JLG 1200SJP 1350SJP Service Manual PDF

Service and Maintenance Manual
Models
1200SJP
1350SJP
P/N - 3121142
July 22, 2014

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 personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
strict attention to these warnings and precautions to avoid
SAFETY VIOLATION.
possible injury to themselves or others, or damage to the
equipment. A maintenance program must be followed to
• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
ensure that the machine is safe to operate. IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. SECURE AT ALL OTHER TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-

The specific precautions to be observed during maintenance
FORMING ANY MAINTENANCE.
are inserted at the appropriate point in the manual. These pre-
cautions are, for the most part, those that apply when servic- • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
ing hydraulic and larger machine component parts. TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
CAUGHT ON OR ENTANGLED IN EQUIPMENT.
Your safety, and that of others, is the first consideration when
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
engaging in the maintenance of equipment. Always be con-
MACHINE AND IN SERVICEMANUAL.
scious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
rest in an unstable position. When raising a portion of the SURFACES AND HAND HOLDS.
equipment, ensure that adequate support is provided.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL-
ANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA IS THE RESPON- BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
SIBILITY OF THE OWNER/OPERATOR. HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-

FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
B HYDRAULIC SYSTEM SAFETY POWER CONTROLS.
It should be noted that the machines hydraulic systems oper-
• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING
ate at extremely high potentially dangerous pressures. Every REPLACEMENT OF ELECTRICAL COMPONENTS.
effort should be made to relieve any system pressure prior to
disconnecting or removing any portion of the system. • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

VENTS.
3121142 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
Original Issue - June 5, 2002

Revised - January 15, 2003
Revised - May 23, 2003
Revised - August 30, 2004
Revised - July 12, 2006
Revised - November 30, 2006
Revised - November 9, 2007
Revised - April 9, 2008
Revised - August 27, 2008
Revised - October 27, 2011
Revised - March 28, 2012
Revised - July 22, 2014
A-2 – JLG Lift – 3121142

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 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Deutz Prior to S/N 0300127698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Deutz S/N 0300127698 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Specifications and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.8 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.9 Lubrication and Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3121142 – JLG Lift – i

TABLE OF CONTENTS

2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do NOT Do the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Extending Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Axle Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Drive/Steering Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.7 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.8 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.9 Oscillating Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.10 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.11 Drive Hub (Prior to S/N 100131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Disassembly of Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Disassembly of the First Stage Planetary Assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Disassembly of Second Stage Planet Gears (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Assembly of First Stage Planetary Assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Assembly of End Cover Unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Initial Start-up And After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Oil Change Interval-Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.12 Drive Hub - Bonfiglioli (S/N 100128 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Installation of the Wheel Drive on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Start Up and Running In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Connecting the Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Filling-up the Gearbox with Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Gearbox Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Changing the Lubricating oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Inspection of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Final Test and Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
ii – JLG Lift – 3121142

TABLE OF CONTENTS

3.13 Drive Hub - Reggiana Riduttori (S/N 134389 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Symbol Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
3.14 Swing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Roll and Leak Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Hub-Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Hub-Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Motor Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.15 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
3.16 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.17 Procedure For Setting Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.18 Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3.19 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3.20 Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3.21 Chassis Tilt Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3.22 Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.23 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
3.24 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3.25 Cold Weather Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3.26 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
Cleaning the Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
3121142 – JLG Lift – iii

TABLE OF CONTENTS

3.27 Deutz EMR 2 (S/N 87579 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
3.28 Bio Fuel in Deutz Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
3.29 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
List of Abbreviations in this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
CAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
MIL Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139
DTC 117- ECT/CHT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
DTC 122- TPS1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
DTC 123- TPS1 Signal Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
DTC 217- ECT Higher Than Expected 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
DTC 219- RPM Higher Than Max Allowed Governed Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
DTC 337- Loss of Crank Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-152
DTC 521- Oil Pressure Sender/Switch High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153
DTC 524- Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154
DTC 562- Battery Voltage (VBat) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-156
DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158
DTC 601- Microprocessor Failure - FLASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
DTC 604- Microprocessor Failure - RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162
DTC 606- Microprocessor Failure - COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-164
DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
DTC 643- 5 Volt External High Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-167
DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168
DTC 1615- Microprocessor Failure - A/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173
DTC 1616- Microprocessor Failure - interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175
DTC 1625- CAN J1939 Shutdown Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177
DTC 1626- CAN J1939 Transmit (Tx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-178
DTC 1627- CAN J1939 Receive (Rx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-179
DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-180
DTC 1629- J1939 TSC1 Message Reciept Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-182
DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-183
DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-184
DTC 2112- Unable to Reach Higher TPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-186
DTC 9999- Throttle Actuator Failsafe Spring Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-187
DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-188
iv – JLG Lift – 3121142

TABLE OF CONTENTS

SECTION 4 - BOOM & PLATFORM
4.1 Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Broken Cable Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive/Steer – Boom Function Interlock System (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Jib Stow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Envelope Tracking System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Moment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Control System (BCS) Functional Check (Push to Test) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Controlled Arc System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Controlled Boom Angle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Slow Down System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Dual Capacity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Boom Control Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2 Boom Removal, Disassembly/Assembly, & Cable Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.3 Boom Lubrication Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4.4 Boom Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4.5 Jib Rotator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.6 Jib Lift End of Stroke Dampening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.7 Load Sensing Pin Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.8 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
One Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Two Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4.9 Hose Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.10 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Eight Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.11 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Boom Section Re-Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4.12 Broken Boom Cable Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Adjusting the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4.13 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.14 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Testing the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Bleeding After Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
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TABLE OF CONTENTS

SECTION 5 - HYDRAULICS
5.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.3 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.4 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Set Up of the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Adjustments made at the Main Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Adjustments Made at the Frame Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Adjustments Made at the Platform Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.5 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Mechanical Centering of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Hydraulic Centering of Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
High Pressure Relief Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Removal and inspection of charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Removal and Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5.6 Function Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Sealing the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Disassembly and Assembly of the Complete Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Tightening Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Pump Control Disassembly For Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.7 Drive & Function Pump Start Up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
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SECTION 6 - JLG CONTROL SYSTEM
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 To Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.6 Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.7 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.8 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.9 Machine Personality Settings/Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6.10 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.11 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.12 Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6.13 Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
6.14 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Platform Leveling Fault Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Fault Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
CAN Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Additional Platform and Jib Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Platform Leveling Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6.15 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
STEP 3: BLEEDING THE PLATFORM VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS . . . . . . . . . . . . . . 6-58
6.16 Calibrating Lift Crack Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
6.17 Calibrating Telescope Crack point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6.18 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
6.19 Calibrating the Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Boom Control System Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
6.20 CANbus Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
CANbus Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Load Moment Pin Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-128
3121142 – JLG Lift – vii

TABLE OF CONTENTS

SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Applying Silicone Dielectric Compound to AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
viii – JLG Lift – 3121142

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Lubrication and Operator Maintenance Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-2. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
2-1. Engine Operating Temperature Specifications - Deutz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2. Engine Operating Temperature Specifications - Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1. Axle Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Conventional Two Wheel Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Crab Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Coordinated Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-5. Chassis Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-6. Chassis Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-7. Turntable and Boom Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-8. Turntable and Boom Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-9. Oscillating Axle - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-10. Oscillating Axle - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-11. Axle Loctite Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-12. Steering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-13. Drive Hub - Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-14. Drive Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-15. Drive Hub Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-16. Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-17. Gearbox engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-18. Gearbox Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-19. Drive Hub S/N 100128 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-20. Drive Hub Special Tools - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3-24. Bearing Track Spacer Mounting C016117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-25. Oil Seal Spacer Mounting C125049 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-26. Bearing Spacer Mountng CO16117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-27. Assembly Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
3-28. Wrench For Ring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-29. Anti-rotation Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-30. Anti-rotation Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-31. Anti-rotation Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-32. Assembly Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-33. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-34. Reggiana Riduttori Hub - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-35. Reggiana Riduttori Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3-36. Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-37. Swing Drive - Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-38. Swing Drive - Motor and Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3-39. Swing Drive - Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3-40. Swing Drive - Hub Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3-41. Swing Drive - Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3-42. Swing Drive - Hub Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3-43. Swing Drive - Carrier Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3-44. Swing Drive - Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3-45. Swing Drive - Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3-46. Swing Drive - Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3-47. Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3-48. Swing Brake 8 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3121142 – JLG Lift – vii

LIST OF FIGURES

3-49. Swing Brake 12 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3-50. Swing Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
3-51. Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-52. Swing Drive Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3-53. Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3-54. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
3-55. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
3-56. Swing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
3-57. Swing Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3-58. Swing Bearing Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3-59. Rotary Coupling Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3-60. Rotary Coupling Cutaway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3-61. Rotary Coupling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
3-62. Rotary Coupling Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
3-63. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
3-64. Auxiliary Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3-65. Cold Weather Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
3-66. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3-67. Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
3-68. EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3-69. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
3-70. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
3-71. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
3-72. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3-73. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3-74. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
3-75. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
3-80. 1st page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3-81. 2nd Page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
4-1. Boom Assembly - Sheet 1 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-8. Boom Assembly Torque Values - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-9. Boom Assembly Torque Values - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-10. Locations for Threadlocker Application - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4-14. Measuring Boom Section Sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4-15. Jib Rotator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4-16. Load Pin Removal Tool, JLG P/N 4846765. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-17. Boom/Jib Sensors and Switches Installation - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4-21. Boom Wiper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4-22. Pivot Pin Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4-23. Powertrack Installation - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-24. Powertrack Installation - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
viii – JLG Lift – 3121142

LIST OF FIGURES

4-25. Powertrack Installation - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4-29. Torque Sequence for Fly Extend Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-30. Wire Rope Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4-31. Outer Mid Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4-32. Fly Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4-33. Wire Rope Adjustment Tools (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4-34. Broken Boom Cable Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-35. Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4-36. Rotary Actuator - Assembly Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
4-37. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
4-38. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-3. Axle Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-4. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-5. Level Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-6. Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-7. Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-8. Steer Cylinder - Prior to S/N 73367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-9. Steer Cylinder - S/N 73367 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-10. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-11. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-12. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-13. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-14. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-15. Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-16. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-17. Installation of Head Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-18. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-19. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-20. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-21. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-22. Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-23. Chassis Control Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-24. Platform Valve Identification - JLG P/N 4641266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-25. Platform Valve Identification - JLG P/N 4641460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-26. Main Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-27. Main Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-27. Main Valve Plug Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-27. Hydraulic Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-28. Steer Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-29. Function Pump - Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-30. Function Pump, Pressure and Flow Control - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Control System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-3. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-6. Analyzer Flow Chart - Calibrations (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . 6-9
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6-10. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-11. Analyzer Connecting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-12. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6-13. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6-14. Boom Sensor Calibration Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6-23. Boom Sensor Calibration Position 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
6-24. Fault Code Light Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
6-25. CANbus Connections Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
6-26. CANbus Connections - Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
6-31. CANbus Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
6-32. Moment Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-132
7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-10. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-17. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-18. Chassis Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-19. Chassis Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-20. Turntable Electrical Components - Prior to S/N 87579 - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-21. Turntable Electrical Components - Prior to S/N 87579 - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-22. Turntable Electrical Components - S/N 87579 to Present - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-23. Turntable Electrical Components - S/N 87579 to Present - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-24. Electrical Schematic - Deutz EMR2 - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-30. Electrical Schematic - Sheet 1 of 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
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7-35. Electrical Schematic - Sheet 6 of 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7-39. Electrical Schematic - Sheet 10 of 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7-43. Hydraulic Schematic - Boom Functions - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7-44. Hydraulic Schematic - Boom Functions - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7-45. Hydraulic Schematic - Axle/Steer Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-46. Hydraulic Schematic - Axle/Steer Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7-47. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7-48. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7-49. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7-50. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
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xii – JLG Lift – 3121142

LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Deutz BF4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5 Caterpillar 3.4T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-6 Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-8 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-9 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-10 Engine Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-11 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-13 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-14 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-15 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-16 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-17 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-18 Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-19 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
2-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 Steering Assembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-2 Brake Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-3 Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade . . . . . . . . . . . . . . . . . . . . . . 3-23
3-4 Drive Hub Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-6 Coupling Port Information Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
3-7 J1939 Diagnostic Lamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
4-1 Hose/Cable Pull Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
4-1 Hose/Cable Pull Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
5-1 Cylinder Head and Tapered Bushing Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-3 Cartridge Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-4 Plug Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-5 Torque Specs for Relief Valves into Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
5-6 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
6-1 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-2 Machine Configuration Programming Information - Version P7.X to Present . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-3 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6-4 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6-5 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-6 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
6-7 Troubleshooting: Platform Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
6-8 Troubleshooting: BLAM Can Communications Lost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-123
6-9 Troubleshooting: Chassis Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-127
6-10 Load Moment Pin Troubleshooting: Can Communications Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-128
6-11 Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range . . . . . . . . . . . . . . . . . . . . . 6-129
6-12 Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range . . . . . . . . . . . . . . . . . . . . . . . . 6-130
6-13 Load Moment Pin Troubleshooting: Moment Pin Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
6-14 Load Moment Pin Troubleshooting: New Moment Pin Detected Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131
3121142 – JLG Lift – xiii

LIST OF TABLES
TABLE NO. TITLE PAGE NO.
xiv – JLG Lift – 3121142

SECTION 1. SPECIFICATIONS
1.1 CAPACITIES Deutz S/N 0300127698 to Present

Table 1-1. Capacities Table 1-4. Deutz TD2011L4 Specifications
Hydraulic Tank 55 gallons (208 liters) Type Liquid Cooled

Fuel Tank 31 gallons (117 liters) Number of Cylinders 4
Hydraulic System 66 gallons (250 liters) Bore 3.7 in. (94 mm)
Stroke 4.4 in. (112 mm)
Total Displacement 190 cu. in. (3108 cm3)
1.2 TIRES Compression Ratio 17.5
Table 1-2. Tire Specifications Firing Order 1-3-4-2
Output 75hp (56 kW)
Size 445/50D710
Oil Capacity
Load Range J
Cooling System 5 Quarts (4.5 L)
Ply Rating 18 w/Filter 11 Quarts (10.5 L)
Load Rating 26,500 lbs. @ 100 psi (12020 kg @ 6.9 Bar) Total Capacity 16 Quarts (15 L)
Foam Fill Poly urethane HD (55 Durometer) Foam Average Fuel Consumption 1.1 gph (4.1 lph)
Max Tire Load Idle Engine RPM 1200
1200SJP 25,000 lbs. (11,340 kg) Mid Engine RPM 1800
1350SJP 26,250 lbs. (11,907 kg)
High Engine RPM 2475
Caterpillar
1.3 ENGINE DATA Table 1-5. Caterpillar 3.4T
Deutz Prior to S/N 0300127698 Type Liquid Cooled, Antifreeze

Table 1-3. Deutz BF4M2011 Specifications Number of Cylinders 4
Bore 3.7 in. (94 mm)
Type Liquid Cooled
Number of Cylinders 4
Bore 3.7 in. (94 mm)
Compression Ratio 19.5:1
Firing Order 1-3-4-2
Output 73.7hp (55 kW)
Compression Ratio 17.5
Oil Capacity 10.5 Quarts (10 L)
Firing Order 1-3-4-2
Average Fuel Consumption 1.36 gph (5.14 lph)
Output 87hp (65 kW)
Idle Engine RPM 1200
Oil Capacity
Cooling System 5 Quarts (4.5 L) Mid Engine RPM 1800
w/Filter 11 Quarts (10.5 L) High Engine RPM 2475
Total Capacity 16 Quarts (15 L)
Average Fuel Consumption 1.1 gph (4.1 lph)
Idle Engine RPM 1200
Mid Engine RPM 1800
High Engine RPM 2475
3121142 – JLG Lift – 1-1

1.4 SPECIFICATIONS AND PERFORMANCE DATA Dimensional Data

Table 1-7. Dimensional Data
Reach Specifications
Overall Width
Table 1-6. Reach Specifications Axles Retracted 8ft. 2in. (2.49 m)
Axles Extended 12ft. 6in. (3.8 m)
Maximum Work Load (Capacity)
Unrestricted 500 lb (230 kg) Stowed Height 10ft. (3.04 m)
Restricted 1000 lb. (450 kg) Stowed Length (Transport Mode)
Max.Vertical Platform Height (Unrestricted) 1200SJP 34ft. 11in. (10.64 m)
1200SJP 120 ft. (36.6 m) 1350SJP 38ft. 11in. (11.86 m)
1350SJP 135 ft. (41.2 m) Stowed Length (Working Mode)
Max.Vertical Platform Height (Restricted) 1200SJP 44ft. 11in. (13.69 m)
1200SJP 115 ft. (35.1 m) 1350SJP 48ft. 11in. (14.91 m)
1350SJP 125 ft. (38.1 m) Wheelbase 12ft. 6in. (3.81 m)
Max.Horizontal Platform Reach (Unrestricted) Tailswing 5ft. 6 in. (1.6 m)
1200SJP 75 ft. (22.9 m) Ground Clearance (Axle) 12 in. (30.4 cm)
1350SJP 80 ft. (24.4 m)
Ground Clearance (Chassis) 25.5 in. (64.7 cm)
Max.Horizontal Platform Reach (Restricted)
1200SJP 65 ft. (19.8 m)
1350SJP 70 ft. (21.3 m) Chassis
JibPLUS Table 1-8. Chassis Specifications
Length 8ft. (2.44m) Maximum Travel Grade With boom in stowed 45%
Horizontal Motion 180° working, 244° position (Gradeability)
stowed
Maximum Travel Grade With boom in stowed 5°
Vertical Motion 130° (+75/-55)
position (Side Slope)
Turning Radius (Axles Retracted)
Outside 22 ft. 6 in. (6.8 m)
Inside 14 ft. 5 in. (4.4 m)
Turning Radius (Axles Extended)
Inside 8 ft. (2.4 m)
Outside 19 ft. 4 in. (5.9 m)
Max Tire Load
1200SJP 25,000 lbs. (11,340 kg)
1350SJP 26,250 lbs. (11,907 kg)
Max Ground Bearing Pressure
1200SJP 100 psi (7.03 kg/cm2)
1350SJP
105 psi (7.38 kg/cm2)
Maximum Drive Speed 3.25 mph (5.2 kph)
Max. Hydraulic System Pressure 4600 psi (317 Bar)
Maximum Wind Speed 28 mph (12.5 m/s)
Maximum Manual Force 400 N
Electrical System Voltage 12 Volts
Gross Machine Weight (Platform Empty)
1200SJP 41,100 lb. (18,643 kg)
1350SJP 44,750 lb. (20,298 kg)
1-2 – JLG Lift – 3121142

1.5 TORQUE REQUIREMENTS 1.6 HYDRAULIC OIL

Table 1-11. Hydraulic Oil Specifications
Table 1-9. Torque Requirements
Hydraulic System
Description Torque Value (Dry) Interval Hours S.A.E. Viscosity
Operating
Grade
Temperature Range
Wheel Bolts 180 ft. lbs. 150
(252 Nm) +0° to + 180° F 10W
(-18° to +83° C)
Swing Bearing Bolts 190 ft. lbs. 50/600* +0° to + 210° F 10W-20, 10W30
(258 Nm) (-18° to +99° C)
Tele Cylinder 13 ft. lbs. As required +50° to + 210° F 20W-20
Regen Valve Mounting Bolts (18 Nm) (+10° to +99° C
Starter Solenoid
Contacts 95 in. lbs. (9.5 Nm) As required NOTE: Hydraulic oils must have anti-wear qualities at least to API
Coil 40 in. lbs. (4 Nm) Service Classification GL-3, and sufficient chemical stabil-
ity for mobile hydraulic system service. JLG Industries rec-
*Check swing bearing bolts for security after first 50 hours of operation and every 600 ommends Mobilfluid 424 hydraulic oil, which has an SAE
hours thereafter. (See Swing Bearing in Section 3.) viscosity index of 152.
NOTE: When maintenance becomes necessary or a fastener has NOTE: When temperatures remain consistently below 20 degrees
loosened, refer to the Torque Chart to determine proper F. (-7 degrees C.), JLG Industries recommends the use of
torque value. Mobil DTE13.
Table 1-10. Engine Torque Requirements Aside from JLG recommendations, it is not advisable to mix oils of
different brands or types, as they may not contain the same
Torque Value Torque Value required additives or be of comparable viscosities. If use of
Description hydraulic oil other than Mobilfluid 424 is desired, contact JLG
Ft. Lb.s Nm
Industries for proper recommendations.
Cylinder Head Cover 6 8.5
Cylinder Head Cover 6 8.5 Table 1-12. Mobilfluid 424 Specs
Rocker Arm Adjustment Screw 15 21 SAE Grade 10W30

Gravity, API 29.0
Intake Manifold 6 8.5
Density, Lb/Gal. 60°F 7.35
Air Intake Pipe 15 21 Pour Point, Max -46°F (-43°C)
Exhaust Manifold 16 22 Flash Point, Min. 442°F (228°C)
Viscosity
Oil Drain Plug 39 55
Brookfield, cP at -18°C 2700
Oil Pan (sheet metal) 15 21 at 40° C 55 cSt
at 100° C 9.3 cSt
Oil Pan (cast) 22 31
Viscosity Index 152
Injection Line Attachment 21 30
Injection Valve Attachment 15 21
Lube Oil Filter Cartridge 19 27
3121142 – JLG Lift – 1-3

Table 1-13. Mobil DTE 13M Specs Table 1-15. Mobil EAL H 46 Specs
ISO Viscosity Grade #32 Type Synthetic Biodegradable

Specific Gravity 0.877 ISO Viscosity Grade 46
Pour Point, Max -40°F (-40°C) Specific Gravity .910
Flash Point, Min. 330°F (166°C) Pour Point -44°F (-42°C)
Viscosity Flash Point 500°F (260°C)
at 40° C 33cSt Operating Temp. 0 to 180°F (-17 to 162°C)
at 100° C 6.6 cSt Weight 7.64 lb. per gal.
(0.9 kg per liter)
at 100° F 169 SUS
Viscosity
at 210° F 48 SUS
at 40° C 45 cSt
cp at -20° F 6,200
at 100° C 8.0 cSt
Viscosity Index 140
Viscosity Index 153
Table 1-14. UCon Hydrolube HP-5046
Table 1-16. Exxon Univis HVI 26 Specs
Type Synthetic Biodegradable
Specific Gravity 32.1
Specific Gravity 1.082
Pour Point -76°F (-60°C)
Pour Point, Max -58°F (-50°C)
pH 9.1 Flash Point 217°F (103°C)
Viscosity
Viscosity
at 0° C (32° F) 340 cSt (1600SUS) at 40° C 25.8 cSt
at 40° C (104° F) 46 cSt (215SUS) at 100° C 9.3 cSt

Viscosity Index 376
at 65° C (150° F) 22 cSt (106SUS)
Viscosity Index 170 NOTE: Mobil/Exxon recommends that this oil be checked on
a yearly basis for viscosity.
1-4 – JLG Lift – 3121142

1.7 MAJOR COMPONENT WEIGHTS 1.8 PRESSURE SETTINGS

Table 1-17. Component Weights Table 1-18. Pressure Settings
Component Pounds Kilograms Circuit PSI Bar

Tire & Wheel 867 393
Function Pump, High 3400 234.4
Drive Hub & Motor 275.5 123
Swing Drive 290 132 Function Pump, Low 300 20.6
Engine Assembly 1275 579 Drive, Pre-Set 5000 344.7
1350 Boom (Complete) 11850 5375
Lift Up 2750 189.6
1200 Boom (Complete) 11100 5035
Lift Cylinder 787 357 Lift Down 1500 103.4
1350 Tele Cylinder 1322 600 Swing 1500 103.4
1200 Tele Cylinder 1170 531
Tele Out 3000 206.8
Jib Cylinder 69 31
Axle Oscillation Cylinder 74 34 Telescope In 3200 220.6
Axle Extend Cylinder 92 42
Steer Right 2000 137.9
Level Cylinder 89 40
Platform 36 x 96 245 111 Steer Left 2500 172.3
Platform 36 x 72 195 89 Platform Level Up 2500 172.3
1350 Counterweight 8500 3856
Platform Level Down 1500 103.4
1200 Counterweight 5494 2492
T/T Assy. (less Cwt) 9450 4286 Jib Up 2750 189.6
Jib Down 2750 189.6
Extendable Axles 2500 172.3
3121142 – JLG Lift – 1-5

13
14
5
4
4
7 10,11
8
9
12
1
2,3
4 4
15
Figure 1-1. Lubrication and Operator Maintenance Diagram
1-6 – JLG Lift – 3121142

1.9 LUBRICATION AND OPERATOR MAINTENANCE 2. Swing Gearbox
NOTE: The following numbers correspond to those in Figure 1-1.,

Lubrication and Operator Maintenance Diagram.
Table 1-19. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. 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) - Fill Plug

Capacity - 79 ounces (2.3 L)
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR- Lube - GL-5
MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ Interval - Check level every 150 hrs/Change every 1200
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION hours of operation. Fill to cover ring gear.
FREQUENCIES MUST BE INCREASED ACCORDINGLY. 3. Swing Brake
NOTE: It is recommended as a good practice to replace all filters at

the same time.
1. Swing Bearing - Remote Lube
Lube Point(s) - 2 Grease Fitting Lube Point(s) - Fill Plug

Capacity - A/R Capacity - 2.7 ounces (80 ml)
Lube - MPG Lube - DTE24
Interval - Every 3 months or 150 hours of operation Interval - Check level every 150 hrs/Change every 1200
hours of operation.
3121142 – JLG Lift – 1-7

NOTE: After S/N 0300134389 machines may be built with either C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to
Bonfiglioli or Reggiana Riduttori wheel drive hubs. Present)
4. A. Wheel Drive Hub - Rexroth (Prior to S/N 100128)
Lube Point(s) - Level/Fill Plug

