Oshkosh JLG 400S Service And Maintenance Manual
  1. Manuals
  2. Brands
  3. Oshkosh Manuals
  4. Lifting Systems
  5. JLG 400S
  6. Service and maintenance manual

Oshkosh JLG 400S Service And Maintenance Manual

Aerial platform
Hide thumbs Also See for JLG 400S:
1
2
3
4
Table Of Contents
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
Table of Contents

Advertisement

Quick Links

Service and Maintenance Manual
Models
400S
460SJ
P/N - 3120895
December 6, 2012

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the JLG 400S and is the answer not in the manual?

Questions and answers

Related Manuals for Oshkosh JLG 400S

Summary of Contents for Oshkosh JLG 400S

  • Page 1 Service and Maintenance Manual Models 400S 460SJ P/N - 3120895 December 6, 2012...

  • Page 3: Bhydraulic System Safety

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS This section contains the general safety precautions OR COMPONENTS. which must be observed during maintenance of the aerial platform.
  • Page 4 INTRODUCTION REVISON LOG Original Issue April 1, 2000 Revised: July 21, 2000 Revised: October 1, 2000 Revised: March 27, 2001 Revised October 1, 2001 Revised January 25,2002 Revised April 10, 2002 Revised June 14, 2004 Revised September 14, 2005 Revised October 1, 2005 Revised April 9, 2007...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ..............A-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Lubrication and Information ............2-3 Hydraulic System.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Drive Brake ..............3-22 Pre-Installation Checks .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 3.19 Ford EFI Engine ............. . .3-68 Performing Diagnostics .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.27 GM Engine Fuel System Repair ...........3-116 Propane Fuel System Pressure Relief .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. DTC 606- Microprocessor Failure - COP........3-184 DTC 642- 5 Volt External Low Voltage .
  • Page 11 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 5 - HYDRAULICS Cylinders - Theory of Operation ...........5-1 Systems Incorporating Double Acting Cylinders .
  • Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS General ..............7-1 Multimeter Basics .
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Serial Number Location............1-6 1-2.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-31. Swing Bearing Feeler Gauge Check..........3-45 3-32.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-77. Pressure Regulator Section ............3-118 3-78.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-18. Tapered Bushing Installation ........... . .5-13 5-19.
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-25. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 1 of 4 ....7-20 7-26.
  • Page 18 LIST OF TABLES TABLE NO. TITLE PAGE NO. Capacities ..............1-1 Ford LRG-425 (Gas or Dual Fuel) .
  • Page 19 LIST OF TABLES TABLE NO. TITLE PAGE NO. Holding Valve Torque Specification..........5-14 Pump Flow Direction with NFPE Control .
  • Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally. – JLG Lift – 3120895...

  • Page 21: Section 1 - Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Table 1-3. Deutz F3M1011F/F3M2011F Table 1-1. Capacities Fuel Diesel Fuel Tank 26 gallons (98.4 liters) No. of Cylinders Hydraulic Tank 40.0 gallons (152 liters) Bore 3.6 in. (91 mm) Hydraulic System (Including Tank) 52 gallons (196.8 liters) Stroke 4.4 in.

  • Page 22: Tires

    SECTION 1 - SPECIFICATIONS 1.4 SPECIFICATIONS AND PERFORMANCE Table 1-6. GM 3.0L DATA Fuel Gasoline or Gasoline/LP Gas No. of Cylinders Table 1-9. Specifications and Performance Data - 400S Maximum Work Load (Capacity): standard Gasoline 83 hp @ 3000 rpm Unrestricted: 500 lbs.

  • Page 23: Torque Requirements

    SECTION 1 - SPECIFICATIONS 1.6 CRITICAL STABILITY WEIGHTS Table 1-10. Specifications and Performance Data - 460SJ Maximum Work Load (Capacity): Table 1-12.Critical Stability Weights Unrestricted: 500 lbs. (230 kg.) Component Maximum Travel Grade, Stowed Position 2 W/D - 30% (Gradeability) 4 W/D - 45% Ford Engine Deutz Engine...

  • Page 24: Major Component Weights

    SECTION 1 - SPECIFICATIONS 1.7 MAJOR COMPONENT WEIGHTS 1.8 FUNCTION SPEEDS Table 1-14.Function Speeds (In Seconds) Table 1-13.Major Component Weights Function Speed Component Main Boom Lift Up 26-32 8 ft Platform Main Boom Lift Down 19-25 6ft. Platform Swing - (10% max diff.) 70-90 5 ft.

  • Page 25: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS 1.10 CYLINDER SPECIFICATIONS Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- Table 1-16.Cylinder Specifications tain the same required additives or be of comparable vis- cosities.

  • Page 26: Welder, Hydraulic (Option)

    SECTION 1 - SPECIFICATIONS 1.12 WELDER, HYDRAULIC (OPTION) Table 1-21.Welder Specifications - Model 225-4 Description Specification Weld Amps Strike Weld Weld Voltage 21.6 - 28 DC Frequency 60 Hz, KVA - 4.2 Kw, Single Phase Oil Flow 18.8 Gpm, 2000 Psi. 1.13 SERIAL NUMBER LOCATION A serial number plate is affixed to the left rear side of the frame.

  • Page 27: Operator Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.14 OPERATOR MAINTENANCE AND 2. Wheel Bearings (2WD Only) LUBRICATION NOTE: The following numbers correspond to those in Figure 1-2., Operator Maintenance and Lubrication Dia- gram. Table 1-22. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177°...

  • Page 28: Deutz Engine Dipstick

    SECTION 1 - SPECIFICATIONS 7. Suction Strainers Lube Point(s) - 2 MINIMUM OIL Interval - Every 2 years or 1200 hours of operation, LEVEL remove and clean at time of hydraulic oil change. 8. Oil Change w/Filter - Ford MAXIMUM OIL LEVEL MINIMUM LEVEL, OIL HOT...
  • Page 29 SECTION 1 - SPECIFICATIONS 12. Oil Change w/Filter - GM 15. Fuel Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element (JLG P/N 7027965) Interval - Every Year or 600 hours of operation Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO 16.

  • Page 30: Draining Oil Build Up From The Propane Regulator

    SECTION 1 - SPECIFICATIONS 21. Electronic Pressure Regulator (LP only) 2. Start the engine and bring to operating temperature. 3. With the engine running, close the manual tank valve and run the engine out of fuel. 4. Push in the Emergency Switch once the engine stops.

  • Page 31: Propane Fuel Filter Replacement

    SECTION 1 - SPECIFICATIONS Propane Fuel Filter Replacement INSTALLATION BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS- ING BEFORE INSTALLING NEW SEAL 1. Install the mounting plate to lock off O-ring seal. 2. Install the retaining bolt seal. 3.
  • Page 32 SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque Torque (Loctite® 242 or 271 Tensile (Loctite® 262 or Vibra- Size Bolt Dia Clamp Load Stress Area (Dry) Lubricated OR Vibra-TITE...
  • Page 33 SECTION 1 - SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque Tensile (Loctite® 242 or 271 (Loctite® 262 or Vibra- (Dry or Loctite® 263) Size Bolt Dia Clamp Load Stress Area OR Vibra-TITE 111 or TITE 131) K= 0.20...
  • Page 34 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load Torque Size Bolt Dia OR Vibra-TITE 111 or (Dry) K = .17 or Vibra-TITE 131) Stress Area See Note 4 140 OR Precoat 85®...
  • Page 35 SECTION 1 - SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Torque Torque Torque (Loctite® 242 or 271 (Loctite® 262 Tensile Clamp Load (Dry) Size Bolt Dia OR Vibra-TITE 111 or or Vibra-TITE 131) Stress Area See Note 4 K = .20 140 OR Precoat 85®...
  • Page 36 SECTION 1 - SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Torque (Loctite® Torque Tensile Clamp Torque (Loctite® 262 or 271 (Dry or Loctite® Size PITCH Stress Load (Lub) OR Vibra- OR Vibra- Area TITE 131) TITE 111 or 140) Sq mm [N.m]...
  • Page 37 SECTION 1 - SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Torque (Lub OR Loctite® Torque Torque Tensile (Dry or Loctite® Clamp or 271 (Loctite® 262 Size PITCH Stress Load Vibra-TITE 111 or Vibra-TITE...
  • Page 38 SECTION 1 - SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Torque Torque (Lub OR Loctite® Torque Tensile (Loctite® 262 (Dry or Loctite® Clamp Load or 271 Size PITCH Stress OR Vibra-TITE See Note 4 OR Vibra-TITE Area 131)

  • Page 39: Section 2 - General

    SECTION 2 - GENERAL SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, increased as environment, severity and frequency of usage requires. AND MAINTENANCE Reference the JLG Pre-Delivery and Frequent Inspection General Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor- This section provides the necessary information needed mance of these inspections.

  • Page 40: Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspec- Prior to use each day; or User or Operator User or Operator Operator and Safety Manual tion At each Operator change. Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG...

  • Page 41: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring When disassembling or reassembling a component, com- Clearly mark or tag hydraulic lines and electrical wiring, as plete the procedural steps in sequence. Do not partially well as their receptacles, when disconnecting or removing disassemble or assemble one part, then start on another.

  • Page 42: Hydraulic Oil

    SECTION 2 - GENERAL cleaned, and/or replaced as necessary, at the speci- Industries recommends changing the hydraulic oil fied intervals required in the Lubrication Chart in annually. Section 1. Always examine filters for evidence of 2. Use every precaution to keep the hydraulic oil clean. metal particles.

  • Page 43: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL 2.6 WELDING ON JLG EQUIPMENT Drift is to be measured at the cylinder rod with a calibrated dial indicator. The cylinder oil must be at ambient temper- ature and temperature stabilized. NOTE: This instruction applies to repairs, or modifications to the machine and to welding performed from the The cylinder must have the normal load, which is the nor- machine on an external structure, or component,...
  • Page 44 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Boom Assembly 1,2,4 1,2,4 Boom Weldments 1,2,9,12 1,2,9,12 Hose/Cable Carrier Installations Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings...
  • Page 45 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground &...
  • Page 46 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Pre-Start Preventive Preventive (Yearly) or Frequent Years Inspection Maintenance Maintenance Inspection Inspection All Decals/Placards Installed, Secure, Legible Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds...
  • Page 47 SECTION 2 - GENERAL 4150548 D Figure 2-1. Engine Operating Temperature Specifications - Deutz 3120895 – JLG Lift –...
  • Page 48 SECTION 2 - GENERAL 4150548 D Figure 2-2. Engine Operating Temperature Specifications - Ford 2-10 – JLG Lift – 3120895...
  • Page 49 SECTION 2 - GENERAL A M B IE N T A IR T E M P E R A T U R E 4150548 D Figure 2-3. Engine Operating Temperature Specifications - Caterpillar 3120895 – JLG Lift – 2-11...
  • Page 50 SECTION 2 - GENERAL 4150548 D Figure 2-4. Engine Operating Temperature Specifications - GM 2-12 – JLG Lift – 3120895...
  • Page 51 SECTION 2 - GENERAL A M B IE N T A IR T E M P E R A T U R E 4150548 D Figure 2-5. Engine Operating Temperature Specifications - Perkins 3120895 – JLG Lift – 2-13...
  • Page 52 SECTION 2 - GENERAL NOTES: 2-14 – JLG Lift – 3120895...

  • Page 53: Section 3. Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Tire Inflation Wheel Replacement The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG prod- The rims installed on each product model have been uct or rim decal for safe and proper operational character-...

  • Page 54: Drive Hub Part No. 2780243 (2Wd Rear) Part No. 2780244 (4Wd Rear)

    SECTION 3 - CHASSIS & TURNTABLE 3. The tightening of the nuts should be done in stages. 10. Compress the disk (59) using a simple fixture or Following the recommended sequence, tighten nuts other suitable device. per wheel torque chart. 11.

  • Page 55: Disassembly Of Cover Unit (8)

    SECTION 3 - CHASSIS & TURNTABLE Disassembly of Cover Unit (8) Final Assembly 1. Loosen and remove hex. hd. bolts (53) and remove 1. Install thrust washer (29) in spindle (60). cover (51). 2. Install O-ring (19) into groove of support ring (6). 2.
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE Figure 3-1. Drive Hub (Part No. 2780243-2WD Rear & Part No. 2780244-4WD Rear) – JLG Lift – 3120895...

  • Page 57: Drive Hub Part No. 2780246 (4Wd Steer Axle Prior To S/N 0300076633)

    SECTION 3 - CHASSIS & TURNTABLE 3.3 DRIVE HUB PART NO. 2780246 (4WD 11. Inspect the planetary stage assemblies as complete units. Thoroughly clean and check both the gearing STEER AXLE PRIOR TO S/N and the bearings for damage and apply new oil. If 0300076633) gears or bearings need replacing, they must be replaced as complete units.

  • Page 58: Assembly Of First Stage Planetary Assembly (7)

    SECTION 3 - CHASSIS & TURNTABLE Assembly of First Stage Planetary Assembly Final Assembly 1. Install thrust washer (29) in spindle (60). 1. Pre-freeze planet pins (5) and install into planet car- 2. Install O-ring (19) into groove of support ring (6). rier (7).

