JLG 600 SC Boom Lift

Service and Maintenance Manual
Model
600SC
660SJC
S/N 0300074875 to
S/N 0300174703
P/N - 3121157
November 22, 2016

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
platform. It is of utmost importance that maintenance per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
sonnel pay strict attention to these warnings and precau- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
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 PLATFORM ING ELECTRICAL STORMS. ENSURE THAT FUEL
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE CAP IS CLOSED AND SECURE AT ALL OTHER
MANUFACTURER. TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
Specific precautions to be observed during maintenance WHEN PERFORMING ANY MAINTENANCE.
are inserted at the appropriate point in the manual. These
precautions are, for the most part, those that apply when • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
servicing hydraulic and larger machine component parts. LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
Your safety, and that of others, is the first consideration IN EQUIPMENT.
when engaging in the maintenance of equipment. Always • OBSERVE AND OBEY ALL WARNINGS AND CAU-
be conscious of weight. Never attempt to move heavy TIONS ON MACHINE AND IN SERVICEMANUAL.
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising • KEEP OIL, GREASE, WATER, ETC. WIPED FROM
a portion of the equipment, ensure that adequate support STANDING SURFACES AND HAND HOLDS.
is provided. • USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY MOVEMENT BY BLOCKING OR OVERHEAD SLING,
IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR. OR BOOM SAFETY PROP HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
B HYDRAULIC SYSTEM SAFETY OFF ALL POWER CONTROLS.
It should be noted the machines hydraulic systems oper- • BATTERY SHOULD ALWAYS BE DISCONNECTED-
ate at extremely high potentially dangerous pressures. DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
Every effort should be made to relieve any system pres-
sure prior to disconnecting or removing any portion of the • KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
system. MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
3121157 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
Original Issue December 4, 2003

Revised November 14, 2005
Revised July 28, 2009
Revised January 20, 2011
Revised May 24, 2011
Revised January 7, 2015
Revised November 22, 2016
A-2 – JLG Lift – 3121157

TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1 Operating specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.4 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.10 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.11 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.12 Operator Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
3121157 – JLG Lift – i

TABLE OF CONTENTS

SECTION 3 - GRADALL CHASSIS
3.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Track tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3.3 Rubber Track Pad Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)
4.1 Duo-Cone Conventional Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Acceptable Lubricants for Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2 System Pressure - Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Procedure for Releasing Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Release Of Hydraulic Pressure From A Single Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . 4-6
Release Of Hydraulic Pressure From Multiple Hydraulic Circuits. . . . . . . . . . . . . . . . . . . . . 4-7
4.3 Track Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.4 Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.5 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.6 Front Idler and Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.7 Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.8 Front Idler and Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.9 Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.10 Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.11 Final Drive and Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.12 Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Measuring Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Adjusting Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Track Adjustment - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
SECTION 5 - CAT CHASSIS (S/N 0300128000 TO S/N 0300174703)
5.1 Precautions For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Lubricating Oil for Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Motor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Overrun Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Setting Self-Priming Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
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TABLE OF CONTENTS

5.3 Construction and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Working Principle of Swash Plate Type Axial Piston Motor . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Working Principle of Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Working Principle of Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Working Principle of Low Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Two-Speed Changeover System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Working Principle of Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Procedures for manually releasing parking brake (This mechanism is optional.) . . . . . . . . 5-11
Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.4 Precautions and warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Piping Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Cautions in Using Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5 Operating Steps and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Precautions at Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Hydraulic Fluid Temperature during Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.6 Periodic Inspection and Change Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Gauging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
New Lubricant Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Inspection for Hydraulic Fluid and Lubricant Leaks, and Torque of Bolts and Plugs . . . . . 5-20
5.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
Troubleshooting for Piston Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Troubleshooting for Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Troubleshooting for High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Troubleshooting for Low Pressure Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Troubleshooting for 2-speed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Troubleshooting for Low Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.8 Maintenance and repair procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
Tools for Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.9 Precautions for Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38
5.10 Disassembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-41
Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Reduction Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Maintenance Standards For Disassembled Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.11 Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-48
5.12 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-48
5.13 Quality Check After Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-54
SECTION 6 - TURNTABLE
6.1 Swing Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Swing Bearing Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3 Swing Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
3121157 – JLG Lift – iii

TABLE OF CONTENTS

6.4 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5 Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6.6 Deutz EMR 2 (S/N 85110 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
6.7 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS . . . . . . . . . . . . . . . . . .6-26
List of Abbreviations in this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
MIL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
DTC 117- ECT/CHT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
DTC 122- TPS1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
DTC 123- TPS1 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
DTC 217- ECT Higher Than Expected 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
DTC 219- RPM Higher Than Max Allowed Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . 6-41
DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
DTC 337- Loss of Crank Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
DTC 521- Oil Pressure Sender/Switch High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
DTC 524- Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
DTC 562- Battery Voltage (VBat) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
DTC 601- Microprocessor Failure - FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
DTC 604- Microprocessor Failure - RAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
DTC 606- Microprocessor Failure - COP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
DTC 643- 5 Volt External High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
DTC 1615- Microprocessor Failure - A/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
DTC 1616- Microprocessor Failure - interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
DTC 1625- CAN J1939 Shutdown Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
DTC 1626- CAN J1939 Transmit (Tx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
DTC 1627- CAN J1939 Receive (Rx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
DTC 1629- J1939 TSC1 Message Reciept Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76
DTC 2112- Unable to Reach Higher TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
DTC 9999- Throttle Actuator Failsafe Spring Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
SECTION 7 - BOOM & PLATFORM
7.1 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Platform Sections Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Boom Rope Torquing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Three Month Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
12 Year or 7000 Hour Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Additional Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.5 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
iv – JLG Lift – 3121157

TABLE OF CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Disassembly of Boom Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.6 Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.7 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
7.8 Rotator - Helac (Prior to S/N 0300132437) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.9 Rotary Actuator (S/N 0300132437 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.10 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
SECTION 8 - HYDRAULICS & HYDRAULIC SCHEMATICS
8.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Cup and Brush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Solenoid Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Systems Incorporating Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Systems Incorporating Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Cylinders Without Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.6 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Main Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.7 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Platform Level Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Platform Level Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Jib Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Jib Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8 Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-20
3121157 – JLG Lift – v

TABLE OF CONTENTS

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Inspect Parts For Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Placing Pump Back Into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.9 Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26
Ports and Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Removal and Installation of FNR and NFPE Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Removal and Installation of FNR and NFPE Control Orifices . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Shaft Seal and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Charge Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8.10 Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-34
8.11 Hydraulic Component Start-Up Procedures and recommendations . . . . . . . . . . . . . . . . . . . . . . .8-34
SECTION 9 - JLG CONTROL SYSTEM
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
9.2 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
9.3 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3
9.4 Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5
9.5 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7
9.6 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
9.7 Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8
9.8 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-23
9.9 Analyzer Diagnostics Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-64
SECTION 10 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.3 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .10-3
Installation of Dielectric Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7
Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 10-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
vi – JLG Lift – 3121157

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
2-1. Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2-2. Engine Operating Temperature Specifications - Caterpillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
3-1. Chassis Service Notes - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Chassis Service Notes - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-3. Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-4. Bottom Track Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-5. Carrier Track Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-6. Hose Routing - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-7. Hose Routing - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-8. Track Chain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-9. Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-10. Spring & Shock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-11. Rotary Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
4-1. Correct Assembly of Conventional Duo-Cone Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-2. Examples of incorrect assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
5-1. Structure of Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-2. Structure of Swash Plate Type Axial Piston Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-3. Structure of Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4. Shuttle Valve (Shuttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-5. Structure of Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-6. Structure of Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-7. Structure of Low Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-8. Structure of Two Speed Changeover System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-9. Structure of Two Speed Changeover System at High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-10. Structure of Two Speed Changeover System at Low Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-11. Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-12. Position of Parking Brake Manual Release Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5-13. Procedures for Manually Releasing Parking Brake (step 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-16. Structure of Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5-17. Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5-18. Oil level of hydraulic fluid at the initial stage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5-19. Lubricant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
5-20. Inspection of oil leak, bolts and plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-21. Exploded View of Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-39
5-22. Exploded View of Reduction Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-40
6-1. Swing Torque Hub Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6-2. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-3. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-4. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-5. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6-6. Swing Brake Assembly (Mico) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-7. Deutz Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6-8. Deutz Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-9. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6-10. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6-11. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
3121157 – JLG Lift – vii

LIST OF FIGURES

6-12. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6-13. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-14. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
6-15. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-16. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19
6-21. Caterpillar Engine Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
6-22. Caterpillar Engine Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
6-23. 1st page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
6-24. 2nd Page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
7-1. Platform Section Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-2. Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-3. Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-4. Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7-5. Boom Assembly Cutaway - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7-8. Location of Components - Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
7-9. Location of Components - Rotator and Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
7-10. Location of Components - Boom Powertrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
7-11. Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-12. Disassembly Wire Rope Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-13. Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-14. Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
7-15. Reassembly of Components - Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
7-16. Boom Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
7-17. Location of Components - Articulating Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
7-18. Limit Switches Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
7-20. Removing Portion of End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
7-21. Heating Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
7-22. Removing Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
7-23. Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
7-19. Rotator Assembly (Helac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
7-24. Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
7-25. Removing Sleeve from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
7-26. Actuator Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
7-27. Rotary Actuator - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
7-28. Rotary Actuator - Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
7-29. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
7-30. Platform Support Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
8-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
8-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
8-3. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
8-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
8-5. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
8-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
8-7. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
8-8. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
8-9. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
8-10. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
8-11. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8
8-12. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
8-13. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
8-14. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
viii – JLG Lift – 3121157

LIST OF FIGURES

8-15. Pressure Setting Adjustments - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
8-16. Pressure Setting Adjustments - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-15
8-17. Location of Components - Main Control Valve (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16
8-18. Location of Components - Main Control Valve (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17
8-19. Main Control Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18
8-20. Platform Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19
8-21. Platform Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19
8-22. Shim Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-27
8-23. Gauge Port Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28
8-24. Plugs/Fittings Size & Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-29
8-25. Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-30
8-26. Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-30
8-27. Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-30
8-28. Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31
8-29. Charge Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-33
8-30. Hydraulic Schematic - Gradall Chassis - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-36
8-33. Hydraulic Schematic - CAT Chassis - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-39
9-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
9-2. ADE Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2
9-3. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4
9-4. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6
9-5. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . .9-9
9-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13
10-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
10-5. Application to Female Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
10-6. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5
10-7. Connector Assembly Figure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7
10-8. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8
10-12. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10
10-13. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
10-14. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
10-15. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
10-16. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
10-17. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
3121157 – JLG Lift – ix

LIST OF FIGURES

10-18. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
10-19. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13
10-20. Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14
10-21. Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
10-22. Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . .10-16
10-26. Electrical Schematic - Deutz EMR2/Gradall - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20
10-30. Electrical Schematic - Deutz/CAT - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-24
x – JLG Lift – 3121157

LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Deutz F4M1011F/F4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 Caterpillar 3044C/Caterpillar 3.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 Hydraulic Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-9 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-10 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-11 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-12 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-13 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-14 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-15 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-16 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-17 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-3 Inspection and Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
4-1 Duo-Cone Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4-2 Track Carrier Roller Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-3 Track Carrier Roller Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-4 Track Roller Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4-5 Track Roller Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4-6 Track Required Tools - Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4-7 Track Required Tools - Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-8 Front Idler & Recoil Spring Required Tools - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-9 Track Required Tools - Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
4-10 Recoil Spring Required Tools - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4-11 Front Idler & Recoil Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
4-12 Track Adjuster Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
4-13 Sprocket Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4-14 Sprocket Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4-15 Final Drive Required Tools - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
4-16 Final Drive Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
5-1 List of Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26
5-2 List of Special Purpose Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
5-3 List of Subsidiary Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36
5-4 List of Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36
6-1 J1939 Diagnostic Lamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30
8-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
8-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10
8-3 Hydraulic Pump Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-25
8-4 Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26
9-1 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-23
9-2 Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27
9-3 Machine Configuration Programming Information Prior to Software Version P5.3 . . . . . . . . . . . .9-38
9-4 Machine Configuration Programming Information Software Version P5.3 to P6.1 . . . . . . . . . . . .9-42
9-5 Machine Configuration Programming Information Software Version P6.1 to Present. . . . . . . . . .9-47
9-6 Fault Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-57
9-7 Adjustments - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-64
9-8 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-67
3121157 – JLG Lift – xi

This Page Intentionally Blank.
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.3 ENGINE DATA

Table 1-1. Operating Specifications Table 1-3. Deutz F4M1011F/F4M2011 Specifications
Maximum Work Load (Capacity) Fuel Diesel

Unrestricted: 500 lb. (230 kg) Oil Capacity
Restricted - 600SC 1000 lb. (450 kg) Cooling System 5 Quarts (4.5 L)
Restricted - 660SJC 500 lb. (230 kg) Crankcase 11 Quarts (10.5 L) w/Filter
Maximum Travel Grade (Gradeability)* 55% Total Capacity 16 Quarts (15 L)
Idle RPM 1000
Maximum Travel Grade (Side Slope)* 5°
Low RPM 1800
Max.Vertical Platform Height:
High RPM 2800
600SC 60 ft. 3 in. (18.36 m)
660SJC 66 ft. 8 in. (20.32 m) Alternator 60 Amp, belt drive
Max.Horizontal Platform Reach: Battery 1000 Cold Cranking Amps, 210
600SC 49 ft. 6 in. (15.09 m) Minutes Reserve Capacity, 12 VDC
660SJC 56 ft. 9 in. (17.3 m) Fuel Consumption
Turning Radius - Inside 0 Low RPM 1.90 GPH (7.19 lph)
High RPM 2.50 GPH (9.46 lph)
Turning Radius - Outside 8 ft. (2.4 m)
Horsepower 65 @ 3000 RPM, full load
Maximum Ground Bearing Pressure
600SC 5.45 psi (0.383 kg/cm2)
660SJC 6.5 psi (0.457 kg/cm2) Table 1-4. Deutz D2011L04 Specifications
Maximum Drive Speed: 1.6 mph (2.6 kph)
Fuel Diesel
Max. Hydraulic System Pressure 4500 psi (310 Bar)
Oil Capacity
Maximum Wind Speed 28 mph (12.5 m/s)
Cooling System 5 Quarts (4.5 L)
Maximum Manual Force 101 lb. (450 N) Crankcase 11 Quarts (10.5 L) w/Filter
Electrical System Voltage 12 Volts Total Capacity 16 Quarts (15 L)
Gross Machine Weight (Platform Empty) Idle RPM 1000
600SC 22,500 lb. (10,205 kg) Low RPM 1800
660SJC 27,100 lb. (12,292 kg)
High RPM 2600
* With boom in stowed position. Alternator 60 Amp, belt drive
Battery 1000 Cold Cranking Amps, 210
Minutes Reserve Capacity, 12 VDC
1.2 CAPACITIES Fuel Consumption
Table 1-2. Capacities Low RPM 1.90 GPH (7.19 lph)
High RPM 2.50 GPH (9.46 lph)
Fuel Tank 39 US. Gallons (147.6 L)
Horsepower 64 @ 2600 RPM, full load
Hydraulic Oil Tank 31 U.S. Gallons (117.3 L)
Hydraulic System (Including Tank) 37.2 U.S. Gallons (140.8 L)
Engine Crankcase
Deutz w/Filter 11 quarts (10.5 L)
Caterpillar (w/filter) 10.6 quarts (10 L)
3121157 – JLG Lift – 1-1

Auxiliary Power Pump

Table 1-5. Caterpillar 3044C/Caterpillar 3.4
Type Four Stroke Cycle Table 1-7. Auxiliary Power Pump

Cylinders 4 in-line 2.6 GPM (9.8 lpm) @
Output
Bore 3.70 inch (94 mm) 1200 PSI (82.7 BAR)
Stroke 4.72 inch (120 mm) Pump Displacement 0.244 cu. in. (14 cm3)
Aspiration turbocharged
Motor Type DC
Compression ratio 19:1
Rotation Clockwise
Displacement 203 in3 (3.33 L)
Firing Order 1-3-4-2 Hydraulic Filters
Rotation (viewed from fly- Counterclockwise
wheel) Table 1-8. Hydraulic Filters
Oil Capacity (w/filter) 10.6 quarts (10 L)
Hydraulic Filter Location In-line
Cooling System (Engine Only) 5.8 quarts (5.5 L)
Return Filter Type Bypass Type
Idle RPM 1000
Low RPM 1800 Return Filter Rating 10 Microns Absolute
High RPM - 3044C 2600 Charge Filter Rating 10 Microns Absolute
High RPM - 3.4 2500 Strainer Rating (In Tank) 30 Microns
Horsepower 63
Alternator 60 Amp, belt drive
Battery 930 Cold Cranking Amps, 205
1.5 PERFORMANCE DATA
Minutes Reserve Capacity, 12
VDC Function Speeds
Table 1-9. Function Speeds
1.4 COMPONENT DATA Main Boom Speed - Lift
Up 46 - 60 Seconds
Down 33 - 43 Seconds
Swing System Swing Speed 360° Left 79 - 101 Seconds
Note 1 Right 79 - 101 Seconds
Table 1-6. Swing System Out 50 - 67 Seconds
Main Boom Speed - Telescope
In 22 - 33 Seconds
Swing Motor Displacement 4.62 cu. in. (75 cm3) Rotator Speed Left 16-25 Seconds
Swing Brake Automatic spring applied hydrau- Note 4 Right 16-25 Seconds
lically released disc brakes. Up 22 - 34 Seconds
Swing Hub Ratio - 50:1 Swing Hub Ratio - 50:1 Jib Boom Speed - Lift
Down 16 - 26 Seconds
Gear Pump @ 1800 rpm 7.9 GPM (29.90 lpm) Drive (Horizontal)
Forward & Reverse 85-90
Pump Displacement 1.02 cu. in. (16 cm3) Note 2
Rotation Clockwise Drive (Out of Transport)

Forward & Reverse 80-85
Note 3
Note 1: No more than 10% difference between swing left and right.
Note 2: 200 ft. (61 m) course
Note 3: 50 ft. (15.2 m) course
Note 4: No more that 15% difference between rotator left and right.
4150501-E
1-2 – JLG Lift – 3121157

Dimensions 1.7 PRESSURE SETTINGS

Table 1-10. Dimensions Table 1-12. Pressure Settings
+60 ft. 2 13/16 in. (18.36 m) Main Relief 3000 PSI (206.85 Bar)
Boom Elevation - 600SC
-6 ft. 1 11/16 in. (1.87 m)
Upper Boom Lift Down 1500 PSI (103.4 Bar)
+60 ft. 5 3/4 in. (18.43 m)
Boom Elevation - 600SCJ Swing 1700 PSI (117.2 Bar)
-9 ft. 9 3/16 in. (2.98 m)
+66 ft. 7 5/8 in. (20.31 m) Platform Level - Forward 2800 PSI (193.06 Bar)
Boom Elevation - 660SCJ Platform Level - Backward 1800 PSI (124.11 Bar)
-11 ft. 5 1/4 in. (3.49 m)
Steel Track - 8’4" (2.54 m) Jib Boom - Up 1500 PSI (103 Bar)
Machine Height (Stowed)
Rubber Track - 8’6" (2.59 m) Jib Boom - Down 1200 PSI (82.7 Bar)
Machine Length (Stowed) 35’ 6" (10.8 m)
Machine Width 8 ft. (2.4 m)
1.8 CYLINDER SPECIFICATIONS
1.6 TORQUE REQUIREMENTS Table 1-13. Cylinder Specifications
BORE STROKE ROD DIA.

Table 1-11. Torque Requirements
660SJ 600S 660SJ 600S 660SJ 600S
Torque Value Interval Lift 6.00 6.00 44.6875 44.6875 3 3
Description
(Dry) Hours (152.4 (152.4) (1135.1 (1135.1 (76.2) (76.2)
) ) )
Bearing To Chassis 240 ft. lbs. 50/600* Telescope 3.5 3.5 168.437 177.75 2.5 2.5
(326 Nm) (88.9) (88.9) (4278.3 (4514.9 (63.5) (63.5)
See Note ) )
Master 3.5 3 13.0625 8.5 1.5 1.5
Bearing To Turntable 240 ft. lbs. 50/600*
(88.9) (76.2) (331.8) (215.9) (38.1) (38.1)
(326 Nm)
See Note Slave Level 3.5 3 13.0625 8.5 1.5 1.5
(88.9) (76.2) (331.8) (215.9) (38.1) (38.1)
Wire Rope 15 ft.lbs. 150 Lift (Jib 3 N/A 25.5 N/A 1.5 N/A
(20 Nm) Boom) (76.2) (647.7) (38.1)
M16 Travel Motor 175 ±30 ft.lbs. As

mounting bolts (240±40 Nm) required 1.9 MAJOR COMPONENT WEIGHTS
M20 Final Drive 390 ±50 ft.lbs. As
Table 1-14. Major Component Weights
mounting bolts (530±70 Nm) required
M20 Track Roller 340 ±44 ft.lbs. As 660SJ 600S

LB. KG. LB. KG.
M24 Carrier Roller 600 ±70 ft.lbs. As
Platform Control Console 250 113 250 113
Platform Level Cylinder 60 27 46 21
*Check swing bearing bolts for security after first 50 hours
of operation and every 600 hours thereafter. (See para- Main Boom (Includes Lift Cyl., Rota- 3783 1716 352 160
graph on Swing Bearing in Section 2.) tor, and Support) 7 0
NOTE: When maintenance becomes necessary or a fas- Turntable Complete (including 9065 4112 731 331
tener has loosened, refer to the Torque Chart to engine) 5 8
determine proper torque value.
3121157 – JLG Lift – 1-3

1.10 SERIAL NUMBER LOCATIONS NOTE: When temperatures remain below 20° F (-7 degrees
C), JLG Industries recommends the use of Mobil
A serial number plate is affixed to the left rear side of the DTE 13M.
frame. If the serial number plate is damaged or missing,
the machine serial number is stamped on the left side of Aside from JLG recommendations, it is not advisable to
the frame. mix oils of different brands or types, as they may not con-
tain the same required additives or be of comparable vis-
cosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommenda-
tions.
Table 1-16. Mobilfluid 424 Specs
SAE Grade 10W30

Gravity, API 29.0
SERIAL Density, Lb/Gal. 60°F 7.35
SERIAL NUMBER
NUMBER (STAMPED Pour Point, Max -46°F (-43°C)
PLATE ON FRAME)
Flash Point, Min. 442°F (228°C)
Viscosity
Brookfield, cP at -18°C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
Figure 1-1. Serial Number Locations
Table 1-17. Mobil DTE 13M Specs
1.11 HYDRAULIC OIL ISO Viscosity Grade #32

Specific Gravity 0.877
Table 1-15. Hydraulic Oil
Pour Point, Max -40°F (-40°C)
HYDRAULIC SYSTEM OPERATING
SAE VISCOSITY GRADE Flash Point, Min. 330°F (166°C)
TEMPERATURE RANGE
+0° to +180° F (-18° C to +83° C) 10W Viscosity
+0° F to +210° F (-18° C to +99° C) 10W-20, 10W-30 at 40° C 33cSt
+50° F to +210° F (+10° C to +210° C) 20W-20 at 100° C 6.6 cSt
at 100° F 169 SUS
NOTE: Hydraulic oils must have anti-wear qualities at least
at 210° F 48 SUS
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser- cp at -20° F 6,200
vice. JLG Industries recommends Mobilfluid 424 Viscosity Index 140
hydraulic oil, which has an SAE viscosity index of
152.
1-4 – JLG Lift – 3121157

Figure 1-2. Operator Maintenance and Lubrication Diagram
1.12 OPERATOR MAINTENANCE AND

LUBRICATION LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION
UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-
NOTE: The following numbers correspond to those in Figure SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON-
1-2., Operator Maintenance and Lubrication Dia- MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
gram. INCREASED ACCORDINGLY.
Table 1-18. Lubrication Specifications 1. Swing Bearing
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. Mobilfluid
424.
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104.
Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.
Lube Point(s) - 2 Grease Fittings

Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access
3121157 – JLG Lift – 1-5

2. Swing Drive Hub 5. Hydraulic Charge Filter
Lube Point(s) - Level/Fill Plug Interval - Change after first 50 hrs. and every 6
Capacity - 17 oz. (1/2 Full) months or 300 hrs. thereafter or as indicated by
Lube - EPGL Condition Indicator.
Interval - Check level every 3 months or 150 hrs of
6. Hydraulic Tank
operation; change every 2 years or 1200 hours of
operation
3. Final Drive Hub
Lube Point(s) - Level/Fill Plug
Capacity - 2.1 gal.(7.9 L); 1/2 Full
NORMAL OPERATING
Lube - EPGL
RANGE WITH BOOM
Interval - Check level every 3 months or 150 hrs of
IN STOWED POSITION
operation; change every 2 years or 1200 hours of
operation
4. Hydraulic Return Filter
Lube Point(s) - Fill Cap

Capacity - 30.6 gal. Tank; 32.7 gal. System
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
Interval - Change after first 50 hrs. and every 6

months or 300 hrs. thereafter or as indicated by
Condition Indicator.
1-6 – JLG Lift – 3121157

7. Suction Strainers (in tank) 10. Fuel Filter - Deutz
REMOVE FILL CAP PLATE FROM

TANK TO GAIN ACCESS TO
STRAINERS
Lube Point(s) - Replaceable Element

Interval - Every Year or 600 hours of operation
11. Fuel Filter - Caterpillar
Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation, Lube Point(s) - Replaceable Element
remove and clean at time of hydraulic oil change. Interval - Every Year or 600 hours of operation
8. Oil Change w/Filter - Deutz 12. Air Filter
Lube Point(s) - Replaceable Element

Lube Point(s) - Fill Cap/Spin-on Element Interval - Every 6 months or 300 hours of operation
Capacity - 11 Quarts Crankcase; 5 Quarts Cooler or as indicated by the condition indicator
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in accor-
dance with engine manual.
9. 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.
3121157 – JLG Lift – 1-7

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 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)
1-8 – JLG Lift – 3121157

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
3. * ASSEMBLY USES HARDENED WASHER
3121157 – JLG Lift – 1-9

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
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
*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.
1-10 – JLG Lift – 3121157

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
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
*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.
3121157 – JLG Lift – 1-11

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
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 (METRIC Fasteners - Sheet 5 of 7)
1-12 – JLG Lift – 3121157

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
3121157 – JLG Lift – 1-13

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
1-14 – JLG Lift – 3121157

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-
This section provides the necessary information needed dures.
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 The Annual Machine Inspection must be performed by a
operation, ensure that all the necessary inspections and Factory-Certified Service Technician on an annual basis,
maintenance have been completed before placing the no later than thirteen (13) months from the date of the
machine into service. prior Annual Machine Inspection. JLG Industries, Inc. rec-
ognizes a Factory-Certified Service Technician as a per-
Preparation, Inspection, and Maintenance 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- Reference the JLG Annual Machine Inspection Form and
ther requirements for aerial work platforms. The frequency the Inspection and Preventative Maintenance Schedule for
of inspections and maintenance must be increased as items requiring inspection during the performance of this
environment, severity and frequency of usage requires. inspection. Reference the appropriate areas of this man-
ual for servicing and maintenance procedures.
Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is
It is the User’s or Operator’s primary responsibility to per- important that JLG Industries, Inc. has updated ownership
form a Pre-Start Inspection of the machine prior to use information for each machine. When performing each
daily or at each change of operator. Reference the Opera- Annual Machine Inspection, notify JLG Industries, Inc. of
tor’s and Safety Manual for completion procedures for the the current machine ownership.
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to per-
forming the Pre-Start Inspection.
Preventative Maintenance
In conjunction with the specified inspections, mainte-
nance shall be performed by a qualified JLG equipment
Pre-Delivery Inspection and Frequent mechanic. JLG Industries, Inc. recognizes a qualified JLG
Inspection equipment mechanic as a person who, by possession of a
The Pre-Delivery Inspection and Frequent Inspection shall recognized degree, certificate, extensive knowledge, train-
be performed by a qualified JLG equipment mechanic. ing, or experience, has successfully demonstrated the
JLG Industries, Inc. recognizes a qualified JLG equipment ability and proficiency to service, repair, and maintain the
mechanic as a person who, by possession of a recog- subject JLG product model.
nized degree, certificate, extensive knowledge, training, or Reference the Preventative Maintenance Schedule and
experience, has successfully demonstrated the ability and the appropriate areas of this manual for servicing and
proficiency to service, repair, and maintain the subject maintenance procedures. The frequency of service and
JLG product model. maintenance must be increased as environment, severity
The Pre-Delivery Inspection and Frequent Inspection pro- and frequency of usage requires.
cedures are performed in the same manner, but at differ-
ent times. The Pre-Delivery Inspection shall be performed
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.
3121157 – 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 Man-
tion At each Operator change. ual
Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or Qualified JLG Service and Maintenance
Inspection rental delivery. User Mechanic Manual and applicable JLG
inspection form.
Frequent Inspec- In service for 3 months or 150 hours, Owner, Dealer, or Qualified JLG Service and Maintenance
tion whichever comes first; or User Mechanic Manual and applicable JLG
Out of service for a period of more than inspection form.
3 months; or
Purchased used.
Annual Machine Annually, no later than 13 months from Owner, Dealer, or Factory-Certified Service and Maintenance
Inspection the date of the prior inspection. User Service Techni- Manual and applicable JLG
cian inspection form.
Preventative At intervals as specified in the Service Owner, Dealer, or Qualified JLG Service and Maintenance
Maintenance and Maintenance Manual. User Mechanic Manual
2.2 SERVICE AND GUIDELINES Cleanliness

1. The most important single item in preserving the
General long service life of a machine is to keep dirt and for-
The following information is provided to assist you in the eign materials out of the vital components. Precau-
use and application of servicing and maintenance proce- tions have been taken to safeguard against this.
dures contained in this book. Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these
Safety and Workmanship items must be maintained on a scheduled basis in
Your safety, and that of others, is the first consideration order to function properly.
when engaging in the maintenance of equipment. Always 2. At any time when air, fuel, or oil lines are discon-
be conscious of weight. Never attempt to move heavy nected, clear adjacent areas as well as the openings
parts without the aid of a mechanical device. Do not allow and fittings themselves. As soon as a line or compo-
heavy objects to rest in an unstable position. When raising nent is disconnected, cap or cover all openings to
a portion of the equipment, ensure that adequate support prevent entry of foreign matter.
is provided.
3. Clean and inspect all parts during servicing or main-
tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
clean. Be sure all parts are clean before they are
installed. New parts should remain in their contain-
ers until they are ready to be used.
2-2 – JLG Lift – 3121157

SECTION 2 - GENERAL
Components Removal and Installation Gaskets

Check that holes in gaskets align with openings in the
1. Use adjustable lifting devices, whenever possible, if
mating parts. If it becomes necessary to hand-fabricate a
mechanical assistance is required. All slings (chains,
gasket, use gasket material or stock of equivalent material
cables, etc.) should be parallel to each other and as
and thickness. Be sure to cut holes in the right location, as
near perpendicular as possible to top of part being
blank gaskets can cause serious system damage.
lifted.
2. Should it be necessary to remove a component on Bolt Usage and Torque Application
an angle, keep in mind that the capacity of an eye-
bolt or similar bracket lessens, as the angle between 1. Use bolts of proper length. A bolt which is too long
the supporting structure and the component will bottom before the head is tight against its related
becomes less than 90 degrees. part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
3. If a part resists removal, check to see whether all When replacing bolts, use only those having the
nuts, bolts, cables, brackets, wiring, etc., have been same specifications of the original, or one which is
removed and that no adjacent parts are interfering. equivalent.
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within
the text, standard torque values should be used on
When disassembling or reassembling a component, com-
heat-treated bolts, studs, and steel nuts, in accor-
plete the procedural steps in sequence. Do not partially
dance with recommended shop practices. (See
disassemble or assemble one part, then start on another.
Torque Chart Section 1.)
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval. Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, as
Pressure-Fit Parts well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
When assembling pressure-fit parts, use an anti-seize or
reinstalled.
molybdenum disulfide base compound to lubricate the
mating surface.
Hydraulic System
Bearings 1. Keep the system clean. If evidence of metal or rub-
ber particles are found in the hydraulic system, drain
1. When a bearing is removed, cover it to keep out dirt
and flush the entire system.
and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed 2. Disassemble and reassemble parts on clean work
air can be used but do not spin the bearing. surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
2. Discard bearings if the races and balls (or rollers)
required, to aid assembly.
are pitted, scored, or burned.
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are
ready to install.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear-
ing is to be installed on a shaft, apply pressure to the
inner race.
3121157 – JLG Lift – 2-3

SECTION 2 - GENERAL
Lubrication 3. Cloudy oils indicate a high moisture content which

permits organic growth, resulting in oxidation or cor-
Service applicable components with the amount, type,
rosion. If this condition occurs, the system must be
and grade of lubricant recommended in this manual, at
drained, flushed, and refilled with clean oil.
the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent 4. It is not advisable to mix oils of different brands or
that meets or exceeds the specifications listed. types, as they may not contain the same required
additives or be of comparable viscosities. Good
Battery grade mineral oils, with viscosities suited to the
Clean battery, using a non-metallic brush and a solution of ambient temperatures in which the machine is oper-
baking soda and water. Rinse with clean water. After ating, are recommended for use.
cleaning, thoroughly dry battery and coat terminals with NOTE: Metal particles may appear in the oil or filters of new
an anti corrosion compound. machines due to the wear-in of meshing compo-
nents.
Lubrication and Servicing
Components and assemblies requiring lubrication and Hydraulic Oil
servicing are shown in the Lubrication Chart in Section 1.
1. Refer to Section 1 for recommendations for viscosity
ranges.
2.3 LUBRICATION AND INFORMATION 2. JLG recommends Mobilfluid 424 hydraulic oil, which
has an SAE viscosity of 10W-30 and a viscosity
Hydraulic System index of 152.
1. The primary enemy of a hydraulic system is contam- NOTE: Start-up of hydraulic system with oil temperatures
ination. Contaminants enter the system by various below -15 degrees F (-26 degrees C) is not recom-
means, e.g., using inadequate hydraulic oil, allowing mended. If it is necessary to start the system in a
moisture, grease, filings, sealing components, sand, sub-zero environment, it will be necessary to heat
etc., to enter when performing maintenance, or by the oil with a low density, 100VAC heater to a mini-
permitting the pump to cavitate due to insufficient mum temperature of -15 degrees F (-26 degrees C).
system warm-up or leaks in the pump supply (suc-
tion) lines. 3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 oil or its equivalent.
2. The design and manufacturing tolerances of the This will allow start up at temperatures down to -20
component working parts are very close, therefore, degrees F (-29 degrees C). However, use of this oil
even the smallest amount of dirt or foreign matter will give poor performance at temperatures above
entering a system can cause wear or damage to the 120 degrees F (49 degrees C). Systems using DTE
components and generally results in faulty opera- 13 oil should not be operated at temperatures above
tion. Every precaution must be taken to keep 200 degrees F (94 degrees C) under any condition.
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the speci-
fied intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.
2-4 – JLG Lift – 3121157

SECTION 2 - GENERAL
Changing Hydraulic Oil 2.4 CYLINDER DRIFT TEST

1. Use of any of the recommended crankcase or Maximum acceptable cylinder drift is to be measured
hydraulic oils eliminates the need for changing the using the following methods.
oil on a regular basis. However, filter elements must
be changed after the first 50 hours of operation and Platform Drift
every 300 hours thereafter. If it is necessary to Measure the drift of the platform to the ground. Lower
change the oil, use only those oils meeting or booms (if equipped) slightly elevated, upper boom fully
exceeding the specifications appearing in this man- extended with the rated load in the platform and power off.
ual. If unable to obtain the same type of oil supplied Maximum allowable drift is 2 inches (5 cm) in 10 minutes.
with the machine, consult local supplier for assis- If the machine does not pass this test, proceed with the
tance in selecting the proper equivalent. Avoid mix- following.
ing petroleum and synthetic base oils.
2. Use every precaution to keep the hydraulic oil clean. Cylinder Drift
If the oil must be poured from the original container
into another, be sure to clean all possible contami-
nants from the service container. Always clean the Table 2-2. Cylinder Drift
mesh element of the filter and replace the cartridge Max. Acceptable Drift
any time the system oil is changed. Cylinder Bore Diameter
in 10 Minutes
3. While the unit is shut down, a good preventive main- inches mm inches mm
tenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as 3 76.2 0.026 0.66
well as a functional check of each system, before 3.5 89 0.019 0.48
placing the machine back in service. 4 101.6 0.015 0.38
5 127 0.009 0.22
Lubrication Specifications 6 152.4 0.006 0.15
Specified lubricants, as recommended by the component
7 177.8 0.005 0.13
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which 8 203.2 0.0038 0.10
meet a variety of single purpose grease requirements. 9 228.6 0.0030 0.08
Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evalua- Drift is to be measured at the cylinder rod with a calibrated
tion. Refer to Section 1 for an explanation of the lubricant dial indicator. The cylinder oil must be at ambient temper-
key designations appearing in the Lubrication Chart. ature and temperature stabilized.
The cylinder must have the normal load, which is the nor-
mal platform load applied.
If the cylinder passes this test, it is acceptable.
NOTE: This information is based on 6 drops per minute cyl-

inder leakage.
3121157 – JLG Lift – 2-5

SECTION 2 - GENERAL
2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT
GUIDELINES NOTE: This instruction applies to repairs, or modifications to
Filament wound bearings. the machine and to welding performed from the
machine on an external structure, or component,
1. Pinned joints should be disassembled and
inspected if the following occurs:
Do the Following When Welding on JLG
a. Excessive sloppiness in joints. Equipment
b. Noise originating from the joint during operation. • Disconnect the battery.
2. Filament wound bearings should be replaced if any • Disconnect the moment pin connection (where fitted)
of the following is observed:
• Ground only to structure being welded.
a. Frayed or separated fibers on the liner surface.
Do NOT Do the Following When Welding
b. Cracked or damaged liner backing.
on JLG Equipment
c. Bearings that have moved or spun in their hous-
ing. • Ground on frame and weld on any other area than the
chassis.
d. Debris embedded in liner surface.
• Ground on turntable and weld on any other area than
3. Pins should be replaced if any of the following is
the turntable.
observed (pin should be properly cleaned prior to
inspection): • Ground on the platform/support and weld on any other
area than the platform/support.
a. Detectable wear in the bearing area.
• Ground on a specific boom section and weld on any
b. Flaking, pealing, scoring, or scratches on the pin
other area than that specific boom section.
surface.
c. Rusting of the pin in the bearing area. • Allow pins, wear pads, wire ropes, bearings, gearing,
seals, valves, electrical wiring, or hoses to be between
4. Re-assembly of pinned joints using filament wound the grounding position and the welded area.
bearings.
a. Housing should be blown out to remove all dirt
and debris...bearings and bearing housings FAILURE TO COMPLY WITH ABOVE REQUIREMENTS MAY
must be free of all contamination. RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
b. Bearing / pins should be cleaned with a solvent SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)
to remove all grease and oil...filament wound
bearing are a dry joint and should not be lubri-
cated unless otherwise instructed (i.e. sheave
pins).
c. Pins should be inspected to ensure it is free of
burrs, nicks, and scratches which would dam-
age the bearing during installation and opera-
tion.
2-6 – JLG Lift – 3121157

SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
Pre-
AREA Weekly Monthly
Delivery2 Annual4
Pre-Start1 Preventive Preventive
Every 2
3 (Yearly) Years
Inspection Maintenance Maintenance or Frequent Inspection
Inspection
Boom Assembly 9
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Platform Assembly 9
Platform 1,2 1,2
Railing 1,2 1 1,2
Gate 5 1 1,5
Floor 1,2 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 2 1,2,10 1,2,10
Turntable Assembly 9
Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly 9
Tires 1 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 1 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components
Drive Motors
Torque Hubs 11 11
Functions/Controls 9
3121157 – JLG Lift – 2-7

SECTION 2 - GENERAL
INTERVAL
Pre-
AREA Weekly Monthly
Delivery2 Annual4
Every 2
3 (Yearly) Years
Inspection
Platform Controls 5 5 6 6
Ground Controls 5 5 6 6
Function Control Locks, Guards, or Detents 1,5 1,5 5 5
Footswitch 1,5 5 5
Emergency Stop Switches (Ground & Platform) 5 5 5
Function Limit or Cutout Switch Systems 5 5
Capacity Indicator 5
Drive Brakes 5
Swing Brakes 5
Boom Synchronization/Sequencing Systems 5
Manual Descent or Auxiliary Power 5 5
Power System 9
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 11 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 5 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5
Hydraulic/Electric System 9
Hydraulic Pumps 1,9 1,2,9
Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2
Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 11 7,11 7,11
Electrical Connections 1 20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operators and Safety Manuals in Storage Box 21 21 21
ANSI and EMI Manuals/Handbooks Installed 21
2-8 – JLG Lift – 3121157

SECTION 2 - GENERAL
INTERVAL
Pre-
AREA Weekly Monthly
Delivery2 Annual4
Every 2
3 (Yearly) Years
Inspection
Capacity Decals Installed, Secure, Legible 21 21 21
All Decals/Placards Installed, Secure, Legible 21 21 21
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
3121157 – JLG Lift – 2-9

SECTION 2 - GENERAL
INTERVAL
Pre-
AREA 1 Weekly Monthly
Delivery2 Annual4 Every 2
Pre-Start Preventive Preventive 3 (Yearly) Years
Inspection
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
2-10 – JLG Lift – 3121157

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120°F(49° C)
NOOPERATIONABOVETHIS
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)
ENGINEWILL START ANDOPERATEUNAIDEDAT THIS WINTER 20° F(-7° C)

GRADE
TEMPERATUREWITHTHERECOMMENDEDFLUIDSANDA FUEL 10°F(-12° C)
FULLYCHARGEDBATTERY.
0°F(-18° C)
ENGINEWILL START ANDOPERATEAT THSTEMPERATUREI WINTER
GRADE -10°F(-23° C)
WITHTHERECOMMENDEDFLUIDS, A FULLYCHARGEDBATTERY
ANDTHEAIDOFA COMPLETEJLGSPECIFIEDCOLDWEATHER FUEL -20°F(-29° C)
WITH
PACKAGE(IE. ENGINEBLOCK HEATER, ETHERINJECTIONOR
KEROSENE -30° F(-34° C)
GLOWPLUGS, BATTERYWARMERANDHYDRAULICOIL TANKHEATER) ADDED
-40° F(-40° C)
NOOPERATIONBELOWTHIS
AMBIENT TEMPERATURE
EXTENDEDDRIVINGWITH
HYDRAULICOIL TANK
TEMPERATURESOF180°F
(82°C) ORABOVE
180° F(82° C)
(HYD. OIL TANKTEMP.)
IFEITHERORBOTHCONDITIONS
AMBIENT AIR EXIST JLGHIGHLYRECOMMENDS
TEMPERATURE THEADDITIONOFA HYDRAULIC
OIL COOLER(CONSULT JLGSERVICE
120° F (49° C)
NOOPERATIONABOVETHIS PROLONGEDOPERATIONIN NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIRTEMPERATURES
OF100°F(38°C) ORABOVE. 1) RECOMMENDATIONSAREFORAMBIENT TEMPERATURES
100° F (38° C)
CONSISTANTLYWITHINSHOWNLIMITS
90° F (32° C)
MOBIL 424 10W-30
2) ALL VALUESAREASSUMEDTOBEAT SEA LEVEL.

80° F (27° C)
70° F (21° C)
EXXONUNIVISHVI 26
60° F (16° C)
HYDRAULIC SUMMER-GRADE WINTER-GRADE
50° F (10° C) FUEL
SPECIFICATIONS FUEL
MOBIL DTE13
40° F (4° C) F C
30° F (-1° C) + 32 0
20° F (-7° C)
10° F (-12° C)
+ 23 -5
AMBIENT TEMPERATURE
0° F (-18° C) DONOT START UPHYDRAULICSYSTEM

WITHOUT HEATINGAIDSWITHMOBILE424 + 14 -10
-10° F (-23° C) HYDRAULICOIL BELOWTHISTEMPERATURE
-20° F (-29° C) +5 -15
DONOT START UPHYDRAULICSYSTEM WITHOUT HEATINGAIDS
-30° F (-34° C) ANDCOLDWEATHERHYDRAULICOIL BELOWTHISTEMPERATURE -4 -20
-40° F (-40° C)
AMBIENT TEMPERATURE -13 -25
-22 -30
0 10 20 30 40 50 60
%OFADDEDKEROSENE
4150548 E
Figure 2-1. Engine Operating Temperature Specifications - Deutz
3121157 – JLG Lift – 2-11

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120 F(49 C)
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)
ENGINEWILL START ANDOPERATEUNAIDEDAT THIS
TEMPERATUREWITHTHERECOMMENDEDFLUIDSANDA 10 F(-12 C)
FULLYCHARGEDBATTERY.
0 F(-18 C)
ENGINEWILL START ANDOPERATEAT THISTEMPERATURE -10 F(-23 C)
WITHTHERECOMMENDEDFLUIDS, A FULLYCHARGEDBATTERY
ANDTHEAIDOFA COMPLETEJLGSPECIFIEDCOLDWEATHER -20 F(-29 C)
PACKAGE(IE. ENGINEBLOCKHEATER, BATTERYWARMERAND
HYDRAULICOIL TANKHEATER) -30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE
EXTENDEDDRIVINGWITH
HYDRAULICOIL TANK
TEMPERATURESOF180° F
(82°C) ORABOVE.
180° F(82° C)
(HYD. OIL TANKTEMP.)
IFEITHERORBOTHCONDITIONS
EXIST JLGHIGHLYRECOMMENDS
AMBIENT AIR THEADDITIONOFAHYDRAULIC
TEMPERATURE
OIL COOLER(CONSULT JLGSERVICE
120° F(49° C) PROLONGEDOPERATIONIN

110° F(43° C) AMBIENT TEMPERATURE AMBIENT AIRTEMPERATURES
OF100° F(38°C) ORABOVE.
100° F(38° C)
MOBIL 424 10W-30
90° F(32° C)
80° F(27° C)
EXXONUNIVISHVI 26
70° F(21° C)
60° F(16° C)
50° F(10° C) HYDRAULIC
MOBIL DTE13
40° F(4° C)
SPECIFICATIONS
30° F(-1° C)
20° F(-7° C)
10° F(-12° C)
0° F(-18° C) DONOT START UPHYDRAULICSYSTEM
WITHOUT HEATINGAIDSWITHMOBILE424
-10° F(-23° C) HYDRAULICOIL BELOWTHISTEMPERATURE
-20° F(-29° C) NOTE:
DONOT START UPHYDRAULICSYSTEM WITHOUT HEATINGAIDS
-30° F(-34° C) ANDCOLDWEATHERHYDRAULICOIL BELOWTHISTEMPERATURE 1) RECOMMENDATIONSAREFORAMBIENT TEMPERATURES
-40° F(-40° C) CONSISTENTLYWITHIN SHOWNLIMITS
AMBIENT TEMPERATURE 2) ALL VALUESAREASSUMEDTOBEAT SEALEVEL.
4150548 E
Figure 2-2. Engine Operating Temperature Specifications - Caterpillar
2-12 – JLG Lift – 3121157

SECTION 3. GRADALL CHASSIS
3.1 ASSEMBLY with bolts using impact wrench. Torque to 230 ft-lbs,
+15-0 (322 Nm, +21 -0).
1. Place frame into upside down position.
2. Make sure roller mounting rails are clean.
3. With air gun, blow out all 48 roller mounting holes.
Wipe mounting surfaces clean with rag. verify all
threads are clean of grease & oil.
4. Using crane, position and align (12) rollers, (6) per
side. Assemble with hardware and loctite. torque
(48) bolts to 200 ft.-lbs, +15-0 (280 Nm, +21 -0).
9. Repeat process to opposite side:

10. Clean machined mounting surface (one side only)
with solvent rags.
NOTE: Sprockets are not directional.
11. Apply never seez to sprocket mounting area. Hook

to crane using strap and alignment pin. lift up and
onto motor drive. Secure with bolts and loctite.
torque to 230 ft-lbs, +15-0 (322 Nm, +21 -0).
5. Using brush and solvent container, wash both inside
and out on both motor mounts areas. Using dry
rags, wipe motor mount area dry, inside and out-
side.
6. Clean the machined mounting surfaces on each
drive motor.
7. Get hardware for mounting drive motors and place
washers onto each bolt and add loctite.
8. Lift the drive assembly into place using an adequate
lifting device and nylon straps. Level, check, and fill
(if needed) the oil content. Apply Never Seez to
motor mount area. Re-align the motor in the nylon
straps as needed & assemble to carbody. Secure
3121157 – JLG Lift – 3-1

Figure 3-1. Chassis Service Notes - Sheet 1 of 2
3-2 – JLG Lift – 3121157

Track tension adjustment to be made between the idler and carrier roller - 0.781 inches (19.8
1
mm)
Never-Seez to be used on master link pin before assembly. Torque Pad bolts over master link to
2
65 ft-lbs +6,-6 then tighten 1/3 (120°)turn further.
3 Fill Plug
4 Check oil level of left & right crawler drives (0.69 gal. [2.6 L] grade 90 Gear Oil)
5 Drain Plug
6 Torque to 200 ft-lbs, +15 -0 (280 Nm, +21 -0)
7 Use Gradall 8381-3109 Large Button Head Grease Fitting Adapter to Adjust Tracks
10 Offset in Idler Spring from centerline of Idler to be oriented down.
12 Add Never-Seez to both mounting pilots Drive Motors
Figure 3-2. Chassis Service Notes - Sheet 2 of 2
3121157 – JLG Lift – 3-3

1. Counterweight 5. Carrier Track Roller 9. Idler Assembly

2. Cover Plate 6. Track Assembly 10. Spring Assembly
3. Drive Assembly 7. Drive Sprocket 11. Shock Assembly
4. Bottom Track Roller 8. Frame
Figure 3-3. Chassis Components
12. Repeat process to opposite side: 16. Using an adequate lifting device, lift & turn over the
frame. Position the left and right frame sides on ply-
13. Assemble fitting and fitting seal into the end of each
wood and idler ends on 4 x 4 blocks.
shock assembly. Torque to chart specifications.
17. Using an adequate lifting device, pick up spring
14. Assemble shock assembly into position. Secure with assembly upright onto idler assembly. Install using
bolts, washers, and loctite. Torque to 65 ft-lbs, +10- bolts, washers, and loctite. Torque to 165 ft-lbs
0 (91 Nm, +15 -0). (+15-0 (231 Nm, +21 -0). (Repeat for the other idler
15. Repeat process to the opposite side. assembly.)
18. Repeat process for opposite side.
3-4 – JLG Lift – 3121157

19. Reference offset in idler spring from centerline of 27. Route brake, shift, and drain hoses through rh side
idler (to be oriented down). Using gantry crane and frame. Lubricate o-rings, and hand tighten hoses to
sling, pick up and slide spring / idler assembly into RH drive motor fittings.
pre-greased slider area, using nylon sledge hammer
lightly to assemble. Repeat for other side.
20. Repeat process for opposite side:

21. Push idler assembly against the seat. Using the spe-
cial adapter, pump in grease to start expanding
shock assembly; just enough to inspect for proper
assembly prior to track installation.
22. Repeat process to opposite side:
23. Assemble fittings for hoses to both drive motors fin-
ger tight until correct positioning is established.
24. Install swivel supports with hardware and loctite.
Torque supports to 53 ft-lbs, +5-0 (74 Nm, +7 -0).
25. Lift swivel using supports previously installed, and

assemble to frame. Use loctite with bolts to help
secure. Torque to 68 ft-lbs.(95 Nm).
26. Guide in hoses from swivel area through each side 28. Repeat hose routing process on LH side frame with
frame. Make initial connections for hoses from correct hoses to drive motor.
swivel to drive motors.
3121157 – JLG Lift – 3-5

1. Guide Roller 4. Bearing 7. Mounting Bracket

2. Shaft 5. Ring 8. O-ring
3. Plug 6. Seal 9. Roll Pin
Figure 3-4. Bottom Track Roller Assembly
3-6 – JLG Lift – 3121157

1. Guide Roller 5. Washer 9. Tension Ring 13. Cover

2. Shaft 6. Roller Bearing 10. Collar 14. Cover Seal
3. Internal Cover 7. Not Used 11. Packing Ring 15. Lockwasher
4. Bolt 8. Seal Ring 12. Seal Ring 16. Bolt
Figure 3-5. Carrier Track Roller Assembly
3121157 – JLG Lift – 3-7

Figure 3-6. Hose Routing - Sheet 1 of 2
3-8 – JLG Lift – 3121157

Figure 3-7. Hose Routing - Sheet 2 of 2
3121157 – JLG Lift – 3-9

29. Route reverse & forward hoses through frame one at 34. Move to drive motors. Starting with brake hose for
a time. Lubricate o-rings, and hand tighten to drive easy access, torque (3) small hoses on both sides of
motor fittings. the drive motor according to torque chart specifica-
tions.
35. Torque (2) large hoses on each drive motor accord-
ing to torque chart specifications.
36. Install the swivel stabilizer and secure With Loctite.
Torque to 93 ft-lbs, +10-0 (130 Nm, +14 -0).
37. Clean split post on each side of the frame, and wipe
off grease from roller assembly. Apply Never-Seez.
Slide roller assembly into split post hole and secure
with nut, bolt, and loctite. Torque to 340 ft-lbs, +25-0
(476 Nm, +35 -0)on both sides.
38. Place washers on cover plate retaining bolts and
apply loctite on each bolt. Install the cover plates
and torque bolts according to chart specifications.
39. Using overhead crane, set the tracks in position on
the shop floor. Unroll track completely by crane lift-
30. Assemble tee fittings in bottom ports '5' & '6'. Torque ing and pushing along. Using bolt cutters to cut wire
per chart specs. route and connect, shift, & drain securing track pin. Unwrap pin and discard in trash.
hoses. Torque hoses according to chart specifica- repeat for second track.
tions. 40. Hook up crane to end of track and curl both ends of
31. Assemble swivel tee fitting in bottom port '7'. Route both tracks inwards (for track pad accessibility).
and connect brake hose. Torque hose & fitting 41. Using an impact wrench, remove (4) track pads; one
according to chart specifications. on each end of each track. Set them aside with the
32. Assemble fittings to center pin for reverse hoses, (4) bolts and nuts in each pad.
ports '3' & '4'. Torque according to chart specifica- 42. Using long pry bar, roll back each end of both tracks
tions. Route and connect hoses to fittings. Torque flat onto the floor. Measure distance between both
hoses according to chart specifications. tracks. Mark spacing on floor with chalk. use pry bar
33. Assemble fittings to center pin for forward hoses, to move track to mark and correct spacing.
ports '1' & '2'. Torque according to chart specifica-
tions. Route and connect hoses to fittings. Torque
hoses according to chart specifications.
3-10 – JLG Lift – 3121157

1. Chain Assembly 4. Bearing 7. Splice Hinge Pin

2. Left Link 5. Hinge Pin 8. Spacer
3. Right Link 6. Bearing Splice 9. Track Cleat
Figure 3-8. Track Chain Assembly
3121157 – JLG Lift – 3-11

1. Idler 5. Mounting Bracket 9. Not Used

2. Shaft 6. Seal 10. O-ring
3. Bearing 7. Seal 11. Plug
4. Roll Pin 8. Seal Holder 12. Bracket
Figure 3-9. Idler Assembly
3-12 – JLG Lift – 3121157

1. Mounting Flange 5. Roll Pin 9. Seal

2. Spring 6. Piston/Rod 10. Seal
3. Base Plate 7. Wiper 11. Fitting
4. Locknut 8. Barrel
Figure 3-10. Spring & Shock Assembly
3121157 – JLG Lift – 3-13

1. Coupling
2. Stabilizer
3. Support
4. Spacer
5. Keeper
Figure 3-11. Rotary Coupling Installation
3-14 – JLG Lift – 3121157

43. Get overhead crane and slings, then connect to the

carbody assembly. Have crane man lift up while
assisting with orientation and move it to the laid out
tracks. Position and align onto tracks and unhook
crane.
47. Apply never seez to pin. Line up end links. start pin
in hole by driving with a hammer. Place portable
power pin press over track and pin. place washers in
press ends. Actuate switch to operate press, then
carefully press in track pin.
44. Start the tracking process:
45. Using overhead crane, hook up and lift and curl
track up over carbody side frame. Perform step to
both ends of track. Align chain and c-clamp spacer
in two places on chain. Hammer in chain link align-
ing pin hole. Insert special alignment pin through
hole to temporarily hold track together.
46. Position wood blocks to frame rail for tracks to lay
onto when connecting track ends to get proper
extension for connecting end links.
3121157 – JLG Lift – 3-15

48. Repeat tracking process to opposite side of frame. 3.2 TRACK TENSIONING
49. Using overhead crane connect top of track to crane.
1. Using special grease fitting tool (P/N 83813109),
Lift slightly and remove wooden blocking used to
pump in grease to add tension to track. Check for
curl in tracks. Repeat on opposite side.
proper adjustment between idler & carrier roller with
50. Re-assemble (4) track pads to assembled links. "level" and gage (0.781in. [19.8 mm]). Remove spe-
cial fitting.
51. Torque track pad bolts to 65 ft-lbs, +6 (91 Nm,
+8.4), then tighten 1/3 turn (120°) further.
52. In special grease fitting, pump in grease to add ten-
sion to track. Check for proper adjustment between
idler & carrier roller with "level" and gage (0.781in.
[19.8 mm]). Remove special fitting.
2. Repeat process on opposite side:

3. In special grease fitting, pump in grease to add ten-
sion to track. Check for proper adjustment between
idler & carrier roller with "level" and gage (0.781).
Remove special fitting.
53. Repeat process on opposite side.
3-16 – JLG Lift – 3121157

3.3 RUBBER TRACK PAD INSTALLATION
1. Seat the rubber track pad over the center rib of the
steel track pad.
2. Apply Loctite #242 to the steel retaining plate bolts.
Install the bolts and flat washers to the end of the
rubber pad.
3. Torque the bolts to 70 ft-lbs. (97 Nm).
3121157 – JLG Lift – 3-17

NOTES:
3-18 – JLG Lift – 3121157

SECTION 4. CAT CHASSIS (PRIOR TO S/N 0300128000)

4.1 DUO-CONE CONVENTIONAL SEALS 1. Remove any film, dust or other foreign matter from
the following components:
Installation a. Rubber toric ring (2)
When the Duo-Cone Seals are installed and assembled, b. Housing ramp (4)
you must use the correct procedures. The Duo-Cone Seal c. Seal ring ramp (7)
may fail from one or more mistakes that are made during
assembly or during installation of the seal components. d. Housing retaining lip (3)
e. Seal ring retaining lip (8)
Table 4-1. Duo-Cone Required Tools - Installation f. Seal ring housing (5)
Required Tools NOTE: Seal rings have very sharp edges. Protective gloves
should be worn in order to prevent injury.
Tool Part Number Part Description Qty.
A 6V-3075 Dial Indicator 1 Use the cleaning agents in Tooling (B) or use isopro-
6V-6167 Contact Point 1 pyl alcohol or other approved cleaning agents. Use
a clean lint free cloth for wiping. All components
3P-1565 Collet Assembly 1
should be completely dry before proceeding.
165-8958 Dial Indicator Base 1
B 169-0503 Installation Kit 1 NOTE: Never permit oil to contact rubber toric ring (2), hous-
ing ramp (4) or seal ring ramp (7) before both seal
rings (1) are assembled in the final position.
2. Put rubber toric ring (2) on seal ring (1). Make sure
that the rubber toric ring is positioned at the bottom
of seal ring ramp (7). The rubber toric ring must rest
against retaining lip (8). The rubber toric ring must
be straight in the seal ring. The rubber toric ring
must not be twisted.
Figure 4-1. Correct Assembly of Conventional Duo-

Cone Seals
Assembly and Installation
AVOID PROLONGED SKIN CONTACT WITH ISOPROPYL ALCOHOL.

AVOID BREATHING THE VAPORS IN ENCLOSED AREAS WITHOUT
ADEQUATE VENTILATION AND DO NOT SMOKE.
ISOPROPYL ALCOHOL IS FLAMMABLE. DO NOT USE NEAR OPEN

FLAME, WELDING OPERATIONS, OR AROUND HEATED SUR-
FACES EXCEEDING 482°C (900°F).
3121157 – JLG Lift – 4-1

NOTE: Be careful when you are working on the rubber toric steps in order to install a rubber toric ring that has a
ring. Nicks, cuts or scratches may cause leaks. large diameter:
3. Use towels or a mat (A) that is made of foam to aid

with installing the toric ring (2).
4. Install rubber toric ring (2) on seal ring (1) with instal- a. Push the rubber toric ring over the seal ring
lation tool (9). Lightly dampen the lower half of rub- retaining lip on one side.
ber toric ring (2) with an appropriate lubricant. Refer
to Acceptable Lubricants for Assembly for additional b. Tap the installation tool with a rubber mallet on
information. Use the following techniques in order to the opposite side of the rubber toric ring. Tap
dampen the rubber toric ring: until the rubber toric ring is past the seal ring
retaining lip of the housing.
a. Wipe the seal with a lint free cloth.
6. Use Tooling (A) to check the assembled height (B) at
b. Place towels or a mat that is made of foam at the four locations that are 90 degrees from each other.
bottom of a container. Soak the towels or the The difference in height must not exceed 1.0 mm
mat with the lubricant. Dip the rubber toric seal (0.04 inch). Refer to the illustration below.
in the container.
NOTE: Periodically inspect the installation tool for damage.

If necessary, replace the installation tool.
5. Make sure that the lower half of rubber toric ring (2)
is still wet. Use installation tool (9) in order to posi-
tion seal ring (1) and rubber toric ring (2) squarely
against seal ring housing (5). Make sure that you
use sudden pressure and even pressure when you
press a toric ring that has a small diameter. Press
rubber toric ring (2) under housing retaining lip (3)
that is part of seal ring housing (5). Use the following Tooling (A)
(B) Assembled height
(10) Dial indicator
(11) Collet assembly
(12) Dial indicator base
(plastic)
4-2 – JLG Lift – 3121157

7. Do not adjust the seal ring (1) by pushing on the 9. Wipe seal ring face (6) that is part of seal rings (1) by
seal ring or by pulling on the seal ring. Use installa- using a lint free cloth. No particles of any kind are
tion tool (9) in order to push down on the seal. permissible on the sealing surfaces. A small piece of
paper from a paper towel can force apart the seal
ring face, which will cause a leak.
8. Rubber toric ring (2) may twist during installation if

the seal is not completely wet or if there are burrs or
fins on housing retaining lip (3) that is part of seal
ring housing (5). Misalignments, twists and bulges
of the rubber toric ring will cause Duo-Cone Seal fail-
ures. If correct installation is not obvious, remove the
toric ring from the housing and repeat the installa-
tion procedure. NOTE: Rubber toric ring (2) must never slip on the ramps of
seal ring (1) or the ramps of seal ring housing (5). In
order to prevent slippage, allow adequate time for
evaporation of the lubricant before proceeding with
the procedure. Once the rubber toric ring is correctly
positioned, the rubber toric ring must roll only on the
ramps.
10. Apply a thin film of clean oil on the entire seal ring
face of one or both seals. Use a lint free cloth or
brush in order to distribute the oil evenly. Be careful
not to get any oil on the rubber toric rings. Lubricate
the seal faces by using the same oil that was used
during assembly. Dye may have been used in the oil
that was used during assembly. Use the same kind
of oil without dye in order to lubricate the seal faces.
Figure 4-2. Examples of incorrect assembly
3121157 – JLG Lift – 4-3

11. Make sure that both seal ring housings (5) are in Acceptable Lubricants for Assembly
correct alignment and that the seal ring housings
are concentric. Move the parts slowly and move the
parts carefully toward each other.
AVOID PROLONGED SKIN CONTACT WITH ISOPROPYL ALCOHOL.
AVOID BREATHING THE VAPORS IN ENCLOSED AREAS WITHOUT
ADEQUATE VENTILATION AND DO NOT SMOKE.
ISOPROPYL ALCOHOL IS FLAMMABLE. DO NOT USE NEAR OPEN

FLAME, WELDING OPERATIONS, OR AROUND HEATED SUR-
FACES EXCEEDING 482°C (900°F).
NOTE: Do not use any liquid that leaves an oil film. Do not
use any liquid that does not evaporate quickly. All of
the guidelines for safety and all of the guidelines for
disposal must be followed when you use a flamma-
ble liquid. The following liquids are acceptable lubri-
cants for assembly:
• Quaker Solvo Clean 68-0

• Houghto-Grind 60 CT
• Isopropyl alcohol
NOTE: Do not force the seal ring and the seal ring housing
together in a sudden manner. The seal component Some seal kits come with silicone toric rings. As an option
could be scratched or the seal component could be to using liquid lubricants to install silicone toric rings, the
broken if the components are slammed together. rings can be chilled for easier installation. This will allow
the toric ring to contract for easier installation.
12. Tighten the bolts after the components are in the If chilling is desired, Seals should be placed in a freezer
correct position. for 5 minutes prior to installation. Temperature in the
freezer should be between -40°C (-40°F) to -18°C (0°F).
Contraction will be sufficient to allow installation. The
seals should be allowed to warm to room temperature
prior to further assembly.
4-4 – JLG Lift – 3121157

RESULT OF INCORRECT ASSEMBLY The illustration below shows the same seal after the lower
The slipping of the rubber toric ring on the housing ramp housing has rotated 180 degrees. In this position, there
or on the seal ring ramp may result in uneven pressure on will be high pressure at Point (B) and at Point (X). These
the seal face. Uneven pressure on the seal face causes points of high pressure may result in galling of the toric
galling, scoring, and leakage. rings. There will be low pressure at Point (A) and at Point
(Y) which will result in possible leakage.
If the rubber toric ring slips at one location but not all the 4.2 SYSTEM PRESSURE - RELEASE
way around the seal ring, the toric ring will twist.
The twisted toric ring could be cocked. Seals that are Procedure for Releasing Pressure
cocked will cause uneven pressure on the seal face. Seals
that are cocked may also cause possible galling, scoring, The release of hydraulic pressure in a hydraulic circuit is
and leakage. required before service is performed to that hydraulic cir-
The twisted toric ring could oscillate when the ring is cuit. Release the pressure in the following hydraulic cir-
rotated. Seals that oscillate may allow dirt into the seal cuits before any hydraulic lines are disconnected or
joint. This is caused by the pumping action that is created removed from that hydraulic circuit.
by the toric ring that is oscillating.
• Boom hydraulic circuit
The illustration below shows a toric ring that is assembled
incorrectly. The upper housing is stationary. The lower • Swing hydraulic circuit
housing is rotating.
• Drive hydraulic circuit
• Pilot hydraulic circuit
• Return hydraulic circuit
NOTE: Refer to the applicable section in this manual for

additional information concerning service of the com-
ponents of specific hydraulic circuits.
3121157 – JLG Lift – 4-5

Release Of Hydraulic Pressure From A Single 5. Place the hydraulic activation control lever in the
UNLOCKED position.
Hydraulic Circuit
6. Move only the joysticks or the pedals of the hydrau-
lic circuit that requires service to the FULL STROKE
positions. This will release the high pressure only in
PERSONAL INJURY CAN RESULT FROM HYDRAULIC OIL PRES- that single hydraulic circuit. This will also release any
SURE AND HOT OIL. pressure that might be present in the pilot hydraulic
circuit.
HYDRAULIC OIL PRESSURE CAN REMAIN IN THE HYDRAULIC
SYSTEM AFTER THE ENGINE HAS BEEN STOPPED. SERIOUS NOTE: If the desired hydraulic circuit that requires service
INJURY CAN BE CAUSED IF THIS PRESSURE IS NOT RELEASED
requires the activation of a switch for operation, acti-
BEFORE ANY SERVICE IS DONE ON THE HYDRAULIC SYSTEM.
vate the necessary switches for the operation of the
hydraulic circuit.
MAKE SURE ALL OF THE ATTACHMENTS HAVE BEEN LOWERED
TO THE GROUND, AND THE OIL IS COOL BEFORE REMOVING ANY
COMPONENTS OR LINES. REMOVE THE OIL FILLER CAP ONLY 7. Place the hydraulic activation control lever in the
WHEN THE ENGINE IS STOPPED, AND THE FILLER CAP IS COOL LOCKED position.
ENOUGH TO TOUCH WITH YOUR BARE HAND.
8. Turn the engine start switch to the OFF position.
CARE MUST BE TAKEN TO ENSURE THAT FLUIDS ARE CON-
TAINED DURING PERFORMANCE OF INSPECTION, MAINTE- 9. Slowly loosen the filler plug on the hydraulic tank
NANCE, TESTING, ADJUSTING AND REPAIR OF THE PRODUCT. and release the pressure from the hydraulic tank.
BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CON- Leave the filler plug loose for a minimum of 45 sec-
TAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEM- onds. This will release the pressure that may be
BLING ANY COMPONENT CONTAINING FLUIDS. present in the return hydraulic circuit.
DISPOSE OF ALL FLUIDS ACCORDING TO LOCAL REGULATIONS 10. Tighten the filler plug on the hydraulic tank to the
AND MANDATES. specified torque.
11. The pressure in the single hydraulic circuit that

Perform the following steps in order to release the hydrau-
requires service is now released and lines and com-
lic pressure from a single hydraulic circuit of the main
hydraulic system. ponents can be disconnected or removed from that
hydraulic circuit.
1. Position the machine on level ground.
2. Fully retract the stick cylinder rod. Adjust the posi-

tion of the bucket so that the bucket is parallel to the
ground. Lower the boom until the bucket is flat on
the ground.
3. Shut off the engine.
4. Turn the engine start switch to the ON position with-

out starting the engine.
4-6 – JLG Lift – 3121157

Release Of Hydraulic Pressure From 7. Place the hydraulic activation control lever in the
LOCKED position.
Multiple Hydraulic Circuits
8. Start the engine.
9. Place the hydraulic activation control lever in the
UNLOCKED position. Do not move any joysticks or
PERSONAL INJURY CAN RESULT FROM HYDRAULIC OIL PRES-
pedals from the NEUTRAL position during this step.
SURE AND HOT OIL.
Do not activate any switches during this Step.
HYDRAULIC OIL PRESSURE CAN REMAIN IN THE HYDRAULIC 10. Return the hydraulic activation control lever to the
SYSTEM AFTER THE ENGINE HAS BEEN STOPPED. SERIOUS LOCKED position.
INJURY CAN BE CAUSED IF THIS PRESSURE IS NOT RELEASED
BEFORE ANY SERVICE IS DONE ON THE HYDRAULIC SYSTEM.
12. Repeat Steps 4 through 11 for each additional
MAKE SURE ALL OF THE ATTACHMENTS HAVE BEEN LOWERED hydraulic circuit that requires service.
TO THE GROUND, AND THE OIL IS COOL BEFORE REMOVING ANY
COMPONENTS OR LINES. REMOVE THE OIL FILLER CAP ONLY 13. After releasing the hydraulic pressure in each of the
WHEN THE ENGINE IS STOPPED, AND THE FILLER CAP IS COOL desired hydraulic circuits, place the hydraulic activa-
ENOUGH TO TOUCH WITH YOUR BARE HAND. tion control lever in the LOCKED position.
14. Turn the engine start switch to the OFF position.
TAINED DURING PERFORMANCE OF INSPECTION, MAINTE- 15. Slowly loosen the filler plug on the hydraulic tank
NANCE, TESTING, ADJUSTING AND REPAIR OF THE PRODUCT. and release the pressure. Leave the filler plug loose
BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CON- for a minimum of 45 seconds. This will release the
TAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEM- pressure that may be present in the return hydraulic
BLING ANY COMPONENT CONTAINING FLUIDS. circuit.
16. Tighten the filler plug on the hydraulic tank to the
DISPOSE OF ALL FLUIDS ACCORDING TO LOCAL REGULATIONS
specified torque.
AND MANDATES.
17. The pressure in the multiple hydraulic circuits that
Perform the following Steps in order to release the hydrau- require service is now released and lines and com-
lic pressure from multiple hydraulic circuits of the main ponents can be disconnected or removed from
hydraulic system. those hydraulic circuits.
1. Position the machine on level ground.
2. Fully retract the stick cylinder rod. Adjust the posi-

tion of the bucket so that the bucket is parallel to the
ground. Lower the boom until the bucket is flat on
the ground.
4. Turn the engine start switch to the ON position with-

out starting the engine.
5. Place the hydraulic activation control lever in the

UNLOCKED position.
6. Move only the joysticks or the pedals of the hydrau-

lic circuit that requires service to the FULL STROKE
positions. This will release the high pressure only in
that hydraulic circuit. This will also release any pres-
sure that might be present in the pilot hydraulic cir-
cuit.
NOTE: If the hydraulic circuit that requires service requires

the activation of a switch for operation, activate the
necessary switches for the operation of the hydraulic
circuit.
3121157 – JLG Lift – 4-7

4.3 TRACK CARRIER ROLLER 4. Use suitable cribbing and Tooling (A) in order to lift
the track from track carrier roller (2). Remove track
carrier roller (2). The weight of track carrier roller (2)
Removal is approximately 14 kg (30 lb).
Table 4-2. Track Carrier Roller Required Tools -

Removal
Required Tools
A 8T-5255 Hydraulic Jack 1
PERSONAL INJURY OR DEATH CAN RESULT FROM GREASE AND

OIL COMING OUT OF THE RELIEF VALVE.
GREASE AND OIL ARE UNDER HIGH PRESSURE COMING OUT OF

THE RELIEF VALVE AND CAN PENETRATE THE BODY.
DO NOT WATCH THE RELIEF VALVE TO SEE IF GREASE IS

ESCAPING. WATCH THE TRACK OR TRACK ADJUSTMENT CYLIN-
DER TO SEE IF THE TRACK IS BEING LOOSENED.
MAKE SURE THE VENT HOLES ARE CLEAN BEFORE THE TENSION
IS RELEASED ON THE TRACK. Installation
1. Start the engine. Park the machine on a hard, level
surface. Shut off the engine. Table 4-3. Track Carrier Roller Required Tools -
Installation
2. Release the tension on the track. Refer to Section
4.12, Track Adjustment. Required Tools
3. Loosen bolt (1) that holds track carrier roller (2) to Tool Part Number Part Description Qty.
the mounting bracket on the undercarriage frame. A 8T-5255 Hydraulic Jack 1
1. Be sure that the shaft of the track carrier roller and

the bore in the mounting bracket on the undercar-
riage frame are clean and free of dirt.
4-8 – JLG Lift – 3121157

2. Position track carrier roller (2) in the mounting 4.4 TRACK ROLLER
bracket. The weight of track carrier roller (2) is
approximately 14 kg (30 lb). Adjust track carrier
roller (2) until Dimension (B) is achieved. Dimension Removal
(B) is 4.5 ± 0.5 mm (0.18 ± 0.02 inch).
Table 4-4. Track Roller Required Tools - Removal
Required Tools
A 8S-7611 Tube Assembly 2
8S-7615 Pin 2
8S-7640 Stand 2
B 183-4797 Track Roller Lifting 1
Fork
NOTE: There is a track guide on each side of the machine.
The procedure that follows removes the track roller
and the track guide.
1. Start the engine. Park the machine on a hard, level

surface. Stop the engine.
PERSONAL INJURY OR DEATH CAN RESULT FROM GREASE AND

GREASE AND OIL ARE UNDER HIGH PRESSURE COMING OUT OF

THE RELIEF VALVE AND CAN PENETRATE THE BODY.

3. After adjusting the position of the carrier roller in the ESCAPING. WATCH THE TRACK OR TRACK ADJUSTMENT CYLIN-
mounting bracket, tighten bolt (1). DER TO SEE IF THE TRACK IS BEING LOOSENED.
4. Be sure that the carrier roller rotates smoothly by MAKE SURE THE VENT HOLES ARE CLEAN BEFORE THE TENSION
hand. Slowly lower the track assembly to track car- IS RELEASED ON THE TRACK.
rier roller (2) with Tooling (A).
2. Release the tension on the track. Refer to the Sec-
5. Tighten the tension of the track. Refer to Section
tion 4.12, Track Adjustment.
4.12, Track Adjustment.
3121157 – JLG Lift – 4-9

3. Lift the side of the machine. Install Tooling (A) under 6. Loosen but do not remove the bolts that secure
undercarriage (1), as shown. Adjust the height of track roller (3) to the undercarriage.
Tooling (A) in order to have sufficient clearance for
the removal of the track rollers.
7. Attach a suitable lifting device to Tooling (B).

8. Position Tooling (B) under track roller (3).
4. Loosen but do not remove the bolts that hold track
guide (2) to the undercarriage. 9. Remove the bolts that secure track roller (3).
Remove track roller (3). The weight of track roller (3)
is approximately 25 kg (55 lb).
Installation
Table 4-5. Track Roller Required Tools - Installation
Required Tools
A 8S-7611 Tube Assembly 2
8S-7615 Pin 2
8S-7640 Stand 2
5. Attach a suitable lifting device to Tooling (B). Posi-
B 183-4797 Track Roller Lifting 1
tion Tooling (B) under track guide (2), as shown.
Fork
Remove the bolts that secure the track guide.
Remove track guide (2). The weight of track guide
NOTE: There is a track guide on each side of the machine.
(2) is approximately 18 kg (40 lb).
The procedure which follows is for the installation of
the track roller and the track guide.
1. Make sure that all the mounting surfaces on the fol-

lowing components are clean and free of debris
before the following components are installed:
• Track Roller
• Track Guide
NOTE: Make sure that the fill/drain plug in the roller faces
toward the outside of the undercarriage.
4-10 – JLG Lift – 3121157

2. Use Tooling (B) in order to position track roller (3) on 7. Remove Tooling (A) from the machine. Lower under-
the undercarriage. The weight of track roller (3) is carriage (1) to the ground.
approximately 25 kg (55 lb).
8. Tighten the track to the proper tension. Refer to Sec-
tion 4.12, Track Adjustment.
4.5 TRACK
Separation
Table 4-6. Track Required Tools - Separation
Required Tools
A 5P-6214 Track Block Assembly 1
3. Install the bolts that hold track roller (3) in position.

Tighten the bolts for track roller (3) to a torque of 270
± 40 Nm (200 ±30 lb ft). PERSONAL INJURY OR DEATH CAN RESULT FROM GREASE AND
4. Use Tooling (B) in order to position track guide (2)
on the undercarriage. Install the bolts that secure GREASE AND OIL ARE UNDER HIGH PRESSURE COMING OUT OF
track guide (2). THE RELIEF VALVE AND CAN PENETRATE THE BODY.

MAKE SURE THE VENT HOLES ARE CLEAN BEFORE THE TENSION
IS RELEASED ON THE TRACK.
PERSONAL INJURY CAN RESULT FROM THE TRACK COMING OFF

OF THE ROLLER FRAME.
THE TRACK CAN MOVE OFF THE TRACK ROLLER FRAME VERY
QUICKLY WHEN A SEPARATION OF THE TRACK IS MADE.
5. Prior to lowering the machine to the ground and
tightening the track, make sure that all of the track KEEP AWAY FROM THE FRONT OF THE MACHINE WHEN THE
rollers rotate smoothly by manually turning the track TRACK IS REMOVED FROM THE TRACK ROLLER FRAME.
rollers.
1. Park the machine on a flat, level surface.
6. Lift the machine off Tooling (A).
2. Position the master pin in a horizontal line through
the center of the idler.
3. Release the tension on the track assembly. Refer to
Section 4.12, Track Adjustment.
3121157 – JLG Lift – 4-11

4. Remove bolts (1). Remove track shoes (2). 7. Attach a suitable lifting device to the track assembly.
Raise the track assembly off Tooling (A). Remove
Tooling (A) from the track assembly and lower the
track assembly to the floor.
Connection
Table 4-7. Track Required Tools - Connection
Required Tools
A 5P-6214 Track Block Assembly 1
B 5P-0960 Molybdenum Grease -
5. Move the track assembly until master pin (3) is in the C 260-9412 Chain As 1
approximate position. Position Tooling (A) under the D 1P-3533 Carrier Bar 1
track grouser, as shown. Position the track onto
Tooling (A). Start By:
a. Thoroughly clean the track assembly, the
sprocket, and the track rollers prior to connect-
ing the track assembly.
1. Install Tooling (C) in the track link and on the
sprocket, as shown.
NOTE: The two spacers and the seals may fall out of the
track links when the track assembly is separated.
6. Remove cotter pin (4) from master pin (3). Remove

master pin (3) from the track links. Separate the
track links, and locate the two spacers and the 2. Slowly move the sprocket forward until the track
seals. Slowly, move the machine in reverse in order assembly is pulled up on the sprocket. Move the
to move the track assembly off the sprocket, the sprocket forward until the end of the track assembly
track carrier roller, and the front idler. is past a vertical line through the center of the
sprocket. Remove Tooling (C).
4-12 – JLG Lift – 3121157

3. Install Tooling (D) between the first bushing in the 8. Put Tooling (B) in the master pin bores in the track
track link and the sprocket, as shown. assembly and on master pin (3). Install master pin
(3). Install cotter pin (4) in order to retain the master
pin. Remove Tooling (A).
4. Move the sprocket forward. Use Tooling (D) to guide

the track assembly over the carrier roller and the
9. Install track shoes (2) over the master pin on the
front idler.
track assembly. Tighten bolts (1) to a torque of 175
5. Slowly move the machine forward until the separa- ± 40 Nm (130 ± 30 lb ft). Tighten bolts (1) by an
tion in the track assembly is below a horizontal line additional 120°.
through the center of the front idler.
6. Put Tooling (B) on spacers (6) in order to hold spac-

ers (6) and the seals in place. Install spacers (6) and
the seals in the track links.
7. Raise the front of the track assembly, and install

Tooling (A) under the track assembly. Slowly move
the machine forward until the separation in the track
assembly closes, and the pin bores in each end of
the track assembly are in alignment with each other.
The machine may need to be moved back and forth
in order to align the pin bores.
10. Adjust the track tension. Refer to Section 4.12, Track
Adjustment.
3121157 – JLG Lift – 4-13

4.6 FRONT IDLER AND RECOIL SPRING 4. Position suitable cribbing under hydraulic track
adjuster (2). Remove bolts (3). Remove front idler
(1). The weight of front idler (1) is approximately 68
Removal kg (150 lb).
Table 4-8. Front Idler & Recoil Spring Required Tools -

Remove
Required Tools
A 180-3033 Jack Stand Gp 1
1. Position the machine onto suitable cribbing in order

to raise the track idler off the ground.
5. Attach a suitable lifting device on hydraulic track

adjuster (2). The weight of hydraulic track adjuster
(2) is approximately 68 kg (150 lb). Remove hydrau-
lic track adjuster (2).
2. Separate the track. Refer Section 4.5, Track.
3. Attach a suitable lifting device onto front idler (1).

Slide front idler (1) and the hydraulic track adjuster
out of the undercarriage frame. The combined
weight of front idler (1) and the hydraulic track
adjuster is approximately 136 kg (300 lb).
4-14 – JLG Lift – 3121157

4.7 RECOIL SPRING 3. Install Tooling (C) on Tooling (B), as shown.
Disassembly
Table 4-9. Track Required Tools - Connection
Required Tools
A 4C-9540 Bench 1
B 8S-7172 Hydraulic Cylinder 1
3S-6224 Electric Hydraulic 1
Pump
8T-0820 Pressure Gauge 1
NOTE: Two adjustable supports (1), reaction plate (2), and
3B-7722 Bushing 2 movable plate (3) are part of Tooling (A).
1P-2376 Coupler Assembly 2
1P-2377 Plug 2 4. Position two supports (1) of Tooling (A) in order to
8F-0024 Hose Assembly 2 support the recoil spring assembly. Make sure that
C 4C-6629 Ram Adapter 1 the two supports are level.
D 4C-8217 55 mm Socket 1
Start By:
a. Remove the track adjuster. Refer to Section 4.9,
Track Adjuster.
1. Prior to disassembling and assembling the recoil
spring assembly, make sure that Tooling (A) is on a
level surface.
2. Thoroughly clean the outside surface of the recoil
spring assembly prior to disassembly.
3121157 – JLG Lift – 4-15

5. Adjust the spacing between reaction plate (2) and 7. Put a level gauge (4) on the recoil spring assembly.
movable plate (3) so that the spacing is approxi- Reposition the recoil spring assembly until the recoil
mately the same length as the recoil spring assem- spring assembly is level. Reposition the recoil spring
bly at free length. assembly until the retaining rod for the recoil spring
and the nut for the recoil spring assembly are cen-
tered in the hole in reaction plate (2). After the recoil
spring assembly is leveled and centered, install two
pins (5) on the back side of reaction plate (2), as
shown. Operate Tooling (B) enough to hold the
recoil spring assembly in position between reaction
plate (2) and movable plate (3). Make sure that the
recoil spring assembly is level and centered.
NOTE: Do not remove the lifting device from the recoil

spring assembly until the unit is leveled, centered,
and locked in Tooling (A).
NOTE: The recoil spring assembly may be installed in Tool-

ing (A) from the end. In this case, reaction plate (2)
must be removed. Then reinstall reaction plate (2)
after the recoil spring assembly is in place on two NOTE: The lifting device is removed from the recoil spring
adjustable supports (1). assembly for photographic purposes.
6. The weight of the recoil spring assembly is approxi-

mately 53 kg (117 lb). Fasten a suitable lifting device
to the recoil spring assembly. Put the recoil spring
assembly in position on two adjustable supports (1)
in Tooling (A). Adjust two adjustable supports (1)
until the centerline of the recoil spring assembly and
the centerline of Tooling (A) are aligned.
4-16 – JLG Lift – 3121157

8. Close covers (6) on Tooling (A). Use Tooling (B) to 10. Open the covers on Tooling (A). Fasten a suitable
compress the recoil spring assembly slightly. lifting device to the disassembled recoil spring
assembly. Remove the reaction plate in order to
remove the recoil spring assembly from Tooling (A).
11. Separate bolt (9), cylinder (10), plate (11), spring

(12), and support (13).
PERSONAL INJURY OR DEATH CAN RESULT FROM RECOIL

SPRING FORCE.
RECOIL SPRING FORCE, IF NOT RELIEVED, CAN RESULT IN PER- 12. Remove O-ring seal (16) and backup ring (17) from
SONAL INJURY OR DEATH. cylinder (10).
R ELIEVE SPRING FORCE BE FORE REMOVING THREADED

RETAINER, PERFORMING REPAIRS ON RECOIL SPRING HOUS-
ING, OR REMOVING RECOIL SPRING.
SEE SERVICE MANUAL FOR DISASSEMBLY INSTRUCTIONS.

MAXIMUM PRESSURE IS 20 700 KPA (3,000 PSI).
9. Remove bolts (15) and strip (14) from nut (7). Use
Tooling (D) to remove nut (7) and washer (8) from
the end of bolt (9).
NOTE: Slowly release the pressure on Tooling (B) in order

to allow spring (12) to relax.
3121157 – JLG Lift – 4-17

Assembly 2. Check the condition of the threads on bolt (9) and

nut (7). If any of the threads are worn or damaged,
install new parts.
Table 4-10. Recoil Spring Required Tools - Assembly
3. Loosely assemble bolt (9), cylinder (10), plate (11),
Required Tools spring (12), and support (13).
A 4C-9540 Bench 1
B 8S-7172 Hydraulic Cylinder 1
3S-6224 Electric Hydraulic 1
Pump
8T-0820 Pressure Gauge 1
3B-7722 Bushing 2
1P-2376 Coupler Assembly 2
1P-2377 Plug 2
8F-0024 Hose Assembly 2
C 4C-6629 Ram Adapter 1
D 4C-8217 55 mm Socket 1 4. Install Tooling (C) on Tooling (B), as shown.
E 5P-3931 Anti-Seize Compound -
F 4C-4030 Thread Lock Com- -
pound
1. Install backup ring (17) and O-ring seal (16) into cyl-
inder (10).
NOTE: Two adjustable supports (1), reaction plate (2) and

movable plate (3) are part of Tooling (A).

SPRING FORCE.
RECOIL SPRING FORCE, IF NOT RELIEVED, CAN RESULT IN PER-

SONAL INJURY OR DEATH.
R ELIEVE SPRING FORCE BEFORE REMOVING THREADED

SEE SERVICE MANUAL FOR DISASSEMBLY INSTRUCTIONS.

MAXIMUM PRESSURE IS 20 700 KPA (3,000 PSI).
4-18 – JLG Lift – 3121157

5. Position two supports (1) of Tooling (A) in order to plate (2) and movable plate (3). Make sure that the
support the recoil spring assembly. Make sure that recoil spring assembly is level and centered.
the two adjustable supports (1) are level.
NOTE: The lifting device is removed for photographic pur-

poses.
6. Adjust the spacing between reaction plate (2) and
movable plate (3) so that the spacing is approxi-
mately the same length as the recoil spring assem-
bly.
NOTE: Do not remove the lifting device from the recoil SPRING FORCE.
spring assembly until the unit is leveled, centered
and locked in Tooling (A). RECOIL SPRING FORCE, IF NOT RELIEVED, CAN RESULT IN PER-
SONAL INJURY OR DEATH.
NOTE: The recoil spring assembly may be installed in Tool-
ing (A) from the end. In this case, reaction plate (2)
R ELIEVE SPRING FORCE BE FORE REMOVING THREADED
must be removed. Then reinstall reaction plate (2)
after the recoil spring assembly is in place on two
adjustable supports (1).
7. The weight of the recoil spring assembly is approxi- SEE SERVICE MANUAL FOR DISASSEMBLY INSTRUCTIONS.
mately 53 kg (117 lb). Put the recoil spring assembly MAXIMUM PRESSURE IS 20 700 KPA (3,000 PSI).
in position on two adjustable supports (1) in Tooling
9. Close covers (6) on Tooling (A). Use Tooling (B) to
(A). Adjust adjustable supports (1) until the center-
compress the recoil spring assembly slightly.
line of the recoil spring assembly and the centerline
of Tooling (A) are aligned.
8. Put a level gauge (4) on the recoil spring assembly.
Reposition the recoil spring assembly until the recoil
spring assembly is level. Reposition the recoil spring
assembly until the retaining rod for the recoil spring
and the nut for the recoil spring assembly are cen-
tered in the hole in reaction plate (2). After the recoil
spring assembly is leveled and centered, install two
pins (5) on the back side of reaction plate (2), as
shown. Operate Tooling (B) enough to hold the
recoil spring assembly in position between reaction
3121157 – JLG Lift – 4-19

10. Open the covers (6) on Tooling (A). Measure Dimen- 4.8 FRONT IDLER AND RECOIL SPRING
sion (X). Dimension (X) equals 377.0 ± 0.7 mm
(14.84 ± 0.03 inch). If the compressed length of Installation
Dimension (X) is not correct, close covers (6) on
Tooling (A) and adjust the length with Tooling (B).
Adjust the length of Dimension (X) until the com- Table 4-11. Front Idler & Recoil Required Tools -
pressed length of Dimension (X) is correct. Installation
Required Tools
A 180-3033 Jack Stand Gp 1
1. Attach a suitable lifting device onto hydraulic track

adjuster (2). The weight of hydraulic track adjuster
(2) is approximately 68 kg (150 lb). Position hydrau-
lic track adjuster (2) into the undercarriage frame.
11. Apply Tooling (E) to the threads of rod (9). Install

washer (8) and nut (7). Tighten nut (7) until there is
sufficient clearance in order to install strip (14) (not
shown).
12. Apply Tooling (F) to the threads of bolts (15) (not

shown). Install strip (14) (not shown) and bolts (15)
(not shown).
13. Fasten a suitable lifting device to the recoil spring 2. Position suitable cribbing under hydraulic track
assembly. The weight of the recoil spring assembly adjuster (2). Attach a suitable lifting device onto front
is approximately 53 kg (117 lb). Remove the recoil idler (1). Position front idler (1). The weight of front
spring assembly from Tooling (A). idler (1) is approximately 68 kg (150 lb). Install bolts
(3).
End By:
a. a. Install the track adjuster. Refer to Section 4.9,

Track Adjuster.
4-20 – JLG Lift – 3121157

3. Slide front idler (1) and the hydraulic track adjuster 4.9 TRACK ADJUSTER
into the undercarriage frame. The combined weight
of front idler (1) and the hydraulic track adjuster is
approximately 136 kg (300 lb).
Removal
Start By:
a. Remove the front idler and the recoil spring.
Refer to Section 4.6, Front Idler and Recoil
Spring.
1. Loosen relief valve (2). Remove piston assembly (1).
4. Connect the track. Refer to Section 4.5, Track. Move

the machine away from the suitable cribbing.
2. Remove lip seal (3).
3121157 – JLG Lift – 4-21

3. Remove bolts (4), plate (5), and plate assembly (6) Installation
from piston assembly (1).
Table 4-12. Track Adjuster Required Tools - Installation
Required Tools
A 1P-0520 Driver Group 1
B 5P-0960 Molybdenum Grease -
4. Remove O-ring seals (7) and (10). Remove backup

rings (8), (9), (11), and (12) from piston assembly
(1).
NOTE: O-ring seals and backup rings must be installed in

the correct position in order to ensure the correct
operation of the hydraulic track adjuster. Backup
rings are distinguished by the color of the ring.
Backup rings (9) and (12) are black in color. Backup
rings (8) and (11) are brown in color.
5. Remove fill valve (13) and relief valve (2) from piston
assembly (1).
1. Completely fill the seal grooves in piston (1) with

Tooling (B). Tooling (B) will displace air when the O-
ring seals and the backup rings are installed. Install
backup rings (9) and (12). Install backup rings (8),
and (11).
4-22 – JLG Lift – 3121157

2. Replace O-ring seals (7) and (10) with new O-ring 6. Put a small amount of Tooling (B) on the sliding sur-
seals. Install O-ring seals (7) and (10). face of piston (1). Put a minimum of 60 cc (4 in3) of
Tooling (B) on the end of piston (1). This will prevent
3. Install fill valve (13) and relief valve (2) to piston air from displacing grease in the cylinder during the
assembly (1). Do not tighten fill valve (13) and relief installation of the piston. Make sure that the grease
valve (2). covers the backup rings and the O-ring seals.
4. Position plate assembly (6) and plate (5) and install
7. Center piston (1) in the cylinder. Insert piston (1) into
bolts (4) on piston assembly (1).
the cylinder.
NOTE: Install lip seal (3) with the lip toward the outside.
NOTE: It may be necessary to use a soft faced hammer to
install piston (1) into the cylinder.
8. Tighten fill valve (13) to a torque of 34 ± 5 Nm (25 ±

4 lb ft).
9. Fill the cavity of the piston with Tooling (B).
10. Make sure that all of the passages in the piston are
filled with Tooling (B). Make sure that air is not
trapped in the passages in the piston.
11. Tighten relief valve (2) to a torque of 34 ± 5 Nm (25

± 4 lb ft).
5. Apply Tooling (B) in the groove for lip seal (3). Use End By:
Tooling (A) to install lip seal (3). Install lip seal (3) to
Dimension (D). Dimension (D) equals 0.5 ± 0.5 mm a. a. Install the front idler and the recoil springs.
(0.02 ± 0.02 inch). Refer to Section 4.8, Front Idler and Recoil
Spring.
3121157 – JLG Lift – 4-23

4.10 SPROCKET 4. Attach Tooling (A) and a suitable lifting device to

sprocket (2). Remove sprocket (2). The weight of
sprocket (2) is approximately 38 kg (85 lb).
Removal
Table 4-13. Sprocket Required Tools - Removal
Required Tools
A 138-7574 Link Bracket 1
1. Position the machine onto suitable cribbing below

the first roller, as shown. Ensure that the master pin
is above the center line of the sprocket.
Installation
Table 4-14. Sprocket Required Tools - Installation
Required Tools
A 138-7574 Link Bracket 1
1. Thoroughly clean the mating surfaces of the

sprocket and the final drive prior to installation of the
2. Separate the track assembly. Refer to Section 4.5, sprocket.
Track.
2. Attach Tooling (A) and a suitable lifting device to
3. Remove bolts (1) which fasten sprocket (2) to the sprocket (2). Position sprocket (2). The weight of
final drive. sprocket (2) is approximately 38 kg (85 lb).
3. Remove Tooling (A) and the suitable lifting device

from sprocket (2).
4-24 – JLG Lift – 3121157

4. Install bolts (1). Tighten bolts (1) to a torque of 270 2. Release the hydraulic system pressure. Refer to
± 40 Nm (200 ± 30 lb ft). Section 4.2, System Pressure - Release.
3. Remove the cap from the hydraulic tank. Install Tool-
ing (A) onto the hydraulic tank. Attach an air supply
hose to Tooling (A). Apply 276 to 414 kPa (40 to 60
psi) of air. This procedure will pull vacuum on the
hydraulic system.
4. Separate the track assembly. Refer to Section 4.5,
Track.
5. Remove cover assembly (1).
5. Connect the track assembly. Refer to Section 4.5,

Track.
6. Remove the cribbing from the front roller.
4.11 FINAL DRIVE AND TRAVEL MOTOR

Removal
Table 4-15. Final Drive Required Tools - Removal
Required Tools
A FT-2674 Vacuum Cap 1

TAINED DURING PERFORMANCE OF INSPECTION, MAINTE-
NANCE, TESTING, ADJUSTING AND REPAIR OF THE PRODUCT.
BE PREPARED TO COLLECT THE FLUID WITH SUITABLE CON-
TAINERS BEFORE OPENING ANY COMPARTMENT OR DISASSEM-
BLING ANY COMPONENT CONTAINING FLUIDS.
DISPOSE OF ALL FLUIDS ACCORDING TO LOCAL REGULATIONS

AND MANDATES.
1. Position the machine onto suitable cribbing below

the first roller, as shown. Ensure that the master pin
is above the center line of the sprocket.
3121157 – JLG Lift – 4-25

6. Disconnect hose assemblies (2). Remove fitting (3). Installation
Table 4-16. Final Drive Required Tools - Installation
Required Tools
A FT-2674 Vacuum Cap 1
1. Attach a suitable lifting device to final drive and

travel motor (4). The weight of final drive and travel
motor (4) is approximately 209 kg (460 lb).
7. Attach a suitable lifting device to final drive and

travel motor (4). The weight of final drive and travel
motor (4) is approximately 209 kg (460 lb).
2. Position final drive and travel motor (4) and install

bolts (5). Tighten bolts (5) to a torque of 175±40Nm
(130±30lbft).
8. Remove bolts (5). Remove final drive and travel

motor (4).
4-26 – JLG Lift – 3121157

3. Install fitting (3). Connect hose assemblies (2). 4.12 TRACK ADJUSTMENT
PERSONAL INJURY OR DEATH CAN RESULT FROM GREASE

UNDER PRESSURE.
GREASE COMING OUT OF THE RELIEF VALVE UNDER PRESSURE

CAN PENETRATE THE BODY CAUSING INJURY OR DEATH.

LOOSEN THE RELIEF VALVE ONE TURN ONLY.

4. Install cover assembly (1).
IF TRACK DOES NOT LOOSEN, CLOSE THE RELIEF VALVE AND
CONTACT YOUR JLG DEALER.
KEEPING THE TRACK PROPERLY ADJUSTED WILL INCREASE THE
SERVICE LIFE OF THE TRACK AND DRIVE COMPONENTS.
NOTE: The track tension must be adjusted according to the

current operating conditions. Keep the track as slack
as possible if the soil is heavy.
Measuring Track Tension

1. Operate the machine in the direction of the idlers.
5. Remove Tooling (A). Install the cap onto the hydrau- 2. Stop with one track pin directly over the front carrier
lic tank. roller. Park the machine and turn off the engine.
6. Connect the track assembly. Refer Section 4.5,
Track.
7. Reposition the machine away from the suitable crib-
bing.
3121157 – JLG Lift – 4-27

3. Place a straight edge on top of the track grousers Adjusting Track Tension
between the front carrier roller and the idler. The
straight edge should be long enough to reach from
the front carrier roller to the idler.
The track adjuster is located on the track frame.

