Jlg 660SJ Service Manual Manuel d'utilisateur

Service and Maintenance ManualModel600S660SJS/N 0300171769to PresentP/N - 3121298February 26, 2014

vi – JLG Lift – 3121298TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3121298Figure 3-75. Deutz D2.9 L4 Engine Installation - Sheet 2 of 21. Coolant Recovery Tank2. R

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-57NOTE: Refer to engine manufacturer’s manual for detailed oper-ating and maintenance instru

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121298Change Oil Filter1. Wipe area around filter to clean any dirt from area.2. Using a suitabl

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-593.12 DEUTZ D2011 ENGINEFigure 3-78. Deutz D2011 Engine Installation - Sheet 1 of 21. Radi

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3121298Figure 3-79. Deutz D2011 Engine Installation - Sheet 2 of 21. Battery2. Battery Hold-Down

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-61NOTE: Refer to engine manufacturer’s manual for detailed oper-ating and maintenance instru

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121298Changing Oil Filter1. Wipe area around filter to clean any dirt from area.2. Using a suita

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-63Clean Fuel Strainer FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE NO

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 31212983.15 DEUTZ EMR 2The EMR2 consists of sensors, control unit, and actuator. Engine-side cont

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-65Figure 3-83. Deutz EMR 2 Troubleshooting Flow Chart

3121298 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121298Figure 3-84. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-67Figure 3-85. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 3121298Figure 3-86. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-69Figure 3-87. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3121298Figure 3-88. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-71Figure 3-89. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3121298Figure 3-90. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-73Figure 3-91. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121298Figure 3-92. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-75Figure 3-93. EMR2 Fault Codes - Sheet 5 of 5

viii – JLG Lift – 3121298LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 31212983.16 BIO FUEL IN DEUTZ ENGINESGeneralUse of bio fuels is permitted for the compact engines

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-77Biological Contamination In FuelsSYMPTOMSThe following symptoms may indicate a fuel tank i

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 31212983.17 GM ENGINE GENERAL MAINTENANCEDrive Belt MaintenanceThe serpentine drive belt utilizes

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-79Changing Engine OilALWAYS CHANGE OIL FILTER WHEN CHANGING OIL. CHANGE OIL WHENENGINE IS WA

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 3121298WITH ENGINE RUNNING OR WHEN SHUTTING OFF ENGINE, SOME HEATED COOLANT MAY SPILL OUT DUE TO

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-81Figure 3-95. GM 3.0 Dual Fuel System Components1. T-MAP Sensor2. Lock-Off Valve3. Mixer4.

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 3121298Direct Electronic Pressure Regulator (DEPR)THE DEPR IS AN EMISSION CONTROL DEVICE AND SHOU

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-83Electronic Throttle Control (ETC)The Electronic Throttle Control device or "Throttle

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3121298Heated Exhaust Gas Oxygen SensorThere are two Heated Exhaust Gas Oxygen Sensors (HEGO). Th

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-85Fuel FilterAfter fuel is drawn into the fuel pump, the fuel flows through the gasoline fue

3121298 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 3121298Propane Fuel Filter ReplacementREMOVAL1. Relieve propane fuel system pressure. Refer to Pr

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-87Check/Drain Oil Build-Up In 2-Stage Vaporizer Refer to Figure 3-95. GM 3.0 Dual Fuel Syste

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 3121298Exhaust System And Catalytic Converter Inspection And MaintenanceEXHAUST SYSTEM ON THIS EM

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-89Electronic Pressure Regulator (EPR) ReplacementREMOVALRefer to Figure 3-95. GM 3.0 Dual Fu

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 3121298Engine Control Module ReplacementREMOVAL1. Disconnect Negative battery cable.2. Remove con

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-913.20 GM ENGINE LPG FUEL SYSTEM DIAGNOSISFuel System DescriptionFigure 3-105. DEPRThe Engi

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3121298Table 3-11. LP Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to this

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-9315 1. Turn the ignition OFF. 2. Close the manual shut-off valve on the LPG tank.CAUTION:

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 3121298Table 3-12. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using This Se

