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Service and Maintenance Manual: Models 600A 600AJ

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0% found this document useful (0 votes)

1K views342 pages

Service and Maintenance Manual: Models 600A 600AJ

Uploaded by

Hari Hara Suthan

We take content rights seriously. If you suspect this is your content, claim it here.

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Download as PDF, TXT or read online on Scribd

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Service and Maintenance Manual

Models
600A
600AJ

S/N 0300080000
to Present

P/N - 3121201

December 10, 2012

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL C MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the aerial
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
platform. It is of utmost importance that maintenance per-
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
sonnel pay strict attention to these warnings and precau- NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
tions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must • ENSURE REPLACEMENT PARTS OR COMPONENTS
be followed to ensure that the machine is safe to operate. ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS
OR COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLAT- ING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
FORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION
TIMES.
FROM THE MANUFACTURER.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
The specific precautions to be observed during mainte-
nance are inserted at the appropriate point in the manual. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
These precautions are, for the most part, those that apply LOOSE-FITTING CLOTHING AND NECKTIES WHICH
when servicing hydraulic and larger machine component ARE APT TO BECOME CAUGHT ON OR ENTANGLED
parts. IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAU-
Your safety, and that of others, is the first consideration TIONS ON MACHINE AND IN SERVICEMANUAL.
when engaging in the maintenance of equipment. Always
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
be conscious of weight. Never attempt to move heavy
STANDING SURFACES AND HAND HOLDS.
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising • USE CAUTION WHEN CHECKING A HOT, PRESSUR-
a portion of the equipment, ensure that adequate support IZED COOLANT SYSTEM.
is provided. • NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON-
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
PERFORMING ANY OTHER MAINTENANCE, SHUT
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER- OFF ALL POWER CONTROLS.
ATOR.
• BATTERY SHOULD ALWAYS BE DISCONNECTED-
DURING REPLACEMENT OF ELECTRICAL COMPO-
B HYDRAULIC SYSTEM SAFETY NENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
It should be noted that the machines hydraulic systems
MENTS STOWED IN THEIR PROPER PLACE.
operate at extremely high potentially dangerous pres-
sures. Every effort should be made to relieve any system • USE ONLY APPROVED, NONFLAMMABLE CLEANING
pressure prior to disconnecting or removing any portion of SOLVENTS.
the system.

Relieve system pressure by cycling the applicable control

several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure
feed lines to system components can then be discon-
nected with minimal fluid loss.

3121201 – JLG Lift – A-1

TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Deutz F4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-5 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Caterpillar 3044C Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-9 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-10 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-11 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-12 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-13 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-14 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-15 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-16 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-17 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-18 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-19 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-20 Cylinder Specifications - 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-21 Cylinder Specifications - 600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-22 Major Component Weights - 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-23 Major Component Weights - 600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1-24 Critical Stability Weights - 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-25 Critical Stability Weights - 600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1-26 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-3 Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-4 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-5 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
3-6 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36
3-7 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3-8 Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3-9 Coupling Port Information Table - 2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-10 Coupling Port Information Table - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-11 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71
3-12 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-114
3-13 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-117
3-14 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-125
4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
5-1 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-2 Cylinder Head and Tapered Bushing Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
6-1 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
6-2 Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6-3 Machine Configuration Programming Information Prior to Software Version P5.3 . . . . . . . . . . . .6-31
6-4 Machine Configuration Programming Information Software Version P5.3 to P6.1 . . . . . . . . . . . .6-35
6-5 Machine Configuration Programming Information Software Version P6.1 to Present. . . . . . . . . .6-40
6-6 Analyzer Fault Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-48
6-7 Adjustments - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56
6-8 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-59

xii – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 CAPACITIES
Table 1-1. Operating Specifications Table 1-2. Capacities

Maximum Work Load (Capacity) Fuel Tank 30 U.S. Gallons (113.6 L)

Unrestricted: 500 lb (230 kg)
Restricted: 1000 lb (450 kg) Hydraulic Oil Tank 30.6 Gallons (115.8 L) with 10%
Maximum Travel Grade (Gradeability) air space
2WD 30%
Hydraulic System (Including Tank) 36.72 Gallons (139 L)
4WD 45%
Maximum Travel Grade (Side Slope) 5° Torque Hub, Drive* 17 ounces (0.50 L)
Turning Radius - (outside)
2WS 17 ft. 8 in. (5.38 m) Engine Crankcase
4WS 11 ft. 8 in. (3.56 m) Ford LRG-425 Gas w/Filter 4.5 quarts (4.25L)
Deutz F4M2011F Diesel w/Filter 11 quarts (10.5 L)
Turning Radius - (outside) narrow chassis
Caterpillar 3044C Diesel w/Filter 10.6 quarts (10 L)
2WS 16 ft. 6 in. (5.03 m) 4.5 qts. (4.25 L)
GM 3.0L w/Filter
4WS 11 ft. 2 in. (3.4 m)
Turning Radius - (inside) Cooling System 16 Quarts (15.14 L.)
2WS 11 ft. 5 in. (3.48 m)
4WS 5 ft. 6 in. (1.68 m) *Torque hubs should be one half full of lubricant.
Turning Radius - (inside) narrow chas-
sis 12 ft. 2 in. (3.71 m) 1.3 COMPONENT DATA
2WS 5 ft. 7 in. (1.7 m)
4WS Engine Data
Maximum Tire Load: 11,500 lbs. (5227 kg)
Ground Bearing Pressure Table 1-3. Ford LRG-425 Specifications
600A 77 psi (5.4 kg/cm2)
Fuel Gasoline
600AJ 75 psi (5.3 kg/cm2)
600A - narrow chassis 94 psi (6.6 kg/cm2) Crankcase Capacity 4.5 Quarts (4.25 L) w/Filter
600AJ - narrow chassis 94 psi (6.6 kg/cm2)
Idle RPM 1000
Maximum Drive Speed - A Models
2WD 3.6 MPH (5.80 Km/hr.) Low RPM 1800
4WD 4 MPH (6.44 Km/hr.)
High RPM 2800
Gross Machine Weight (Approximate)
600A 21,500 lbs. (9,752 kg) Alternator 40 Amp, Belt Drive
600AJ 22,200 lbs. (10,025 kg)
600A - narrow chassis 23,900 lbs. (10,841 kg) Battery 85 Amphour, 550 Cold Cranking
600AJ - narrow chassis 24,000 lbs. (10,886 kg) Amps, 12 VDC

Fuel Consumption
Low RPM 3.45 GPH (13.06 lph)
High RPM 4.60 GPH (17.41 lph)

Horsepower 54 @ 2400 RPM, full load

Cooling System 16 Quarts (15.14 L.)

Spark Plug AWSF-52-C

Spark Plug Gap 0.044 in. (1.117 mm)

3121201 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Table 1-4. Deutz F4M2011 Specifications Table 1-6. Caterpillar 3044C Specifications

Fuel Diesel Type Four Stroke Cycle

Cylinders 4 in-line
Oil Capacity
Bore 3.70 inch (94 mm)
Cooling System 5 Quarts (4.5 L)
Crankcase w/Filter 11 Quarts (10.5 L) Stroke 4.72 inch (120 mm)
Total Capacity 16 Quarts (15 L) Aspiration turbocharged

Idle RPM 1000 Compression ratio 19:1

Displacement 203 in3 (3.33 L)
Low RPM 1800
Firing Order 1-3-4-2
High RPM 2800 Rotation (viewed from flywheel) Counterclockwise
Alternator 60 Amp, belt drive Oil Capacity (w/filter) 10.6 quarts (10 L)
Cooling System (Engine Only) 5.8 quarts (5.5 L)
Battery 1000 Cold Cranking Amps,
Idle RPM 1000
210 Minutes Reserve Capacity,
12 VDC Low RPM 1800
High RPM 2800
Fuel Consumption
Low RPM 1.90 GPH (7.19 lph) Alternator 60 Amp, belt drive
High RPM 2.50 GPH (9.46 lph) Battery 930 Cold Cranking Amps, 205
Minutes Reserve Capacity, 12
Horsepower 65 @ 3000 RPM, full load VDC

Table 1-5. Deutz D2011L04 Specifications Table 1-7. GM 3.0L

Fuel Diesel Fuel Gasoline or Gasoline/LP Gas
Oil Capacity No. of Cylinders 4
Cooling System 5 Quarts (4.5 L)
BHP
Crankcase 11 Quarts (10.5 L) w/Filter
Gasoline 83 hp @ 3000 rpm
Total Capacity 16 Quarts (15 L)
LP 75 hp @ 3000 rpm
Idle RPM 1000
Bore 4.0 in. (101.6 mm)
Low RPM 1800
Stroke 3.6 in. (91.44 mm)
High RPM 2500
Displacement 181 cu.in. (3.0 L, 2966 cc)
Alternator 60 Amp, belt drive
Oil Capacity w/filter 4.5 qts. (4.25 L)
Battery 950 Cold Cranking Amps, 205
Minimum Oil Pressure
Minutes Reserve Capacity, 12 VDC
at idle 6 psi (0.4 Bar) @ 1000 rpm
Fuel Consumption Hot 18 psi (1.2 Bar) @ 2000 rpm
Low RPM 1.90 GPH (7.19 lph)
Compression Ratio 9.2:1
High RPM 2.50 GPH (9.46 lph)
Firing Order 1-3-4-2
Horsepower 49 @ 2500 RPM, full load
Max. RPM 2800

1-2 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

Tires Hydraulic Filters

Table 1-8. Tire Specifications Table 1-12. Pumps

Size 14 x 17.5 14 x 17.5 14 x 17.5 IN355/ IN355/ 18x625 Return - Bypass Type 10 Microns Absolute
55D625 55D625 Charge 10 Microns Absolute
Load Range G G * G G H Hydraulic Strainers (In Tank) 30 Microns
Ply Rating 14 14 N/A 14 14 16
Tire Pres- 90 PSI Foam- Air-Boss 90 PSI 90 PSI 75 PSI Dimensional Data
sure (6 Bar) Filled (6 Bar) (6 Bar) (5.2 Bar)
Table 1-13. Dimensional Data
* Load Capacity - 11,800 lb. (5353 kg) -
Static Machine Height (Stowed) 8 ft. 3.75 in. (2.53 m)

Machine Length (Stowed)

Drive System 600A Over Drive Axle 26 ft. 5 in. (8.05 m)
600AJ Over Drive Axle 28 ft. 11.4375 in. (8.82 m)
Table 1-9. Drive System
Machine Width
Drive Motor Displacement 2.8 cu. in. max. 1.1 cu. in. min.(46 Standard 8 ft. (2.44 m)
cm3] max. 18 cm3] min.) Narrow Chassis 7 ft. (2.13 m)
Drive Hub Ratio 39.96:1 Wheelbase 8 ft. 0 in. (2.44 m)
Drive Brake Automatic spring applied,
hydraulically released disc brakes Boom Elevation - 600A +60 ft. 5 3/8 in. (18.42 m)
-11 in. (0.28 m)

Swing System Boom Elevation - 600AJ +60 ft. 6 3/4 in. (18.46 m)
-2 ft. 8 13/16 in. (0.83 m)

Table 1-10. Swing System

Swing Motor Displacement 4.62 cu. in. (75 cm3])

Swing Brake Automatic spring applied
hydraulically released disc brakes
Swing Hub Ratio 50:1
Hydraulic Gear Pump @ 1800 7.9 GPM (29.90 lpm)
RPM
Pump Displacement 1.02 cu. in. (16 cm3)
Rotation Clockwise

Pumps
Table 1-11. Pumps

Hydraulic Gear Pump

Output @ 1800 RPM 7.9 GPM (29.90 lpm)
Displacement 1.02 cu. in. (16 cm3)
Rotation Clockwise
Auxiliary Power Pump
Output 2.6 gpm 1200 psi
(9.8 lpm @82.7 BAR)
Pump Displacement 0.244 cu. in. (14 cm3)
Motor Type DC
Rotation Clockwise

3121201 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

1.4 FUNCTION SPEEDS Table 1-14. Function Speeds (In Seconds)

Function Speed
Machine Orientation When Doing Speed Lift Up 26-32
Tests Lift Down 26-32
Lift: Boom Retracted. Telescope Retracted. Lift Up, Swing Right & Left* 79-101
Record Time, Lift Down, Record Time. Telescope Out 35-50
Swing: Boom at Full Elevation. Telescope Retracted. Telescope In 22-30
Swing the Turntable off center and stop. Swing the oppo- Platform Rotate Right & Left** 16-25
site direction and start the test when the turntable is cen- Jib Up 22-34
tered up. This eliminates ramp up and down on the
Jib Down 16-26
controller affecting times.
Lower Lift Up 37-50
Telescope: Boom at Full Elevation; Telescope Retracted;
Lower Lift Down 28-38
Telescope Out, Record Time. Telescope In, Record Time.
Lower Telescope Out 15-23
Drive: Test to be done on a smooth level surface. Drive Lower Telescope In 09-15
Select Switch should be set to High Speed. Start approxi-
mately 25 ft. (7.62 m) from the starting point so that the Drive Forward & Reverse (2WD & 4WD) Deutz Engines 33-37
unit is at maximum speed when starting the test. Results Drive Forward & Reverse (2WD & 4WD) Other Engines 30-34
should be recorded for a 200 ft. (60.96 m) course. Drive Drive Above Horizontal Forward & Reverse (2WD & 46-54
Forward, Record Time. Drive Reverse, Record Time. 4WD)
Drive (Above Horizontal): Test should be done on a *Max 10% Difference Between Left & Right
smooth level surface. Drive Select Switch should be set to **Max 15% Difference Between Left & Right
Low Engine. The boom should be raised above horizon- 4150501 - D

tal. Results should be recorded for a 50 ft. (15.24 m)

course. Drive Forward, Record Time. Drive Reverse, 1.5 TORQUE REQUIREMENTS
Record Time.

Platform Rotate: Platform level and completely rotated Table 1-15. Torque Requirements
one direction. Rotate the opposite direction, Record Time.
Rotate the other direction, Record Time. Interval
Description Torque Value (Dry)
Hours
Articulating Jib: Platform level and centered with the
boom. Start with the Jib down. Jib Up, Record Time. Jib Bearing To Chassis 190 ft. lbs. 50/600*
Down, Record Time. (260 Nm)
See Note
Lower Lift: Upper boom horizontal, telescoped in, Lower
Lift up, Record Time. Lower Lift Down, Record Time. Bearing To Turntable 190 ft. lbs. 50/600*
(260 Nm)
Lower Telescope: Lower Lift fully elevated, Upper Boom See Note
horizontal, telescoped in. Lower Tele Out, Record Time.
Lower Tele In, Record Time. Wire Rope 15 ft. lbs (20 Nm) 150

Wheel Lugs 170 ft. lbs. (231 Nm) 150

Test Notes
Engine Mounting Bolts 165 ft. lbs. (231 Nm) A/R
1. Stop watch should be started with the function, not
with the controller or switch. Engine Manifold Mounting 30 ft. lbs. (42 Nm) A/R
Bolts
2. All speed tests are run from the platform. These
speeds do not reflect the ground control operation. *Check swing bearing bolts for security after first 50 hours of opera-
tion and every 600 hours thereafter. (See Swing Bearing in Section
3. The platform speed knob control must be at full
3.)
speed (turned clockwise completely).

4. Function speeds may vary due to cold, thick hydrau- NOTE: When maintenance becomes necessary or a
lic oil. Test should be run with the oil temperature fastener has loosened, refer to the Torque Chart
to determine proper torque value.
above 100° F (38° C).

1-4 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

1.6 LUBRICATION Aside from JLG recommendations, it is not advisable to

mix oils of different brands or types, as they may not con-
tain the same required additives or be of comparable vis-
Hydraulic Oil cosities. If use of hydraulic oil other than Kendall Hyken
052 or Mobilfluid 424 is desired, contact JLG Industries for
Table 1-16. Hydraulic Oil proper recommendations.
HYDRAULIC SYSTEM OPERATING SAE VISCOSITY
TEMPERATURE RANGE GRADE
1.7 PRESSURE SETTINGS
+0° to +180° F (-18° C to +83° C) 10W Table 1-19. Pressure Settings
+0° F to +210° F (-18° C to +99° C) 10W-20, 10W-30 Main Relief 3000 PSI (206.85 Bar)
+50° F to +210° F (+10° C to +210° C) 20W-20 Upper Boom Lift Down 1200 PSI (83 Bar)
Swing 1700 PSI (117.2 Bar)
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient Platform Level Forward 2800 PSI (193 Bar)
chemical stability for mobile hydraulic system ser- Platform Level Backward 1800 PSI (124 Bar)
vice. JLG Industries recommends Mobilfluid 424 Steer 1800 PSI (124 Bar)
hydraulic oil, which has an SAE viscosity index of
152. Steer Reliefs - 4WS Front & Rear 2500 PSI (172 Bar)
Articulating Jib Boom Up 1500 PSI (103 Bar)
Articulating Jib Boom Down 1200 PSI (83 Bar)
Table 1-17. Mobilfluid 424 Specs

SAE Grade 10W30 1.8 CYLINDER SPECIFICATIONS

Gravity, API 29.0 Table 1-20. Cylinder Specifications - 600A
Density, Lb/Gal. 60°F 7.35
DESCRIPTON BORE STROKE ROD DIA.
Pour Point, Max -46°F (-43°C)
442°F (228°C) Lower Lift 6.5 34.0625 2.5
Flash Point, Min.
(165.1) (865.2) (63.5)
Viscosity
Brookfield, cP at -18°C 2700 Tower Telescope 3 63.75 2
(76.2) (1619.3) (50.8)
at 40° C 55 cSt
at 100° C 9.3 cSt Upright Level 6 34.625 3
(152.4) (879.5) (76.2)
Viscosity Index 152
Upper Lift 4 36.625 2.5
NOTE: When temperatures remain below 20° F (-7 degrees (101.6) (930.3) (63.5)
C), JLG Industries recommends the use of Mobil Upper Telescope 3 177.75 2
DTE 13M. (76.2) (4514.9) (50.8)

Steer (2WD/ 2.5 8.812 1.25

Table 1-18. Mobil DTE 13M Specs
2WS) (63.5) (204.7) (31.8)
ISO Viscosity Grade #32
Steer (4WD/ 2.5 10.75 1.25
Specific Gravity 0.877 2WS) (63.5) (273.1) (31.8)
Pour Point, Max -40°F (-40°C)
Lockout (2WD) 3.5 3.875 2.5
Flash Point, Min. 330°F (166°C)
(88.9) (98.4) (63.5)
Viscosity
at 40° C 33cSt Lockout (4WD 3.5 3.875 2.5
(88.9) (98.4) (63.5)
at 100° C 6.6 cSt
at 100° F 169 SUS Master 3 8.5 1.5
at 210° F 48 SUS (76.2) (215.9) (38.1)

cp at -20° F 6,200 Slave 3 8.5 1.5

Viscosity Index 140 (76.2) (215.9) (38.1)

3121201 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Table 1-21. Cylinder Specifications - 600AJ 1.9 MAJOR COMPONENT WEIGHTS

DESRIPTON BORE STROKE ROD DIA. Table 1-22. Major Component Weights - 600A

Lower Lift 6.5 34.0625 2.5 LB. KG.

(165.1) (865.2) (63.5)
Platform Control Console 250 113
Tower Tele- 3 63.75 2
scope (76.2) (1619.3) (50.8) Platform Level Cylinder 46 21

Upright Level 6 34.625 3 Main Boom (Includes Lift Cyl., Rotator, and Support) 1832 831
(152.4) (879.5) (76.2) Upright including Master Cylinder 547 248
Upper Lift 4 36.625 2.5 Upright Level Cylinder 316 143
(101.6) (930.3) (63.5)
Tower Boom Complete 1218 553
Upper Tele- 3 134.375 2
scope (76.2) (3413.1) (50.8) Turntable Complete (including engine) 9240 4191

Steer (2WD/ 2.5 8.812 1.25 Chassis Complete (w/pneumatic tires) 6834 3100
2WSl (63.5) (204.7) (31.8)
Chassis Complete (w/foam-filled tires) 7918 3592
Steer (4WD/ 2.5 10.75 1.25
2WS) (63.5) (273.1) (31.8) Pneumatic Tire & Wheel Assembly 235 107

Lockout (2WD) 3.5 3.875 2.5 Foam-filled Tire & Wheel Assembly 440 200
(88.9) (98.4) (63.5)
Segmented Tire & Wheel Assembly 320 145.5
Lockout (4WD 3.5 3.875 2.5
Machine Complete (GVW) - 2WD w/pneumatic tires 20700 9390
(88.9) (98.4) (63.5)
Machine Complete (GVW) - 4WD w/pneumatic tires 21150 9594
Master 3.5 13.0625 1.5
(88.9) (331.8) (38.1)
Table 1-23. Major Component Weights - 600AJ
Slave 3.5 13.0625 1.5
(88.9) (331.8) (38.1) LB. KG.
Lift (Articulat- 3 25.5 1.5 Platform Control Console 250 113
ing Jib Boom) (76.2) (647.7) (38.1)
Platform Level Cylinder 60 27

Main Boom (Includes Lift Cyl., Rotator, and Support) 1685 764

Upright including Master Cylinder 547 248

Upright Level Cylinder 316 143

Tower Boom Complete 1218 553

Turntable Complete (including engine) 9740 4418

Chassis Complete (w/pneumatic tires) 6834 3100

Chassis Complete (w/foam-filled tires) 7918 3592

Pneumatic Tire & Wheel Assembly 235 107

Foam-filled Tire & Wheel Assembly 440 200

Segmented Tire & Wheel Assembly 320 145.5

Machine Complete (GVW) - 2WD w/pneumatic tires 22100 10025

Machine Complete (GVW) - 4WD w/pneumatic tires 22295 10113

1-6 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

1.10 CRITICAL STABILITY WEIGHTS 1.11 SERIAL NUMBER LOCATIONS

A serial number plate is affixed to the left rear side of the
frame. If the serial number plate is damaged or missing,
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS the machine serial number is stamped on the left side of
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: the frame.
BATTERIES, FILLED TIRES, COUNTERWEIGHT, ENGINE & PLAT-
FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABIL-
ITY.

Table 1-24. Critical Stability Weights - 600A

LB. KG.

Tire and Wheel (Ballasted Size (14-17.5) 165 75

Only)

Engine Ford 460 209

Figure 1-1. Serial Number Locations
Deutz 534 242

Continental 558 253

Counterweight Weight 5700 2586

Platform 6 ft. (1.83 M) 205 93

8 ft. (2.44 M) 230 105

Table 1-25. Critical Stability Weights - 600AJ

LB. KG.

Tire and Wheel (Ballasted Size (14-17.5) 165 75

Only)

Engine Ford 460 209

Deutz 534 242

Continental 558 253

Counterweight Weight 6200 2812

Platform 6 ft. (1.83 M) 205 93

8 ft. (2.44 M) 230 105

3121201 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication & Maintenance Point Location

1.12 LUBRICATION & MAINTENANCE 1. Swing Bearing

NOTE: The following numbers correspond to those in Fig-

ure 1-2., Lubrication & Maintenance Point Location.

Table 1-26. Lubrication Specifications

KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of
350° F (177° C). Excellent water resistance and adhesive
qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobil- Lube Point(s) - 2 Grease Fittings
fluid 424. Capacity - A/R
Lube - MPG
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L- Interval - Every 3 months or 150 hrs of operation
2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L- Comments - Remote Access
2104C.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION

UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-
SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON-
MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.

1-8 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

2. Wheel Bearings 4. Wheel Drive Hub

Lube Point(s) - Repack Lube Point(s) - Level/Fill Plug

Capacity - A/R
Capacity - 17 oz. (1/2 Full)
Lube - MPG
Lube - EPGL
Interval - Every 2 years or 1200 hours of operation
Interval - Check level every 3 months or 150 hrs of
3. Swing Drive Hub operation; change every 2 years or 1200 hours of
operation

5. Hydraulic Return Filter

Lube Point(s) - Level/Fill Plug

Capacity - 17 oz. (1/2 Full)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of Interval - Change after first 50 hrs. and every 6
operation months or 300 hrs. thereafter or as indicated by
Condition Indicator.

3121201 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

6. Hydraulic Charge Filter 8. Suction Strainers (in tank)

REMOVE FILL CAP PLATE FROM

TANK TO GAIN ACCESS TO
STRAINERS

Interval - Change after first 50 hrs. and every 6

months or 300 hrs. thereafter or as indicated by
Condition Indicator.

7. Hydraulic Tank Lube Point(s) - 2

Interval - Every 2 years or 1200 hours of operation,
remove and clean at time of hydraulic oil change.

9. Oil Change w/Filter - Ford LRG425

NORMAL OPERATING
RANGE WITH BOOM
IN STOWED POSITION

Lube Point(s) - Fill Cap

Capacity - 31 gal. (117.3 L) Tank; 37.2 gal. (140.8 L)
System
Lube - HO Lube Point(s) - Fill Cap/Spin-on Element
Interval - Check Level daily; Change every 2 years or Capacity - 4.5 Quarts
1200 hours of operation. Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor-
dance with engine manual.

1-10 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

10. Oil Change w/Filter - Deutz 11. Oil Change w/Filter - Caterpillar
Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 10.6 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor-
dance with engine manual.
12. Oil Change w/Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 11 Quarts Crankcase; 5 Quarts Cooler
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check oil level, fill oil to max marking
on the dipstick. Check level daily/Change in accor-
dance with engine manual. Refer to Figure 1-3.,
Deutz Engine Dipstick.

Lube Point(s) - Fill Cap/Spin-on Element

(JLG P/N 7027965)
MINIMUM OIL Capacity - 4.5 qt. (4.25 L) w/filter
LEVEL Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor-
dance with engine manual.
13. Fuel Filter - Ford
MAXIMUM OIL
LEVEL

MINIMUM LEVEL,
OIL HOT
MAXIMUM LEVEL,
OIL HOT

MINIMUM LEVEL, Lube Point(s) - Replaceable Element

OIL COLD Interval - Every Year or 1200 hours of operation
MAXIMUM LEVEL,
OIL COLD

NOTE: Hot oil checks should not be made until the engine
has been shut down for a period of 5 minutes.

Figure 1-3. Deutz Engine Dipstick

3121201 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

14. Fuel Filter - Deutz 18. Electronic Pressure Regulator (LP only)

Interval - 3 Months or 150 hours of operation

Lube Point(s) - Replaceable Element Comments - Drain oil build up. Refer to Draining Oil
Interval - Every Year or 600 hours of operation Build Up From The Propane Regulator

15. Fuel Filter - Caterpillar 19. Fuel Filter (Propane) - GM Engine

Lube Point(s) - Replaceable Element
Interval - Every Year or 600 hours of operation
16. Fuel Filter (Gasoline) - GM
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation
17. Air Filter

Interval - 3 Months or 150 hours of operation

Comments - Replace filter. Refer to Propane Fuel Fil-
ter Replacement

Draining Oil Build Up From The Propane

Regulator
During the course of normal operation oils may build
Lube Point(s) - Replaceable Element inside the primary and secondary chambers of the pro-
Interval - Every 6 months or 300 hours of operation pane pressure regulator. These oils may be a result of
or as indicated by the condition indicator poor fuel quality, contamination of the fuel supply
chain, or regional variation in the make up of the fuel. If
the build up of the oil is significant this can effect the
operation of the fuel control system. Refer to Section
1.12, Lubrication & Maintenance for maintenance inter-
vals. More frequent draining may be required if the fuel
supply has been contaminated.

FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM-

PERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO
BE LIQUID AND FLOW FREELY FROM THE REGULATOR.

1. Move the equipment to a well ventilated area.

Ensure there are no external ignition sources.

1-12 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

2. Start the engine and bring to operating temperature. Propane Fuel Filter Replacement
3. With the engine running, close the manual tank
valve and run the engine out of fuel.

4. Push in the Emergency Switch once the engine

stops.

5. Disconnect the electrical connection to the LPG fuel

temperature sensor in the auxiliary fuel port of the
EPR.

1. Electric Lock Off Solenoid 7. Electrical Connector

2. Mounting Plate 8. Fuel Outlet
3. Housing Seal 9. O-ring
4. Filter Magnet 10. Filter
5. Filter Housing 11. Fuel Inlet
6. Seal 12. Retaining Bolt
Figure 1-4. Filter Lock Assembly
6. Remove the retainer clip for the LPG fuel tempera-
ture sensor and remove the sensor from the regula- REMOVAL
tor body.
1. Relieve the propane fuel system pressure. Refer to
Propane Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing retaining bolt and
remove it.
4. Pull the filter housing from the Electric lock off
assembly .
5. Locate Filter magnet and remove it.
6. Remove the filter from the housing.
7. Remove and discard the housing seal.
8. Remove and discard the retaining bolt seal.
NOTE: Have a small container ready to collect oil that will
drain freely from the regulator at this point. 9. Remove and discard mounting plate to lock off O-
ring seal.
7. Once all of the oil has been drained, reinstall the
LPG fuel temperature sensor and reconnect the
electrical connector.

8. Open the fuel tank manual valve.

9. Start the engine and verify all connections are

secure.

10. Dispose of any drained oil in a safe and proper fash-

ion.

3121201 – JLG Lift – 1-13

SECTION 1 - SPECIFICATIONS

INSTALLATION Propane Fuel System Pressure Relief

BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS- THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
ING BEFORE INSTALLING NEW SEAL 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER-
SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES-
1. Install the mounting plate to lock off O-ring seal. SURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE
FUEL SYSTEM COMPONENTS.
2. Install the retaining bolt seal.
To relieve propane fuel system pressure:
3. Install the housing seal.
1. Close the manual shut-off valve on the propane fuel
4. Drop the magnet into the bottom of the filter hous- tank.
ing.
2. Start and run the vehicle until the engine stalls.
5. Install the filter into the housing.
3. Turn the ignition switch OFF.
6. Install the retaining bolt into the filter housing.

7. Install the filter up to the bottom of the electric lock

RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
off.
SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
8. Tighten the filter retaining bolt to 106 in lbs (12 Nm). BEFORE DISCONNECTING ANY FUEL LINE.

9. Open manual shut-off valve. Start the vehicle and

leak check the propane fuel system at each serviced
fitting. Refer to Propane Fuel System Leak Test.

1-14 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia Clamp Load TM
(Loctite® 262TM or Vibra-
Stress Area (Dry) Lubricated OR Vibra-TITE 111 or
TITETM 131)
140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N Description

0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)

0100019 271TM Vibra-TITE TM 140 High Strength (Red)
0100071 262TM Vibra-TITE TM 131 Medium - High Strength (Red)

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 1 of 7)

3121201 – JLG Lift – 1-15

SECTION 1 - SPECIFICATIONS

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque Torque
Torque
Tensile (Loctite® 242TM or 271TM (Loctite® 262TM or Vibra-
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Stress Area
K= 0.20 OR Vibra-TITE TM 111 or TITETM 131)
140) K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

Figure 1-6. Torque Chart (SAE Fasteners - Sheet 2 of 7)

1-16 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*
Torque
Torque
(Loctite® 242TM or 271TM (Loctite® 262TM
Tensile Clamp Load Torque
Size TPI Bolt Dia
Stress Area See Note 4 (Dry) K = .17 OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
140 OR Precoat 85® K=0.15
K=0.16
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-7. Torque Chart (SAE Fasteners - Sheet 3 of 7)

3121201 – JLG Lift – 1-17

SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners (Ref 4150707)*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-8. Torque Chart (SAE Fasteners - Sheet 4 of 7)

1-18 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

Torque
Torque (Loctite®
Tensile Torque
Clamp Torque (Loctite® 262TM 242TM or 271TM
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 7)

3121201 – JLG Lift – 1-19

SECTION 1 - SPECIFICATIONS

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
Size PITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

1-20 – JLG Lift – 3121201

SECTION 1 - SPECIFICATIONS

Magni Coating (Ref 4150701)*

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

Torque
Torque
Torque (Lub OR Loctite®
Tensile (Loctite® 262TM
Clamp Load (Dry or Loctite® 242TM or 271TM
Size PITCH Stress OR Vibra-TITE TM
See Note 4 263TM) OR Vibra-TITE TM
Area 131)
K = .17 111 or 140)
K = .15
K = .16

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-11. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

3121201 – JLG Lift – 1-21

SECTION 1 - SPECIFICATIONS

NOTES:

1-22 – JLG Lift – 3121201

SECTION 2 - GENERAL

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
General areas of this manual for servicing and maintenance proce-
dures.
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe Annual Machine Inspection
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and The Annual Machine Inspection must be performed by a
maintenance have been completed before placing the Factory-Certified Service Technician on an annual basis,
machine into service. no later than thirteen (13) months from the date of the
prior Annual Machine Inspection. JLG Industries, Inc. rec-
Preparation, Inspection, and Maintenance ognizes a Factory-Certified Service Technician as a per-
son who has successfully completed the JLG Service
It is important to establish and conform to a comprehen- Training School for the subject JLG product model. Refer-
sive inspection and preventive maintenance program. The ence the machine Service and Maintenance Manual and
following table outlines the periodic machine inspections appropriate JLG inspection form for performance of this
and maintenance recommended by JLG Industries, Inc. inspection.
Consult your national, regional, or local regulations for fur-
ther requirements for aerial work platforms. The frequency Reference the JLG Annual Machine Inspection Form and
of inspections and maintenance must be increased as the Inspection and Preventative Maintenance Schedule for
environment, severity and frequency of usage requires. items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this man-
Pre-Start Inspection ual for servicing and maintenance procedures.
It is the User’s or Operator’s primary responsibility to per- For the purpose of receiving safety-related bulletins, it is
form a Pre-Start Inspection of the machine prior to use important that JLG Industries, Inc. has updated ownership
daily or at each change of operator. Reference the Opera- information for each machine. When performing each
tor’s and Safety Manual for completion procedures for the Annual Machine Inspection, notify JLG Industries, Inc. of
Pre-Start Inspection. The Operator and Safety Manual the current machine ownership.
must be read in its entirety and understood prior to per-
forming the Pre-Start Inspection.
Preventative Maintenance
Pre-Delivery Inspection and Frequent
In conjunction with the specified inspections, mainte-
Inspection nance shall be performed by a qualified JLG equipment
The Pre-Delivery Inspection and Frequent Inspection shall mechanic. JLG Industries, Inc. recognizes a qualified JLG
be performed by a qualified JLG equipment mechanic. equipment mechanic as a person who, by possession of a
JLG Industries, Inc. recognizes a qualified JLG equipment recognized degree, certificate, extensive knowledge, train-
mechanic as a person who, by possession of a recog- ing, or experience, has successfully demonstrated the
nized degree, certificate, extensive knowledge, training, or ability and proficiency to service, repair, and maintain the
experience, has successfully demonstrated the ability and subject JLG product model.
proficiency to service, repair, and maintain the subject
Reference the Preventative Maintenance Schedule and
JLG product model.
the appropriate areas of this manual for servicing and
The Pre-Delivery Inspection and Frequent Inspection pro- maintenance procedures. The frequency of service and
cedures are performed in the same manner, but at differ- maintenance must be increased as environment, severity
ent times. The Pre-Delivery Inspection shall be performed and frequency of usage requires.
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser-
vice for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
increased as environment, severity and frequency of
usage requires.

3121201 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Primary Service
Type Frequency Reference
Responsibility Qualification

Pre-Start Inspec- Prior to use each day; or User or Operator User or Operator Operator and Safety Manual
tion At each Operator change.

Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance
Inspection rental delivery. Mechanic Manual and applicable JLG
inspection form.

Frequent Inspec- In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance
tion ever comes first; or Mechanic Manual and applicable JLG
Out of service for a period of more than 3 inspection form.
months; or
Purchased used.

Annual Machine Annually, no later than 13 months from the Owner, Dealer, or User Factory-Certified Service and Maintenance
Inspection date of the prior inspection. Service Technician Manual and applicable JLG
inspection form.

Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance Maintenance Manual. Mechanic Manual

2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo-
General nent is disconnected, cap or cover all openings to
The following information is provided to assist you in the prevent entry of foreign matter.
use and application of servicing and maintenance proce-
3. Clean and inspect all parts during servicing or main-
dures contained in this book.
tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
Safety and Workmanship clean. Be sure all parts are clean before they are
Your safety, and that of others, is the first consideration installed. New parts should remain in their contain-
when engaging in the maintenance of equipment. Always ers until they are ready to be used.
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow Components Removal and Installation
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support 1. Use adjustable lifting devices, whenever possible, if
is provided. mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
Cleanliness lifted.
1. The most important single item in preserving the 2. Should it be necessary to remove a component on
long service life of a machine is to keep dirt and for- an angle, keep in mind that the capacity of an eye-
eign materials out of the vital components. Precau- bolt or similar bracket lessens, as the angle between
tions have been taken to safeguard against this. the supporting structure and the component
Shields, covers, seals, and filters are provided to becomes less than 90 degrees.
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in 3. If a part resists removal, check to see whether all
order to function properly. nuts, bolts, cables, brackets, wiring, etc., have been
removed and that no adjacent parts are interfering.

2-2 – JLG Lift – 3121201

SECTION 2 - GENERAL

Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring

When disassembling or reassembling a component, com- Clearly mark or tag hydraulic lines and electrical wiring, as
plete the procedural steps in sequence. Do not partially well as their receptacles, when disconnecting or removing
disassemble or assemble one part, then start on another. them from the unit. This will assure that they are correctly
Always recheck your work to assure that nothing has been reinstalled.
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval. Hydraulic System
1. Keep the system clean. If evidence of metal or rub-
Pressure-Fit Parts ber particles are found in the hydraulic system, drain
and flush the entire system.
When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the 2. Disassemble and reassemble parts on clean work
mating surface. surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
Bearings required, to aid assembly.

1. When a bearing is removed, cover it to keep out dirt Lubrication

and abrasives. Clean bearings in nonflammable
Service applicable components with the amount, type,
cleaning solvent and allow to drip dry. Compressed
and grade of lubricant recommended in this manual, at
air can be used but do not spin the bearing.
the specified intervals. When recommended lubricants are
2. Discard bearings if the races and balls (or rollers) not available, consult your local supplier for an equivalent
are pitted, scored, or burned. that meets or exceeds the specifications listed.

3. If bearing is found to be serviceable, apply a light Battery

coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are Clean battery, using a non-metallic brush and a solution of
ready to install. baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with
4. Lubricate new or used serviceable bearings before an anti corrosion compound.
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear- Lubrication and Servicing
ing is to be installed on a shaft, apply pressure to the
inner race. Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section 1.
Gaskets
2.3 LUBRICATION AND INFORMATION
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a Hydraulic System
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as 1. The primary enemy of a hydraulic system is contam-
blank gaskets can cause serious system damage. ination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
Bolt Usage and Torque Application moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by
1. Use bolts of proper length. A bolt which is too long permitting the pump to cavitate due to insufficient
will bottom before the head is tight against its related system warm-up or leaks in the pump supply (suc-
part. If a bolt is too short, there will not be enough tion) lines.
thread area to engage and hold the part properly.
When replacing bolts, use only those having the 2. The design and manufacturing tolerances of the
same specifications of the original, or one which is component working parts are very close, therefore,
equivalent. even the smallest amount of dirt or foreign matter
entering a system can cause wear or damage to the
2. Unless specific torque requirements are given within components and generally results in faulty opera-
the text, standard torque values should be used on tion. Every precaution must be taken to keep
heat-treated bolts, studs, and steel nuts, in accor- hydraulic oil clean, including reserve oil in storage.
dance with recommended shop practices. (See Hydraulic system filters should be checked,
Torque Chart Section 1.) cleaned, and/or replaced as necessary, at the speci-

3121201 – JLG Lift – 2-3

SECTION 2 - GENERAL

fied intervals required in the Lubrication Chart in 2. Use every precaution to keep the hydraulic oil clean.
Section 1. Always examine filters for evidence of If the oil must be poured from the original container
metal particles. into another, be sure to clean all possible contami-
nants from the service container. Always clean the
3. Cloudy oils indicate a high moisture content which mesh element of the filter and replace the cartridge
permits organic growth, resulting in oxidation or cor- any time the system oil is changed.
rosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil. 3. While the unit is shut down, a good preventive main-
tenance measure is to make a thorough inspection
4. It is not advisable to mix oils of different brands or of all hydraulic components, lines, fittings, etc., as
types, as they may not contain the same required well as a functional check of each system, before
additives or be of comparable viscosities. Good placing the machine back in service.
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is oper- Lubrication Specifications
ating, are recommended for use.
Specified lubricants, as recommended by the component
NOTE: Metal particles may appear in the oil or filters of new manufacturers, are always the best choice, however,
machines due to the wear-in of meshing compo- multi-purpose greases usually have the qualities which
nents. meet a variety of single purpose grease requirements.
Should any question arise, regarding the use of greases in
Hydraulic Oil maintenance stock, consult your local supplier for evalua-
tion. Refer to Section 1 for an explanation of the lubricant
1. Refer to Section 1 for recommendations for viscosity key designations appearing in the Lubrication Chart.
ranges.
2. JLG recommends Mobilfluid 424 hydraulic oil, which 2.4 CYLINDER DRIFT TEST
has an SAE viscosity of 10W-30 and a viscosity
index of 152. Maximum acceptable cylinder drift is to be measured
using the following methods.
NOTE: Start-up of hydraulic system with oil temperatures
below -15 degrees F (-26 degrees C) is not recom- Platform Drift
mended. If it is necessary to start the system in a
sub-zero environment, it will be necessary to heat Measure the drift of the platform to the ground. Lower
the oil with a low density, 100VAC heater to a mini- booms (if equipped) slightly elevated, upper boom fully
mum temperature of -15 degrees F (-26 degrees C). extended with the rated load in the platform and power off.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes.
3. The only exception to the above is to drain and fill If the machine does not pass this test, proceed with the
the system with Mobil DTE 13 oil or its equivalent. following.
This will allow start up at temperatures down to -20
degrees F (-29 degrees C). However, use of this oil
will give poor performance at temperatures above
120 degrees F (49 degrees C). Systems using DTE
13 oil should not be operated at temperatures above
200 degrees F (94 degrees C) under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
oil on a regular basis. However, filter elements must
be changed after the first 50 hours of operation and
every 300 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or
exceeding the specifications appearing in this man-
ual. If unable to obtain the same type of oil supplied
with the machine, consult local supplier for assis-
tance in selecting the proper equivalent. Avoid mix-
ing petroleum and synthetic base oils. JLG
Industries recommends changing the hydraulic oil
annually.

2-4 – JLG Lift – 3121201

SECTION 2 - GENERAL

Pre-Start1 Preventive Preventive or Frequent3
Every 2
(Yearly) Years
Inspection Maintenance Maintenance Inspection Inspection

Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection

Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill

2-8 – JLG Lift – 3121201

SECTION 2 - GENERAL

AMBIENT AIR
TEMPERATURE

120°F(49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110°F(43°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
SUMMER
GRADE 70°F(21°C)
ENGINE FUEL
60°F(16°C)
SPECIFICATIONS 50°F(10°C)
40°F(4°C)
30°F(-1°C)
WINTER 20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10°F(-12°C)
FULLY CHARGED BATTERY.
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10°F(-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20°F(-29°C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
ADDED
-40°F(-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS
TEMPERATURE THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE. 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
100° F (38° C) CONSISTANTLY WITHIN SHOWN LIMITS
MOBIL 424 10W-30

90° F (32° C)
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC SUMMER-GRADE WINTER-GRADE
MOBIL DTE 13

SPECIFICATIONS FUEL FUEL

40° F (4° C) F C
30° F (-1° C) +32 0
20° F (-7° C)
+23 -5
AMBIENT TEMPERATURE

10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424 +14 -10
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) +5 -15
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -4 -20
-40° F (-40° C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE -13 -25

-22 -30
0 10 20 30 40 50 60

% OF ADDED KEROSENE

4150548 E

Figure 2-1. Engine Operating Temperature Specifications - Deutz

3121201 – JLG Lift – 2-9

SECTION 2 - GENERAL

AMBIENT AIR
TEMPERATURE

120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)
-10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82° C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS
AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS
TEMPERATURE THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F (38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30

90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
HYDRAULIC
50° F (10° C)
MOBIL DTE 13

SPECIFICATIONS
40° F (4° C) NOTE:
30° F (-1° C)
1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
20° F (-7° C) CONSISTANTLY WITHIN SHOWN LIMITS
10° F (-12° C) C) 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
DO NOT START UP HYDRAULIC SYSTEM
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) C)
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE
-40° F (-40° C) C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

4150548 E

Figure 2-2. Engine Operating Temperature Specifications - Ford

2-10 – JLG Lift – 3121201

SECTION 2 - GENERAL

AMBIENT AIR
TEMPERATURE

120°F(49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110°F(43°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
70°F(21°C)
ENGINE 60°F(16°C)
SPECIFICATIONS
50°F(10°C)
40°F(4°C)
30°F(-1°C)
20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10°F(-12°C)
FULLY CHARGED BATTERY.
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30°F(-34°C)
-40°F(-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F (38° C) OR ABOVE.
100° F (38° C)
90° F (32° C)
MOBIL 424 10W-30

80° F (27° C)
70° F (21° C)
EXXON UNIVIS HVI 26

60° F (16° C)
50° F (10° C)
HYDRAULIC
SPECIFICATIONS
MOBIL DTE 13

40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
DO NOT START UP HYDRAULIC SYSTEM
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C)
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE
-40° F (-40° C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

NOTE:
1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
CONSISTENTLY WITHIN SHOWN LIMITS
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

4150548 E

Figure 2-3. Engine Operating Temperature Specifications - Caterpillar

3121201 – JLG Lift – 2-11

SECTION 2 - GENERAL

AMBIENT AIR
TEMPERATURE

ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, -10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82° C) OR ABOVE.
180° F(82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F(38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30

90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC
MOBIL DTE 13

SPECIFICATIONS
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
DO NOT START UP HYDRAULIC SYSTEM
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C)
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE:
-40° F (-40° C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
CONSISTENTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

4150548 E

Figure 2-4. Engine Operating Temperature Specifications - GM

2-12 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS Wheel Installation

It is extremely important to apply and maintain proper
Tire Inflation wheel mounting torque.
The air pressure for pneumatic tires must be equal to
the air pressure that is stenciled on the side of the JLG
product or rim decal for safe and proper operational WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE
characteristics. PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS,
AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE
Tire Damage AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE
ANGLE OF THE WHEEL.
For pneumatic tires, JLG Industries, Inc. recommends that
Tighten the lug nuts to the proper torque to prevent
when any cut, rip, or tear is discovered that exposes side-
wheels from coming loose. Use a torque wrench to tighten
wall or tread area cords in the tire, measures must be
the fasteners. If you do not have a torque wrench, tighten
taken to remove the JLG product from service immedi-
the fasteners with a lug wrench, then immediately have a
ately. Arrangements must be made for replacement of the
service garage or dealer tighten the lug nuts to the proper
tire or tire assembly.
torque. Over-tightening will result in breaking the studs or
For polyurethane foam filled tires, JLG Industries, Inc. rec- permanently deforming the mounting stud holes in the
ommends that when any of the following are discovered, wheels. The proper procedure for attaching wheels is as
measures must be taken to remove the JLG product from follows:
service immediately and arrangements must be made for 1. Start all nuts by hand to prevent cross threading. DO
replacement of the tire or tire assembly. NOT use a lubricant on threads or nuts.
• a smooth, even cut through the cord plies which 2. Tighten nuts in the following sequence:
exceeds 3 inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies
which exceeds 1 inch (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire 1 8
3 6
If a tire is damaged but is within the above noted criteria,
the tire must be inspected on a daily basis to insure the 5 4

damage has not propagated beyond the allowable crite- 7 2

ria. 9

Wheel and Tire Replacement

The rims installed on each product model have been 9 LUG PATTERN
designed for stability requirements which consist of track
width, tire pressure, and load capacity. Size changes such
as rim width, center piece location, larger or smaller diam-
eter, etc., without written factory recommendations, may
result in an unsafe condition regarding stability.