Lube Point(s) - Level/Fill Plug Capacity - 0.5 quarts (0.5 liters) ± 10%
Capacity - 0.5 liters (1/2 full) Lube - EPGL
Lube - EPGL Interval - Change after first 150 hours then every 1200
Interval - Change after first 150 hours then every 1200 hours of operation
hours of operation Comments - Place Fill port at 12 o’clock position and
Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position. Pour lubricant into
Check port at 3 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port.
fill port until it just starts to flow out of check port. 5. Hydraulic Return Filter
B: Wheel Drive Hub - Bonfiglioli (S/N 100131 to Present)
Lube Point(s) - Replaceable Element

Interval - Change after first 50 hours and every 300 hours
Lube Point(s) - Level/Fill Plug
thereafter or as indicated by condition indicator
Capacity - 2.1 quarts (2 liters) ± 10%
Lube - EPGL 6. Hydraulic Charge Filter
Interval - Change after first 150 hours then every 1200
hours of operation Lube Point(s) - Replaceable Element
Comments - Place Fill port at 12 o’clock position and Interval - Change after first 50 hours and every 300 hours
Check port at 8 o’clock position. Pour lubricant into thereafter or as indicated by condition indicator.
fill port until it just starts to flow out of check port.
1-8 – JLG Lift – 3121142

7. Hydraulic Oil 9. Oil Change w/Filter - Deutz
FULL LEVEL (HOT OIL)
FULL LEVEL (COLD OIL)
Lube Point(s) - Fill Cap/Spin-on Element

Capacity -
5 Quarts (4.5 L) Cooling System
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L) Total Capacity
Lube - EO
Lube Point(s) - Fill Cap Interval - Check level daily; change every 500 hours or
Capacity - 55 gallons (208 liters) Tank six months, whichever comes first. Adjust final oil
Lube - HO level by mark on dipstick. Refer to Figure 1-2., Deutz
Interval - Check level daily. Change every 2 years or 1200 Engine Dipstick.
hours of operation.
8. Suction Strainers (In Tank)
MINIMUM OIL
LEVEL
MAXIMUM OIL
LEVEL
MINIMUM LEVEL,
OIL HOT
MAXIMUM LEVEL,
OIL HOT
Lube Point(s) - 2 MINIMUM LEVEL,

OIL COLD
Interval - Every 2 years or 1200 hours of operation. MAXIMUM LEVEL,
Remove and clean at time of hydraulic oil change. OIL COLD
NOTE: Hot oil checks should not be made until the engine
has been shut down for a period of 5 minutes.
Figure 1-2. Deutz Engine Dipstick
3121142 – JLG Lift – 1-9

10. Fuel Filter - Deutz 12. Oil Change w/Filter - CAT

Interval - Every year or 600 hours of operation
Lube Point(s) - Fill Cap/Spin-on Element
11. Fuel Strainer Capacity - 10.5 Quarts (10 L)
Lube - EO
Interval - Check level daily; change every 150 hours or
three months, whichever comes first. Adjust final oil
level by mark on dipstick.
13. Fuel Filter - CAT


1-10 – JLG Lift – 3121142

14. Air Filter 15. Platform Filter
Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation Interval - Change after first 50 hours and then every year
or as indicated by the condition indicator or 600 hours of operation thereafter
3121142 – JLG Lift – 1-11

Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
1-12 – JLG Lift – 3121142

To rqu e
Torqu e
Torq ue
Tor que
Torq ue
3121142 – JLG Lift – 1-13

Torq ue
Tor que
Torqu e
Cl amp L oa d
Torq ue
To rqu e
To rque
1-14 – JLG Lift – 3121142

To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
3121142 – JLG Lift – 1-15

To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
1-16 – JLG Lift – 3121142

SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND these inspections. Reference the appropriate areas of this
manual for servicing and maintenance procedures.
MAINTENANCE
General Annual Machine Inspection

This section provides the necessary information needed by The Annual Machine Inspection must be performed on an
those personnel that are responsible to place the machine in annual basis, no later than thirteen (13) months from the date
operation readiness and maintain its safe operating condition. of the prior Annual Machine Inspection. JLG Industries recom-
For maximum service life and safe operation, ensure that all mends this task be performed by a Factory-Trained Service
the necessary inspections and maintenance have been com- Technician. JLG Industries, Inc. recognizes a Factory-Trained
pleted before placing the machine into service. Service Technician as a person who has successfully com-
pleted the JLG Service Training School for the subject JLG
Preparation, Inspection, and Maintenance product model. Reference the machine Service and Mainte-
It is important to establish and conform to a comprehensive nance Manual and appropriate JLG inspection form for perfor-
inspection and preventive maintenance program. The follow- mance of this inspection.
ing table outlines the periodic machine inspections and main-
tenance recommended by JLG Industries, Inc. Consult your Reference the JLG Annual Machine Inspection Form and the
national, regional, or local regulations for further requirements Inspection and Preventative Maintenance Schedule for items
for aerial work platforms. The frequency of inspections and requiring inspection during the performance of this inspec-
maintenance must be increased as environment, severity and tion. Reference the appropriate areas of this manual for servic-
frequency of usage requires. ing 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 perform a important that JLG Industries, Inc. has updated ownership
Pre-Start Inspection of the machine prior to use daily or at information for each machine. When performing each Annual
each change of operator. Reference the Operator’s and Safety Machine Inspection, notify JLG Industries, Inc. of the current
Manual for completion procedures for the Pre-Start Inspec- machine ownership.
tion. The Operator and Safety Manual must be read in its
entirety and understood prior to performing the Pre-Start
Inspection. Preventative Maintenance
In conjunction with the specified inspections, maintenance
Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic.
The Pre-Delivery Inspection and Frequent Inspection shall be JLG Industries, Inc. recognizes a qualified JLG equipment
performed by a qualified JLG equipment mechanic. JLG Indus- mechanic as a person who, by possession of a recognized
tries, Inc. recognizes a qualified JLG equipment mechanic as a degree, certificate, extensive knowledge, training, or experi-
person who, by possession of a recognized degree, certificate, ence, has successfully demonstrated the ability and profi-
extensive knowledge, training, or experience, has successfully ciency to service, repair, and maintain the subject JLG product
demonstrated the ability and proficiency to service, repair, and model.
maintain the subject JLG product model.
Reference the Preventative Maintenance Schedule and the
The Pre-Delivery Inspection and Frequent Inspection proce-
dures are performed in the same manner, but at different appropriate areas of this manual for servicing and mainte-
times. The Pre-Delivery Inspection shall be performed prior to nance procedures. The frequency of service and maintenance
each sale, lease, or rental delivery. The Frequent Inspection must be increased as environment, severity and frequency of
shall be accomplished for each machine in service for 3 usage requires.
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 environ-
ment, severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection Form

and the Inspection and Preventative Maintenance Schedule
for items requiring inspection during the performance of
3121142 – JLG Lift – 2-1

SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operator and Safety Manual
At each Operator change.
Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
Purchased used.
Annual Machine Inspec- Annually, no later than 13 months from the date of Owner, Dealer, or User Factory-Certified Ser- Service and Maintenance Manual
tion the prior inspection. vice Technician and applicable JLG inspection form.
(recommended)
Preventative At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are disconnected,
clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon-
General nected, cap or cover all openings to prevent entry of for-
eign matter.
The following information is provided to assist you in the use
and application of servicing and maintenance procedures 3. Clean and inspect all parts during servicing or mainte-
contained in this book. nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Safety and Workmanship sure all parts are clean before they are installed. New
parts should remain in their containers until they are
Your safety, and that of others, is the first consideration when ready to be used.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to
Components Removal and Installation
rest in an unstable position. When raising a portion of the 1. Use adjustable lifting devices, whenever possible, if
equipment, ensure that adequate support is provided. mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as near
Cleanliness perpendicular as possible to top of part being lifted.
2. Should it be necessary to remove a component on an
1. The most important single item in preserving the long angle, keep in mind that the capacity of an eyebolt or
service life of a machine is to keep dirt and foreign mate- similar bracket lessens, as the angle between the sup-
rials out of the vital components. Precautions have been porting structure and the component becomes less
taken to safeguard against this. Shields, covers, seals, than 90 degrees.
and filters are provided to keep air, fuel, and oil supplies
clean; however, these items must be maintained on a 3. If a part resists removal, check to see whether all nuts,
scheduled basis in order to function properly. bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.
2-2 – JLG Lift – 3121142

SECTION 2 - GENERAL
Component Disassembly and Reassembly Hydraulic Lines and Electrical Wiring

When disassembling or reassembling a component, complete Clearly mark or tag hydraulic lines and electrical wiring, as well
the procedural steps in sequence. Do not partially disassemble as their receptacles, when disconnecting or removing them
or assemble one part, then start on another. Always recheck from the unit. This will assure that they are correctly rein-
your work to assure that nothing has been overlooked. Do not stalled.
make any adjustments, other than those recommended, with-
out obtaining proper approval. Hydraulic System
Pressure-Fit Parts 1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
When assembling pressure-fit parts, use an anti-seize or
flush the entire system.
molybdenum disulfide base compound to lubricate the mat-
ing surface. 2. Disassemble and reassemble parts on clean work sur-
face. Clean all metal parts with non-flammable cleaning
Bearings solvent. Lubricate components, as required, to aid
assembly.
1. When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning sol- Lubrication
vent and allow to drip dry. Compressed air can be used
Service applicable components with the amount, type, and
but do not spin the bearing.
grade of lubricant recommended in this manual, at the speci-
2. Discard bearings if the races and balls (or rollers) are pit- fied intervals. When recommended lubricants are not avail-
ted, scored, or burned. able, consult your local supplier for an equivalent that meets
or exceeds the specifications listed.
3. If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap Battery
reusable or new bearings until they are ready to install.
Clean battery, using a non-metallic brush and a solution of
4. Lubricate new or used serviceable bearings before baking soda and water. Rinse with clean water. After cleaning,
installation. When pressing a bearing into a retainer or thoroughly dry battery and coat terminals with an anti corro-
bore, apply pressure to the outer race. If the bearing is to sion compound.
be installed on a shaft, apply pressure to the inner race.
Lubrication and Servicing
Gaskets Components and assemblies requiring lubrication and servic-
Check that holes in gaskets align with openings in the mating ing are shown in the Lubrication Chart in Section 1.
parts. If it becomes necessary to hand-fabricate a gasket, use
gasket material or stock of equivalent material and thickness.
Be sure to cut holes in the right location, as blank gaskets can 2.3 LUBRICATION AND INFORMATION
cause serious system damage.
Hydraulic System
Bolt Usage and Torque Application
1. The primary enemy of a hydraulic system is contamina-
1. Use bolts of proper length. A bolt which is too long will tion. Contaminants enter the system by various means,
bottom before the head is tight against its related part. If e.g., using inadequate hydraulic oil, allowing moisture,
a bolt is too short, there will not be enough thread area grease, filings, sealing components, sand, etc., to enter
to engage and hold the part properly. When replacing when performing maintenance, or by permitting the
bolts, use only those having the same specifications of pump to cavitate due to insufficient system warm-up or
the original, or one which is equivalent. leaks in the pump supply (suction) lines.
2. Unless specific torque requirements are given within the 2. The design and manufacturing tolerances of the compo-
text, standard torque values should be used on heat- nent working parts are very close, therefore, even the
treated bolts, studs, and steel nuts, in accordance with smallest amount of dirt or foreign matter entering a sys-
recommended shop practices. (See Torque Chart Sec- tem can cause wear or damage to the components and
tion 1.) generally results in faulty operation. Every precaution
must be taken to keep hydraulic oil clean, including
reserve oil in storage. Hydraulic system filters should be
checked, cleaned, and/or replaced as necessary, at the
specified intervals required in the Lubrication Chart in
3121142 – JLG Lift – 2-3

SECTION 2 - GENERAL
Section 1. Always examine filters for evidence of metal Changing Hydraulic Oil
particles.
1. Filter elements must be changed after the first 50 hours
3. Cloudy oils indicate a high moisture content which per- of operation and every 300 hours (unless specified oth-
mits organic growth, resulting in oxidation or corrosion. erwise) thereafter. If it is necessary to change the oil, use
If this condition occurs, the system must be drained, only those oils meeting or exceeding the specifications
flushed, and refilled with clean oil. appearing in this manual. If unable to obtain the same
type of oil supplied with the machine, consult local sup-
4. It is not advisable to mix oils of different brands or types, plier for assistance in selecting the proper equivalent.
as they may not contain the same required additives or Avoid mixing petroleum and synthetic base oils.
be of comparable viscosities. Good grade mineral oils,
with viscosities suited to the ambient temperatures in 2. Use every precaution to keep the hydraulic oil clean. If
which the machine is operating, are recommended for the oil must be poured from the original container into
use. another, be sure to clean all possible contaminants from
the service container. Always clean the mesh element of
NOTE: Metal particles may appear in the oil or filters of new the filter and replace the cartridge any time the system
machines due to the wear-in of meshing components. oil is changed.
3. While the unit is shut down, a good preventive mainte-

Hydraulic Oil nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
1. Refer to Section 1 for recommendations for viscosity functional check of each system, before placing the
ranges. machine back in service.
2. JLG recommends Mobilfluid 424 hydraulic oil, which has Lubrication Specifications
an SAE viscosity of 10W-30 and a viscosity index of 152.
Specified lubricants, as recommended by the component
NOTE: Start-up of hydraulic system with oil temperatures below - manufacturers, are always the best choice, however, multi-pur-
15 degrees F (-26 degrees C) is not recommended. If it is pose greases usually have the qualities which meet a variety of
single purpose grease requirements. Should any question
necessary to start the system in a sub-zero environment, it
arise, regarding the use of greases in maintenance stock, con-
will be necessary to heat the oil with a low density, 100VAC
sult your local supplier for evaluation. Refer to Section 1 for an
heater to a minimum temperature of -15 degrees F (-26
explanation of the lubricant key designations appearing in the
degrees C).
Lubrication Chart.
3. The only exception to the above is to drain and fill the

system with Mobil DTE 13 oil or its equivalent. This will 2.4 CYLINDER DRIFT TEST
allow start up at temperatures down to -20 degrees F (-
29 degrees C). However, use of this oil will give poor per- Maximum acceptable cylinder drift is to be measured using
formance at temperatures above 120 degrees F (49 the following methods.
degrees C). Systems using DTE 13 oil should not be oper-
ated at temperatures above 200 degrees F (94 degrees Platform Drift
C) under any condition.
Measure the drift of the platform to the ground. Lower booms
(if equipped) slightly elevated, main boom fully extended with
the rated load in the platform and power off. Maximum allow-
able drift is 2 inches (5 cm) in 10 minutes. If the machine does
not pass this test, proceed with the following.
2-4 – JLG Lift – 3121142

SECTION 2 - GENERAL
Cylinder Drift b. Flaking, pealing, scoring, or scratches on the pin sur-

face.
Table 2-2. Cylinder Drift
c. Rusting of the pin in the bearing area.
Max. Acceptable Drift
Cylinder Bore Diameter 4. Re-assembly of pinned joints using filament wound
in 10 Minutes
bearings.
inches mm inches mm
3 76.2 0.026 0.66 a. Housing should be blown out to remove all dirt and
debris...bearings and bearing housings must be free
3.5 89 0.019 0.48 of all contamination.
4 101.6 0.015 0.38
b. Bearing / pins should be cleaned with a solvent to
5 127 0.009 0.22 remove all grease and oil...filament wound bearing
6 152.4 0.006 0.15 are a dry joint and should not be lubricated unless
7 177.8 0.005 0.13 otherwise instructed (i.e. sheave pins).
8 203.2 0.0038 0.10 c. Pins should be inspected to ensure it is free of burrs,
9 228.6 0.0030 0.08 nicks, and scratches which would damage the bear-
ing during installation and operation.
Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temperature
and temperature stabilized. 2.6 WELDING ON JLG EQUIPMENT
The cylinder must have the normal load, which is the normal NOTE: This instruction applies to repairs, or modifications to the
platform load applied. machine and to welding performed from the machine on
an external structure, or component,
If the cylinder passes this test, it is acceptable.
NOTE: This information is based on 6 drops per minute cylinder

Do the Following When Welding on JLG
leakage. Equipment
• Disconnect the battery.
2.5 PINS AND COMPOSITE BEARING REPAIR • Disconnect the moment pin connection (where fitted)
GUIDELINES • Ground only to structure being welded.
Filament wound bearings.
1. Pinned joints should be disassembled and inspected if

Do NOT Do the Following When Welding on JLG
the following occurs: Equipment
a. Excessive sloppiness in joints. • Ground on frame and weld on any other area than the
chassis.
b. Noise originating from the joint during operation.
• Ground on turntable and weld on any other area than the
2. Filament wound bearings should be replaced if any of turntable.
the following is observed:
• Ground on the platform/support and weld on any other
a. Frayed or separated fibers on the liner surface. area than the platform/support.
b. Cracked or damaged liner backing.
• Ground on a specific boom section and weld on any other
c. Bearings that have moved or spun in their housing. area than that specific boom section.
d. Debris embedded in liner surface.
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
3. Pins should be replaced if any of the following is valves, electrical wiring, or hoses to be between the
observed (pin should be properly cleaned prior to grounding position and the welded area.
inspection):
a. Detectable wear in the bearing area.

FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
RING, BOOM WIRE ROPES ETC.)
3121142 – JLG Lift – 2-5

SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Weekly Monthly Pre-Delivery2 Annual4

Pre-Start1 Preventive Preventive
Every 2
Inspection or Frequent3 (Yearly) Years
Maintenance Maintenance 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 11 11
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
Drive Hubs 11 11
Functions/Controls 9
Platform Controls 5 5 6 6
2-6 – JLG Lift – 3121142

SECTION 2 - GENERAL
INTERVAL

Every 2
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 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
Capacity Decals Installed, Secure, Legible 21 21 21
All Decals/Placards Installed, Secure, Legible 21 21 21
3121142 – JLG Lift – 2-7

SECTION 2 - GENERAL
INTERVAL

Every 2
Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21
No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
2-8 – JLG Lift – 3121142

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
SUMMER
GRADE 70 F(21 C)
ENGINE FUEL
60 F(16 C)
SPECIFICATIONS 50 F(10 C)
40 F(4 C)
30 F(-1 C)
WINTER 20 F(-7 C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10 F(-12 C)
FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10 F(-23 C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20 F(-29 C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR
KEROSENE -30 F(-34 C)
GLOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER) ADDED
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
EXTENDED DRIVING WITH HYDRAULIC OIL TANK

TEMPERATURES OF 180°F (82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE
120° F (49° C)
NO OPERATION ABOVE THIS PROLONGED OPERATION IN NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F (38°C) OR ABOVE. 1) RECOMMENDATIONSAREFORAMBIENTTEMPERATURES
100° F (38° C)
CONSISTANTLYWITHIN SHOWN LIMITS
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C) 2) ALLVALUESAREASSUMED TO BEATSEA LEVEL.
EXXON UNIVIS HVI 26
70° F (21° C)
SUMMER-GRADE WINTER-GRADE
60° F (16° C) FUEL FUEL
50° F (10° C) HYDRAULIC F C
MOBIL DTE 13
SPECIFICATIONS + 32 0
40° F (4° C)
30° F (-1° C)
AMBIENTTEMPERATURE
+ 23 -5
20° F (-7° C)
10° F (-12° C) + 14 -10
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424 +5 -15
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) -4 -20
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -13 -25
-40° F (-40° C)
AMBIENT TEMPERATURE -22 -30
0 10 20 30 40 50 60
% OFADDED KEROSENE
4150548 D
Figure 2-1. Engine Operating Temperature Specifications - Deutz
3121142 – JLG Lift – 2-9

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)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10 F(-12 C)
FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE
EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE
OIL COOLER (CONSULT JLG SERVICE
120° F (49° C) PROLONGED OPERATION IN

110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F (38°C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26
70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC
MOBIL DTE 13
40° F (4° C)
SPECIFICATIONS
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) NOTE:
DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS
-30° F (-34° C) AND COLD WEATHERHYDRAULIC OIL BELOW THIS TEMPERATURE 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
-40° F (-40° C) CONSISTENTLY WITHIN SHOWN LIMITS
AMBIENT TEMPERATURE 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
4150548 E
Figure 2-2. Engine Operating Temperature Specifications - Caterpillar
2-10 – JLG Lift – 3121142

SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES & WHEELS ers. If you do not have a torque wrench, tighten the fasteners
with a lug wrench, then immediately have a service garage or
Tire Inflation dealer tighten the lug nuts to the proper torque. Over-tighten-
ing will result in breaking the studs or permanently deforming
The air pressure for pneumatic tires must be equal to the air
the mounting stud holes in the wheels.
pressure that is stenciled on the side of the JLG product or rim
decal for safe and proper operational characteristics. The proper procedure for attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO
Tire Damage NOT use a lubricant on threads or nuts.
For pneumatic tires, JLG Industries, Inc. recommends that
when any cut, rip, or tear is discovered that exposes sidewall or 2. Tighten nuts in the following sequence:
tread area cords in the tire, measures must be taken to remove
the JLG product from service immediately. Arrangements
must be made for replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. recom-

mends that when any of the following are discovered, mea-
sures must be taken to remove the JLG product from service
immediately and arrangements must be made for replace-
ment of the tire or tire assembly.
• a smooth, even cut through the cord plies which exceeds 3

inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies which
exceeds 1 inch (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the

tire must be inspected on a daily basis to insure the damage
hasn’t propagated beyond the allowable criteria.
Wheel and Tire Replacement 3. The tightening of the nuts should be done in stages. Fol-
lowing the recommended sequence, tighten nuts per
The rims installed on each product model have been designed
wheel torque chart.
for stability requirements which consist of track width, tire
pressure, and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc., without
Table 3-1. Wheel Torque Chart
written factory recommendations, may result in an unsafe
condition regarding stability. TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
Wheel Installation
45 ft. lbs. 100 ft. lbs. 180 ft. lbs.
It is extremely important to apply and maintain proper wheel
(60 Nm) (140 Nm) (252 Nm)
mounting torque.
4. Wheel nuts should be torqued before first road use and

after each wheel removal. Check and torque every 3
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE months or 150 hours of operation.
TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS
MATCHED TO THE CONE ANGLE OF THE WHEEL.
Tighten the lug nuts to the proper torque to prevent wheels
from coming loose. Use a torque wrench to tighten the fasten-
3121142 – JLG Lift – 3-1

3.2 EXTENDING AXLES NOTE: For more detailed information concerning system adjust-
ment and operation, refer to Section 6 - JLG Control Sys-
The Axle Extension System allows each of the four axles to be tem.
extended and retracted together while maintaining full steer-
ing control as the machine is driven. The system allows the
axles to extend or retract only while the boom is in the trans- 3.3 AXLE LIMIT SWITCH ADJUSTMENT PROCEDURE
port position and in order to minimize wheel scrubbing during
axle movement, a minimum drive speed must be attained 1. Fully extend the axles.
before axle extension/retraction will be permitted. The system 2. Initially position the limit switch arm straight.
uses four limit switches (one at each axle) to sense when the
axles are fully extended. If any of the switches are not made, 3. Select the mounting plate bolt pattern to position the
the control system considers the axles retracted. To extend/ switch roller within 0.125 inches (3.1 mm) from the edge
retract the axles, the user engages the axle extend/retract of the axle cutout. It may be necessary to reposition the
switch on the platform console and the drive control at the switch arm ±10° to accomplish this.
same time. The axle set indicator will be off when the axles are
4. Ensure the arm will clear the axle (without bottoming
not fully extended and the axle extend/retract switch is not
out to 70° stroke of the switch) in the retracted position.
engaged. It will flash while the axles are extending or retract-
ing and will be on constantly when the axles are fully 5. Check for proper operation. Axle set light is to deacti-
extended. With the axles not fully extended, the boom is vate when the axle is retracted 0.625 inches (16 mm)
restricted to operation within the transport position. If a signal maximum from fully extended.
from any axle extend sensing switch is lost when the boom
beyond the transport position, the axle set indicator will flash
and drive/steer functions will be disabled until the boom is
brought back into the transport position. The steering angle
will be automatically limited to +/- 25 degrees anytime the
axles are not fully extended. If the wheel angle is more than +/
- 25 degrees when the axle retract command is engaged, the
control system will automatically reduce the wheel angle to 25
degrees during axle retraction.
Figure 3-1. Axle Limit Switch Adjustment
3-2 – JLG Lift – 3121142

3.4 DRIVE SYSTEM

The drive system utilizes 2 traction pumps so each side is pow-
ered individually. This produces maximum tractive effort to
wheels by minimizing flow divider losses. The maximum drive
speed is modulated with the steered angle of the wheels to
eliminate the whiplash effect of driving at full speed and maxi-
mum steering lock.
3.5 STEERING CONTROL SYSTEM

