Oshkosh Corporation JLG 450AJ Service And Maintenance Manual
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Oshkosh Corporation JLG 450AJ Service And Maintenance Manual

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Service and Maintenance Manual
Model
450AJ
S/N 0300199221
to Present
P/N - 3121659
October 9, 2015

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Summary of Contents for Oshkosh Corporation JLG 450AJ

  • Page 1 Service and Maintenance Manual Model 450AJ S/N 0300199221 to Present P/N - 3121659 October 9, 2015...

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue - March 13, 2015 Revised - October 9, 2015 – JLG Lift – 3121659...

  • 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. SECTION 3 - CHASSIS & TURNTABLE Tires and Wheels ................. . . 3-1 Tire Damage .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Lubricating O-Rings in the Hydraulic System ............5-1 Cup and Brush .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS General ................... . 7-1 Multimeter Basics .
  • Page 9 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram - Deutz 2.3 Engine ......... . . 1-10 1-2.
  • Page 10 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-8. Cables and Clamps Installation - Sheet 1 of 8 ............4-10 4-9.
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-7. Analyzer Connecting Points ............... . 6-13 6-8.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-39. Platform Valve Harness - Sheet 1 of 2 ..............7-34 7-40.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-83. Deutz 2.9 Harness - Sheet 1 of 12 ..............7-78 7-84.
  • Page 14 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Dimensional Data .

  • Page 15: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.3 CAPACITIES Table 1-1. Operating Specifications Table 1-3. Capacities Capacity: Unrestricted: 550 lbs. (249.5 kg) Hydraulic System 38 gal. (143.8 L) Maximum Travel Grade, stowed Hydraulic Oil Tank (to Full Level) 31.7 Gal.

  • Page 16: Engine Data

    SECTION 1 - SPECIFICATIONS 1.5 ENGINE DATA Table 1-7. GM 3.0L Fuel Gasoline or Gasoline/LP Gas Table 1-5. Deutz D2011L03 No. of Cylinders Fuel Diesel Gasoline 82 hp @ 3000 rpm No. of Cylinders 75 hp @ 3000 rpm Bore 3.7 in (94 mm) Bore 4.0 in (101.6 mm)
  • Page 17 SECTION 1 - SPECIFICATIONS desired, contact JLG Industries for proper recommenda- tions. Table 1-12. Mobil EAL 224H Specs Table 1-9. Mobilfluid 424 Specs Type Synthetic Biodegradable SAE Grade 10W30 ISO Viscosity Grade 32/46 Gravity, API 29.0 Specific Gravity .922 Density, Lb/Gal. 60°F 7.35 Pour Point, Max -25°F (-32°C)

  • Page 18: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 2. Swing Bearing/Worm Gear Teeth 1.7 MAINTENANCE AND LUBRICATION NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram - Deutz 2.3 Engine, Figure 1-2., Maintenance and Lubrication Dia- gram - GM Engine, and Figure 1-3., Maintenance and Lubrication Diagram - Deutz 2.9 Engine.
  • Page 19 SECTION 1 - SPECIFICATIONS 3. Hydraulic Tank 5. Hydraulic Tank Breather Lube Point(s) - Fill Cap Capacity - 36 Gal. (136.3 L), 31.7 Gal. (119.9 L) to Full Level; 28.8 Gal (109.0 L) to Low Level Interval - Change after first 50 hrs. and every 6 months Lube - HO or 300 hrs.
  • Page 20 SECTION 1 - SPECIFICATIONS 7. Drive Brake 9. Oil Change w/Filter - Deutz 2.9 L4 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.4 gal (8.9 L) Lube Point(s) - Fill Plug Lube - EO Capacity - 27 oz. (0.8 L) Interval - Every Year or 600 hours of operation Lube - DTE-13M Comments - Check level daily/Change in accordance...
  • Page 21 SECTION 1 - SPECIFICATIONS 10. Oil Change w/Filter - GM 11. Fuel Filter/Water Separator - Deutz 2.3 L3 Lube Point(s) - Replaceable Element Interval - Every year or 500 hours of operation 12. Fuel Pre-Filter - Deutz D2.9 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element Capacity - 4.5 qt (4.25 L) w/filter Interval - Drain water daily;...
  • Page 22 SECTION 1 - SPECIFICATIONS 13. Fuel Filter - Deutz D2.9 15. Fuel Filter (Propane) - GM Engine Interval - 3 Months or 150 hours of operation Comments - Replace filter. 16. Charge Filter Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation 14.
  • Page 23 SECTION 1 - SPECIFICATIONS 17. Air Filter 18. Engine Coolant Lube Point(s) - Fill Cap Lube Point(s) - Replaceable Element Capacity (Deutz 2.9L)- 2.9 gal. (11.3L) Interval - Every 6 months or 300 hours of operation or Capacity (GM 3.0L)- 2.4 gal. (9.1L) as indicated by the condition indicator Lube - Anti-Freeze Comments - Check Dust Valve daily...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-1. Maintenance and Lubrication Diagram - Deutz 2.3 Engine 1-10 – JLG Lift – 3121659...
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-2. Maintenance and Lubrication Diagram - GM Engine 3121659 – JLG Lift – 1-11...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-3. Maintenance and Lubrication Diagram - Deutz 2.9 Engine 1-12 – JLG Lift – 3121659...
  • Page 27 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 3121659 – JLG Lift – 1-13...
  • Page 28 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 1-14 – JLG Lift – 3121659...
  • Page 29 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 3121659 – JLG Lift – 1-15...
  • Page 30 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 1-16 – JLG Lift – 3121659...
  • Page 31 SECTION 1 - SPECIFICATIONS Figure 1-8. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 3121659 – JLG Lift – 1-17...
  • Page 32 SECTION 1 - SPECIFICATIONS NOTES: 1-18 – JLG Lift – 3121659...

  • Page 33: General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, AND inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures. MAINTENANCE Annual Machine Inspection General The Annual Machine Inspection must be performed on an This section provides the necessary information needed by annual basis, no later than thirteen (13) months from the date those personnel that are responsible to place the machine in of the prior Annual Machine Inspection.

  • Page 34: Service And Guidelines

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

  • Page 35: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the text, standard torque values should be used on heat- When disassembling or reassembling a component, complete treated bolts, studs, and steel nuts, in accordance with the procedural steps in sequence.

  • Page 36: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION Changing Hydraulic Oil 1. Filter elements must be changed after the first 50 hours Hydraulic System of operation and every 300 hours (unless specified oth- erwise) thereafter. If it is necessary to change the oil, use 1.

