Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be discon- nected with minimal fluid loss. 3121202 – JLG Lift –...
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Original Issue - October 15, 2004 Revised - May 23, 2005 Revised - October 11, 2005 Revised - March 2, 2006 Revised - March 12, 2008 Revised - November 20, 2012 Revised - February 26, 2014 – JLG Lift – 3121202...
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Welding on JLG Equipment ............2-5 Do the Following When Welding on JLG Equipment ......2-5 Do NOT Do the Following When Welding on JLG Equipment .
4.5 MPH (7.25 Km/hr.) Machine Length (Stowed) 4 MPH (6.44 Km/hr.) 600S Over Drive Axle 27 ft. 11.125 in. (8.51 m) 600SJ Over Drive Axle 32 ft. 11.75 in. (10.05 m) Gradeability 660SJ Over Drive Axle 35 ft. 2.875 in. (11.40 m)
Start with the Jib down. Jib Up, Record Time. Jib Reverse 58-68 Down, Record Time. Drive Above Horizontal - Forward & Reverse 46-54 (4WD) *Max 10% Difference Between Left & Right **Max 15% Difference Between Left & Right 4150501 - B – JLG Lift – 3121202...
NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C Above +32°F. (+0°C.) or have properties of API classification CC/CD Above +50°F. (+10°C.) grades. Multi-Viscosity Oil. (SF, SF-SE, SF-CC, SF-CD) *Not recommended for severe service, including high RPM operation 3121202 – JLG Lift –...
152. Aside from JLG recommendations, it is not advisable to NOTE: When temperatures remain below 20° F (-7° C), JLG mix oils of different brands or types, as they may not con- Industries recommends the use of Mobil DTE 13M.
Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/ MIL-L-2104C. Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Remote Access 3121202 – JLG Lift –...
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2 years or 1200 hours of operation 6. Hydraulic Charge Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. 1-10 – JLG Lift – 3121202...
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11. Oil Change w/Filter - Caterpillar Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10.6 Quarts Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accor- dance with engine manual. 3121202 – JLG Lift – 1-11...
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Lube Point(s) - Replaceable Element Interval - Every Year or 1200 hours of operation Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 1-12 – JLG Lift – 3121202...
5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Propane Fuel Fil- ter Replacement 3121202 – JLG Lift – 1-13...
6. Remove the filter from the housing. 7. Remove and discard the housing seal. 8. Remove and discard the retaining bolt seal. 9. Remove and discard mounting plate to lock off O- ring seal. 1-14 – JLG Lift – 3121202...
A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame. Figure 1-3. Serial Number Locations 3121202 – JLG Lift – 1-15...
(13) months from the maintenance have been completed before placing the date of the prior Annual Machine Inspection. JLG Indus- machine into service. tries recommends this task be performed by a Factory- Trained Service Technician.
Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance tion rental delivery. Mechanic Manual and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, Owner, Dealer, or User Qualified JLG Service and Maintenance whichever comes first;...
If a bolt is too short, tion) lines. there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 3121202 – JLG Lift –...
(if equipped) slightly elevated, main boom fully extended with the rated load in the platform and power off. Maximum allowable drift is 2 inches (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following. – JLG Lift – 3121202...
The cylinder must have the normal load, which is the nor- mal platform load applied. Do the Following When Welding on JLG Equipment If the cylinder passes this test, it is acceptable. NOTE: This information is based on 6 drops per minute cyl- •...
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7,11 7,11 Hydraulic Fluid Electrical Connections 5,23 Instruments, Gauges, Switches, Lights, Horn General Operators and Safety Manuals in Storage Box ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible 3121202 – JLG Lift –...
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21, 22 Function Test of All Systems Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to use each day; or at each Operator change Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...
The air pressure for pneumatic tires must be equal to the The rims installed on each product model have been air pressure that is stenciled on the side of the JLG prod- designed for stability requirements which consist of track uct or rim decal for safe and proper operational character- width, tire pressure, and load capacity.
If a leak is detected in a seal, o- ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi for 20 minutes. THE BRAKE TEST – JLG Lift – 3121202...
4. Remove the Cover Subassembly (6) from the unit. ing bolts. The unit can be carefully pressurized with air to pop 4. Now use a torque wrench to apply the specified the cover out of the unit. torque to bolt "A". 3121202 – JLG Lift –...
Input Shaft (9) will need to be removed together. sembling the unit. 9. Loosen and remove the three Flat Head Bolts (19) that retain the Ring Gear (1E) to the Housing (1G). 10. Lift the Ring Gear (1E) off of the Housing (1D). 3121202 – JLG Lift –...
(3B) out of the Carrier (3A). 5. Remove the 14 needle Bearings (3C) from the bore of the Planet Gear (3F). 6. Repeat steps 1 through 5 for each of the two remain- ing planet gears. 3121202 – JLG Lift –...
4. While supporting the unit on Hub (1D) flange, press (1C) out of Hub (1D). Spindle (1A) out of Hub (1D). 5. Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q) from Hub (1D) if applicable. – JLG Lift – 3121202...
