Jlg 800A_AJ ANSI Service Manual Manuel d'utilisateur

Service and Maintenance ManualModels800A800AJP/N - 3120740December 12, 2012

vi – JLG Lift – 3120740TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3120740Figure 3-33. Swing Bearing Tolerance Boom Placement. (Sheet 1 of 2)

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-45Figure 3-34. Swing Bearing Tolerance Boom Placement.(Sheet 2 of 2)

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3120740Wear Tolerance1. From the underside of the machine, at rear center,with the upper boom ful

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-47Figure 3-37. Swing Bearing Torque SequenceNOTE: Swing Bearing Torque Sequence is typical

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3120740h. Carefully place the turntable on a suitably sup-ported trestle.i. Use a suitable tool t

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-493.12 SWING HUB INSTALLATION1. Ensure mounting plate and mounting location of thebase plate

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 31207403.13 SWING HUB (PRIOR TO S/N 0300068040)Disassembly1. Loosen all 12 Cover Bolts (12) 8 (13

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-51Also at this time locate and mark the 4 counterbeamed holes in the face of the Hub (1G). T

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31207408. Input Gear (8) is installed, meshing with the teeth ofthe large diameter Cluster Gear (

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-5313. Install regular Grade 8 Bolts (12) into remainingholes. 14. Pipe Plugs (20) are to be

3120740 – JLG Lift – vii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 31207404. Returning the Hub (1G) to locate on the large diame-ter end, the Output Shaft (1A) is c

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-558. Bearing Spacer (1H) is installed around the OutputShaft (1A) and locates on Bearing Con

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3120740Carrier Sub-Assembly1. Apply a coat of grease or petroleum jelly to ClusterGear bore.2. Pl

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-576. While keeping Thrust Washers in place, slide ClusterGear into Carrier with the larger g

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3120740Figure 3-39. Swing Hub

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-593.14 SWING BRAKE - AUSCO (PRIOR TO S/N 0300068040)Disassembly1. With the shaft protrusion

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3120740Figure 3-40. Swing Brake Assembly (Ausco) (Prior to S/N 0300068040)

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-613.15 SWING MOTOR (EATON) (PRIOR TO S/N 0300068040)Cleanliness is extremely important when

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3120740housing. Apply just enough heat to remove screw, do notover heat the motor housing or moun

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-63BE SURE THE EXCLUSION SEAL AND PRESSURE SEAL AREUNDAMAGED AND PROPERLY SEATED.5. Clamp the

viii – JLG Lift – 3120740TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 31207401. Capscrew2. Exclusion Seal3. Mounting Flange4. Backup Ring5. Pressure Seal6. Seal7. Bear

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-653.16 SWING HUB (S/N 0300068040 TO PRESENT)Disassembly1. Loosen all 12 cover bolts (12)&

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 31207403. Place O-ring (5) into hub counterbore. Use petro-leum jelly to hold O-ring in place. Al

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-678. Input gear (8) is installed, meshing with teeth of thelarge diameter cluster gear (3F).

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 312074014. Pipe plugs (20) are to be installed into cover (6)using a lubricant of some sort.15. T

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-695. The shaft seal (1B) is installed over the output shaft(1A) and into the counterbore of

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 312074010. A soft metal punch should be used to insure that thisretaining ring (1I) is completely

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-714. Place second set of sixteen needle rollers into clus-ter gear.5. Apply grease or petrol

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3120740Figure 3-43. Swing Drive Hub (Fairfield) (S/N 0300068040 to Present)

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-733.17 SWING BRAKE (S/N 0300068040 TO PRESENT)Disassembly1. Remove pressure plate (2) from c

3120740 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3120740Figure 3-44. Swing Brake (S/N 0300068040 to Present)* Items Included in Repair Kit1. Caps

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-753.18 SWING MOTOR (S/N 0300068040 TO PRESENT)DisassemblyCleanliness is extremely important

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 312074013. Reposition motor in vise. Clamp across ports asshown above. Do not clamp side of housi

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-7717. A metal plug, with seal, plugs a machining hole inthe housing. It is not necessary to

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 3120740 2. Lubricate output shaft with hydraulic oil, then installshaft in housing.DO NOT PERMIT

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-7910. Before installing flange and seal assembly overshaft, place protective sleeve or bulle

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 3120740Reverse rotation align any star valley with marked tooth(see figure below).1. Rotate gerot

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-811. Capscrew2. Exclusion Seal3. Mounting Flange4. Backup Ring (-008, -009 M

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 31207403.19 ROTARY COUPLINGUse the following procedure to install the seal kit.NOTE: Step 1 is ap

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-831. Center Body2. Seal3. Housing4. O-ring5. Seal6. Thrust Ring7. Snap Ring8. Valve Block (A

x – JLG Lift – 3120740LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3120740Figure 3-48. Rotary Coupling Port Location

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-851817201910978111213141615141312118382514861. Loctite #2422. Bolt3. Bolt4. Bolt5. Bracket6.

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 31207403.20 TILT ALARM SWITCH (PRIOR TO S/N 0300065534)PERFORM TILT ALARM SWITCH LEVELING PROCEDU

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-87This page left blank intentionally.