3121201 – JLG Lift – 3-1

SECTION 3 - CHASSIS & TURNTABLE

3.2 DRIVE TORQUE HUB

Roll, Leak and Brake Testing
Torque-Hub units should always be roll and leak tested
before disassembly and after assembly to make sure that
the unit's gears, bearings and seals are working properly.
The following information briefly outlines what to look for
when performing these tests.

NOTE: The brake must be released before performing the

roll test. This can be accomplished by either pressur-
izing the brake using the Brake Leak Test procedure
8 LUG PATTERN below or by tightening the bolts into the piston
through the end plate (See Brake Disassembly Pro-
cedure)

NOTE: Bolts must be removed while performing brake

3. The tightening of the nuts should be done in stages.
release test
Following the recommended sequence, tighten nuts
per wheel torque chart.
THE ROLL TEST

The purpose of the roll test is to determine if the unit's

Table 3-1. Wheel Torque Chart gears are rotating freely and properly. You should be able
to rotate the gears in your unit by applying constant force
TORQUE SEQUENCE to the roll checker. If you feel more drag in the gears only
1st Stage 2nd Stage 3rd Stage at certain points, then the gears are not rolling freely and
should be examined for improper installation or defects.
40 ft. lbs. 95 ft. lbs. 170 ft. lbs.
Some gear packages roll with more difficulty than others.
(55 Nm) (130 Nm) (230 Nm)
Do not be concerned if the gears in your unit seem to roll
hard as long as they roll with consistency.
4. Wheel nuts should be torqued before first road use
THE LEAK TEST (MAIN UNIT)
and after each wheel removal. Check and torque
every 3 months or 150 hours of operation. The purpose of a leak test is to make sure the unit is air
tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to fall
after the unit has been pressurized and allowed to equal-
ize. Leaks will most likely occur at the pipe plugs, the main
seal or wherever o-rings or gaskets are located. The exact
location of a leak can usually be detected by brushing a
soap and water solution around the main seal and where
the o-rings or gaskets meet on the exterior of the unit, then
checking for air bubbles. If a leak is detected in a seal, o-
ring or gasket, the part must be replaced, and the unit
rechecked. Leak test at 10 psi for 20 minutes.

3-2 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

THE BRAKE TEST 5. Using the same sequence, crisscross around the
bolt circle and apply an equal torque to the remain-
Reference: Sample Model 7HBE01F0B30057. The under-
ing bolts.
lined letter is the brake option. Options are A, B, C, D, E,
or X.

A Input Brake 2,200 in-lb (248 Nm) Static, 280 psi (19.3 bar) Full
Release 3000 psi (207 bar) maximum o-ring check.

B Input Brake 1,900 in-lb (215 Nm) Static, 240 psi (16.5 bar) Full
Release 3000 psi (207 bar) maximum o-ring check.

C Input Brake 1,600 in-lb (181 Nm) Static, 200 psi (13.8 bar) Full
Release 3000 psi (207 bar) maximum o-ring check.

D Input Brake 1,400 in-lb (158 Nm) Static, 180 psi (12.4 bar) Full
Release 3000 psi (207 bar) maximum o-ring check.

E Input Brake 1,250 in-lb (141 Nm) Static, 160 psi (11.0 bar) Full
Release 3000 psi (207 bar) maximum o-ring check.

X — No Brake

If brake does not release at these pressure values, brake

has to be inspected, repaired or replaced.

NOTE: Failure to perform this test may result in damaged or

ineffective brake parts.
Main Disassembly
Tightening and Torquing Bolts 1. Perform Roll Check, Leak Check and Brake Check if
If an air impact wrench is used to tighten bolts, extreme applicable prior to disassembling the unit.
care should be taken to ensure that the bolts are not tight- 2. Drain oil from unit. Note the condition and volume of
ened beyond their specified torque. the oil.
The following steps describe how to tighten and torque 3. Remove Retaining Ring (6G) by prying the open end
bolts or socket head cap screws in a bolt circle. of Retaining Ring out of the groove in the Ring Gear
1. Tighten (but do not torque) bolt "A" until snug. (1E) with a screwdriver, then grasp the loose end
with pliers and pull the Retaining Ring completely
2. Go to the opposite side of the bolt circle and tighten out of the groove.
bolt "B" until equally snug.
4. Remove the Cover Subassembly (6) from the unit.
3. Crisscross around the bolt circle and tighten remain- The unit can be carefully pressurized with air to pop
ing bolts. the cover out of the unit.
4. Now use a torque wrench to apply the specified
torque to bolt "A".

3121201 – JLG Lift – 3-3

SECTION 3 - CHASSIS & TURNTABLE

6. Cover
6G. Retaining Ring
15. ID Plate

Figure 3-1. Main Disassembly

3-4 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

1A. Spindle 4. Planet Gear 5. Retaining Ring 18. O-ring

1D. Housing 4E. Planet Shaft 9. Input Shaft 19. Bolt
1E. Ring Gear 4G. Roll Pin 10. First Stage Sun Gear 20. Retaining Ring
3. Input Carrier 4H. Thrust Washer 11. Second Stage Sun Gear

Figure 3-2. Input Carrier

5. Remove the First Stage Sun Gear (10) if applicable. 11. Remove the O-ring (18) from between the Housing
(1D) and the Ring Gear (1E).
NOTE: On units with ratios greater than 36:1 numerically,
there will not be a separate First Stage Sun Gear 12. Using a 1/8” diameter punch, drive the Roll Pin (4G)
(10), as the gear teeth will be integral to the Input into the Planet Shaft (4E) until it bottoms against the
Shaft (9). Spindle (1A).
13. Grasp the Roll Pin (4G) using needle nosed pliers or
6. Remove the Input Carrier Subassembly (3).
some sort of hooked tool, and pull the Planet Shaft
7. Remove the Input Shaft (9). (4E) out of the Spindle (1A).

8. Remove the Second Stage Sun Gear (11). 14. Using a 1/8” diameter punch, drive the Roll Pin (4G)
out of the Planet Shaft (4E).
NOTE: On units with a ratio 48:1, the Sun Gear (11) and the
Input Shaft (9) will need to be removed together. NOTE: The Roll Pins (4G) should not be reused when reas-
sembling the unit.
9. Loosen and remove the three Flat Head Bolts (19)
that retain the Ring Gear (1E) to the Housing (1G).
10. Lift the Ring Gear (1E) off of the Housing (1D).

3121201 – JLG Lift – 3-5

SECTION 3 - CHASSIS & TURNTABLE

15. Slide the Planet Gear Subassembly (4) out of the 17. Repeat Steps 12 though 16 for the remaining two
Spindle (1A) being careful to not drop the Needle Planet Gears (4F).
Bearings (4C) in the process.
18. Remove the Thrust Washer (4H) from the counter-
16. Remove 4 Thrust Washers (4B), 28 Needle Rollers
bore in the Spindle (1A).
(4C) and the Thrust Spacer (4D) from the Second
Stage Planet Gear (4F).

4B. Thrust Washer 4D. Thrust Spacer

4C. Needle Roller 4F. Planet Gear

Figure 3-3. Planet Gear Sub Assembly

3-6 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Input Carrier Disassembly

3A. Carrier 3F. Planet Gear

3B. Thrust Washer 4G. Roll Pin
3E. Planet Shaft

Figure 3-4. Input Carrier

1. Using a 1/8” diameter punch, drive the Roll Pin (4G)
into the Planet Shaft (3E) until it bottoms against the
Carrier (3A).

2. Using a soft face hammer, tap the Planet Shaft (3E)

out of the Carrier (3A).

3. Using a 1/8” diameter punch, drive the Roll Pin (4G)

out of the Planet Shaft (3E).

NOTE: The Roll Pins (4G) should not be reused when reas-
sembling the unit.

4. Slide the Planet Gear (3F) and the two Thrust Wash-
ers (3B) out of the Carrier (3A).
3C. Needle Bearing
3F. Planet Gear 5. Remove the 14 needle Bearings (3C) from the bore
of the Planet Gear (3F).
Figure 3-5. Planet Gear Subassembly
6. Repeat steps 1 through 5 for each of the two remain-
ing planet gears.

3121201 – JLG Lift – 3-7

SECTION 3 - CHASSIS & TURNTABLE

Hub-Spindle Disassembly

1A. Barrel 1F. Bearing Nut

1B. Seal 1G. Setscrew
1C. Bearing Cone 1H. Stud
1D. Hub 1Q. Boot Seal

Figure 3-6. Hub Spindle

1. Place unit on bench with Spindle (1A) end down. 6. If necessary, press 9 Studs (1H) out of Hub (1D).
Locate Hub (1D) on Seal (1B) end.
2. Remove 2 Set Screws (1G) and Bearing Nut (1F)
using T-206569. 7. Remove Seal (1B) from Hub (1D).

NOTE: The Seal (1B) should NOT be reused when reas-

NOTE: The holes in the Bearing Nut (1F) for the Set Screws sembling the unit.
(1G) were staked for retention of the Set Screws
(1G). The holes will need to be cleaned up prior to 8. Remove “B” position Bearing Cone (1C) from Bear-
removing the Set Screws. ing Cup (1C) in Hub (1D).
9. Remove “B” position Bearing Cone (1C) from Hub
3. Remove “A” position Bearing Cone (1C) from Bear- (1D).
ing Cup (1C) in Hub (1D).
10. Using a soft steel rod, knock both Bearing Cups
4. While supporting the unit on Hub (1D) flange, press (1C) out of Hub (1D).
Spindle (1A) out of Hub (1D).

5. Lift Hub (1D) off of Spindle (1A). Remove Boot Seal

(1Q) from Hub (1D) if applicable.

3-8 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Spindle-Brake Disassembly

1A. Spindle 8C. Retaining Ring 8H. Backup Ring 12. Plastic Plug
7. Coupling Subassembly 8D. O-Ring 8J. Rotor 21. Pipe Plug
8A. Piston 8E. Backup Ring 8K. Stator 22. Flat Head Capscrew
8B. Pressure Plate 8F. O-Ring 8L. Compression Spring

Figure 3-7. Spindle Brake

3121201 – JLG Lift – 3-9

SECTION 3 - CHASSIS & TURNTABLE

3. Back Flat Head Cap Screws (22) incrementally out

of Piston (8A) until spring force is relieved from the
Pressure Plate (8B). Then, remove Flat Head Cap
Screws (22) and Pressure Plate (8B) from brake cav-
ity in Spindle (1A).
4. Remove Compression Springs (8L) from Piston (8A).

EYE PROTECTION MUST BE WORN WHILE PERFORMING THE

NEXT STEP IN THIS PROCEDURE.

5. Using an air hose, slowly and carefully pressurize

the brake port in the Spindle (1A) until the Piston
(8A) comes out of piston bore of Spindle (1A), Then
pull the Piston (8A) the rest of the way out of the
1K. Retaining Ring Spindle (1A) by hand.
1L. Spring 6. Remove Backup Rings (8E) & (8H) and O-rings (8D)
1M. Spacer & (8F) from grooves in Piston (8A).
7. Coupling
7. Remove Rotors (8J) and Stators (8K) from brake
Figure 3-8. Coupling Subassembly cavity in Spindle (1A).
8. Remove Coupling Subassembly (7) from brake cav-
NOTE: This procedure applies only to units with integral ity in Spindle (1A).
Input Brake (8). 9. Remove Retaining Ring (1K) out of the internal
groove using appropriate tool.
10. Remove the Spacer (1M) & Spring (1L) out of the
bore of Coupling (7).
EYE PROTECTION MUST BE WORN WHILE PERFORMING THE
STEPS 1-3 IN THIS PROCEDURE. 11. Remove Plastic Plug (12) & Pipe Plug (21) from
Spindle (1A) if applicable.
1. Compress the Compression Springs (8L) by install-
ing two 1/4-20 x 5/8” Flat Head Cap Screws (22)
through Pressure Plate (8B) and into Piston (8A) and
tightening incrementally until spring force has been
taken off of the Retaining Ring (8C).

NOTE: Flat Head Cap Screws (22) are removed prior to

shipping new units since they are for transit and ser-
vice only. They are included in most brake repair kits.

2. Using retaining ring pliers, remove Retaining Ring

(8C) from the groove in the Spindle (1A).

3-10 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Cover Disassembly

2. Thrust Washer 6D. Disengage Rod

6A. Cover 6E. O-Ring
6B. Disengage Cap 6F. Pipe Plug
6C. Bolt 17. O-Ring

Figure 3-9. Cover

1. Remove O-Ring (17) from groove in Cover (6A). 5. Use appropriate tool to remove O-ring (6E) from
internal groove in Cover (6A).
2. Remove Thrust Washer (2) from Cover (6A) pockets.
6. Remove two O-Ring Pipe Plugs (6F) from Cover
3. Unscrew two Hex Head Bolts (6C) and remove Dis- (6A).
engage Cap (6B) from Cover (6A).

4. Pull Disengage Rod (6D) out from Cover (6A).

3121201 – JLG Lift – 3-11

SECTION 3 - CHASSIS & TURNTABLE

Input Carrier Sub-Assembly Output Planet Gear Sub-Assembly

1. Apply a liberal coat of grease to the bore of one 1. Apply a liberal coat of grease to the bore of one Out-
Input Planet Gear (3F). put Planet Gear (4F).
2. Line the inside of the Planet Gear (3F) with 14 Nee- 2. Line the inside of the Planet Gear (4F) with 14 Nee-
dle Rollers (3C). dle Rollers (4C).

NOTE: The last roller installed must be installed end wise. NOTE: The last roller installed must be installed end wise.
That is, the end of the last roller must be placed in That is, the end of the last roller must be placed in
between the ends of the two rollers which form the between the ends of the two rollers which form the
space, and then slid, parallel to the other rollers, into space, and then slid, parallel to the other rollers, into
place. place.

3. Set Carrier (3A) in an upright position. 3. Place Spacer (4D) into the bore of the Output Planet
(4F).
4. Insert a Planet Shaft (3E) into the planet shaft hole in
the end of the Carrier (3A) opposite the splined end. 4. Repeat Step 2 to put in second roll of Needle Rollers
The end of the planet shaft that does NOT have the (4C).
roll pin hole should be inserted into the carrier
FIRST. 5. Apply grease to hold two Thrust Washers (4B)
together and onto Output Planet Gear (4F) counter-
5. Place one Thrust Washer (3B) onto the end of Planet bore. Do the same to the other side.
Shaft (3E). Make sure the flat faces towards the
inside of the carrier and make sure the button fits in 6. Repeat Steps 1-5 to finish the assembly of the two
the pocket on the inside of the Carrier (3A) towards remaining Output Planet Gears (4F).
the OD.
Spindle - Brake Sub-Assembly
6. Following the thrust washer, place Planet Gear (3F)
with needle rollers, onto Planet Shaft (3E). 1. Place Spindle (1A) such that the flange side is up.

7. Following the planet gear, place one more Thrust 2. Place Stator (8K) into the Spindle (1A) scallop cuts.
Washer (3B) onto Planet Shaft (3E). Align the Thrust
3. Place Rotor (8J) on top of Stator (8K).
Washer (3B) in the same manner described in Step
5. 4. Repeat steps 2 & 3 until there are a total of 9 Stators
(8K) and 8 Rotors (8J) installed.
8. Now insert Planet Shaft (3E) through the opposite
planet shaft hole on Carrier (3A). Use an alignment 5. Place Piston (8A) such that the smaller O.D. end is
punch or similar tool to align the roll pin holes on facing upward. Grease the two O-Rings and the two
Carrier (3A) and Planet Shaft (3E). Backup Rings.
NOTE: Be sure not to hit the Planet Gears (3F) when driving 6. Install large Backup Ring (8E) in the large-diameter
in the Roll Pins (4G). groove at the bottom of the Piston (8A).

9. Drive Roll Pin (4G) down into the aligned roll pin 7. Install large O-Ring (8D) in the large-diameter
holes. Pin should be flush with the flat of carrier. groove at the bottom of the Piston (8A), on top of the
large Backup Ring (8E).
10. Repeat Steps 1-9 for the installation of the two
remaining Planet Gears (3F). 8. Install small O-Ring (8F) in the small-diameter
groove near the top of the Piston (8A). Make sure
NOTE: Some grease may need to be applied to the Thrust the O-Ring is seated on the bottom of the groove.
Washers (3B) to hold them in place while installing
the planet gears.

3-12 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

9. Install small Backup Ring (8H) in the small-diameter 7. Install Bearing Cone of part (1C) into Bearing Cup,
groove near the top of the Piston (8A), on top of the position "A".
small O-Ring (8F).
8. Apply Loctite 243 on Bearing Nut (1F) thread. Screw
10. Insert Piston (8A) into Spindle (1A) until it contacts Nut (1F) on top of Bearing Cone of part (1C). Leave
the Stator (8K). 0.003-0.005 inches endplay to check the initial roll-
ing torque with the unit tied down. Then torque Bear-
11. Insert the appropriate number of Springs (8L),
ing Nut (1F) until rolling torque is 40 to 50 in-lbs
based on the assembly print, into Piston (8A)coun-
greater than initial rolling torque. Using tool T-
terbore.
206569 for the Bearing Nut.
12. Place Spring (1L) into Coupling (7) counterbore.
Place the Pressure plate (1M) on top of Spring (1L). NOTE: Final torque is initial rolling torque plus 40-50 in-lbs.
E.g., if the initial rolling torque is 30 in-lbs, the final
13. Use appropriate tool to install Retaining Ring (1K) rolling torque is between 70-80 in-lbs. Be sure to
into the retaining ring groove in the coupling (7) rotate hub as the torque is applied to properly seat
counterbore. the bearing. Be sure the torque wrench is tangent to
the Hub (1D) OD.
14. Insert Coupling sub-Assembly (7) through Rotors
(8J).
9. Using appropriate tool, install two Set Screws (1G)
15. Place Pressure Plate (8B) on top of Springs (8L). into Bearing Nut (1F) threaded holes. Make sure Set
Screw is driven into the spindle thread. Tighten the
16. Use two ¼ -20 x 0.625 flat head Cap Screws (22) by
set screws to damage the thread and stake the edge
bolting the Pressure Plate (8B) and Piston (8A)
of the nut around the Set Screws (1G) so the nut will
together or some other appropriate tools to install
not loosen.
Retaining Ring on top of Pressure Plate (8B) until
Retaining Ring (8C) is seated. 10. Place Thrust Washer (4H) into counterbore of Spin-
dle (1A).
NOTE: Remove 2 Screws from units when done, otherwise
brake will not function. 11. Place Planet Gear Sub-assembly (4) into Spindle
(1A) through gap between two Studs (1H). Align the
17. Install Pipe Plug (21) if applicable planet gear bore with one of the planet shaft holes
on the spindle (1A) assembly using T-209919.
Hub-Spindle Sub-Assembly
12. Insert a Planet Shaft (4E) into the planet shaft hole
NOTE: Spray a light film of oil on all component parts during described in Step (11) on Spindle (1A). The end of
assembly. Spray a generous amount of oil on bear- the planet shaft that does NOT have the roll pin hole
ings during installation. should be inserted into the Spindle FIRST.
13. Now insert Planet Shaft (4E) through the first set of
1. Press Bearing Cup of part (1C), position "A", into
Thrust Washers (4B), Planet gear, then the second
Hub using T-158422 pressing tool.
set of Washers (4B). Use an alignment punch or sim-
2. Turn hub over and press Bearing Cup of part (1C), ilar tool to align roll pin holes on Spindle (1A) and
position "B", into hub using T-158422 pressing Planet Shaft (4E).
tool.(T).
NOTE: Be sure not to hit the Planet Gears (4F) when driving
3. Place Bearing Cone of part (1C), into Bearing Cup of in Roll Pins (4G).
part (1C), position "B".
4. Grease Seal (1B) lip and press seal into Hub (1D) 14. Drive Roll Pin (4G) down into the aligned roll pin
using appropriate tool until seal is flush with end of holes. Pin should be flush with OD of spindle.
hub.(T). 15. Repeat Steps (11-14) for the installation of the two
5. Place Hub (1D) into pressing base. Press nine Studs remaining Planet Gears (4F).
(1H) into Hub.

NOTE: Use enough pressure to press in studs. Don t use

excessively high pressure to press in studs or hub
may crack.

6. Set Spindle assembly (1A) on the bench with the

flange down. Turn Hub (1D) over and lower onto
Spindle (5). Install boot (21) if applicable.

3121201 – JLG Lift – 3-13

SECTION 3 - CHASSIS & TURNTABLE

Cover Sub-Assembly 11. Install Cover Sub-Assembly (6) into Ring Gear (1E)
counterbore and install Retaining Ring (6G) into
1. Grease O-Ring (6E) and insert into internal groove in groove in Ring Gear (1E).
Cover (6A).
12. Attach ID Tag (15) onto unit using Drive Screws (16).
2. Assemble Disengage Cap (6B) onto Cover (6A) 13. Check disconnect, roll and air check unit, leak check
using two Hex Head Bolts (6C). Torque bolts to 70- brake, and record release pressure.
80 in-lbs.
14. Insert Plastic Plug (12) into place if applicable.
3. Insert Disengage Rod (6D) into hole in Cover (6A)
until it touches the inside of the Disengage Cap (6B). Integral Brake Check
NOTE: The Disengage Rod can be inserted either end first. 1. Using appropriate fittings, connect hydraulic line
from hand pump to brake port.
4. Grease Face of Thrust Washer (2) and place in
Cover (6A) making sure that tangs on washer seat 2. Check to see that brake is set by trying to rotate
into pockets in cover. Input Shaft (9). This can be accomplished by install-
ing an appropriate tool (any tool that can locate on
5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The the splines of the Input Coupling (7), such as a mat-
plugs should be hand tight. ing splined shaft) into Input Coupling (7).
3. Bleed brake. Increase hydraulic pressure gradually
Main Assembly while trying to rotate the input until brake just starts
to release. Note this pressure. Make sure the pres-
NOTE: All components should receive a generous amount
sure falls into the appropriate range below.
of lubricant oil as they are being assembled.

1. Place Hub-Spindle Sub-Assembly on the bench. JUST RELEASE

BRAKE PRESSURE RANGE
2. Grease O-Ring (18) and place it into groove of Hub CODE
PSI BAR
(1D).
A 200-260 13.7-17.9
3. Place Ring Gear (1E) onto Hub (1D). Align the three B 170-220 11.7-15.1
shipping Cap Screw Holes on Hub (1D) and Ring C 140-185 9.6-12.7
Gear (1E). D 130-155 8.9-10.6
4. Install three shipping Cap Screws (19) into ring gear E 115-145 7.9-9.9
and hub. Torque them to 15-20 ft-lbs.
4. Increase pressure to 1,000 psi and hold for 30 sec-
5. Place External Retaining Ring (5) over 13T spline to onds to check for leaks. Repair leaks if necessary.
the retaining groove on Input Shaft (9).
NOTE: Make sure that brake re-engages when pressure is
NOTE: For ratio 48:1, assemble Output Sun Gear (11) over released.
Input Shaft (9) first, then install External Retaining
Ring (5). NOTE: When done, make sure Input Coupling (7) is cen-
tered in Spindle (1A) to make installation of motor
6. Using appropriate tool to install Retaining Ring (20) possible without release of brake.
into groove on Output Sun (11).

7. Place Input Shaft (9) spline end into mesh with Inter-
nal Coupling (7) splines.

8. With the modified spline end facing up, place the

Output Gear (11) into mesh with the planet gears
from the Hub-Spindle Sub-Assembly.

9. Place Input Carrier Sub-Assembly (3A) onto Output

Sun Gear (11) splines. Drop Input Sun (10) into
mesh with planet gears for specific ratios, if
required. (No timing required).

10. Grease O-Ring (17) and insert into groove in Cover

Sub-Assembly (6).

3-14 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

1A. Spindle 1M. Thrust Washer 4C. Needle Bearing 6C. Bolt 8D. O-Ring 11. Sun Gear
1B. Lip Seal 1Q. Seal Boot 4D. Thrust Spacer 6D. Dowel Pin 8E. Backup Ring 12. Plastic Plug
1C. Tapered Bearing 2. Thrust Spacer 4E. Planet Shaft 6E. O-Ring 8F. O-Ring 15. ID Plate
1D. Housing 3A. Carrier 4F. Planet Gear 6F. Pipe Plug 8H. Backup Ring 16. Drive Screw
1E. Ring Gear 3B. Thrust Washer 4G. Roll Pin 6G. Retaining Ring 8J. Brake Rotor 17. O-Ring
1F. Bearing Nut 3C. Needle Bearing 4H. Thrust Washer 7. Coupling 8K. Brake Stator 18. O-Ring
1G. Setscrew 3E. Planet Shaft 5. Retaining Ring 8A. Brake Piston 8L. Spring 19. Bolt
1H. Stud 3F. Planet Gear 6A. Cover 8B. Pressure Plate 9. Input Shaft 20. Retaining Ring
1K. Retaining Ring 4B. Thrust Washer 6B. Disengage Cap 8C. Retaining Ring 10. Sun Gear 21. O-Ring Plug
1L. Spring

Figure 3-10. Hub Assembly

3121201 – JLG Lift – 3-15

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-11. Bearing Cup Pressing Tool

Figure 3-12. Seal Pressing Tool

3-16 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-13. Bearing Cup Pressing Tool

Figure 3-14. Drift Pin for Lining Up Thrust Washers with Output Planet Gear

3121201 – JLG Lift – 3-17

SECTION 3 - CHASSIS & TURNTABLE

3.3 DRIVE BRAKE - MICO (S/N 56718 TO 3. Press bearing (18) into position until it bottoms out
on borestep.
81836)
NOTE: Cover plate (16) must be supported as indicated in
Disassembly Figure 1.

1. Remove pressure plate (3) from cover plate (16) by

4. Install retaining ring (20) in cover plate (16).
removing cap screws (1) and washers (2).
5. Press shaft (10) into bearing (18) until it bottoms on
shoulder.
PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXI-
NOTE: Bearing (18) inner race and cover plate (16) must be
MATELY 907 KGF (2000 IBS). THE TWO CAP SCREWS MUST BE
supported as indicated in Figure 1 during this opera-
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
tion.
PRESS IS AVAILABLE, 1361 KGF (3000 IBS) MINIMUM, THE
PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING
THE CAP SCREWS. COVER PLATE (16) MUST BE SUPPORTED AS 6. Install retaining ring (19) on shaft (10).
SHOWN IN FIGURE 3-15.
7. Insert dowel pins (15) and springs (14) in cover plate
2. Remove case seal (4) from cover plate (16). (16).

3. Remove piston (7) from pressure plate (3). NOTE: Be sure to use the same number of springs and
spring pattern as recorded during disassembly.
4. Remove a-ring (5), back-up ring (6), a-ring (8) and
back-up ring (9) from piston (7).
8. Position return plate (13) on springs (14).
5. Remove stator disc (11), rotor disc (12) and return
plate (13) from cover (16). NOTE: Discs (11 & 12) and return plate (13) must remain
dry during installation. No oil residue must be
NOTE: Not all models use the same number of springs or allowed to contaminate disc surfaces.
spring pattern.
9. Install rotor disc (12) and stator disc (13).
6. Remove dowel pins (15) and springs (14) from cover
plate (16). Record this information for assembly pur- 10. Install o-ring (5), back-up ring (6), a-ring (8) and
poses. back-up ring (9) on piston (7). Note order of a-rings
7. Remove retaining ring (19) from cover plate (16). and back-up rings. Insert piston (7) into pressure
plate (3).
8. Remove shaft (10) by pressing or using a soft mallet
on male end of shaft (10). NOTE: Be careful not to shear o-rings or back-up rings. Be
careful not to scratch or mar piston.
NOTE: Cover plate (16) must be supported as shown in FIG-
URE 3-15.
11. Install new case seal (4) in cover plate (16).
9. Remove retaining ring (20) from cover plate (16) and 12. Position pressure plate (3) on cover plate (16) align-
press out oil seal (17) and bearing (18) if required. ing dowel pins (15) with holes in pressure plate.
NOTE: Cover plate (16) must be sup¦ported as indicated in
13. Install cap screws (1) and washers (2) and tighten
Figure 3-15.
evenly to draw pressure plate (3) to cover plate (16).
Torque cap screws 65.1-67.8 N-m (48-50 Ib-ft).
Assembly
NOTE: A hydraulic press will simplify installation of pressure
plate on cover. Clamp pressure plate in position
while tighten¦ing the cap screws. Cover plate (16)
LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH must be supported as indicated in Figure 3-15.
CLEAN TYPE FLUID USED IN THE SYSTEM.

1. Use an alkaline wash to clean parts before assem-

bly.
IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
2. Press oil seal (17) into cover plate (16) until it is flush BRAKE ASSEMBLY, RELEASE PRESSURE MUST NOT EXCEED
with bearing shoulder. Note direction of seal. 134.5 BAR (500 PSI).

3-18 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

1. Capscrew 8. O-ring 15. Dowel Pin

2. Washer 9. Backup Ring 16. Cover Plate
3. Pressure Plate 10. Shaft 17. Oil Seal
4. Case Seal 11. Stator Disc 18. Bearing
5. O-ring 12. Rotor Disc 19. Retaining Ring
6. Backup Ring 13. Return Plate 20. Retaining Ring
7. Piston 14. Springs
Figure 3-15. Drive Brake - Mico

3121201 – JLG Lift – 3-19

SECTION 3 - CHASSIS & TURNTABLE

Bleeding top port. Pressure should not exceed 100 psi (6.9
bar) during bleeding.
1. Install brake in system and connect pressure lines. 3. Apply sufficient pressure to release brake and check
for proper operation in system.
2. Bleed pressure release section of brake by pressur-
izing side inlet port and allowing air to escape from

Table 3-2. Troubleshooting

PROBLEM CAUSE EXPLANATION ACTION

Brake slips Excessive pressure in hydraulic system If there is back pressure in the actuation Check filters, hose size, restrictions in
line of the brake, holding torque will be other hydraulic components.
reduced.
Oil in brake if designed for dry use Wet linings generate 67% of the dry Replace oil seal in brake.
torque rating. If the brake has oil in it, Check motor seal
check the type of oil hydraulic or gearbox. Check piston seals
1 . Gearbox oil
2. Hydraulic oil NOTE: Internal components will
need to be inspected,
cleaned and replaced as
required.
Disc plates worn The thickness of the disc stack sets the Check disc thickness.
torque level. A thin stack reduces torque.
Springs broken or have taken a perma- Broken or set springs can cause reduced Check release pressure. (See spring
nent set torque - a rare occurrence. replacement).
Brake drags or runs hot Low actuation pressure The brake should be pressurized to mini- Place pressure gauge in bleed port &
mum of 1.38 bar (20 psi) over the full check pressure with system on.
release pressure under normal operating
conditions. Lower pressures will cause
the brake to drag thus generating heat.
Bearing failure If the bearing should fail, a large amount of Replace bearing.
drag can be generated.
Brake will not release Stuck or clogged valve Brakes are designed to come on when Place pressure gauge in bleed port -
system pressure drops below stated check for adequate pressure. Replace
release pressure. If pressure cannot get to inoperative line or component.
brake, the brake will not release.
Bad o-rings If release piston will not hold pressure, Replace o-rings.
brake will not release.
Discs frozen These brakes are designed for only lim- Replace disc stack.
ited dynamic braking. A severe emer-
gency stop or prolonged reduced release
pressure operation may result in this type
of damage.

3-20 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

3.4 FREE WHEELING OPTION 3.5 DRIVE MOTOR - 4WD (PRIOR TO S/N
81836)
To Disengage Drive Motors and Brakes (Free
Wheel) for Towing, etc. Spare Parts Kits
Sealing kit, existing spare parts: shaft sealing ring, 6 differ-
1. Chock wheels securely if not on flat level surface.
ent O-rings and a circlip (sealing mat.: perbunan)
2. Disconnect both drive hubs by inverting disconnect
caps in center of hubs.

3. If equipped, move steer/tow selector valve to float

(tow) position by pulling valve knob out.

To Engage Drive Motors and Brakes (Normal

Operation)
1. If equipped, move steer/tow valve to steer position
by pushing valve knob in.

2. Connect both drive hubs by inverting disconnect Same sealing kit like shown above only seal material
cap in center of hub. changed to Viton

3. Remove chocks from wheels as required.

DISCONNECT
CAP

Drive Hub Engaged Drive shaft

DRIVE
HUB

DISCONNECT
CAP
(REVERSED)

DRIVE
HUB Drive Hub Disconnected

Figure 3-16. Disconnecting the Drive Hubs

3121201 – JLG Lift – 3-21

SECTION 3 - CHASSIS & TURNTABLE

Bearing set/miscellaneous parts Parts of the control device: control piston, piston rod,
plug, spring stopper max flow, hex. nut, and hex. head nut

Rotary group complete 9 pistons, cylinder sub-assembly,

valve plate (cw or ccw corresponding to the order) retain- Spare parts kit DFR pilot valve
ing plate and retaining ball.

Swash Plate

3-22 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Replacing the Drive Shaft Seal 4. Assemble the sealing ring. The fitting tool will hold
the sealing ring in the correct position in the pump
1. Remove the snap ring housing.

2. Change the shaft seal and check its sliding surface 5. Assemble the snap ring.
(drive shaft) and housing, grease the sealing ring.

6. Assemble the snap ring in the correct position.

3. Be careful while you seal the drive shaft, use an
adhesive tape to protect the splines.

3121201 – JLG Lift – 3-23

SECTION 3 - CHASSIS & TURNTABLE

Disassembly and Assembly 4. Remove the O-ring.

1. Disassemble the pilot valve.

5. Disassemble the taper roller bearing.

2. Mark the position of the port plate and remove the

socket screw from the port plate.

6. Remove the adjustment shim.

3. Remove the port plate together with the valve plate

(hold the valve plate so that the plate can’t fall
down).

7. Unscrew the cap nut and remove it.

3-24 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

8. Loosen the retaining nut of the stopper max flow and 12. Remove the threaded pin (stopper - max.flow)
remove it.

13. Disassemble the plug.

9. Turn in the stopper max flow to get swivel angle
zero.

14. Disassemble the control piston while moving the

swash plate.
10. Disassemble the rotary group in horizontal position.

15. The swash plate must be lifted a little bit to disas-

11. Disassemble the stopper - max. flow. semble the piston rod.

3121201 – JLG Lift – 3-25

SECTION 3 - CHASSIS & TURNTABLE

16. Disassembly of the swash plate. 20. Remove the snap ring.

17. Remove the spring. 21. Disassemble the sealing ring.

18. Remove both bearing shells.

22. The external front bearing ring is pulled out of the

pump housing.

19. Remove the drive shaft.

3-26 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

23. Remove the O-ring. Lifting of the valve plate isn’t Assembly Notes
shown.
1. Measurement of the taper roller bearing pretension.

24. A usual commercial bearing puller is used to disas- 2. Note that there is a correct connection of the piston
semble the external bearing ring of the taper roller rod and the swash plate.
bearing inside the port plate. Take care not to dam-
age the surface of the port plate.

3. Pumps clockwise driven must have a position to the

valve plate 4 degrees out of center in the same
direction de-centered like drive direction. (Note
25. The spring has additional pretension while you dis- spare parts exist as cw and ccw valve plates.)
assemble the three pressure pins inside the cylinder.

3121201 – JLG Lift – 3-27

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Differential volume if you are rotating the threaded pin -

each rotation is appr. 3,1 cm3.

Figure 3-17. Flow Control Pilot Valves

3-28 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

4. Pumps counterclockwise driven must have a posi- Testing and Setup

tion of the valve plate 4 degrees de-centered in ccw
position. DR: When pressure line is closed adjust the pressure of
the controller (if it’s DFR design then open the adjustable
orifice and increase force of the spring - FR -).

5. Assembly of the port plate and the pump housing:

Note the correct position of the drilling that connects FR: If swivel angle is in the mid position adjust differential
high pressure to the control valve. Check control pressure 14 bar adjustable orifice is partly closed).
valve drill position at the pump housing and fit
together.

Mechanical flow limiter: While screwing in the threaded

pin you will be able to reduce the flow from Vg max to 50%
of Vg max.
Taper Roller Bearing Initial Tension
Cast iron pump housing must have initial tension of the
bearings: 0........0,05 mm, grind Pos. 12 if necessary.

3121201 – JLG Lift – 3-29

SECTION 3 - CHASSIS & TURNTABLE

3.6 DRIVE MOTOR - 2WD (PRIOR TO S/N 3.7 DRIVE MOTOR (S/N 81836 TO PRESENT)
81836)
Description
Shaft Seal Replacement The drive motors are low to medium power, two-position
axial piston motors incorporating an integral servo piston.
Lip type shaft seals are used an the drive motors. These
They are designed for operation in both open and closed
seals can be replaced without major disassembly of the
circuit applications. The standard control is a direct acting
unit. However, replacement of the shaft seal requires
single line hydraulic control. The integral servo piston con-
removal of the pump or motor from the machine.
trols motor displacement.
1. Remove the retaining ring from the housing.
The motors are spring biased to maximum displacement
Carefully remove the seal from the housing bore. The face and hydraulically shifted to minimum displacement. Mini-
of the seal may be punctured with a sharp instrument mum and maximum displacement can be set with fixed
(such as a screw driver) to aid in prying the seal out, or a internal stops. The large diameter servo piston allows
slide hammer type puller may be used to remove the seal. smooth acceleration and deceleration with relatively large
Care must be taken not to damage the housing bore or circuit orificing.
shaft. Once removed the seal ia not reusable.
Bias spring
Servo piston
Minimum
Angle Swashplate
Stop

Output
Cylinder Shaft
Block

Shaft
Prior to installing the new seal, inspect the sealing area on Seal
the shaft for rust, wear, or contamination. Polish the seal-
ing area on the shaft if necessary. Piston
Endcap Slipper Bearing
Valve plate
Wrap the spline or key end of shaft with thin plastic to pre-
vent damage to the seal lip during installation. Lubricate Figure 3-18. Drive Motor Cross Section
the inside diameter of the new seal with petroleum jelly.

NOTE: The outside diameter of the seal may be lightly

coated with a sealant (such as Loctite High Perfor-
mance Sealant #59231) prior to installation This will
aid in preventing leaks caused by damage to the
housing seal bore.

Slide the new seal over the shaft and press it into the
housing bore. Be careful not to damage seal. A seal
installer tool can be made to aid in installing the seal.
Reinstall the seal retaining ring.

3-30 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Shaft Seal Replacement INSPECT THE COMPONENTS

Inspect the new seal, the motor housing seal bore, and
REMOVAL the sealing area on the shaft for rust, wear, and contami-
nation. Polish the shaft and clean the housing if neces-
1. Remove the snap ring (1) retaining the shaft seal sary.
and support washer.
INSTALLATION
1
1. Cover the shaft splines with an installation sleeve to
protect the shaft seal during installation.
2
2. Install a new shaft seal with the cupped side facing
the motor. Press seal into housing until it bottoms
3 out. Press evenly to avoid binding and damaging
the seal.
3. Install seal support washer.
4. Install snap ring.
5. Remove the installation sleeve.

1. Snap Ring
2. Support Washer
3. Shaft Seal

Figure 3-19. Removing the Shaft Seal

2. Remove the support washer (2).

3. Carefully pry out the shaft seal (3).

To avoid damaging the shaft during removal, install

a large sheet metal screw into the chuck of a slide
hammer. Drive the screw into the seal surface and
use the slide hammer to pull the seal.
4. Discard the seal.

3121201 – JLG Lift – 3-31

SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting

Table 3-3. Excessive Noise and/or Vibration

Item Description Action

Fill the reservoir to the proper level and ensure that oil supply
Check oil level in reservoir Insufficient hydraulic fluid could lead to cavitation that would
to the motor is adequate and the lines are unobstructed.
and oil supply to the motor. cause system noise.

Ensure that all of the system lines and components are

Air trapped within the system lines, or the motor itself, could
Check for air in the system. purged of air.
result in cavitation that would cause system noise.

Ensure that the correct coupling is used and that it fits prop-
Inspect the output shaft A loose or incorrect shaft coupling will produce vibrations
erly onto the shaft.
couplings. that could result in system noise.

Inspect the output shaft Misaligned shafts create excessive frictional vibration that Ensure that the shafts are properly aligned.
alignment. could result in system noise.
Hydraulic oil viscosity Viscosity above acceptable limits will result in cavitation that Replace hydraulic oil with appropriate fluid for operating
above limits. would lead to system noise. conditions.

Table 3-4. System Operating Hot

Item Description Action

Check oil level in reservoir Insufficient amount of hydraulic fluid will not meet the cool- Fill the reservoir to the proper level.
and oil supply to the pump. ing demands of the system.
Ensure that heat exchanger is receiving adequate air flow
Inspect the heat exchanger, If the heat exchanger fails, or becomes obstructed, it may and that the heat exchanger is in good operating condition.
(if so equipped). not meet the cooling demands of the system. Repair or replace as necessary.

Repair or replace any malfunctioning relief valves as appli-

If a system relief valve becomes unseated for an extended
Check the system relief cable and verify that the loads on the machine are not exces-
period of time or fails for any other reason, the system could
valves. sive.
become overheated.

Table 3-5. Won’t Shift or Slow to Start

Item Description Action

Obstructed or restricted flow through the servo control sig- Ensure that the signal lines are not obstructed or restricted
Check the signal line to the
nal lines could result in slow shift or no shift conditions and that signal pressure is adequate to shift the motor.
servo control port.
within the motor.
Check that the correct sup- Ensure that the proper control orifices are installed in the
Supply and drain orifices determine the shift rate of the
ply and drain orifices are motor and verify that they are not obstructed. Clean or
motor. The smaller the orifice, the longer the time it takes to
properly installed, and are replace as necessary.
shift the motor. Obstruction will also increase shift times.
not obstructed.

3-32 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Loop Flushing Valve INSPECT THE COMPONENTS

Inspect new O-rings and the sealing area for rust, wear, or
contamination. Also check springs and poppet for wear.
REMOVAL
INSTALLATION
1. Using a 11/16 in internal hex wrench remove plug
(1) and (2). 1. Install orifice poppet (13).
6 2. Install shift spool (12).
9
11 3. Install spring retaining washers onto springs (10 and
2
11).
11/16 in
27 ft.lbs. 4. Carefully install centering springs (7, 8, and 9).
(37 Nm)
5. Install new O-rings (6, 4, and 5).
6. Using a 1/4 in hex wrench torque plug (3) to 20 ft.
lbs. (27 Nm).
7. Using a 11/16 in internal hex, torque plugs (2 and 1)
10 12 to 27 ft.lbs. (37 Nm).
8
4

1 13
11/16 in
27 ft.lbs.
(37 Nm) 7

5/8 in
5 3 20 ft.lbs.
(27 Nm)

1. Plug 6. O-ring 11. Washer

2. Plug 7. Spring 12. Shift Spool
3. Plug 8. Spring 13. Orifice Poppet
4. O-ring 9. Spring
5. O-ring 10. Washer

Figure 3-20. Loop Flushing Spool

2. Using a 1/4 in hex wrench remove plug (3).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

3121201 – JLG Lift – 3-33

SECTION 3 - CHASSIS & TURNTABLE

Disassembly
17
NOTE: Removal of the endcap voids warranty. 19

During assembly, coat all moving parts with a film of

clean hydraulic oil. This assures that these parts will
be lubricated during start-up. 15

Replace all O-Rings and gaskets.

It is recommended that all O-rings be replaced.

Lightly lubricate all O-rings with clean petroleum jelly
prior to assembly.
21

6
9
11 18
5 2
7
13
3

12 16
10
8
4
20

1
14. Lock Nut 18. Cavity Plug
15. O-ring Plug 19. Drain Plug
16. Control Line Plug 20. Drain Plug
17. Control Line Plug 21. Work Port Plug

Figure 3-22. Plugs, Fittings, and Speed Sen-

sor

1. Plug 5. O-ring 9. Spring 12. Shift Spool 8. Remove all fittings from the unit. Discard any O-rings
2. Plug 6. O-ring 10. Washer 13. Orifice Poppet on the fittings.
3. Plug 7. Spring 11. Washer
9. Using an 11/16 inch hex wrench, loosen the speed
4. O-ring 8. Spring
sensor lock nut (14) if equipped. Then remove the
Figure 3-21. Loop Flushing Spool speed sensor using a Vi inch hex wrench. Units with-
out speed sensor have an O-ring plug (15) installed
in that location; remove it with a Va inch internal hex
1. Using a 11/16 in wrench remove plug (1) and (2). wrench.

2. Using a 5/8 in hex wrench remove plug (3). 10. Using a 1/4 inch internal hex wrench, remove control
line plugs (16, 17). Discard O-rings. Using a 3 mm
3. Remove O-rings (4, 5, and 6). hex wrench, remove cavity plug (18, if equipped with
two-line control) from X2 cavity.
4. Using pliers, remove centering springs (7, 8, and 9).
11. Using a 5/16 inch internal hex wrench, remove drain
5. Remove spring retaining washers (10 and 11). plugs (19, 20). Discard O-rings.

6. Remove shift spool (12). 12. Using a 9/16 inch internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard
7. Remove orifice poppet (13). O-rings.

3-34 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

25
22

27
30

23 29
29
26
24
28

22. Screw
23. End Cap 25. Valve Plate
24. O-ring 26. End Cap
27. O-ring
Figure 3-23. End Cap 28. O-ring
29. Angle Stop
13. Using an 8 mm internal hex wrench, remove the 30. Servo Spring
endcap screws (22).
Figure 3-24. Valve Plate & Rear Shaft Bearing
14. Remove the endcap (23). Remove O-ring (24) from
the housing or endcap.

