Jlg 740AJ Service Manual Manuel d'utilisateur

Service and Maintenance ManualModels740A740AJP/N - 3121160January 8, 2013

vi – JLG Lift – 3121160TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3121160h. Carefully place the turntable on a suitably sup-ported trestle.i. Use a suitable tool t

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-49c. Refer to the Torque Sequence diagram asshown in Figure 3-38., Swing Bearing TorqueSeque

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 312116010. The Bearing Cups (1C) &(1E) will remain in Hub(1G) as will Bearing Cone (1F). Bear

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-514. Thrust Spacer (9) is installed into the bore of theOutput Shaft (1A). This should be a

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31211609. Thrust Washer (10) is installed onto the Input Gear(8) and should locate on the gear te

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-5315. Torque Shoulder Bolts (13) to 23-27 ft.-lbs. and regu-lar Grade 8 Bolts (12) to 23-27

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 31211606. The Bearing Cone (1F) is an interference fit and hasto be pressed or tapped on.7. Pipe

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-5512. If the assembly is not going to be used right away, itshould be oiled and covered to h

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 31211606. While keeping Thrust Washers in place, slide ClusterGear into Carrier with the larger g

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-57Figure 3-39. Swing Hub

3121160 – JLG Lift – vii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 31211603.14 SWING BRAKE - AUSCO (PRIOR TO S/N 0300068040)Disassembly1. With the shaft protrusion

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-59Figure 3-40. Swing Brake Assembly (Ausco) (Prior to S/N 0300068040)

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 31211603.15 SWING MOTOR (EATON) (PRIOR TO S/N 0300068040)Cleanliness is extremely important when

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-61housing. Apply just enough heat to remove screw, do notover heat the motor housing or moun

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121160BE SURE THE EXCLUSION SEAL AND PRESSURE SEAL AREUNDAMAGED AND PROPERLY SEATED.5. Clamp the

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-631. Capscrew2. Exclusion Seal3. Mounting Flange4. Backup Ring5. Pressure Seal6. Seal7. Bear

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 31211603.16 SWING HUB (S/N 0300068040 TO PRESENT)Disassembly1. Loosen all 12 cover bolts (12)&

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-653. Place O-ring (5) into hub counterbore. Use petro-leum jelly to hold O-ring in place. Al

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 31211608. Input gear (8) is installed, meshing with teeth of thelarge diameter cluster gear (3F).

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-6714. Pipe plugs (20) are to be installed into cover (6)using a lubricant of some sort.15. T

viii – JLG Lift – 3121160TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 31211605. The shaft seal (1B) is installed over the output shaft(1A) and into the counterbore of

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-6910. A soft metal punch should be used to insure that thisretaining ring (1I) is completely

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 31211604. Place second set of sixteen needle rollers into clus-ter gear.5. Apply grease or petrol

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-71Figure 3-43. Swing Drive Hub (Fairfield) (S/N 0300068040 to Present)

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 31211603.17 SWING BRAKE (S/N 0300068040 TO PRESENT)Disassembly1. Remove pressure plate (2) from c

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-73Figure 3-44. Swing Brake (S/N 0300068040 to Present)* Items Included in Repair Kit1. Caps

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 31211603.18 SWING MOTOR (S/N 0300068040 TO PRESENT)DisassemblyCleanliness is extremely important

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-7513. Reposition motor in vise. Clamp across ports asshown above. Do not clamp side of housi

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 312116017. A metal plug, with seal, plugs a machining hole inthe housing. It is not necessary to

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-77 2. Lubricate output shaft with hydraulic oil, then installshaft in housing.DO NOT PERMIT

3121160 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 312116010. Before installing flange and seal assembly overshaft, place protective sleeve or bulle

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-79Reverse rotation align any star valley with marked tooth(see figure below).1. Rotate gerot

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 31211601. Capscrew2. Exclusion Seal3. Mounting Flange4. Backup Ring (-008, -009 Motors)5. Pressur

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-813.19 ROTARY COUPLINGUse the following procedure to install the seal kit.NOTE: Step 1 is ap

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 31211601. Center Body2. Seal3. Housing4. O-ring5. Seal6. Thrust Ring7. Snap Ring8. Valve Block (A

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-83Figure 3-48. Rotary Coupling Port Location

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 31211601817201910978111213141615141312118382514861. Loctite #2422. Bolt3. Bolt4. Bolt5. Bracket6.

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-853.20 TILT ALARM SWITCH (PRIOR TO S/N 0300062045)PERFORM TILT ALARM SWITCH LEVELING PROCEDU

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 3121160ABDDBCFigure 3-51. Auxiliary Pump - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-87Figure 3-52. Auxiliary Pump - Sheet 2 of 21. DC Motor2. Coupling Half3. Washer4. Lockwash

xii – JLG Lift – 3121160LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 31211603.22 GENERATOREvery 250 hoursEvery 250 hours of operation, check the drive belt forproper

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-8911/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must rideco

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 31211603.23 DUAL FUEL SYSTEMIT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THEOTHER WITHOUT ALL

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-91Engine Module and SensorsCRANKSHAFT POSITION (CKP) SENSORThe crankshaft position (CKP) sen

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3121160Table 3-10. ECM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription11All Systems OK12