  • Page 59: Drive Hub (Part No. 2780246-4Wd Steer)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-2. Drive Hub (Part No. 2780246-4WD Steer) 3120895 – JLG Lift –...

  • Page 60: Torque Hub - 4Wd (Machines Built After S/N 0300076633)

    SECTION 3 - CHASSIS & TURNTABLE 3.4 TORQUE HUB - 4WD (MACHINES BUILT Oil Information AFTER S/N 0300076633) 1. 1. TYPE – EP90 On normal applications, use EP90. On applications Roll and Leak Testing where the lubricant must meet special requirements, the O.E.M should be able to recommend a suitable Always roll and leak test Torque-Hubs after assembly to substitute.

  • Page 61: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE 11. Lift input shaft sub-assembly (7) out of middle of 5. Bearing cone (1F) should be lying loose in wide end spindle (1A), and stand input shaft (7A) on its of hub (1G). Remove bearing cone (1F) from inside splined end.

  • Page 62: Assembly Of The Carrier

    SECTION 3 - CHASSIS & TURNTABLE NOTE: If you don’t drive the roll pin all the way into the 2. Place one spacer (3D) inside cluster gear (3F) so planet shaft t, you could damage the carrier when that it rests on top of the needle rollers. you remove the planet shaft from the carrier.
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE 5. Place one thrust washer (3B) onto the end of planet 8. Use an alignment punch or similar tool to align the shaft (3E) inside carrier. Fit tang of thrust washer into roll pin holes in carrier housing (3A) and planet shaft the slot on the inside edge of the planet shaft hole.

  • Page 64: Cover Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Sub-Assembly 4. Set cover (6Aon table, exterior side up. Place cover cap (6B) onto cover (6A), aligning the pipe plug hole 1. Using the disconnect rod, push o-ring (6F) into the in the cover cap over the pipe plug hole in the cover. groove inside the cover cap (6B).

  • Page 65: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE 7. With the large end down, place the disconnect cap 10. Apply a light coat of "Never-Seize" to pipe plug (6H) (6D) onto the cover cap (6B), aligning the pipe plug and tighten it into the pipe plug hole in the cover hole in the disconnect cap over the pipe plug hole in (6A).
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 3. Apply a light coat of "Never-Seize" to two pipe plugs 6. Press seal (1B) into the small end of hub (1G). (1J) and tighten them into the two pipe plug holes in the side of the hub (1G). 7.

  • Page 67: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly 9. Place spacer (1H) onto spindle (1A) in hub (1G). BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING THE O-RING 1. Grease o-ring (5) and place it into the counterbore in hub (1G). NOTE: O-ring may be stretched or pinched together to make it fit the counterbore exactly.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 3. Place internal gear (2) into hub (1G) so that its inter- 6. Place one spring (7C) onto the smooth end of input nal splines mesh with the external splines of spindle shaft (7A). (1A).
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE 9. With large splined end down, place input shaft sub- NOTE: This will hold the punch marks in position while assembly (7) into spindle (1A). installing the carrier into the hub. 10. Place thrust spacer (9) onto input shaft (7). 13.
  • Page 70 SECTION 3 - CHASSIS & TURNTABLE 15. Oil all exposed surfaces inside the hub (1G). Place 17. Place cover sub-assembly (6) onto ring gear (4), thrust washer (11) into the counterbore in top of the aligning the pipe plug holes according to the align- carrier.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 19. Place shoulder bolts (13) into the four shoulder bolt 21. Place the 12 bolts into the remaining bolt holes in holes in cover (6) and tighten by hand. cover (6) and tighten. 20. Place the remaining 12 flatwashers (16) onto the 22.

  • Page 72: Tool List

    SECTION 3 - CHASSIS & TURNTABLE 23. Turn hub (1G) over onto its side. Insert coupling (14) 26. At this point the main assembly is complete. into the end of the spindle (1A). Tool List 24. Roll test the unit in both clockwise and counterclock- wise directions.

  • Page 73: Re-Aligning Torque Hub Input Coupling

    SECTION 3 - CHASSIS & TURNTABLE 2. T-138903 ASSEMBLY PRESSING TOOL for CUP 4. T-109691 ASSEMSLY PRESSING TOOL for CONE (1C) (1F) * These tools are for specific seals, cups or cones. There is a specific tool for each cup and cone. 3.

  • Page 74: Drive Brake

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE BRAKE of 3000 psi (200bar) and check that brake shaft (1) is free to rotate. Pre-Installation Checks Remove hydraulic supply from brake, checking to ensure that the friction plates (3 & 6) have engaged thus prevent- MECHANICAL ing rotation of brake shaft (1) Check, That in the handling prior to assembly, the mount-...

  • Page 75: Installation

    SECTION 3 - CHASSIS & TURNTABLE Installation 9.Using arbor press or similar to break Loctite seal, remove brake shaft (1) from housing (2) and lay Position 1-off gasket (5) over male pilot on brake housing aside. (4). 10.Reverse housing (2) and press out ball bearing (10). Locate brake shaft (1) and secure brake in position using Shaft seal (12) can also be removed if necessary.
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE ing rings are assembled opposite ti the pressurized 8.Align two holes in cylinder with dowel pins (19) and side of piston (9). assemble piston & cylinder sub-assembly to remain- der of brake securing with 6-off socket head cap 5.Correctly orientate piston (9) aligning spaces with the screws and washers (13 &...

  • Page 77: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE MOTOR Shaft Seal Replacement Description REMOVAL 1. Remove the snap ring (1) retaining the shaft seal The drive motors are low to medium power, two-position and support washer. axial piston motors incorporating an integral servo piston. They are designed for operation in both open and closed circuit applications.

  • Page 78: Loop Flushing Valve

    SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve INSPECT THE COMPONENTS Inspect new O-rings and the sealing area for rust, wear, or contamination. Also check springs and poppet for wear. REMOVAL 1. Using a 11/16 in internal hex wrench remove plug INSTALLATION (1) and (2).

  • Page 79: Troubleshooting

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

  • Page 80: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of the endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. Replace all O-Rings and gaskets. It is recommended that all O-rings be replaced.

  • Page 81: Valve Plate & Rear Shaft Bearing

    SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 23. End Cap 26. End Cap 24. O-ring 27. O-ring Figure 3-11. End Cap 28. O-ring 29. Angle Stop 30. Servo Spring 13. Using an 8 mm internal hex wrench, remove the endcap screws (22).

  • Page 82: Shaft Seal

    SECTION 3 - CHASSIS & TURNTABLE 18. Remove minimum angle stop (29) and servo spring shaft seal (34). Discard the seal. (30) from the housing. To avoid damaging the shaft during seal removal. Install a large sheet metal screw into the chuck of a slide hammer.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE Lift here 39. Swashplate 40. Servo Piston 41. Piston Seal 42. O-ring 43. Journal Bearings Figure 3-16. Swash Plate & Servo Piston 44. Piston 49. Retaining Ring 45. Slipper Retainer 50. Block Spring Washer 23.

  • Page 84: Inspection

    SECTION 3 - CHASSIS & TURNTABLE 28. Turn the block over. Using a press, apply pressure SLIPPERS on the block spring washer (50) to compress the Inspect the running surface of the slippers. Replace any block spring. Compress the spring enough to safely piston assemblies with scored or excessively rounded remove the spiral retaining ring (51).
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE BALL GUIDE AND SLIPPER RETAINER Replace swashplate if the difference in thickness from one side to the other exceeds specification. Inspect the ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper retainer indicates excessive heat.

  • Page 86: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly SERVO PISTON AND MINIMUM ANGLE STOP Inspect the minimum angle stop, servo piston head, and 1. Install new O-ring (1) and piston seal (2) to the servo servo piston ball-socket for damage or excessive wear. piston (3).

  • Page 87: Swash Plate And Journal Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3. Install the inner block spring washer (4), block 6. Install the journal bearings (13) into the housing spring (5), and outer washer (6) into the cylinder seats. Use assembly grease to keep the bearings block.

  • Page 88: Shaft And Front Bearing

    SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press 10. Verify swashplate and bearings are properly seated. bearing onto shaft with lettering facing out. Lubricate Install the cylinder kit (19) onto the shaft. Install with bearing rollers.

  • Page 89: Valve Plate And Rear Bearing

    SECTION 3 - CHASSIS & TURNTABLE 12. Press the rear shaft bearing (22) into the endcap. 15. Install the endcap (25) onto the housing with the Install the bearing with letters facing out. Press until endcap screws (26). Check to ensure the endcap bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) will properly seat onto the housing without interfer- above endcap surface.

  • Page 90: Shaft Seal

    SECTION 3 - CHASSIS & TURNTABLE 18. Cover shaft splines with an installation sleeve. Install 19. Install remaining plugs and fittings to the housing. a new shaft seal (27) with the cup side facing the Refer to the drawing below for wrench sizes and motor.

  • Page 91: Initial Start-Up Procedures

    SECTION 3 - CHASSIS & TURNTABLE Initial Start-up Procedures 20. Install orifice poppet (30). Follow this procedure when starting-up a new motor or when installing a motor that has been removed. Prior to installing the motor, inspect for damage incurred 11/16 in during shipping.

  • Page 92: Adjustment Procedure For Lockout Valve

    SECTION 3 - CHASSIS & TURNTABLE 3.8 ADJUSTMENT PROCEDURE FOR 3.9 TOE-IN ADJUSTMENT LOCKOUT VALVE 1. Measure from the same point, on the tire, from the front side, then on the back side. 1. With the turntable centered, adjust the bracket with the washers to push the plunger in 5/16”...

  • Page 93: 2Wd Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.10 2WD HUB 5. Use the inner cone and a mild steel bar to drive the seal out of the hub. Take care to ensure the bar doesn’t damage the bearing cone or cage. Removal &...

  • Page 94: Assembly & Installation

    SECTION 3 - CHASSIS & TURNTABLE 1. Dust Cap 2. Spindle 3. Hub 4. Inner Bearing Cup 5. Outer Bearing Cup 6. Inner Bearing Cone 7. Outer Bearing Cone 8. Seal 9. Castle Nut 10. Cotter Pin 11. Spindle Washer 12.

  • Page 95: Oscillating Axle Bleeding Procedure

    SECTION 3 - CHASSIS & TURNTABLE 3.11 OSCILLATING AXLE BLEEDING 8. Lower machine so both of the lockout cylinders are oscillated; one extended, the other retracted. PROCEDURE 9. Use suitable containers to retain any residual hydraulic fluid, place containers under each lockout cylinder.

  • Page 96: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING BEARING 6. Have an assistant check to see that right front wheel remains locked in position off of ground. Turntable Bearing Mounting Bolt Condition 7. Carefully activate SWING control lever and return boom to stowed position (centered between drive Check wheels).

  • Page 97: Wear Tolerance

    SECTION 3 - CHASSIS & TURNTABLE Wear Tolerance Check the turntable to bearing. Attach bolts as follows: 1. Elevate the fully retracted boom to full elevation and 1. With the boom positioned over the side of the rotate the platform 90 machine, the Boom horizontal with telescope fully 2.

  • Page 98: Replacement Of Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE Replacement of Swing Bearing 4. Using suitable lifting equipment, install bearing/ assembly to frame with soft spot (red) 90 degree rel- Removal of the swing bearing is as follows: ative to load axis. If reusing old bearing, ensure that scribed line of outer race of the bearing aligns with 1.

  • Page 99: Swing Bearing Torque Value

    SECTION 3 - CHASSIS & TURNTABLE Swing Drive Installation 14. Using all applicable safety precautions, activate the hydraulic system and functionally check swing sys- tem for proper and safe operation 1. Insure that the T/T mounting plate is clean and free of paint runs and drips.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE Figure 3-35. Swing Drive Installation 3-48 – JLG Lift – 3120895...
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE Figure 3-36. Swing Motor 3120895 – JLG Lift – 3-49...

  • Page 102: Swing Brake (Prior To S/N 64802)

    SECTION 3 - CHASSIS & TURNTABLE 3.14 SWING BRAKE (PRIOR TO S/N 64802) 3. Remove the piston from the power plate by introduc- ing low pressure air (15 psi) into the hydraulic inlet. The multi disc brake is spring loaded to apply the brake Make sure the piston is directed away from the oper- and hydraulic pressure is required to release or hold off ator.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 1. Housing 9. Gasket 17. Backup Ring 2. Compression Spring 10. Primary Disc 18. O-ring 3. Compression Spring 11. Stationary Disc 19. Rotating Disc 4. Spring Retainer 12. Gasket 20. Torque Pin 5. Bearing 13.

  • Page 104: Swing Brake S/N 64802 To Present

    SECTION 3 - CHASSIS & TURNTABLE 3.15 SWING BRAKE S/N 64802 TO PRESENT 7. Insert dowel pins (15), spring retainer (14) and springs (13) in cover (16). Disassembly NOTE: Be sure to use the same number of springs and the same spring pattern as recorded during disassem- 1.
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE Figure 3-38. Swing Brake S/N 64802 to Present 3120895 – JLG Lift – 3-53...