When the endcap screws are removed, pressure

TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE
from the servo spring will cause the endcap to bind
on the shaft. Press down on the portion of the end- PLATE.
cap covering the servo piston and hold the endcap
level while removing. 15. Remove the valve plate (25) and timing pin (26) from
the endcap.

Each displacement has a unique valve plate. For

identification, the last two digits of the valve plate
part number are stamped on its surface.

16. Remove and discard the O-rings (27, 28).

17. Remove the rear shaft bearing (29) from the endcap
with a bearing puller.

The bearing may be difficult to remove with a puller.

Try this as an alternative: Pack the bearing cavity
with heavy grease. After the shaft is removed, insert
it into the bearing cavity and tap lightly with a soft
mallet on the splined end. The grease will force the
bearing out. Use caution not to drive the bearing
past the rear shaft journal as the bearing may
become trapped on the shaft and damaged.

3121201 – JLG Lift – 3-35

SECTION 3 - CHASSIS & TURNTABLE

18. Remove minimum angle stop (29) and servo spring 20. Turn the housing over and remove the snap ring (32)
(30) from the housing. retaining the shaft seal and support washer. Remove
the support washer (33) and carefully pry out the
shaft seal (34). Discard the seal.

To avoid damaging the shaft during seal removal.

Install a large sheet metal screw into the chuck of a
slide hammer. Drive the screw into the seal surface
31 and use the slide hammer to pull the seal.

36
35
37
31. Cylinder Kit Assembly

Figure 3-25. Cylinder Kit

19. Turn the housing on its side and remove the cylinder
kit assembly (31). Set the assembly aside, being
careful not to scratch the running surface.

NOTE: Grooves on the surface of the cylinder kit identify its

displacement: 35. Inner Snap Ring
36. Snap Ring
Table 3-6. Displacement Identifiers 37. Bearing
38. Shaft
# of Grooves Frame L Frame K
Figure 3-27. Shaft & Front Bearing
1 25 38
2 30 45
21. Remove the inner snap ring (35) and the shaft /
3 35 -- bearing assembly.
22. Remove the snap-ring (36) retaining the shaft front
bearing. Pull the bearing (37) off of the shaft (38).
32

32. Snap Ring

33. Support Washer
34. Shaft Seal

Figure 3-26. Shaft Seal

3-36 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Lift here
44
39

47
40
48
43
42
49
41

39. Swashplate 50
40. Servo Piston
41. Piston Seal 51
42. O-ring
43. Journal Bearings

Figure 3-28. Swash Plate & Servo Piston

44. Piston 49. Retaining Ring
45. Slipper Retainer 50. Block Spring Washer
23. Turn housing over and remove the swashplate (39) 46. Cylinder Block 51. Spiral Retaining Ring
by lifting on the end opposite the servo lever. 47. Ball Guide 52. Block Spring
24. Remove the servo piston (40). Remove the piston 48. Holddown Pins 53. Inner Block Spring Washer
seal (41) and O-ring (42) from the servo piston. Dis- Figure 3-29. Cylinder Kit Disassembly
card the seal and O-ring.
25. Remove the journal bearings (43) from the housing. 26. Remove pistons (44) and slipper retainer (45) from
If the bearings are to be reused, note the location the cylinder block (46).
and orientation of each bearing for reassembly.
The pistons are not selectively fitted, however units
with high hourly usage may develop wear patterns.
Number the pistons and bores for reassembly if they
are to be reused.

27. Remove the ball guide (47), hold-down pins (48),

and retaining ring (49) from the cylinder block.

NOTE: Most repairs do not require block spring removal.

Perform this procedure only if you suspect problems
with the block spring.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING

REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A
PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO
REMOVE THE SPIRAL RETAINING RING. RELEASE THE PRESSURE
SLOWLY AFTER THE RETAINING RING IS REMOVED.

3121201 – JLG Lift – 3-37

SECTION 3 - CHASSIS & TURNTABLE

28. Turn the block over. Using a press, apply pressure SLIPPERS
on the block spring washer (50) to compress the Inspect the running surface of the slippers. Replace any
block spring. Compress the spring enough to safely piston assemblies with scored or excessively rounded
remove the spiral retaining ring (51). While maintain- slipper edges. Measure the slipper foot thickness.
ing pressure, unwind the spiral retaining ring (51). Replace any piston assemblies with excessively worn slip-
Carefully release the pressure and remove the outer pers. Check the slipper axial end-play. Replace any piston
block spring washer (50), block spring (52), and assemblies with excessive end-play.
inner block spring washer (53) from the cylinder
block. Minimum slipper foot thickness and maximum axial end-
play are given in the table below.
Inspection Table 3-7. Slipper Foot Thickness & End Play
After disassembly, wash all parts (including the end-cap
and housing) thoroughly with clean solvent and allow to Measurement L Frame K Frame
air dry. Blow out oil passages in the housing and endcap mm 2.71 4.07
Slipper Foot Thickness
with compressed air. Conduct inspection in a clean area (in.) (0.11) (0.16)
and keep all parts free from contamination. Clean and dry 0.15
parts again after any rework or resurfacing. Piston/Slipper End Play
(0.006)
PISTON
Inspect the pistons for damage and discoloration. Discol- CYLINDER BLOCK
ored pistons may indicate excessive heat; do not reuse. Measure the cylinder block height. Replace blocks worn
beyond the minimum height specification. Inspect the run-
ning surface of the cylinder block. Replace or resurface
worn or scratched blocks. Blocks may be resurfaced to
the specifications shown in the drawing, provided resur-
facing will not reduce the block height below the minimum
specification. Table 3-8, Cylinder Block Measurements.

Table 3-8. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
(A)
0.002 0.002 0.002 0.002 0.002
Cylinder Block Surface Flatness
(0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079)

3-38 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

BALL GUIDE AND SLIPPER RETAINER Replace swashplate if the difference in thickness from one
Inspect the ball guide and slipper retainer for damage, side to the other exceeds specification.
discoloration, or excessive wear. A discolored ball guide
or slipper retainer indicates excessive heat. Do not reuse.
0.0025 mm
[0.0001 in]
Slipper retainer

25.8 mm
LV [1.015 in]

Ball guide KV 24.6 mm

[0.969 in]
Thickness equality
side to side:
0.05 mm [0.002 in]

VALVE PLATE
The condition of the valve plate is critical to the efficiency
of the motor. Inspect the valve plate surfaces carefully for
excessive wear, grooves, or scratches. Replace or resur-
face grooved or scratched valve plates. Measure the valve
plate thickness and replace if worn beyond the minimum
specification. Valve plates may be resurfaced to the speci- Inspect the journal bearings for damage or excessive
fications shown in the drawing, provided resurfacing will wear. Replace journal bearings if scratched, warped, or
not reduce the thickness below the minimum specifica- excessively worn. The polymer wear layer must be
tion. smooth and intact.
3.83 mm [0.151 in] min.
SHAFT BEARINGS
0.025 mm Inspect bearings for excessive wear or contamination.
[0.001 in]
Rotate the bearings while feeling for uneven movement.
Bearings should spin smoothly and freely. Replace bear-
ings that appear worn or do not rotate smoothly.

0.0076 mm
[0.00030 in]
convex max

SWASHPLATE AND JOURNAL BEARINGS

Inspect the running face, servo ball-joint, and swashplate
journal surfaces for damage or excessive wear. Some SHAFT
material transfer may appear on these surfaces and is Inspect the motor shaft. Look for damage or excessive
acceptable providing the surface condition meets specifi- wear on the output and block splines. Inspect the bearing
cations shown. Measure the swashplate thickness from surfaces and sealing surface. Replace shafts with dam-
the journals to the running face. Replace swashplate if aged or excessively worn splines, bearing surfaces, or
damaged or worn beyond minimum specification. sealing surfaces.

SERVO PISTON AND MINIMUM ANGLE STOP Replace if necessary.

Inspect the minimum angle stop, servo piston head, and
servo piston ball-socket for damage or excessive wear.

3121201 – JLG Lift – 3-39

SECTION 3 - CHASSIS & TURNTABLE

LOOP FLUSHING SPOOL Assembly

Inspect the loop flushing spool. Check for cracks or dam-
age. Replace if necessary. 1. Install new O-ring (1) and piston seal (2) to the servo
piston (3). Install the piston seal over the O-ring.

Installing the piston seal stretches it, making it diffi-

cult to install the servo piston in its bore. Allow 30
minutes for the seal to relax after installation. To
speed up seal relaxation, compress the seal by
installing the piston head into the servo cavity in the
end-cap and let it stand for at least five minutes.

2
3

1. O-ring
2. Piston Seal
3. Servo Piston

Figure 3-30. Servo Piston

2. After piston seal has relaxed, lubricate and install

servo piston into the housing bore. Align the piston
with the ball socket facing the inside of the housing.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING

REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A
PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
EFFORT. ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO
INSTALL THE SPIRAL RETAINING RING. RELEASE THE PRESSURE
SLOWLY AFTER THE RETAINING RING IS INSTALLED.

3. Install the inner block spring washer (4), block

spring (5), and outer washer (6) into the cylinder
block. Using a press, compress the block spring

3-40 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

enough to expose the retaining ring groove. Wind 6. Install the journal bearings (13) into the housing
the spiral retaining ring (7) into the groove in the cyl- seats. Use assembly grease to keep the bearings
inder block. seated during assembly. Ensure the locating nubs
drop into the cavities in the seats. If you're reusing
the bearings, install them in the original location and
11
orientation. Lubricate the journal bearings.
12
14
13
10

9
8

7 13. Journal Bearings

14. Swash Plate

Figure 3-32. Swash Plate and Journal Bearing

4. Block Spring Washer 9. Holddown Pins

5. Block Spring 10. Ball Guide 7. Install the swashplate (14) into the housing. Tilt the
6. Outer Washer 11. Piston swashplate and guide the servo lever ball into its
7. Spiral Retaining Ring 12. Slipper Retainer socket in the servo piston rod. Ensure the swash-
8. Retaining Ring plate seats into the journal bearings and moves
Figure 3-31. Cylinder Kit Assembly freely. Lubricate the running surface of the swash-
plate.

4. Turn the block over and install the retaining ring (8),
hold-down pins (9), and ball guide (10) to the cylin-
der block.
5. Install the pistons (11) to the slipper retainer (12).
Install the piston/retainer assembly into the cylinder
block. Ensure the concave surface of the retainer
seats on the ball guide. If you're reusing the pistons,
install them to the original block bores. Lubricate the
pistons, slippers, retainer, and ball guide before
assembly. Set the cylinder kit aside on a clean sur-
face until needed.

3121201 – JLG Lift – 3-41

SECTION 3 - CHASSIS & TURNTABLE

8. Press front shaft bearing (15) onto shaft (16). Press 10. Verify swashplate and bearings are properly seated.
bearing onto shaft with lettering facing out. Lubricate Install the cylinder kit (19) onto the shaft. Install with
bearing rollers. Install snap-ring (17) onto shaft. the slippers facing the swashplate. Rock the shaft to
align the block splines and slide the cylinder kit into
place. Orient the motor with the shaft pointing down-
ward and verify the cylinder kit, swashplate, journal
bearings, and servo piston are all secure and prop-
erly installed.

15
16

19. Cylinder Kit

17
Figure 3-34. Cylinder Kit Installation
18

11. Lubricate and install the servo spring (20), and mini-
15. Front Shaft Bearing
16. Shaft mum angle stop (21) into the housing bore.
17. Snap Ring
18. Snap Ring

Figure 3-33. Shaft and Front Bearing

9. While holding the swashplate in place, turn the

housing on its side. Install the install shaft/bearing 20
assembly into housing from the flange end. Install
the snap-ring (18).

20. Servo Spring

21. Minimum Angle Stop

Figure 3-35. Servo Spring and Minimum

Angle Stop

3-42 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

12. Press the rear shaft bearing (22) into the endcap. 15. Install the endcap (25) onto the housing with the
Install the bearing with letters facing out. Press until endcap screws (26). Check to ensure the endcap
bearing surface is 0.08 ±0.01 in (2 ±0.25 mm) will properly seat onto the housing without interfer-
above endcap surface. ence. Improper assembly of the internal compo-
nents may prevent the endcap from seating
22
23
3 mm
[0.12 in]
properly. Ensure the O-rings seat properly when
2 mm
[0.08 in]
installing the endcap.
26
8 mm
23 35-45 ft.lbs.
(47-61 Nm)
22

24
25

22. Rear Shaft Bearing 25. End Cap

23. Timing Pin 26. Screw
24. Valve Plate
Figure 3-37. End Cap
Figure 3-36. Valve Plate and Rear Bearing
16. Using an 8 mm internal hex wrench, tighten the end-
13. Install timing pin (23) into its bore in the endcap. cap screws. Tighten the screws in opposite corners
Install the pin with its groove facing toward or away slowly and evenly to compress the servo spring and
from the shaft. Press the pin until the end protrudes properly seat the endcap. Torque endcap screws
0.12 ±0.01 in (3 ±0.25 mm) above endcap surface. 35-45 ft.lbs. (47-61 Nm).

17. Before installing the shaft seal, ensure the shaft

14. Install the valve plate (24) onto the endcap. Install
turns smoothly with less than 120 in.lbs. (13.5 Nm)
the valve plate with the yellow surface toward the
of force. If the shaft does not turn smoothly within
cylinder block. Align the slot in the valve plate with
the specified maximum force, disassemble and
the timing pin. Apply a liberal coat of assembly
check the unit.
grease to the endcap side of the valve plate to keep
it in place during installation.

3121201 – JLG Lift – 3-43

SECTION 3 - CHASSIS & TURNTABLE

18. Cover shaft splines with an installation sleeve. Install 19. Install remaining plugs and fittings to the housing.
a new shaft seal (27) with the cup side facing the Refer to the drawing below for wrench sizes and
motor. Press seal into housing until it bottoms out. installation torques.
Press evenly to avoid binding and damaging the 1/4 in
5/16 in
seal. Install seal support washer (28) and snap ring 63 ft.lbs. 33 ft.lbs.
(29). (85 Nm) (45 Nm)

9/16 in
125 ft.lbs.
(170 Nm)

3 mm
27. Shaft Seal 1.5 to 2.5 ft.lbs.
(2.03 to 3.39 Nm)
28. Seal Support Washer
29. Snap Ring

Figure 3-38. Shaft Seal

1/4 in
33 ft.lbs.
(45 Nm)

5/16in
63 ft.lbs.
(85 Nm)

Figure 3-39. Plugs and Fittings Installation

3-44 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

20. Install orifice poppet (30). Initial Start-up Procedures

37
Follow this procedure when starting-up a new motor or
36
33 when installing a motor that has been removed.
39 41
34
30 11/16 in Prior to installing the motor, inspect for damage incurred
40 27 ft.lbs. during shipping. Make certain all system components
(37 Nm)
5/8 in (reservoir, hoses, valves, fittings, heat exchanger, etc.) are
20 ft.lbs. clean prior to filling with fluid.
(27 Nm)
1. Fill the reservoir with recommended hydraulic fluid.
31
32 Always filter fluid through a 10 micron filter when
38
35
pouring into the reservoir. Never reuse hydraulic
fluid.
42
11/16 in 2. Fill the inlet line leading from the pump to the reser-
27 ft.lbs. voir. Check the inlet line for properly tightened fit-
(37 Nm)
tings and be certain it is free of restrictions and air
leaks.

3. Fill the pump and motor housing with clean hydrau-

lic fluid. Pour filtered oil directly into the upper most
30. Orifice Poppet 34. Spring 37. O-ring 40. Plug case drain port.
31. Shift Spool 35. Spring 38. O-ring 41. Plug
4. To ensure the pump and motor stay filled with oil,
32. Spring 36. Spring 39. O-ring 42. Plug
install case drain lines into the upper most case
33. Spring
drain ports.
Figure 3-40. Loop Flushing Spool
5. Install a 0 to 500 psi (0 to 35 bar) gauge in the
charge pressure gauge port of the pump to monitor
21. Install shift spool (31). system pressure during start up.
22. Install spring retaining washers onto springs (32 and 6. While watching the pressure gauge, run the engine
33). at the lowest possible speed until system pressure
builds to normal levels (minimum 160 psi [11 bar]).
23. Carefully install centering springs (34, 35, and 36). Once system pressure is established, increase to full
24. Install new O-rings (37, 38, and 39). operating speed. If system pressure is not main-
tained, shut down the prime mover, determine
25. Using a 5/8 in wrench torque plug (40) to 20 ft.lbs. cause, and take corrective action.
(27 Nm).
7. Operate the hydraulic system for at least fifteen min-
26. Using a 11/16 in wrench, torque plugs (41 and 42) to utes under light load conditions.
27 ft.lbs. (37 Nm).
8. Check and adjust control settings as necessary after
installation.

9. Shut down the prime mover and remove the pres-

sure gauge. Replace plug at the charge pressure
gauge port.

10. Check the fluid level in the reservoir; add clean fil-
tered fluid if necessary. The motor is now ready for
operation.

3121201 – JLG Lift – 3-45

SECTION 3 - CHASSIS & TURNTABLE

3.8 OSCILLATING AXLE BLEEDING 5. Open both bleeder screws (one on each lockout cyl-
inder).
PROCEDURE AND LOCKOUT TEST
Lockout Cylinder Bleeding

ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CEN-

TERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING PRO-
CEDURE.

ENSURE MACHINE IS ON A LEVEL SURFACE AND REAR WHEELS

ARE BLOCKED, BRAKE WIRE IS DISCONNECTED.

1. Making sure machine is on a level surface and rear

wheels are blocked, brake wire is disconnected.
2. Center boom over rear axle to make sure that the
oscillation valve in the rotary coupling is activated.
6. Start the engine, position drive control lever to for-
3. Using a Phillips screwdriver, remove screw from ward or reverse.
connection on the brake valve and disconnect the
solenoid from the valve 7. Close bleeder screws when there is no more air in
the hydraulic oil coming out of the bleeder valve.

8. Perform oscillating axle lockout test.

9. If necessary, repeat steps 1 thru 8.

Oscillating Axle Lockout Test

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,

ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and cen-

tered between drive wheels prior to beginning lock-
out cylinder test.

4. Place suitable containers under each lockout cylin-

1. Place a 6 inch (15.2 cm) high block with ascension
der to catch any residual hydraulic fluid.
ramp in front of left front wheel.

2. From platform control station, activate machine

hydraulic system.

3. Place FUNCTION SPEED CONTROL and DRIVE

SPEED/TORQUE SELECT control switches to their
respective LOW positions.

3-46 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-41. Swing Torque Hub Adjustment

4. Place DRIVE control lever to FORWARD position tion, lockout cylinders should release and allow
and carefully drive machine up ascension ramp until wheel to rest on ground, it may be necessary acti-
left front wheel is on top of block. vate DRIVE to release cylinders.
5. Carefully activate SWING control lever and position 15. If lockout cylinders do not function properly, have
boom over right side of machine. qualified personnel correct the malfunction prior to
any further operation.
6. With boom over right side of machine, place DRIVE
control lever to REVERSE and drive machine off of
block and ramp. 3.9 SWING HUB
7. Have an assistant check to see that left front wheel
remains locked in position off of ground.
Adjustment Procedures
8. Carefully activate SWING control lever and return NOTE: The swing bearing high spot is usually marked with a
boom to stowed position (centered between drive colored paint.
wheels). When boom reaches center, stowed posi-
tion, lockout cylinders should release and allow 1. Ensure swing drive is located on bearing gear max
wheel to rest on ground, it may be necessary acti- eccentric tooth (high spot).
vate DRIVE to release cylinders.
2. With mounting free to slide, shim between pinion
9. Place the 6 inch (15.2 cm) high block with ascension
and bearing gear teeth to achieve 0.008 - 0.012 in.
ramp in front of right front wheel.
(0.20 - 0.30 mm) backlash.
10. Place DRIVE control lever to FORWARD and care-
fully drive machine up ascension ramp until right 3. Install a pry bar into hole in turntable base plate and
front wheel is on top of block. pry swing hub back tight against shim and bearing.

11. Carefully activate SWING control lever and position 4. Torque bolts according to the torque chart in Section
boom over left side of machine. 1.

12. With boom over left side of machine, place DRIVE

control lever to REVERSE and drive machine off of
block and ramp.
13. Have an assistant check to see that right front wheel
remains locked in position off of ground.
14. Carefully activate SWING control lever and return
boom to stowed position (centered between drive
wheels). When boom reaches center, stowed posi-

3121201 – JLG Lift – 3-47

SECTION 3 - CHASSIS & TURNTABLE

Disassembly Main Assembly Procedure

1. Loosen all 12 cover bolts (12)&(13) and drain the oil
from the unit. 1. With the hub shaft sub-assembly resting on the shaft
2. Remove the 12 cover bolts (12)& (13) and lift off the (1A) install internal gear (2). The spline of the inter-
cover (6). Remove and discard the O-ring (5) from nal gear (2) bore will mesh the spline of the output
the counterbore of the cover (6). shaft (1A).

3. Remove the input gear (8) and thrust washer (10).

4. Lift out the carrier assembly (3) and top thrust
washer (11). The thrust washer (11) may stick to the
inside of the carrier (3).
5. Remove the input thrust spacer (9).
6. Lift out the internal gear (2) and thrust washer (11).
The thrust washer (11) may stick to the under side of
the carrier (3).
7. Remove the retaining ring (1I) from the output shaft
(1A) and discard.

2. Thrust washer (11) is installed on the face of the out-

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING put shaft (1A). Sufficient grease or petroleum jelly
(1I) REMOVAL. should be used to hold thrust washer in place.

8. Remove bearing shim (1H) from the output shaft

(1A).
9. The output shaft (1A) may now be pressed out of the
hub (1G).
10. THe bearing cups (1C)&(1E) will remain in hub (1G)
as will bearing cone (1F). Bearing cone (1D) will
remain on the same output shaft (1A). The seal (1B)
will be automatically removed during this procedure.

NOTE: If bearing replacement is necessary, the bearing

cups can be removed with a slide hammer puller
driven out with a punch.

11. To remove the cluster gears (3F) from the carrier

(3A), drive the anti-roll pin (3G) into the planet shaft
(3E) may now be tapped out of the carrier. After
planet shaft (3E) has been removed the roll pin (3G)
can be driven out.
12. The cluster gear (3F) can now be removed from the
carrier (3A). THe thrust washers (3B) will be
removed with the cluster gear (3F).
13. The needle rollers (3C) and spacer (3D) are now
removed from the cluster gear (3F).

WHEN REBUILDING OR REPAIRING THE UNIT, THE RETAINING

RING (1I), O-RINGS (5) AND SEAL (1B) SHOULD ALWAYS BE
REPLACED.

3-48 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

3. Place O-ring (5) into hub counterbore. Use petro- 6. With shoulder side of ring gear (4) facing down,
leum jelly to hold O-ring in place. Also at this time place ring gear over (into mesh with) large gears. Be
locate and mark the 4 counter beamed holes in the sure that punch marks remain in correct location
face of the hub (1G). This is for identification later in during ring gear installation. The side of the ring
the assembly. gear with an x stamped on it should be up.

4. Thrust spacer (9) is installed into the bore of the out- 7. While holding ring gear (4) and cluster gears (3F) in
put shaft (1A). This should be a slip fit and thrust mesh, place small side of cluster gears (3F) into
spaces should rotate in this location. mesh with the internal gear (2) and input gear (13).
On the ring gear locate the hole marked “x” over one
of the marked counterbore holes (step 3) in hub
(1G).

5. Place carrier assembly (3) on a flat surface with the

large gears (3F) up and positioned as shown. Find
the punch marked tooth on each large gear (3F) and
locate at 12 0’clock (straight-up) from each planet NOTE: If gears do not mesh easily or carrier assembly does
pin. Marked tooth will be located just under the car- not rotate freely, then remove the carrier and ring
rier (3A) on upper two gears (3F). gear and check the cluster gear timing.

3121201 – JLG Lift – 3-49

SECTION 3 - CHASSIS & TURNTABLE

8. Input gear (8) is installed, meshing with teeth of the

large diameter cluster gear (3F). The counterbore on
the input gear (8) locates on the shoulder of the BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEAT-
thrust spacer (9). This is to be a slip fit and operate ING THIS O-RING.
freely.

9. Thrust washer (10) is installed onto the input gear 12. THe cover (6) is now installed on this assembly. Tak-
(8) and should locate on the gear teeth shoulder. ing care to correctly align pipe plug hole (20) with
those in the hub (1J), usually 90° to one another.
Locate the 4 counterbore holes in hub (1G) (marked
in step 3) and install 4 shoulder bolts (13). A slight
tap with a hammer may be necessary to align shoul-
der bolt with hub (1G) counterbore.

10. Thrust washer (11) is installed into the counterbore

of the carrier (3).

13. Install regular grade 8 bolts (12) into remaining

holes.

11. Place O-ring (5) into cover (6) counterbore. Use

petroleum jelly to hold O-ring in place.

3-50 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

14. Pipe plugs (20) are to be installed into cover (6) 2. Press bearing cup (1C) into hub (1G) taking care to
using a lubricant of some sort. insure cup start square with the bore of the hub.

15. Torque shoulder bolts (13) to 23-27 ft./lbs. and regu- 3. Invert hub (1G) and press bearing cup (1E) into inter
lar grade 8 bolts (12) to 23-27 ft./lbs, counterbore of hub (1G).

This completes the assembly. THe unit must be filled one- 4. Returning the hub (1G) to locate on the large diame-
half full of EP 90 lubricant before operation if the unit is ter end, the output shaft (1A) is carefully installed
mounted horizontally, and completely filled if mounted into the hub (1G).
vertically. In vertical mounting application case oil circula-
tion is recommended.

Hub Shaft Sub-Assembly

1. Press bearing cone (1D) onto shaft (1A).

3121201 – JLG Lift – 3-51

SECTION 3 - CHASSIS & TURNTABLE

5. The shaft seal (1B) is installed over the output shaft 8. Bearing spacer (1H) is installed around the output
(1A) and into the counterbore of the hub (1G). Care shaft (1A) and locates on bearing cone (1F).
should be taken to insure the seal (1B) is being cor-
rectly installed (smooth face up and located just
flush with the counterbore face).

9. Retaining ring (1I) installed into groove provided in

the output shaft (1A). This retaining ring (1I) should
never be reused in a repair or rebuild.
6. The bearing cone (1F) is an interference fit and has
to be pressed or tapped on.

EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.

7. Pipe plugs (1J & 1K) should be checked and/ or

installed at this time in the assembly.

3-52 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

10. A soft metal punch should be used to insure that this Carrier Sub-Assembly
retaining ring (1I) is completely seated in the groove
of the output shaft (1A). 1. Apply a coat of grease or petroleum jelly to cluster
gear bore.

EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.

2. Place sixteen needle rollers into cluster gear bore.

11. Upon completion of step 10, rap the internal end of

the output shaft (1A) twice with a piece of soft metal
rod. This will release the preload which was on the
bearings.

3. Place spacer washer into opposite side of cluster

gear and against needle rollers.

This completes the hub shaft sub-assembly —items (1A)

through (1J). If this assembly is not going to be used right
away, it should be oiled and covered to help prevent rust-
ing,

3121201 – JLG Lift – 3-53

SECTION 3 - CHASSIS & TURNTABLE

4. Place second set of sixteen needle rollers into clus- 7. Line up cluster gear and thrust washer with hole in
ter gear. carrier and slide planet shaft through. Line up cham-
fered side of hole in planet shaft with pin hole in car-
rier.

5. Apply grease or petroleum jelly to the tang side of

two thrust washers. Place thrust washers against
8. Drive anti-roll pin flush into carrier hole, thereby lock-
bosses in carrier with washer tang fitting into slot in ing planet shaft into place.
carrier outside diameter. Repeat these steps for remaining two cluster gears
to complete carrier assembly.
NOTE: Some old style carriers will not have slots and tangs
should be located inside boss relief.

6. While keeping thrust washers in place, slide cluster

gear into carrier with the larger gear on the side with
the small pin hole.

3-54 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-42. Swing Drive Hub (Fairfield)

3121201 – JLG Lift – 3-55

SECTION 3 - CHASSIS & TURNTABLE

3.10 SWING BEARING head and hardened washer at the arrow indi-
cated position.
Turntable Bearing Mounting Bolt Condition
Check
NOTE: This check is designed to replace the existing bear-
ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and .0015" Feeler Gauge
retorquing bolt or bolts recheck all existing bolts for
looseness. Figure 3-43. Swing Bearing Bolt Feeler Gauge Check

1. Check the frame to bearing. Attach bolts as follows:

Wear Tolerance
a. Elevate the fully retracted boom to 70 degrees
(full elevation).
1. From the underside of the machine, at rear center,
b. At the positions indicated on Figure 3-43. try and with the boom fully elevated and fully retracted, as
insert the 0.0015" feeler gauge between the bolt shown in and Figure 3-44., Swing Bearing Tolerance
head and hardened washer at the arrow indi-
Boom Placement - Swing Bearing Tolerance Boom
cated position.
Placement) A, using a magnetic base dial indicator,
c. Assure that the 0.0015" feeler gauge will not measure and record the distance between the swing
penetrate under the bolt head to the bolt shank.
bearing and turntable. (Figure 3-45., Swing Bearing
d. Swing the turntable 90 degrees, and check Tolerance Measuring Point)
some selected bolts at the new position.
e. Continue rotating the turntable at 90 degrees 2. At the same point, with the boom at horizontal and
intervals until a sampling of bolts have been fully extended, and the tower boom fully elevated as
checked in all quadrants. shown in (Figure 3-44., Swing Bearing Tolerance
Boom Placement - Swing Bearing Tolerance Boom
2. Check the turntable to bearing. Attach bolts as fol-
lows: Placement) B, using a magnetic base dial indicator,
measure and record the distance between the swing
a. Elevate the fully retracted boom to 70 degrees bearing and turntable. (Figure 3-45., Swing Bearing
(full elevation). Tolerance Measuring Point)
b. At the positions indicated on Figure 3-43. try and
insert the 0.0015" feeler gauge between the bolt 3. If a difference greater than 0.079 in. (2.00 mm) is
head and hardened washer at the arrow indi- determined, the swing bearing should be replaced.
cated position.
c. Lower the boom to horizontal and fully extend 4. If a difference less than 0.079 in. (2.00 mm) is deter-
the boom. mined, and any of the following conditions exist, the
d. At the position indicated on Figure 3-43. try and bearing should be removed, disassembled, and
insert the 0.0015" feeler gauge between the bolt inspected for the following:

a. Metal particles in the grease.

b. Increased drive power required.

c. Noise.

d. Rough rotation.

3-56 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-44. Swing Bearing Tolerance Boom Placement

3121201 – JLG Lift – 3-57

SECTION 3 - CHASSIS & TURNTABLE

5. If bearing inspection shows no defects, reassemble e. Attach suitable overhead lifting equipment to the
and return to service. base of the turntable weldment.
f. Use a suitable tool to scribe a line on the inner
race of the swing bearing and on the underside
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON of the turntable. This will aid in aligning the bear-
AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ing upon installation. Remove the bolts and
ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE washers which attach the turntable to the bear-
OF THIS, PROPER MAINTENANCE OF THE SWING BEARING ing inner race. Discard the bolts.
BOLTS IS A MUST FOR SAFE OPERATION. g. Use the lifting equipment to carefully lift the com-
plete turntable assembly from the bearing.
TURNTABLE REF. Ensure that no damage occurs to the turntable,
bearing or frame-mounted components.
h. Carefully place the turntable on a suitably sup-
ported trestle.
MEASURING SWING
BEARING i. Use a suitable tool to scribe a line on the outer
POINT race of the swing bearing and the frame. This
line will aid in aligning the bearing upon installa-
tion. Remove the bolts and washers which
attach the outer race of the bearing to the frame.
FRAME REF. Discard the bolts. Use suitable lifting equipment
to remove the bearing from the frame, then
Figure 3-45. Swing Bearing Tolerance Measuring move the bearing to a clean, suitably supported
Point work area.

2. Installation.
Swing Bearing Replacement
a. Using suitable lifting equipment, carefully lower
1. Removal. the swing bearing into position on the frame.
Ensure the scribed line of the outer race of the
a. From Ground Control station, operate the boom bearing aligns with the scribed line on the frame.
adequately to provide access to frame opening If a new swing bearing is used, ensure that the
or, if equipped, to rotary coupling. filler plug fitting is at 90 degrees from the fore
and aft center line of the frame.

NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING

BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING
SLING SUPPORT AND/OR BLOCKING.
BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE
b. Attach an adequate support sling to the boom THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN
and draw all slack from sling. Prop or block the THE FRAME AND TURNTABLE, IT IS IMPERATIVE THAT SUCH
boom if feasible. REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE
c. From inside turntable, remove mounting hard- OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
ware which attach rotary coupling retaining yoke
brackets to turntable. b. Apply a light coating of Loctite #271 to the new
bearing bolts, and loosely install the bolts and
washers through the frame and outer race of
bearing.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT
d. Tag and disconnect the hydraulic lines from the WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT
fittings on the top of the rotary coupling. Use a BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD
suitable container to retain any residual hydrau- BE CHECKED PRIOR TO USE.
lic fluid. Immediately cap lines and ports.

3-58 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-46. Swing Bearing Torque Sequence

c. Refer to the Torque Sequence diagram as attaching bolts and secure the yoke to the turn-
shown in Figure 3-46., Swing Bearing Torque table with the mounting hardware.
Sequence. Clean any residue off the new bear- k. Connect the hydraulic lines to the rotary cou-
ing bolts, then apply a light coating of Loctite pling as tagged prior to removal.
#271 and install the bolts and washers through
l. At ground control station, use boom lift control
the frame and outer race of the bearing. Tighten
to lower boom to stowed position.
the bolts to an initial torque of 190 FT. LBS. (260
Nm) w/Loctite. m. Using all applicable safety precautions, activate
the hydraulic system and check the swing sys-
d. Remove the lifting equipment from the bearing. tem for proper and safe operation.
e. Using suitable lifting equipment, carefully posi-
tion the turntable assembly above the machine Swing Bearing Torque Values
frame.
1. Outer Race - 190 ft. lbs. (260 Nm) w/Loctite.
f. Carefully lower the turntable onto the swing
bearing, ensuring that the scribed line of the 2. Inner Race - 190 ft. lbs. (260 Nm) w/Loctite.
inner race of the bearing aligns with scribed line 3. See Swing Bearing Torquing Sequence.
on the turntable. If a new swing bearing is used,
ensure that the filler plug fitting is at 90 degrees
from the fore and aft center line of the turntable.
CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR
g. Clean any residue off the new bearing bolts,
MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERA-
then apply a light coating of Loctite #271 and
TION, AND EVERY 600 HOURS THEREAFTER.
install the bolts and washers through the turnta-
ble and inner race of the bearing.
h. Following the Torque Sequence diagram shown
i n F i g u r e 2 - 4 9 . S w i n g B e a r i n g To r q u i n g
Sequence, tighten the bolts to a torque of 190 ft.
lbs. (260 Nm) w/Loctite.
i. Remove the lifting equipment.
j. Install the rotary coupling retaining yoke brack-
ets, apply a light coating of Loctite #242 to the

3121201 – JLG Lift – 3-59

SECTION 3 - CHASSIS & TURNTABLE

3.11 SWING BRAKE - MICO Assembly

Disassembly NOTE: Lubricate all seals and o-rings with clean hydraulic
oil prior to assembly.
1. With shaft protrusion downward, remove end cover
(13) by removing capscrews (12). 1. Press new rotary seal (1) into housing (52). Note the
direction of seal.
2. Install new bearing (2) on shaft (51).
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 3. Install shaft assembly and retaining ring (3) into
2000 POUNDS (681 KG). THE FOUR CAPSCREWS SHOULD BE housing (52).
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
PRESS IS AVAILABLE (3000 LBS (1362 KG) MAXIMUM), THE 4. Install dowel pins (15), spring retainer (55), and
COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP- springs (5 & 6) into housing (52).
SCREWS AND LOCKWASHERS. NOTE: Be sure to use the same number of springs and
spring pattern as recorded during disassembly.
2. Remove case seal (11) from housing (7) then
remove bleeder screw (14) from end cover (52). 5. Position new large diameter return plate (8) in hous-
3. Remove piston (22) from end cover (13). ing with tabs guided by dowel pins (15) until disc
rests on springs (5 & 6).
4. Remove o-ring (17), back-up ring (16), o-ring (19)
and back-up ring (18) from piston (22). NOTE: Discs (21 & 8) and friction discs (20) should remain
dry during installation. Oil will contaminate disc sur-
5. Remove separators (10) from housing (52). faces.
6. Remove stack assembly, consisting of discs (21), 6. Place new disc (20) on shaft (51) until it contacts
return plate (8) and friction discs (20) from housing
return plate (8).
(52).
7. Add additional discs (21) as required to complete
7. Remove dowel pins (15), springs (5 & 6) from hous- assembly.
ing (52).
8. Insert separators (10) in holes of return plate (8).
8. Remove retaining ring (3) from housing (52).
9. Install new o-ring (17), new back-up ring (16), new o-
9. Remove shaft by pressing or using a soft mallet on ring (19) and new back-up ring (18) on piston (22).
male end of shaft (51). Insert piston (22) into end cover (13), being careful
not to shear o-rings or back-up rings.
10. Remove retaining ring (54) bearing (2) from shaft
(51). 10. Install new case seal (11) in housing (52), then
install bleeder screw (14) in end cover.
11. Press rotary seal (1) from housing (51).
11. Position end cover (13) on housing (52), aligning
Inspection dowel pins (15) with holes in end cover.

1. Clean all parts thoroughly. 12. Insert capscrews (12) and tighten evenly to draw
end cover (13) to housing (52). Torque capscrews to
2. Closely inspect all parts for excessive wear, cracks 55 ft. lbs. (75 Nm).
and chips. Replace parts as necessary.
3. Discard seals and o-rings.
4. Closely inspect bearings and bearing contact sur-
faces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

3-60 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-47. Swing Brake Assembly (Mico)

3121201 – JLG Lift – 3-61

SECTION 3 - CHASSIS & TURNTABLE

3.12 ROTARY COUPLING - S/N 81836 TO Table 3-9. Coupling Port Information Table - 2WS

PRESENT Port Port

Operating Proof
Outlet Description Pressure Pressure
No. Size
Use the following procedure to install the seal kit. PSI (Bar) PSI (Bar)

1. If not already removed, remove the axle oscillation 1 1 -8 Brake 450 (31) 675 (47)
valve from the cylinder barrel. The spool of the valve 2 2 -6 2 Speed 4500 (310) 6750 (465)
protrudes into the barrel and will damage the spool 3 1 -6 Steer 2500 (172) 3750 (259)
and seals if left in place.
4 1 -6 Steer 2500 (172) 3750 (259)
2. Remove snap ring (12) from end. 5 2 -6, -16 Drive Reverse 4500 (310) 6750 (465)
6 1 -16 Drive Forward 4500 (310) 6750 (465)
3. Remove thrust ring (13) from the same end.
7 3 -8, -6 Case Drain 250 (17) 375 (26)
4. Remove center body (10) from housing (11).
Table 3-10. Coupling Port Information Table - 4WS
5. Cut off old seals (14,15,17,18).
Operating Proof
6. Assemble lip seals (14) in direction shown in Figure Port Port
Outlet Description Pressure Pressure
3-49., Rotary Coupling - Sheet 2 of 2. No. Size
PSI (Bar) PSI (Bar)
7. Reassemble O-ring (18). 1 1 -8 Brake 450 (31) 675 (47)
2 2 -6 2 Speed 4500 (310) 6750 (465)
8. Heat cap seals (17) in hydraulic oil for 5 minutes at
3 1 -6 Steer 2500 (172) 3750 (259)
300° F (149° C).
4 1 -6 Steer 2500 (172) 3750 (259)
9. Assemble cap seals over O-rings 5 2 -6, -16 Drive Reverse 4500 (310) 6750 (465)
10. Reinsert center body into housing (lube with hydrau- 6 1 -16 Drive Forward 4500 (310) 6750 (465)
lic oil). 7 3 -8, -6 Case Drain 250 (17) 375 (26)
8 1 -6 Steer 2500 (172) 3750 (259)
11. Replace thrust ring and snap ring.
9 1 -6 Steer 2500 (172) 3750 (259)

3-62 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

1. Rotary Coupling 5. Bolt

2. Torque Lug 6. Nut
3. Locknut 7. Bracket
4. Flatwasher

Figure 3-48. Rotary Coupling - Sheet 1 of 2

3121201 – JLG Lift – 3-63

SECTION 3 - CHASSIS & TURNTABLE

1. O-ring 6. Spring 11. Housing 16. Bearing

2. Plug 7. Valve Block Plunger 12. Retaining Ring 17. Cap Seal
3. Check Valve 8. Valve Block 13. Ring 18. O-ring
4. Screw 9. O-ring 14. Oil Seal
5. Plug 10. Body 15. O-ring

Figure 3-49. Rotary Coupling - Sheet 2 of 2

3-64 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-50. Rotary Coupling Port Location - 2WS

3121201 – JLG Lift – 3-65

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-51. Rotary Coupling Port Location - 4WS

3-66 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

3.13 GENERATOR Overload Protection

Every 250 hours

STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE
Every 250 hours of operation, check the drive belt for
CIRCUIT BREAKER.
proper tension.
The circuit breaker protects the generator windings from
overload. If the circuit breaker opens, generator output
stops. If the circuit breaker continues to open, check for
faulty equipment connected to the platform receptacles.
1/2 in.
(13 mm)

CIRCUIT
BREAKER

Every 500 hours

Every 500 hours of operation, service the generator
brushes and slip rings. Hostile environments may require
more frequent service.

Inspecting Brushes, Replacing Brushes, and

Cleaning Slip Rings
Refer to Figure 3-52., Inspecting Generator Brushes,
Replacing Brushes, and Cleaning Slip Rings.

INSPECTING BRUSH POSITION

Every 500 hours of service, blow out the inside of the gen- Inspect brush alignment with slip rings. View alignment
erator. If operating in a hostile environment, clean through the air vents in the stator barrel. The brushes
monthly. must ride completely on the slip rings.

INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the
brush holder assembly. Pull the brushes from the holders.

Replace the brushes if damaged, or if the brush is at or

near minimum length.

CLEANING SLIP RINGS

Visually inspect the slip rings. Under normal use, the rings
turn dark brown.

If the slip rings are corroded or their surface is uneven,

remove the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little
material as possible. If the rings are deeply pitted and do
not clean up, consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.

3121201 – JLG Lift – 3-67

SECTION 3 - CHASSIS & TURNTABLE

Brush Position On Slip Rings

2
3

Acceptable Unacceptable
Brushes must ride
completely on slip
rings

1/4 in (6 mm)
Or Less - Replace

7/16 in - 1/2 in
2 (11 - 12 mm) New

1. Brush Holder Assembly

2. Brushes
3. Slip Rings

Figure 3-52. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings

3-68 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

3.14 SPARK ARRESTER CLEANING Changing from LP Gas to Gasoline

INSTRUCTIONS 1. With engine operating on LP under a no load condi-
tion, throw the LPG/Gasoline switch at the ground
1. Remove the cleanout plug in the bottom of spark
control station to the “Gasoline” position.
arrester (muffler).
2. If engine “stumbles” because of lack of gasoline,
2. Without causing deformation (or any type of dam-
place the switch to the LPG position until engine
age to the spark arrester) repeatedly tap on the
regains smoothness, then return the switch to the
arrester near the cleanout plug. This may be enough
Gasoline position. Repeat as necessary until engine
to begin drainage of the spark trap.
runs smoothly on gasoline.
3. An industrial vacuum cleaner can do a complete job
3. Close the hand valve on the LP gas supply tank by
at this point.
turning clockwise.
a. Or, IN A SAFE AREA, start the engine. Then
alternate between low idle and high idle for two 3.16 FORD EFI ENGINE
to three minutes.
b. Or, operate the engine as required by the appli- Performing Diagnostics
cation for two to three minutes.
1. Verify the complaint and determine if it is a deviation
4. Install the cleanout plug. from normal operation.

2. Once the complaint has been verified, preliminary

3.15 DUAL FUEL SYSTEM checks can be done. Conduct a thorough visual
inspection, be alert for unusual sounds or odors,
and gather diagnostic trouble code information.
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE 3. Perform a system check that will verify the proper
OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME operation of the system in question and check for
CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS recent information updates.
MUST BE FOLLOWED.
4. If a diagnostic trouble code (DTC) is stored, contact
a JLG distributor to make an effective repair.
Changing from Gasoline to LP Gas
5. If no DTC is stored, select the symptom from the
1. Start the engine from the ground control station. symptom tables and follow the diagnostic path or
suggestions to complete the repair.
2. Open the hand valve on the LP gas supply tank by
turning counterclockwise. 6. After the repair has been made and validated for
proper operation, the old part should be momen-
tarily re-installed to verify that it was indeed the
source of the problem.
BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO
LP GAS. If no matching symptom is available, analyze the com-
plaint and develop a plan for diagnostics utilizing the wir-
3. While the engine is operating, place the three posi- ing diagrams, technical assistance, and repair history.
tion LPG/Gasoline switch at the ground control sta-
tion to the center “off” position. Allow the engine to Intermittent conditions may be resolved by using a check
operate without load, until the engine begins to sheet to pinpoint the circuit or electrical system compo-
“stumble” from lack of gasoline. nent. Some diagnostic charts contain Diagnostic Aids
which give additional information about a system. Be sure
4. As the engine begins to “stumble”, place the switch to use all of the information that is available to you.
to the LPG position, allowing the LP fuel to be sent
to the fuel regulator.