  • Page 37: Cylinder Drift

    SECTION 2 - GENERAL Cylinder Drift 4. Re-assembly of pinned joints using filament wound bearings. Table 2-2. Cylinder Drift a. Housing should be blown out to remove all dirt and debris...bearings and bearing housings must be free Max. Acceptable Drift of all contamination.
  • Page 38 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Preventive Preventive (Yearly) or Frequent Years Maintenance Maintenance Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings...
  • Page 39 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Preventive Preventive (Yearly) or Frequent Years Maintenance Maintenance Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground &...
  • Page 40 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Weekly Monthly Pre-Delivery Annual AREA Every 2 Preventive Preventive (Yearly) or Frequent Years Maintenance Maintenance Inspection Inspection Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers Grease and Lubricate to Specifications...
  • Page 41 SECTION 2 - GENERAL 1001159163 A Figure 2-1. Engine Operating Temperature Specifications - Deutz 2.9 3121659 – JLG Lift –...
  • Page 42 SECTION 2 - GENERAL HYDRAULIC FLUID OPERATION CHART MACHINE OPERAT ION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF T HE T EMPERATURE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY RESULT IN PREMAT URE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYST EM.
  • Page 43 SECTION 2 - GENERAL Figure 2-3. GM Engine and Hydraulic Oil Operating Temperature Specifications 3121659 – JLG Lift – 2-11...
  • Page 44 SECTION 2 - GENERAL Figure 2-4. Deutz 2011 Engine and Hydraulic Oil Operating Temperature Specifications 2-12 – JLG Lift – 3121659...

  • Page 45: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE The proper procedure for attaching wheels is as follows: 3.1 TIRES AND WHEELS 1. Start all nuts by hand to prevent cross threading. DO Tire Damage NOT use a lubricant on threads or nuts. For pneumatic tires, JLG Industries, Inc.

  • Page 46: Torque Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.2 TORQUE HUB Tightening and Torquing Bolts Roll and Leak Testing Always roll and leak test Torque-Hubs after assembly to make USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN sure that the unit’s gears and sealants are working properly. BOLTS BEYOND THEIR TORQUE SPECIFICATION.

  • Page 47: Main Disassembly For "B" Drives

    SECTION 3 - CHASSIS & TURNTABLE MAIN DISASSEMBLY for “B” Drives Hub-Spindle Disassembly 1. Turn hub (1G) on side, Remove coupling (14) from wide NOTE: Start with large end of hub facing up and large end of spin- end of spindle (1A). dle facing down.
  • Page 48 SECTION 3 - CHASSIS & TURNTABLE Figure 3-2. Drive Hub and Brake Assembly (2WD and 4WD) - Sheet 1 of 2 – JLG Lift – 3121659...
  • Page 49 SECTION 3 - CHASSIS & TURNTABLE Spindle/Housing Assembly Roll Pin Thrust Spacer Outer Plate 1A Spindle Ring Gear Sun Gear Gasket 1B Seal O-Ring Thrust Washer Cylinder 1C Bearing Cone O-Ring Bolt Piston 1D Bearing Cup Cover Assembly Dowel Pin Ball Bearing 1E Bearing Cup Thrust Spacer...
  • Page 50 SECTION 3 - CHASSIS & TURNTABLE Figure 3-4. Drive Hub (4WD Front Only) -Sheet 1 of 2 – JLG Lift – 3121659...
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE Spindle/Housing Assembly Carrier Assembly Cover Assembly Shaft Spindle 3A Carrier Thrust Spacer Retaining Ring Seal 3B Retaining Ring Cover Plate Spring Bearing Cone 3C Needle Bearing O-Ring Thrust Spacer Bearing Cup 3D Thrust Washer Disconnect Rod Gear, Sun Bearing Cup...

  • Page 52: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Assemble Carrier Cover Disassembly 1. Apply grease to inside of one cluster gear (3F) and line one half of cluster gear with 16 needle rollers (3C). 1. Remove two bolts (6C) holding disconnect cap (6D) to cover (6A).
  • Page 53 SECTION 3 - CHASSIS & TURNTABLE 4. Set carrier housing (3A) on table, sideways. Insert a 7. Following cluster gear, place one more thrust washer planet shaft (3E), roll pin hole last, into one of the planet (3B) onto planet shaft (3E) through opposite planet shaft shaft holes from roll-pin-holed side of carrier housing hole in carrier housing (3A).

  • Page 54: Cover Sub-Assembly

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

  • Page 55: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE 7. With large end down, place disconnect cap (6D) on 10. Apply a light coat of “Never-Seize” to pipe plug (6H) and cover cap (6B), aligning pipe plug hole in disconnect cap tighten it in pipe plug hole in cover (6A). over pipe plug hole in cover cap.
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE 3. Apply a light coat of “Never-Seize” to two pipe plugs (1J) 6. Press seal (1B) in small end of hub (1G). and tighten them in two pipe plug holes in side of hub (1G).

  • Page 57: Main Assembly

    SECTION 3 - CHASSIS & TURNTABLE 9. Place spacer (1H) on spindle (1A) in hub (1G). Main Assembly SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP EDGES IN COUNTERBORE WHEN REMOVING O-RING. 1. Grease O-ring (5) and place it into counterbore in hub (1G).
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE 3. Place thrust washer (11) around spindle (1A) so it rests 6. Place other spacer (7D) on smooth end of input shaft on bottom of internal gear (2). (7A). 4. Stand input shaft (7A) on splined end. Place one spacer (7D) on smooth end of input shaft (7A).
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 9. Place thrust spacer (9) onto input shaft (7). 12. Place carrier sub assembly (3) and ring gear (4) together into mesh with internal gear (2), aligning “X” marked shoulder bolt hole in ring gear (4) over one of the shoul- der bolt holes in hub.
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 18. Place shoulder bolts (13) in four shoulder bolt holes in cover (6) and hand-tighten. SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY WHEN INSTALL- ING O-RING. 15. Set cover (6A) on table, interior side up. Grease O-ring (5) and place in counterbore around edge of cover (6A).
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 21. Torque shoulder bolts (13) 18 to 25 ft-lb (25 to 34 Nm). 23. Roll test unit in clockwise and counterclockwise direc- Torque bolts (12) 18 to 25 ft-lb (25 to 34 Nm). tions. Perform same number of turns in each direction as the ratio of the unit.

  • Page 62: Tool List

    SECTION 3 - CHASSIS & TURNTABLE Tool List 3. T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E). The following specialized tools are used to assemble this unit. Tool diagrams in this manual are intended for the customer who may wish to have a tool made. All tools are one piece and must be made from mild steel.

  • Page 63: Re-Align Torque Hub Input Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.3 RE-ALIGN TORQUE HUB INPUT COUPLING 3.4 DRIVE MOTOR This procedure applies to torque hubs with integral brakes: Description Drive motors are low to medium power, two-position axial pis- Equipment Required ton motors incorporating an integral servo piston. They are designed for operation in open and closed circuit applications.

  • Page 64: Shaft Seal Replacement

    SECTION 3 - CHASSIS & TURNTABLE Shaft Seal Replacement Loop Flushing Valve REMOVAL REMOVAL 1. Remove snap ring (1) and support washer (2). 1. Remove plug (1) and (2) with 11/16" internal hex wrench. 1. Snap Ring 2. Support Washer 3.