Each wheel is individually steered by means of a closed circuit
control system utilizing a steer sensor on each wheel, 4 steer
cylinders, and proportional valves.
Figure 3-4. Coordinated Steer Mode
The control system senses the wheel position in relation to the Each wheel has its own steer cylinder, wheel angle sensor, and
steering command (direction and steering mode) and auto- proportional valve, allowing the control system to position
matically synchronizes the movement of all 4 wheels to the each wheel to the ideal angle for all steering modes and all
desired position. steering commands. Changes in steering modes while the
There are three different modes of steering selectable by the footswitch is depressed causes the wheels to automatically
position of the steer select switch on the platform control adjust to the appropriate angle for the selected steering mode
panel: conventional two wheel steering, crab and coordinated. based on the position of the inside front wheel. If the steer
These are shown below. select switch is changed without the footswitch depressed or
the EMS is off, the wheels will not move until the footswitch is
depressed and a steering or drive command has been initi-
ated. The steering angles are limited to +/- 25 degrees anytime
the axles are not fully extended. If a wheel cannot achieve its
commanded angle within a specified time, it is considered
jammed. When a wheel is considered jammed during steering,
a fault is reported and the remaining wheels will continue to
their commanded position. The fault is cleared when the foot-
switch is cycled. If a wheel is jammed making it significantly
out of position, with regard to the other wheels, the drive
motors are restricted to their maximum displacement (slow
speed). Wheel angle sensor failures will result in an approxi-
mated steering control logic that will allow the operator to
move the machine until it can be repaired. The wheel at the
Figure 3-2. Conventional Two Wheel Steer Mode failed sensor will be driven based on the information available
from the other sensors. This wheel will not track perfectly and
will become farther out of position over time. When the wheel
becomes prohibitively out of position, the wheels can be re
synchronized by fully steering against the mechanical stops.
NOTE: For more detailed information concerning system adjust-

tem.
Figure 3-3. Crab Steer Mode
3121142 – JLG Lift – 3-3

3.6 DRIVE/STEERING SPEED CONTROL 3.8 DRIVE ORIENTATION SYSTEM

The Drive/Steering Speed Control system uses the steering The Drive Orientation System (DOS) is intended to indicate to
sensors from the steering control system to increase operator the operator conditions that could make the direction of
control and comfort by reducing the effect of turning the movement of the chassis different than the direction of move-
chassis on the resulting lateral platform speed. The system ment of the drive/steer control handle. The system indicates to
proportionally varies the drive speed based on the predicted the operator the need to match the black and white direc-
turning radius of the chassis for both coordinated and conventional arrows on the platform control panel to the arrows on
tional two wheel steer modes. The tighter the turn the slower the chassis. The system uses a proximity switch mounted on
the allowable drive speed. As crab steer does not steer on a the hydraulic swivel, an indicator light and an override switch
radius, full drive speed is maintained regardless of steer angle. on the platform display panel. The proximity switch trips when
the turntable is swung +/- 45 degrees off center of the normal
NOTE: For more detailed information concerning system adjust- driving position. This occurs roughly when the boom is swung
ment and operation, refer to Section 6 - JLG Control Sys- past a rear tire. When the turntable is in the normal drive posi-
tem. tion with the boom between the rear tires, no indications or
interlocks are made. When the machine is actively driving
when the turntable is swung past the switch point, the system
3.7 TRACTION CONTROL SYSTEM is ignored until drive/steer is released. When drive is initiated
The traction control system uses the steering sensors from the with the boom swung past the switch point, the DOS indicator
steering control system to optimize the performance of the will flash and the drive/steer functions will be disabled. The
drive system. This is especially important due to the disparity operator must engage the DOS override switch to enable
of wheel speeds generated between the inside and outside Drive/steer (high drive will remain disabled). When the DOS is
wheels of the extended axle chassis with large steering angle enabled, the DOS indicator will be illuminated continuously
capability. The steering sensors are used to predict the rolling and a 3-second enable timer will be started and will continue
path and therefore the required wheel speed of each wheel as for 3 seconds after the end the last drive/steer command. If the
the steering angles change and steering modes change. The timer expires, the DOS override switch must be re-engaged to
control system can then command the ideal flow from each of enable drive/steer.
the two drive pumps, one for the right side of the machine and
one for he left side. Two flow dividers, one for the right side
front to back and one for the left side front to back absorb the
tem.
variation in wheel speed front to back.

tem.
3-4 – JLG Lift – 3121142

3121142 – JLG Lift – 3-5

Figure 3-5. Chassis Component Location - Sheet 1 of 2
3-6 – JLG Lift – 3121142

1. Axle Limit Switch (Right Front) 9. Axle Limit Switch (Left Rear)
2. Steer Angle Sensor (Right Front) 10. Steer Angle Sensor (Left Rear)
3. Steer Valve (Front) 11. Chassis Module
4. Axle Lockout Valve 12. Swivel/Collector Ring
5. Traction Valve 13. Axle Lockout Pressure Switch
6. Steer Valve (Rear) 14. Steer Angle Sensor (Left Front)
7. Steer Angle Sensor (Right Rear) 15. Axle Limit Switch (Left Front)
8. Axle Limit Switch (Right Rear)
Figure 3-6. Chassis Component Location - Sheet 2 of 2
3121142 – JLG Lift – 3-7

Figure 3-7. Turntable and Boom Component Location - Sheet 1 of 2
3-8 – JLG Lift – 3121142

1. Platform Control Valve 23. Headlight

2. Jib Stow Switch 24. Deutz EMR2 Module
3. Platform Level Sensor (Secondary - Left) 25. 110V / 220V Generator
4. Tail Lights 26. Generator Control Box
5. Skypower Generator 27. Alternator
6. Alarm 28. Throttle Actuator
7. Main Control Valve 29. Oil Temperature Switch
8. Auxiliary Power Pump 30. Oil Pressure Switch
9. Auxiliary Power Relay 31. Intake Heaters
10. Chassis Power Distribution Relay 32. In Head Glow Plug
11. Headlight/Tail Light Relay 33. Engine Speed Sensor
12. Horn 34. Starter
13. Lift Cylinder Pivot Pin 35. Drive Pump (Right Side)
14. Fuel Level Sensor 36. Drive Pump (Left Side)
15. B.L.A.M. Module 37. Function Pump
16. Strobe Light 38. Starter Relay
17. Headlight 39. Glow Plug Relay
18. Ground Control Box 40. Swivel/Collector Ring
19. Boom Angle Sensor (Left) 41. Transport Limit Switch
20. Broken Cable Proximity Switch 42. Platform Level Sensor (Primary - Right)
21. Boom Length Sensor 43. Dual Capacity Jib Position Switch
22. Boom Angle Sensor (Right)
Figure 3-8. Turntable and Boom Component Location - Sheet 2 of 2
3121142 – JLG Lift – 3-9

3
1 DETAIL A
6 * AXLE STOP SHIMMING PROCEDURE:

2 1. ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL
SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME.
2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST
SHIM.
DETAIL B
Figure 3-9. Oscillating Axle - Sheet 1 of 2
3-10 – JLG Lift – 3121142

9
3
11,12,B,G
6
11,12,A,G
8
10
11,12,C,G DETAIL A
11,12,D,G
11,12,E,G
11,12,F,G
2
4
A - Assemble to Axle Box Mid Plate; Typical 8 Places
B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 DETAIL B
inches (12.7 ± 1.587 mm) thread engagement.
C - Assemble to Side Plates of Axle Weldments; Typical 16 Places.
D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
E - Assemble to Top Plate of Axle Weldment; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5
±0.062 inches (12.7 ± 1.587 mm) thread engagement.
F - Assemble to Bottom Plate of Axle Box Weldment; Typical 8 Places.
G - See Axle Stop Shimming Procedure on Sheet 1
1. Axle Oscillation Cylinder 5. Axle Pivot Pin 9. Hose Clamp

2. Axle 6. Axle Limit Switch 10. Stop Block
3. Axle Powertrack 7. Axle Stop Pin 11. Wear Pad
4. Extension Cylinder 8. Rubber Pad 12. Shim
Figure 3-10. Oscillating Axle - Sheet 2 of 2
3121142 – JLG Lift – 3-11

Figure 3-11. Axle Loctite Application
3-12 – JLG Lift – 3121142

Table 3-2. Steering Assembly Notes
A Apply Loctite #242
B Apply Loctite #271
C Apply Loctite #222
D Preload Torque 100-300 ft. lb. (140-420 Nm)

on Slot Nut
1. Spindle 4. Steer Cylinder Pivot Pin

2. Angle Sensor Assembly 5. King Pin
3. Steer Cylinder 6. Axle
Figure 3-12. Steering Installation
3121142 – JLG Lift – 3-13

3.9 OSCILLATING AXLE SYSTEM 3.10 OSCILLATING AXLE BLEEDING PROCEDURE AND
The oscillating front axle is attached to the frame by a pivot LOCKOUT TEST
pin, which allows all four wheels to remain on the ground
when traveling on rough terrain. The oscillating axle also Lockout Cylinder Bleeding
incorporates two lockout cylinders connected between the
To start the test, the axle must be fully oscillated in one direc-
frame and the axle. The lockout cylinders permit axle oscilla-
tion. Start with oscillating the axle so that the left lock-out cyl.
tion when the boom is in the transport position and drive is
is fully retracted (left front tire up), and the right lock-out cyl. Is
commanded. The lockout cylinders will lock and hold the axle
fully extended (right front tire down).
when drive is not commanded or when the boom is outside
the transport position. The cylinders unlock when pilot pres-
sure is applied to the holding valves mounted on the cylinders
and lock when pilot pressure is removed. Pilot pressure is avail-
ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR
able from brake pressure and is controlled by a solenoid oper-
AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE. MAKING SURE MACHINE
ated NC lockout valve mounted in the frame. To ensure the
IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, BRAKE WIRE IS
lockout valve is functioning correctly, a NO pressure switch is
DISCONNECTED.
mounted between the lockout valve and the holding valves.
The system is “healthy” when pressure trips the pressure
switch when the lockout valve is commanded to be open and 1. Making sure machine is on a level surface and rear
conversely is healthy when the lack of pressure resets the pres- wheels are blocked, machine is in transport mode.
sure switch when the lockout valve is commanded to be
2. Disengage the drive hubs.
closed. Failures in the oscillating axle system will cause the
control system to disallow lift up and telescope out when the 3. Use suitable container to catch any residual hydraulic
boom is within the transport position and will disallow drive/ fluid, place container under the lockout cylinder.
steer, lift up and telescope out when the boom is beyond the
transport position. 4. With the left lock-out cyl. retracted, open the bleeder on
top of the cylinder, then have an operator from the plat-
NOTE: For more detailed information concerning system adjust- form (on high engine) feather drive. Activate drive fully.
5. Close the bleeder when there is a steady stream of oil
tem.
and not air.
6. With the axle in the same position, go to the right lock-
out cyl. and open the bleeder at the rod end. Activate
drive in the same manner and close when all air has
been purged.
7. Close the bleeder when there is a steady stream of oil
and not air.
8. Oscillate the axle the other direction, left lock-out cyl.
extended (tire down), right lock-out cyl. retracted (tire
up). Use the same procedure for the bleeder in the rod
end of the left lock-out cyl., Then the piston end of the
right lock-out cyl. then close.
9. Repeat this process one more time to ensure that all air
has been purged from the system.
10. Perform oscillating axle lockout test.
11. If necessary, repeat steps 1 thru 9.
NOTE: Bleeding of the oscillating axles is an infrequent operation

performed after hydraulic line failure and or lock-out cylin-
der repair.
3-14 – JLG Lift – 3121142

Oscillating Axle Lockout Test 11. Telescope the boom out of the transport position.
The front axles will oscillate when the boom is in the transport 12. Drive machine off of block and ramp back onto the level
position (i.e. when the boom is less than 15° above horizontal surface.
and not extended beyond 12" [30.4 cm] on the1350SJP or 24"
[60.9 cm] on the 1200SJP) and drive is selected. 13. Have an assistant check to see that right front wheel
remains locked in position off of ground.
14. Retract the boom back in to the transport position. Acti-
vate drive and the lockout cylinders should release.
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS-
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS 15. If lockout cylinders do not function properly, have quali-
SUSPECTED. fied personnel correct the malfunction prior to any fur-
ther operation.
NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels prior to beginning lockout cylinder
test. The axles must also be fully extended.
1. Place a 6 inch (15.2 cm) high block with ascension ramp

in front of left front wheel.
2. From platform control station, activate machine hydrau-
lic system.
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/
TORQUE SELECT control switches to their respective
LOW positions.
4. Place DRIVE control lever to FORWARD position and
carefully drive machine up ascension ramp until left
front wheel is on top of block.
5. Telescope the boom out of the transport position.
6. Drive machine off of block and ramp back onto the level
surface.
7. Have an assistant check to see that left front wheel
remains locked in position off of ground.
8. Retract the boom back in to the transport position. Acti-
vate drive and the lockout cylinders should release.
9. Place the 6 inch (15.2 cm) high block with ascension
ramp in front of right front wheel.
10. Place DRIVE control lever to FORWARD and carefully
drive machine up ascension ramp until right front wheel
is on top of block.
3121142 – JLG Lift – 3-15

3.11 DRIVE HUB (PRIOR TO S/N 100131) 14. Inspect the planetary stage assemblies as complete
units. Thoroughly clean and check both the gearing and
The final drive consists of two planetary stages with an inte- the bearings for damage and apply new oil. If the gears
grated disconnect mechanism. Each stage incorporates a set or bearings need replacing, they must be replaced as
of matched planetary gears, which provide an equal load dis- complete sets.
tribution. All torque transmitting components are made of
forged quenched and tempered high-alloy steels. External 15. The first stage planetary gears (2) must be changed in
gears are carburized. Precision roller bearings support the sets of three pieces.
sprocket or wheel loads. A shaft seal protects the unit against 16. The first stage planetary gears (2) must be changed as a
contamination. complete set of three and JLG recommends changing
the sun gear shaft (43) along with this set of planets.
Disassembly 17. The second stage planetary bearings (11) must be
1. Position drive so that one of the fill holes is at the bot- replaced in sets of four pieces.
tom of the end cover and drain the oil. 18. The second stage planetary gears (1) must be changed
2. Remove all bolts holding the motor and Remove motor as a complete set of four and JLG recommends changing
from drive. the sun gear (3) along with this set of planets.
3. Compress the spring (55) using a simple fixture or other

suitable device.
Disassembly of Cover
Loosen and remove hex head bolts (53) to remove cover (51).
4. Remove snap ring (66) and release pressure on the
spring (55) until loose.
Disassembly of the First Stage Planetary
5. Remove the spring (55). Assembly (7)
6. Turn unit so that cover (8) is in the up position.
1. Push sun gear shaft (43) out of the first stage.
7. Remove the screw plugs (21) and seal rings (22).
2. Remove snap rings (14).
8. Remove “o” ring (33).
3. Press planet pins (5) out of the planet gears (2).
9. Remove the first stage planetary assembly (7).
4. Pull cylindrical roller bearing (10) out of the planet gears
10. Remove hex bolts (23). (2).
11. Remove ring gear (30) and “o” ring (19). 5. Remove snap ring (16) from sun gear (3) and Remove
planet carrier (7) from sun gear (3).
12. Remove snap rings (15).
13. Pull off planet gears (1) together with cylindrical roller Disassembly of Second Stage Planet Gears (1)
bearings (11) from spindle (60). Press cylindrical roller bearings out of planet gears (1).
NOTE: Further disassembly of the hub is discouraged. reinstalla-
tion of the shaft nut (4) requires a special tool and a torque
of 626 ft./ lbs. (876 Nm) for proper reassembly. These com-
ponents Will Fail if not properly reassembled.
3-16 – JLG Lift – 3121142

Assembly of First Stage Planetary Assembly (7) 6. Before installation of motor, CHECK THAT THERE IS 1-2
mm OF CLEARANCE BETWEEN THE MOTOR SPLINE
1. Pre-freeze planet pins (5) and install into planet carrier SHAFT SHOULDER AND THE COUPLER (62).
(7).
7. Install the motor and reconnect hydraulic lines.
2. Install planet carrier (7) together with planet pins (5) on
8. Roll motor so that one fill plug is at 12 o’clock position,
sun gear (3), and install snap ring (16).
and the other is at 3 o’clock. Fill to bottom of 3 o’ clock
3. Put sun gear shaft (43) into sun gear (3). plug with gear oil. reinstall plugs.
4. Pre-heat stay rings (17) and install onto planet pins (5).
Initial Start-up And After Repairs
5. Pre-heat cylindrical roller bearings (10) and install onto Before operating the machine, make sure that the drive is filled
planet pins (5) and fix bearings with snap rings (14). with clean oil, approximately 0.2 US gallons(0.8 L). An accurate
oil level is determined by the oil level plug, which should be
Assembly of End Cover Unit (8) removed before oil fill.
1. Install “o” ring (54) into groove of cover (8). With the gear case filled to their proper levels, start the
2. Install the cover (51) into cover (8) and fix cover (51) with machine and allow sufficient time for run-in at moderate pres-
hex bolts (53). Tighten bolts with torque wrench to 6.3 sure and speed before running at full speed. After 4 hours of
ft. lbs. (8.5 Nm). operation, recheck oil level.Maintenance
Daily: - Check for oil leakage
Final Assembly
Weekly: - Check oil level
1. Install planet gears (1) onto planet pins which are part of
Monthly: - Check mounting bolt torque
spindle (60).
2. Install snap rings (15) on planet pins of spindle (60) in Oil Change Interval-Gear Drive
order to fix the planet gears (1).
1. Perform the first oil change after approximately 150
3. Insert the first stage planetary assembly (7) into drive. hours.
4. Install “o” ring (33) in groove of ring gear (30). 2. Subsequent changes, every 1500 hours or annually,
5. Install seal rings (22) and screw plugs (21). whichever occurs first.
NOTE: Flush the drive before filling with new oil.
3121142 – JLG Lift – 3-17

Figure 3-13. Drive Hub - Sheet 1 of 2)
3-18 – JLG Lift – 3121142

3121142
1. Planet Gear 16. Snap Ring 31. Not Used 51. Cover 68. Retaining Ring
2. Planet Gear 17. Stay Rings 32. Not Used 52. Thrust Washer 69. Bolt
3. Sun Gear 18. Not Used 33. O-ring 53. Bolt 70. Not Used
4. Shaft Nut 19. O-ring 34. thru 40. Not Used 54. O-ring 71. Not Used
5. Planet Pin 20. Shaft Seal 41. Planet Carrier 55. Spring 72. Brake Disc
6. Not Used 21. Plug 42. Sun Gear 56. thru 59. Not Used 73. Brake Disc
7. Planet Carrier 22. Seal Ring 43. Sun Gear 60. Spindle 74. Spring
8. Cover 23. Bolt 44. Not Used 61. Piston 75. Backup Ring
9. Thrust Button 24. Detent Ball 45. Planet Pin 62. Coupler 76. Seal
10. Roller Bearing 25. Not Used 46. Roller Bearing 63. Ring Locator 77. Backup Ring
– JLG Lift –
11. Roller Bearing 26. Not Used 47. Retaining Ring 64. Backup Plate 78. Seal
12. Ball Bearing 27. Bolt 48. Retaining Ring 65. Backup Plate 79. Not Used
13. Hex Bolt 28. Washer 49. Not Used 66. Retaining Ring 80. Not Used
14. Snap Ring 29. Not Used 50. Not Used 67. Retaining Ring 81. O-ring
15. Snap Ring 30. Ring Gear
Figure 3-14. Drive Hub - Sheet 2 of 2
3-19
3.12 DRIVE HUB - BONFIGLIOLI (S/N 100128 TO Installation of the Wheel Drive on the Machine
PRESENT) 1. Clean the mating surfaces from oils or paint and fit the
wheel drive on the machine frame.
NOTE: After S/N 0300134389 machines may be built with either
Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec- 2. Attach the gearbox to the machine frame with the
tion 3.13, Drive Hub - Reggiana Riduttori (S/N 134389 to mounting bolts and torque to 178 ft.lbs. (241 Nm).
Present). Do not use different hubs on the same machine.
Product Identification Start Up and Running In

The identification data of the hub is shown on a name plates on If new hubs are being installed, it is advised to follow the
the hub. Figure 3-15., Drive Hub Identification Plate shows measures given below:
how the information is displayed.
1. Bleed air from every part of the hydraulic and add oil in
The informations stamped on the name plates must always be the tank if necessary.
readable. Use the identification data (at least serial number)
for spare part enquiries, information and service, etc.
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL BE REC-
Hydraulic Motor Installation OGNIZED BY THE PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A
The mating areas and the pilot diameter of the gearbox JERKING OF THE MOTOR AS WELL AS EXCESSIVE NOISE COMING FROM THE
where the motor is to be mounted must be clean and without MOTOR AND THE VALVES.
burrs.
2. Start the gearmotor at a low speed and gradually
Before assembling the hydraulic motor, verify by a depth slide increase it after having verified that it is functioning cor-
gauge the correct assembly of the unit checking the axial dis- rectly without any noises or vibrations.
tance as shown in the scheme below as shown in the scheme
below.
1. Fit the O-ring seal, supplied with the gearbox, in its seat DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN
in the hydraulic motor, and assemble it to the gearbox FILTERED TO ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
being careful not to damage the seal already fitted.
NOTE: During the running-in stage follow the steps given
2. Torque the bolts to 63.5 ft.lbs. (86 Nm) torque.
below.
3. Check the correct revolution and direction of rota-

tion.
4. Make sure that the functioning is regular and without
any excessive noises and vibrations.
Figure 3-15. Drive Hub Identification Plate
3-20 – JLG Lift – 3121142

5. Make sure that the oil temperature does not exceed Connecting the Brake
values listed previously.
The gearbox is fitted with a negative multi disk safety brake
After having finished running-in the gearbox, follow the steps with hydraulic control release (parking brake). For information
given below. regarding the characteristics of the brake refer to the installa-
tion drawing.
6. Check that there are no oil leaks. If leaks are present,
fix them before proceeding. Table 3-2. Brake Technical Data
7. Check the level of oil in the gearmotor. Brake Release Pressure (16 bar)
8. It possible that the presence of air in the system Maximum Operating Pressure Brake (50 bar)
during the first start up could cause the application of Braking Torque (265 ± 10% Nm)
the brake to be slowed down. It is advised to
repeat the application and release functions of the
brake to purge air from the brake. Filling-up the Gearbox with Lubricating Oil
The motor and the gearbox have separate lubrication. The
9. Check that there are no other problems in general. gearbox is lubricated by oil splashing. The recommended type
of oil is SAE 80W/90 or SAE 85W/140 with EP features comply-
General Information ing with MIL-L-2105 C & API GL5. Refer to Table 3-3, Suggested
The gearbox is designed and built for wheel drive. Lubricants According SAE 80W/90 and SAE 85W/140 API GL5
Grade.
The unit includes planetary gearbox, 3 stages, rotating hous-
ing type. NOTE: During operation the oil temperature must not exceed 85-
90° C intermittent.
The illustrations show the parts and the main functions of the
gearbox.
A strict and consistent compliance with the specifications of
this technical manual ensure the minimum operating costs
and a longer unit life.
Photographic documentation and drawings are supplied for
educational purposes, so as to safely and properly carry out
maintenance operations.
Minor deviations from pictures of this manual may appear on
the actual gearbox. However, these discrepancies are not rele-
vant to the main parameters, or maintenance functions.
3121142 – JLG Lift – 3-21

1= M18x1,5..........................Filling, draining and oil level plugs

2= 7/16" - 20 UNF - 2B..........Brake port
Figure 3-16. Hub Assembly
3-22 – JLG Lift – 3121142

Table 3-3. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade
Ambient temperature -20°C / +30°C +10°C / +45°C

Oil viscosity SAE 80W/90 SAE 85W/140
Manufacturer Oil Brand
SHELL SPIRAX HD SPIRAX HD
AGIP ROTRA MP ROTRA MP
ARAL GETRIEBEOL HYP GETRIEBEOL HYP
BP-MACH HYPOGEAR EP HYPOGEAR EP
CASTROL HYPOY HYPOY
CHEVRON UNIVERSAL GEAR LUBRICANT UNIVERSAL GEAR LUBRICANT
ELF TRANSELF B TRANSELF B
ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP
I.P. PONTIAX HD PONTIAX HD
MOBIL MOBILUBE HD MOBILUBE HD
TOTAL TRASMISSION TM TRASMISSION TM
NOTE: Do not mix together oils of different brands or characteris- 4. Tighten the fill and level oil plug (B) and let the gearbox
tics. run. After a few minutes, stop and check the oil level.
5. If necessary, refill with lubricant oil. Approximate oil
NOTE: The gearbox is supplied without oil; before putting the
capacity = 2 liters ±10%
gearbox into operation, it is necessary to fill it with oil.
This procedure is undertaken following the indications given Gearbox Disengagement

below. The gearbox is supplied with mechanical disengagement.
1. Check that the gearbox axis is horizontal. Rotate the
gearbox housing until the drain plug (A) is on the bot-
tom on the vertical axis of the end cover. THE DISENGAGEMENT OPTION MUST BE CONNECTED OR DISCONNECTED ONLY
WHEN THE GEARBOX IS STOPPED ON FLAT GROUND.
2. Unscrew the fill and level oil plug (B).
3. Fill from the hole until the lubricant flows out.
3121142 – JLG Lift – 3-23

3. Take out the cap nut (5).
THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25
REV/MIN.
4. Turn the cap nut (5) upside down. As result the pin (3)
will be pushed inside in order to permit disengagement
of the gearbox.
Figure 3-17. Gearbox engaged
1. Unscrew the 2 socket head screws M8x16 (4), grade 8.8,

of the end cover (7) with a male hex head wrench.
5. Rotate the cap nut (5).
2. Rotate the cap nut (5).
3-24 – JLG Lift – 3121142

6. Tighten the 2 socket head screws M8x16 (4) with a male Should irregularities in function arise, it will be necessary to
hex head torque wrench at 18.4 ft.lbs. (25 Nm) torque. consult the troubleshooting checklist to find the most ade-
quate solution.
If unsuccessful, it may be necessary to partially or completely
disassemble the gearbox.
Table 3-4. Drive Hub Maintenance Schedule
Inspection Frequency Action

