Jlg 460SJ Service Manual Manuel d'utilisateur

Service and Maintenance ManualModels400S460SJP/N - 3120895December 6, 2012

vi – JLG Lift – 3120895TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3120895Figure 3-35. Swing Drive Installation

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-49Figure 3-36. Swing Motor

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 31208953.14 SWING BRAKE (PRIOR TO S/N 64802)The multi disc brake is spring loaded to apply the br

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-511. Housing2. Compression Spring3. Compression Spring4. Spring Retainer5.

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31208953.15 SWING BRAKE S/N 64802 TO PRESENTDisassembly1. Remove pressure plate (2) from cover (1

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-53 Figure 3-38. Swing Brake S/N 64802 to Present

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 31208953.16 SWING DRIVE TORQUE HUBDisassembly Procedure1. Loosen all 12 cover bolts (12)&(13)

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-55Figure 3-39. Swing Torque Hub

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 312089514. With the Hub Shaft Sub assembly resting on theShaft (1A), install Internal Gear (2). T

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-57Be sure that punch marks remain in correct locationduring Ring gear installation. The side

3120895 – JLG Lift – vii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 312089525. The Cover (6) is now installed on this assembly. Tak-ing care to correctly align Pipe

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-593. Invert Hub (1G) and press Bearing Cup (1E) intocounterbore of Hub (1G).4. Returning the

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 31208959. Retaining Ring (1I) installed into the groove providedin the output Shaft (1A). This re

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-614. Place second set of sixteen Needle Rollers into Clus-ter Gear.5. Apply grease or petrol

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3120895 Removing the TrackIf the tracks are muddy, it is a good idea to wash them offor drive the

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-63Table 3-8. Adjustment ChartMove1 Hole 2 Holes 3 Holes 4 Holes 5 Holes6 Holes7 Holes8 Holes

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3120895ABCDCEFigure 3-40. Auxiliary Pump - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-65Figure 3-41. Auxiliary Pump - Sheet 2 of 21. Motor2. Adapter3. Setscrew4. Mounting Gasket

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 31208953.18 GENERATOREvery 250 hoursEvery 250 hours of operation, check the drive belt forproper

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-6711/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must ridecom

viii – JLG Lift – 3120895TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 31208953.19 FORD EFI ENGINEPerforming Diagnostics1. Verify the complaint and determine if it is a

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-69 When reading Diagnostic Trouble Codes thru the MIL, thefollowing conditions apply:• The f

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3120895ENGINE COOLANT TEMPERATURE (ECT) SENSORThe engine coolant temperature (ECT) sensor is a gt

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-71other. A fault in the engine coolant sensor circuit will setDTC 33 or DTC 43.ELECTRICALLY

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3120895Figure 3-44. EFI Component Location

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-73INTAKE AIR TEMPERATURE (IAT) SENSORThe intake air temperature (IAT) sensor is a thermistor

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3120895The ECM is designed to maintain exhaust emission levelsto government mandated standards wh

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-75ELECTROSTATIC DISCHARGE DAMAGEElectronic components used in the ECM are oftendesigned to c

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 3120895FUEL METERING SYSTEM PURPOSEThe basic function of the air/fuel metering system is tocontro

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-77FUEL PRESSURE REGULATORThe fuel pressure regulator is a relief valve mounted in thefuel fi

3120895 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 3120895OPEN LOOP AND CLOSED LOOP OPERATIONThe ECM will operate in the following two modes:• Open

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-79IGNITION COILThe electronic ignition system uses a coil pack with oneignition coil for eac

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 3120895ProcedureNOTE: Never run fuel tank dry. Diesel engines cannot berestarted after running ou

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-81Green and either Amber light followed by a red light.orthenAction:1. Inspect and clean wir

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 31208951.25 - 1.38 in.When final settingsare completed torqueto 49 in. Lbs. Dry.Actuator should b

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-833.21 TILT ALARM SWITCH (PRIOR TO S/N 61718)PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3120895Figure 3-49. Valve Location - Chassis

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-85Figure 3-50. Hyd Tank Installation

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 31208953.22 HYDRAULIC WELDER (225-4)1. To remove top cover.a. Remove 4 screws on each side.b. P

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-87Rotor Replacement1. Remove coupling guard held with two 10/32 screws.2. Un-bolt motor moun

x – JLG Lift – 3120895LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 3120895Replacement of Weld Rectifier Bridge1. Remove top cover ad control panel.2. Disconnect thr

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-89Replacement of Couplings1. Remove coupling held by two 10/32 screws andnuts.2. Un-bolt hyd

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 31208953.23 TROUBLESHOOTING OF THE SKY WELDERLow Sky Welder SpeedIf the welder/generator is runni

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-91This page left blank intentionally.

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3120895Figure 3-51. Hydraulic Welder 225-4 (sht 1 of 2)

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-931. Air Intake.2. Slip ring cover.3. Varistor.4A. Single-ph rectifier Brid

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 3120895No Output on Weld Receptacle but AC Receptacle Output OKIf you have no welding power at al

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-953.24 DEUTZ EMR 2 (S/N 77682 TO PRESENT)The EMR2 consists of the sensors, the control unit

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3120895Figure 3-53. EMR 2 Engine Side EquipmentGLOW PLUGPOWER SUPPLYCOOLANT TEMPERATURESENSORCON

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-97Figure 3-54. Deutz EMR 2 Troubleshooting Flow Chart

3120895 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3120895Figure 3-55. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-99Figure 3-56. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3120895Figure 3-57. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-101Figure 3-58. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3120895Figure 3-59. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-103Figure 3-60. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 3120895Figure 3-61. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-105Figure 3-62. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3-106 – JLG Lift – 3120895Figure 3-63. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-107Figure 3-64. EMR2 Fault Codes - Sheet 5 of 5

xii – JLG Lift – 3120895LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-108 – JLG Lift – 31208953.25 GM ENGINE GENERAL MAINTENANCEMaintenance of the Drive BeltThe serpentine drive belt