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-95Intermittent Malfunction Indicator Lamp (MIL)The following components can cause intermitte

x – JLG Lift – 3121298LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3121298Exhaust System Checks  Ch ec k t he e xh au st sy ste m f or a p oss ib le res tr ic

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-97Additional Checks Cuts Out, MissesDEFINITION: A surging or jerking that follows engine sp

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3121298Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition s

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-99Fuel System Checks  Check for a restricted fuel filter, contaminated fuel, or improper fu

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3121298Additional Check  Check the transmission shift pattern. Refer to the OEM Transmission Co

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-101Fuel System Checks  Check for Rich or Lean symptom that causes the condition. Drive the

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3121298Table 3-13. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 Crank

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-103562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid 628

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 3121298NOTES:

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM SYSTEMSRemoval1. Remove platform/support as follows:a.

3121298 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121298h. With powertrack support and using all applicable safety precautions, remove bolts #3 and #4

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-34.3 BOOM DISASSEMBLY/ASSEMBLY & CABLE REPLACEMENTBoom Section Disassembly1. Remove hardware

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31212984.4 WIRE ROPEWIRE ROPE CAN HAVE SHARP EDGES AND CAUSE SERIOUS INJURY. NEVER HANDLE WIRE ROPE WI

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-54.5 WIRE ROPE TENSIONING ADJUSTMENTWire Rope Tensioning Procedure1. Position boom in fully down

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121298Figure 4-12. Boom Assembly Cutaway - Sheet 1 of 3

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-7Figure 4-13. Boom Assembly Cutaway - Sheet 2 of 3

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3121298Figure 4-14. Boom Assembly Cutaway - Sheet 3 of 310. Carefully remove telescope cylinder and s

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-916. Remove fly boom section from mid section using an overhead crane or suitable lifting device

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 31212982. Inspect extend and retract wire rope sheave bearings for wear, scoring or other damage, and

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-11Figure 4-19. Boom Powertrack Installation

xii – JLG Lift – 3121298LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 31212987. Slide fly boom section into mid boom section. Shim boom, if necessary, for a total of 1/16

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-1322. Align holes in aft end of mid boom section with holes in wire rope mounting block. Secure

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31212984.6 ARTICULATING JIB BOOMRemoval1. For platform/support removal see platform/support removal d

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-15AssemblyNOTE: For location of components See Section 4-22., Articulating Jib Boom Components.1

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3121298Figure 4-23. Horizontal Limit and Dual Capacity Limit Switches Adjustments

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-17Figure 4-24. Transport Switch Adjustments - CE Machines Only

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 31212984.9 ROTARY ACTUATORTheory of OperationThe L20 Series rotary actuator is a simple mechanism tha

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-19PARTS1. Housing 2. S ha ft 3. P is to n Sl ee ve 4. E nd CapHARDWARE103

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3121298PARTS1. Ho us in g 2. Sh af t 3. Pi sto n S le eve 4. En d Ca pHARDWARE10

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-21Disassembly1. Remove capscrews (113) over end cap lock pins (109). 2. Using a 1/8” (3.18mm) dr

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATATable 1-1. Operating Spec

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 31212987. Remove stop tube if installed. 8. Actuator has timing marks for proper engagement. 9. Befor

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-2311. Before removing piston (3), mark housing (1) ring gear in relation to piston O.D. gear. Th

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 312129815. Remove wear guides (302) from end cap (4) and shaft (2). 16. To remove main pressure seals

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-2520. Remove piston I.D. seal (200). Inspection1. Clean all parts in a solvent tank and dry with

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121298Assembly1. Gather all components and tools to one location. Use cut away drawing to reference

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-276. Install inner T-seal (200) in piston (3) using a circular motion. Install outer T-seal (202

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 312129810. Looking from opposite end of housing (1) when timing marks line up, tap piston (3) in unti

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-2916. Install 0-ring (204) and back-up ring (207) in inner seal groove on end cap (4). 17. Thre

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3121298Installing Counterbalance ValveRefer to Figure 4-27., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-31Testing ActuatorIf equipment is available, test actuator on a hydraulic test bench. Breakaway