Tightening bolts After the first 50 operating hours Bolt tightening torque
of the gearbox check
Oil level Every 150 operating hours of the Refill oil if necessary
gearbox
1st oil change At 150 operating hours of the Oil replacement
gearbox
Next oil change Every 1200 operating hours Oil replacement
Changing the Lubricating oil

1. Check that the gearbox axis is horizontal. Rotate the
gearbox housing until the drain plug is on the bottom of
the vertical axis of the end cover.
Figure 3-18. Gearbox Disengaged
7. Repeat the above steps to engage the gearbox again.
Operation:
a. Engaged gearbox 2. Unscrew the both plugs (Fill and Drain) and let the oil
flow in a large enough container; in order to facilitate
At this condition the motion is transmitted from the draining the oil must still be warm.
hydraulic motor to the gearbox.
3. Wait a few minutes until all the oil is drained and then
b. Disengaged gearbox proceed to screw on the plugs.
4. Proceed with the oil fill-up. Refer to Filling-up the Gear-
box with Lubricating Oil.
AT THIS CONDITION THE HYDRAULIC MOTOR AND THE BRAKE ARE DISCON-
NECTED TO THE GEARBOX: THE WHEEL IS IDLE. NOTE: Never mix mineral oils with synthetic oils and vice versa.
Maintenance Information
PERIODIC MAINTENANCE DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT. BE CAREFUL TO
The gearbox only requires the scheduled maintenance proce- ELIMINATE IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS
dures set out by the manufacturer (see Table 3-4). THAT GOVERN LOCALLY.
Good maintenance will ensure an ongoing functioning in time

as well as maximum reliability.
3121142 – JLG Lift – 3-25

Troubleshooting
The following table is provided to help locate problems in the
gearbox.
Table 3-5. Troubleshooting
Symptom Causes Remedies

External oil leakage:
From the lifetime seal a)Lifetime seal damaged a)Replace lifetime seal
From the end cover a)O-ring seal damaged a)Replace O-ring seals
From the plugs a)Plug seal damaged a)Replace plug seal
b)Plugs or screws loose b)Tighten the plugs/screws
Too much noise:
Hydraulic noise (during the slowing down a)Hydraulic circuit malfunctioning a)Verify hydraulic circuit
of the motor speed)
Inside the gearmotor (reductions) a)Internal damage a)Check the gearbox
Other:
Overheating a)Insufficient oil level a)Check the oil level and refill if necessary
b)Hydraulic oil too warm b)Check the hydraulic circuit
c)Brake not fully released c)Check brake release pressure
Parking brake malfunctioning
Insufficient braking torque a)Brake discs worn a)Replace brake disc pack
b)Damaged parts b)Check brake components
Wheel Locked a)Parking brake locked a)Check the complete brake release
b)Mechanical components damaged b)Replace damaged parts
Disassembly Information 2. Making sure that the coupling surfaces are not dam-
aged.
It is also important that this procedure is undertaken in a
workshop that is equipped with the proper tools. As well as 3. Handle with care so as to be sure that there are no risks
normal workshop tools it will be necessary to use special tools for personnel safety and to guarantee the reliability of
that can be made (see special tools attachment) or may be the gearbox.
requested from the manufacturer.
4. Making available a work area that is in line with work
Special Tools: and health safety in the workplace guidelines.
Puller...............................................Code/: 6689960240
Disassembly Procedure
Tool for lifetime seal assembly........Code/: 6689960300
NOTE: Below are all the steps to follow during Disassembly and
Puller for brake disassembly..........Code/: 6689960310
Assembly. Numbers in brackets in the text correspond to
Torque multiplier............................Code/: ATZ.09.016.0 the references in the exploded view.
To be able to produce these special tools refer to Figure 3-20.
Initial inspection can be made without disassembling the hub
thru Figure 3-23.
from the machine. Before wheel drive disassembling, make
It is important to strictly adhere to all the procedures for disas- sure that the oil is drained from the hub.
sembling and reassembling the gearbox. Proceed with these
Unscrew and remove the nos. 2 screws M12, grade 8,8, and
instructions using all the necessary safety measures, for exam-
remove the hydraulic motor and its O-ring seal (48).
ple:
1. Plug all the Hydraulic ports on the gearbox to avoid the
introduction of any foreign particles in the circuit and
the gearbox.
3-26 – JLG Lift – 3121142

1. Install the special tool (6689960310) on the flanged hub 4. Mark the position of the springs (45) as a reference for
(31) and turn the screw until it compresses the springs the reassembly.
(45).
5. Remove the springs (45) from their seats in the brake

2. Remove the circlip (47) and remove the special tool. piston (44).
3. Remove the spring retainer disc (46). 6. By using pliers remove the circlip (36) from its seat in the
brake shaft (35).
3121142 – JLG Lift – 3-27

1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring
2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring
3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43. Backup Ring
4. Screw 14. Splined Shaft 24. Bearing 34. Spacer 44. Brake Piston
5. Cap Nut 15. Disengagement Shaft 25. Spacer 35. Brake Shaft 45. Springs
6. Oil Plug 16. 1st Reduction Assembly 26. Spacer 36. Circlip 46. Retainer Disc
7. End Cover 17. 2nd Stage Sun Gear 27. O-ring 37. Backup Ring 47. Circlip
8. Pad 18. 2nd Reduction Assembly 28. Spacer 38. O-ring
9. O-ring 19. Circlip 29. Half Seal 39. Spacer
10. 1st Stage Sun Gear 20. 3rd Reduction Assembly 30. Seal Ring 40. Backup Ring
Figure 3-19. Drive Hub S/N 100128 to Present
3-28 – JLG Lift – 3121142

7. By using a puller remove, at the same time, the brake 10. Remove the external O-Ring seal (38) and the backup
piston (44), the spacer (39) and the brake shaft (35). ring (37) from their seat in the spacer (39).
11. Remove the O-ring seal (42) and the backup ring (43)
from their seats in the flanged hub (31).
8. Remove the spacer (39) from the brake piston (44).
12. Remove brake discs pack (32-33).

9. Remove the internal O-Ring seal (41) and the backup
ring (40) from their seat in the spacer (39).
3121142 – JLG Lift – 3-29

13. Remove the disengagement shaft kit (15). 16. By using pliers remove the elastic ring (11) from the
splined shaft (14).
14. Place the disengagement shaft kit (15) inside the special
tool (6689960240). 17. Remove the special tool and remove the spring (13) and
the washers (12).
15. Tighten the 2 screws M5x16, grade 8.8, of the cover by a

torque wrench to 18.4 ft.lbs. (25 Nm). 18. Turn the gearbox upside down and unscrew the 2
screws M8x16 (4), grade 8.8, of the end cover (7).
3-30 – JLG Lift – 3121142

19. Remove the cap nut (5). 22. Unscrew the draining-filling-level oil plugs (6) by a male
hex head wrench.
20. Remove the pin (3).

23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the
end cover (7).
21. Remove the O-ring seal (2) from its seat in the end cover
(7).
24. Remove the end cover (7).
3121142 – JLG Lift – 3-31

25. Remove the O-ring seal (9) from its seat in the end cover 28. Remove the 2nd stage sun gear (17).
(7).
29. Remove the 2nd reduction assembly (18).

26. Remove the 1st stage sun gear (10).
30. By using pliers remove the circlips (19) from their seats
27. Remove the 1st reduction assembly (16). in the flanged hub's pins (31).
3-32 – JLG Lift – 3121142

31. By using a puller remove the planet assemblies of the 34. By using a tackle place the torque multiplier
3rd reduction (20). (ATZ.09.016.0) on the ring nut (22).
32. Remove the spacer (21) from their seats in the pins of 35. By using the torque multiplier (ATZ.09.016.0) loosen the
the flanged hub (31). ring nut (22).
NOTE: In order to proceed with the gearbox disassembly, it is now 36. Take out the ring nut (22).
necessary to remove it from the machine and bring it to a
properly equipped workshop.
33. By using a drill remove the caulkings on the ring nut

(22).
3121142 – JLG Lift – 3-33

37. By using a puller and a metal stopper, remove the 40. By using a screwdriver, remove the 1st half-seal (29)
flanged hub (31) from the gearbox housing (23). from the flanged hub (31).
38. By using a tackle remove the gearbox housing (23) from 41. By using a screwdriver, remove the 2nd half-seal (29)
the flanged hub (31). from the gearbox housing (23).
39. Remove the seal ring (30) from its seat in the flanged NOTE: The gearbox disassembly ends with the above operation.
hub (31). All items are now available for the necessary inspections.
Inspection of Parts
The pieces that are subject to general wear and tear are the
following:
- Gears.
- Bearings.
- All the seals
Replace the used or irregular parts using the following steps:
1. Remove dirt, and in particular properly clean the seals,
bearings and locking rings seating.
2. Lubricate the parts before connecting them.
NOTE: In case of oil leaks, it may be necessary to check and even- 3. In the case of damaged gears, for example a planetary,
tually replace the lifetime seal (29), which means both the do not proceed to replace the individual gear but the
metal rings parts and the O-ring seals. entire reduction assembly.
3-34 – JLG Lift – 3121142

4. When reassembling a part always replace all the seals c. Carefully clean the lapped surface (D) of metal rings
involved. Add some grease on the seats and on the new (E) and remove dust or fingerprints. Then lubricate
seals to make reassembly easier. them with a thin oil film, taking care not to oil the
other components.
5. Replace all the damaged parts with original spare parts.
2. Assemble the half seal (29) on the tool (6689960300).
Assembly
Apply grease TECNOLUBE SEAL GS730 on the gearbox hous-
ing (23).
3. Assemble the 1st half seal (29) on the gearbox housing

(23).
1. Follow the steps below to prepare the lifetime seal for

assembly:
a. Carefully clean the seats (A and B) using, if neces-
sary, metallic brushes or solvent (surfaces in contact
with or (C) must be perfectly clean and dry).
b. Make sure that sealing surfaces (D) of metal rings (E)

are free from scratches, dinges or foreign sub-
stances; metallic ring surfaces must be perfectly
clean and dry. We suggest to dip the metallic rings
in volatile solvent or industrial degreasing alcohol.
3121142 – JLG Lift – 3-35

4. Using the same tool (6689960300), assemble the 2nd 7. Apply grease TECNOLUBE SEAL GS730 on the seal ring
half seal (29) on the flanged hub (31). (30).
5. Carefully clean the metallic faces of the lifetime seal (29)

and lube the surfaces with oil.
AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL (29)
8. By using a hoist, place the gearbox housing (23) on the

flanged hub (31).
6. Insert the seal ring (30) in its seat in the flanged hub (31).
3-36 – JLG Lift – 3121142

9. By using a press and a metallic stopper, push the gear- 11. By using the mutiplier (ATZ.09.016.0), tighten the ring
box housing (23) against the shoulder on the flanged nut (22), using a torque wrench with an input multiplier
hub (31) until assembling of the unit is complete. torque of 71 ± 3 ft.lbs.(96,5 ± 4, 5 Nm) corresponding to
an output multiplier torque of 3688 ± 184 ft.lbs. (5000 ±
250 Nm).
SCREW THE NUT (22) ON PARTIALLY IN ORDER TO PREVENT THE FLANGED 12. Stake the ring nut (22) near 2 seats at 180° of the flanged
HUB (31) FROM COMING OUT OF THE GEARBOX HOUSING (23) DURING THE hub (31) on the right side.
FOLLOWING STEPS.
NOTE: Stake Ø 4+5 mm (depth 1+1,5 mm).

10. By using a hoist place the torque multiplier
(ATZ.09.016.0) on the ring nut (22).
3121142 – JLG Lift – 3-37

13. Assemble correctly the spacers (21) on the pins of the 16. By using pliers, assemble the circlips (19) in the flanged
flanged hub (31). hub pin seats (31).
14. Place the 5 planet assemblies of the 3rd reduction (20) in 17. Assemble the 2nd reduction assembly (18).
the flanged hub's pin (31).
18. Insert the 2nd stage sun gear (17).

15. By using a rubber hammer and a metal stopper push the
planet assemblies of the 3rd reduction (20) against the
shoulder until assembly is complete.
3-38 – JLG Lift – 3121142

19. Assemble the 1st reduction assembly (16). 22. Place the end cover (7) on the gearbox housing (23).
20. Insert the 1st stage sun gear (10). 23. Tighten the 10 socket head screws M10x25 (1),grade
12,9, by a torque wrench at 62.7 ft.lbs. torque (85 Nm).
21. Assemble the O-ring seal (9) into its seat in the end
cover (7). 24. Insert the plugs (6) into the oil draining-filling holes of
the end cover (7). Torque the plugs to 52 ± 7 ft.lbs.
(70±10 Nm).
3121142 – JLG Lift – 3-39

25. Assemble the O-ring seal (2) into its seat in the end 28. Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs.
cover (7). (25 Nm).
26. Protect the seat and the pin (3) with grease type 29. Insert the 1st washer (12) in the splined shaft (14).
MOLYKOTE G6000. Wait 15 minutes for it to completely
dry. Insert the pin (3) in its seat in the end cover (7).
30. Insert the spring (13) in the splined shaft (14).
27. Assemble the cap nut (5).
3-40 – JLG Lift – 3121142

31. Insert the splined shaft (14) in the equipment 34. By using pliers, assemble the elastic ring (11) into its seat
(6689960240). in the splined shaft (14).
32. Insert the 2nd washer (12) correctly in the splined shaft
(14).
35. Insert the disengagement shaft kit (15) in the flanged

hub (31).
33. Torque the 2 screws M5x16, grade 8.8, of the cover to

18.4 ft.lbs. (25 Nm).
3121142 – JLG Lift – 3-41

36. By using pliers assemble the circlip (36) into its seat in 39. Then insert an internally toothed steel disc (32). Repeat
the brake shaft (35). the operation until all 5 sintered bronze discs and 4 steel
discs have been assembled.
37. Turn the gearbox upside down and assemble the brake
shaft (35) inside the flanged hub (31). 40. Fit the internal O-ring seal (41) and the backup ring (40)
into their seats in the spacer (39).
38. Assemble the brake discs package according to the fol-

lowing order: first, insert one sintered bronze disc with 41. Fit the external O-ring seal (38) and the backup ring (37)
external teeth (33). into their seats in the spacer (39).
3-42 – JLG Lift – 3121142

42. Insert the spacer (39) inside the flanged hub (31), paying 44. Lube the seal seats into the flanged hub (31) and assem-
attention not to damage the seals already fitted. ble the O-ring seal (42) and the backup ring (43).
43. By using a rubber hammer and a metal stopper push the NOTE: The O-ring seals (A) and backup rings (B) must be fitted in
spacer (39) against the flanged hub (31), paying atten- the seats according the mutual position as shown in the
tion not to damage the seals already fitted. scheme.
3121142 – JLG Lift – 3-43

45. Insert the brake piston (44) inside the flanged hub (31), 47. Insert the springs (45) into the holes in the brake piston
paying attention not to damage the seals already fitted. (44) marked previously.
46. By using a rubber hammer and a metal stopper push the 48. Insert the spring retainer disc (46).
brake piston (44) against the flanged hub (31), paying
attention not to damage the seals already fitted.
3-44 – JLG Lift – 3121142

49. Install the special tool (6689960310) on the flanged hub Final Test and Reinstallation
(31) and turn the screw until it compresses the springs
Check the product by remounting it to the machine.
(45).
Check the function of the drive hub following all the checks
shown in Startup and Running In.
If work on the brake was undertaken, it is important to check
that there are no oil leaks. Follow the procedure below:
1. Connect the pressure pilot line with the manometer
(with a base scale of 100 bars) to the brake release port.
50. Assemble the circlip (47) in its seat and remove the spe-
cial tool.
2. Open the flow valve and release the brake with the pilot
pressure of 50 bar.
NOTE: Before assembling the hydraulic motor, verify by a depth
slide gauge the correct assembly of the unit checking the 3. Close the flow valve and keep the brake released 3 min-
axial distance as shown below. utes or longer.
4. Using the manometer, check that the pressure remains
constant.
NOTE: If the pressure drops it may mean that the brake seals are
not tight and consequently they must be replaced or it may
mean that the reassembling was not completed properly.
5. After having reassembled the gearbox, install the

hydraulic motor.
6. Fill the gearmotor with the lubricant oil.
3121142 – JLG Lift – 3-45

Figure 3-20. Drive Hub Special Tools - Sheet 1 of 4
3-46 – JLG Lift – 3121142

3121142 – JLG Lift – 3-47

3-48 – JLG Lift – 3121142

3121142 – JLG Lift – 3-49

3.13 DRIVE HUB - REGGIANA RIDUTTORI (S/N 134389 8. Wrench for M6, M8, M10 socket head screws and 1/4"G
plug.
TO PRESENT)
9. Socket wrench for M6 hexagonal screw.
NOTE: After S/N 0300134389 machines may be built with either
Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec-
tion 3.12, Drive Hub - Bonfiglioli (S/N 100128 to Present).
Do not use different hubs on the same machine. M- 1326
Symbol Nomenclature Ø240
Ø130
Ø30 5x45°
35
= ADHESIVE °
15
R5
10
5
Ø224
Ø233
Ø240
= LUBRICANT 60°
°
60
60
°
A A
= GREASE
N° 6 Hole to 120° Ø30
= TORQUE WRENCH
Figure 3-24. Bearing Track Spacer Mounting C016117
= DISPOSAL
M- 1537
Ø249
Ø130
Tools
Ø30
Tools required for assembling and disassembling the wheel N° 4 Hole to 90° Ø30
gear RRTD1701TB
29.5
1. Hammer;
2. Clamps for inner retention rings;
Ø210
14.5
10
3. Clamps for outer retention rings; Ø219

4. Electric or pneumatic screwdriver;
5. Special spacer mounting; Figure 3-25. Oil Seal Spacer Mounting C125049
6. Torque wrench;
7. Hydraulic press;
3-50 – JLG Lift – 3121142

Ø210
5x45°
Ø130
25
Ø30
M- 1321
LOCTITE 2701
N° 4 Hole to 90° Ø40
110
M- 1320
Ø197.5
Ø210
Figure 3-26. Bearing Spacer Mountng CO16117
Figure 3-27. Assembly Diagram 1
3121142 – JLG Lift – 3-51

M- 1316 M- 1020
30
Ø34 35 35
10
10 10
M- 1317
45°
45°
8 M- 1317
N° 4 R
35
45°
45°
70
A A
35
50
M- 1317
50
216.5 70
Ø
12
10
Ø11
Ø230
20
M- 1316 10x45°
60
90
Ø16
70
Ø17
55
38
11
M- 1317
M- 1317
M- 1317 Figure 3-30. Anti-rotation Block
16 n° 8 Routing to 45°
Ø205
Figure 3-28. Wrench For Ring Nut

M- 1126
Ø20
Ø12
M- 1125
T.U.9
Ø180
n° 12 Fori a 30° Ø35
Ø80
30
50
Ø20 H7 (+0.021) n°12 Hole to 30°

10.5
0
20
n° 12 Hole to 30° Ø6.5

M6
32
n° 12 Spot-facing to 30° Ø10.5

T.U.15
Figure 3-31. Anti-rotation Pin

6.5
n° 4 Hole to 90° M10

Ø50
Ø275
Ø305
30° 30°
0
°
30
3
°
30°
30°
A A
Figure 3-29. Anti-rotation Flange
3-52 – JLG Lift – 3121142

M- 1126 M- 1126
M- 1125 VTCEI M6X12 n°12
M- 1020
VTCEI M10X60 n°4
Figure 3-32. Assembly Diagram 2
3121142 – JLG Lift – 3-53

Ø105 M- 1546 M- 1548

Ø93.5
+0.1
Ø48
Ø20+0.2 Ø46
5
5
9
80
70
50
8.5
20
Ø8.5
Ø13.5 Ø40.5
5
Ø46
2.5x15° M- 1547
Ø39.5
t.u. 12
88.5
3.5
0 M8
Ø20 -0.1
VTCEI M8X16 n°1
Figure 3-33. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram
3-54 – JLG Lift – 3121142

Disassembly 3. Release the screws from the release cover and pull the
pin out.
1. Remove the plugs and pour the lubricant in a container.
4. Remove the BR250 ring and pull the cover out avoiding
to damage the O-Ring.
2. Release the screws to disassemble the motor flange tak-

ing care not to damage the O-Ring.
5. Pull the reduction gears out.
3121142 – JLG Lift – 3-55

Figure 3-34. Reggiana Riduttori Hub - Sheet 1 of 2
3-56 – JLG Lift – 3121142

3121142
1. Screw 13. Iron Brake Disc 25. Tapered Roller Bearing 37. O-ring
2. Motor Support 14. Plastic Plug 26. Bearing Support 38. Crown Gear
3. O-ring 15. Spindle 27. Ring Nut 39. Crown Gear Screw
4. Inner Retention Ring 16. Planet Wheel 28. Sphere 40. O-ring
5. Brake Spring Spacer 17. Bearing 29. Screw 41. Support Tablet
6. Brake Spring 18. Outer Retention Ring 30. Pinion 42. O-ring
7. Brake Piston 19. Input Shaft 31. Reduction Gears 43. Cover
8. Parbak 20. Input Shaft Bearing 32. Outer Retention Ring 44. Steel Plug
9. O-ring 21. Ring 33. Pinion 45. Cover Retaining Ring
– JLG Lift –
10. O-ring 22. Disengagement Spring 34. Reduction Gears 46. Disengagement Stud
11. Parbak 23. Disengagement Shaft 35. Outer Retention Ring 47. Disengagement Cap
12. Sintered Brake Disc 24. Spindle Oil Seal 36. Pinion 48. Disengagement Screw
Figure 3-35. Reggiana Riduttori Hub - Sheet 2 of 2
3-57
6. Loosen the M10x25 flathead socket screws and remove 9. Loosen the M6x6 socket headless screws and also
the planetary ring without damaging the O-Ring. remove the 3/16" balls.
7. Remove the release joint together with the spring. 10. Loosen the ring nut using the special wrench.
8. Disassemble the Ø40 outer snap rings and using an 11. Remove the hub support together with the roller bear-
extractor remove the planetary gears from the spindle ing inner track.
pins.
3-58 – JLG Lift – 3121142

12. Disassemble the Ø160 inner snap ring and pull the Assembly
spring holder spacer out. Remove the springs and using
a compressed air jet in the brake control hole pull the 1. Make sure all the component parts of the wheel gear are
piston out of the spindle. devoid of burrs, machining residues and that they are
correctly washed.
2. Fit the ball bearing in the input shaft and lock with a Ø40
outer snap ring.
13. Remove the brake discs and seals.