  • Page 106: Swing Drive Torque Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.16 SWING DRIVE TORQUE HUB NOTE: If bearing replacement is necessary, the bearing cups can be removed with a slide hammer puller or Disassembly Procedure driven out with a punch. 11. To remove the Cluster Gears (3F) from the Carrier 1.
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE Figure 3-39. Swing Torque Hub 3120895 – JLG Lift – 3-55...
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE Also at this time locate and mark the 4 counter beamed holes in the face of the Hub (1G). This is for Identification later in the assembly. 14. With the Hub Shaft Sub assembly resting on the Shaft (1A), install Internal Gear (2).
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE Be sure that punch marks remain in correct location during Ring gear installation. The side of the Ring Gear with “X” stamped on it should be up. 22. Thrust Washer (10) is installed onto the Input Gear (8) and should locate on the gear teeth shoulder.

  • Page 110: Hub Shaft Sub-Assembly Procedure

    SECTION 3 - CHASSIS & TURNTABLE 25. The Cover (6) is now installed on this assembly. Tak- 28. Torque Shoulder Bolts (13) to 23-27 ft.lbs. (31-37 ing care to correctly align Pipe Plug hole (20) with Nm) and regular Grade 8 Bolts (12) to 23-23 ft.lbs. (31-37 Nm) those in the Hub (1J), usually 90 to one another.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE 3. Invert Hub (1G) and press Bearing Cup (1E) into 6. The Bearing Cone (1F) is an interference fit and has counterbore of Hub (1G). to be pressed or tapped on. 4. Returning the Hub (1G) to locate on the large diame- 7.

  • Page 112: Carrier Sub-Assembly Procedure

    SECTION 3 - CHASSIS & TURNTABLE rod. This will release the preload which was on the bearings. Carrier Sub-Assembly Procedure 9. Retaining Ring (1I) installed into the groove provided in the output Shaft (1A). This retaining Ring (1I) should never be reused in a repair or rebuild. 1.

  • Page 113: Semi-Track

    SECTION 3 - CHASSIS & TURNTABLE 4. Place second set of sixteen Needle Rollers into Clus- 7. Line up Cluster Gear and Thrust Washers with hole ter Gear. in Carrier and slide Planet Shaft through. Line up chamfered side of hole in Planet Shaft with pin hole in Carrier.

  • Page 114: Removing The Track

    SECTION 3 - CHASSIS & TURNTABLE Removing the Track Adjustment If the tracks are muddy, it is a good idea to wash them off or drive the loader through water before removing. If the tracks are going to be stored in the laid out position just IMPROPER SLACK ADJUSTMENT COULD CAUSE TRACK PARTS as they come off the machine, then move the machine to TO BREAK.
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE Table 3-8. Adjustment Chart 1 Hole 2 Holes 3 Holes 4 Holes 5 Holes 6 Holes 7 Holes 8 Holes 9 Holes 10 Holes 11 Holes 12 Holes Move 0.81 in 1.62 in 2.43 in 3.25 in 4.06 in 4.87 in...
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE Figure 3-40. Auxiliary Pump - Sheet 1 of 2 3-64 – JLG Lift – 3120895...
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 11. Seat 21. O-ring 1. Motor 2. Adapter 12. Needle Bearing 22. Gear Housing 3. Setscrew 13. Washer 23. I.D. Label 4. Mounting Gasket 14. Screw 24. Gasket 5. Coupling 15. Retaining Ring 25. Gear Housing 6.

  • Page 118: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.18 GENERATOR Overload Protection Every 250 hours STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE Every 250 hours of operation, check the drive belt for CIRCUIT BREAKER. proper tension. The circuit breaker protects the generator windings from overload.
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE Brush Position On Slip Rings Acceptable Unacceptable Brushes must ride completely on slip rings 1/4 in (6 mm) Or Less - Replace 7/16 in - 1/2 in (11 - 12 mm) New 1. Brush Holder Assembly 2.

  • Page 120: Ford Efi Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.19 FORD EFI ENGINE • Inspect engine for modifications or aftermarket equip- ment that can contribute to the symptom; verify that all electrical and mechanical loads or accessory equip- Performing Diagnostics ment is “OFF” or disconnected before performing diagnosis.

  • Page 121: Ecm And Sensors

    SECTION 3 - CHASSIS & TURNTABLE ECM and Sensors CRANKSHAFT POSITION (CKP) SENSOR The crankshaft position (CKP) sensor provides a signal used by the engine control module (ECM) to calculate the ignition sequence. The CKP sensor initiates the reference pulses which the ECM uses to calculate RPM and crank- shaft position.
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE Table 3-9. ECM Diagnostic Trouble Codes Diagnostic Trouble Description Code All Systems OK Throttle Position (TP) Sensor Low Voltage Manifold Absolute Pressure (MAP) Low Voltage Overspeed Throttle Position (TP) Sensor High Voltage Manifold Absolute Pressure (MAP) High Voltage Fuel Pump Low Voltage Heated Oxygen Sensor (HO2S) Low Voltage Engine Coolant Temperature (ECT) Sensor High Voltage...
  • Page 123 SECTION 3 - CHASSIS & TURNTABLE other. A fault in the engine coolant sensor circuit will set HEATED OXYGEN SENSOR DTC 33 or DTC 43. The heated oxygen sensor is mounted in the exhaust stream where it can monitor the oxygen content of the exhaust gas.
  • Page 124 SECTION 3 - CHASSIS & TURNTABLE 3-72 – JLG Lift – 3120895...
  • Page 125 SECTION 3 - CHASSIS & TURNTABLE INTAKE AIR TEMPERATURE (IAT) SENSOR If the ECM detects a voltage that is significantly lower than the estimated MAP value for 2 or more consecutive sec- The intake air temperature (IAT) sensor is a thermistor onds, DTC 14 will be set.
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE The ECM is designed to maintain exhaust emission levels • When measuring voltages, use only a digital voltmeter to government mandated standards while providing excel- with an input impedance of at least 10 megohms. lent operation and fuel efficiency.

  • Page 127: Fuel System

    SECTION 3 - CHASSIS & TURNTABLE ELECTROSTATIC DISCHARGE DAMAGE A fuel injector which is stuck partly open will cause a loss of fuel pressure after the engine is shut down, causing Electronic components used in the ECM are often long crank times. designed to carry very low voltage.
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI. Figure 3-45. Typical Fuel System FUEL METERING SYSTEM PURPOSE The ECM monitors signals from several sensors in order to determine the fuel needs of the engine. Fuel is deliv- The basic function of the air/fuel metering system is to ered under one of several conditions called “modes.”...
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE FUEL PRESSURE REGULATOR ELECTRONIC GOVERNOR AND THROTTLE BODY The fuel pressure regulator is a relief valve mounted in the fuel filter. It provides a constant fuel pressure of 441 kPa In the 2.5L EFI industrial engine, throttle control is (64 psi).
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE OPEN LOOP AND CLOSED LOOP OPERATION CRANKSHAFT POSITION (CKP) SENSOR The ECM will operate in the following two modes: The crankshaft position (CKP) sensor provides a signal used by the engine control module (ECM) to calculate the •...

  • Page 131: Throttle Checks And Adjustments - Deutz Engine (Prior To S/N 61718)

    SECTION 3 - CHASSIS & TURNTABLE 3.20 THROTTLE CHECKS AND ADJUSTMENTS IGNITION COIL The electronic ignition system uses a coil pack with one - DEUTZ ENGINE (PRIOR TO S/N 61718) ignition coil for each two cylinders in the engine. Each cyl- inder is paired with its opposing cylinder in the firing order, General so that one cylinder on compression fires simultaneously...

  • Page 132: Procedure

    SECTION 3 - CHASSIS & TURNTABLE Procedure NOTE: Never run fuel tank dry. Diesel engines cannot be restarted after running out of fuel until fuel system has been air-vented or bled of air. See Deutz Instruc- tion Manual for procedure. 1.
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE Green and either Amber light followed by a red light. Action: 1. Inspect and clean wiring connections. 2. Examine throttle linkage for any damage or bent components and correct. 3. With linkage disconnected, check each potentiome- ter for operation.
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE When final settings are completed torque to 49 in. Lbs. Dry. 1.25 - 1.38 in. Actuator should be free to pivot on shoulder bolt when properly installed shoulder bolt should be installed into the actuator block with loctite # 242. Note: Addco actuator must be adjusted to be sure the mechanical stroke is centered and has adjustment outside...

  • Page 135: Tilt Alarm Switch (Prior To S/N 61718)

    SECTION 3 - CHASSIS & TURNTABLE 3.21 TILT ALARM SWITCH (PRIOR TO S/N 4. Individually push down on one corner at a time; there should be enough travel to cause the switch to 61718) trip. If the switch does not trip in all three tests, the flange nuts have been tightened too far.
  • Page 136 SECTION 3 - CHASSIS & TURNTABLE Figure 3-49. Valve Location - Chassis 3-84 – JLG Lift – 3120895...
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE Figure 3-50. Hyd Tank Installation 3120895 – JLG Lift – 3-85...

  • Page 138: Hydraulic Welder (225-4)

    SECTION 3 - CHASSIS & TURNTABLE 3.22 HYDRAULIC WELDER (225-4) NOTE: Be sure to align coupling. 1. To remove top cover. 9. Slide couplings together and tighten setscrews. a. Remove 4 screws on each side. 10. Remove back cover from motor and install flow reg- ulator on back.

  • Page 139: Rotor Replacement

    SECTION 3 - CHASSIS & TURNTABLE Rotor Replacement 30. Re-install receptacle panel. 31. Re-install welder on base plate. 1. Remove coupling guard held with two 10/32 screws. 32. Lift motor mount onto welder. 2. Un-bolt motor mount from welder (four each 5/16-18 NOTE: Be sure coupling jaws are aligned.

  • Page 140: Replacement Of Weld Rectifier Bridge

    SECTION 3 - CHASSIS & TURNTABLE Replacement of Weld Rectifier Bridge 10. Reading should be a 22 ohms ± 3 ohms. 11. Install new brush holder with brushes. 1. Remove top cover ad control panel. NOTE: Make sure brush holder is seated (dimple in casting). 2.

  • Page 141: Replacement Of Couplings

    SECTION 3 - CHASSIS & TURNTABLE Replacement of Couplings Voltage Change Over - 120/240 Volt 1. The welder/generator has a connector with 4 wires, 1. Remove coupling held by two 10/32 screws and located in the lower portion of the welder. nuts.

  • Page 142: Troubleshooting Of The Sky Welder

    SECTION 3 - CHASSIS & TURNTABLE 3.23 TROUBLESHOOTING OF THE SKY combination between terminals you should get a high and low reading. If any one of the readings come out the WELDER same, the bridge is defective. Low Sky Welder Speed No Output on Weld Receptacles or AC Receptacles If the welder/generator is running below 3600 RPM, the...
  • Page 143 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3120895 – JLG Lift – 3-91...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE 3-92 – JLG Lift – 3120895...
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-93...

  • Page 146: No Output On Weld Receptacle But Ac Receptacle Output Ok

    SECTION 3 - CHASSIS & TURNTABLE No Output on Weld Receptacle but AC Welder Completely Dead - No AC or Weld Receptacle Output OK Power If you have no welding power at all but the AC (120 volts) Make sure welder is at proper speed = 3600RPM. Unplug is fully operational, this could be caused by three compo- all external connections.

  • Page 147: Deutz Emr 2 (S/N 77682 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.24 DEUTZ EMR 2 (S/N 77682 TO PRESENT) The EMR2 is equipped with safety devices and measures in the hardware and software in order to ensure emer- The EMR2 consists of the sensors, the control unit and the gency running (Limp home) functions.
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE CONTROL ROD POSITION SENSOR/ACTUATOR POWER SUPPLY COOLANT TEMPERATURE CAMSHAFT SPEED SENSOR SENSOR JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS;...
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-97...
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE 3-98 – JLG Lift – 3120895...
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-99...
  • Page 152 SECTION 3 - CHASSIS & TURNTABLE 3-100 – JLG Lift – 3120895...
  • Page 153 SECTION 3 - CHASSIS & TURNTABLE Figure 3-58. EMR 2 Engine Plug Pin Identification 3120895 – JLG Lift – 3-101...
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE Figure 3-59. EMR 2 Vehicle Plug Pin Identification 3-102 – JLG Lift – 3120895...
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-103...
  • Page 156 SECTION 3 - CHASSIS & TURNTABLE 3-104 – JLG Lift – 3120895...
  • Page 157 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-105...
  • Page 158 SECTION 3 - CHASSIS & TURNTABLE 3-106 – JLG Lift – 3120895...
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-107...

  • Page 160: Gm Engine General Maintenance

    SECTION 3 - CHASSIS & TURNTABLE 3.25 GM ENGINE GENERAL MAINTENANCE • Check ignition coil and spark plug cables for harden- ing, cracking, chafing, separation, split boot covers and proper fit Maintenance of the Drive Belt • Replace spark plugs at the proper intervals as pre- The serpentine drive belt utilizes a spring loaded tensioner scribed in the engine manufacturer’s manual which keeps the belt properly adjusted.