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-1096. If the oil level is below the "ADD" mark, proceed toStep 7 and 8 and reinsta

SECTION 3 - CHASSIS & TURNTABLE3-110 – JLG Lift – 31208952.Remove the radiator cap. Fill the radiator with coolant until coolant starts to appear

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-1113.26 GM ENGINE DUAL FUEL SYSTEMThe Dual Fuel system allows the operator to operate theve

SECTION 3 - CHASSIS & TURNTABLE3-112 – JLG Lift – 3120895EPR AssemblyThe EPR assembly is a combination Low Pressure Regu-lator and a Voice Coil As

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-113Air Fuel MixerThe air valve mixer is an air-fuel metering device and iscompletely self-co

SECTION 3 - CHASSIS & TURNTABLE3-114 – JLG Lift – 3120895Engine Control ModuleTo obtain maximum effect from the catalyst and accuratecontrol of th

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-115Gasoline Fuel PumpThe Gasoline is stored as a liquid in the fuel tank and indrawn into th

SECTION 3 - CHASSIS & TURNTABLE3-116 – JLG Lift – 31208953.27 GM ENGINE FUEL SYSTEM REPAIRPropane Fuel System Pressure ReliefTHE PROPANE FUEL SYST

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-1174. Drop the magnet into the bottom of the filter hous-ing. 5. Install the filter into the

3120895 – JLG Lift – xiii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-118 – JLG Lift – 31208958. Connect the EPR electrical connector. 9. Open the manual valve. 10. Start the vehicle

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-119Electronic Throttle Control Replacement See Figure 3-78.REMOVAL1. Disconnect the negative

SECTION 3 - CHASSIS & TURNTABLE3-120 – JLG Lift – 31208954. Place gasket on intake manifold and attach mixer/throttle assembly to manifold.MIXER R

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-121Engine Control Module ReplacementREMOVAL1. Disconnect Negative battery cable.2. Remove co

SECTION 3 - CHASSIS & TURNTABLE3-122 – JLG Lift – 3120895Diagnostic AidsThis procedure is intended to diagnose a vehicle operat-ing on LPG. If the

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-123Table 3-11. LPF Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to th

SECTION 3 - CHASSIS & TURNTABLE3-124 – JLG Lift – 312089513 1. Turn OFF the ignition.2. Disconnect the LPL connector.3. Install a test light betwe

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-12525 The fuel supply system is operating normally, if a failure of the control solenoids is

SECTION 3 - CHASSIS & TURNTABLE3-126 – JLG Lift – 3120895Table 3-12. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using This S

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-127Intermittent Malfunction Indicator Lamp (MIL)The following components can cause intermitt

xiv – JLG Lift – 3120895LIST OF TABLES TABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-128 – JLG Lift – 3120895Exhaust System Checks  Check the exhaust system for a possible restriction:

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-129Exhaust System Checks  Check the exhaust system for a possible restriction: - Inspec

SECTION 3 - CHASSIS & TURNTABLE3-130 – JLG Lift – 3120895Hesitation, Sag, StumbleDEFINITION: The vehicle has a momentary lack of response when dep

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-131Lack of Power, Sluggishness, or SponginessDEFINITION: The engine delivers less than exp

SECTION 3 - CHASSIS & TURNTABLE3-132 – JLG Lift – 3120895Ignition System Checks  Verify that the spark plugs are correct for use with LPG (R42LT

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-133Engine Mechan ical Check  Che ck the engine for the follow in g:

SECTION 3 - CHASSIS & TURNTABLE3-134 – JLG Lift – 3120895Table 3-13. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 Crank

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-135562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid 628

SECTION 3 - CHASSIS & TURNTABLE3-136 – JLG Lift – 3120895 1. Battery2. Coolant Overflow3. Air Cleaner4. Radiator5. Alternator6. O2 Sensor7. Cranks

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-13716. O2 Sensor17. Dipstick18. Control Module19. Starter20. Distributor21. Oil Filter22. Wa

3120895 – JLG Lift – xv LIST OF TABLESTABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-138 – JLG Lift – 31208953.29 PERKINS ENGINE GENERAL MAINTENANCEReplacing the Engine Crankcase BreatherKEEP ALL PA

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-139***234567811. Dipstick2. Crankcase Breather3. Coolant Sensor4. Oil Pressure Sensor5. Oil

SECTION 3 - CHASSIS & TURNTABLE3-140 – JLG Lift – 3120895Do not drain the oil when the engine is cold. As the oilcools, suspended waste particles

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-141Setting the Actuator1. Remove the bolt from the control linkage2. With the control linkag

SECTION 3 - CHASSIS & TURNTABLE3-142 – JLG Lift – 3120895tor linkage and using two wrenches to prevent bind-ing of clevis heads. Speed Sensor Inst

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-1434.Remove the plug from the adapter and add coolant at this location until the radiator ho

SECTION 3 - CHASSIS & TURNTABLE3-144 – JLG Lift – 31208953.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONSThis section defines the diagnost

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-145List of Abbreviations in this SectionAL Adaptive Learn LED Light Emitting DiodeBP Baromet

SECTION 3 - CHASSIS & TURNTABLE3-146 – JLG Lift – 3120895Fault Code BroadcastAll diagnostic trouble codes are broadcast through EDISfor display on

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-147are assigned based on the configuration outlined in Table3-14.MIL OutputThe MIL output is

xvi – JLG Lift – 3120895LIST OF TABLES TABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-148 – JLG Lift – 3120895Fault/Diagnostic Trouble Code InteractionAll fault and diagnostic information is managed

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-149Once an active fault has occurred two sets of data arerecorded, fault snapshot and flight

SECTION 3 - CHASSIS & TURNTABLE3-150 – JLG Lift – 3120895Accessing fault information is accomplished through adouble left-click of the fault LED i