Retaining Ring (8C). NOTE: Flat Head Cap Screws (22) are removed prior to shipping new units since they are for transit and ser- vice only. They are included in most brake repair kits. 3-10 – JLG Lift – 3121202...
6. Remove two O-Ring Pipe Plugs (6F) from Cover (6A). 3. Unscrew two Hex Head Bolts (6C) and remove Dis- engage Cap (6B) from Cover (6A). 4. Pull Disengage Rod (6D) out from Cover (6A). 3121202 – JLG Lift – 3-11...
Piston (8A). Make sure the O-Ring is seated on the bottom of the groove. NOTE: Some grease may need to be applied to the Thrust Washers (3B) to hold them in place while installing the planet gears. 3-12 – JLG Lift – 3121202...
6. Set Spindle assembly (1A) on the bench with the flange down. Turn Hub (1D) over and lower onto Spindle (5). Install boot (21) if applicable. 3121202 – JLG Lift – 3-13...
9. Place Input Carrier Sub-Assembly (3A) onto Output Sun Gear (11) splines. Drop Input Sun (10) into mesh with planet gears for specific ratios, if required. (No timing required). 10. Grease O-Ring (17) and insert into groove in Cover Sub-Assembly (6). 3-14 – JLG Lift – 3121202...
To avoid damaging the shaft during removal, install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal. 4. Discard the seal. 3121202 – JLG Lift – 3-19...
Clean or motor. The smaller the orifice, the longer the time it takes to properly installed, and are replace as necessary. shift the motor. Obstruction will also increase shift times. not obstructed. 3121202 – JLG Lift – 3-21...
11. Using a 5/16 inch internal hex wrench, remove drain plugs (19, 20). Discard O-rings. 12. Using a 9/16 inch internal hex wrench, remove work port plugs (21, if equipped with axial ports). Discard O-rings. 3-22 – JLG Lift – 3121202...
The grease will force the bearing out. Use caution not to drive the bearing past the rear shaft journal as the bearing may become trapped on the shaft and damaged. 3121202 – JLG Lift – 3-23...
22. Remove the snap-ring (36) retaining the shaft front bearing. Pull the bearing (37) off of the shaft (38). 32. Snap Ring 33. Support Washer 34. Shaft Seal Figure 3-24. Shaft Seal 3-24 – JLG Lift – 3121202...
A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON- ABLE EFFOR T. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED. 3121202 – JLG Lift – 3-25...
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Measure the swashplate thickness from sealing surfaces. the journals to the running face. Replace swashplate if damaged or worn beyond minimum specification. 3121202 – JLG Lift – 3-27...
ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS INSTALLED. 3. Install the inner block spring washer (4), block spring (5), and outer washer (6) into the cylinder 3-28 – JLG Lift – 3121202...
If you're reusing the pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder kit aside on a clean sur- face until needed. 3121202 – JLG Lift – 3-29...
Install the install shaft/bearing assembly into housing from the flange end. Install the snap-ring (18). 20. Servo Spring 21. Minimum Angle Stop Figure 3-33. Servo Spring and Minimum Angle Stop 3-30 – JLG Lift – 3121202...
Apply a liberal coat of assembly check the unit. grease to the endcap side of the valve plate to keep it in place during installation. 3121202 – JLG Lift – 3-31...
9. Shut down the prime mover and remove the pres- sure gauge. Replace plug at the charge pressure gauge port. 10. Check the fluid level in the reservoir; add clean fil- tered fluid if necessary. The motor is now ready for operation. 3121202 – JLG Lift – 3-33...
5. Carefully activate SWING control lever and position boom over right side of machine. 6. With boom over right side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp. 3-34 – JLG Lift – 3121202...
#2 to contact axle. (2WS/2WD) Spindles do not stop on cylinder stroke. Adjust steer- ing stops as follows: Adjust item #1 to achieve 39° inside turn angles. Steer full left and adjust RH item 3121202 – JLG Lift – 3-35...
6. Lift out the internal gear (2) and thrust washer (11). 13. The needle rollers (3C) and spacer (3D) are now The thrust washer (11) may stick to the under side of the carrier (3). removed from the cluster gear (3F). 3-36 – JLG Lift – 3121202...
(3F) and locate at 12 0’clock (straight-up) from each planet pin. Marked tooth will be located just under the car- rier (3A) on upper two gears (3F). 3121202 – JLG Lift – 3-37...
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NOTE: If gears do not mesh easily or carrier assembly does not rotate freely, then remove the carrier and ring gear and check the cluster gear timing. 11. Place O-ring (5) into cover (6) counterbore. Use petroleum jelly to hold O-ring in place. 3-38 – JLG Lift – 3121202...
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EP 90 lubricant before operation if the unit is mounted horizontally, and completely filled if mounted vertically. In vertical mounting application case oil circula- tion is recommended. 13. Install regular grade 8 bolts (12) into remaining holes. 3121202 – JLG Lift – 3-39...