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-93Table 3-11. EPM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription Cause for Setting

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 3121160145Adaptive Learn High (Natural Gas) This fault will set if the adaptive multiplier excee

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-95232 MAP Low Voltage This fault will set when the MAP reading is lower than the sensor sho

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3121160321Injector Driver #4 Open (2.5L) This fault will set if the EPM detects 10 injector firi

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-97513FP P1 Hig her Th an I VS L imit Th is fa ult wi ll set if the IVS is a t id le

3121160 – JLG Lift – xiii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3121160535TPS1 Higher Than TPS2 This fault will set if TPS1 is 20% (or more) higher than TPS2. At

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-99612Invalid Interrupt Several different things can happen within the microprocessor that w

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3121160ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)The electrically erasable pro

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-101Figure 3-54. EFI Component Location

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3121160MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORThe manifold absolute pressure (MAP) sensor respon

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-103ENGINE MODULE SERVICE PRECAUTIONSThe Engine Module is designed to withstand normal cur-re

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 3121160Figure 3-55. ECM/EPM IdentificationECMEPM

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-105ELECTROSTATIC DISCHARGE DAMAGEElectronic components used in the Engine Module areoften de

SECTION 3 - CHASSIS & TURNTABLE3-106 – JLG Lift – 3121160FUEL METERING SYSTEM PURPOSEThe basic function of the air/fuel metering system is tocontr

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-107FUEL PRESSURE REGULATORThe fuel pressure regulator is a relief valve mounted in thefuel f

xiv – JLG Lift – 3121160LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-108 – JLG Lift – 3121160The electronic governor also acts as an idle air control(IAC) valve. Changes in engine lo

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-109ELECTRONIC IGNITIONThe electronic ignition system controls fuel combustion byproviding a

SECTION 3 - CHASSIS & TURNTABLE3-110 – JLG Lift – 31211603.25 FORD LPG SYSTEM (S/N 0300077500 TO PRESENT)NOTE: +20° F (-6.6° C) is the low tempera

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-111MegajectorRegulator Lockoff SolenoidFigure 3-57. LPG System Components (S/N 0300077500 t

SECTION 3 - CHASSIS & TURNTABLE3-112 – JLG Lift – 3121160Lockoff SolenoidThe lockoff solenoid is used to reduce the possibility ofbackfires. The E

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-113DTC 362 - Megajector voltage supply low.a. Voltage - Check battery voltage. If the voltag

SECTION 3 - CHASSIS & TURNTABLE3-114 – JLG Lift – 3121160The EMR2 is equipped with safety devices and measuresin the hardware and software in orde

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-115Figure 3-59. Deutz EMR 2 Troubleshooting Flow Chart

SECTION 3 - CHASSIS & TURNTABLE3-116 – JLG Lift – 3121160Figure 3-60. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-117Figure 3-61. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

3121160 – JLG Lift – xv LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-118 – JLG Lift – 3121160Figure 3-62. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-119Figure 3-63. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-120 – JLG Lift – 3121160Figure 3-64. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-121Figure 3-65. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3-122 – JLG Lift – 3121160Figure 3-66. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-123Figure 3-67. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3-124 – JLG Lift – 3121160Figure 3-68. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-125Figure 3-69. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS & TURNTABLE3-126 – JLG Lift – 31211603.27 GM ENGINE GENERAL MAINTENANCEMaintenance of the Drive BeltThe serpentine drive belt

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-1276. If the oil level is below the "ADD" mark, proceed toStep 7 and 8 and reinsta

xvi – JLG Lift – 3121160LIST OF TABLES TABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-128 – JLG Lift – 31211602. Remove the radiator cap. Fill the radiator with cool-ant until coolant starts to appea

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-1293.28 GM ENGINE DUAL FUEL SYSTEMNOTE: +20° F (-6.6° C) is the low temperature limit for LP

SECTION 3 - CHASSIS & TURNTABLE3-130 – JLG Lift – 3121160Low Pressure Regulator (LPR)The LPR is a combination vaporizer, pressure regulatingdevice

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-131Electronic Throttle Control (ETC)Engine speed and load control is maintained by an ETCdev

SECTION 3 - CHASSIS & TURNTABLE3-132 – JLG Lift – 3121160Heated Exhaust Gas Oxygen SensorThere are two Heated Exhaust Gas Oxygen Sensors(HEGO). Th

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-133Fuel FilterAfter the fuel is drawn into the fuel pump, the fuel flowsthrough the gasoline

SECTION 3 - CHASSIS & TURNTABLE3-134 – JLG Lift – 3121160Propane Fuel Filter ReplacementREMOVAL1. Relieve the propane fuel system pressure. Refer

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-135Electronic Pressure Regulator (EPR) Assembly ReplacementThe EPR assembly is a made up of

SECTION 3 - CHASSIS & TURNTABLE3-136 – JLG Lift – 312116010. Start the vehicle and leak check the propane fuelsystem at each serviced fitting Refe

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-137Electronic Throttle Control Replacement See Figure 3-83.REMOVAL1. Disconnect the negative

3121160 – JLG Lift – xvii LIST OF TABLESTABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-138 – JLG Lift – 31211604. Place gasket on intake manifold and attach mixer/throttle assembly to manifold.Mixer R