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-151Figure 3-89. Historic Fault Information InterfaceTable 3-16. Historic Fault Informatio

SECTION 3 - CHASSIS & TURNTABLE3-152 – JLG Lift – 3120895Figure 3-90. Snapshot Data InterfaceFigure 3-91. Flight Data Recorder Interface

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-153DBW Diagnostic TestThe DGC engine control module incorporates a diagnos-tic test that may

SECTION 3 - CHASSIS & TURNTABLE3-154 – JLG Lift – 31208953.32 DIAGNOSTIC TROUBLE CODE FAULT DESCRIPTIONSDTC 116- ECT Higher Than Expected Stage 1•

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-155DTC 117- ECT/CHT Low Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine R

SECTION 3 - CHASSIS & TURNTABLE3-156 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-157DTC 118- ECT/CHT High Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 ENGINE SPECIFICATIONSNOTE: RPM Tolerances are ± 100.Tabl

SECTION 3 - CHASSIS & TURNTABLE3-158 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-159DTC 122- TPS1 Signal Voltage LowElectronic Throttle Actuator w/Serial Position Feedback21

SECTION 3 - CHASSIS & TURNTABLE3-160 – JLG Lift – 3120895• Throttle Position Sensor 1• Check Condition-Key On, Engine Off• Fault Condition-TPS1 se

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-161

SECTION 3 - CHASSIS & TURNTABLE3-162 – JLG Lift – 3120895DTC 123- TPS1 Signal Voltage High• Throttle Position Sensor 1• Check Condition-Key On, En

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-163The second type, with digital position feedback, providesa serial data signal to the ECM

SECTION 3 - CHASSIS & TURNTABLE3-164 – JLG Lift – 3120895DTC 217- ECT Higher Than Expected 2• Engine Coolant Temperature Sensor• Check Condition-E

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-165DTC 219- RPM Higher Than Max Allowed Governed Speed• Max Govern Speed Override- Crankshaf

SECTION 3 - CHASSIS & TURNTABLE3-166 – JLG Lift – 3120895DTC 336- Crank Signal Input Noise• Crankshaft Position sensor• Check Condition- Key On, E

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-167• Key On, Engine Running• System Mode= “Running”Does DTC 336 reset ?Intermittent faultNoY

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31208951.3 TIRES1.4 SPECIFICATIONS AND PERFORMANCE DATATable 1-6. GM 3.0LFuel Gasoline or Gasoline/LP GasNo

SECTION 3 - CHASSIS & TURNTABLE3-168 – JLG Lift – 3120895DTC 337- Loss of Crank Input Signal• Crankshaft Position sensor• Check Condition- Key On,

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-169DTC 521- Oil Pressure Sender/Switch High Pressure• Engine Oil Pressure• Check Condition-

SECTION 3 - CHASSIS & TURNTABLE3-170 – JLG Lift – 3120895Normally Open SwitchNormally Closed Switch• Key-On, Engine Off• System Mode= “Stopped”Doe

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-171Sensor/Transducer Type

SECTION 3 - CHASSIS & TURNTABLE3-172 – JLG Lift – 3120895DTC 524- Oil Pressure Low• Engine Oil Pressure• Check Condition- Key on, Engine on• Fault

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-173Normally Open Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to n

SECTION 3 - CHASSIS & TURNTABLE3-174 – JLG Lift – 3120895Normally Closed Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-175Sensor/Transducer Type

SECTION 3 - CHASSIS & TURNTABLE3-176 – JLG Lift – 3120895DTC 562- Battery Voltage (VBat) Low• System voltage to ECM• Check Condition- Key on, Engi

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-177

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-31.5 TORQUE REQUIREMENTS1.6 CRITICAL STABILITY WEIGHTSTable 1-10. Specifications and Performance Data

SECTION 3 - CHASSIS & TURNTABLE3-178 – JLG Lift – 3120895DTC 563- Battery Voltage (VBat) High• System voltage to ECM• Check Condition- Key on, Eng

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-179

SECTION 3 - CHASSIS & TURNTABLE3-180 – JLG Lift – 3120895DTC 601- Microprocessor Failure - FLASH• Engine Control Module- Flash Memory• Check Condi

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-181

SECTION 3 - CHASSIS & TURNTABLE3-182 – JLG Lift – 3120895DTC 604- Microprocessor Failure - RAM• Engine Control Module- Random Access Memory• Check

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-183

SECTION 3 - CHASSIS & TURNTABLE3-184 – JLG Lift – 3120895DTC 606- Microprocessor Failure - COP• Engine Control Module• Check Condition- Key on• Fa

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-185

SECTION 3 - CHASSIS & TURNTABLE3-186 – JLG Lift – 3120895DTC 642- 5 Volt External Low VoltageElectronic Throttle Actuator w/Serial Position Feedba

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-187• Engine Control Module• Check Condition- Key on• Fault Condition- ECM 5-volt output is b

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31208951.7 MAJOR COMPONENT WEIGHTS 1.8 FUNCTION SPEEDS 1.9 PRESSURE SETTINGS - PSI (BAR)Cold temperatures h

SECTION 3 - CHASSIS & TURNTABLE3-188 – JLG Lift – 3120895DTC 643- 5 Volt External High VoltageElectronic Throttle Actuator w/Serial Position Feedb

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-189• Engine Control Module• Check Condition- Key on• Fault Condition- ECM 5-volt output is a

SECTION 3 - CHASSIS & TURNTABLE3-190 – JLG Lift – 3120895DTC 1612- Microprocessor Failure - RTI 1• Engine Control Module• Check Condition- Key on•

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-191DTC 1613- Microprocessor Failure - RTI 2• Engine Control Module• Check Condition- Key on•

SECTION 3 - CHASSIS & TURNTABLE3-192 – JLG Lift – 3120895SFC 555- RTI 2 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 555