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31212981.3 CAPACITIES1.4 TIRES1.5 ENGINE DATA Table 1-3. CapacitiesFuel Tank 40 Gallons (151 L)Hydraulic Oi

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 3121298TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-334.10 FOOT SWITCH ADJUSTMENTAdjust foot switch to operate functions when pedal is at center of

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 31212984.12 POWERTRACK MAINTENANCERemove LinkNOTE: Hoses shown in powertrack are for example only. Ac

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-35REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE.3. To remove a link, r

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 31212986. Insert flat head screwdriver between links. Twist and pull links apart. 7. Remove link from

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-37Install New Link1. Squeeze cut-out end of new link into half-shear (female) end of track secti

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 31212984. Pull moving end over track so new connection is posi-tioned in curve of powertrack. Round h

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-39NOTE: Make sure snap rings are seated in pin groove and closed properly.1. Install new 8-32 x

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 31212983. Install new 8-32 x 0.500 self threading screw on other side. Torque to 18-20 in-lb (2-2.25

SECTION 4 - BOOM & PLATFORM3121298 – JLG Lift – 4-412. Parts used: Bracket Center Pin and Center Pin Snap Ring. 3. Take new bracket and install br

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-31.6 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsLift: Boom retracted. Telescope retract

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 31212982. Install center pin with snap ring in new bracket.3. Install radius pins and snap rings in o

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 O-RING LUBRICATIONWhen assembling connectors, all fittings with O-rings must b

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121298DipNOTE: This method works best with Face Seal O-rings, but will work for all O-ring fitting types.Tools

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-35.2 CYLINDERS - THEORY OF OPERATIONSystems With Double Acting CylindersSystems with double acting cylind

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3121298Cylinders With Single Counterbalance Valve(Upper Lift Cylinder)OPERATE ALL FUNCTIONS FROM GROUND CONTROL

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-55.4 CYLINDER REMOVAL AND INSTALLATIONMain Boom Telescope Cylinder Removal1. Place machine on a flat and

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 3121298Main Boom Lift Cylinder Removal1. Place machine on a flat and level surface. Start engine and place main

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-7Cylinder LocationsItem Cylinder1Main Lift2Master3 Telescope4 Slave (Platform Level)5Jib Lift6 Steer7 Axl

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 3121298Main Lift CylinderDISASSEMBLYNOTE: Refer to Figure 5-6.CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE C

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-9

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31212981.8 HYDRAULIC OILNOTE: Hydraulic oils require anti-wear qualities at least API Ser-vice Classificati

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31212988. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to pisto

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-11AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual.Apply a

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31212986. If applicable, place new O-ring and back-up rings in inner piston diameter groove.Figure 5-13. Pist

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-13Master CylinderDISASSEMBLYNOTE: Refer to Figure 5-19. Master Cylinder.CONTAMINATION MAY DAMAGE EQUIPMEN

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31212981. Barrel1a.

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-158. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to pisto

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3121298AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual.Apply a

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-176. If applicable, place new O-ring and back-up rings in inner piston diameter groove.Figure 5-26. Pist

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3121298Telescope CylinderDISASSEMBLYCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK S

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-191. Barrel 2. Rod3. H

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-51.9 MAJOR COMPONENT WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31212988. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to pisto

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-21AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual.Apply a

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 31212986. If applicable, place new O-ring and back-up rings in inner piston diameter groove.Figure 5-39. Pist

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-23Platform Level (Slave) CylinderDISASSEMBLYCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3121298

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-258. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to pisto

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121298AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual.Apply a

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-276. If applicable, place new O-ring and back-up rings in inner piston diameter groove.Figure 5-52. Pist

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 3121298Jib Lift Cylinder (SJ Only)DISASSEMBLYCCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CL

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-29

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3121298Figure 1-1. Operator Maintenance and Lubrication1.10 OPERATOR MAINTENANCENOTE: The following number

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 31212988. Using suitable protection, clamp cylinder rod in a vise or similar holding fixture as close to pisto

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-31AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See your JLG Parts Manual.Apply a