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-139Engine Control Module ReplacementREMOVAL1. Disconnect Negative battery cable.2. Remove co

SECTION 3 - CHASSIS & TURNTABLE3-140 – JLG Lift – 3121160Diagnostic AidsThis procedure is intended to diagnose a vehicle operat-ing on LPG. If the

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-141Table 3-12. LPF Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to th

SECTION 3 - CHASSIS & TURNTABLE3-142 – JLG Lift – 312116013 1. Turn OFF the ignition.2. Disconnect the LPL connector.3. Install a test light betwe

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-14325 The fuel supply system is operating normally, if a failure of the control solenoids is

SECTION 3 - CHASSIS & TURNTABLE3-144 – JLG Lift – 3121160Table 3-13. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using This S

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-145Intermittent Malfunction Indicator Lamp (MIL)The following components can cause intermitt

SECTION 3 - CHASSIS & TURNTABLE3-146 – JLG Lift – 3121160Exhaust System Checks  Check the exhaust system for a possible restriction:

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-147Exhaust System Checks  Check the exhaust system for a possible restriction: - Inspec

xviii – JLG Lift – 3121160LIST OF TABLES TABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-148 – JLG Lift – 3121160Hesitation, Sag, StumbleDEFINITION: The vehicle has a momentary lack of response when dep

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-149Lack of Power, Sluggishness, or SponginessDEFINITION: The engine delivers less than exp

SECTION 3 - CHASSIS & TURNTABLE3-150 – JLG Lift – 3121160Ignition System Checks  Verify that the spark plugs are correct for use with LPG (R42LT

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-151Engine Mechan ical Check  Check the engine for the following:

SECTION 3 - CHASSIS & TURNTABLE3-152 – JLG Lift – 3121160Table 3-14. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 Crank

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-153562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid 628

SECTION 3 - CHASSIS & TURNTABLE3-154 – JLG Lift – 31211603.31 AIR COMPRESSORDescriptionThe compressor consists of a heavy duty rotary screw aircom

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-1551. Compressor Assembly2. A i r Fi lte r Ele ment3. Coalescer Spin-On Element

SECTION 3 - CHASSIS & TURNTABLE3-156 – JLG Lift – 3121160Minimum Pressure Valve/Check Valve AssemblyThis combined valve located in the filter supp

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-15715. Allow all air to vent to atmosphere, then check com-pressor oil level - top up if nec

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 ENGINE DATA Table 1-1. CapacitiesFuel Tank Approx. 39

SECTION 3 - CHASSIS & TURNTABLE3-158 – JLG Lift – 3121160Lubrication Guide IT IS IMPORTANT THAT THE COMPRESSOR OIL BE OF A RECOM-MENDED TYPE AND T

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-1593. Run compressor and test for leaks. Coalescer (Air/Oil Separator) ReplacementThis is a

SECTION 3 - CHASSIS & TURNTABLE3-160 – JLG Lift – 3121160Cooler Core Cleaning (Exterior) Remove leaves, papers, etc. from outside face. Use com-pr

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-161Intake ControlThe intake control consists of two main sub-assemblies: 1. Inlet Valve Asse

SECTION 3 - CHASSIS & TURNTABLE3-162 – JLG Lift – 3121160Table 3-16. Air Compressor TroubleshootingSYMPTOM PROBABLE CAUSE SOLUTION1. Compress

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-1634. Insuf6cient air delivery a. Plugged air filter b. Plugged coalescer c. Mo

SECTION 3 - CHASSIS & TURNTABLE3-164 – JLG Lift – 31211607. System retains pressure after shut-downa. Solenoid valve stuck b. Leak back fr

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCEPlatform/Support Removal1. Disconnect electr

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121160Support Installation1. Using a suitable device, support the platform sup-port and position it o

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-34.2 ROTATOR AND SLAVE CYLINDERRemoval1. Tag and disconnect hydraulic lines to rotator. Usesuita

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31211601.3 TIRES1.4 DRIVE SYSTEM1.5 SWING SYSTEM1.6 HYDRAULIC DRIVE PUMP1.7 VARIABLE DISPLACEMENT PUMP1.8 H

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31211605. Supporting the slave, cylinder remove the hardwarefrom pin #3. Using a suitable brass drift

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-5Round Bar/Poly Bar Removal1. Use a small ¼” ratchet with a T-25 Torx bit. Removethe 10-24 x 0.8

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121160Removing and Installing Links1. To remove the links, the rivets holding the linkstogether must

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-74. To install new links, extend the upper moving endover the lower part of the track so the new

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3121160NOTE: When installing snap rings make sure they areseated in the pin groove and closed properly

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-9Installing a New Flat Bar1. While holding the flat bar, install new 8-32 x 0.500self threading

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121160Replacing a Fixed End Bracket1. Remove the bracket by removing the center pin,washer, and snap

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-11Replacing a One Piece Bracket1. Remove all pins, washers, and snap rings and slidethe bracket

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 31211604.5 MAIN BOOM ASSEMBLY Removal1. Using a suitable lifting equipment, adequately sup-port boom

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-137. Using all applicable safety precautions, carefully liftboom assembly clear of upright and l