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-193DTC 1614- Microprocessor Failure - RTI 3• Engine Control Module• Check Condition- Key on•

SECTION 3 - CHASSIS & TURNTABLE3-194 – JLG Lift – 3120895SFC 556- RTI 3 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 556

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-195DTC 1615- Microprocessor Failure - A/D• Engine Control Module• Check Condition- Key on• F

SECTION 3 - CHASSIS & TURNTABLE3-196 – JLG Lift – 3120895SFC 513- A/D LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 513 re

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-197DTC 1616- Microprocessor Failure - interrupt• Engine Control Module• Check Condition- Key

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-51.10 CYLINDER SPECIFICATIONS1.11 LUBRICATIONHydraulic OilNOTE: Hydraulic oils must have anti-wear qu

SECTION 3 - CHASSIS & TURNTABLE3-198 – JLG Lift – 3120895SFC 512- Invalid InterruptKey On - Engine RunningSystem Data ModeClear System FaultDoes S

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-199DTC 1625- CAN J1939 Shutdown Request• Controller Area Network• Check Condition- Key On, E

SECTION 3 - CHASSIS & TURNTABLE3-200 – JLG Lift – 3120895DTC 1626- CAN J1939 Transmit (Tx) Fault• Controller Area Network• Check Condition- Key On

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-201DTC 1627- CAN J1939 Receive (Rx) Fault• Controller Area Network• Check Condition- Key On,

SECTION 3 - CHASSIS & TURNTABLE3-202 – JLG Lift – 3120895DTC 1628- CAN Address Conflict Failure•CAN device(s)• Check Condition- Key On, Engine on•

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-203

SECTION 3 - CHASSIS & TURNTABLE3-204 – JLG Lift – 3120895DTC 1629- J1939 TSC1 Message Reciept Loss• Controller Area Network• Check Condition- Key

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-205DTC 1652- TPS1 Loss of Communications• Throttle Actuator (with serial/digital position fe

SECTION 3 - CHASSIS & TURNTABLE3-206 – JLG Lift – 3120895DTC 2111- Unable to Reach Lower TPS• Throttle Position Sensor• Check Condition-Cranking o

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-207

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31208951.12 WELDER, HYDRAULIC (OPTION)1.13 SERIAL NUMBER LOCATIONA serial number plate is affixed to the le

SECTION 3 - CHASSIS & TURNTABLE3-208 – JLG Lift – 3120895DTC 2112- Unable to Reach Higher TPS• Throttle Position Sensor• Check Condition-Cranking

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-209DTC 9999- Throttle Actuator Failsafe Spring Failure• Throttle Actuator• Check Condition-

SECTION 3 - CHASSIS & TURNTABLE3-210 – JLG Lift – 3120895DTC to SPN/FMI TableFAULTINDEXDESCRIPTIONDTC SETSPN FMI2 DTC 118: ECT voltage high 110 33

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-211ABCDA. Exhaust VenturiB. 1/4" (6.35 mm) minimum clearance all around.C. 3

SECTION 3 - CHASSIS & TURNTABLE3-212 – JLG Lift – 3120895NOTES:

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOMRemoval1. Remove the platform and platform support as fo

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3120895a. Disconnect wiring harness from ground controlharness connector.HYDRAULIC LINES AND PORTS SHO

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-37. Remove hardware securing the front wear pads onbase boom section, remove wear pads.8. Remove

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31208956. Inspect all threaded components for damage suchas stretching, thread deformation, or twistin

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-5so that fly boom section is centered in base boomsection.12. Retract boom section fully. Using

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-71.14 OPERATOR MAINTENANCE AND LUBRICATIONNOTE: The following numbers correspond to those in Figure1-

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31208954.2 ARTICULATING JIBRemoval1. Place the Articulating Jib in a horizontal position andsupport th

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-7Figure 4-5. Limit Switches - 500 / 1000 LB (230 / 450 kg) CapacitySWITCH TO ACTIVATE WHEN BOOM

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3120895Figure 4-6. Limit Switches - 750 LB (340 kg) CapacitySWITCH TO ACTIVATE WHEN BOOM IS EXTENDED

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-9Figure 4-7. Limit Switches - CE MachinesSWITCH TO ACTIVATE WHEN BOOM IS EXTENDED 84.375"

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 31208954.4 DRIVE CARD SETUP PROCEDURESMachine Orientation When Doing Speed TestsLift: Boom Retracted.

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-11NOTE: The following procedures are to be used as a begin-ning basis for controller adjustment.

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3120895the meter for the time it takes the output to go from 0current to maximum current. This is ram

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-134.5 HELAC ROTARY ACTUATORTheory Of OperationThe rotary actuator is a simple mechanism that use

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31208951. Housing2. Sha ft3. Piston Sleeve4. End Ca p109. Lock Pin113. Cap S

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-151. Hou sing2. Shaft3. Piston Sleeve4. End Cap109. Lock Pin113. Cap Scr

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31208957. Suction StrainersLube Point(s) - 2Interval - Every 2 years or 1200 hours of operation,remove and

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3120895Tools Required for Assembly/DisassemblyUpon assembly and disassembly of the actuator there are

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-174. Install the end cap (4) removal tools provided withthe Helac seal kit.5. Using a metal bar,

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 31208959. Prior to removing the shaft, (2), use a felt marker toclearly indicate the timing marks bet

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-1915. Remove the wear guides (302) from the end cap (4)and shaft (2).16. To remove the main pres

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3120895Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-214. Using a seal tool install the main pressure seal (205)onto shaft (2) and end cap (4). Use t

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 31208959. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 4 - BOOM & PLATFORM3120895 – JLG Lift – 4-2315. Install the O-ring (204) and back-up ring (207) intothe inner seal groove on the end cap (

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3120895Figure 4-12. Rotator Counterbalance Valve

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 CYLINDERS - THEORY OF OPERATIONSystems Incorporating Double Acting CylindersCy

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-912. Oil Change w/Filter - GMLube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965)Capacity

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3120895NOTE: The following are general procedures that apply toall of the cylinders on this machine. Procedures

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-36. Attach a suitable pulling device to the cylinder rodport block end or cylinder rod end, as applicable

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31208958. Inspect seal and o-ring grooves in piston for burrsand sharp edges. Dress applicable surfaces as nec-

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-53414151616191578101112136910201684139 D1. Barrel2. Not Used3. Wear Ring4. T-Seal5. Wear Ring6. O-ring7.