3. Invert hub (1G) and press bearing cup (1E) into inter counterbore of hub (1G). 6. The bearing cone (1F) is an interference fit and has to be pressed or tapped on. 3-40 – JLG Lift – 3121202...
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EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. This completes the hub shaft sub-assembly —items (1A) through (1J). If this assembly is not going to be used right away, it should be oiled and covered to help prevent rust- ing, 3121202 – JLG Lift – 3-41...
NOTE: Some old style carriers will not have slots and tangs should be located inside boss relief. 3. Place spacer washer into opposite side of cluster gear and against needle rollers. 3-42 – JLG Lift – 3121202...
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7. Line up cluster gear and thrust washer with hole in carrier and slide planet shaft through. Line up cham- fered side of hole in planet shaft with pin hole in car- rier. 3121202 – JLG Lift – 3-43...
Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bear- ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter.
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING. JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN b.
Sequence, tighten the bolts to a torque of 190 ft. lbs. (258 Nm) w/Loctite. i. Remove the lifting equipment. j. Install the rotary coupling retaining yoke brack- ets, apply a light coating of Loctite #242 to the 3-48 – JLG Lift – 3121202...
3. Discard seals and o-rings. 4. Closely inspect bearings and bearing contact sur- faces. Replace as necessary. NOTE: Bearings may be reused if, after thorough inspection, they are found to be in good condition. 3121202 – JLG Lift – 3-49...
8. Heat cap seals (17) in hydraulic oil for 5 minutes at 300° F (149° C). 9. Assemble cap seals over O-rings 10. Reinsert center body into housing (lube with hydrau- lic oil). 11. Replace thrust ring and snap ring. 3121202 – JLG Lift – 3-51...
250 (17) 375 (26) Steer 2500 (172) 3750 (259) Steer 2500 (172) 3750 (259) Every 500 hours of service, blow out the inside of the gen- erator. If operating in a hostile environment, clean monthly. 3-56 – JLG Lift – 3121202...
Clean the rings with 220 grit emery paper. Remove as little material as possible. If the rings are deeply pitted and do not clean up, consult generator factory service. Reinstall the belt, brush holder assembly, and end panel. 3121202 – JLG Lift – 3-57...
If no matching symptom is available, analyze the com- If the glow plug option is enabled in the JLG Control Sys- plaint and develop a plan for diagnostics utilizing the wir- tem, the glow plug and indicator lamp will be energized ing diagrams, technical assistance, and repair history.
• Inspect intake air system and air filter for restrictions. • Inspect battery condition and starter current draw. If no evidence of a problem is found after visual/physical engine check has been performed, proceed to MIL DTC retrieval procedure. 3-60 – JLG Lift – 3121202...
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If the ECM is replaced, the new ECM will need to be pro- grammed. An IBM-compatible computer and software containing the correct program and calibration for the application are required to program the ECM. 3121202 – JLG Lift – 3-61...
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• Engine vacuum level for engine control purposes. the ground or the power feed circuit through transistors or • Barometric pressure (BARO) other solid state devices. 3121202 – JLG Lift – 3-63...
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ECM circuit and result in component damage. For volt- apply voltage to any of the ECM/EPM's circuits unless age measurements, use only a digital voltmeter with an instructed to do so. input impedance of at least 10 megohms. 3-64 – JLG Lift – 3121202...
The fuel is injected under pressure in a conical spray pat- tern at the opening of the intake valve. Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank. 3121202 – JLG Lift – 3-65...
1 part of gasoline by weight, which provides the most efficient combustion. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injec- tion system is called a "closed loop" system. 3-66 – JLG Lift – 3121202...
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(MAP) with throttle position. When the ECM/EPM detects a change in engine load, it can adjust idle speed by changing the PWM signal to the governor. 3121202 – JLG Lift – 3-67...
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• Remote mounting capability ter on the power stroke. • No mechanical load on the engine • More coil cooldown time between firing events • Elimination of mechanical timing adjustments • Increased available ignition coil saturation time 3-68 – JLG Lift – 3121202...
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• Intake air temperature (IAT) sensor The primary coils in the coil pack are triggered by the • Throttle position sensor "Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals from the ECM/EPM. • Crankshaft position sensor 3121202 – JLG Lift – 3-69...
O depending on the speed and load of the engine. The megajector must be mounted per the 2.5L 2004 Emission Installation Instructions. Torque mounting bolts to a maxi- mum of 60 in.lbs. (7 Nm). 3-70 – JLG Lift – 3121202...
-4.00 inches (10.1 cm) of Control System senses a fault dealing with the megajec- tor. Refer to Section 6 - JLG Control System for more infor- a. Fuel Supply - Check fuel supply pressure at the mation concerning the Control System.
Megajector - Megajector has an internal failure. BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO Contact JLG Industries for further assistance. LP GAS. DTC 364 - Megajector Internal Circuitry Fault Detection. 3. While the engine is operating, place the three posi- a.
