring 22. Wear Ring 4. Capscrew 8. O-Ring Plug 13. Not Used 18. Rod Seal 23. Locking Compound Figure 5-58. Jib Lift Cylinder Assembly(600SJ) 3121298 – JLG Lift – 5-29...

  • Page 222: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 5-30 – JLG Lift – 3121298...

  • Page 223: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. Figure 5-62. Poly-Pak Piston Seal Installation 3121298 – JLG Lift – 5-31...

  • Page 224: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, platform (slave) level, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-67. Rod Assembly Installation Figure 5-66. Tapered Bushing Installation 5-32 – JLG Lift – 3121298...

  • Page 225: Steer Cylinder

    6. Clamp barrel securely. Apply pressure to rod pulling device and carefully withdraw complete rod assembly from cylinder barrel. Figure 5-68. Cylinder Barrel Support 4. Remove burrs and contamination from cylinder before disassembly. Figure 5-70. Cylinder Rod Support 3121298 – JLG Lift – 5-33...

  • Page 226: Steer Cylinder Assembly

    5. Barrel 9. Back-Up Ring 12. Wiper 2. Seal 6. Rod 10. Seal 13. Spanner Nut 3. O-Ring 7. Head 11. O-Ring 14. Composite Bushing 4. Setscrew 8. O-Ring Figure 5-71. Steer Cylinder Assembly 5-34 – JLG Lift – 3121298...

  • Page 227: Cleaning And Inspection

    8. Inspect threads, and seal and O-Ring grooves in head for burrs, sharp edges, and other damage. Dress surfaces as necessary. 9. Inspect oil ports for blockage or contamination. Repair Figure 5-73. Cylinder Head Disassembly as necessary. 3121298 – JLG Lift – 5-35...

  • Page 228: Assembly

    8. Apply Locking Primer and Loctite 242 (or equivalent) to threads of Spanner Nut (3). Tighten spanner nut (3) with hook spanner to 57-63 ft-lb (77-85 Nm). Figure 5-75. Cylinder Head Assembly Figure 5-77. Spanner Nut Torque 5-36 – JLG Lift – 3121298...

  • Page 229: Assembly

    5. Inspect bore and piston for scoring, pitting, or excessive wear. 6. Remove minor surface blemishes with wet 2000-grit sandpaper. Pitting requires replacement of housing or piston. 7. Clean all parts with approved solvent and dry with com- pressed air. 3121298 – JLG Lift – 5-37...

  • Page 230: Axle Lockout Cylinder

    ROD CAN FALL OUT WHEN BLEEDER VALVE IS OPENED. 1. Barrel 6. Wiper 2. Rod 7. Rod Seal 3. Plug 8. Bleeder 4. Pilot Piston 9. Cartridge Valve 5. Wear Ring Figure 5-78. Axle Lockout Cylinder 5-38 – JLG Lift – 3121298...

  • Page 231: Hydraulic Pump (Gear)

    4. Remove key from drive shaft if applicable. 5. Clamp mounting flange in a protected jaw vise with pump shaft facing down. 6. Loosen four metric hex head bolts. 3121298 – JLG Lift – 5-39...
  • Page 232 15. Remove oil seal from mounting flange. Do not mar or NOTE: Shaft seal will be replaced. scratch seal bore. 16. Remove dowel pins from gear housing. Do not lose pins. 17. Remove and discard seals from both bearing blocks. 5-40 – JLG Lift – 3121298...

  • Page 233: Inspect Parts For Wear

    There should not ation of shaft is allowable. be excessive wear, deep scratches, or gouges. 3. Inspect drive gear shaft and idler gear shafts at bearing points and seal area for rough surfaces and excessive wear. 3121298 – JLG Lift – 5-41...

  • Page 234: General Information

    (Note: W900 series pump - In center of backup ring and E- vent seal misalignment or damage. seal there is a notch. Make sure notches line up so backup ring will set flush with E-seal). Backup ring in W1500 pump is symmetrical. 5-42 – JLG Lift – 3121298...
  • Page 235 Remove seal sleeve from shaft. 9. Install idler gear shaft in remaining position in bearing block. Apply a light coat of clean oil to face of drive and idler gears. 3121298 – JLG Lift – 5-43...
  • Page 236 17. Remove pump from vise. 18. Place a small amount of clean oil in pump inlet and rotate drive shaft away from inlet one revolution. If drive shaft binds, disassemble pump and check for assembly problems. Reassemble pump. 5-44 – JLG Lift – 3121298...