  • Page 161: Changing The Engine Oil

    SECTION 3 - CHASSIS & TURNTABLE Coolant Fill Procedure - Dual Fuel Engine 6. If the oil level is below the "ADD" mark, proceed to Step 7 and 8 and reinstall the dipstick into the dip- stick tube. 7. Remove the oil filter cap from the valve rocker arm DAMAGE TO THE ENGINE COULD OCCUR IF NOT PROPERLY cover.
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE 2.Remove the radiator cap. Fill the radiator with coolant 6.Fill radiator with coolant as needed and install the radi- until coolant starts to appear from the previously ator cap. Next, remove the cap off the coolant recov- removed hose at the EPR.

  • Page 163: Gm Engine Dual Fuel System

    SECTION 3 - CHASSIS & TURNTABLE 3.26 GM ENGINE DUAL FUEL SYSTEM Fuel Filter The Dual Fuel system allows the operator to operate the Propane fuel like all other motor fuels is subject to con- vehicle on either gasoline or LPG by positioning a selector tamination from outside sources.

  • Page 164: Epr Assembly

    SECTION 3 - CHASSIS & TURNTABLE EPR Assembly Low Pressure Regulator (LPR) The EPR assembly is a combination Low Pressure Regu- The LPR is a combination vaporizer, pressure regulating lator and a Voice Coil Assembly. The Voice coil is an elec- device.

  • Page 165: Air Fuel Mixer

    SECTION 3 - CHASSIS & TURNTABLE Air Fuel Mixer Electronic Throttle Control (ETC) The air valve mixer is an air-fuel metering device and is Engine speed and load control is maintained by an ETC completely self-contained. The mixer is an air valve device.

  • Page 166: Engine Control Module

    SECTION 3 - CHASSIS & TURNTABLE Engine Control Module Heated Exhaust Gas Oxygen Sensor To obtain maximum effect from the catalyst and accurate There are two Heated Exhaust Gas Oxygen Sensors control of the air fuel ratio the emission certified engine is (HEGO).

  • Page 167: Gasoline Fuel Pump

    SECTION 3 - CHASSIS & TURNTABLE Gasoline Fuel Pump Fuel Filter The Gasoline is stored as a liquid in the fuel tank and in After the fuel is drawn into the fuel pump, the fuel flows drawn into the fuel system by an electric fuel pump. The through the gasoline fuel filter.

  • Page 168: Gm Engine Fuel System Repair

    SECTION 3 - CHASSIS & TURNTABLE 3.27 GM ENGINE FUEL SYSTEM REPAIR Propane Fuel Filter Replacement Propane Fuel System Pressure Relief THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER- SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES- SURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS.

  • Page 169: Electronic Pressure Regulator (Epr) Assembly Replacement

    SECTION 3 - CHASSIS & TURNTABLE 4. Drop the magnet into the bottom of the filter hous- 5. Remove the Electric Lock Off from the regulator. ing. 6. Remove the lock pin from the vapor fitting on the 5. Install the filter into the housing. regulator housing and remove the fitting and hose and retain the pin.

  • Page 170: Temperature Manifold Absolute Pressure (Tmap) Sensor

    SECTION 3 - CHASSIS & TURNTABLE Temperature Manifold Absolute Pressure 8. Connect the EPR electrical connector. (TMAP) Sensor 9. Open the manual valve. 10. Start the vehicle and leak check the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test.

  • Page 171: Electronic Throttle Control Replacement

    SECTION 3 - CHASSIS & TURNTABLE Electronic Throttle Control Replacement 2. Install the two quad seals. Install one seal at a time to insure the seal does not roll. The seal must sit flat See Figure 3-78. on the throttle body. REMOVAL 1.

  • Page 172: Mixer Replacement

    SECTION 3 - CHASSIS & TURNTABLE Coolant Hose Replacement 4. Place gasket on intake manifold and attach mixer/ throttle assembly to manifold. REMOVAL 1. Drain the coolant. 2. Using hose clamp pliers, disconnect both hose clamps on each hose. 3. Remove the hose from each of the fittings. INSTALLATION NOTE: Use hose material and lengths specified by JLG.

  • Page 173: Engine Control Module Replacement

    SECTION 3 - CHASSIS & TURNTABLE Engine Control Module Replacement 3.28 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS REMOVAL 1. Disconnect Negative battery cable. Fuel System Description 2. Remove controller from mounting bracket. 3. Push connector lock back to unlock connector. 4.

  • Page 174: Diagnostic Aids

    SECTION 3 - CHASSIS & TURNTABLE Diagnostic Aids Pressure Gauges • IMPCO ITK-2 Test kit This procedure is intended to diagnose a vehicle operat- ing on LPG. If the vehicle will not continue to run on LPG, • Water Column Gauge / Manometer (GM 7333-6 or refer to Hard Start for preliminary checks.
  • Page 175 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. LPF Fuel System Diagnosis STEP ACTION VALUE(S) Were you referred to this procedure by a DTC diagnostic chart? Go to Step 3 Go to Step 2 Perform the On Board Diagnostic (OBD) System Check. Go to the Go to Step 3 Are any DTCs present in the ECM?
  • Page 176 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. LPF Fuel System Diagnosis STEP ACTION VALUE(S) 1. Turn OFF the ignition. Go to Step 14 Go to Step 16 2. Disconnect the LPL connector. 3. Install a test light between the pins of the LPL connector. 4.
  • Page 177 SECTION 3 - CHASSIS & TURNTABLE Table 3-11. LPF Fuel System Diagnosis STEP ACTION VALUE(S) The fuel supply system is operating normally, if a failure of the control solenoids is System OK suspected. Refer to Fuel Control System Diagnosis. 1. Install the test plug in the LPR secondary chamber. 2.
  • Page 178 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Important Preliminary Checks Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that: 1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. 2.
  • Page 179 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Intermittent Malfunction Indicator The following components can cause intermittent MIL and no DTC(s): Lamp (MIL) A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur when the faulty component is operating.
  • Page 180 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Exhaust System Checks Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter.
  • Page 181 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Exhaust System Checks Check the exhaust system for a possible restriction: - Inspect the exhaust system for damaged or collapsed pipes - Inspect the muffler for signs of heat distress or for possible internal failure. Check for possible plugged catalytic converter.
  • Page 182 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Hesitation, Sag, Stumble DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it's severe enough. Preliminary Checks Refer to Important Preliminary Checks.
  • Page 183 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Lack of Power, Sluggishness, or Sponginess DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal. Preliminary Checks Refer to Important Preliminary Checks.
  • Page 184 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Ignition System Checks Verify that the spark plugs are correct for use with LPG (R42LTS) Check the spark plugs. Remove the plugs and inspect them for the following conditions: - Wet plugs - Cracks - Wear...
  • Page 185 SECTION 3 - CHASSIS & TURNTABLE Table 3-12. Symptom Diagnosis Checks Action Engine Mechanical Check Check the engine for the following: - Broken motor mounts - Improper valve timing - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes Surges/Chuggles DEFINITION: The engine has a power variation under a steady throttle or cruise.
  • Page 186 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. DTC to SPN/FMI Cross Reference Chart Description SPN Code FMI Code Crank Never Synced at Start Fuel Pump Low Voltage Fuel Pump High Voltage MAP Low Voltage MAP High Pressure IAT Higher Than Expected 1 IAT Low Voltage IAT High Voltage ECT Higher Than Expected 1...
  • Page 187 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. DTC to SPN/FMI Cross Reference Chart Description SPN Code FMI Code System Voltage Low System Voltage High Flash Checksum Invalid RAM Failure COP Failure External 5V Reference Low 1079 External 5V Reference High 1079 Power Relay Open 1485...
  • Page 188 SECTION 3 - CHASSIS & TURNTABLE 1. Battery 6. O2 Sensor 11. Gear Pump 2. Coolant Overflow 7. Crankshaft Position Sensor 12. Motor Mount 3. Air Cleaner 8. Oil Drain Valve 13. Start/Aux Power Relays 4. Radiator 9. Muffler 14. Engine Tray Pivot 5.
  • Page 189 SECTION 3 - CHASSIS & TURNTABLE 16. O2 Sensor 21. Oil Filter 26. Mixer 17. Dipstick 22. Water Pump 27. PCV Valve 18. Control Module 23. Coolant Sensor 28. Oil Pressure Switch 19. Starter 24. Pressure Regulator 29. Coil 20. Distributor 25.

  • Page 190: Perkins Engine General Maintenance

    SECTION 3 - CHASSIS & TURNTABLE 3.29 PERKINS ENGINE GENERAL 5. Install a new spring (3). MAINTENANCE 6. Install the breather cover (2) and the four screws (1). Tighten the screws. Replacing the Engine Crankcase Breather Engine Oil Level - Check KEEP ALL PARTS CLEAN FROM CONTAMINANTS.
  • Page 191 SECTION 3 - CHASSIS & TURNTABLE * Torque to 10 ft. lbs. (13.5 Nm) ** Torque to 21 ft. lbs. (28.5 Nm) 1. Dipstick 5. Oil Drain Valve 2. Crankcase Breather 6. Oil Filter 3. Coolant Sensor 7. Speed Sensor 4.

  • Page 192: Fuel Filter/Water Separator

    SECTION 3 - CHASSIS & TURNTABLE Fuel Filter/Water Separator Do not drain the oil when the engine is cold. As the oil cools, suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with the draining cold oil.

  • Page 193: Setting The Actuator

    SECTION 3 - CHASSIS & TURNTABLE Setting the Actuator DURING THIS PROCEDURE IT’S VERY IMPORTANT TO KEEP THE 1. Remove the bolt from the control linkage CONTROL LINKAGE PUSHED AGAINST THE STOP. 3. Once the adjustments have been made to align the spherical rod end bearing with the control linkage bolt hole, lengthen the actuator linkage by continu- ing to turn the spherical rod end and threaded rod 2-...

  • Page 194: Speed Sensor Installation

    SECTION 3 - CHASSIS & TURNTABLE 3.30 ENGINE RADIATOR FILL PROCEDURE - tor linkage and using two wrenches to prevent bind- ing of clevis heads. PERKINS & CATERPILLAR DUE TO THE CONFIGURATION OF THE COOLING SYSTEM, SOME ENGINES REQUIRE A SPECIAL RADIATOR FILL PROCEDURE. FAILURE TO FOLLOW THIS PROCEDURE CAN RESULT IN DAM- AGE TO THE ENGINE.
  • Page 195 SECTION 3 - CHASSIS & TURNTABLE 4.Remove the plug from the adapter and add coolant at 8. Make sure the coolant reaches the hot level line on the this location until the radiator hose is full of coolant. coolant recovery reservoir. Add coolant as needed. 5.Using sealant JLG P/N 0100020 (Loctite #567), install the plug back into the adapter.

  • Page 196: Dgc Diagnostic Support And Trouble Code Definitions

    SECTION 3 - CHASSIS & TURNTABLE 3.31 DGC DIAGNOSTIC SUPPORT AND Diesel Governor Control (DGC) engine control module (ECM) for use on industrial engines. TROUBLE CODE DEFINITIONS Section Layout This section defines the diagnostics and recommended troubleshooting procedures associated with an EControls This section is organized in the following manner: DTC XXXX- Diagnostic Condition Block Diagram of Circuit...

  • Page 197: List Of Abbreviations In This Section

    SECTION 3 - CHASSIS & TURNTABLE List of Abbreviations in this Section Adaptive Learn Light Emitting Diode Barometric Pressure Liquefied Propane Gas Controller Area Network Manifold Absolute Pressure CAN Calibration Protocol MGCP Marine Global Control Platform Cylinder Head Temperature μP Microprocessor Closed Loop Manufacture...

  • Page 198: Fault Code Broadcast

    SECTION 3 - CHASSIS & TURNTABLE Fault Snapshot Waste-Gate Pressure Fuel Temperature Global Control Platform Heavy-Duty Global Control Platform HDGCP (On-Road Heavy-Duty) HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S) HO2S Heated Oxygen Sensor (same as HEGO) Idle Air Control Intake Air Temperature ICAV Instant Crank Angle Velocity...

  • Page 199: Mil Output

    SECTION 3 - CHASSIS & TURNTABLE MIL Output are assigned based on the configuration outlined in Table 3-14. The MIL output is used to convey fault information to the equipment operator. The MIL is always on (grounded) Table 3-14. J1939 Diagnostic Lamp Configuration when the system is in a key-on (Vsw), engine-off state.

  • Page 200: Fault/Diagnostic Trouble Code Interaction

    SECTION 3 - CHASSIS & TURNTABLE Fault/Diagnostic Trouble Code Interaction may not be active in real-time. Once a fault has become active, it is immediately logged as historic and a snapshot All fault and diagnostic information is managed through and flight data log is saved. Figure 3-86. shows an exam- the Faults page.
  • Page 201 SECTION 3 - CHASSIS & TURNTABLE Figure 3-87. Faults Page with Historic Fault Message Once an active fault has occurred two sets of data are Both sets of data are accessed from the Historic Fault recorded, fault snapshot and flight data recorder. The fault Information interface and can be saved to the PC upon snapshot (FSS) is a sample of data taken at the instance retrieval.
  • Page 202 SECTION 3 - CHASSIS & TURNTABLE Figure 3-88. Custom Fault Variable Interface Accessing fault information is accomplished through a Figure 3-91. shows the Flight Data Recorder interface after double left-click of the fault LED in the historic fault list. View Flight Data Recorder is selected. The FDR captures a This produces the Historic Fault Information interface ten second (eight seconds prior and two seconds after shown in Figure 3-89.
  • Page 203 SECTION 3 - CHASSIS & TURNTABLE Figure 3-89. Historic Fault Information Interface Table 3-16. Historic Fault Information Interface Functions Fault Description Message Box Customized text that references the DTC flash code and describes the fault. Fault During Key Cycle Checkbox Informs that the fault occurred during the current key-on event.
  • Page 204 SECTION 3 - CHASSIS & TURNTABLE Figure 3-90. Snapshot Data Interface Figure 3-91. Flight Data Recorder Interface 3-152 – JLG Lift – 3120895...