3121201 – JLG Lift – 3-69

SECTION 3 - CHASSIS & TURNTABLE

VISUAL/PHYSICAL ENGINE INSPECTION ECM AND SENSORS

CHECK
Perform a careful visual and physical engine inspection CRANKSHAFT POSITION (CKP) SENSOR
before performing any diagnostic procedure. Perform all The crankshaft position (CKP) sensor provides a signal
necessary repairs before proceeding with additional diag- used by the engine control module (ECM) to calculate the
nosis, this can often lead to repairing a problem without ignition sequence. The CKP sensor initiates the reference
performing unnecessary steps. Use the following guide- pulses which the ECM uses to calculate RPM and crank-
lines when performing a visual/physical inspection check: shaft position.
• Inspect engine for modifications or aftermarket equip- CAMSHAFT POSITION (CMP) SENSOR AND
ment that can contribute to the symptom; verify that all
SIGNAL
electrical and mechanical loads or accessory equip-
The camshaft position (CMP) sensor sends a CMP signal
ment is "OFF" or disconnected before performing diag-
to the ECM. The ECM uses this signal as a "sync pulse" to
nosis.
trigger the injectors in the proper sequence. The ECM
• Inspect engine fluids for correct levels and evidence of uses the CMP signal to indicate the position of the #1 pis-
leaks. ton during its power stroke. The CMP uses a Hall Effect
sensor to measure piston position. This allows the ECM to
• Inspect vacuum hoses for damage, leaks, cracks, calculate true sequential fuel injection (SFI) mode of oper-
kinks and improper routing, inspect intake manifold ation. If the ECM detects an incorrect CMP signal while
sealing surface for a possible vacuum leak. the engine is running, DTC 53 will set. If the CMP signal is
• Inspect PCV valve for proper installation and operation. lost while the engine is running, the fuel injection system
will shift to a calculated sequential fuel injection mode
• Inspect all wires and harnesses for proper connections based on the last fuel injection pulse, and the engine will
and routing; bent or broken connector pins; burned, continue to nun. As long as the fault is present, the engine
chafed, or pinched wires; and corrosion. Verify that can be restarted. It will run in the previously established
harness grounds are clean and tight. injection sequence.
• Inspect engine control module (ECM), sensors, and
actuators for physical damage.
• Inspect ECM grounds for cleanliness, tightness, and
proper location.
• Inspect fuel system for adequate fuel level, and fuel
quality (concerns such as proper octane, contamina-
tion, winter/summer blend).
• Inspect intake air system and air filter for restrictions.
• Inspect battery condition and starter current draw.
If no evidence of a problem is found after visual/physical
engine check has been performed, proceed to MIL DTC
retrieval procedure.

3-70 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Table 3-11. ECM Diagnostic Trouble Codes

Diagnostic
Trouble Description
Code

11 All Systems OK

12 Throttle Position (TP) Sensor Low Voltage

14 Manifold Absolute Pressure (MAP) Low Voltage

21 Overspeed

22 Throttle Position (TP) Sensor High Voltage

24 Manifold Absolute Pressure (MAP) High Voltage

31 Fuel Pump Low Voltage

32 Heated Oxygen Sensor (HO2S) Low Voltage

33 Engine Coolant Temperature (ECT) Sensor High Voltage

35 Intake Air Temperature (IAT) Sensor High Voltage

41 Fuel Pump High Voltage

42 Heated Oxygen Sensor (HO2S) High Voltage

43 Engine Coolant Temperature (ECT) Sensor Low Voltage

45 Intake Air Temperature (IAT) Sensor Low Voltage

51 Low Oil Pressure

52 Crankshaft Position (CKP) Sensor Extra/Missing Pulses

53 Camshaft Position Sensor (CMP) Sensor Illegal Pattern

54 Engine Control Module (ECM) Fault Illegal Operation

55 Engine Control Module (ECM) Fault Illegal Interruption

56 Engine Control Module (ECM) Fault COP (Computer Operating Properly) Failure

61 System Voltage Low

62 System Voltage High

3121201 – JLG Lift – 3-71

SECTION 3 - CHASSIS & TURNTABLE

ENGINE COOLANT TEMPERATURE (ECT) HEATED OXYGEN SENSOR

SENSOR The heated oxygen sensor is mounted in the exhaust
stream where it can monitor the oxygen content of the
The engine coolant temperature (ECT) sensor is a g
exhaust gas. The oxygen present in the exhaust gas
thermistor (a resistor which changes value based on tem-
reacts with the sensor to produce a voltage output. This
perature) mounted in the engine coolant stream. Low
voltage should constantly fluctuate from approximately
coolant temperature produces a high resistance of
100 mV to 900 mV. The heated oxygen sensor voltage can
100,000 ohms at -40°C (-40°F). High temperature causes
be monitored on an IBM PC-compatible computer with
a low resistance of 70 ohms at 130°C (266°F). The ECM
diagnostic software. By monitoring the voltage out-put of
supplies a 5-volt signal to the ECT sensor through resis-
the oxygen sensor, the ECM calculates the pulse width
tors in the ECM and measures the voltage. The signal volt-
command for the injectors to produce the proper combus-
age will be high when the engine is cold and low when the
tion chamber mixture.
engine is hot. By measuring the voltage, the ECM calcu-
lates the engine coolant temperature. Engine coolant tem-
Low HO2S voltage indicates a lean mixture which will
perature affects most of the systems that the ECM
result in a rich command to compensate.
controls.
High HO2S voltage indicates a rich mixture which will
After engine start-up, the temperature should rise steadily
result in a lean command to compensate.
to about 85°C (185°F). it then stabilizes when the thermo-
stat opens. If the engine has not been run for several
A constant voltage below 200 mV for 10 consecutive sec-
hours (overnight), the engine coolant temperature and
onds will set OTC 32. A constant voltage above 650 mV
intake air temperature displays should be close to each
for 10 consecutive seconds will set OTC 42.
other. A fault in the engine coolant sensor circuit will set
DTC 33 or DTC 43.

ELECTRICALLY ERASABLE PROGRAMMABLE

READ ONLY MEMORY (EEPROM)
The electrically erasable programmable read only mem-
ory (EEPROM) is a permanent memory chip that is
located within the ECM. The EEPROM contains the pro-
gram and the calibration information that the ECM needs
to control engine operations.
If the ECM is replaced, the new ECM will need to be pro-
grammed. An IBM-compatible computer and software
containing the correct program and calibration for the
application are required to program the ECM.

3-72 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-53. EFI Component Location

3121201 – JLG Lift – 3-73

SECTION 3 - CHASSIS & TURNTABLE

INTAKE AIR TEMPERATURE (IAT) SENSOR If the ECM detects a voltage that is significantly lower than
The intake air temperature (IAT) sensor is a thermistor the estimated MAP value for 2 or more consecutive sec-
which changes its resistance based on the temperature of onds, DTC 14 will be set. A signal voltage significantly
air entering the engine. Low temperature produces a high higher than the estimated MAP value for 2 or more con-
resistance of 100,000 ohms at -40°C (-40°F). High temper- secutive seconds will set DTC 24.
ature causes a low resistance of 70 ohms at 130°C
(266°F). The ECM supplies a 5-volt signal to the sensor
through a resistor in the ECM and monitors the signal volt-
age. The signal voltage will be high when the incoming air
is cold and low when the incoming air is hot. By measur-
ing the voltage, the ECM calculates the incoming air tem-
perature. The IAT sensor signal is used to adjust spark
timing according to the incoming air density. An IBM PC-
compatible computer with diagnostic soft-ware can be
used to display the temperature of the air entering the
engine. The temperature should read close to the ambient
air temperature when the engine is cold, and rise as
engine compartment temperature increases. If the engine
has not been run for several hours (overnight), the IAT
sensor temperature and engine coolant temperature
should read close to each other. A failure in the IAT sensor
circuit will set DTC 35 or DTC 45.
ENGINE CONTROL MODULE (ECM)
The ECM controls the following:

• Fuel metering system

• Ignition timing
• On-board diagnostics for engine functions
The ECM constantly observes the information from vari-
ous sensors. The ECM controls the systems that affect
engine performance. The ECM performs the diagnostic
function of the system. It can recognize operational prob-
lems, alert the operator through the Malfunction Indicator
Lamp (MIL), and store diagnostic trouble codes (DTCs).
DTCs identify the problem areas to aid the technician in
making repairs.
MANIFOLD ABSOLUTE PRESSURE (MAP) The ECM supplies either 5 or 12 volts to power various
SENSOR sensors or switches. The power is supplied through resis-
The manifold absolute pressure (MAP) sensor responds tances in the ECM which are so huh in value that a test
to changes in intake manifold pressure (vacuum). The light will not light when connected to the circuit. In some
MAP sensor signal voltage to the ECM varies from below 2 cases, even an ordinary shop voltmeter will not give an
volts at idle (high vacuum) to above 4 volts with the igni- accurate reading because its resistance is too low. There-
tion ON, engine not running or at wide-open throttle (low fore, a digital voltmeter with at least 10 meg ohms input
vacuum). impedance is required to ensure accurate voltage read-
ings. The ECM controls output circuits such as the fuel
The MAP sensor is used to determine the following: injectors, electronic governor, etc., by control ling the
ground or the power feed circuit through transistors or
• Engine vacuum level for engine control purposes.
other solid state devices.
• Barometric pressure (BARO)

3-74 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

The ECM is designed to maintain exhaust emission levels • When measuring voltages, use only a digital voltmeter
to government mandated standards while providing excel- with an input impedance of at least 10 megohms.
lent operation and fuel efficiency. The ECM monitors
numerous engine functions via electronic sensors such as • Do not jump start with more than 12 volts. This could
the throttle position (TP) sensor and the heated oxygen cause damage to the electronic components.
sensor (HO2S).
• Do not employ any non-standard practices such as
charging the battery with an arc welder.

• Take proper precautions to avoid static damage to the

ECM. Refer to "Electrostatic Discharge Damage" for
more information.

THROTTLE POSITION (TP) SENSOR

The throttle position (TP) sensor is a potentiometer con-
nected to the throttle shaft on the throttle body which is
built into the electronic governor. The ECM monitors the
voltage on the signal line and calculates throttle position.
As the throttle valve angle is changed, the TP sensor sig-
ECM INPUTS/OUTPUTS nal also changes. At a closed throttle position, the output
Inputs—Operating Conditions of the TP sensor is low. As the throttle valve opens, the
output increases so that at wide open throttle (WOT), the
• Engine Coolant Temperature output voltage should be above 4 volts.
• Crankshaft Position
The ECM calculates fuel delivery based on throttle valve
• Exhaust Oxygen Content
angle (operator demand). A broken or loose TP sensor
• Manifold Absolute Pressure may cause intermittent bursts of fuel from an injector and
unstable idle because the ECM thinks the throttle is mov-
• Battery Voltage
ing. A hard failure in the TP sensor 5-Volt reference or sig-
• Throttle Position nal circuits for greater than 2 consecutive seconds will set
either a DTC 12 or DTC 22. A hard failure with the TP sen-
• Fuel Pump Voltage
sor ground circuit for more than two consecutive seconds
• Intake Air Temperature may set DTC 22. If either DTC 12 or DTC 22 are set, the
throttle will be forced to a 6% (idle) position.
• Camshaft Position
Outputs - System Controlled
• Fuel Control
• Idle Air Control
• Electric Fuel Pump
• Diagnostics:
- Malfunction Indicator Lamp
- Data Link Connector (DLC)

ECM SERVICE PRECAUTIONS

The ECM is designed to withstand normal current draws
associated with engine operation. When servicing the
ECM, observe the following guidelines:
• Do not overload any circuit.
USE OF CIRCUIT TESTING TOOLS
• Do not probe wires for testing. This can cause a volt- Do not use a test light to diagnose the engine electrical
age drop that would be critical to the operation of the
systems unless specifically instructed by the diagnostic
ECM.
procedures. A test light can put an excessive load on an
• When testing for opens and shorts, do not ground or ECM circuit and result in component damage. For volt-
apply voltage to any of the ECM's circuits unless age measurements, use only a digital voltmeter with an
instructed to do so. input impedance of at least 10 megohms.

3121201 – JLG Lift – 3-75

SECTION 3 - CHASSIS & TURNTABLE

ELECTROSTATIC DISCHARGE DAMAGE A fuel injector which is stuck partly open will cause a loss
Electronic components used in the ECM are often of fuel pressure after the engine is shut down, causing
designed to carry very low voltage. Electronic compo- long crank times.
nents are susceptible to damage caused by electrostatic
discharge. Less than 100 volts of static electricity can
cause damage to some electronic components. By com-
parison, It takes as much as 4000 volts for a person to feel
the spark of a static discharge.

There are several ways for a person to become statically

charged. The most common methods of charging are by
friction and induction.
FUEL METERING SYSTEM COMPONENTS
An example of charging by friction is a person sliding The fuel metering system is made up of the following
across a seat. parts:

Charge by induction occurs when a person with well-insu- • The fuel injectors
lated shoes stands near a highly charged object and
• The fuel rail
momentarily touches ground. Charges of the same polar-
ity are drained off, leaving the person highly charged with • The fuel pressure regulator/filter assembly
the opposite polarity. Static charges can cause damage,
therefore it is important to-use care when handling and • The electronic governor
testing electronic components.
• The ECM
To prevent possible electrostatic discharge damage, fol- • The crankshaft position (CKP) sensor
low these guidelines:
• The camshaft position (CMP) sensor
• Do not touch the ECM connector pins or soldered
components on the ECM board. • The fuel pump

• Do not open the replacement part package until the • The fuel pump relay
part is ready to be installed.
BASIC SYSTEM OPERATION
• Before removing the part from the package, ground
the package to a known good ground on the equip- The fuel metering system starts with the fuel in the fuel
ment. tank. The fuel is drawn up to the fuel pump through a pre-
filter. The electric fuel pump then delivers the fuel to the
• If the part has been handled while sliding across a fuel rail through an inane fuel filter. The pump is designed
seat, while sitting down from a standing position, or to provide fuel at a pressure above the pressure needed
while walking a distance, touch a known good ground by the injectors. A fuel pressure regulator in the fuel filter
before installing the part. assembly keeps fuel available to the fuel injectors at a
constant pressure. A return line delivers unused fuel back
Fuel System to the tank.

FUEL INJECTOR
The Electronic Fuel Injection (EFI) fuel injector is a sole-
noid-operated device controlled by the ECM. The ECM
energizes the solenoid, which opens a valve to allow fuel
delivery.

The fuel is injected under pressure in a conical spray pat-

tern at the opening of the intake valve. Excess fuel not
used by the injectors passes through the fuel pressure
regulator before being returned to the fuel tank.

3-76 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI.

Figure 3-54. Typical Fuel System

FUEL METERING SYSTEM PURPOSE The ECM monitors signals from several sensors in order
The basic function of the air/fuel metering system is to to determine the fuel needs of the engine. Fuel is deliv-
control the air/fuel delivery to the engine. Fuel is delivered ered under one of several conditions called "modes." All
to the engine by individual fuel injectors mounted in the modes are controlled by the ECM. Refer to "Open Loop
intake manifold near each intake valve. and Closed Loop Operation" for more information.

The main control sensor is the heated oxygen sensor

(H02S) located in the exhaust system. The H02S tells the
ECM how much oxygen is in the exhaust gas. The ECM
changes the air/fuel ratio to the engine by control-ling the
amount of time that the fuel injector is "ON." The best mix-
ture to minimize exhaust emissions is 14.7 parts of air to 1
part of gasoline by weight, which provides the most effi-
cient combustion. Because of the constant measuring and
adjusting of the air/fuel ratio, the fuel injection system is
called a "closed loop" system.

3121201 – JLG Lift – 3-77

SECTION 3 - CHASSIS & TURNTABLE

FUEL PRESSURE REGULATOR ELECTRONIC GOVERNOR AND THROTTLE

The fuel pressure regulator is a relief valve mounted in the BODY
fuel filter. It provides a constant fuel pressure of 441 kPa
In the 2.5L EFI industrial engine, throttle control is
(64 psi).
achieved by using an electronic governor which is con-
trolled by the engine control module (ECM).
If the pressure is too low, poor performance and a DTC 32
will set. If the pressure is too high, excessive odor and/or a
DTC 42 will result.

When replacing the fuel filter, be sure to use an identical

filter/regulator assembly. A standard fuel filter does not
regulate pressure and could cause engine problems or
component damage.

The electronic governor consists of a throttle body, an

electronically-actuated throttle plate, and a built-in throttle
position (TP) sensor. There are two pigtails that exit the
governor body. The 3-wire pigtail connects the TP sensor
to the ECM. Refer to "Throttle Position (TP) Sensor" for
more information.

FUEL PUMP ELECTRICAL CIRCUIT The 2-wire pigtail carries the throttle signal from the ECM
When the key is first turned "ON," the ECM energizes the to the governor. Desired engine speeds are stored in the
fuel pump relay for two seconds to build up the fuel pres- configuration program for each specific application, and
sure quickly. If the engine is not started within two sec- can be changed with the ECM calibration software. When
onds, the ECM shuts the fuel pump off and waits until the an engine speed is selected with the toggle switch, the
engine is cranked. When the engine is cranked and crank- ECM sends the appropriate signal to the governor. This is
shaft position signal has been detected by the SECM, the a pulse-width modulated (PWM) signal which cannot be
ECM supplies 12 volts to the fuel pump relay to energize read with conventional diagnostic tools such as a voltme-
the electric fuel pump. ter. A 12-volt signal is pulsed on and off at a high rate of
speed. The width of the "on" pulse determines the amount
An inoperative fuel pump will cause a "no-start" condition. of throttle opening. The ECM sends a signal with the
A fuel pump which does not provide enough pressure will appropriate pulse width to the governor based on the
result in poor performance. operator's choice of switch settings.

FUEL RAIL The electronic governor also acts as an idle air control
The fuel rail is mounted to the top of the engine and dis- (IAC) valve. Changes in engine load are detected by the
tributes fuel to the individual injectors. Fuel is delivered to ECM by comparing manifold absolute pressure (MAP)
the fuel inlet tube of the fuel rail by the fuel lines. with throttle position. When the ECM detects a change in
engine load, it can adjust idle speed by changing the
PWM signal to the governor.

3-78 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

OPEN LOOP AND CLOSED LOOP OPERATION CRANKSHAFT POSITION (CKP) SENSOR
The ECM will operate in the following two modes: The crankshaft position (CKP) sensor provides a signal
used by the engine control module (ECM) to calculate the
• Open loop ignition sequence. The sensor initiates the reference
pulses which the ECM uses to calculate RPM and crank-
• Closed loop shaft position.
When the engine is first started, the system is in "open
loop" operation. In open loop, the ECM ignores the signal
from the heated oxygen sensor (HO2S). it uses a pre-pro-
grammed routine to calculate the air/fuel ratio based on
inputs from the TP, ECT, and MAP sensors.

The system remains in open loop until the following condi-

tions are met:

• The HO2S has a varying voltage output showing that it

is hot enough to operate properly (this depends on
temperature).

• The ECT has reached 160°F (71°C).

• Seven minutes has elapsed since starting the engine.

After these conditions are met, the engine is said to be

operating in "closed loop." In closed loop, The ECM con-
tinuously adjusts the air/fuel ratio by responding to signals ELECTRONIC IGNITION
from the HO2S (except at wide-open throttle). When the The electronic ignition system controls fuel combustion by
HO2S reports a lean condition (low sensor signal voltage), providing a spark to ignite the compressed air/fuel w mix-
the ECM responds by increasing the "on" time of the fuel ture at the correct time. To provide optimum engine perfor-
injectors, thus enriching the mixture. When the HO2S mance, fuel economy, and control of exhaust emissions,
reports a rich condition (high sensor signal Voltages the the ECM controls the spark advance of the ignition system.
ECM responds by reducing the "on" time of the fuel injec- Electronic ignition has the following advantages over a
tors, thus leaning out the mixture. mechanical distributor system:

CAMSHAFT POSITION (CMP) SENSOR • No moving parts

The CMP sensor uses a variable reactor sensor to detect
• Less maintenance
camshaft position. The CMP signal is created as piston #1
is a predetermined number of degrees after top dead cen- • Remote mounting capability
ter on the power stroke.
• No mechanical load on the engine

• More coil cooldown time between firing events

• Elimination of mechanical timing adjustments

• Increased available ignition coil saturation time

3121201 – JLG Lift – 3-79

SECTION 3 - CHASSIS & TURNTABLE

IGNITION COIL ENGINE CONTROL MODULE (ECM)

The electronic ignition system uses a coil pack with one The ECM is responsible for maintaining proper spark and
ignition coil for each two cylinders in the engine. Each cyl- fuel injection timing for all operating conditions. To provide
inder is paired with its opposing cylinder in the firing order, optimum operation and emissions, the ECM monitors the
so that one cylinder on compression fires simultaneously input signals from the following components in order to
with the opposing cylinder on exhaust. The spark that calculate spark timing:
occurs in the cylinder on the exhaust stroke is referred to • Engine coolant temperature (ECT) sensor
as a "waste spark."
• Intake air temperature (IAT) sensor
The primary coils in the coil pack are triggered by the • Throttle position sensor
"Ignition Coil Feed #1" and "Ignition Coil Feed #2" Signals
• Crankshaft position sensor
from the ECM.

3-80 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

3.17 FORD LPG SYSTEM Megajector

NOTE: +20° F (-6.6° C) is the low temperature limit for LP The megajector is an electronic pressure regulator. This
gas, for both starting and operation. This applies to electronic regulator outputs a specific pressure needed at
all LP gas powered engines. the mixer to maintain the desired air to fuel ratio. The
megajector accepts LPG vapor at the regulator outlet
pressure (1.5 to 2.5 inches [3.8 to 6.3 cm] of H2O) and
Description reduces it to a pressure value commanded by the EPM.
The LPG system starts at the tank. The liquid propane The pressure command is sent by the EPM over the CAN
exits the tank, flows through the fuel lockoff solenoid, link via the megajector harness. The megajector outlet
flows through the regulator (regulator converts the liquid pressure has units of inches of H2O. The megajector out-
to a vapor), flows through the megajector, flows through let pressure is defined as the difference between the
the mixer and into the engine. megajector outlet gas pressure and the balance line pres-
sure (usually at or near barometric pressure depending on
Regulator air intake restriction). The megajector outlet pressure can
vary between -1.00 to -5.00 inches (-2.5 to -12.7 cm) of
The regulator accepts LPG liquid at tank pressure (min = H2O depending on the speed and load of the engine. The
30 psi; max = 312 psi [min = 207 kPa; max = 2151 kPa]) megajector must be mounted per the 2.5L 2004 Emission
and reduces it to a regulator outlet pressure of 1.5 to 2.5 Installation Instructions. Torque mounting bolts to a maxi-
inches (3.8 to 6.3 cm) of H 2O at idle flow (approx. 750 mum of 60 in.lbs. (7 Nm).
RPM / no load). This regulator must have engine coolant
flowing through it whenever the engine is running. Mixer
The mixer accepts LPG vapor at the megajector outlet
pressure (-1.00 to -5.00 inches [-2.5 to -12.7 cm] of H2O)
and mixes it with clean air. This mixture is then sucked into
the engine via the actuator.

3121201 – JLG Lift – 3-81

SECTION 3 - CHASSIS & TURNTABLE

Megajector

Mixer

Regulator Lockoff Solenoid

3-82 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Lockoff Solenoid DTC 354 - Megajector delivery pressure lower than

expected. This code will set if the difference between the
The lockoff solenoid is used to reduce the possibility of Megajector actual pressure and the Megajector com-
backfires. The EPM controls the opening and closing of manded pressure is less than -4.00 inches (10.1 cm) of
the lockoff so that as a shutdown is commanded, the lock- H2O.
off is closed, but the ignition system continues to operate
to burn off unburned fuel in the manifold. This will cause a. Fuel Supply - Check fuel supply pressure at the
longer than usual start times, because the manifold must megajector inlet fitting. Fuel supply pressure on
fill up with fuel again before the engine will fire. This will LPG applications should be between 3-5" (7.6-
also cause the engine to run for one to two seconds after 12.7 cm) H2O.
ignition is turned off. b. Fuel System Hoses - Make sure all fuel system
hoses are in good condition. They should be
Megajector Diagnostic Code Descriptions clamped tight, free from kinks with no cuts,
pinches, etc.
The following diagnostic codes are specific to the mega-
jector. They will be displayed on the analyzer if the JLG c. Lockoff Solenoid - Check the lock off to make
Control System senses a fault dealing with the megajec- sure it is opening properly. If it is not opening
tor. Refer to Section 6 - JLG Control System for more infor- completely, it could cause low fuel pressure.
mation concerning the Control System. d. Reference Line - Make sure the reference line is
in place between the Megajector and the carbu-
DTC 353 - Megajector delivery pressure higher than
retor balance port. Make sure the hose is not
expected. This code will set if the difference between the
kinked or restricted in any way and has no holes
Megajector actual pressure and the Megajector com-
in it.
manded pressure is greater than 4.00 inches (10.1 cm) of
H2O. e. Regulator - Observe the regulator with the
engine running to see if it is icing up. If it’s icing
a. Fuel Supply - Check fuel supply pressure at the up, refer to Engine Cooling System below.
megajector inlet fitting. Fuel supply pressure on
f. Engine Cooling System - Make sure the engine
LPG applications should be between 3-5" (7.6-
cooling system is operating properly and there
12.7 cm) H2O.
are no air locks in the system. Make sure the
b. Lockoff Solenoid - Check the lockoff to make engine is operating at the proper temperature.
sure it is sealing when closed. If it is not com- Check the coolant hoses at the regulator and
pletely sealing, it could allow pressure creep in make sure they are both warm to verify proper
the fuel system. coolant circulation.
c. Reference Line - Make sure the reference line is If the fuel system is operating properly, the Megajector
in place between the Megajector and the carbu- has an internal failure and must be replaced.
retor balance port. Make sure the hose is not
kinked or restricted in any way and has no holes
in it.
d. Regulator - Observe the regulator with the
engine running to see if it is icing up. If it’s icing
up, refer to Engine Cooling System below.
e. Engine Cooling System - Make sure the engine
cooling system is operating properly and there
are no air locks in the system. Make sure the
engine is operating at the proper temperature.
Check the coolant hoses at the regulator and
make sure they are both warm to verify proper
coolant circulation.
If the fuel system is operating properly, the Megajector
has an internal failure and must be replaced.

3121201 – JLG Lift – 3-83

SECTION 3 - CHASSIS & TURNTABLE

DTC 355 - Megajector comm. lost. This codes will set if DTC 363 - Megajector Internal Actuator Fault Detection.
the communication (CAN link) between the Megajector
a. Connections - Check power, ground, and CAN
and the EPM is not present.
circuits at the Megajector in addition to all elec-
a. CAN Circuits - Check CAN circuits for continuity trical connections. Repair as necessary and
and shorts to power or ground and for proper retest.
connections. b. Megajector - Megajector has an internal failure.
If the CAN circuits are ok and all wiring connections are Contact JLG Industries for further assistance.
good, the Megajector has an internal failure and must be DTC 364 - Megajector Internal Circuitry Fault Detection.
replaced.
a. Connections - Check power, ground, and CAN
DTC 361 - Megajector voltage supply high. circuits at the Megajector in addition to all elec-
a. Voltage - Check battery voltage. If the voltage at trical connections. Repair as necessary and
the battery is greater than 18 volts, either the retest.
charging system or the megajector is faulty. b. Megajector - Megajector has an internal failure.
DTC 362 - Megajector voltage supply low. Contact JLG Industries for further assistance.
DTC 365 - Megajector Internal Comm Fault Detection.
a. Voltage - Check battery voltage. If the voltage at
the battery is less than 9.5 volts: a. Connections - Check power, ground, and CAN
The battery is faulty circuits at the Megajector in addition to all elec-
trical connections. Repair as necessary and
or retest.
The charging system is faulty Megajector - Megajector has an internal failure. Contact
or JLG Industries for further assistance.
The Megajector is faulty.

3-84 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-55. Deutz Sensors for JLG Control System

3121201 – JLG Lift – 3-85

SECTION 3 - CHASSIS & TURNTABLE

3.18 DEUTZ EMR 2 (S/N 84711 TO PRESENT) The EMR2 is equipped with safety devices and measures
in the hardware and software in order to ensure emer-
The EMR2 consists of the sensors, the control unit and the gency running (Limp home) functions.
actuator. Engine-side controls as well as the JLG Control In order to switch the engine off, the EMR2 is switched in a
System are connected by means of separate cable har- de-energized fashion over the ignition switch. A strong
nesses to the EMR control unit. spring in the actuator presses the control rod in the de-
energized condition into the zero position. As a redun-
The sensors attached to the engine provide the electron- dancy measure, an additional solenoid serves for switch-
ics in the control unit with all the relevant physical parame- ing off and this, independently of the actuator, also moves
ters In accordance with the information of the current the control rod in the de-energized condition into the zero
condition of the engine and the preconditions (throttle position.
position etc.), the EMR2 controls an actuator that operates
the control rod of the injection pump and thus doses the After the programming, that is carried out over the
fuel quantity in accordance with the performance require- ISO9141 interface, the EMR2 is possesses a motor-spe-
ments. cific data set and this is then fixedly assigned to the
engine. Included in this are the various application cases
The exact position of the regulating rod is reported back as well as the customer’s wishes regarding a particular
and, if necessary, is corrected, by means of the control scope of function.
rod travel sensor, situated together with the rotation mag- Each EMR2 module is matched by serial number to the
nets in a housing of the actuator. engine. Modules cannot be swapped between engines.

3-86 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY

COOLANT TEMPERATURE CAMSHAFT SPEED

SENSOR SENSOR

JLG SYSTEM HANDLES ENGINE START/

STOP; EMR2 TAKES CONTROL OF THE
ENGINE AT 700RPM
GLOW PLUG

JLG SYSTEM USES JLG ANALYZER TO

REPORT FAULTS

DIAGNOSIS INTERFACE/CAN-BUS; JLG SYS-

OIL PRESSURE TEM USES THIS TO CONTROL THE ENGINE &
SENSOR FAULT REPORTING.

Figure 3-56. EMR 2 Engine Side Equipment

3121201 – JLG Lift – 3-87

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-57. Deutz EMR 2 Troubleshooting Flow Chart

3-88 – JLG Lift – 3121201

3121201
– JLG Lift –
Figure 3-58. Deutz EMR 2 Vehicle Side Connection Diagram

3-89
SECTION 3 - CHASSIS & TURNTABLE
3-90
SECTION 3 - CHASSIS & TURNTABLE

– JLG Lift –
Figure 3-59. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

3121201
3121201
– JLG Lift –
Figure 3-60. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

3-91
SECTION 3 - CHASSIS & TURNTABLE
SECTION 3 - CHASSIS & TURNTABLE

Figure 3-61. EMR 2 Engine Plug Pin Identification

3-92 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-62. EMR 2 Vehicle Plug Pin Identification

3121201 – JLG Lift – 3-93

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-63. EMR2 Fault Codes - Sheet 1 of 5

3-94 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-64. EMR2 Fault Codes - Sheet 2 of 5

3121201 – JLG Lift – 3-95

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-65. EMR2 Fault Codes - Sheet 3 of 5

3-96 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-66. EMR2 Fault Codes - Sheet 4 of 5

3121201 – JLG Lift – 3-97

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-67. EMR2 Fault Codes - Sheet 5 of 5

3-98 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

3.19 GM ENGINE GENERAL MAINTENANCE • Check ignition coil and spark plug cables for harden-
ing, cracking, chafing, separation, split boot covers
and proper fit
Maintenance of the Drive Belt
• Replace spark plugs at the proper intervals as pre-
The serpentine drive belt utilizes a spring loaded tensioner scribed in the engine manufacturer’s manual
which keeps the belt properly adjusted. The drive belt is
an integral part of the cooling and charging systems and • Check to make sure all electrical components are fitted
should be inspected frequently. securely

When inspecting the belts check for: • Check the ground and platform control stations to
insure all warning indicator lights are functioning
• Cracks or breaks
• Chunking of the belt Checking/Filling Engine Oil Level
• Splits
• Material hanging from the belt
AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED
• Glazing and hardening FULL MARK) CAN CAUSE AN OIL LEAK, A FLUCTUATION OR
DROP IN THE OIL PRESSURE, AND ROCKER ARM "CLATTER" IN
• Damaged or improperly aligned pulleys
THE ENGINE.
• Improperly performing tensioner
Check the belt tensioner by pressing down on the midway
point of the longest stretch between pulleys. The belt
CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL LEVEL.
should not depress beyond 1/2 inch (13mm). If the
OIL LEVEL MUST BE MAINTAINED BETWEEN THE "ADD" MARK
depression is more than allowable adjust the tension.
AND "FULL" MARK ON THE DIPSTICK.

To ensure that you are not getting a false reading, make

THE ENGINE MANUFACTURER DOES NOT RECOMMEND THE USE sure the following steps are taken to before check the oil
OF "BELT DRESSING" OR "ANTI SLIPPING AGENTS" ON THE level.
DRIVE BELT.
1. Stop the engine if in use.

Engine Electrical System Maintenance 2. Allow sufficient time (approximately 5 minutes) for
the oil to drain back into the oil pan.
The engine electrical system incorporates computers and
microprocessors to control the engine ignition, fuel con- 3. Remove the dipstick. Wipe with a clean cloth or
trol, and emissions. Due to the sensitivity of the computers paper towel and reinstall. Push the dipstick all the
to good electrical connections periodic inspection of the way into the dipstick tube.
electrical wiring is necessary. When inspecting the electri-
4. Remove the dipstick and note the oil level.
cal system use the following:
5. Oil level must be between the "FULL" and "ADD"
• Check and clean the battery terminal connections and
marks.
insure the connections are tight
• Check the battery for any cracks or damage to the
case
• Check the Positive and Negative battery cables for any
corrosion build up, rubbing or chafing, check connec-
tion on the chassis to insure they are tight
• Check the entire engine wire harness for rubbing chaf-
ing, cuts or damaged connections, repair if necessary
Figure 3-68. Engine Oil Dip Stick
• Check all wire harness connectors to insure they are
fully seated and locked

3121201 – JLG Lift – 3-99

SECTION 3 - CHASSIS & TURNTABLE

6. If the oil level is below the "ADD" mark, proceed to Coolant Fill Procedure - Dual Fuel Engine
Step 7 and 8 and reinstall the dipstick into the dip-
stick tube.

7. Remove the oil filter cap from the valve rocker arm
DAMAGE TO THE ENGINE COULD OCCUR IF NOT PROPERLY
cover.
FILLED WITH COOLANT. LPG FUELED ENGINES ARE MOST
8. Add the required amount of oil to bring the level up PRONE TO CREATING AN AIR LOCK DURING A COOLANT FILL
to but not over "FULL" mark on the dipstick. OPERATION DUE TO THE ELECTRONIC PRESSURE REGULATOR
(EPR) BEING THE HIGHEST POINT IN THE COOLING SYSTEM. AN
9. Reinstall the oil fill cap to the valve rocker cover and EPR THAT APPEARS TO HAVE FROST FORMING ON IT IS A SIGN
wipe away any excess oil. THAT THE ENGINE COOLING SYSTEM CONTAINS AIR. THE
APPEARANCE AND TEMPERATURE OF THE EPR SHOULD BE
Changing The Engine Oil MONITORED DURING THE COOLANT FILL OPERATION. A WARM
EPR IS AN INDICATION THAT THE COOLING SYSTEM IS PROP-
ERLY FILLED AND FUNCTIONING.

WHEN CHANGING THE OIL, ALWAYS CHANGE THE OIL FILTER.

CHANGE OIL WHEN THE ENGINE IS WARM FROM OPERATION AS
THE OILS WILL FLOW FREELY AND CARRY AWAY MORE IMPU-
RITIES. MAKE SURE ENGINE IS COOL BEFORE PERFORMING ANY MAIN-
TENANCE WORK.
To change the oil use the following steps:
1. Loosen the worm gear clamp on the coolant line
1. Start the engine and run until it reaches normal running into the EPR as shown below and remove
operating temperature. the hose from the EPR. Place a rag under the hose
to prevent coolant from running onto the engine/
2. Stop the engine.
machine.
3. Remove the drain plug and allow the oil to drain.

4. Remove and discard the oil filter and its sealing ring.

5. Coat the sealing ring on the filter with clean engine

oil and wipe the sealing surface on the filter
mounting surface to remove any dust, dirt and
debris. Tighten the filter securely (follow the filter
manufacturers instructions). Do not over tighten.

6. Check the sealing ring on drain plug for any dam-

age, replace if necessary, wipe the plug with a clean
rag, and wipe the sealing surface on the pan and
reinstall the pan plug. Do not over tighten.

7. Fill the crankcase with oil.

8. Start the engine and check for oil leaks.

9. Stop the engine and check the oil level to insure the
oil level is at "FULL".

10. Dispose of the oil and filter in a safe manner.

3-100 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

2. Remove the radiator cap. Fill the radiator with cool- 6. Fill radiator with coolant as needed and install the
ant until coolant starts to appear from the previously radiator cap. Next, remove the cap off the coolant
removed hose at the EPR. Reinstall the hose back recovery bottle and fill just below the HOT FULL line
onto the EPR and continue to fill radiator with cool- and reinstall the caps.
ant.

3.20 GM ENGINE DUAL FUEL SYSTEM

3. With the radiator cap still removed, start the engine
and run until the thermostat opens. The thermostat The Dual Fuel system allows the operator to operate the
opens at 170° F (77° C), which can be checked vehicle on either gasoline or LPG by positioning a selector
using the JLG handheld analyzer. switch in the operator's platform. When the operator
places the selector switch in the gasoline mode the gaso-
line fuel pump is energized. While in the gasoline mode
the LPG fuel lock-off is isolated and will not energize. In
WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRES- addition the gasoline injector circuit is enabled and injec-
ENT COMING FROM THE RADIATOR. THIS IS NORMAL. tor pulses are provided to each injector and the ECM cali-
bration for gasoline is also enabled. When the operator
selects the LPG mode the Low Pressure LPG lock-off is
4. After running the engine for 5 minutes after it has
energized and fuel from the LPG tank flows to the Elec-
reached operating temperature, shut the engine off
tronic Pressure Regulator (EPR). The EPR receives an
and continue to step 5.
electronic signal to position the secondary lever for the
start or run positions and when the engine begins to crank
the mixer air valve will rise and fuel will begin flowing to
WITH THE ENGINE RUNNING OR WHEN SHUTTING OFF THE engine. During this mode the gasoline fuel pump is iso-
ENGINE, SOME HEATED COOLANT MAY SPILL OUT DUE TO AIR lated and will not be activated. The primary components
"BURPING" OUT OF THE SYSTEM WITH THE RADIATOR CAP OFF. of the gasoline dual fuel system are the gasoline tank,
electric fuel pump and filter, fuel supply line, injector rail
and injectors and the fuel pressure regulator. The primary
5. Next, verify that the 2 coolant hoses on the EPR are components of the LPG dual fuel system are the LPG fuel
warm. If they are not warm repeat step 3 and 4, oth- tank, in-fuel filter, LPG Low Pressure lock-off, Electronic
erwise continue to step 6. Pressure Regulator (EPR) and the fuel mixer module. The
LPG fuel system operates at pressures which range from
14.0 inches (355.60 mm) of water column up to 312 psi
(21.5 BAR).
A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM
UPPER RADIATOR HOSE AND A WARM EPR HOSE. IF THE UPPER Components which are shared by both systems include
RADIATOR HOSE AND/OR EPR HOSE ARE NOT WARM TO THE the Electronic Throttle Control and the ECM. The ECM
TOUCH AFTER THE ENGINE HAS RUN FOR 5-8 MINUTES AFTER contains a dual calibration; one controls the gasoline fuel
REACHING OPERATING TEMPERATURE, THE SYSTEM MAY STILL system during gasoline operation and one controls the
CONTAIN AIR. IT MAY BE NECESSARY TO REPEAT THE ABOVE LPG fuel system during LPG operation.
STEPS.

3121201 – JLG Lift – 3-101

SECTION 3 - CHASSIS & TURNTABLE

Fuel Filter EPR Assembly

Propane fuel like all other motor fuels is subject to con- The EPR assembly is a combination Low Pressure Regu-
lator and a Voice Coil Assembly. The Voice coil is an elec-
tamination from outside sources. Refueling of the equip-
tronic actuator which is controlled by an internal
ment’s tank and removal of the tank from the equipment
microprocessor. The microprocessor provides output data
can inadvertently introduce dirt and other foreign matter to the ECM and receives input data over a CAN BUS con-
into the fuel system. It is therefore necessary to filter the nection. The internal microprocessor receives electrical
fuel prior to entering the fuel system components down- signals from the Fuel Pressure Sensor FPS and the Fuel
stream of the tank. An inline fuel filter has been installed in Temperature Pressure FTP and communicates the data to
the fuel system to remove the dirt and foreign matter from the ECM. The ECM uses the FPS and FTP data to calcu-
the fuel. The inline filter is replaceable as a unit only. Main- late the location of the secondary lever in the LPR and
tenance of the filter is critical to proper operation of the sends that data back to the EPR via the CAN BUS. The
fuel system and should be replaced as Section 1. In internal microprocessor in the EPR will then output a sig-
severe operating condition more frequent replacement of nal, which causes the voice coil to move and position the
secondary lever to the correct location.
the filter may be necessary.

Electric Lock Off

The Electric Lock Off device is an integrated assembly.
When energized the solenoid opens the valve and allows
the Propane fuel to flow through the device. The valve
opens during cranking and run cycles of the engine. The
lock off supply voltage is controlled by the engine control
module (ECM).

1. Pressure Regulator Section 4. Primary Test Port

2. Fuel Inlet 5. Secondary Test Port
Figure 3-69. Electric Fuel Lock Off 3. Coolant Passage 6. Voice Coil Section
Figure 3-70. EPR Assembly

3-102 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Low Pressure Regulator (LPR) Air Fuel Mixer

The LPR is a combination vaporizer, pressure regulating The air valve mixer is an air-fuel metering device and is
device. The LPR is a negative pressure, two stage regula- completely self-contained. The mixer is an air valve
tor that is normally closed when the engine is not running. design, utilizing a relatively constant pressure drop to
When the engine is cranking or running, a partial vacuum draw fuel into the mixer from cranking to full load. The
is created in the fuel line which connects the regulator to mixer is mounted in the air stream ahead of the throttle
the mixer. This partial vacuum opens the regulator permit- control device.
ting fuel to flow to the mixer.
When the engine begins to crank, it draws in air with the
Propane fuel enters the primary port of the LPR and air valve covering the inlet, negative pressure begins to
passes through the primary jet and into the primary/ build. This negative pressure signal is communicated to
exchanger chamber. As the propane passes through the the top of the air valve chamber through 4 vacuum ports in
heat exchanger the fuel expands and creates pressure the air valve assembly. A pressure/force imbalance begins
inside the chamber. The pressure rises as the fuel to build across the air valve diaphragm between the air
expands when the pressure rises above 1.5 psi (10.34 valve vacuum chamber and the atmospheric pressure
kpa), sufficient pressure is exerted on the primary dia- below the diaphragm. The air valve vacuum spring is cali-
phragm to cause the diaphragm plate to pivot and press brated to generate from 4.0 inches (101.6 mm) of water
against the primary valve pin thus closing off the flow of column at start to as high as 14.0 inches (355.60 mm) of
fuel. This action causes the flow of fuel into the regulator water column at full throttle. The vacuum being created is
to be regulated. referred to as Air Valve Vacuum (AVV). As the air valve
vacuum reaches 4.0 inches (101.6mm) of water column,
When the engine is cranking, sufficient vacuum will be
the air valve begins to lift against the air valve spring. The
introduced into the secondary chamber from the mixer
amount of AVV generated is a direct result of the throttle
drawing the secondary diaphragm down onto the spring
position. At low engine speed the air valve vacuum is low
loaded lever and opening the secondary valve allowing
and the air valve position is low thus creating a small ven-
vaporized fuel to pass to the mixer. This mechanical action
turi for the fuel to flow. As the engine speed increase the
in conjunction with the EPR reactions causes the down-
AVV increases and the air valve is lifted higher thus creat-
ward action on the secondary lever causing it to open
ing a much larger venturi. This air valve vacuum is com-
wider allowing more fuel to flow to the mixer.
municated from the mixer venture to the LPR secondary
chamber via the low pressure fuel supply hose. As the
AVV increases in the secondary chamber the secondary
THE VOICE COIL SECTION OF THE EPR ASSEMBLY IS AN EMIS- diaphragm is drawn further down forcing the secondary
SIONS CONTROL DEVICE AND CANNOT BE REBUILT. IF THE COIL valve lever to open wider.
ASSEMBLY FAILS TO OPERATE PROPERLY, REPLACE IT WITH AN
OEM REPLACEMENT PART ONLY.

Figure 3-71. Low Pressure Regulators

Figure 3-72. Air Fuel Mixer

3121201 – JLG Lift – 3-103

SECTION 3 - CHASSIS & TURNTABLE

Electronic Throttle Control (ETC) Engine Control Module

Engine speed and load control is maintained by an ETC To obtain maximum effect from the catalyst and accurate
device. Speed and load control are determined by the
control of the air fuel ratio the emission certified engine is
ECM. Defaults programmed into the ECM software and
throttle position sensors allow the ECM to maintain safe equipped with an onboard computer or Engine Control
operating control over the engine. The Electronic Throttle Unit (ECM). The ECM is a 32 bit controller which receives
Control device or "throttle body assembly" is connected to input data from sensors fitted to the engine and fuel sys-
the intake manifold of the engine. The electronic throttle tem and then outputs various signals to control engine
control device utilizes an electric motor connected to the operation.
throttle shaft. When the engine is running electrical signals
are sent from the equipment controls to the engine ECM One specific function of the controller is to maintain
when the operator depresses an equipment function "closed loop fuel control". Closed loop fuel control is
switch. The ECM then sends an electrical signal to the accomplished when the exhaust gas oxygen sensor
motor on the electronic throttle control to increase or (HEGO) mounted in the exhaust system sends a voltage
decrease the angle of the throttle blade thus increasing or
signal to the controller. The controller then calculates any
decreasing the air/fuel flow to the engine.
correction that may need to be made to the air fuel ratio.
The electronic throttle control device also incorporates The controller then outputs signals to the EPR to correct
two internal Throttle Position Sensors (TPS) which provide the amount of fuel being supplied to the mixer. At the
output signals to the ECM as to the location of the throttle same time the ECM may correct the throttle blade position
shaft and blade. The TPS information is used by the ECM
to correct speed and load of the engine.
to correct speed and load control as well as emission con-
trol.
The controller also performs diagnostic functions on the
fuel system and notifies the operator of malfunctions by
turning on a Malfunction Indicator Light (MIL) mounted in
the Ground Control Station and the Platform Control Sta-
tion. Malfunctions in the system are identified by a Diag-
nostic Code number. In addition to notifying the operator
of the malfunction in the system the controller also stores
the information about the malfunction in its memory.