  • Page 65: Troubleshooting

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

  • Page 66: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This ensures parts are lubricated dur- ing start-up. Replace all O-Rings and gaskets. Lightly lubricate O-rings with clean petroleum jelly prior to assembly.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 22. Screw 25. Valve Plate 27. O-ring 29. Angle Stop 23. End Cap 26. End Cap 28. O-ring Servo Spring 24. O-ring Figure 3-12. End Cap Figure 3-13. Valve Plate & Rear Shaft Bearing 13.
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 30. Cylinder Kit Assembly Figure 3-14. Cylinder Kit 19. Turn housing on its side and remove cylinder kit assem- bly (31). Set assembly aside. Do not to scratch running 31. Snap Ring surface. 32. Support Washer NOTE: Grooves on surface of cylinder kit identify its displacement: 33.
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE Lift here 38. Swashplate 39. Servo Piston 40. Piston Seal 41. O-ring 42. Journal Bearings Figure 3-17. Swash Plate & Servo Piston 43. Piston 48. Retaining Ring 44. Slipper Retainer 49. Block Spring Washer 23.

  • Page 70: Inspection

    SECTION 3 - CHASSIS & TURNTABLE Inspection Table 3-6. Slipper Foot Thickness & End Play Wash all parts after disassembly (including end-cap and hous- Measurement L Frame K Frame ing) thoroughly with clean solvent and allow to air dry. Blow Slipper Foot Thickness 2.71 4.07...
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE VALVE PLATE Inspect journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively Valve plate condition is critical to motor efficiency. Inspect worn. Polymer wear layer must be smooth and intact. valve plate surfaces for excessive wear, grooves, or scratches.

  • Page 72: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly 1. Install new O-ring (1) and piston seal (2) to servo piston COMPRESSED SPRING MAY FLY OUT AND CAUSE SERIOUS INJURY. COMPRESS- (3). Install piston seal over O-ring. ING BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE NOTE: Installing piston seal stretches it, making it difficult to EFFORT.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 8. Press front shaft bearing (15) onto shaft (16). Press bear- ing onto shaft with lettering facing out. Lubricate bear- IF REUSING PISTONS, INSTALL THEM IN ORIGINAL BLOCK BORES. ing rollers. Install snap-ring (17) on shaft. 5.
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE 10. Verify swashplate and bearings are properly seated. 12. Press rear shaft bearing (22) into endcap. Install bearing Install cylinder kit (19) onto shaft. Install with slippers with letters facing out. Press until bearing surface is 0.08 facing swashplate.
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE 15. Install endcap (25) on housing with endcap screws (26). 18. Cover shaft splines with an installation sleeve. Install a Check endcap properly seats on housing without interfer- new shaft seal (27) with cup side facing motor. Press seal ence.

  • Page 76: Initial Start-Up Procedures

    SECTION 3 - CHASSIS & TURNTABLE 20. Install orifice poppet (30). Initial Start-Up Procedures Follow this procedure when starting up a new motor or after 21. Install shift spool (31). reinstalling a motor. 22. Install spring retaining washers on springs (32 and 33). Prior to installing motor, inspect for damage incurred during 23.

  • Page 77: Drive Brake

    SECTION 3 - CHASSIS & TURNTABLE 3.5 DRIVE BRAKE Assembly 1. Lightly lubricate the rotary shaft seal (12) and assemble Refer to Figure 3-30., Drive Brake. it to the housing (2) taking care not to damage the seal lip. Disassembly 2.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 1. Brake Shaft 2. Housing 3. Inner Friction Plate 4. Pressure Plate 5. Gasket (Not Shown) 6. Outer Plate 7. Gasket 8. Cylinder 9. Piston 10. Ball Bearing 11. Retaining Ring 12. Rotary Shaft Seal 13.

  • Page 79: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE Main Boom Disassembly 1. Loosen jam nuts on aft end of fly boom wear pad adjust- ment and loosen adjustments. DO NOT USE A LIFTING DEVICE TO LIFT BOOMS UNLESS 2.
  • Page 80 SECTION 4 - BOOM & PLATFORM Figure 4-1. Boom Assembly – JLG Lift – 3121659...
  • Page 81 SECTION 4 - BOOM & PLATFORM 3121659 – JLG Lift –...
  • Page 82 SECTION 4 - BOOM & PLATFORM Figure 4-3. Main Boom Assembly - Sheet 2 of 2 – JLG Lift – 3121659...
  • Page 83 SECTION 4 - BOOM & PLATFORM Figure 4-4. Upper Boom Assembly 3121659 – JLG Lift –...
  • Page 84 SECTION 4 - BOOM & PLATFORM Figure 4-5. Jib Assembly – JLG Lift – 3121659...

  • Page 85: Inspection

    SECTION 4 - BOOM & PLATFORM Inspection 7. Measure distance between telescope cylinder port block attach point on base boom section and attach 1. Inspect all boom pivot pins for wear, scoring or other point on fly boom section. damage, and tapering or ovality. Replace pins as 8.

  • Page 86: Install Boom Assembly

    SECTION 4 - BOOM & PLATFORM Install Boom Assembly 4.2 BOOM CLEANLINESS GUIDELINES The following are guidelines for internal boom cleanliness for 1. Using suitable lifting equipment, position boom assem- machines that are used in excessively dirty environments. bly on turntable so boom pivot holes in boom and turn- 1.

  • Page 87: Boom Shimming Procedure

    SECTION 4 - BOOM & PLATFORM 4.3 BOOM SHIMMING PROCEDURE 7. Install the side pads and shims into the base boom. Dis- tribute shims to each side to match the distribution noted in Step 2. Positions #5/6 must match positions #1/ NOTE: When installing wear pads, the wear pad bolt lengths may 2.
  • Page 88 SECTION 4 - BOOM & PLATFORM Figure 4-8. Cables and Clamps Installation - Sheet 1 of 8 4-10 – JLG Lift – 3121659...
  • Page 89 SECTION 4 - BOOM & PLATFORM Figure 4-9. Cables and Clamps Installation - Sheet 2 of 8 3121659 – JLG Lift – 4-11...
  • Page 90 SECTION 4 - BOOM & PLATFORM Figure 4-10. Cables and Clamps Installation - Sheet 3 of 8 4-12 – JLG Lift – 3121659...
  • Page 91 SECTION 4 - BOOM & PLATFORM Figure 4-11. Cables and Clamps Installation - Sheet 4 of 8 3121659 – JLG Lift – 4-13...
  • Page 92 SECTION 4 - BOOM & PLATFORM Figure 4-12. Cables and Clamps Installation - Sheet 5 of 8 4-14 – JLG Lift – 3121659...
  • Page 93 SECTION 4 - BOOM & PLATFORM Figure 4-13. Cables and Clamps Installation - Sheet 6 of 8 3121659 – JLG Lift – 4-15...
  • Page 94 SECTION 4 - BOOM & PLATFORM Figure 4-14. Cables and Clamps Installation - Sheet 7 of 8 4-16 – JLG Lift – 3121659...
  • Page 95 SECTION 4 - BOOM & PLATFORM 3121659 – JLG Lift – 4-17...