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 31212986. If applicable, place new O-ring and back-up rings in inner piston diameter groove.Figure 5-65. Pist

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-33Steer CylinderDISASSEMBLYNOTE: Refer to Figure 5-71.CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYL

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 3121298 1. Pis

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-357. Remove two Seals (2) and O-Ring (3) from Piston (1).8. Loosen two Setscrews (4) in Piston (1). Unscr

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 3121298Assembly NOTE: Apply a light film of hydraulic oil to all components before assembly.1. Position cylin

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-37Axle Lockout CylinderNOTE: Refer to Figure 5-78., Axle Lockout Cylinder.DISASSEMBLYCONTAMINATION MAY DA

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 31212981. Barrel2. Rod3. Plug4. Pilot Piston5. Wear Ring6. Wiper7. Rod Seal8. Bleeder9. Cartridge ValveFigure

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-395.6 HYDRAULIC PUMP (GEAR)DisassemblyNOTE: The following general instructions also apply to multiple sec

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-72. Wheel Bearings (If equipped)Lube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 y

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 312129810. Remove rear bearing block from drive and idler shafts.11. Remove idler shaft from bearing block.12.

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-41Inspect Parts For Wear1. Clean and dry all parts thoroughly before inspection. It is not necessary to i

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 3121298General InformationFAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT WITH LITTLE OR NO FLOW AT RATED P

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-435. Place mounting flange, with shaft seal side down, on a clean flat surface.6. Apply a light coating o

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 312129813. Gently slide gear housing over rear bearing block assembly. Slide housing down until it engages dow

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-45Placing Pump Back Into Service1. If shop test stand is available, use the following proce-dure for tes

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 3121298Remove and Install FNR and NFPE Modules1. Clean pump and module housings.2. Remove four screws retainin

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-47Figure 5-80. Gauge Port Locations1. System Pressure Gauge Port M2 7. Case Drain Port L22. System Press

SECTION 5 - HYDRAULICS5-48 – JLG Lift – 3121298Figure 5-81. Plugs/Fittings Size & Torque#Plug/FittingTorquelb. ft. Nm1 Servo Gauge Port M4N/A N/A

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-495. Install new O-ring on valve plug. Reinstall poppet, spring, and plug (with shims and O-ring) into pu

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31212987. Hydraulic Charge FilterInterval - Change after first 50 hrs. and every 6 months or 300 hrs. there

SECTION 5 - HYDRAULICS5-50 – JLG Lift – 31212981. Position pump with shaft facing up.NOTE: If unit is positioned horizontally when shaft is removed, c

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-51Charge PumpNOTE: Disassemble charge pump to inspect and clean, or change auxiliary shaft drive coupling

SECTION 5 - HYDRAULICS5-52 – JLG Lift – 31212985.8 HYDRAULIC COMPONENT START-UPThe goal at hydrostatic system start up is to preserve the designed lif

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-535.9 PRESSURE SETTING PROCEDURESCOLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS. JLG IN

SECTION 5 - HYDRAULICS5-54 – JLG Lift – 3121298Figure 5-88. Main Control Valve - Sheet 1 of 2

SECTION 5 - HYDRAULICS3121298 – JLG Lift – 5-55Figure 5-89. Main Control Valve - Sheet 1 of 2

SECTION 5 - HYDRAULICS5-56 – JLG Lift – 3121298Figure 5-90. Location of Components - Main Control Valve1.

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121298Figure 6-2. Controller Block Diagram

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-3Connect JLG Control System Analyzer1. Connect four pin end of cable supplied with hand-held or w

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-910. Oil Change w/Filter - Deutz D2.9Lube Point(s) - Fill Cap/Spin-on ElementCapacity - 8.45 Qt (8 L

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121298If ENTER is selected at the HELP: PRESS ENTER display, and a fault is present, the analyzer di

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-5Press ENTER to select the ACCESS LEVEL menu.Using the UP or DOWN arrow keys, enter first d

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121298Machine SetupWhen a machine digit item is selected, press UP or DOWN arrow keys to adjust it

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-7Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERATEACT ACTIVEA/D ANALOG DIGITA