  • Page 237: Placing Pump Back Into Service

    O-rings. FNR and NFPE orifice plugs are located inside the servo piston covers. NFPH orifice plugs are located in the NFPH ports. Ori- fice plugs may be cleaned or replaced. 3121298 – JLG Lift – 5-45...

  • Page 238: Remove And Install Fnr And Nfpe Modules

    4 bar / 1.25 mm (58 psi / 0.050 in). Effective setting will vary. To confirm charge relief valve setting, measure charge pressure (port M3) with pump in stroke. Charge pressure should level off when relief setting is reached. 5-46 – JLG Lift – 3121298...

  • Page 239: Gauge Port Locations

    Case Drain Port L1 System Pressure Gauge Port M1 Case Drain Port L1 (non-feedback) Servo Pressure Gauge Port M5 Charge Pressure Gauge Case Drain Port L2 (non-feedback) Charge Pump Inlet Port S Figure 5-80. Gauge Port Locations 3121298 – JLG Lift – 5-47...

  • Page 240: Plugs/Fittings Size & Torque

    System Gauge M1 & M2 10 System Ports A&B 11 11/16 20-35 27-47 12 9/16 70-100 95-135 13 11/16 20-35 27-47 14 Servo Gauge M5 15 11/16 20-35 27-47 Figure 5-81. Plugs/Fittings Size & Torque 5-48 – JLG Lift – 3121298...

  • Page 241: Shaft Seal And Shaft Replacement

    1. O-Ring 4. Sealant may be used on outside diameter 2. Seal 5. Inside Lip (face down) 3. Seal Carrier 6. Press Seal to Bottom of Seal Carrier Figure 5-84. Installation of Shaft Seal 3121298 – JLG Lift – 5-49...

  • Page 242: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication

    Coat pump and drive coupling splines with Lithium Soap Base 14. Install retaining ring. Grease (TEXACO CODE 1912 OR EQUIVALENT ) whenever pump or pump drive coupling is removed. Coupling is greased prior to assembly. 5-50 – JLG Lift – 3121298...

  • Page 243: Charge Pump

    Figure 5-86. Charge Pump Components 14. Install charge pump cover. Cover must engage gerotor cover and locating pins. Install charge pump cover screws. Torque evenly to 26 - 32 ft-lb (36-43 Nm). 15. Reinstall auxiliary pump if necessary. 3121298 – JLG Lift – 5-51...

  • Page 244: Hydraulic Component Start-Up

    NOTE: It may be easier to fill housing before installing the case drain line. Component (especially motor) location may prevent case drain port access after installation. 5-52 – JLG Lift – 3121298...

  • Page 245: Main Valve Block Pressure Settings

    NOTE: Rear steer relief cartridges are preset and not field adjust- HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES able. PRIOR TO CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CALI- BRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF WITHIN +/- 5% OF SPECIFIED PRESSURES.

  • Page 246: Deutz Td2.9L4 Engines (Sn 0300171769 Through 0300188198)

    15. Cartridge without Coil 4. Relief Valve Cartridge 8. Relief Valve Cartridge 12. Coil Figure 5-87. Main Control Valve Block Assembly Deutz D2011 and GM Engines (SN 0300171769 through 0300181890), Deutz TD2.9L4 Engines (SN 0300171769 through 0300188198) 5-54 – JLG Lift – 3121298...

  • Page 247: Present), Deutz Td2.9L4 Engines (Sn 0300188199 To Present)

    11. Test Port MP 4. Directional Control Valve 8. Cover Plate Figure 5-88. Main Control Valve Block Assembly - 4WS Deutz D2011 and GM Engines (SN 0300181891 to Present), Deutz TD2.9L4 Engines (SN 0300188199 to Present) 3121298 – JLG Lift – 5-55...