  • Page 96: Rotary Actuator

    SECTION 4 - BOOM & PLATFORM 4.4 ROTARY ACTUATOR Required Tools Basic tools required for assembly and disassembly of the actu- Theory of Operation ator and their intended functions are as follows: The L20 Series rotary actuator converts linear piston motion to shaft rotation.
  • Page 97 SECTION 4 - BOOM & PLATFORM 1. Housing 4. End Cap 9. Cap Seal 12. Piston Seal 16. Thrust Washer 2. Shaft 5. Exclusion Seal 10. Cap Ring 13. Bearing Packing 17. Counterbalance Valve 3. Piston Sleeve 8. Bolt 11. Rod Seal 14.

  • Page 98: Disassembly

    SECTION 4 - BOOM & PLATFORM Disassembly 4. Install end cap (4) removal tools provided with Helac seal kit. 1. Remove capscrews (54) over end cap lock pins (53). 5. Using a metal bar or similar, unscrew end cap (4) by 2.
  • Page 99 SECTION 4 - BOOM & PLATFORM 7. Actuator has timing marks for proper engagement. 9. Remove shaft (2). It may be necessary to strike threaded end of shaft with a rubber mallet. 10. Mark housing (1) ring gear in relation to piston O.D. gear before removing piston sleeve (3).
  • Page 100 SECTION 4 - BOOM & PLATFORM 12. Mark piston and housing with a marker where piston 15. To remove main pressure seals (13), it is easiest to cut gear teeth come out of engagement with housing gear them using a sharp razor blade being careful not to teeth as shown.

  • Page 101: Inspection

    SECTION 4 - BOOM & PLATFORM 18. Remove piston O.D. seal (12). Inspection 1. Clean parts in a solvent tank and dry with compressed air before inspecting. Inspect seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore, and gear teeth for surface finish abnormalities.

  • Page 102: Assembly

    SECTION 4 - BOOM & PLATFORM 3. Inspect wear guide condition. Measure thickness not Assembly less than 0.123" (3.12 mm). 1. Gather all components and tools to one location. 2. Install thrust washer (16) on shaft (2) and end cap (4). 3.
  • Page 103 SECTION 4 - BOOM & PLATFORM 4. Use seal tool in a circular motion to install main pressure 7. Install outer T-seal (12) by stretching it around groove in seal (13) on shaft (2) and end cap (4). a circular motion. Each T-seal has 2 back-up rings (see drawing for orientation).
  • Page 104 SECTION 4 - BOOM & PLATFORM 10. Insert piston (3) in housing (1) until outer piston seal (12) teeth mesh together. Tap piston into housing until it is touching inside housing bore. bottoms out. 14. Install shaft (2) into piston (3). Do not damage seals. Do 11.
  • Page 105 SECTION 4 - BOOM & PLATFORM of piston (3). Now tap flange end of shaft with a rubber 17. Coat threads on end of shaft with anti-seize grease to mallet until gear teeth engage. prevent galling. 16. Install 2 bolts in threaded holes in flange. Using a bar, 18.
  • Page 106 SECTION 4 - BOOM & PLATFORM 19. Thread end cap (4) on shaft (2) end. Make sure wear 21. Place lock pins (53) provided in Helac seal kit in holes guide stays in place on end cap as it is threaded in hous- with dimple side up.

  • Page 107: Installing Counterbalance Valve

    SECTION 4 - BOOM & PLATFORM Installing Counterbalance Valve 3. Bolts that come with valve are grade 8 bolts. Install new bolts with a new valve. Apply Loctite #242 to shank of Refer to Figure 4-17., Rotator Counterbalance Valve. three bolts during installation. 1.
  • Page 108 SECTION 4 - BOOM & PLATFORM NOTE: Retorque all bolts on rotator if any rotator bolts are replaced. Torque to 50 ft-lb (68 Nm) Loctite #242 Torque to 480 ft-lb (650 Nm) Check torque every 150 hours of operation Torque to 85 ft-lb (115 Nm) Figure 4-18.

  • Page 109: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.5 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack. Remove Link NOTE: Hoses shown in powertrack are for example only. Actual hose and cable arrangements are different. 1.
  • Page 110 SECTION 4 - BOOM & PLATFORM NOTE: It may be necessary to loosen fixed end brackets from machine to move track section enough to disconnect links. REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE- VENT DAMAGE. 3. To remove a link, rivets holding links together must be removed.
  • Page 111 SECTION 4 - BOOM & PLATFORM 6. Insert flat head screwdriver between links. Twist and pull 7. Remove link from other section of powertrack using links apart. screwdriver. 3121659 – JLG Lift – 4-33...

  • Page 112: Install New Link

    SECTION 4 - BOOM & PLATFORM Install New Link 2. Spread half-shear (female) end of new link and slide cut- out end of track section into it. Use a screwdriver if nec- 1. Squeeze cut-out end of new link into half-shear (female) essary.
  • Page 113 SECTION 4 - BOOM & PLATFORM 4. Pull moving end over track so new connection is posi- 6. Push pin through center hole then slide washer on pin. tioned in curve of powertrack. Round half-shears will rotate into cut-outs. 7. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed.
  • Page 114 SECTION 4 - BOOM & PLATFORM NOTE: Make sure snap rings are seated in pin groove and closed 2. Pull up on other end of round bar and slide new poly properly. roller on bar. Incorrect Correct 1. Install new 8-32 x 0.500 self-threading torx head screw in end of new aluminum round bar.

  • Page 115: Replace Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM 3. Install new 8-32 x 0.500 self threading screw on other Replace Fixed End Brackets side. Torque to 18-20 in-lb (2-2.25 Nm). REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE- VENT DAMAGE. 1. Remove rivets as shown in link removal instructions on page 4-20.

  • Page 116: Replace Moving End Brackets

    SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. Replace Moving End Brackets 3. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it. REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE- VENT DAMAGE.
  • Page 117 SECTION 4 - BOOM & PLATFORM 2. Install center pin with snap ring in new bracket. NOTE: When installing snap rings make sure they are seated in pin groove and closed properly. Incorrect Correct 4. Make sure both brackets rotate correctly. 3.
  • Page 118 SECTION 4 - BOOM & PLATFORM NOTES: 4-40 – JLG Lift – 3121659...

  • Page 119: Basic Hydraulic Information & Hydraulic Schematics

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.