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 3120740ABDDBCFigure 3-51. Auxiliary Pump - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-89Figure 3-52. Auxiliary Pump - Sheet 2 of 21. DC Motor2. Coupling Half3. Washer4. Lockwash

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 31207403.22 GENERATOREvery 250 hoursEvery 250 hours of operation, check the drive belt forproper

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-9111/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must ridecom

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 31207403.23 DUAL FUEL SYSTEMIT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THEOTHER WITHOUT ALL

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-93EFI Diagnostics (Prior to S/N 0300065534)The EFI diagnostics are designed to assist in loc

3120740 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 3120740Table 3-10. ECM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription11All Systems OK12

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-95ENGINE COOLANT TEMPERATURE (ECT) SENSORThe engine coolant temperature (ECT) sensor is a gt

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3120740Figure 3-55. EFI Component Location

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-97INTAKE AIR TEMPERATURE (IAT) SENSORThe intake air temperature (IAT) sensor is a thermistor

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3120740The ECM is designed to maintain exhaust emission levelsto government mandated standards wh

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-99may set DTC 22. If either DTC 12 or DTC 22 are set, thethrottle will be forced to a 6% (id

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3120740assembly keeps fuel available to the fuel injectors at aconstant pressure. A return line

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-101regulate pressure and could cause engine problems orcomponent damage.FUEL PUMP ELECTRICAL

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3120740grammed routine to calculate the air/fuel ratio based oninputs from the TP, ECT, and MAP

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-103"Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signalsfrom the E

xii – JLG Lift – 3120740LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 3120740MegajectorRegulator Lockoff SolenoidFigure 3-57. LPG System Components (S/N 0300077500 t

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-105Lockoff SolenoidThe lockoff solenoid is used to reduce the possibility ofbackfires. The E

SECTION 3 - CHASSIS & TURNTABLE3-106 – JLG Lift – 3120740DTC 362 - Megajector voltage supply low.a. Voltage - Check battery voltage. If the voltag

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-107Mounting-ActuatorThe Actuator may be mounted in any attitude - there is nopreferred orien

SECTION 3 - CHASSIS & TURNTABLE3-108 – JLG Lift – 3120740Many “governing” problems are really caused by bindingof the butterfly and its shaft in t

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-109Gain:This adjustment is made by turning the plastic screwclockwise (CW to increase govern

SECTION 3 - CHASSIS & TURNTABLE3-110 – JLG Lift – 3120740

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-1114. Carefully adjust Gain. You are looking for the bestcompromise between quick response a

SECTION 3 - CHASSIS & TURNTABLE3-112 – JLG Lift – 31207404. No speed signal to Governor.5. Damaged Controller or Actuator.(1.) No power - Use a mu

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-113d. Speed seems to slowly wander (5-15 secondperiods) around at speed, particularly at hig

3120740 – JLG Lift – xiii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-114 – JLG Lift – 3120740ProcedureNOTE: Never run fuel tank dry. Diesel engines cannot berestarted after running o

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-115Failure ModesImmediate Red LightAction:1. Recycle power to determine if the problem is in

SECTION 3 - CHASSIS & TURNTABLE3-116 – JLG Lift – 31207403.28 DEUTZ EMR 2 (S/N 85331 TO PRESENT)The EMR2 consists of the sensors, the control unit

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-117Figure 3-59. EMR 2 Engine Side EquipmentGLOW PLUGPOWER SUPPLYCOOLANT TEMPERATURESENSORCO

SECTION 3 - CHASSIS & TURNTABLE3-118 – JLG Lift – 3120740Figure 3-60. Deutz EMR 2 Troubleshooting Flow Chart

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-119Figure 3-61. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3-120 – JLG Lift – 3120740Figure 3-62. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-121Figure 3-63. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3-122 – JLG Lift – 3120740Figure 3-64. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-123Figure 3-65. EMR 2 Vehicle Plug Pin Identification

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

SECTION 3 - CHASSIS & TURNTABLE3-124 – JLG Lift – 3120740Figure 3-66. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-125Figure 3-67. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3-126 – JLG Lift – 3120740Figure 3-68. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-127Figure 3-69. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3-128 – JLG Lift – 3120740Figure 3-70. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-1293.29 GM ENGINE GENERAL MAINTENANCEMaintenance of the Drive BeltThe serpentine drive belt

SECTION 3 - CHASSIS & TURNTABLE3-130 – JLG Lift – 31207406. If the oil level is below the "ADD" mark, proceed toStep 7 and 8 and reinsta

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-1312. Remove the radiator cap. Fill the radiator with cool-ant until coolant starts to appea

SECTION 3 - CHASSIS & TURNTABLE3-132 – JLG Lift – 31207403.30 GM ENGINE DUAL FUEL SYSTEMNOTE: +20° F (-6.6° C) is the low temperature limit for LP

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-133Low Pressure Regulator (LPR)The LPR is a combination vaporizer, pressure regulatingdevice

– JLG Lift – xv LIST OF TABLESTABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-134 – JLG Lift – 3120740Electronic Throttle Control (ETC)Engine speed and load control is maintained by an ETCdev

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-135Heated Exhaust Gas Oxygen SensorThere are two Heated Exhaust Gas Oxygen Sensors(HEGO). Th

SECTION 3 - CHASSIS & TURNTABLE3-136 – JLG Lift – 3120740Fuel FilterAfter the fuel is drawn into the fuel pump, the fuel flowsthrough the gasoline

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-137Propane Fuel Filter ReplacementREMOVAL1. Relieve the propane fuel system pressure. Refer

SECTION 3 - CHASSIS & TURNTABLE3-138 – JLG Lift – 3120740Electronic Pressure Regulator (EPR) Assembly ReplacementThe EPR assembly is a made up of

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-1396. Install the electric lock off into the regulator inlet andtighten into proper location

SECTION 3 - CHASSIS & TURNTABLE3-140 – JLG Lift – 3120740Temperature Manifold Absolute Pressure (TMAP) SensorREMOVAL1. Disconnect the TMAP electri

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-1412. Install the two quad seals. Install one seal at a timeto insure the seal does not roll

SECTION 3 - CHASSIS & TURNTABLE3-142 – JLG Lift – 3120740Coolant Hose ReplacementREMOVAL1. Drain the coolant. 2. Using hose clamp pliers, disconne

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-1433.32 GM ENGINE LPG FUEL SYSTEM DIAGNOSISFuel System DescriptionTo maintain fuel and emiss

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

SECTION 3 - CHASSIS & TURNTABLE3-144 – JLG Lift – 3120740Table 3-12. LPF Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to th

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-14513 1. Turn OFF the ignition.2. Disconnect the LPL connector.3. Install a test light betwe

SECTION 3 - CHASSIS & TURNTABLE3-146 – JLG Lift – 312074025 The fuel supply system is operating normally, if a failure of the control solenoids is