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31208951. Barrel1A. Bushing2. Rod2A. Bushing3. Piston4. Head5. Tapered Bushing6. Spacer7. Valve Cartridge8. O

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-76889681 2181912 1616175A1A511261414151510432120221683609 G1. Barrel1A. Bushing2. Head3. Ring Washer4. B

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 312089545118261229***66661,2**,281079132**,3**,232217211625202018182415151927*1683776 E1. Loctite #2422. Lockin

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-98 10 62322721201819171724 161615541414131312691684284 B1. Loctite #2422. Locking Primer3. Not Used4. Bol

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 312089513621112397108181079312111684412 A1. Barrel2. Rod3. Cylinder Head4. Anti-Seize5. Not Used6. Wear Ring7.

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-114612221229101414172716131821719202453232526232382931253091684194 C1. Loctite #2422. Locking Primer3. Lo

INTRODUCTION3120895 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 312089521. Electronic Pressure Regulator (LP only)Interval - 3 Months or 150 hours of operationComments -

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3120895.3. Place a new o-ring and back-up seal in the applica-ble outside diameter groove of the cylinder head

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-13 12. Tighten the capscrews evenly and progressively inrotation to the specified torque value. (See Ta

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3120895NOTE: If applicable, install the cartridge-type holding valveand fittings in the rod port block, using

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-15Figure 5-22. Main Valve

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3120895Ft-Lbs. Nm1 18-20 24.5-27.22 4-5 6.5-9.53 25-27 34-36.74 59.5Figure 5-23. Main Valve Cartridge Torque

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-17Relief ValvesRelief valves are installed at various points within thehydraulic system to protect associ

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3120895cartridge on the jib block. Turn clockwise to increase,counterclockwise to decrease. 6. Articulating Ji

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-193. Remove end cap.4. Remove seal from end cap.5. Remove gerotor.6. Remove seal from gerotor.7. Remove d

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 3120895SOME MOTORS MAY HAVE A QUAD SEAL AND BACK - UP RINGIN PLACE OF THE PRESSURE SEAL. THE QUAD SEAL AND BAC

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-21c. Wire brush screw threads ton remove curedLoctite and other debris. Discard any screwsthat have damag

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-11Propane Fuel Filter ReplacementREMOVAL1. Relieve the propane fuel system pressure. Refer toPropane

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 31208959. Apply 3 or 4 drops of Loctite sealant at top of threadfor each of four holes in housing.Do not allow

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-23Timing Procedurea. Install drive. Use felt tip marker to mark onetooth. Align this tooth with timing do

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 312089516. Install drive spacer if applicable.17. Install 2 7/8 in. (73 mm) seal in end cap. Carefullyplace en

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-25Figure 5-25. Variable Displacement Hydraulic Pump.

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 31208955.6 HYDRAULIC PUMP “NEUTRAL” OR NULL ADJUSTMENTThe pump neutral or null adjustment sets the position of

SECTION 5 - HYDRAULICS3120895 – JLG Lift – 5-275.8 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSFrom a hydrostatic component standpoint,

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 3120895It is recommended that the external control input signal,(electrical connections for EDC), be disconnec

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6.1 INTRODUCTIONWHEN

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-2 – JLG Lift – 3120895Figure 6-2. ADE Block Diagram

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-36.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the four pin end

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120895Figure 1-5. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-4 – JLG Lift – 3120895Figure 6-3. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-5When a top level menu is selected, a new set of menuitems may be offered:

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

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-7Once the correct password is displayed, press ENTER.The access level shou

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-8 – JLG Lift – 31208956.6 MACHINE SETUPWhen a machine digit item is selected, press the UP orDO

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-9ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTOMENU:MACHIN

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-10 – JLG Lift – 3120895FROMPERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:UPPER TELES

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-11FROMMENU:PERSONALITIESMENU:MACHINE SETUPTOMENU:CALIBRATIONSMODEL NUMBER:

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-12 – JLG Lift – 3120895Figure 6-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-13Figure 6-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4NOT

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-13Figure 1-6. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-14 – JLG Lift – 3120895Figure 6-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-15FROM:MENU:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL NUMBE

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-16 – JLG Lift – 3120895MENU:HELP:PRESS ENTERHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU:CALI

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-176.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjus

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-18 – JLG Lift – 3120895TELEscope ACCELeration 0.1 to 5.0 2.8DECELeration 0.1 to 3.0 0.8MINimum

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-19GROUND MODE LIFT UP speed 0 to 100 60LIFT DOWN speed 0 to 100 60SWING sp

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-20 – JLG Lift – 3120895Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-212/3 Flash code 2/3 indicates problems with boom function selection. 3LIF

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-22 – JLG Lift – 31208953/2 Flash code 3/2 indicates that a contactor did not open when energize

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-239/9 Flash code 9/9 indicates problems with the controller. 11PLATFORM MO

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3120895Figure 1-7. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-24 – JLG Lift – 3120895Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-252/2 Flash code 2/2 indicates problems with drive & steer selection.

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-26 – JLG Lift – 31208952/5 Flash code 2/5 indicates that a function is prevented due to a cutou

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-273/3 Flash code 3/3 indicates a driver problem. All driver faults are det

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-28 – JLG Lift – 3120895LP LOCK SHORT TO BATTERY Only occurs on machines with dual-fuel engines.