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-31.9 AUXILIARY POWER PUMP1.10 HYDRAULIC FILTER - IN-LINE1.11 COMPRESSOR1.12 DIMENSIONAL DATA1.13 OPER

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31211604.6 UPRIGHTRemovalHYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-ATELY AFTER DISCONNECTING

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-15Inspection1. Inspect tower boom pivot pin for wear scoring,tapering, and ovality, or other dam

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3121160Tower Out of SyncTower is out of sync backwards, upright leaning towardthe platform.When tower

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-17Tower is out of sync forwards, upright leaning towardthe steer axle. When towering down, the l

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 31211604.8 ARTICULATING JIB BOOMRemoval1. For platform/support removal see platform/supportremoval di

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-19Assembly1. Align lift cylinder with attach holes in articulating jibboom. Using a soft head ma

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3121160Figure 4-7. Boom Valve and Limit Switches Location0271989-A

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-21Figure 4-8. Transportation Switch Installation. (CE Only)0258384-A

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3121160Figure 4-9. Tower Power Track Installation. (Sheet 1 of 2)

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-23Figure 4-10. Tower Power Track Installation. (Sheet 2 of 2)

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31211601.14 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsTo w e r L i f t : Upper Boom Horizon

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 31211604.10 PLATFORMPlatform Sections ReplacementThe platform is made up of five sections: floor, rig

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-25Main Boom1. Shim up wear pads to within 1/32 inch (.79 mm)clearance between wear pad and adjac

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 31211604. Using a torch, apply heat to the setscrews on thebottom of actuator.5. Remove the two (2) s

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-27AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulicoil prior to assembly.1. Ins

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 3121160Figure 4-14. Rotator Assembly (HELAC)

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-294.13 ROTATOR ASSEMBLY (S/N 0300130881 TO PRESENT)Theory of OperationThe L20 Series rotary actu

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3121160The seal tool is merely a customized standard flat headscrewdriver. To make this tool you will

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-31PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 3121160Disassembly1. Remove the cap screws (113) over end cap lockpins (109). 2. Using a 1/8” (3.18mm

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-336. Remove the end cap (4) and set aside for laterinspection. 7. Remove the stop tube if includ

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-51.15 TORQUE REQUIREMENTS 1.16 LUBRICATIONHydraulic OilNOTE: Hydraulic oils must have anti-wear quali

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 312116010. Remove the shaft (2). It may be necessary to strikethe threaded end of the shaft with a ru

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-3516. To remove the main pressure seals (205), it is easi-est to cut them using a sharp razor bl

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 3121160Inspection1.Clean all parts in a solvent tank and dry with com-pressed air prior to inspecting

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-372. Install the thrust washer (304) onto shaft (2) and endcap (4). 3. Install the wiper seal (3

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 31211606. Install the inner T-seal (200) into the piston (3) usinga circular motion. Install the oute

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-399. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 312116014. Coat the threads on the end of the shaft with anti-seize grease to prevent galling. 15. In

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-41Installing Counterbalance ValveRefer to Figure 4-17., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 3121160Testing the ActuatorIf the equipment is available, the actuator should be testedon a hydraulic

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-43TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31211601.17 CYLINDER SPECIFICATIONSTable 1-21. Mobil DTE 13M SpecsISO Viscosity Grade #32Specific Gravity

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 31211604.14 DRIVE CARD SETUP PROCEDURESLift, Swing, and Drive Cards5. Center the input potentiometers

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-45 4.15 FOOT SWITCH ADJUSTMENTAdjust so that functions will operate when pedal is at cen-ter of

SECTION 4 - BOOM & PLATFORM4-46 – JLG Lift – 312116090° 90°90°90°Figure 4-20. Boom Upright PositioningUPRIGHT MUST BE 90° (VERTICAL) RELATIVETO TH

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-47Calibration - Pre ADE MachinesCALIBRATION OF THE UPRIGHT MONITORING SYSTEMREQUIRES THE MACHINE

SECTION 4 - BOOM & PLATFORM4-48 – JLG Lift – 3121160c. Press "ENTER" , and the following screenwill be displayed asking if you wish to

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-49NOTE: By pressing the left or right arrows in this screen, youmay view the output of each sens

SECTION 4 - BOOM & PLATFORM4-50 – JLG Lift – 3121160After the required activation time has passed,release the function switch and press "ENTE

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-51Calibration - ADE Equipped Machines1. Connect the JLG Hand-held analyzer to the originalanalyz

SECTION 4 - BOOM & PLATFORM4-52 – JLG Lift – 3121160IT IS NOT NECESSARY TO CALIBRATE THE TILT SENSOR IN THEGROUND CONTROL MODULE AT THIS TIME. HOW

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-53g. After the main boom has been fully elevated,press "ENTER" . The analyzer will

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-71.18 MAJOR COMPONENT WEIGHTS 1.19 PRESSURE SETTINGS1.20 CRITICAL STABILITY WEIGHTSDO NOT REPLACE ITE

SECTION 4 - BOOM & PLATFORM4-54 – JLG Lift – 3121160i. When viewing the above display, press"ENTER" . The screen will display the fol-lo

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-55If the calibration has not been completed suc-cessfully, the display will automatically change

SECTION 4 - BOOM & PLATFORM4-56 – JLG Lift – 3121160Function CheckON ADE EQUIPPED MACHINES, DO NOT CONNECT TO THE ANA-LYZER CONNECTION PORT INSTAL

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-576. The controller will now display the following:or, by pressing the up and down arrow keys:7.