  • Page 120: Dip Method

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- 2.
  • Page 121 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-1. Hydraulics Installation - Sheet 1 of 30 3121659 – JLG Lift –...
  • Page 122 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-2. Hydraulics Installation - Sheet 2 of 30 – JLG Lift – 3121659...
  • Page 123 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3121659 – JLG Lift –...
  • Page 124 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-4. Hydraulics Installation - Sheet 4 of 30 – JLG Lift – 3121659...
  • Page 125 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-5. Hydraulics Installation - Sheet 5 of 30 3121659 – JLG Lift –...
  • Page 126 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-6. Hydraulics Installation - Sheet 6 of 30 – JLG Lift – 3121659...
  • Page 127 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3121659 – JLG Lift –...
  • Page 128 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-8. Hydraulics Installation - Sheet 8 of 30 5-10 – JLG Lift – 3121659...
  • Page 129 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3121659 – JLG Lift – 5-11...
  • Page 130 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-10. Hydraulics Installation - Sheet 10 of 30 5-12 – JLG Lift – 3121659...
  • Page 131 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-11. Hydraulics Installation - Sheet 11 of 30 3121659 – JLG Lift – 5-13...
  • Page 132 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-12. Hydraulics Installation - Sheet 12 of 30 5-14 – JLG Lift – 3121659...
  • Page 133 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-13. Hydraulics Installation - Sheet 13 of 30 3121659 – JLG Lift – 5-15...
  • Page 134 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-14. Hydraulics Installation - Sheet 14 of 30 5-16 – JLG Lift – 3121659...
  • Page 135 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-15. Hydraulics Installation - Sheet 15 of 30 3121659 – JLG Lift – 5-17...
  • Page 136 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-16. Hydraulics Installation - Sheet 16 of 30 5-18 – JLG Lift – 3121659...
  • Page 137 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-17. Hydraulics Installation - Sheet 17 of 30 3121659 – JLG Lift – 5-19...
  • Page 138 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-18. Hydraulics Installation - Sheet 18 of 30 5-20 – JLG Lift – 3121659...
  • Page 139 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-19. Hydraulics Installation - Sheet 19 of 30 3121659 – JLG Lift – 5-21...
  • Page 140 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-20. Hydraulics Installation - Sheet 20 of 30 5-22 – JLG Lift – 3121659...
  • Page 141 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-21. Hydraulics Installation - Sheet 21 of 30 3121659 – JLG Lift – 5-23...
  • Page 142 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5-24 – JLG Lift – 3121659...
  • Page 143 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-23. Hydraulics Installation - Sheet 23 of 30 3121659 – JLG Lift – 5-25...
  • Page 144 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-24. Hydraulics Installation - Sheet 24 of 30 5-26 – JLG Lift – 3121659...
  • Page 145 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 3121659 – JLG Lift – 5-27...
  • Page 146 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-26. Hydraulics Installation - Sheet 26 of 30 5-28 – JLG Lift – 3121659...
  • Page 147 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-27. Hydraulics Installation - Sheet 27 of 30 3121659 – JLG Lift – 5-29...
  • Page 148 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5-30 – JLG Lift – 3121659...
  • Page 149 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-29. Hydraulics Installation - Sheet 29 of 30 3121659 – JLG Lift – 5-31...
  • Page 150 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-30. Hydraulics Installation - Sheet 30 of 30 5-32 – JLG Lift – 3121659...

  • Page 151: Pressure Setting Procedure

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS 5.2 PRESSURE SETTING PROCEDURE Swing Relief Cold temperatures have a significant impact on pressure read- 1. Install a pressure gauge at port MP1 of the Main Control ings. JLG Industries Inc. recommends operating the machine Valve capable of reading pressures up to 3000 psi (207 until the hydraulic system has warmed to normal operating Bar).

  • Page 152: Platform Level Down Relief

    SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Platform Level Down Relief e. Prefilling of the hydraulic drive pump w/oil cooler option is complete (Step #4 can be omitted at this The Platform Level Down relief is preset and does not normally point.) need checked or adjusted.
  • Page 153 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS This Sheet Left Blank Intentionally 3121659 – JLG Lift – 5-35...
  • Page 154 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-31. Hydraulic Schematic - Sheet 1 of 2 5-36 – JLG Lift – 3121659...
  • Page 155 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS Figure 5-32. Hydraulic Schematic - Sheet 2 of 2 3121659 – JLG Lift – 5-37...
  • Page 156 SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS NOTES: 5-38 – JLG Lift – 3121659...

  • Page 157: Jlg Control System

    SECTION 6 - JLG CONTROL SYSTEM SECTION 6. JLG CONTROL SYSTEM 6.1 JLG CONTROL SYSTEM ANALYZER KIT viewing and adjusting the various personality settings for smooth control of: acceleration, deceleration, creep, min INSTRUCTIONS speed, and max.-speed for all boom, drive, and steering func- tions.

  • Page 158: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM To Connect the JLG Control System Analyzer Using the Analyzer 1. Connect the four pin end of the cable supplied with the With the machine power on and the analyzer connected prop- analyzer, to the motor controller module located in the erly, the analyzer will display the following: platform box or at the power module and connect the remaining end of the cable to the analyzer.

  • Page 159: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: When a top level menu is selected, a new set of menu items may be offered: for example: HELP DIAGNOSTICS DRIVE ACTIVATE TEST BOOM ACCESS LEVEL SYSTEM PERSONALITIES DATALOG MACHINE SETUP...

  • Page 160: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Press ENTER to select the ACCESS LEVEL menu. Analyzer Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

  • Page 161: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press the UP DOWN arrow keys to adjust its value, for example: CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.

  • Page 162: Tilt Sensor Calibration

    SECTION 6 - JLG CONTROL SYSTEM Tilt Sensor Calibration 4. Using the arrow keys, navigate to the Tilt Sensor calibra- Refer to Figure 6-2., Tilt Sensor Location. tion as shown below and press ENTER DO NOT CALIBRATE THE TILT SENSOR EXCEPT ON A LEVEL SURFACE. 1.
  • Page 163 SECTION 6 - JLG CONTROL SYSTEM 5. When the sensor is calibrated in that position, the screen 7. When the calibration is complete the screen will read as will read: shown below. Return the machine to the travel position. 6. Swing the machine 180 degrees, making sure the boom is centered and in the transport position, and ENTER .
  • Page 164 SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. Tilt Sensor Location – JLG Lift – 3121659...