4. Measure the maximum amount of sag in the track.
The sag is measured from the highest point of the TIGHTENING THE TRACK
track grouser to the bottom of the straight edge. A
track that is properly adjusted will have a sag of 40.0
to 55.0 mm (1.57 to 2.17 inch).
5. If the track is too tight, or if the track is too loose,
adjust the track tension according to the appropriate
procedure below.
GREASE FIT- RELIEF
WIPE THE FITTING BEFORE YOU ADD GREASE.
1. Add grease through grease fitting (1) until the cor-

rect track tension is reached.
2. Operate the machine back and forth in order to

equalize the pressure.
3. Check the amount of sag. Adjust the track, as

needed.
4-28 – JLG Lift – 3121157

LOOSENING THE TRACK Track Adjustment - Inspect
GREASE FIT- RELIEF
1. Loosen relief valve (2) carefully until the track begins

Check the track adjustment. Check the track for wear and
to loosen. One turn should be the maximum.
for excessive dirt buildup.
2. Tighten relief valve (2) to 34 ± 5 Nm (25 ± 4 lb ft) If the track appears to be too tight or too loose, readjust as
when the desired track tension is reached. necessary.
3. Operate the machine back and forth in order to
equalize the pressure.
4. Check the amount of sag. Adjust the track, as
needed.
3121157 – JLG Lift – 4-29

NOTES:
4-30 – JLG Lift – 3121157

SECTION 5. CAT Chassis (S/N 0300128000 to S/N 0300174703)
5.1 PRECAUTIONS FOR USE

General WHEN THE MACHINE IS NOT OPERATED FOR AN EXTENDED
PERIOD OF TIME, BE SURE TO FILL THE MOTOR CIRCUIT WITH
HYDRAULIC FLUID BEFORE OPERATION.
WHEN THE MACHINE IS NOT OPERATED FOR AN EXTENDED
REMOVE THE MOTOR FROM THE MACHINE BEFORE DISASSEMBLY PERIOD OF TIME, AERATION MAY OCCUR IN THE MOTOR CIRCUIT
AND REASSEMBLY OF THE MOTOR. DISASSEMBLY WHILE THE DUE TO LEAKS FROM THE HYDRAULIC MOTOR AND COUNTER BAL-
MOTOR IS INSTALLED TO THE MACHINE MAY CAUSE RUNAWAY OF ANCE VALVE. INSTALL A SELF-PRIMING CIRCUIT TO PREVENT AER-
THE MACHINE. ATION.
DO NOT DISASSEMBLE OR REASSEMBLE THE MOTOR IF IT IS HOT. OPERATION WITH AERATION IN THE MOTOR CIRCUIT WILL GENER-
DOING SO WILL RESULT IN BURNS. ATE CAVITATION, CAUSING DAMAGE TO THE EQUIPMENT. IN ADDI-
TION, A RUNAWAY PHENOMENON OCCURS IN THE HYDRAULIC
MOTOR, LEADING TO A SUDDEN DROP OF LIFTED LOAD.
FOLLOW THE MAINTENANCE MANUAL AND USE SPECIFIED TOOLS

TO DISASSEMBLE AND REASSEMBLE THE MOTOR.
CHECK FOR INFLOW DIRECTION OF OIL AND ROTATION DIRECTION
Installation OF THE MOTOR BEFORE PERFORMING PIPING WORK. FOR INFLOW
DIRECTION OF OIL AND ROTATION DIRECTION OF THE MOTOR,
REFER TO THE OUTLINE DRAWING.
PERFORMING PIPING WORK WITHOUT CHECKING FOR INFLOW
WHEN INSTALLING THE MOTOR, BE SURE TO OBSERVE INSTRUC- DIRECTION OF OIL AND ROTATION DIRECTION OF THE MOTOR IS
TIONS DESCRIBED IN THE OPERATING MANUAL. VERY DANGEROUS, AS THE MOTOR MAY ROTATE IN A DIRECTION
DO NOT PLACE RADIAL LOAD AND THRUST LOAD EXCEEDING THE NOT INTENDED BY AN OPERATOR.
PERMISSIBLE VALUES ON THE OUTPUT SHAFT. EXCESSIVE LOAD
MAY CAUSE EARLY BREAKAGE OF BEARINGS. USE THE MACHINE
WITHIN THE PERMISSIBLE RANGE, REFERRING TO THE LIFE CURVE
OF THE BEARINGS IN THE CATALOG. WHEN PIPING EACH PORT, BE SURE TO OBSERVE INSTRUCTIONS
WHEN INSTALLING, MAKE THE ECCENTRIC AMOUNT TO THE DESCRIBED IN THE OPERATING MANUAL.
DRIVEN SHAFT AT 0.1 MM (FIR) OR LESS. LARGE ECCENTRICITY
MAY CAUSE EARLY BREAKAGE OF THE BEARINGS AND BREAKAGE
OF THE INSIDE OF THE MOTOR.
TAKE OUT DRAIN PIPING FROM THE DRAIN PORT (DR) ON THE
Hydraulic System UPPERMOST POSITION, AND PLACE IT HIGHER THAN THE TOP END
OF THE MOTOR. THEN, RETURN IT DIRECTLY INTO OIL IN THE
TANK.
NO OIL IN THE MOTOR CASE MAY CAUSE SEIZURE ON EACH SLID-
SET THE HYDRAULIC PRESSURE TANK SO THAT ITS OIL LEVEL IS ING SURFACE, LEADING TO AN INABILITY OF THE MOTOR TO OPER-
ABOVE THE MOTOR. IF THE OIL LEVEL OF THE HYDRAULIC PRES- ATE.
SURE TANK IS BELOW THE MOTOR, INSTALL A CHECK VALVE IN
THE PIPING TO PREVENT OIL FROM COMING OUT OF THE MOTOR
CIRCUIT.
IF OIL COMES OUT OF THE MOTOR CIRCUIT, AERATION WILL KEEP DRAIN PRESSURE IN THE CASING AT 0.2 MPA OR LESS
OCCUR IN THE MOTOR CIRCUIT. THIS IS VERY DANGEROUS, AS (WORKING CONDITION) AS PERMISSIBLE PRESSURE, AND BE
LIFTED LOAD MAY DROP SUDDENLY. SURE TO RETURN THE PIPING END INTO OIL.
IF NO OIL REMAINS IN THE MAIN PIPING, AERATION WILL OCCUR IF DRAIN PRESSURE EXCEEDS THE PERMISSIBLE VALUE, DAMAGE
IN THE MOTOR CIRCUIT DURING OPERATION, CAUSING DAMAGE TO OIL SEALS AND OIL LEAKS MAY BE CAUSED.
TO THE EQUIPMENT. IN ADDITION, A RUNAWAY PHENOMENON
OCCURS IN THE MOTOR CIRCUIT, LEADING TO A SUDDEN DROP OF Hydraulic Fluid
LIFTED LOAD. IN SOME CASES, THE MOTOR BECOMES IMPOSSI-
BLE TO CONTROL, WHICH IS VERY DANGEROUS.
KEEP THE CONTAMINATION LEVEL OF HYDRAULIC FLUID BELOW

NAS CLASS 9. INSTALL FILTERS GRADATION OF WHICH IS NOT
3121157 – JLG Lift – 5-1

GREATER THAN 10 M IN THE HYDRAULIC CIRCUIT. AS PRESSURE IN THE CIRCUIT BECOMES NEGATIVE, THE MOTOR
THE CONTAMINATION LEVEL OF HYDRAULIC FLUID HAS A GREAT CANNOT BE CONTROLLED, WHICH MAY LEAD TO A SUDDEN DROP
INFLUENCE ON LIFE-SPAN OF A MOTOR. POOR CONTROL OF OF LIFTED LOAD OR RUNAWAY.
CLEANLINESS OF HYDRAULIC FLUID MAY CAUSE SEIZURE AND
EARLY WEAR IN EACH SLIDING SURFACE, RESULTING IN AN
INABILITY OF THE MOTOR TO OPERATE.
WHEN OPERATING THE MOTOR, BE SURE TO OBSERVE INSTRUC-
TIONS DESCRIBED IN THE OPERATING MANUAL.
FOR TYPE OF HYDRAULIC FLUID IN USE, USE RECOMMENDED

HYDRAULIC FLUIDS. KEEP THE TEMPERATURE AND VISCOSITY OF
HYDRAULIC FLUID IN USE WITHIN THE USAGE CONDITION LIMIT. OPERATE THE MOTOR WITHIN THE SPECIFICATION RANGE. IF THE
USE OF HYDRAULIC FLUID WITH THE TEMPERATURE AND VISCOS- MOTOR IS OPERATED BEYOND THE SPECIFICATION RANGE,
ITY BEYOND THE USAGE CONDITION LIMIT MAY CAUSE EARLY PLEASE CONTACT US.
WEAR OF EACH SLIDING SURFACE AND SEIZURE, RESULTING IN
AN INABILITY OF THE MOTOR TO OPERATE.
BEFORE OPERATING THE MOTOR, LUBRICATE HYDRAULIC FLUID

INTO THE MOTOR CASE FROM DRAIN PORT ON THE UPPER SIDE.
IF YOU USE FIRE-RESISTANT HYDRAULIC FLUID, OR USE HYDRAU-
LIC FLUID BEYOND THE PERMISSIBLE OIL TEMPERATURE, PLEASE OPERATION OF MOTOR WITH MOTOR CASE EMPTY MAY CAUSE
CONTACT US. BREAKAGE OF THE INSIDE OF THE MOTOR, LEADING TO AN INABIL-
USAGE AREA OF THE MOTOR MAY BE LIMITED. ITY OF THE MOTOR TO OPERATE.
Lubricating Oil for Reduction Gears

For lubricating oil for reduction gears, use recommended KEEP THE PRESSURE WITHIN THE USAGE CONDITION LIMIT.
lubricant, and change lubricant according to the following FAILURE TO DO SO MAY NOT ONLY SHORTEN THE LIFE-SPAN OF
interval. THE MOTOR DRASTICALLY, BUT ALSO BREAK STRUCTURAL COM-
Recommended lubricant: Diamond Hypoid Gear Oil #90 PONENTS.
from Mitsubishi Oil (equivalent to API category GL-4#90)
Interval of oil change
• Initial oil change: 100 - 250 hours of operation KEEP ROTATION SPEED IN USE WITHIN PRODUCT SPECIFICATION
• Succeeding oil change: every 1000 - 1500 hours of RANGE. KEEP FLOW RATE WITHIN USAGE CONDITION LIMIT. FAIL-
operation URE TO DO SO MAY CAUSE SEIZURE ON EACH SLIDING SURFACE,
RESULTING IN BREAKAGE OF THE INSIDE OF THE MOTOR.
Periodic oil change extends life-span of reduction gears,
and ensures stable performance.
Hydraulic fluids with the oil of different property should not
be mixed. When changing hydraulic fluid type, flush the KEEP REVERSE INPUT TORQUE WITHIN USAGE CONDITION LIMIT.
reduction gears. FAILURE TO DO SO MAY CAUSE BENDING BREAKAGE OF REDUC-
TION GEARS AND FAILURE OF STRUCTURAL COMPONENTS.
KEEP TEMPERATURE OF LUBRICANT FOR REDUCTION GEAR

WITHIN THE USAGE CONDITION LIMIT. FAILURE TO DO SO WILL APPLY EXTERNAL RADIAL LOAD ON THE SPECIFIED LOCATION. DO
DRASTICALLY SHORTEN THE LIFE-SPAN OF THE REDUCTION GEAR, NOT APPLY LOAD EXCEEDING PERMISSIBLE RANGE. FAILURE TO
CAUSING EARLY BREAKAGE. DO SO WILL DRASTICALLY SHORTEN REDUCTION GEAR LIFE-SPAN
AND BREAKAGE OF MAIN BEARING WILL OCCUR.
Motor Operation
DO NOT APPLY AN AXIAL LOAD. AXIAL LOADS MAY CAUSE EARLY

DO NOT GENERATE CAVITATION. EXCESSIVE ROTATION SPEED OF
WEAR OF REDUCTION GEAR
MOTOR MAY CAUSE SEIZURE ON EACH SLIDING SURFACE. AS
PRESSURE IN THE CIRCUIT BECOMES NEGATIVE, THE INSIDE MAY
FAIL.
5-2 – JLG Lift – 3121157

Parking Brake Setting Self-Priming Circuit
RELEASE PARKING BRAKE TO OPERATE MOTOR. IF MOTOR IS LEAKS FROM THE HYDRAULIC MOTOR AND COUNTER BALANCE
OPERATED WITH PARKING BRAKE ENGAGED, A DISK FOR THE VALVE MAY CAUSE AERATION IN THE HYDRAULIC MOTOR CIR-
PARKING BRAKE MAY WEAR QUICKLY, RESULTING IN PARKING CUIT, LEADING TO CAVITATION AND TRAVEL MOVEMENT OF THE
BRAKE FAILURE. A PARKING BRAKE FAILURE WILL LEAD TO A HYDRAULIC MOTOR. INSTALLATION OF A SELF-PRIMING CIRCUIT
DROP OF LIFTED LOAD OR RUNAWAY, WHICH IS VERY DANGER- IS NECESSARY TO PREVENT CAVITATION AND TRAVEL MOVEMENT
OUS. OF THE HYDRAULIC MOTOR.
DO NOT USE THE PARKING BRAKE FOR CONTROLLING ROTATION ESPECIALLY AFTER A LONG PERIOD OF QUIESCENT OPERATION, IT
OF THE MOTOR. EARLY BREAKAGE OF THE DISK FOR THE PARKING IS ESSENTIAL TO FILL HYDRAULIC MOTOR CIRCUIT WITH
BRAKE LEADS TO A PARKING BRAKE FAILURE. AS A RESULT, HYDRAULIC FLUID. THUS, INSTALL THE SELF-PRIMING CIRCUIT,
LIFTED LOAD MAY DROP, WHICH IS VERY DANGEROUS. CONSIDERING LOCATION RELATIONSHIP BETWEEN HYDRAULIC
MOTOR AND THE OIL LEVEL OF THE HYDRAULIC PRESSURE TANK.
EXCESSIVE TORQUE EXERTED ON THE MOTOR SHAFT AND DRIVE EXERT PRESSURE OF 0.3 TO 0.5 MPA ON THE SELF-PRIMING CIR-
GEAR SHAFT OF THE REDUCTION GEAR WILL CAUSE BREAKAGE OF CUIT TO PREVENT CAVITATION DURING HALTS OF MOTOR ROTA-
THE MOTOR SHAFT AND DRIVE GEAR SHAFT OF THE REDUCTION TION.
GEAR. THE RESULT WILL LEAD TO A DROP OF LIFTED LOAD DUR-
ING OPERATION, WHICH IS VERY DANGEROUS.
IF THE HYDRAULIC MOTOR IS POSITIONED LOWER THAN THE OIL

LEVEL OF THE HYDRAULIC PRESSURE TANK, AND THE CONTROL
WHEN STOPPING THE MOTOR, BE SURE TO APPLY THE PARKING VALVE OPERATES FROM A TO B, AND TO T OPEN, NO INSTALLA-
BRAKE. FAILURE TO DO SO IS VERY DANGEROUS BECAUSE LIFTED TION OF THE SELF-PRIMING CIRCUIT IS NECESSARY IN PRINCIPLE.
LOAD MAY DROP OR MOTOR MAY RUNAWAY.
Hydraulic Circuit
Overrun Prevention
SET BACK PRESSURE VALUE SO NO CAVITATION OCCURS.

DEPENDING ON PIPING VOLUME FROM HYDRAULIC SUPPLY TO
HYDRAULIC MOTOR, AND PROPERTY OF THE COUNTER BALANCE
VALVE, THE HYDRAULIC MOTOR MAY OVERRUN, RESULTING IN
EARLY BREAKAGE OF THE HYDRAULIC MOTOR. THEREFORE, PRE- IF HYDRAULIC MOTOR IS POSITIONED HIGHER THAN OIL LEVEL IN
VENT THE MOTOR FROM OVERRUNNING FOR PROTECTION OF THE HYDRAULIC TANK, FILL HYDRAULIC MOTOR CIRCUIT WITH
EQUIPMENT AND USE FOR AN EXTENDED PERIOD OF TIME (ESPE- HYDRAULIC FLUID BEFORE OPERATING HYDRAULIC MOTOR.
CIALLY DURING WINDING DOWN). IF OCCURRENCE OF OVERRUN
CANNOT BE FULLY PREVENTED, ADJUST SO THAT THE MAXIMUM
ROTATION SPEED OF THE MOTOR WHEN OVERRUN OCCURS
BECOMES WITHIN THE ROTATION SPEED RANGE OF THE EQUIP- PROVIDE THE SELF-PRIMING CIRCUIT.
MENT SPECIFICATIONS.
PLEASE CONTACT US IF ANY CIRCUIT OTHER THAN THE ONES

DESCRIBED IN ATTACHED PAPERS IS USED.
3121157 – JLG Lift – 5-3

5.2 GENERAL Features:

This manual describes specifications, structure and han- 1. The motor is light-weight and compact unit,
dling method of the motor MAG-85VP series for closed equipped with shuttle valves, crossover relief valves,
loop in order to assure reliable performance for a long low pressure relief valves, swash plate type axial pis-
period of time and to prevent it from improper use. ton motor, and reduction gear as one package.
Description 2. The reduction gear is of casing rotation type to
ensure sufficient durability.
Design of Drive Motor:
3. A double stage planetary reduction gear ensures
The drive motor is a swash plate type axial piston motor high efficiency and long life.
integrated with a reduction gear, consisting of seven func-
tions; swash plate axial piston motor, shuttle valves, cross- 4. The integrated parking brake prevents the machine
over relief valves, low pressure relief valves, two-speed from slipping on a slope, and securely engages the
changeover system, parking brake, and reduction gear. mechanical brake when it is parked or stopped.
The piston motor converts fluid energy of pressurized oil Design Type:
delivered from a hydraulic pump to mechanical energy,
and transfers high speed and low torque power to the Axial piston motor - Swash plate piston motor (2-speed
reduction gear. The reduction gear changes the high changeover system, integrated parking brake)
speed and low torque power to low speed and high Valve function - Low pressure shuttle function, low pres-
torque power, and transfers the power to a drum. sure relief function, high pressure relief function (installed
on cross-line)
Reduction gear - Double stage planetary pinion gear sys-
tem
Model Code Identification:
MAG – 85 V P – 1400 – X
Axial piston motor with reduction gear
Motor displacement(cm3/rev approximation)
With two-speed changeover system
With parking brake
Output torque (kgf-m)
Design number
5-4 – JLG Lift – 3121157

5.3 CONSTRUCTION AND FUNCTION Working Principle of Swash Plate Type Axial
Piston Motor
Cylinder block
Valve plate
Shaft
Swash plate
Piston sub assembly
Figure 5-2. Structure of Swash Plate Type Axial Piston

Motor
Nine piston sub assemblies are assembled in the cylinder
Figure 5-1. Structure of Drive Motor block. The end of the cylinder block is adjacent to the
The drive motor consists of swash plate type axial piston valve plate with two half moon shaped ports, B and C
motor, shuttle valves, crossover relief valves, low pressure (high and low pressure ports). When supplying pressure
relief valves, and reduction gear as one component. fluid (pressure P) to B port, the force of piston sub assem-
blies having F=PEA (A: Piston pressure area) pushes the
swash plate. The piston sub assemblies receive reaction
force from it, and reaction force (Ft) in rotating direction is
produced. The total force of high pressure side piston sub
assemblies in rotating direction produces a rotating force
in the cylinder block, and the force through a spline con-
veys the torque to the shaft, which causes the shaft to
rotate.
According to the above working principle, the output
torque and rotating speed of the piston motor are deter-
mined by supply pressure (P) and flow rate (Q), and are
calculated by the following formula.
3121157 – JLG Lift – 5-5

Working Principle of Shuttle Valve Shuttle Valve Action
P1 P2 P1 P2
Figure 5-4. Shuttle Valve (Shuttle)

Figure 5-3. Structure of Shuttle Valve
When the hydraulic fluid discharged from the hydraulic
The shuttle valve prevents the axial piston motor from pump is directed to port P1 of the shuttle valve through
overheating. When the control valve is in neutral position, the control valve, the hydraulic fluid passes orifice, acts on
no pressure exists at ports P1 and P2. Thus, the plunger is the end of the plunger, and tries to push the plunger right-
in neutral state, blocking the oil passage to the low pres- ward with the force in proportion to pressure against
sure relief valve. spring on the opposite side.
When the hydraulic pressure rises to a certain pressure,
the plunger starts moving rightward, and oil passage to
the low pressure relief valve on port P2 opens. The
hydraulic fluid at port P2 passes through the notch of the
outer circular of the plunger, and acts on the low pressure
relief valve.
5-6 – JLG Lift – 3121157

Working Principle of Relief Valve Working Principle of Low Pressure Relief

Relief valve which determines driving and braking forces
Valve
on traveling for the vibrating roller or carrier is mounted on The low pressure relief valve keeps charge pressure of the
the cross-line. charge pump at necessary pressure level. The low pres-
The structure of relief valve is differential surface direct sure relief valve is of direct acting type, as shown in Figure
acting type, as is shown in Figure 5-5. 5-7.
REFRAIN FROM ADJUSTING UNLESS ANY MALFUNCTION IS

FOUND.
Figure 5-7. Structure of Low Pressure Relief Valve
Pressurized surface of the low pressure valve becomes

poppet seat surface (S1). Therefore, when pressure P
which passes through the notch of outer circular of the
Figure 5-5. Structure of Relief Valve plunger and acts on the fore side of the poppet reaches P
= F/S1, the relief valve operates, releasing pressurized oil
Working of Relief Valve in the low pressure side of the motor circuit to drain. F:
Spring set load
When the piston motor is driven or braked by operation of
the control valve, pressurized oil in the fore side of the
poppet passes orifice and acts on the spring chamber.
Thus, pressurized surface of the poppet becomes a differ-
ential surface (S1-S2). S1 and S2 are poppet seat surface
and poppet sliding diameter surface, respectively.
Therefore, when the pressure P at full surface of the pop-
pet becomes P = F/(S1 - S2), the poppet lifts, releasing
pressurized oil from the high pressure side to the low
pressure side.(Refer to Fig.5-1.) F: Spring set load
Figure 5-6. Structure of Relief Valve
3121157 – JLG Lift – 5-7

Two-Speed Changeover System
Structure of two-speed changeover system

Swash plate has three faces, "A" through "C" as shown in
Figure 5-8., and is held against the flange holder by two
steel balls in a tiltable state. The two-speed changeover
valve is installed inside the base plate.
Operation of Two-Speed System

Refer to Figure 5-9.
If pilot pressure for changeover is exerted on the 2-speed
changeover valve from port Ps, the 2-speed changeover
valve is changed as in the figure, with motor driving pres-
sure exerting on the 2-speed control piston. This pushes
up the swash plate, which tilts and rolls to a position
where the resultant of thrust of piston sub assembly and
spring force is balanced with thrust of the 2-speed control
piston. The swash plate is settled when its side B contacts
the flange holder. The swash plate inclination becomes ß,
obtaining speed two (high speed) rotation for the motor. Figure 5-8. Structure of Two Speed Changeover System
Figure 5-9. Structure of Two Speed Changeover System at High Speed
5-8 – JLG Lift – 3121157

If exertion of pilot pressure for changeover is stopped, the swash plate inclination becomes a, obtaining speed one
2-speed changeover valve is changed as in the figure. The (low speed) rotation for the motor.
2-speed control piston chamber is connected to drain in While the engine stops, the swash plate is pushed by
the motor case. The swash plate is pushed by the resul- spring force, and its side A contacts the flange holder. The
tant of thrust of piston sub assembly and spring force, and swash plate inclination becomes a, obtaining speed one
is settled when its side A contacts the flange holder. The (low speed) rotation for the motor.
Figure 5-10. Structure of Two Speed Changeover System at Low Speed
3121157 – JLG Lift – 5-9

Working Principle of Parking Brake sponding to the pressure surface area of brake piston.
This force overcomes spring force, pushing up brake pis-
Parking brake is a negative brake consisting of a rotating ton and releasing parking brake. When parking brake
disk (frictional material), brake piston and spring. Refer to release port (Pp) is connected to the tank, pressurized oil
the Figure 5-11. in cylinder chamber for parking brake release is released
Pressurized oil, when acting on parking brake release port into the tank, and brake piston pushed by spring force
(Pp), is directed to cylinder chamber for parking brake activates the parking brake.
release, and pushes up brake piston with thrust corre-
Pp port
Figure 5-11. Parking Brake System
5-10 – JLG Lift – 3121157

Procedures for manually releasing parking 3. When socket head bolts for parking brake manual
release are evenly screwed, and parking brake pis-
brake (This mechanism is optional.)
ton is pulled up, parking brake disk and friction plate
1. Remove blind plugs in PF1/4 of parking brake become in a free state, and parking brake is
release ports. (Refer to Figure 5-12. and Figure 5- released. (Refer to Figure 5-15.)
13.)
NOTE: Some of motors do not have lubricating ports or
2. Install socket head bolts (M10 x 1.5 x 110 L) for park- parking manual release ports on baseplate.
ing brake manual release and flat washers (for M10)
in two locations of parking brake manual release
ports. (Refer to Figure 5-14.)
Lubricating port for reduction Parking brake manual

gear lubricant release port
Baseplate
Lubricating port for

reduction gear lubricant
Discharge port for

reduction gear lubricant Parking brake manual
release port
Figure 5-12. Position of Parking Brake Manual Release Ports
3121157 – JLG Lift – 5-11

Plug for parking brake manual release port

(PF1/4 / 2 locations / Hex.6)
Figure 5-13. Procedures for Manually Releasing Parking Brake (step 1)
Socket head bolt for parking brake manual

release
Flat washer for M10 Brake piston stroke amount

(2 locations) (1.5mm)
5-12 – JLG Lift – 3121157

Reduction Gears Reduction gear ratio "i" is shown as follows by primary and
secondary reduction gear ratios "i1" and "i2".
Reduction gears consist of a double stage planetary pin-
ion gear system. * Reduction Gear Ratio (i)
Z1 +Z 3 Z 4 +Z 6
(7) i = i1×i 2 - 1 = × -1
(6) Z1 Z4
(2) z1: number of drive gear tooth
z3: number of ring gear tooth
(5) z4: number of sun gear tooth
z6: number of ring gear tooth
* Reduction Gear Output Torque (T)

(1) T = TM × i × m
TM : input torque (motor output torque)

(4) i : reduction gear ratio
Figure 5-16. Structure of Reduction Gear hm: mechanical efficiency

* Reduction Gear Output Rotating Speed (N)
Drive gear (1) is engaged with the primary planetary gear
NM
(2), secondary sun gear (4) with secondary planetary gear N =
(5). Secondary planetary carrier (6) is fixed to the machine i
body. Planetary gears (2) and (5) are engaged with ring
gear (7) (housing). NM: input speed of rotation (output motor speed)
Driving force of 1st stage is transferred from piston motor
to drive gear (1) with the speed reduced by each gear.
The final driving force is transferred from 1st stage one to
ring gear (7) through planetary gear (5) of planetary car-
rier (6) fixed on the machine body. (Driving force is also
transferred from primary planetary gear {2}.) Direction of
input rotation and that of output rotation are reverse.
3121157 – JLG Lift – 5-13

5.4 PRECAUTIONS AND WARNINGS Direction of Rotation

Inspection The relation between the flow direction of hydraulic fluid
and the direction of rotation is shown in the following
Check the following points before installing the motor. table.
1. Are there any portions of the motor missing or dam-
aged by transportation? DIRECTION OF ROTATION
2. Is there any looseness in the tightening portions? OIL INLET PORT OIL OUTLET PORT (VIEW FROM B SIDE EDGE OF
REDUCTION GEAR)
3. Are port flange faces and drain ports completely
P1 P2 Counterclockwise Rotation
sealed to prevent debris from entering into the
motor? P2 P1 Clockwise Rotation
P1
P2
Figure 5-17. Direction of Rotation
5-14 – JLG Lift – 3121157

Hydraulic Fluid Piping Work

1. Hydraulic fluid is an important factor for transmission 1. Do acid-cleaning and remove scales inside the
of power and lubrication of hydraulic components. tubes thoroughly before the assembly.
Selection and handling of the hydraulic fluid have a
2. Ensure that foreign articles will not enter into the pis-
great influence on the performance and life-span of
ton motor case from each port during the piping
hydraulic equipment.
work.
Lubricating oil having superior quality is generally 3. Flush the pipes thoroughly upon completion of pip-
used as hydraulic fluid. It must be excellent in lubri- ing work.
cating ability, oxidization stability, corrosion protec- 4. The drain piping should be separate and connected
tion and anti-emulsification. It must not be erosive to
directly to the tank.
packing and sealing materials. Hydraulic fluids with
the oil of different property should not be mixed. DRAIN PRESSURE IN PISTON MOTOR CASE
2. Range of Viscosity Constant at 0.2 MPa or less
EQUIVALENT OIL Intermittent at 0.5 MPa or less
VISCOSITY
TEMPERATURE (DEG) 5. It is recommended that the piston motor case be
Optimum Range of Viscosity 25 to 100 +22 to +55 constantly filled with oil to maintain satisfactory lubri-
cation.
Practical Range of Viscosity 20 to 500 – 3 to +63
(Idemitsu Daphne Hydraulic Fluid 46WR)

Lubricating Oil for Reduction Gears
When starting up in low temperature, operate hydraulic The following products are recommended.
equipment in idle with no load. Mitsubishi Diamond Hypoid Gear Oil #90 (Equivalent
to GL-4)
Filters
BRAND MANUFACTURER
The piston motor and the shuttle valve are so designed (*)Diamond Hypoid Gear Oil #90 Mitsubishi Oil
that each of its parts is high in accuracy, clearance among
Apolloil Gear HE90 Idemitsu Kosan
parts is very much limited, and parts are much sensitive to
foreign matters, such as sludge, iron powder, rust, filings, Shell Hypoid Gear Oil CT90 Shell Oil
grinding powder, etc. Cosmo Gear GL-490 Cosmo Oil
Performance degradation of the piston motor and the Gear Lub SP90 Nippon Oil
shuttle valves, and wear in sliding parts may be avoided Notes:
by keeping the oil clean.
1. Gear oil marked (*) is filled at the time of shipment
Therefore, adequate filters are required to keep hydraulic
from our factory.
fluid in the hydraulic system clean, durable and reliable for
long term services with less maintenance and inspection. 2. Use the same brand,if the oil is supplied.
The contamination level should be below NAS Class 9. 3. Select any of the above listed products at time of oil
Filters should be placed at the discharge side of hydraulic change.
pump or at the return side of piston motor. Filter gradation
should be smaller than 10 microns (nominal). Use filter(s) Cautions in Using Parking Brake
with a visual indicator by which the clogging is found from
the outside, and with a relief valve which by-passes the oil This motor is equipped with parking brake. (Refer to Fig-
depending on the clogged condition when the filter ele- ure 5-11. for working principle of parking brake.)
ment is clogged. The parking brake is so designed as to operate when the
It is recommended that the contamination level of machine is stopped or parked. If the parking brake is used
hydraulic fluid should be below NAS Class 9. as a brake during traveling of the machine (for braking
motor rotation), the motor shaft or reduction gear drive
gear may break as well as the disk plate may quickly wear.
This will result in brake failure, leading to personal injuries
by runaway of the machine.
Therefore, never use the parking brake as a brake while
the machine is traveling (for braking motor rotation).
3121157 – JLG Lift – 5-15

5.5 OPERATING STEPS AND PRECAUTIONS NOTE: The reduction gear box has been fully lubricated up
to the specified level at the time of shipment from our
Precautions at Startup factory.
Some of motors do not have lubricating ports or
After installation of a new or serviced drive motor on the parking manual release ports on base-plate.
machine, prepare for inspection and startup using the fol-
lowing procedures. Initial Operation
1. Fill the piston motor case with hydraulic fluid. (See Repeat the initial operations at low speed. Residual air in
Figure 5-18.) Remove air from the hydraulic circuit. the circuit may cause unusual noise at the valve, but con-
NOTE: When a hand-operated or electrically operated pump tinue the operation at low speed. Ensure that there is no
in small capacity is used, carefully check to see that oil leakage around the equipment. Ensure that the resid-
the internal pressure of the motor case does not ual air is purged and there is no oil leakage and that there
exceed 0.3 MPa. is no unusual noise or vibration caused by the drive motor
under loaded conditions, prior to start of working opera-
2. Fill the reduction gear case with the lubricating oil up tions.
to the specified level. (See Figure 5-19.) Remove the
plugs of lubricating and gauging ports, and add
lubricant until it flows out of the gauging port. Rein-
stall and tighten the plug of each port after making
sure that lubricant flows out. (Standard Lubricant
Quantity: 2600 cm2)
Fill the piston motor case with

hydraulic fluid up to this level.
Figure 5-18. Oil level of hydraulic fluid at the initial stage
5-16 – JLG Lift – 3121157

Gauging port Filling port
Oil level
Baseplate
Lubricant discharge port

< Side of the motor>
Filling port
Gauging port
Oil level
< Side of the reduction gear> Lubricant discharge port
Figure 5-19. Lubricant Change
3121157 – JLG Lift – 5-17

Hydraulic Fluid Temperature during Operation 5.6 PERIODIC INSPECTION AND CHANGE
Temperature control of the hydraulic fluid is very important
CRITERIA
in the hydraulic system. Higher temperature may degrade
the anti-oxidant resistivity and accelerate deterioration of Hydraulic Fluid
the hydraulic fluid. Therefore, take the following precau- Although the hydraulic oil is clean at first, it will be dirtied
tions: with sediment such as sludge in the circuit and the tank
1. Maintain the temperature during continuous opera- after a long operation, and it may cause damage to
tion within the range from +10 to +80 degree. hydraulic components. The hydraulic fluid will also be
degraded and will result in wear of the sliding compo-
2. Minimum start-up temperature should be at minus
nents. Therefore, it is necessary to check the hydraulic
+20 degree or higher. Maximum allowable tempera-
fluid periodically and to change the fluid depending on the
ture is +100 degree only for a short time (total accu-
state of degradation. However, it may be difficult to judge
mulative operating time under 100 degree should be
quantitatively on site whether the fluid is degraded or not.
within 100h). These temperatures have been estab-
The following table is provided for information to be used
lished in consideration of degradation to viscosity
as a basis of visual inspection.
and anti-oxidant resistivity of the hydraulic fluid and
to the O-ring and oil seals. The motor life will be It is recommended to replace the oil with new after the first
shortened if the motor is continuously run at temper- 500-hours of operation.
ature of +80 degree or higher. When hydraulic fluid is replaced, deposits such as deteri-
orated hydraulic fluid and sludge, and water are contained
Maintenance and Inspection in the circuit and tank. If left as they are, they will cause
operation failure of the motor and shorten its life-span. Be
Perform maintenance and inspection of the motor for the
sure to clean the tank and flush piping before replacing
following check points unless a malfunction is detected:
with new hydraulic fluid.
1. Is there any oil leakage at flange connections and
joints of the equipment? COUNTERM
APPEARANCE * SMELL JUDGMENT
EASURES
2. Is there any looseness in tightened bolts?
Transparent
3. Is there any damage on the appearance? Good Good Use as is
(no discoloration)
4. Is there contamination in the lubricant?
Transparent Foreign sub- Use after
Good
(but dark spots are noted) stances mixed filtration
Discolored (milky) Good Water contained Change oil
Discolored (darkish) Bad Oxidized Change oil
* Visual Inspection Method
(Compare the old and new fluids in the test tubes)
Filters
Filtration effectivity is lowered if filter elements are
clogged. Periodic inspections are essential to maintain the
filters in good conditions.
Filters should be replaced with new ones after the first 50
hours of running, and checked after every 250 hours of
running. Where a differential pressure gauge is not pro-
vided, the filters should be replaced with new ones after
the first 50 hours and every 250 hours thereafter. The fil-
ters must be replaced with new ones when the hydraulic
fluid is replaced with new.
5-18 – JLG Lift – 3121157

Lubricating Oil for Reduction Gears New Lubricant Replacement Procedure

1. Inspection of Contaminated Lubricating Oil Motor with the lubricating port on base-plate.
Check for metal powder or any other foreign sub- Discharge old lubricant completely by removing socket
stances deposited in the fluid at the time of oil head bolts for lubricating port (50) and discharge port on
change. the base-plate (32) and plug for gauging port (45). Then,
lubricate new lubricant until lubricant flows out of the
2. Frequencies of Oil Change gauging port. (Refer Figure 5-19.)
Initial Oil Change 100 - 250 hrs Motor with/without the lubricating port on base-plate.
Succeeding Oil Change every 1000 - 1500 hrs Discharge old lubricant completely by removing plugs for
lubricating port (1-8) and discharge port on the cover (1-
27) and plug for gauging port (1-8).
Gauging Procedure
Then, lubricate new lubricant until lubricant flows out of
Motor with the lubricating port on base-plate. the gauging port.(Refer Figure 5-19.)
Remove socket head bolt for lubricating port (50) on the
base-plate (32) and plug for gauging port, and make sure
that lubricant flows out of the oil level detection port (45).
(Refer Figure 5-19.)
Motor with/without the lubricating port on base-plate.
Remove plug for lubricating port (1-8) on the cover (1-27)
and plug for gauging port, and make sure that lubricant
flows out of the oil level detection port (1-8). (Refer Figure
5-19.)
3121157 – JLG Lift – 5-19

Inspection for Hydraulic Fluid and Lubricant Leaks, and Torque of Bolts and Plugs
<type A> Oil leak inspection location
1. Oil leak inspection location Tightening torque of

bolts and plugs
2. Tightening torque of bolts
<type B>
Oil leak inspection location
Figure 5-20. Inspection of oil leak, bolts and plugs
5-20 – JLG Lift – 3121157

5.7 TROUBLESHOOTING
In the event a failure occurs while in operation, refer to the following troubleshooting list for the causes of failure and neces-
sary actions.
Troubleshooting for Piston Motor
TROUBLES (TYPE OF FAILURE) POSSIBLE CAUSES CORRECTIVE ACTIONS

Motor does not rotate. The components other than piston motor and reduc- Check to see if the inlet of motor is pressurized or not,
tion gear do not work properly. and provide necessary corrections.
Sliding components of the motor are excessively Replace excessively worn parts with new ones.
worn and pressurized oil is leaked. Remove scratches or burrs, clean all parts thor-
oughly, and reassemble them.
Major parts of the motor are damaged. In this case, Disassemble the motor and replace all damaged
the motor produces abnormal noises. parts with new ones. Clean up all parts and reassem-
ble them.
Motor load is so great that relief valve operates. Check for load condition, and operate motor under
load corresponding to relief set pressure.
Motor speed is low. Insufficient inflow caused by oil pump and pressure Check to see if there is necessary flow at the inlet of
control valve motor. Provide necessary repairs.
Required rpm is not obtained because of lowered vol- Disassemble the motor and check all sliding parts for
umetric efficiency of the motor. excessive wear. Repair or replace worn parts as nec-
essary.
Motor rotates at unstable speed. Pressurized oil in large amount leaking from drain port Disassemble the motor for excessive wear. Replace
caused by wear of motor sliding surface results in a all worn parts with new ones. Clean up all the parts,
reduction or variations in speed of rotations. Or, motor and reassemble them.
speed is affected by wear of bearings.
Motor load is so great that automatic 2-speed system Check for load condition, and operate motor under
operates. load corresponding to automatic 2-speed set pres-
sure.
Oil leakage Damaged oil seals or O-rings have caused oil leakage. Replace damaged oil seals and O-rings with new
ones. When inserting oil seals, take sufficient care not
to damage lips. Oil seals and O-rings can be safely
used up to 80° C. If the hydraulic fluid temperature in
the motor rises above 80° C , measures such as set-
ting a cooler in the hydraulic circuit are necessary.
Pressurized motor case caused by (1-2) and (3-1) Repair the motor in the same procedures as in (1-2)
damages oil seals, resulting in oil leakage. and (3-1), and replace oil seals with new ones. When
* Pressure resistance of oil seals Working: 0.2 MPa inserting oil seals, pay full attention not to damage
Intermittent maximum: 0.5 MPa lips.
Clogged drain piping by foreign substances or nar- Clean clogging of drain piping. Review the piping sys-
row, long piping makes supply pressure high, which tem and lessen piping resistance. With above mea-
causes damage to oil seals and results in oil leaks. sures, prevent pressure greater than 0.3 MPa from
*Pressure resistance of oil seals Working: 0.2 MPa being exerted on oil seals, and replace oil seals with
Intermittent maximum: 0.5 MPa new ones. When inserting oil seals, pay full attention
not to damage lips.
Abnormal noise, and variations in rota- When motor performs pump operation, when closed Provide proper boost pressure by reviewing hydraulic
tion and pressure caused by cavitation loop is used, when boost is low (standard: 0.4 to 0.5 circuit and replacing low pressure relief with new one.
are remarkable. MPa), boost pressure lowers with set pressure of low Then, disassemble the motor, and replace abnormally
pressure relief lowered, causing cavitation. worn parts and damaged parts. Clean all the parts
before reassembly.
3121157 – JLG Lift – 5-21

Troubleshooting for Parking Brake

Shortage of braking force or one-sided Brake disk is worn. Replace the worn disk with new one. Remove foreign
braking substances thoroughly, repair damaged parts, and
reassemble them after cleaning.
Deterioration or poor contact of disk surfaces Polish and correct the surface. Clean it before reas-
sembly. If it is too much degraded, replace it with new
one.
Worn or damaged springs Replace the spring with new one. Remove foreign
substances thoroughly, and clean it before reassem-
bly.
The bolt for manually releasing brake is mounted. Remove the bolt for manually releasing brake, and
install a blind plug.
Pilot pressure for releasing brake is in operation. Check to see if pressurized oil in the pilot for releasing
brake is ON or OFF, and then, provide each equipment
with necessary inspection and maintenance.
Abnormal heating due to brake dragging Brake release failure:
1) Oil leakage due to O-ring breakage - Replace the damaged O-ring with new one.
2) Clogged orifice - Wash the orifice before reassembly.
3) Pressurized oil in the pilot for releasing brake is not - Check to see if the pilot port is pressurized or not, and
in operation. provide equipment with necessary inspection and
4) Pilot pressure for releasing brake is low. maintenance.
Parking brake cannot be manually Tightening of bolts for manual release is uneven. Tighten the bolts evenly.
released.
Troubleshooting for High Pressure Relief Valve

Motor does not rotate or rotates slowly. Relief valve receipt malfunctions; - Remove foreign articles thoroughly. Repair damaged
1) Foreign articles are jammed in. parts, and reassemble the parts after cleanup. If deep
2) Spring is broken. scratches or more than normal wear are found on the
parts, the parts should be replaced with new ones.
- Replace spring with new one. Then, remove foreign
articles thoroughly.
Cracking pressure of the relief valve is lowered; - Replace relief valve sub assembly with new one.
1) Spring wear-out - Wash and clean the clogged orifice prior to reassem-
2) Clogged poppet orifice bly.
2. Motor does not stop or stops slowly. Relief valve receipt malfunctions; - Remove foreign articles thoroughly. Repair damaged
1) Foreign articles are jammed in. parts, and reassemble the parts after cleanup. If deep
2) Spring is broken. scratches or more than normal wear are found on the
- Replace spring with new one.
Cracking pressure of the relief valve is lowered; - Replace relief valve sub assembly with new one.
1) Spring wear-out - Wash and clean the clogged orifice prior to reassem-
2) Clogged poppet orifice bly.
5-22 – JLG Lift – 3121157

Troubleshooting for Low Pressure Shuttle Valve

Motor rotates slowly. Operation failure of plunger; - Remove foreign articles thoroughly. Repair dam-
1) Foreign substances are jammed between plunger aged parts, and reassemble the parts after cleanup. If
and body. deep scratches or more than normal wear are found
2) Spring is broken. on the parts, the parts should be replaced with new
ones.
Motor does not stop or stops slowly. Plunger does not return; - Remove foreign articles thoroughly. Repair dam-
1) Foreign substances are jammed. aged parts, and reassemble the parts after cleanup. If
2) Spring is broken. deep scratches or more than normal wear are found
3) Spring is not assembled. on the parts, the parts should be replaced with new
ones.
- Install spring in proper position.
Rise in oil temperature of circuit Operation failure of plunger - Remove foreign articles thoroughly. Repair dam-
1) Foreign substances are jammed. aged parts, and reassemble the parts after cleanup. If
2) Orifice is clogged. deep scratches or more than normal wear are found
on the parts, the parts should be replaced with new
ones.
- Wash the orifice before reassembly.
3121157 – JLG Lift – 5-23

Troubleshooting for 2-speed Controls

The machine does not go straight. Plunger is not shifted; - Remove foreign articles thoroughly. Repair dam-
1) Foreign substances are bitten between plunger and aged parts, and reassemble the parts after cleanup. If
body. deep scratches or more than normal wear are found
2) Spring is not installed in place. on the parts, the parts should be replaced with new
3) Spring is broken. ones.
- Install spring in proper position.
articles thoroughly. Repair damaged parts, and reas-
semble the parts after cleanup. If deep scratches or
more than normal wear are found on the parts, the
parts should be replaced with new ones.
Oil leaks by abnormal wear on 2-seed control piston. Replace 2-speed control piston with new one.
Remove foreign substances thoroughly, and wash
the parts before reassembly.
2-speed control piston is not installed in place. Install 2-speed control piston in proper location.
Steel balls are excessively worn. Replace steel balls with new ones. Then, remove for-
eign articles thoroughly. Repair damaged parts, and
clean the parts before reassembly.
Orifice in oil passage of 2-speed control piston cham- Check for orifice diameter.
ber is different.
Orifice in oil passage of 2-speed control piston cham- Wash orifice before reassembly.
ber is clogged.
Plunger is installed backward. Check plunger for installing direction, and install it in a
proper direction.
Speed Two cannot be engaged. Plunger is not shifted; Remove foreign articles thoroughly. Repair damaged
Foreign substances are bitten between plunger and parts, and reassemble the parts after cleanup. If deep
body. scratches or more than normal wear are found on the
Wash the orifice before reassembly.
Oil leaks due to abnormal wear on 2-seed control pis- Replace 2-speed control piston with new one.
ton. Remove foreign substances thoroughly, and wash
the parts before reassembly.
2-speed control piston is not installed in place. Install 2-speed control piston in proper location.
Orifice in oil passage of 2-speed control piston cham- Wash orifice before reassembly.
ber is clogged.
proper direction.
3. Speed One cannot be engaged. Spring is not set in place. Install spring in proper position.
Spring is broken. Replace spring with new one. Then, remove foreign
proper direction.
5-24 – JLG Lift – 3121157

Troubleshooting for Low Pressure Relief Valve

1. Rise in circuit temperature Operation failure of relief valve; - Replace spring with new one. Then, remove foreign
Spring is broken. articles thoroughly. Repair damaged parts, and reas-
2. Abnormal noises such as cavitation Lowered set pressure of relief valve; - Remove foreign articles thoroughly. Repair dam-
1) Seat failure due to foreign substance jamming aged parts, and reassemble the parts after cleanup. If
2) Spring is broken. deep scratches or more than normal wear are found
3) Wear-out of spring on the parts, the parts should be replaced with new
4) Lack of necessary parts ones.
- Check the parts again.
3121157 – JLG Lift – 5-25

5.8 MAINTENANCE AND REPAIR PROCEDURES

Tools for Disassembly and Reassembly
Table 5-1. List of Standard Tools
APPLICABLE
NO. PARTS NAME STANDARD TYPE AND DIMENSIONS
COMPONENTS OR PARTS
1 Torque wrench (Preset type) JIS B 4650 Nominal size 60 [2 to 6 N-m] (19),(29)
2 Nominal size 230 [7 to 2.3 N-m] (1-7),(1-30), (45)
Nominal size 900 [20 to 90 N-m] (1-5),(1-14), (1-29),(60),
3
(64),(65)
4 Nominal size 2800 [60 to 280 N-m] (1-8),(41), (55)
5 Nominal size 4200 [100 to 420 N-m] (38)
6 Ratchet handle for socket wrench JIS B 4641
7 Socket for socket wrench JIS B 4636 Width across flats 27 (38)
8 Width across flats 32 (55)
9 Hexagonal bit for socket wrench Width across flats 2.5 (19),(29)
10 Width across flats 4 (1-30),(45)
11 Width across flats 6 (1-7),(1-29), (64)
15 Spanner Width across flats 27 (38)
17 Hexagonal rod spanner JIS B 4636 Width across flats 2.5 (19),(29)
19 Width across flats 6 (1-7),(1-29), (64)
23 Long-nose pliers JIS B 4631 (38)
24 Snap ring pliers S-2 type (11)
25 Punch Approx. 10 mm "(9),(27),(29) "
26 Flatblade screwdriver JIS B 4633 (32)
27 Pliers JIS B 4623 Nominal size 150 (1-21),(23) (27)
28 Hand hammer JIS B 4613 OF-05 nominal size #1
29 Plastic hammer
30 Parallel vise
5-26 – JLG Lift – 3121157

Table 5-2. List of Special Purpose Tools
Applicable Components
No. Parts Name Standard Type and Dimensions
or Parts
1 Angular bearing disassembly jig 20946-99388 (1-3)
2 Angular bearing outer ring press fitting jig 20946-99387 (1-3)
3 Angular bearing inner ring press fitting jig 20946-99390 (1-3)
4 Ring nut disassembly and tightening jig (1-4)
5 Brake piston positioning jig 20468-99903 (17)
6 Oil seal press fitting jig (4)
7 Snap ring assembly jig (11)
8 Bearing assembly jig (28)
9 Floating seal assembly jig (1-2)
Screw disassembly and assembly jig JIS B 1015 Drive size of Hexalobular
10 ISO 10664 driving feature for screw (1-14)
is T50(No.50)
11 Crane Lifting load 200 kgf
12 Eyebolt For PT 1/2
13 For M16
14 Chain string (wire)
NOTE: No.8: TORX T-shaped drive T50 (manufactured by Saga Tekkou)
3121157 – JLG Lift – 5-27

Tool - Angular Bearing Disassembly
5-28 – JLG Lift – 3121157

Tool - Angular Bearing Outer Ring Press Fitting
3121157 – JLG Lift – 5-29

Tool - Angular Bearing Inner Ring Press Fitting
Ring Nut Disassembly and Tightening
5-30 – JLG Lift – 3121157

Brake Piston Positioning
Brake Piston Positioning (PLATE)
3121157 – JLG Lift – 5-31

Brake Piston Positioning (PIN)
Snap Ring Assembly
5-32 – JLG Lift – 3121157

Tool - Angular Bearing Outer Ring Press Fitting
3121157 – JLG Lift – 5-33

Motor Bearing Assembly
Floating Seal Assembly
5-34 – JLG Lift – 3121157

Floating Seal #1 - Assembly
Floating Seal #2 - Assembly
3121157 – JLG Lift – 5-35

Table 5-3. List of Subsidiary Material
Applicable Components
No. Parts Name Standard Type and Dimensions
or Parts
1 Spring balance 196 N-m or more (1-1), (1-4)
2 Seal tape (1-7), (1-8), (45)
3 Engine oil Equivalent to SAE 30CD class
4 Refined kerosene JIS K 2203 Equivalent to No.2
5 Thinner
6 Lapping plate For correcting sliding surfaces (5), (7), (15), (26)
7 Lapping agent #1000 (5), (7), (15), (26)
8 Copper plate (32), (33)
Grease Shell Albania Grease 2 (1-2), (1-28), (4), (18), (20),
(21), (22), (26), (30), (31),
9
(38-7), (38-14), (38-17),
(38-18), (42), (61)
10 Tube brush For washing inside of bore (7), (32)
11 Bamboo brush For washing
12 Oil pan For receiving hydraulic fluid
13 Plastic container Containing grease
14 Waste cloth
Table 5-4. List of Tightening Torque
Hexagon Width Across Applicable Components

Parts Name Nominal Size Tightening Torque
Flats (mm) or Parts(1)
25 ft lb (± 3)
Plug PT 3/8 8 (1-5)
34.3 N-m (±4.9)
9 ft lb (± 1)
Plug PT 1/4 6 (1-7)
12.3 N-m (±2.5)
32 ft lb (±3)
Plug PT 1/2 10 (1-8)
44.1 N-m (±4.9)
115 ft lb (± 5)
Plug PF 3/4 12 (1-8)
157 N-m (±8)
25 ft lb (± 3)
Screw M10 Special type (1-14)
34.3 N-m (±4.9)
21 ft lb (± 1)
Socket head bolt M8 6 (1-29)
29.4 N-m (±2.0)
7 ft lb (±0.7)
Plug NPTF1/16 3.96 (1-30), (45)
9.8 N-m (±1.0)
2 ft lb (±0.36 )
Orifice M5*0.8*5L 2.5 (19), (36)
2.45 N-m (±0.49)
275 ft lb (±15 )
Plug 27 (38-6)
373 N-m (±20)
5-36 – JLG Lift – 3121157

Table 5-4. List of Tightening Torque
Hexagon Width Across Applicable Components

Parts Name Nominal Size Tightening Torque
Flats (mm) or Parts(1)
29 ft lb (± 3)
Nut M12 17 (38-16)
39.2 N-m (±4.9)
87 ft lb (±3)
Plug PF 1/2 10 (41)
118 N-m (±4.9)
140 ft lb (±11)
Socket head bolt M14*2.0*40L 12 (47)
191 N-m (±15)
80 ft lb (±7)
108 N-m (±10)
61 ft lb (±3)
Plug 31.75 (55)
83.4 N-m (±4.9)
43 ft lb (±3)
58.8 N-m (±4.9)
NOTE: (1) Refer to Figure 5-21. and Figure 5-22. exploded views.
3121157 – JLG Lift – 5-37

5.9 PRECAUTIONS FOR DISASSEMBLY 3. Do not leave the parts disassembled. Parts may be
soiled or may be rusted when exposed to damp air
1. Since all parts are precisely machined, extreme care or dusts. When work must be discontinued, provide
should be taken so the parts may be neither dented an adequate cover to protect the parts from rusts or
nor scratched by drop and/or contact of such parts. dusts.
2. Do not try to hit or wrench when the parts are tightly 4. Wash the surface of the motor thoroughly.
fastened. Perform works carefully and patiently, as
hitting or wrenching will cause burrs or damage to 5. Drain all hydraulic fluids in piston motor case and oil
parts, resulting in inability of reassembly, oil leaks passage ports.
and degradation of performance. 6. Select a clean working place to prevent parts from
soil or dusts.
5-38 – JLG Lift – 3121157

Figure 5-21. Exploded View of Motor
3121157 – JLG Lift – 5-39

Figure 5-22. Exploded View of Reduction Gear Assembly
5-40 – JLG Lift – 3121157

5.10 DISASSEMBLY INSTRUCTIONS

Perform disassembly in accordance with the following
procedures. Reference exploded views of assembly Fig-
ure 5-21. and Figure 5-22., if necessary.
Motor Disassembly
3. Loosen socket head bolts (47), (50) to remove base

plate (32). If it is tight to remove, lightly tap it with a
plastic hammer in the pulling direction.
If it is still tight, remove it by lightly prying with a
screwdriver.
NOTE: Be careful that cylinder block will not pull out.
1. Loosen plug (41), and remove spool (39) and spring

(40).
NOTE: Pull out the spool slowly while turning it. Be careful
not to damage the circumference.
4. Remove valve plate (26) and O-ring (31), and pull

out pins (23), (27) with pliers. Remove also spring
(22).
NOTE: When pulling out pins, protect the circumference

with waste cloth to prevent damage to it.
2. Loosen plug (38-6), and remove relief valve (38).