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121298S/C SHORT CIRCUITSEL SELECTORSN SERIAL NUMBERSPD SPEEDSTOW STOWEDSTOWD STOWEDSW SWITCH or SOFTWA

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-9Figure 6-5. Analyzer Software Version 6.8 - Sheet 1 of 6 MENU: HELP:PRESS ENTER HELP: (001

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121298Figure 6-6. Analyzer Software Version 6.8 - Sheet 2 of 6FromDIAGNOSTICS:BOOM FUNCTIONSTODIAGNO

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-11Figure 6-7. Analyzer Software Version 6.8 - Sheet 3 of 6 CALIBRATION DATA LOAD 500LB: CALIBRAT

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121298Figure 6-8. Analyzer Software Version 6.8 - Sheet 4 of 6FROM MENU:DIAGNOSTICSTO PERSONALITIES:

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-13Figure 6-9. Analyzer Software Version 6.8 - Sheet 5 of 6FROM PERSONALITIES:RIGHT TRACK PERSONA

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 312129812. Oil Change w/Filter - GMLube Point(s) - Fill Cap/Spin-on Element  (JLG P/N 7027965)Capaci

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121298Figure 6-10. Analyzer Software Version 6.8 - Sheet 6 of 6FROMMENU:PERSONALITIES MENU: MACHINE

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-156.2 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustme

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121298SWING ACCELeration 0.1 to 5.0s 2.0DECELeration 0.1 to 3.0s 1.8MINimum LEFT speed 0 to 50% 30MAX

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-17BASKET ROTATE ACCELeration 0.1 to 5.0 1.8DECELeration 0.1 to 3.0 0.7MlNimum LEFT speed 0 to 65

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121298Table 6-3. Help Fault Codes, Displayed Faults, and DescriptionsFault FlashCodeCommunicated (Dis

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-19D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if the Vref voltage i

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121298l/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when center tap voltage is not

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-21HORN SHORT TO BATTERYAUX POWER SHORT TO GROUNDAUX POWER OPEN CIRCUITAUX POWER SHORT TO BATTERY

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121298GROUND ALARM OPEN CIRCUITGROUND ALARM SHORT TO BATTERYGENERATOR SHORT TO GROUNDGENERATOR OPEN

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-23BASKET RIGHT OPEN CIRCUITBASKET RIGHT SHORT TO BATTERYJIB UP SHORT TO GROUNDJIB UP OPEN CIRCUI

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-11Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121298LIFT UP DUMP SHORT TO BATTERYLIFT DOWN HOLDING SHORT TO GROUNDLIFT DOWN HOLDING OPEN CIR-CUITL

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-25JIB DOWN SHORT TO BATTERYJIB DOWN SHORT TO GROUNDJIB DOWN OPEN CIRCUITJIB LEFT SHORT TO BATTER

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121298FUEL SENSOR SHORT TO GROUNDIndicates fuel sensor is reading below 0.2 volts.4/4 Flash code 4/4

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-27Table 6-4. Help Message/Fault ListingHELP MESSAGE FAULT FAULT REMOVALOK 0 0 CLEARS WHEN FAULT I

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121298FORD ECM POWER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTHORN SHORT TO GROU

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-29ALARM SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTGENERATOR SHORT TO GROUND

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121298TOWER UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTTOWER UP OPEN CIRCUIT 3

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-31FORD FAULT CODE 31 4 3 CLEARS WHEN FAULT IS REMOVEDFORD FAULT CODE 32 4 3 CLEARS WHEN FAULT IS

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121298NO ALTERNATOR OUTPUT 4 3 CLEARS WHEN FAULT IS REMOVEDOIL PRESSURE LOW 4 3 CLEARS WHEN FAULT IS

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-33Table 6-5. Machine Configuration Programming InformationConfiguration Digit Number DescriptionD

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121298Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121298TILT:8123455 DEGREES: Reduces the maximum speed of all boom functions to creep when t

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-35H & T LIGHTS:1401NO: No head and tail lights installed.YES: Head and tail lights installed.