  • Page 248: Present), Deutz Td2.9L4 Engines (Sn 0300188199 To Present)

    6. Telescope Pressure Relief Valve 9. Test Port MP Figure 5-89. Main Control Valve Block Assembly - 2WS Deutz D2011 and GM Engines (SN 0300181891 to Present), Deutz TD2.9L4 Engines (SN 0300188199 to Present) 5-56 – JLG Lift – 3121298...

  • Page 249: Present), Deutz Td2.9L4 Engines (Sn 0300188199 To Present)

    6. Relief Valve 9. Relief Valve 12. Test Port M3 Figure 5-90. Location of Components - Main Control Valve Deutz D2011 and GM Engines (SN 0300181891 to Present), Deutz TD2.9L4 Engines (SN 0300188199 to Present) 3121298 – JLG Lift – 5-57...
  • Page 250 SECTION 5 - HYDRAULICS NOTES: 5-58 – JLG Lift – 3121298...

  • Page 251: Jlg Control System

    Each module has a label with JLG part number and a serial number smooth control of: acceleration, deceleration, creep, min containing a date code.

  • Page 252: Controller Block Diagram

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. Controller Block Diagram – JLG Lift – 3121298...

  • Page 253: Connect Jlg Control System Analyzer

    NOTE: Follow instructions provided with Wireless Analyzer (WAN- menu item press ESC . Scroll using right and left arrow ALYZER) kit. JLG Analyzer application must be downloaded keys to select a different menu item. and installed to your smartphone or tablet device.

  • Page 254: Changing Access Level

    SECTION 6 - JLG CONTROL SYSTEM If ENTER is selected at the HELP: PRESS ENTER display, Pressing ENTER with any of the above displayed menus, and a fault is present, the analyzer display scrolls the fault displays additional sub-menus within the selected menu. In across the screen.

  • Page 255: Adjust Parameters

    SECTION 6 - JLG CONTROL SYSTEM Adjust Parameters Press ENTER to select the ACCESS LEVEL menu. Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter first is selected, press the UP...

  • Page 256: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press UP DOWN arrow keys to adjust its value, for example: CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFOR- MANCE OF YOUR MACHINE.
  • Page 257 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND ACCEL ACCELERATE GREEN ACTIVE GROUND MODULE ANALOG DIGITAL CONVERTER COUNT HOURS AMB. AMBIENT HARDWARE ANGLE HWFS HARDWARE FAILSAFE AUXILIARY IN or CURRENT...
  • Page 258 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP...
  • Page 259 SECTION 6 - JLG CONTROL SYSTEM MENU: HELP: (001) HELP:PRESS ENTER EVERYTHING OK LOG:(xxx) x:xxxxxxxxxxx DIAGNOSTICS: MENU: DIAGNOSTICS: DIAGNOSTICS: BOOM FUNCTIONS DIAGNOSTICS DRIVE/STEER ENGINE JOYSTICK LIFT: JOYSTICK DRIVE: MAIN UP XXX% FORWARD XXX% JOYSTICK STEER: LIFT OUTPUT: LEFT XXX% MAIN UP XXX%...
  • Page 260 SECTION 6 - JLG CONTROL SYSTEM From DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: ENGINE SYSTEM BOOM FUNCTIONS LOAD CHASSIS TILT START SEQUENCE: GROUND MODULE: NOT ACTIVE ANGLE: XX.X BATTERY: XX.XV UMS TO TURNTABLE BATTERY VOLTAGE: PLATFORM MODULE: ANGLE: XX.X XX.XV BATTERY: XX.XV...
  • Page 261 SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS CAPACITY LENGTH CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE SWITCH: CLOSED RX/SEC: X LOAD ZERO: ON: XXXh XXm SOFTWARE: XX.XX...
  • Page 262 SECTION 6 - JLG CONTROL SYSTEM FROM MENU: DIAGNOSTICS MENU: SYSTEM TEST: SYSTEM TEST ACTIVATE? MENU: ACCESS LEVEL: ACCESS LEVEL CODE XXXXXX MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES DRIVE STEER LEFT TRACK RIGHT TRACK MAIN LIFT STEER: LEFT TRACK:...
  • Page 263 SECTION 6 - JLG CONTROL SYSTEM FROM PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE RIGHT TRACK MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE: ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS...
  • Page 264 SECTION 6 - JLG CONTROL SYSTEM FROM MENU: PERSONALITIES MENU: MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: MACHINE SETUP 600S PERKINS ECM 133 TEETH IN-CYLINDER STARTER LOCKOUT: ENGINE SHUTDOWN: TILT: JIB: 4 WHEEL STEER: DISABLED ENABLED 5 DEGREES STOUCH/SKYGUARD:...