Plug (38-6) and relief housing sub assembly (38-1)
are lightly press fitted. If they come off, remove them
while turning by pinching the circumference of relief
housing sub assembly (38-1) with long nose pliers.
NOTE: Do not loosen set screw (38-15) nut (38-16). Do not

disassemble relief valve unless necessary. wrap
housing with waste cloth before pinching housing
sub assembly with long nose pliers.
3121157 – JLG Lift – 5-41

5. Remove brake piston (17) by blowing compressed

air from oil passage of parking brake release port. 7. Remove swash plate (5), steel balls (6), piston (24),
Remove also collar (21) using a jig. and spring (25).
6. Pull out cylinder block (7), pin (12), retainer holder

(13), retainer plate (14), and piston sub assembly
(15).
NOTE: Be careful not to damage sliding surface of cylinder

block.
8. Grip the base plate (32) with vise. Loosen socket
head bolts (60) to remove flange (37).
9. Remove spring (35) and spring seat (34).
5-42 – JLG Lift – 3121157

10. Pull out plunger sub assembly (33). 13. Remove collar (10), spring (9), and collar (8).
NOTE: Slowly pull it out while turning it. Be careful not to
damage the circumference. Reduction Gear Disassembly
14. Remove plugs (1-8), (1-5) and bolt (1-29). Tap the
center of cover (1-27) with plastic hammer. When
cover (1-27) starts to float up, remove cover (1-27).
11. Loosen plug (55), and pull out spring seat (59),
spring (58), and poppet (57).
15. Remove thrust plate (1-23) and drive gear (1-22).
12. After removing pin (12), retainer holder (13), retainer

plate (14), and piston sub assembly (15), remove
snap ring (11) by making spring (9) flex using a jig or
press.
3121157 – JLG Lift – 5-43

16. Remove planetary gear A (1-18) and needle bearing

(1-1), and then remove holder (1-17).
19. Loosen plug (1-5), and remove ring nut (1-4) using a
jig.
17. Remove sun gear B, and loosen screw (1-14) to

remove thrust plate (1-13).
20. Secure reduction gears (1) to angular bearing disas-

sembly jig, and place plate on flange holder (1-1).
Then, pull out press fit of angular bearing (1-3) by
pushing flange holder (1-1) with a press.
18. Remove planetary gear B (1-9), needle bearing (1-

10), floating bushing (1-11), and thrust washer (1-
12).
21. Remove angular bearing inner ring sub assembly (1-

3) and floating seal (1-2).
The disassembly procedure is now complete.
5-44 – JLG Lift – 3121157

Maintenance Standards For Disassembled Parts

Wash all parts disassembled in treated oil, and dry them with compressed air. Perform maintenance including replacement
or corrections in accordance with the following criterion.
Motor Maintenance
Parts Name Appearance Standard Value Allowance Replacement Parts

Piston sub assembly (15) When remarkable flaws or high surface *** *** Cylinder block kit
roughness are found on each sliding
surface
When clearance between piston sub 0.03 0.06
assembly and cylinder block bore is
great
When looseness in shoe ball parts is 0.15 0.4
great
Cylinder block (7) When remarkable flaws or high surface Roughness 0.2 a There should be no seizure Cylinder block kit / Perform
roughness are found on each sliding and remarkable flaws (over lapping (#1000). Replace if
surface 0.02 mm in thickness). flaws cannot be completely
removed.
When wear inside bore is great *** ***
When abnormal wear and breakage *** ***
develop on mating teeth
Valve plate - 26 When remarkable flaws or high surface Roughness 0.2 a Roughness 0.8 a There Cylinder block kit / Perform
roughness are found on each sliding should be no seizure and lapping (#1000). Replace if
surface remarkable flaws (over 0.02 flaws cannot be completely
mm in thickness). removed.
Retainer plate (14) / Retainer When remarkable flaws or high surface Roughness 0.2 a Roughness 0.8 a Retainer plate kit
holder (13) roughness are found on each sliding
surface
Swash plate (5) When remarkable flaws or high surface Roughness 0.2 a Roughness 0.8 a There Swash plate / Steel ball / Per-
roughness are found on each sliding should be no remarkable form lapping (#1000).
surface flaws (over 0.02 mm in thick- Replace if flaws cannot be
ness). completely removed.
When remarkable flaws or seizure are Ball depth 14.3 14.5
found on contact surface with steel balls
(10)
Shaft (2) When remarkable flaws or high surface Roughness 0.8 a Roughness 1.6 a Shaft
roughness are found on sliding surface
of oil seal (21)
When abnormal wear and breakage *** ***
develop on mating teeth
Brake piston (17) When remarkable flaws or high surface Wear amount 0 0.3 Brake piston / Friction plate
roughness are found in each sliding sur- Roughness 1 a
face 2.5a
Disk plate (16) When remarkable flaws or abrasion are Thickness 3.5 3.2 Disk plate
found on disks (friction material)
3121157 – JLG Lift – 5-45


Roller bearing (3) / Roller When flaking and abrasion develop on *** *** Roller bearing
bearing (28) rolling surface
When indentation is found on rolling sur- *** ***
face
When abnormality is found in rotation *** ***
(abnormal noise, irregular rotation)
Piston sub assembly (15) When remarkable flaws or high surface *** *** Piston sub assembly / Case
roughness are found on each sliding
surface
When clearance to case is great 0.020 0.040
When looseness in shoe ball parts is 0.5 1.0
great
Steel ball (6) When seizure is found on contact sur- *** *** Swash plate/ Steel ball
face with swash plate (9)
Plunger (33) When clearance to base plate (2-1) is 0.020 0.060 Base plate sub assembly
great
Base plate (32) When remarkable flaws or high surface *** *** Base plate sub assembly
When flaws which may cause oil leaks *** ***
are found
Spool (39) When remarkable flaws or high surface *** *** Base plate sub assembly
When clearance to base plate (32) is 0.025 0.050
great
Poppet (57) When remarkable flaws or high surface *** *** Base plate sub assembly
When clearance to base plate (32) is *** ***
great
When remarkable flaws or high surface *** ***
roughness are found on seat surface
When breakage or deformation is great Free length Each spring
Spring (9) 52.2 50.7
Spring (22) 37.7 36.2
Spring (25) 24.0 22.5
Spring (35) 51.7 50.2
Spring (40) 40.0 38.5
Spring (58) 45.0 43.5
5-46 – JLG Lift – 3121157

Reduction Gear Maintenance

Drive gear (1-22) / Sun gear When pitching (note 1) and abrasion *** *** Drive gear (1-22) / Sun gear
B (1-15) / Housing (1-6) develop on gear tooth surface B (1-15) / Housing (1-6)
Planetary gear A (1-18) / When pitching (note 1) and abrasion *** *** Planetary gear A (1-18) /
Planetary gear B (1-9) develop on gear tooth surface Planetary gear B (1-9)
When flaking and abrasion develop on *** ***
rolling surface of needle bearing
Needle bearing (1-19) / Inner When flaking and abrasion develop on *** *** Needle bearing (1-19) / Inner
race (1-20) / Needle bearing needle and rolling surface race (1-20) / Needle bearing
(1-10) / Floating bushing (1- (1-10) / Floating bushing (1-
11) 11)
When indentation is found on needle *** ***
and rolling surface
When abnormality is found in rotation of *** ***
bearings (abnormal noise, irregular
rotation)
Thrust washer (1-12) 3.5 3.4 Thrust washer (1-12)
Thrust plate (1-23) 2.6 2.5 Thrust plate (1-23)
3.0 2.9
3.4 3.3
Ring nut (1-4) When replaced Ring nut (1-4) / Plug (1-5)
Floating seal (1-2) When flaws that may cause oil leaks Floating seal (1-2)
develop on sliding surface
Thrust plate (1-13) When remarkable deformation is found 6 5.6 Thrust plate (1-13)
NOTE: Pitching in this instance refers to a case where pitching occurs in more than 10% of engagement area per tooth surface.
3121157 – JLG Lift – 5-47

5.11 PRECAUTIONS FOR REASSEMBLY 5.12 REASSEMBLY

1. Wash all parts in treated oil, and remove metal Perform reassembly in accordance with the following pro-
pieces and foreign substances. Ensure that there cedures. Reference exploded views of assembly Figure 5-
are no burrs or bruise. 21. and Figure 5-22., if necessary.
2. Replace seals, bearings and pins with new ones in

principle.
3. Take care not to damage seals at time of reassem-
bly. (Apply a small amount of grease prior to installa-
tion.)
4. Protect all cleaned parts from dusts, flaws and other
damages. Handle them with extreme care.
5. Tighten bolts to specified torque.
6. After reassembly, plug all ports with shipping plugs
to prevent dusts from entering.
1. Apply grease to floating seal (1-2) and install it on

flange holder (1-1).
NOTE: Apply grease or gear oil to seal surface.
2. Press fit both outer rings of angular bearing (1-3) to

housing (1-6).
3. Apply grease to the second floating seal (1-2) and

install it on housing (1-6).
NOTE: Apply grease or gear oil to seal surface.
5-48 – JLG Lift – 3121157

7. Fasten ring nut (1-4). Install ring nut between angu-

lar bearings and flange holder, and tightly fasten the
ring nut until there is no gap between the angular
bearings and flange holder. Measure the startup
4. Install inner ring sub assembly of the second angu- load at the housing mounting screw (M16) after a
lar bearing (1-3) on flange holder (1-1). couple of times rotation. This startup load is called F
[N]. Fasten ring nut so as to adjust the startup load
to be equal to F + (108 to 127) [N]. Tighten plug (1-
5). Do not apply seal tape to the plug. Caulk the plug
by punching at two diametrically opposed locations
to prevent the plug (1-5) from loosening.
5. Install housing (1-6) on flange holder (1-1).
8. Install thrust washer (1-12), floating bushing (1-11),

needle bearing (1-10) and planetary gear (1-9) to the
flange holder (1-1) in this order.
6. Install the second inner ring sub assembly of angu-

lar bearing (1-3) on flange holder (1-1).
9. Place thrust plate (1-13) and tightly fasten screw (1-

14) applied with Loctite #262.
NOTE: Degrease all parts prior to application of Loctite and

hardening agent.
3121157 – JLG Lift – 5-49

10. Assemble sun gear B (1-15) mounted with snap ring

(1-16).
13. Assemble thrust plate (1-23).
NOTE: Note: Before installation, select a thrust plate so that

A dimension will be 0.3 to 0.8 mm.
11. Assemble holder (1-17) mounted with inner race (1-

20) and spring pin (1-21).
14. Apply liquid gasket (ThreeBond 11041) evenly to the

circumference of contact surface of cover (1-27) and
housing (1-6), and assemble cover so that bolt holes
will align.
12. Assemble needle bearing (1-19) and planetary gear

A (1-18) in this order, and then assemble drive gear
(1-22).
5-50 – JLG Lift – 3121157

15. Apply Loctite #262 (16 locations) to bolt (1-29), and

tighten it to specified torque. Apply seal tape to 18. Assemble piston sub assembly (15) on retainer plate
plugs (1-8), (1-5) and tighten them to specified (14), and assemble it on cylinder block (7).
torque.
NOTE: Apply hydraulic fluid to the circumference of piston
sub assembly and nine holes on cylinder block.
16. Assemble collar (8), spring (9) and collar (10) on cyl-
inder block (7) in this order, and then assemble snap
ring (11).
19. Press oil seal (4) to flange holder (1-1), and assem-
ble outer ring sub-assembly of roller bearing (3).
17. Apply grease to pins (12) and insert each pin into
three holes on cylinder block (7). Then, assemble
retainer holder (13).
20. Assemble shaft (2) press fitted with inner ring of

roller bearing (3), engaging it with spline at tip of
drive gear (1-22).
NOTE: Apply grease to lips of oil seals. Insert shaft while

lightly turning it, taking care not to damage lips.
3121157 – JLG Lift – 5-51

21. Assemble steel ball (6), spring (25) and piston sub
assembly (24), and then assemble swash plate (5).
NOTE: Align hole on sphere of swash plate with steel ball.

After assembly, make sure, using aluminum rod, that 24. Assemble collar (21) on brake piston (17), and then
swash plate tilts and rolls smoothly with steel balls as assemble it on flange holder (1-1).
fulcrum and that it does not rotate.
NOTE: Make two pin holes on brake piston in line with two
pin holes on flange holder.
22. Assemble cylinder block sub assembly which have

been assembled in foregoing sections 16, 17 and
18, using spline of shaft as a guide. Then, assemble 25. Place a positioning jig, and insert brake piston by
disk (16) and friction plate (62). lightly tapping jig head evenly with a plastic hammer.
NOTE: Apply hydraulic fluid to swash plate. Make sure that

cylinder block sub assembly rotates smoothly and
that piston sub assembly moves freely.
26. Assemble spring (22) (8 pieces) on brake piston

(17), and O-rings (30), (31) on flange holder (1-1).
23. Assemble greased O-rings (18), (20) and back-up

rings (21), (54) on brake piston (17). Assemble
greased O-ring (54) on collar (21).
5-52 – JLG Lift – 3121157

27. Grip base plate (32) with vise, and assemble plunger 30. Assemble base plate on reduction gear.
sub assembly (33).
NOTE: Apply hydraulic fluid to sliding surface of cylinder
NOTE: Insert plunger sub assembly while slowly turning it. block. Pay attention to assembling direction of base
plate. Align pins with pin holes.
28. Assemble spring seat (34) and spring (35) in this

order. After assembling flange (37), tighten socket 31. Tighten socket head bolts (47) to specified torque.
head bolts (60) to specified torque.
NOTE: Note: Tighten the bolts evenly, as base plate is
pushed by spring.
29. Secure base plate (32) on workbench, and assem-

ble outer ring sub assembly (27) of roller bearing
(28), pin (27), pins (23) (4 pieces) and O-rings (43) 32. Assemble relief valve sub assembly (38) on base
(2 pieces), and then assemble valve plate (26). plate (32), and tighten it to specified torque. Assem-
ble poppet (57), spring (58) and spring seat (59) in
NOTE: Apply grease to non-sliding surface of valve plate this order, and tighten plug (41) to specified torque.
and to base plate. Be careful not to damage sliding
surface of valve plate.
3121157 – JLG Lift – 5-53

5.13 QUALITY CHECK AFTER REASSEMBLY

1. Air Leak Test of Reduction Gear Assembly
Remove one plug (1-8) of the reduction gear assem-
bly and apply compressed air (0.03 MPa) through
tapped hole of plug in water for two minutes, and
observe that there are no bubbles.
2. Air Leak Test of Motor
Seal all piping ports on the motor except one port
with plugs, and apply compressed air (0.3 MPa)
through open port in water. Observe that there are
33. Insert spool (39) and spring (40) into base plate, and no bubbles.
assemble plugs (41), (43) mounted with O-rings 3. Upon completion of leak tests in subparagraphs (1)
(42), (43), and then tighten them to specified torque. and (2) above, fill the motor case with fresh hydrau-
Assemble poppet (57), spring (58) and spring seat lic fluid. Run the motor crosswise for two minutes fill-
(59) in this order, and tighten plug (41) to specified ing hydraulic fluid at flow rate of 20 liters per minute.
torque. Verify that there is no excessive heat, vibration or
noise during running.
34. Assemble bonded seal (51) and socket head bolt

(50) in this order. Lubricate one location of socket
head bolt (50) with specified amount (2600 cc) of
tightening lubricant, and then tighten remaining plug
(45) and socket head bolt (50).
NOTE: Apply seal tape to plug (45).
The reassembly process is now complete.
5-54 – JLG Lift – 3121157

SECTION 6. TURNTABLE
6.1 SWING HUB 1. Check the frame to bearing. Attach bolts as follows:
a. Elevate the fully retracted boom to 70 degrees
Adjustment Procedures (full elevation).
b. At the positions indicated on Figure 2-45. try and
1. Ensure swing drive is located on bearing gear max insert the 0.0015" feeler gauge between the bolt
eccentric tooth (high spot). head and hardened washer at the arrow indi-
2. With mounting free to slide, shim between pinion cated position.
and bearing gear teeth to achieve 0.008 - 0.012 c. Assure that the 0.0015" feeler gauge will not
backlash. penetrate under the bolt head to the bolt shank.
3. Install a pry bar into hole in turntable base plate and d. Swing the turntable 90 degrees, and check
pry swing hub back tight against shim and bearing. some selected bolts at the new position.
e. Continue rotating the turntable at 90 degrees
4. Torque bolts according to the torque chart in Section
intervals until a sampling of bolts have been
1.
checked in all quadrants.
2. Check the turntable to bearing. Attach bolts as fol-
6.2 SWING BEARING lows:
a. Elevate the fully retracted boom to 70 degrees
Turntable Bearing Mounting Bolt Condition (full elevation).
Check b. At the positions indicated on Figure 2-45. try and
insert the 0.0015" feeler gauge between the bolt
NOTE: This check is designed to replace the existing bear- head and hardened washer at the arrow indi-
ing bolt torque checks on JLG Lifts in service. This cated position.
check must be performed after the first 50 hours of
c. Lower the boom to horizontal and fully extend
machine operation and every 600 hours of machine
the boom.
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
retorquing bolt or bolts recheck all existing bolts for
looseness.
Figure 6-1. Swing Torque Hub Adjustment
3121157 – JLG Lift – 6-1

d. At the position indicated on figure 2-45. try and 5. If bearing inspection shows no defects, reassemble
insert the 0.0015" feeler gauge between the bolt and return to service.
head and hardened washer at the arrow indi-
cated position.
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON
AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFTING
ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE
OF THIS, PROPER MAINTENANCE OF THE SWING BEARING
BOLTS IS A MUST FOR SAFE OPERATION.
TURNTABLE REF.
.0015" Feeler Gauge MEASURING SWING

POINT BEARING
Figure 6-2. Swing Bearing Bolt Feeler Gauge Check
Wear Tolerance FRAME REF.

1. From the underside of the machine, at rear center,
Figure 6-3. Swing Bearing Tolerance Measuring Point
with the boom fully elevated and fully retracted, as
shown in A, Figure 6-4., Swing Bearing Tolerance
Boom Placement, using a magnetic base dial indica-
tor, measure and record the distance between the Swing Bearing Replacement
swing bearing and turntable. (See Figure 6-3., Swing
Bearing Tolerance Measuring Point.) 1. Removal.
2. At the same point, with the boom at horizontal and a. From Ground Control station, operate the boom
fully extended, and the tower boom fully elevated as adequately to provide access to frame opening
shown in (Figure 6-4., Swing Bearing Tolerance or, if equipped, to rotary coupling.
Boom Placement) B, using a magnetic base dial
indicator, measure and record the distance between
the swing bearing and turntable. (See Figure 6-3., NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING
Swing Bearing Tolerance Measuring Point.) BOOM SAFETY PROP OR PROVIDING ADEQUATE OVERHEAD
3. If a difference greater than 0.079 in. (2.00 mm) is SLING SUPPORT AND/OR BLOCKING.
determined, the swing bearing should be replaced.
b. Attach an adequate support sling to the boom
4. If a difference less than 0.079 in. (2.00 mm) is deter- and draw all slack from sling. Prop or block the
mined, and any of the following conditions exist, the boom if feasible.
bearing should be removed, disassembled, and c. From inside turntable, remove mounting hard-
inspected for the following: ware which attach rotary coupling retaining yoke
a. Metal particles in the grease. brackets to turntable.
b. Increased drive power required.
c. Noise.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
d. Rough rotation. ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF
CONTAMINANTS INTO THE SYSTEM.
d. Tag and disconnect the hydraulic lines from the

fittings on the top of the rotary coupling. Use a
suitable container to retain any residual hydrau-
lic fluid. Immediately cap lines and ports.
e. Attach suitable overhead lifting equipment to the
base of the turntable weldment.
6-2 – JLG Lift – 3121157

Figure 6-4. Swing Bearing Tolerance Boom Placement
3121157 – JLG Lift – 6-3

f. Use a suitable tool to scribe a line on the inner

race of the swing bearing and on the underside
of the turntable. This will aid in aligning the bear- JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING
ing upon installation. Remove the bolts and BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE
washers which attach the turntable to the bear- THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN
ing inner race. Discard the bolts. THE FRAME AND TURNTABLE, IT IS IMPERATIVE THAT SUCH
g. Use the lifting equipment to carefully lift the com- REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE
plete turntable assembly from the bearing. OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
Ensure that no damage occurs to the turntable,
bearing or frame-mounted components. b. Apply a light coating of Loctite #271 to the new
bearing bolts, and loosely install the bolts and
h. Carefully place the turntable on a suitably sup-
washers through the frame and outer race of
ported trestle.
bearing.
i. Use a suitable tool to scribe a line on the outer
race of the swing bearing and the frame. This
line will aid in aligning the bearing upon installa-
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT
tion. Remove the bolts and washers which
WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT
attach the outer race of the bearing to the frame.
BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD
Discard the bolts. Use suitable lifting equipment
BE CHECKED PRIOR TO USE.
to remove the bearing from the frame, then
move the bearing to a clean, suitably supported c. Refer to the Torque Sequence diagram as
work area. shown in Figure 6-5., Swing Bearing Torque
2. Installation. Sequence. Spray a light coat of Safety Solvent
13 on the new bearing bolts. Then apply a light
a. Using suitable lifting equipment, carefully lower coating of Loctite #271 to the new bearing bolts,
the swing bearing into position on the frame. and install the bolts and washers through the
Ensure the scribed line of the outer race of the frame and outer race of the bearing. Tighten the
bearing aligns with the scribed line on the frame. bolts to an initial torque of 240 FT. LBS. (326
If a new swing bearing is used, ensure that the Nm) w/Loctite.
filler plug fitting is at 90 degrees from the fore
d. Remove the lifting equipment from the bearing.
and aft center line of the frame.
Figure 6-5. Swing Bearing Torque Sequence
6-4 – JLG Lift – 3121157

e. Using suitable lifting equipment, carefully posi- 6.3 SWING BRAKE - MICO
tion the turntable assembly above the machine
frame.
f. Carefully lower the turntable onto the swing
Disassembly
bearing, ensuring that the scribed line of the 1. With shaft protrusion downward, remove end cover
inner race of the bearing aligns with scribed line (13) by removing capscrews (12).
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.
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
g. Spray a light coat of Safety Solvent 13 on the
2000 POUNDS (681 KG). THE FOUR CAPSCREWS SHOULD BE
new bearing bolts. Then apply a light coating of
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC
Loctite #271 to the new bearing bolts, and
PRESS IS AVAILABLE (3000 LBS (1362 KG) MAXIMUM), THE
install the bolts and washers through the turnta-
COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP-
ble and inner race of the bearing.
SCREWS AND LOCKWASHERS.
h. Following the Torque Sequence diagram shown
in Figure 6-5., Swing Bearing Torque Sequence, 2. Remove case seal (11) from housing (7) then
tighten the bolts to a torque of 240 ft. lbs. (326 remove bleeder screw (14) from end cover (52).
Nm) w/Loctite.
3. Remove piston (22) from end cover (13).
i. Remove the lifting equipment.
j. Install the rotary coupling retaining yoke brack- 4. Remove o-ring (17), back-up ring (16), o-ring (19)
ets, apply a light coating of Loctite #242 to the and back-up ring (18) from piston (22).
attaching bolts and secure the yoke to the turn- 5. Remove separators (10) from housing (52).
table with the mounting hardware.
6. Remove stack assembly, consisting of discs (21),
k. Connect the hydraulic lines to the rotary cou-
return plate (8) and friction discs (20) from housing
pling as tagged prior to removal.
(52).
l. At ground control station, use boom lift control
to lower boom to stowed position. 7. Remove dowel pins (15), springs (5 & 6) from hous-
ing (52).
m. Using all applicable safety precautions, activate
the hydraulic system and check the swing sys- 8. Remove retaining ring (3) from housing (52).
tem for proper and safe operation.
9. Remove shaft by pressing or using a soft mallet on
male end of shaft (51).
Swing Bearing Torque Values.
10. Remove retaining ring (54) bearing (2) from shaft
1. Outer Race - 240 ft. lbs. (326 Nm) w/Loctite. (51).
2. Inner Race - 240 ft. lbs. (326 Nm) w/Loctite. 11. Press rotary seal (1) from housing (51).
3. See Swing Bearing Torquing Sequence.
Inspection
1. Clean all parts thoroughly.
CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR
MISSING OR LOOSENESS AFTER FIRST 50 HOURS OF OPERA- 2. Closely inspect all parts for excessive wear, cracks
TION, AND EVERY 600 HOURS THEREAFTER. 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 inspec-

tion, they are found to be in good condition.
3121157 – JLG Lift – 6-5

Figure 6-6. Swing Brake Assembly (Mico)
6-6 – JLG Lift – 3121157

Assembly 6.4 GENERATOR

NOTE: Lubricate all seals and o-rings with clean hydraulic Every 250 hours
oil prior to assembly.
Every 250 hours of operation, check the drive belt for
1. Press new rotary seal (1) into housing (52). Note the proper tension.
direction of seal.
2. Install new bearing (2) on shaft (51).
3. Install shaft assembly and retaining ring (3) into
housing (52).
1/2 in.
4. Install dowel pins (15), spring retainer (55), and
springs (5 & 6) into housing (52). (13 mm)
NOTE: Be sure to use the same number of springs and
spring pattern as recorded during disassembly.
5. Position new large diameter return plate (8) in hous-

ing with tabs guided by dowel pins (15) until disc
rests on springs (5 & 6).
Every 500 hours
NOTE: Discs (21 & 8) and friction discs (20) should remain
dry during installation. Oil will contaminate disc sur- Every 500 hours of operation, service the generator
faces. brushes and slip rings. Hostile environments may require
more frequent service.
6. Place new disc (20) on shaft (51) until it contacts
return plate (8).
7. Add additional discs (21) as required to complete
assembly.
8. Insert separators (10) in holes of return plate (8).
9. Install new o-ring (17), new back-up ring (16), new o-
ring (19) and new back-up ring (18) on piston (22).
Insert piston (22) into end cover (13), being careful
not to shear o-rings or back-up rings.
Every 500 hours of service, blow out the inside of the gen-
10. Install new case seal (11) in housing (52), then erator. If operating in a hostile environment, clean
install bleeder screw (14) in end cover. monthly.
11. Position end cover (13) on housing (52), aligning
dowel pins (15) with holes in end cover.
12. Insert capscrews (12) and tighten evenly to draw
end cover (13) to housing (52). Torque capscrews to
55 ft. lbs. (75 Nm).
3121157 – JLG Lift – 6-7

Overload Protection 6.5 SPARK ARRESTER CLEANING

INSTRUCTIONS
1. Remove the cleanout plug in the bottom of spark
STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE
arrester (muffler).
CIRCUIT BREAKER.
2. Without causing deformation (or any type of dam-
The circuit breaker protects the generator windings from age to the spark arrester) repeatedly tap on the
overload. If the circuit breaker opens, generator output arrester near the cleanout plug. This may be enough
stops. If the circuit breaker continues to open, check for to begin drainage of the spark trap.
faulty equipment connected to the platform receptacles.
3. An industrial vacuum cleaner can do a complete job
at this point.
a. Or, IN A SAFE AREA, start the engine. Then
alternate between low idle and high idle for two
to three minutes.
b. Or, operate the engine as required by the appli-
cation for two to three minutes.
4. Install the cleanout plug. (See Table 2-4. Preventive
CIRCUIT
BREAKER Maintenance and Inspection Schedule.)
6-8 – JLG Lift – 3121157

1. Battery 5. Air Cleaner 9. Front Right Engine Mounting Plate 13. Starter Relay
2. Battery Holddown 6. Fan 10. Front Bottom Engine Mounting Plate 14. Aux Pump Relay
3. Gear Pump 7. Motor Mount 11. Rear Engine Mounting Plate 15. Restriction Indicator
4. Piston Pump 8. Muffler 12. Radiator 16. Oil Drain Valve
Figure 6-7. Deutz Engine Installation - Sheet 1 of 2
3121157 – JLG Lift – 6-9

17. Engine Tray 22. Filler Cap 26. Fuel Filter 29. Temperature Sender
18. Engine Mounting Plate 23. Oil Lube Pump 27. Fuel Supply Pump 30. Oil Pressure Sensor
19. Hayes Coupling 24. Oil Filter 28. Alternator 31. Speed Sensor
20. Pump Adapter Plate 25. Injector Pump 28. Starter 32. Throttle Actuator
21. Dipstick
Figure 6-8. Deutz Engine Installation - Sheet 2 of 2
6-10 – JLG Lift – 3121157

6.6 DEUTZ EMR 2 (S/N 85110 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-
The sensors attached to the engine provide the electron- energized condition into the zero position. As a redun-
ics in the control unit with all the relevant physical parame- dancy measure, an additional solenoid serves for switch-
ters In accordance with the information of the current ing off and this, independently of the actuator, also moves
condition of the engine and the preconditions (throttle the control rod in the de-energized condition into the zero
position etc.), the EMR2 controls an actuator that operates position.
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
The exact position of the regulating rod is reported back engine. Included in this are the various application cases
and, if necessary, is corrected, by means of the control as well as the customer’s wishes regarding a particular
rod travel sensor, situated together with the rotation mag- scope of function.
nets in a housing of the actuator.
Each EMR2 module is matched by serial number to the
engine. Modules cannot be swapped between engines.
3121157 – JLG Lift – 6-11

CONTROL ROD POSI-

TION POWER SUP-
COOLANT TEMPERA- CAMSHAFT

TURE SPEED
JLG SYSTEM HANDLES ENGINE

START/STOP; EMR2 TAKES CON-
TROL OF THE ENGINE AT 700RPM
GLOW
JLG SYSTEM USES JLG ANA-

LYZER TO REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS;
OIL PRESSURE JLG SYSTEM USES THIS TO CONTROL
SENSOR THE ENGINE & FAULT REPORTING.
Figure 6-9. EMR 2 Engine Side Equipment
6-12 – JLG Lift – 3121157

3121157
– JLG Lift –
Figure 6-10. Deutz EMR 2 Troubleshooting Flow Chart
6-13
6-14
– JLG Lift –
Figure 6-11. Deutz EMR 2 Vehicle Side Connection Diagram
3121157
3121157
– JLG Lift –
Figure 6-12. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
6-15
6-16
– JLG Lift –
Figure 6-13. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3121157
Figure 6-14. EMR 2 Engine Plug Pin Identification
3121157 – JLG Lift – 6-17

Figure 6-15. EMR 2 Vehicle Plug Pin Identification
6-18 – JLG Lift – 3121157

Figure 6-16. EMR2 Fault Codes - Sheet 1 of 5
3121157 – JLG Lift – 6-19

6-20 – JLG Lift – 3121157

3121157 – JLG Lift – 6-21

6-22 – JLG Lift – 3121157

3121157 – JLG Lift – 6-23

1. Battery Hold-down 8. Muffler

2. Battery 9. Radiator
3. Air Cleaner 10. Starter Relay
4. Coolant Overflow Container 11. Glow Plug Relay
5. Pump Coupling 12. Aux Power Relay
6. Fan 13. Restriction Indicator
7. Engine Mount 14. Oil Drain Valve
Figure 6-21. Caterpillar Engine Installation - Sheet 1 of 2
6-24 – JLG Lift – 3121157

15. Engine Tray 22. Starter

16. Piston Pump 23. Dipstick
17. Gear Pump 24. Engine Temperature Sender
18. Fuel Filter 25. Throttle Actuator
19. Alternator 26. Fuel Supply Pump
20. Oil Pressure Switch 27. Water Pump
21. Oil Filter
Figure 6-22. Caterpillar Engine Installation - Sheet 2 of 2
3121157 – JLG Lift – 6-25

6.7 CAT DGC DIAGNOSTIC SUPPORT AND This section is organized in the following manner:
TROUBLE CODE DEFINITIONS 1st page of Diagnostic Information for a Given Fault (See
Figure 6-23.) then:
This section defines the diagnostics and recommended
troubleshooting procedures associated with the engine 2nd Page of Diagnostic Information for a Given Fault (See
control module (ECM) on the CAT 3.4 engine. Figure 6-24.)
DTC XXXX- Diagnostic Condition
Block Diagram of Circuit
External Hardware Input/Output- This identifies the hardware that either sends an input
to the ECM or is driven by and ECM output.
Check Condition- This defines what condition to troubleshoot the fault condition.
Fault Condition(s)- This identifies the condition(s) that set the fault.
Corrective Action(s)- This identifies the RECOMMENED corrective action(s) that the
ECM is generally programmed to perform. In some instances, the calibration
engineer(s) may choose to perform a different action.
Emissions or Non-emissions related fault
Text to identify the circuit of interest and its use for control.
Text to describe t he conditions that cause the fault to set.
Figure 6-23. 1st page of Diagnostic Information for a Given Fault
6-26 – JLG Lift – 3121157

DTC XXXX- Diagnostic Condition
Note: Helpful tips used to aid troubleshooting
Yes
Troubleshooting flow
chart
No
Figure 6-24. 2nd Page of Diagnostic Information for a Given Fault
3121157 – JLG Lift – 6-27

List of Abbreviations in this Section

AL Adaptive Learn LED Light Emitting Diode
BP Barometric Pressure LPG Liquefied Propane Gas
CAN Controller Area Network MAP Manifold Absolute Pressure
CCP CAN Calibration Protocol MGCP Marine Global Control Platform
CHT Cylinder Head Temperature μP Microprocessor
CL Closed Loop Mfg Manufacture
CNG Compressed Natural Gas MIL Malfunction Indicator Lamp
DBW Drive-By-Wire NG Natural Gas
DGC Diesel Governor Control OBD On-Board Diagnostics
DM Diagnostic Message OEM Original Equipment Manufacture
DMM Digital Multi-Meter (high impedance) PC Personal Computer
DST Diagnostic Scan Tool PCU Powertrain Control Unit
DTC Diagnostic Trouble Code PFI Port Fuel Injection
DVOM Digital Voltage and Ohm Meter (high impedance) PGN Parameter Group Number
ECI EControls Inc. PWM Pulse Width Modulated
ECIPP EControls Inc. Proprietary Protocol RAM Random Access Memory
ECM Engine Control Module RPM Revolutions Per Minute
ECT Engine Coolant Temperature Rx Receive
ECU Engine Control Unit SAE Society of Automotive Engineering
EDIS EControls Display and Interface Software SA Source Address
EGO Exhaust Gas Oxygen Sensor, typically heated SPFI Sequential Port Fuel Injection
EMWT Exhaust Manifold Water Temperature SPN Suspect Parameter Number
EPR Electronic Pressure Regulator Tach Tachometer
ERWT Exhaust Manifold Riser Temperature TBI Throttle Body Injection
ETB Electronic Throttle Body TDC Top Dead Center
ETC Electronic Throttle Control TIP Throttle Inlet Pressure
FDR Flight Data Recorder TPS Throttle Position Sensor
FMI Failure Mode Indicator TSC Torque/Speed Control
FO Firing Order Tx Transmit
6-28 – JLG Lift – 3121157

Universal Exhaust Gas Oxygen Sensor

FP Fuel Pressure UEGO
(also called wide-range EGO)
FPP Foot Pedal Position VDC Voltage, Direct Current
FRP Fuel Rail Pressure VR Variable Reluctance
FRT Fuel Rail Temperature Vsw Switched, Ignition Voltage
FSS Fault Snapshot WGP Waste-Gate Pressure
FT Fuel Temperature
GCP Global Control Platform
Heavy-Duty Global Control Platform

HDGCP
(On-Road Heavy-Duty)
HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S)
HO2S Heated Oxygen Sensor (same as HEGO)
IAC Idle Air Control
IAT Intake Air Temperature
ICAV Instant Crank Angle Velocity
IVS Idle Validation Switch
Light-Duty Global Control Platform (Industrial, Smart/

LDGCP
Logic Coil)
3121157 – JLG Lift – 6-29

Diagnostic Trouble Codes • Byte 15: Index into FSS_storage table for Fault Snap
Shot retrieval
The numeric diagnostic trouble codes assigned to the
faults in this section are cross-referenced to SAE’s "Rec- Resetting active and previously active DTCs is handled
ommended Practice for Diagnostic Trouble Code Defini- through DM11 and DM3, respectively DM1 and DM2 lamp
tions" (SAE J2012). While these codes are recommended, indicators are assigned to each fault based on the fault.s
the manufacturer may define their own codes by assign- diagnostic action as defined in the calibration. The lamps
ing a new number to the flash code in the diagnostic cali- are assigned based on the configuration outlined in Table
bration. This will assign both the DTC as displayed in 6-1.
EDIS as well as the flash code output on the MIL output
pin. EDIS may be used to connect to the DGC ECM via
Table 6-1. J1939 Diagnostic Lamp Configuration
CAN.
ECI DIAGNOSTIC ACTION J1939 LAMP
CAN
The DGC supports SAE J1939 CAN based diagnostic MIL MIL
support. This includes:
Soft Warning Amber
• DM1: Active Diagnostic Trouble Codes
• DM2: Previously Active Diagnostic Trouble Codes Hard Warning, Low Rev Limit,
Red Stop
Shutdown
• DM3: Diagnostic Data Clear/Reset of Previously Active
DTCs Power Derate 1 & 2 Protect
• DM4: Freeze Frame Parameters
None (use in combination with
• DM5: Diagnostic Readiness (bytes 1, 2, and 3 are sup- Forced Idle
other action)
ported)
• DM11: Diagnostic Data Clear/Reset For Active DTCs
MIL Output
• DM12: Emissions-Related Active Diagnostic Trouble The MIL output is used to convey fault information to the
Codes equipment operator. The MIL is always on (grounded)
• DM19: Calibration Information when the system is in a key-on (Vsw), engine-off state.
This provides assurance that the output is functional. If a
All diagnostic trouble codes broadcast over CAN will be DTC is logged as previously-active (historic), the MIL will
SAE J1939 DM1 and DM2 formatted messages. DGC send a single flash for the “Blink on-time” every “Blink off-
ECMs are compliant with J1939 OBD-M, supporting the time.”
Diagnostic Messages above as well as user indicators and
CAN data defined in the OBD-M protocol. Faults available
for broadcast and their respective SPN/FMI numbers are
dependent on the application and engine calibration.
There are 4 CAN SPN/FMI lists available in the DGC soft-
ware set, contact EControls Inc. for a list of CAN SPN/
FMIs.
The data capture at the occurrence of a fault, known in the
ECM as fault snapshot (FSS), is available upon DM4
request. The following bytes are supported for DM4 if con-
figured in the ECM software:
• Byte 1: Freeze Frame Length
• Byte 2-6: SPN, FMI, SPN Conversion Method, and
Occurrence
• Byte 7: Manifold Absolute Pressure
• Byte 8-9: Engine Speed
• Byte 10: Engine Load (MAP based estimate)
• Byte 11: Engine Coolant Temperature
• Byte 14: # of starts since fault was last active
6-30 – JLG Lift – 3121157

DTC 116- ECT Higher Than Expected Stage

1
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor Diagnostic Aids

• Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the
• Fault Condition-Engine Coolant Temperature reading troubleshooting procedures for that fault as it may have
or estimate greater than the stage 1 limit when operat- caused "ECT Higher Than Expected 1."
ing at a speed greater than defined in the diagnostic If the cooling system utilizes an air-to-water heat
calibration exchanger (radiator) and fan:
• Corrective Action(s): Sound audible warning or illumi-
• Check that the radiator has a proper amount of ethyl-
nate secondary warning lamp, disable adaptive learn
ene glycol/water and that the radiator is not leaking
fueling correction during active fault. Recommend a
power derate 1/2 and/or a low rev limit to protect • Ensure that there is no trapped air in the cooling path
engine from possible damage. • Inspect the cooling system (radiator and hoses) for
• Non-emissions related fault cracks and ensure connections are leak free
The Engine Coolant Temperature sensor is a thermistor • Check that the fan is operating properly
(temperature sensitive resistor) located in the engine cool- • Check that the thermostat is not stuck closed
ant. Some engines use a CHT sensor that is located in the
coolant in the cylinder head. Some engines use an ECT If the cooling system utilizes a water-to-water heat
(Engine Coolant Temperature) sensor that is located in the exchanger:
coolant near the thermostat. If the engine is equipped with • Check that the heat exchanger has a proper amount of
a CHT sensor then the ECT value is estimated. If equipped ethylene glycol/water and that the heat exchanger is
with an ECT sensor then the CHT value is estimated. They not leaking
are used for engine airflow calculation, ignition timing con-
trol, to enable certain features, and for engine protection. • Ensure that there is no trapped air in the cooling path
The ECM provides a voltage divider circuit so when the • Inspect the cooling system (radiator and hoses) for
sensor reading is cool the sensor reads higher voltage, cracks and ensure connections are leak free
and lower when warm.
• Check that the raw water pickup is not blocked/
This fault will help protect the engine in the event of over restricted by debris and that the hose is tightly con-
temperature. When the coolant exceeds x deg. F and nected
engine RPM exceeds y RPM for the latch time this fault will
set. • Check that the thermostat is not stuck closed
• Check that the raw water pump/impeller is tact and that
it is not restricted
3121157 – JLG Lift – 6-31

DTC 117- ECT/CHT Low Voltage
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor This fault will set if the signal voltage is less than the limit
defined in the diagnostic calibration anytime the engine is
• Check Condition-Engine Running
running. The limit is generally set to 0.10 VDC. The ECM
• Fault Condition-CHT/ECT sensor voltage less than the will use a default value for the CHT/ECT sensor in the
limit defined in the diagnostic calibration event of this fault.
• Corrective Action(s)- Sound audible warning or illumi-
nate secondary warning lamp, disable adaptive learn
fueling correction during active fault, or any combina-
tion thereof as defined in calibration. Recommend a
power derate 1/2 to reduce the possibility of engine
damage due to the inability to sense temperature.
• Non-emissions related fault
The Engine Coolant Temperature sensor is a thermistor
(temperature sensitive resistor) located in the engine cool-
ant. Some engines use an ECT sensor that is located in
the coolant near the thermostat. Some engines use a CHT
(Cylinder Head Temperature) sensor that is located in the
coolant in the cylinder head. If the engine is equipped with
an ECT sensor then the CHT value is estimated. If
equipped with a CHT sensor then the ECT value is esti-
mated. The ECM provides a voltage divider circuit so that
when the coolant is cool, the signal reads higher voltage,
6-32 – JLG Lift – 3121157

·Key On, Engine Running

·System Mode = “Running”
· Key Off
Does DST display an ECT Yes · Disconnect ECT sensor from harness
voltage less the limit
defined in calibration? · Key On, Engine Off
· System Mode = “Stopped”
No
· Intermittent Problem Yes

Does DST display ECT · Faulty ECT
voltage of 4.9 VDC or Sensor
greater?
No
· Sensor signal circuit shorted to ground,

check wire harness for ground short
· Faulty ECM
3121157 – JLG Lift – 6-33

DTC 118- ECT/CHT High Voltage
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor This fault will set if the signal voltage is higher than the
high voltage limit as defined in the diagnostic calibration
anytime the engine is running. The limit is generally set to
• Fault Condition-CHT/ECT sensor voltage higher than 4.90 VDC. In many cases, this condition is caused by the
the limit defined in the diagnostic calibration CHT/ECT sensor being disconnected from the engine har-
• Corrective Action(s)- Sound audible warning or illumi- ness, an open-circuit or short-to-power of the CHT/ECT
nate secondary warning lamp, disable adaptive learn circuit in the wire harness, or a failure of the sensor. The
fueling correction during active fault, or any combina- ECM will use a default value for the CHT/ECT sensor in
tion thereof as defined in calibration. Recommend a the event of this fault.
power derate 1/2 to reduce the possibility of engine
damage due to the inability to sense temperature.
The Engine Coolant Temperature sensor is a thermistor
ant. Some engines use an ECT sensor that is located in
the coolant near the thermostat. Some engines use a CHT
(Cylinder Head Temperature) sensor that is located in the
coolant in the cylinder head. If the engine is equipped with
an ECT sensor then the CHT value is estimated. If
equipped with a CHT sensor then the ECT value is esti-
mated. The ECM provides a voltage divider circuit so that
when the coolant is cool, the signal reads higher voltage,
6-34 – JLG Lift – 3121157

3121157 – JLG Lift – 6-35

DTC 122- TPS1 Signal Voltage Low
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor 1 This fault will set if TPS1 voltage is lower than the low volt-
age limit as defined in the diagnostic calibration at any
• Check Condition-Key On, Engine Off
operating condition while the engine is cranking or run-
• Fault Condition-TPS1 sensor voltage lower than the ning. The limit is generally set to 4.90 VDC. In many
limit defined in the diagnostic calibration cases, this condition is caused by the TPS sensor being
• Corrective Action(s): Sound audible warning or illumi- disconnected from the engine harness, an open-circuit or
nate secondary warning lamp, shutdown engine short-to-ground of the TPS circuit in the wire harness, or a
failure of the sensor. This fault should be configured to
• Non-emissions related fault trigger an engine shutdown and the engine will not start
In the case of a diesel engine, an actuator controls a fuel with this fault active.
injection pump, directly affecting the fueling level into the
cylinders. This may be by direct manipulation of the fuel
injection pump rack or by manipulation of the mechanical
governor control level or "throttle arm." In the DGC ECM
and EDIS, references to the throttle and throttle position
sensor refer to these fuel injection pump control actuators
and their position feedback sensors. When the fuel injec-
tion pump is electronically controlled it can be used to
control the idle stability and limit engine speed based on
operating conditions.
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit or
2) a non-contact hall-effect sensor to determine throttle
actuator position, and is located within the throttle actua-
tor.
There are two types of throttle actuators;
1) actuator with analog position feedback and
2) actuator with digital position feedback
The first type, with analog position feedback, provides an
analog return signal between 0 and 5 volts that is propor-
tional to the throttle actuator position. The second type,
with digital position feedback, provides a serial data signal
to the ECM with the throttle actuator position voltage level
encoded in the data stream.
6-36 – JLG Lift – 3121157

3121157 – JLG Lift – 6-37

DTC 123- TPS1 Signal Voltage High
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor 1 There are two types of throttle actuators, 1) actuator with
analog position feedback and 2) actuator with digital posi-
• Check Condition-Key On, Engine Off
tion feedback. The first type, with analog position feed-
• Fault Condition-TPS1 sensor voltage higher than the back, provides an analog return signal between 0 and 5
limit defined in the diagnostic calibration volts that is proportional to the throttle actuator position.
• Corrective Action(s): Sound audible warning or illumi- The second type, with digital position feedback, provides
nate secondary warning lamp, shutdown engine a serial data signal to the ECM with the throttle actuator
position voltage level encoded in the data stream.
This fault will set if TPS1 voltage is higher than the limit set
In the case of a diesel engine, an actuator controls a fuel in the diagnostic calibration at any operating condition
injection pump, directly affecting the fueling level into the while the engine is cranking or running. The limit is gener-
cylinders. This may be by direct manipulation of the fuel ally set to 4.90 VDC. In many cases, this condition is
injection pump rack or by manipulation of the mechanical caused by a short-to-power of the TPS circuit in the wire
governor control level or "throttle arm." In the DGC ECM harness or a failure of the sensor. This fault should be con-
and EDIS, references to the throttle and throttle position figured to trigger an engine shutdown and the engine will
sensor refer to these fuel injection pump control actuators not start with this fault active.
and their position feedback sensors. When the fuel injec-
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit or
2) a non-contact hall-effect sensor to determine throttle
actuator position, and is located within the throttle actua-
tor.
6-38 – JLG Lift – 3121157

3121157 – JLG Lift – 6-39

DTC 217- ECT Higher Than Expected 2
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor Diagnostic Aids