Figure 3-73. ETC throttle control device

Figure 3-74. LPG Engine Control Unit (ECM)

Figure 3-75. ECM Assembly

3-104 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Heated Exhaust Gas Oxygen Sensor Gasoline Fuel Pump

There are two Heated Exhaust Gas Oxygen Sensors The Gasoline is stored as a liquid in the fuel tank and in
(HEGO). The first HEGO is mounted in the exhaust system drawn into the fuel system by an electric fuel pump. The
downstream of the engine. It is used to measure the fuel pump will receive a signal from the ECM to prime the
amount of oxygen present in the exhaust stream and com- fuel system for approximately 2 seconds prior to start.
municate that to the ECM via an electrical signal. The Priming of the fuel system provides for a quicker start,
amount of oxygen present in the exhaust stream indicates when the engine begins to crank.
whether the fuel/air ratio is too rich or too lean. If the
HEGO sensor signal indicates that the exhaust stream is Gasoline Pressure And Temperature Sensor
too rich the ECM will decrease or lean the fuel mixture dur-
ing engine operation, if the mixture is too lean the ECM Manifold
will richen the mixture. The ECM continuously monitors
This engine is equipped with a fuel injector rail that does
the HEGO sensor output. If a rich or lean condition is pres-
not have a pressure regulator or a return circuit to the fuel
ent for an extended period of time, and the ECM cannot
tank. Fuel pressure for this engine is regulated by the
correct the condition, the ECM will set a diagnostic code
engine’s ECM. The ECM receive fuel pressure and tem-
and turn on the MIL light in control box.
perature feedback from the gasoline fuel sensor manifold
The second HEGO is mounted in the exhaust system after and uses this information to control the ground side of the
the muffler. It measures the amount of oxygen in the fuel pump. Fuel pressure is regulated by the ECM pulse
exhaust system after the catalyst treatment has been com- width modulating (PWM) the fuel pump. The fuel pressure
pleted in the muffler. If the ECM detects that the catalytic and temperature sensor manifold has a return or "bleed"
action in the muffler is not sufficient and fuel correction circuit that connects back to the fuel tank. This circuit is
cannot correct the malfunction the MIL light is illuminated used to bleed off any vapor that develops in the line and
in the control box and a DTC code will stored in the com- return a small amount of fuel to the tank. The fuel comes
puter. from the fuel tank and passes through the fuel pump. Fuel
exits the fuel pump, passes through the filter and then
enters the fuel pressure and temperature manifold assem-
bly. Fuel flows through the feed circuit and is delivered to
THE HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION the fuel injector rail. Fuel that enters the bleed circuits
CONTROL DEVICE. IF THE HEGO FAILS TO OPERATE, REPLACE IT through they bypass valve in the manifold is returned to
WITH AN OEM REPLACEMENT PART. THE HEGO SENSOR IS SEN- the fuel tank.
SITIVE TO SILICONE OR SILICONE BASED PRODUCTS AND CAN
BECOME CONTAMINATED. AVOID USING SILICONE SEALERS OR
HOSES TREATED WITH SILICONE LUBRICANTS IN THE AIR
STREAM OR FUEL LINES.

Figure 3-76. Heated Exhaust Gas Oxygen Sensor

(HEGO)

Gasoline Multi Point Fuel Injection System

(MPFI)
The primary components of the Gasoline Multi Point Fuel
Injection (MPFI) fuel system are the fuel tank, electric fuel Figure 3-77. Gasoline Fuel Pressure and Temperature
pump, fuel pressure and temperature sensor manifold, Manifold Assembly
fuel filter and fuel rail.

3121201 – JLG Lift – 3-105

SECTION 3 - CHASSIS & TURNTABLE

Fuel Filter 3.21 GM ENGINE FUEL SYSTEM REPAIR

After the fuel is drawn into the fuel pump, the fuel flows Propane Fuel System Pressure Relief
through the gasoline fuel filter. The fuel filter will trap small
particles as the fuel passes through the filter to remove
debris and prevents the fuel pressure and temperature
manifold and fuel injectors from becoming damaged. THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
Maintenance of the fuel filter is required as indicated in 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER-
Section 1. SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES-
SURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE
FUEL SYSTEM COMPONENTS.
Fuel Injector Rail
To relieve propane fuel system pressure:
Fuel flows from the fuel pressure and temperature mani-
fold assembly to the fuel rails where the fuel is delivered to 1. Close the manual shut-off valve on the propane fuel
the fuel injectors. The fuel rail also contains a Schrader tank.
valve which is utilized to test the regulated pressure of the
fuel system. 2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.
Fuel Injector
The fuel supply is maintained on the top of the injector RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
from the injector rail. The injector is fed a "pulse" signal SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
through the wire harness which causes the injector to BEFORE DISCONNECTING ANY FUEL LINE.
open. During regular operating conditions the ECM con-
trols the opening and duration of opening of the injector.
During lower RPM operation the injector signals or
Propane Fuel System Leak Test
"pulses" are less frequent then when the engine is operat-
ing at higher RPMs. The engine has been calibrated to
deliver the precise amount of fuel for optimum perfor- NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR PRO-
mance and emission control. PANE FUEL SYSTEM LEAKS.

Always inspect the propane fuel system for leaks after per-
forming service. Check for leaks at the fittings of the ser-
viced or replaced component. Use a commercially
available liquid leak detector or an electronic leak detec-
tor. When using both methods, use the electronic leak
detector first to avoid contamination by the liquid leak
detector.

3-106 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Propane Fuel Filter Replacement 4. Drop the magnet into the bottom of the filter hous-
ing.

5. Install the filter into the housing.

6. Install the retaining bolt into the filter housing.

7. Install the filter up to the bottom of the electric lock

off.

8. Tighten the filter retaining bolt to 106 in lbs (12 Nm).

9. Open manual shut-off valve. Start the vehicle and

leak check the propane fuel system at each serviced
fitting Refer to Propane Fuel System Leak Test.

Electronic Pressure Regulator (EPR)

Assembly Replacement

1. Electric Lock Off Solenoid 7. Electrical Connector

2. Mounting Plate 8. Fuel Outlet
3. Housing Seal 9. O-ring
4. Filter Magnet 10. Filter
5. Filter Housing 11. Fuel Inlet
6. Seal 12. Retaining Bolt
Figure 3-78. Filter Lock Assembly

REMOVAL
1. Relieve the propane fuel system pressure. Refer to
Propane Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing retaining bolt and
remove it. 1. Pressure Regulator Section 4. Primary Test Port
2. Fuel Inlet 5. Secondary Test Port
4. Pull the filter housing from the Electric lock off
3. Coolant Passage 6. Voice Coil Section
assembly.
Figure 3-79. EPR Assembly
5. Locate Filter magnet and remove it.
The EPR assembly is a made up of two separate compo-
6. Remove the filter from the housing.
nents. The Voice Coil Section is not serviceable and can
7. Remove and discard the housing seal. only be replaced as an assembly. The pressure regulator
section is serviceable and will be detailed in this section.
8. Remove and discard the retaining bolt seal.
REMOVAL
9. Remove and discard mounting plate to lock off O-
ring seal. 1. Relieve the propane fuel system pressure. Refer to
Propane Fuel System Pressure Relief.
INSTALLATION
2. Disconnect the negative battery cable.

3. Slowly remove the fuel inlet fitting at the Electric

BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS- Lock Off.
ING BEFORE INSTALLING NEW SEAL.
NOTE: Residual vapor pressure will be present in the fuel
1. Install the mounting plate to lock off O-ring seal. system.
2. Install the retaining bolt seal.
4. Disconnect the electrical connector to the Electric
3. Install the housing seal. Lock off .

3121201 – JLG Lift – 3-107

SECTION 3 - CHASSIS & TURNTABLE

5. Remove the Electric Lock Off from the regulator. 8. Connect the EPR electrical connector.
6. Remove the lock pin from the vapor fitting on the 9. Open the manual valve.
regulator housing and remove the fitting and hose
10. Start the vehicle and leak check the propane fuel
and retain the pin.
system at each serviced fitting Refer to Propane Fuel
7. Remove the lock pin from the pressure sensor on System Leak Test.
the regulator housing and remove the Sensor and
retain the pin.
8. Using a clamp pliers pinch off the hoses on the cool-
ant lines to the regulator
9. Remove the lock pin from both the water fittings on
the regulator housing and remove the fittings and
hoses and retain the pin
10. Disconnect the EPR electrical connector
11. Remove the (3) three nuts from the EPR isolators
and the EPR mounting bracket
Figure 3-80. Pressure Regulator Section
12. Remove the EPR from the bracket
13. Remove the (3) three mounting isolators PRESSURE REGULATOR SECTION REMOVAL

INSTALLATION 1. Remove the EPR refer to EPR Removal Procedure.

2. Remove the six (6) regulator to voice coil screws
using the special tool and separate the regulator
DO NOT USE TEFLON TAPE ON ANY FUEL FITTING. USE A LIQUID from the actuator.
PIPE THREAD SEALANT WHEN INSTALLING FITTINGS.

CHECK ALL THE O-RINGS ON THE VAPOR AND WATER FITTINGS DO NOT REMOVE THE SECONDARY DIAPHRAGM RETAINING
FOR ANY DAMAGE REPLACE IF NECESSARY. PLATE AND DIAPHRAGM THIS WILL VOID THE WARRANTY OF
THE ACTUATOR SECTION.
LUBE ALL THE O -RINGS WITH AN O -RING LUBE BEFORE
INSTALLING. PRESSURE REGULATOR SECTION INSTALLATION

1. Install the three (3) rubber isolators to the bottom of 1. Install the regulator to the actuator section using the
the EPR six (6) retaining screws and tighten 70 in lbs (8 Nm).

2. Install the EPR assembly to the bracket and tighten 2. Install the EPR refer to EPR Installation.
the retaining nuts.

NOTE: Do not over tighten the isolators and cause a separa-

tion of the isolators.

3. Install the fuel temperature sensor into the regulator

opening and lock in place with the locking pin, con-
nect the electrical connector.
4. Insert the fuel vapor line and fitting into the regulator
port and lock in place with the locking pin.
5. Install both the water hoses and fittings into the reg-
ulator and lock in place with the locking pin remove
the clamp pliers from the hoses.
6. Install the electric lock off into the regulator inlet and
tighten into proper location, connect the electrical
connector.
7. Connect the fuel supply line and tighten until fully
seated.

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SECTION 3 - CHASSIS & TURNTABLE

Temperature Manifold Absolute Pressure Electronic Throttle Control Replacement

(TMAP) Sensor See Figure 3-81.

REMOVAL
1. Disconnect the negative battery cable.
2. Remove the air intake duct.
3. Release the hose clamp on the vapor fuel line and
remove the vapor hose.
4. Disconnect the TMAP electrical connector.
5. Disconnect the electronic throttle control connector.
6. Remove the manifold to throttle body adapter bolts
and remove the throttle body mixer assembly.
7. Pull the throttle body assembly from the adapter.
Figure 3-81. (TMAP) Sensor & Electronic Throttle 8. Remove electronic throttle control device.
Control (ETC)
9. Remove the O-rings gasket and discard.

REMOVAL INSTALLATION

1. Disconnect the TMAP electrical connector.

2. Remove the two retaining bolts. LIGHTLY LUBRICATE BOTH THROTTLE CONTROL DEVICE TO
ADAPTER O-RINGS.
3. Remove the TMAP.
1. Install the O-ring on throttle body. Press it down to
INSTALLATION the bottom of the surface.

NOTE: Apply a small amount of O-ring lubricant before

installation.

1. Install in the TMAP.

2. Tighten retaining bolts to 62 lb-in (7 Nm).

3. Start the vehicle and check for proper operation.

3121201 – JLG Lift – 3-109

SECTION 3 - CHASSIS & TURNTABLE

2. Install the two quad seals. Install one seal at a time 4. Place gasket on intake manifold and attach mixer/
to insure the seal does not roll. The seal must sit flat throttle assembly to manifold.
on the throttle body.

Figure 3-82. Mixer Assembly

Mixer Replacement
3. Attach mixer and throttle body together. The two See Figure 3-82.
parts do not bolt together; they will be secured when
you mount it on the intake. Notice the orientation of
the air inlet and throttle body cover. REMOVAL

1. Remove the Throttle control device Refer to Elec-

tronic Throttle Body Replacement.

2. Remove the four (4) bolts to the throttle control

device to mixer adapter bolts.

3. Remove and discard the mixer to adapter gasket.

INSTALLATION

COVER THROTTLE BODY ADAPTER OPENING TO PREVENT

DEBRIS FROM ENTERING ENGINE UNTIL REASSEMBLY.

1. Install Mixer to adapter gasket onto the mixer.

2. Install the mixer to the throttle control device to

mixer adapter and secure with the 4 retaining
screws. Tighten 80 lb-in (9 Nm)

3. Install Throttle body. Refer to Electronic Throttle

Control Device Replacement.

4. Start the engine and leak check all fittings and con-
nections.

3-110 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Coolant Hose Replacement Engine Control Module Replacement

REMOVAL REMOVAL
1. Drain the coolant. 1. Disconnect Negative battery cable.
2. Using hose clamp pliers, disconnect both hose 2. Remove controller from mounting bracket.
clamps on each hose.
3. Push connector lock back to unlock connector.
3. Remove the hose from each of the fittings.
4. Unplug controller and remove.
INSTALLATION
INSTALLATION
NOTE: Use hose material and lengths specified by JLG.

1. Install the hose clamps to each hose and set the

clamp back on each hose to make installation eas- THE CONTROLLER IS CALIBRATED FOR EACH ENGINE VERIFY
ier. YOU HAVE THE CORRECT CONTROLLER
2. Fit the hose to the fittings.
1. Plug connector into controller.
3. Secure by positioning each of the clamps.
2. Push lock into place.
Vapor Hose Replacement 3. Mount controller into mounting bracket.
REMOVAL
4. Reconnect the battery cable.
1. Using hose clamp pliers disconnect both hose
clamps. 5. Start engine.

2. Remove the vapor hose from each fitting. 6. Check for any DTC codes and clear.

INSTALLATION 7. Verify engine is in closed loop and no warning lights

are illuminated.

THE VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED, DO NOT

Heated Exhaust Gas Oxygen Sensor
USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED Replacement
PARTS.
REMOVAL
1. Install hose clamps and set back on each hose.
1. Disconnect Negative battery cable.
2. Reinstall the vapor hose to each fitting.
2. Disconnect the O2 sensor electrical connector.
3. Reset clamps.
3. Using an O2 Sensor socket, remove the O2 Sensor
4. Start engine and check for leaks. and discard.

INSTALLATION

BEFORE INSTALL THE O2 SENSOR LUBRICATE THREADS WITH

ANTI-SEIZE COMPOUND GM P/N 5613695 OR EQUIVALENT.
AVOID GETTING COMPOUND ON THE SENSOR TIP.

1. Install O2 sensor. Tighten to 30 lb-ft (41 Nm).

2. Start engine.

3. Check for any DTC codes and clear.

4. Verify engine is in closed loop and no warning lights

are illuminated.

3121201 – JLG Lift – 3-111

SECTION 3 - CHASSIS & TURNTABLE

3.22 LP GAS FITTING INSPECTION the straight tube fitting and the hood-mounting
bracket, proceed to Step 10. If adequate clearance
DOES NOT EXIST between the straight tube fitting
and the hood-mounting bracket, proceed to Step 7.
USE ALL APPLICABLE SAFETY PRECAUTIONS WHILE WORKING
ON, UNDER, OR AROUND ANY MACHINERY.
ENSURE THE LP GAS SUPPLY AT THE LP TANK IS CLOSED OFF
PRIOR TO PROCEEDING.

DO NOT SMOKE DURING THIS PROCEDURE. 7. As necessary, disassemble the LP gas system
between the lock-off valve and the LP mixer to allow
1. Position the machine on a firm, level surface in a for reorientation of the 1/4” NPT X 1/4” SPT X 90
well-ventilated area free from any heat sources. degree elbow (JLG P/N 70001307).
2. Lower the platform to the stowed position. 8. Properly clean all old thread sealant from the LP gas
fittings.
3. Depress the Emergency Stop button at the ground
control panel and remove the key from the key 9. Apply Permatex Thread Sealant (Permatex P/N
switch. 56525) to the LP gas fittings. Reassemble, allowing
for proper clearance of the hood-mounting bracket
and the LP gas system that was disassembled in
Step 7. Refer to Figure 3-84., Hood Mounting
ENSURE THE ENGINE IS COOL PRIOR TO PERFORMING THIS Bracket Clearance for proper clearance. Properly
INSPECTION. tighten all LP gas connections.

4. Locate the 2-1/2” straight fitting between the LP gas

lockoff valve and the LP gas mixer. Refer to Figure 3-
83., LP Gas Fitting Components.

Make sure there is a minimum of 0.5 inches (13 mm) clearance

between the hood mounting bracket and the straight tube fitting.

Figure 3-84. Hood Mounting Bracket Clearance

1. LP Gas Lockoff Valve
2. 1/4" NPT x 2-1/2" Straight Fitting 10. Check the LP system for evidence of leaks. If any
3. 1/4" NPT x 1/4" SPT x 90 Degree Elbow leaks are detected, properly repair them prior to
4. Hood Mounting Bracket returning the unit to service.

Figure 3-83. LP Gas Fitting Components

5. Refer to Figure 3-83., LP Gas Fitting Components

and ensure that the hood-mounting bracket does
not interfere with the 1/4“ NPT X 2-1/2” straight tube
fitting (JLG P/N 70001531).

6. Refer to Figure 3-84., Hood Mounting Bracket Clear-

ance. If adequate clearance DOES EXIST between

3-112 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

3.23 GM ENGINE LPG FUEL SYSTEM Diagnostic Aids

DIAGNOSIS This procedure is intended to diagnose a vehicle operat-
ing on LPG. If the vehicle will not continue to run on LPG,
Fuel System Description refer to Hard Start for preliminary checks. Before proceed-
ing with this procedure, verify that the vehicle has a suffi-
cient quantity of fuel and that liquid fuel is being delivered
to the LPR. Also, ensure that the manual shut off valve on
the LPG tank is fully opened and that the excess flow valve
has not been activated.
Tools Required:
• 7/16 Open end wrench (for test port plugs)
• DVOM (GM J 39200, Fluke 88 or equivalent).
• 12 volt test light
Diagnostic Scan Tool
• Diagnostic Display tool.
Figure 3-85. EPR Assembly
Pressure Gauges
• IMPCO ITK-2 Test kit
To maintain fuel and emission control on the LPG fuel sys-
tem the Engine Control Units (ECM) relies on numerous • Water Column Gauge / Manometer (GM 7333-6 or
engine sensor and output data from the Electronic Pres- equivalent).
sure Regulator (EPR). The ECM will then determine the • 0-10 PSI Gauge
target fuel calibration and command the EPR to reposition
Test Description
the voice coil to the proper position which, subsequently
reposition the secondary lever in the pressure regulator to The numbers below refer to step numbers on the diagnos-
maintain proper control. The EPR and ECM will continue tic table.
to communicate back and forth during normal operation.
5. This step determines if the LPR requires replacement
In the event that the EPR fails to communicate or the Com- 6. This step determines if the problems are in the mechan-
munications Area Network (CAN) cable fails to transmit ical side of the Pressure Regulator or the Electronic Voice
data the regulator will operate in an open loop configura- Coil
tion. As the air valve vacuum in the mixer venturi is com-
10. This step determines if the Mixer requires replacement
municated to the secondary chamber of the regulator the
secondary diaphragm will be drawn in a downwards 14. This step determines if the Lock Off requires replace-
motion. This downward motion will cause the secondary ment
lever to open thus allowing more fuel to enter the mixer.
17. This step determines if the Fuel Filter requires replace-
In the (LPR) the fuel is vaporized and the pressure ment.
reduced in two stages. The first stage reduces the pres-
sure to approximately 1.0 to 3.0 psi (6.8 to 20.6 kPa). The
second stage reduces the pressure to approximately neg-
ative 1.5" of water column.

The fuel is then drawn from the secondary chamber of the

LPR by the vacuum generated by air flowing through the
mixer. This vacuum signal is also used to generate lift for
the mixer air valve. This vacuum signal is most commonly
referred to as air valve vacuum. In the mixer, the fuel mixes
with the air entering the engine. This air/ fuel mixture is
then drawn into the engine for combustion.

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SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. LPF Fuel System Diagnosis

STEP ACTION VALUE(S) YES NO

1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2
2 Perform the On Board Diagnostic (OBD) System Check. -- Gotothe Go to Step 3
Are any DTCs present in the ECM? applicable DTC Table
3 Verify that the LPG fuel tank has a minimum of 1/4 tank of fuel, that the manual -- Go to Step 4 --
valve is open and the tank quick connect is fully engaged
Does the vehicle have fuel?
4 1. Connect a water column gauge or a manometer to the secondary test port of -- Go to Step 5 Go to Step 8
the low pressure regulator (LPR).
2. Start the engine and allow it to reach operating temperature.
Does the engine start and run?
5 With the engine idling, observe the pressure reading for the LPR secondary -1.0" to Go to Step 25 Go to Step 6
pressure. -2.0" w.c
Does the fuel pressure fluctuate rhythmically OUTSIDE the specified range?
6 1. Disconnect the EPR electrical connectors. NOTE: This action will cause a -1.0" to Go to Fuel Control Go to Step 7
DTC to be set by the ECM -2.0" w.c System Diagnosis
2. With the engine idling observe the pressure reading on the secondary test
port.
Is the fuel pressure WITHIN the specified range?
7 1. Inspect the air intake stream between the mixer assembly and the throttle -- Go to Step 26 Go to Step 22
body for leaks.
2. Inspect the fuel hose connection between the LPR and mixer assembly for
damage or leakage.
3. Inspect any vacuum hoses for leaks
Was a problem found and corrected?
8 1. Connect a water column gauge or a manometer to the secondary test port of -- Go to Step 12 Go to Step 9
the low pressure regulator (LPR).
2. Crank the engine and observe the pressure reading for the LPR secondary
pressure.
Does the fuel pressure indicate a vacuum is present?
9 1. Remove Air induction hose to the mixer -- Go to Step 11 Go to Step 10
2. Observe the air valve for movement while the engine is cranking. Note: Move-
ment of the air valve will be minimal at cranking speeds.
Does the air valve move when the engine is cranked?
10 1. Inspect the air intake stream to the mixer assembly and the throttle body for -- Go to Step 26 Go to Step 24
vacuum leaks.
2. Inspect the vacuum hoses from the mixer for proper connection and condition.
Was a problem found and repaired?
11 Inspect the fuel hose connection between the LPR and the mixer assembly for -- Go to Step 26 Go to Step 12
damage or leakage.
Was a problem found and repaired?
12 1. Connect a 0-10 psi gauge to the primary test port of the low pressure regulator 1- 3 PSI Go to Step 22 Go to Step 13
(LPR).
2. Crank the engine and observe the pressure reading for the LPR primary pres-
sure.
Is the fuel pressure ABOVE the specified value?

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SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. LPF Fuel System Diagnosis

STEP ACTION VALUE(S) YES NO

13 1. Turn OFF the ignition. -- Go to Step 14 Go to Step 16
2. Disconnect the LPL connector.
3. Install a test light between the pins of the LPL connector.
4. Crank the engine. The test light should illuminate.
Does the test light illuminate?
14 Using a DVOM, check the resistance of the low pressure lock-off (LPL). 12W - 16W Go to Step 15 Go to Step 23
Is the resistance within the specified range?
15 1. Turn the ignition OFF. -- Go to Step 23 Go to Step 17
2. Close the manual shut-off valve on the LPG tank.
CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present. Per-
form this step in a well ventilated area.
3. Loosen the fuel inlet hose fitting at the inlet of the LPL.
Was fuel present when the fitting was loosened?
16 1. Turn OFF the ignition. -- Go to Step 20 Go to Step 21
2. Connect the test light to chassis ground and probe pin A of the LPL connector.
3. Crank the engine. The test light should illuminate.
Does the test light illuminate?
17 1. Remove the LPG fuel filter / LPL. -- Go to Step 19 Go to Step 18
2. Remove the filter from the LPL.
3. Empty the contents of the inlet side of the LPG fuel filter onto a clean surface.
4. Inspect the contents of the LPG fuel filter for an excessive amount of foreign
material or water. If necessary, locate and repair the source of contamination.
5. Verify the LPG fuel filter is not restricted or plugged.
Was a problem found?
18 The fuel supply system or hoses are plugged or restricted, locate and repair the -- Go to Step 26 --
problem.
Is the action complete?
19 Replace the fuel filter. Refer to Fuel Filter Replacement. -- Go to Step 26 --
Is the action complete?
20 Repair the open in the lock-off ground circuit. -- Go to Step 26 --
Is the action complete?
21 Repair the open in the lock-off power circuit. -- Go to Step 26 --
Is the action complete?
22 Replace the low pressure regulator (LPR). Refer to Low Pressure Regulator -- Go to Step 26 --
Replacement.
Is the action complete?
23 Replace the lock-off. Refer to Lock-off Replacement. -- Go to Step 26 --
Is the action complete?
24 Replace the mixer assembly. Refer to Fuel Mixer Replacement. -- Go to Step 26 --
Is the action complete?

3121201 – JLG Lift – 3-115

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. LPF Fuel System Diagnosis

STEP ACTION VALUE(S) YES NO

25 The fuel supply system is operating normally, if a failure of the control solenoids is -- System OK --
suspected. Refer to Fuel Control System Diagnosis.

1. Install the test plug in the LPR secondary chamber.

2. If you were sent to this routine by another diagnostic chart, return to the previ-
ous diagnostic procedure.
Is the action complete?
26 1. Disconnect all test equipment -- System OK --
2. Install the primary and secondary test port plugs.
3. Start the engine.
4. Using SNOOP or equivalent, leak check the test port plugs.
Is the action complete?

3-116 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Table 3-13. Symptom Diagnosis

Checks Action
Important Preliminary Checks
Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL.

Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks
are very important. The checks can lead to correcting a problem without further checks that may save valuable time.
LPG Fuel System Check 1. Verify the customer complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich.

IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at
that time.
Visual and Physical Checks Check all ECM system fuses and circuit breakers.
Check the ECM ground for being clean, tight and in its proper location.
Check the vacuum hoses for splits, kinks and proper connections.
Check thoroughly for any type of leak or restriction.
Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
Check for proper installation of the mixer module assembly.
Check for air leaks at the mixer assembly.
Check the ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
Check the wiring for the following items:
- Proper connections, pinches or cuts.
The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is
not important. If the scan tool readings do not indicate the problems, then proceed in a logical order, easiest to check or
most likely to cause first.
Intermittent
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks Refer to Important Preliminary Checks.
Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good
parts.
Faulty Electrical Connections or Faulty electrical connections or wiring can cause most intermittent problems.
Wiring Check the suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient.
Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If nec-
essary, replace all the connector terminals in the problem circuit in order to ensure the proper contact tension.
Checking for poor terminal to wire connections requires removing the terminal from the connector body.
Operational Test If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the prob-
lem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit.

3121201 – JLG Lift – 3-117

SECTION 3 - CHASSIS & TURNTABLE

Table 3-13. Symptom Diagnosis

Table 3-13. Symptom Diagnosis

Checks Action
Engine Mechanical Check Check the engine for the following:
- Broken motor mounts
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
Surges/Chuggles
DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accel-
erator pedal.
Preliminary Checks Refer to Important Preliminary Checks.
Sensor Checks Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
Fuel System Checks Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring
the oxygen sensors will help identify the problem.
Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis.
Verify proper fuel control solenoid operation.
Verify that the LPG manual shut-off valve is fully open.
Check the in-line fuel filter for restrictions.
Ignition System Checks Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
Verify that the spark plugs are correct for use with LPG (R42LTS)
Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
- Check the Crankshaft Position (CKP) sensor.
Additional Check Check the ECM grounds for being clean, tight, and in their proper locations.
Check the generator output voltage.
Check the vacuum hoses for kinks or leaks.
Check Transmission

3-124 – JLG Lift – 3121201

SECTION 3 - CHASSIS & TURNTABLE

Table 3-14. DTC to SPN/FMI Cross Reference Chart

DTC Description SPN Code FMI Code

16 Crank Never Synced at Start 636 8
91 Fuel Pump Low Voltage 94 4
92 Fuel Pump High Voltage 94 3
107 MAP Low Voltage 106 4
108 MAP High Pressure 106 16
111 IAT Higher Than Expected 1 105 15
112 IAT Low Voltage 105 4
113 IAT High Voltage 105 3
116 ECT Higher Than Expected 1 110 15
117 ECT Low Voltage 110 4
118 ECT High Voltage 110 3
121 TPS 1 Lower Than TPS 2 51 1
122 TPS 1 Signal Voltage Low 51 4
123 TPS 1 Signal Voltage High 51 3
127 IAT Higher Than Expected 2 105 0
129 BP Low Pressure 108 1
134 EGO 1 Open/Inactive 724 10
154 EGO 2 Open/Inactive 520208 10
171 Adaptive Learn High Gasoline 520200 0
172 Adaptive Learn Low Gasoline 520200 1
182 Fuel Temp Gasoline Low Voltage 174 4
183 Fuel Temp Gasoline High Voltage 174 3
187 Fuel Temp LPG Low Voltage 520240 4
188 Fuel Temp LPG High Voltage 520240 3
217 ECT Higher Than Expected 2 110 0
219 Max Govern Speed Override 515 15
221 TPS 2 Signal Voltage Low 51 0
222 TPS 2 Signal Low Voltage 520251 4
223 TPS 2 Signal High Voltage 520251 3
261 Injector Driver 1 Open 651 5
262 Injector Driver 1 Shorted 651 6
264 Injector Driver 2 Open 652 5
265 Injector Driver 2 Shorted 652 6
267 Injector Driver 3 Open 653 5
268 Injector Driver 3 Shorted 653 6
270 Injector Driver 4 Open 654 5
271 Injector Driver 4 Shorted 654 6
336 Crank Sync Noise 636 2
337 Crank Loss 636 4
341 Cam Sync Noise 723 2
342 Cam Sensor Loss 723 4
420 Gasoline Cat Monitor 520211 10
524 Oil Pressure Low 100 1

3121201 – JLG Lift – 3-125

SECTION 3 - CHASSIS & TURNTABLE

Table 3-14. DTC to SPN/FMI Cross Reference Chart

DTC Description SPN Code FMI Code

562 System Voltage Low 168 17
563 System Voltage High 168 15
601 Flash Checksum Invalid 628 13
604 RAM Failure 630 12
606 COP Failure 629 31
642 External 5V Reference Low 1079 4
643 External 5V Reference High 1079 3
685 Power Relay Open 1485 5
686 Power Relay Shorted 1485 4
687 Power Relay Short to Power 1485 3
1111 Fuel Rev Limit 515 16
1112 Spark Rev Limit 515 0
1151 Closed Loop Multiplier High LPG 520206 0
1152 Closed Loop Multiplier Low LPG 520206 1
1155 Closed Loop Multiplier High Gasoline 520204 0
1156 Closed Loop Multiplier Low Gasoline 520204 1
1161 Adaptive Learn High LPG 520202 0
1162 Adaptive Learn Low LPG 520202 1
1165 LPG Cat Monitor 520213 10
1171 LPG Pressure Higher Than Expected 520260 0
1172 LPG Pressure Lower Than Expected 520260 1
1173 EPR Comm Lost 520260 31
1174 EPR Voltage Supply High 520260 3
1175 EPR Voltage Supply Low 520260 4
1176 EPR Internal Actuator Fault 520260 12
1177 EPR Internal Circuitry Fault 520260 12
1178 EPR Internal Comm Fault 520260 12
1612 RTI 1 loss 629 31
1613 RTI 2 Loss 629 31
1614 RTI 3 Loss 629 31
1615 A/D Loss 629 31
1616 Invalid Interrupt 629 31
1625 Shutdown Request 1384 31
1626 CAN Tx Failure 639 12
1627 CAN Rx Failure 639 12
1628 CAN Address Conflict Failure 639 13
1629 Loss of TSC 1 639 31
2111 Unable to Reach Lower TPS 51 7
2112 Unable to Reach Higher TPS 51
2135 TPS 1/2 Simultaneous Voltages 51 31
2229 BP Pressure High 108 0

3-126 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

4.1 WEAR PADS Tower Boom

1. Shim up wear pads until snug to adjacent surface.

2. Replace wear pads when worn within 1/16 inch (1.59

mm) of threaded insert.

3. When adjusting wear pads, removing or adding

shims, bolt length must also be changed.

a. When adding shims, longer bolts must be used

to ensure proper thread engagement in insert.
b. When shims are removed, shorter bolts must be
used so bolt does not protrude from insert and
come into contact with boom surface.

Main Boom
1. Shim up wear pads to within 1/32 inch (.79 mm) tol-
erance between wear pad and adjacent surface.

2. Replace wear pads when worn within 1/16 inch (1.59

mm) and 1/8 inch (3.18 mm) - B, C, D of threaded
insert. See Location and Thickness Of Wear Pads.

3. Adjusting wear pads, removing or adding shims,

bolt length must also be changed.

a. When adding shims, longer bolts must be used

to ensure proper thread engagement in insert.
b. When shims are removed, shorter bolts must be
used so bolt does not protrude from insert and
come into contact with boom surface.

Figure 4-1. Location and Thickness of Wear Pads

3121201 – JLG Lift – 4-1

SECTION 4 - BOOM & PLATFORM

Figure 4-2. Boom Powertrack Installation

4-2 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

4.2 BOOM MAINTENANCE f. Tag and disconnect hydraulic lines to slave level-
ing cylinder. Use suitable container to retain any
residual hydraulic fluid. Cap hydraulic lines and
Removal ports. Remove slave cylinder.
1. For platform/support removal see platform/support
removal diagram. (Boom Maintenance. S Models).

2. Remove rotator and slave level cylinder from fly

boom as follows:

a. Tag and disconnect hydraulic lines to rotator.

Use suitable container to retain any residual
hydraulic fluid. Cap hydraulic lines and ports.
b. Remove hardware from pin #1. Using a suitable
brass drift and hammer remove pin #1 from the
fly boom.
c. Supporting the rotator, remove hardware from
pin #2. Using a suitable brass drift and hammer
remove pin #2 from the fly boom and remove
rotator.
d. Telescope boom fly section out approximately
20 inches (50.8 cm) to gain access to slave lev-
eling cylinder. (600AJ Model)
e. Supporting the slave cylinder, remove the hard-
ware from pin #3. Using a suitable brass drift
and hammer, remove pin #3 from the fly boom.

Figure 4-3. Reassembly of Components - Rotator and

Slave Leveling Cylinder

3. Remove powertrack from boom as follows:

a. Disconnect wiring harness connectors located in

tower upright.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-

ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON-
TAMINANTS INTO SYSTEM.

b. Tag and disconnect hydraulic lines from connec-

tors at boom assembly. Use suitable container
to retain any residual hydraulic fluid. Cap
hydraulic lines and ports.
c. Disconnect dual capacity indicator limit switch
from side of boom section.
d. Remove hydraulic lines and electrical cables
from powertrack.
e. Using suitable lifting equipment, adequately
support powertrack weight along entire length.

3121201 – JLG Lift – 4-3

a. Tag and disconnect hydraulic lines to upper lift

cylinder. Use suitable container to retain any
residual hydraulic fluid. Cap hydraulic lines and
ports.
b. Using suitable lifting device, support the upper
lift cylinder.
c. Remove mounting hardware from upper lift cyl-
inder barrel end. Using a suitable brass drift and Figure 4-5. Location of Components - Upright
hammer remove pin #1 from tower upright.
d. Tag and disconnect hydraulic lines to master cyl- 2. Remove the tower boom as follows:
inder. Use a suitable container to retain any
residual hydraulic fluid. Cap hydraulic lines and
ports. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
e. Remove mounting hardware from master cylin- ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON-
der barrel end. Using a suitable brass drift and TAMINANTS INTO SYSTEM.
hammer remove pin #2 from tower upright.
f. Disconnect wiring hardness to horizontal limit a. Tag and disconnect all hydraulic lines from the
switch and dual capacity limit switch. tower boom assembly to turntable components.
Use suitable container to retain any residual
g. Using a suitable lifting device, support the tower
hydraulic fluid. Cap hydraulic lines and ports.
upright.
b. Disconnect wiring harness from the ground con-
h. Remove mounting hardware securing hose
trol box.
bracket in tower upright, remove hose bracket.
c. Using suitable lifting device, support the tower
i. Remove mounting hardware from tower leveling
boom assembly at it’s approximate center of
cylinder. Using a suitable brass drift and ham-
gravity.
mer remove pin #3 from tower upright.
d. Remove mounting hardware from lower lift cylin-
j. Remove mounting hardware from upright pivot
der rod end. Using a suitable brass drift and
pin. Using a suitable brass drift and hammer,
hammer, remove pin #1 from the tower boom
assembly.
e. Remove mounting hardware from tower boom
pivot pin. Using a suitable brass drift and ham-
mer, remove pin #2 from the turntable assembly.

4-6 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

f. Remove tower boom assembly from turntable 7. Remove mounting hardware which secures the wear
upright. Place tower boom assembly on a well pads to front of tower base boom section; remove
supported trestles. the wear pads from the top, sides and bottom of the
tower base boom.
8. Using an overhead crane or suitable lifting device,
remove fly assembly from base section.
9. Remove mounting hardware which secures the
tower telescope cylinder to the fly section. Using a
suitable brass drift and hammer, remove the pin
from the fly boom section.
10. Remove mounting hardware which secures the wear
pads to aft end of tower fly boom section; remove
the wear pads from the top, sides and bottom of the
fly boom.
11. Remove mounting hardware which secures the
upright leveling cylinder to the fly section. Using a
suitable brass drift and hammer, remove the pin
from the fly boom section.
12. Remove hardware which secures the wear pads to
Figure 4-6. Location of Components - Tower Boom the aft end of fly tower boom section; remove the
wear pads from the top, sides and bottom of the fly
boom section.
Disassembly
1. Remove brackets securing hoses and wiring har-
nesses to push tubes and top of tower boom assem-
bly.

2. Mark all hoses and wiring harnesses at bracket on

aft end of tower base boom section for future
assembly. Remove hoses and wiring harness from
tower boom powertrack.

3. Remove mounting hardware which secures the

push tubes to the tower fly boom section.

Removal NOTE: When inspecting pins and bearings refer to Section 2
- General.
1. For platform/support removal see platform/support
removal diagram. Position the articulating jib boom 1. Inspect articulating fly boom pivot pin for wear, scor-
level with ground. ing, tapering and ovality, or other damage. Replace
pins as necessary.
2. Remove mounting hardware from slave leveling cyl-
inder pin #1. Using a suitable brass drift and ham- 2. Inspect articulating fly boom pivot attach points for
mer, remove the cylinder pin from articulating jib scoring, tapering and ovality, or other damage.
boom. Replace pins as necessary.
3. Inspect inner diameter of articulating fly boom pivot
bearings for scoring, distortion, wear, or other dam-
age. Replace bearings as necessary.
4. Inspect lift cylinder attach pin for wear, scoring,
tapering and ovality, or other damage. Ensure pin
surfaces are protected prior to installation. Replace
pins as necessary.
5. Inspect inner diameter of rotator attach point bear-
ings for scoring, distortion, wear, or other damage.
Replace bearing as necessary.
6. Inspect all threaded components for damage such
Figure 4-8. Location of Components - Articulating Jib
as stretching, thread deformation, or twisting.
Boom
Replace as necessary.
3. Remove mounting hardware from articulating jib 7. Inspect structural units of articulating jib boom
boom pivot pin #2. Using a suitable brass drift and assembly for bending, cracking, separation of
hammer, remove the pivot pin from boom assembly. welds, or other damage. Replace boom sections as
necessary.
Disassembly
1. Remove mounting hardware from articulating jib Assembly
boom pivot pins #3 and #4. Using a suitable brass
NOTE: For location of components See Section 4-8., Loca-
drift and hammer, remove the pins from articulating
tion of Components - Articulating Jib Boom.
jib boom pivot weldment.
2. Remove mounting hardware from rotator support 1. Align lift cylinder with attach holes in articulating jib
pins #5 and #6. Using a suitable brass drift and boom. Using a soft head mallet, install cylinder pin
hammer, remove the pins from rotator support. #7 into articulating jib boom and secure with mount-
ing hardware.
3. Remove mounting hardware from lift cylinder pin
#7. Using a suitable brass drift and hammer, remove 2. Align rotator support with attach hole in articulating
the cylinder pin from articulating jib boom. jib boom. Using a soft head mallet, install rotator
support pin #6 into articulating jib boom and secure
with mounting hardware.

4-10 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

3. Align bottom tubes with attach holes in rotator sup-

port. Using a soft head mallet, install rotator support
pin #5 into articulating jib boom and secure with
mounting hardware.
4. Align articulating jib boom with attach hole in articu-
lating jib boom pivot weldment. Using a soft head
mallet, install rotator support pin #4 into articulating
jib boom and secure with mounting hardware.
5. Align bottom tubes with attach holes in articulating
jib boom pivot weldment. Using a soft head mallet,
install rotator support pin #3 into articulating jib
boom pivot weldment and secure with mounting
hardware.
6. Align articulating jib boom pivot weldment with
attach holes in fly boom assembly. Using a soft head
mallet, install pivot pin #2 into fly boom assembly
and secure with mounting hardware.
7. Align the slave leveling cylinder with attach holes in
articulating jib boom pivot weldment. Using a soft
head mallet, install slave leveling cylinder pin #1
into articulating jib boom pivot weldment and secure
with mounting hardware.

4.6 LIMIT SWITCHES AND CAM VALVE

ADJUSTMENT
Adjust switches and cam valve as shown in Figure 4-9.,
Boom Limit Switch Adjustments.

3121201 – JLG Lift – 4-11

SECTION 4 - BOOM & PLATFORM

DUAL CAPACITY SWITCH TO ACTIVATE WHEN BOOM IS LOWERED TO 50°,

+5° -0°. SWITCH TO RESET WHEN BOOM IS RAISED TO 60°, +5° -0°.

SWITCH TO ACTIVATE WHEN BOOM IS 126 ± 1"

(320 ± 2.5 CM) FROM BEING FULLY EXTENDED

SWITCH TO ACTIVATE WHEN BOOM

REACHES 0° TO 5° ABOVE HORIZONTAL.
SWITCH TO RESET WHEN BOOM IS
LOWERED 4°TO 9° BELOW HORIZONTAL.

NOTE: ADJUST SCREWS SO THAT PLUNGER ON

VALVES HAS 0.25" (6.35 mm) TRAVEL REMAIN-
ING WHEN LOWER BOOM IS FULLY RAISED AND
RETRACTED
SWITCH TO ACTIVATE WHEN
UPRIGHT IS RAISED TO 40° - 42°
FROM STOWED POSITION. SWITCH
TO RESET WHEN UPRIGHT IS LOW-
ERED 25° TO 30° FROM ACTIVATED
POSITION.

PLUNGER VALVE TO ACTIVATE WHEN BOOM IS

RAISED BETWEEN 76° - 79°
NOTE: ADJUST SCREWS SO THAT PLUNGER ON VALVES HAS
0.25" (6.35 mm) TRAVEL REMAINING WHEN LOWER BOOM IS
FULLY RAISED AND RETRACTED

Figure 4-9. Boom Limit Switch Adjustments

4-12 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

SWITCH TO ACTIVATE WHEN BOOM IS 126 ± 1"

(320 ± 2.5 CM) FROM BEING FULLY EXTENDED

Figure 4-10. Fiberglass Bar Installation

3121201 – JLG Lift – 4-13

SECTION 4 - BOOM & PLATFORM

4.7 PLATFORM 3. Using a suitable hammer and chisel remove the por-
tion of end cap securing setscrew.
Platform Sections Replacement
The platform is made up of five sections: floor, right side,
left side, back (console box mounting.) and gate. The sec-
tions are secured with huck magna grip fastener and col-
lars. Replace damaged platform sections as follows:
1. Support the huck collar with a sledge hammer or
other suitable support.
2. Using a hammer and chisel, remove the collar from
the fastener as shown in the diagram below.

Figure 4-13. Removing Portion of End Cap

4. Using a torch, apply heat to the setscrews on the

bottom of actuator.

Figure 4-11. Platform Section Replacement

3. When installing new section of platform replace

huck fasteners with 1/4 x 20 NC x 2 1/4" grade 5
bolts, flatwashers and locknuts.
4. When installing a new gate to platform, replace riv-
ets with 1/4 x 20 NC x 2 “grade 5 bolts, flatwashers
and locknuts.

4.8 ROTATOR - HELAC (PRIOR TO S/N Figure 4-14. Heating Setscrew

0300132474)
5. Remove the two (2) setscrew (4) from bottom of
actuator (1). Discard setscrew.
Disassembly
1. Place actuator on a clean workbench.
2. Remove all hydraulic fittings.

Figure 4-15. Removing Setscrew

4-14 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

Figure 4-12. Rotator Assembly (Helac)

3121201 – JLG Lift – 4-15

SECTION 4 - BOOM & PLATFORM

6. Place two (2) 3/8"x16NC bolts in threaded holes in 8. Remove piston sleeve (3) from housing (1).
bottom of the actuator. Using a suitable bar, unscrew
the end cap (5). Remove the end cap from actuator
(1).

Figure 4-18. Removing Sleeve from Housing

Figure 4-16. Removing End Cap 9. Remove all seals and bearings from grooves. Dis-
card seals.
7. Remove the shaft (2) from piston sleeve (3) and the
actuator housing (1). Inspection
1. Clean all parts thoroughly.
2. Closely inspect all parts for excessive wear, cracks
and chips. Replace parts as necessary.

NOTE: A small amount of wear in the spline teeth will have

little effect on the actuator strength. New spline sets
are manufactured with a backlash of about 0.005 in.
per mating set. After long service, a backlash of
about 0.015 per set may still be acceptable in most
cases, depending on the required accuracy of the
application.

3. Check the ring gear for wear and weld damage to

the pins.
4. Inspect the cylinder bore for wear and scratches.

Assembly
Figure 4-17. Removing Shaft from Housing
NOTE: Lubricate all seals and o-rings with clean hydraulic
oil prior to assembly.

1. Install new seal (7) and bearing (6) on the piston

sleeve (3).

NOTE: Apply a coat of grease to the thrust ring before slid-

ing onto the shaft.

2. Install new seal (8), thrust ring (10) and bearing (9)
on shaft (2).

NOTE: Apply a coat of grease to the thrust ring before slid-

ing onto the end cap.

4-16 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

3. Install new seals (11), back-up ring (12), cap bearing 4.9 ROTARY ACTUATOR (S/N 0300132474
(13), bearing packing (14) and thrust ring (10) on
end cap (5). TO PRESENT)
4. Place the actuator in the vertical position, install the
piston sleeve (3) in timed relation to the housing (1). Theory of Operation
The L20 Series rotary actuator is a simple mechanism that
uses the sliding spline operating concept to convert linear
DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY, AS IT piston motion into powerful shaft rotation. Each actuator is
WILL MARK THE CYLINDER BORE. composed of a housing with integrated gear teeth (01)
and only two moving parts: the central shaft with inte-
NOTE: The timing marks (the small punch marks on the grated bearing tube and mounting flange (02), and the
face of each gear), must be aligned for proper shaft annular piston sleeve (03). Helical spline teeth machined
orientation. (See Actuator Timing.) on the shaft engage matching splines on the inside
diameter of the piston. The outside diameter of the piston
5. Install the shaft (2) into housing (1) by aligning the carries a second set of splines, of opposite hand, which
proper punched timing marks. (See Actuator Tim- engage with matching splines in the housing. As hydraulic
ing.) pressure is applied, the piston is displaced axially within
the housing - similar to the operation of a hydraulic cylin-
6. Temporarily tape the threaded portion of the shaft der - while the splines cause the shaft to rotate. When the
will help installation past the shaft seals (masking control valve is closed, oil is trapped inside the actuator,
tape). preventing piston movement and locking the shaft in posi-
tion.
7. The end cap (5) is torqued to 40 - 50 ft. lbs. (54 - 68
Nm), such that the actuator begins rotation at
approximately 100 psi (6.895 Bar) pressure.