  • Page 205: Dbw Diagnostic Test

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-92. Clear Faults Prompt DBW Diagnostic Test The DGC engine control module incorporates a diagnos- tic test that may be used to verify proper drive-by-wire throttle actuator operation. This diagnostic test is software selectable through the EDIS using the ECIPP protocol.

  • Page 206: Diagnostic Trouble Code Fault Descriptions

    SECTION 3 - CHASSIS & TURNTABLE 3.32 DIAGNOSTIC TROUBLE CODE FAULT DESCRIPTIONS DTC 116- ECT Higher Than Expected Stage 1 Diagnostic Aids • Engine Coolant Temperature Sensor • Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the troubleshooting procedures for that fault as it may have •...

  • Page 207: Dtc 117- Ect/Cht Low Voltage

    SECTION 3 - CHASSIS & TURNTABLE DTC 117- ECT/CHT Low Voltage • Engine Coolant Temperature Sensor The Engine Coolant Temperature sensor is a thermistor (temperature sensitive resistor) located in the engine cool- • Check Condition-Engine Running ant. Some engines use an ECT sensor that is located in •...
  • Page 208 SECTION 3 - CHASSIS & TURNTABLE 3-156 – JLG Lift – 3120895...

  • Page 209: Dtc 118- Ect/Cht High Voltage

    SECTION 3 - CHASSIS & TURNTABLE DTC 118- ECT/CHT High Voltage • Engine Coolant Temperature Sensor The Engine Coolant Temperature sensor is a thermistor (temperature sensitive resistor) located in the engine cool- • Check Condition-Engine Running ant. Some engines use an ECT sensor that is located in •...
  • Page 210 SECTION 3 - CHASSIS & TURNTABLE 3-158 – JLG Lift – 3120895...

  • Page 211: Dtc 122- Tps1 Signal Voltage Low

    SECTION 3 - CHASSIS & TURNTABLE DTC 122- TPS1 Signal Voltage Low DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback 3120895 – JLG Lift – 3-159...
  • Page 212 SECTION 3 - CHASSIS & TURNTABLE • Throttle Position Sensor 1 There are two types of throttle actuators; • Check Condition-Key On, Engine Off 1) actuator with analog position feedback and • Fault Condition-TPS1 sensor voltage lower than the 2) actuator with digital position feedback limit defined in the diagnostic calibration The first type, with analog position feedback, provides an •...
  • Page 213 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-161...

  • Page 214: Dtc 123- Tps1 Signal Voltage High

    SECTION 3 - CHASSIS & TURNTABLE DTC 123- TPS1 Signal Voltage High DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback • Throttle Position Sensor 1 and their position feedback sensors.
  • Page 215 SECTION 3 - CHASSIS & TURNTABLE The second type, with digital position feedback, provides ally set to 4.90 VDC. In many cases, this condition is a serial data signal to the ECM with the throttle actuator caused by a short-to-power of the TPS circuit in the wire position voltage level encoded in the data stream.

  • Page 216: Dtc 217- Ect Higher Than Expected 2

    SECTION 3 - CHASSIS & TURNTABLE DTC 217- ECT Higher Than Expected 2 Diagnostic Aids • Engine Coolant Temperature Sensor • Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the • Fault Condition-Engine Coolant Temperature reading troubleshooting procedures for that fault as it may have or estimate greater than the stage 2 limit when operat- caused "ECT Higher Than Expected 2."...

  • Page 217: Dtc 219- Rpm Higher Than Max Allowed Governed Speed

    SECTION 3 - CHASSIS & TURNTABLE DTC 219- RPM Higher Than Max Allowed Governed Speed DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback • Max Govern Speed Override- Crankshaft Position Sen- speeds programmed by the user.

  • Page 218: Dtc 336- Crank Signal Input Noise

    SECTION 3 - CHASSIS & TURNTABLE DTC 336- Crank Signal Input Noise • Crankshaft Position sensor The ECM must see a valid crankshaft position signal while running. If no signal is present, the signal amplitude is too • Check Condition- Key On, Engine On high (due to improper air gap with respect to trigger •...
  • Page 219 SECTION 3 - CHASSIS & TURNTABLE • Key On, Engine Running • System Mode= “Running” Operate engine at condition that set fault based on fault snapshot Is crank sensor a VR/ Check wiring and electrical connections Does DTC 336 reset ? magnetic pick-up? between crankshaft position sensor and ECM Is the wiring OK?

  • Page 220: Dtc 337- Loss Of Crank Input Signal

    SECTION 3 - CHASSIS & TURNTABLE DTC 337- Loss of Crank Input Signal • Crankshaft Position sensor The ECM must see a valid crankshaft position signal while running. If no signal is present while x cam pulses con- • Check Condition- Key On, Engine On tinue the fault will set.

  • Page 221: Dtc 521- Oil Pressure Sender/Switch High Pressure

    SECTION 3 - CHASSIS & TURNTABLE DTC 521- Oil Pressure Sender/Switch High Pressure • Engine Oil Pressure symptom of a failed oil pressure switch. The ECM can monitor oil pressure indication when the engine is • Check Condition- Key on, Engine on (or Engine off) stopped for this failure mode.
  • Page 222 SECTION 3 - CHASSIS & TURNTABLE Normally Open Switch • Key-On, Engine Off • System Mode= “Stopped” • Key Off • Disconnect harness from Oil Pressure switch Does DTC 524 • Check continuity through switch to ground. reset ? Intermittent Problem •...
  • Page 223 SECTION 3 - CHASSIS & TURNTABLE Sensor/Transducer Type 3120895 – JLG Lift – 3-171...

  • Page 224: Dtc 524- Oil Pressure Low

    SECTION 3 - CHASSIS & TURNTABLE DTC 524- Oil Pressure Low • Engine Oil Pressure For systems that use a transducer, this fault sets if the engine oil pressure is less than x psia and engine speed is • Check Condition- Key on, Engine on greater than y RPM after the engine has been running for •...
  • Page 225 SECTION 3 - CHASSIS & TURNTABLE Normally Open Switch • Key-On, Engine On • System Mode= “Running” • Key Off • Disconnect harness from Oil Pressure switch • Clear DTC 524 • Warm engine at idle to normal • Key On, Engine On operating temperature •...
  • Page 226 SECTION 3 - CHASSIS & TURNTABLE Normally Closed Switch • Key-On, Engine On • System Mode= “Running” • Key Off • Disconnect harness from Oil Pressure switch • Jumper Oil Pressure signal wire to ground • Clear DTC 524 • Warm engine at idle to normal •...
  • Page 227 SECTION 3 - CHASSIS & TURNTABLE Sensor/Transducer Type 3120895 – JLG Lift – 3-175...

  • Page 228: Dtc 562- Battery Voltage (Vbat) Low

    SECTION 3 - CHASSIS & TURNTABLE DTC 562- Battery Voltage (VBat) Low • System voltage to ECM The battery voltage powers the ECM and must be within limits to correctly operate throttle actuator, power sup- • Check Condition- Key on, Engine on plies, and other powered devices that the ECM controls.
  • Page 229 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-177...

  • Page 230: Dtc 563- Battery Voltage (Vbat) High

    SECTION 3 - CHASSIS & TURNTABLE DTC 563- Battery Voltage (VBat) High • System voltage to ECM The battery voltage powers the ECM and must be within limits to correctly operate throttle acutator, power sup- • Check Condition- Key on, Engine Cranking or Running plies, and other powered devices that the ECM controls.
  • Page 231 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-179...

  • Page 232: Dtc 601- Microprocessor Failure - Flash

    SECTION 3 - CHASSIS & TURNTABLE DTC 601- Microprocessor Failure - FLASH • Engine Control Module- Flash Memory The ECM has checks that must be satisfied each time an instruction is executed. Several different things can hap- • Check Condition- Key on pen within the microprocessor that will cause this fault.
  • Page 233 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-181...

  • Page 234: Dtc 604- Microprocessor Failure - Ram

    SECTION 3 - CHASSIS & TURNTABLE DTC 604- Microprocessor Failure - RAM • Engine Control Module- Random Access Memory Random Access Memory is located within the micropro- cessor and can be read from or written to at any time. • Check Condition- Key on Data stored in RAM include DTCs (when fault configura- •...
  • Page 235 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-183...

  • Page 236: Dtc 606- Microprocessor Failure - Cop

    SECTION 3 - CHASSIS & TURNTABLE DTC 606- Microprocessor Failure - COP • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can hap- • Check Condition- Key on pen within the microprocessor that will cause this fault.
  • Page 237 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-185...

  • Page 238: Dtc 642- 5 Volt External Low Voltage

    SECTION 3 - CHASSIS & TURNTABLE DTC 642- 5 Volt External Low Voltage DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback 3-186 – JLG Lift – 3120895...
  • Page 239 SECTION 3 - CHASSIS & TURNTABLE Diagnostic Aids • Engine Control Module • Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key on and the engine stopped. Verify that the output is • Fault Condition- ECM 5-volt output is below the accept- lower than the fault thresholds configured in the diag- able limit nostic calibration.

  • Page 240: Dtc 643- 5 Volt External High Voltage

    SECTION 3 - CHASSIS & TURNTABLE DTC 643- 5 Volt External High Voltage DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback 3-188 – JLG Lift – 3120895...
  • Page 241 SECTION 3 - CHASSIS & TURNTABLE Diagnostic Aids • Engine Control Module • Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key on and the engine stopped. Verify that the output is • Fault Condition- ECM 5-volt output is above the lower than the fault thresholds configured in the diag- acceptable limit nostic calibration.

  • Page 242: Dtc 1612- Microprocessor Failure - Rti 1

    SECTION 3 - CHASSIS & TURNTABLE DTC 1612- Microprocessor Failure - RTI 1 • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can hap- • Check Condition- Key on pen within the microprocessor that will cause this fault.

  • Page 243: Dtc 1613- Microprocessor Failure - Rti 2

    SECTION 3 - CHASSIS & TURNTABLE DTC 1613- Microprocessor Failure - RTI 2 • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can hap- • Check Condition- Key on pen within the microprocessor that will cause this fault.
  • Page 244 SECTION 3 - CHASSIS & TURNTABLE SFC 555- RTI 2 Loss Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 555 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...

  • Page 245: Dtc 1614- Microprocessor Failure - Rti 3

    SECTION 3 - CHASSIS & TURNTABLE DTC 1614- Microprocessor Failure - RTI 3 • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can hap- • Check Condition- Key on pen within the microprocessor that will cause this fault.
  • Page 246 SECTION 3 - CHASSIS & TURNTABLE SFC 556- RTI 3 Loss Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 556 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...

  • Page 247: Dtc 1615- Microprocessor Failure - A/D

    SECTION 3 - CHASSIS & TURNTABLE DTC 1615- Microprocessor Failure - A/D • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can hap- • Check Condition- Key on pen within the microprocessor that will cause this fault.
  • Page 248 SECTION 3 - CHASSIS & TURNTABLE SFC 513- A/D Loss Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 513 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...

  • Page 249: Dtc 1616- Microprocessor Failure - Interrupt

    SECTION 3 - CHASSIS & TURNTABLE DTC 1616- Microprocessor Failure - interrupt • Engine Control Module The ECM has checks that must be satisfied each time an instruction is executed. Several different things can hap- • Check Condition- Key on pen within the microprocessor that will cause this fault.
  • Page 250 SECTION 3 - CHASSIS & TURNTABLE SFC 512- Invalid Interrupt Key On - Engine Running System Data Mode Check all power and Clear System Fault ground circuits to ECM Does SFC 512 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent...

  • Page 251: Dtc 1625- Can J1939 Shutdown Request

    SECTION 3 - CHASSIS & TURNTABLE DTC 1625- CAN J1939 Shutdown Request • Controller Area Network In some situations, external controllers may send a request to the ECM to shutdown engine operation and • Check Condition- Key On, Engine Off and/or Running stop the engine.

  • Page 252: Dtc 1626- Can J1939 Transmit (Tx) Fault

    SECTION 3 - CHASSIS & TURNTABLE DTC 1626- CAN J1939 Transmit (Tx) Fault Diagnostic Aids • Controller Area Network • Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are prop- erly grounded •...

  • Page 253: Dtc 1627- Can J1939 Receive (Rx) Fault

    SECTION 3 - CHASSIS & TURNTABLE DTC 1627- CAN J1939 Receive (Rx) Fault Diagnostic Aids • Controller Area Network • Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are prop- erly grounded •...