SECTION 4 - BOOM & PLATFORM4-58 – JLG Lift – 31211604. Scroll through the top level menu until SERVICEMODE appears. Press "ENTER" to s

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-597. Enter the service code "81075" and press the"ENTER" key. The controll

SECTION 4 - BOOM & PLATFORM4-60 – JLG Lift – 3121160THIS SENSORON NON ADEMACHINES ONLYFigure 4-21. UMS Sensor Location

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-61ADEMACHINESNON-ADEMACHINESFigure 4-22. UMS Module Location

SECTION 4 - BOOM & PLATFORM4-62 – JLG Lift – 3121160J1 J21 IGN POWER (7-33V) 1 +5V ANALOG EXCITATION2 GROUND 2 ANALOG INPUT 03 DIGITAL INPUT 0 3

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-634.17 UMS TROUBLESHOOTING AND FAULT MESSAGES - NON-ADE MACHINESTower Lift Down Permanently clos

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31211601.21 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1-1., Operator M

SECTION 4 - BOOM & PLATFORM4-64 – JLG Lift – 3121160UMS Sensor Not Calibrated Message8/1 UMS SENSOR NOT CALIBRATEDIf the control system detects a

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-65Turntable Sensor Faulted8/1 TURNTABLE FAULTEDIf the system detects that the Chassis tilt senso

SECTION 4 - BOOM & PLATFORM4-66 – JLG Lift – 3121160Out of Usable Range Message8/1 UMS SENSOR OUT OF USABLE RANGEWhen both the Chassis tilt sensor

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-674.19 USE AND CARE OF FALL ARREST SYSTEMThe external fall arrest system is designed to provide

SECTION 4 - BOOM & PLATFORM4-68 – JLG Lift – 3121160Shown below is the slip indicator with a gap, signifyingthat the fall arrest system should be

SECTION 4 - BOOM & PLATFORM3121160 – JLG Lift – 4-69Figure 4-24. Fall Arrest System1. Transfastener2. Bracket3. Cable4. Swage/Slip In

SECTION 4 - BOOM & PLATFORM4-70 – JLG Lift – 3121160NOTES:

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121160Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-35.2 VALVES - THEORY OF OPERATIONSolenoid Control Valve - RexrothControl valves used are four-way three-p

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-92.Wheel BearingsLube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 years or 1200 hours

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31211605. With cylinder fully retracted, shut down engine andcarefully disconnect hydraulic hose from cylindere

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-53. There will be initial weeping of hydraulic fluid, whichcan be caught in a suitable container. After t

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31211609. Using suitable protection, clamp the cylinder rod ina vise or similar holding fixture as close to the

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-7NOTE: Install pin into the Gar-Max bearing dry. Lubricationis not required with nickel plated pins and b

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31211604. Install washer ring onto rod, carefully install the headgland on the rod, ensuring that the wiper and

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-916. Secure the cylinder head gland using the washerring and socket head bolts.17. After the cylinder has

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31211605.6 CYLINDER REMOVAL AND INSTALLATIONMain Boom Telescope Cylinder Removal1. Place machine on a flat and

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-116. Remove mounting hardware securing the Main LiftCylinder rod end to the base boom.7. Using a suitable

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31211605. Remove overhead crane and sling. Activate hydrau-lic system.6. Using all applicable safety precautio

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-1312. Using all applicable safety precautions, operate theboom functions. Check for correct operation and

INTRODUCTION3121160 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 31211607.Suction StrainersLube Point(s) - 2Interval - Every 2 years or 1200 hours of operation,remove and

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31211607. Using all applicable safety precautions, start themachine from the ground control and fully raise an

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-151. Steer Left 2. Upper Lift Down3. Pressure Check Port 4. Platform Level Down5. Pressure CheckPort 6. P

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3121160* When removing the control valve, it is important to observe the tag on the face of the valve, as the

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-17Table 5-3. Cartridge Torque ValuesFt-Lbs. NmA 18-20 24.5-27.2B 12-14 16.3-19C 25-27 34-36D 33-37 44.9-5

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31211603. SteerUsing the same gauge at the same port. Activatesteer left or right. The gauge should read 1800

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-195.9 HYDRAULIC OIL CHANGE-OUT PROCEDUREThis procedure is written to change out JLG std. hydraulicoil (Mo

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31211605.10 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSFrom a hydrostatic component standpoint

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-21Figure 5-17. Variable Displacement Pump. (Rexroth)

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 31211605.12 SAUER PISTON PUMP S/N 0300121643 TO PRESENTTable 5-4. Symbols UsedSymbol MeaningSymbol MeaningNon

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-23Initial start-up proceduresFollow this procedure when starting-up a new pump orwhen the pump has been r

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-1110. Oil Change w/Filter - GMLube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965)Capacity

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3121160Table 5-7. Actuator Response Is SluggishItem Description ActionCheck external system relief valve sett

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-25Table 5-9. Low Pump Output FlowItem Description ActionCheck fluid level in reservoir. Insufficient hyd