(Limp home) functions. The EMR2 consists of the sensors, the control unit and the actuator. Engine-side controls as well as the JLG Control In order to switch the engine off, the EMR2 is switched in a System are connected by means of separate cable har- de-energized fashion over the ignition switch.
SENSOR JLG SYSTEM HANDLES ENGINE START/ STOP; EMR2 TAKES CONTROL OF THE ENGINE AT 700RPM GLOW PLUG JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS DIAGNOSIS INTERFACE/CAN-BUS; JLG SYS- TEM USES THIS TO CONTROL THE ENGINE & OIL PRESSURE FAULT REPORTING.
EN 590 and ASTM D 975. No emission values are guaranteed with the other fuels described. It is the obligation of the owner to check the permission for use of the fuels in accordance with regional regulations. 3-94 – JLG Lift – 3121202...
The use of fuel additives is not permitted. The flow improv- of various manufacturers is not allowed and leads to loss ers mentioned above are an exception. Use of unsuitable of warranty rights. additives will result in loss of warranty. 3121202 – JLG Lift – 3-95...
• Check the entire engine wire harness for rubbing chaf- ing, cuts or damaged connections, repair if necessary Figure 3-74. Engine Oil Dip Stick • Check all wire harness connectors to insure they are fully seated and locked 3-96 – JLG Lift – 3121202...
8. Start the engine and check for oil leaks. 9. Stop the engine and check the oil level to insure the oil level is at "FULL". 10. Dispose of the oil and filter in a safe manner. 3121202 – JLG Lift – 3-97...
170° F (77° C), which can be checked switch in the operator's platform. When the operator using the JLG handheld analyzer. places the selector switch in the gasoline mode the gaso- line fuel pump is energized. While in the gasoline mode the LPG fuel lock-off is isolated and will not energize.
SIONS CONTROL DEVICE AND CANNOT BE REBUILT. IF THE COIL ASSEMBLY FAILS TO OPERATE PROPERLY, REPLACE IT WITH AN OEM REPLACEMENT PART ONLY. Figure 3-78. Air Fuel Mixer Figure 3-77. Low Pressure Regulators 3-100 – JLG Lift – 3121202...
The primary components of the Gasoline Multi Point Fuel Injection (MPFI) fuel system are the fuel tank, electric fuel Figure 3-83. Gasoline Fuel Pressure and Temperature pump, fuel pressure and temperature sensor manifold, Manifold Assembly fuel filter and fuel rail. 3-102 – JLG Lift – 3121202...
Use a commercially available liquid leak detector or an electronic leak detec- tor. When using both methods, use the electronic leak detector first to avoid contamination by the liquid leak detector. 3121202 – JLG Lift – 3-103...
NOTE: Residual vapor pressure will be present in the fuel 1. Install the mounting plate to lock off O-ring seal. system. 2. Install the retaining bolt seal. 4.Disconnect the electrical connector to the Electric Lock 3. Install the housing seal. off. 3-104 – JLG Lift – 3121202...
6. Install the electric lock off into the regulator inlet and tighten into proper location, connect the electrical connector. 7. Connect the fuel supply line and tighten until fully seated. 3121202 – JLG Lift – 3-105...
NOTE: Apply a small amount of O-ring lubricant before installation. 1. Install in the TMAP . 2. Tighten retaining bolts to 62 lb-in (7 Nm). 3. Start the vehicle and check for proper operation. 3-106 – JLG Lift – 3121202...
4. Unplug controller and remove. INSTALLATION INSTALLATION NOTE: Use hose material and lengths specified by JLG. 1. Install the hose clamps to each hose and set the clamp back on each hose to make installation eas- THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY ier.
This vacuum signal is most commonly referred to as air valve vacuum. In the mixer, the fuel mixes with the air entering the engine. This air/ fuel mixture is then drawn into the engine for combustion. 3121202 – JLG Lift – 3-109...
(LPR). 2. Crank the engine and observe the pressure reading for the LPR primary 1- 3 PSI Go to Step 22 Go to Step 13 pressure. Is the fuel pressure ABOVE the specified value? 3-110 – JLG Lift – 3121202...
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Is the action complete? Replace the lock-off. Refer to Lock-off Replacement. Go to Step 26 Is the action complete? Replace the mixer assembly. Refer to Fuel Mixer Replacement. Go to Step 26 Is the action complete? 3121202 – JLG Lift – 3-111...
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1. Disconnect all test equipment 2. Install the primary and secondary test port plugs. 3. Start the engine. System OK 4. Using SNOOP or equivalent, leak check the test port plugs. Is the action complete? 3-112 – JLG Lift – 3121202...
If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the Operational Test problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit. 3121202 – JLG Lift – 3-113...
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- Improper valve timing Engine Mechanical Checks - Low compression - Bent pushrods - Worn rocker arms - Broken or weak valve springs - Worn camshaft lobes. ² Check the intake and exhaust manifolds for casting flash. 3121202 – JLG Lift – 3-115...