  • Page 165: Ground Control Console Display Gauge

    SECTION 6 - JLG CONTROL SYSTEM Ground Control Console Display Gauge The Engine Diagnostics Screen will show SPN (Suspect Parameter Number), FMI (Failure Mode Identifier), and Occurrence count information. Engine SPN text is not scrol- (See Figure 6-6., Ground Control Console Display Gauge) lable.
  • Page 166 SECTION 6 - JLG CONTROL SYSTEM INDICATOR LAMP FUEL LEVEL ENGINE HOURS NAVIGATE BACK ARROW NAVIGATE FORWARD ARROW NAVIGATION BUTTONS Figure 6-6. Ground Control Console Display Gauge 6-10 – JLG Lift – 3121659...
  • Page 167 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING GROUND ACCEL ACCELERATE GREEN ACTIVE GROUND MODULE ANALOG DIGITAL CONVERTER COUNT HOURS AMB. AMBIENT HARDWARE ANGLE HWFS HARDWARE FAILSAFE AUXILIARY IN or CURRENT BOOM CONTROL SYSTEM JOYSTICK BOOM LENGTH ANGLE MODULE...
  • Page 168 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING SHORT CIRCUIT SELECTOR SERIAL NUMBER SPEED STOW STOWED STOWD STOWED SWITCH or SOFTWARE TELE TELESCOPE TEMP TEMPERATURE TORQ. TORQUE TRANSPORT TURNTABLE TOWER TURNTBL TURNTABLE TOWER UPPER or UP VOLT VERSION VALVE...
  • Page 169 SECTION 6 - JLG CONTROL SYSTEM Figure 6-7. Analyzer Connecting Points 3121659 – JLG Lift – 6-13...
  • Page 170 SECTION 6 - JLG CONTROL SYSTEM 6-14 – JLG Lift – 3121659...
  • Page 171 SECTION 6 - JLG CONTROL SYSTEM 3121659 – JLG Lift – 6-15...
  • Page 172 SECTION 6 - JLG CONTROL SYSTEM 6-16 – JLG Lift – 3121659...
  • Page 173 SECTION 6 - JLG CONTROL SYSTEM 3121659 – JLG Lift – 6-17...
  • Page 174 SECTION 6 - JLG CONTROL SYSTEM 6-18 – JLG Lift – 3121659...
  • Page 175 SECTION 6 - JLG CONTROL SYSTEM 3121659 – JLG Lift – 6-19...
  • Page 176 SECTION 6 - JLG CONTROL SYSTEM 6-20 – JLG Lift – 3121659...
  • Page 177 SECTION 6 - JLG CONTROL SYSTEM 3121659 – JLG Lift – 6-21...
  • Page 178 SECTION 6 - JLG CONTROL SYSTEM Figure 6-16. Ground Control Module - Sheet 1 of 3 6-22 – JLG Lift – 3121659...
  • Page 179 SECTION 6 - JLG CONTROL SYSTEM Figure 6-17. Ground Control Module - Sheet 2 of 3 3121659 – JLG Lift – 6-23...
  • Page 180 SECTION 6 - JLG CONTROL SYSTEM Figure 6-18. Ground Control Module - Sheet 3 of 3 6-24 – JLG Lift – 3121659...
  • Page 181 SECTION 6 - JLG CONTROL SYSTEM Figure 6-19. Platform Module - Sheet 1 of 2 3121659 – JLG Lift – 6-25...
  • Page 182 SECTION 6 - JLG CONTROL SYSTEM Figure 6-20. Platform Module - Sheet 2 of 2 6-26 – JLG Lift – 3121659...
  • Page 183 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configurationn Default Number Description Label/Digit Number MODEL NUMBER: ????: Visible only on a Non-Configured UGM 340AJ 400S 450AJ 18RS 24RS MARKET: ANSI USA ANSI EXPORT AUSTRALIA JAPAN ENGINE: KUBOTA D1105 DUEL FUEL ECM: GM/PSI 0.97L Duel Fuel (Tier 3) DEUTZ EMR2: (Tier 4i)
  • Page 184 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configurationn Default Number Description Label/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. ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre- glow is finished.
  • Page 185 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configurationn Default Number Description Label/Digit Number 4 WHEEL STEER: NO: No four-wheel steer installed. YES: Four-wheel steer installed. * This item not visible. SOFT TOUCH: NO: No Soft Touch system installed. YES: Soft Touch system installed.
  • Page 186 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configurationn Default Number Description Label/Digit Number FUNCTION CUTOUT: NO: No drive cutout. BOOM CUTOUT: Boom function cutout while driving above elevation. DRIVE CUTOUT: Drive & steer cutout above elevation. DRIVE CUT E&T: Drive &...
  • Page 187 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information Configurationn Default Number Description Label/Digit Number TEMP CUTOUT: NO: No Low Temp Cutout system installed YES: Low Temp Cutout system installed PLAT LVL OVR CUT: NO: Platform Level functions above elevation YES: Platform Level does not function above elevation DUAL CAPACITY: NO: No Dual Capacity system installed...
  • Page 188 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings 450AJ 450AJ Function Cutout Model Number Market Engine Ground Alarm Flywheel Teeth Glow Plug Drive Type Starter Lockout Display Units Engine Shutdown Leveling Mode Clearsky Fuel Cutout...

  • Page 189: Machine Model Adjustment

    SECTION 6 - JLG CONTROL SYSTEM 6.2 MACHINE MODEL ADJUSTMENT DRIVE (ABOVE ELEVATION) 1. Test should be done on a smooth, Adjustment Notes level surface. The Drive Select Switch should be in the "Max 1. Personality settings can be adjusted anywhere within Speed"...
  • Page 190 SECTION 6 - JLG CONTROL SYSTEM SWING MAIN LIFT 1. Boom at full elevation, Telescope retracted. Swing Right 1. Main Lift in stowed position, Telescope Retracted. until over rear axle or end stop (if equipped). 2. Main Lift Up, record time. 2.
  • Page 191 SECTION 6 - JLG CONTROL SYSTEM JIB LIFT PLATFORM ROTATE 1. Platform level and centered with the boom. Jib Lift 1. Platform level, Rotate Platform Right until stop Down until stop. 2. Platform Left, record time. 2. Jib Lift Up, record time. 3.
  • Page 192 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Model Adjustment Speeds MODEL TIME RANGES 450AJ / 520AJ (IN SECONDS) ADJUSTMENT FUNCTION MODEL RANGES DEFAULTS 450AJ 520AJ DRIVE Accel 25 – 2000mA/s 275 mA/s Decel 25 – 2000mA/s 800 mA/s 250 –...
  • Page 193 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Model Adjustment Speeds MODEL TIME RANGES 450AJ / 520AJ (IN SECONDS) ADJUSTMENT FUNCTION MODEL RANGES DEFAULTS 450AJ 520AJ Soft Down 250 – 1400mA 450 mA Soft Down 250 – 1400mA 450 mA TELECOPE Accel 0 –...
  • Page 194 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Model Adjustment Speeds MODEL TIME RANGES 450AJ / 520AJ (IN SECONDS) ADJUSTMENT FUNCTION MODEL RANGES DEFAULTS 450AJ 520AJ SWING Left 250 – 1400mA 995 mA Right 250 – 1400mA 995 mA TOWER LIFT 250 –...
  • Page 195 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 196 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 197 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 198 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 199 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 200 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 201 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 202 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 203 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 204 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 205 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 206 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 207 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 208 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 209 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 210 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 211 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 212 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 213 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 214 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 215 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 216 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 217 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 218 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 219 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 220 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 221 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 222 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 223 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Diagnostic Trouble Code Chart Fault Condition/Trigger Required Control (For configurable items, fault applies only if Conditions Required for Movement Help Message Response or State configured. All listed conditions to be met unless and/or to Clear Fault Assignment stated otherwise)
  • Page 224 SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-68 – JLG Lift – 3121659...