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121160HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGEINTERNAL PUMP COMPONENTS.Table 5-11. System Pressu

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-27Shaft Seal ReplacementA lip type shaft seal is used in the pump and can bereplaced without major disass

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 31211604. Remove the plug (C103), O-ring (C103A),and Pres-sure Compensator spool (C132) from the controlhousin

SECTION 5 - HYDRAULICS3121160 – JLG Lift – 5-29Plug and Fitting Sizes and TorquesIf any plugs or fittings are removed from the unit duringservice, ins

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 3121160NOTES:

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING ANY NEW MODULE CONTROLLER ON THEMA

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121160Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERATEACT ACTIVEA/D ANALOG DIGITA

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-3Figure 6-2. ADE Block Diagram

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121160Draining Oil Build Up From The Propane RegulatorDuring the course of normal operation oils may buil

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121160ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTOMENU:MACHINE SETUPPERSONALITIES:DR

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-5FROMPERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:UPPER TELESCOPEPERSONALITIES:BASKET

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121160FROMMENU:PERSONALITIESMENU:MACHINE SETUPTOMENU:CALIBRATIONSMODEL NUMBER:1=400ENGINE:1=FORD EFI G

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-7Figure 6-6. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121160Figure 6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4NOTE: Some screens may not

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-9Figure 6-8. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121160FROM:MENU:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL NUMBER:400SENGINE:FORD EFI G

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-11MENU:HELP:PRESS ENTERHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU:CALIBRATIONSMENU:DIAGNOSTIC

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121160Figure 6-11. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-13Figure 6-12. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-13Propane Fuel Filter ReplacementREMOVAL1. Relieve the propane fuel system pressure. Refer toPropane

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 31211606.2 CANBUS COMMUNICATIONSCANbus: CAN (Control Area Network) is a two wire differ-ential serial

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-15The top level menus are as follows:HELPDIAGNOSTICSSYSTEM TESTACCESS LEVELPERSONALITIESMACHINE S

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121160Then using the RIGHT arrow key, position the cursor tothe right one space to enter the second d

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-176.7 MACHINE SETUPWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjus

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121160Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3Configur

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-19GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: Automatic pre-glow time

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121160GEN SET CUTOUT:12* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-21GROUND ALARM:18* * Certain market selections will alter default setting.0123NO: No ground alarm

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121160Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1Configura

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-23ENGINE:3* * Engine selections vary depending on model selec-tion.12345678910111213FORD EFI GAS

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121160Propane Fuel System Pressure ReliefTHE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO312 PSI (21.5

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121160ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant temperatu

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-25GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121160FUNCTION CUTOUT:18* * Only visible under certain market selections. * Certain market selectio

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-27Table 6-4. Machine Configuration Programming Information Software Version P6.1 to PresentConfig

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121160ENGINE:3* * Engine selections vary depending on model selec-tion.123456789101112131415FORD EFI

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-29STARTER LOCKOUT:601DISABLED: Automatic pre-glow time determined by ambient air temperature; eng

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121160GEN SET/WELDER:1201NO: No generator installed.BELT DRIVE: Belt driven setup.0GEN SET CUTOUT:13*

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-31LOAD SENSOR:17* * Only visible if Load Sen-sor Menu selection is not 0 and under certain marke

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121160LEVELING MODE:22* * Only visible on 800S models.01ALL FUNCTIONS: Platform level with all funct

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-33740AJMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUTENGINE SHUTDOWNTILTJIB4 WHE

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-15Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121160Table 6-5. Machine Configuration ParametersConfiguration DigitParameter (Displayed on Analyzer

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-356 Tilt: 1=5Deg2=4Deg3=3DegDisplays/adjusts tilt sensor function1235 degree – reduces the maxi-m

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 312116013 Head & Tail LIGHTS0=NO1=YESDisplays presence of head and tail lights01No Head and Tail L

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-3720 PLATFORM ALARM0=NO1=FAULT CODEDisplays/adjusts platform alarm presence/functions0 1Sounds Co

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 31211606.9 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within theadjustmen

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-39SWING ACCELeration 0.1 to 5.0s 2.0DECELeration 0.1 to 3.0s 1.8MINimum LEFT speed 0 to 50% 35MAX

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3121160BASKET ROTATE ACCELeration 0.1 to 5.0 1.8DECELeration 0.1 to 3.0 0.3MlNimum LEFT speed 0 to 65

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-41Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066931Fault

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 31211602/3 Flash code 2/3 indicates problems with boom function selection. 3LIFT/SWING JOYSTICK FAULTY

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-433/2 Flash code 3/2 indicates that a contactor did not open when energized.NOT REQUIRED3/3 Flash

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121160Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3))

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 31211609/9 Flash code 9/9 indicates problems with the controller. 11PLATFORM MODULE FAILURE: hwfs CODE

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-45Table 6-8. Analyzer Fault Code ListingDTC Analyzer Text001 EVERYTHING OK002 GROUND MODE OK0010

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121160331 BRAKE - SHORT TO BATTERY332 BRAKE - OPEN CIRCUIT3311 GROUND ALARM - SHORT TO BATTERY3316 RI