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² A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present. ² If the problem exists, check the routing of the secondary wires and the ground circuit. 3-116 – JLG Lift – 3121202...
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Sticking or leaking valves Exhaust system leakage ² Check the intake and exhaust system for casting flash or other restrictions. Fuel System Checks ² Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis. 3121202 – JLG Lift – 3-117...
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² Suggest that a different operator use the equipment and record the results. ² Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis. Fuel System Checks ² Check the fuel system for leakage. Sensor Checks ² Check the Temperature Manifold Absolute Pressure (TMAP) sensor. 3-118 – JLG Lift – 3121202...
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²Check the ECM grounds for being clean, tight, and in their proper locations. ²Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed resulting in poor idle quality. 3121202 – JLG Lift – 3-119...
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² Check the ECM grounds for being clean, tight, and in their proper locations. ² Check the generator output voltage. Additional Check ² Check the vacuum hoses for kinks or leaks. ² Check Transmission 3-120 – JLG Lift – 3121202...
When adding shims, longer bolts must be used to ensure proper thread engagement in insert. b. When shims are removed, shorter bolts must be used so bolt does not protrude from insert and come into contact with boom surface. – JLG Lift – 3121202...
6. Ropes with 6 total broken wires in one rope lay, 3 in one strand in one rope lay, 1 valley break, or 1 break f. Tag and disconnect hydraulic lines to the slave at any end termination. leveling cylinder. Use a suitable container to 3121202 – JLG Lift –...
Using a suitable brass drift and hammer, remove e. Using a suitable lifting equipment, adequately the master cylinder pin from the base boom. support powertrack weight along entire length. f. Remove bolts #1 securing the push tube on the fly boom section. – JLG Lift – 3121202...
8. Pull the telescope cylinder and wire ropes partially from aft end of the base boom section; secure the cylinder with a suitable sling and lifting device at approximately the center of gravity. 3121202 – JLG Lift –...
Remove hardware from the wear pads; remove wear pads from cylinder. b. Remove hardware from the wire rope guard; remove guard from cylinder. Figure 4-11. Disassembly of Sheave Assembly – JLG Lift – 3121202...
NOTE: When inspecting pins and bearings Refer to the guidelines established in Section 2 - General. 1. Inspect all sheaves (extend and retract wire ropes and telescope cylinder) for excessive groove wear, burrs or other damage. Replace sheaves as neces- sary. 3121202 – JLG Lift –...
4. Inspect telescope cylinder sheave pin for scoring, tapering and ovality. Replace pins as necessary. 5. Inspect boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as nec- essary. 4-10 – JLG Lift – 3121202...
SLIDING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS, TOOLS, AND OTHER OBSTRUCTIONS. 6. Shim the insides of the boom sections for a total of 1/16 inch (0.062) clearance (if the action is centered, there will be 1/32 clearance on each side). 3121202 – JLG Lift – 4-11...
SLOWLY INTO POSITION. DAMAGE TO COMPONENTS MAY 15. Align the telescope cylinder barrel-to-sheave attach- ment point. Install extend sheave pin through the RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES. Figure 4-16. Installing the Proximity Switch 3121202 – JLG Lift – 4-13...
7. Connect all hydraulic lines running along side of through the powertrack rail, powertrack and boom assembly. push tube. Tighten or install all clamping or securing apparatus to the hoses or cables, as necessary. 4-14 – JLG Lift – 3121202...
Components - Articulating Jib Boom. ments. 1. JLG recommends the use of the JLG Hostile Envi- 1. Align lift cylinder with attach holes in articulating jib ronment Package to keep the internal portions of a boom.
2. Install new seal (8), thrust ring (10) and bearing (9) on shaft (2). NOTE: Apply a coat of grease to the thrust ring before slid- ing onto the end cap. 3121202 – JLG Lift – 4-21...
The shaft is supported radially by the large upper radial bearing and the lower radial bearing. Axially, the shaft is separated from the housing by the upper and lower thrust 4-22 – JLG Lift – 3121202...
(4) by turning it counter clockwise. 16” (4.76mm). 3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). If the pin will not come out with the ”Easy Out”, use 4-26 – JLG Lift – 3121202...
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9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assem- bly. 3121202 – JLG Lift – 4-27...
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15. Remove the wear guides (302) from the end cap (4) 12. To remove the piston (3) use a rubber mallet and a and shaft (2). plastic mandrel so the piston is not damaged. 4-28 – JLG Lift – 3121202...
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17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2). 3121202 – JLG Lift – 4-29...
2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within specifications (Not less than 0.092” or 2.34 mm). 4-30 – JLG Lift – 3121202...
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(304). 6. Install the inner T-seal (200) into the piston (3) using a circular motion. Install the outer T-seal (202) by stretching it around the groove in a circular motion. 3121202 – JLG Lift – 4-31...