3. Mount the motor shaft in the spindle and lock with BR68
ring. Lubricate the bearing.
14. Fit the ball bearing into the input shaft and lock it with a
Ø40 outer snap ring. Then mount the motor shaft in the
spindle and lock with a BR68 ring. Lubricate the bearing.
3121142 – JLG Lift – 3-59

4. Fit the brake sealing rings O-Ring and PARBAK (lubri- 6. Prepare the hub support, mounting on it the two roller
cated with grease) in the respective spindle seats. Place bearing outer tracks. Place the first roller bearing inner
the brake discs making sure to centre them on the spin- track.
dle and on the input shaft.
7. Fit the oil seal lubricated with grease onto the support
5. Insert the brake piston and place the springs into the with the special spacer mounting (see figure A).
piston holes. Close the brake fitting the spring holder
plate, then lock with the Ø160 inner snap ring. Check the
brake leakage, if any, as well as the static torque and Fig.A
minimum opening pressure.
8. Place the hub support already assembled on the spindle

making sure that the first roller bearing inner track goes
correctly against it; then fit the second roller bearing
inner track by means of the spacer mounting. Tighten
the ring nut.
3-60 – JLG Lift – 3121142

9. Now check the unit roll torque and proceed in the fol- 11. Using the special tool and hammer make four dents on
lowing order: the spindle thread by the M6 holes of the ring nut.
10. 7.) By keeping the spindle locked, apply a setting pre-
load by tightening the ring nut at 40daNm, turn com-
pletely the hub support twice using the special wrench
to recover any bearing cage misalignments. Release and
tighten the ring nut at the final torque of 30daNm (alter-
nate tightening and some setting turns). Check the roll
torque with seal which must be within 1÷1,5 daNm.
12. Fit the 4 3/16" balls and tighten with LOCTITE 243 the 4
M6x6 socket headless screws at the torque of 1daNm.
NOTE: Place the ring nut with its convex part facing the roller
bearing as shown below.
13. Fit the bearings onto the 3rd stage planetary gears and
using a spacer mounting mount everything on the spin-
3121142 – JLG Lift – 3-61

dle pins. Lock with a ÿ40 outer snap ring. Lubricate the 15. Place the hub onto the support making the two holes
bearings. coincide for tightening the M10x25 flathead socket
screws at the torque of 5daNm.
16. Fit the reduction gears and the pinion in the unit.
14. Using a marking pen, make a mark between the snap

ring and the bearing. Fit the greased spring and the
release joint. Use grease to fit the O-Ring 2-275 in the
hub support seat.
3-62 – JLG Lift – 3121142

17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit the O-Ring 2-163 suitably greased, onto the motor
ably greased and lock it with the shimming ring. Lubri- coupling flange S-D LC/KC. Mount the flange on the
cate the bearings. spindle with 6 M8x25 socket cap screws at the torque of
2.4daNm with LOCTITE 243 Insert the pin and carry out
the rotation test according to PGQ-22 standard.
18. Fit the O-Ring 2-177 suitably greased, mount the cover
locking it with the BR250 ring.
20. Mount the release cover fastening it with 2 M6x20 hex-
agonal screws at the torque of 1daNm. Mount the 1/
4"GAS plugs on the cover at the torque of 1daNm.
3121142 – JLG Lift – 3-63

1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-36. Swing System
3-64 – JLG Lift – 3121142

3.14 SWING DRIVE Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
Roll and Leak Testing should be taken to ensure that the bolts are not tightened
beyond their specified torque.
Torque-Hub units should always be roll and leak tested before
disassembly and after assembly to make sure that the unit's The following steps describe how to tighten and torque bolts
gears, bearings and seals are working properly. The following or socket head cap screws in a bolt circle.
information briefly outlines what to look for when performing
these tests.
NOTE: The brake must be released before performing the roll test.
This can be accomplished by either pressure testing using
the Brake Leak Test procedure below or by tightening the
12 bolts into the piston through the end plate (See Brake
Disassembly Procedure)
NOTE: Bolts must be removed while performing brake release test
Roll Test
The purpose of the roll test is to determine if the unit's gears
are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con-
cerned if the gears in your unit seem to roll hard as long as
they roll with consistency.
LEAK TEST (MAIN UNIT) 1. Tighten (but do not torque) bolt “A" until snug.
The purpose of a leak test is to make sure the unit is air tight. 2. Go to the opposite side of the bolt circle and tighten
You can tell if your unit has a leak if the pressure gauge read- bolt °B" until equally snug.
ing on your air checker starts to fall after the unit has been
pressurized and allowed to equalize. Leaks will most likely 3. Crisscross around the bolt circle and tighten remaining
occur at the pipe plugs, the main seal or wherever o-rings or bolts.
gaskets are located. The exact location of a leak can usually be 4. Now use a torque wrench to apply the specified torque
detected by brushing a soap and water solution around the to bolt "A".
main seal and where the o-rings or gaskets meet on the exte-
rior of the unit, then checking for air bubbles. If a leak is 5. Using the same sequence, crisscross around the bolt cir-
detected in a seal, o-ring or gasket, the part must be replaced, cle and apply an equal torque to the remaining bolts.
and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 min-
utes.
3121142 – JLG Lift – 3-65

Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36)
and remove fittings from Brake (26) and Motor Control
1. Place unit on bench with the motor end up. Valve (32).
2. Remove O-ring Plug (1J) and drain the oil from the gear- 5. Remove O-ring Plugs (21) from Motor Control Valve (32).
box.
6. Remove Motor Control Valve (32) from Motor (10) by
3. Remove Hydraulic Tubing Assembly (35) by loosening removing the four Bolts (34) and washers (33).
fittings on both ends of tube with a wrench.
1J. O-Ring Plug 32. Motor Control Valve

10. Hydraulic Motor 33. Lockwasher
21. Plug 34. Hex Bolt
24. ID Plate 35. Hydraulic Tubing
25. Drive Screw 36. Elbow
26. Hydraulic Brake
Figure 3-37. Swing Drive - Motor Control Valve Disassembly
3-66 – JLG Lift – 3121142

Motor and Brake Disassembly 3. Remove Gasket (31) from between Brake (26) and Motor
(10).
1. With unit resting on bench with Motor (10) end up,
4. Remove Brake (26) from Main Torque-Hub Assembly
loosen Hex Bolts (29) and remove Lift Lugs (28) from the
and dump oil out of Brake (26).
Motor (10).
5. Remove O-ring (27) from between Motor (10) and Brake
2. Pull Motor (10) straight up and remove Motor (10) from
(26).
Brake (26).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-38. Swing Drive - Motor and Brake Disassembly
3121142 – JLG Lift – 3-67

Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15)
from between Input Cover (6) and Carrier (3A) Subas-
1. With the unit resting on the Output Shaft (Pinion) (1A), sembly.
remove the eight Bolts (17), four Shoulder Bolts (18) and
7. Remove Ring Gear (4) from Housing (1G).
four Lock Washers (19) from the Input Cover (6).
8. Remove O-ring (5) from between Ring Gear (4) and
2. Thread either 1/2-13 UNC eye bolts or motor mounting
Housing (1G).
Bolts (29) into threaded holes in Input Cover (6) and pull
Input Cover (6) off on the main assembly. 9. Remove Carrier (3A) Subassembly.
3. Remove O-ring (5) from between Input Cover (6) and 10. Remove Thrust Washers (16) and Thrust Bearing (15)
Ring Gear (4). from between Carrier (3A) Subassembly and Internal
Gear (2).
4. Remove Thrust Washer (8) from end of Sun Gear (13).
11. Remove Internal Gear (2).
5. Remove Sun Gear (13).
2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-39. Swing Drive - Main Disassembly
3-68 – JLG Lift – 3121142

Hub-Shaft Disassembly 4. Remove the Bearing Cone (1F) from the Housing (1G).
5. Invert the Housing (1G) and remove the Lip Seal (1B) if
1. Using retaining ring pliers, remove Retaining Ring (1I)
not already removed when Output Shaft (1A) was
from groove in Output Shaft (1A) and discard.
pressed out of Housing (1G).
6. Remove the Bearing Cone (1D).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 7. Bearing Cups (1C & 1E) will remain in Housing (1G).
2. Remove Thrust Washer (1H). NOTE: If bearing replacement is necessary, the Bearing Cups (1C &
1E) can be removed with a slide hammer puller or driven
3. While supporting the Housing (1G) on the Output Shaft out with a punch.
(1A) end, press the Output Shaft (1A) out of the Housing
(1G).
NOTE: The Lip Seal (1B) may or may not be pressed out of the
Housing (1G) by the Bearing Cone (1D) during this step.
1A. Output Shaft 1F. Tapered Bearing Cone

1B. Lip Seal 1G. Housing
1C. Tapered Bearing Cup 1H. Thrust Washer
1D. Tapered Bearing Cone 1I. Retaining Ring
1E. Tapered Bearing Cup 1J. O-Ring Plug
Figure 3-40. Swing Drive - Hub Shaft Disassembly
3121142 – JLG Lift – 3-69

Carrier Disassembly 3. Slide the Planet Gear (3F), two Ball-Indented Thrust
Washers (3H) and the two Thrust Washers (3B) out of the
1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G) which Carrier (3A).
holds the Planet Shaft (3E) in the Carrier (3A) down into
4. Remove both rows of Needle Bearings (3C) and the
the Planet Shaft (3E) until it bottoms.
Spacer (3D) from the bore of the Planet Gear (3F).
NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam-
5. Repeat Steps 1 thru 4 for the remaining two Cluster
age to the carrier could occur when the Planet Shaft is
Gears(3F).
removed.
2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a
small punch to remove the Roll Pin (3G) from the Planet
Shaft (3E).
3A. Carrier 3E. Planet Shaft

3B. Tanged Thrust Washer 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Thrust Washer 3H. Ball Indented Washer
Figure 3-41. Swing Drive - Carrier Disassembly
3-70 – JLG Lift – 3121142

Hub-Shaft Sub-Assembly 9. Install Bearing Spacer (1H) onto Output Shaft (1A) and
against Bearing Cone (1F).
1. Press Bearing Cone (1D) onto Shaft (1A).
10. Install Retaining Ring (1I) into the groove in the Output
2. Press Bearing Cup (1C) into Housing (1G), take care to Shaft (1A). This Retaining Ring (1I) should never be
insure cup starts square with bore of Hub (1G). reused in a repair or rebuild.
3. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
1G).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
4. Press or tap Seal (1B) into the counterbore of Housing
(1G) to the point where it becomes flush with the Hous-
11. Tap the Retaining Ring (1I) with a soft metal punch to
ing (1G) face. Care should be taken to insure Seal (1B) is
ensure that the Retaining Ring (1I) is completely seated
being correctly installed (smooth face up).
in the groove of the Output Shaft (1A).
5. Invert Hub (1G) and press Bearing Cup (1E) into counter-
bore of Housing (1G).
6. Carefully lower Housing (1G) onto the Output Shaft (1A). EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
7. Start the Bearing Cone (1F) onto the Output Shaft (1A).
12. Install O-ring Plug (1J) and torque 23 to 24 ft-lbs.(32 -
8. Press or tap the Bearing Cone (1F) onto the Output Shaft 33.5 Nm).
(1A) until it is seated in the Bearing Cup (1E).
1A. Output Shaft 1D. Tapered Bearing Cone 1G. Housing 1I. Retaining Ring
1B. Lip Seal 1E. Tapered Bearing Cup 1H. Thrust Washer 1J. O-Ring Plug
1C. Tapered Bearing Cup 1F. Tapered Bearing Cone
Figure 3-42. Swing Drive - Hub Shaft Sub-Assembly
3121142 – JLG Lift – 3-71

Carrier Sub-Assembly 8. Slide the second Thrust Washer (3E) between the Cluster
Gear (3F) and the Carrier (3A) with the tang of the
1. Apply a liberal coat of grease to the bore of Cluster Gear washer located in the cast slot of the Carrier (3A). Slide
(3F). This will enable the Needle Rollers (3C) to be held in ball-indented Thrust Washer (3H) onto the end of the
place during assembly. Planet Shaft with the indents against the second thrust
Washer. Finish sliding the Planet Shaft (3E) through the
2. Install the first row of 14 Needle Rollers (3C) into the
Thrust Washers (3H) & (3B) and into the Carrier (3A).
bore of Cluster Gear (3F).
9. Position the non-chamfered side on the Planet Shaft (3E)
3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of
roll pin hole so that it is in line with the hole in the Car-
the Needle Rollers (3C).
rier (3A) using a 1/8" (3 mm) diameter punch.
4. Place second row of Needle Rollers (3C) into bore of
10. After using a 3/16" (5 mm) punch to align the two roll
Cluster Gear (3F) against Spacer (3D) and remove Planet
pin holes. Drive the Roll Pin (3G) through Carrier (3A)
Shaft (3E).
and into the Planet Shaft (3E) until the Roll Pin (3G) is
5. Place Carrier (3A) into tool fixture so that one of the roll flush with the bottom of the cast tang slot in the Carrier
pin holes is straight up. (3A). Use a 1/4" (6 mm) pin punch to make sure the Roll
Pin (3G) is flush in the slot.
6. Start Planet Shaft (3E) through the hole in Carrier (3A).
Using ample grease to hold it in position, slide one 11. Repeat Steps 1 thru 10 for the remaining two Cluster
Thrust Washer (3B) over the Planet Shaft (3E) with the Gears(3F).
tang resting in the cast slot of the Carrier (3A). Place Ball-
Indented Thrust Washer (3H) on the Planet Shaft (3E)
with the indents against the first washer.
7. With large end of Cluster Gear (3F) facing the roll pin
hole in the carrier, place the cluster gear into position in
Carrier (3A) and push Planet Shaft (3E) through the Clus-
ter Gear (3F) without going all the way through.
3-72 – JLG Lift – 3121142

3A. Carrier 3E. Planet Shaft

3B. Tanged Thrust Washer 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Thrust Washer 3H. Ball Indented Washer
Figure 3-43. Swing Drive - Carrier Sub-Assembly
3121142 – JLG Lift – 3-73

Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
1. With the Hub Shaft Sub-Assembly resting on the Shaft with the Internal Gear (2) and Input Gear (13). On the
(1A) install Internal Gear (2). The spline of the Internal Ring Gear (4) locate the hole marked "X", or punch
Gear (2) bore will mesh with the spline of the Output marked, over one of the marked counter-bored holes
Shaft (1A). (Step 5) in Hub (1G). Check timing through the slots in
the carrier. Rotate carrier in assembly to check for free-
2. Inspect the location of the Internal Gear (2) on the Out-
dom of rotation.
put Shaft (1A). The portion of the Output Shaft (1A),
which does not have full spline, should protrude NOTE: NOTE: If gears do not mesh easily or Carrier Assembly does
through the Internal Gear (2) bore. not rotate freely, then remove the Carrier and Ring Gear
and check the Cluster Gear timing
3. Install two Thrust Washers (15) and one Thrust Bearing
(16) on the portion of Output Shaft (1A) which protrudes
10. Install Thrust Washer (15)/Thrust Bearing (16) set into
through Internal Gear (2).
the counter-bore in the face of the carrier. Use grease to
4. Center the Input Gear (13) on the end of the Output hold in place.
Shaft (1A) opposite the gear with the large diameter
11. Place O-ring (5) into Cover (6) counter-bore. Use grease
down.
to hold O-Ring in place.
5. Place O-ring (5) into Hub counter-bore. Use grease to
hold O-ring in place.
CAUTION: BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING
THIS O-RING.
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE SEATING THIS O-
RING. 12. Using sufficient grease to hold in place, install Thrust
Washer (8) into the counter-bore of the interface of the
6. Also at this time locate and mark the four counter Cover (6).
reamed holes in the face of the Hub (1G). This is for iden-
13. The Cover (6) is now installed, taking care to correctly
tification later in the assembly.
align Pipe Plug hole (20) with those in the Hub (1J).
7. Place Carrier (3A) Subassembly on bench with the large Check timing sheet.
end of Cluster Gears (3F) up with one at the 12 o clock
14. Locate the 4 counter-bored holes in Hub (1G) [marked in
position. Find the punch marked tooth on each gear at
Step 5] and install 4 Shoulder Bolts (18) with Lockwash-
the large end and locate at 12 o'clock (straight up) from
ers (19). Start the shoulder bolts by hand.
each planet pin. Marked tooth will be located just under
the Carrier on upper two gears. Check the timing 15. Install Grade 8 Bolts (17) with Lockwashers (19) into
through the slots in the carrier. remaining holes.
8. With large shoulder side of Ring Gear (4) facing down, 16. Torque Shoulder Bolts (18) 43 to 47 ft.-lbs. (60 to 65 Nm)
place Ring Gear (4) over (into mesh with) large end of and Grade 8 Bolts (17) to 43 to 47 ft.-lbs. (60 to 65 Nm).
gears. Be sure that punch marks remain in correct loca- Roll and leak test the assembly.
tion during Ring Gear (4) installation. The side of the
Ring Gear (4) with an "X" or punch mark stamped on it 17. With gearbox standing on the pinion end fill gearbox
should be up. with GEAROIL 80W90, to bottom of plug hole in cover at
Pipe Plug (20).
18. Install Pipe Plug (20) into Cover (6) using thread sealant.
3-74 – JLG Lift – 3121142

2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-44. Swing Drive - Main Assembly
3121142 – JLG Lift – 3-75

Motor and Brake Assembly 4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble
Hex Bolts (29) with Lift Lugs through the Motor (10) and
1. Place O-ring (27) onto end of Brake (26) and locate brake Brake (26) against the motor flange. Torque to 35 ft-lbs.
into pilot of cover.
5. Fill Brake (26) with 2.7 oz. (80cc) of BRAKOILVG32
2. Place Gasket (31) onto the brake face and line up the (DTE24).
holes.
3. Place Motor (10) into Brake pilot against the Gasket (31).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-45. Swing Drive - Motor and Brake Assembly
3-76 – JLG Lift – 3121142

Motor Control Valve Assembly 4. Assemble Tube (35) into Elbow Fittings (36) and torque
13 to 15 ft-lbs. (18 to 21 Nm).
1. Lay assembly down with motor ports facing up. Remove
5. Install O-ring Plugs (21) into Motor Control Valve (32)
the two plastic plugs in the motor ports, being careful
and torque 30 to 31 ft-lbs. (42 to 43 Nm).
not to loose the O-ring in each port. Assemble the Motor
control Valve (32) onto the Motor (10) with Bolt (34) and 6. Pressure test brake, tube and control valve connections
Lock Washers (33). Torque Bolts (33) 23 to 27 ft-lbs. (32 to by applying 3000 psi (207 bar) pressure to the brake
38 Nm). bleed port and holding for 1 minute. Check for leaks at
the control-valve-motor interface and the tube connec-
NOTE: Be sure to align the holes in the control valve with the
tions. Release pressure.
motor ports.
7. Place I.D. Plate (24) onto Housing (1G) with two Drive
2. Install Elbow Fittings (36) into Brake (26) and torque 13 Screws (25). I.D. Plate (24) is to be inline with O-ring Plug
to 15 ft-lbs. (18 to 21 Nm). (1J) as shown on assembly print.
3. Install Elbow Fittings (36) into Motor Control Valve (32)
and torque to 13 to 15 ft-lbs. (18 to 21 Nm).
1J. O-Ring Plug 25. Drive Screw 34. Hex Bolt

10. Hydraulic Motor 26. Hydraulic Brake 35. Hydraulic Tubing
21. Plug 32. Motor Control Valve 36. Elbow
24. ID Plate 33. Lockwasher
Figure 3-46. Swing Drive - Motor Control Valve Assembly
3121142 – JLG Lift – 3-77

3.15 SWING BRAKE To check brake release, connect an appropriate hydraulic pres-
sure supply set to the required level up to a maximum of 3000
psi (200bar) and check that brake shaft (1) is free to rotate.
Pre-Installation Checks
MECHANICAL Remove hydraulic supply from brake, checking to ensure that
the friction plates (3 & 6) have engaged thus preventing rota-
Check, That in the handling prior to assembly, the mounting
tion of brake shaft (1)
features and other parts of the brake are undamaged. Ensure
that the shaft to which the brake is mounted are clean and free
from burrs and swellings.
RELEASE PRESSURE DURING BENCH TESTING SHOULD BE LIMITED TO 2000
HYDRAULIC/MECHANICAL PSI (138 BAR) UNLESS BRAKE IS FULLY INSTALLED USING 2-OFF 1/2” UNC
MOUNTING BOLTS IN THE THROUGH (MOUNTING) HOLES.
1. Brake Shaft 9. Piston 17. O-Ring

2. Housing 10. Deep Groove Ball Bearing 18. Backing Ring
3. Inner Friction Plate 11. Internal Retaining Ring 19. Dowel Pin
4. Pressure Plate 12. Rotary Shaft Seal 20. Hexagon Plug
5. Gasket 13. Socket Head Cap Screw 21. Plastic Plug
6. Outer Plate 14. Shakeproof Washer 21A. Socket Pressure Plug
7. Gasket 15. O-Ring 22. Spring (Natural)
8. Cylinder 16. Backing Ring 23. Spring (Blue)
Figure 3-47. Swing Brake
3-78 – JLG Lift – 3121142

Installation 5. Remove 2-off dowel pins (19).

Position 1-off gasket (5) over male pilot on brake housing (4). 6. Remove springs (8). Take note of quantity and orienta-
Locate brake shaft (1) and secure brake in position using 2-off tion of springs.
1/2” UNC mounting bolts in the through mounting (fixing)
holes provided. 7. Should it be necessary to replace ball bearing (10) or
Connect hydraulic pressure supply to brake pressure inlet shaft seal (12), reverse remainder of brake sub-assembly,
port. Ensure that the hydraulic pressure is set to the required supporting on face “c” of housing (2).
level up to a maximum of 3000 psi (200 bar) and check that the 8. Remove internal retaining ring (11).
brake disengages and re-engages correctly.
9. Using arbor press or similar to break Loctite seal, remove
brake shaft (1) from housing (2) and lay aside.
Maintenance
The brake is required to be kept in good working order and 10. Reverse housing (2) and press out ball bearing (10).
must be included in the planned maintenance program for the Shaft seal (12) can also be removed if necessary.
equipment to which the brake is installed.
This must include torque testing together with inspection and Examination
replacement of the working parts such as friction plates (3 & 6) All components can now be examined and inspected, paying
and, springs (22 & 23). The frequency of inspection depends particular attention to the following.
on the duty demanded of the brake.
1. Inspect friction plates (3 & 6) and friction surface on
Disassembly pressure plate (4) for wear or damage.
To remove brake from its installed position, reverse procedure 2. Examine friction plates (3) and brake shaft (1) for wear or
previously described in the installation instructions. damage to splines.
Place the complete brake assembly on a clean, dry work
bench. 3. Examine input and output splines of brake shaft (1) for
wear or damage.
Remove external gasket (5) as necessary.
4. Examine compression springs (22 & 23) for damage or
NOTE: Refer to Diagrams for the following. fatigue.
5. Check ball bearing (10) for axial float or wear.
1. Supporting brake face “A”, remove the six socket head
cap screws and washers (items 13 & 14) in equal incre- 6. Examine O-ring seals (15 & 17) and backing rings (16 &
ments to ensure the spring pressure within the brake is 18) for damage.
reduced gradually and evenly.
7. Obtain replacement parts as required.
Alternatively, if press is available, the cylinder housing
(8) can be restrained on face “B” while removing the six
socket head cap screws and washers (13 & 14). Assembly
The brake assembly can now be fully dismantled and Clean all parts thoroughly.
parts examined. Reverse procedure previously outlined in Dismantling instruc-
tions taking particular care with.
2. Remove cylinder housing (8) and piston (9) subassembly
and dismantle if required, removing O-ring seals (15 & a. Assembly of shaft seal (12).
17) and backing rings (16 & 18) as necessary.
b. Assembly of bearing (10).
3. Remove gasket (7) from housing (2). c. Quantity and orientation of springs (8).
4. Remove friction plates (3 & 6) and pressure plate (4). d. Assembly sequence of friction plates (3 & 6).
1. Lightly lubricate rotary shaft seal (12) and assemble to
housing (2) taking care not to damage seal lip.
3121142 – JLG Lift – 3-79

2. Apply ring of Loctite 641 or equivalent adhesive to full 4. Lubricate O-ring seals (15 & 17) with Molykote 55M (or
circumference of housing (2) bearing recess adjacent to equivalent) silicone grease and assemble together with
shoulder. backing rings (16 & 18) to piston (9). To ensure correct
Apply complete coverage of Loctite 641 to outside brake operation, it is important that the backing rings
diameter of bearing (10) and assemble fully in housing are assembled opposite ti the pressurized side of piston
(2), retaining with internal retaining ring (11). Remove (9).
excess adhesive with clean cloth.
5. Correctly orientate piston (9) aligning spaces with the
Press shaft (1) through bearing (10), ensuring bearing
two dowel pin holes and, assemble into cylinder hous-
inner ring is adequately supported.
ing (2) taking care not to damage seals and carefully lay
3. Assemble correct quantity of springs (8) in orientation aside.
required. Refer to (See Figure 3-48.) and (See Figure 3-
6. Loctite 2-off pins (19) in housing (2) followed by pres-
49.).
sure plate (4) and friction plates i.e. an inner (3) followed
by an outer (6) in correct sequence.
7. Position gasket (7) in correct orientation.
8. Align two holes in cylinder with dowel pins (19) and
assemble piston & cylinder sub-assembly to remainder
of brake securing with 6-off socket head cap screws and
washers (13 & 14). Torque to 55ft/lbs. (75 Nm).
NOTE: The use of a suitable press (hydraulic or arbor) Pressing

down on cylinder end face “B” will ease assembly of the
socket head cap screws (13).
Figure 3-48. Swing Brake 8 Spring Orientation
Figure 3-49. Swing Brake 12 Spring Orientation
3-80 – JLG Lift – 3121142

1. Brake Shaft 8. Cylinder 15. O-Ring

2. Housing 9. Piston 16. Backing Ring
3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring
4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring
5. Gasket 12. Rotary Shaft Seal 19. Dowel Pin
6. Outer Plate 13. Socket Head Cap Screw 20. Hexagon Plug
7. Gasket 14. Shakeproof Washer 21. Plastic Plug
21A. Socket Pressure Plug
Figure 3-50. Swing Brake Assembly
3121142 – JLG Lift – 3-81

3.16 SWING MOTOR
Disassembly and inspection

1. Place the Torqlink™ in a soft jawed vice, with coupling
shaft (12) pointed down and the vise jaws clamping
firmly on the sides of the housing (18) mounting flange
or port bosses. Remove manifold port O-Rings (18A) if
applicable.
3. Remove the five, six, or seven special ring head bolts (1)
using an appropriate 1/2 or 9/16 inch size socket.
Inspect bolts for damaged threads, or sealing rings,
under the bolt head. Replace damaged bolts.
IFTHETORQLINK™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED

DURINGTHE SERVICE PROCEDURES, CAUSING INJURY.
2. Scribe an alignment mark down and across the Torq-

link™ components from end cover (2) to housing (18) to
facilitate reassembly orientation where required. Loosen
two shuttle or relief valve plugs (21) for disassembly
later if included in end cover. 3/16 or 3/8 inch Allen 4. Remove end cover assembly (2) and seal ring (4). Discard
wrench or 1 inch hex socket required. seal ring.
NOTE: Refer to the appropriate “alternate cover construction” on

the exploded view to determine the end cover construction
being serviced.
3-82 – JLG Lift – 3121142

1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing

2. End Cover 8C. Vane 16. Seal
3. Seal Ring-Commutator 8D. Stator Half 17. Back-up Washer
4. Seal Ring 9. Wear Plate 18. Housing
5. Commutator Ring 10. Drive Link 18A. O-Ring
6. Commutator Ring 11. Not Used 19. Bearing/Bushing, Outer
7. Manifold 12. Coupling Shaft 20. Dirt & Water Seal
8. Rotor Set 13. Bearing/Bushing, Inner 21. Plug
8A. Rotor 14. Thrust Washer
Figure 3-51. Swing Drive Motor
5. If the end cover (2) is equipped with shuttle valve com-

ponents, remove the two previously loosened plugs
(21). BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS
THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE
REMOVED.
NOTE: The insert and if included the orifice plug in the end cover
(2) must not be removed as they are serviced as an integral
part of the end cover.
3121142 – JLG Lift – 3-83