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-147Table 3-13. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using This S

SECTION 3 - CHASSIS & TURNTABLE3-148 – JLG Lift – 3120740Intermittent Malfunction Indicator Lamp (MIL)The following components can cause intermitt

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-149Exhaust System Checks  Check the exhaust system for a possible restriction:

SECTION 3 - CHASSIS & TURNTABLE3-150 – JLG Lift – 3120740Exhaust System Checks  Check the exhaust system for a possible restriction: - Inspec

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-151Hesitation, Sag, StumbleDEFINITION: The vehicle has a momentary lack of response when dep

SECTION 3 - CHASSIS & TURNTABLE3-152 – JLG Lift – 3120740Lack of Power, Sluggishness, or SponginessDEFINITION: The engine delivers less than exp

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-153Ignition System Checks  Verify that the spark plugs are correct for use with LPG (R42LT

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS Capacities1.2 COMPONENT DATAEngine DataTable

SECTION 3 - CHASSIS & TURNTABLE3-154 – JLG Lift – 3120740Engine Mechan ical Check  C heck the engine for the foll ow ing:

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-155Table 3-14. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 Crank

SECTION 3 - CHASSIS & TURNTABLE3-156 – JLG Lift – 3120740562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid 628

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-157ABDCA. Exhaust VenturiB. 1/4" (6.35 mm) minimum clearance all around.C. 3

SECTION 3 - CHASSIS & TURNTABLE3-158 – JLG Lift – 3120740B,CB,CB,CB,CB,CAAA. Actual Weight StampingB. Apply Loctite #242 to Bolt Threads a

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 PLATFORMSupport Removal1. Disconnect electrical cable from c

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3120740Support Installation1. Using a suitable device, support the platform sup-port and position it o

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-34.2 ROTATOR AND SLAVE CYLINDERRemoval1. Tag and disconnect hydraulic lines to rotator. Usesuita

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31207403. Supporting the rotator, remove the hardware frompin #2. Using a suitable brass drift and ham

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-53. Using a suitable brass drift and hammer, removehardware securing the upper lift cylinder rod

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120740 Table 1-4. Deutz F4M2011F SpecificationsType Liquid Cooled (Oil)Fuel DieselOil Capacity Coolin

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3120740Disassembly1. Remove hardware securing telescope cylinder toback end of the base boom section.2

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-7Installation1. Using all applicable safety precautions, carefully liftboom assembly to align th

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31207404.5 UPRIGHT RemovalHYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-ATELY AFTER DISCONNECTING

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-9InstallationNOTE: Steps 1 thru 4 are only necessary if the upright levelcylinder is to be remov

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3120740b. Remove mounting hardware that secures thepowertrack to tower base boom and remove thepowert

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-11WHEN ASSEMBLING TOWER BOOM SECTIONS, ENSURE THATTHE BOOM SLIDING TRAJECTORIES HAVE BEEN CLEARE

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3120740Tower Out of SyncTower is out of sync backwards, upright leaning towardthe platform.When tower

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-13Tower is out of sync forwards, upright leaning towardthe steer axle. When towering down, the l

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31207404.7 ARTICULATING JIBNOTE: Pin numbers listed in the following procedures arereferenced in Figu

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-157. Inspect structural units of articulating jib boomassembly for bending, cracking, separation

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-3TiresDrive SystemSwing SystemHydraulic Drive PumpVariable Displacement PumpHydraulic Load Sense Pump

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3120740Figure 4-9. Boom Valve and Limit Switches Location. (Sheet 1 of 3)0258217-LUPPER SWITCH (DUAL

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-17Figure 4-10. Boom Valve and Limit Switches Location. (Sheet 2 of 3)0258217-LSee Section 4.10,

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3120740Figure 4-11. Boom Valve and Limit Switches Location. (Sheet 3 of 3)0258217-LSee Section 4.10,

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-19Figure 4-12. Dual Capacity Switches Installation (800 Only if equipped)0258338-F

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3120740Figure 4-13. Transportation Switch Installation. (CE Only)0258384-C

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-21Figure 4-14. Tower Power Track Installation. (Sheet 1 of 2)

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3120740Figure 4-15. Tower Power Track Installation. (Sheet 2 of 2)

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-23Dual Capacity Angle Limit Switch (800A only)NOTE: The boom position and location of the Upper

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 31207404.11 WEAR PADSTower Boom1. Shim up wear pads until 1/32 inch (0.8 mm) clear-ance to adjacent s

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-255. Remove the two (2) setscrews (4) from bottom of theactuator (1). Discard setscrew.6. Place

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120740Hydraulic Filter - In-line1.3 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsTo w e r L i

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3120740AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulicoil prior to assembly.1. Ins

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-27Figure 4-18. Rotator Assembly (Prior to S/N 0300067538)

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 31207404.13 ROTATOR ASSEMBLY (S/N 0300067538 TO PRESENT)Theory of OperationThe L20 Series rotary actu

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-29The seal tool is merely a customized standard flat headscrewdriver. To make this tool you will

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3120740PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-31Disassembly1. Remove the cap screws (113) over end cap lockpins (109). 2. Using a 1/8” (3.18mm

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 31207406. Remove the end cap (4) and set aside for laterinspection. 7. Remove the stop tube if includ

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-3310. Remove the shaft (2). It may be necessary to strikethe threaded end of the shaft with a ru

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 312074016. To remove the main pressure seals (205), it is easi-est to cut them using a sharp razor bl

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-35Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-51.4 TORQUE REQUIREMENTS 1.5 LUBRICATIONHydraulic OilNOTE: Hydraulic oils must have anti-wear qualiti

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 31207402. Install the thrust washer (304) onto shaft (2) and endcap (4). 3. Install the wiper seal (3

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-376. Install the inner T-seal (200) into the piston (3) usinga circular motion. Install the oute

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 31207409. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-3914. Coat the threads on the end of the shaft with anti-seize grease to prevent galling. 15. In