  • Page 225: Basic Electrical Information & Electrical Schematics

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS GENERAL that the leads are connected to the device under test correctly. Also check that the lead on the "COM" port goes to the Ground This section contains basic electrical information and sche- or negative side of the signal and the lead on the other port matics to be used for locating and correcting most of the oper-...

  • Page 226: Resistance Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Resistance Measurement Continuity Measurement Figure 7-3. Continuity Measurement • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing conti- Figure 7-2.

  • Page 227: Current Measurement

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Current Measurement APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS NOTE: This section is not applicable for battery terminals. JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- RIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connec- tions: •...

  • Page 228: Installation Of Dielectric Grease

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

  • Page 229: Amp Mate-N-Lok

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS DIN Connectors This connector is typically used on hydraulic valves. Follow the installation instructions. Figure 7-6. Use of Seal Plugs Exclusions AMP Mate-N-Lok A limited number of connectors do not benefit from dielectric grease, or may be permanently damaged by application.
  • Page 230 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER The connector uses gold contact material to resist corrosion This type of connector uses back-seals for moisture integrity. and an o-ring seal for moisture integrity. If dielectric grease is However, the low-force contacts cannot displace dielectric mistakenly applied to this connector system, the low-force grease and create electrical contact.

  • Page 231: Amp Connector

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 7-9.). Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-7.).
  • Page 232 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL 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 233: Disassembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-12. Connector Disassembly Disassembly Service - Voltage Reading 1. Insert a 4.8 mm (3/16") wide screwdriver blade between the mating seal and one of the red wedge lock tabs. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. 2.
  • Page 234 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-13. Connector Installation 7-10 – JLG Lift – 3121659...

  • Page 235: Deutsch Connectors

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly DT/DTP Series Assembly Figure 7-15. DT/DTP Contact Removal Figure 7-14. DT/DTP Contact Installation 1. Remove wedgelock using needlenose pliers or a hook 1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.

  • Page 236: Hd30/Hdp20 Series Assembly

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL 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 crimp 1. With rear insert toward you, snap appropriate size barrel.