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(1) during disassembly line up as shown. Using Repeat this step for the outer seal (202). a rubber mallet, tap the piston into the housing up to the point where the gear teeth meet. 4-32 – JLG Lift – 3121202...
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13. Install the stop tube onto the shaft end. Stop tube is an available option to limit the rotation of an actua- tor. 3121202 – JLG Lift – 4-33...
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19. Insert the set screws (113) over the lock pins. it is threaded into the housing (1). Tighten them to 25 in. lbs. (2.825 Nm). 4-34 – JLG Lift – 3121202...
(15.8 Nm). Do not torque over 145 inch 2. Make sure the new valve has the O-rings in the pounds (16.3 Nm). counterbores of the valve to seal it to the actuator housing. Figure 4-32. Rotator Counterbalance Valve 3121202 – JLG Lift – 4-35...
1. Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the two bleed nipples. Secure them with hose clamps. Place the vinyl tubes in a clean 5-gallon container to 4-36 – JLG Lift – 3121202...
Operate the actuator through the housing ports. Conduct the internal leakage test as described in the Testing section on page 24 of this manual. c. Air in actuator c. Purge air from actuator. See bleeding proce- dures 3121202 – JLG Lift – 4-37...
After the initial discharge, there should be no further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the counterbalance valve is defective and must be replaced. 3121202 – JLG Lift –...
Note: Do not clamp on threads. Remove jam nuts and loosen adjustment nuts so there is slack in the cables. (See Section 4 - Boom & Platform). 6. Remove the hardware securing push bar to turnta- ble and telescope cylinder. – JLG Lift – 3121202...
Loosely install nuts and jam nuts 9. Remove cylinder port plugs and hydraulic line caps onto the threaded end of cables. and correctly attach lines to cylinder ports. Figure 5-1. Boom Positioning and Support, Cylinder Repair 3121202 – JLG Lift –...
5. Remove boom prop and overhead crane. Activate hydraulic system. 6. Using all applicable safety precautions, operate the boom functions. Check for correct operation and hydraulic leaks. Secure as necessary. – JLG Lift – 3121202...
Pull the ring out of the groove toward the wall mouth. Once one end of the retaining ring is free from the groove, the remainder can be easily pried free using ones fingers or pliers. 3121202 – JLG Lift –...
Repair as necessary. 7. Inspect threaded portion of piston for damage. 17. If applicable, inspect piston rings for cracks or other Dress threads as necessary. damage. Replace as necessary. – JLG Lift – 3121202...
NOTE: Prior to cylinder assembly, ensure that the proper groove. cylinder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly.
11. Assemble the tapered bushing loosely into the pis- one side. This side faces the solid seal.(See magni- ton and insert JLG capscrews (not vendor cap- fied insert in Figure 5-11.)The split of seals and screws) through the drilled holes in the bushing and backup rings are to be positioned so as not to be in into the tapped holes in the piston.
CYLINDER BARREL SURFACES. 18. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged. 3121202 – JLG Lift –...
TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING Articulating 50 ft. lbs. 9 ft. lbs. ROD. Master Cylinder (68 Nm) (12 Nm) Steer Cylinder Piston Nut Torque Specifications Steer Cylinder LBS. 150 ft. lbs 204 Nm 5-10 – JLG Lift – 3121202...
THE CYLINDER IF THE BLEEDER SCREW IS LOOSENED. 1. Barrel 4. Wear Ring 7. Bleeder 2. Rod 5. Wiper Ring 8. Cartridge Valve 3. Not Used 6. Rod Seal Figure 5-15. Axle Lockout Cylinder 3121202 – JLG Lift – 5-11...
23. Not Used 3. Piston 10. Locking Primer (Not Shown) 17. Back-Up Ring 24. Plug Fitting 4. Head 11. Seal 18. Rod Seal 5. Tapered Bushing 12. Lock Ring 19. Wiper Figure 5-19. Master Cylinder 3121202 – JLG Lift – 5-15...
Inspect for foreign material holding the poppet open, and for scoring or wear on the poppet and seat in the housing. Adjustments of the charge pressure is accomplished by changing the shim thickness behind the spring. 5-22 – JLG Lift – 3121202...
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5. Remove spacer, re-install orifices, gaskets, and cov- ers. Torque grade 5 bolts 8 to 11 ft.lbs. (10.8 to 14.9 Nm) and grade 8 bolts 11 to 13 ft.lbs. (14.9 to 17.8 Nm). 3121202 – JLG Lift – 5-23...
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7. Stop the engine. Connect the control input. Remove amount of rotation noted above. the servo pressure gauges. Return the machine to normal operating condition. Restart the engine and assure that the hydrostatic system is in neutral. 5-24 – JLG Lift – 3121202...
Polish the sealing area on the shaft if necessary. 4. Wrap the spline or key end of the shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the inside diameter of the new seal with petroleum jelly. 3121202 – JLG Lift – 5-25...