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 3120740Installing Counterbalance ValveRefer to Figure 4-21., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-41Testing the ActuatorIf the equipment is available, the actuator should be testedon a hydraulic

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 3120740TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-434.14 DRIVE CARD SETUP PROCEDURESLift, Swing, and Drive Cards1. Center the input potentiometers

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 31207404.15 FOOT SWITCH ADJUSTMENTAdjust so that functions will operate when pedal is at cen-ter of t

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-4590° 90°90°90°Figure 4-24. Boom Upright PositioningUPRIGHT MUST BE 90° (VERTICAL) RELATIVETO TH

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31207401.6 PRESSURE SETTINGSTable 1-21. Mobil DTE 13M SpecsISO Viscosity Grade #32Specific Gravity 0.877Po

SECTION 4 - BOOM & PLATFORM4-46 – JLG Lift – 3120740Calibration - Pre ADE MachinesCALIBRATION OF THE UPRIGHT MONITORING SYSTEMREQUIRES THE MACHINE

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-47c. Press "ENTER" , and the following screenwill be displayed asking if you wish to

SECTION 4 - BOOM & PLATFORM4-48 – JLG Lift – 3120740NOTE: By pressing the left or right arrows in this screen, youmay view the output of each sens

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-49After the required activation time has passed,release the function switch and press "ENTE

SECTION 4 - BOOM & PLATFORM4-50 – JLG Lift – 3120740Calibration - ADE Equipped Machines1. Connect the JLG Hand-held analyzer to the originalanalyz

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-51IT IS NOT NECESSARY TO CALIBRATE THE TILT SENSOR IN THEGROUND CONTROL MODULE AT THIS TIME. HOW

SECTION 4 - BOOM & PLATFORM4-52 – JLG Lift – 3120740g. After the main boom has been fully elevated,press "ENTER" . The analyzer will

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-53i. When viewing the above display, press"ENTER" . The screen will display the fol-lo

SECTION 4 - BOOM & PLATFORM4-54 – JLG Lift – 3120740If the calibration has not been completed suc-cessfully, the display will automatically change

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-55Function CheckON ADE EQUIPPED MACHINES, DO NOT CONNECT TO THE ANA-LYZER CONNECTION PORT INSTAL

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-71.7 CYLINDER SPECIFICATIONSTable 1-26. Cylinder Specifications - 800ADESCRIPTION BORE STROKE ROD DIA

SECTION 4 - BOOM & PLATFORM4-56 – JLG Lift – 31207406. The controller will now display the following:or, by pressing the up and down arrow keys:7.

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-574. Scroll through the top level menu until SERVICEMODE appears. Press "ENTER" to s

SECTION 4 - BOOM & PLATFORM4-58 – JLG Lift – 31207407. Enter the service code "81075" and press the"ENTER" key. The controll

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-59THIS SENSORON NON ADEMACHINES ONLYFigure 4-25. UMS Sensor Location

SECTION 4 - BOOM & PLATFORM4-60 – JLG Lift – 3120740ADEMACHINESNON-ADEMACHINESFigure 4-26. UMS Module Location

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-61J1 J21 IGN POWER (7-33V) 1 +5V ANALOG EXCITATION2 GROUND 2 ANALOG INPUT 03 DIGITAL INPUT 0 3

SECTION 4 - BOOM & PLATFORM4-62 – JLG Lift – 31207404.17 UMS TROUBLESHOOTING AND FAULT MESSAGES - NON-ADE MACHINESTower Lift Down Permanently clos

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-63UMS Sensor Not Calibrated Message8/1 UMS SENSOR NOT CALIBRATEDIf the control system detects a

SECTION 4 - BOOM & PLATFORM4-64 – JLG Lift – 3120740Turntable Sensor Faulted8/1 TURNTABLE FAULTEDIf the system detects that the Chassis tilt senso

SECTION 4 - BOOM & PLATFORM3120740 – JLG Lift – 4-65Out of Usable Range Message8/1 UMS SENSOR OUT OF USABLE RANGEWhen both the Chassis tilt sensor

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31207401.8 MAJOR COMPONENT WEIGHTSTable 1-28. Major Component Weights - 800AMAJOR COMPONENTS LBS. KG.Platfo

SECTION 4 - BOOM & PLATFORM4-66 – JLG Lift – 3120740NOTES:

SECTION 5 - HYDRAULICS3120740 – 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 – 3120740Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-35.2 VALVES - THEORY OF OPERATIONSolenoid Control Valve - RexrothControl valves used are four-way three-p

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31207405. Check the Tower lift up holding valve function as fol-lows:a. Fully retract and fully lower the main

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-55.5 CYLINDER CHECKING PROCEDURENOTE: Cylinder check must be performed anytime a systemcomponent is repla

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 3120740Cylinders With Dual Counterbalance Valves(Articulating Jib Boom Lift, and Slave, Slave Level, TowerLift,

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-75.6 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31207401. Barrel2. Rod3. Piston4. Head5. Bushing6. Not Used7. Bolt8. Counterbalance Valve9. O-ring Plug10. O-ri

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-972661415151417161712121 320 2122 18,24,25191121010812129 5,23,2441684497 A1683546 H1. Rod2. Barrel3. Hea

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-9Critical Stability WeightsDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMSOF DIFFERENT WEIGHT O

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 3120740688681 432181912 13916175A1A511261414151510212022161683609 G1. Barrel2. Head3. Ring Washer4. Bolt5. Rod

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-1151191926211213630181611111017164223132419 19 2 8715141683547 J1. Barrel2. Rod3. Piston4. Tapered Bushin

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3120740711010866910104212617161715145141518192012132221683537 G1. Barrel2. Head3. Not Used4. Rod5. Piston6. O-

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-1319,1,2137121720211418 6151615112210112439544 81683608 F1. Loctite #2422. Locking Primer3. Tapered Bushi

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31207405583412211021121416142217131171920,2,231518,1,2961683682 C1. Loctite #2422. Locking Primer3. Capscrew4.