  • Page 254: Dtc 1628- Can Address Conflict Failure

    SECTION 3 - CHASSIS & TURNTABLE DTC 1628- CAN Address Conflict Failure • CAN device(s) The Controller Area Network serves as a communication portal between intelligent devices. These devices may be • Check Condition- Key On, Engine on but are not limited to other engine ECMs (slave), diagnos- •...
  • Page 255 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-203...

  • Page 256: Dtc 1629- J1939 Tsc1 Message Reciept Loss

    SECTION 3 - CHASSIS & TURNTABLE DTC 1629- J1939 TSC1 Message Reciept Loss • Controller Area Network J1939 TSC1 may be used to send a commanded (or desired) engine speed to the ECM. If configured, the ECM • Check Condition- Key On, Engine Running will govern the engine speed to this commanded speed if •...

  • Page 257: Dtc 1652- Tps1 Loss Of Communications

    SECTION 3 - CHASSIS & TURNTABLE DTC 1652- TPS1 Loss of Communications • Throttle Actuator (with serial/digital position feedback) In the case of a throttle actuator with serial/digital position feedback, the ECM receives a constant data stream from • Check Condition- Key On, Engine Running and/or the throttle actuator.

  • Page 258: Dtc 2111- Unable To Reach Lower Tps

    SECTION 3 - CHASSIS & TURNTABLE DTC 2111- Unable to Reach Lower TPS DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback • Throttle Position Sensor control the idle stability and limit engine speed based on operating conditions.
  • Page 259 SECTION 3 - CHASSIS & TURNTABLE 3120895 – JLG Lift – 3-207...

  • Page 260: Dtc 2112- Unable To Reach Higher Tps

    SECTION 3 - CHASSIS & TURNTABLE DTC 2112- Unable to Reach Higher TPS DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback • Throttle Position Sensor control the idle stability and limit engine speed based on operating conditions.

  • Page 261: Dtc 9999- Throttle Actuator Failsafe Spring Failure

    SECTION 3 - CHASSIS & TURNTABLE DTC 9999- Throttle Actuator Failsafe Spring Failure DBW+ Motor H-Bridge DBW- TPS1 5V_ext Vs=+5 VDC TPS SER + Serial TPS SER - xmitter 5V_rtn Electronic Throttle Actuator w/Serial Position Feedback • Throttle Actuator the ECM detects the throttle position to be above x volts when the key is off (as determined by the diagnostic cali- •...

  • Page 262: Dtc To Spn/Fmi Table

    SECTION 3 - CHASSIS & TURNTABLE DTC to SPN/FMI Table DTC SET FAULT DESCRIPTION INDEX DTC 118: ECT voltage high DTC 117: ECT voltage low DTC 116: ECT higher than expected stage 1 DTC 563: Vbat voltage high DTC 562: Vbat voltage low DTC 643: Sensor supply voltage 1 high 1079 DTC 642: Sensor supply voltage 1 low...
  • Page 263 SECTION 3 - CHASSIS & TURNTABLE NOTE: The outlet pipe must be centered within 1/4" (6.35 mm) minimum clearance to the exhaust venturi all around the venturi’s perimeter. If the exhaust pipe touches the venturi, it will transfer heat and melt the hood. If the exhaust pipe is not centered, adjust the muffler or outlet as needed to achieve the necessary clearance.
  • Page 264 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-212 – JLG Lift – 3120895...

  • Page 265: Section 4 - Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM Removal 1. Remove the platform and platform support as fol- lows: a. Disconnect electrical cable from the platform control console. b. Using an overhead crane or suitable lifting device, use nylon support straps to support the platform/support.

  • Page 266: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly a. Disconnect wiring harness from ground control harness connector. 1. Using a portable power source, attach hose to tele- scope cylinder port block. Using all applicable safety precautions, activate hydraulic system and HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI- extend cylinder to gain access to cylinder rod retain- ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON- ing pin.

  • Page 267: Inspection

    SECTION 4 - BOOM & PLATFORM 7. Remove hardware securing the front wear pads on 10. If necessary, remove the wear pads from the rear of base boom section, remove wear pads. the fly boom section. 8. Remove hardware securing the powertrack to the front end of the fly boom section.

  • Page 268: Assembly

    SECTION 4 - BOOM & PLATFORM 6. Inspect all threaded components for damage such 6. Connect a suitable auxiliary hydraulic power source as stretching, thread deformation, or twisting. to the telescope cylinder port block. Replace as necessary. 7. Extend the telescope cylinder the distance of the 7.

  • Page 269: Installation

    SECTION 4 - BOOM & PLATFORM so that fly boom section is centered in base boom 6. Install the platform to the boom assembly. section. 7. Connect all hosing and wiring at platform control station. 8. Using all safety precautions, operate machine sys- tems and extend and retract boom for four or five cycles.

  • Page 270: Articulating Jib

    SECTION 4 - BOOM & PLATFORM 4.2 ARTICULATING JIB 4.3 LIMIT SWITCH ADJUSTMENTS See Figure 4-5., Figure 4-6., Figure 4-7., and Figure 4-8. Removal Boom Horizontal Limit Switch 1. Place the Articulating Jib in a horizontal position and support the complete assembly with adequate 1.
  • Page 271 SECTION 4 - BOOM & PLATFORM CAPACITY SWITCH TO ACTIVATE ABOVE HORIZONTAL SWITCH WHEN BASE BOOM IS RAISED 47° TO ACTIVATE WHEN BASE TO 55° ABOVE HORIZONTAL. BOOM IS RAISED 5° TO 10° SWITCH TO RESET WHEN BASE ABOVE HORIZONTAL. SWITCH BOOM LOWERED 47°...
  • Page 272 SECTION 4 - BOOM & PLATFORM CAPACITY SWITCH TO ACTIVATE ABOVE HORIZONTAL SWITCH WHEN BASE BOOM IS RAISED 47° TO ACTIVATE WHEN BASE TO 55° ABOVE HORIZONTAL. BOOM IS RAISED 5° TO 10° SWITCH TO RESET WHEN BASE ABOVE HORIZONTAL. SWITCH BOOM LOWERED 47°...
  • Page 273 SECTION 4 - BOOM & PLATFORM ABOVE HORIZONTAL SWITCH TO ACTIVATE WHEN BASE BOOM IS RAISED 5° TO 10° ABOVE HORIZONTAL. SWITCH TO RESET WHEN BASE BOOM LOWERED 1° BELOW TO 4° ABOVE HORIZONTAL. DETAIL A SEE DETAIL B SEE DETAIL A SWITCH TO ACTIVATE WHEN BOOM IS EXTENDED 84.375"...

  • Page 274: Drive Card Setup Procedures

    SECTION 4 - BOOM & PLATFORM ABOVE HORIZONTAL SWITCH TO ACTIVATE WHEN BASE BOOM IS RAISED 5° TO 10° ABOVE HORIZONTAL. SWITCH TO RESET WHEN BASE BOOM LOWERED 1° BELOW TO 4° ABOVE HORIZONTAL. DETAIL A SEE DETAIL A 0271166-D Figure 4-8.

  • Page 275: Lift, Swing, And Drive Cards

    SECTION 4 - BOOM & PLATFORM output. To set the maximum current for the “A” out- NOTE: The following procedures are to be used as a begin- put, hold the joystick in its maximum position. Turn ning basis for controller adjustment. After completing P3 clockwise until the meter reading equals the set- the procedure, final adjustments are to be made ting in table #1.
  • Page 276 SECTION 4 - BOOM & PLATFORM the meter for the time it takes the output to go from 0 Table 4-3. Flow Control Card Ramp Time current to maximum current. This is ramp up time. Adjust P1 until this time matches the time in table 2. Function Ramp Time Rotating the adjustment potentiometer clockwise...

  • Page 277: Helac Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.5 HELAC ROTARY ACTUATOR Theory Of Operation The rotary actuator is a simple mechanism that uses the sliding spline operating concept to convert linear piston motion into powerful shaft rotation. Each actuator is com- posed of a housing with integrated gear teeth (01) and only two moving parts: the central shaft with integrated bearing tube and mounting flange (02), and the annular...
  • Page 278 SECTION 4 - BOOM & PLATFORM 1. Housing 200. T-Seal 304. Thrust Washer 2. Shaft 202. T-Seal 304.1. Wiper Seal 3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207.
  • Page 279 SECTION 4 - BOOM & PLATFORM 1. Housing 200. T-Seal 304. Thrust Washer 2. Shaft 202. T-Seal 304.1. Wiper Seal 3. Piston Sleeve 204. O-Ring 400. Stop Tube (Optional) 4. End Cap 205. Cup Seal 401. Counterbalance Valve 109. Lock Pin 207.

  • Page 280: Tools Required For Assembly/Disassembly

    SECTION 4 - BOOM & PLATFORM Tools Required for Assembly/Disassembly Disassembly Upon assembly and disassembly of the actuator there are basic tools required. The tools and their intended func- tions are as follows: 1. Flashlight- helps examine timing marks, component failure and overall condition.
  • Page 281 SECTION 4 - BOOM & PLATFORM 4. Install the end cap (4) removal tools provided with 7. Remove the stop tube if included. The stop tube is the Helac seal kit. an available option to limit the rotation of the actua- tor.
  • Page 282 SECTION 4 - BOOM & PLATFORM 9. Prior to removing the shaft, (2), use a felt marker to 12. To remove the piston (3) use a rubber mallet and a clearly indicate the timing marks between shaft and plastic mandrel so the piston is no damaged. piston.
  • Page 283 SECTION 4 - BOOM & PLATFORM 15. Remove the wear guides (302) from the end cap (4) 18. Remove the wiper seal (304.1) from its groove in the and shaft (2). end cap (4) and shaft (2). 16. To remove the main pressure seals (205), it is easi- 19.

  • Page 284: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection Assembly 1. Clean all parts in a solvent tank and dry with com- 1. Gather all the components and tools into one loca- pressed air prior to inspecting. Carefully inspect all tion prior to re-assembly. Use the cut away drawing critical areas for any surface finish abnormalities: to reference the seal orientations.
  • Page 285 SECTION 4 - BOOM & PLATFORM Beginning with the inner seal (200) insert one end of b/u 4. Using a seal tool install the main pressure seal (205) ring in the lower groove and feed the rest in using a circu- onto shaft (2) and end cap (4).
  • Page 286 SECTION 4 - BOOM & PLATFORM 9. Looking from the opposite end of the housing (1) 12. Install 2 bolts in the threaded holes in the flange. you can see if your timing marks are lining up. When Using a bar, rotate the shaft in a clockwise direction they do, tap the piston (3) in until the gear teeth until the wear guides are seated inside the housing mesh together.

  • Page 287: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM 15. Install the O-ring (204) and back-up ring (207) into 18. Place the lock pins (109) provided in the Helac seal the inner seal groove on the end cap (4). kit in the holes with the dimple side up. Then, using a punch, tap the lock pins to the bottom of the hole.
  • Page 288 SECTION 4 - BOOM & PLATFORM Figure 4-12. Rotator Counterbalance Valve 4-24 – JLG Lift – 3120895...

  • Page 289: Section 5 - Hydraulics

    SECTION 5 - HYDRAULICS SECTION 5. HYDRAULICS 5.1 CYLINDERS - THEORY OF OPERATION 7. If extend port leakage is less than 6-8 drops per min- ute, carefully reconnect hose to extend port, than activate cylinder through one complete cycle and Systems Incorporating Double Acting check for leaks.

  • Page 290: Disassembly

    SECTION 5 - HYDRAULICS Figure 5-1. Boom Prop Configuration NOTE: The following are general procedures that apply to all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

  • Page 291: Cleaning And Inspection

    SECTION 5 - HYDRAULICS 10. 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. 11. Remove the bushing from the piston. Figure 5-3.

  • Page 292: Assembly

    SECTION 5 - HYDRAULICS 8. Inspect seal and o-ring grooves in piston for burrs Assembly and sharp edges. Dress applicable surfaces as nec- essary. NOTE: Prior to cylinder assembly, ensure that the proper 9. Inspect cylinder head inside diameter for scoring or cylinder seal kit is used.
  • Page 293 SECTION 5 - HYDRAULICS 1684139 D 1. Barrel 5. Wear Ring 9. Seal 13. Bolt 17. Loctite #242 2. Not Used 6. O-ring 10. Rod 14. Valve Cartridge 18. Locking Primer 3. Wear Ring 7. Backup Ring 11. Cap 15. Bleeder Valve 19.
  • Page 294 SECTION 5 - HYDRAULICS – JLG Lift – 3120895...
  • Page 295 SECTION 5 - HYDRAULICS 1683609 G 1. Barrel 5. Rod 9. O-ring Plug 14. Lock Ring 19. Backup Ring 24. Locking Primer 1A. Bushing 5A. Bushing 10. Piston 15. Piston Seal 20. Seal 25. Not Used 2. Head 6. Valve Cartridge 11.
  • Page 296 SECTION 5 - HYDRAULICS 29*** 1,2**,28 2**,3**,23 * Prior to S/N 78894 ** Prior to S/N 102048 *** Torque to 20 ft.lbs. (27 Nm) Max 1683776 E 1. Loctite #242 7. Head 13. Plug 19. Seal 25. Tube Spacer 2. Locking Primer 8.
  • Page 297 SECTION 5 - HYDRAULICS 1684284 B 1. Loctite #242 6. Bushing 11. Not Used 16. Backup Ring 21. Wiper 2. Locking Primer 7. Head 12. Piston 17. Wear Ring 22. Washer Ring 3. Not Used 8. Barrel 13. Hydrolock Ring 18.
  • Page 298 SECTION 5 - HYDRAULICS 1684412 A 1. Barrel 6. Wear Ring 11. Wiper 2. Rod 7. Backup Ring 12. Seal 3. Cylinder Head 8. Wear Ring 13. T-Seal 4. Anti-Seize 9. O-ring 5. Not Used 10. O-ring Figure 5-13. Steer Cylinder 5-10 –...
  • Page 299 SECTION 5 - HYDRAULICS 3120895 – JLG Lift – 5-11...
  • Page 300 SECTION 5 - HYDRAULICS Figure 5-15. Wiper Seal Installation 3. Place a new o-ring and back-up seal in the applica- ble outside diameter groove of the cylinder head. Figure 5-17. Piston Seal Kit Installation. 8. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.
  • Page 301 SECTION 5 - HYDRAULICS 15. Remove the cylinder rod from the holding fixture. 16. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (See Figure 5-17., Piston Seal Kit Installation.) Figure 5-20. Poly-Pak Piston Seal Installation 17.