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-29HEAD TAIL LIGHT OPEN CIRCUIT Only occurs on machines with the headlights

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-30 – JLG Lift – 3120895JIB DOWN OPEN CIRCUITJIB DOWN SHORT TO BATTERYJIB LEFT SHORT TO GROUNDJI

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-31LIFT DOWN AUX VALVE OPEN CIR-CUITOnly occurs on machines with gravity li

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-32 – JLG Lift – 31208953/4 Flash code 3/4 indicates a driver problem on a platform valve block

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-334/2 Flash code 4/2 indicates that the engine is over temperature. NOT RE

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-15Figure 1-8. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-34 – JLG Lift – 31208954/5 Flash code 4/5 indicates problems with the S-D CAN based PVG valves

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-35MAIN LIFT PVG VALVE COMMAND IMPROPERMain boom lift pvg valve received an

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-36 – JLG Lift – 31208955/5 Flash code 5/5 indicates problems with vehicle engine RPM or the enc

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-378/3 Flash code 8/3 indicates problems with the Basket Leveling system. 1

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-38 – JLG Lift – 31208958/4 Flash code 8/4 indicates problems with the envelope system. Only occ

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-39TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOWThis fault is reported by th

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-40 – JLG Lift – 31208958/5 Flash code 8/5 indicates problems with the moment or load pin system

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-418/6 Flash code 8/6 indicates problems with the steering system. Except a

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-42 – JLG Lift – 3120895REAR LEFT WHEEL BLOCKED The wheel is not responding to steer commands. F

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-439/9 Flash code 9/9 indicates problems with the controller or the user di

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3120895Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-44 – JLG Lift – 3120895BLAM SENSOR SUPPLY OUT OF RANGE HIGHIndicates that the supply voltage fo

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-45Table 6-4. Machine Configuration Programming Information Prior to Softwa

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-46 – JLG Lift – 3120895GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: A

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-47GEN SET CUTOUT:12* * Only visible if Gen Set / Welder Menu selection is

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-48 – JLG Lift – 3120895GROUND ALARM:18* * Certain market selections will alter default setting.

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-49Table 6-5. Machine Configuration Programming Information Software Versio

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-50 – JLG Lift – 3120895ENGINE:3* * Engine selections vary depending on model selec-tion.123456

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-51ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-52 – JLG Lift – 3120895GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selection is

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-53FUNCTION CUTOUT:18* * Only visible under certain market selections. *

SECTION 1 - SPECIFICATIONS3120895 – JLG Lift – 1-17Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-54 – JLG Lift – 3120895Table 6-6. Machine Configuration Programming Information Software Versio

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-55ENGINE:3* * Engine selections vary depending on model selec-tion.123456

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-56 – JLG Lift – 3120895STARTER LOCKOUT:601DISABLED: Automatic pre-glow time determined by ambie

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-57GEN SET/WELDER:1201NO: No generator installed.BELT DRIVE: Belt driven se

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-58 – JLG Lift – 3120895LOAD SENSOR:17* * Only visible if Load Sen-sor Menu selection is not 0

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-59LEVELING MODE:22* * Only visible on 800S models.01ALL FUNCTIONS: Platfo

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-60 – JLG Lift – 3120895400SMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUTENGIN

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-61460SJMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUTENGI

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-62 – JLG Lift – 31208956.9 SYSTEM TESTThe Control System Incorporates a built-in system test to

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-63Figure 6-13. System Test Flow Chart - Platform Tests

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3120895Figure 1-11. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-64 – JLG Lift – 3120895Test from the Ground Station1. Position the Platform/Ground select switc

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-65Figure 6-14. System Test Flow Chart - Ground Station Tests

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-66 – JLG Lift – 3120895Table 6-7. System Test MessagesMessage Displayed onAnalyzerMessage Displ

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-67TESTING VALVES Indicates that the valve test is beginning. Each valve is

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-68 – JLG Lift – 3120895TEST ALL INPUTS? Prompts whether to check every operator input. If ESC i

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-69Table 6-8. Machine Configuration ParametersConfiguration DigitParameter

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-70 – JLG Lift – 31208956 Tilt: 1=5Deg2=4Deg3=3DegDisplays/adjusts tilt sensor function1235 degr

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-7113 Head & Tail LIGHTS0=NO1=YESDisplays presence of head and tail lig

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-72 – JLG Lift – 312089520 PLATFORM ALARM0=NO1=FAULT CODEDisplays/adjusts platform alarm presenc

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-73Table 6-9. Analyzer Fault Code ListingDTC Analyzer Text001 EVERYTHING OK

SECTION 2 - GENERAL3120895 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-74 – JLG Lift – 3120895331 BRAKE - SHORT TO BATTERY332 BRAKE - OPEN CIRCUIT3311 GROUND ALARM -

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-753370 TWO SPEED VALVE - SHORT TO BATTERY3371 GROUND ALARM - SHORT TO GROU

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-76 – JLG Lift – 312089533115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND33116 TOWER TELESCOPE O

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-7733315 FLOW CONTROL VALVE - SHORT TO BATTERY33316 FLOW CONTROL VALVE - SH

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-78 – JLG Lift – 3120895431 FUEL SENSOR - SHORT TO BATTERY432 FUEL SENSOR - SHORT TO GROUND433 O

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-798311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY8312 PLATFORM LEVEL SENS

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-80 – JLG Lift – 31208959920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE9921 GROUND MODULE FAILURE

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-816.10 ANALYZER DIAGNOSTICS MENU STRUCTURE In the following structure desc

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-82 – JLG Lift – 3120895SWINGACCEL … Displays/adjusts swing accelerationDECEL … Displays/adjusts

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-83JIB LIFT Not displayed if JIB = NOACCEL … Displays/adjusts jib accelerat