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-15910 92425551814 62122114122012201616231317 5581915731683610 E1684408 A1683677 B1684228 A1. Loctite #242

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 312074014172489101312141461135141683605 A1683740 B1. Locknut2. Piston3. Seal4. O-ring5. Barrel6. Rod7. Head8.

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-177191010962626A182433121581417221352116161621232511232041683607 G1683672 G1. Loctite #2422. Locking Prim

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3120740155417163161714156713121110933321919243434343621812223302524242620213527 1683606 J1. Barrel2. Rod3. Pis

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-19EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD O

INTRODUCTION3120740 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 31207401.9 LUBRICATION AND OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 312074010. Inspect threaded portion of head for damage. Dressthreads as necessary.11. Inspect seal and o-ring

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-213. Place a new “o”ring and back-up seal in the applica-ble outside diameter groove of the cylinder head

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 312074010. Thread piston onto rod until it abuts the spacer endand install the tapered bushing.NOTE: When inst

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-23NOTE: *Steer cylinder spanner nut is tightened as per Spec."CYR" Cylinder spanner nut tighten

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 31207405.7 CYLINDER REMOVAL AND INSTALLATIONUpper Boom Telescope Cylinder Removal1. Place machine on a flat an

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-25Upper Boom Telescope Cylinder Installation1. Attach a hydraulic power supply to the telescopecylinder p

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3120740Upper Boom Lift Cylinder Installation1. Using suitable lifting device and sling, lift the upperboom to

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-27Upright Level Cylinder Installation1. Place the leveling cylinder in position in the towerboom, then al

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 3120740Tower Lift Cylinder Installation1. With the upper boom and tower boom supported.Place the tower lift cy

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-29Slave Cylinder Installation1. Remove fittings from old cylinder and install in newslave cylinder. Plug

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-112.Wheel BearingsLube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 years or 1200 hour

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 3120740MACHINES S/N 0300121643 TO PRESENT1. Set Stand by pressure or load sense pressure. a. Install a low pre

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-31Figure 5-27. Main Control Valve Pressure Adjustments

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 31207401. Front Steer Right Solenoid 2. Front Steer Relief 3. Load Sensing Cartridge4. Swing Right Solenoid5.

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-331. Front Steer Left Solenoid 2. Load Sensing Cartridge 3. Front Steer Relief4. Swing Relief5. Swing Lef

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 3120740Ft. Lbs. NmNOTE: When removing control valves from the manifold, it is important to observe the tagon t

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-35Ft. Lbs. NmNOTE: When removing control valves from the manifold, it is important to observe the tagon t

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 3120740SECOND: Adjustments Made at the Main Valve BlockMAIN RELIEF, STEER, SWING AND LIFT DOWN1. Upper (main)

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-374 WHEEL STEER (IF EQUIPPED)1. At the platform console using the steer select switchactivate “2 wheel st

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 312074011. Disconnect the 1/4" hose at the port marked "MT"(plug the port). Drain the hose into

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-39The inlet line leading from the reservoir to the pump mustbe filled prior to start-up. Check the inlet

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 31207407.Suction StrainersLube Point(s) - 2Interval - Every 2 years or 1200 hours of operation,remove and

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 31207405.12 REXROTH VARIABLE DISPLACEMENT PUMP PRIOR TO S/N 0300121643The variable displacement axial piston p

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-41Figure 5-33. Variable Displacement Pump. (Rexroth)

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 31207405.13 SAUER PISTON PUMP S/N 0300121643 TO PRESENTTable 5-3. Symbols UsedSymbol MeaningSymbol MeaningNon

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-43Initial start-up proceduresFollow this procedure when starting-up a new pump orwhen the pump has been r

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 3120740Table 5-6. Actuator Response Is SluggishItem Description ActionCheck external system relief valve sett

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-45Table 5-8. Low Pump Output FlowItem Description ActionCheck fluid level in reservoir. Insufficient hyd

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 3120740HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGEINTERNAL PUMP COMPONENTS.Table 5-10. System Pressu

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-47Shaft Seal ReplacementA lip type shaft seal is used in the pump and can bereplaced without major disass

SECTION 5 - HYDRAULICS5-48 – JLG Lift – 31207404. Remove the plug (C103), O-ring (C103A),and Pres-sure Compensator spool (C132) from the controlhousin

SECTION 5 - HYDRAULICS3120740 – JLG Lift – 5-49Plug and Fitting Sizes and TorquesIf any plugs or fittings are removed from the unit duringservice, ins

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-1310.Oil Change w/Filter - IsuzuLube Point(s) - Fill Cap/Spin-on ElementCapacity - 8.5 qt. (8.0L) eng

SECTION 5 - HYDRAULICS5-50 – JLG Lift – 3120740NOTES:

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6.1 INTROD

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-2 – JLG Lift – 3120740Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERAT

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-3Figure 6-2. ADE Block Diagram

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-4 – JLG Lift – 3120740ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTOMENU:M

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-5FROMPERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:UPPER T

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-6 – JLG Lift – 3120740FROMMENU:PERSONALITIESMENU:MACHINE SETUPTOMENU:CALIBRATIONSMODEL NUM

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-7Figure 6-6. Analyzer Flow Chart, Prior to Version 5.X Software - Sh

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-8 – JLG Lift – 3120740Figure 6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-9Figure 6-8. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 312074019.Electronic Pressure Regulator (LP only)Interval - 3 Months or 150 hours of operationComments - D

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-10 – JLG Lift – 3120740FROM:MENU:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-11MENU:HELP:PRESS ENTERHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-12 – JLG Lift – 3120740Figure 6-11. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-13Figure 6-12. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND C

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-14 – JLG Lift – 31207406.2 CANBUS COMMUNICATIONSCANbus: CAN (Control Area Network) is a tw

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-15The top level menus are as follows:HELPDIAGNOSTICSSYSTEM TESTACCESS

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-16 – JLG Lift – 3120740Then using the RIGHT arrow key, position the cursor tothe right one

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-176.7 MACHINE SETUPWhen a machine digit item is selected, press the U