  • Page 265: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM NOTE: Personality settings can be adjusted within the adjustment 6.2 MACHINE PERSONALITY SETTINGS range for optimum machine performance. Table 6-2. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S DRIVE ACCELeration 0.1s to 5.0s DECELeration 0.1s to 3.0s...
  • Page 266 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S SWING ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed...
  • Page 267 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S BASKET ROTATE ACCELeration 0.1 to 5.0 DECELeration 0.1 to 3.0 MlNimum LEFT speed 0 to 65% MAXimum LEFT speed 0 to 100% MINimum RIGHT speed...
  • Page 268 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. 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 vehicle is not behaving as expected.
  • Page 269 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1 volts.
  • Page 270 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. 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 center tap voltage is not between 3.08 volts and 3.83 volts.
  • Page 271 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault HORN SHORT TO BATTERY AUX POWER SHORT TO GROUND AUX POWER OPEN CIRCUIT AUX POWER SHORT TO...
  • Page 272 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault GROUND ALARM OPEN CIRCUIT GROUND ALARM SHORT TO BATTERY GENERATOR SHORT TO GROUND GENERATOR OPEN CIRCUIT...
  • Page 273 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BASKET RIGHT OPEN CIRCUIT BASKET RIGHT SHORT TO BATTERY JIB UP SHORT TO GROUND JIB UP OPEN CIRCUIT...
  • Page 274 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault LIFT UP DUMP SHORT TO BATTERY LIFT DOWN HOLDING SHORT TO GROUND LIFT DOWN HOLDING OPEN CIR-...
  • Page 275 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault JIB DOWN SHORT TO BATTERY JIB DOWN SHORT TO GROUND JIB DOWN OPEN CIRCUIT JIB LEFT SHORT TO BATTERY...
  • Page 276 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault FUEL SENSOR SHORT TO Indicates fuel sensor is reading below 0.2 volts. GROUND Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second power-up.
  • Page 277 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault Listing HELP MESSAGE FAULT FAULT REMOVAL CLEARS WHEN FAULT IS REMOVED DRIVING AT CREEP - TILTED CLEARS WHEN FAULT IS REMOVED FSW OPEN CLEARS WHEN FAULT IS REMOVED RUNNING AT CREEP - CREEP SWITCH OPEN...
  • Page 278 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault 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 279 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault 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 280 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault 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 281 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault 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 282 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault 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 283 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: Machine configuration must be completed before any personality settings can be changed. Changing personality set- tings first and then changing the model number of the machine configuration will cause personality settings to return to...
  • Page 284 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number TILT: 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also reduces drive speed to creep.
  • Page 285 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number H & T LIGHTS: NO: No head and tail lights installed. YES: Head and tail lights installed. CABLE SWITCH: NO: No broken cable switch installed.
  • Page 286 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number FUNCTION CUT- NO: No drive cutout. OUT: BOOM CUTOUT: Boom function cutout while driving above elevation. DRIVE CUTOUT: Drive cutout above elevation.

  • Page 287: Machine Orientation When Setting Function Speeds

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number CLEARSKY: NO: ClearSky Telematics system not installed. YES: ClearSky Telematics system installed. CRIBBING OPTION: NO: Cribbing Option is disabled. YES: Cribbing Option is enabled.