8. The end cap must be secured against the shaft by

installing axial set screws (4).

Bars indicate starting posi- As fluid pressure is applied,

Figure 4-19. Actuator Timing tio ns of pisto n and shaft. the piston is displaced axially
Arrows indicate direction they while the helical gearing
will rotate. The housing with causes the piston and shaft to
integral ring gear remains sta- rotate simultaneously. The
tionary. double helix design com-
pounds rotation: shaft rota-
tion is about twice that of the
piston.

The shaft is supported radially by the large upper radial

bearing and the lower radial bearing. Axially, the shaft is
separated from the housing by the upper and lower thrust

3121201 – JLG Lift – 4-17

SECTION 4 - BOOM & PLATFORM

washers. The end cap is adjusted for axial clearance and some slight modifications for your own personal prefer-
locked in position by set screws or pins. ence.

Required Tools
Upon assembly and disassembly of the actuator there are
basic tools required. The tools and their intended func-
tions are as follows:

1. Flashlight - helps examine timing marks, component

failure and overall condition.
2. Felt Marker - match mark the timing marks and out-
line troubled areas.
3. Allen wrench - removal of port plugs and set screws.
4. Box knife - removal of seals.
5. Seal tool - assembly and disassembly of seals and
wear guides.
6. Pry bar - removal of end cap and manual rotation of
shaft.
7. Rubber mallet- removal and installation of shaft and
piston sleeve assembly.
8. Nylon drift - installation of piston sleeve
9. End cap dowel pins - removal and installation of end
cap (sold with Helac seal kit).
The seal tool is merely a customized standard flat head
screwdriver. To make this tool you will need to heat the flat
end with a torch. Secure the heated end of the screwdriver
in a vice and physically bend the heated end to a slight
radius. Once the radius is achieved round off all sharp
edges of the heated end by using a grinder. There may be

4-18 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal

Figure 4-20. Rotary Actuator - Exploded View

3121201 – JLG Lift – 4-19

SECTION 4 - BOOM & PLATFORM

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

Figure 4-21. Rotary Actuator - Assembly Drawing

4-20 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

Disassembly 5/1 6” drill bit to a depth of 1/2” (12.7mm) to drill out

the entire pin.
1. Remove the capscrews (113) over end cap lock pins 4. Install the end cap (4) removal tools provided with
(109). the Helac seal kit.

2. Using a 1/8” (3.18mm) drill bit, drill a hole in the cen-

5. Using a metal bar, or something similar, unscrew the
ter of each lock pin to a depth of approximately 3/ end cap (4) by turning it counter clockwise.
16” (4.76mm).

3. Remove the lock pins using an ”Easy Out” (a size

#2 is shown).

If the pin will not come out with the ”Easy Out”, use

3121201 – JLG Lift – 4-21

SECTION 4 - BOOM & PLATFORM

6. Remove the end cap (4) and set aside for later 8. Every actuator has timing marks for proper engage-
inspection. ment.

7. Remove the stop tube if included. The stop tube is

an available option to limit the rotation of the actua-
tor.

9. Prior to removing the shaft, (2), use a felt marker to

clearly indicate the timing marks between shaft and
piston. This will greatly simplify timing during assem-
bly.

4-22 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

10. Remove the shaft (2). It may be necessary to strike 13. At the point when the piston gear teeth come out of
the threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the
piston and housing with a marker as shown.

11. Before removing the piston (3), mark the housing (1)
ring gear in relation to the piston O.D. gear. There 14. Remove the o-ring (204) and backup ring (207) from
should now be timing marks on the housing (1) ring end cap (4) and set aside for inspection.
gear, the piston (3) and the shaft (2).

15. Remove the wear guides (302) from the end cap (4)
12. To remove the piston (3) use a rubber mallet and a and shaft (2).
plastic mandrel so the piston is not damaged.

3121201 – JLG Lift – 4-23

SECTION 4 - BOOM & PLATFORM

16. To remove the main pressure seals (205), it is easi- 19. Remove the piston O.D. seal (202).
est to cut them using a sharp razor blade being
careful not to damage the seal groove.

20. Remove the piston I.D. seal (200). You may now pro-
ceed to the inspection process.

17. Remove the thrust washers (304), from the end cap
(4) and shaft (2).

18. Remove the wiper seal (304.1) from its groove in the
end cap (4) and shaft (2).

4-24 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

Inspection 3. Inspect the wear guide condition and measure thick-

ness (not less than 0.123” or 3.12 mm).
1. Clean all parts in a solvent tank and dry with com-
pressed air prior to inspecting. Carefully inspect all
critical areas for any surface finish abnormalities:
Seal grooves, bearing grooves, thrust surfaces, rod
surface, housing bore and gear teeth.

Assembly
1. Gather all the components and tools into one loca-
tion prior to re-assembly. Use the cut away drawing
to reference the seal orientations.
2. Inspect the thrust washers (304) for rough or worn
edges and surfaces. Measure it’s thickness to make
sure it is within specifications (Not less than 0.092”
or 2.34 mm).

3121201 – JLG Lift – 4-25

SECTION 4 - BOOM & PLATFORM

2. Install the thrust washer (304) onto shaft (2) and end 4. Using a seal tool install the main pressure seal (205)
cap (4). onto shaft (2) and end cap (4). Use the seal tool in a
circular motion.

3. Install the wiper seal (304.1/green 0-ring) into it’s 5. Install the wear guide (302) on the end cap (4) and
groove on the shaft (2) and end cap (4) around the shaft (2).
outside edge of the thrust washer (304).

6. Install the inner T-seal (200) into the piston (3) using
a circular motion.

Install the outer T-seal (202) by stretching it around

the groove in a circular motion.

4-26 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

Each T-seal has 2 back-up rings (see drawing for ori- 7. Insert the piston (3) into the housing (1) as shown,
entation). until the outer piston seal (202) is touching inside
the housing bore.

Beginning with the inner seal (200) insert one end of

b/u ring in the lower groove and feed the rest in
using a circular motion. Make sure the wedged ends 8. Looking from the angle shown, rotate the piston (3)
overlap correctly. until the marks you put on the piston and the hous-
ing (1) during disassembly line up as shown. Using
Repeat this step for the outer seal (202). a rubber mallet, tap the piston into the housing up to
the point where the gear teeth meet.

3121201 – JLG Lift – 4-27

SECTION 4 - BOOM & PLATFORM

9. Looking from the opposite end of the housing (1) 11. Looking from the view shown, use the existing tim-
you can see if your timing marks are lining up. When ing marks to line up the gear teeth on the shaft (2)
they do, tap the piston (3) in until the gear teeth with the gear teeth on the inside of the piston (3).
mesh together. Tap the piston into the housing the Now tap the flange end of the shaft with a rubber
rest of the way until it bottoms out. mallet until the gear teeth engage.

12. Install 2 bolts in the threaded holes in the flange.

10. Install the shaft (2) into the piston (3). Be careful not Using a bar, rotate the shaft in a clockwise direction
to damage the seals. Do not engage the piston gear until the wear guides are seated inside the housing
teeth yet. bore.

13. Install the stop tube onto the shaft end. Stop tube is
an available option to limit the rotation of an actua-
tor.

4-28 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

14. Coat the threads on the end of the shaft with anti- 17. Tighten the end cap (4). In most cases the original
seize grease to prevent galling. holes for the lock pins will line up.

18. Place the lock pins (109) provided in the Helac seal
15. Install the 0-ring (204) and back-up ring (207) into
kit in the holes with the dimple side up. Then, using
the inner seal groove on the end cap (4).
a punch, tap the lock pins to the bottom of the hole.

16. Thread the end cap (4) onto the shaft (2) end. Make
sure the wear guide stays in place on the end cap as 19. Insert the set screws (113) over the lock pins.
it is threaded into the housing (1). Tighten them to 25 in. lbs. (2.825 Nm).

3121201 – JLG Lift – 4-29

SECTION 4 - BOOM & PLATFORM

Installing Counterbalance Valve 3. The bolts that come with the valve are grade 8 bolts.
New bolts should be installed with a new valve. Loc-
Refer to Figure 4-22., Rotator Counterbalance Valve. tite #242 should be applied to the shank of the three
bolts at the time of installation.
1. Make sure the surface of the actuator is clean, free
of any contamination and foreign debris including 4. Torque the 1/4-inch bolts 110 to 120 inch pounds
old Loctite. (12.4 to 13.5 Nm). Do not torque over 125 inch
pounds (14.1 Nm). Torque the 5/16-inch bolts 140
2. Make sure the new valve has the O-rings in the inch pounds (15.8 Nm). Do not torque over 145 inch
counterbores of the valve to seal it to the actuator pounds (16.3 Nm).
housing.

Figure 4-22. Rotator Counterbalance Valve

4-30 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

Testing the Actuator collect the purged oil. The oil can be returned to the
reservoir after this procedure is completed.
If the equipment is available, the actuator should be tested
on a hydraulic test bench. The breakaway pressure — the
pressure at which the shaft begins to rotate — should be
approximately 400 psi (28 bar). Cycle the actuator at least
25 times at 3000 psi (210 bar) pressure. After the 25 rota-
tions, increase the pressure to 4500 psi (315 bar) to check
for leaks and cracks. Perform the test again at the end of
the rotation in the opposite direction.

TESTING THE ACTUATOR FOR INTERNAL

LEAKAGE
If the actuator is equipped with a counterbalance valve,
plug the valve ports. Connect the hydraulic lines to the
housing ports. Bleed all air from the actuator (see Installa-
tion and Bleeding) Rotate the shaft to the end of rotation
at 3000 psi (210 bar) and maintain pressure. Remove the
hydraulic line from the non-pressurized side.
Continuous oil flow from the open housing port indicates
internal leakage across the piston. Replace the line and
rotate the shaft to the end of rotation in the opposite direc-
tion. Repeat the test procedure outlined above for the TYPICAL CONFIGURATION
other port. If there is an internal leak, disassemble, inspect OF ACTUATOR
and repair.

Installation and Bleeding 2. With an operator in the platform, open both bleed
After installation of the actuator on the equipment, it is nipples 1/4 turn. Hydraulically rotate the platform to
important that all safety devices such as tie rods or safety the end of rotation (either clockwise or counterclock-
cables are properly reattached. wise), and maintain hydraulic pressure. Oil with
small air bubbles will be seen flowing through the
To purge air from the hydraulic lines, connect them tubes. Allow a 1/2 gallon of fluid to be purged from
together to create a closed loop and pump hydraulic fluid the actuator.
through them. Review the hydraulic schematic to deter-
mine which hydraulic lines to connect. The linear feet and 3. Keep the fittings open and rotate the platform in the
inside diameter of the hydraulic supply lines together with opposite direction to the end position. Maintain
pump capacity will determine the amount of pumping time hydraulic pressure until an additional 1/4 gallon of
required to fully purge the hydraulic system. fluid is pumped into the container.
Bleeding may be necessary if excessive backlash is exhib-
4. Repeat steps 2 & 3. After the last 1/2 gallon is
ited after the actuator is connected to the hydraulic sys-
tem. The following steps are recommended when a purged, close both bleed nipples before rotating
minimum of two gallons (8 liters) is purged. away from the end position.

1. Connect a 3/16" inside diameter x 5/16" outside

diameter x 5 foot clear, vinyl drain tube to each of the
two bleed nipples. Secure them with hose clamps.
Place the vinyl tubes in a clean 5-gallon container to

3121201 – JLG Lift – 4-31

SECTION 4 - BOOM & PLATFORM

Troubleshooting
Table 4-1. Troubleshooting

Problem Cause Solution

1. Shaft rotates slowly or not at all a. Insufficient torque output a. Verify correct operating pressure. Do not
exceed OEM’s pressure specifications. Load may
be above maximum capacity of the actuator.

b. Low rate of fluid flow b. Inspect ports for obstructions and hydraulic
lines for restrictions and leaks.

c. Control or counterbalance valve has internal c. Disconnect hydraulic lines and bypass valve.
leak Leave valve ports open and operate the actuator
through housing ports (do not exceed OEM’s
operating pressure). The valve must be replaced if
a steady flow of fluid is seen coming from the valve
ports.

d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in
the Testing section on page 24 of this manual.

e. Corrosion build-up on the thrust surfaces e. Re-build the actuator. Remove all rust then pol-
ish. Replacement parts may be needed.

f. Swollen seals and composite bearings caused f. Re-build the actuator. Use fluid that is compati-
by incompatible hydraulic fluid ble with seals and bearings.
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. See bleeding proce-
dures.
3. Shaft will not fully rotate a. Twisted or chipped gear teeth a. Check for gear binding. Actuator may not be
able to be re-built and may need to be replaced.
Damage could be a result of overload or shock.

b. Port fittings are obstructing the piston b. Check thread length of port fittings. Fittings
should during stroke not reach inside the housing
bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal a. Disconnect hydraulic lines and bypass valve.
leak Leave valve ports open and operate the actuator
through housing ports (do not exceed OEM’s
operating pressure). The valve must be replaced if
a steady flow of fluid is seen coming from the valve
ports.

b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports.
Operate the actuator through the housing ports.
Conduct the internal leakage test as described in
the Testing section on page 24 of this manual.

c. Air in actuator c. Purge air from actuator. See bleeding proce-

dures

4-32 – JLG Lift – 3121201

SECTION 4 - BOOM & PLATFORM

4.10 FOOT SWITCH ADJUSTMENT 2. Pull the red knob located under the manual descent
control valve.
Adjust so that functions will operate when pedal is at cen-
ter of travel. If switch operates within last 1/4 in. (6.35 mm) 3. From Ground Control, activate the lift control switch,
of travel, top or bottom, it should be adjusted. raise Lower Boom 6 feet (1.83m).

4. After raising Lower Boom, release the red knob.

4.11 BOOM SYNCHRONIZING PROCEDURE
5. Activate Lower Boom Down, fully lower boom.
NOTE: If the Lower Boom assembly does not fully lower:
6. Repeat step 1 thru 5 if necessary.
1. Remove all personnel from the platform.

A,B,D NOTE: If any rotator bolts are replaced, all bolts

on the rotator should be retorqued.

C,D

A Torque to 50 ft.lbs. (68 Nm)

B Loctite #242
C Torque to 480 ft. lbs. (650 Nm)
D Check torque every 150 hours of operation
E Torque to 85 ft. lbs. (115 Nm)

Figure 4-23. Platform Support Torque Values

3121201 – JLG Lift – 4-33

SECTION 4 - BOOM & PLATFORM

NOTES:

4-34 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

SECTION 5. HYDRAULICS
5.1 LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in
HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com-
pletely saturated.
When assembling connectors in the hydraulic that use o-
ring fittings, it is necessary to lubricate all fittings with
hydraulic oil prior to assembly. To lubricate the fittings, use
one of the following procedures.

NOTE: All O-ring fittings must be pre-lubricated with hydrau-

lic oil prior to assembly.

Cup and Brush

The following is needed to correctly oil the o-ring in this
manner:

• A small container for hydraulic oil

• Small paint brush 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring
is coated with hydraulic oil.

1. Hold the fitting in one hand while using the brush

with the other hand to dip into the container.
Remove excess hydraulic oil from the brush so an
even film of oil is applied on the o-ring.

3121201 – JLG Lift – 5-1

6. If used, remove lifting device from upright or remove

prop from below main boom, activate hydraulic sys-
OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION tem and run cylinder through one complete cycle to
ONLY. check for leaks.

1. Using all applicable safety precautions, activate

5.4 CYLINDER REPAIR
hydraulic system.
NOTE: The following are general procedures that apply to
all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted.
IF WORKING ON THE TOWER BOOM LIFT CYLINDER, RAISE
TOWER BOOM HALFWAY, FULLY ELEVATE MAIN BOOM WITH Disassembly
TELESCOPE CYLINDER FULLY RETRACTED AND ATTACH AN
OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT, LEAVING
APPROXIMATELY 1 INCH (2.54 CM) OF SLACK IN CHAIN OR
SLING FOR TEST PURPOSES. IF WORKING ON THE UPRIGHT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A
LEVEL, RAISE THE TOWER BOOM HALFWAY, THEN RAISE MAIN CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
BOOM TO HORIZONTAL AND POSITION A SUITABLE BOOM PROP
APPROXIMATELY 1 INCH (2.54 CM) BELOW MAIN BOOM. IF
1. Connect a suitable auxiliary hydraulic power source
WORKING ON THE PLATFORM LEVEL CYLINDER, STROKE PLAT-
to the cylinder port block fitting.
FORM LEVEL CYLINDER FORWARD UNTIL PLATFORM SITS AT A
45 DEGREES ANGLE.

2. Shut down hydraulic system and allow machine to DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
sit for 10-15 minutes. If machine is equipped with RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
bang-bang or proportional control valves, turn IGNI-
TION SWITCH to ON, move control switch or lever 2. Operate the hydraulic power source and extend the
for applicable cylinder in each direction, then turn cylinder. Shut down and disconnect the power
IGNITION SWITCH to OFF. If machine is equipped source. Adequately support the cylinder rod, if appli-
with hydraulic control valves, move control lever for cable.
applicable cylinder in each direction. This is done to
relieve pressure in the hydraulic lines. Carefully 3. If applicable, remove the cartridge-type holding
remove hydraulic hoses from appropriate cylinder valve and fittings from the cylinder port block. Dis-
port block. card o-rings.

5-4 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

4. Place the cylinder barrel into a suitable holding fix-

ture.

8. Attach a suitable pulling device to the cylinder rod

port block end or cylinder rod end, as applicable.

Figure 5-1. Cylinder Barrel Support

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
5. Mark cylinder head and barrel with a center punch CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
for easy realignment. Using an allen wrench, loosen CYLINDER BARREL SURFACES.
the eight (8) cylinder head retainer cap screws, and
remove cap screws from cylinder barrel. 9. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.

Figure 5-2. Cap Screw Removal

NOTE: Steps 6 and 7 apply only to the steer cylinder. Figure 5-3. Cylinder Rod Support

6. Using a spanner wrench, loosen the spanner nut 10. Using suitable protection, clamp the cylinder rod in
retainer, and remove spanner nut from cylinder bar- a vise or similar holding fixture as close to the piston
rel. as possible.

NOTE: Step 11 applies only to the steer cylinder.

7. Being careful not to mar the surface of the rod, use a
punch or wooden dowel and hammer to drive the
11. Loosen and remove nut which attaches the piston to
rod guide about one inch down into the cylinder
the rod, and remove the piston.
bore. Using a screw driver, carefully push one end of
the round retaining ring back towards the inside of 12. Loosen and remove the cap screw(s), if applicable,
the cylinder and then slip the screwdriver tip under which attach the tapered bushing to the piston.
that end. Pull the ring out of the groove toward the
wall mouth. Once one end of the retaining ring is
free from the groove, the remainder can be easily
pried free using ones fingers or pliers.

3121201 – JLG Lift – 5-5

SECTION 5 - HYDRAULICS

13. Insert the cap screw(s) in the threaded holes in the 8. Inspect seal and o-ring grooves in piston for burrs
outer piece of the tapered bushing. Progressively and sharp edges. Dress applicable surfaces as nec-
tighten the cap screw(s) until the bushing is loose essary.
on the piston.
9. Inspect cylinder head inside diameter for scoring or
14. Remove the bushing from the piston. other damage and for ovality and tapering. Replace
as necessary.
10. Inspect threaded portion of head for damage. Dress
threads as necessary.
11. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as nec-
essary.
12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.
13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs,
Figure 5-4. Tapered Bushing Removal dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage.
15. Screw the piston CCW, by hand, and remove the If steel bushing is worn or damaged, rod/barrel
piston from cylinder rod. must be replaced.
16. Remove and discard the piston o-rings, seal rings, c. Lubricate inside of steel bushing with WD40
and backup rings. prior to bearing installation.
d. Using an arbor of the correct size, carefully
17. Remove piston spacer, if applicable, from the rod.
press the bearing into steel bushing.
18. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer plate, if applica- NOTE: Install pin into the composite bearing dry. Lubrication
ble. Discard the o-rings, back-up rings, rod seals, is not required with nickel plated pins and bearings.
and wiper seals.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning
solvent.
2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive dam-
age. Dress threads as necessary. Figure 5-5. Composite Bearing Installation
4. Inspect inner surface of cylinder barrel tube for scor-
ing or other damage. Check inside diameter for 14. Inspect travel limiting collar or spacer for burrs and
tapering or ovality. Replace if necessary. sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary. 15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston 16. Inspect the oil ports for blockage or the presence of
as necessary. dirt or other foreign material. Repair as necessary.
7. Inspect threaded portion of piston for damage. 17. If applicable, inspect piston rings for cracks or other
Dress threads as necessary. damage. Replace as necessary.

5-6 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

Assembly 2. Use a soft mallet to tap a new wiper seal into the
applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head gland
NOTE: Prior to cylinder assembly, ensure that the proper
groove.
cylinder seal kit is used. See your JLG Parts Manual.

Apply a light film of hydraulic oil to all components prior to

assembly.

1. A special tool is used to install a new rod seal into

the applicable cylinder head gland groove.

Figure 5-7. Poly-Pak Piston Seal Installation

Figure 5-6. Rod Seal Installation

WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS Figure 5-8. Wiper Seal Installation
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA-
TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND 3. Place a new “O-ring and back-up seal in the applica-
IMPROPER CYLINDER OPERATION. ble outside diameter groove of the cylinder head.

WHEN INSTALLING THE WIPER SEAL ON THE LOWER (TOWER)

LIFT CYLINDER, APPLY LOCTITE #609 ON THE WIPER SEAL IN
THREE EVENLY SPACED PLACES TO AID IN RETENTION OF THE
SEAL.

Figure 5-9. Installation of Head Seal Kit

3121201 – JLG Lift – 5-7

SECTION 5 - HYDRAULICS

4. Install washer ring onto rod, carefully install the head 9. Carefully thread the piston on the cylinder rod hand
gland on the rod, ensuring that the wiper and rod tight, ensuring that the o-ring and back-up rings are
seals are not damaged or dislodged. Push the head not damaged or dislodged.
along the rod to the rod end, as applicable.
10. Thread piston onto rod until it abuts the spacer end
5. Carefully slide the piston spacer on the rod. and install the tapered bushing.
NOTE: Upper telescope cylinder piston has an o-ring
installed inside the spacer. NOTE: When installing the tapered bushing, piston and mat-
ing end of rod must be free of oil.
6. If applicable, correctly place new o-ring in the inner
piston diameter groove. (The backup ring side fac-
ing the O-ring is grooved.)
WHEN REBUILDING THE MASTER, SLAVE, LOWER LIFT, UPPER
7. If applicable, correctly place new seals and guide LIFT, ARTICULATING FLY BOOM LIFT, UPRIGHT LEVEL, TOWER
lock rings in the outer piston diameter groove. (A TELESCOPE, OR UPPER TELESCOPE CYLINDERS, TIGHTEN
tube, with I.D. slightly larger than the O.D.of the pis- SECURELY. (SEE TABLE 2-1 AND 2-3. TORQUE SPECIFICATIONS).
ton is recommended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on 11. Assemble the tapered bushing loosely into the pis-
one side. This side faces the solid seal.(See magni- ton and insert JLG capscrews (not vendor cap-
fied insert in Figure 5-10.)The split of seals and screws) through the drilled holes in the bushing and
backup rings are to be positioned so as not to be in into the tapped holes in the piston.
alignment with each other.

Figure 5-11. Tapered Bushing Installation

12. Tighten the capscrews evenly and progressively in

rotation to the specified torque value. (See Table 5-2,
Cylinder Head and Tapered Bushing Torque Specifi-
cations.

13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass
shaft (approximately 3/4" in diameter) as follows;
Figure 5-10. Piston Seal Kit Installation
a. Place the shaft against the cylinder rod and in
8. Using suitable protection, clamp the cylinder rod in contact with the bushing in the spaces between
a vise or similar holding fixture as close to piston as the capscrews.
possible.

5-8 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

1. Install lift cylinder in place using suitable slings or 1. With the aid of an assistant, manually override the
supports, aligning attach pin mounting holes on the Plunger Valve with a pry bar, and from Ground Con-
upright. trol, using auxiliary power, extend the tower tele-
scope out to gain access to leveling cylinder rod
2. Using a suitable drift, drive barrel end attach pin #3 end pin #3.
through the mounting holes in the lift cylinder and
the upright. Secure in place with the pin retaining
hardware.

3. Remove cylinder port plugs and hydraulic line caps

and correctly attach lines to cylinder ports.

4. Using auxiliary power extend the cylinder rod until

the attach pin hole aligns with those in the boom.
Using a suitable drift drive cylinder rod attach pin #2
through the aligned holes, taking care to align the
grooved pin holes. Secure the pin in place with
attaching hardware.

5. Remove boom prop and overhead crane. Activate

hydraulic system.
Figure 5-16. Overriding the Plunger Valve
6. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and 2. With the main boom positioned and supported as
hydraulic leaks. Secure as necessary. shown in Leveling Cylinder Removal, prepare to
remove the upright level cylinder.
7. Check fluid level of hydraulic tank and adjust as nec-
essary. 3. Remove the mounting hardware from pin #1, secur-
ing leveling cylinder to upright.

Figure 5-15. Leveling Cylinder Removal

5-12 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

Figure 5-17. Boom Positioning and Support, Cylinder Repair

3121201 – JLG Lift – 5-13

SECTION 5 - HYDRAULICS

4. With overhead crane supporting upper boom Upright Level Cylinder Installation
assembly. Raise boom until tension is released from
cylinder pin #1. 1. Place the leveling cylinder in position in the tower
boom, then align holes in tower boom and leveling
5. Using a suitable drift, drive the barrel end attach pin
cylinder. Install leveling cylinder attach pin #3 using
#1 through the mounting holes in the upright and
a suitable rubber mallet.
leveling cylinder.
2. Secure pin to tower boom with mounting hardware.
6. Remove the mounting hardware from upright pivot
pin #2 which secures upright to tower boom assem- 3. Remove cylinder port plugs and hydraulic line caps
bly. and correctly attach lines to cylinder ports.
7. Using a suitable drift, drive pivot pin #2 through the 4. Using all applicable safety precautions, operate the
mounting holes in the upright and tower boom overhead crane to move upright and upper boom
assembly. assembly in proper position with tower boom.
8. Using all applicable safety precautions, operate the 5. Align holes in upright and tower boom assembly
overhead crane to move upright and upper boom and install upright pivot pin #2 using a suitable rub-
assembly forward to clear tower boom. ber mallet. Secure pin with mounting hardware.
9. Using all applicable safety precautions, operate the 6. Align holes in upright and leveling cylinder barrel
overhead crane to move upright and upper boom end and install leveling cylinder pin #1 using a suit-
assembly forward to clear tower boom. able rubber mallet. Secure pin with mounting hard-
10. After moving assemblies forward, operate overhead ware.
crane to the left far enough to remove leveling cylin-
7. Remove overhead crane from upper boom. Activate
der.
hydraulic system.
11. Tag, disconnect and cap hydraulic lines to level cyl-
8. Using all applicable safety precautions, operate the
inder.
boom functions. Check for correct operation and
12. Remove the mounting hardware from leveling cylin- hydraulic leaks. Secure as necessary.
der rod end pin #3 which secures cylinder to tower
9. Check fluid level of hydraulic tank and adjust as nec-
boom fly assembly.
essary.
13. Using a suitable drift, drive leveling cylinder pin #3
through the mounting holes in the tower boom fly
and leveling cylinder, then remove leveling cylinder.

5-14 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

Tower Boom Lift Cylinder Removal 4. Remove mounting hardware securing the cylinder
rod pin to the tower boom. Using a suitable brass
1. Place machine on a flat and level surface. Place the drift, drive out the cylinder rod attach pin.
main boom in a horizontal position with the tele-
scope cylinder fully retracted. Place the tower boom 5. Tag, disconnect and cap the tower lift cylinder
in a fully elevated and fully retracted position (See hydraulic lines and ports.
Figure 5-17., Boom Positioning and Support, Cylin-
6. Remove mounting hardware securing the cylinder
der Repair.
barrel pin to the turntable. Using a suitable brass
2. Support the main boom with a prop. Support the drift, drive out the cylinder barrel pin.
upright with an overhead crane. (See Figure 5-17.,
Boom Positioning and Support, Cylinder Repair. 7. Carefully remove restraining slings and remove
tower lift cylinder from turntable. Place in a suitable
3. Using slings restrain tower lift cylinder. work area.

8. If necessary, use an auxiliary power source and fully

retract lift cylinder.

Figure 5-18. Tower Telescope Cylinder Removal

3121201 – JLG Lift – 5-15

SECTION 5 - HYDRAULICS

Tower Lift Cylinder Installation 8. Carefully slide the telescope cylinder from the
boom. Place cylinder on a suitable work area.
1. With the main boom and tower boom positioned
and supported as in Figure 5-17., Boom Positioning Tower Telescope Cylinder Installation
and Support, Cylinder Repair, place the tower lift cyl-
1. With the boom positioned as in Figure 5-18., Tower
inder in position on the turntable and secure in place
Telescope Cylinder Removal, slide the telescope cyl-
using slings.
inder into the boom, aligning the cylinder port block
2. Align holes in turntable and lift cylinder. Using a suit- end with slotted holes in Base Boom. Secure tele-
able rubber mallet, install the cylinder barrel pin and scope cylinder with mounting hardware.
secure with mounting hardware.
2. Remove caps and plugs from hydraulic lines and
3. Connect an auxiliary power source to the cylinder ports. Properly connect hydraulic lines to cylinder as
and extend cylinder rod until the cylinder rod bush- tagged during Removal. Reinstall cover plate.
ing aligns with bushings on boom. 3. Start engine. With the aid of an assistant, manually
override the plunger valve. Activate Tower telescope
4. Using an appropriate brass drift, drive the rod attach
out to align attaching pin holes in Fly Boom. Shut
pin through the aligned bushings. Secure pin with
down engine.
attaching hardware.
4. Using a brass drift, drive in the attach pin. Secure in
5. Remove caps from cylinder hydraulic lines and cor-
place with mounting hardware.
rectly install lines to cylinder as previously tagged.
5. Align holes in base boom and powertrack. Secure
6. Remove boom prop and overhead crane. Activate the powertrack with mounting hardware.
hydraulic system.
6. Remove boom prop and overhead crane. Activate
7. Using all applicable safety precautions, operate the hydraulic system.
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary. 7. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
8. Check fluid level of hydraulic tank and adjust as nec- hydraulic leaks. Secure as necessary.
essary.
8. Check fluid level of hydraulic tank and adjust as nec-
essary.
Tower Telescope Cylinder Removal
1. Place machine on a flat and level surface, with main
boom in the horizontal position. Shut down engine
and prop the boom See Figure 5-18., Tower Tele-
scope Cylinder Removal.

2. With the aid of an assistant, manually override the

Plunger Valve with a pry bar, and from Ground Con-
trol, using auxiliary power, extend the tower tele-
scope out to gain access to fly attach pin.

3. Remove lower cover plate.

4. Remove mounting hardware securing powertrack to

tower boom assembly. After removing mounting
hardware, slide powertrack backward far enough to
move holes and wiring harness to the side to gain
access to telescope cylinder.

5. Tag, disconnect and cap hydraulic hoses to Tower

Telescope Cylinder. Plug cylinder ports.

6. Remove mounting hardware securing upper cylin-

der pin to fly boom. Using a suitable brass drift, drive
out the cylinder rod pin.

7. Remove mounting hardware attaching retaining

plates to base boom and remove plate.

5-16 – JLG Lift – 3121201

Figure 5-23. Steer Cylinder

3121201 – JLG Lift – 5-21

SECTION 5 - HYDRAULICS

10
25

5
11
12

12
11
14
13
6
15
17
16
22
3
9
18
19

1. Barrel 5. Tapered Bushing 11. Lock Ring 17. Back-Up Ring 22. Washer Ring
1A. Bushing 6. Tube Spacer 12. Hydrolock Seal 18. Rod Seal 23. Not Used
2. Rod 7. Valve Cartridge 13. O-Ring 19. Wiper Ring 24. Bolt
2A. Bushing 8. Valve Cartridge 14. Back-Up Ring 20. Loctite #242 (Not Shown) 25. O-Ring Plug
3. Head 9. Socket Head Capscrew 15. Wear Ring 21. Locking Primer (Not 26. Loctite #609
4. Piston 10. O-Ring Plug 16. O-Ring Shown)

Figure 5-24. Level (Upright) Cylinder

5-22 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

1. Barrel 6. Tapered Bushing 13. Rod Seal 19. Lock Ring

1A. Bushing 7. Cartridge Valve 14. O-Ring 20. Seal
2. Rod 8. Cartridge Valve 15. Back-Up Ring 21. Loctite #242 (Not Shown)
2A. Bushing 9. Socket Head Capscrew 16. Wear Ring 22. Locking Primer (Not Shown)
3. Head 10. Washer Ring 17. 17. O-Ring 23. Not Used
4. Piston 11. O-Ring Plug 18. Back-Up Ring 24. Bolt
5. Spacer 12. Wiper

Figure 5-25. Main Boom Lift Cylinder

3121201 – JLG Lift – 5-23

SECTION 5 - HYDRAULICS

1. Barrel 6. Spacer 13. Seal 20. Rod Seal

1A. Bushing 7. Cartridge Valve 14. Lock Ring 21. Wiper
2. Rod 8. O-Ring Plug 15. O-Ring 22. Not Used
2A. Bushing 9. Washer Ring 16. Back-Up Ring 23. O-Ring Plug
3. Piston 10. Socket Head Capscrew 17. Wear Ring 24. Counterbalance Valve
4. Head 11. Loctite #242 (Not Shown) 18. O-Ring 25. Bolt
5. Tapered Bushing 12. Locking Primer (Not Shown) 19. Back-Up Ring 26. Loctite #609

Figure 5-26. Tower Boom Lift Cylinder

5-24 – JLG Lift – 3121201

Figure 5-30. Troubleshooting - System Operating Hot

Figure 5-31. Troubleshooting - Transmission Operates in One Direction Only

5-28 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

Figure 5-32. Troubleshooting - System Response is Sluggish

3121201 – JLG Lift – 5-29

SECTION 5 - HYDRAULICS

Figure 5-33. Troubleshooting - System Will Not Operate in Either Direction

Inspections and Adjustments

CHECK/HIGH PRESSURE RELIEF VALVES THE RELIEF VALVES ARE FACTORY SET AND SHOULD NOT BE
TAMPERED WITH EXCEPT FOR REPLACING THE ENTIRE CAR-
The system check/relief valves have the dual purpose of
TRIDGE. DISASSEMBLY MAY CHANGE THE SETTING AND
providing make-up oil during by-directional rotation and
CAUSE ERRATIC UNIT OPERATION OR PREMATURE FAILURE.
providing protection from system over pressure. When the
problem occurs in one direction only, interchange the
PUMP CHARGE RELIEF VALVE
check/relief valves to see if the problem changes to the
other direction. If so, one check/relief valve cartridge is If charge pressure is low (less than 220 psi [15.2 Bar]
either malfunctioning or does not have the proper setting. above case pressure), the charge relief valve should be
inspected. Inspect for foreign material holding the poppet
open, and for scoring or wear on the poppet and seat in
the housing.
Adjustments of the charge pressure is accomplished by
changing the shim thickness behind the spring.

5-30 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

ELECTRICAL DISPLACEMENT CONTROL ORIFICES 3. Remove the bolts from the servo cover on the neu-
tral adjustment side. Install a spacer or sprocket,
NOTE: The pump should have two control orifices located approximately 0.75 in. (19 mm) long, under the
under the servo covers. servo cover opposite the neutral adjustment.

1. With a 7/16" wrench, remove the five bolts from the

servo cover opposite the neutral adjustment (cover
without the adjustment screw).

4. Re-install the bolts and tighten until the servo cover

on the neutral adjustment side of the pump sepa-
rates 0.125 in. (3 mm) from the housing. Turn the
cover and remove and inspect the orifice.

2. With a 7/32" internal wrench, remove and inspect the

orifice.

NOTE: The Displacement Control may first have to be

removed in order to rotate the servo cover.

5. Remove spacer, re-install orifices, gaskets, and cov-

ers. Torque grade 5 bolts 8 to 11 ft.lbs. (10.8 to 14.9
Nm) and grade 8 bolts 11 to 13 ft.lbs. (14.9 to 17.8
Nm).

3121201 – JLG Lift – 5-31

SECTION 5 - HYDRAULICS

SWASHPLATE NEUTRAL ADJUSTMENT 8. While holding the servo adjustment screw from turn-
ing, torque the servo lock nut 13 to 18 ft.lbs. (17.6 to
1. Using a low pressure line (500 psi [35 Bar] min.), 24.4 Nm). Stop the engine, install a new protective
cross port servo port F to servo port G. This cap, remove the servo cross-port line, and proceed
removes the effects of any control pressure on the to the appropriate control adjustment.
servo piston.
EDC NEUTRAL ADJUSTMENT

1. Remove the electrical connector at the EDC.

Remove the servo cross port line (installed while
making the swash plate neutral adjustment) and
install a 0 to 300 PSI (0 to 21 BAR) gauge in each
servo port.

THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO

2. Install pressure gauges (10,000 psi [690 Bar]) in the BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK FUNC-
system pressure gauge ports. Start the engine and TION DISCONNECTED, ETC.) WHILE PERFORMING THE PROCE-
slowly accelerate to normal operating RPM. DURES IN ORDER TO PREVENT INJURY TO THE TECHNICIAN AND
BYSTANDERS.
3. Remove the protective cap and loosen the servo
lock nut while holding the servo adjustment screw in 2. Start the engine and accelerate to normal operating
position. RPM.

3. Loosen lock nut with 1/2” wrench and slowly rotate

the neutral adjustment screw, with 5/32” internal hex
wrench, until the pressure is equal on both servo
gauges.

4. Turn the servo adjustment screw until the two sys-

tem pressure gauge readings are equal.

5. Turn the servo adjustment screw clockwise until one

of the system pressures starts to increase.

4. Slowly rotate the neutral adjustment screw until one

of the servo gauges starts to increase in pressure.

5. Noting the amount of rotation, slowly rotate the neu-

tral adjust screw in the opposite direction until the
other servo gauge begins to increase in pressure.

6. Turn the neutral adjust screw back one - half the

6. Noting the amount of rotation, turn the servo adjust- amount noted above. Hold the neutral adjust screw
ment screw counter-clockwise until the other system and torque the lock nut to 25 to 30 in.lbs. (2.8 to 3.4
pressure starts to increase. NM).

7. Turn the servo adjustment screw clockwise half the 7. Stop the engine. Connect the control input. Remove
amount of rotation noted above. the servo pressure gauges. Return the machine to
normal operating condition. Restart the engine and
assure that the hydrostatic system is in neutral.

5-32 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

Minor Repair and Replacement 1. Remove the retaining ring from the housing.

Minor repairs may be performed, following the procedures

in this section.

Cleanliness is a primary means of assuring satisfactory

transmission life, on either new or repaired units. Cleaning
parts by using solvent wash and air drying is usually ade-
quate. As with any precision equipment, all parts must be
kept free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities
from damage and foreign material.
It is recommended that all gaskets and O-rings be
replaced. Lightly lubricate all O-rings with clean petroleum
jelly prior to assembly. All gasket sealing surfaces must be
cleaned prior to installing new gaskets.

2. Carefully remove the seal from the housing bore.

The face of the seal may be punctured with a sharp
instrument (such as a screw driver) to aid in prying
the seal out, or a slide hammer type puller may be
used to remove the seal. Care must be taken so as
not to damage the housing bore or shaft. Once
removed, the seal is not reusable.

Figure 5-34. Variable Displacement Pump

SHAFT SEAL
Lip type shafts are used on Series 40 - M46 pumps and
motors. These seals can be replaced without major disas-
sembly of the unit. However, replacement of the shaft seal
requires removal of the pump from the machine.

3. Prior to installing the new seal, inspect the sealing

area on the shaft for rust, wear, or contamination.
Polish the sealing area on the shaft if necessary.

4. Wrap the spline or key end of the shaft with thin

plastic to prevent damage to the seal lip during
installation. Lubricate the inside diameter of the new
seal with petroleum jelly.

3121201 – JLG Lift – 5-33

SECTION 5 - HYDRAULICS

NOTE: The outside diameter of the seal may be lightly CHARGE CHECK AND HIGH PRESSURE RELIEF
coated with sealant (such as Loctite High Perfor- VALVES
mance Sealant #59231) prior to installation. This will
aid in preventing leaks caused by damage to the 1. Remove the charge check and high pressure relief
housing seal bore. valve hex plug.

5. Slide the new seal over the shaft and press it into the
housing bore. Be careful not to damage seal. A seal
installer tool can be made to aid in installing the
seal.

7”
2.75
0.75”
0.37”

2.45”
2” 1.24”
1.50” 3.0”

6. Reinstall the seal retaining ring. 2. Remove the spring and check poppet or valve car-
BYPASS VALVE (PUMP) tridge from the housing. Inspect the valve and mat-
ing seat in the housing for damage or foreign
1. Unscrew the bypass valve from the housing. Inspect
material. It will be necessary to replace the housing
the valve and mating seat for damage or foreign
if the seat is damaged.
material. It is recommended that the O-ring and
back - up ring be replaced.

3. Several designs of charge check and high pressure

NOTE: Bypass valves are available with integral bypass ori- relief valves have been used. Do not attempt to mix
fices for specific applications. Refer to the appropri- different vintage parts.
ate Service Parts Manual for more information.

2. Reinstall the bypass valve into the housing. Torque

to 7 to 10 ft. lbs. (9.5 - 13.6 Nm).

5-34 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

The appropriate check valve kit and/ or check and 3. Reinstall the poppet, spring, and plug (with shims
relief valve kit should be used. Refer to appropriate and O-ring) into the housing. Torque the plug to 30
Service Parts Manual. to 70 ft. lbs.(41 to 95 Nm).
NOTE: Always replace ball type charge check valves with ELECTRICAL DISPLACEMENT CONTROLS (EDC)
the poppet type.

4. Reinstall the valve cartridge, spring, and plug (with

O-ring) into the housing. Torque the plug to 30 to 70 THE REMOVAL OF ANY PORTION OF THE CONTROL MECHA-
ft. lbs. (41 to 95 Nm). NISM MAY RESULT IN LOSS OF NEUTRAL, WHICH WILL NECES-
SITATE READJUSTMENT.

THE RELIEF VALVES ARE FACTORY SET AND SHOULD NOT BE 1. Remove the four control mounting screws using an
TAMPERED WITH EXCEPT FOR REPLACING THE ENTIRE CAR- internal hex wrench (3/16”).
TRIDGE. DISASSEMBLY MAY CHANGE THE SETTING AND
CAUSE ERRATIC UNIT OPERATION OR PREMATURE FAILURE.

CHARGE PRESSURE RELIEF VALVE

1. Remove charge relief valve hex plug.

2. Carefully lift the control off the pump housing.

SECTION 5 - HYDRAULICS

Figure 5-38. Location of Components - Main Control Valve

3121201 – JLG Lift – 5-41

SECTION 5 - HYDRAULICS

4 Wheel Steer (If Equipped) Fill the reservoir with recommended hydraulic fluid. This
fluid should be passed through a 10 micron (nominal, no
1. At the platform console using the steer select switch bypass) filter prior to entering the reservoir. The use of
activate " 2 wheel steer". contaminated fluid will cause damage to the components,
which may result in unexpected vehicle/machine move-
2. Install a pressure gauge in port MP on main control ment.
valve.
NOTE: If a pump or motor is being replaced due to internal
3. With the aid of an assistant, activate steer left and damage, the remaining units (pump or motors) need
right, adjust front steer relief valve to 2500 PSI (172.4 to be inspected for damage and contamination, and
Bar). This pressure only affects the front axle. the entire hydraulic system will need to be flushed
and the fluid replaced. Failure to do so may cause
4. At the platform console using the steer select switch considerable damage to the entire system.
activate “crab” or “coordinated” steer.

5. At the main control valve block disconnect the wire The inlet line leading from the reservoir to the pump must
din connectors on the front steer valve. When steer be filled prior to start-up. Check the inlet line for property
is activated only the rear steer will work. tightened fittings and make sure it is free of restrictions
and air leaks.
6. Install a pressure gauge in port MP on main control
NOTE: In most cases, the reservoir is above the pump inlet
valve.
so that the pressure head created by the higher oil
7. With the aid of an assistant, activate steer left and level helps to keep the inlet pressures within an
right, adjust rear steer relief valve to 2500 PSI (172.4 acceptable range and prevent high vacuum levels.
Bar). Reading at the valve bank 2500 PSI (172.4 Bar) However, due to hose routing or low reservoir loca-
will give you 2000PSI (137.9 Bar) at the cylinders. tions, there may be air trapped within this line. It is
important to assure that the air is bled from this line.
8. Re-connect the front steer din connectors at the This can be accomplished by loosening the hose at
valve bank. the fitting closest the pump. When oil begins to flow,
the line is full, the air has been purged, and the fitting
5.9 HYDRAULIC COMPONENT START-UP can be retightened to its specified torque. If the tank
PROCEDURES AND needs to be pressurized in order to start the flow of
oil, a vacuum reading should be taken at the inlet of
RECOMMENDATIONS the pump during operation in order to verify that the
pump is not being asked to draw an inlet vacuum
From a hydrostatic component standpoint, the goal at higher than it is capable of.
system start up is to put into functional operation, the
hydrostatic system in such a way as to preserve the Be certain to fill the pump and/or motor housing with
designed life span of the system. The following start-up clean hydraulic fluid prior to start up. Fill the housing by
procedure should be adhered to whenever a new pump pouring filtered oil into the upper case drain port.
or motor is initially installed into a machine, or a system is
restarted after either a pump or motor has been removed NOTE: It is highly recommended to use the highest possible
and/or replaced. case drain port, this ensures that the housing con-
tains as much oil as possible and offers the greatest
amount of lubrication to the internal components.

THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO NOTE: In initial start-up conditions, it may be convenient to
BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK FUNC- fill the housing, just prior to installing the case drain
TIONS DISCONNECTED, ETC.) WHILE PERFORMING THE PROCE- line. Component, (especially motor), location may be
DURE IN ORDER TO PREVENT INJURY. TAKE NECESSARY SAFETY such that access to the case drain port after installa-
PRECAUTIONS BEFORE MOVING THE VEHICLE/MACHINE. tion is not realistic.

Prior to installing the pump and/or motor, inspect the NOTE: Make certain that the oil being used to fill the compo-
unit(s) for damage that may have been incurred during nent housing is as clean as possible, and store the
shipping and handling. Make certain that all system com- fill container in such a way as to prevent it from
ponents (reservoir, hoses, valves, fittings, heat exchanger, becoming contaminated.
etc.) are clean prior to filling with fluid.

5-42 – JLG Lift – 3121201

SECTION 5 - HYDRAULICS

Install a 60 bar (or 1000 psi) pressure gauge in the charge

pressure gauge port in order to monitor the charge pres-
sure during start-up. INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA-
TOR'S ABILITY TO CONTROL THE MACHINE.
It is recommended that the external control input signal,
(electrical connections for EDC), be disconnected at the Shut down the engine and connect the external control
pump control until after initial start-up. This will ensure that input signal. Also reconnect the machine function(s), if
the pump remains in its neutral position. disconnected earlier. Start the engine, checking to be cer-
tain the pump remains in neutral. With the engine at nor-
mal operating RPM, slowly check for forward and reverse
DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL machine operation.
POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU- Charge pressure may slightly decrease during forward or
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS reverse operation. Continue to cycle slowly between for-
ACTUATED DURING INITIAL START-UP. ward and reverse for at least five minutes.

"Jog" or slowly rotate the engine until charge pressure Shut down engine, remove gauges, and plug ports.
starts to rise. Start the engine and run at the lowest possi- Check reservoir level and add filtered fluid if needed.
ble RPM until charge pressure has been established. The machine is now ready for operation.
Excess air should be bled from the system lines as close
to the motors as possible. 5.10 HYDRAULIC PUMP W/HAYES PUMP
NOTE: With the engine on low idle, "crack", (loosen-don't DRIVE COUPLING LUBRICATION
remove), the system lines at the motor(s). Continue
to run the engine at low idle and tighten the system Any time pump or pump drive coupling is removed coat,
lines as soon as oil is observed to leak from them. pump and drive coupling splines with Lithium Soap Base
When oil is observed to "leak" at the motor the line is Grease (TEXACO CODE 1912 OR EQUIVALENT) coupling
full, the air has been purged, and the system hoses is greased prior to assembly.
should be retightened to their specified torque.

Once charge pressure has been established, increase

speed to normal operating RPM. Charge pressure should
be as indicated in the pump model code. If charge pres-
sure is inadequate, shut down and determine the cause
for improper pressure.

3121201 – JLG Lift – 5-43

SECTION 5 - HYDRAULICS

NOTES:

5-44 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

SECTION 6. JLG CONTROL SYSTEM

6.1 INTRODUCTION creep, min speed, and max.-speed for all boom, drive,
and steering functions.
The upper lift, swing, and drive are controlled by individual
joysticks, with steering being controlled by a rocker switch
WHEN INSTALLING A NEW GROUND MODULE CONTROLLER ON built into the top the drive joystick. To activate Drive, Lift,
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- and Swing simply pull up on the slide lock location on the
TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUD- joystick and move the handle into the direction desired.
ING OPTIONS.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation
and maximum cycle time. Ground control speeds for all
boom functions can also be programmed into the control
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
system.
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- The JLG Control System controller has a built in LED to
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC- indicate any faults. The system stores recent faults which
OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A may be accessed for troubleshooting. Optional equip-
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM ment includes a soft touch system, head and tail lights,
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO- and ground alarm. These options may be added later but
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE must be programmed into the control system when
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION. installed.
The Control System may be accessed utilizing a custom
The JLG designed Control System is a 12 volt based designed, hand held analyzer (Analyzer Kit, JLG part no.
motor control unit installed on the boom lift. 2901443) which will display two lines of information at a
time, by scrolling through the program.
The JLG Control System has reduced the need for
NOTE: Each module has a label with the JLG part number
exposed terminal strips, diodes and trimpots and provides
and a serial number which contains a date code.
simplicity in viewing and adjusting the various personality
settings for smooth control of: acceleration, deceleration,

Analyzer Display

Enter Key
Escape Key
Stores and selects Top Level, Sub
To return home or access
Level, and item menus
previous menu

Left & Right Arrow Keys

Up & Down Arrow Keys Used to move between Top Level,
Value Selector
Sub Level, and item menus

Figure 6-1. Hand Held Analyzer

3121201 – JLG Lift – 6-1

When a top level menu is selected, a new set of menu

items may be offered: for example:
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected
menu. In some cases, such as DRIVE, the next level is the
parameter or information to be changed. Refer to the flow
chart for what menus are available within the top level
menus. You may only view the personality settings for
selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the
ESC. key.

6.4 CHANGING THE ACCESS LEVEL OF THE

HAND HELD ANALYZER
When the analyzer is first connected, you will be in access
level 2 which enables you to only view most settings
which cannot be changed until you enter a password to
advance to a lower level. This ensures that a setting can-
not be accidentally altered. To change the access level, MENU:
the correct password must be entered. To enter the pass- ACCESS LEVEL 2
word, scroll to the ACCESS LEVEL menu. For example: Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the pass-
word.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.

3121201 – JLG Lift – 6-5

SECTION 6 - JLG CONTROL SYSTEM

Figure 6-4. Control Module Location

6-6 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Once the correct password is displayed, press ENTER. 6.5 ADJUSTING PARAMETERS USING THE
The access level should display the following, if the pass-
word was entered correctly:
HAND HELD ANALYZER
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:

MENU:
ACCESS LEVEL 1

Repeat the above steps if the correct access level is not

displayed or you can not adjust the personality settings. PERSONALITIES:
DRIVE ACCEL 1.0s

There will be a minimum and maximum for the value to

ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular per-
sonality. If the value does not change when pressing the
up and won arrows, check the access level to ensure you
are at access level 1.

3121201 – JLG Lift – 6-7

SECTION 6 - JLG CONTROL SYSTEM

6.6 MACHINE SETUP

When a machine digit item is selected, press the UP or ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
DOWN arrow keys to adjust its value, for example: TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOM-
MENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

6.7 LEVEL VEHICLE DESCRIPTION

A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE

TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.

DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL

SURFACE.

GROUND ALARM:
2 = LIFT DOWN

The effect of the machine digit value is displayed along

with its value. The above display would be selected if the
machine was equipped with a ground alarm and you
wanted it to sound when lifting down. There are certain
settings allowed to install optional features or select the
machine model.

When selection the machine model to match the size of

the machine, the personality settings will all default to the
factory recommended setting.

NOTE: Refer to Table 6-1, Personality Ranges/Defaults, and

in this Service Manual for the recommended factory
settings.

NOTE: Password 33271 will give you access to level 1,

Place machine in stowed position with the boom between
which will permit you to change all machine person-
the rear wheels.
ality settings.
To level machine chose:
There is a setting that JLG strongly recommends that you
do not change. This setting is so noted below: CALIBRATION:
TILT SENSOR
ELEVATION CUTBACK
Press ENTER.

When prompted, swing machine 180°

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER- Press ENTER.
FORMANCE OF YOUR MACHINE.

6-8 – JLG Lift – 3121201

3121201
ACCESS LEVEL:
CODE 33271

MENU: ACCESS LEVEL: TO

ACCESS LEVEL 1 CODE 00000 PERSONALITIES:
TOWER LIFT

MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

PERSONALITIES DRIVE STEER LEFT TRACK RIGHT TRACK MAIN LIFT SWING

DRIVE: STEER: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:

ACCEL X.XS MAX SPEED X% ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS

DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:

DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS

DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:

MIN FORWARD X% MIN FORWARD X% MIN FORWARD X% MIN UP X% MIN LEFT X%
DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:
MAX FORWARD X% MAX FORWARD X% MAX FORWARD X% MAX UP X% MAX LEFT X%

– JLG Lift –
DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:
MIN REVERSE X% MIN REVERSE X% MIN REVERSE X% CREEP UP X% CREEP LEFT X%
DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:
MAX REVERSE X% MAX REVERSE X% MAX REVERSE X% MIN DOWN X% MIN RIGHT X%

DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:

ELEV. MAX X% ELEV F MAX X% ELEV F MAX X% MAX DOWN X% MAX RIGHT X%
DRIVE: LEFT TRACK: RIGHT TRACK: MAIN LIFT: SWING:
CREEP MAX X% ELEV R MAX X% ELEV R MAX X% CREEP DOWN X% CREEP RIGHT X%

LEFT TRACK: RIGHT TRACK:

CREEP F MAX X% CREEP F MAX X%

LEFT TRACK: RIGHT TRACK:

CREEP R MAX X% CREEP R MAX X%

TO Note: Some screens may not be available depending upon machine configuration.
MENU:
MACHINE SETUP
Figure 6-5. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4

6-9
SECTION 6 - JLG CONTROL SYSTEM
6-10
FROM
PERSONALITIES:
SWING

PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

TOWER LIFT UPPER TELESCOPE TOWER TELESCOPE BASKET LEVEL BASKET ROTATE JIB LIFT GROUND MODE GEN SET/WELDER

TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE: GEN SET/WELDER:
SECTION 6 - JLG CONTROL SYSTEM

ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS U. LIFT UP X% ENGINE 1800 RPM

TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE:
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS U. LIFT DOWN X%

TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE:
MIN UP X% MIN IN X% MIN IN X% MIN UP X% MIN LEFT X% MIN UP X% SWING X%

TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE:
MAX UP X% MAX IN X% MAX IN X% MAX UP X% MAX LEFT X% MAX UP X% BASKET LEVEL X%

TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE:

– JLG Lift –
MIN DOWN X% MIN OUT X% MIN OUT X% MIN DOWN X% MIN RIGHT X% MIN DOWN X% BASKET ROTATE X%

TOWER LIFT: UPPER TELESCOPE: TOWER TELESCOPE: BASKET LEVEL: BASKET ROTATE: JIB LIFT: GROUND MODE:
MAX DOWN X% MAX OUT X% MAX OUT X% MAX DOWN X% MAX RIGHT X% MAX DOWN X% UPPER TELE X%

GROUND MODE:
TOWER TELE X%
GROUND MODE:
T. LIFT UP X%
GROUND MODE:
T. LIFT DN X%

GROUND MODE:
JIB (U/D) X%

Figure 6-6. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4

3121201
3121201
FROM
MENU:
PERSONALITIES

MENU: MODEL NUMBER: ENGINE: GLOW PLUG: ENGINE SHUTDOWN: TILT: TOWER LIFT: TOWER TELE: JIB: 4 WHEEL STEER:
MACHINE SETUP 1=400 1=FORD EFI GAS 0=NO GLOW PLUGS 1=SHUTDOWN 1=5 DEG 0=NO 0=NO 0=NO 0=NO

MODEL NUMBER: ENGINE: GLOW PLUG: ENGINE SHUTDOWN: TILT: TOWER LIFT: TOWER TELE: JIB: 4 WHEEL STEER:
2=450 2=FORD EFI D/F 15=15 SECONDS 0=NO 2=4 DEG 1=YES 1=YES 0=YES 0=YES

TO MODEL NUMBER: ENGINE: TILT:

MENU: 3=600 3=DEUTZ F4 3=3 DEG
CALIBRATIONS
MODEL NUMBER: ENGINE: TILT:
4=601 4=DEUTZ F3 4=4 DEG + CUT

MODEL NUMBER: ENGINE: TILT:

5=800A 5=CAT. 3024C 5=3 DEG + CUT

MODEL NUMBER: ENGINE:

6=800S 6=CAT. 3044C

MODEL NUMBER:
9=600C

MODEL NUMBER:
10=510A

– JLG Lift –
MODEL NUMBER:
11=740A

SOFT TOUCH: GEN SET/WELDER: H & T LIGHTS: CABLE SWITCH: LOAD: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM: T PROX SWITCHES: DRIVE: FLYWHEEL TEETH:
0=NO 0=NO 0=NO 0=NO 0=NO 0=1 ON ROTATOR 0=NO 0=NO 0=NO 0=4WD 0=133 TEETH

SOFT TOUCH: GEN SET/WELDER: H & T LIGHTS: CABLE SWITCH: LOAD: LOAD TYPE: FUNCTION CUTOUT: GROUND ALARM: T PROX SWITCHES: DRIVE: FLYWHEEL TEETH:
1=YES 1=BELT DRIVE 1=YES 1=YES 1=WARN ONLY 1=4 UNDER BASKET 1=BOOM CUTOUT 1=DRIVE 1=YES 1=2WD 1=110 TEETH

GEN SET/WELDER: LOAD: FUNCTION CUTOUT: GROUND ALARM:

2=HYD. DRIVE 2=CUTOUT PLAT 2=DRIVE CUTOUT 2=LIFT DOWN

LOAD: FUNCTION CUTOUT: GROUND ALARM:

3=CUTOUT ALL 3=DRIVE CUT E&T 3=BOOM & DRIVE

LOAD:
4=SPECIAL 1

Figure 6-7. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4

6-11
SECTION 6 - JLG CONTROL SYSTEM
6-12
SECTION 6 - JLG CONTROL SYSTEM

– JLG Lift –
Figure 6-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4

3121201
3121201
– JLG Lift –
NOTE: Some screens may not be available depending upon machine configuration.

Figure 6-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4

6-13
SECTION 6 - JLG CONTROL SYSTEM
6-14
SECTION 6 - JLG CONTROL SYSTEM

– JLG Lift –
Figure 6-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4

3121201
3121201
FROM:
MENU:
PERSONALITIES

MENU: MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: TILT: JIB: 4 WHEEL STEER: SOFT TOUCH:
MACHINE SETUP 400S ANSI USA FORD EFI GAS 110 TEETH NO GLOW PLUGS DISABLED ENABLED 5 DEGREES NO NO NO
MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN: TILT: JIB: 4 WHEEL STEER: SOFT TOUCH:
450A ANSI EXPORT FORD EFI D/F 133 TEETH AIR INTAKE ENABLED DISABLED 4 DEGREES YES YES YES
MODEL NUMBER: MARKET: ENGINE: GLOW PLUG: TILT:
510A CSA DEUTZ F4 TIER1 IN-CYLINDER 3 DEGREES

TO: MODEL NUMBER: MARKET: ENGINE: TILT:

MENU: 600S CE DEUTZ F3 TIER1 4 DEGREES + CUT
CALIBRATIONS
MODEL NUMBER: MARKET: ENGINE: TILT:
600A AUSTRALIA CAT. 3024C 3 DEGREES + CUT
MODEL NUMBER: MARKET: ENGINE:
600SC JAPAN CAT. 3044C
MODEL NUMBER: ENGINE:
601S PERKINS 404C
MODEL NUMBER: ENGINE:
740A DEUTZ F4 TIER2
MODEL NUMBER: ENGINE:
800A DEUTZ F3 TIER2
MODEL NUMBER: ENGINE:
800S FORD GAS TIER2

– JLG Lift –
ENGINE:
FORD D/F TIER2
ENGINE:
DEUTZ ECM
ENGINE:
DUAL FUEL ECM

GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: CABLE SWITCH: LOAD SYSTEM: LOAD SENSOR: FUNCTION CUTOUT: GROUND ALARM: DRIVE: TEMPERATURE: LEVELING MODE:
NO MOTION ENABLED NO NO NO 4 UNDER PLATFORM NO NO 4WD CELSIUS ALL FUNCTIONS
GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: CABLE SWITCH: LOAD SYSTEM: LOAD SENSOR: FUNCTION CUTOUT: GROUND ALARM: DRIVE: TEMPERATURE: LEVELING MODE:
BELT DRIVE MOTION CUTOUT YES YES WARN ONLY 1 ON ROTATOR BOOM CUTOUT DRIVE 2WD FAHRENHEIT LIFT/TELESCOPE
LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM: DRIVE:
CUTOUT PLATFORM DRIVE CUTOUT DESCENT 2WD W/ 2-SPEED
LOAD SYSTEM: FUNCTION CUTOUT: GROUND ALARM:
CUTOUT ALL DRIVE CUT E&T MOTION
LOAD SYSTEM:
SPECIAL 1

Figure 6-11. Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4

6-15
SECTION 6 - JLG CONTROL SYSTEM
6-16
FROM:
MENU:
MACHINE SETUP

MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

CALIBRATIONS TILT SENSOR UMS SENSOR DEUTZ SETUP LEVEL UP CRKPT LEVEL DOWN CRKPT

TILT SENSOR UMS SENSOR: DEUTZ SETUP LEVEL UP CRKPT LEVEL DOWN CRKPT
CALIBRATE? CALIBRATE? SETUP X CALIBRATE? CALIBRATE?

MENU: HELP:
HELP:PRESS ENTER GROUND MODE OK

MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: CREEP DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS DRIVE/STEER BOOM FUNCTIONS ENGINE SYSTEM SWITCH: CLOSED UMS LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS

JOYSTICK DRIVE: JOYSTICK LIFT: START SEQUENCE: GROUND MODULE CREEP MODE: CHASSIS TILT PLATFORM LOAD CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE
FORWARD XXX% MAIN UP XXX% NOT ACTIVE BATTERY: XX.XV OFF ANGLE XXX.X STATE:OK RX/SEC: X LOAD ZERO: XXX ON: XXH XXM SOFTWARE: P5.0
SECTION 6 - JLG CONTROL SYSTEM

JOYSTICK STEER: JOYSTICK SWING: AIR FILTER PLATFORM MODULE CHASSIS TILT: UMS TO TURNTABLE PERCENT OF MAX CAN STATISTICS CALABRATION DATA DATALOG: GROUND MODULE
LEFT XXX% LEFT XXX% SWITCH: OPEN BATTERY: XX.XV XX.X DEGREES ANGLE XXX.X LOAD: XXXX% TX/SEC: X LOAD 500LB: XXX ENGINE: XH XM CNST. DATA: PX.X

DRIVE OUTPUT: LIFT OUTPUT: BATTERY VOLTAGE: AMBIENT AUXILIARY POWER UMS INCLINATION CAPACITY ANGLE CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE
FORWARD XXX% MAIN UP XXX% XX.XV TEMPERATURE:XXXC SWITCH: OPEN ANGLE XXX.X SWITCH: CLOSED BUS OFF: X PLATFORM UP: XXX DRIVE: XH XM HARDWARE: REV X

STEER OUTPUT: SWING OUTPUT: COOLANT PLATFORM SELECT HORN UMS STATUS: CAPACITY LENGTH CAN STATISTICS CALABRATION DATA DATALOG: GROUND MODULE
LEFT XXX% LEFT XXX% TEMPERATURE:XXXC KEYSWITCH: OPEN SWITCH: OPEN NORMAL SWITCH: CLOSED PASSIVE: 1 PLATFORM DN: XXX LIFT: XH XM S/N: XXXXXX

LEFT TRACK PLATFORM LEVEL: ELECTRIC FAN GROUND SELECT RETURN HYDRAULIC CAN STATISTICS DATALOG: PLATFORM MODULE
OUTPUT: FWD XXX% UP XXX% OUTPUT: OFF KEYSWITCH:CLOSED FILTER: OPEN MSG ERROR: XXXX SWING: XH XM SOFTWARE: P5.0

RIGHT TRACK PLATFORM ROTATE: ELECTRIC FUEL STATION CONTROL: CHARGE PUMP DATALOG: PLATFORM MODULE
OUTPUT: FWD XXX% RIGHT XXX% PUMP OUTPUT: OFF GROUND FILTER: OPEN TELE: XH XM HARDWARE: REV X

– JLG Lift –
STEER TYPE: MAIN TELESCOPE: ENGINE OIL FOOTSWITCH INPUT SOFT TOUCH LIMIT DATALOG: PLATFORM MODULE
NORMAL IN XXX% PRESSURE:XXXXPSI GROUND: OPEN SWITCH: OPEN MAX TEMP: XXC S/N: XXXXXX

BRAKES STATUS: TOWER TELESCOPE: FUEL SELECTION FOOTSWITCH INPUT SOFT TOUCH DATALOG: PROPULSION MOD.
LOCKED IN XXX% SWITCH:GAS PLATFORM: CLOSED OVERRIDE: OPEN MIN TEMP: XXC SOFTWARE: PX.X

CREEP TOWER LIFT: FUEL SELECTION TRANSPORT GENSET/WELDER DATALOG: ANALYZER:

SWITCH: CLOSED DOWN XXX% STATUS:GAS SWITCHES: OPEN SWITCH: OPEN MAX VOLTS: XX.XV ANALYZER V6.3

CREEP MODE: JIB LIFT: AMBIENT TRANSPORT MODE: LIGHTS DATALOG:

OFF UP XXX% TEMPERATURE:XXXC OUT OF TRANSPORT SWITCH: OPEN RENTAL: XH XM

2-SPEED PLATFORM CONTROL FUEL LEVEL END OF STROKE PLATFORM TILT1 DATALOG:
SWITCH: OPEN VALVE: OFF SENSOR: OK PROXIMITY: OPEN ANGLE: XX.X DEG ERASE RENTAL?

2-SPEED VALVE FUNCTION SPEED: STARTER TOWER LIFT PLATFORM TILT2

OUTPUT: OFF PUMP POT XXX% CRANK TIME: XX S PROXIMITY:CLOSED ANGLE: XX.X DEG

HIGH ENGINE CREEP ENGINE SPEED TOWER TELESCOPE PLATFORM TILT1

SWITCH: OPEN SWITCH: CLOSED ACTUAL: XXXX RPM PROXIMITY:CLOSED VOLTAGE: XXXX MV

DRIVE MODE: CREEP MODE: ENGINE SPEED TOWER POSITION: PLATFORM TILT2
MID ENGINE OFF TARGET: XXXX RPM UP/RETRACTED VOLTAGE: XXXX MV

CABLE BREAK CHASSIS TILT:

SWITCH: CLOSED X-AXIS XX.X

CHASSIS TILT:
Y-AXIS XX.X

MENU: SYSTEM TEST:

SYSTEM TEST ACTIVATE?

Figure 6-12. Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4

3121201
SECTION 6 - JLG CONTROL SYSTEM

6.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the
adjustment range in order to achieve optimum
machine performance.

Table 6-1. Personality Ranges/Defaults

FUNCTION PERSONALITY RANGE DEFAULTS

DRIVE ACCELeration 0.1s to 5.0s 2.0

DECELeration 0.1s to 3.0s 2.0

Forward MINimum speed 0 to 35% 4

Forward MAXimum speed 0 to 100% 35

REVerse MINimum speed 0 to 35% 4

REVerse MAXimum speed 0 to 100% 22

ELEVATED MAXimum speed 0 to 50% 10

CREEP MAXimum speed 0 to 50% 25

Engine RPM 800 to 2900 1800

TOWER LIFT ACCELeration 0.1 to 5.0 1.0

DECELeration 0.1 to 3.0 0.5

MlNimum UP speed 0 to 60% 50

MAXimum UP speed 0 to 100% 100

MINimum DOWN speed 0 to 60% 50

MAXimum DOWN speed 0 to 100% 100

Engine RPM 800 to 2900 1800

UPPER LIFT ACCELeration 0.1 to 5.0 2.0

DECELeration 0.1 to 3.0 0.7

MlNimum UP speed 0 to 60% 30

MAXimum UP speed 0 to 100% 55

CREEP Maximum UP speed 0 to 65% 55

MINimum DOWN speed 0 to 60% 40

MAXimum DOWN speed 0 to 100% 65

CREEP maximum DOWN speed 0 to 75% 55

Engine RPM 800 to 2900 1800

3121201 – JLG Lift – 6-17

SECTION 6 - JLG CONTROL SYSTEM

Table 6-1. Personality Ranges/Defaults

FUNCTION PERSONALITY RANGE DEFAULTS

SWING ACCELeration 0.1 to 5.0s 2.0

DECELeration 0.1 to 3.0s 1.8

MINimum LEFT speed 0 to 50% 30

MAXimum LEFT speed 0 to 100% 95

CREEP maximum LEFT speed 0 to 65% 53

MINimum RIGHT speed 0 to 50% 30

MAXimum RIGHT speed 0 to 100% 95

CREEP maximum RIGHT speed 0 to 65% 53

Engine RPM 800 to 2900 1400

TELESCOPE UPPER ACCELeration 0.1 to 5.0 3.5

DECELeration 0.1 to 3.0 0.8

MINimum IN speed 0 to 65% 45

MAXimum IN speed 0 to 100% 75

MINimum OUT speed 0 to 65% 45

MAXimum OUT speed 0 to 100% 70

Engine RPM 800 to 2900 1800

TELESCOPE TOWER ACCELeration 0.1 to 5.0 1.0

DECELeration 0.1 to 3.0 0.5

MINimum IN speed 0 to 65% 50

MAXimum IN speed 0 to 100% 100

MINimum OUT speed 0 to 65% 50

MAXimum OUT speed 0 to 100% 100

Engine RPM 800 to 2900 1800

BASKET LEVEL ACCELeration 0.1 to 5.0 2.5

DECELeration 0.1 to 3.0 0.5

MINimum UP speed 0 to 65% 48

MAXimum UP speed 0 to 100% 52

MlNimum DOWN speed 0 to 65% 45

MAXimum DOWN speed 0 to 100% 50

Engine RPM 800 to 2900 1500

6-18 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-1. Personality Ranges/Defaults

FUNCTION PERSONALITY RANGE DEFAULTS

BASKET ROTATE ACCELeration 0.1 to 5.0 1.8

DECELeration 0.1 to 3.0 0.7

MlNimum LEFT speed 0 to 65% 46

MAXimum LEFT speed 0 to 100% 50

MINimum RIGHT speed 0 to 65% 46

MAXimum RIGHT speed 0 to 100% 50

Engine RPM 800 to 2900 1500

JIB LIFT ACCELeration 0.1 to 5.0 5.0

DECELeration 0.1 to 3.0 1.0

MINimum UP speed 0 to 65% 46

MAXimum UP speed 0 to 100% 52

MINimum DOWN speed 0 to 65% 45

MAXimum DOWN speed 0 to 100% 52

Engine RPM 800 to 2900 1800

STEER MAXimum speed 0 to 100% 100

Engine RPM 800 to 2900 1800

GROUND MODE Tower LIFT UP speed 0 to 100% 100

Tower LIFT DOWN speed 0 to 100% 100

Upper LIFT UP 0 to 100% 60

Upper LIFT DOWN 0 to 100% 60

SWING speed 0 to 100% 60

Upper TELEscope speed 0 to 100% 70

Tower TELEscope speed 0 to 100% 100

BASKET ROTATE speed 0 to 100% 50

BASKET LEVEL speed 0 to 100% 50

Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3

Configuration Digit Number Description Default Number

MODEL NUMBER: 1 400S 1

1 2 450A
3 510A
4 600S
5 600A
6 600SC
7 601S
8 740A
9 800A
10 800S

MARKET: 0 ANSI USA 0

2 1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN

ENGINE: 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 11

3*
* Engine selections vary 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
depending on model selec-
tion. 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)

4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1)

5 CAT. 3024C: CAT 3024C Diesel (Tier 2)

6 CAT. 3044C: CAT 3044C Diesel (Tier 2)

7 DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)

8 DEUTZ F3 TIER2: Deutz F3M2011 Diesel (Tier 2)

9 FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)

10 FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)

11 DEUTZ ECM: Engine Control Module - ECM

FLYWHEEL TEETH: 0 133 TEETH: 133 flywheel teeth. 1

4*
* This menu item is only visible if 1 110 TEETH: 110 flywheel teeth.
Deutz engine selections 3 or 4 are
selected.

3121201 – JLG Lift – 6-31

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3

Configuration Digit Number Description Default Number

GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 1

5
1 W/O STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;
engine start can be attempted at any time during pre-glow.

2 W/ STARTER LOCK: Automatic pre-glow time determined by ambient air temperature;

engine start is NOT permitted until pre-glow is finished.

ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

6
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the
oil pressure is less than 8 psi.

TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted 1
7* more than 5 degrees and above elevation; also reduces drive speed to creep.
* Certain market selections
will limit tilt options. 2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 4 degrees and above elevation; also reduces drive speed to creep.

3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 3 degrees and above elevation; also reduces drive speed to creep.

4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 4 degrees and above elevation; also disallows tower lift up, tower tele-
scope out, drive, main telescope out and main lift up.

5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 3 degrees and above elevation; also disallows tower lift up, tower tele-
scope out, drive, main telescope out and main lift up.

Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and
will sound the platform alarm when the machine is also above elevation.

JIB: 0 NO: No jib installed. 0

8*
* Only visible under certain 1 YES: Jib installed which has up and down movements only.
model selections

4 WHEEL STEER: 0 NO: No four-wheel steer installed. 0

9*
* Only visible under certain 1 YES: Four-wheel steer installed.
model selections.

SOFT TOUCH: 0 NO: No soft touch system installed. 0

10*
* Only visible under certain 1 YES: Soft touch system installed.
model selections.

GEN SET/WELDER: 0 NO: No generator installed. 0

11
1 BELT DRIVE: Belt driven setup.

6-32 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3

Configuration Digit Number Description Default Number

GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
12*
* Only visible if Gen Set / 1 MOTION CUTOUT: Motion cutout in platform mode only.
Welder Menu selection is not 0.

H & T LIGHTS: 0 NO: No head and tail lights installed. 0

13
1 YES: Head and tail lights installed.

CABLE SWITCH: 0 NO: No broken cable switch installed. 0

14*
* Only visible under certain 1 YES: Broken cable switch installed.
model selections.
* Certain market and model
selections will alter the default
setting.

LOAD SYSTEM: 0 NO: No load sensor installed. 0

15*
* Only visible under certain 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2
model selections. sec OFF).
* Certain market selections will
limit load system options or 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5
alter default setting.
sec ON, 2 sec OFF).

3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform
alarm beeps (5 sec ON, 2 sec OFF).

4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift
up, platform alarm beeps (5 sec ON, 2 sec OFF).
LOAD SENSOR: 0 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the 1
16* Leveling Platform Module.
* Only visible if Load Sensor
Menu selection is not 0. 1 4 UNDER PLATFORM: Use the EIM for load sensing.
* Market selections will limit
certain load sensor options.

FUNCTION CUTOUT: 0 NO: No drive cutout. 0

17*
* Only visible under certain 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
market selections.
* Certain market selections 2 DRIVE CUTOUT: Drive cutout above elevation.
will limit function cutout options
or alter default setting.
3 DRIVE CUT E&T: Drive cutout above elevation and tilted.

3121201 – JLG Lift – 6-33

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3

Configuration Digit Number Description Default Number

GROUND ALARM: 0 NO: No ground alarm installed. 0

18*
* Certain market selections will 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
alter default setting.
2 DESCENT: Descent alarm sounds when lift down is active (Option).

3 MOTION: Motion alarm sounds when any function is active (Option).

DRIVE: 0 4WD: Four wheel drive. 0

19*
* Only visible under certain 1 2WD: Two wheel drive.
model selections.
2 2WD W/ 2-SPEED: Two wheel drive with 2-speed valve.
TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1
20
1 FAHRENHEIT: Fahrenheit unit selection.

LEVELING MODE: 0 ALL FUNCTIONS: Platform level with all functions. 0

21*
* Only visible on 800S models. 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
4150364-14

6-34 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1

Configuration Label/ Default

Number Description
Digit Number

MODEL NUMBER: 1 400S 1

1
2 450A

3 510A

4 600S

5 600A

6 600SC

7 601S

8 740A

9 800A

10 800S

MARKET: 0 ANSI USA 0

2
1 ANSI EXPORT

2 CSA

3 CE

4 AUSTRALIA

5 JAPAN

3121201 – JLG Lift – 6-35

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1

Configuration Label/ Default

Number Description
Digit Number

ENGINE: 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 7

3*
* Engine selections vary 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
depending on model selec-
tion. 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)

4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1)

5 CAT. 3024C: CAT 3024C Diesel (Tier 2)

6 CAT. 3044C: CAT 3044C Diesel (Tier 2)

7 PERKINS 404C (Tier 2)

8 DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)

9 DEUTZ F3 TIER2: Deutz F3M2011 Diesel (Tier 2)

10 FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)

11 FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)

12 DEUTZ ECM: Engine Control Module - ECM

13 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)

FLYWHEEL TEETH: 0 133 TEETH: 133 flywheel teeth. 1

4*
* This menu item is only 1 110 TEETH: 110 flywheel teeth.
visible if Deutz engine
selections 3 or 4 are
selected.

GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.

2 IN-CYLINDER: Glow plugs installed in each cylinder.

STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine 0
6 start can be attempted at any time during pre-glow.

1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine

start is NOT permitted until pre-glow is finished.

6-36 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1

Configuration Label/ Default

Number Description
Digit Number

ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the
oil pressure is less than 8 PSI.

TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted 1
8* more than 5 degrees and above elevation; also reduces drive speed to creep.
* Certain market selections
will limit tilt options and alter 2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
default setting. more than 4 degrees and above elevation; also reduces drive speed to creep.

Note: Any of the selections 3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
above will light the tilt lamp more than 3 degrees and above elevation; also reduces drive speed to creep.
when a tilted condition
occurs and will sound the 4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
platform alarm when the tilted more than 4 degrees and above elevation; also disallows tower lift up, tower tele-
machine is also above ele- scope out, drive, main telescope out and main lift up.
vation.
5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when
tilted more than 3 degrees and above elevation; also disallows tower lift up, tower tele-
scope out, drive, main telescope out and main lift up.

JIB: 0 NO: No jib installed. 0

9*
* Only visible under certain 1 YES: Jib installed which has up and down movements only.
model selections.

4 WHEEL STEER: 0 NO: No four-wheel steer installed. 0

10*
* Only visible under certain 1 YES: Four-wheel steer installed.
model selections.

SOFT TOUCH: 0 NO: No soft touch system installed. 0

11*
* Only visible under certain 1 YES: Soft touch system installed.
model selections.

GEN SET/WELDER: 0 NO: No generator installed. 0

12
1 BELT DRIVE: Belt driven setup.

3121201 – JLG Lift – 6-37

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1

Configuration Label/ Default

Number Description
Digit Number

GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
13*
* Only visible if Gen Set / 1 MOTION CUTOUT: Motion cutout in platform mode only.
Welder Menu selection is
not 0.

H & T LIGHTS: 0 NO: No head and tail lights installed. 0

14
1 YES: Head and tail lights installed.

CABLE SWITCH: 0 NO: No broken cable switch installed. 0

15*
* Only visible under certain 1 YES: Broken cable switch installed.
model selections.
* Certain market and
model selections will alter
the default setting.

LOAD SYSTEM: 0 NO: No load sensor installed. 0

16*
* Only visible under certain 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2
market selections. sec OFF).
* Certain market selections
will limit load system 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5
options or alter default set- sec ON, 2 sec OFF).
ting.
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform
alarm beeps (5 sec ON, 2 sec OFF).

4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift
up, platform alarm beeps (5 sec ON, 2 sec OFF).

LOAD SENSOR: 0 1 ON ROTATOR: Use the on-board load sensor for all models except those which use the 1
17* Leveling Platform Module.
* Only visible if Load Sen-
sor Menu selection is not 0 1 4 UNDER PLATFORM: Use the EIM for load sensing.
and under certain market
selections.
* Certain market selections
will limit load sensor
options.

6-38 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1

Configuration Label/ Default

Number Description
Digit Number

FUNCTION CUTOUT: 0 NO: No drive cutout. 0

18*
* Only visible under certain 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
market selections.
* Certain market selections 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
will limit function cutout
options or alter default set- 3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
ting.

GROUND ALARM: 0 NO: No ground alarm installed. 3

19*
* Certain market selections 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
will alter default setting.
2 DESCENT: Descent alarm sounds when lift down is active (Option).

3 MOTION: Motion alarm sounds when any function is active (Option).

DRIVE: 0 4WD: Four wheel drive. 0

20*
* Only visible under certain 1 2WD: Two wheel drive.
model selections.
2 2WD W/ 2-SPEED: Two wheel drive with 2-speed valve.

TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1

21*
* Certain market selections 1 FAHRENHEIT: Fahrenheit unit selection.
will alter default setting.

LEVELING MODE: 0 ALL FUNCTIONS: Platform level with all functions. 0

22*
* Only visible on 800S 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
models.

4150364-18

3121201 – JLG Lift – 6-39

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present

Configuration Label/ Default

Number Description
Digit Number

MODEL NUMBER: 1 400S 1

1
2 450A

3 510A

4 600S

5 600A

6 600SC

7 601S

8 740A

9 800A

10 800S

MARKET: 0 ANSI USA 0

2
1 ANSI EXPORT

2 CSA

3 CE

4 AUSTRALIA

5 JAPAN

6-40 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present

Configuration Label/ Default

Number Description
Digit Number

ENGINE: 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 14

3*
* Engine selections vary 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
depending on model selec-
tion. 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)

4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1)

5 CAT. 3024C: CAT 3024C Diesel (Tier 2)

6 CAT. 3044C: CAT 3044C Diesel (Tier 2)

7 PERKINS 404C (Tier 2)

8 DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)

9 DEUTZ F3 TIER2: Deutz F3M2011 Diesel (Tier 2)

10 FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)

11 FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)

12 DEUTZ ECM: Engine Control Module - ECM (Tier 2 and Tier 3)

13 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)

14 PERKINS ECM

15 CAT ECM

FLYWHEEL TEETH: 0 133 TEETH: 133 flywheel teeth. 1

4*
* This menu item is only 1 110 TEETH: 110 flywheel teeth.
visible if Deutz engine
selections 3 or 4 are
selected.

GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.

2 IN-CYLINDER: Glow plugs installed in each cylinder.

3121201 – JLG Lift – 6-41

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present

Configuration Label/ Default

Number Description
Digit Number

STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine 0
6 start can be attempted at any time during pre-glow.

1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine

start is NOT permitted until pre-glow is finished.

ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the
oil pressure is less than 8 PSI.

JIB: 0 NO: No jib installed. 0

9*
* Only visible under certain 1 YES: Jib installed which has up and down movements only.
model selections.

4 WHEEL STEER: 0 NO: No four-wheel steer installed. 0

10*
* Only visible under certain 1 YES: Four-wheel steer installed.
model selections.

SOFT TOUCH: 0 NO: No soft touch system installed. 0

11*
* Only visible under certain 1 YES: Soft touch system installed.
model selections.

6-42 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present

Configuration Label/ Default

Number Description
Digit Number

GEN SET/WELDER: 0 NO: No generator installed. 0

12
1 BELT DRIVE: Belt driven setup.

GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
13*
* Only visible if Gen Set / 1 MOTION CUTOUT: Motion cutout in platform mode only.
Welder Menu selection is
not 0.

H & T LIGHTS: 0 NO: No head and tail lights installed. 0

14
1 YES: Head and tail lights installed.

CABLE SWITCH: 0 NO: No broken cable switch installed. 0

15*
* Only visible under certain 1 YES: Broken cable switch installed.
model selections.
* Certain market and
model selections will alter
the default setting.

LOAD SYSTEM: 0 NO: No load sensor installed. 0

4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift
up, platform alarm beeps (5 sec ON, 2 sec OFF).

3121201 – JLG Lift – 6-43

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present

Configuration Label/ Default

Number Description
Digit Number

FUNCTION CUTOUT: 0 NO: No drive cutout. 0

GROUND ALARM: 0 NO: No ground alarm installed. 3

19*
* Certain market selections 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
will alter default setting.
2 DESCENT: Descent alarm sounds when lift down is active (Option).

3 MOTION: Motion alarm sounds when any function is active (Option).

DRIVE: 0 4WD: Four wheel drive. 0

20*
* Only visible under certain 1 2WD: Two wheel drive.
model selections.
2 2WD W/ 2-SPEED: Two wheel drive with 2-speed valve.

TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1

21*
* Certain market selections 1 FAHRENHEIT: Fahrenheit unit selection.
will alter default setting.

6-44 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information Software Version P6.1 to Present

Configuration Label/ Default

Number Description
Digit Number

LEVELING MODE: 0 ALL FUNCTIONS: Platform level with all functions. 0

22*
* Only visible on 800S 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
models.

DRIVE CONTROL: 0 NORMAL: Drive coils are energized from the Ground Module. 2
23
1 PROPULSION: Drive coils are energized from the Propulsion Module.

2 ENHANCED: Drive coils are energized from the Ground Module and the ground side of
the drive coils are brought back to current feedback returns.

CLEARSKY: 0 NO: Clearsky (telematics) option is disabled. 0

24
1 YES: Clearsky (telematics) option is enabled.

CRIBBING OPTION: 0 NO: Cribbing Option is disabled. 0

25
1 YES: Cribbing Option is enabled.

4150364-19

3121201 – JLG Lift – 6-45

SECTION 6 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic
underlined numbers indicate the default when the option is factory installed.

ENGINE SHUTDOWN
STARTER LOCKOUT

GEN SET / WELDER

FLYWHEEL TEETH

GEN SET CUTOUT

MODEL NUMBER

4 WHEEL STEER
GLOW PLUGS

SOFT TOUCH
MARKET
ENGINE

TILT
600A

JIB
ANSI USA 5 0 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
ANSI EXPORT 5 1 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
CSA 5 2 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
CE 5 3 11 0 1 0 1 2 0 1 0 1 X X 3 X 5 0 0 0 1 0 1 0 1
AUSTRALIA 5 4 11 0 1 0 1 2 0 1 0 1 X X 3 X 5 0 0 0 1 0 1 0 1
JAPAN 5 5 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1
CABLE BREAK SWITCH
HEAD & TAIL LIGHTS

FUNCTION CUTOUT

GROUND ALARM

LEVELING MODE
TEMPERATURE
LOAD SENSOR
LOAD SYSTEM

DRIVE TYPE
600A

ANSI USA 0 1 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0 1 2 0 1 0 1
ANSI EXPORT 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CSA 0 1 0 1 0 X X X X 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CE 0 1 0 1 0 X 2 3 X 0 1 0 1 X X 0 1 2 3 0 1 2 0 1 0 1
AUSTRALIA 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
JAPAN 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1

6-46 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic
underlined numbers indicate the default when the option is factory installed.

ENGINE SHUTDOWN
STARTER LOCKOUT

GEN SET / WELDER

FLYWHEEL TEETH

GEN SET CUTOUT

MODEL NUMBER

4 WHEEL STEER
GLOW PLUGS

SOFT TOUCH
MARKET
ENGINE

TILT
600AJ

JIB
ANSI USA 5 0 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
ANSI EXPORT 5 1 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
CSA 5 2 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
CE 5 3 11 0 1 0 1 2 0 1 0 1 X X 3 X 5 1 0 0 1 0 1 0 1
AUSTRALIA 5 4 11 0 1 0 1 2 0 1 0 1 X X 3 X 5 1 0 0 1 0 1 0 1
JAPAN 5 5 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
CABLE BREAK SWITCH
HEAD & TAIL LIGHTS

FUNCTION CUTOUT

GROUND ALARM

DTC Analyzer Text

9920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE
9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY
9922 PLATFORM MODULE FAILURE - HWFS CODE 1
9923 GROUND MODULE FAILURE - HWFS CODE 1
9924 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED
9944 CURRENT FEEDBACK GAINS OUT OF RANGE
9945 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT

3121201 – JLG Lift – 6-55

SECTION 6 - JLG CONTROL SYSTEM

6.9 ANALYZER DIAGNOSTICS MENU In the following structure descriptions, an intended item is
selected by pressing ENTER; pressing ESC steps back to
STRUCTURE the next outer level. The LEFT/RIGHT arrow keys move
between items in the same level. The UP/DOWN arrow
keys alter a value if allowed

Table 6-7. Adjustments - Personality Descriptions

DRIVE

ACCEL … Displays/adjusts drive acceleration

DECEL … Displays/adjusts drive deceleration

MIN FORWARD … Displays/adjusts minimum forward drive speed

MAX FORWARD … Displays/adjusts maximum forward drive speed

MIN REVERSE … Displays/adjusts minimum reverse drive speed

MAX REVERSE … Displays/adjusts maximum reverse drive speed

ELEVATED MAX … Displays/adjusts maximum drive speed

NOTE: used when elevation cutout switches are limiting maximum speed

CREEP MAX … Displays/adjusts maximum drive speed

NOTE: used when creep switch on pump pot is active

STEER MAX … Displays/adjusts the maximum steer speed

LIFT

ACCEL … Displays/adjusts upper lift acceleration

DECEL … Displays/adjusts upper lift deceleration

MIN UP … Displays/adjusts minimum upper lift up speed

MAX UP … Displays/adjusts maximum upper lift up speed

CREEP UP … Displays/adjusts maximum upper lift up speed

NOTE: used when creep switch on pump pot is active

MIN DOWN … Displays/adjusts minimum upper lift down speed

MAX DOWN … Displays/adjusts maximum upper lift down speed

CREEP DOWN … Displays/adjusts maximum upper lift down speed

NOTE: used when creep switch on pump pot is active

6-56 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-7. Adjustments - Personality Descriptions

SWING

ACCEL … Displays/adjusts swing acceleration

DECEL … Displays/adjusts swing deceleration

MIN LEFT … Displays/adjusts minimum swing left speed

MAX LEFT … Displays/adjusts maximum swing left speed

CREEP LEFT … Displays/adjusts maximum swing left speed

NOTE: used when creep switch on pump pot is active

MIN RIGHT … Displays/adjusts minimum swing right speed

MAX RIGHT … Displays/adjusts maximum swing right speed

CREEP RIGHT … Displays/adjusts maximum swing right speed

NOTE: used when creep switch on pump pot is active

UPPER TELESCOPE

ACCEL … Displays/adjusts telescope acceleration

DECEL … Displays/adjusts telescope deceleration

MIN IN … Displays/adjusts minimum telescope in speed

MAX IN … Displays/adjusts maximum telescope in speed

MIN OUT … Displays/adjusts minimum telescope out speed

MAX OUT … Displays/adjusts maximum telescope out speed

BASKET LEVEL

ACCEL … Displays/adjusts basket level acceleration

DECEL … Displays/adjusts basket level deceleration

MIN UP … Displays/adjusts minimum basket level up speed

MAX UP … Displays/adjusts maximum basket level up speed

MIN DOWN … Displays/adjusts minimum basket level down speed

MAX DOWN … Displays/adjusts maximum basket level down speed

BASKET ROTATE

ACCEL … Displays/adjusts basket rotate acceleration

DECEL … Displays/adjusts basket rotate deceleration

MIN LEFT … Displays/adjusts minimum basket rotate left speed

MAX LEFT … Displays/adjusts maximum basket rotate left speed

MIN RIGHT … Displays/adjusts minimum basket rotate right speed

MAX RIGHT … Displays/adjusts maximum basket rotate right speed

3121201 – JLG Lift – 6-57

SECTION 6 - JLG CONTROL SYSTEM

Table 6-7. Adjustments - Personality Descriptions

JIB LIFT Not displayed if JIB = NO

ACCEL … Displays/adjusts jib acceleration

DECEL … Displays/adjusts jib deceleration

MIN UP … Displays/adjusts minimum jib up speed

MAX UP … Displays/adjusts maximum jib up speed

MIN DOWN … Displays/adjusts minimum jib down speed

MAX DOWN … Displays/adjusts maximum jib down speed

MIN LEFT … Displays/adjusts minimum jib left speed

MAX LEFT … Displays/adjusts maximum jib left speed

MIN RIGHT … Displays/adjusts minimum jib right speed

MAX RIGHT … Displays/adjusts maximum jib right speed

STEER

MAX SPEED … Displays/adjusts maximum steer speed, which applies when vehicle speed is at minimum

GROUND MODE

LIFT UP … Displays/adjusts fixed lift up speed

LIFT DOWN … Displays/adjusts fixed lift down speed

SWING … Displays/adjusts fixed swing speed

TELE … Displays/adjusts fixed telescope speed

BASKETLEVEL … Displays/adjusts fixed basket level speed

BASKETROTATE … Displays/adjusts fixed basket rotate speed

JIB (U/D) … Displays/adjusts jib lift speed

Not displayed if JIB = NO

JIB (L/R)… Displays/adjusts jib swing speed

Not displayed if JIB = NO

6-58 – JLG Lift – 3121201

SECTION 6 - JLG CONTROL SYSTEM

Table 6-8. Diagnostic Menu Descriptions

DRIVE

DRIVE FOR … Displays drive joystick direction & demand

STEER … Displays steer switch direction & demand

NOTE: steer demand is inversely proportional to vehicle speed

BRAKES … Displays brake control system status

CREEP … Displays pump pot creep switch status

TWO SPEED ... Displays two speed switch status

2 SPEED MODE Displays status of two speed valve

HIGH ENGINE Displays high engine switch status

BOOM

U LIFT UP … Displays lift joystick direction & demand

SWING LEFT … Displays swing joystick direction & demand

LEVEL UP … Displays basket level switch direction & demand

NOTE: demand is controlled by the pump pot

ROT. LEFT … Displays basket rotate switch direction & demand

NOTE: demand is controlled by the pump pot

U TELE IN … Displays telescope switch direction & demand

NOTE: demand is controlled by the pump pot

JIB UP … Displays jib lift switch direction & demand

NOTE: demand is controlled by the pump pot
Not displayed if JIB = NO

JIB LEFT … Displays jib swing switch direction & demand

NOTE: demand is controlled by the pump pot
Not displayed if JIB = NO

PUMP POT … Displays pump pot demand

ENGINE

START … Displays start switch status

AIR FILTER … Displays air filter status

BATTERY … Displays measured battery voltage

COOLANT … Displays coolant temperature

OIL PRS … Displays oil pressure status

FUEL SELECT … Displays selected fuel (Dual Fuel only)

FUEL LEVEL … Displays fuel level status

RPM Displays Engine RPM

GM BATTERY Displays battery voltage at ground module

3121201 – JLG Lift – 6-59

SECTION 6 - JLG CONTROL SYSTEM

Table 6-8. Diagnostic Menu Descriptions

PM BATTERY … Displays battery voltage at platform module

TEMP ... Displays ground module temperature

ELEV. CUTOUT … Displays elevation cutout switch status

FUNC. CUTOUT … Displays function cutout switch status

CREEP… Displays creep switch status

TILT … Displays measured vehicle tilt

AUX POWER … Displays status of auxiliary power switch

HORN … Displays status of horn switch

R FILTER … Displays status of return filter switch

C FILTER … Displays status of charge pump filter

LOAD LENGTH … Displays length switch status

ANGLE … Displays angle switch status

LOAD … Displays load sensor value

NOTE: Not displayed if load = 0.