INTRODUCTIONA-2 – JLG Lift – 3120895REVISON LOGOriginal Issue April 1, 2000Revised: July 21, 2000Revised: October 1, 2000Revised:

SECTION 2 - GENERAL2-2 – JLG Lift – 31208952.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-84 – JLG Lift – 3120895Table 6-11. Diagnostic Menu DescriptionsDRIVEDRIVE FOR … Displays drive

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)3120895 – JLG Lift – 6-85PM BATTERY … Displays battery voltage at platform moduleTEMP... Display

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)6-86 – JLG Lift – 3120895NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3120895Resistance Measurement•First test meter and leads by touching leadsto

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-3Current Measurement•Set up the meter for the expected current range•B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 3120895Automatic SwitchesIf the switch is actuated automatically, by tempera

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-53. Anderson connectors for the battery boxes and bat-tery chargers sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3120895AMP Mate-N-LokFollow the installation instructions.DIN ConnectorsThis

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-7AMP JUNIOR TIMERThis type of connector uses back-seals for moisture i

SECTION 2 - GENERAL3120895 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31208957.5 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-93. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3120895Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebet

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-11Figure 7-13. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 31208957.6 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-13HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the con

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3120895Figure 7-20. Electrical Components Installation w/o JLG Control Sys

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-15Figure 7-21. Electrical Components Installation w/o JLG Control Sys

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3120895J5J6J7J2J2J1J8J3J1J8DIAGNOSTICANALYZERPLATFORMCONTROLBOXGROUNDCONTRO

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-17JIBVALVESTROBELIGHT335AFUELLEVELSENSOR2500WGENERATORRELAY7500WGENERA

SECTION 2 - GENERAL2-4 – JLG Lift – 3120895cleaned, and/or replaced as necessary, at the speci-fied intervals required in the Lubrication Chart inSect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3120895This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-19Figure 7-24. On Board Generator Electrical Schematic. (if equipped)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3120895Figure 7-25. Electrical Schematic - Ford Engine w/o JLG Control Sys

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-21Figure 7-26. Electrical Schematic - Ford Engine w/o JLG Control Sys

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3120895Figure 7-27. Electrical Schematic - Ford Engine w/o JLG Control Sys

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-23CFigure 7-28. Electrical Schematic - Ford Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3120895Figure 7-29. Electrical Schematic - Deutz Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-25Figure 7-30. Electrical Schematic - Deutz Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3120895Figure 7-31. Electrical Schematic - Deutz Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-27Figure 7-32. Electrical Schematic - Deutz Engine w/o JLG Control Sy

SECTION 2 - GENERAL3120895 – JLG Lift – 2-5Drift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil must be at am

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3120895Figure 7-33. Electrical Schematic - Isuzu Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-29Figure 7-34. Electrical Schematic - Isuzu Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-30 – JLG Lift – 3120895Figure 7-35. Electrical Schematic - Isuzu Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-31Figure 7-36. Electrical Schematic - Isuzu Engine w/o JLG Control Sy

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-32 – JLG Lift – 3120895Figure 7-37. Electrical Schematic - Caterpillar Engine - Sheet 1 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-33Figure 7-38. Electrical Schematic - Caterpillar Engine - Sheet 2 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-34 – JLG Lift – 3120895Figure 7-39. Electrical Schematic - Caterpillar Engine - Sheet 3 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-35Figure 7-40. Electrical Schematic - Caterpillar Engine - Sheet 4 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-36 – JLG Lift – 3120895Figure 7-41. Electrical Schematic - Caterpillar Engine - Sheet 5 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-37Figure 7-42. Electrical Schematic - Caterpillar Engine - Sheet 6 of

SECTION 2 - GENERAL2-6 – JLG Lift – 3120895Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-38 – JLG Lift – 3120895Figure 7-43. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-39Figure 7-44. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-40 – JLG Lift – 3120895Figure 7-45. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-41Figure 7-46. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-42 – JLG Lift – 3120895Figure 7-47. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-43Figure 7-48. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-44 – JLG Lift – 3120895Figure 7-49. Electrical Schematic - Hydraulic Welder

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-45This page left intentionally blank.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-46 – JLG Lift – 3120895Figure 7-50. Electrical Schematic - Deutz, GM, & CAT Engine - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-47Figure 7-51. Electrical Schematic - Deutz, GM, & CAT Engine - S

SECTION 2 - GENERAL3120895 – JLG Lift – 2-7Platform Controls 55 66Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitc

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-48 – JLG Lift – 3120895Figure 7-52. Electrical Schematic - Deutz, GM, & CAT Engine - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-49Figure 7-53. Electrical Schematic - Deutz, GM, & CAT Engine - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-50 – JLG Lift – 3120895Figure 7-54. Electrical Schematic - Deutz, GM, & CAT Engine - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-51Figure 7-55. Electrical Schematic - Deutz, GM, & CAT Engine - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-52 – JLG Lift – 3120895Figure 7-56. Hydraulic Schematic - (Sheet 1 of 6)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-53Figure 7-57. Hydraulic Schematic - (Sheet 2 of 6)1001093691 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-54 – JLG Lift – 3120895Figure 7-58. Hydraulic Schematic - (Sheet 3 of 6)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-55Figure 7-59. Hydraulic Schematic - (Sheet 4 of 6)1001093691 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-56 – JLG Lift – 3120895Figure 7-60. Hydraulic Schematic - (Sheet 5 of 6)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120895 – JLG Lift – 7-57Figure 7-61. Hydraulic Schematic - (Sheet 6 of 6)1001093691 A

SECTION 2 - GENERAL2-8 – JLG Lift – 3120895All Decals/Placards Installed, Secure, Legible 21 21 21Walk-Around Inspection Performed 21Annual Machine In

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-58 – JLG Lift – 3120895NOTES:

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (Au

SECTION 2 - GENERAL3120895 – JLG Lift – 2-9Figure 2-1. Engine Operating Temperature Specifications - Deutz4150548 D