  • Page 237: Wiring Harness Connector Labels

    SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7.6 WIRING HARNESS CONNECTOR LABELS Table 7-1. Wiring Harness Connector Labels Component Category Label Connector Labels Audible Alarms Connectors between harnesses are identified by the prefix "X" Horns and a sequentially assigned number. An optional suffix (letters Battery Batteries &...
  • Page 238 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Table 7-1. Wiring Harness Connector Labels Component Category Label Other Switches Disconnect Foot HVAC Park brake Pump pot Push Shifter Turn signal Relay 5 Pin 4 Pin Contactor Power module Rocker Switch Sensor Angle Fuel...
  • Page 239 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-20. Electrical Installation - Sheet 1 of 10 3121659 – JLG Lift – 7-15...
  • Page 240 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-21. Electrical Installation - Sheet 2 of 10 7-16 – JLG Lift – 3121659...
  • Page 241 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-22. Electrical Installation - Sheet 3 of 10 3121659 – JLG Lift – 7-17...
  • Page 242 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-23. Electrical Installation - Sheet 4 of 10 7-18 – JLG Lift – 3121659...
  • Page 243 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-24. Electrical Installation - Sheet 5 of 10 3121659 – JLG Lift – 7-19...
  • Page 244 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-25. Electrical Installation - Sheet 6 of 10 7-20 – JLG Lift – 3121659...
  • Page 245 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-26. Electrical Installation - Sheet 7 of 10 3121659 – JLG Lift – 7-21...
  • Page 246 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-27. Electrical Installation - Sheet 8 of 10 7-22 – JLG Lift – 3121659...
  • Page 247 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-28. Electrical Installation - Sheet 9 of 10 3121659 – JLG Lift – 7-23...
  • Page 248 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-29. Electrical Installation - Sheet 10 of 10 7-24 – JLG Lift – 3121659...
  • Page 249 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-25...
  • Page 250 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-31. Platform Console Harness - Sheet 2 of 9 7-26 – JLG Lift – 3121659...
  • Page 251 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-32. Platform Console Harness - Sheet 3 of 9 3121659 – JLG Lift – 7-27...
  • Page 252 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-28 – JLG Lift – 3121659...
  • Page 253 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-34. Platform Console Harness - Sheet 5 of 9 3121659 – JLG Lift – 7-29...
  • Page 254 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-30 – JLG Lift – 3121659...
  • Page 255 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-36. Platform Console Harness - Sheet 7 of 9 3121659 – JLG Lift – 7-31...
  • Page 256 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-37. Platform Console Harness - Sheet 8 of 9 7-32 – JLG Lift – 3121659...
  • Page 257 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-33...
  • Page 258 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-39. Platform Valve Harness - Sheet 1 of 2 7-34 – JLG Lift – 3121659...
  • Page 259 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-35...
  • Page 260 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-36 – JLG Lift – 3121659...
  • Page 261 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-37...
  • Page 262 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-38 – JLG Lift – 3121659...
  • Page 263 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-39...
  • Page 264 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-40 – JLG Lift – 3121659...
  • Page 265 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-41...
  • Page 266 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-47. Turntable Harness - Sheet 3 of 14 7-42 – JLG Lift – 3121659...
  • Page 267 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-43...
  • Page 268 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-49. Turntable Harness - Sheet 5 of 14 7-44 – JLG Lift – 3121659...
  • Page 269 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-50. Turntable Harness - Sheet 6 of 14 3121659 – JLG Lift – 7-45...
  • Page 270 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-51. Turntable Harness - Sheet 7 of 14 7-46 – JLG Lift – 3121659...
  • Page 271 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-47...
  • Page 272 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-53. Turntable Harness - Sheet 9 of 14 7-48 – JLG Lift – 3121659...
  • Page 273 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-54. Turntable Harness - Sheet 10 of 14 3121659 – JLG Lift – 7-49...
  • Page 274 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-50 – JLG Lift – 3121659...
  • Page 275 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-56. Turntable Harness - Sheet 12 of 14 3121659 – JLG Lift – 7-51...
  • Page 276 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-57. Turntable Harness - Sheet 13 of 14 7-52 – JLG Lift – 3121659...
  • Page 277 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-53...
  • Page 278 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-54 – JLG Lift – 3121659...
  • Page 279 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-60. Chassis Solenoid Harness - Sheet 2 of 3 3121659 – JLG Lift – 7-55...
  • Page 280 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-56 – JLG Lift – 3121659...
  • Page 281 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-57...
  • Page 282 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-63. Main Valve Harness - Sheet 2 of 8 7-58 – JLG Lift – 3121659...
  • Page 283 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-64. Main Valve Harness - Sheet 3 of 8 3121659 – JLG Lift – 7-59...
  • Page 284 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-65. Main Valve Harness - Sheet 4 of 8 7-60 – JLG Lift – 3121659...
  • Page 285 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-61...
  • Page 286 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-67. Main Valve Harness - Sheet 6 of 8 7-62 – JLG Lift – 3121659...
  • Page 287 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-68. Main Valve Harness - Sheet 7 of 8 3121659 – JLG Lift – 7-63...
  • Page 288 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-69. Main Valve Harness - Sheet 8 of 8 7-64 – JLG Lift – 3121659...
  • Page 289 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-65...
  • Page 290 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-66 – JLG Lift – 3121659...
  • Page 291 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-72. Tower Upright Valve Harness - Sheet 3 of 7 3121659 – JLG Lift – 7-67...
  • Page 292 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-68 – JLG Lift – 3121659...
  • Page 293 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-74. Tower Upright Valve Harness - Sheet 5 of 7 3121659 – JLG Lift – 7-69...
  • Page 294 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-70 – JLG Lift – 3121659...
  • Page 295 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-76. Tower Upright Valve Harness - Sheet 7 of 7 3121659 – JLG Lift – 7-71...
  • Page 296 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-72 – JLG Lift – 3121659...
  • Page 297 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-73...
  • Page 298 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-79. Ground Control Panel Harness - Sheet 3 of 6 7-74 – JLG Lift – 3121659...
  • Page 299 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-75...
  • Page 300 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-81. Ground Control Panel Harness - Sheet 5 of 6 7-76 – JLG Lift – 3121659...
  • Page 301 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-82. Ground Control Panel Harness - Sheet 6 of 6 3121659 – JLG Lift – 7-77...
  • Page 302 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-78 – JLG Lift – 3121659...
  • Page 303 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-84. Deutz 2.9 Harness - Sheet 2 of 12 3121659 – JLG Lift – 7-79...
  • Page 304 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-85. Deutz 2.9 Harness - Sheet 3 of 12 7-80 – JLG Lift – 3121659...
  • Page 305 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-81...
  • Page 306 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-87. Deutz 2.9 Harness - Sheet 5 of 12 7-82 – JLG Lift – 3121659...
  • Page 307 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-88. Deutz 2.9 Harness - Sheet 6 of 12 3121659 – JLG Lift – 7-83...
  • Page 308 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-89. Deutz 2.9 Harness - Sheet 7 of 12 7-84 – JLG Lift – 3121659...
  • Page 309 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-90. Deutz 2.9 Harness - Sheet 8 of 12 3121659 – JLG Lift – 7-85...
  • Page 310 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-91. Deutz 2.9 Harness - Sheet 9 of 12 7-86 – JLG Lift – 3121659...
  • Page 311 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-92. Deutz 2.9 Harness - Sheet 10 of 12 3121659 – JLG Lift – 7-87...
  • Page 312 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-93. Deutz 2.9 Harness - Sheet 11 of 12 7-88 – JLG Lift – 3121659...
  • Page 313 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-89...
  • Page 314 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-90 – JLG Lift – 3121659...
  • Page 315 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-91...
  • Page 316 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-97. GM Engine Harness - Sheet 3 of 3 7-92 – JLG Lift – 3121659...
  • Page 317 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-93...
  • Page 318 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 7-94 – JLG Lift – 3121659...
  • Page 319 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-100. Chassis Head and Tail Lights Harness - Sheet 3 of 5 3121659 – JLG Lift – 7-95...
  • Page 320 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-101. Chassis Head and Tail Lights Harness - Sheet 4 of 5 7-96 – JLG Lift – 3121659...
  • Page 321 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 3121659 – JLG Lift – 7-97...
  • Page 322 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS This page left blank intentionally 7-98 – JLG Lift – 3121659...
  • Page 323 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS S HE E T 2: P LATFO RM CO NS O LE B O X HA RNE S S S HE E T 3: P LATFO RM A ND B O O M CO M P O NE NTS P LATFO RM VA LV E HA RNE S S B O O M LO W E R - S TA NDA RD, A RCTIC B O O M UP P E R - S TA NDA RD, A RCTIC, 520A J...
  • Page 324 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS P U M P P O T S O FT TC H / S K Y G U A R D H O R N O V E R R I D E S W174 C O 01- J1 WH T 1- 91 S T S WI TC H...
  • Page 325 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001157930 C Figure 7-105. Electrical Schematic - Sheet 3 of 17 3121659 – JLG Lift – 7-101...
  • Page 326 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-106. Electrical Schematic - Sheet 4 of 17 7-102 – JLG Lift – 3121659...
  • Page 327 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001157930 c Figure 7-107. Electrical Schematic - Sheet 5 of 17 3121659 – JLG Lift – 7-103...
  • Page 328 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-108. Electrical Schematic - Sheet 6 of 17 7-104 – JLG Lift – 3121659...
  • Page 329 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001157930 C Figure 7-109. Electrical Schematic - Sheet 7 of 17 3121659 – JLG Lift – 7-105...
  • Page 330 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-110. Electrical Schematic - Sheet 8 of 17 7-106 – JLG Lift – 3121659...
  • Page 331 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001157930 C Figure 7-111. Electrical Schematic - Sheet 9 of 17 3121659 – JLG Lift – 7-107...
  • Page 332 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-112. Electrical Schematic - Sheet 10 of 17 7-108 – JLG Lift – 3121659...
  • Page 333 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001157930 C Figure 7-113. Electrical Schematic - Sheet 11 of 17 3121659 – JLG Lift – 7-109...
  • Page 334 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-114. Electrical Schematic - Sheet 12 of 17 7-110 – JLG Lift – 3121659...
  • Page 335 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001157930 C Figure 7-115. Electrical Schematic - Sheet 13 of 17 3121659 – JLG Lift – 7-111...
  • Page 336 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-116. Electrical Schematic - Sheet 14 of 17 7-112 – JLG Lift – 3121659...
  • Page 337 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS 1001157930 C Figure 7-117. Electrical Schematic - Sheet 15 of 17 3121659 – JLG Lift – 7-113...
  • Page 338 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS Figure 7-118. Electrical Schematic - Sheet 16 of 17 7-114 – JLG Lift – 3121659...
  • Page 339 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS SHEET 9 1001157930 c Figure 7-119. Electrical Schematic - Sheet 17 of 17 3121659 – JLG Lift – 7-115...
  • Page 340 SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS NOTES: 7-116 – JLG Lift – 3121659...
  • Page 342 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161(Corporate) (800) 554-5438(Service) (717) 485-6417 JLG Worldwide Locations JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin) 358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Equipment Technology LTD Regents Park Breitwaterstraat 12A...

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