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121298FUNCTION CUT-OUT:18*0123NO: No drive cutout.BOOM CUTOUT: Boom function cutout while driving abo

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-376.3 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDSLIFT UP: from platform control, lowest elev

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121298Test Notes1. Personality settings can be adjusted anywhere within the adjustment range for opti

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-39.Table 6-6. Fault Code ListDTC Text001 EVERYTHING OK0010 RUNNING AT CUTBACK - OUT OF TRANSPORT

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 31212982371 FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED2372 FUNCTION PROBLEM - SWING LEFT PE

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-413374 GEN SET/WELDER - OPEN CIRCUIT3375 GEN SET/WELDER - SHORT TO BATTERY3376 HEAD TAIL LIGHT -

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 312129833281 GLOWPLUG - SHORT TO GROUND33287 LIFT - CURRENT FEEDBACK READING TOO LOW33295 SWING LEFT V

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-433419 JIB LIFT DOWN VALVE - SHORT TO BATTERY3420 JIB LIFT DOWN VALVE - SHORT TO GROUND431 FUEL S

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-13Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 31212988211 LSS READING UNDER WEIGHT8639 FRONT LEFT STEER VALVE - OPEN CIRCUIT8640 FRONT LEFT STEER VA

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-45600SMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSTARTER LOCKOUTENGINE SHUTDOWNTILTJIB4 WHEEL

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121298600SDRIVE TYPEDISPLAY UNITSLEVELING MODEDRIVE CONTROLBOOM CONTROLCLEARSKYCRIBBING OPFUEL TANK S

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-47600SJGEN SET / WELDERGEN SET CUTOUTHEAD & TAIL LIGHTSCABLE BREAK SWITCHLOAD SYSTEMLOAD SENS

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 3121298Figure 6-11. Control Module Locations

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-49Figure 6-12. Ground Control Module Pin Connections 1 of 3   

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121298Figure 6-13. Ground Control Module Pin Connections 2 of 3   

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-51Figure 6-14. Ground Control Module Pin Connections 3 of 3   

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121298Figure 6-15. Platform Control Module Pin Connections 1 of 2  

SECTION 6 - JLG CONTROL SYSTEM3121298 – JLG Lift – 6-53Figure 6-16. Platform Control Module Pin Connections 2 of 2  

INTRODUCTION3121298 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121298Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121298NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121298Resistance Measurement• First test meter and leads by touching leads

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-3Current Measurement• Set up meter for expected current range• Be sure

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 3121298Dielectric Grease ApplicationBefore following these instructions, ref

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-5AMP Mate-N-LokFollow manufacturer installation instructions.Figure 7-

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 31212987.4 AMP CONNECTORPlug and header assembly colors are mechanically key

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-74. After all contacts are inserted, close wedge lock to its locked po

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31212987.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact (1) about 25mm behind cont

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-15Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121298Figure 7-26. Electrical Components 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-11Figure 7-27. Electrical Components 2 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121298Figure 7-28. Platform and Ground Control Electrical Schematic - 1 o

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-13Figure 7-29. Platform and Ground Control Electrical Schematic - 2 o

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121298Figure 7-30. Generator Wiring Schematic 1 of 21001110345D - Sheet 3

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-15Figure 7-31. Generator Wiring Schematic 2 of 21001110345D - Sheet 3

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121298Figure 7-32. Deutz Engine Harness Electrical Schematic1001110345D -

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-17Figure 7-33. GM/PSI Engine Harness Electrical Schematic1001110345D

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121298Figure 7-34. Deutz Tier 4 Final Engine Harness Electrical Schematic

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-19Figure 7-35. Deutz Tier 4 Final Engine Harness Electrical Schematic

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121298Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121298Figure 7-36. Hydraulic Schematic2792605D - Sheet 1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-21Figure 7-37. Hydraulic Schematic2792605D - Sheet 1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121298Figure 7-38. Hydraulic Schematic 2-Wheel Drive - 1 of 22792605D - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-23Figure 7-39. Hydraulic Schematic 2-Wheel Drive - 2 of 22792605D - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121298Figure 7-40. Hydraulic Schematic 4-Wheel Drive - 1 of 22792605D - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121298 – JLG Lift – 7-25Figure 7-41. Hydraulic Schematic 4-Wheel Drive - 2 of 22792605D - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3121298NOTES:

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

SECTION 1 - SPECIFICATIONS3121298 – JLG Lift – 1-17Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3121298NOTES:

SECTION 2 - GENERAL3121298 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides informa

SECTION 2 - GENERAL2-2 – JLG Lift – 31212982.2 SERVICE AND GUIDELINESGeneralFollowing information is provided to assist you in using servic-ing and ma

SECTION 2 - GENERAL3121298 – JLG Lift – 2-3Component Disassembly and ReassemblyComplete procedural steps in sequence when disassembling or reassemblin

SECTION 2 - GENERAL2-4 – JLG Lift – 31212982.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contamina-tion

SECTION 2 - GENERAL3121298 – JLG Lift – 2-52.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINESFilament wound bearings.1. Pinned joints should be disassem

INTRODUCTIONA-2 – JLG Lift – 3121298REVISON LOGOriginal Issue - August 7, 2013Revised - October 10, 2013Revised - November 25, 2013Revised - February

SECTION 2 - GENERAL2-6 – JLG Lift – 3121298Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALWeeklyPreventiveMaintenanceMonthlyPrev

SECTION 2 - GENERAL3121298 – JLG Lift – 2-7Functions/ControlsPlatform Controls 5 6 6Ground Controls 5 6 6Function Control Locks, Guards, or Detents 1,

SECTION 2 - GENERAL2-8 – JLG Lift – 3121298Annual Machine Inspection Due 21No Unauthorized Modifications or Additions 21 21All Relevant Safety Publica

SECTION 2 - GENERAL3121298 – JLG Lift – 2-9Figure 2-1. Deutz Engine and Hydraulic Operating Temperature Specifications

SECTION 2 - GENERAL2-10 – JLG Lift – 3121298Figure 2-2. GM Engine and Hydraulic Operating Temperature Specifications

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationPneumatic tire air p

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31212983. Torque to specifications shown in Table 3-1 below.4. Torque wheel nuts after first 50 ho

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-3Figure 3-3. Torque Hub3B3F3C3B191120591E4G3E2176A6E6D6B6C6G15166F1B1C1H1D181C1F1G1G8C8B8L8

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3121298Main Disassembly1. Perform Roll Check, Leak Check, and Brake Check if applicable before dis

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-5Output Carrier Disassembly1. Use a 1/8” diameter punch to drive Roll Pin (4G) in Planet Sha

3121298 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121298Hub-Spindle Disassembly1. Place unit on bench with Spindle (1A) end down.2. Remove 2 Set S

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-7Spindle-Brake DisassemblyNOTE: Units with integral Input Brake (8) only.COMPRESSED SPRINGS

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121298Cover Disassembly1. Remove O-Ring (17) from groove in Cover (6A).2. Remove Thrust Washer (2

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-9Input Carrier Assembly1. Apply a liberal coat of grease to bore of one Input Planet Gear (3

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121298Spindle - Brake Assembly1. Place Spindle (1A) with flange side up.2. Place Stator (8K) in

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-11 Hub-Spindle AssemblyNOTE: Spray a light film of oil on all component parts during assembl

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121298Output Planet Gear Assembly1. Apply a liberal coat of grease to the bore of one Output Pla

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-13Main AssemblyNOTE: Coat all components with a generous amount of lubricant oil as they are

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121298Figure 3-15. Hub Assembly1A. Spindle1B. Lip Seal1C. Tapered Bearing1D. Housing1E.

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-15Figure 3-16. Bearing Cup Pressing ToolFigure 3-17. Seal Pressing Tool

ii – JLG Lift – 3121298TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121298Figure 3-18. Bearing Cup Pressing ToolFigure 3-19. Drift Pin for Lining Up Thrust Washer

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-173.3 FREE WHEELING OPTIONDisengage Drive Motors & Brakes for Towing, etc. (Free Wheel)1

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121298Shaft Seal ReplacementREMOVAL1. Remove snap ring (1) retaining shaft seal, and support was

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-19Loop Flushing ValveREMOVAL1. Using a 11/16 in internal hex wrench remove plug (1) and (2).