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-18 – JLG Lift – 3120740Table 6-2. Machine Configuration Programming Information Prior to S

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-19GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LO

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-15Propane Fuel Filter ReplacementREMOVAL1. Relieve the propane fuel system pressure. Refer toPropane

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-20 – JLG Lift – 3120740GEN SET CUTOUT:12* * Only visible if Gen Set / Welder Menu selecti

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-21GROUND ALARM:18* * Certain market selections will alter default set

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-22 – JLG Lift – 3120740Table 6-3. Machine Configuration Programming Information Software V

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-23ENGINE:3* * Engine selections vary depending on model selec-tion.1

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-24 – JLG Lift – 3120740ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown e

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-25GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selecti

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-26 – JLG Lift – 3120740FUNCTION CUTOUT:18* * Only visible under certain market selections

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-27Table 6-4. Machine Configuration Programming Information Software V

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-28 – JLG Lift – 3120740ENGINE:3* * Engine selections vary depending on model selec-tion.1

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-29STARTER LOCKOUT:601DISABLED: Automatic pre-glow time determined by

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3120740Propane Fuel System Pressure ReliefTHE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO312 PSI (21.5

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-30 – JLG Lift – 3120740GEN SET/WELDER:1201NO: No generator installed.BELT DRIVE: Belt driv

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-31LOAD SENSOR:17* * Only visible if Load Sen-sor Menu selection is n

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-32 – JLG Lift – 3120740LEVELING MODE:22* * Only visible on 800S models.01ALL FUNCTIONS: P

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-33800AMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUT

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-34 – JLG Lift – 3120740800AJMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOU

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-35Table 6-5. Machine Configuration ParametersConfiguration DigitParam

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-36 – JLG Lift – 31207406 Tilt: 1=5Deg2=4Deg3=3DegDisplays/adjusts tilt sensor function1235

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-3713 Head & Tail LIGHTS0=NO1=YESDisplays presence of head and tai

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-38 – JLG Lift – 312074020 PLATFORM ALARM0=NO1=FAULT CODEDisplays/adjusts platform alarm pr

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-396.9 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-17Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 4)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-40 – JLG Lift – 3120740SWING ACCELeration 0.1 to 5.0s 2.0DECELeration 0.1 to 3.0s 1.8MINim

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-41BASKET ROTATE ACCELeration 0.1 to 5.0 1.8DECELeration 0.1 to 3.0 0.

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-42 – JLG Lift – 3120740Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - P

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-432/3 Flash code 2/3 indicates problems with boom function selection.

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-44 – JLG Lift – 31207402/8 Flash code 2/8 indicates that the hydraulic filter is being byp

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-456/6 Flash code 6/6 indicates problems with the CAN bus. 10CAN BUS F

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-46 – JLG Lift – 3120740Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-472/2 Flash code 2/2 indicates problems with drive & steer select

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-48 – JLG Lift – 31207402/3 Flash code 2/3 indicates problems with boom function selection.

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-492/5 Flash code 2/5 indicates that a function is prevented due to a

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3120740Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 4)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-50 – JLG Lift – 3120740LP LOCK OPEN CIRCUITLP LOCK SHORT TO BATTERYLP START ASSIST SHORT T

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-51BASKET UP OVERRIDE OPEN CIR-CUITOnly occurs on machines with electr

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-52 – JLG Lift – 3120740TOWER DOWN SHORT TO BAT-TERYTOWER IN SHORT TO GROUNDTOWER IN OPEN C

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-53BASKET DOWN SHORT TO BAT-TERY OR OPEN CIRCUITOnly occurs on machine

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-54 – JLG Lift – 3120740COOLANT TEMPERATURE SHORT TO GROUNDIf a Deutz engine is installed,

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-559/9 Flash code 9/9 indicates problems with the controller. 11PLATFO

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-56 – JLG Lift – 3120740Table 6-9. Analyzer Fault Code ListingDTC Analyzer Text001 EVERYTHI

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-57331 BRAKE - SHORT TO BATTERY332 BRAKE - OPEN CIRCUIT3311 GROUND ALA

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-58 – JLG Lift – 31207403370 TWO SPEED VALVE - SHORT TO BATTERY3371 GROUND ALARM - SHORT TO

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-5933115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND33116 TOWER TELESC

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-19Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 4Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-60 – JLG Lift – 312074033315 FLOW CONTROL VALVE - SHORT TO BATTERY33316 FLOW CONTROL VALVE

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-61431 FUEL SENSOR - SHORT TO BATTERY432 FUEL SENSOR - SHORT TO GROUND

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-62 – JLG Lift – 31207408311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY8312 PLATFORM LEVEL

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-639920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE9921 GROUND MODULE FAI

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-64 – JLG Lift – 3120740Analyzer Diagnostics Menu Structure In the following structure desc

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-65SWINGACCEL … Displays/adjusts swing accelerationDECEL … Displays/ad

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-66 – JLG Lift – 3120740ACCEL … Displays/adjusts jib accelerationDECEL … Displays/adjusts j

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)3120740 – JLG Lift – 6-67Table 6-11. Diagnostic Menu DescriptionsDRIVEDRIVE FOR … Displays d

SECTION 6 - JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)6-68 – JLG Lift – 3120740PM BATTERY … Displays battery voltage at platform moduleTEMP ... D

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

INTRODUCTIONA-2 – JLG Lift – 3120740REVISON LOGOriginal Issue - August, 1998Revised - August 2, 2001Revised - January 14, 2003Revised - October 19, 20

SECTION 1 - SPECIFICATIONS1-20 – JLG Lift – 3120740Figure 1-7. Torque Chart (SAE Fasteners - Sheet 4 of 4)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3120740Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31207407.4 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-53. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3120740Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-7Figure 7-11. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31207407.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the cont

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3120740 Figure 7-18. Electrical Components Installation (Prior to S/N 0300

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-11 Figure 7-19. Electrical Components Installation (Prior to S/N 0300

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-21Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 1 of 3)Size PITCHTensile Stress AreaClamp LoadT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3120740Figure 7-20. Electrical Components Installation (S/N 0300065534 to