6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal
blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into
ing the internal orifice plug, are free of contamination. ring groove until seal ring is lifted out and discard seal
Inspect end cover for cracks and the bolt head recesses ring. Inspect commutator for cracks or burrs, wear, scor-
for good bolt head sealing surfaces. Replace end cover ing, spalling or brinelling. If any of these conditions exist,
as necessary. replace commutator and commutator ring as a matched
set.
NOTE: A polished pattern (not scratches) on the cover from rota-

tion of the commutator (5) is normal. Discoloration would
indicate excess fluid temperature, thermal shock, or excess
speed and require system investigation for cause and close
inspection of end cover, commutator, manifold, and rotor
set.
7. Remove commutator ring (6). Inspect commutator ring

for cracks, or burrs.
9. Remove manifold (7) and inspect for cracks surface scor-

ing, brinelling or spalling. Replace manifold if any of
these conditions exist. A polished pattern on the ground
surface from commutator or rotor rotation is normal.
Remove and discard the seal rings (4) that are on both
sides of the manifold.
3-84 – JLG Lift – 3121142

NOTE: The manifold is constructed of plates bonded together to

form an integral component not subject to further disas-
sembly for service. Compare configuration of both sides oft
hem an if old to ensure that same surface is reassembled
against the rotor set.
10. Remove rotor set (8) and warplane (9), together to retain
the rotor set in its assembled form, maintaining the
same rotor vane (8C) to stator (8B) contact surfaces. The
drive link (10) may come away from the coupling shaft
(12) with the rotor set, and wearplate.You may have to
shift the rotor set on the warplane to work the drive link
out of the rotor (8A) and warplane. Inspect the rotor set
in its assembled form for nicks, scoring, or spalling on
any surface and for broken or worn splines. If the rotor NOTE: Series TG Torqlinks™ may have a rotor set with two stator
set component requires replacement, the complete halves (8B) with a seal ring (4) between them and two sets
rotor set must be replaced as it is a matched set. Inspect of seven vanes (8C). Discard seal ring only if stator halves
the warplane for cracks, brinelling, or scoring. Discard become disassembled during the service procedures.
seal ring (4) that is between the rotor set and wearplate.
NOTE: A polished pattern on the wear plate from rotor rotation is
normal.
11. Place rotor set (8) and wear plate (9) on a flat surface
and center rotor (8A) in stator (8B) such that two
rotor lobes (180 degrees apart) and a roller vane
(8C) centerline are on the same stator centerline.
Check the rotor lobe to roller vane clearance with a
feeler gage at this common centerline. If there is
more than 0.005 inches (0.13 mm) of clearance,
replace rotor set.
NOTE: The rotor set (8) components may become disassembled

during service procedures. Marking the surface of the rotor
and stator that is facing UP, with etching ink or grease pen-
cil before removal from Torqlink™ will ensure correct reas-
sembly of rotor into stator and rotor set
intoTorqlink™.Marking all rotor components and mating
spline components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set
andTorqlink™.
NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets
of seven vanes (8C & 8E) as shown in the alternate con-
struction TG rotor set assembly view, check the rotor lobe
to roller vane clearance at both ends of rotor.
3121142 – JLG Lift – 3-85

12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output
not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur-
link for cracks and worn or damaged splines. No percep- faces for spalling, nicks, grooves, severe wear or corro-
tible lash (play) should be noted between mating spline sion and discoloration. Inspect for damaged or worn
parts. Remove and discard seal ring (4) from housing internal and external splines or keyway. Replace cou-
(18). pling shaft if any of these conditions exist.
13. Remove thrust bearing (11) from top of coupling shaft

(12). Inspect for wear, brinelling, corrosion and a full
complement of retained rollers.
NOTE: Minor shaft wear in seal area is permissible. If wear

exceeds 0.020 inches (0.51 mm) diametrically, replace cou-
pling shaft.
14. Check exposed portion of coupling shaft (12) to be sure
you have removed all signs of rust and corrosion which
NOTE: A slight “polish” is permissible in the shaft bearing areas.
might prevent its withdrawal through the seal and bear-
Anything more would require coupling shaft replacement.
ing. Crocus cloth or fine emery paper may be used.
16. 16. Remove and discard seal ring (4) from housing (18).
3-86 – JLG Lift – 3121142

17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and
Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is
ment of retained rollers. required.
18. Remove seal (16) and back up washer (17) from Small 20. Inspect housing (18) assembly for cracks, the machined
Frame, housing (18). Discard both. surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimen-
sional characteristics. Inspect tapped holes for thread
damage. If the housing is defective in these areas, dis-
card the housing assembly.
21. If the housing (18) assembly has passed inspection to

this point, inspect the housing bearings/bushings (19)
and (13) and if they are captured in the housing cavity
the two thrust washers (14) and thrust bearing (15). The
bearing rollers must be firmly retained in the bearing
cages, but must rotate and orbit freely. All rollers and
thrust washers must be free of brinelling and corrosion.
The bushing (19) or (13) to coupling shaft diameter
clearance must not exceed 0.010 inch (0.025 mm). A
bearing, bushing, or thrust washer that does not pass
inspection must be replaced. If the housing has passed
3121142 – JLG Lift – 3-87

this inspection the disassembly of the Torqlink™ is com- NOTE: The depth or location of bearing/bushing (13) in relation to
pleted. the housing wear plate surface and the depth or location
of bearing/bushing (19) in relation to the beginning of
bearing/bushing counter bore should be measured and
noted before removing the bearings/ bushings. This will
facilitate the correct reassembly of new bearings/bushings.
22. If the bearings, bushing or thrust washers must be

replaced use a suitable size bearing puller to remove
bearing/bushings (19) and (13) from housing (18) with-
out damaging the housing. Remove thrust washers (14)
and thrust bearing (15) if they were previously retained
in the housing by bearing (13).
3-88 – JLG Lift – 3121142

Assembly
Replace all seals and seal rings with new ones each time you
reassemble the Torqlink™ unit. Lubricate all seals and seal rings
with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal

kit are available. The parts should be available through
most OEM parts distributors or Parker approved Torqlink™
distributors. (Contact your local dealer for availability).
NOTE: Unless otherwise indicated, do not oil or grease parts

before assembly.
Wash all parts in clean petroleum-based solvents before NOTE: Bearing mandrel must be pressed against the lettered end
assembly. Blow them dry with compressed air. Remove any of bearing shell. Take care that the housing bore is square
paint chips from mating surfaces of the end cover, commuta- with the press base and the bearing/bushing is not cocked
tor set, manifold rotor set, wear plate and housing and from when pressing a bearing/bushing into the housing.
port and sealing areas.
IF THE BEARING MANDREL SPECIFIED IN THE “TOOLS AND MATERIALS

SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY REQUIRED FOR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE
SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE
DEATH. BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-
QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-
PONENTS WHEN ASSEMBLED.
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-
IMUM AIR PRESSURE REQUIREMENTS.
BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE
1. If the housing (18) bearing components were removed HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE
for replacement, thoroughly coat and pack a new outer REUSED.
bearing/bushing (19) with clean corrosion resistant
grease recommended in the material section. Press the
new bearing/bushing into the counterbore at the
mounting flange end of the housing, using the appro-
priate sized bearing mandrel, which will control the
bearing/ bushing depth.
Torqlink™ housings require the use of bearing mandrel

to press bearing/ bushing (19) into the housing to a
required depth of 0.151/0.161 inches (3.84/4.09 mm)
from the end of the bearing counterbore.
3121142 – JLG Lift – 3-89

2. The Torqlink™ inner housing bearing/bushing (13) can

now be pressed into its counterbore in housing (18)
flush to 0.03 inch (.76 mm) below the housing wear
plate contact face. Use the opposite end of the bearing
mandrel that was used to press in the outer bearing/
bushing (19).
3. Press a new dirt and water seal (20) into the housing (18)
outer bearing counterbore.
The Torqlink™ dirt and water seal (20) must be pressed in

until its’ flange is flush against the housing.
3-90 – JLG Lift – 3121142

4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15)
the coupling shaft bore down, clamping against the that was removed from the Torqlink™.
mounting flange.
NOTE: Torqlinks™ require one thrust washer (14) with thrust bear-
5. On the Torqlinks™ assemble a new backup washer (17) ing (15).The coupling shaft will be seated directly against
and new seal (16) with the seal lip facing toward the the thrust
inside of Torqlink™, into their respective counterbores in
housing (18) if they were not assembled in procedure 2. 7. Apply masking tape around splines or keyway on shaft
(12) to prevent damage to seal.
8. Be sure that a generous amount of clean corrosion resis-

tant grease has been applied to the lower (outer) hous-
ing bearing/bushing (19). Install the coupling shaft (12)
into housing (18), seating it against the thrust bearing
(15) in the housings.
ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE

BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A
NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
3121142 – JLG Lift – 3-91

9. Apply a small amount of clean grease to a new seal ring

(4) and insert it into the housing (18) seal ring groove.
THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC
FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED
GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT
#K-70M.
NOTE: Mobil Mobilith SHC ® 460
NOTE: A 102Tube (P/N 406010) is included in each seal kit.
NOTE: The coupling shaft (12) will be flush or just below the hous-
ing wear plate surface on Torqlinks™ when properly
seated. The coupling shaft must rotate smoothly on the
thrust bearing package.
NOTE: One or two alignment studs screwed finger tight into

housing (18) bolt holes, approximately 180 degrees apart,
will facilitate the assembly and alignment of components
as required in the following procedures.The studs can be
made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 inch (12.7
mm) longer than the bolts (1) used in the Torqlink™.
10. Install drive link (10) the long splined end down into the
coupling shaft (12) and engage the drive link splines
into mesh with the coupling shaft splines.
NOTE: Use any alignment marks put on the coupling shaft and
drive link before disassembly to assemble the drive link
splines in their original position in the mating coupling
shaft splines.
3-92 – JLG Lift – 3121142

11. Assemble wear plate (9) over the drive link (10) and NOTE: The rotor set rotor counterbore side must be down against
alignment studs onto the housing (18). wear plate for drive link clearance and to maintain the
original rotor-drive link spline contact. A rotor set without
a counterbore and that was not etched before disassembly
can be reinstalled using the drive link spline pattern on the
rotor splines if apparent, to determine which side was
down.The rotor set seal ring groove faces toward the wear
plate (9).
14. Apply clean grease to a new seal ring (4) and assemble it
in the seal ring groove in the rotor set contact side of
manifold (7).
12. Apply a small amount of clean grease to a new seal ring

(4) and assemble it into the seal ring groove on the wear
plate side of the rotor set stator (8B).
NOTE: The manifold (7) is made up of several plates bonded

together permanently to form an integral component.The
manifold surface that must contact the rotor set has it’s
series of irregular shaped cavities on the largest circumfer-
ence or circle around the inside diameter.The polished
impression left on the manifold by the rotor set is another
indication of which surface must contact the rotor set.
13. Install the assembled rotor set (8) onto wear plate (9)
with rotor (8A) counterbore and seal ring side down and
15. Assemble the manifold (7) over the alignment studs and
the splines into mesh with the drive link splines.
drive link (10) and onto the rotor set. Be sure the correct
manifold surface is against the rotor set.
NOTE: It may be necessary to turn one alignment stud out of the

housing (18) temporarily to assemble rotor set (8) or mani-
fold (7) over the drive link.
NOTE: If necessary, go to the appropriate, “Rotor Set Component

Assembly Procedure.”
3121142 – JLG Lift – 3-93

16. Apply grease to a new seal ring (4) and insert it in the
seal ring groove exposed on the manifold.
19. If shuttle valve components items #21, were removed

17. Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one
onto the manifold. end of the valve cavity in the end cover. A 3/16 inch
Allen wrench is required.
20. Assemble a new seal ring (4) into end cover (2) and
assemble end cover over the alignment studs and onto
the commutator set. If the end cover has only 5 bolt
holes be sure the cover holes are aligned with the 5
threaded holes in housing (18).The correct 5 bolt end
cover bolt hole relationship to housing port bosses.
18. Assemble a new seal ring (3) flat side up, into commuta-
tor (5) and assemble commutator over the end of drive
link (10) onto manifold (7) with seal ring side up.
3-94 – JLG Lift – 3121142

NOTE: If the end cover has a valve (24) or has five bolt holes, use
the line you previously scribed on the cover to radially align
the end cover into its original position.
21. Assemble the 5 or 7 special bolts (1) and screw in finger

tight. Remove and replace the two alignment studs with
bolts after the other bolts are in place. Alternately and NOTE: The special bolts required for use with the relief or shuttle
progressively tighten the bolts to pull the end cover and valve (24) end cover assembly (2) are longer than the bolts
other components into place with a final torque of 22-26 required with standard and cover assembly. Refer to the
ft. lbs. 45-55 ft. lbs.(61-75 N m) for the seven 3/8-24 individual service parts lists or parts list charts for correct
threaded bolts. service part number if replacement is required.
22. Torque the two shuttle valve plug assemblies (21) in end
cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so
equipped.
Torque the two relief valve plug assemblies (21) in end

cover assembly to 45-55 ft. lbs.(61-75 Nm) if cover is so
equipped.
3121142 – JLG Lift – 3-95

One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read-
ily assemble into the stator vane pockets.
A disassembled rotor (8A) stator (8B) and vanes (8C) that can-
not be readily assembled by hand can be assembled by the
following procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4)
side down, after following Torqlink™ assembly proce-
dures 1 through 13. Be sure the seal ring is in place.
EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD
SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.
5. Grasp the output end of coupling shaft (12) with locking

2. If assembly alignment studs are not being utilized, align pliers or other appropriate turning device and rotate
stator bolt holes with wear plate and housing bolt holes coupling shaft, drive link and rotor to seat the rotor and
and turn two bolts (1) finger tight into bolt holes the assembled vanes (8C) into stator (8B), creating the
approximately 180 degrees apart to retain stator and necessary clearance to assemble the seventh or full
wear plate stationary. complement of seven vanes. Assemble the seven vanes
using minimum force.
3. Assemble the rotor (8A), counterbore down if applica-
ble, into stator (8B), and onto wear plate (9) with rotor
splines into mesh with drive link (10) splines.
NOTE: If the manifold side of the rotor was etched during Torqlink
disassembly, this side should be up. If the rotor is not
etched and does not have a counterbore, use the drive link
spline contact pattern apparent on the rotor splines to
determine the rotor side that must be against the wear
plate. 6. Remove the two assembled bolts (1) if used to retain sta-
tor and wear plate.
3-96 – JLG Lift – 3121142

3.17 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque the capscrews (shown below) to 90 foot-
pounds (122 Nm) with Loctite #271.
1. Set backlash to 0.010 to 0.015" using the following pro-
cedure.
2. Place shim (JLG p/n 4071041) between pinion and bear-
ing on the bearing high spot. The bearing high spot
should be stamped with an "X" on the surface below the
teeth and marked with yellow paint in the tooth space.
3. Torque the shoulder screw (shown below) to 660 foot- 6. Tighten the setscrew (shown below) until the pinion is
pounds (896 Nm) with Loctite #271. completely snug against the shim and bearing and then
back off the setscrew.
4. Remove the turntable lock pin.

7. Torque the setscrew to 50 foot-pounds (68 Nm).
3121142 – JLG Lift – 3-97

8. Tighten the jam nut (shown below) with Loctite #271. The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API
Service Classification GL-5 Extreme Pressure Gear Lube. Fill to
cover the ring gear.
1.195 IN. (30.35 mm) TOP OF HOUSING TO TOP

OF RING GEAR. TO BE FILLED TO COVER RING
GEAR.
9. Torque the capscrews shown in step 5 to 660 foot-

pounds (896 Nm).
10. Remove shim and discard.
3.18 SWING DRIVE LUBRICATION

Figure 3-53. Swing Drive Lubrication
The Swing Brake is to be filled half full, 2.7 ounces (80 ml), with
DTE24 oil.
1 Brake Bleed Port

2 Brake Fill Port
3 Gearbox Fill Port
4 Gearbox Drain Port
Figure 3-52. Swing Drive Ports
3-98 – JLG Lift – 3121142

3.19 SWING BEARING c. Ensure that the 0.0015” feeler gauge will not pene-
trate under the bolt head to the bolt shank.
d. Swing the turntable 90 degrees, and check some
Turntable Bearing Mounting Bolt Condition selected bolts at the new position.
Check e. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
all quadrants.
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL 2. Check the turntable to bearing Attach bolts as follows:
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE a. Elevate the fully retracted main boom to full eleva-
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. tion.
b. At the position indicated on Figure 3-56. try to insert
NOTE: This check is designed to replace the existing bearing bolt the 0.0015” feeler gauge between the bolt head and
torque checks on JLG Lifts in service. This check must be hardened washer at the arrow indicated position.
performed after the first 50 hours of machine operation c. Lower the boom to horizontal and fully extend the
and every 600 hours of machine operation thereafter. If boom.
during this check any bolts are found to be missing or
loose, replace missing or loose bolts with new bolts and d. At the position indicated on Figure 3-55., try and
torque to the value specified in the torque chart, after insert the 0.0015” feeler gauge between the bolt
applying loctite #271 to the bolt threads. After replacing head and hardened washer at the arrow indicated
and retorquing bolt or bolts recheck all existing bolts for position.
looseness.
1. Check the frame to bearing attach bolts as follows:

a. Fully elevate the main boom. (See Figure 3-54.)
b. At the position indicated on Figure 3-54., try to
insert a 0.0015 feeler gauge between the bolt and
hardened washer at the arrow indicated position.
3121142 – JLG Lift – 3-99

BOOM
FULLY ELEVATED
FEELER GAUGE DIAL INDICATOR

MEASURING POINT MEASURING POINT
Figure 3-54. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2
3-100 – JLG Lift – 3121142

3121142
TELESCOPE
FULLY EXTENDED
– JLG Lift –
DIAL INDICATOR &
FEELER GAUGE
MEASURING POINT
Figure 3-55. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2
3-101
3. If the measurement is greater than 0.094 in. (2.387 mm),

the swing bearing should be replaced.
4. If the measurement is less than 0.094 in. (2.387 mm), and
any of the following conditions exist, the bearing should
be removed, disassembled, and inspected for the fol-
lowing:
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble and
Figure 3-56. Swing Bolt Feeler Gauge Check return to service.
Wear Tolerance Swing Bearing Removal

1. From the underside of the machine, at rear center, with 1. From Ground Control station, operate the boom ade-
the main boom fully elevated and fully retracted, as quately to provide access to frame opening to rotary
shown in Figure 3-54., Swing Bearing Tolerance Boom coupling.
Placement - Sheet 1 of 2, set up a magnetic base dial
indicator as shown below and set the indicator to 0
(zero).
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCK-
ING.
2. Attach an adequate support sling to the boom and draw

all slack from sling. Prop or block the boom if feasible.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS-
TEM.
3. Tag and disconnect the hydraulic lines from the fittings

on the top of the rotary coupling. Use a suitable con-
tainer to retain any residual hydraulic fluid. Immediately
cap lines and ports.
2. Next, position the main boom fully extended and hori-

zontal as shown in Figure 3-55., Swing Bearing Tolerance
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-
Boom Placement - Sheet 2 of 2. Read the measurement
CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS-
recorded on the dial indicator gauge.
TEM.
4. From inside turntable, remove mounting hardware

which attach rotary coupling retaining yoke brackets to
turntable.
3-102 – JLG Lift – 3121142

3121142
1350SJP Upperstructure - 30,250 lbs. (13,721 kg)
1200SJP Upperstructure - 26,150 lbs. (11,861 kg)
13” (33 cm)-1350SJP 18” (45 cm)-1200SJP
CENTER
OF
GRAVITY
– JLG Lift –
C
L ROTATION
Figure 3-57. Swing Bearing Removal
3-103
5. At the rear of the main valve, remove the lift hose from Swing Bearing Installation
port #4. Immediately cap the line and port.
NOTE: The swing bearing weighs approximately 300 lbs. (136 kg).
BACK OF VALVE 1. Using suitable lifting equipment, carefully lower the

swing bearing into position on the frame. Ensure the
scribed line of the outer race of the bearing aligns with
the scribed line on the frame. If a new swing bearing is
used, ensure that the spot with minimum gear backlash
(marked with yellow paint) is towards the centerline of
the swing drive (as close as the bolt pattern will allow).
JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS-

CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE
ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPER-
ATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS.
USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
6. Attach suitable overhead lifting equipment to the
machine. Refer to Figure 3-57., Swing Bearing Removal. 2. Apply a light coating of Loctite #271 to the new bearing
bolts, and loosely install the bolts and washers through
7. Use a suitable tool to scribe a line on the inner race of the frame and outer race of bearing.
the swing bearing and on the underside of the turnta-
ble. This will aid in aligning the bearing upon installa-
tion. Remove the bolts and washers which attach the
turntable to the bearing inner race. Discard the bolts. IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED
FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING
8. Use the lifting equipment to carefully lift the complete ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.
turntable assembly from the bearing. Ensure that no
damage occurs to the turntable, bearing or frame-
mounted components.
9. Carefully place the turntable on a suitably supported
trestle.
NOTE: The swing bearing weighs approximately 300 lbs. (136 kg).
10. 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 installation. Remove the bolts
and washers which attach the outer race of the bearing
to the frame. Discard the bolts. Use suitable lifting
equipment to remove the bearing from the frame, then
move the bearing to a clean, suitably supported work
area.
3-104 – JLG Lift – 3121142

3. Refer to the Torque Sequence diagram as shown in Fig- 9. Connect the hydraulic lines to the rotary coupling as
ure 3-58., Swing Bearing Torque Sequence. Spray a light tagged prior to removal.
coat of Safety Solvent 13 on the new bearing bolts. Then
10. Install the rotary coupling retaining yoke brackets, apply
apply a light coating of Loctite #271 to the new bearing
a light coating of Loctite #242 to the attaching bolts and
bolts, and install the bolts and washers through the
secure the yoke to the turntable with the mounting
frame and outer race of the bearing. Tighten the bolts to
hardware.
an initial torque of 190 ft. lbs. (258 Nm) w/Loctite.
11. Connect the hydraulic line disconnected during removal
4. Remove the lifting equipment from the bearing.
back to port #4 on the back of the main hydraulic valve.
5. Using suitable lifting equipment, carefully position the
12. Remove the lifting equipment.
turntable assembly above the machine frame.
13. At ground control station, use boom lift control to lower
6. Carefully lower the turntable onto the swing bearing,
boom to stowed position.
ensuring that the scribed line of the inner race of the
bearing aligns with scribed line on the turntable. If a 14. Using all applicable safety precautions, activate the
new swing bearing is used, ensure that the filler plug fit- hydraulic system and check the swing system for proper
ting is at 90 degrees from the fore and aft center line of and safe operation.
the turntable.
7. Spray a light coat of Safety Solvent 13 on the new bear- Swing Bearing Torque Values
ing bolts. Then apply a light coating of Loctite #271 to
1. Outer Race - 190 ft. lbs. (258 Nm) w/Loctite.
the new bearing bolts, and install the bolts and washers
through the turntable and inner race of the bearing. 2. Inner Race - 190 ft. lbs. (258 Nm) w/Loctite.
8. Following the Torque Sequence diagram shown in Fig- 3. See Swing Bearing Torquing Sequence.
ure 3-58., Swing Bearing Torque Sequence, tighten the
bolts to a torque of 190 ft. lbs. (258 Nm) w/Loctite.
CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR
LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS
THEREAFTER.
3121142 – JLG Lift – 3-105

NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races.
Figure 3-58. Swing Bearing Torque Sequence
3.20 SWING SPEED PROPORTIONING Beyond Transport - Drive Speed Cutback System, the tilt sen-
sor will cause an alarm to sound, and automatically put all
Swing Speed Proportioning uses the boom length and angle functions in the creep speed mode. With the exception of the
sensors to improve the comfort, speed and control of the turn- speed cutback, this is a warning system only. The machine will
table swing function. Turntable swing speed is increased as continue to function. The operator is responsible to prevent
the distance of the platform to the center of rotation is the machine from attaining an unstable position. The 8.0
decreased. This results in approximately constant platform degree angle is used exclusively for the purpose of automati-
speeds regardless of boom position. Swing speed proportion- cally shifting the drive motors to the maximum displacement
ing is disabled with any envelope sensors failure. Disabling of position (slow speed). The control system responds to indi-
swing speed proportioning will default to the slowest swing cated angle readings 0.5 degrees smaller than the required
speed setting. angles to account for calibration and sensor variation.
NOTE: For more detailed information concerning system adjust- NOTE: For more detailed information concerning system adjust-
ment and operation, refer to Section 6 - JLG Control Sys- ment and operation, refer to Section 6 - JLG Control Sys-
tem. tem.
3.21 CHASSIS TILT INDICATOR SYSTEM

The Chassis Tilt Indicator System measures the turntable angle
with respect to level ground. The tilt sensor (which is an inte-
gral part of the ground module) has two settings; 5.0 and 8.0
degrees. The smaller angle is used for the purpose of warning
the operator by means of the chassis tilt light in the platform
display panel. Additionally when used in conjunction with the
3-106 – JLG Lift – 3121142

3.22 ROTARY COUPLING 6. Reassemble O-ring (4).
Use the following procedure to for installing the seal kit. 7. Heat cap seals (5) in hydraulic oil for 5 minutes at 300° F
(149° C).
1. Remove snap ring (7) from end.
8. Assemble cap seals over O-rings
2. Remove thrust ring (3) from same end.
9. Reinsert center body into housing (lube with hydraulic
3. Remove center body (1) from housing (3). oil).
4. Cut off old seals (2,3,5). 10. Replace thrust ring and snap ring.
5. Assemble lip seals (2) in direction shown in Figure 3-59.,
Rotary Coupling Seal Installation.
Figure 3-59. Rotary Coupling Seal Installation
3121142 – JLG Lift – 3-107