SECTION 2 - GENERAL2-10 – JLG Lift – 3120895Figure 2-2. Engine Operating Temperature Specifications - Ford4150548 D

SECTION 2 - GENERAL3120895 – JLG Lift – 2-11AMBIENT AIRTEMPERATUREFigure 2-3. Engine Operating Temperature Specifications - Caterpillar4150548 D

3120895 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - GENERAL2-12 – JLG Lift – 3120895Figure 2-4. Engine Operating Temperature Specifications - GM4150548 D

SECTION 2 - GENERAL3120895 – JLG Lift – 2-13AMBIENT AIRTEMPERATUREFigure 2-5. Engine Operating Temperature Specifications - Perkins4150548 D

SECTION 2 - GENERAL2-14 – JLG Lift – 3120895NOTES:

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31208953. The tightening of the nuts should be done in stages.Following the recommended sequence,

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-3Disassembly of Cover Unit (8)1. Loosen and remove hex. hd. bolts (53) and removecover (51).

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3120895Figure 3-1. Drive Hub (Part No. 2780243-2WD Rear & Part No. 2780244-4WD Rear)

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-53.3 DRIVE HUB PART NO. 2780246 (4WD STEER AXLE PRIOR TO S/N 0300076633)The final drive cons

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3120895Assembly of First Stage Planetary Assembly (7)1. Pre-freeze planet pins (5) and install int

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-7Figure 3-2. Drive Hub (Part No. 2780246-4WD Steer)

ii – JLG Lift – 3120895TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 31208953.4 TORQUE HUB - 4WD (MACHINES BUILT AFTER S/N 0300076633)Roll and Leak Testing Always roll

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-911. Lift input shaft sub-assembly (7) out of middle ofspindle (1A), and stand input shaft (

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3120895NOTE: If you don’t drive the roll pin all the way into theplanet shaft t, you could damage

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-115. Place one thrust washer (3B) onto the end of planetshaft (3E) inside carrier. Fit tang

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3120895Cover Sub-Assembly1. Using the disconnect rod, push o-ring (6F) into thegroove inside the

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-137. With the large end down, place the disconnect cap(6D) onto the cover cap (6B), aligning

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31208953. Apply a light coat of "Never-Seize" to two pipe plugs(1J) and tighten them in

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-159. Place spacer (1H) onto spindle (1A) in hub (1G).NOTE: Make sure the retaining ring is s

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 31208953. Place internal gear (2) into hub (1G) so that its inter-nal splines mesh with the exter

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-179. With large splined end down, place input shaft sub-assembly (7) into spindle (1A). 10.

3120895 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 312089515. Oil all exposed surfaces inside the hub (1G). Placethrust washer (11) into the counter

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-1919. Place shoulder bolts (13) into the four shoulder boltholes in cover (6) and tighten by

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 312089523. Turn hub (1G) over onto its side. Insert coupling (14)into the end of the spindle (1A)

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-212. T-138903 ASSEMBLY PRESSING TOOL for CUP(1C)3. T-140433 ASSEMBLY PRESSING TOOL for CUP(1

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31208953.6 DRIVE BRAKEPre-Installation ChecksMECHANICALCheck, That in the handling prior to assem

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-23InstallationPosition 1-off gasket (5) over male pilot on brake housing(4).Locate brake sha

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3120895ing rings are assembled opposite ti the pressurizedside of piston (9).5.Correctly orientat

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-253.7 DRIVE MOTORDescriptionThe drive motors are low to medium power, two-positionaxial pist

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3120895Loop Flushing ValveREMOVAL1. Using a 11/16 in internal hex wrench remove plug(1) and (2).2

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-27TroubleshootingTable 3-2. Excessive Noise and/or VibrationItem Description ActionCheck oil

iv – JLG Lift – 3120895TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3120895DisassemblyNOTE: Removal of the endcap voids warranty.During assembly, coat all moving par

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-2913. Using an 8 mm internal hex wrench, remove theendcap screws (22).14. Remove the endcap

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 312089518. Remove minimum angle stop (29) and servo spring(30) from the housing.19. Turn the hous

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-3123. Turn housing over and remove the swashplate (39)by lifting on the end opposite the ser

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 312089528. Turn the block over. Using a press, apply pressureon the block spring washer (50) to c

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-33BALL GUIDE AND SLIPPER RETAINERInspect the ball guide and slipper retainer for damage,disc

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 3120895SERVO PISTON AND MINIMUM ANGLE STOPInspect the minimum angle stop, servo piston head, ands

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-353. Install the inner block spring washer (4), blockspring (5), and outer washer (6) into t

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 31208958. Press front shaft bearing (15) onto shaft (16). Pressbearing onto shaft with lettering

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-3712. Press the rear shaft bearing (22) into the endcap.Install the bearing with letters fac

3120895 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 312089518. Cover shaft splines with an installation sleeve. Installa new shaft seal (27) with the

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-3920. Install orifice poppet (30).21. Install shift spool (31).22. Install spring retaining

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 31208953.8 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE1. With the turntable centered, adjust the brack

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-413.10 2WD HUBRemoval & Disassembly1. Remove the tire and wheel. Refer to Section 3.1,Ti

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3120895Assembly & Installation1. Use a cup driver or mild steel bar to press or drivethe new

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-433.11 OSCILLATING AXLE BLEEDING PROCEDUREENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CEN-T

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 31208956. Have an assistant check to see that right front wheelremains locked in position off of

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-45Check the turntable to bearing. Attach bolts as follows:1. Elevate the fully retracted boo

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3120895Replacement of Swing BearingRemoval of the swing bearing is as follows:1. Attach an adequa

SECTION 3 - CHASSIS & TURNTABLE3120895 – JLG Lift – 3-4714. Using all applicable safety precautions, activate thehydraulic system and functionally