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121298TroubleshootingTable 3-3. Excessive Noise and/or VibrationItem Description ActionCheck o

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-21DisassemblyNOTE: Removal of endcap voids warranty.During assembly, coat all moving parts

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 3121298Figure 3-26. End Cap13. Using an 8 mm internal hex wrench, remove endcap screws (22).14.

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-23Figure 3-28. Cylinder Kit18. Turn housing on its side and remove cylinder kit assem-bly (

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121298.Figure 3-30. Shaft & Front Bearing2. Remove inner snap ring (35) and shaft/bearing a

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-25Figure 3-32. Cylinder Kit Disassembly7. Remove pistons (44) and slipper retainer (45) fro

3121298 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121298CYLINDER BLOCKMeasure cylinder block height. Replace blocks worn beyond minimum height spe

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-27SHAFT BEARINGSInspect bearings for excessive wear or contamination. Rotate bearings while

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3121298RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-298. Press front shaft bearing (15) on shaft (16). Press bearing on shaft with lettering fac

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 312129812. Press rear shaft bearing (22) in endcap. Install bearing with letters facing out. Pres

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-3118. Cover shaft splines with an installation sleeve. Install a new shaft seal (27) with cu

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 3121298Initial Start-up ProceduresFollow this procedure when starting-up a new motor or when inst

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-33Oscillating Axle Lockout TestLOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A S

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 31212983.7 SWING DRIVEFigure 3-45. Swing Drive Assembly21I1H1E1G1J131C1A122065A45113114481A. Out

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-35Figure 3-46. Swing Motor and Brake Assembly1011021041051031061071041091081101121041041041

iv – JLG Lift – 3121298TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121298Gear BacklashSet backlash to .010 - .015 in (0.254 to 0.381mm).1. Insert shim (JLG P/N 407

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-37Motor Control Valve Disassembly1. Place unit on bench with motor end up.2. Remove Drain Pl

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121298Main Disassembly1. Remove Sun Gear (8) with Retaining Ring (44) inside.2. With unit restin

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-39Carrier Disassembly1. Using a 3/16" punch drive Roll Pin (3G) holding Planet Shaft (3

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121298Hub-Shaft Subassembly1. Press Bearing Cup (1C) in Housing (1G). Make sure cup starts squar

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-41Carrier Subassembly1. Apply a liberal coat of grease to bore of Cluster Gear (3F). This ho

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121298Main Assembly1. With Hub Shaft Subassembly resting on Shaft (1A) install Internal Gear (2)

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-43Motor and Brake Assembly1. Insert Stator (8K) (O.D. lobes) in bore of Brake Housing (6). A

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 31212983.8 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is design

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-45Measuring PointMeasuring Pointa. Boom fully elevated and fully retracted.b. Boom horizonta

3121298 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121298Swing Bearing ReplacementREMOVAL1. Operate boom from Ground Control station to provide acc

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-476. Following Torque Sequence diagram shown in Figure 3-64., Swing Bearing Torque Sequence,

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 31212983.9 ROTARY COUPLINGUse the following procedure to install the seal kit.1. If not already r

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-49Figure 3-66. Rotary Coupling - Sheet 2 of 21. O -ri ng 2. P lu g3. C he ck

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121298Figure 3-67. Rotary Coupling Port Location - 2WS3412234677312345771,57523742,7656172

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-51Figure 3-68. Rotary Coupling Port Location - 4WS1,5,9752,83742,76561723412234677899831234

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31212983.10 GENERATOREvery 250 hours Check drive belt tension every 250 hours of operation,.Figur

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-53Overload ProtectionSTOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER.The circuit

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121298Figure 3-73. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings11/4

SECTION 3 - CHASSIS & TURNTABLE3121298 – JLG Lift – 3-553.11 DEUTZ D2.9 L4 ENGINEFigure 3-74. Deutz D2.9 L4 Engine Installation - Sheet 1 of 21.