If the "ECT High Voltage" fault is also present, follow the
• Fault Condition-Engine Coolant Temperature reading troubleshooting procedures for that fault as it may have
or estimate greater than the stage 2 limit when operat- caused "ECT Higher Than Expected 2."
ing at a speed greater than defined in the diagnostic
calibration If the cooling system utilizes an air-to-water heat
exchanger (radiator) and fan:
• Corrective Action(s)- Sound audible warning or illumi-
nate secondary warning lamp, disable adaptive learn • Check that the radiator has a proper amount of ethyl-
fueling correction during active fault. Recommend a ene glycol/water and that the radiator is not leaking
power derate 2 and/or a forced idle or engine shut- • Ensure that there is no trapped air in the cooling path
down to protect engine from possible damage.
• Inspect the cooling system (radiator and hoses) for
• Non-emissions related fault cracks and ensure connections are leak free
The Engine Coolant Temperature sensor is a thermistor • Check that the fan is operating properly
• Check that the thermostat is not stuck closed
ant. Some engines use a CHT sensor that is located in the
coolant in the cylinder head. Some engines use an ECT If the cooling system utilizes a water-to-water heat
(Engine Coolant Temperature) sensor that is located in the exchanger:
coolant near the thermostat. If the engine is equipped with • Check that the heat exchanger has a proper amount of
a CHT sensor then the ECT value is estimated. If equipped ethylene glycol/water and that the heat exchanger is
with an ECT sensor then the CHT value is estimated. The not leaking
ECM provides a voltage divider circuit so when the sensor
reading is cool the sensor reads higher voltage, and lower • Ensure that there is no trapped air in the cooling path
when warm. • Inspect the cooling system (radiator and hoses) for
cracks and ensure connections are leak free
This fault will help protect the engine in the event of over
temperature. When the coolant exceeds x deg. F and • Check that the raw water pickup is not blocked/
engine RPM exceeds y RPM for the latch time this fault will restricted by debris and that the hose is tightly con-
set. nected
• Check that the thermostat is not stuck closed
• Check that the raw water pump/impeller is tact and that
it is not restricted
6-40 – JLG Lift – 3121157

DTC 219- RPM Higher Than Max Allowed

Governed Speed
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Max Govern Speed Override- Crankshaft Position Sen- Diagnostic Aids

sor
NOTE: If any other DTCs are present, diagnose those first.
• Ensure that no programmed governor speeds exceed
• Fault Condition-Engine speed greater than the max
the limit set in the diagnostic calibration for Max Gov
governor override speed as defined in the diagnostic
Override Speed
calibration
• Check mechanical operation of the throttle actuator
• Corrective Action(s): Sound audible warning or illumi-
nate secondary warning lamp, reduce throttle to limit
speed. Recommend closed loop and adaptive learn
fueling correction remains active during fault.
This fault will set anytime the engine RPM exceeds the
limit set in the diagnostic calibration for the latch time or
more. This speed overrides any higher max governor
speeds programmed by the user. This fault is designed to
help prevent engine or equipment damage.
The throttle will be lowered in order to govern the engine
to the speed set in the diagnostic calibration.
DTC 219- RPM Higher Than Max Allowed Governed
Speed (continued)
3121157 – JLG Lift – 6-41

DTC 336- Crank Signal Input Noise
2 WHITE/PURPLE PURPLE/WHITE
WHITE/PURPLE
1 PURPLE/WHITE
• Crankshaft Position sensor The ECM must see a valid crankshaft position signal while
running. If no signal is present, the signal amplitude is too
• Check Condition- Key On, Engine On
high (due to improper air gap with respect to trigger
• Fault Condition- Electrical noise or irregular crank pat- wheel), or an irregular crank pattern is detected causing
tern detected causing x number of crank resynchroni- the ECM to resynchronize x times for y ms or longer as
zation events as defined in the diagnostic calibration defined in the diagnostic calibration, this fault will set.
• Corrective Action(s)- Illuminate MIL and/or sound audi- Irregular crank patterns can be detected by the ECM due
ble warning or illuminate secondary warning lamp and to electrical noise, poor machining of trigger wheel, or trig-
disable adaptive fueling correction for remainder of ger wheel runout and/or gear lash.
key-cycle. Ensure crank circuit used with VR/magnetic pick-up sen-
• Emissions related fault sors are properly twisted.
The crankshaft position sensor is a magnetic sensor (vari-

able reluctant/magnetic pick-up or halleffect) installed in
the engine block adjacent to a "coded" trigger wheel
located on the crankshaft. The sensor-trigger wheel com-
bination is used to determine crankshaft position (with
respect to TDC cylinder #1 compression) and the rota-
tional engine speed. Determination of the crankshaft posi-
tion and speed is necessary to properly activate the
ignition, fuel injection, and throttle governing systems for
precise engine control.
6-42 – JLG Lift – 3121157

• Key On, Engine Running

• System Mode= “Running”
Operate engine at condition

that set fault based on fault
snapshot
Yes Is crank sensor a VR/ No Check wiring and electrical connections

Does DTC 336 reset ?
magnetic pick-up? between crankshaft position sensor and ECM
No Yes
No
Is the wiring OK? Repair wireharness
Intermittent fault
Yes
Faulty wireharness No Is wiring between sensor
(twist circuit) and ECM properly twisted?
• Poor system ground
• Bad crankshaft position sensor
• Bad ECM
Yes
Yes
Increase the air gap between Does fault only occur at
sensor and trigger wheel high operating speeds?
No
Check wiring and electrical connections

between crankshaft position sensor and ECM
No
Repair wireharness Is the wiring OK?
Yes
• Poor system ground

• Bad crankshaft position sensor
• Bad ECM
3121157 – JLG Lift – 6-43

DTC 337- Loss of Crank Input Signal
2 WHITE/PURPLE PURPLE/WHITE
WHITE/PURPLE
1 PURPLE/WHITE
• Crankshaft Position sensor The ECM must see a valid crankshaft position signal while
running. If no signal is present while x cam pulses con-
• Check Condition- Key On, Engine On
tinue the fault will set. The engine typically stalls or dies as
• Fault Condition- Loss of crankshaft position signal a result of this fault condition due to the lack of crankshaft
while valid camshaft position signals continue for x speed input resulting in the inability to control ignition tim-
number of cam pulses as defined in the diagnostic cal- ing.
ibration
DTC 337- Loss of Crank Input Signal (continued)
• Corrective Action(s)- Illuminate MIL and/or sound audi-
ble warning or illuminate secondary warning lamp Diagnostic Aids
• Emissions related fault • Check that crankshaft position sensor is securely con-
nected to harness
The crankshaft position sensor is a magnetic sensor (vari-
able reluctant/magnetic pick-up or halleffect) installed in • Check that crankshaft position sensor is securely
the engine block adjacent to a ¡§coded¡¨ trigger wheel installed into engine block
located on the crankshaft. The sensor-trigger wheel com- • Check crankshaft position sensor circuit wiring for
bination is used to determine crankshaft position (with open circuit
respect to TDC cylinder #1 compression) and the rota-
tional engine speed. Determination of the crankshaft posi-
tion and speed is necessary to properly activate the
ignition, fuel injection, and throttle governing systems for
precise engine control.
6-44 – JLG Lift – 3121157

DTC 521- Oil Pressure Sender/Switch High The ECM can be configured to monitor oil pressure
through a proportional transducer or through a switch. Oil
Pressure pressure monitoring is important to prevent engine dam-
age due to low oil pressure resulting in higher friction and
19 lack of lubrication. In addition, high oil pressure can be
BLACK/GREEN undesirable because it can cause oil to leak past seals
2 1 BLUE and rings, can be a result of a restriction in the oil flow
path, or can be a sign of a malfunctioning oiling system.
Additionally for normally-open type oil pressure switches,
a high pressure indication while the engine is off is a
symptom of a failed oil pressure switch. The ECM can
• Engine Oil Pressure monitor oil pressure indication when the engine is
stopped for this failure mode.
• Check Condition- Key on, Engine on (or Engine off)
• Fault Condition- For sender types, oil pressure higher For sender types, this fault sets if the engine oil pressure is
than x psia while engine speed is greater that y RPM. higher than x psia and engine speed greater than y RPM
For switch types, oil pressure is indicating high when as defined in the diagnostic calibration. For switch types,
the engine has been stopped for more than n seconds. this fault sets if the engine oil pressure is indicating high
when the engine is stopped for more than n seconds.
• Corrective Action(s)- Illuminate MIL and/or sound audi- Recommend a power derate and/or low rev limit to help
ble warning or illuminate secondary warning lamp, prevent possible engine damage and reduce oil pressure.
possibly configure for power derate 1 or low rev limit
Normally Closed Switch
• Key-On, Engine Off

• System Mode= “Stopped”
• Key Off
No • Disconnect harness from Oil Pressure switch
Does DTC 524 • Check continuity through switch to ground.
reset ?
Yes
Intermittent Problem
No • Oil Pressure circuit shorted-to-ground in harness

Is switch open?
• Faulty ECM
Yes
• Faulty Oil Pressure Switch (short circuit)

• Faulty engine oiling system (verify with
mechanical gauge)
3121157 – JLG Lift – 6-45

DTC 524- Oil Pressure Low For systems that use a transducer, this fault sets if the
engine oil pressure is less than x psia and engine speed is
greater than y RPM after the engine has been running for
19
z seconds as defined in the diagnostic calibration. For
BLACK/GREEN
2 1 BLUE systems that use a switch this fault can be configured two
different ways. It may use a normally closed switch or a
normally open switch. If the switch is normally open, the
fault will set if the circuit becomes grounded. If the switch
is normally closed, the fault will set if the circuit becomes
open. Go to the Faults page in EDIS to determine how the
input is configured. ("Open=OK" is normally open and
• Engine Oil Pressure
"Ground=OK" is normally closed). The engine will should
• Check Condition- Key on, Engine on be configured to derate or force idle and/or shut down in
• Fault Condition- Engine oil pressure lower than the event of this fault to help prevent possible damage.
expected while engine has been running for a mini-
mum amount of time while engine speed is above
some limit as defined in the diagnostic calibration
ble warning or illuminate secondary warning lamp,
generally configured to derate the engine and trigger
an engine shutdown
The ECM can be configured to monitor oil pressure
through a proportional transducer or through a switch. Oil
pressure monitoring is important to prevent engine dam-
age due to low oil pressure resulting in higher friction and
lack of lubrication. In addition, high oil pressure can be
undesirable because it can cause oil to leak past seals
and rings, can be a result of a restriction in the oil flow
path, or can be a sign of a malfunctioning oiling system.
6-46 – JLG Lift – 3121157

Normally Closed Switch
• Key-On, Engine On
• System Mode= “Running”
• Key Off
• Disconnect harness from Oil Pressure switch
• Jumper Oil Pressure signal wire to ground
• Warm engine at idle to normal • Clear DTC 524
operating temperature • Key On, Engine On
• Increase RPM above limit set • System Mode= “Running”
in diagnostic calibration • Operate engine et idle for at least one minute
• Increase RPM above limit set in diagnostic calibration
• Disconnect wireharness header from ECM

• Carefully remove yellow lock from header
Yes at device output terminal
Does DTC 524 • CAREFULLY check resistance between
reset ? Oil Pressure signal at ECM header and
Does DTC 524 Yes signal at sensor. NOTE: DO NOT
reset? INSERT probe or object into terminals
No as this will cause the terminal to
spread and may no longer make
No contact with ECM pin. Spread pins will
void warranty! Probe on the side of
Intermittent Problem terminal.
• Faulty Oil Pressure Switch (open circuit)
• Faulty engine oiling system (verify with
mechanical gauge)
• Faulty connection at sensor Yes Does DMM indicate a

• Faulty ECM resistance < 5.0 ohms?
No
• Faulty harness
(open circuit)
3121157 – JLG Lift – 6-47

DTC 562- Battery Voltage (VBat) Low
BLACK
RED/TAN
• System voltage to ECM The battery voltage powers the ECM and must be within
limits to correctly operate throttle actuator, power sup-
• Check Condition- Key on, Engine on
plies, and other powered devices that the ECM controls.
• Fault Condition- Battery voltage to ECM less than x
volts while the engine is operating at y RPM or greater This fault will set if the ECM detects system voltage less
as defined in the diagnostic calibration than x volts while the engine is operating at y RPM as
defined in the diagnostic calibration as the alternator
• Corrective Action(s)- Illuminate MIL and/or sound audi- should be charging the system.
ble warning or illuminate secondary warning lamp, dis-
able adaptive fueling correction for remainder of key
cycle
6-48 – JLG Lift – 3121157

3121157 – JLG Lift – 6-49

DTC 563- Battery Voltage (VBat) High
BLACK
RED/TAN
• System voltage to ECM The battery voltage powers the ECM and must be within
limits to correctly operate throttle acutator, power sup-
• Check Condition- Key on, Engine Cranking or Running
plies, and other powered devices that the ECM controls.
• Fault Condition- Battery voltage to ECM greater than x
volts while the engine is running as defined in the diag- This fault will set if the ECM detects system voltage
nostic calibration greater than x volts while the engine is running or cranking
as defined in the diagnostic calibration.
ble warning or illuminate secondary warning lamp, dis-
able adaptive fueling correction for remainder of key
cycle
6-50 – JLG Lift – 3121157

3121157 – JLG Lift – 6-51

DTC 601- Microprocessor Failure - FLASH
ECM
Microprocessor
RAM
• Engine Control Module- Flash Memory The ECM has checks that must be satisfied each time an
instruction is executed. Several different things can hap-
• Check Condition- Key on
pen within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error
If this fault sets, the ECM will reset itself and log the code.
• Corrective Action(s)- Illuminate MIL and/or sound audi- The fault should be configured to never forget and will not
ble warning or illuminate secondary warning lamp, dis- self-erase and will not clear until a technician performs
able adaptive fueling correction for remainder of key diagnostics and manually clears the code. This fault
cycle, recommend power derate 2 and low rev limit to should be configured to set a power derate 2 and low rev
reduce possible engine damage and/or overspeed limit to reduce possible engine damage and reduce possi-
condition bility of an overspeed condition. A fault of flash memory
• Non-emissions related fault can occur for any calibration variable set and thus could
cause undesirable operation.
6-52 – JLG Lift – 3121157

3121157 – JLG Lift – 6-53

DTC 604- Microprocessor Failure - RAM
ECM
Microprocessor
RAM
• Engine Control Module- Random Access Memory This fault will set if the ECM detects a problem accessing
or writing information to RAM and should be configured to
set a power derate 2 and low rev limit to reduce possible
• Fault Condition- Internal ECM microprocessor memory engine damage and reduce possibility of an overspeed
access failure condition. If this fault sets, the ECM will reset itself and log
• Corrective Action(s)- Illuminate MIL and/or sound audi- the code. This fault should be erased by a technician after
ble warning or illuminate secondary warning lamp, dis- diagnostics are performed. The fault should be configured
able adaptive fueling correction for remainder of key to never forget and will not self-erase.
cycle, recommend power derate 2 and low rev limit to
reduce possible engine damage and/or overspeed
condition
Random Access Memory is located within the micropro-
cessor and can be read from or written to at any time.
Data stored in RAM include DTCs (when fault configura-
tion is set to "Battery Power Retained"), adaptive fuel learn
tables, octane adaptation table, misfire adaption tables,
and closed loop fuel multipliers. The ECM has checks that
must be satisfied each time an instruction is executed.
6-54 – JLG Lift – 3121157

3121157 – JLG Lift – 6-55

DTC 606- Microprocessor Failure - COP
ECM
Microprocessor
RAM
• Engine Control Module The ECM has checks that must be satisfied each time an
• Fault Condition- Internal microprocessor error
If this fault sets, the ECM will reset itself and log the code.
• Corrective Action(s) - Illuminate MIL and/or sound The fault should be configured to never forget and will not
audible warning or illuminate secondary warning lamp, self-erase and will not clear until a technician performs
disable adaptive fueling correction for remainder of key diagnostics and manually clears the code. This fault
cycle, recommend power derate 2 and low rev limit to should be configured to set a power derate 2 and low rev
reduce possible engine damage and/or overspeed limit to reduce possible engine damage and reduce possi-
condition bility of an overspeed condition.
6-56 – JLG Lift – 3121157

3121157 – JLG Lift – 6-57

DTC 642- 5 Volt External Low Voltage
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Engine Control Module Diagnostic Aids

• Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the
• Fault Condition- ECM 5-volt output is below the accept- key on and the engine stopped. Verify that the output is
able limit lower than the fault thresholds configured in the diag-
nostic calibration.
ble warning or illuminate secondary warning lamp • Inspect the 5-Volt output circuit in the wire harness and
look for shorts to ground or other harness circuits.
• Disconnect each device powered by the 5-volt output
The ECM supplies 5-volt power to sensors, switches, and of the ECM one-at-a-time. Powered devices may
actuators external to the ECM. By supplying the power to include the throttle actuator, smart sensors, smart actu-
these devices, the ECM can accurately measure their out- ators, etc. After disconnecting device, observe the sys-
put relative to its own ground reference. The ECM can tem fault and determine if the fault has cleared. If the
also control when the devices are active and put the fault clears, troubleshoot the disconnected device for
devices in a low or no power state based on the current failures.
operating condition of the engine or vehicle.
• With all 5-volt powered devices disconnected, look for
If this fault sets, something other than the ECM is drawing a change in the fault state and measure the 5-volt out-
the 5-volt power output of the ECM below an acceptable put of the ECM and verify it is within acceptable limits.
threshold. This may be due to a short in the wire harness,
malfunctioning device, or failure of the ECM power output
circuitry.
6-58 – JLG Lift – 3121157

DTC 643- 5 Volt External High Voltage
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Engine Control Module Diagnostic Aids

• Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the
• Fault Condition- ECM 5-volt output is above the key on and the engine stopped. Verify that the output is
acceptable limit lower than the fault thresholds configured in the diag-
nostic calibration.
ble warning or illuminate secondary warning lamp • Inspect the 5-Volt output circuit in the wire harness and
look for shorts to ground or other harness circuits.
• Disconnect each device powered by the 5-volt output
The ECM supplies 5-volt power to sensors, switches, and of the ECM one-at-a-time. Powered devices may
actuators external to the ECM. By supplying the power to include the throttle actuator, smart sensors, smart actu-
these devices, the ECM can accurately measure their out- ators, etc. After disconnecting device, observe the sys-
put relative to its own ground reference. The ECM can tem fault and determine if the fault has cleared. If the
also control when the devices are active and put the fault clears, troubleshoot the disconnected device for
devices in a low or no power state based on the current failures.
operating condition of the engine or vehicle.
• With all 5-volt powered devices disconnected, look for a
If this fault sets, something other than the ECM is drawing change in the fault state and measure the 5-volt output
the 5-volt power output of the ECM above an acceptable of the ECM and verify it is within acceptable limits.
threshold. This may be due to a short in the wire harness,
malfunctioning device, or failure of the ECM power output
circuitry.
3121157 – JLG Lift – 6-59

DTC 1612- Microprocessor Failure - RTI 1
ECM
Microprocessor
RAM
• Fault Condition- Internal microprocessor error The ECM will reset itself in the event this fault is set, and
• MIL- On until code is cleared by technician the MIL will be on until the code is cleared. This fault
should be erased after diagnosis by removing battery
• Adaptive- Disabled for the remainder of the key-on power. It will not self-erase.
cycle
During this active fault, Power Derate (level 2) will be
• Closed Loop- Enabled enforced. When this is enforced, maximum throttle posi-
• Power Derate (level 2 until fault is cleared manually) tion will be 20%. This is enforced until the fault is manually
cleared.
6-60 – JLG Lift – 3121157

ECM
Microprocessor
RAM
cycle
cleared.
3121157 – JLG Lift – 6-61

SFC 555- RTI 2 Loss
Key On - Engine Running

System Data Mode
Check all power and

Clear System Fault
ground circuits to ECM
Does SFC 555 reset Yes

with engine idling?
Yes Replace ECM with known
Are all circuits ok?
good part and retest
No
No
Fault is intermittent
Repair wiring to
ECM and retest
6-62 – JLG Lift – 3121157

ECM
Microprocessor
RAM
cycle
cleared.
3121157 – JLG Lift – 6-63

SFC 556- RTI 3 Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 556 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
6-64 – JLG Lift – 3121157

DTC 1615- Microprocessor Failure - A/D
ECM
Microprocessor
RAM
cycle
cleared.
3121157 – JLG Lift – 6-65

SFC 513- A/D Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 513 reset

with engine idling?
Yes
Replace ECM with known
No
No
Repair wiring to
ECM and retest
6-66 – JLG Lift – 3121157

DTC 1616- Microprocessor Failure -

interrupt
ECM
Microprocessor
RAM
cycle
cleared.
3121157 – JLG Lift – 6-67

SFC 512- Invalid Interrupt

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 512 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
6-68 – JLG Lift – 3121157

DTC 1625- CAN J1939 Shutdown Request
BLUE/RED or PINK
BLUE/WHITE
• Controller Area Network Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running • The ECM has shutdown the engine upon command by
• Fault Condition- ECM has received shutdown message a external controller. This is the requested and
from another CAN device and is shutdown on request. expected behavior.
• Corrective Action(s)- Illuminate MIL, sound audible
warning or illuminate secondary warning lamp
In some situations, external controllers may send a
request to the ECM to shutdown engine operation and
stop the engine. This request may be sent in response to
a safety related condition in the vehicle.
This fault will set if the ECM receives the J1939 shutdown
request via the CAN interface. This is the expected behav-
ior.
3121157 – JLG Lift – 6-69

DTC 1626- CAN J1939 Transmit (Tx) Fault
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are prop-
• Fault Condition- ECM CAN transceiver transmit error erly grounded
counts greater than the limit defined in the diagnostic • Verify that the CAN network is properly terminated
calibration (must be < 125 failures)
• Check CAN wire routing with respect to noise sources
• Corrective Action(s)- Illuminate MIL, sound audible (ignition coils, spark plug coil wires, etc.) and shield if
warning or illuminate secondary warning lamp necessary
• Non-emissions related fault • Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communica-
tion network used to transmit and receive data between
intelligent devices. Systems that utilize CAN communica-
tion include smart actuators, smart sensors, dash panels
and gauges, and other microcomputers. Each smart sen-
sor, actuator, or controller incorporates a CAN transceiver
that interprets logic level signals on the network and trans-
lates the information into digital data.
This fault will set if CAN communication is enabled and the
ECM transceiver broadcasts a number of packets (as
defined in the diagnostic calibration, must be set to less
than 125 failures) to the network that are not received.
6-70 – JLG Lift – 3121157

DTC 1627- CAN J1939 Receive (Rx) Fault
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are prop-
• Fault Condition- ECM CAN transceiver receive error erly grounded
counts greater than the limit defined in the diagnostic • Verify that the CAN network is properly terminated
calibration (must be < 125 failures)
• Check CAN wire routing with respect to noise sources
• Corrective Action(s)- Illuminate MIL, sound audible (ignition coils, spark plug coil wires, etc.) and shield if
warning or illuminate secondary warning lamp necessary
• Non-emissions related fault • Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communica-
tion network used to transmit and receive data between
intelligent devices. Systems that utilize CAN communica-
tion include smart actuators, smart sensors, dash panels
and gauges, and other microcomputers. Each smart sen-
sor, actuator, or controller incorporates a CAN transceiver
that interprets logic level signals on the network and trans-
lates the information into digital data.
This fault will set if CAN communication is enabled and the
ECM transceiver is expecting to see network traffic and
either does not see traffic (as defined in the diagnostic cal-
ibration, must be set to less than 125 failures).
3121157 – JLG Lift – 6-71

DTC 1628- CAN Address Conflict Failure
BLUE/RED or PINK
BLUE/WHITE
• CAN device(s) The Controller Area Network serves as a communication

portal between intelligent devices. These devices may be
• Check Condition- Key On, Engine on
but are not limited to other engine ECMs (slave), diagnos-
• Fault Condition- two or more devices on the network tic tools, "smart" gauges, "smart" sensors, powertrain con-
that contain the same SA trol units, vehicle controllers, actuators, etc. The network
• Corrective Action(s)- Sound audible warning or illumi- permits several devices to communicate with each other
nate secondary warning lamp receiving and broadcasting commands as programmed.
This type of network allows devices to be added to an
• Non-emissions related fault entire system through only two conductors and permits all
other devices to broadcast and receive commands to and
from the device when properly commanded.
This fault indicates that there are two (2) or more devices
on the network that use the same source address.
6-72 – JLG Lift – 3121157

3121157 – JLG Lift – 6-73

DTC 1629- J1939 TSC1 Message Reciept

Loss
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Running • Verify that that the CAN device generating the TSC1
• Fault Condition- ECM is expecting to receive J1939 message is powered and properly grounded
TSC1 messages and has not received a message for • Verify that the CAN network is properly terminated
more than n seconds (as defined in the diagnostic cali-
bration). • Check CAN wire routing with respect to noise sources
(ignition coils, spark plug coil wires, etc.) and shield if
• Corrective Action(s)- Illuminate MIL, sound audible necessary
warning or illuminate secondary warning lamp. Govern
engine speed at a forced idle. • Check CAN (+) and (-) wires for short circuits

J1939 TSC1 may be used to send a commanded (or
desired) engine speed to the ECM. If configured, the ECM
will govern the engine speed to this commanded speed if
possible. When operating in this mode, the ECM expects
to receive TSC1 messages on a regular interval. When this
message is not received, the ECM must operate the
engine at a default idle speed until commanded to do oth-
erwise.
This fault will set if CAN communication is enabled, the
engine is running, and no TSC1 messages are received
over the CAN bus for more than n seconds (as determined
by the diagnostic calibration).
6-74 – JLG Lift – 3121157

DTC 1652- TPS1 Loss of Communications
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Actuator (with serial/digital position feedback) Diagnostic Aids

• Check Condition- Key On, Engine Running and/or • Verify that the throttle actuator 5V supply voltage is
Stopped present at the actuator.
• Fault Condition- ECM is expecting to receive throttle • Check for a all four TPS feedback wires for short cir-
position information from the throttle actuator and is cuits.
not.
• Check TPS SER+ and TPS SER- wire routing with
• Corrective Action(s)- Illuminate MIL, sound audible respect to noise sources (ignition coils, spark plug coil
warning or illuminate secondary warning lamp. Shut- wires, etc.) and shield if necessary.
down engine.
In the case of a throttle actuator with serial/digital position
feedback, the ECM receives a constant data stream from
the throttle actuator. If the communication is absent or
interrupted, the ECM can no longer control the position of
the throttle.
This fault will set if the key is on, the throttle actuator is
receiving power, and the ECM is not receiving digital infor-
mation from the actuator.
3121157 – JLG Lift – 6-75

DTC 2111- Unable to Reach Lower TPS
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable
resistor and voltage divider circuit or 2) a non-contact hall-
• Check Condition-Cranking or Running
effect sensor to determine throttle actuator position, and is
• Fault Condition-Throttle command is 20% less than located within the throttle actuator.
throttle position for 200ms or longer
There are two types of throttle actuators, 1) actuator with
• MIL-On during active fault analog position feedback and 2) actuator with digital posi-
• Engine Shut Down tion feedback. The first type, with analog position feed-
back, provides an analog return signal between 0 and 5
In the case of a diesel engine, an actuator controls a fuel volts that is proportional to the throttle actuator position.
injection pump, directly affecting the fueling level into the The second type, with digital position feedback, provides
cylinders. This may be by direct manipulation of the fuel a serial data signal to the ECM with the throttle actuator
injection pump rack or by manipulation of the mechanical position voltage level encoded in the data stream.
and EDIS, references to the throttle and throttle position This fault will set if the throttle command is 20% less than
sensor refer to these fuel injection pump control actuators the actual throttle position. During this active fault the MIL
and their position feedback sensors. When the fuel injec- light will be on and the engine will shut down.
6-76 – JLG Lift – 3121157

3121157 – JLG Lift – 6-77

DTC 2112- Unable to Reach Higher TPS
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable
resistor and voltage divider circuit or 2) a non-contact hall-
• Check Condition-Cranking or Running
effect sensor to determine throttle actuator position, and is
• Fault Condition-Throttle command is 20% more than located within the throttle actuator.
actual throttle position
There are two types of throttle actuators, 1) actuator with
• MIL-On during active fault analog position feedback and 2) actuator with digital posi-
• Engine Shut Down tion feedback. The first type, with analog position feed-
back, provides an analog return signal between 0 and 5
In the case of a diesel engine, an actuator controls a fuel volts that is proportional to the throttle actuator position.
injection pump, directly affecting the fueling level into the The second type, with digital position feedback, provides
cylinders. This may be by direct manipulation of the fuel a serial data signal to the ECM with the throttle actuator
injection pump rack or by manipulation of the mechanical position voltage level encoded in the data stream.
and EDIS, references to the throttle and throttle position This fault will set if the throttle command is 20% or more
sensor refer to these fuel injection pump control actuators than the actual throttle position. During this active fault the
and their position feedback sensors. When the fuel injec- MIL light will be on and the engine will shut down.
6-78 – JLG Lift – 3121157

DTC 9999- Throttle Actuator Failsafe

Spring Failure
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Actuator Diagnostic Aids

• Check Condition- Key Off, Engine Stopped • Disconnect the throttle actuator from the wire harness.
• Fault Condition- When the key is off (or the actuator is Remove the throttle actuator from the engine and man-
unpowered), the ECM is expecting the failsafe spring in ually move it. Verify that the internal spring forces the
the actuator to return the throttle position to near 0%. If throttle back to near 0% position.
the throttle does not reach this position when the actu- • Inspect the throttle arm or fuel rack on the fuel pump.
ator is powered, a fault is generated. Verify that it is not stuck.
• Corrective Action(s)- Illuminate MIL, sound audible
warning or illuminate secondary warning lamp. Govern
the engine speed to a forced idle speed.
The throttle actuator has a return spring that causes the
throttle to move to a near 0% position when powered off.
This causes the engine to shutdown following a key off. If
the ECM detects the throttle position to be above x volts
when the key is off (as determined by the diagnostic cali-
bration), it will power up the actuator and attempt to drive
it to a zero position. This should ensure that the engine is
stopped.
This fault will set if the throttle does not return to a near 0%
position with the key is off.
3121157 – JLG Lift – 6-79

DTC to SPN/FMI Table
FAULT DTC SET

DESCRIPTION
INDEX SPN FMI
2 DTC 118: ECT voltage high 110 3
3 DTC 117: ECT voltage low 110 4
4 DTC 116: ECT higher than expected stage 1 110 15
9 DTC 563: Vbat voltage high 168 15
10 DTC 562: Vbat voltage low 168 17
11 DTC 643: Sensor supply voltage 1 high 1079 3
12 DTC 642: Sensor supply voltage 1 low 1079 4
13 DTC 123: TPS1 voltage high 51 3
14 DTC 122: TPS1 voltage low 51 4
29 DTC 524: Oil pressure low 100 1
86 DTC 217: ECT higher than expected stage 2 110 0
89 DTC 2112: Unable to reach higher TPS 51 7
90 DTC 2111: Unable to reach lower TPS 51 7
96 DTC 336: CRANK input signal noise 636 2
98 DTC 606: Microprocessor failure - COP 629 31
99 DTC 1612: Microprocessor failure - RTI 1 629 31
102 DTC 1615: Microprocessor failure - A/D 629 31
103 DTC 1616: Microprocessor failure - Interrupt 629 31
104 DTC 601: Microprocessor failure - FLASH 628 13
105 DTC 604: Microprocessor failure - RAM 630 12
106 DTC 219: RPM higher than max allowed govern speed 515 15
144 DTC 337: Crank signal loss 636 4
145 DTC 1625: J1939 shutdown request 1384 31
146 DTC 1626: CAN-J1939 Tx fault 639 12
147 DTC 1627: CAN-J1939 Rx fault 639 12
175 DTC 1628: J1939 CAN address / engine-number conflict 639 13
188 DTC 521: Oil pressure high 100 0
189 DTC 1652: TPS1 loss of communications 51 9
190 DTC 1629: CAN-J1939 TSC1 Parameter Rx Fault 695 9
191 DTC 1113: Unable to achieve lower RPM 515 31
192 DTC 9999: TPS1 failsafe spring failure 51 7
6-80 – JLG Lift – 3121157

SECTION 7. BOOM & PLATFORM
7.1 PLATFORM 7.2 BOOM ROPE TORQUING PROCEDURES
Platform Sections Replacement Torque Procedures

The platform is made up of five sections: floor, right side,
1. Position boom in fully down and fully retracted posi-
left side, back (console box mounting.) and gate. The sec-
tion.
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 7-2. Dimensions of Boom Sections
2. Clamp both threaded ends of wire rope to prevent

rotation.
NOTE: Do not clamp on threads.
Figure 7-1. 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.
Figure 7-3. Clamping Wire Ropes
3. Install adjusting nuts (or remove nylon collar lock-

nuts if re-adjusting) to both retract and extend wire
ropes.
4. Torque retract adjusting nuts (platform end) to 15 ft.
lbs. (20 Nm) alternating between the two wire ropes
and keeping approximately the same amount of
thread beyond the adjusting nut.
NOTE: Do not allow wire rope to rotate. This may damage

the wire rope.
3121157 – JLG Lift – 7-1

5. Repeat the torque procedure in step #4 to the

extend wire ropes (turntable end).
6. Extend the boom 2 - 3 feet using the telescope func-
tion. Repeat step #4.
7. Retract the boom 1 - 2 feet using the telescope func-
tion. Do not bottom out telescope cylinder. Repeat
step #5.
8. Extend the boom approximately 2 - 3 feet again and
check torque on the retract wire ropes.
9. Retract the boom without bottoming out telescope
cylinder and check torque on the extend wire ropes.
NOTE: Step #8 and #9 may need to be repeated to equalize

the torque on all 4 wire ropes.
10. After all wire ropes have been properly torqued,

install nylon collar locknuts. Remove all clamping
devices and install all covers and guards. Check the
boom for proper function.
7.3 WEAR PADS
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 Figure 7-4. Location and Thickness of Wear Pads
used so bolt does not protrude from insert and
come into contact with boom surface.
7-2 – JLG Lift – 3121157

7.4 WIRE ROPE Three Month Inspection

NOTE: The pictures in this paragraph are just samples to 1. Remove boom covers and visually (with flashlight)
show the replacement criteria of the rope. inspect the ropes for rust, broken wires, frays,
abuse, or any signs of abnormalities.
Inspection 2. Check rope tension by deflecting the ropes by
hand...properly tensioned ropes should have little or
1. Inspect ropes for broken wires, particularly valley
no movement.
wire breaks and breaks at end terminations.
12 Year or 7000 Hour Replacement

1. Mandatory wire rope and sheave replacement.
Additional inspection required if:
Flexing a wire rope can often expose broken wires a. Machine is exposed to hostile environment or
hidden in valleys between strands. conditions.
b. Erratic boom operation or unusual noise exists.
1. Inspect ropes for corrosion. c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.
2. Inspect ropes for kinks or abuse.
e. Boom exposed to electrical arc...wires may be
fused internally.
Additional Replacement Criteria

1. Sheaves and wire rope must be replaced as sets.
A kink is caused by pulling down a loop 2. Rusted or corroded wire ropes.
in a slack line during improper handling,
installation, or operation. 3. Kinked, “bird caged”, or crushed ropes.
4. Ropes at end of adjustment range.
1. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.) 5. Sheaves failing wearout gage inspection.
2. Inspect sheaves for condition of flanges. (See 6. Ropes with 6 total broken wires in one rope lay, 3 in
Dimension Of Sheaves for proper dimension.) one strand in one rope lay, 1 valley break, or 1 break
at any end termination.
3. Inspect sheaves with a groove wearout gauge for
excessive wear.
7.5 BOOM MAINTENANCE
Removal
1. Remove the platform/support as follows:
a. Disconnect electrical cable from control con-
sole.
b. Remove the eight (8) bolts securing the platform
to the platform support, then remove the plat-
Observe the groove so that it may be clearly seen form.
whether the contour of the gauge matches the
contour of the bottom of the groove. c. Using an overhead crane or suitable lifting
device, strap support the platform support.
1. Ropes passing inspection should be lubricated with
d. Remove the six (6) bolts and locknuts securing
wire rope lubricant before reassembly.
the support to the rotator.
3121157 – JLG Lift – 7-3

Figure 7-5. Boom Assembly Cutaway - Sheet 1 of 3
7-4 – JLG Lift – 3121157

3121157 – JLG Lift – 7-5

e. Using a suitable brass drift and hammer, remove b. Remove hardware from pin #1. Using a suitable
the rotator shaft, then remove the support from brass drift and hammer remove pin #1 from the
the rotator. fly boom.
c. Supporting the rotator, remove the hardware
from pin #2. Using a suitable brass drift and
hammer, remove pin #2 from the fly boom and
remove the rotator.
d. Telescope the fly section out approximately 20
inches (50.8 cm) to gain access to the slave lev-
eling cylinder.
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 7-8. Location of Components - Platform Support
f. Tag and disconnect hydraulic lines to the slave
leveling cylinder. Use a suitable container to
2. Remove the rotator and slave level cylinder from the
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.
7-6 – JLG Lift – 3121157

retain any residual hydraulic fluid. Cap hydraulic securing rail to the base boom section. Remove
lines and ports. Remove the slave cylinder. powertrack from boom section.
Figure 7-10. Location of Components - Boom Pow-
4. Remove boom assembly from machine as follows:

a. Using suitable lifting equipment, adequately
support boom assembly weight along entire
length.
Figure 7-9. Location of Components - Rotator and
Leveling Cylinder

3. Remove the powertrack from the boom as follows:
ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON-
a. Disconnect wiring harness from ground control TAMINANTS INTO SYSTEM.
box.
b. Tag and disconnect hydraulic lines from tele-
scope cylinder. Use a suitable container to retain
any residual hydraulic fluid. Cap hydraulic lines
and ports.
ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON-
TAMINANTS INTO SYSTEM. c. Remove hardware securing the lift cylinder rod
end to the base boom section.
b. Tag and disconnect hydraulic lines from boom d. Using a suitable brass drift and hammer, remove
to control valve. Use a suitable container to the lift cylinder pin from the base boom.
retain any residual hydraulic fluid. Cap hydraulic e. Remove hardware securing the master cylinder
lines and ports. rod end to the base boom section.
c. Disconnect the dual capacity indicator limit f. Using a suitable brass drift and hammer, remove
switch from side of boom section. the master cylinder pin from the base boom.
d. Remove hydraulic lines and electrical cables g. Remove hardware securing the pushbar to the
from powertrack. turntable upright.
e. Using a suitable lifting equipment, adequately
support powertrack weight along entire length.
f. Remove bolts #1 securing the push tube on the WHEN REMOVING PIN FROM PUSHBAR. CARE MUST BE TAKEN
fly boom section. NOT TO DROP THE PUSHBAR ONTO THE WIRE ROPE ADJUST-
g. Remove bolts #2 securing the push tube on the MENT THREADS. FAILURE TO DO SO WILL RESULT IN DAMAGING
mid boom section. THREADS.
h. With powertrack support and using all applica-
ble safety precautions, remove bolts #3 and #4 h. Using a suitable brass drift and hammer, remove
the push bar pin from the turntable upright.
i. Remove hardware securing the boom pivot pin
to the turntable upright.
j. Using a suitable brass drift and hammer, remove
the pivot pin from the turntable upright.
k. Using all applicable safety precautions, carefully
lift boom assembly clear of turntable and lower
to ground or suitably supported work surface.
3121157 – JLG Lift – 7-7

Disassembly of Boom Sections c. Remove hardware from the sheave pin; remove
pin and sheave from cylinder.
1. Remove hardware securing the push bar to aft end
of the telescope cylinder, then remove pin from cyl-
inder.
2. Remove hardware securing the cover plate on the
bottom front of the base boom section.
NOTE: Do not allow wire rope to rotate. This may damage

the wire rope.
3. Clamp both threaded ends of wire rope to prevent

rotation. Note: Do not clamp on threads. Remove
jam nuts and nuts which secure the wire rope
adjustments to the bottom front of the base boom
section.
4. Remove hardware securing the wire rope adjust-
ment block to aft end of the base boom section and
remove the block.
Figure 7-11. Disassembly of Sheave Assembly
5. Remove hardware securing the telescope cylinder
to aft end of the mid boom section.
9. Remove hardware which secures the wear pads to
the front of base boom section; remove wear pads
from the top, sides and bottom of the base boom
WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM, section.
IT MAY BE NECESSARY AT SOME POINT IN ORDER TO CLEAR
ASSEMBLIES MOUNTED WITHIN THE BOOM. CARE MUST BE 10. Using an overhead crane or suitable lifting device,
TAKEN TO MOVE THE CYLINDER SLOWLY FROM THE BOOM. remove mid and fly boom sections from base sec-
DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE tion. Note: When removing mid and fly boom sec-
IMPACT WITH THESE ASSEMBLIES. tions from base boom section, retract wire rope
must be dragged along with boom sections.
6. Remove bolts securing wire rope attach bar to top of 11. Remove hardware which secures the wear pads to
fly boom section. the aft end of mid boom section; remove the wear
7. Pull the telescope cylinder and wire ropes partially pads from the top, sides and bottom of the mid
from aft end of the base boom section; secure the boom section.
cylinder with a suitable sling and lifting device at 12. Remove hardware which secures the sheave guards
approximately the center of gravity. and sheave assemblies to mid boom section,
8. Carefully remove the telescope cylinder and sheave remove sheave assemblies from mid boom section.
assembly. Place telescope cylinder on a suitable 13. Remove hardware which secures the wear pads to
trestle. the front of mid boom section; remove wear pads
a. Remove hardware from the wear pads; remove from the top, sides and bottom of the mid boom sec-
wear pads from cylinder. tion.
b. Remove hardware from the wire rope guard; 14. Using an overhead crane or suitable lifting device,
remove guard from cylinder. remove fly boom section from mid section. Note:
When removing fly boom section from mid boom
section, retract wire rope must be dragged along
with fly boom section.
15. Remove hardware which secures the wear pads to
the aft end of fly boom section; remove wear pads
from the top, sides and bottom of the fly boom sec-
tion.
7-8 – JLG Lift – 3121157

16. When removing wire rope from fly boom section, NOTE: To check the size, contour and amount of wear, a
push the cable into fly boom. Route wire rope back groove gauge is used. Replace the sheave if worn
through holes in the side of the fly boom section. as shown in the following drawing.
Figure 7-13. Dimension of Sheaves When New
2. Inspect extend and retract wire rope sheave bear-

ings for wear, scoring, or other damage, and for
ovality.
Figure 7-12. Disassembly Wire Rope Routing Proce-
3. Inspect extend wire rope and retract wire rope
sheave pins for scoring, tapering and ovality.
Inspection Replace pins as necessary.
NOTE: When inspecting pins and bearings Ref. to Pins and 4. Inspect telescope cylinder sheave pin for scoring,
Composite Bearing Repair Guidelines in Section 2. tapering and ovality. Replace pins as necessary.
5. Inspect boom pivot pin for wear, scoring, tapering
1. Inspect all sheaves (extend and retract wire ropes and ovality, or other damage. Replace pins as nec-
and telescope cylinder) for excessive groove wear, essary.
burrs or other damage. Replace sheaves as neces-
sary. 6. Inspect telescope cylinder attach point for scoring,
tapering and ovality. Replace pins as necessary.
7. Inspect upper lift cylinder attach pin for wear, scor-
ing, tapering and ovality, or other damage. Ensure
pin surfaces are protected prior to installation.
Replace pins as necessary.
8. Inspect inner diameter of boom pivot bushing for
scoring, distortion, wear, or other damage. Replace
bearing as necessary.
9. Inspect all wear pads for excessive wear or other
damage. Replace pads when worn to within 1/8 inch
(3.2 mm) of threaded insert.
3121157 – JLG Lift – 7-9

10. Inspect extend and retract wire rope attach point 4. Install retract wire ropes into aft end of fly section,
components for cracks, stretching, distortion, or route wire ropes thru holes in side of fly boom sec-
other damage. Replace components as necessary. tion and pull into slot.
11. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting.
Replace as necessary.
12. Inspect structural units of boom assembly for bend-
ing, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
Assembly
NOTE: When installing fly section wear pads, install same
number and thickness of shims as were removed
during disassembly.
1. Measure inside dimensions of the base and mid

sections to determine the number of shims required
for proper lift.
2. Measure inside dimensions of the mid section to
determine the number of shims required for proper
lift.
3. Install side, top and bottom wear pads to the aft end
of fly section; shim evenly to the measurements of
the inside of mid section.
Figure 7-14. Routing Installation of Retract Wire Ropes
5. Install side, top and bottom wear pads to the aft end
of mid section; shim evenly to the measurements of
the inside of mid section.
WHEN ASSEMBLING BOOM SECTIONS, ENSURE THAT THE BOOM

SLIDING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS,
TOOLS, AND OTHER OBSTRUCTIONS.
6. Shim the insides of the boom sections for a total of

1/16 inch (0.062) clearance (if the action is centered,
there will be 1/32 clearance on each side).
7. Slide fly boom section into the mid boom section.
Shim boom, if necessary, for a total of 1/16 inch
(0.062) clearance.
8. Install wear pads into the forward position of the mid
boom section. Shim boom, if necessary, for a total of
2/10 inch (0.20 m) clearance.
9. Properly position the retraction wire rope sheaves
assemblies at the aft end of the mid boom section;
ensure all sheave-to-mounting block attachment
holes align. Install the sheave pins and secure them
with mounting hardware. Position retract wire ropes
onto the sheaves.
7-10 – JLG Lift – 3121157

10. Install sheave guards to aft end of mid boom section 22. Align holes in rod end of the telescope cylinder with
and secure with mounting hardware. holes in push bar. Install push bar pin and secure
with mounting hardware.
11. Slide mid boom section into the base boom section.
Allow the retraction wire ropes to trail between the 23. Install the hydraulic lines and electrical cables, and
bottom surfaces of boom sections. Shim boom, if the harnessing powertrack components as follows:
necessary, for a total of 1/16 inch (0.062) clearance.
a. Align holes in powertrack rail with attachment
12. Install wear pads into the forward position of the holes in side of the base boom section. Secure
base boom section. Shim boom, if necessary, for a the rail with mounting hardware.
total of 2/10 inch (0.20) clearance. b. Install powertrack to rail with mounting hard-
13. Install sheave block to bottom of base boom section ware.
and adjust block so that retract wire ropes do not c. Attach push tube bracket to the side of the mid
come into contact with boom surfaces. boom section with mounting hardware.
14. Install wire rope threaded ends thru attachment NOTE: Do not over tighten attach bolt on push tube bracket.
holes in the bottom of base boom section. Loosely It should pivot freely.
install nuts and jam nuts onto the threaded ends of
wire ropes. d. Install slide block and wear pads to the pow-
ertrack rail with mounting hardware.
15. Align the telescope cylinder barrel-to-sheave attach-
ment point. Install extend sheave pin through the e. Install powertrack to push tube with mounting
telescope cylinder barrel and sheave assembly; hardware.
secure pin with mounting hardware. f. Carefully feed the hoses and electrical cables
through the aft end of the powertrack rail, pow-
16. Route extend wire ropes around extend sheave and
ertrack and push tube.
secure wire ropes to the telescope cylinder.
g. Ensure all hoses and cables are properly routed
17. Install extend wire rope mounting blocks to threaded through the powertrack rail, powertrack and
ends of wire ropes. Loosely install nuts and jam nuts push tube. Tighten or install all clamping or
onto the threaded ends of wire ropes. securing apparatus to the hoses or cables, as
NOTE: When installing wire ropes, care must be taken not to necessary.
twist or cross the wire ropes. h. Install powertrack cover and push tube rods with
mounting hardware.
18. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,

IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLINDER
SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN
THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYLINDER
SLOWLY INTO POSITION. DAMAGE TO COMPONENTS MAY
RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES.
19. Align the cylinder with the slots at aft end of mid
boom section, then secure cylinder with mounting Figure 7-15. Reassembly of Components - Boom
hardware. Powertrack Assembly
20. Align holes in aft end of the fly boom section with
holes in wire rope mounting block, then secure with
mounting hardware.
21. Align holes in aft end of the mid boom section with
holes in wire rope mounting block, then secure with
mounting hardware.
NOTE: Boom wire ropes must be torqued after installation of

the boom assembly.
3121157 – JLG Lift – 7-11

Figure 7-16. Boom Powertrack Installation
7-12 – JLG Lift – 3121157

Installation mer, remove the cylinder pin from articulating jib

boom.
1. Using a suitable lifting device, position boom
assembly on turntable so that the pivot holes in both
boom and turntable are aligned.
2. Install boom pivot pin, ensuring that location of hole
in pin is aligned with attach point on turntable.
3. If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.
4. Align push bar pivot hole with pivot holes in turnta-
ble. Install push bar pivot pin, ensuring that location
of hole in pin is aligned with attach point on turnta-
ble.
5. If necessary, gently tap pin into position with soft Figure 7-17. Location of Components - Articulating
headed mallet. Secure pin mounting hardware. Jib Boom
6. Connect all wiring to the ground control box. 4. Remove mounting hardware from articulating jib
boom pivot pin #2. Using a suitable brass drift and
7. Connect all hydraulic lines running along side of hammer, remove the pivot pin from boom assembly.
boom assembly.
8. Using all applicable safety precautions, operate lift- Disassembly
ing device in order to position boom lift cylinder so
that holes in the cylinder rod end and boom struc- 1. Remove mounting hardware from articulating jib
ture are aligned. Insert the lift cylinder pin, ensuring boom pivot pins #3 and #4. Using a suitable brass
that location of hole in pin is aligned with attach drift and hammer, remove the pins from articulating
point on boom. jib boom pivot weldment.
9. Align holes in boom structure with hole in master 2. Remove mounting hardware from rotator support
cylinder. Insert the master cylinder pin, ensuring that pins #5 and #6. Using a suitable brass drift and
location of hole in pin is aligned with attach point on hammer, remove the pins from rotator support.
boom. 3. Remove mounting hardware from lift cylinder pin
10. Adjust retract and extend cables to the proper #7. Using a suitable brass drift and hammer, remove
torque. Refer to paragraph 2-6, boom cable torque the cylinder pin from articulating jib boom.
procedures.
11. Using all applicable safety precautions, operate
Inspection
machine systems and raise and extend boom fully, NOTE: When inspecting pins and bearings refer to Pins and
noting the performance of the extension cycle. Composite Bearing Repair Guidelines in Section 2.
12. Retract and lower boom, noting the performance of
the retraction cycle. 1. Inspect articulating fly boom pivot pin for wear, scor-
ing, tapering and ovality, or other damage. Replace
pins as necessary.
7.6 ARTICULATING JIB BOOM 2. Inspect articulating fly boom pivot attach points for
scoring, tapering and ovality, or other damage.
Removal Replace pins as necessary.
1. For platform/support removal see platform/support 3. Inspect inner diameter of articulating fly boom pivot
removal diagram. See Section 7.5, Boom Mainte- bearings for scoring, distortion, wear, or other dam-
nance. age. Replace bearings as necessary.
2. Position the articulating jib boom level with ground. 4. Inspect lift cylinder attach pin for wear, scoring,
tapering and ovality, or other damage. Ensure pin
3. Remove mounting hardware from slave leveling cyl- surfaces are protected prior to installation. Replace
inder pin #1. Using a suitable brass drift and ham- pins as necessary.
3121157 – JLG Lift – 7-13