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Do not attempt to mix ate Service Parts Manual for more information. different vintage parts. 2. Reinstall the bypass valve into the housing. Torque to 7 to 10 ft. lbs. (9.5 - 13.6 Nm). 5-26 – JLG Lift – 3121202...
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2. Remove the spring and poppet from the housing. Do not alter the shims or interchange parts with another valve. Inspect the poppet and mating seat in the end cap for damage or foreign material. 3121202 – JLG Lift – 5-27...
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Refer to the Service Parts Manual for plug part numbers. 6. Replace the O-ring on the bottom of the control housing.Lightly lubricate all O-rings with clean petro- leum jelly prior to assembly. The control spool and 5-28 – JLG Lift – 3121202...
At the same time other ports would be blocked to flow. The spool is spring loaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit. 3121202 – JLG Lift – 5-29...
ATING THE MACHINE UNTIL THE HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES PRIOR TO 3. While monitoring pressure gauge, adjust platform CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CAL- level relief to 2800 PSI (193.06 Bar). IBRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF 4.
Make certain that all system com- fill container in such a way as to prevent it from ponents (reservoir, hoses, valves, fittings, heat exchanger, becoming contaminated. etc.) are clean prior to filling with fluid. 5-34 – JLG Lift – 3121202...
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Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code. If charge pres- sure is inadequate, shut down and determine the cause for improper pressure. 3121202 – JLG Lift – 5-35...
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- The JLG Control System controller has a built in LED to WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- indicate any faults. The system stores recent faults which CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
SECTION 6 - JLG CONTROL SYSTEM 6.2 TO CONNECT THE JLG CONTROL The top level menus are as follows: SYSTEM ANALYZER HELP DIAGNOSTICS 1. Connect the four pin end of the cable supplied with SYSTEM TEST the analyzer, to the controller module located in the...
SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu.
SECTION 6 - JLG CONTROL SYSTEM 6.5 ADJUSTING PARAMETERS USING THE Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- HAND HELD ANALYZER word was entered correctly: Once you have gained access to level 1, and a personality...
To level machine chose: There is a setting that JLG strongly recommends that you CALIBRATION: do not change. This setting is so noted below: TILT SENSOR ELEVATION CUTBACK Press ENTER.
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SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift –...
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SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3121202...
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SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift – 6-11...
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SECTION 6 - JLG CONTROL SYSTEM 6-12 – JLG Lift – 3121202...
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SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift – 6-13...
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SECTION 6 - JLG CONTROL SYSTEM 6-14 – JLG Lift – 3121202...
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SECTION 6 - JLG CONTROL SYSTEM 3121202 – JLG Lift – 6-15...
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SECTION 6 - JLG CONTROL SYSTEM 6-16 – JLG Lift – 3121202...
SECTION 6 - JLG CONTROL SYSTEM 6.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S DRIVE ACCELeration 0.1s to 5.0s DECELeration 0.1s to 3.0s...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S SWING ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S BASKET ROTATE ACCELeration 0.1 to 5.0 DECELeration 0.1 to 3.0 MlNimum LEFT speed 0 to 65% MAXimum LEFT speed 0 to 100% MINimum RIGHT speed...
SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault None No flash code is indicated for the following help messages. They are intended to hint at a possible problem if the vehicle is not behaving as expected.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault D/S JOY. OUT OF RANGE Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1 HIGH volts.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault l/s joy. center tap bad Resistive joysticks: These faults occur when the center tap voltage is not between 3.08 volts and 3.83 volts.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault HOUR METER SHORT TO BATTERY HORN SHORT TO GROUND HORN OPEN CIRCUIT HORN SHORT TO BATTERY...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault STEER DUMP OPEN CIRCUIT STEER DUMP SHORT TO BATTERY TWO SPEED SHORT TO GROUND TWO SPEED OPEN CIRCUIT...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BASKET DOWN SHORT TO BATTERY BASKET DOWN OVERRIDE Only occurs on machines with electronic leveling systems.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault TOWER DOWN OPEN CIR- CUIT TOWER DOWN SHORT TO BATTERY TOWER IN SHORT TO GROUND...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All driver faults are detected in a similar manner. Open cir- cuit faults are detected when the analog feedback reads too high and the output is commanded off.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault JIB LEFT OPEN CIRCUIT JIB RIGHT SHORT TO BAT- TERY JIB RIGHT SHORT TO GROUND...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second power-up.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault CHASSIS TILT SENSOR NOT Indicates that the chassis tilt sensor calibration information has been lost.
SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / MOTION CUTOUT: Motion cutout in platform mode only.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3 Configuration Digit Number Description Default Number GROUND ALARM: NO: No ground alarm installed. DRIVE: Travel alarm sounds when the drive function is active (Option).
SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number ENGINE SHUTDOWN: DISABLED: No engine shutdown. ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON. * Only visible if Gen Set / MOTION CUTOUT: Motion cutout in platform mode only.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1 Configuration Label/ Default Number Description Digit Number FUNCTION CUTOUT: NO: No drive cutout. * Only visible under certain BOOM CUTOUT: Boom function cutout while driving above elevation.
SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number MODEL NUMBER: 400S 450A 510A 600S 600A 600SC 601S 740A 800A 800S MARKET: ANSI USA ANSI EXPORT...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number ENGINE: FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) * Engine selections vary FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1) depending on model selec- tion.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number STARTER LOCKOUT: DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number GEN SET/WELDER: NO: No generator installed. BELT DRIVE: Belt driven setup. GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LOAD SENSOR: 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the Leveling Platform Module.
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SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present Configuration Label/ Default Number Description Digit Number LEVELING MODE: ALL FUNCTIONS: Platform level with all functions. * Only visible on 800S LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
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SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 600S ANSI USA 0 11 ANSI EXPORT...
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SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined numbers indicate the default when the option is factory installed. 600SJ ANSI USA 0 11 0 ANSI EXPORT...
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SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined numbers indicate the default when the option is factory installed. 660SJ ANSI USA 0 11 ANSI EXPORT 1 11...
SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL CLEARS WHEN FAULT IS REMOVED DRIVING AT CREEP - TILTED CLEARS WHEN FAULT IS REMOVED FSW OPEN CLEARS WHEN FAULT IS REMOVED RUNNING AT CREEP - CREEP SWITCH OPEN...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL FORD ECM POWER SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT HORN SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL ALARM SHORT TO BATTERY REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT GENERATOR SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL TOWER UP SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT TOWER UP OPEN CIRCUIT REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL FORD FAULT CODE 31 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 32 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 33 CLEARS WHEN FAULT IS REMOVED...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL NO ALTERNATOR OUTPUT CLEARS WHEN FAULT IS REMOVED OIL PRESSURE LOW CLEARS WHEN FAULT IS REMOVED 485 COMMUNICATIONS LOST CLEARS WHEN FAULT IS REMOVED...
SECTION 6 - JLG CONTROL SYSTEM 6.9 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;...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Adjustments - Personality Descriptions SWING ACCEL … Displays/adjusts swing acceleration DECEL … Displays/adjusts swing deceleration MIN LEFT … Displays/adjusts minimum swing left speed MAX LEFT … Displays/adjusts maximum swing left speed CREEP LEFT …...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Adjustments - Personality Descriptions JIB LIFT Not displayed if JIB = NO ACCEL … Displays/adjusts jib acceleration DECEL … Displays/adjusts jib deceleration MIN UP … Displays/adjusts minimum jib up speed MAX UP …...
SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Menu Descriptions DRIVE DRIVE FOR … Displays drive joystick direction & demand STEER … Displays steer switch direction & demand NOTE: steer demand is inversely proportional to vehicle speed BRAKES …...
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SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Diagnostic Menu Descriptions PM BATTERY … Displays battery voltage at platform module TEMP ... Displays ground module temperature ELEV. CUTOUT … Displays elevation cutout switch status FUNC. CUTOUT … Displays function cutout switch status CREEP…...
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SECTION 6 - JLG CONTROL SYSTEM NOTES: 6-60 – JLG Lift – 3121202...
• First test meter and leads by touching leads • If meter is not auto ranging, set it to the correct together. Meter should produce an audible alarm, range (See multimeter’s operation manual) indicating continuity – JLG Lift – 3121202...
NOTE: Do NOT apply dielectric grease to the following con- nections: NOTE: Curing-type sealants might also be used to prevent • Main Boom Rotary sensor connections (on Celesco shorting and would be less messy, but would make Sensor), future pin removal more difficult. 3121202 – JLG Lift –...
3. Install a hole plug into this and/or any unused wire lbs. to be sure the retention fingers are holding the seal that has silicone dielectric compound escaping contact (See Figure 7-7.). from it. Figure 7-6. AMP Connector – JLG Lift – 3121202...
The wedge lock has slotted openings in the forward, or the wire strands. This nullifies the effectiveness of the con- mating end. These slots accommodate circuit testing in nector seals and could result in system failure. – JLG Lift – 3121202...
The wedgelock will snap into place. Rectangular 3. Hold the rear seal in place, as removing the contact wedges are not oriented. Thy may go in either way. may displace the seal. – JLG Lift – 3121202...
3. Pull contact-wire assembly out of connector. Figure 7-15. HD/HDP Locking Contacts Into Position Figure 7-17. HD/HDP Unlocking Contacts NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing NOTE: Do Not twist or insert tool at an angle. 3121202 – JLG Lift –...
CAT ENGINE ONLY BLUE WHT/YEL ORN/RED 49-84 BROWN TOWER TELE. ORN/RED 49-85 BLACK PROX. SWITCH (800 A/AJ ONLY} BLUE ORN/RED 49-93 1870215 B Figure 7-23. Electrical Schematic - ADE - Sheet 2 of 6 3121202 – JLG Lift – 7-15...