  • Page 288: Test Notes

    SECTION 6 - JLG CONTROL SYSTEM Test Notes Interlocks: Any device that sends an electrical input. (For an example a limit switch, proximity switch, etc;) 1. Personality settings can be adjusted anywhere within Platform Level: The GROUND MODULE stores default values the adjustment range for optimum machine perfor- and handles interlocks.
  • Page 289 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text EVERYTHING OK 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0011 FSW OPEN 0012 RUNNING AT CREEP - CREEP SWITCH OPEN 0013 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION...
  • Page 290 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 2371 FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED 2372 FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED 2373 FUNCTION PROBLEM - SWING RIGHT PERMANENTLY SELECTED 23104 BOOM TRANSPORT SWITCH DISAGREEMENT...
  • Page 291 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 3374 GEN SET/WELDER - OPEN CIRCUIT 3375 GEN SET/WELDER - SHORT TO BATTERY 3376 HEAD TAIL LIGHT - SHORT TO GROUND 3377 HEAD TAIL LIGHT - OPEN CIRCUIT...
  • Page 292 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 33281 GLOWPLUG - SHORT TO GROUND 33287 LIFT - CURRENT FEEDBACK READING TOO LOW 33295 SWING LEFT VALVE - OPEN CIRCUIT 33314 FLOW CONTROL VALVE - OPEN CIRCUIT...
  • Page 293 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 3419 JIB LIFT DOWN VALVE - SHORT TO BATTERY 3420 JIB LIFT DOWN VALVE - SHORT TO GROUND FUEL SENSOR - SHORT TO BATTERY FUEL SENSOR - SHORT TO GROUND...
  • Page 294 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 8211 LSS READING UNDER WEIGHT 8639 FRONT LEFT STEER VALVE - OPEN CIRCUIT 8640 FRONT LEFT STEER VALVE - SHORT TO BATTERY 8641 FRONT LEFT STEER VALVE - SHORT TO GROUND...
  • Page 295 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined num- bers indicate the default when the option is factory installed. 600S ANSI USA ANSI EXPORT AUSTRALIA...
  • Page 296 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined num- bers indicate the default when the option is factory installed. 600S ANSI USA ANSI EXPORT AUSTRALIA JAPAN NOTE: Bold Italic Numbers indicate the default setting.
  • Page 297 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. 600SJ ANSI USA ANSI EXPORT AUSTRALIA JAPAN NOTE: Bold Italic Numbers indicate the default setting.
  • Page 298 SECTION 6 - JLG CONTROL SYSTEM Figure 6-11. Control Module Locations 6-48 – JLG Lift – 3121298...
  • Page 299 SECTION 6 - JLG CONTROL SYSTEM Figure 6-12. Ground Control Module Pin Connections 1 of 3 3121298 – JLG Lift – 6-49...
  • Page 300 SECTION 6 - JLG CONTROL SYSTEM Figure 6-13. Ground Control Module Pin Connections 2 of 3 6-50 – JLG Lift – 3121298...
  • Page 301 SECTION 6 - JLG CONTROL SYSTEM Figure 6-14. Ground Control Module Pin Connections 3 of 3 3121298 – JLG Lift – 6-51...
  • Page 302 SECTION 6 - JLG CONTROL SYSTEM Figure 6-15. Platform Control Module Pin Connections 1 of 2 6-52 – JLG Lift – 3121298...
  • Page 303 SECTION 6 - JLG CONTROL SYSTEM Figure 6-16. Platform Control Module Pin Connections 2 of 2 3121298 – JLG Lift – 6-53...
  • Page 304 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-54 – JLG Lift – 3121298...

  • Page 305: Basic Electrical Information & Schematics

    "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while alone. For example, you can read voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held down. 3121298 – JLG Lift –...

  • Page 306: Resistance Measurement

    Meter should produce an audible alarm, indicating tance continuity • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads – JLG Lift – 3121298...

  • Page 307: Current Measurement

    Dielectric grease shall be applied to all electrical connectors at the time of connection (except those noted under Exclusions). JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- RIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connec- tions: •...

  • Page 308: Dielectric Grease Application

    Figure 7-7. Dielectric Grease On Female Contacts After assembly, install a seal plug (JLG #4460905) to keep out moisture. Seal plugs may also be installed by the wire harness manufacturer if an unused wire seal was damaged during assembly.

  • Page 309: Amp Mate-N-Lok

    O-ring seal for moisture integrity. Low-force contacts cannot displace dielectric grease to achieve electrical contact. Once contaminated, replacement of female contacts is required. The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 con- nector system.

  • Page 310: Amp Connector

    3. Pull on contact wire with a force of 1 - 2 lb to be sure shown in Figure 7-14. retention fingers are holding contact. 2. Crimp connector. Do not damage cutoff tab. Figure 7-16. AMP Contact Installation Figure 7-14. AMP Contact Assembly – JLG Lift – 3121298...