5. Inspect inner diameter of rotator attach point bear- 4. Align articulating jib boom with attach hole in articu-
ings for scoring, distortion, wear, or other damage. lating jib boom pivot weldment. Using a soft head
Replace bearing as necessary. mallet, install rotator support pin #4 into articulating
jib boom and secure with mounting hardware.
6. Inspect all threaded components for damage such
as stretching, thread deformation, or twisting. 5. Align bottom tubes with attach holes in articulating
Replace as necessary. jib boom pivot weldment. Using a soft head mallet,
install rotator support pin #3 into articulating jib
7. Inspect structural units of articulating jib boom
boom pivot weldment and secure with mounting
assembly for bending, cracking, separation of
hardware.
welds, or other damage. Replace boom sections as
necessary. 6. Align articulating jib boom pivot weldment with
attach holes in fly boom assembly. Using a soft head
Assembly mallet, install pivot pin #2 into fly boom assembly
and secure with mounting hardware.
NOTE: For location of components See Section 7-17., Loca-
7. Align the slave leveling cylinder with attach holes in
tion of Components - Articulating Jib Boom.
articulating jib boom pivot weldment. Using a soft
head mallet, install slave leveling cylinder pin #1
1. Align lift cylinder with attach holes in articulating jib
into articulating jib boom pivot weldment and secure
boom. Using a soft head mallet, install cylinder pin
#7 into articulating jib boom and secure with mount-
ing hardware.
2. Align rotator support with attach hole in articulating 7.7 LIMIT SWITCH ADJUSTMENT
jib boom. Using a soft head mallet, install rotator Adjust switches and cam valve as shown in Limit Switches
support pin #6 into articulating jib boom and secure Adjustment.
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.
7-14 – JLG Lift – 3121157

Figure 7-18. Limit Switches Adjustments
3121157 – JLG Lift – 7-15

7.8 ROTATOR - HELAC (PRIOR TO S/N 5. Remove the two (2) setscrew (4) from bottom of
actuator (1). Discard setscrew.
0300132437)
Disassembly
1. Place actuator on a clean workbench.
2. Remove all hydraulic fittings.
3. Using a suitable hammer and chisel remove the por-
tion of end cap securing setscrew.
Figure 7-22. Removing Setscrew
6. Place two (2) 3/8"x16NC bolts in threaded holes in

bottom of the actuator. Using a suitable bar, unscrew
the end cap (5). Remove the end cap from actuator
(1).
Figure 7-20. Removing Portion of End Cap
4. Using a torch, apply heat to the setscrews on the

bottom of actuator.
Figure 7-23. Removing End Cap
Figure 7-21. Heating Setscrew
7-16 – JLG Lift – 3121157

Figure 7-19. Rotator Assembly (Helac)
3121157 – JLG Lift – 7-17

7. Remove the shaft (2) from piston sleeve (3) and the cases, depending on the required accuracy of the
actuator housing (1). application.
3. Check the ring gear for wear and weld damage to

the pins.
4. Inspect the cylinder bore for wear and scratches.
Assembly
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).
Figure 7-24. Removing Shaft from Housing
NOTE: Apply a coat of grease to the thrust ring before slid-
ing onto the end cap.
8. Remove piston sleeve (3) from housing (1).
3. Install new seals (11), back-up ring (12), cap bearing
(13), bearing packing (14) and thrust ring (10) on
end cap (5).
4. Place the actuator in the vertical position, install the
piston sleeve (3) in timed relation to the housing (1).
DO NOT MISALIGN THE SLEEVE TOO MUCH ANY ONE WAY, AS IT

WILL MARK THE CYLINDER BORE.
NOTE: The timing marks (the small punch marks on the

face of each gear), must be aligned for proper shaft
orientation. (See Actuator Timing.)
5. Install the shaft (2) into housing (1) by aligning the

proper punched timing marks. (See Actuator Tim-
ing.)
Figure 7-25. Removing Sleeve from Housing
6. Temporarily tape the threaded portion of the shaft
9. Remove all seals and bearings from grooves. Dis- will help installation past the shaft seals (masking
card seals. tape).
7. The end cap (5) is torqued to 40 - 50 ft. lbs. (54 - 68
Inspection Nm), such that the actuator begins rotation at
1. Clean all parts thoroughly. approximately 100 psi (6.895 Bar) pressure.
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
7-18 – JLG Lift – 3121157

8. The end cap must be secured against the shaft by preventing piston movement and locking the shaft in posi-
installing axial set screws (4). tion.
Figure 7-26. Actuator Timing
7.9 ROTARY ACTUATOR (S/N 0300132437

TO PRESENT)
Bars indicate starting posi- As fluid pressure is applied,
tio ns of pisto n and shaft. the piston is displaced axially
Theory of Operation Arrows indicate direction they while the helical gearing
will rotate. The housing with causes the piston and shaft to
The L20 Series rotary actuator is a simple mechanism that
integral ring gear remains sta- rotate simultaneously. The
uses the sliding spline operating concept to convert linear tionary. double helix design com-
piston motion into powerful shaft rotation. Each actuator is pounds rotation: shaft rota-
composed of a housing with integrated gear teeth (01) tion is about twice that of the
and only two moving parts: the central shaft with inte- piston.
grated bearing tube and mounting flange (02), and the
annular piston sleeve (03). Helical spline teeth machined
on the shaft engage matching splines on the inside The shaft is supported radially by the large upper radial
diameter of the piston. The outside diameter of the piston bearing and the lower radial bearing. Axially, the shaft is
carries a second set of splines, of opposite hand, which separated from the housing by the upper and lower thrust
engage with matching splines in the housing. As hydraulic washers. The end cap is adjusted for axial clearance and
pressure is applied, the piston is displaced axially within locked in position by set screws or pins.
the housing - similar to the operation of a hydraulic cylin-
der - while the splines cause the shaft to rotate. When the
control valve is closed, oil is trapped inside the actuator,
3121157 – JLG Lift – 7-19

Required Tools 5. Seal tool - assembly and disassembly of seals and

wear guides.
Upon assembly and disassembly of the actuator there are
basic tools required. The tools and their intended func- 6. Pry bar - removal of end cap and manual rotation of
tions are as follows: 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
some slight modifications for your own personal prefer-
ence.
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.
7-20 – JLG Lift – 3121157

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 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring Washer 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 7-27. Rotary Actuator - Exploded View
3121157 – JLG Lift – 7-21

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 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring Washer 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 7-28. Rotary Actuator - Assembly Drawing
7-22 – JLG Lift – 3121157

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-

ter of each lock pin to a depth of approximately 3/ 5. Using a metal bar, or something similar, unscrew the
16” (4.76mm). end cap (4) by turning it counter clockwise.
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
3121157 – JLG Lift – 7-23

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.
7-24 – JLG Lift – 3121157

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.
3121157 – JLG Lift – 7-25

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).
7-26 – JLG Lift – 3121157

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).
3121157 – JLG Lift – 7-27

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.
7-28 – JLG Lift – 3121157

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 8. Looking from the angle shown, rotate the piston (3)
using a circular motion. Make sure the wedged ends until the marks you put on the piston and the hous-
overlap correctly. 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.
3121157 – JLG Lift – 7-29

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.
10. Install the shaft (2) into the piston (3). Be careful not 12. Install 2 bolts in the threaded holes in the flange.
to damage the seals. Do not engage the piston gear Using a bar, rotate the shaft in a clockwise direction
teeth yet. until the wear guides are seated inside the housing
bore.
13. Install the stop tube onto the shaft end. Stop tube is
an available option to limit the rotation of an actua-
tor.
7-30 – JLG Lift – 3121157

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).
3121157 – JLG Lift – 7-31

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 7-29., 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 7-29. Rotator Counterbalance Valve
7-32 – JLG Lift – 3121157

7.10 FOOT SWITCH ADJUSTMENT

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)
of travel, top or bottom, it should be adjusted.
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 oper-
E ation
Torque to 85 ft. lbs. (115 Nm)
Figure 7-30. Platform Support Torque Values
3121157 – JLG Lift – 7-33

NOTES:
7-34 – JLG Lift – 3121157

SECTION 8. HYDRAULICS & HYDRAULIC SCHEMATICS

8.1 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-
When assembling connectors in the hydraulic that use o- pletely saturated.
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.
3121157 – JLG Lift – 8-1

Dip Method Spray Method

NOTE: This method works best with Face Seal o-rings, but This method requires a pump or trigger spray bottle.
will work for all o-ring fitting types.
1. Fill the spray bottle with hydraulic oil.
The following is needed to correctly oil the o-ring in this 2. Hold the fitting over a suitable catch can.
manner:
3. Spray the entire o-ring surface with a medium coat
• A small leak proof container of oil.
• Sponge cut to fit inside the container

• A small amount of hydraulic oil to saturate the sponge.
1. Place the sponge inside the container and add
hydraulic oil to the sponge until it is fully saturated.
2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and
drip from the bottom of the fitting. This should signify
an even coating of oil on the fitting.
Brush-on Method
This method requires a sealed bottle brush.
1. Fill the bottle with hydraulic oil.

2. Using slight pressure to the body of the spray bottle,
invert the bottle so the brush end is in the downward
position.
3. Brush hydraulic oil on the entire o-ring, applying an
3. O-ring Boss type fittings will require more pressure even coat of oil.
in able to immerse more of the fitting into the satu-
rated sponge. This will also cause more oil to be dis-
persed from the sponge.
8-2 – JLG Lift – 3121157

8.2 VALVES - THEORY OF OPERATION 8.3 CYLINDERS - THEORY OF OPERATION
Solenoid Control Valve Systems Incorporating Double Acting

Control valves used are four-way three-position solenoid Cylinders
valves of the sliding spool design. When a circuit is acti-
Cylinders are of the double acting type. Systems incorpo-
vated and the control valve solenoid energizes, the spool
rating double acting cylinders are as follows: Slave Level,
is shifted and the corresponding work port opens to per-
Master Level, Lift, Telescope, Articulating Jib Boom Lift. A
mit oil flow to the component in the selected circuit with
double acting cylinder is one that requires oil flow to oper-
the opposite work port opening to reservoir. Once the cir-
ate the cylinder rod in both directions. Directing oil (by
cuit is deactivated (control returned to neutral) the valve
actuating the corresponding control valve to the piston
spool returns to neutral (center) and oil flow is then
side of the cylinder) forces the piston to travel toward the
directed through the valve body and returns to reservoir. A
rod end of the barrel, extending the cylinder rod (piston
typical control valve consist of the valve body, sliding
attached to rod). When the oil flow is stopped, movement
spool, and two solenoid assemblies. The spool is
of rod will stop. By directing oil to the rod side of the cylin-
machine fitted in the bore of the valve body. Lands on the
der, the piston will be forced in the opposite direction and
spool divide the bore into various chambers, which, when
the cylinder rod will retract.
the spool is shifted, align with corresponding ports in the
valve body open to common flow. At the same time other
ports would be blocked to flow. The spool is spring loaded Systems Incorporating Holding Valves
to center position, therefore when the control is released, Holding valves are used in the - Lift, Telescope, Lockout,
the spool automatically returns to neutral, prohibiting any Slave Level and Articulating Jib Boom Lift circuits to pre-
flow through the circuit. vent retraction of the cylinder rod should a hydraulic line
rupture or a leak develop between the cylinder and its
Relief Valves related control valve.
Relief valves are installed at various points within the
hydraulic system to protect associated systems and com- 8.4 CYLINDER CHECKING PROCEDURE
ponents against excessive pressure. Excessive pressure
can be developed when a cylinder reaches its limit of NOTE: Cylinder check must be performed anytime a system
travel and the flow of pressurized fluid continues from the component is replaced or when improper system
system control. The relief valve provides an alternate path operation is suspected.
for the continuing flow from the pump, thus preventing
rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving cir-
Cylinders Without Counterbalance Valves
cuit pressure. The relief valve is installed in the circuit Master Cylinder and Steer Cylinder
between the pump outlet (pressure line) and the cylinder
of the circuit, generally as an integral part of the system 1. Using all applicable safety precautions, activate
valve bank. Relief pressures are set slightly higher than engine and fully extend cylinder to be checked. Shut
the load requirement, with the valve diverting excess down engine.
pump delivery back to the reservoir when operating pres- 2. Carefully disconnect hydraulic hoses from retract
sure of the component is reached. port of cylinder. There will be some initial weeping of
hydraulic fluid which can be caught in a suitable
container. After the initial discharge, there should be
no further drainage from the retract port.
3. Activate engine and extend cylinder.
4. If cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to port and
retract cylinder. If leakage continues at a rate of 6-8
drops per minute or more, cylinder repair must be
made.
5. With cylinder fully retracted, shut down engine and
carefully disconnect hydraulic hose from cylinder
extend port.
6. Activate engine and retract cylinder. Check extend
port for leakage.
3121157 – JLG Lift – 8-3

7. If extend port leakage is less than 6-8 drops per min- tem and run cylinder through one complete cycle to
ute, carefully reconnect hose to extend port, than check for leaks.
activate cylinder through one complete cycle and
check for leaks. If leakage continues at a rate of 6-8 Cylinders With Dual Counterbalance
drops per minute or more, cylinder repairs must be
made. Valves
Articulating Jib Boom Lift, and Slave), Slave Level,
Cylinders With Single Counterbalance Telescope
Valve
Lift Cylinder
OPERATE ALL FUNCTIONS FROM GROUND CONTROLS ONLY.
1. Using all applicable safety precautions, activate

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION hydraulic system.
ONLY.
1. Using all applicable safety precautions, activate

IF WORKING ON THE PLATFORM LEVEL CYLINDER, STROKE
hydraulic system.
PLATFORM LEVEL CYLINDER FORWARD UNTIL PLATFORM SITS
AT A 45 DEGREE ANGLE.
WHEN WORKING ON THE MAIN LIFT CYLINDER, RAISE THE 2. Shut down hydraulic system and allow machine to
BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXI- sit for 10-15 minutes. If machine is equipped with
MATELY 1 INCH (2.54 CM) BELOW THE MAIN BOOM. DO NOT bang-bang or proportional control valves, turn IGNI-
WORK ON THE CYLINDER WITHOUT A SUITABLE PROP IN PLACE. TION SWITCH to ON, move control switch or lever
for applicable cylinder in each direction, then turn
2. Shut down hydraulic system and allow machine to IGNITION SWITCH to OFF. If machine is equipped
sit for 10-15 minutes. If machine is equipped with with hydraulic control valves, move control lever for
bang-bang or proportional control valves, turn IGNI- applicable cylinder in each direction. This is done to
TION SWITCH to ON, move control switch or lever relieve pressure in the hydraulic lines. Remove
for applicable cylinder in each direction, then turn hoses from appropriate cylinder port block.
IGNITION SWITCH to OFF. If machine is equipped
3. There will be initial weeping of hydraulic fluid, which
with hydraulic control valves, move control lever for
can be caught in a suitable container. After the initial
applicable cylinder in each direction. This is done to
discharge, there should be no further leakage from
relieve pressure in the hydraulic lines. Carefully
the ports. If leakage continues at a rate of 6-8 drops
remove hydraulic hoses from appropriate cylinder
per minute or more, the counterbalance valve is
port block.
defective and must be replaced.
3. There will be initial weeping of hydraulic fluid, which
4. To check piston seals, carefully remove the counter-
can be caught in a suitable container. After the initial
balance valve from the retract port. After initial dis-
discharge, there should be no further leakage from
charge, there should be no further leakage from the
the ports. If leakage continues at a rate of 6-8 drops
ports. If leakage occurs at a rate of 6-8 drops per
per minute or more, the counterbalance valve is
minute or more, the piston seals are defective and
defective and must be replaced.
must be replaced.
4. To check piston seals, carefully remove the counter-
5. If no repairs are necessary or when repairs have
balance valve from the retract port. After initial dis-
been made, replace counterbalance valve and care-
charge, there should be no further leakage from the
fully connect hydraulic hoses to cylinder port block.
ports. If leakage occurs at a rate of 6-8 drops per
minute or more, the piston seals are defective and 6. If used, remove lifting device from upright or remove
must be replaced. prop from below main boom, activate hydraulic sys-
tem and run cylinder through one complete cycle to
5. If no repairs are necessary or when repairs have
check for leaks.
been made, replace counterbalance valve and care-
fully connect hydraulic hoses to cylinder port block.
6. If used, remove lifting device from upright or remove
prop from below main boom, activate hydraulic sys-
8-4 – JLG Lift – 3121157

8.5 CYLINDER REPAIR the eight (8) cylinder head retainer cap screws, and
remove cap screws from cylinder barrel.
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.
Disassembly
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A

CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source

to the cylinder port block fitting.
Figure 8-2. Cap Screw Removal

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
6. Attach a suitable pulling device to the cylinder rod
2. Operate the hydraulic power source and extend the port block end or cylinder rod end, as applicable.
cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if appli-
cable. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL-
3. If applicable, remove the cartridge-type holding INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
valve and fittings from the cylinder port block. Dis- CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
card o-rings. CYLINDER BARREL SURFACES.
4. Place the cylinder barrel into a suitable holding fix- 7. With the barrel clamped securely, apply pressure to
ture. the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.
Figure 8-1. Cylinder Barrel Support

Figure 8-3. Cylinder Rod Support
5. Mark cylinder head and barrel with a center punch 8. Using suitable protection, clamp the cylinder rod in
for easy realignment. Using an allen wrench, loosen a vise or similar holding fixture as close to the piston
as possible.
3121157 – JLG Lift – 8-5

9. Loosen and remove the cap screw(s), if applicable, 7. Inspect threaded portion of piston for damage.
which attach the tapered bushing to the piston. Dress threads as necessary.
10. 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
11. 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 8-4. Tapered Bushing Removal dirt etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage.
12. 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.
c. Lubricate inside of steel bushing with WD40
13. Remove and discard the piston o-rings, seal rings,
prior to bearing installation.
and backup rings.
d. Using an arbor of the correct size, carefully
14. Remove piston spacer, if applicable, from the rod. press the bearing into steel bushing.
15. Remove the rod from the holding fixture. Remove NOTE: Install pin into the composite bearing dry. Lubrication
the cylinder head gland and retainer plate, if applica- is not required with nickel plated pins and bearings.
ble. Discard the o-rings, back-up rings, rod seals,
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 8-5. Composite Bearing Installation
4. Inspect inner surface of cylinder barrel tube for scor-

14. Inspect travel limiting collar or spacer for burrs and
ing or other damage. Check inside diameter for
sharp edges. If necessary, dress inside diameter
tapering or ovality. Replace if necessary.
surface with Scotch Brite or equivalent.
5. Inspect threaded portion of barrel for damage. Dress
15. If applicable, inspect port block fittings and holding
threads as necessary.
valve. Replace as necessary.
6. Inspect piston surface for damage and scoring and
16. Inspect the oil ports for blockage or the presence of
for distortion. Dress piston surface or replace piston
dirt or other foreign material. Repair as necessary.
as necessary.
8-6 – JLG Lift – 3121157

17. If applicable, inspect piston rings for cracks or other groove.

damage. Replace as necessary.
Assembly
NOTE: Prior to cylinder assembly, ensure that the proper
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 Figure 8-7. Poly-Pak Piston Seal Installation
the applicable cylinder head gland groove.
Figure 8-6. Rod Seal Installation Figure 8-8. Wiper Seal Installation
3. Place a new “o”ring and back-up seal in the applica-

ble outside diameter groove of the cylinder head.
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLA-
TION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
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
Figure 8-9. Installation of Head Seal Kit
4. Install washer ring onto rod, carefully install the head

gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.
5. Carefully slide the piston spacer on the rod.
NOTE: Upper telescope cylinder piston has an o-ring

installed inside the spacer.
3121157 – JLG Lift – 8-7

6. If applicable, correctly place new o-ring in the inner NOTE: When installing the tapered bushing, piston and mat-
piston diameter groove. (The backup ring side facing end of rod must be free of oil.
ing the O-ring is grooved.)
7. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove. (A
TIGHTEN THE CAPSCREWS FOR THE TAPERED BUSHING
tube, with I.D. slightly larger than the O.D.of the pis-
SECURELY. (SEE TABLE 8-1, CYLINDER HEAD AND TAPERED
ton is recommended to install the solid seal.)
BUSHING TORQUE SPECIFICATIONS.)
NOTE: The backup rings for the solid seal have a radius on
one side. This side faces the solid seal.(See magni- 11. Assemble the tapered bushing loosely into the pis-
fied insert in Figure 8-10.)The split of seals and ton and insert JLG capscrews (not vendor cap-
backup rings are to be positioned so as not to be in screws) through the drilled holes in the bushing and
alignment with each other. into the tapped holes in the piston.
PISTON
BACKUP
SPLIT SEAL
RINGS
Figure 8-11. Tapered Bushing Installation

SPLIT
BACKUP
RING 12. Tighten the capscrews evenly and progressively in
O-RING
rotation to the specified torque value. (See Table 8-1,
Cylinder Head and Tapered Bushing Torque Specifi-
cations.
T - RING 13. After the screws have been torqued, tap the tapered
SEAL bushing with a hammer (16 to 24 oz.) and brass
SPLIT BACKUP RING
shaft (approximately 3/4" in diameter) as follows;
Figure 8-10. Piston Seal Kit Installation a. Place the shaft against the cylinder rod and in
contact with the bushing in the spaces between
8. Using suitable protection, clamp the cylinder rod in the capscrews.
a vise or similar holding fixture as close to piston as
possible.
9. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.
10. Thread piston onto rod until it abuts the spacer end
and install the tapered bushing.
8-8 – JLG Lift – 3121157

b. Tap each space once; this means the tapered 20. Secure the cylinder head gland using the washer
bushing is tapped 3 times as there are 3 spaces ring and socket head bolts. (See Table 8-1.)
between the capscrews.
Figure 8-13. Rod Assembly Installation
21. After the cylinder has been reassembled, the rod

should be pushed all the way in (fully retracted) prior
Figure 8-12. Seating the Tapered Bearing
to the reinstallation of any holding valve or valves.
14. Retorque the capscrews evenly and progressively in 22. If applicable, install the cartridge-type holding valve
rotation to the specified torque value. (See Table 8-1, and fittings in the rod port block, using new o-rings
Cylinder Head and Tapered Bushing Torque Specifi- as applicable. (See Table 8-2, Holding Valve Torque
cations.) Specifications).
15. Remove the cylinder rod from the holding fixture.
16. Place new guide locks and seals in the applicable Table 8-1. Cylinder Head and Tapered Bushing Torque
outside diameter grooves of the cylinder piston. Specifications.
(See Figure 8-10.)
Tapered
17. Position the cylinder barrel in a suitable holding fix- Description
Head Torque
Bushing Torque
ture. Value (Wet)
Value (Wet)
Lift Cylinder 240 ft. lbs. 30 ft. lbs.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYL- (325 Nm) (41 Nm)
INDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFF-
Articulating Lift Cyl- 30 ft. lbs. 5 ft. lbs.
CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
inder (41 Nm) (9 Nm)
CYLINDER BARREL SURFACES.
Slave Cylinder 30 ft. lbs. 5 ft. lbs.
18. With barrel clamped securely, and while adequately (41 Nm) (9 Nm)
supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring Master Cylinder 30 ft. lbs. 5 ft. lbs.
and seal ring are not damaged or dislodged. (41 Nm) (9 Nm)
19. Continue pushing the rod into the barrel until the cyl- Telescope 50 ft. lbs. 9 ft. lbs.
inder head gland can be inserted into the barrel cyl- Cylinder (68 Nm) (12 Nm)
inder.
Lockout Cylinder 80 ft. lbs. N/A
(109 Nm)
Articulating Slave 50 ft. lbs. 9 ft. lbs.

Cylinder (68 Nm) (12 Nm)
Articulating 50 ft. lbs. 9 ft. lbs.

Master Cylinder (68 Nm) (12 Nm)
3121157 – JLG Lift – 8-9

Table 8-2. Holding Valve Torque Specifications
Description Torque Value
SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

(41-48 Nm)
SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

(61-68 Nm)
SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

(204-217 Nm)
RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.

(68-75 Nm)

(102-109 Nm)

(136-149 Nm)
IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON

THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE EITHER
A TRAVELING OVERHEAD HOIST, FORK-LIFT, OR OTHER MEANS
TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING
ROD.
8-10 – JLG Lift – 3121157

8.6 CYLINDER REMOVAL AND 8. Remove hardware securing telescope cylinder to aft
end of the mid boom section.
INSTALLATION
Main Boom Telescope Cylinder Removal WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM,
1. Place machine on a flat and level surface, with main
boom in the horizontal position.
2. Shut down engine. Support main boom basket end SLOWLY INTO POSITION: DAMAGE TO COMPONENTS MAY
with a prop. (See Figure 8-14., Boom Positioning RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES.
and Support, Cylinder Repair).
9. Remove bolts securing cable attach bar to top of fly
boom section.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI- 10. Pull the telescope cylinder and cables partially from
ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF aft end of the base boom section; secure the cylin-
CONTAMINANTS INTO THE SYSTEM. der with a suitable sling and lifting device at approxi-
mately the center of gravity.
3. Tag and disconnect hydraulic lines to telescope cyl-
inder. Use a suitable container to retain any residual 11. Carefully remove the telescope cylinder and sheave
hydraulic fluid. Cap hydraulic lines and ports. assembly. Place telescope cylinder on a suitable
trestle.
4. Remove the hardware securing cover plate on bot-
tom of the base boom section and remove cover. Main Boom Telescope Cylinder Installation
NOTE: Do not allow cable to rotate. This may damage the
1. Route extend cables around extend sheave and
cable.
secure cables to the telescope cylinder.
5. Clamp both threaded ends of cable to prevent rota- 2. Install extend cables mounting blocks to threaded
tion. Note: Do not clamp on threads. Remove jam ends of cables. Loosely install nuts and jam nuts
nuts and loosen adjustment nuts so there is slack in onto the threaded end of cables.
the cables. Remove the hardware securing push bar
to turntable and telescope cylinder. NOTE: When installing cables care must be taken not to
twist or cross the cables.
6. Using a suitable brass drift, carefully drive the push
bar pins from the telescope cylinder rod and turnta- 3. Secure the sling and lifting device at the telescope
ble. cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
7. Remove hardware securing cable adjustment block
to aft end of the base boom section and remove
block.
Figure 8-14. Boom Positioning and Support, Cylinder Repair
3121157 – JLG Lift – 8-11

4. Install extend cable mounting blocks to threaded Main Boom Lift Cylinder Removal
ends of cables. Loosely install nuts and jam nuts
onto the threaded ends of cables. 1. Place the machine on a flat and level surface. Start
the engine and place the main boom in the horizon-
NOTE: When installing cables, care must be taken not to tal position. Shut down engine and prop the boom.
twist or cross the cables. (See Figure 8-14., Boom Positioning and Support,
Cylinder Repair).
5. Secure the sling and lifting device at the telescope
cylinder’s approximate center of gravity, and lift the 2. Remove the hardware retaining the cylinder rod
cylinder to the aft end of the boom assembly. attach pin to the boom. Using a suitable brass drift,
drive out the cylinder rod attach pin.
3. Using auxiliary power, retract the lift cylinder rod
WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM, completely.
4. Disconnect, cap and tag the main boom lift cylinder
hydraulic lines and ports.
SLOWLY INTO POSITION: DAMAGE TO COMPONENTS MAY 5. Remove barrel end attach pin retaining hardware.
RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES. Using a suitable brass drift drive out the barrel end
attach pin from the turntable.
6. Carefully install the telescope cylinder barrel end
support into slots in mid boom and secure with 6. Remove the cylinder from the turntable and place in
blocks and bolts. Use Loctite #242 on bolts. a suitable work area.
7. Align holes in aft end of the fly boom section with

holes in cable mounting block, then secure with
Main Boom Lift Cylinder Installation
mounting hardware. 1. Install lift cylinder in place using suitable slings or
8. Align holes in aft end of the base boom section with supports, aligning attach pin mounting holes on the
holes in cable mounting block, then secure with turntable.
mounting hardware. 2. Using a suitable drift, drive the barrel end attach pin
9. Remove cylinder port plugs and hydraulic line caps through the mounting holes in the lift cylinder and
and correctly attach lines to cylinder ports. the turntable. Secure in place with the pin retaining
hardware.
10. Align holes in rod end of the telescope cylinder with
holes in push bar. Install push bar pin and secure 3. Remove cylinder port plugs and hydraulic line caps
with mounting hardware. and correctly attach lines to cylinder ports.
11. Align holes in push bar with holes in turntable. Install 4. Using auxiliary power, extend the cylinder rod until
push bar pin and secure with mounting hardware. the attach pin hole aligns with those in the boom.
Using a suitable soft mallet, drive the cylinder rod
NOTE: Boom cables must be torqued after installation of the attach pin through the boom and lift cylinder. Secure
telescope cylinder. (See Section 4 - Boom & Plat- the pin in place with attaching hardware.
form)
5. Remove boom prop and overhead crane. Activate
hydraulic system.
6. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
7. Check fluid level of hydraulic tank and adjust as nec-
essary.
8-12 – JLG Lift – 3121157

8.7 PRESSURE SETTING PROCEDURES of the stroke. This will release the pressure and allow
installation of a pressure gauge.
Cold temperatures have a significant impact on pressure
readings. JLG Industries Inc. recommends operating the 2. With the aid of an assistant, activate level up.
machine until the hydraulic system has warmed to normal 3. While monitoring pressure gauge, adjust the level
operating temperatures prior to checking pressures. JLG up relief to 2800 PSI (193 Bar). Turn the adjuster
Industries Inc. also recommends the use of a calibrated clockwise to increase pressure or counterclockwise
gauge. Pressure readings are acceptable if they are within to decrease pressure.
± 5% of specified pressures.
Platform Level Down
Main Relief
1. Install pressure gauge at quick disconnect on port
MP on main valve. PRESSURE IS TRAPPED AT PORT M4.
2. With the aid of an assistant, activate telescope in. 1. Install pressure gauge at quick disconnect on port
3. While monitoring pressure gauge, adjust main relief M4 on main valve after releasing the pressure. To
to 3000 PSI (206.85 Bar). Turn the adjuster clock- release the pressure, activate level up to the end of
wise to increase pressure or counterclockwise to the stroke. This will release the pressure and allow
decrease pressure. installation of a pressure gauge.
2. With the aid of an assistant, activate level down.
Lift Down 3. While monitoring pressure gauge, adjust the level
1. Install pressure gauge at quick disconnect on port up relief to 1800 PSI (124 Bar). Turn the adjuster
MP on main valve. clockwise to increase pressure or counterclockwise
to decrease pressure.
2. With the aid of an assistant, activate lift down.
3. While monitoring pressure gauge, adjust the lift Jib Up
down relief to 1500 PSI (103 Bar). Turn the adjuster
clockwise to increase pressure or counterclockwise 1. Install pressure gauge on the M port on the jib block.
to decrease pressure. 2. With the aid of an assistant, activate jib up.
3. While monitoring pressure gauge, adjust the jib up
Swing relief to 1500 PSI (103 Bar). Turn the adjuster clock-
NOTE: Left and right swing pressures are set with one wise to increase pressure or counterclockwise to
adjustment. decrease pressure.
1. Install pressure gauge at quick disconnect on port Jib Down

MP on main valve.
1. Install pressure gauge on the M port on the jib block.
2. Lock the turntable using the turntable lock.
2. With the aid of an assistant, activate jib down.
3. With the aid of an assistant, activate swing left or
right 3. While monitoring pressure gauge, adjust the jib
down relief to 1200 PSI (82 Bar). Turn the adjuster
4. While monitoring pressure gauge, adjust the swing clockwise to increase pressure or counterclockwise
relief to 1700 PSI (117 Bar). Turn the adjuster clock- to decrease pressure.
wise to increase pressure or counterclockwise to
decrease pressure.
Platform Level Up
PRESSURE IS TRAPPED AT PORT M3.
1. Install pressure gauge at quick disconnect on port

M3 on main valve after releasing the pressure. To
release the pressure, activate level down to the end
3121157 – JLG Lift – 8-13

Figure 8-15. Pressure Setting Adjustments - Sheet 1 of 2
8-14 – JLG Lift – 3121157

Figure 8-16. Pressure Setting Adjustments - Sheet 2 of 2
3121157 – JLG Lift – 8-15

Figure 8-17. Location of Components - Main Control Valve (Sheet 1 of 2)
8-16 – JLG Lift – 3121157

Figure 8-18. Location of Components - Main Control Valve (Sheet 2 of 2)
3121157 – JLG Lift – 8-17

A. 18-20 ft.lbs. (24.5-27

Nm)
B. 25-27 ft.lbs. (34-37 Nm)
C. 4-5 ft.lbs. (6.5-9.5 Nm)
Figure 8-19. Main Control Valve Torque Values
8-18 – JLG Lift – 3121157

1. Flow Control Cartridge

2. Directional Control
Valve
3. Relief Cartridge
Figure 8-20. Platform Valve Identification
A. 18-20 ft.lbs. (24.5-27

Nm)
Figure 8-21. Platform Valve Torque Values
3121157 – JLG Lift – 8-19

8.8 HYDRAULIC PUMP (GEAR) 7. Remove pump from vise and place on clean work
bench, remove the four hex head bolts and spacers
if applicable.
Disassembly
NOTE: The following general instructions also apply to mul-
tiple section gear pumps, the only extra parts are the
coupling between the drive shafts and the center dis-
tance plate which divides the two pump sections.
This repair procedure also applies to the "W" series
Gear Motors.
1. It is very important to work in a clean work area

when repairing hydraulic products. Plug ports and
wash exterior of pump with a proper cleaning sol-
vent before continuing.
2. Remove port plugs and drain oil from pump.
8. Lift and remove end cover.
3. Use a permanent marker pen to mark a line across

9. Carefully remove gear housing and place on work
the mounting flange, gear housing and end cover.
bench. Make sure the rear bearing block remains on
This will assure proper reassembly and rotation of
the drive and idler shafts.
pump.
4. Remove key from drive shaft if applicable.
5. Clamp the mounting flange in a protected jaw vise

with the pump shaft facing down.
6. Loosen the four metric hex head bolts.
8-20 – JLG Lift – 3121157

10. Remove rear bearing block from drive and idler 13. Remove the front bearing block.
shafts.
14. Turn the mounting flange over, with the shaft seal up,
11. Remove idler shaft from bearing block. and remove the retaining ring with proper snap ring
pliers.
12. Remove drive shaft from mounting flange. There is

no need to protect the shaft seal as it will be 15. Remove the oil seal from mounting flange, be care-
replaced as a new item. ful not to mar or scratch the seal bore.
16. Remove the dowel pins from the gear housing. Do
not lose pins.
17. Remove seals from both bearing blocks and dis-

card.
3121157 – JLG Lift – 8-21

Inspect Parts For Wear 20. Inspect both the drive gear shaft and idler gear
shafts at the bearing points and seal area for rough
18. Clean and dry all parts thoroughly prior to inspec- surfaces and excessive wear.
tion. It is not necessary to inspect the seals as they
will be placed as new items.
21. Inspect gear face for scoring or excessive wear. If

the face edge of gear teeth are sharp, they will mill
19. Check drive shaft spine for twisted or broken teeth, into the bearing blocks. If wear has occurred, the
check keyed drive shaft for broken or chipped key- parts are unusable.
way. No marks or grooves on shaft in seal area,
some discoloration of shaft is allowable.
22. Inspect bearing blocks for excessive wear or scoring

on the surfaces which are in contact with the gears.
Also inspect the bearings for excessive wear or scor-
ing.
23. Inspect the area inside the gear housing. It is normal
for the surface inside the gear housing to show a
clean "wipe" on the inside surface on the intake side.
There should not be excessive wear or deep
scratches and gouges.
8-22 – JLG Lift – 3121157

General Information bore. Uniform pressure must be used to prevent

misalignment or damage to the seal.
It is important that the relationship of the mounting flange,
bearing blocks and gear housing is correct. Failure to
properly assemble this pump will result with little or no
flow at rated pressure.
Reverse Shaft Rotation of Pump

NOTE: This pump is not bi-rotational, if the shaft rotation
must be changed the following procedure must be
followed.
Reversing the shaft rotation of the "W" series gear pump

may be accomplished by rotating, as a group, the two
bearing blocks and the gear housing 180° in relationship
to the remaining parts of the pump. This procedure will 2. Install retaining ring in groove in seal bore of mount-
place the pressure port on the opposite side of the pump ing flange.
from its original position.
Assembly
NOTE: New seals should be installed upon reassembly of
pump or motor. deter to page 8 for the necessary kit
part numbers for the W-600, W-900 and W-1500
pumps and motors.
3. Place front and back bearing blocks on a clean sur-

face with the E-seal grooves facing up. Apply a light
coating of petroleum jelly in the grooves. Also coat
the E-seal and backup with the petroleum jelly, this
will help keep the seals in place during reassembly.
1. Install new shaft seal in mounting flange with part

lumber side facing outboard. Press the seal into the
seal lore until the seal reaches the bottom of the
4. Place the E-seals, flat side outward, into the grooves

in both bearing blocks. Follow by carefully placing
the backup ring, flat side outward, in the groove
made by the E-seal and the groove in the bearing
block. (Note: in the W900 series pump, in the center
of the backup ring and E-seal there is a notch make
sure that these notches line up so the backup ring
will set flush with the E-seal). The backup ring in the
W1500 pump is symmetrical.
3121157 – JLG Lift – 8-23

5. Place mounting flange, with shaft seal side down, on 11. Install two dowel pins in the holes in the mounting
a clean flat surface. flange or two long dowel pins through gear housing
if pump is a multiple section pump.
6. Apply a light coating of petroleum jelly to the
exposed face of the front bearing block.
12. To install the O-rings in the gear housing, apply a

7. Insert the drive end of the drive shaft through the light coating of petroleum jelly in the grooves on
bearing block with the seal side down, and the open both sides of the gear housing. Also coat the new O-
side of the E-seal pointing to the intake side of the rings and install them in the grooves.
pump.
8. Install the seal sleeve over the drive shaft and care-
fully slide the drive shaft through the shaft seal.
Remove the seal sleeve from shaft.
13. Gently slide the gear housing over the rear bearing
block assembly, slide housing down until the hous-
ing engages the dowel pins. Press firmly in place
with hands, do not force or use any tool. Check to
9. Install the idler gear shaft in the remaining position in make sure the in-take port in the housing is on the
the bearing block. Apply a light coat of clean oil to same side as the open end of the E-seal and that the
the face of the drive and idler gears. marked lines on the mounting flange and gear hous-
ing are in alignment.
14. The surface of the rear bearing block should be
slightly below the face of the gear housing. If the
bearing block sits higher then the rear face of the
gear housing then the E-seal or o-ring have shifted
10. Pick up the rear bearing block, with seal side up and
with open end of the E-seal facing the intake side of
the pump, place over the drive and idler gear shafts.
8-24 – JLG Lift – 3121157

out of the groove. If this is the case, remove the gear the pump and check for assembly problems, then
housing and check for proper seal installation. reassemble the pump.
15. Install the two remaining dowel pins in the rear of the 20. The name plate located on the end cover contains
gear housing, if applicable, and place the end cover the build date code and the model number. Please
over the back of the pump. refer to this information when corresponding with
the J.S. Barnes Service Department.
Table 8-3.Hydraulic Pump Bolt Torque Chart
Torque Torque
Values, Values, Zinc
Pump Series Thread Size
Black Oxide Plated End
End Cover Cover
W-600 M 8 x 1.25 18-21 ft.lb. 16-18 ft.lb.

24-30 Nm 21.7-24.4
Nm
16. Install the four spacers, if applicable, and hex head W-900 M 10 x 1.5 50-55 ft.lb. 38-43 ft.lb.
bolts through the bolt holes in the end cover, hand 68-75 Nm 51.5-58.3
tighten. Nm
W-1500 M 12 x 1.75 80-85 ft.lb. 68-73 ft.lb.

108-115 Nm 92.2-99 Nm
17. Place mounting flange of the pump back in the pro-

tected jawed vise and alternately torque the bolts to
the torque specifications in the torque chart. All
torque figures are for "dry torque" bolts.
18. Remove pump from vise.
19. Place a small amount of clean oil in the inlet of the
pump and rotate the drive shaft away from the inlet
one revolution. If the drive shaft binds, disassemble
3121157 – JLG Lift – 8-25

Placing Pump Back Into Service 8.9 VARIABLE PUMP

1. If shop test stand is available, the following proce-
dure for testing rebuilt pumps is recommended: Ports and Pressure Gauges
Proper servicing of pumps and motors requires that pres-
a. Mount pump on test stand making sure that the sure be measured and monitored at various points in the
proper level of clean oil is available in the reser- hydraulic circuit. The Series 42 pump has several loca-
voir. Check suction line for leaks and obstructions at which to take these measurements. The following
tions. outlines show the locations of the various gauge ports.
b. Start pump and run for three minutes at zero The following table shows the recommended gauge size
pressure. and the fitting size for each port.
c. Intermittently load pump to 500 P.S.I. for three
minutes. Table 8-4. Recommended Gauge Size
d. Intermittently load pump to 1000 P.S.I. for three
Recommended
minutes. Gauge
Pressure Gauge Size
e. Intermittently load pump to 2000 P.S.I. for three Port Fitting
Measured
minutes. Name
PSI Bar
f. Remove pump from test stand and check for
M1 & System 10000 600 9/16-18 ORF
freeness of drive shaft. Check pump for signs of
M2 Pressure
external leakage. Ports A & B
2. If shop test stand is not available, the following pro-
M3 Charge 1000 60 3/4-16 ORF
cedure for testing rebuilt pumps is recommended:
a. For engine driven pumps, mount pump on M4 & Servo 1000 60 9/16-18 ORF
equipment and run pump at 1/2 engine speed at M5
zero pressure for three minutes. Case
L1 & 500 35 1-1/16-12
b. By operating control valve, build pressure inter- L2 ORF
mittently for three minutes.
S Charge Pump 30 in. Hg 1 1-1/16-12
c. Increase engine speed to full throttle and build
Inlet Vacuum Vac. ORF
pressure intermittently for three minutes.
d. Stop engine and check pump for external leaks.
NFPE Control
The 3-position FNR control and the electric and hydraulic
non-feedback proportional (NFPE and NFPH) controls are
non-feedback type controls. The FNR and NFPE controls
consist of modules mounted on the pump housing. The
hydraulic input for NFPH is received through ports on the
top of the pump [9/16–18 SAE O-ring fitting].
The non-feedback controls are set at the factory. The con-
trol modules can be removed to clean the ports and
change the O-rings.
The orifice plugs for the FNR and NFPE are located inside
the servo piston covers. The orifice plugs for the NFPH are
located in the NFPH ports. Orifice plugs may be cleaned
or replaced.
8-26 – JLG Lift – 3121157

Removal and Installation of FNR and NFPE SHIM ADJUSTABLE STYLE
Modules
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to housing
[4 mm Int. Hex], and remove module from pump
housing.
3. Remove O-rings from the control ports. Examine
ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft•lbf].
Removal and Installation of FNR and NFPE

Control Orifices
NOTE: Future models may contain an orifice plate between 1. Plug 4. Spring T-
module and pump housing. This will take the place 2. O-ring Seal
of the orifice plugs beneath the servo piston cover. 3. Shims 5. Poppet
1. Remove servo piston cover. Figure 8-22. Shim Adjustable Charge Relief Valve
Components
2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
1. Remove the shim adjustable charge relief valve plug
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft•lbf)]. [1 in Hex] from the pump housing. Remove the O-
ring from the plug.
Charge Relief Valve 2. Remove the spring and poppet from the housing.
The charge relief valve may be removed for cleaning and
3. Do not alter the shims which may be installed
installation of fresh O-rings. The pressure setting may be
between the spring and valve plug, or interchange
changed. However, note that the setting will vary for differ-
parts with another valve. Inspect the poppet and
ent charge flows which depends on charge pump size
mating seat in the housing for damage or foreign
and pump speed. The factory setting is set relative to case
material.
pressure at 1800 rpm. The actual charge pressure will
vary at different speeds. 4. If desired, the charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar /
1.25 mm (58 psi / 0.050 in). The effective setting will
vary.
To confirm the charge relief valve setting, measure

charge pressure (port M3) with the pump in stroke.
The charge pressure should level off when the relief
setting is reached.
3121157 – JLG Lift – 8-27

1. System Pressure Gauge Port M2
2. System Pressure Port B
3. System Pressure Port A
4. System Pressure Gauge Port M1
5. Servo Pressure Gauge Port M5
6. Case Drain Port L2 (non-feed-

back)
7. Case Drain Port L2
8. Servo Pressure Gauge Port L4
9. Case Drain Port L1
10. Case Drain Port L1 (non-feed-

back)
11. Charge Pressure Gauge
12. Charge Pump Inlet Port S
Figure 8-23. Gauge Port Locations
8-28 – JLG Lift – 3121157

Plug/ Torque
#
Fitting lb. ft. Nm
1 Servo Gauge Port N/A N/A
M4
2 11/16 20-35 27-47
3 9/16 70-100 95-135
4 Case Drain Port N/A N/A
L1
5 Charge Pressure N/A N/A
Gauge M3
6 Charge Pump Inlet 85 115
Port S
7 Case Drain Port N/A N/A
L2
8 Port N N/A N/A
9 System Gauge M1 N/A N/A
& M2
10 System Ports 85 115
A&B
11 11/16 20-35 27-47
12 9/16 70-100 95-135
13 11/16 20-35 27-47
Figure 8-24. Plugs/Fittings Size & Torque
3121157 – JLG Lift – 8-29

5. Install a new O-ring on the valve plug. Reinstall the Shaft Seal and Shaft Replacement
poppet, spring, and plug (with shims and O-ring)
into the pump housing [55-135 Nm (40-100 ft•lbf)].
SCREW ADJUSTABLE STYLE
1. Retaining 2. Seal Carrier Assem-

1. Lock Nut 4. Spring T- Ring bly
2. O-ring Seal
3. Plug 5. Poppet Figure 8-26. Shaft Seal Components
Figure 8-25. Screw Adjustable Charge Relief A lip type shaft seal is used in Series 42 pumps. This seal
Valve Components and/or the shaft can be replaced without major disassem-
bly of the unit. Replacement generally requires removal of
the pump from the machine.
1. Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and housing so as to
approximately maintain the original adjustment
when assembling, Remove the screw adjustable
charge relief valve plug by loosening the lock nut [1-
1/16 in Hex] and unscrewing the plug [8 mm Int.
Hex]. Remove the O-ring from the plug.
2. Remove the spring and poppet from the housing.
3. Inspect the poppet and mating seat in the housing
for damage or foreign material.
4. Install a new O-ring on the valve plug. Reinstall the
poppet and spring. Reinstall the plug with its lock
nut [47-57 Nm (34-42 ft•lbf)], aligning the marks
made at disassembly.
5. Check and adjust, if necessary, the charge pressure.
For screw adjustable "anti-stall" charge relief valves,
an approximate rule of thumb is 2.8 bar / quarter
turn (40 psi / quarter turn).
1. O-ring 4. Sealant may be used on outside diam-
To confirm the charge relief valve setting, measure 2. Seal eter
charge pressure (port M3) with the pump in stroke. 3. Seal Car- 5. Inside Lip (face down)
The charge pressure should level off when the relief rier 6. Press Seal to Bottom of Seal Carrier
setting is reached.
Figure 8-27. Installation of Shaft Seal
8-30 – JLG Lift – 3121157

1. Position the pump with the shaft facing up. rier. If the shaft is not being replaced proceed to step
11.
NOTE: If the unit is positioned horizontally when the shaft is
removed, the cylinder block could move out of
place, making shaft installation difficult.
2. Remove the retaining ring from the housing.