  • Page 302: Valves - Theory Of Operation

    SECTION 5 - HYDRAULICS NOTE: If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON as applicable. (See Table 5-2, Holding Valve Torque THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE Specification.) THAT THE OUTER END OF THE ROD IS SUPPORTED.
  • Page 303 SECTION 5 - HYDRAULICS 3120895 – JLG Lift – 5-15...
  • Page 304 SECTION 5 - HYDRAULICS Ft-Lbs. 18-20 24.5-27.2 6.5-9.5 25-27 34-36.7 Figure 5-23. Main Valve Cartridge Torque Values 5-16 – JLG Lift – 3120895...

  • Page 305: Relief Valves

    SECTION 5 - HYDRAULICS Relief Valves ings are acceptable if within +/- 5% of specified pres- sures. Relief valves are installed at various points within the hydraulic system to protect associated systems and com- NOTE: Engine RPM’s must be correct. Mid engine 1800, ponents against excessive pressure.

  • Page 306: Articulating Jib Down

    SECTION 5 - HYDRAULICS 5.5 HYDRAULIC MOTOR REPAIR (H SERIES cartridge on the jib block. Turn clockwise to increase, counterclockwise to decrease. CHAR-LYNN) 6. Articulating Jib Down; Cleanliness is extremely important when repairing these motors. Work in a clean area. Before disconnecting lines, Install a high pressure gauge on the “M”...
  • Page 307 SECTION 5 - HYDRAULICS 3. Remove end cap. clamping pressure on side of housing causes distor- tion. 4. Remove seal from end cap. 5. Remove gerotor. 6. Remove seal from gerotor. 14. Remove cap screws from mounting flange. These screws are assembled with Loctite to hold them in 7.

  • Page 308: Reassembly Shaft End

    SECTION 5 - HYDRAULICS 17. A metal plug, with seal, plugs a machining hole in the housing. It is not necessary to remove plug and SOME MOTORS MAY HAVE A QUAD SEAL AND BACK - UP RING replace seal unless leakage occurs around plug. To IN PLACE OF THE PRESSURE SEAL.
  • Page 309 SECTION 5 - HYDRAULICS c. Wire brush screw threads ton remove cured 4. Install exclusion seal in flange. Carefully press exclu- Loctite and other debris. Discard any screws sion seal into place. that have damaged threads or rounded heads. d. Wash screws with non - petroleum base solvent. Blow dry with compressed air.

  • Page 310: Gerotor End

    SECTION 5 - HYDRAULICS 9. Apply 3 or 4 drops of Loctite sealant at top of thread 11. After removing bullet, clamp motor in vise as shown for each of four holes in housing.Do not allow parts in Figure 2-49. Make sure shaft cannot fall out. Install with Loctite applied to come in contact with any dry screws and alternately torque them immediately metal parts other than those for assembly.

  • Page 311: Timing Procedure

    SECTION 5 - HYDRAULICS Timing Procedure Reverse Rotation a. Install drive. Use felt tip marker to mark one Align any star valley with marked tooth. tooth. Align this tooth with timing dot on shaft. NOTE: If drive is not symmetrical, install lager splined end into shaft.
  • Page 312 SECTION 5 - HYDRAULICS 16. Install drive spacer if applicable. 18. Install cap screws and seal washers (if applicable) in end cap. Pretighten screws to 40 in-lbs (4 Nm). 17. Install 2 7/8 in. (73 mm) seal in end cap. Carefully Make sure seals are properly seated.
  • Page 313 SECTION 5 - HYDRAULICS Figure 5-25. Variable Displacement Hydraulic Pump. 3120895 – JLG Lift – 5-25...

  • Page 314: Hydraulic Pump "Neutral" Or Null Adjustment

    SECTION 5 - HYDRAULICS 5.6 HYDRAULIC PUMP “NEUTRAL” OR NULL 5.7 NON-FEEDBACK, PROPORTIONAL ADJUSTMENT ELECTRICAL CONTROL - NFPE The pump neutral or null adjustment sets the position of The Non-Feedback Proportional Electric (NFPE) control is the servo piston and pump swash plate relative to the con- a hydraulic control in which an electric input signal acti- trolling mechanism.

  • Page 315: Hydraulic Component Start-Up Procedures And Recommendations

    SECTION 5 - HYDRAULICS 5.8 HYDRAULIC COMPONENT START-UP NOTE: In most cases, the reservoir is above the pump inlet so that the pressure head created by the higher oil PROCEDURES AND level helps to keep the inlet pressures within an RECOMMENDATIONS acceptable range and prevent high vacuum levels.
  • Page 316 SECTION 5 - HYDRAULICS It is recommended that the external control input signal, Once charge pressure has been established, increase (electrical connections for EDC), be disconnected at the speed to normal operating RPM. Charge pressure should pump control until after initial start-up. This will ensure that be as indicated in the pump model code.

  • Page 317: Section 6 - Jlg Control System (S/N 61718 To Present)

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) SECTION 6. JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6.1 INTRODUCTION The upper lift, swing, and drive are controlled by individual joysticks, with steering being controlled by a rocker switch built into the top the drive joystick.
  • Page 318 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Figure 6-2. ADE Block Diagram – JLG Lift – 3120895...

  • Page 319: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6.2 TO CONNECT THE JLG CONTROL The top level menus are as follows: SYSTEM ANALYZER HELP DIAGNOSTICS 1. Connect the four pin end of the cable supplied with SYSTEM TEST the analyzer, to the controller module located in the ACCESS LEVEL platform box or at the controller module in the...
  • Page 320 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-3. Analyzer Connecting Points – JLG Lift – 3120895...

  • Page 321: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 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 322 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Figure 6-4. Control Module Location – JLG Lift – 3120895...

  • Page 323: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6.5 ADJUSTING PARAMETERS USING THE Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- HAND HELD ANALYZER word was entered correctly: Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example:...

  • Page 324: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6.6 MACHINE SETUP When a machine digit item is selected, press the UP or ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- DOWN arrow keys to adjust its value, for example: TRICAL/ELECTRONIC COMPONENTS.
  • Page 325 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 3120895 – JLG Lift –...
  • Page 326 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6-10 – JLG Lift – 3120895...
  • Page 327 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 3120895 – JLG Lift – 6-11...
  • Page 328 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6-12 – JLG Lift – 3120895...
  • Page 329 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 3120895 – JLG Lift – 6-13...
  • Page 330 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6-14 – JLG Lift – 3120895...
  • Page 331 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 3120895 – JLG Lift – 6-15...
  • Page 332 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6-16 – JLG Lift – 3120895...

  • Page 333: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS DRIVE ACCELeration 0.1s to 5.0s DECELeration...
  • Page 334 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS TELEscope ACCELeration 0.1 to 5.0 DECELeration 0.1 to 3.0 MINimum IN speed 0 to 65 MAXimum IN speed 0 to 100 MINimum OUT speed 0 to 65 MAXimum OUT speed 0 to 100...
  • Page 335 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS GROUND MODE LIFT UP speed 0 to 100 LIFT DOWN speed 0 to 100 SWING speed 0 to 100 TELEscope speed 0 to 100 BASKET ROTATE speed 0 to 100 BASKET LEVEL speed...
  • Page 336 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66995 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 337 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66995 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 338 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66995 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. ADD DRIVER FAULTS Flash code 3/5 indicates a brake pressure problem.
  • Page 339 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66995 Flash code 9/9 indicates problems with the controller. PLATFORM MODULE FAILURE: Platform module V(Low) FET has failed hwfs CODE 1 GROUND MODULE FAILURE: Ground module V(Low) FET has failed...
  • Page 340 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 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 341 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 2/2 indicates problems with drive & steer selection. Except where noted, these faults are not reported during 2 second power-up sequence.
  • Page 342 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 2/5 indicates that a function is prevented due to a cutout. BOOM PREVENTED —...
  • Page 343 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 3/3 indicates a driver problem. All driver faults are detected in a similar manner.
  • Page 344 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault LP LOCK SHORT TO BATTERY Only occurs on machines with dual-fuel engines. LP START ASSIST SHORT TO Only occurs on machines with dual-fuel engines.
  • Page 345 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault HEAD TAIL LIGHT OPEN CIRCUIT Only occurs on machines with the headlights option configured. HEAD TAIL LIGHT SHORT TO BAT- Only occurs on machines with the headlights option configured.
  • Page 346 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault JIB DOWN OPEN CIRCUIT JIB DOWN SHORT TO BATTERY JIB LEFT SHORT TO GROUND JIB LEFT OPEN CIRCUIT JIB LEFT SHORT TO BATTERY...
  • Page 347 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault LIFT DOWN AUX VALVE OPEN CIR- Only occurs on machines with gravity lift down.
  • Page 348 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 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 349 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 4/2 indicates that the engine is over temperature. NOT REQUIRED Flash code 4/3 indicates problems with the engine.
  • Page 350 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 4/5 indicates problems with the S-D CAN based PVG valves currently used on the 1250AJP only.
  • Page 351 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault MAIN LIFT PVG VALVE COMMAND Main boom lift pvg valve received an invalid command from the control system. IMPROPER TOWER LIFT PVG VALVE COMMAND Tower boom lift pvg valve received an invalid command from the control sys-...
  • Page 352 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 5/5 indicates problems with vehicle engine RPM or the encoder.
  • Page 353 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 8/3 indicates problems with the Basket Leveling system. BASKET LEVELING CRACKPOINT UP Only occurs on machines with electronic leveling systems.
  • Page 354 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 8/4 indicates problems with the envelope system. Only occur on machines with envelope control.
  • Page 355 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault TWR LENGTH SENSOR ONE VALUE This fault is reported by the Ground module when the length sensor value is OUT OF RANGE LOW outside the constant data limit TWR LENGTH SENSOR TWO VALUE...
  • Page 356 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 8/5 indicates problems with the moment or load pin system. Only occur on machines with moment or load pin control.
  • Page 357 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 8/6 indicates problems with the steering system. Except as noted, an EMS cycle is required.
  • Page 358 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault REAR LEFT WHEEL BLOCKED The wheel is not responding to steer commands. Fault clears when condition clears.
  • Page 359 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 9/9 indicates problems with the controller or the user dis- abling safety systems from Access Level 0.
  • Page 360 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BLAM SENSOR SUPPLY OUT OF Indicates that the supply voltage for the boom angle sensors is above the RANGE HIGH expected range.
  • Page 361 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 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 AUSTRALIA...
  • Page 362 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 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; engine start can be attempted at any time during pre-glow.
  • Page 363 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 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 364 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 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). * Certain market selections will alter default setting.
  • Page 365 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 366 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
  • Page 367 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI.
  • Page 368 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / MOTION CUTOUT: Motion cutout in platform mode only.
  • Page 369 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-5. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number FUNCTION CUTOUT: NO: No drive cutout. * Only visible under certain BOOM CUTOUT: Boom function cutout while driving above elevation. market selections.
  • Page 370 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-6. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
  • Page 371 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-6. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
  • Page 372 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-6. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number STARTER LOCKOUT: DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
  • Page 373 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-6. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number GEN SET/WELDER: NO: No generator installed. BELT DRIVE: Belt driven setup. GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON.
  • Page 374 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-6. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LOAD SENSOR: 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform Module.
  • Page 375 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-6. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LEVELING MODE: ALL FUNCTIONS: Platform level with all functions. * Only visible on 800S LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
  • Page 376 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 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. Shaded cells indicate a hidden menu or selection.
  • Page 377 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 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. Shaded cells indicate a hidden menu or selection.

  • Page 378: System Test

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6.9 SYSTEM TEST 3.Pull out the Emergency Stop switch and Start the engine. The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures.
  • Page 379 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 3120895 – JLG Lift – 6-63...