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-473370 TWO SPEED VALVE - SHORT TO BATTERY3371 GROUND ALARM - SHORT TO GROUND3372 GROUND ALARM - O

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 312116033115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND33116 TOWER TELESCOPE OUT VALVE - OPEN CIRCUIT

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-4933315 FLOW CONTROL VALVE - SHORT TO BATTERY33316 FLOW CONTROL VALVE - SHORT TO GROUND33317 DRIV

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121160431 FUEL SENSOR - SHORT TO BATTERY432 FUEL SENSOR - SHORT TO GROUND433 OIL PRESSURE - SHORT TO

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-518311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY8312 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 31211609920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTO

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-53Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item i

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-17Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121160SWINGACCEL … Displays/adjusts swing accelerationDECEL … Displays/adjusts swing decelerationMIN

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-55ACCEL … Displays/adjusts jib accelerationDECEL … Displays/adjusts jib decelerationMIN UP … Disp

SECTION 6 - JLG CONTROL SYSTEM6-56 – JLG Lift – 3121160Table 6-10. Diagnostic Menu DescriptionsDRIVEDRIVE FOR … Displays drive joystick direction &

SECTION 6 - JLG CONTROL SYSTEM3121160 – JLG Lift – 6-57PM BATTERY … Displays battery voltage at platform moduleTEMP ... Displays ground module temper

SECTION 6 - JLG CONTROL SYSTEM6-58 – JLG Lift – 3121160NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121160Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31211607.4 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-53. After all required contacts have been inserted, thewedge lock must

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3121160Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3121160Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-7Figure 7-11. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31211607.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the cont

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121160J5J6J7J2J1J8PLATFORMCONTROLBOXMAIN BOOMELEVATIONLIMIT SWITCHTOWER BO

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-11JIBVALVE4WSVALVESTROBELIGHTFUELLEVELSENSOR2500WGENERATORRELAYAUXPUMP

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121160Figure 7-20. Electrical Schematic - Deutz & Ford Engines - Shee

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-13Figure 7-21. Electrical Schematic - Deutz & Ford Engines - Shee

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121160Figure 7-22. Electrical Schematic - Deutz EMR2 & GM Engines (Pr

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-15Figure 7-23. Electrical Schematic - Deutz EMR2 & GM Engines (Pr

SECTION 1 - SPECIFICATIONS3121160 – JLG Lift – 1-19Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 2 of 3))

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121160Figure 7-24. Electrical Schematic - Deutz EMR2 & GM Engines (Pr

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-17Figure 7-25. Electrical Schematic - Deutz EMR2 & GM Engines (Pr

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121160Figure 7-26. Electrical Schematic - Deutz EMR2 & GM Engines (Pr

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-19Figure 7-27. Electrical Schematic - Deutz EMR2 & GM Engines (Pr

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121160Figure 7-28. Electrical Schematic - Deutz EMR2 & GM Engines (S/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-21Figure 7-29. Electrical Schematic - Deutz EMR2 & GM Engines (S/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121160Figure 7-30. Electrical Schematic - Deutz EMR2 & GM Engines (S/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-23Figure 7-31. Electrical Schematic - Deutz EMR2 & GM Engines (S/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121160Figure 7-32. Electrical Schematic - Deutz EMR2 & GM Engines (S/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-25Figure 7-33. Electrical Schematic - Deutz EMR2 & GM Engines (S/

INTRODUCTIONA-2 – JLG Lift – 3121160REVISON LOGOriginal Issue - November 4, 2002Revised - September 8, 2003Revised - March 10, 2006Revised - September

SECTION 1 - SPECIFICATIONS1-20 – JLG Lift – 3121160Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3121160Figure 7-34. Hydraulic Schematic - Sheet 1 of 6

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-27Figure 7-35. Hydraulic Schematic - Sheet 2 of 62792535 B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3121160Figure 7-36. Hydraulic Schematic - Sheet 3 of 6

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-29Figure 7-37. Hydraulic Schematic - Sheet 4 of 62792535 B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-30 – JLG Lift – 3121160Figure 7-38. Hydraulic Schematic - Sheet 5 of 6

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121160 – JLG Lift – 7-31Figure 7-39. Hydraulic Schematic - Sheet 6 of 62792535 B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-32 – JLG Lift – 3121160NOTES:

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

SECTION 2 - GENERAL3121160 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31211602.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121160 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 3121160fied intervals required in the Lubrication Chart inSection 1. Always examine filters for evidence ofmetal p

SECTION 2 - GENERAL3121160 – JLG Lift – 2-5Drift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil must be at am

SECTION 2 - GENERAL2-6 – JLG Lift – 3121160Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3121160 – JLG Lift – 2-7Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 2 - GENERAL2-8 – JLG Lift – 3121160Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 2 - GENERAL3121160 – JLG Lift – 2-9-40° F(-40° C)-30° F(-34° C)-20°F(-29°C)-10°F(-23°C) 0°F(-18°C) 10°F(-12°C) 20°F( - 7°C) 30°F( - 1°C) 40°F

3121160 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - GENERAL2-10 – JLG Lift – 3121160Figure 2-2. Engine Operating Temperature Specifications - Ford4150548 E

SECTION 2 - GENERAL3121160 – JLG Lift – 2-11Figure 2-3. Engine Operating Temperature Specifications - GM4150548 E