3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To install a
new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the shaft
bearing side down, and press out the old seal. An
appropriately sized pipe spacer or socket wrench
can be used as a press tool. Once removed, the seal
is not reusable.
6. Inspect the seal carrier and the new seal for dam-
age. Inspect the sealing area on the shaft for rust,
wear, or contamination. Polish the sealing area on
the shaft if necessary.
7. Press the new seal into the shaft bearing side of the
seal carrier. The seal lip must face the outside of the
pump. Be careful not to damage the seal. The out-
side diameter of the seal may be coated with a seal-
ant (e.g. Loctite High Performance Sealant #59231)
prior to installation. This aids in preventing leaks
caused by damage to the seal bore in the seal car-
1. Key 4. Roller Bear-

2. Shaft Assem- ing
bly 5. Shaft
3. Retaining
Ring
8. Remove the shaft and roller bearing assembly from

the pump or motor. The bearing assembly can be
transferred to the new shaft (steps 9 and 10).
9. Remove the retaining ring that secures roller bearing
assembly with a snap ring plier. Remove the roller
bearing assembly. Place roller bearing assembly on
new shaft and secure with the retaining ring.
10. Place roller bearing assembly on new shaft and
secure with the retaining ring.
11. Wrap the spline or key end of shaft with thin plastic
to prevent damage to the seal lip during installation.
64 Lubricate the inside diameter of the shaft seal
with petroleum jelly.
3121157 – JLG Lift – 8-31

12. Place the O-ring onto the shaft bearing and lubricate 7. Prior to assembly, lubricate the gerotor assembly
with petroleum jelly. with clean hydraulic oil.
13. Slide the seal carrier assembly over the shaft and 8. Install the gerotor drive pin into the hole in the drive
into the housing bore. Press against O-ring. Hold coupling, and retain with grease or petroleum jelly.
inward pressure against the shaft to compress the
9. Install the drive coupling onto the pump shaft with
cylinder block spring while pressing the seal carrier
the smaller outside diameter oriented away from the
into place.
pump shaft. Different couplings are used with the
14. Install the retaining ring. different auxiliary pad options.
10. Install the gerotor assembly onto the coupling.
Charge Pump 11. Install the gerotor cover locating pin into the pump
housing. Install the gerotor cover assembly over the
The charge pump may be disassembled to inspect
gerotor. The locating pin must engage the slot in the
and clean, or to change the auxiliary shaft drive cou-
gerotor cover.
pling.
NOTE: The charge pump rotation is determined by the loca-
1. Remove auxiliary pump, if necessary.
tion of the gerotor recess and pressure balance hole
2. Remove the screws retaining the charge pump in the gerotor cover. Different gerotor covers are
cover to the pump housing [Torx T45] (seven (7) used for clockwise and counterclockwise rotation
screws are used with the "no pad" or SAE "A" auxil- pumps.
iary mounting pad charge pump cover, while six (6)
12. Install new pressure balance O-rings onto the gero-
screws are used with the SAE "B" auxiliary mounting
tor cover and retain with petroleum jelly or grease.
pad charge pump cover). Remove the charge pump
(An additional O-ring was used on the gerotor cover
cover, gasket, and the cover locating pins.
of very early production pumps with the SAE "A" pad
3. Remove the gerotor cover assembly from the option.)
charge pump cover or the back of the pump hous-
13. Install the charge pump cover locating pins and a
ing. Remove the gerotor cover O-rings. Two (2) O-
new charge pump cover gasket.
rings are used on the gerotor cover of all pumps.
(An additional O-ring was used on the gerotor cover 14. Install the charge pump cover. The cover must
of very early production pumps with the SAE "A" pad engage the gerotor cover and the locating pins.
option.) Install the charge pump cover screws and torque
evenly [36-43 Nm (26-32 ft•lbf)].
4. Remove the gerotor assembly from the gerotor
cover or pump housing. 15. If necessary, reinstall auxiliary pump.
5. Remove the gerotor drive pin and drive coupling.
Remove the gerotor cover locating pin from the
pump housing.
6. Each part should be inspected separately if they are
to be reused. If either of the gerotor assembly parts
needs to be replaced, they must both be replaced.
Always replace the O-rings and charge pump cover
gasket. Inspect the journal bearing in the gerotor
cover for excessive wear.
8-32 – JLG Lift – 3121157

1 Cover Retaining Screw

.
2 O-ring
.
3 Gerotor Cover
.
4 Gerotor Assembly
.
5 Drive Coupling
.
6 Gerotor Cover Locating Pin
.
Figure 8-29. Charge Pump Components
3121157 – JLG Lift – 8-33

8.10 HYDRAULIC PUMP W/HAYES PUMP NOTE: In most cases, the reservoir is above the pump inlet
so that the pressure head created by the higher oil
DRIVE COUPLING LUBRICATION level helps to keep the inlet pressures within an
Any time pump or pump drive coupling is removed coat, acceptable range and prevent high vacuum levels.
pump and drive coupling splines with Lithium Soap Base However, due to hose routing or low reservoir loca-
Grease (TEXACO CODE 1912 OR EQUIVALENT) coupling tions, there may be air trapped within this line. It is
is greased before assembly. important to assure that the air is bled from this line.
This can be accomplished by loosening the hose at
the fitting closest the pump. When oil begins to flow,
8.11 HYDRAULIC COMPONENT START-UP the line is full, the air has been purged, and the fitting
can be retightened to its specified torque. If the tank
PROCEDURES AND needs to be pressurized in order to start the flow of
RECOMMENDATIONS oil, a vacuum reading should be taken at the inlet of
the pump during operation in order to verify that the
From a hydrostatic component standpoint, the goal at pump is not being asked to draw an inlet vacuum
system start up is to put into functional operation, the higher than it is capable of.
hydrostatic system in such a way as to preserve the
designed life span of the system. The following start-up Be certain to fill the pump and/or motor housing with
procedure should be adhered to whenever a new pump clean hydraulic fluid prior to start up. Fill the housing by
or motor is initially installed into a machine, or a system is pouring filtered oil into the upper case drain port.
restarted after either a pump or motor has been removed
and/or replaced. NOTE: It is highly recommended to use the highest possible
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
BE DISABLED (WHEELS RAISED OFF THE GROUND, WORK FUNC-
NOTE: In initial start-up conditions, it may be convenient to
TIONS DISCONNECTED, ETC.) WHILE PERFORMING THE PROCE-
fill the housing, just prior to installing the case drain
DURE IN ORDER TO PREVENT INJURY. TAKE NECESSARY SAFETY
line. Component, (especially motor), location may be
PRECAUTIONS BEFORE MOVING THE VEHICLE/MACHINE.
such that access to the case drain port after installa-
tion is not realistic.
Prior to installing the pump and/or motor, inspect the
unit(s) for damage that may have been incurred during
NOTE: Make certain that the oil being used to fill the compo-
shipping and handling. Make certain that all system com-
nent housing is as clean as possible, and store the
ponents (reservoir, hoses, valves, fittings, heat exchanger,
fill container in such a way as to prevent it from
etc.) are clean prior to filling with fluid.
becoming contaminated.
Fill the reservoir with recommended hydraulic fluid. This
fluid should be passed through a 10 micron (nominal, no Install a 60 bar (or 1000 psi) pressure gauge in the charge
bypass) filter prior to entering the reservoir. The use of pressure gauge port in order to monitor the charge pres-
contaminated fluid will cause damage to the components, sure during start-up.
which may result in unexpected vehicle/machine move-
It is recommended that the external control input signal,
ment.
(electrical connections for EDC), be disconnected at the
NOTE: If a pump or motor is being replaced due to internal pump control until after initial start-up. This will ensure that
damage, the remaining units (pump or motors) need the pump remains in its neutral position.
to be inspected for damage and contamination, and
the entire hydraulic system will need to be flushed
and the fluid replaced. Failure to do so may cause DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRAL
considerable damage to the entire system. POSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU-
TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS
The inlet line leading from the reservoir to the pump must ACTUATED DURING INITIAL START-UP.
be filled prior to start-up. Check the inlet line for property
tightened fittings and make sure it is free of restrictions "Jog" or slowly rotate the engine until charge pressure
and air leaks. starts to rise. Start the engine and run at the lowest possi-
ble RPM until charge pressure has been established.
Excess air should be bled from the system lines as close
to the motors as possible.
8-34 – JLG Lift – 3121157

NOTE: With engine on low idle, "crack", (loosen-don't

remove), system lines at the motor(s). Continue to
run engine at low idle and tighten system lines as
soon as oil is observed to leak from them. When oil
is observed to "leak" at the motor, line is full and air
has been purged.Tighten system hoses 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.
INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA-

TOR'S ABILITY TO CONTROL THE MACHINE.
Shut down engine and connect external control input sig-

nal. Reconnect machine function(s), if disconnected ear-
lier. Start engine, checking to be certain pump remains in
neutral. With engine at normal operating RPM, slowly
check forward and reverse machine operation.
Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between for-
ward and reverse for at least five minutes.
Shut down engine, remove gauges, and plug ports.
Check reservoir level and add filtered fluid if needed.
Machine is now ready for operation.
3121157 – JLG Lift – 8-35

2792593-C
Figure 8-30. Hydraulic Schematic - Gradall Chassis - Sheet 2 of 4
8-36 – JLG Lift – 3121157

3121157 – JLG Lift – 8-37

2792593-C
8-38 – JLG Lift – 3121157

Figure 8-33. Hydraulic Schematic - CAT Chassis - Sheet 1 of 4
3121157 – JLG Lift – 8-39

1001107109-A
8-40 – JLG Lift – 3121157

3121157 – JLG Lift – 8-41

1001107109-A
8-42 – JLG Lift – 3121157

SECTION 9. JLG CONTROL SYSTEM
9.1 INTRODUCTION The upper lift, swing, and drive are controlled by individual
joysticks, with steering being controlled by a rocker switch
built into the top the drive joystick. To activate Drive, Lift,
and Swing simply pull up on the slide lock location on the
WHEN INSTALLING A NEW GROUND MODULE CONTROLLER ON joystick and move the handle into the direction desired.
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON-
TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUD- The control system will control the voltage output to the
ING OPTIONS. 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
system.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
The JLG Control System controller has a built in LED to
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
indicate any faults. The system stores recent faults which
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC-
may be accessed for troubleshooting. Optional equip-
OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
ment includes a soft touch system, head and tail lights,
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM
and ground alarm. These options may be added later but
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
must be programmed into the control system when
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
installed.
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
The JLG designed Control System is a 12 volt based The Control System may be accessed utilizing a custom
motor control unit installed on the boom lift. designed, hand held analyzer (Analyzer Kit, JLG part no.
2901443) which will display two lines of information at a
The JLG Control System has reduced the need for time, by scrolling through the program.
exposed terminal strips, diodes and trimpots and provides
simplicity in viewing and adjusting the various personality NOTE: Each module has a label with the JLG part number
settings for smooth control of: acceleration, deceleration, and a serial number which contains a date code.
creep, min speed, and max.-speed for all boom, drive,
and steering functions.
Analyzer Dis-
Enter Key
Escape Key
Stores and selects Top Level,
To return home or
Sub Level, and item menus
access previous menu
Left & Right Arrow Keys

Up & Down Arrow Used to move between Top
Keys Level, Sub Level, and item
Figure 9-1. Hand Held Analyzer
3121157 – JLG Lift – 9-1

Figure 9-2. ADE Block Diagram
9-2 – JLG Lift – 3121157

9.2 TO CONNECT THE JLG CONTROL The top level menus are as follows:
SYSTEM ANALYZER HELP

DIAGNOSTICS
1. Connect the four pin end of the cable supplied with SYSTEM TEST
the analyzer, to the controller module located in the ACCESS LEVEL
platform box or at the controller module in the PERSONALITIES
ground control box and connect the remaining end MACHINE SETUP
of the cable to the analyzer. CALIBRATIONS (view only)
NOTE: The cable has a four pin connector at each end of If you press ENTER, at the HELP: PRESS ENTER display,
the cable; the cable cannot be connected back- and a fault is present, the analyzer display will scroll the
wards. fault across the screen. If there was no fault detected, the
display will read: HELP: EVERYTHING OK. If powered up
2. Power up the Control System by turning the lower at the ground station, the display will read: GROUND OK.
key to the platform or ground position and pulling
both emergency stop buttons on. If ENTER is pressed again, the display moves to the fol-
lowing display:
9.3 USING THE ANALYZER

With the machine power on and the analyzer connected
properly, the analyzer will display the following:
LOGGED HELP
1: POWER CYCLE (0/0)
At this point, the analyzer will display the last fault the sys-
tem has seen, if any are present. You may scroll through
HELP:
the fault logs to view what the last 25 faults were. Use the
PRESS ENTER
right and left arrow keys to scroll through the fault logs. To
At this point, using the RIGHT and LEFT arrow keys, you return to the beginning, press ESC. two times. POWER
can move between the top level menu items. To select a CYCLE (0/0) indicates a power up.
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
3121157 – JLG Lift – 9-3

PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 9-3. Analyzer Connecting Points
9-4 – JLG Lift – 3121157

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.
9.4 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 MENU:
which cannot be changed until you enter a password to ACCESS LEVEL 2
advance to a lower level. This ensures that a setting can- Press ENTER to select the ACCESS LEVEL menu.
not be accidentally altered. To change the access level,
the correct password must be entered. To enter the pass- Using the UP or DOWN arrow keys, enter the first digit of
word, scroll to the ACCESS LEVEL menu. For example: 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.
3121157 – JLG Lift – 9-5

Figure 9-4. Control Module Location
9-6 – JLG Lift – 3121157

Once the correct password is displayed, press ENTER. 9.5 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.
3121157 – JLG Lift – 9-7

9.6 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.
9.7 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 9-1, Personality Ranges/Defaults, and

in this Service Manual for the recommended factory
settings.
NOTE: Password 33271 will give you access to level 1,

which will permit you to change all machine person- Place machine in stowed position with the boom between
ality settings. the rear wheels.
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.
9-8 – JLG Lift – 3121157

3121157
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

MIN FORWARD X% MIN FORWARD X% MIN FORWARD X% MIN UP X% MIN LEFT X%
MAX FORWARD X% MAX FORWARD X% MAX FORWARD X% MAX UP X% MAX LEFT X%
– JLG Lift –
MIN REVERSE X% MIN REVERSE X% MIN REVERSE X% CREEP UP X% CREEP LEFT X%
MAX REVERSE X% MAX REVERSE X% MAX REVERSE X% MIN DOWN X% MIN RIGHT X%

ELEV. MAX X% ELEV F MAX X% ELEV F MAX X% MAX DOWN X% MAX RIGHT X%
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%

CREEP R MAX X% CREEP R MAX X%
TO Note: Some screens may not be available depending upon machine configuration.
MENU:
MACHINE SETUP
Figure 9-5. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4
9-9
9-10
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:
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%
MIN UP X% MIN IN X% MIN IN X% MIN UP X% MIN LEFT X% MIN UP X% SWING X%
MAX UP X% MAX IN X% MAX IN X% MAX UP X% MAX LEFT X% MAX UP X% BASKET LEVEL X%
– JLG Lift –
MIN DOWN X% MIN OUT X% MIN OUT X% MIN DOWN X% MIN RIGHT X% MIN DOWN X% BASKET ROTATE X%
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%
3121157
3121157
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
9-11
9-12
– JLG Lift –
3121157
3121157
– JLG Lift –
NOTE: Some screens may not be available depending upon machine configuration.
Figure 9-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4
9-13
9-14
– JLG Lift –
3121157
3121157
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
601S PERKINS 404C
740A DEUTZ F4 TIER2
800A DEUTZ F3 TIER2
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
9-15
9-16
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
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?
3121157
3121157
ACCESS LEVEL:
CODE 33271
MENU: ACCESS LEVEL:

ACCESS LEVEL 1 CODE 00000
TO:
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
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS
MIN FORWARD X% MIN FORWARD X% MIN FORWARD X% MIN UP X% MIN LEFT X%
– JLG Lift –
MAX FORWARD X% MAX FORWARD X% MAX FORWARD X% MAX UP X% MAX LEFT X%
MIN REVERSE X% MIN REVERSE X% MIN REVERSE X% CREEP UP X% CREEP LEFT X%
MAX REVERSE X% MAX REVERSE X% MAX REVERSE X% MIN DOWN X% MIN RIGHT X%
ELEV. MAX X% ELEV F MAX X% ELEV F MAX X% MAX DOWN X% MAX RIGHT X%
CREEP MAX X% ELEV R MAX X% ELEV R MAX X% CREEP DOWN X% CREEP RIGHT X%
TO:
CREEP F MAX X% CREEP F MAX X%
MENU:
MACHINE SETUP LEFT TRACK: RIGHT TRACK:
CREEP R MAX X% CREEP R MAX X%
9-17
9-18
FROM:
PERSONALITIES:
SWING
PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE PLATFORM LEVEL PLATFORM ROTATE JIB LIFT GROUND MODE GEN SET/WELDER
TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE: PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: GROUND MODE: GEN SET/WELDER:
ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS MAIN UP: XXX% ENGINE 1800 RPM
TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE: PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: GROUND MODE:
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS MAIN DOWN: XXX%
MIN UP X% MIN IN X% MIN IN X% MIN UP X% MIN LEFT X% MIN UP X% SWING: XX%
MAX UP X% MAX IN X% MAX IN X% MAX UP X% MAX LEFT X% MAX UP X% PLT LEVEL: XXX%
– JLG Lift –
MIN DOWN X% MIN OUT X% MIN OUT X% MIN DOWN X% MIN RIGHT X% MIN DOWN X% PLT ROTATE: XXX%
MAX DOWN X% MAX OUT X% MAX OUT X% MAX DOWN X% MAX RIGHT X% MAX DOWN X% MAIN TELE: XXX%
GROUND MODE:
TOWER TELE: XXX%
GROUND MODE:
TOWER UP: XXX%
GROUND MODE:
TOWER DOWN: XXX%
GROUND MODE:
JIB LIFT: XXX%
3121157
3121157
FROM:
MENU:
PERSONALITIES
MENU: MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN:
TO
MACHINE SETUP 400S ANSI USA FORD EFI GAS 110 TEETH NO GLOW PLUGS DISABLED ENABLED
TILT:
MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN:
450A ANSI EXPORT FORD EFI D/F 133 TEETH AIR INTAKE ENABLED DISABLED
MODEL NUMBER: MARKET: ENGINE: GLOW PLUG:

510A CSA DEUTZ F4 TIER1 IN-CYLINDER
TO: MODEL NUMBER: MARKET: ENGINE:

MENU: 600S CE DEUTZ F3 TIER1
CALIBRATIONS
600A AUSTRALIA CAT. 3024C

600SC JAPAN CAT. 3044C

601S DEUTZ F4 TIER2
740A
– JLG Lift –
DEUTZ F3 TIER2
800A FORD GAS TIER2
800S FORD D/F TIER2
ENGINE:
DEUTZ ECM
ENGINE:
DUAL FUEL ECM
ENGINE:
PERKINS ECM
ENGINE:
CAT ECM
9-19
9-20
FROM: TILT: JIB: 4 WHEEL STEER: SOFT TOUCH: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM: TO
ENGINE SHUTDOWN: 5 DEGREES NO NO NO NO MOTION ENABLED NO NO LOAD SENSOR:
TILT: JIB: 4 WHEEL STEER: SOFT TOUCH: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM:
4 DEGREES YES YES YES BELT DRIVE MOTION CUTOUT YES WARN ONLY
TILT: LOAD SYSTEM:
3 DEGREES CUTOUT PLATFORM
TILT: LOAD SYSTEM:
– JLG Lift –
4 DEGREES + CUT CUTOUT ALL
TILT: LOAD SYSTEM:
3 DEGREES + CUT SPECIAL 1
3121157
3121157
FROM LOAD SENSOR: FUNCTION CUTOUT: GROUND ALARM: DRIVE: TEMPERATURE: DRIVE CONTROL: CLEARSKY: CRIBBING OPTION:
LOAD SYSTEM: 4 UNDER PLATFORM NO NO 4WD CELSIUS NORMAL NO NO
LOAD SENSOR: FUNCTION CUTOUT: GROUND ALARM: DRIVE: TEMPERATURE: DRIVE CONTROL: CLEARSKY: CRIBBING OPTION:
1 ON ROTATOR BOOM CUTOUT DRIVE 2WD FAHRENHEIT PROPULSION YES YES
FUNCTION CUTOUT: GROUND ALARM: DRIVE: DRIVE CONTROL:

DRIVE CUTOUT DESCENT 2WD W/ 2-SPEED ENHANCED
– JLG Lift –
FUNCTION CUTOUT: GROUND ALARM:
DRIVE CUT E&T MOTION
9-21
FROM:
MENU:
9-22
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:
SERVICE MODE
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 CAPACITY LENGTH CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE
FORWARD XXX% MAIN UP XXX% NOT ACTIVE BATTERY: XX.XV OFF ANGLE XXX.X SWITCH: CLOSED RX/SEC: X LOAD ZERO: XXX ON: XXH XXM SOFTWARE: P5.X
JOYSTICK STEER: JOYSTICK SWING: BATTERY VOLTAGE: PLATFORM MODULE CHASSIS TILT: UMS TO TURNTABLE CAPACITY ANGLE CAN STATISTICS CALABRATION DATA DATALOG: GROUND MODULE
LEFT XXX% LEFT XXX% XX.XV BATTERY: XX.XV XX.X DEGREES ANGLE XXX.X SWITCH: CLOSED TX/SEC: X LOAD 500LB: XXX ENGINE: XH XM CNST. DATA: PX.X
DRIVE OUTPUT: LIFT OUTPUT: COOLANT AMBIENT CHASSIS TILT: UMS INCLINATION PERCENT OF MAX CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE
FORWARD XXX% MAIN UP XXX% TEMPERATURE:XXXC TEMPERATURE:XXXC X-AXIS: 0.0 ANGLE XXX.X LOAD: XXXX% BUS OFF: X PLATFORM UP: XXX DRIVE: XH XM HARDWARE: REV X
DRIVE FORWARD SWING OUTPUT: ELECTRIC FAN PLATFORM SELECT CHASSIS TILT: UMS STATUS: PLATFORM LOAD CAN STATISTICS CALABRATION DATA DATALOG: GROUND MODULE
COMMANDED:XXXXMA LEFT XXX% OUTPUT: OFF KEYSWITCH: OPEN Y-AXIS: 0.0 SENSOR FAULT STATE:OK PASSIVE: 1 PLATFORM DN: XXX LIFT: XH XM S/N: XXXXXX
DRIVE REVERSE PLATFORM LEVEL: ELECTRIC FUEL GROUND SELECT AUXILIARY POWER CAN STATISTICS DATALOG: PLATFORM MODULE
COMMANDED:XXXXMA UP XXX% PUMP OUTPUT: OFF KEYSWITCH:CLOSED SWITCH: OPEN MSG ERROR: XXXX SWING: XH XM SOFTWARE: P5.X
DRIVE OUTPUT PLATFORM ROTATE: ENGINE OIL STATION CONTROL: HORN DATALOG: PLATFORM MODULE
ACTUAL:XXXXMA RIGHT XXX% PRESSURE:XXXXPSI GROUND SWITCH: OPEN TELE: XH XM HARDWARE: REV X
STEER OUTPUT: MAIN TELESCOPE: FUEL SELECTION FOOTSWITCH INPUT RETURN HYDRAULIC DATALOG: PLATFORM MODULE
LEFT XXX% IN XXX% SWITCH:GAS GROUND: OPEN FILTER: OPEN MAX TEMP: XXC S/N: XXXXXX
LEFT TRACK TOWER TELESCOPE: FUEL SELECTION FOOTSWITCH INPUT CHARGE PUMP DATALOG: TCU MODULE
OUTPUT: FWD XXX% IN XXX% STATUS:GAS PLATFORM: CLOSED FILTER: OPEN MIN TEMP: XXC SOFTWARE: XXX
RIGHT TRACK TOWER LIFT: AMBIENT TRANSPORT SOFT TOUCH LIMIT DATALOG: TCU MODULE
OUTPUT: FWD XXX% DOWN XXX% TEMPERATURE:XXXC SWITCHES: OPEN SWITCH: OPEN MAX VOLTS: XX.XV HARDWARE REV XXX
STEER TYPE: JIB LIFT: FUEL LEVEL TRANSPORT MODE: SOFT TOUCH DATALOG: TCU MODULE
NORMAL UP XXX% SENSOR: OK OUT OF TRANSPORT OVERRIDE: OPEN RENTAL: XH XM S/N: XXXXXXX
– JLG Lift –
BRAKES STATUS: PLATFORM CONTROL STARTER END OF STROKE GENSET/WELDER DATALOG: GATEWAY MODULE
LOCKED VALVE: OFF CRANK TIME: XX S PROXIMITY: OPEN SWITCH: OPEN ERASE RENTAL? SOFTWARE: XXX
CREEP FUNCTION SPEED: ENGINE SPEED TOWER LIFT LIGHTS GATEWAY MODULE
SWITCH: CLOSED PUMP POT XXX% ACTUAL: XXXX RPM PROXIMITY:CLOSED SWITCH: OPEN HARDWARE REV XXX
CREEP MODE: CREEP ENGINE SPEED TOWER TELESCOPE PLATFORM TILT1 ANALYZER:
OFF SWITCH: CLOSED TARGET: XXXX RPM PROXIMITY:CLOSED ANGLE: XX.X DEG ANALYZER V6.3
2-SPEED CREEP MODE: TOWER POSITION: PLATFORM TILT2
SWITCH: OPEN OFF UP/RETRACTED ANGLE: XX.X DEG
2-SPEED VALVE CABLE BREAK PLATFORM TILT1
OUTPUT: OFF SWITCH: CLOSED VOLTAGE: XXXX MV
HIGH ENGINE PLATFORM TILT2
SWITCH: OPEN VOLTAGE: XXXX MV
DRIVE MODE:
MID ENGINE
DRV. ORIENTATION
FEATURE:ENABLED
DRV. ORIENTATION
DRV. ORIENTATION
OVERRIDE:OPEN
DRV. ORIENTATION
STATUS:CONFIRMED
DRIVE CONTROL:
ENHANCED
MENU: SYSTEM TEST:

SYSTEM TEST ACTIVATE?
3121157
9.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the
adjustment range in order to achieve optimum
machine performance.
Table 9-1. Personality Ranges/Defaults
DEFAULTS -
FUNCTION PERSONALITY RANGE
600SC
DRIVE Acceleration 0.1s to 5.0 sec N/A
Deceleration 0.1s to 3.0 sec N/A
Forward Minimum Speed 0 to 35% N/A
Forward Maximum Speed 0 to 100% N/A
Reverse Minimum Speed 0 to 35% N/A
Reverse Maximum Speed 0 to 100% N/A
Elevated Maximum Speed 0 to 50% N/A
Creep Maximum Speed 0 to 50% N/A
Engine RPM 800 to 2900 N/A
LEFT TRACK Accel 0.1 to 5.0 sec 2.0
Decel 0.1 to 3.0 sec 0.7
For. Min. 0 to 100% 15
For. Max. 0 to 100% 39
Rev. Min. 0 to 100% 13
Rev. Max. 0 to 100% 38
Elevated Fwd. Max. 0 to 100% 31
Elevated Rev. Max. 0 to 100% 30
Creep Fwd. Max 0 to 100% 22
Creep Rev. Max 0 to 100% 22
Engine RPM 1200 to 1600 1800
3121157 – JLG Lift – 9-23

DEFAULTS -
600SC
RIGHT TRACK Accel 0.1 to 5.0 sec 2.0
For. Min. 0 to 100% 12
For. Max. 0 to 100% 36
Rev. Min. 0 to 100% 19
Rev. Max. 0 to 100% 45
Elevated Fwd. Max. 0 to 100% 29
Elevated Rev. Max. 0 to 100% 35
Creep Fwd. Max 0 to 100% 19
Creep Rev. Max 0 to 100% 28
Engine RPM 1200 to 1600 1800
TOWER LIFT Accel 0.1 to 5.0 sec N/A
Decel 0.1 to 3.0 sec N/A
Mlnimum Up Speed 0 to 60% N/A
Maximum Up Speed 0 to 100% N/A
Minimum Down Speed 0 to 60% N/A
Maximum Down Speed 0 to 100% N/A
UPPER LIFT Accel 0.1 to 5.0 sec 2.0
Mlnimum Up Speed 0 to 60% 40
Maximum Up Speed 0 to 100% 66
Creep Maximum Up Speed 0 to 65% 55
Minimum Down Speed 0 to 60% 40
Maximum Down Speed 0 to 100% 85
Creep Maximum Down Speed 0 to 75% 55
Engine RPM 800 to 2900 1800
9-24 – JLG Lift – 3121157

DEFAULTS -
600SC
SWING Accel 0.1 to 5.0 sec 2.0
Deceleration 0.1 to 3.0 sec 1.8
Minimum Left Speed 0 to 50% 30
Maximum Left Speed 0 to 100% 65
Creep Maximum Left Speed 0 to 65% 45
Minimum Right Speed 0 to 50% 30
Maximum Right Speed 0 to 100% 65
Creep Maximum Right Speed 0 to 65% 45
TELESCOPE UPPER Accel 0.1 to 5.0 sec 3.5
Minimum In Speed 0 to 65% 53
Maximum In Speed 0 to 100% 80
Minimum Out Speed 0 to 65% 55
Maximum Out Speed 0 to 100% 75
TELESCOPE TOWER Accel 0.1 to 5.0 sec N/A
Deceleration 0.1 to 3.0 sec N/A
Minimum In Speed 0 to 65% N/A
Maximum In Speed 0 to 100% N/A
Minimum Out Speed 0 to 65% N/A
Maximum Out Speed 0 to 100% N/A
BASKET LEVEL Accel 0.1 to 5.0 sec 2.5
Minimum Up Speed 0 to 65% 48
Mlnimum Down Speed 0 to 65% 45
3121157 – JLG Lift – 9-25

DEFAULTS -
600SC
BASKET ROTATE Acceleration 0.1 to 5.0 sec 1.8
Mlnimum Left Speed 0 to 65% 42
Maximum Left Speed 0 to 100% 50
Minimum Right Speed 0 to 65% 42
Maximum Right Speed 0 to 100% 50
JIB LIFT Acceleration 0.1 to 5.0 sec 5.0
Minimum Up Speed 0 to 65% 46
Minimum Down Speed 0 to 65% 46
STEER MAXimum speed 0 to 100% N/A
GROUND MODE Tower Lift Up Speed 0 to 100% N/A
Tower Lift Down Speed 0 to 100% N/A
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% N/A
Basket Rotate Speed 0 to 100% 50
Basket Level Speed 0 to 100% 50
Jib Lift Speed 0 to 100% 50
Jib Swing 0 to 100% N/A
NOTE: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.
4150365-6
9-26 – JLG Lift – 3121157

Table 9-2. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash Communicated (Displayed on Priorit

Description
Code Analyzer) Fault y
None No flash code is indicated for the following help messages. They are 1
intended to hint at a possible problem if the vehicle is not behaving as
expected.
EVERYTHING OK The “normal” help message in platform mode
GROUND MODE OK The “normal” help message in ground mode
FSW OPEN A drive or boom function has been selected but footswitch is open.
RUNNING AT CREEP – All function speeds are limited to creep because the creep switch is open.
CREEP SWITCH OPEN
RUNNING AT CREEP – TILTED All boom function speeds are limited to creep because the vehicle is tilted
AND ABOVE ELEVATION and above elevation.
RUNNING AT CUTBACK – Drive speed is limited to “ELEVATED MAX” because the vehicle is above
ABOVE ELEVATION elevation.
TILT SENSOR OUT OF RANGE The tilt sensor has indicated a tilt angle greater than 19 degrees for more
than 4 seconds. Not reported during 2 second power-up.
LOAD SENSOR READING The load sensor is reading 20% or more under the calibrated zero point.
UNDER WEIGHT This fault may occur if the basket is resting on the ground. Not reported
during 2 second power-up.
1/1 Flash code 1/1 indicates a “sleep” mode.
NOT REQUIRED
2/1 Flash code 2/1 indicates problems with footswitch. 2
FSW FAULTY The two footswitch inputs have read the same state for more than one sec-
ond.
KEYSWITCH FAULTY Both platform and ground modes are selected simultaneously
2/2 Flash code 2/2 indicates problems with drive & steer selection. Except 3
where noted, these faults are not reported during 2 second power-up
sequence.
DRIVE LOCKED – JOYSTICK Drive was selected before and during footswitch closure. Can be reported
MOVED BEFORE FOOT- during power-up sequence.
SWITCH
FSW INTERLOCK TRIPPED Footswitch was closed for seven seconds with no function selected. Can
be reported during power-up sequence.
STEER LOCKED – SELECTED Steer was selected before and during footswitch closure.
BEFORE FOOTSWITCH
STEER SWITCHES FAULTY Both steer switches are active together.
DRIVE / STEER WITH NO This fault only occurs with inductive joysticks. It occurs if the joystick is
QPROX moved out of the neutral position with no Qprox sensors active.
D/S JOY. QPROX BAD These faults only occur with inductive joysticks. They indicate that the Q-
Prox sensor is reading above 3.18 volts.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage
is less than the centertap voltage minus half the center tap voltage minus
0.3 volts. If the centertap is at the high end of the range, these faults will be
triggered below 1.05 volts. If the centertap is at the low end of the range,
these faults will be triggered below 0.79 volts.
3121157 – JLG Lift – 9-27


Description
D/S JOY. OUT OF RANGE Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1
HIGH volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to
battery has occurred.
is more than the centertap voltage plus half the centertap voltage plus 0.3
volts. If the centertap is at the high end of the range, these faults will be trig-
gered above 4.35 volts. If the centertap is at the low end of the range, these
faults will be triggered above 3.8 volts.
D/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when the center tap voltage is not
between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-
.1 volt range around these values where the fault may be indicated.
Inductive joysticks: These faults occur when the center tap voltage is not
WAITING FOR FSW TO BE Footswitch was closed when platform mode was selected. Can be
OPEN reported during power-up sequence.
2/3 Flash code 2/3 indicates problems with boom function selection. 3
LIFT/SWING LOCKED – JOY- Platform upper lift or swing was selected before and during footswitch clo-
STICK MOVED BEFORE sure.
FOOTSWITCH
PUMP SWITCHES FAULTY – A boom function (lower lift, telescope, basket level, basket rotate, jib) has
CHECK DIAGNOSTICS/ both directions selected together.
BOOM
PUMP SWITCHES LOCKED – A platform boom function (lower lift, telescope, basket level, basket rotate,
SELECTED BEFORE FOOT- jib) was selected before key switch or footswitch closure.
SWITCH
PUMP SWITCHES LOCKED – A ground boom function (lower lift, telescope, basket level, basket rotate,
SELECTED BEFORE AUX jib) was selected before aux power.
POWER
LIFT / SWING WITH NO This fault only occurs with inductive joysticks. It occurs if the joystick is
QPROX moved out of the neutral position with no Qprox sensors active.
l/s joy. qprox bad These faults only occur with inductive joysticks. They indicate that the Q-
Prox sensor is reading above 3.18 volts.
l/s joy. out of range low Resistive joysticks: These faults do not occur.
is less than the centertap voltage minus half the center tap voltage minus
0.3 volts. If the centertap is at the high end of the range, these faults will be
triggered below 1.05 volts. If the centertap is at the low end of the range,
these faults will be triggered below 0.79 volts.
l/s joy. out of range high Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1
volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to
battery has occurred.
is more than the centertap voltage plus half the centertap voltage plus 0.3
volts. If the centertap is at the high end of the range, these faults will be trig-
gered above 4.35 volts. If the centertap is at the low end of the range, these
faults will be triggered above 3.8 volts.
9-28 – JLG Lift – 3121157


Description
l/s joy. center tap bad Resistive joysticks: These faults occur when the center tap voltage is not
Inductive joysticks: These faults occur when the center tap voltage is not
PUMP SWITCHES LOCKED – This fault occurs when a hydraulic function switch is closed before the start
SELECTED BEFORE START switch is closed.
SWTICH
FOOTSWITCH SELECTED The user attempted to start the machine with the footswitch engaged.
BEFORE START
2/4 Flash code 2/4 indicates that steering digital inputs are faulty.
NOT REQUIRED
2/5 Flash code 2/5 indicates that a function is prevented due to a cutout. 4
BOOM PREVENTED – DRIVE A boom function is selected while a drive function is selected and drive cut-
SELECTED out is configured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED – ABOVE Drive is selected while above elevation and drive cutout is configured to
ELEVATION prevent drive.
DRIVE PREVENTED – BOOM Drive is selected while a boom function is selected and drive cutout is con-
SELECTED figured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED – TILTED Drive is selected while tilted and above elevation and tilt is configured to
& ABOVE ELEVATION cutout drive.
MODEL CHANGED – User changed the model number using the analyzer. User must cycle 11
HYDRAULICS SUSPENDED – power before the hydraulics system will be active again.
CYCLE EMS
2/7 Flash code 2/7 indicates that the accelerator input is faulty.
NOT REQUIRED
2/8 Flash code 2/8 indicates a problem with a hydraulic filter. Not 5
reported during 2 second power-up.
RETURN FILTER BYPASSED Hydraulic return filter clogged
charge pump filter bypassed Charge pump filter clogged
3/1 Flash code 3/1 indicates that a contactor did not close when ener-
gized.
NOT REQUIRED
3/2 Flash code 3/2 indicates that a contactor did not open when ener-
gized.
NOT REQUIRED
3/3 Flash code 3/3 indicates a driver problem. All driver faults are 6
detected in a similar manner. Open circuit faults are detected when the
analog feedback reads too high and the output is commanded off.
Short to ground is detected when the analog feedback reads low and
the output is commanded on. Short to battery is detected when the
analog feedback reads Vbat and the output is commanded off. Not
ALTERNATOR/ECM POWER
SHORT TO GROUND
HOUR METER SHORT TO
GROUND
3121157 – JLG Lift – 9-29


Description
HOUR METER SHORT TO
BATTERY
HORN SHORT TO GROUND
HORN OPEN CIRCUIT
HORN SHORT TO BATTERY
AUX POWER SHORT TO
GROUND
AUX POWER OPEN CIRCUIT
AUX POWER SHORT TO BAT-
TERY
GLOW PLUG SHORT TO
GROUND
GLOW PLUG OPEN CIRCUIT
GLOW PLUG SHORT TO BAT-
TERY
LP LOCK SHORT TO
GROUND
LP LOCK OPEN CIRCUIT
LP LOCK SHORT TO BAT-
TERY
LP START ASSIST SHORT TO
GROUND
LP START ASSIST OPEN CIR-
CUIT
LP START ASSIST SHORT TO
BATTERY
MAIN DUMP SHORT TO
GROUND
MAIN DUMP OPEN CIRCUIT
MAIN DUMP SHORT TO BAT-
TERY
PARKING BRAKE SHORT TO
GROUND
PARKING BRAKE OPEN CIR-
CUIT
PARKING BRAKE SHORT TO
BATTERY
START SOLENOID SHORT TO
GROUND
START SOLENOID OPEN CIR-
CUIT
START SOLENOID SHORT TO
BATTERY
STEER DUMP SHORT TO
GROUND
9-30 – JLG Lift – 3121157


Description
STEER DUMP OPEN CIRCUIT
STEER DUMP SHORT TO
BATTERY
TWO SPEED SHORT TO
GROUND
TWO SPEED OPEN CIRCUIT
TWO SPEED SHORT TO BAT-
TERY
GROUND ALARM SHORT TO
GROUND
GROUND ALARM OPEN CIR-
CUIT
GROUND ALARM SHORT TO
BATTERY
GENERATOR SHORT TO
GROUND
GENERATOR OPEN CIRCUIT
GENERATOR SHORT TO BAT-
TERY
WELDER SHORT TO
GROUND
WELDER OPEN CIRCUIT
WELDER SHORT TO BAT-
TERY
HEAD TAIL LIGHT SHORT TO
GROUND
HEAD TAIL LIGHT OPEN CIR-
CUIT
HEAD TAIL LIGHT SHORT TO
BATTERY
BASKET UP OVERRIDE Only occurs on machines with electronic leveling systems.
SHORT TO GROUND
BASKET UP OVERRIDE OPEN Only occurs on machines with electronic leveling systems.
CIRCUIT
BASKET UP OVERRIDE Only occurs on machines with electronic leveling systems.
SHORT TO BATTERY
BASKET UP SHORT TO
GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO BAT-
TERY
BASKET DOWN SHORT TO
GROUND
BASKET DOWN OPEN CIR-
CUIT
3121157 – JLG Lift – 9-31


Description
BATTERY
BASKET DOWN OVERRIDE Only occurs on machines with electronic leveling systems.
SHORT TO GROUND
OPEN CIRCUIT
SHORT TO BATTERY
BASKET LEFT OPEN CIRCUIT
BASKET LEFT SHORT TO
BATTERY
GROUND
BASKET RIGHT SHORT TO
GROUND
BASKET RIGHT OPEN CIR-
CUIT
BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB DOWN SHORT TO
GROUND
JIB DOWN OPEN CIRCUIT
JIB DOWN SHORT TO BAT-
TERY
JIB LEFT SHORT TO
GROUND
JIB LEFT OPEN CIRCUIT
JIB LEFT SHORT TO BAT-
TERY
JIB RIGHT SHORT TO
GROUND
JIB RIGHT OPEN CIRCUIT
JIB RIGHT SHORT TO BAT-
TERY
TOWER UP SHORT TO
GROUND
TOWER UP OPEN CIRCUIT
TOWER UP SHORT TO BAT-
TERY
TOWER DOWN SHORT TO
GROUND
9-32 – JLG Lift – 3121157


Description
TOWER DOWN OPEN CIR-
CUIT
TOWER DOWN SHORT TO
BATTERY
TOWER IN SHORT TO
GROUND
TOWER IN OPEN CIRCUIT
TOWER IN SHORT TO BAT-
TERY
TOWER OUT SHORT TO
GROUND
TOWER OUT OPEN CIRCUIT
TOWER OUT SHORT TO BAT-
TERY
UPPER IN SHORT TO
GROUND
UPPER IN OPEN CIRCUIT
UPPER IN SHORT TO BAT-
TERY
UPPER OUT SHORT TO
GROUND
UPPER OUT OPEN CIRCUIT
UPPER OUT SHORT TO BAT-
TERY
LIFT UP DUMP SHORT TO
GROUND
LIFT UP DUMP OPEN CIR-
CUIT
LIFT UP DUMP SHORT TO
BATTERY
LIFT DOWN HOLDING
SHORT TO GROUND
LIFT DOWN HOLDING OPEN
CIRCUIT
LIFT DOWN SHORT TO BAT-
TERY
HOUR METER OPEN CIRCUIT This fault cannot be detected during normal operation. It may be reported
during self test.
FORD ECM POWER OPEN This fault cannot be detected during normal operation. It may be reported
CIRCUIT during self test.
FORD ECM POWER SHORT This fault cannot be detected during normal operation. It may be reported
TO BATTERY during self test.
3121157 – JLG Lift – 9-33


Description
3/4 Flash code 3/4 indicates a driver problem on a platform valve block 6
valve driver. All driver faults are detected in a similar manner. Open cir-
cuit faults are detected when the analog feedback reads too high and
the output is commanded off. Short to ground is detected when the
analog feedback reads low and the output is commanded on. Short to
battery is detected when the analog feedback reads Vbat and the out-
put is commanded off. Not reported during 2 second power-up.
BASKET UP SHORT TO BAT-
TERY
BASKET UP SHORT TO
GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO Only occurs on machines with electronic basket leveling
BATTERY OR OPEN CIRCUIT
BATTERY
GROUND
bASKET DOWN OPEN CIR-
CUIT
BASKET DOWN SHORT TO Only occurs on machines with electronic basket leveling.
BATTERY OR OPEN CIRCUIT
BATTERY
BASKER LEFT SHORT TO
GROUND
BASKET LEFT OPEN CIRCUIT
BATTERY
GROUND
BASKET RIGHT OPEN CIR-
CUIT
JIB UP SHORT TO BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB DOWN SHORT TO BAT-
TERY
JIB DOWN SHORT TO
GROUND
JIB DOWN OPEN CIRCUIT
JIB LEFT SHORT TO BAT-
TERY
JIB LEFT SHORT TO
GROUND
9-34 – JLG Lift – 3121157


Description
JIB LEFT OPEN CIRCUIT
JIB RIGHT SHORT TO BAT-
TERY
JIB RIGHT SHORT TO
GROUND
JIB RIGHT OPEN CIRCUIT
PLATFORM CONTROL VALVE Only occurs on machines with electronic basket leveling
SHORT TO BATTERY
SHORT TO GROUND
OPEN CIRCUIT
3/5 Flash code 3/5 indicates a brake pressure problem.
NOT REQUIRED
4/2 Flash code 4/2 indicates that the engine is over temperature. NOT
REQUIRED
4/3 Flash code 4/3 indicates problems with the engine. Except where 9
noted, these faults are not reported during 2 second power-up
sequence.
high engine temp Occurs when the engine temperature is above 117 degrees Celsius for the
Ford engines, and above 130 degrees Celsius for the Deutz engines.
AIR FILTER BYPASSED Air filter clogged
NO aLTERNATOR OUTPUT The engine has been running for 15 seconds or more and the battery volt-
age is still below 12.5 volts.
LOW Oil PrESSURE If a Deutz engine is installed, the oil pressure is below 8 PSI and the engine
has been running for at least 10 seconds. If a Ford engine is installed, the
Ford ECM has reported a low oil pressure fault.
OIL PRESSURE SHORT TO If a Deutz engine is installed, this indicates that the oil pressure sensor is
BATTERY reading above 6.6 volts.
OIL PRESSURE SHORT TO If a Deutz engine is installed, this indicates that the oil pressure sensor is
GROUNd reading below 0.1 volts for more than 5 seconds. This fault is not detected
during crank.
COOLANT TEMPERATURE If a Deutz engine is installed, this indicates that the coolant temperature is
SHORT TO GROUND reading below 0.1 volts.
FORD FAULT CODE ## All Ford fault codes except 63 are simply passed through from the FORD
ECM. They only occur if a Ford engine is selected in the machine configu-
ration digits. Can be reported during power-up sequence.
FORD FAULT CODE An unrecognized Ford ECM fault code has been received. Can be
UNKNOWN reported during power-up sequence.
485 communications lost This fault only occurs with a Ford engine. It occurs when no responses are
received from the ECM for 2.5 seconds. Can be reported during power-up
sequence.
FUEL SENSOR SHORT TO Indicates that the fuel sensor is reading above 4.3 volts.
BATTERY
FUEL SENSOR SHORT TO Indicates that the fuel sensor is reading below 0.2 volts.
GROUND
3121157 – JLG Lift – 9-35


Description
4/4 Flash code 4/4 indicates problems with the battery supply. Not 7
BATTERY LOW Battery voltage is below 11V for more than 5 seconds. This fault is not
detected during crank. This is a warning – the controller does not shut
down.
BATTERY TOO HIGH – Battery voltage is above 16V. EMS recycle required.
SYSTEM SHUT DOWN
BATTERY TOO LOW – Battery voltage is below 9V.
SYSTEM SHUT DOWN
5/5 Flash code 5/5 indicates problems with vehicle engine RPM or the 8
encoder. Not reported during 2 second power-up.
SPEED SENSOR READING This fault is detected with diesel engines only. The RPM pickup is indicat-
INVALID SPEED ing a speed that greater than 4000 RPM or approximately 8875 Hz.
SPEED INPUT LOST This fault is detected with diesel engines only. It occurs if there is no RPM
detected and the oil pressure input is reading above 8 PSI for more than
three seconds. This is probably due to wiring problems at the ground mod-
ule or a faulty speed sensor.
6/6 Flash code 6/6 indicates problems with the CAN bus. 10
CAN BUS FAILURE: The ground module or platform module is not receiving CAN messages.
This is probably due to wiring problems between the platform and ground
modules.
7/7 Flash code 7/7 indicates problems with a motor.
NOT REQUIRED
9/9 Flash code 9/9 indicates problems with the controller. 11
PLATFORM MODULE Platform module code is too old to support the EIM or BPE load sensor and
SOFTWARE UPDATE the machine is configured to use one of these two sensors. The PM code
REQUIRED must be updated to a newer version.
HIGH RESOLUTION A2D The ADS1213 chip in the platform module has stopped asserting its inter-
FAILURE –INTERRUPT LOST rupt(DRDY) line for some reason. An EMS cycle is required.
HIGH RESOLUTION A2D The ADS1213 has needed to be reset 3 or more times.
FAILURE-REINIT LIMIT
PLATFORM MODULE FAIL- Platform module V(Low) FET has failed
URE: hwfs CODE 1
GROUND MODULE FAILURE: Ground module V(Low) FET has failed
hwfs CODE 1
GROUND SENSOR REF These faults occur when the seven volt reference voltage used for the joy-
VOLTAGE OUT OF RANGE sticks, sensors, etc. goes out of range. Not reported during 2 second
power-up.
PLATFORM SENSOR REF These faults occur when the seven volt reference voltage used for the joy-
VOLTAGE OUT OF RANGE sticks, sensors, etc. goes out of range. Not reported during 2 second
power-up.
EEPROM FAILURE – CHECK A critical failure occurred with the EEPROM. Personalities, machine con-
ALL SETTINGS figuration digits, etc. may be reset to default values and should be
checked.
9-36 – JLG Lift – 3121157


Description
CHASSIS TILT SENSOR NOT Indicates that the chassis tilt sensor calibration information has been lost.
GAIN CALIBRATED Machine will indicate that it is tilted at all times. This calibration data is pro-
grammed into the unit at the factory.
CHASSIS TILT SENSOR GAIN Indicates that the chassis tilt sensor calibration has become corrupted.
OUT OF RANGE
3121157 – JLG Lift – 9-37

Table 9-3. Machine Configuration Programming Information Prior to Software Version P5.3
Numbe Default
Configuration Digit Description
r 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
selection. 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)
7 DEUTZ F4 TIER2: Deutz F4M2011 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 1 110 TEETH: 110 flywheel teeth.
if Deutz engine selections 3 or 4
are selected.
9-38 – JLG Lift – 3121157

Numbe Default
r 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 SHUT- 0 DISABLED: No engine shutdown. 1

DOWN:
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 1
7* tilted more than 5 degrees and above elevation; also reduces drive speed to
* Certain market selections creep.
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
3 creep.
3 DEGREES: Reduces the maximum speed of all boom functions to creep when
4 tilted more than 3 degrees and above elevation; also reduces drive speed to
creep.
4 DEGREES + CUT: Reduces the maximum speed of all boom functions to

5 creep when tilted more than 4 degrees and above elevation; also disallows tower
lift up, tower telescope out, drive, main telescope out and main lift up.

creep when tilted more than 3 degrees and above elevation; also disallows tower
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 eleva-
tion.
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.
3121157 – JLG Lift – 9-39

Numbe Default
r 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
model selections. sec ON, 2 sec OFF).
* Certain market selections
will limit load system 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm
options or alter default set-
beeps (5 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 1
16* which use the Leveling Platform Module.
* Only visible if Load Sen-
sor 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 cer- 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
tain market selections.
* Certain market selections 2 DRIVE CUTOUT: Drive cutout above elevation.
will limit function cutout
options or alter default set-
3 DRIVE CUT E&T: Drive cutout above elevation and tilted.
ting.
9-40 – JLG Lift – 3121157

Numbe Default
r Number
GROUND ALARM: 0 NO: No ground alarm installed. 0

18*
* 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

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 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
models.
4150364-14
3121157 – JLG Lift – 9-41

Table 9-4. Machine Configuration Programming Information Software Version P5.3 to P6.1
Configuration Label/ Numbe Default

Description
Digit r Number

1
2 450A
3 510A
4 600S
5 600A
6 600SC
7 601S
8 740A
9 800A
10 800S

2
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
9-42 – JLG Lift – 3121157


Description
Digit r Number

3*
depending on model
7 PERKINS 404C (Tier 2)
12 DEUTZ ECM: Engine Control Module - ECM
13 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)

4*
* This menu item is only 1 110 TEETH: 110 flywheel teeth.
visible if Deutz engine
selections 3 or 4 are
selected.

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; 0
6 engine 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.
3121157 – JLG Lift – 9-43


Description
Digit r Number

DOWN:
deg. C or the oil pressure is less than 8 PSI.
* Certain market selec- creep.
tions will limit tilt 2
options and alter default 4 DEGREES: Reduces the maximum speed of all boom functions to creep when
setting. tilted more than 4 degrees and above elevation; also reduces drive speed to
3 creep.
Note: Any of the selec-
tions above will light the 3 DEGREES: Reduces the maximum speed of all boom functions to creep when
tilt lamp when a tilted 4 tilted more than 3 degrees and above elevation; also reduces drive speed to
condition occurs and creep.
will sound the platform
alarm when the machine 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to
is also above elevation. 5 creep when tilted more than 4 degrees and above elevation; also disallows tower


9*
* Only visible under 1 YES: Jib installed which has up and down movements only.
certain model selections.

10*
* Only visible under 1 YES: Four-wheel steer installed.

11*
* Only visible under 1 YES: Soft touch system installed.

12
9-44 – JLG Lift – 3121157


Description
Digit r Number
13*
* Only visible if Gen Set 1 MOTION CUTOUT: Motion cutout in platform mode only.
/ Welder Menu selection
is not 0.

14

15*
* Only visible under 1 YES: Broken cable switch installed.
* Certain market and
model selections will
alter the default setting.

16*
* Only visible under 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5
certain market selec- sec ON, 2 sec OFF).
tions.
* Certain market selec- 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm
tions will limit load sys- beeps (5 sec ON, 2 sec OFF).
tem options or alter
default setting. 3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS
* Only visible if Load
Sensor Menu selection is 1 4 UNDER PLATFORM: Use the EIM for load sensing.
not 0 and under certain
market selections.
* Certain market selec-
tions will limit load sen-
sor options.
3121157 – JLG Lift – 9-45


Description
Digit r Number

18*
* Only visible under 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
certain market selec-
tions. 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
tions will limit function 3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
cutout options or alter
default setting.

19*
* Certain market selec- 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
tions will alter default
setting. 2 DESCENT: Descent alarm sounds when lift down is active (Option).