1. Center Body 5. Seal

2. Seal 6. Thrust Ring
3. Housing 7. Snap Ring
4. O-ring
Figure 3-60. Rotary Coupling Cutaway
3-108 – JLG Lift – 3121142

5 1,2
6 8
8
1,9
8
5A
5B
1. Loctite #242 5B. Rotary Circuit Contactor

2. Bolt 6. Locknut
3. Bolt 7. Not Used
4. Swivel Bracket 8. Flatwasher
5. Rotary Coupling & Collector Ring Assembly 9. Nut
5A. Rotary Coupling
Figure 3-61. Rotary Coupling Installation
3121142 – JLG Lift – 3-109

6
2 1
6
4
7 1
5
4 2
5 3
1 2
3
1
2 1
3 2
3
4
5
6
7 7 7
Figure 3-62. Rotary Coupling Port Location
3-110 – JLG Lift – 3121142

Every 500 hours

Table 3-6. Coupling Port Information Table
Every 500 hours of operation, service the generator brushes
Operating Proof and slip rings. Hostile environments may require more fre-
Port Port quent service.
Outlets Description Pressure Pressure
No. Size
PSI (Bar) PSI (Bar)
1 2 -12 Steer/Axle Extend 250 (17) 375 (26)
(Tank)
2 2 -10 Steer/Axle Extend (Pres- 3000 (207) 4500 (310)
sure)
3 1 -10 Drive A 3000 (207) 4500 (310)
4 1 -10 Drive B 3000 (207) 4500 (310)
5 1 -10 Drive A 3000 (207) 4500 (310)
6 1 -10 Drive B 3000 (207) 4500 (310) Every 500 hours of service, blow out the inside of the genera-
7 2 -12 Case Drain 250 (17) 375 (26) tor. If operating in a hostile environment, clean monthly.
3.23 GENERATOR
Every 250 hours
Every 250 hours of operation, check the drive belt for proper
tension.
1/2 in.
(13 mm)
3121142 – JLG Lift – 3-111

Overload Protection Inspecting Brushes, Replacing Brushes, and

Cleaning Slip Rings
Refer to Figure 3-63., Inspecting Generator Brushes, Replacing
STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes, and Cleaning Slip Rings.
BREAKER.
INSPECTING BRUSH POSITION
The circuit breaker protects the generator windings from over-
load. If the circuit breaker opens, generator output stops. If the Inspect brush alignment with slip rings. View alignment
circuit breaker continues to open, check for faulty equipment through the air vents in the stator barrel. The brushes must
connected to the platform receptacles. ride completely on the slip rings.
INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the brush
holder assembly. Pull the brushes from the holders.
Replace the brushes if damaged, or if the brush is at or near

minimum length.
CLEANING SLIP RINGS
CIRCUIT
BREAKER Visually inspect the slip rings. Under normal use, the rings turn
dark brown.
If the slip rings are corroded or their surface is uneven, remove

the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little
material as possible. If the rings are deeply pitted and do not
clean up, consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.
3-112 – JLG Lift – 3121142

Brush Position On Slip Rings
2
3
Acceptable Unacceptable
Brushes must ride
completely on slip
rings
1/4 in (6 mm)
Or Less - Replace
7/16 in - 1/2 in
2 (11 - 12 mm) New
1. Brush Holder Assembly

2. Brushes
3. Slip Rings
Figure 3-63. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3121142 – JLG Lift – 3-113

3.24 AUXILIARY POWER SYSTEM ity. The auxiliary power lift down function supplies pilot pres-
sure to the lift cylinder allowing gravity to lower the boom.
The auxiliary power system is intended as a secondary means The system redirects discharge oil from the lift cylinder to
of moving the boom in the event of primary power loss. This retract the telescope cylinder. When the boom is retracted to
system uses an electric motor/pump unit powered by a 12V the transport length, the telescope in valve is dropped out and
battery capable of operating all functions except drive, con- lift down is operated alone allowing the platform to reach the
trolled arc, controlled boom angle, and envelope tracking. ground. This not only greatly reduces the power required for
During lift up or down functions, no other functions are per- these functions but also lowers the boom within the envelope
mitted and during lift up functions, automatic platform level- regardless of starting position. Envelope control and moment
ing is not active. To reduce the demand on the battery and control remain active during the auxiliary power function.
therefore extend the run time of the system, the auxiliary
power functionality differs from the primary power functional-
1. Auxiliary Pump
2. Power Relay
3. Battery
Figure 3-64. Auxiliary Pump Installation
3-114 – JLG Lift – 3121142

HYDRAULIC OIL
TANK HEATER CABLE
BATTERY HEATER CABLE
BATTERY HEATER CABLE
BATTERY
REF AUX PUMP
BATTERY HEATER BATTERY HEATER
VIEW A-A
A A
B B
TANK HEATER
VIEW B-B
Figure 3-65. Cold Weather Package
3121142 – JLG Lift – 3-115

3.25 COLD WEATHER PACKAGE Check the oil level, and if necessary, top the oil level up
to the MAX mark with an approved grade and type of
As an option, a cold weather package is available to allow the oil as outlined in the engine manufacturer’s opera-
machine to be operated in lower temperatures. The package tor’s manual. Refer to Figure 3-66., Deutz Engine Dip-
consists of battery heaters, a hydraulic tank heater, Exxon Uni- stick.
vis hydraulic oil, and diesel fuel conditioner. See Figure 3-65.,
Cold Weather Package.
MINIMUM OIL
3.26 ENGINE LEVEL
NOTE: Refer to the engine manufacturer’s manual for detailed

operating and maintenance instructions.
Glow Plugs MAXIMUM OIL

If the glow plug option is enabled in the JLG Control System, LEVEL
the glow plug and indicator lamp will be energized when the
Power/Emergency Stop switch is pulled on if the ambient air
temperature is less than 50° F (10° C) and the engine coolant
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has
been pulled on. The lamp and glow plugs will remain ener-
gized for the period of time specified by the setting in the JLG MINIMUM LEVEL,
Control System. Engine start shall be disabled during this OIL HOT
MAXIMUM LEVEL,
period. On Deutz engines, the glow plugs will continue (post OIL HOT
glow) after the engine has started for three times the machine
digit setting.
MINIMUM LEVEL,
Checking Oil Level OIL COLD
MAXIMUM LEVEL,
1. Switch the engine off before checking oil level. OIL COLD
NOTE: Hot oil checks should not be made until the engine
2. Make sure the machine and engine are level. has been shut down for a period of 5 minutes.
3. Remove the oil dipstick.

Figure 3-66. Deutz Engine Dipstick
4. Wipe the dipstick with non-fibrous, clean cloth.
6. Replace the dipstick making sure that it is fully seated in
5. Insert the dipstick to the stop and remove again.
the dipstick tube to seal off the crankcase.
Changing Engine Oil

1. Allow the engine to warm up. The engine oil should
reach approximately 176° F (80° C).
2. Make sure the machine and engine are level.
3. Switch off the engine.
4. Place an oil tray under the engine.
3-116 – JLG Lift – 3121142

5. Open the oil drain valve. Changing the Oil Filter
WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING. 1. Wipe the area around the filter to clean any dirt from the
area.
2. Using a suitable oil filter removal tool, loosen the lube oil
DO NOT LET USED OIL RUN INTO THE SOIL; COLLECT THE USED OIL IN A CON- filter cartridge and spin off.
TAINER SUITABLE FOR DISPOSAL OR RECYCLING. DISPOSE OF THE USED
ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
6. Drain the oil.

7. Close the oil drain valve.
8. Pour in new engine oil. Refer to Section 1 for capacity
and refer to Figure 3-67., Engine Oil Viscosity for the
proper grade.
3. Catch any escaping oil.

4. Clean any dirt from the filter carrier sealing surface.
5. Lightly oil the rubber gasket on the new oil filter.
Figure 3-67. Engine Oil Viscosity
3121142 – JLG Lift – 3-117

6. Manually screw in the new filter until the gasket is flush. 8. Open the fuel shut-off valve.
9. Check for leaks.
Cleaning the Fuel Strainer
7. Tighten the filter another half-turn.

8. Check the oil level.
9. Check the oil pressure.
10. Check the oil filter cartridge and make sure there are no
leaks.
Replacing the Fuel Filter WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE
FUEL SYSTEM.
1. Unscrew the hexagonal nut (1).
WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE
FUEL SYSTEM.
1. Wipe the area around the filter to clean any dirt from the
area.
2. Undo the fuel filter cartridge and spin off. 2. Remove the fuel strainer cover (2).
3. Catch any escaping fuel. 3. Clean the fuel strainer with diesel fuel, replace if neces-
sary.
4. Clean any dirt from the filter carrier sealing surface.
4. Place the seal (3) in position.
5. Apply a light film of oil or diesel fuel to the rubber gas-
ket of the new filter cartridge. 5. Install the fuel strainer cover (2) in position and tighten
the hexagonal screw (1).
6. Manually screw in the new filter until the gasket is flush.
6. Check for leaks.
7. Tighten the fuel filter cartridge with a final half-turn.
3-118 – JLG Lift – 3121142

3.27 DEUTZ EMR 2 (S/N 87579 TO PRESENT) The EMR2 is equipped with safety devices and measures in the
hardware and software in order to ensure emergency running
NOTE: S/N 87532 also incorporates EMR2. S/N 87765 incorporates (Limp home) functions.
old Engine controls.
In order to switch the engine off, the EMR2 is switched in a de-
energized fashion over the ignition switch. A strong spring in
The EMR2 consists of the sensors, the control unit and the
the actuator presses the control rod in the de-energized con-
actuator. Engine-side controls as well as the JLG Control Sys-
dition into the zero position. As a redundancy measure, an
tem are connected by means of separate cable harnesses to
additional solenoid serves for switching off and this, indepen-
the EMR control unit.
dently of the actuator, also moves the control rod in the de-
The sensors attached to the engine provide the electronics in energized condition into the zero position.
the control unit with all the relevant physical parameters In
After the programming, that is carried out over the ISO9141
accordance with the information of the current condition of
interface, the EMR2 is possesses a motor-specific data set and
the engine and the preconditions (throttle position etc.), the
this is then fixedly assigned to the engine. Included in this are
EMR2 controls an actuator that operates the control rod of the
the various application cases as well as the customer’s wishes
injection pump and thus doses the fuel quantity in accordance
regarding a particular scope of function.
with the performance requirements.
Each EMR2 module is matched by serial number to the engine.
The exact position of the regulating rod is reported back and,
Modules cannot be swapped between engines.
if necessary, is corrected, by means of the control rod travel
sensor, situated together with the rotation magnets in a hous-
ing of the actuator.
3121142 – JLG Lift – 3-119

CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE FLYWHEEL SPEED

SENSOR SENSOR
JLG SYSTEM HANDLES ENGINE START/STOP; EMR2

TAKES CONTROL OF THE ENGINE AT 700RPM
GLOW PLUG
JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS

OIL PRESSURE TO CONTROL THE ENGINE & FAULT REPORTING.
SENSOR
Figure 3-68. EMR 2 Engine Side Equipment
3-120 – JLG Lift – 3121142

Deutz EMR2;
3121142
Fails to Start/
Runs Abnormally
Does the machine Add fuel or

have fuel and a NO replace/
charged battery? recharge
battery.
YES
The starter and/
Connect or starter solenoid
Verify the needs replaced
JLG starter relay
Analyzer is getting
12V when
the start
Cycle Power YES switch is YES
engaged.
Unplug the vehicle NO
side engine module
Are there any Does the fault connector. Verify On the analyzer, are
faults listed since indicate the engine there is 12V across Can you start there faults indicating Does the
the power was YES module is not YES pins 1 (Ground) & 14 the engine? NO Cycle Power NO starter crank?
(Battery +). Verify an open circuit on
cycled? detected? the starter relay?
there is 60 Ohms
across pins 12 & 13
NO (CAN High & Low)
YES
NO
Does the
engine operate YES
– JLG Lift –
correctly?
The EMR2 needs
NO replaced.
Contact
Deutz
Service
Department
Connect Does the fault

Laptop to Replace/Repair
use Deutz indicate a Deutz the faulty
Diagnostic NO fault code YES wiring/
Software number? component(s)
YES
Does the
diagnostic software
indicate a problem?
Figure 3-69. Deutz EMR 2 Troubleshooting Flow Chart
3-121
3-122
– JLG Lift –
Figure 3-70. Deutz EMR 2 Vehicle Side Connection Diagram
3121142
3121142
– JLG Lift –
Figure 3-71. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3-123
3-124
– JLG Lift –
Figure 3-72. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3121142
Figure 3-73. EMR 2 Engine Plug Pin Identification
3121142 – JLG Lift – 3-125

Figure 3-74. EMR 2 Vehicle Plug Pin Identification
3-126 – JLG Lift – 3121142

Figure 3-75. EMR2 Fault Codes - Sheet 1 of 5
3121142 – JLG Lift – 3-127

3-128 – JLG Lift – 3121142

3121142 – JLG Lift – 3-129

3-130 – JLG Lift – 3121142

3121142 – JLG Lift – 3-131

3.28 BIO FUEL IN DEUTZ ENGINES The use of US bio-diesel based on soy oil methylester is only
permissible in mixtures with diesel fuel with a bio-diesel part of
a max. 20 weight-%. The US bio-diesel used for the mixture must
General
comply with the ASTM D6751-07a (B100) standard.
Use of bio fuels is permitted for the compact engines made by
APPROVED ENGINES
DEUTZ.
The 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and
Distillate fuels with residue oil percentages or mixed fuels may 513 series are approved for bio-diesel from year of manufac-
not be used in DEUTZ compact engines. ture 1993 under compliance with the basic conditions speci-
The DEUTZ vehicle engines are designed for diesel fuels in fied below.
accordance with EN 590 with a cetane number of at least 51. BASIC CONDITIONS TO BE OBSERVED
DEUTZ engines for mobile machinery are designed for a cetane
number of at least 45. When using fuels of a low cetane num- • A power loss of 5-9 % in relation to diesel fuel in accor-
ber, disturbing white smoke and ignition misfires are to be dance with EN 590 is possible due to the lower heating
expected under some circumstances. value. Blocking of the fuel injector is not allowed.
• The lubricating oil quality must correspond to TR 0199-
A cetane number of at least 40 is permissible for the US market,
99-3002. The lubricating oil change interval must be
therefore special engine models have been developed to
halved in relation to operation with diesel fuel in accor-
avoid starting difficulties, extreme white smoke or increased
dance with EN 590.
hydrocarbon emissions (EPA specification - US EPA REGULA-
TIONS FOR LARGE NONROAD COMPRESSION-IGNITION • Standstills of longer than 4 to 6 weeks must be avoided
ENGINES). with bio-diesel. Otherwise the engine must be started and
stopped with diesel fuel.
If the white smoke behavior is unacceptable when using a very
low cetane number, the use of ignition improvers is to be rec- • Bio-diesels can be mixed with normal diesel fuel but the
ommended as a later remedial measure. basic conditions described in this subsection apply for mix-
tures. Mixtures with up to 5 % (m/m) bio-diesel (B5) which
The certification measurements for compliance with the legal have recently been on sale at European fuel stations are
emission limits are carried out with the test fuels prescribed by excepted. These fuels must be treated like normal diesel
law. These correspond to the diesel fuels in accordance with fuels because EN 590 expressly permits adding up to 5 %
EN 590 and ASTM D 975. No emission values are guaranteed (m/m) bio-diesel in accordance with EN 14214.
with the other fuels described. It is the obligation of the owner
to check the permission for use of the fuels in accordance with • Approx. 30-50 hours after changing over from diesel fuel to
regional regulations. bio-diesel, the fuel filter should be changed as a preventive
measure to avoid a drop in performance due to clogged fuel
Bio Fuel filters. Deposited fuel ageing products are dissolved by bio-
diesel and transported into the fuel filter. They should not
PERMITTED BIO-DIESEL FUELS be changed immediately but after approx. 30 to 50 hours
Originally only rape seed oil methylester (RME) was sold as a because the dissolving of dirt takes a certain amount of
bio-diesel fuel in Europe but fatty acid methylester (FAME) time.
based on other oils have come onto the market increasingly in
recent years. However, with the latter there is a risk that the limit
values of EN 14214 are not kept in the field. Anyone who uses
bio-diesel fuel in DEUTZ engines must therefore choose his
supplier very carefully and have him guarantee compliance
with the EN 14214 limit values. Since experience has shown
that rape seed oil methylester (RME) exceeds the limit values
less often that other esters, it is expressly recommended to use
only rape seed oil methyester. DEUTZ customers in Germany
can additionally ensure the quality by buying bio-diesel fuel
with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Man-
agement Biodiesel e.V.).
3-132 – JLG Lift – 3121142

PLANT OIL PREVENTIVE MEASURES

• Keep the storage tank clean, regular cleaning of the tank
by specialist companies
PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS • Installation of fuel pre-filters with water traps, especially in
BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPER- countries with frequently fluctuating fuel qualities and high
ATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH percentage of water.
VISCOSITY, POOR EVAPORATION BEHAVIOR.
If the fuel system and storage tank have already been attacked
The conversion of DEUTZ engines to rape seed oil fuel opera- by micro-organisms. The biocide must be dosed according to
tion with conversion kits and modified tanks systems of vari- the manufacturer's specifications.
ous manufacturers is not allowed and leads to loss of warranty • Avoid direct exposure of the storage tank to sunlight
rights.
• Use smaller storage tanks with corresponding low dwell
Biological Contamination In Fuels times of the stored fuel
FUEL ADDITIVES
SYMPTOMS
The use of fuel additives is not permitted. The flow improvers
The following symptoms may indicate that a fuel tank is con-
mentioned above are an exception. Use of unsuitable additives
taminated by micro-organisms:
will result in loss of warranty.
• Internal tank corrosion,
• Filter blockage and the associated loss of power due to gel-
like deposits on the fuel filter (especially after long stand-
stills)
CAUSE
Micro-organisms (bacteria, yeasts, funguses) can form bio-
sludge under unfavorable conditions (favoured particularly by
heat and water).
Penetration by water is usually caused by condensation of the
water in the air. Water does not dissolve in fuel so that the pene-
trating water collects at the bottom of the tank. The bacteria and
funguses grow in the watery phase, at the phase boundary to
the fuel phase, from which they draw their nutrition. There is an
increased risk especially with bio-diesel (FAME).
3121142 – JLG Lift – 3-133

3.29 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE This section is organized in the following manner:
CODE DEFINITIONS 1st page of Diagnostic Information for a Given Fault (See Fig-
ure 3-80.) then:
This section defines the diagnostics and recommended trou-
bleshooting procedures associated with the engine control 2nd Page of Diagnostic Information for a Given Fault (See Fig-
module (ECM) on the CAT 3.4 engine. ure 3-81.)
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 3-80. 1st page of Diagnostic Information for a Given Fault
3-134 – JLG Lift – 3121142

DTC XXXX- Diagnostic Condition
Note: Helpful tips used to aid troubleshooting
Yes
Troubleshooting flow
chart
No
Figure 3-81. 2nd Page of Diagnostic Information for a Given Fault
3121142 – JLG Lift – 3-135

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
3-136 – JLG Lift – 3121142

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
LDGCP Light-Duty Global Control Platform (Industrial, Smart/Logic Coil)
3121142 – JLG Lift – 3-137

Diagnostic Trouble Codes Resetting active and previously active DTCs is handled
through DM11 and DM3, respectively DM1 and DM2 lamp
The numeric diagnostic trouble codes assigned to the faults in
indicators are assigned to each fault based on the fault.s diag-
this section are cross-referenced to SAE’s "Recommended
nostic action as defined in the calibration. The lamps are
Practice for Diagnostic Trouble Code Definitions" (SAE J2012).
assigned based on the configuration outlined in Table 3-7.
While these codes are recommended, the manufacturer may
define their own codes by assigning a new number to the flash
code in the diagnostic calibration. This will assign both the Table 3-7. J1939 Diagnostic Lamp Configuration
DTC as displayed in EDIS as well as the flash code output on
the MIL output pin. EDIS may be used to connect to the DGC ECI DIAGNOSTIC ACTION J1939 LAMP
ECM via CAN.
MIL MIL
CAN
Soft Warning Amber
The DGC supports SAE J1939 CAN based diagnostic support.
This includes: Hard Warning, Low Rev Limit, Shutdown Red Stop
• DM1: Active Diagnostic Trouble Codes
Power Derate 1 & 2 Protect
• DM2: Previously Active Diagnostic Trouble Codes
• DM3: Diagnostic Data Clear/Reset of Previously Active None (use in combination with other
Forced Idle
DTCs action)
• DM4: Freeze Frame Parameters

• DM5: Diagnostic Readiness (bytes 1, 2, and 3 are sup-
MIL Output
ported) The MIL output is used to convey fault information to the
equipment operator. The MIL is always on (grounded) when
• DM11: Diagnostic Data Clear/Reset For Active DTCs the system is in a key-on (Vsw), engine-off state. This provides
• DM12: Emissions-Related Active Diagnostic Trouble Codes assurance that the output is functional. If a DTC is logged as
previously-active (historic), the MIL will send a single flash for
• DM19: Calibration Information the “Blink on-time” every “Blink off-time.”
All diagnostic trouble codes broadcast over CAN will be SAE
J1939 DM1 and DM2 formatted messages. DGC ECMs are com-
pliant with J1939 OBD-M, supporting the 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 applica-
tion and engine calibration. There are 4 CAN SPN/FMI lists
available in the DGC software 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 configured in the
ECM software:
• Byte 1: Freeze Frame Length
• Byte 2-6: SPN, FMI, SPN Conversion Method, and Occur-
rence
• 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
• Byte 15: Index into FSS_storage table for Fault Snap Shot
retrieval
3-138 – JLG Lift – 3121142

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 trou-
• Fault Condition-Engine Coolant Temperature reading or bleshooting procedures for that fault as it may have caused
estimate greater than the stage 1 limit when operating at a "ECT Higher Than Expected 1."
speed greater than defined in the diagnostic calibration If the cooling system utilizes an air-to-water heat exchanger
• Corrective Action(s): Sound audible warning or illuminate (radiator) and fan:
secondary warning lamp, disable adaptive learn fueling
• Check that the radiator has a proper amount of ethylene
correction during active fault. Recommend a power derate
glycol/water and that the radiator is not leaking
1/2 and/or a low rev limit to protect engine from possible
damage. • Ensure that there is no trapped air in the cooling path
• Non-emissions related fault • Inspect the cooling system (radiator and hoses) for cracks
and ensure connections are leak free
The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in the engine coolant. • Check that the fan is operating properly
Some engines use a CHT sensor that is located in the coolant • Check that the thermostat is not stuck closed
in the cylinder head. Some engines use an ECT (Engine Cool-
ant Temperature) sensor that is located in the coolant near the If the cooling system utilizes a water-to-water heat exchanger:
thermostat. If the engine is equipped with a CHT sensor then • Check that the heat exchanger has a proper amount of eth-
the ECT value is estimated. If equipped with an ECT sensor ylene glycol/water and that the heat exchanger is not leak-
then the CHT value is estimated. They are used for engine air- ing
flow calculation, ignition timing control, to enable certain fea-
tures, and for engine protection. The ECM provides a voltage • Ensure that there is no trapped air in the cooling path
divider circuit so when the sensor reading is cool the sensor • Inspect the cooling system (radiator and hoses) for cracks
reads higher voltage, and lower when warm. and ensure connections are leak free
This fault will help protect the engine in the event of over tem- • Check that the raw water pickup is not blocked/restricted
perature. When the coolant exceeds x deg. F and engine RPM by debris and that the hose is tightly connected
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
3121142 – JLG Lift – 3-139

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 will
• Fault Condition-CHT/ECT sensor voltage less than the limit use a default value for the CHT/ECT sensor in the event of this
defined in the diagnostic calibration fault.
• Corrective Action(s)- Sound audible warning or illuminate
correction during active fault, or any combination 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
perature sensitive resistor) located in the engine coolant.
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 cylin-
der 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 estimated. The ECM provides a voltage divider
circuit so that when the coolant is cool, the signal reads higher
voltage, and lower when warm.
3-140 – JLG Lift – 3121142

· 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
3121142 – JLG Lift – 3-141

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 4.90 VDC. In
• Fault Condition-CHT/ECT sensor voltage higher than the many cases, this condition is caused by the CHT/ECT sensor
limit defined in the diagnostic calibration being disconnected from the engine harness, an open-circuit
• Corrective Action(s)- Sound audible warning or illuminate or short-to-power of the CHT/ECT circuit in the wire harness,
secondary warning lamp, disable adaptive learn fueling or a failure of the sensor. The ECM will use a default value for
correction during active fault, or any combination thereof the CHT/ECT sensor in the event of this fault.
as defined in calibration. Recommend a power derate 1/2
to reduce the possibility of engine damage due to the
inability to sense temperature.
perature sensitive resistor) located in the engine coolant.
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 cylin-
der 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 estimated. The ECM provides a voltage divider
circuit so that when the coolant is cool, the signal reads higher
voltage, and lower when warm.
3-142 – JLG Lift – 3121142

3121142 – JLG Lift – 3-143

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 condition while the engine is cranking or running. The limit is
generally set to 4.90 VDC. In many cases, this condition is
• Check Condition-Key On, Engine Off
caused by the TPS sensor being disconnected from the engine
• Fault Condition-TPS1 sensor voltage lower than the limit harness, an open-circuit or short-to-ground of the TPS circuit
defined in the diagnostic calibration in the wire harness, or a failure of the sensor. This fault should
• Corrective Action(s): Sound audible warning or illuminate be configured to trigger an engine shutdown and the engine
secondary warning lamp, shutdown engine will not start with this fault active.