DATALOG

ON … Displays total controller on (EMS) time

ENGINE … Displays engine run time

DRIVE … Displays total controller drive operation time

LIFT … Displays total controller lift operation time

SWING … Displays total controller swing operation time

TELE … Displays total controller tele operation time

MAX.TEMP … Displays maximum measured heatsink temp.

MIN.TEMP … Displays minimum measured heatsink temp.

MAX.VOLTS … Displays maximum measured battery voltage

RENTAL … Displays total controller operation time

NOTE: can be reset

ERASE RENTAL Not available at password level 2

YES:ENTER, NO:ESC ENTER resets rental datalog time to zero

VERSIONS

GROUND … Displays ground module software version

PLATFORM … Displays platform module software version

ANALYSER … Displays Analyzer software version

6-60 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL are reversed. Check what reading is expected, the loca-
tion of the signal and that the leads are connected to the
This section contains basic electrical information and device under test correctly. Also check that the lead on the
schematics to be used for locating and correcting most of "COM" port goes to the Ground or negative side of the sig-
the operating problems which may develop. If a problem nal and the lead on the other port goes to the positive side
should develop which is not presented in this section or of the signal.
which is not corrected by listed corrective actions, techni-
cally qualified guidance should be obtained before pro- Scale
ceeding with any maintenance.
M = Mega = 1,000,000 * (Displayed Number)
7.2 MULTIMETER BASICS
k = kilo = 1,000 * (Displayed Number)
A wide variety of multimeters or Volt Ohm Meters (VOM)
can be used for troubleshooting your equipment. This m = milli = (Displayed Number) / 1,000
section shows diagrams of a common, digital VOM con-
μ = micro = (Displayed Number) / 1,000,000
figured for several different circuit measurements. Instruc-
tions for your VOM may vary. Please consult the meter Example: 1.2 k = 1200 
operator’s manual for more information.
Example: 50 mA = 0.05 A
Grounding
Voltage Measurement
"Grounding the meter" means to take the black lead
(which is connected to the COM (common) or negative
port) and touch it to a good path to the negative side of
the Voltage source.

Backprobing
To "backprobe" means to take the measurement by
accessing a connector’s contact on the same side as the
wires, the back of the connector. Readings can be done
while maintaining circuit continuity this way. If the connec-
tor is the sealed type, great care must be taken to avoid
damaging the seal around the wire. It is best to use
probes or probe tips specifically designed for this tech-
nique, especially on sealed connectors. Whenever possi-
ble insert probes into the side of the connector such that
the test also checks both terminals of the connection. It is
possible to inspect a connection within a closed connec-
tor by backprobing both sides of a connector terminal and
measuring resistance. Do this after giving each wire a
gentle pull to ensure the wires are still attached to the con-
tact and contacts are seated in the connector.

Min/Max Figure 7-1. Voltage Measurement (DC)

Use of the "Min/Max" recording feature of some meters • If meter is not auto ranging, set it to the correct
can help when taking measurements of intermittent condi- range (See multimeter’s operation manual)
tions while alone. For example, you can read the Voltage
applied to a solenoid when it is only operational while a • Use firm contact with meter leads
switch, far from the solenoid and meter, is held down.

Polarity
Getting a negative Voltage or current reading when
expecting a positive reading frequently means the leads

3121201 – JLG Lift – 7-1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Resistance Measurement • Use firm contact with meter leads

Continuity Measurement

Figure 7-3. Continuity Measurement

• Some meters require a separate button press to

Figure 7-2. Resistance Measurement enable audible continuity testing
• First test meter and leads by touching leads • Circuit power must be turned OFF before testing
together. Resistance should read a short circuit continuity
(very low resistance)
• Disconnect component from circuit before testing
• Circuit power must be turned OFF before testing
resistance • Use firm contact with meter leads
• Disconnect component from circuit before testing
• First test meter and leads by touching leads
• If meter is not auto ranging, set it to the correct together. Meter should produce an audible alarm,
range (See multimeter’s operation manual) indicating continuity

7-2 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Current Measurement • LSS Modules connections,

• Deutz EMR 2 ECM connection.

Silicone Dielectric Compound must be used on all electri-

cal connections except for those mentioned above for the
following reasons:

• To prevent oxidation at the mechanical joint between

male and female pins.

• To prevent electrical malfunction caused by low level

conductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric

Compound to the electrical connectors. This procedure
applies to all plug connections not enclosed in a box. Sili-
cone grease should not be applied to connectors with
external seals.

1. To prevent oxidation, silicone grease must be

packed completely around male and female pins on
the inside of the connector prior to assembly. This is
most easily achieved by using a syringe.

NOTE: Over a period of time, oxidation increases electrical

resistance at the connection, eventually causing cir-
cuit failure.
Figure 7-4. Current Measurement (DC)
2. To prevent shorting, silicone grease must be packed
• Set up the meter for the expected current range around each wire where they enter the outside of the
• Be sure to connect the meter leads to the correct connector housing. Also, silicone grease must be
jacks for the current range you have selected applied at the joint where the male and female con-
nectors come together. Any other joints (around
• If meter is not auto ranging, set it to the correct strain reliefs, etc.) where water could enter the con-
range (See multi meter’s operation manual) nector should also be sealed.
• Use firm contact with meter leads
NOTE: This condition is especially common when machines
7.3 APPLYING SILICONE DIELECTRIC are pressure washed since the washing solution is
much more conductive than water.
COMPOUND TO ELECTRICAL
CONNECTIONS 3. Anderson connectors for the battery boxes and bat-
tery chargers should have silicone grease applied to
NOTE: Do NOT apply dielectric grease to the following con- the contacts only.
nections:
NOTE: Curing-type sealants might also be used to prevent
• Main Boom Rotary sensor connections (on Celesco shorting and would be less messy, but would make
Sensor), future pin removal more difficult.

3121201 – JLG Lift – 7-3

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.4 AMP CONNECTOR Assembly

Applying Silicone Dielectric Compound to Check to be sure the wedge lock is in the open, or as-
shipped, position (See Figure 7-5.). Proceed as follows:
AMP Connectors
Silicone Dielectric Compound must be used on the AMP
connections for the following reasons:

• To prevent oxidation at the mechanical joint between

male and female pins.
• To prevent electrical malfunction caused by low level
conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors.

1. To prevent oxidation and low level conductivity, sili-

cone dielectric grease must be packed completely
around male and female pins on the inside of the
connector after the mating of the housing to the
header. This is easily achieved by using a syringe to
fill the header with silicone dielectric compound, to a
point just above the top of the male pins inside the
header. When assembling the housing to the
header, it is possible that the housing will become Figure 7-5. Connector Assembly Figure 1
air locked, thus preventing the housing latch from
engaging.

2. Pierce one of the unused wire seals to allow the 1. To insert a contact, push it straight into the appropri-
trapped air inside the housing to escape. ate circuit cavity as far as it will go (See Figure 7-7.).

3. Install a hole plug into this and/or any unused wire 2. Pull back on the contact wire with a force of 1 or 2
seal that has silicone dielectric compound escaping lbs. to be sure the retention fingers are holding the
from it. contact (See Figure 7-7.).

Figure 7-6. AMP Connector

7-4 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-7. Connector Assembly Figure 2

3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-9.).
Release the locking latches by squeezing them
inward (See Figure 7-8.).

Figure 7-9. Connector Assembly Figure 4

Figure 7-8. Connector Assembly Figure 3

3121201 – JLG Lift – 7-5

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-10. Connector Disassembly

Disassembly the field, by using a flat probe such as a pocket knife. DO

NOT use a sharp point such as an ice pick.
1. Insert a 4.8 mm (3/16") wide screwdriver blade
between the mating seal and one of the red wedge Service - Voltage Reading
lock tabs.
2. Pry open the wedge lock to the open position.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READ-
3. While rotating the wire back and forth over a half
INGS.
turn (1/4 turn in each direction), gently pull the wire
until the contact is removed.
It has been common practice in electrical troubleshooting
NOTE: The wedge lock should never be removed from the to probe wires by piercing the insulation with a sharp
housing for insertion or removal of the contacts. point. This practice should be discouraged when dealing
with the AMPSEAL plug assembly, or any other sealed
Wedge Lock connector system. The resulting pinholes in the insulation
will allow moisture to invade the system by traveling along
The wedge lock has slotted openings in the forward, or the wire strands. This nullifies the effectiveness of the con-
mating end. These slots accommodate circuit testing in nector seals and could result in system failure.

7-6 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-11. Connector Installation

3121201 – JLG Lift – 7-7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.5 DEUTSCH CONNECTORS NOTE: The receptacle is shown - use the same procedure
for plug.
DT/DTP Series Assembly
DT/DTP Series Disassembly

A B

C D
Figure 7-12. DT/DTP Contact Installation
C
1. Grasp crimped contact about 25mm behind the con-
Figure 7-13. DT/DTP Contact Removal
tact barrel.
2. Hold connector with rear grommet facing you. 1. Remove wedgelock using needlenose pliers or a
hook shaped wire to pull wedge straight out.
3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly 2. To remove the contacts, gently pull wire backwards,
locked in place. while at the same time releasing the locking finger
by moving it away from the contact with a screw-
4. Once all contacts are in place, insert wedgelock with driver.
arrow pointing toward exterior locking mechanism.
The wedgelock will snap into place. Rectangular 3. Hold the rear seal in place, as removing the contact
wedges are not oriented. Thy may go in either way. may displace the seal.

7-8 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly

A B A B

C C
Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal

1. Grasp contact about 25mm behind the contact

crimp barrel. 1. With rear insert toward you, snap appropriate size
extractor tool over the wire of contact to be
2. Hold connector with rear grommet facing you. removed.
3. Push contact straight into connector grommet until a
2. Slide tool along into the insert cavity until it engages
positive stop is felt. A slight tug will confirm that it is
contact and resistance is felt.
properly locked in place.
3. Pull contact-wire assembly out of connector.

Figure 7-15. HD/HDP Locking Contacts Into Position

Figure 7-17. HD/HDP Unlocking Contacts
NOTE: For unused wire cavities, insert sealing plugs for full
environmental sealing NOTE: Do Not twist or insert tool at an angle.

3121201 – JLG Lift – 7-9

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-18. Electrical Harness - S/N 80000 to 87000 - Sheet 1 of 2

7-10 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-19. Electrical Harness - S/N 80000 to 87000 - Sheet 2 of 2

3121201 – JLG Lift – 7-11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GENERATOR
JUNCTION BOX
DEUTZ ENGINES
CE & AUSTRALIAN SPEC
S/N 0300122784
TO PRESENT
PLATFORM
FLOODLIGHTS

2500W
FOOTSWITCH GENERATOR

GENERATOR
SWITCH
J7

J1
PLATFORM
WORK LIGHTS
J5 J6

J2
MAIN BOOM
ELEVATION
J8

LIMIT SWITCH

TOWER BOOM
ELEVATION
LIMIT SWITCH

BOOM CAPACITY ANGLE

LIMIT SWITCH (600A
ANSI, ANSI EXPORT,
BRAZILIAN & JAPANESE
SPECS)

BOOM LENGTH
LIMIT SWITCH

PLATFORM
CONTROL
BOX

GROUND (DEUTZ)
CONTROL
BOX
J8

(DEUTZ/GM
J1

ONLY)
J7
J2

HEADLIGHTS

(DEUTZ)
DIAGNOSTIC TAILLIGHTS
ANALYZER

Figure 7-20. Electrical Harness - S/N 87000 to Present - Sheet 1 of 2

7-12 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GENERATOR
CONTROL BOX
DEUTZ ENGINES
CE & AUSTRALIAN SPEC
S/N 87000 TO S/N 0300122784 &
ALL ANSI & ANSI EXPORT SPEC
2500W
GENERATOR
RELAY

7500W
7500W GENERATOR 7500W
CONTROL BOX GENERATOR 7500W
GENERATOR SKYPOWER
PLATFORM RELAYS
GENERATOR
BOX

LP CONVERTOR THROTTLE
(FORD) CONTROL
ALTERNATOR (FORD)
THROTTLE
ACTUATOR
(CAT)

ENGINE
FUEL CONTROL
SHUT (DEUTZ)
BOSCH FUEL OFF
REGULATOR SWITCH
(GM) FUEL (CAT) AUX
PUMP SENDING PUMP
(CAT) UNIT
(CAT)
FUEL ENGINE
REGULATOR HARNESS
(GM HARNESS) (DEUTZ)

+ –
TACH
SENSOR/
SPEED GLOW
PICK-UP 2 SPEED BATTERY
& BRAKE PLUGS
(CAT) VALVE
HYDRAULIC GLOW
PUMPS START PLUG
STARTER RELAY RELAY
STROBE
LIGHT
AUX
RELAY

MAIN
CONTROL
VALVE
HORN
JIB
VALVE
FUEL 4WS
LEVEL VALVE
SENSOR
ALARM
Figure 7-21. Electrical Harness - S/N 87000 to Present - Sheet 2 of 2

3121201 – JLG Lift – 7-13

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

PLATFORM WORK LIGHTS

PLATFORM BOX

RED
BLACK 18 BLK/WHT (12) 18 BLACK (12)

RED
BLACK
STROBE LIGHT

15 YEL/BLK(18) 15 BLU/ORN 52-11 1

15 AMP 2
C.B.

BLU/ORN 52-11

YEL/RED
MTB

2-5-1
SELECT
SWITCH
MAIN TELE IN BROWN 13-1 5 19 ORN/RED 49-4 PLATFORM
ALARM EMS
MAIN TELE OUT BROWN 14-1 6 YEL/RED YEL/RED
20 BLACK 13 ORN/BLK 13 2 B1 YEL/RED
GRAY 24-1 2-5 2-5
ROTATE RIGHT 7
33 GRAY 23-1 3 LEFT ROTATE 4 2-4 (12)
ROATE LEFT GRAY 23-1 8 YEL/RED YEL/RED
34 GRAY 24-1 4 RIGHT ROTATE 10 ORN(12) 10 1 B YEL/RED
LEVEL UP PINK 25-1 9 2-2(12) 2-2(12)
21 PINK 25-1 2 UP LEVEL 3 2-1(12)
LEVEL DOWN PINK 26-1 10
22 PINK 26-1 1 DOWN LEVEL
J7 (BLACK)

JIB UP BLUE 27-1 11

25 BLUE 27-1 5 UP JIB
JIB DOWN BLUE 28-1

YEL/RED 2-3(16)
12 26 BLUE 28-1 6 DOWN JIB YEL/RED YEL/RED
FUEL SELECT BLU/ORN 52-20 33 23 BLACK 7 UPPER 2-30-4 2-1-3
Ref.V RED/ORN 4 RED/WHT 55-30 34 (12)
PUMP 28 VALVE
WIPER GREEN 6 RED/WHT 55-31 35 29 450ASII
POTENTIOMETER
GND BRN/BLK 5 BLACK 13 10 VOLT REF. ONLY
SPARE 30
CREEP 2 ORN/RED 49-11 32 13 INPUT ANALOG 86 85
19 14 GND 87a
87
15 YEL/RED 2-37 20 31 CAN HI RED (18) 3 RED (18) 3
ORN/YEL
BLU/YEL

21 30 CAN LO BLACK (18) BLACK (18)

2 2

BLACK 0-1
22 32 CAN SHIELD SHIELD
1 1
23 EMS PTF TO MTB output YEL/RED 2-3-1 4
3 ORANGE (18) 4
J1 (WHITE)

3 24 GND MODE
1 YEL/RED 2-30-1
2 PTF EMS
25
YEL/RED 2-10 18 27

YEL/RED 2-1-1(12)
TOWER UP TAN 5-1 1 35 SPARE FOOTSWITCH 2

J1-19
TOWER DOWN TAN 6-1 2 8 ORN/RED 49-70 7 BLACK
TOWER TELE IN BROWN 15-1 3 4 ORN/RED 49-71 8 WHITE 7 GREEN 6 YELLOW (18) 6
TOWER TELE OUT BROWN 16-1 4
17 WHITE 8
CRAB STEER YELLOW 55-16 16 JIB BLOCK LIMIT SW 8 HOLE PLUG
6 BLACK
COORDINATED STEER YELLOW 55-17 17 14 HOLE PLUG 14
18 YEL/RED 2-63 3 WHT BLK 4 SOFT
26 R
WHT 5 TOUCH 17 HOLE PLUG 17
14 7 ORN/RED 49-69 6 BLK L
START SWITCH WHT/YEL 48-1 19 HOLE PLUG 19
9 BLU/ORN 52-4 1
AUX POWER BRN/ORN 53-1 15 GENERATOR
5 BLU/ORN 52-3 2
ENGINE SPEED WHT/YEL 48-5 28 16 BLACK (12) 16
11 ORN/RED 49-72 9
TWO SPEED ORANGE 55-46 27
HORN 12 ORN/RED 49-73 10 12 RED (12) 12
BLU/ORN 52-1 31
SOFT TOUCH OVERIDE 15 ORN/RED 49-75 12 11 BLU/BLK 11
ORN/RED 49-40 29
HEAD/TAIL LIGHTS 16 ORN/RED 49-74 11
BLU/ORN 52-12 30 9 RED/BLK (18) 9
24 BLACK
TILT 7 BROWN (18) 7
ORN/RED 49-3 6
5 BLUE (18) 5
SYSTEM DISTRESS BRN/WHT 47-12 8
FOOTSWITCH/ENABLE
J8 (BLACK)

YEL/RED 2-21 7 GND FROM GND MODULE

CREEP ORN/RED 49-15 9 1 BLACK (12)
GND EMS
CABLE SERVICE ORN/RED 49-101 2 YEL/RED 2-1-2 IGN POWER
10
CONNECTOR
OVERLOAD
J2 (GRAY)

ORN/RED 49-100 11
226KG/500# CAPACITY RED/YEL 54-2 12
YEL/RED 2-4 (16)
453KG/1000# CAPACITY RED/YEL 54-3 13 RED (18) CAN HI
CAN LO
AXLE SET 14 BLACK (18)
CAN SHIELD
GENERATOR ON BLU/ORN 52-4-1 15
SOFT TOUCH ORN/RED 49-42 16 ORN/RED 49-86
GLOW PLUG WHT/YEL 48-6 17
YEL/RED 2-1-99 (16)

DRIVE DISABLED BRN/WHT 47-14 19

YEL/RED 2-1-98

800A/AJ UPRIGHT TILTED ORN/RED 49-102 20

BLACK 18
FUEL GAGE

BRN/WHT 47-4
RED 1-2

FULL 35
6 SWING
3/4 BRN/WHT 47-3 23
1/2 BRN/WHT 47-2 24 5 WHITE 5K
1
J5 (WHITE)

1/4 BRN/WHT 47-1 22 RED/BLU

BLACK 25 4 GRN/YEL
2 GREEN
LOW FUEL LAMP BLACK 25
(N/A WITH FUEL GAGE) BRN/WHT 47-13 21
C
B

3
A

BROWN LIFT
1 7 BLACK OR BLU/YEL 5K
SEE SHEET 2

2
SEE SHEET 2

34
4 5 WHT/GRN LEFT
STEER
33 6 WHT/YEL RIGHT
J6 (BLACK)

14 YEL/RED 2-36 32 4
30 2 BLUE
RED ORN/RED 49-92 26 1 RED OR WHT/RED
11
GREEN 10 ORN/RED 49-91 28 3 BROWN
WHITE 9 ORN/RED 49-90 29 7 BLACK
ORN/RED 49-89 27 DRIVE
BLACK/SHIELD 8
3
31
5
ANALYZER TRANSMIT
ANALYZER RECEIVE

ANALYZER GROUND
ANALYZER POWER

800A/AJ UPRIGHT
TILT SWITCH
1 2 3
LOCATED IN UPRIGHT

WHITE
BLACK= GROUND
1 2 3 4 BLACK GREEN= N.O. RELAY CONTACT
GREEN RED= 12 VDC
WHITE= N.C. RELAY CONTACT
RED

Figure 7-22. Electrical Schematic - ADE - Sheet 1 of 6

7-14 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

GROUND CONTROL BOX

30 AMP
RED 1-2(10)

TO BATTERY NEG.
+12 VDC
24 OUTPUT
YEL/RED 2-40-9 WHEN ON
MAIN TELE IN BROWN 13-2 7 GROUND 17 BLACK HORN GND
MAIN TELE OUT BROWN 14-2 30 CONTROLS 2 BLU/ORN 52-2 HORN OUTPUT
ROTATE RIGHT GRAY 24-2 18
10 GRAY 23-3 LEFT ROTATE
ROTATE LEFT GRAY 23-2 6
21 GRAY 24-3 RIGHT ROTATE
LEVEL UP PINK 25-2 17
5 PINK 25-3 UP LEVEL
LEVEL DOWN PINK 26-2 5
7 PINK 26-3 DOWN LEVEL
START SWITCH WHT/YEL 48-1 4
12 BLUE 27-3 UP JIB
AUX POWER/ENABLE BRN/ORN 53-2 16
23 BLUE 28-3 DOWN JIB
20 13 RED/WHT 50-1 MAIN DUMP
9

J4 (BLUE)
1 YELLOW 55-2 STEER DUMP
MTB BLUE 27-2
EMS JIB UP 19 31 RED/WHT 50-6 FLOW CONTROL
JIB DOWN BLUE 28-2 8 33 TAN 5-3 UP TOWER LIFT
MAIN LIFT UP TAN 3-2 23

J2 (GRAY)
32 TAN 6-3 DOWN TOWER LIFT
MAIN LIFT DOWN TAN 4-2 33 3 BROWN 15-3 IN TOWER TELE.
WHITE 22-2 35
SWING RIGHT 15 BROWN 16-3 OUT TOWER TELE
SWING LEFT WHITE 21-2 34
4 BROWN 13-3 IN MAIN TELE
TOWER LIFT UP TAN 5-2 10 16 BROWN 14-3 OUT MAIN TELE
TOWER LIFT DOWN TAN 6-2 21
8 YELLOW 10-1 RIGHT FRONT STEER
BROWN 15-2 11
TOWER TELE IN 19 YELLOW 9-1 LEFT FRONT STEER
BROWN 16-2 22 +12 VDC
TOWER TELE OUT 11 TAN 3-3 UP MAIN LIFT
YEL/RED 2-40 25 OUTPUT
22 TAN 4-3 DOWN MAIN LIFT
WHEN ON
1 GROUND 35 WHITE 22-3 RIGHT SWING
HOURMETER CONTROLS 34 WHITE 21-3
BRN/WHT 47-8 12 LEFT SWING
ENGINE LOW 9 YELLOW 12-1 RIGHT REAR STEER
OIL PRESSURE BRN/WHT 47-5-1 29
20 YELLOW 11-1 LEFT REAR STEER
ENGINE HIGH
TEMPERATURE BRN/WHT 47-6-1 28 14 BLACK HEAD/TAIL LIGHT OUTPUT
NO CHARGE BRN/WHT 47-8-1 26 30 BLACK 87
87a
27 29 BLACK ALARM 85
BLACK (10)

86
PLATFORM 27 BLU/ORN 52-10 30 14 GA.
OVERLOAD ORN/RED 49-100 14 FUSE LINK
26 BLU/ORN 52-12 12 BLU/ORN 52-12 RED 1-1 (12)
BOOM MALFUNCTION 13 18 BLACK 0-5 13
INDICATOR BRN/WHT 47-15 15 24
(800A/AJ ONLY) 25 UNITS WITH 4 LED
28 SPARE-GND FUEL GAGE IN
2 PLATFORM.
25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL) 6
GLOW PLUG WHT/YEL 48-6 3 6 BLACK SENSOR (GROUND) 25
BLACK 31 6 UNITS WITH LOW
32 1 FUEL LIGHT IN
PLATFORM
GND FROM BATTERY 2
1 3 ORANGE 7-2 DRIVE FORWARD
MTB EMS input
2
J8 (BLACK)

GND TO PLATFORM 6 ORANGE 8-2 DRIVE REVERSE

BLACK (12) 3 23 ORANGE 55-45 BRAKE
MTB EMS TO PLATFORM
YEL/RED 2-1-2(12) 4 20 ORANGE 55-47 2-SPEED
5 BLACK 0-4
18 BLACK 0-2
27 BLACK 0-3
4 AUXILIARY POWER
RED (18) CAN HI 8 PUMP
13 NOTE: NOT ALL BLACK GROUND WIRES
CAN LO 9 MOTOR
BLACK (18) 24 ARE NUMBERED ON ALL MODELS M
CAN SHIELD 12
18
J1 (WHITE)

YEL/RED 2-3-1 PTF EMS 1 13 BRN/ORN 53-2

YEL/RED 2-21 FOOTSWITCH 28
15 YEL/RED ANALYZER POWER 1
YEL/RED 2-30 MTB MODE SELECT 3 29 ORN/RED 49-91 ANALYZER RECEIVE 2
PLATFORM MODE INPUT
YEL/RED 2-2-1 2 30 ORN/RED 49-90 ANALYZER TRANSMIT 3
MTB MODE OUTPUT
YEL/RED 2-30-1 14 31 BLACK 0-2 ANALYZER GROUND 4
9 10 SEE SHEET 2
POWERMITE FOR 7500 W
23 11 GENERATOR
25 14 GENERATOR
5 15 87 87a
31 85 14 GA.
22 BLU/ORN 52-5 14 BLU/ORN 52-5 86
35 30 FUSE LINK
BLK ORN/RED 49-66 4 16
10
DUAL CAPACITY CAPACITY ANGLE SWITCH 24
WHT 9 YEL/RED 2-62 16
MACHINES ONLY BLK 8 ORN/RED 49-65 7 25
CAPACITY LENGTH SWITCH
WHT 7 YEL/RED 2-61 26 26
J7 (BLACK)

TRANSPORT LENGTH 7
SWITCH (CE ONLY) 10
21
4 ORN/RED 49-62 5 WHT BLK 6 ORN/RED 49-64 29 17
ORN/RED 49-77 34
30
ORN/RED 49-76 3 ORN/RED 49-60 2 BLK WHT YEL/RED 2-60 11 32
1 B+
33
BLK WHT MAIN BOOM ELEVATION
TOWER ELEVATION 450ASII 19
ALL MODELS 8
600 A/AJ, 800A/AJ ONLY 35
28
CABLE SERVICE BROWN 2 ORN/RED 49-87 32
SWITCH (CE ONLY) 4 1 BLACK 3 ORN/RED 49-88 12 2 12 VDC
4 BATTERY
1 BLUE 3 8
BROWN 2 ORN/RED 49-87 34 9
TOWER LIFT
PROX. SWITCH 4 1 BLACK 3 ORN/RED 49-88 22 6
(800 A/AJ ONLY) 6 7
1 BLUE CAT ENGINE ONLY WHT/YEL 17 13
3
BROWN 5 ORN/RED 49-84 33 14
TOWER TELE. 3
PROX. SWITCH 4 1 BLACK 6 ORN/RED 49-85 21
(800 A/AJ ONLY} 10
3 BLUE 4 ORN/RED 49-93 19 11
27 1
20 5
12

1870215 B

Figure 7-23. Electrical Schematic - ADE - Sheet 2 of 6

3121201 – JLG Lift – 7-15

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

RED 1-1(10) STARTER

STARTER FUEL
MOTOR PUMP

FUSIBLE LINK
MOTOR
SOL. SOL.
FAN STARTER 1 2
STARTER
MOTOR MOTOR MOTOR

BLACK
CAT ENGINE

WHT/YEL 48-8
400S, 450A/AJ

B+

WHT/YEL 48-12(12)
WHT/YEL 48-12(12)

FUEL PUMP RELAY

14 GA. FUSE LINK

D+ (LOCATED IN M.T.B.)
WHT/YEL 48-10 (12)

REGULATOR
GLOW PLUGS 87a 87

14 GA. FUSE LINK

GLOW PLUGS
30 86 85
FLYWHEEL
SPEED GLOW

BLACK 0-6
PICKUP PLUG

RED 1-10
START SOL. FLYWHEEL
SOL. W SPEED GLOW
PICKUP PLUG
START SOL.
SOL.

WHT/YEL 48-15
THROTTLE
ACTUATOR
C B A 87a 87
RED 1-3 (12)

THROTTLE
COOLANT TEMP. ACTUATOR
86 85 SENSOR C B A

11
30
BRN/WHT 47-21
ORN/RED 49-51
WHT/YEL 48-9
WHT/YEL 48-3
ORN/RED 49-50

OIL PRESSURE
ORN/RED 49-54
BLACK 0-5

BRN/WHT 47-8
BLACK

SENSOR
BRN/WHT 47-6

FUEL ON

BLACK

WHT/YEL 48-9

ORN/RED 49-51
WHT/YEL 48-3
ORN/RED 49-50
ORN/RED 49-54
SOLENOID

BLACK
WHT/YEL 48-6

BRN/WHT 47-5

ORN/RED 49-53

J1-17
J1-16
J1-12

J1-11
J1-16

J1-1

J1-15

J1-12
J7-27

J1-14

J1-7
J1-11

J7-27

J1-1
J1-8

J1-7

J1-8

120 OHM
RESISTOR

FUEL ON 87 87a
ALTERNATOR
RELAY 86 85 EXCITATION
30 RELAY
400S/SJ, 450A/AJ CAT ONLY
YEL/RED 2-6-2 87 87a
86 85
30
CAT ENGINE
BLACK 0-6

YEL/RED 2-4-1 ONLY

YEL/RED 2-6-2

BLACK 0-1

YEL/RED 2-4-1 (12)

J1-17

GM ENGINE
J1-10

J1-19

B
PLATFORM
GM ENGINE GROUND
CONNECTOR #1
SEE SHT 3
SELECT
SWITCH
N
P

A
C
F

BRN/WHT 47-8-2
BRN/WHT 47-8-1
BLACK (18)
RED (18)

BRN/WHT 47-8
CAN LO
CAN HI

AUXILIARY
CAN SHIELD

WHT/YEL 48-8

SOLENOID
BLACK
WHT/YEL 48-3

STARTER
YEL/RED 2-1-99 (16)

MOTOR
SOL. SEE
SHT 3
STARTER
MOTOR
C
B
A
SEE SHT 1

FUEL IGN POWER

C-5
J1-11

PUMP CONNECTOR
SEE SHT 1

Figure 7-24. Electrical Schematic - ADE - Sheet 3 of 6

7-16 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

RECTIFER
B+ FUSIBLE

RED 1-1(10)
STATOR LINK
CAT ENGINE
600A, 600S, 800A

RED 1-1(10)
STARTER ALTERNATOR
MOTOR
SOL. REGULATOR
ALTERNATOR WITH PLUG CONNECTOR
B+ FUSIBLE STARTER SENSING AND
MOTOR SWITCHING
LINK CIRCUITS
P D+
1
IG
STATOR 2

BRN/WHT 47-20
WHT/YEL 48-13 (8)

WHT/YEL 48-12(12)
MIC L

BRN/WHT 47-8-1
3

BRN/WHT 47-8
ALTERNATOR

BRN/WHT 47-21
GLOW PLUGS

BATTERY CABLE (1 GA.)

GLOW
START
PLUG
COOLANT TEMP. SOL.
SOL.
SENSOR FUEL ON
SOLENOID
BRN/WHT 47-6

OIL PRESSURE
ORN/RED 49-53

SENSOR
BRN/WHT 47-5

11
WHT/YEL 48-3

WHT/YEL 48-9
J1-11
DEUTZ ENGINE
J1-14
J1-15

J1-12

BRN/WHT 47-8

MTB TO EMR2 ENGINE CONTROL

COOLANT 2 8 GRD(TempAll)
TEMPERATURE
1 9 ADC7(TEMP3) 1

EMR2 ENGINE CONTROL TO ENGINE

ENGINE 2 13 SPEED 2
SPEED
1 12 GRD (SPEED)
CAMSHAFT 10
1 23 GRD (ACD2)
11
CHARGE AIR2 4 ADC5(TEMP1)
PRESSURE 3 25 +5Vref(ADC2) 12
4 24 ADC2
13
1 22 +5Vref(ADC4)
ENGINE OIL 14
2 21 ADC4
PRESSURE
3 20 GND (ADC4)
1 14 ActorOut
EMR 2 15 ActorOut

YEL/RED 2-1-99 (16)

ACTUATOR 3 17 RackMeasCom
4 19 RackMeasSignal
5 18 RackMeasRef

120 OHM
J1-22

RESISTOR

CAN SHIELD
CAN LO
CAN HI

BLACK (16)

ORN/RED 49-198
ORN/RED 49-199

YEL/RED 2-1-98
BLACK 0-1
BLACK (18)
RED (18)
BLU/ORN 52-5

5 AMP
7500 W
GENERATOR

GENERATOR
CONTROL
B+ BOX B L K A
C
B
A

J1-8

B A C
12 VDC
SEE SHEET 1
CONNECTOR
7

DEUTZ
IGN POWER

SEE SHEET 1

BATTERY DIANOSTICS
PLUG
BLU/ORN 52-6
YEL/RED 2-20
BLACK
BLU/ORN 52-5

87 87a
86 85
30
87 87a
86 85
30

RED RED

1870215 B

Figure 7-25. Electrical Schematic - ADE - Sheet 4 of 6

3121201 – JLG Lift – 7-17

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

WHT/LT GRN
D GASOLINE
LT GRN/RED SENSOR TWR
C
LT GRN/WHT WHT/RED A LPG TEMP.
B WHT/BLK A
BLK/LT GRN BLK/LT GRN
A B PNK/TAN LOCKOFF
B

1 DR GRN/ORN
EGO 1
2 DR GRN/WHT
EGO 2
3
EGO 3
4
EGO 4
5 PUR/LT BLU
TPS 1
6 LT BLU/DK BLU
TPS 2
7 LT GREEN
MAP
8 TAN/DK GRN
AUX ANA PDI
9 DR BLU/ORN
FPP 1
10 PUR/YEL
FPP2/1VS
11
AUX ANA PD2
12
AUX ANA PD3
13 WHT/ORN
CAN1 TERM +
14 BLU/PNK
CAN1 +
15 BLU/WHT
CAN1 -
16 CRANKSHAFT
CAN2 -
17 POSITION
CAN2 +
18
CAN2 TERM +
19 LT GRN/RED PUR/WHT A
5V EXT 1
20 BLK/LT GRN WHT/PUR
5V EXT B
21 PUR/WHT
CRANK +
CRANK - 22 WHT/PUR
23 GRY/BRN
CAM +
24 PUR/ORN
CAM -
25 RED/WHT
ROAD SPEED +
26 RED/BLK
ROAD SPEED -
27
KNOCK1 +
KNOCK1 - 28
29
KNOCK2 +
30
KNOCK2 -
31 YELLOW
SPK COIL 1A
32
SPK COIL 1B
33
SPK COIL 2A
34
SPK COIL 2B
35
SPK COIL 3A
36
SPK COIL 3B
37
SPK COIL 4A
38
SPK COIL 4B
39 YEL/GRY
1AT
40 TAN/WHT
ECT
41 WHT/RED
LP TEMP
42 TAN/BRN
AUX DIG 1
43 TAN/RED
AUX DIG 2
44 TAN/BLK
AUX DIG 3
45 PNK/TAN
VSW
46 DR BLU/YEL
AUX ANA PU1
47 YEL/DR BLU
AUX ANA PU2
48 LT GRN/WHT
AUX ANA PU3
49 LT GRN/PUR
(FPP 2 ONLY) 5V EXT 2
50 LT GRN/BLK
5V RTM
51 GRY/DR BLUE
GOV1
52 GRY/ORN
GOV2
53 LT BLUE
OIL PRES
54 WHT/LT GRN
(FRP) AUX ANA PUD1
55 DR GREEN
PC TX
56 ORANGE
PC RX
57
PULSE IN
58 GRAY
TACH
59
EPR PWR
60 RED/TAN IGNITION
VBAT
61 BRN/LT BLU COIL
INJ1 LS
62 BRN/ LT GRN PNK/DR GRN
INJ2 LS A
63 BRN/YEL YEL/BLK
INJ3 LS B
64 BRN/WHT PLUG
INJ4 LS C
65 D
INJ5 LS BLACK 16
66 C IGNITION
INJ6 LS MODULE
67 YELLOW B
INJ7 LS PNK/DK GRN
68 A
INJ8 LS
69 BLACK 16
GROUND
70
STARTER
71 WHT/LT BLU
RELAY
72 BLK/WHT
EGOH 1
73 BLK/YEL
EGOH 2
74
EGOH 3
75 WHT/BLK
LOCKOFF
76
BUZZER
77 BRN/WHT
PWM5
78 WHT/BRN
PWM5 RECIRC
79 RED/TAN
VBAT
80 GRN/YEL
MIL
81 BLACK 16
GROUND
82 PNK/WHT
DBW +
83 TAN/ORN
DBW -
84 TAN/BLK
FUEL PUMP RELAY
85 PNK/YEL
AUX PWM3 RECIR
86 BLK/RED
(FUEL PUMP) PWM3
87 TAN
AUX PWM1
88 DR BLUE
AUX PWM2
89 PNK/BLK
AUX PWM3
90 BLK/LT GRN TWR
AUX PWM4 RECIR PUR/ORN
A
GRY/BRN CAMSHAFT
B POSITION
LT GRN/RED C

PUR/LT BLU
6
LT BLU/DR BLU 5
PNK/WHT 4 BOSCH
LT GRN/RED THROTTLE
3
BLK/LT GRN 2
TAN/ORN
1
BRN/YEL BRN/LT BLU
BRN/WHT
BRN/ LT GRN

PNK/DR GRN 16 PNK/DR GRN 16 PNK/DR GRN 16 PNK/DR GRN 16

Figure 7-26. Electrical Schematic - ADE - Sheet 5 of 6

7-18 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

BLK/YEL BLK/WHT
D EGO 2 D
BLK/LT GRN BLK/LT GRN
C C
PNK/DK GRN PNK/DK GRN EGO 1
B B
DR GRN/WHT DR GRN/ORN
A A

TAN/WHT A
BLK/LT GRN ECT
B
C

LT GREEN
4
LT GRN/RED 3 BOSCH
YEL/GRY 2 TMAP
BLK/LT GRN CONNECTOR 2
1

PINK/DR GRN S 12V RELAYED POWER

TAN/DR GRN R AUX ANA PD1
RED/BLK P VS-
RED/WHT N VS+
TAN/BLK M AUX DIG 3
TAN/RED L AUX DIG 2
GRY/DR BLU K GOV SELECT 1
LT BLUE J GOV SELECT 2
GRY/ORN
DR BLU/YEL H AUX ANA PU1
OIL PRESS.
BLACK YEL/DR BLU G AUX ANA PU1
SWITCH
TAN 18 F AUX PWM 2
BLACK 16 E GROUND
GRAY D TACH
BRN/WHT 16 C AUX PWM 5
BLACK (12) WHT/BRN 16 B AUX PWM 5 RECIRC
GROUND
A AUX PWM 1

TAN 16 VEHICLE INTERFACE CONNECTORS

LT BLU/PNK 16
CONNECTOR 1

LT GRN/PUR S 5V EXT 2 (FPP2 ONLY)

LT GRN/BLK R 5V RTN 2
BLU/WHT P CAN1 -
BLU/PNK N CAN1 +
LT GRN/RED M 5V EXT 1
BLK/LT GRN L 5V RTN 1
DR BLU/ORN K FPP1
PUR/YEL J FPP2/1VS
TAN/BRN H FUEL SELECT (AUX DIG)
GRN/YEL G MIL
LT BLU/PNK 16 F START IN (INTERRUPT TYPE)
DK BLU 18 E START IN (AUTOCRANKING)
PNK/YEL 16 D FUEL PUMP +
BLK/RED 16 C FUEL PUMP -
PURPLE 16 B ALT EXCITE
87a
30 PINK A VSW
WHITE 16
87 RED/TAN 16
LT BLU/PNK
86 START RELAY
DIAGNOSTIC
CONNECTOR
PNK/BLK 85

BLK/LT GRN 1 ANA RTN

LT GRN/RED 2 5V REF
DR GRN 3 PC TX
ORANGE 4 PC RX
5 UNUSED
6 UNUSED
BLU/PNK 7 CAN +
FUEL PUMP
BLU/WHT 8 CAN1 -
PNK/DR GRN 16 F5 PNK/YEL 16
15A
PNK/TAN F1 PINK
5A
VSW
RED/TAN 16 F6 RED 16 60A
RED 10
15A
MAXI FUSE
STARTER

RED 10
ALTERNATOR B+
RED/TAN 14 F2 RED 14 RED 12
20A
PNK/DR GRN 16 F4 PNK/DR GRN 16 ECM
15A B+ RED 16
A ALTERNATOR
IGNITION STARTER PURPLE 16
SOLENOID B
PNK/DR GRN 16
RED 16 STARTER
MOTOR

WHT/LT BLU 85
RED 16 30 SEE SHT-2 BLACK 10
PNK/DR GRN 14 87 FOR BATTERY
RED/TAN 86 CONNECTION
GROUND
POWER RELAY ALTERNATOR -

TAN/BLK 85
EPR PNK/YEL 16 87
CONNECTOR RED 16 30
PNK/TAN 86
BLU/WHT 1 CAN -
WHITE 2 CAN + FUEL PUMP RELAY
BLU/PNK 3 CAN +
4 UNUSED
5 UNUSED
BLACK 16 6 GROUND
RED/LT BLU 16 7 VBAT
8 UNUSED
EPR FUSE
RED/LT BLU 16 F3 PNK/DR GRN 16
10A

1870215 B

Figure 7-27. Electrical Schematic - ADE - Sheet 6 of 6

3121201 – JLG Lift – 7-19

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-28. Hydraulic Schematic - Sheet 1 of 6

7-20 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792691A

Figure 7-29. Hydraulic Schematic - Sheet 2 of 6

3121201 – JLG Lift – 7-21

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-30. Hydraulic Schematic - Sheet 3 of 6

7-22 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792691A

Figure 7-31. Hydraulic Schematic - Sheet 4 of 6

3121201 – JLG Lift – 7-23

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-32. Hydraulic Schematic - Sheet 5 of 6

7-24 – JLG Lift – 3121201

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792691A

Figure 7-33. Hydraulic Schematic - Sheet 6 of 6

3121201 – JLG Lift – 7-25

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

7-26 – JLG Lift – 3121201

3121201

Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65813058 +44 (0)161 654 1001

JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI Ltd
Germany Sheung Shui N. T. Italy 29 Tuas Ave 4,
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Jurong Industrial Estate
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 Singapore, 639379
(852) 2639 5797 +65-6591 9030
+65-6591 9031

Plataformas Elevadoras JLG Sverige AB

JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 176 27 Jarfalla
08755 Castellbisbal, Barcelona Sweden
Spain +46 (0)850 659 500
+34 93 772 4700 +46 (0)850 659 534
+34 93 771 1762

www.jlg.com

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