  • Page 311: Disassembly

    3. While rotating wire back and forth over a half turn (1/4 tem. Resulting pinholes in the insulation allows moisture to turn in each direction), gently pull wire until contact is enter by traveling along wire strands and could result in sys- removed. tem failure. 3121298 – JLG Lift –...

  • Page 312: Deutsch Connectors

    Rectangular wedges are not oriented. They may go in either way. NOTE: Receptacle shown - use same procedure for plug. Figure 7-21. DT/DTP Contact Removal Figure 7-20. DT/DTP Contact Installation – JLG Lift – 3121298...

  • Page 313: Hd30/Hdp20 Series Assembly

    NOTE: Do Not twist or insert tool at an angle. Figure 7-23. HD/HDP Locking Contacts Into Position Figure 7-25. HD/HDP Unlocking Contacts NOTE: Insert sealing plugs in unused wire cavities for full environ- mental sealing. 3121298 – JLG Lift –...
  • Page 314 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26. Electrical Components 1 of 2 7-10 – JLG Lift – 3121298...
  • Page 315 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-27. Electrical Components 2 of 2 3121298 – JLG Lift – 7-11...
  • Page 316 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 2 Figure 7-28. Platform and Ground Control Electrical Schematic - 1 of 2 7-12 – JLG Lift – 3121298...
  • Page 317 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 2 Figure 7-29. Platform and Ground Control Electrical Schematic - 2 of 2 3121298 – JLG Lift – 7-13...

  • Page 318: Generator Wiring Schematic 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 3 Figure 7-30. Generator Wiring Schematic 1 of 2 7-14 – JLG Lift – 3121298...

  • Page 319: Generator Wiring Schematic 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 3 Figure 7-31. Generator Wiring Schematic 2 of 2 3121298 – JLG Lift – 7-15...

  • Page 320: Deutz Engine Harness Electrical Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 5 Figure 7-32. Deutz Engine Harness Electrical Schematic 7-16 – JLG Lift – 3121298...

  • Page 321: Gm/Psi Engine Harness Electrical Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 5 Figure 7-33. GM/PSI Engine Harness Electrical Schematic 3121298 – JLG Lift – 7-17...

  • Page 322: Deutz Tier 4 Final Engine Harness Electrical Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 6 Figure 7-34. Deutz Tier 4 Final Engine Harness Electrical Schematic 7-18 – JLG Lift – 3121298...

  • Page 323: Deutz Tier 4 Final Engine Harness Electrical Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001110345D - Sheet 6 Figure 7-35. Deutz Tier 4 Final Engine Harness Electrical Schematic 3121298 – JLG Lift – 7-19...

  • Page 324: Hydraulic Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605D - Sheet 1 Figure 7-36. Hydraulic Schematic 7-20 – JLG Lift – 3121298...

  • Page 325: Hydraulic Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605D - Sheet 1 Figure 7-37. Hydraulic Schematic 3121298 – JLG Lift – 7-21...

  • Page 326: Hydraulic Schematic 2-Wheel Drive - 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605D - Sheet 3 Figure 7-38. Hydraulic Schematic 2-Wheel Drive - 1 of 2 7-22 – JLG Lift – 3121298...

  • Page 327: Hydraulic Schematic 2-Wheel Drive - 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605D - Sheet 3 Figure 7-39. Hydraulic Schematic 2-Wheel Drive - 2 of 2 3121298 – JLG Lift – 7-23...

  • Page 328: Hydraulic Schematic 4-Wheel Drive - 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605D - Sheet 4 Figure 7-40. Hydraulic Schematic 4-Wheel Drive - 1 of 2 7-24 – JLG Lift – 3121298...

  • Page 329: Hydraulic Schematic 4-Wheel Drive - 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2792605D - Sheet 4 Figure 7-41. Hydraulic Schematic 4-Wheel Drive - 2 of 2 3121298 – JLG Lift – 7-25...
  • Page 330 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-26 – JLG Lift – 3121298...
  • Page 332 +33 (0) 553 84 85 74 +(852) 2639 5797 Email:german-parts@jlg.com 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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