SECTION 2 - GENERAL2-12 – JLG Lift – 3121160NOTES:

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31211603. The tightening of the nuts should be done in stages.Following the recommended sequence,

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-3Oscillating Axle Lockout TestLOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,ANY TIME A SYS

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31211603.4 TORQUE HUB, DRIVEDisassembly1. Position hub over suitable container and removedrain plu

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-52. Carrier Assembly.a. Drive anti-roll pin (19) into planet shaft (17) usinga suitable punc

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121160o. Drive anti-roll pin flush into carrier hole, lockingplanet shaft into place.p. repeat st

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-73. Press new seal (2) into hub counter bore with flatmetal side facing in. Use a flat objec

ii – JLG Lift – 3121160TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 31211609. Install thrust washers and thrust bearing (39, 40) onthe portion of the spindle which ex

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-915. Place carrier assembly on a flat surface with largegears up and positioned as shown. Fi

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 312116021. Place o-ring (22) into cover assembly counter bore.Use petroleum jelly or grease to ho

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-11Figure 3-3. Torque Hub Drive (Fairfield)1. Spindle2. Seal3. Bearing Cup4. Bearing Cone5.

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31211603.5 DRIVE BRAKE - AUSCO (PRIOR TO S/N 56875)Disassembly1. With shaft protrusion downward,

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-13. Figure 3-4. Drive Brake, Ausco1. Housing2. Gasket3. Torque Pin4. Ball Bearing5. Retaini

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31211603.6 DRIVE BRAKE - MICO (S/N 56875 TO 83332)Disassembly1.Remove pressure plate (3) from cov

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-151. Capscrew2. Washer3. Pressure Plate4. Case Seal5. O-ring6. Backup Ring7. Piston8. O-ring

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121160Bleeding1.Install brake in system and connect pressure lines.2. Bleed pressure release sec

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-173.7 DRIVE BRAKE (S/N 83332 TO PRESENT)Disassembly1. Supporting brake on face A:, remove th

3121160 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 31211605111012212192223433197814131615181720661. Shaft2. Housing3. Friction Plate4. Pressure Plat

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-193.8 DRIVE MOTOR (PRIOR TO S/N 83332)Spare Parts KitsSealing kit, existing spare parts: sha

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121160Replacing the Drive Shaft Seal1. Remove the snap ring 2. Change the shaft seal and check i

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-213. Be careful while you seal the drive shaft, use anadhesive tape to protect the splines.

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31211604. Remove the O-ring. 5. Disassemble the taper roller bearing.6. Remove the adjustment shi

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-2312. Remove the threaded pin (stopper - max.flow) 13. Disassemble the plug. 14. Disassemble

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 312116020. Remove the snap ring. 21. Disassemble the sealing ring.22. The external front bearing

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-25Assembly Notes1. Measurement of the taper roller bearing pretension. 2. Note that there is

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121160NOTE: Differential volume if you are rotating the threaded pin -each rotation is appr. 3,1

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-27Testing and SetupDR: When pressure line is closed adjust the pressure ofthe controller (if

iv – JLG Lift – 3121160TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 31211603.10 DRIVE MOTOR (S/N 83332 TO PRESENT)DescriptionThe drive motors are low to medium power

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-29Loop Flushing ValveREMOVAL1. Using a 11/16 in internal hex wrench remove plug(1) and (2).2

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121160TroubleshootingTable 3-3. Excessive Noise and/or VibrationItem Description ActionCheck oi

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-31DisassemblyNOTE: Removal of the endcap voids warranty.During assembly, coat all moving par

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 312116013. Using an 8 mm internal hex wrench, remove theendcap screws (22).14. Remove the endcap

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-3318. Remove minimum angle stop (29) and servo spring(30) from the housing.19. Turn the hous

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312116023. Turn housing over and remove the swashplate (39)by lifting on the end opposite the ser

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-3528. Turn the block over. Using a press, apply pressureon the block spring washer (50) to c

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121160BALL GUIDE AND SLIPPER RETAINERInspect the ball guide and slipper retainer for damage,disc

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-37SERVO PISTON AND MINIMUM ANGLE STOPInspect the minimum angle stop, servo piston head, ands

3121160 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121160RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRINGREQUIRES ABOUT 80 TO 90 LBF (350 TO 4

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-398. Press front shaft bearing (15) onto shaft (16). Pressbearing onto shaft with lettering

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 312116012. Press the rear shaft bearing (22) into the endcap.Install the bearing with letters fac

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-4118. Cover shaft splines with an installation sleeve. Installa new shaft seal (27) with the

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 312116020. Install orifice poppet (30).21. Install shift spool (31).22. Install spring retaining

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-433.11 SWING HUB INSTALLATION1. Ensure mounting plate and mounting location of thebase plate

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 31211603.12 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is desig

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-45Figure 3-34. Swing Bearing Tolerance Boom Placement. (Sheet 1 of 2)

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121160Figure 3-35. Swing Bearing Tolerance Boom Placement.(Sheet 2 of 2)

SECTION 3 - CHASSIS & TURNTABLE3121160 – JLG Lift – 3-47Wear Tolerance1. From the underside of the machine, at rear center,with the main boom full