  • Page 380: Test From The Ground Station

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Test from the Ground Station 3.Pull out the Emergency Stop switch. and Start the engine. 1. Position the Platform/Ground select switch to the Ground position. 4.The analyzer screen should read: 2.Plug the analyzer into the connector inside the Ground control box.
  • Page 381 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 3120895 – JLG Lift – 6-65...
  • Page 382 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-7. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer RUNNING Initial display when system test is run; certain “critical” checks are made. Prob- lems that can be reported include below messages. ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
  • Page 383 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-7. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open- and short- circuit valve coils. NOTE: In platform mode, the footswitch must be closed.
  • Page 384 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-7. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.
  • Page 385 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-8. Machine Configuration Parameters Description Rang Definition Default Configuration Parameter Parameter Value Data Digit (Displayed on (Displayed on Analyzer Increment Value 2nd Line) Analyzer 1 Line) Model Number: 1=400 Displays/adjusts 2=450 machine model...
  • Page 386 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-8. Machine Configuration Parameters Tilt: 1=5Deg Displays/adjusts tilt 5 degree – reduces the maxi- 2=4Deg sensor function mum speed of all boom func- 3=3Deg tions to creep when tilted and above elevation.
  • Page 387 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-8. Machine Configuration Parameters Head & Tail 0=NO Displays presence No Head and Tail Lights LIGHTS 1=YES of head and tail installed lights BROKEN Cable 0=NO Displays presence No Broken Cable Switch switch 1=YES of broken cable...
  • Page 388 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-8. Machine Configuration Parameters PLATFORM 0=NO Displays/adjusts Sounds Continuously When ALARM 1=FAULT CODE platform alarm Above Elevation And Tilted presence/functions Only. Sounds Continuously When Above Elevation And Tilted, And In Conjunction With Fault Code Flashes.
  • Page 389 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text EVERYTHING OK GROUND MODE OK 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0011 FSW OPEN 0012 RUNNING AT CREEP - CREEP SWITCH OPEN 0013 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION 0014...
  • Page 390 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text BRAKE - SHORT TO BATTERY BRAKE - OPEN CIRCUIT 3311 GROUND ALARM - SHORT TO BATTERY 3316 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND 3319 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY OR OPEN CIRCUIT 3320...
  • Page 391 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text 3370 TWO SPEED VALVE - SHORT TO BATTERY 3371 GROUND ALARM - SHORT TO GROUND 3372 GROUND ALARM - OPEN CIRCUIT 3373 GEN SET/WELDER - SHORT TO GROUND 3374 GEN SET/WELDER - OPEN CIRCUIT...
  • Page 392 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text 33115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND 33116 TOWER TELESCOPE OUT VALVE - OPEN CIRCUIT 33117 TOWER TELESCOPE OUT VALVE - SHORT TO BATTERY 33118 SWING RIGHT VALVE - SHORT TO GROUND 33119...
  • Page 393 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text 33315 FLOW CONTROL VALVE - SHORT TO BATTERY 33316 FLOW CONTROL VALVE - SHORT TO GROUND 33317 DRIVE FORWARD VALVE - OPEN CIRCUIT 33318 DRIVE FORWARD VALVE - SHORT TO BATTERY 33319...
  • Page 394 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text FUEL SENSOR - SHORT TO BATTERY FUEL SENSOR - SHORT TO GROUND OIL PRESSURE - SHORT TO BATTERY OIL PRESSURE - SHORT TO GROUND COOLANT TEMPERATURE - SHORT TO GROUND FORD FAULT CODE ## ENGINE TROUBLE CODE...
  • Page 395 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text 8311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY 8312 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT 8313 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE 8314 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE...
  • Page 396 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-9. Analyzer Fault Code Listing Analyzer Text 9920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE 9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY 9922 PLATFORM MODULE FAILURE - HWFS CODE 1 9923 GROUND MODULE FAILURE - HWFS CODE 1 9924...

  • Page 397: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) 6.10 ANALYZER DIAGNOSTICS MENU the next outer level. The LEFT/RIGHT arrow keys move between items in the same level. The UP/DOWN arrow STRUCTURE keys alter a value if allowed In the following structure descriptions, an intended item is selected by pressing ENTER;...
  • Page 398 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-10. 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 399 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-10. 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 400 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-11. 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 401 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) Table 6-11. 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 402 SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT) NOTES: 6-86 – JLG Lift – 3120895...

  • Page 403: Section 7 - Basic Electrical Information & Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 GENERAL are reversed. Check what reading is expected, the loca- tion of the signal and that the leads are connected to the This section contains basic electrical information and device under test correctly.

  • Page 404: Resistance Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Resistance Measurement •Use firm contact with meter leads Continuity Measurement Figure 7-3. Continuity Measurement •Some meters require a separate button press to Figure 7-2. Resistance Measurement enable audible continuity testing •First test meter and leads by touching leads •Circuit power must be turned OFF before testing together.

  • Page 405: Current Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Current Measurement b. Change the switch position. c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an open. If the meter was reading open it should read short.

  • Page 406: Automatic Switches

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL If the switch is actuated automatically, by temperature or CONNECTIONS pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pres- NOTE: This section is not applicable for battery terminals.

  • Page 407: Installation Of Dielectric Grease

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Deutsch HD, DT, DTM, DRC Series 3. Anderson connectors for the battery boxes and bat- tery chargers should have silicone grease applied to the contacts only. The Deutsch connector system is commonly used for harsh environment interconnect.

  • Page 408: Amp Mate-N-Lok

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Exclusions A limited number of connectors do not benefit from dielec- tric grease, or may be permanently damaged by applica- tion. Dielectric grease may not be required in properly sealed enclosures. BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gold contact material to resist corro- sion and an o-ring seal for moisture integrity.
  • Page 409 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS AMP JUNIOR TIMER MIL-C-5015 SPEC CONNECTORS Crown Connector Inc's recommendation is to not use This type of connector uses back-seals for moisture integ- dielectric grease for this series connector. For similar rity. However, the low-force contacts cannot displace model series connectors, the manufacturer should be dielectric grease and create electrical contact.

  • Page 410: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.5 AMP CONNECTOR Assembly Check to be sure the wedge lock is in the open, or as- Applying Silicone Dielectric Compound to shipped, position (See Figure 7-7.). Proceed as follows: AMP Connectors Silicone Dielectric Compound must be used on the AMP connections for the following reasons: •...
  • Page 411 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-9. Connector Assembly Figure 2 3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).

  • Page 412: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-12. Connector Disassembly Disassembly the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. 1. Insert a 4.8 mm (3/16") wide screwdriver blade Service - Voltage Reading between the mating seal and one of the red wedge lock tabs.
  • Page 413 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-13. Connector Installation 3120895 – JLG Lift – 7-11...

  • Page 414: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.6 DEUTSCH CONNECTORS NOTE: The receptacle is shown - use the same procedure for plug. DT/DTP Series Assembly DT/DTP Series Disassembly Figure 7-14. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the con- Figure 7-15.

  • Page 415: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal 1. Grasp contact about 25mm behind the contact 1. With rear insert toward you, snap appropriate size crimp barrel.
  • Page 416 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20. Electrical Components Installation w/o JLG Control System - Sheet 1 of 2 7-14 – JLG Lift – 3120895...
  • Page 417 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21. Electrical Components Installation w/o JLG Control System - Sheet 2 of 2 3120895 – JLG Lift – 7-15...
  • Page 418 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS FOOTSWITCH PLATFORM GENERATOR FLOODLIGHTS SWITCH PLATFORM WORK LIGHTS SOFT TOUCH LIMIT SWITCH TRANSPORT LIMIT SWITCH (400S ONLY) ABOVE HORIZONTAL LIMIT SWITCH CAPACITY ANGLE LIMIT SWITCH (ALL SPECS EXCEPT CE SPEC) HEADLIGHTS TAILLIGHTS PLATFORM CONTROL GROUND...
  • Page 419 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 2500W 2500W GENERATOR GENERATOR RELAY GENERATOR CONTROL BOX 7500W 7500W 7500W GENERATOR 7500W GENERATOR GENERATOR CONTROL BOX SKYPOWER RELAYS PLATFORM GENERATOR THROTTLE ACTUATOR (CAT) ENGINE CONTROL (DEUTZ) BOSCH FUEL ELECTRIC REGULATOR FUEL (GM) RELAY ELECTRIC...
  • Page 420 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally. 7-18 – JLG Lift – 3120895...
  • Page 421 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-24. On Board Generator Electrical Schematic. (if equipped) 3120895 – JLG Lift – 7-19...
  • Page 422 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-25. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 1 of 4 7-20 – JLG Lift – 3120895...
  • Page 423 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-26. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 2 of 4 3120895 – JLG Lift – 7-21...
  • Page 424 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-27. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 3 of 4 7-22 – JLG Lift – 3120895...
  • Page 425 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 4 of 4 3120895 – JLG Lift – 7-23...
  • Page 426 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-29. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 1 of 4 7-24 – JLG Lift – 3120895...
  • Page 427 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-30. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 2 of 4 3120895 – JLG Lift – 7-25...
  • Page 428 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-31. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 3 of 4 7-26 – JLG Lift – 3120895...
  • Page 429 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 4 of 4 3120895 – JLG Lift – 7-27...
  • Page 430 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-33. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 1 of 4 7-28 – JLG Lift – 3120895...
  • Page 431 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-34. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 2 of 4 3120895 – JLG Lift – 7-29...
  • Page 432 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-35. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 3 of 4 7-30 – JLG Lift – 3120895...
  • Page 433 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-36. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 4 of 4 3120895 – JLG Lift – 7-31...
  • Page 434 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 99084. Figure 7-37. Electrical Schematic - Caterpillar Engine - Sheet 1 of 6 7-32 – JLG Lift – 3120895...
  • Page 435 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870132 M Figure 7-38. Electrical Schematic - Caterpillar Engine - Sheet 2 of 6 3120895 – JLG Lift – 7-33...
  • Page 436 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 99084. Figure 7-39. Electrical Schematic - Caterpillar Engine - Sheet 3 of 6 7-34 – JLG Lift – 3120895...
  • Page 437 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870132 M Figure 7-40. Electrical Schematic - Caterpillar Engine - Sheet 4 of 6 3120895 – JLG Lift – 7-35...
  • Page 438 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 99084. Figure 7-41. Electrical Schematic - Caterpillar Engine - Sheet 5 of 6 7-36 – JLG Lift – 3120895...
  • Page 439 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870132 M Figure 7-42. Electrical Schematic - Caterpillar Engine - Sheet 6 of 6 3120895 – JLG Lift – 7-37...
  • Page 440 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 99084. Figure 7-43. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 1 of 6 7-38 – JLG Lift – 3120895...
  • Page 441 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-44. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 2 of 6 3120895 – JLG Lift – 7-39...
  • Page 442 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 99084. Figure 7-45. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 3 of 6 7-40 – JLG Lift – 3120895...
  • Page 443 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-46. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 4 of 6 3120895 – JLG Lift – 7-41...
  • Page 444 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built prior to S/N 99084. Figure 7-47. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 5 of 6 7-42 – JLG Lift – 3120895...
  • Page 445 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870191 G Figure 7-48. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 6 of 6 3120895 – JLG Lift – 7-43...
  • Page 446 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-49. Electrical Schematic - Hydraulic Welder 7-44 – JLG Lift – 3120895...
  • Page 447 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS This page left intentionally blank. 3120895 – JLG Lift – 7-45...
  • Page 448 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built S/N 99084 to Present. Figure 7-50. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1 of 6 7-46 – JLG Lift – 3120895...
  • Page 449 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870215 B Figure 7-51. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 2 of 6 3120895 – JLG Lift – 7-47...
  • Page 450 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built S/N 99084 to Present. Figure 7-52. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 3 of 6 7-48 – JLG Lift – 3120895...
  • Page 451 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870215 B Figure 7-53. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 4 of 6 3120895 – JLG Lift – 7-49...
  • Page 452 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTE: This Schematic covers machines built S/N 99084 to Present. Figure 7-54. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 5 of 6 7-50 – JLG Lift – 3120895...
  • Page 453 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1870215 B Figure 7-55. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 6 of 6 3120895 – JLG Lift – 7-51...
  • Page 454 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-56. Hydraulic Schematic - (Sheet 1 of 6) 7-52 – JLG Lift – 3120895...
  • Page 455 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001093691 A Figure 7-57. Hydraulic Schematic - (Sheet 2 of 6) 3120895 – JLG Lift – 7-53...
  • Page 456 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-58. Hydraulic Schematic - (Sheet 3 of 6) 7-54 – JLG Lift – 3120895...
  • Page 457 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001093691 A Figure 7-59. Hydraulic Schematic - (Sheet 4 of 6) 3120895 – JLG Lift – 7-55...
  • Page 458 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-60. Hydraulic Schematic - (Sheet 5 of 6) 7-56 – JLG Lift – 3120895...
  • Page 459 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 1001093691 A Figure 7-61. Hydraulic Schematic - (Sheet 6 of 6) 3120895 – JLG Lift – 7-57...
  • Page 460 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-58 – JLG Lift – 3120895...
  • Page 462 +55 19 3295 1025 +61 2 65813058 +44 (0)161 654 1001 JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte D - 27721 Ritterhude - Ihlpohl...

This manual is also suitable for:

Jlg 460sj

Table of Contents

Save PDF