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-13Figure 7-21. Electrical Components Installation (S/N 0300065534 to

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3120740Figure 7-22. Electrical Components Installation w/ADE (S/N 03000640

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-15Figure 7-23. Electrical Components Installation w/ADE (S/N 03000640

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3120740J5J6J7J2J2J1J8J3J1J8DIAGNOSTICANALYZERPLATFORMCONTROLBOXGROUNDCONTRO

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-17JIBVALVE4WSVALVESTROBELIGHTFUELLEVELSENSOR2500WGENERATORRELAY7500WGE

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3120740Figure 7-26. Electrical Schematic - Deutz Engine (Prior to S/N 0300

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-19Figure 7-27. Electrical Schematic - Deutz Engine (Prior to S/N 0300

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3120740Figure 7-28. Electrical Schematic - Ford Engine (Prior to S/N 03000

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-211870062 BFigure 7-29. Electrical Schematic - Ford Engine (Prior to

SECTION 1 - SPECIFICATIONS1-22 – JLG Lift – 3120740Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 2 of 3)Size PITCHTensile Stress AreaClamp LoadT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3120740Figure 7-30. Electrical Schematic - Ford Engine (Prior to S/N 03000

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-231870062 BFigure 7-31. Electrical Schematic - Ford Engine (Prior to

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3120740Figure 7-32. Electrical Schematic - Ford EFI Engine (S/N 0300048538

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-25Figure 7-33. Electrical Schematic - Ford EFI Engine (S/N 0300048538

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3120740Figure 7-34. Electrical Schematic Isuzu Engine (Sheet 1 of 2)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-27Figure 7-35. Electrical Schematic Isuzu Engine (Sheet 2 of 2)187012

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3120740Figure 7-36. Electrical Schematic - UL - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-29Figure 7-37. Electrical Schematic - UL - Sheet 2 of 21870160 CNOTE:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-30 – JLG Lift – 3120740Figure 7-38. Electrical Schematic ADE W/External Tilt - Sheet 1 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-31Figure 7-39. Electrical Schematic ADE W/External Tilt - Sheet 2 of

SECTION 1 - SPECIFICATIONS3120740 – JLG Lift – 1-23Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 3 of 3)Size PITCHTensile Stress AreaClamp Load

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-32 – JLG Lift – 3120740Figure 7-40. Electrical Schematic ADE W/External Tilt - Sheet 3 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-33Figure 7-41. Electrical Schematic ADE W/External Tilt - Sheet 4 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-34 – JLG Lift – 3120740Figure 7-42. Electrical Schematic w/Internal Tilt - Deutz S/N 65634

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-35Figure 7-43. Electrical Schematic w/Internal Tilt - Deutz S/N 65634

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-36 – JLG Lift – 3120740Figure 7-44. Electrical Schematic w/Internal Tilt - Deutz S/N 65634

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-37Figure 7-45. Electrical Schematic w/Internal Tilt - Deutz S/N 65634

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-38 – JLG Lift – 3120740Figure 7-46. Electrical Schematic w/Internal Tilt - Deutz S/N 65634

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-39Figure 7-47. Electrical Schematic w/Internal Tilt - Deutz S/N 65634

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-40 – JLG Lift – 3120740Figure 7-48. Electrical Schematic w/Internal Tilt - Deutz & GM

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-41Figure 7-49. Electrical Schematic w/Internal Tilt - Deutz & GM

SECTION 1 - SPECIFICATIONS1-24 – JLG Lift – 3120740NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-42 – JLG Lift – 3120740Figure 7-50. Electrical Schematic w/Internal Tilt - Deutz & GM

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-43Figure 7-51. Electrical Schematic w/Internal Tilt - Deutz & GM

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-44 – JLG Lift – 3120740Figure 7-52. Electrical Schematic w/Internal Tilt - Deutz & GM

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-45Figure 7-53. Electrical Schematic w/Internal Tilt - Deutz & GM

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-46 – JLG Lift – 3120740REDBLACKBLACKREDPLATFORMWORK LIGHTSALARMMAIN TELE INMAIN TELE OUTROT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-47AUXILIARY POWERPUMPMOTORMUP LEVELDOWN LEVELRIGHT ROTATE LEFT ROTATED

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-48 – JLG Lift – 3120740Figure 7-56. Electrical Schematic - Caterpillar, Deutz, & GM S/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-491001096461 CFigure 7-57. Electrical Schematic - Caterpillar, Deutz,

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-50 – JLG Lift – 3120740Figure 7-58. Electrical Schematic - Caterpillar, Deutz, & GM S/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-511001096461 CFigure 7-59. Electrical Schematic - Caterpillar, Deutz,

SECTION 2 - GENERAL3120740 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-52 – JLG Lift – 3120740Figure 7-60. Hydraulic Schematic 2 Wheel Drive - Prior to S/N 83332

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-53This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-54 – JLG Lift – 3120740Figure 7-61. Hydraulic Schematic 4 Wheel Drive - Prior to S/N 83332

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-55Figure 7-62. Hydraulic Schematic 4 Wheel Drive - Prior to S/N 83332

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-56 – JLG Lift – 3120740Figure 7-63. Hydraulic Schematic - Prior to S/N 83332 (Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-57Figure 7-64. Hydraulic Schematic - Prior to S/N 83332 (Sheet 2 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-58 – JLG Lift – 3120740Figure 7-65. Hydraulic Schematic - S/N 83332 to Present (Sheet 1 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-59Figure 7-66. Hydraulic Schematic - S/N 83332 to Present (Sheet 2 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-60 – JLG Lift – 3120740Figure 7-67. Hydraulic Schematic - S/N 83332 to Present (Sheet 3 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-61Figure 7-68. Hydraulic Schematic - S/N 83332 to Present (Sheet 4 of