20*
* Only visible under 1 2WD: Two wheel drive.

21*
* Certain market selec- 1 FAHRENHEIT: Fahrenheit unit selection.
setting.

22*
models.
4150364-18
9-46 – JLG Lift – 3121157

Table 9-5. Machine Configuration Programming Information Software Version P6.1 to Present

Description
Digit r Number

1
2 450A
3 510A
4 600S
5 600A
6 600SC
7 601S
8 740A
9 800A
10 800S

2
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
3121157 – JLG Lift – 9-47


Description
Digit r Number

3*
depending on model
7 PERKINS 404C (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

4*
* This menu item is only 1 110 TEETH: 110 flywheel teeth.
visible if Deutz engine
selections 3 or 4 are
selected.

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
9-48 – JLG Lift – 3121157


Description
Digit r Number
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; 0
6 engine 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.

DOWN:
deg. C or the oil pressure is less than 8 PSI.
* Certain market selec- creep.
tions will limit tilt 2
options and alter default 4 DEGREES: Reduces the maximum speed of all boom functions to creep when
setting. tilted more than 4 degrees and above elevation; also reduces drive speed to
3 creep.
Note: Any of the selec-
tions above will light the 3 DEGREES: Reduces the maximum speed of all boom functions to creep when
tilt lamp when a tilted 4 tilted more than 3 degrees and above elevation; also reduces drive speed to
condition occurs and creep.
will sound the platform
alarm when the machine 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to
is also above elevation. 5 creep when tilted more than 4 degrees and above elevation; also disallows tower


9*
* Only visible under 1 YES: Jib installed which has up and down movements only.

10*
* Only visible under 1 YES: Four-wheel steer installed.
3121157 – JLG Lift – 9-49


Description
Digit r Number

11*
* Only visible under 1 YES: Soft touch system installed.

12
13*
* Only visible if Gen Set 1 MOTION CUTOUT: Motion cutout in platform mode only.
/ Welder Menu selection
is not 0.

14

15*
* Only visible under 1 YES: Broken cable switch installed.
* Certain market and
model selections will
alter the default setting.

16*
* Only visible under 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5
certain market selec- sec ON, 2 sec OFF).
tions.
* Certain market selec- 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm
tions will limit load sys- beeps (5 sec ON, 2 sec OFF).
tem options or alter
default setting. 3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS
9-50 – JLG Lift – 3121157


Description
Digit r Number
* Only visible if Load
Sensor Menu selection is 1 4 UNDER PLATFORM: Use the EIM for load sensing.
not 0 and under certain
market selections.
tions will limit load sen-
sor options.

18*
* Only visible under 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
certain market selec-
tions. 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
tions will limit function 3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
cutout options or alter
default setting.

19*
* Certain market selec- 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
setting. 2 DESCENT: Descent alarm sounds when lift down is active (Option).

20*
* Only visible under 1 2WD: Two wheel drive.

21*
* Certain market selec- 1 FAHRENHEIT: Fahrenheit unit selection.
setting.
3121157 – JLG Lift – 9-51


Description
Digit r Number

22*
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
9-52 – JLG Lift – 3121157

3121157
600SC
JIB
TILT
ENGINE
MARKET
SOFT TOUCH
GLOW PLUGS
4 WHEEL STEER
MODEL NUMBER
GEN SET CUTOUT
GEN SET / WELDER
ENGINE SHUTDOWN
HEAD & TAIL LIGHTS
CABLE BREAK SWITCH
ANSI USA 6 0 11 0 1 2 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1 0 1 0 1
ANSI EXPORT 6 1 11 0 1 2 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1 0 1 0 1
CSA 6 2 11 0 1 2 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1 0 1 0 1
– JLG Lift –
CE 6 3 11 0 1 2 0 1 X X 3 X 5 0 0 0 1 0 1 0 1 0 1 0 1
AUSTRALIA 6 4 11 0 1 2 0 1 X X 3 X 5 0 0 0 1 0 1 0 1 0 1 0 1
JAPAN 6 5 11 0 1 2 0 1 1 2 3 4 5 0 0 0 1 0 1 0 1 0 1 0 1
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.
9-53
9-54
600SC
DRIVE TYPE
LOAD SENSOR
LOAD SYSTEM
TEMPERATURE
GROUND ALARM
LEVELING MODE
FUNCTION CUTOUT
ANSI USA 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 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
– JLG Lift –
CSA 0 X X X X 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CE 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 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
JAPAN 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
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.
3121157
3121157
600SJC
JIB
TILT
ENGINE
MARKET
SOFT TOUCH
GLOW PLUGS
4 WHEEL STEER
MODEL NUMBER
GEN SET CUTOUT
GEN SET / WELDER
ENGINE SHUTDOWN
HEAD & TAIL LIGHTS
– JLG Lift –
ANSI USA 6 0 11 0 1 2 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1 0 1
ANSI EXPORT 6 1 11 0 1 2 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1 0 1
CSA 6 2 11 0 1 2 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1 0 1
CE 6 3 11 0 1 2 0 1 X X 3 X 5 1 0 0 1 0 1 0 1 0 1
AUSTRALIA 6 4 11 0 1 2 0 1 X X 3 X 5 1 0 0 1 0 1 0 1 0 1
JAPAN 6 5 11 0 1 2 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1 0 1
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined
numbers indicate the default when the option is factory installed.
9-55
9-56
660SJC
DRIVE TYPE
LOAD SENSOR
LOAD SYSTEM
TEMPERATURE
GROUND ALARM
LEVELING MODE
FUNCTION CUTOUT
CABLE BREAK SWITCH

ANSI USA 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0 1 2 0 1 0 1
– JLG Lift –
ANSI EXPORT 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 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 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 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 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Italic, underlined
numbers indicate the default when the option is factory installed.
3121157
Table 9-6. Fault Code Listing
HELP MESSAGE FAULT FAULT REMOVAL
OK 0 0 CLEARS WHEN FAULT IS REMOVED
DRIVING AT CREEP - TILTED 0 0 CLEARS WHEN FAULT IS REMOVED
FSW OPEN 0 0 CLEARS WHEN FAULT IS REMOVED
RUNNING AT CREEP - CREEP SWITCH OPEN 0 0 CLEARS WHEN FAULT IS REMOVED
RUNNING AT CREEP - TILTED AND ABOVE ELEVATION 0 0 CLEARS WHEN FAULT IS REMOVED
RUNNING AT CUTBACK - ABOVE ELEVATION 0 0 CLEARS WHEN FAULT IS REMOVED
TILT SENSOR OUT OF RANGE 0 0 CLEARS WHEN FAULT IS REMOVED
LOAD SENSOR READING UNDER WEIGHT 0 0 CLEARS WHEN FAULT IS REMOVED
FSW FAULTY 2 1 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
KEYSWITCH FAULTY 2 1 CLEARS WHEN FAULT IS REMOVED
DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOT- 2 2 CLEARS WHEN FAULT IS REMOVED
SWITCH
FSW INTERLOCK TRIPPED 2 2 CLEARS WHEN FAULT IS REMOVED
STEER LOCKED - SELECTED BEFORE FOOTSWITCH 2 2 CLEARS WHEN FAULT IS REMOVED
STEER SWITCHES FAULTY 2 2 CLEARS WHEN FAULT IS REMOVED
D/S JOY. QPROX BAD 2 2 CLEARS WHEN FAULT IS REMOVED
L/S JOY. QPROX BAD 2 3 CLEARS WHEN FAULT IS REMOVED
D/S JOY. OUT OF RANGE LOW 2 2 CLEARS WHEN FAULT IS REMOVED
D/S JOY. OUT OF RANGE HIGH 2 2 CLEARS WHEN FAULT IS REMOVED
L/S JOY. OUT OF RANGE LOW 2 3 CLEARS WHEN FAULT IS REMOVED
L/S JOY. OUT OF RANGE HIGH 2 3 CLEARS WHEN FAULT IS REMOVED
D/S JOY. CENTER TAP BAD 2 2 CLEARS WHEN FAULT IS REMOVED
L/S JOY. CENTER TAP BAD 2 3 CLEARS WHEN FAULT IS REMOVED
WAITING FOR FSW TO BE OPEN 2 2 CLEARS WHEN FAULT IS REMOVED
PUMP POT FAULTY 2 3 CLEARS WHEN FAULT IS REMOVED
PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM 2 3 CLEARS WHEN FAULT IS REMOVED
PUMP SWITCHES LOCKED - SELECTED BEFORE FOOT- 2 3 CLEARS WHEN FAULT IS REMOVED
SWITCH
PUMP SWITCHES LOCKED - SELECTED BEFORE START 2 3 CLEARS WHEN FAULT IS REMOVED
SWITCH
FOOTSWITCH SELECTED BEFORE START 2 3 CLEARS WHEN FAULT IS REMOVED
BOOM PREVENTED - DRIVE SELECTED 2 5 CLEARS WHEN FAULT IS REMOVED
DRIVE PREVENTED - ABOVE ELEVATION 2 5 CLEARS WHEN FAULT IS REMOVED
3121157 – JLG Lift – 9-57

DRIVE PREVENTED - TILTED & ABOVE ELEVATION 2 5 CLEARS WHEN FAULT IS REMOVED
DRIVE PREVENTED - BOOM SELECTED 2 5 CLEARS WHEN FAULT IS REMOVED
FORD ECM POWER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
HORN SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
HORN OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
HORN SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
AUX POWER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
AUX POWER OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
AUX POWER SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
GLOW PLUG SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
GLOW PLUG OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
GLOW PLUG SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
LP LOCK SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
LP LOCK OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
LP LOCK SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
LP START ASSIST SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
LP START ASSIST OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
LP START ASSIST SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
MAIN DUMP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
MAIN DUMP OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
MAIN DUMP SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
9-58 – JLG Lift – 3121157

PARKING BRAKE SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
PARKING BRAKE OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
PARKING BRAKE SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
START SOLENOID SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
START SOLENOID OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
START SOLENOID SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
STEER DUMP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
STEER DUMP OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
STEER DUMP SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TWO SPEED SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
TWO SPEED OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TWO SPEED SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
ALARM SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
ALARM OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
ALARM SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
GENERATOR SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
GENERATOR OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
GENERATOR SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
HEAD TAIL LIGHT SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
HEAD TAIL LIGHT OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
3121157 – JLG Lift – 9-59

HEAD TAIL LIGHT SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
HOUR METER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
HOUR METER SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
BASKET UP OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET UP SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET DOWN SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET DOWN OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET DOWN SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET LEFT SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
BASKET LEFT OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET LEFT SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET RIGHT SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET RIGHT OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BASKET RIGHT SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB UP OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB UP SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB DOWN SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB DOWN OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
9-60 – JLG Lift – 3121157

JIB DOWN SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB LEFT SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB LEFT OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB LEFT SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
JIB RIGHT SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB RIGHT OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
JIB RIGHT SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER UP OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER UP SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
TOWER DOWN SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER DOWN OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER DOWN SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER IN SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER IN OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER IN SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER OUT SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER OUT OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
TOWER OUT SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
UPPER IN SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
3121157 – JLG Lift – 9-61

UPPER IN OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
UPPER IN SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
UPPER OUT SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
UPPER OUT OPEN CIRCUIT 3 3 REQUIRES EMS TO BE RECYCLED TO
CLEAR FAULT
UPPER OUT SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
FUEL SENSOR SHORT TO BATTERY 3 3 CLEARS WHEN FAULT IS REMOVED

FUEL SENSOR SHORT TO GROUND 3 3 CLEARS WHEN FAULT IS REMOVED
OIL PRESSURE SHORT TO BATTERY 4 3 CLEARS WHEN FAULT IS REMOVED
OIL PRESSURE SHORT TO GROUND 4 3 CLEARS WHEN FAULT IS REMOVED
COOLANT TEMPERATURE SHORT TO GROUND 4 3 CLEARS WHEN FAULT IS REMOVED
FORD FAULT CODE 12 4 3 CLEARS WHEN FAULT IS REMOVED

9-62 – JLG Lift – 3121157

FORD FAULT CODE UNKNOWN 4 3 CLEARS WHEN FAULT IS REMOVED
RETURN FILTER BYPASSED 2 8 CLEARS WHEN FAULT IS REMOVED
CHARGE PUMP FILTER BYPASSED 2 8 CLEARS WHEN FAULT IS REMOVED
BATTERY LOW 4 4 CLEARS WHEN FAULT IS REMOVED
BATTERY TOO HIGH - SYSTEM SHUT DOWN 4 4 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
BATTERY TOO LOW - SYSTEM SHUT DOWN 4 4 CLEARS WHEN FAULT IS REMOVED
SPEED SENSOR READING INVALID SPEED 5 5 CLEARS WHEN FAULT IS REMOVED
SPEED INPUT LOST 5 5 CLEARS WHEN FAULT IS REMOVED
ENGINE TEMP HIGH 4 3 CLEARS WHEN FAULT IS REMOVED
AIR FILTER BYPASSED 4 3 CLEARS WHEN FAULT IS REMOVED
NO ALTERNATOR OUTPUT 4 3 CLEARS WHEN FAULT IS REMOVED
OIL PRESSURE LOW 4 3 CLEARS WHEN FAULT IS REMOVED
485 COMMUNICATIONS LOST 4 3 CLEARS WHEN FAULT IS REMOVED
CAN BUS FAILURE 6 6 CLEARS WHEN FAULT IS REMOVED
LOAD SENSOR NOT CALIBRATED 9 9 CLEARS WHEN FAULT IS REMOVED
TILT SENSOR NOT CALIBRATED 9 9 CLEARS WHEN FAULT IS REMOVED
EEPROM FAILURE - CHECK ALL SETTINGS 9 9 REQUIRES EMS TO BE RECYCLED TO

CLEAR FAULT
PLATFORM MODULE FAILURE: HWFS CODE 1 9 9 CLEARS WHEN FAULT IS REMOVED

GROUND MODULE FAILURE: HWFS CODE 1 9 9 CLEARS WHEN FAULT IS REMOVED
3121157 – JLG Lift – 9-63

9.9 ANALYZER DIAGNOSTICS MENU the next outer level. The LEFT/RIGHT arrow keys move
between items in the same level. The UP/DOWN arrow
STRUCTURE keys alter a value if allowed
In the following structure descriptions, an intended item is
selected by pressing ENTER; pressing ESC steps back to
Table 9-7. 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

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

9-64 – JLG Lift – 3121157

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

MIN RIGHT … Displays/adjusts minimum swing right speed
MAX RIGHT … Displays/adjusts maximum swing right speed
CREEP RIGHT … Displays/adjusts maximum swing right speed

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
3121157 – JLG Lift – 9-65

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

9-66 – JLG Lift – 3121157

Table 9-8. 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

U TELE IN … Displays telescope switch direction & demand

JIB UP … Displays jib lift switch direction & demand

JIB LEFT … Displays jib swing switch direction & demand

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
3121157 – JLG Lift – 9-67

Table 9-8. 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
9-68 – JLG Lift – 3121157

SECTION 10. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

10.1 GENERAL device under test correctly. Also check that the lead on the
"COM" port goes to the Ground or negative side of the sig-
This section contains basic electrical information and nal and the lead on the other port goes to the positive side
schematics to be used for locating and correcting most of of the signal.
the operating problems which may develop. If a problem
should develop which is not presented in this section or Scale
which is not corrected by listed corrective actions, techni-
cally qualified guidance should be obtained before pro- M = Mega = 1,000,000 * (Displayed Number)
ceeding with any maintenance. k = kilo = 1,000 * (Displayed Number)
10.2 MULTIMETER BASICS m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM) μ = micro = (Displayed Number) / 1,000,000
can be used for troubleshooting your equipment. This Example: 1.2 kΩ = 1200 Ω
section shows diagrams of a common, digital VOM con- Example: 50 mA = 0.05 A
figured for several different circuit measurements. Instruc-
tions for your VOM may vary. Please consult the meter Voltage Measurement
operator’s manual for more information.
Grounding
"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- Figure 10-1. Voltage Measurement (DC)
tact and contacts are seated in the connector.
• If meter is not auto ranging, set it to the correct
Min/Max range (See multimeter’s operation manual)
Use of the "Min/Max" recording feature of some meters • Use firm contact with meter leads
can help when taking measurements of intermittent condi-
tions while alone. For example, you can read the Voltage
applied to a solenoid when it is only operational while a
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
are reversed. Check what reading is expected, the loca-
tion of the signal and that the leads are connected to the
3121157 – JLG Lift – 10-1

Resistance Measurement Continuity Measurement
Figure 10-3. Continuity Measurement
• Some meters require a separate button press to

enable audible continuity testing
• Circuit power must be turned OFF before testing
Figure 10-2. Resistance Measurement continuity
• First test meter and leads by touching leads • Disconnect component from circuit before testing
together. Resistance should read a short circuit
• Use firm contact with meter leads
(very low resistance)
• First test meter and leads by touching leads
• Circuit power must be turned OFF before testing
together. Meter should produce an audible alarm,
resistance
indicating continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct
range (See multimeter’s operation manual)
10-2 – JLG Lift – 3121157

Current Measurement 10.3 APPLYING SILICONE DIELECTRIC

COMPOUND TO ELECTRICAL
CONNECTIONS
NOTE: This section is not applicable for battery terminals.
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS

THE ONLY MATERIAL APPROVED FOR USE AS A DIELECTRIC
GREASE.
NOTE: Do NOT apply dielectric grease to the following con-

nections:
• Main Boom Rotary sensor connections (on Celesco

Sensor),
• 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.
Figure 10-4. Current Measurement (DC)
• To prevent electrical malfunction caused by low level
• Set up the meter for the expected current range conductivity between pins when wet.
• Be sure to connect the meter leads to the correct Use the following procedure to apply Silicone Dielectric
jacks for the current range you have selected Compound to the electrical connectors. This procedure
• If meter is not auto ranging, set it to the correct applies to all plug connections not enclosed in a box. Sili-
range (See multi meter’s operation manual) 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.
2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female con-
nectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the con-
nector should also be sealed.
NOTE: This condition is especially common when machines

are pressure washed since the washing solution is
much more conductive than water.
3121157 – JLG Lift – 10-3

3. Anderson connectors for the battery boxes and bat- Deutsch HD, DT, DTM, DRC Series
tery chargers should have silicone grease applied to
the contacts only. The Deutsch connector system is commonly used for
harsh environment interconnect. Follow the installation
NOTE: Curing-type sealants might also be used to prevent instructions.
shorting and would be less messy, but would make
future pin removal more difficult.
When applied to electrical connections, dielectric grease

helps to prevent corrosion of electrical contacts and
improper conductivity between contacts from moisture
intrusion. Open and sealed connectors benefit from the
application of dielectric grease.
Dielectric grease shall be applied to all electrical connec-
tors at the time of connection (except those noted under
Exclusions).
Installation of Dielectric Grease

Before following these instructions, refer to excluded con-
nector types (See Exclusions below).
1. Use dielectric grease in a tube for larger connection AMP Seal
points or apply with a syringe for small connectors.
The AMP Seal connector system is used on the Control
2. Apply dielectric grease to the female contact (fill it ADE Platform and Ground Modules.
approximately ½ full; see example below)
Apply dielectric grease to the female contact. If trapped air
3. Leave a thin layer of dielectric grease on the face of prevents the connector from latching, pierce one of the
the connector unused wire seals. After assembly, install a seal plug (JLG
4. Assemble the connector system immediately to pre- #4460905) in that location to prevent moisture ingress.
vent moisture ingress or dust contamination Note that seal plugs may be installed by the wire harness
5. Pierce one of the unused wire seals prior to assem- manufacturer if an unused wire seal becomes compro-
bly if the connector system tends to trap air (i.e. mised (wire inserted in the wrong cavity during assembly
AMP Seal) and then install a seal plug. and then corrected).
Figure 10-5. Application to Female Contacts
10-4 – JLG Lift – 3121157

DIN Connectors
This connector is typically used on hydraulic valves. Fol-
low the installation instructions.
Figure 10-6. Use of Seal Plugs

Exclusions
A limited number of connectors do not benefit from dielec-
AMP Mate-N-Lok tric grease, or may be permanently damaged by applica-
Follow the installation instructions. tion. Dielectric grease may not be required in properly
sealed enclosures.
3121157 – JLG Lift – 10-5

BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER

The connector uses gold contact material to resist corro- This type of connector uses back-seals for moisture integ-
sion and an o-ring seal for moisture integrity. If dielectric rity. However, the low-force contacts cannot displace
grease is mistakenly applied to this connector system, the dielectric grease and create electrical contact. It is possi-
low-force contacts cannot displace the grease to achieve ble to use solvents (i.e. contact cleaner or mineral spirits)
electrical contact. Once contaminated, there is no practi- for the removal of improperly applied dielectric grease.
cal way to remove the dielectric grease (replacement of The EMR2 engine control module from Deutz employs
female contacts required). The JLG Load Sensing System this connector system (for example).
and 1250AJP Rotary Angle Sensors are examples of com-
ponents with the M12 connector system.
SEALED ENCLOSURES
Application of dielectric grease is not required in properly
sealed enclosures. To meet criteria, the enclosure must
be rated to at least IP66 (dust tight; protected from power-
ful jets of water). The enclosure must be fitted with a high
quality, continuous gasket and all wiring must pass
through cable entrances.
10-6 – JLG Lift – 3121157

MIL-C-5015 SPEC CONNECTORS Assembly

Crown Connector Inc's recommendation is to not use
dielectric grease for this series connector. For similar Check to be sure the wedge lock is in the open, or as-
model series connectors, the manufacturer should be shipped, position (See Figure 10-7.). Proceed as follows:
contacted for confirmation before applying dielectric
grease. A typical application for this connector is on David
Clark Intercom connections in Aerial Work Platforms.
10.4 AMP CONNECTOR Figure 10-7. Connector Assembly Figure 1
Applying Silicone Dielectric Compound to

1. To insert a contact, push it straight into the appropri-
AMP Connectors ate circuit cavity as far as it will go (See Figure 10-
Silicone Dielectric Compound must be used on the AMP 9.).
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
air locked, thus preventing the housing latch from
engaging.
2. Pierce one of the unused wire seals to allow the
trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire
seal that has silicone dielectric compound escaping
from it.
3121157 – JLG Lift – 10-7

2. Pull back on the contact wire with a force of 1 or 2

lbs. to be sure the retention fingers are holding the
contact (See Figure 10-9.).
Figure 10-9. Connector Assembly Figure 2
3. After all required contacts have been inserted, the

wedge lock must be closed to its locked position.
Figure 10-8. AMP Connector
10-8 – JLG Lift – 3121157

Release the locking latches by squeezing them

inward (See Figure 10-10.).
4. Slide the wedge lock into the housing until it is flush

with the housing (See Figure 10-11.).
3121157 – JLG Lift – 10-9

Disassembly Wedge Lock

1. Insert a 4.8 mm (3/16") wide screwdriver blade The wedge lock has slotted openings in the forward, or
between the mating seal and one of the red wedge mating end. These slots accommodate circuit testing in
lock tabs. the field, by using a flat probe such as a pocket knife. DO
NOT use a sharp point such as an ice pick.
2. Pry open the wedge lock to the open position.
3. While rotating the wire back and forth over a half Service - Voltage Reading
turn (1/4 turn in each direction), gently pull the wire
until the contact is removed.
NOTE: The wedge lock should never be removed from the DO NOT PIERCE WIRE INSULATION TO TAKE VOLT-
housing for insertion or removal of the contacts. AGE READINGS.
It has been common practice in electrical troubleshooting

to probe wires by piercing the insulation with a sharp
point. This practice should be discouraged when dealing
with the AMPSEAL plug assembly, or any other sealed
connector system. The resulting pinholes in the insulation
will allow moisture to invade the system by traveling along
the wire strands. This nullifies the effectiveness of the con-
nector seals and could result in system failure.
Figure 10-12. Connector Disassembly
10-10 – JLG Lift – 3121157

Figure 10-13. Connector Installation
3121157 – JLG Lift – 10-11

10.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly
A B
A B
C
C D
Figure 10-14. DT/DTP Contact Installation Figure 10-15. DT/DTP Contact Removal
1. Remove wedgelock using needlenose pliers or a

1. Grasp crimped contact about 25mm behind the con- hook shaped wire to pull wedge straight out.
tact barrel.
2. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you. while at the same time releasing the locking finger
3. Push contact straight into connector grommet until a by moving it away from the contact with a screw-
click is felt. A slight tug will confirm that it is properly driver.
locked in place. 3. Hold the rear seal in place, as removing the contact
4. Once all contacts are in place, insert wedgelock with may displace the seal.
arrow pointing toward exterior locking mechanism.
The wedgelock will snap into place. Rectangular
wedges are not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure

for plug.
10-12 – JLG Lift – 3121157

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 10-16. HD/HDP Contact Installation Figure 10-18. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact

1. With rear insert toward you, snap appropriate size
crimp barrel.
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 10-17. HD/HDP Locking Contacts Into Position Figure 10-19. HD/HDP Unlocking Contacts
NOTE: For unused wire cavities, insert sealing plugs for full NOTE: Do Not twist or insert tool at an angle.
environmental sealing
3121157 – JLG Lift – 10-13

Figure 10-20. Electrical Components - Sheet 1 of 2
10-14 – JLG Lift – 3121157

Figure 10-21. Electrical Components - Sheet 2 of 2
3121157 – JLG Lift – 10-15

Figure 10-22. Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 1 of 2
10-16 – JLG Lift – 3121157

1870174-D
3121157 – JLG Lift – 10-17

10-18 – JLG Lift – 3121157

1870174-D
3121157 – JLG Lift – 10-19

Figure 10-26. Electrical Schematic - Deutz EMR2/Gradall - Sheet 1 of 4
10-20 – JLG Lift – 3121157

1870194-B
3121157 – JLG Lift – 10-21

10-22 – JLG Lift – 3121157

1870194-B
3121157 – JLG Lift – 10-23

SEE
SHEET 1
ZONE B2
PLATFORM WORK LIGHTS
RED 5 AMP
BLACK 18 BLK/WHT (12) 18 BLACK (12)
RED
BLACK
STROBE LIGHT
RED 1-90
15 YEL/BLK(18) 15 BLU/ORN 52-11 1
15 AMP 2
C.B.
BLU/ORN 52-11
PLATFORM BOX
YEL/RED
MTB
2-5-1
SELECT
SWITCH MTB
MAIN TELE IN BROWN 13-1 5 19 ORN/RED 49-4 PLATFORM
ALARM EMS YEL/RED EMS
MAIN TELE OUT BROWN 14-1 6 YEL/RED
20 BLACK 13 ORN/BLK 13 2 B1 YEL/RED
GRAY 24-1 2-5 2-5
ROTATE RIGHT 7 2-4 (12)
33 GRAY 23-1 3 4
ROATE LEFT GRAY 23-1 8 YEL/RED YEL/RED
34 GRAY 24-1 4 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 3 2-1(12)
LEVEL DOWN PINK 26-1 10
22 PINK 26-1 1
J7 (BLACK)
JIB UP BLUE 27-1 11

25 BLUE 27-1 5
JIB DOWN BLUE 28-1 12
YEL/RED 2-3(16)
26 BLUE 28-1 6 YEL/RED
FUEL SELECT YEL/RED
BLU/ORN 52-20 33 27 2-30-4 2-1-3
Ref.V RED/ORN 4 RED/WHT 55-30 34 (12)
PUMP 28
WIPER
POTENTIOMETER GREEN 6 RED/WHT 55-31 35 29
GND BRN/BLK 5 BLACK 13 10 VOLT REF. 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
BLACK
2
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)
BLACK
3 24 GND MODE
1 YEL/RED 2-30-1
ORN 55-52 2 PTF EMS
25
YEL/RED 2-10
J1-19
18 23 BLACK 7
YEL/RED 2-1-1(12)
1 24 SPARE
2 35 BLACK TO SOFT TOUCH IND.
FOOTSWITCH 2 5 BLUE 5
3 8 ORN/RED 49-70 7 BLACK
4 4 ORN/RED 49-71 8 WHITE 7 GREEN 6 YELLOW (18) 6
SHT 4, ZONE D7
SHT 2, ZONE E6
16 WHITE
17 7 BROWN (18) 7
17 JIB BLOCK LIMIT SW
6 BLACK
26 8 HOLE PLUG 8
18 YEL/RED 2-63 3 WHT BLK 4 SOFT
14 R RED/BLK (18)
START SWITCH WHT/YEL 48-1 WHT 5 TOUCH 9 9
7 ORN/RED 49-69 6 BLK L
AUX POWER BRN/ORN 53-1 15
9 BLU/ORN 52-4 1
ENGINE SPEED WHT/YEL 48-5 28 GENERATOR BLACK (12)
5 BLU/ORN 52-3 2 16 16
TWO SPEED ORANGE 55-46 27
HORN 11 ORN/RED 49-72 9 12 RED (12) 12
BLU/ORN 52-1 31
SOFT TOUCH OVERIDE 12 ORN/RED 49-73 10 11 BLU/BLK 11
ORN/RED 49-40 29
HEAD/TAIL LIGHTS 15 ORN/RED 49-75 12
BLU/ORN 52-12 30 14 HOLE PLUG 14
16 ORN/RED 49-74 11
17 HOLE PLUG 17
30
19 HOLE PLUG 19
TILT ORN/RED 49-3 6
SYSTEM DISTRESS BRN/WHT 47-12 8 IGN POWER
J8 (BLACK)
GND FROM GND MODULE CONNECTOR

FOOTSWITCH/ENABLE YEL/RED 2-21 7 1 BLACK (12)
GND EMS
CREEP ORN/RED 49-15 9 2 YEL/RED 2-1-2
YEL/RED 2-4 (16)
CABLE SERVICE CAN HI
ORN/RED 49-101 10 RED (18)
BLACK (18) CAN LO
OVERLOAD
J2 (GRAY)
ORN/RED 49-100 11 CAN SHIELD

226KG/500# CAPACITY RED/YEL 54-2 12 ORN/RED 49-86
453KG/1000# CAPACITY YEL/RED 2-63
RED/YEL 54-3 13
DRIVE ORIENTATION ORN 55-51 14
GENERATOR ON BLU/ORN 52-4-1 15
24 SWING
YEL/RED 2-1-99 (16)
GLOW PLUG WHT/YEL 48-6 17 5K

6
DRIVE DISABLED BRN/WHT 47-14 19
YEL/RED 2-90
5 WHITE
SPARE 20 1
J5 (WHITE)
RED/BLU
RED 1-2
BLACK 18 4 GRN/YEL
35 2 GREEN
LIFT
23
3 BROWN 5K
TO J7-35
SOFT TOUCH ORN/RED 49-42 16 7 BLACK OR BLU/YEL
BLACK 25
LOW FUEL LAMP GRAY
BRN/WHT 47-13 21
1 DRIVE
2
34
DRIVE ORIENTATION 4
OVERIDE SWITCH ORN 55-50 ORANGE
5 AMP
5 7 VIOLET
3
3 GREEN
33
J6 (BLACK)
YEL/RED 2-36 32 2 WHITE

14
{ C
B
A
BLUE
31
STEER
ZONE C5
ZONE F7
SHEET 2
SHEET 4
RED 11 ORN/RED 49-92 26 YELLOW

5
SEE
28
OR
GREEN 10 ORN/RED 49-91 RED

1
WHITE 9 ORN/RED 49-90 29
BLACK/SHIELD 8 ORN/RED 49-89 27 WHT/RED
6
4 WHT/YEL
ANALYZER TRANSMIT
ANALYZER RECEIVE
ANALYZER GROUND
ANALYZER POWER
1 2 3 4
Figure 10-30. Electrical Schematic - Deutz/CAT - Sheet 1 of 7
10-24 – JLG Lift – 3121157

30 AMP
RED 1-2(10)
GROUND CONTROL BOX

TO BATTERY NEG.
+12 VDC
YEL/RED 2-40-9 24 OUTPUT
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
JIB UP BLUE 27-2 19 31 RED/WHT 50-6 FLOW CONTROL
JIB DOWN BLUE 28-2 8 33
MAIN LIFT UP TAN 3-2 23
J2 (GRAY)
32
MAIN LIFT DOWN TAN 4-2 33 3
SWING RIGHT WHITE 22-2 35 15
SWING LEFT WHITE 21-2 34
4 BROWN 13-3 IN MAIN TELE
10 16 BROWN 14-3 OUT MAIN TELE
21
19 ORANGE 7-3
11 8 ORANGE 8-3
22 +12 VDC UP MAIN LIFT
11 TAN 3-3
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
OIL PRESSURE BRN/WHT 47-5-1 29
20
ENGINE HIGH HEAD/TAIL
TEMPERATURE BRN/WHT 47-6-1 28 14 BLACK
LIGHT OUTPUT
NO CHARGE BRN/WHT 47-8-1 26 30 BLACK 87
87a
27 29 BLACK ALARM 86 85
BLACK (10)
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)
2 18 BLACK 13
15 24
28 SPARE-GND
13
25 BRN/WHT 47-12 FUEL SENSOR (SIGNAL) 1
GLOW PLUG WHT/YEL 48-6 3 6 SENSOR (GROUND) 2 UNITS WITH LOW
BLACK
BLACK 31 FUEL LIGHT IN
PLATFORM
32 1
GND FROM BATTERY 2
1 3 ORANGE 7-4
MTB EMS input
2
J8 (BLACK)
GND TO PLATFORM 6 ORANGE 8-4

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
RED (18) CAN HI 18
13
CAN LO 7
BLACK (18) 24
CAN SHIELD 4 AUXILIARY POWER
18
YEL/RED 2-3-1 PTF EMS 1 8 PUMP
YEL/RED 2-21 FOOTSWITCH 9 MOTOR
15 M
YEL/RED 2-30 MTB MODE SELECT 3 12
J1 (WHITE)
PLATFORM MODE INPUT

YEL/RED 2-2-1 2 13 BRN/ORN 53-2
MTB MODE OUTPUT
YEL/RED 2-30-1 14 28 YEL/RED ANALYZER POWER 1
9 29 ORN/RED 49-91 ANALYZER RECEIVE 2
23 30 ORN/RED 49-90 ANALYZER TRANSMIT 3
25 31 BLACK ANALYZER GROUND 4
DRIVE ORIEN. 5 10
PROX. SW 33 11
YEL/RED 2-63 2 1 ORN/RED 49-106 35 14
DRIVE DISABLE/CAPACITY ANGLE SWITCH BLK 10 ORN/RED 49-66 4 15
DRIVE DISABLE ONLY 660SJC WHT 9 YEL/RED 2-62 16
22
DRIVE DISABLE/CAPACITY LENGTH SWITCH BLK 8 ORN/RED 49-65 7
DRIVE DISABLE ONLY 660SJC WHT 7 YEL/RED 2-61 26 16
J7 (BLACK)
TRANSPORT LENGTH SWITCH (CE ONLY) 35

10 NOTE: NOT ALL BLACK GROUND WIRES
3 ORN/RED 49-76 4 5 ORN/RED 49-77 6 ORN/RED 49-64 25 ARE NUMBERED ON ALL MODELS
ORN/RED 49-76 29
17
ORN/RED 49-60 2 BLK WHT 1 YEL/RED 2-60 11 27
30 21
TRANSPORT SWITCH
26
8 34
31 32
CABLE SERVICE BROWN 2 ORN/RED 49-87 32 33
LEFT TRACK
SWITCH 4 1 BLACK 3 ORN/RED 49-88 12 19 REAR PUMP
24 REVERSE
1 BLUE 3 6
20 2 LEFT TRACK ORANGE 8-4
22 4 REAR PUMP ORANGE 7-4
8 FORWARD
SEE
17 9 SHEET 2
28 1 WHT/BLK 58-3 RIGHT TRACK ZONE G5
7 FRONT PUMP OR
21 SHEET 4
REVERSE
J3
13
ZONE E6
19 14
3 RIGHT TRACK ORANGE 8-3
27
10 FRONT PUMP ORANGE 7-3
34 11 FORWARD
6 WHT/BLK 58-2 B+
5
12
BLACK A 12 VDC
3 CAN HI C BATTERY
J12
4 CAN LO D DIAGNOSTICS
5 SHIELD E CONNECTOR
YEL/RED 2-90 H
RED 1-90 B
SEE
SHEET 1
ZONE H4
1001108900-B
3121157 – JLG Lift – 10-25

SEE
SHEET 1
ZONE B6
1 YEL/RED 2-1-99 (16)

2 WHT/YEL 48-3 J1-11 ON SHEET 1 ZONE D3
}
ENGINE 3 RED CAN HI
CONNECTOR 4 BLK CAN LO SEE SHEET 1, ZONE B5
5 BRN/WHT 47-8-1 SHIELD
6
120 OHM
BRN/WHT 47-8
87 87a
BRN/WHT 47-8-2
14 BLU/ORN 52-5
YEL/RED 2-6-2 86 85
30
YEL/RED 2-4-1 (12) TERMINAL B

BLACK
J1-10 MTB STATION

J1-22
ON SELECT SWITCH
ON
SHEET 1 SHEET 1, ZONE G5
SHEET 1
A B ZONE D3
ZONE D3
GENERATOR
RECEPTACLE SEE
SHEET 1
ZONE E5
JLG WIRING
FOR
CAT ENGINE
10-26 – JLG Lift – 3121157

BATTERY +
SHEET 1
ZONE C1 GENERATOR
CONTROL
7500 W BOX
GENERATOR B A C
STARTER
YEL/RED 2-20
MOTOR BLU/ORN 52-6
87 87a
A
GENERATOR BLU/ORN 52-5 86 85
PLUG 30
B
87 87a
BRN/WHT 47-8-2 86 85
SEE VENDOR 30
SCHEMATIC DETAIL
RED
SHEET 4 GLOW 5 AMP
ZONE E/G2 PLUGS
RED RED
POWERMITE
2500 W GENERATOR
14 GA FUSE LINK GENERATOR
SEE VENDOR B+
SCHEMATIC DETAIL
SHEET 2
D+
REGULATOR
ZONE G/E2
87 87a
A
GENERATOR BLU/ORN 52-5 86 85
PLUG 30
B
1001108900-B
3121157 – JLG Lift – 10-27

VENDOR SCHEMATIC
CAT ENGINE HARNESS
BOSCH GPA-S ACTUATOR
PURPLE/LT GREEN 18
1 SENSOR OUT
BLACK/LT GREEN 18 2 5V RTN
TAN/ORANGE 18
3 DBW +
PINK/WHITE 18
4 DBW -
LT GREEN/RED 18
5 5V EXT
BOSCH_872-860-521 CONN
BOSCH_C-TAB 2 99 00 49262 2 TERMINAL
OIL BOSCH_1 99 00 44435 2 SEAL
PRESSURE
BLACK/LT GREEN 18 2
LT BLUE 18
1
DEUTSCH_DT06-2S CONN
DEUTSCH_0462-201-16141 TERMINAL
AMP23 DEUTSCH_W2S LOCK
PINK/WHITE 18
DBW + 1
DBW - 2 TAN/ORANGE 18
STARTER LOCKOUT 3
RED/BLACK 18
GLOW CONTROL 4
WHITE/BLACK 18
SHUT OFF CONTROL 5
6 GROUND
7
BLACK 14 13MM RING W/
8
STAR WASHER
9
BLACK 16 BLACK 18
GROUND 10
RED/TAN 16
VBAT 11
TPS 12 PURPLE/LT BLUE 18
13
LT BLUE 18
OIL PRESSURE 14
PINK/TAN 18
VSW 15
LT GREEN/RED 18
5V EXT 16
17
TAN/WHITE 18
ECT 18
BLACK/LT GREEN 18 ECM
5V RTN 19
BLUE/PINK 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH RED/TAN 16 F2 RED 16
CAN + 20
BLUE/WHITE 18 10A
CAN - 21
CRANK - 22 WHITE/PURPLE 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
PURPLE/WHITE 18
CRANK + 23 A
TAN/WHITE 18
AMP_770680_1 CONNECTOR
AMP_770520_1 TERMINAL (TIN PLATED)
BLACK/LT GREEN 18 B ECT
PED_12162193 CONNECTOR
PED_12124075 TERMINAL
DIAGNOSTIC CONNECTOR
UNUSED 1 ANA RTN
UNUSED 2 5V REF
UNUSED 3 PC TX
UNUSED 4 PC RX
UNUSED 5 VBAT EPC_1F1T-14A624-AA-004 CONN
GTS_0330-930009 TERM (18-29)
UNUSED 6 GROUND GTS_0330-940001 TERM (14-16)
BLUE/PINK 18
7 CAN1 + EPC_E6DB-14A468-DA LOCK
BLUE/WHITE 18
8 CAN1 - EPC_F5AB-14A666-AA CAP
DEUTSCH_0413-204-2005 PLUG
CRANK SENSOR
WHITE/PURPLE 18
2 CRANK -
PURPLE/WHITE 18
1 CRANK +
DEUTSCH_DT06-2S CONN
DEUTSCH_W2S LOCK
10-28 – JLG Lift – 3121157

GLOW PLUG GLOW PLUG

SOLENOID RAIL
RED 8
8MM RING 5MM RING
GLOW PLUG
SOLENOID ALTERNATOR
F3 BLACK/RED 18 UNUSED
1
10A BROWN/WHITE 18 CAT 1073134 CONNECTOR
2 CAT 1073135 TERMINAL
BROWN/WHITE 18
GLOW 5MM RING 3
PLUGS
18-22 GAUGE INSULATED BUTT CONNECTOR
RED/BLACK 18 2
STARTER B+
BLACK/RED 18 3
RED 14 10MM RING
RED 18 5 RED 8
PINK/TAN 18 1
4
GLOW CONTROL
ALTERNATOR +
RED 8
7MM RING
PINK/TAN 18 F1 PINK 18
5A
VSW
VEHICLE INTERFACE
RED 16 PINK 18 1
VSW
LT BLUE/PINK 18 2
START
BLUE/PINK 18 3
CAN +
87a BLUE/WHITE 18 4
30 CAN -
WHITE 16 BROWN/WHITE 18 5
87 RED 16 ALT. EXCITE
6
UNUSED
LT BLUE/PINK 18 86 DEUTSCH_DT06-6S CONN

STARTER DEUTSCH_W6S LOCK
DEUTSCH_114017 CAVITY PLUG
BLACK 18
85
RELAY
WHITE 16 STARTER
7MM RING
SOLENOID
WHITE/BLACK 18 2
SHUT OFF SOLENOID
BK/W 18 F4 BLACK/WHITE 18 3
TYCO_172128-1 CONNECTOR 10A
TYCO_63648-1 TERMINAL RED 18 5
SHUT OFF PINK/TAN 18 1
4
SHUT OFF RELAY
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
1001108900-B
3121157 – JLG Lift – 10-29

RECTIFER
B+ FUSIBLE
STATOR LINK
RED 1-1(10)
STARTER ALTERNATOR
MOTOR
SOL. REGULATOR
STARTER SENSING AND
MOTOR SWITCHING
CIRCUITS D+
DEUTZ ENGINE WHT/YEL 48-13 (8)
WHT/YEL 48-12(12)
BRN/WHT 47-8-1
IN HEAD GLOW PLUGS
BATTERY CABLE (1 GA.)

BLACK (16)
sol.
sol. RED 1-4 (16)
J1-22
ON 87 87a 1 2
SHEET 1 86 85
ZONE D3 EGR VALVE
30
SWITCH TIER III
11
ENGINES ONLY
WHT/YEL 48-3
RED 1-3 (12)

A
WHT/YEL 48-9
GENERATOR BLU/ORN 52-5

RECEPTACLE BRN/WHT 47-8-2
B
LINK
{
SEE J1-11
SHEET 1
ZONE D3 J1-12
BRN/WHT 47-8 BRN/WHT 47-8-1
B+
SHEET 1
87 87a ZONE C1
MTB TO EMR2 ENGINE CONTROL
COOLANT 2 8 GRD(TempAll)
86 85
TEMPERATURE
1 9 ADC7(TEMP3) 1
EMR2 ENGINE CONTROL TO ENGINE
30
ENGINE 2 13 SPEED 2
SPEED
1 12 GRD (SPEED)
CAMSHAFT 10
TERMINAL B 1 23 GRD (ACD2)
11
BLACK
YEL/RED 2-4-1 (12) MTB STATION CHARGE AIR2 4 ADC5(TEMP1)

YEL/RED 2-6-2
SELECT SWITCH PRESSURE 3 25 +5Vref(ADC2) 12

SHEET 1, ZONE G5 4 24 ADC2
13
1 22 +5Vref(ADC4)
ENGINE OIL
PRESSURE 2 21 ADC4 14
3 20 GND (ADC4)
1 14 ActorOut
J1-10 SEE 2 15 ActorOut
ON SHEET 1 EMR
ACTUATOR 3 17 RackMeasCom
SHEET 1 ZONE E5
YEL/RED 2-1-99
ZONE D3 4 19 RackMeasSignal
5 18 RackMeasRef
120 OHM
RESISTOR
CAN SHIELD
BLACK (16)
YEL/RED 2-70 (16)

CAN LO
CAN HI
BLACK 0-1
ORN/RED 49-199
ORN/RED 49-198
YEL/RED 2-1-98
BLACK (18)
RED (18)
B L K A
C
B
A
J1-8
{
DEUTZ
SEE SHEET 1
DIANOSTICS
ZONE C5
PLUG
SEE SHEET 1, ZONE D3
1001108900-B
10-30 – JLG Lift – 3121157

3121157
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161(Corporate)
(800) 554-5438(Service)
(717) 485-6417
JLG Worldwide Locations

JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin)
358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Equipment Technology LTD
Regents Park Breitwaterstraat 12A Distrito Industrial Joao Narezzi Shanghai Branch
NSW 2143 3630 Maasmechelen Indaiatuba-SP 13347-404 No 465 Xiao Nan Road
Sydney 2143 Belgium Brasil Feng Xian District
Australia +32 (0) 89 84 82 26 +55 (19) 3936 7664 (Parts) Shanghai 201204
+6 (12) 87186300 Email: [email protected] +55(19)3936 9049 (Service) China
+6 (12) 65813058 Email: [email protected] +86 (21) 800 819 0050
Email: [email protected] Email: [email protected]
JLG Industries Dubai JLG France SAS JLG Deutschland GmbH JLG Equipment Services Ltd.
Jafza View Z.I. Guillaume Mon Amy Max Planck Str. 21 Rm 1107 Landmark North
PO Box 262728, LB 19 30204 Fauillet 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue
20th Floor, Office 05 47400 Tonniens Germany Sheung Shui N. T.
Jebel Ali, Dubai France +49 (0) 421 69350-0 Hong Kong
+971 (0) 4 884 1131 +33 (0) 553 84 85 86 +49 (0) 421 69350-45 +(852) 2639 5783
+971 (0) 4 884 7683 +33 (0) 553 84 85 74 Email:[email protected] +(852) 2639 5797
Email: [email protected] Email: [email protected]
JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries
Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b.
20010 Pregnana Milanese (MI) 2132 JH Hoofdorf 2B Fisher Cresent Khimki
Italy The Netherlands Mt Wellington 1060 Moscow Region 141400
+39 (0) 2 9359 5210 +31 (0) 23 565 5665 Auckland, New Zealand Russia Federation
+39 (0) 2 9359 5211 Email: [email protected] +6 (12) 87186300 +7 (499) 922 06 99
Email: [email protected] +6 (12) 65813058 +7 (499) 922 06 99
Email:[email protected]
Oshkosh-JLG Singapore JLG Iberica S.L. JLG Sverige AB JLG Industries (UK) Ltd.
Technology Equipment Pte Ltd. Trapadella, 2 Enkopingsvagen 150 Bentley House
35 Tuas Avenue 2 Pol. Ind. Castellbisbal Sur 176 27 Jarfalla Bentley Avenue
Jurong Industrial Estate 08755 Castellbisbal Barcelona Sweden Middleton, Greater
Singapore 639454 Spain +46 (0) 8 506 595 00 Manchester
+65 6591 9030 +34 (0) 93 772 47 00 +46 (0) 8 506 595 27 M24 2GP
+65 6591 9045 +34 (0) 93 771 1762 Email: [email protected] United Kingdom
Email: [email protected] Email:[email protected] +44 (0) 161 654 1000
+44 (0) 161 654 1003
Email: [email protected]

JLG 600 SC Boom Lift

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Service and Maintenance Manual

November 22, 2016

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

3121157 – JLG Lift – A-1

Original Issue December 4, 2003

A-2 – JLG Lift – 3121157

SECTION NO. TITLE PAGE NO.

3121157 – JLG Lift – i

SECTION NO. TITLE PAGE NO.

ii – JLG Lift – 3121157

SECTION NO. TITLE PAGE NO.

3121157 – JLG Lift – iii

SECTION NO. TITLE PAGE NO.

iv – JLG Lift – 3121157

SECTION NO. TITLE PAGE NO.

3121157 – JLG Lift – v

SECTION NO. TITLE PAGE NO.

vi – JLG Lift – 3121157

FIGURE NO. TITLE PAGE NO.

3121157 – JLG Lift – vii

FIGURE NO. TITLE PAGE NO.

viii – JLG Lift – 3121157

FIGURE NO. TITLE PAGE NO.

3121157 – JLG Lift – ix

FIGURE NO. TITLE PAGE NO.

x – JLG Lift – 3121157

TABLE NO. TITLE PAGE NO.

3121157 – JLG Lift – xi

1.1 OPERATING SPECIFICATIONS 1.3 ENGINE DATA

Maximum Work Load (Capacity) Fuel Diesel

3121157 – JLG Lift – 1-1

Auxiliary Power Pump

Type Four Stroke Cycle Table 1-7. Auxiliary Power Pump

Rotation Clockwise Drive (Out of Transport)

1-2 – JLG Lift – 3121157

Dimensions 1.7 PRESSURE SETTINGS

BORE STROKE ROD DIA.

M16 Travel Motor 175 ±30 ft.lbs. As

M20 Track Roller 340 ±44 ft.lbs. As 660SJ 600S

3121157 – JLG Lift – 1-3

Table 1-16. Mobilfluid 424 Specs

SAE Grade 10W30

Table 1-17. Mobil DTE 13M Specs

1.11 HYDRAULIC OIL ISO Viscosity Grade #32

1-4 – JLG Lift – 3121157

Figure 1-2. Operator Maintenance and Lubrication Diagram

1.12 OPERATOR MAINTENANCE AND

Lube Point(s) - 2 Grease Fittings

3121157 – JLG Lift – 1-5

2. Swing Drive Hub 5. Hydraulic Charge Filter

Lube Point(s) - Fill Cap

Interval - Change after first 50 hrs. and every 6

1-6 – JLG Lift – 3121157

7. Suction Strainers (in tank) 10. Fuel Filter - Deutz

REMOVE FILL CAP PLATE FROM

Lube Point(s) - Replaceable Element

8. Oil Change w/Filter - Deutz 12. Air Filter

Lube Point(s) - Replaceable Element

3121157 – JLG Lift – 1-7