SECTION 2 - GENERAL2-2 – JLG Lift – 31207402.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-62 – JLG Lift – 3120740Figure 7-69. Hydraulic Schematic - S/N 83332 to Present (Sheet 5 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3120740 – JLG Lift – 7-63Figure 7-70. Hydraulic Schematic - S/N 83332 to Present (Sheet 6 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-64 – JLG Lift – 3120740NOTES:

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

SECTION 2 - GENERAL3120740 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 3120740Section 1. Always examine filters for evidence ofmetal particles.3. Cloudy oils indicate a high moisture co

SECTION 2 - GENERAL3120740 – JLG Lift – 2-5ature and temperature stabilized.The cylinder must have the normal load, which is the nor-mal platform load

3120740 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - GENERAL2-6 – JLG Lift – 3120740Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3120740 – JLG Lift – 2-7Platform Controls 55 66Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitc

SECTION 2 - GENERAL2-8 – JLG Lift – 3120740Capacity Decals Installed, Secure, Legible 21 21 21All Decals/Placards Installed, Secure, Legible 21 21 21W

SECTION 2 - GENERAL3120740 – 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

SECTION 2 - GENERAL2-10 – JLG Lift – 3120740Figure 2-2. Engine Operating Temperature Specifications - Ford4150548 E

SECTION 2 - GENERAL3120740 – JLG Lift – 2-11-40 F(-40 C)-30 F(-34 C)-20 F(-29 C)-10 F(-23 C) 0F(-18C) 10 F(-12 C) 20 F(-7 C) 30 F(-1 C) 40 F(4 C) 50

SECTION 2 - GENERAL2-12 – JLG Lift – 3120740Figure 2-4. Engine Operating Temperature Specifications - GM4150548 E

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31207403. The tightening of the nuts should be done in stages.Following the recommended sequence,

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-3Oscillating Axle Lockout TestLOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,ANY TIME A SYS

ii – JLG Lift – 3120740TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31207403.4 TORQUE HUB, DRIVEDisassembly1. Position hub over suitable container and removedrain plu

SECTION 3 - CHASSIS & TURNTABLE3120740 – 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 – 3120740o. Drive anti-roll pin flush into carrier hole, lockingplanet shaft into place.p. repeat st

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-73. Press new seal (2) into hub counter bore with flatmetal side facing in. Use a flat objec

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 31207408. Place internal gear (12) onto end of spindle.9. Install thrust washers and thrust bearin

SECTION 3 - CHASSIS & TURNTABLE3120740 – 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 – 312074021. Place o-ring (22) into cover assembly counter bore.Use petroleum jelly or grease to ho

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-11Figure 3-3. Torque Hub Drive (Fairfield)1. Spindle2. Seal3. Bearing Cup4. Bearing Cone5.

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31207403.5 DRIVE BRAKE - AUSCO (PRIOR TO S/N 56875)Disassembly1. With shaft protrusion downward,

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-13 Figure 3-4. Drive Brake, Ausco1. Housing2. Gasket3. Torque Pin4. Ball Bearing5. Retainin

3120740 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31207403.6 DRIVE BRAKE - MICO (S/N 56875 TO 83332)Disassembly1. Remove pressure plate (3) from co

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-151. Capscrew2. Washer3. Pressure Plate4. Case Seal5. O-ring6. Backup Ring7. Piston8. O-ring

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3120740Bleeding1. Install brake in system and connect pressure lines.2. Bleed pressure release se

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-173.7 DRIVE BRAKE (S/N 83332 TO PRESENT)Disassembly1. Supporting brake on face A:, remove th

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 31207405111012212192223433197814131615181720661. Shaft2. Housing3. Friction Plate4. Pressure Plat

SECTION 3 - CHASSIS & TURNTABLE3120740 – 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 – 3120740Replacing the Drive Shaft Seal1. Remove the snap ring 2. Change the shaft seal and check i

SECTION 3 - CHASSIS & TURNTABLE3120740 – 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 – 31207404. Remove the O-ring. 5. Disassemble the taper roller bearing.6. Remove the adjustment shi

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-2312. Remove the threaded pin (stopper - max.flow) 13. Disassemble the plug. 14. Disassemble

iv – JLG Lift – 3120740TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 312074020. Remove the snap ring. 21. Disassemble the sealing ring.22. The external front bearing

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-25Assembly Notes1. Measurement of the taper roller bearing pretension. 2. Note that there is

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3120740NOTE: Differential volume if you are rotating the threaded pin -each rotation is appr. 3,1

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-27Testing and SetupDR: When pressure line is closed adjust the pressure ofthe controller (if

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 31207403.10 DRIVE MOTOR (S/N 83332 TO PRESENT)DescriptionThe drive motors are low to medium power

SECTION 3 - CHASSIS & TURNTABLE3120740 – 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 – 3120740TroubleshootingTable 3-3. Excessive Noise and/or VibrationItem Description ActionCheck oi

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-31DisassemblyNOTE: Removal of the endcap voids warranty.During assembly, coat all moving par

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 312074013. Using an 8 mm internal hex wrench, remove theendcap screws (22).14. Remove the endcap

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-3318. Remove minimum angle stop (29) and servo spring(30) from the housing.19. Turn the hous

3120740 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312074023. Turn housing over and remove the swashplate (39)by lifting on the end opposite the ser

SECTION 3 - CHASSIS & TURNTABLE3120740 – 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 – 3120740BALL GUIDE AND SLIPPER RETAINERInspect the ball guide and slipper retainer for damage,disc

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-37SERVO PISTON AND MINIMUM ANGLE STOPInspect the minimum angle stop, servo piston head, ands

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3120740RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRINGREQUIRES ABOUT 80 TO 90 LBF (350 TO 4

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-398. Press front shaft bearing (15) onto shaft (16). Pressbearing onto shaft with lettering

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 312074012. Press the rear shaft bearing (22) into the endcap.Install the bearing with letters fac

SECTION 3 - CHASSIS & TURNTABLE3120740 – 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 – 312074020. Install orifice poppet (30).21. Install shift spool (31).22. Install spring retaining

SECTION 3 - CHASSIS & TURNTABLE3120740 – JLG Lift – 3-433.11 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is desig