In the case of a diesel engine, an actuator controls a fuel injec-
tion pump, directly affecting the fueling level into the cylin-
ders. 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, refer-
ences to the throttle and throttle position sensor refer to these
fuel injection pump control actuators and their position feed-
back sensors. When the fuel injection 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 actu-
ator position, and is located within the throttle actuator.
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 ana-
log return signal between 0 and 5 volts that is proportional 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.
This fault will set if TPS1 voltage is lower than the low voltage
limit as defined in the diagnostic calibration at any operating
3-144 – JLG Lift – 3121142

3121142 – JLG Lift – 3-145

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 ana-
log position feedback and 2) actuator with digital position
• Check Condition-Key On, Engine Off
feedback. The first type, with analog position feedback, pro-
• Fault Condition-TPS1 sensor voltage higher than the limit vides an analog return signal between 0 and 5 volts that is pro-
defined in the diagnostic calibration portional to the throttle actuator position. The second type,
• Corrective Action(s): Sound audible warning or illuminate with digital position feedback, provides a serial data signal to
secondary warning lamp, shutdown engine 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
In the case of a diesel engine, an actuator controls a fuel injec- the diagnostic calibration at any operating condition while the
tion pump, directly affecting the fueling level into the cylin- engine is cranking or running. The limit is generally set to 4.90
ders. This may be by direct manipulation of the fuel injection VDC. In many cases, this condition is caused by a short-to-
pump rack or by manipulation of the mechanical governor power of the TPS circuit in the wire harness or a failure of the
control level or "throttle arm." In the DGC ECM and EDIS, refer- sensor. This fault should be configured to trigger an engine
ences to the throttle and throttle position sensor refer to these shutdown and the engine will not start with this fault active.
fuel injection pump control actuators and their position feed-
back sensors. When the fuel injection pump is electronically
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 actu-
ator position, and is located within the throttle actuator.
3-146 – JLG Lift – 3121142

3121142 – JLG Lift – 3-147

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 trou-
• Fault Condition-Engine Coolant Temperature reading or bleshooting procedures for that fault as it may have caused
estimate greater than the stage 2 limit when operating at a "ECT Higher Than Expected 2."
speed greater than defined in the diagnostic calibration
If the cooling system utilizes an air-to-water heat exchanger
• Corrective Action(s)- Sound audible warning or illuminate
(radiator) and fan:
correction during active fault. Recommend a power derate • Check that the radiator has a proper amount of ethylene
2 and/or a forced idle or engine shutdown to protect glycol/water and that the radiator is not leaking
engine from possible damage. • Ensure that there is no trapped air in the cooling path
• Non-emissions related fault • Inspect the cooling system (radiator and hoses) for cracks
The Engine Coolant Temperature sensor is a thermistor (tem- and ensure connections are leak free
perature sensitive resistor) located in the engine coolant. • Check that the fan is operating properly
Some engines use a CHT sensor that is located in the coolant
in the cylinder head. Some engines use an ECT (Engine Cool-
ant Temperature) sensor that is located in the coolant near the If the cooling system utilizes a water-to-water heat exchanger:
thermostat. If the engine is equipped with a CHT sensor then • Check that the heat exchanger has a proper amount of eth-
the ECT value is estimated. If equipped with an ECT sensor ylene glycol/water and that the heat exchanger is not leak-
then the CHT value is estimated. The ECM provides a voltage ing
divider circuit so when the sensor reading is cool the sensor
reads higher voltage, and lower when warm. • Ensure that there is no trapped air in the cooling path
• Inspect the cooling system (radiator and hoses) for cracks
This fault will help protect the engine in the event of over tem- and ensure connections are leak free
perature. When the coolant exceeds x deg. F and engine RPM
exceeds y RPM for the latch time this fault will set. • Check that the raw water pickup is not blocked/restricted
by debris and that the hose is tightly connected
• Check that the raw water pump/impeller is tact and that it
is not restricted
3-148 – JLG Lift – 3121142

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 Sensor Diagnostic Aids

• Check Condition-Engine Running NOTE: If any other DTCs are present, diagnose those first.
• Fault Condition-Engine speed greater than the max gover-
• Ensure that no programmed governor speeds exceed the
nor override speed as defined in the diagnostic calibration
limit set in the diagnostic calibration for Max Gov Override
• Corrective Action(s): Sound audible warning or illuminate Speed
secondary warning lamp, reduce throttle to limit speed.
• Check mechanical operation of the throttle actuator
Recommend closed loop and adaptive learn fueling correc-
tion 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 pro-
grammed 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)
3121142 – JLG Lift – 3-149

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 run-
ning. If no signal is present, the signal amplitude is too high
• Check Condition- Key On, Engine On
(due to improper air gap with respect to trigger wheel), or an
• Fault Condition- Electrical noise or irregular crank pattern irregular crank pattern is detected causing the ECM to resyn-
detected causing x number of crank resynchronization chronize x times for y ms or longer as defined in the diagnostic
events as defined in the diagnostic calibration calibration, this fault will set. Irregular crank patterns can be
• Corrective Action(s)- Illuminate MIL and/or sound audible detected by the ECM due to electrical noise, poor machining
warning or illuminate secondary warning lamp and disable of trigger wheel, or trigger wheel runout and/or gear lash.
adaptive fueling correction for remainder of key-cycle. Ensure crank circuit used with VR/magnetic pick-up sensors
• Emissions related fault are properly twisted.
The crankshaft position sensor is a magnetic sensor (variable

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 combination is used
to determine crankshaft position (with respect to TDC cylinder
#1 compression) and the rotational engine speed. Determina-
tion of the crankshaft position and speed is necessary to prop-
erly activate the ignition, fuel injection, and throttle governing
systems for precise engine control.
3-150 – JLG Lift – 3121142

• 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
3121142 – JLG Lift – 3-151

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 run-
ning. If no signal is present while x cam pulses continue the
• Check Condition- Key On, Engine On
fault will set. The engine typically stalls or dies as a result of
• Fault Condition- Loss of crankshaft position signal while this fault condition due to the lack of crankshaft speed input
valid camshaft position signals continue for x number of resulting in the inability to control ignition timing.
cam pulses as defined in the diagnostic calibration
DTC 337- Loss of Crank Input Signal (continued)
• Corrective Action(s)- Illuminate MIL and/or sound audible
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 (variable
reluctant/magnetic pick-up or halleffect) installed in the • Check that crankshaft position sensor is securely installed
engine block adjacent to a ¡§coded¡¨ trigger wheel located on into engine block
the crankshaft. The sensor-trigger wheel combination is used • Check crankshaft position sensor circuit wiring for open cir-
to determine crankshaft position (with respect to TDC cylinder cuit
#1 compression) and the rotational engine speed. Determina-
tion of the crankshaft position and speed is necessary to prop-
erly activate the ignition, fuel injection, and throttle governing
systems for precise engine control.
3-152 – JLG Lift – 3121142

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 damage due to low
oil pressure resulting in higher friction and lack of lubrication.
19 In addition, high oil pressure can be undesirable because it
BLACK/GREEN can cause oil to leak past seals and rings, can be a result of a
2 1 BLUE restriction in the oil flow path, or can be a sign of a malfunc-
tioning 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 monitor oil pres-
• Engine Oil Pressure sure 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 than For sender types, this fault sets if the engine oil pressure is
x psia while engine speed is greater that y RPM. For switch higher than x psia and engine speed greater than y RPM as
types, oil pressure is indicating high when the engine has defined in the diagnostic calibration. For switch types, this
been stopped for more than n seconds. fault sets if the engine oil pressure is indicating high when the
engine is stopped for more than n seconds. Recommend a
• Corrective Action(s)- Illuminate MIL and/or sound audible power derate and/or low rev limit to help prevent possible
warning or illuminate secondary warning lamp, possibly engine damage and reduce oil pressure.
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)
3121142 – JLG Lift – 3-153

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 z seconds as
19
defined in the diagnostic calibration. For systems that use a
BLACK/GREEN
2 1 BLUE 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 nor-
mally open and "Ground=OK" is normally closed). The engine
• Engine Oil Pressure
will should be configured to derate or force idle and/or shut
• Check Condition- Key on, Engine on down in the event of this fault to help prevent possible dam-
• Fault Condition- Engine oil pressure lower than expected age.
while engine has been running for a minimum amount of
time while engine speed is above some limit as defined in
the diagnostic calibration
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 damage 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 malfunc-
tioning oiling system.
3-154 – JLG Lift – 3121142

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)
3121142 – JLG Lift – 3-155

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 supplies, and
• Check Condition- Key on, Engine on
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 as This fault will set if the ECM detects system voltage less than x
defined in the diagnostic calibration volts while the engine is operating at y RPM as defined in the
diagnostic calibration as the alternator should be charging the
• Corrective Action(s)- Illuminate MIL and/or sound audible system.
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle
3-156 – JLG Lift – 3121142

3121142 – JLG Lift – 3-157

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 supplies, and
• Check Condition- Key on, Engine Cranking or Running
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 diagnos- This fault will set if the ECM detects system voltage greater
tic calibration than x volts while the engine is running or cranking as defined
in the diagnostic calibration.
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle
3-158 – JLG Lift – 3121142

3121142 – JLG Lift – 3-159

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 happen
• Check Condition- Key on
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. The
• Corrective Action(s)- Illuminate MIL and/or sound audible fault should be configured to never forget and will not self-
warning or illuminate secondary warning lamp, disable erase and will not clear until a technician performs diagnostics
adaptive fueling correction for remainder of key cycle, rec- and manually clears the code. This fault should be configured
ommend power derate 2 and low rev limit to reduce possi- to set a power derate 2 and low rev limit to reduce possible
ble engine damage and/or overspeed condition engine damage and reduce possibility of an overspeed condi-
• Non-emissions related fault tion. A fault of flash memory can occur for any calibration vari-
able set and thus could cause undesirable operation.
3-160 – JLG Lift – 3121142

3121142 – JLG Lift – 3-161

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 engine
• Fault Condition- Internal ECM microprocessor memory damage and reduce possibility of an overspeed condition. If
access failure this fault sets, the ECM will reset itself and log the code. This
• Corrective Action(s)- Illuminate MIL and/or sound audible fault should be erased by a technician after diagnostics are
warning or illuminate secondary warning lamp, disable performed. The fault should be configured to never forget and
adaptive fueling correction for remainder of key cycle, rec- will not self-erase.
ommend power derate 2 and low rev limit to reduce possi-
ble engine damage and/or overspeed condition
Random Access Memory is located within the microprocessor
and can be read from or written to at any time. Data stored in
RAM include DTCs (when fault configuration is set to "Battery
Power Retained"), adaptive fuel learn tables, octane adapta-
tion table, misfire adaption tables, and closed loop fuel multi-
pliers. The ECM has checks that must be satisfied each time an
instruction is executed.
3-162 – JLG Lift – 3121142

3121142 – JLG Lift – 3-163

DTC 606- Microprocessor Failure - COP
ECM
Microprocessor
RAM
• Engine Control Module The ECM has checks that must be satisfied each time an
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. The
• Corrective Action(s) - Illuminate MIL and/or sound audible fault should be configured to never forget and will not self-
warning or illuminate secondary warning lamp, disable erase and will not clear until a technician performs diagnostics
adaptive fueling correction for remainder of key cycle, rec- and manually clears the code. This fault should be configured
ommend power derate 2 and low rev limit to reduce possi- to set a power derate 2 and low rev limit to reduce possible
ble engine damage and/or overspeed condition engine damage and reduce possibility of an overspeed condi-
• Non-emissions related fault tion.
3-164 – JLG Lift – 3121142

3121142 – JLG Lift – 3-165

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 key
• Fault Condition- ECM 5-volt output is below the acceptable on and the engine stopped. Verify that the output is lower
limit than the fault thresholds configured in the diagnostic cali-
bration.
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 of
The ECM supplies 5-volt power to sensors, switches, and actu- the ECM one-at-a-time. Powered devices may include the
ators external to the ECM. By supplying the power to these throttle actuator, smart sensors, smart actuators, etc. After
devices, the ECM can accurately measure their output relative disconnecting device, observe the system fault and deter-
to its own ground reference. The ECM can also control when mine if the fault has cleared. If the fault clears, troubleshoot
the devices are active and put the devices in a low or no power the disconnected device for failures.
state based on the current operating condition of the engine
or vehicle. • With all 5-volt powered devices disconnected, look for a
change in the fault state and measure the 5-volt output of
If this fault sets, something other than the ECM is drawing the the ECM and verify it is within acceptable limits.
5-volt power output of the ECM below an acceptable thresh-
old. This may be due to a short in the wire harness, malfunc-
tioning device, or failure of the ECM power output circuitry.
3-166 – JLG Lift – 3121142

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 key
• Fault Condition- ECM 5-volt output is above the acceptable on and the engine stopped. Verify that the output is lower
limit than the fault thresholds configured in the diagnostic cali-
bration.
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 of
The ECM supplies 5-volt power to sensors, switches, and actu- the ECM one-at-a-time. Powered devices may include the
ators external to the ECM. By supplying the power to these throttle actuator, smart sensors, smart actuators, etc. After
devices, the ECM can accurately measure their output relative disconnecting device, observe the system fault and deter-
to its own ground reference. The ECM can also control when mine if the fault has cleared. If the fault clears, troubleshoot
the devices are active and put the devices in a low or no power the disconnected device for failures.
state based on the current operating condition of the engine
or vehicle. • With all 5-volt powered devices disconnected, look for a
change in the fault state and measure the 5-volt output of
If this fault sets, something other than the ECM is drawing the the ECM and verify it is within acceptable limits.
5-volt power output of the ECM above an acceptable thresh-
old. This may be due to a short in the wire harness, malfunc-
tioning device, or failure of the ECM power output circuitry.
3121142 – JLG Lift – 3-167

DTC 1612- Microprocessor Failure - RTI 1
ECM
Microprocessor
RAM
within the microprocessor that will cause this fault. The ECM
• Fault Condition- Internal microprocessor error will reset itself in the event this fault is set, and the MIL will be
• MIL- On until code is cleared by technician on until the code is cleared. This fault should be erased after
diagnosis by removing battery power. It will not self-erase.
• Adaptive- Disabled for the remainder of the key-on cycle
During this active fault, Power Derate (level 2) will be enforced.
• Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%.
• Power Derate (level 2 until fault is cleared manually) This is enforced until the fault is manually cleared.
3-168 – JLG Lift – 3121142

ECM
Microprocessor
RAM
3121142 – JLG Lift – 3-169

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
3-170 – JLG Lift – 3121142

ECM
Microprocessor
RAM
3121142 – JLG Lift – 3-171

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
3-172 – JLG Lift – 3121142

DTC 1615- Microprocessor Failure - A/D
ECM
Microprocessor
RAM
3121142 – JLG Lift – 3-173

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
3-174 – JLG Lift – 3121142

DTC 1616- Microprocessor Failure - interrupt
ECM
Microprocessor
RAM
3121142 – JLG Lift – 3-175

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
3-176 – JLG Lift – 3121142

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 a
• Fault Condition- ECM has received shutdown message external controller. This is the requested and expected
from another CAN device and is shutdown on request. behavior.
• Corrective Action(s)- Illuminate MIL, sound audible warn-
ing 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 condi-
tion in the vehicle.
This fault will set if the ECM receives the J1939 shutdown
request via the CAN interface. This is the expected behavior.
3121142 – JLG Lift – 3-177

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 properly
• Fault Condition- ECM CAN transceiver transmit error grounded
counts greater than the limit defined in the diagnostic cali- • Verify that the CAN network is properly terminated
bration (must be < 125 failures)
• Check CAN wire routing with respect to noise sources (igni-
• Corrective Action(s)- Illuminate MIL, sound audible warn- tion coils, spark plug coil wires, etc.) and shield if necessary
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital 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 fail-
ures) to the network that are not received.
3-178 – JLG Lift – 3121142

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 properly
• Fault Condition- ECM CAN transceiver receive error counts grounded
greater than the limit defined in the diagnostic calibration • Verify that the CAN network is properly terminated
(must be < 125 failures)
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital 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 calibration,
must be set to less than 125 failures).
3121142 – JLG Lift – 3-179

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 but are not
• Check Condition- Key On, Engine on
limited to other engine ECMs (slave), diagnostic tools, "smart"
• Fault Condition- two or more devices on the network that gauges, "smart" sensors, powertrain control units, vehicle con-
contain the same SA trollers, actuators, etc. The network permits several devices to
• Corrective Action(s)- Sound audible warning or illuminate communicate with each other receiving and broadcasting
secondary warning lamp commands as programmed. This type of network allows
devices to be added to an entire system through only two con-
• Non-emissions related fault ductors and permits all other devices to broadcast and receive
commands to and from the device when properly com-
manded.
This fault indicates that there are two (2) or more devices on
the network that use the same source address.
3-180 – JLG Lift – 3121142

3121142 – JLG Lift – 3-181

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 mes-
• Fault Condition- ECM is expecting to receive J1939 TSC1 sage is powered and properly grounded
messages and has not received a message for more than n • Verify that the CAN network is properly terminated
seconds (as defined in the diagnostic calibration).
ing 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 mes-
sages 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 otherwise.
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).
3-182 – JLG Lift – 3121142

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 Stopped • Verify that the throttle actuator 5V supply voltage is pres-
• Fault Condition- ECM is expecting to receive throttle posi- ent at the actuator.
tion information from the throttle actuator and is not. • Check for a all four TPS feedback wires for short circuits.
• Corrective Action(s)- Illuminate MIL, sound audible warn- • Check TPS SER+ and TPS SER- wire routing with respect to
ing or illuminate secondary warning lamp. Shutdown noise sources (ignition coils, spark plug coil wires, etc.) and
engine. shield if necessary.
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 inter-
rupted, the ECM can no longer control the position of the
throttle.
This fault will set if the key is on, the throttle actuator is receiv-
ing power, and the ECM is not receiving digital information
from the actuator.
3121142 – JLG Lift – 3-183

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-effect sen-
• Check Condition-Cranking or Running
sor to determine throttle actuator position, and is located
• Fault Condition-Throttle command is 20% less than throttle within the throttle actuator.
position for 200ms or longer
There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault log position feedback and 2) actuator with digital position
• Engine Shut Down feedback. The first type, with analog position feedback, pro-
vides an analog return signal between 0 and 5 volts that is pro-
In the case of a diesel engine, an actuator controls a fuel injec- portional to the throttle actuator position. The second type,
tion pump, directly affecting the fueling level into the cylin- with digital position feedback, provides a serial data signal to
ders. This may be by direct manipulation of the fuel injection the ECM with the throttle actuator position voltage level
pump rack or by manipulation of the mechanical governor encoded in the data stream.
ences to the throttle and throttle position sensor refer to these This fault will set if the throttle command is 20% less than the
fuel injection pump control actuators and their position feed- actual throttle position. During this active fault the MIL light
back sensors. When the fuel injection pump is electronically will be on and the engine will shut down.
3-184 – JLG Lift – 3121142

3121142 – JLG Lift – 3-185

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-effect sen-
• Check Condition-Cranking or Running
sor to determine throttle actuator position, and is located
• Fault Condition-Throttle command is 20% more than within the throttle actuator.
actual throttle position
There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault log position feedback and 2) actuator with digital position
• Engine Shut Down feedback. The first type, with analog position feedback, pro-
vides an analog return signal between 0 and 5 volts that is pro-
In the case of a diesel engine, an actuator controls a fuel injec- portional to the throttle actuator position. The second type,
tion pump, directly affecting the fueling level into the cylin- with digital position feedback, provides a serial data signal to
ders. This may be by direct manipulation of the fuel injection the ECM with the throttle actuator position voltage level
pump rack or by manipulation of the mechanical governor encoded in the data stream.
ences to the throttle and throttle position sensor refer to these This fault will set if the throttle command is 20% or more than
fuel injection pump control actuators and their position feed- the actual throttle position. During this active fault the MIL
back sensors. When the fuel injection pump is electronically light will be on and the engine will shut down.
3-186 – JLG Lift – 3121142

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 manu-
unpowered), the ECM is expecting the failsafe spring in the ally move it. Verify that the internal spring forces the throt-
actuator to return the throttle position to near 0%. If the tle back to near 0% position.
throttle does not reach this position when the actuator is • Inspect the throttle arm or fuel rack on the fuel pump. Ver-
powered, a fault is generated. ify that it is not stuck.
• Corrective Action(s)- Illuminate MIL, sound audible warn-
ing or illuminate secondary warning lamp. Govern the
engine speed to a forced idle speed.
The throttle actuator has a return spring that causes the throt-
tle 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 calibration), it will
power up the actuator and attempt to drive it to a zero posi-
tion. 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.
3121142 – JLG Lift – 3-187

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
3-188 – JLG Lift – 3121142

SECTION 4. BOOM & PLATFORM
4.1 BOOM SYSTEMS Transport Position Sensing System

The transport position sensing system uses the boom angle
Broken Cable Indicator System sensors and the boom length sensor mounted in the pivot end
of the base boom in addition to the boom length switch
The boom on this model is a 4 section proportionally driven
mounted on the platform end of the base boom to sense
telescopic boom. The inner mid boom is driven directly by the
when the boom is in the position associated with high speed
telescope cylinder. The outer mid and fly booms are each
travel. Above transport angle is recognized when one angle
driven by separate wire rope systems. Each rope system con-
sensor reads more than 15° with respect to gravity and resets
tains redundant ropes that are capable of allowing the opera-
to within transport position when both angle sensors read less
tor to unknowingly continue use of the machine with a single
than 10° with respect to gravity. Transport length is recog-
rope failure. These kinds of failures with the extend ropes are
nized when both the length switch and length sensor read less
self revealing to the operator so proper action can be taken.
than 1 ft extension for the 1350SJP (2 ft extension for the
Failures within the fly extend ropes are self revealing as they
1200SJP). During failures of either the length switch or length
are exposed on the exterior of the boom where a broken rope
sensor, the transport length will be determined by the remain-
would be obvious. Failures within the outer mid ropes require
ing sensor or switch. The position of the articulated jib is not
the addition of the Broken Cable Indicator System in order to
considered.
be self-revealing to the operator. This system uses a proximity
sensor to detect excessive movement of the sensed rope as This system is used to control the following systems:
would be expected with a rope failure. A broken rope detec-
tion results in illuminating the Cable Break indicator on the • Beyond Transport - Drive Speed Cutback System
platform control panel. No restrictions are made to the func- • Drive/Steer – Boom Function Interlock System – CE Only
tionality of the control system. It is the responsibility of the
• Jib Stow System
operator to take the appropriate action.
• Axle Extension System
ment and operation, refer to Section 6 - JLG Control Sys- • Oscillating Axle System
tem.
Platform Control Enable System tem.
The platform controls make use of a time dependent enable
circuit to limit the time availability of “live” or enabled controls. Beyond Transport - Drive Speed Cutback System
When the footswitch is depressed, the controls are enabled
When boom is positioned beyond the Transport Position, the
and the operator has 7 seconds to operate any control. The
drive motors are automatically restricted to their maximum
controls will remain enabled as long as the operator continues
displacement position (slow speed).
to use any function and will remain enabled 7 seconds after
the last function has been used. While the controls are “live”, NOTE: For more detailed information concerning system adjust-
the enabled light will be illuminated in the platform display ment and operation, refer to Section 6 - JLG Control Sys-
panel. When the time limit has been reached, the enabled tem.
light will turn off and the controls will be “dead” or disabled. To
continue use of the machine the controls must be re-enabled
to start the timer system over again. This is done by releasing
all functions, then releasing and re-depressing the footswitch.

tem.
3121142 – JLG Lift – 4-1

Drive/Steer – Boom Function Interlock System (CE Envelope Tracking System

ONLY) The Envelope Tracking System uses the envelope control sen-
sors to enhance the control of the boom within the working
The Drive/Steer – Boom Function Interlock System uses the
envelope. Due to the shape of the working envelope, the max-
Transport Position Sensing System to sense when the boom is
imum boom angle varies with telescope length. To maintain
out of the transport position. All controls are simultaneously
unrestricted operation of the boom, the lift down function is
functional when the booms are within the transport position
automatically introduced while telescoping in only when the
as on the standard machine. When the boom is beyond the
boom is on the rearward edge of the envelope. This only
transport position, the control functions are interlocked to
occurs when telescoping in along the rearward edge and is
prevent simultaneous operation of any boom function with
not used elsewhere within the envelope or when telescoping
drive/steer. The first function set to be operated in this mode,
out. Envelope tracking is disabled with any envelope or
becomes the master function set. In other words, while oper-
moment violations or failures. The envelope tracking function-
ating drive/steer functions the boom functions are inoperable.
ality and be turned off using the manual position of the boom
Likewise, while operating boom functions drive/steer func-
control select switch. Refer to Boom Control Select.
tions are inoperable.
tem.
tem.
Jib Stow System

This machine is equipped with a full function side swing rota-
tor that is mechanically limited to 90 degree rotation to the
left and electrically limited to 90 degrees to the right through
the use of a positive action limit switch mounted on the rota-
tor assembly. The machines stowed length can be reduced to
facilitate transportation on standard trailers by swinging the
jib further to the right using the hydraulic power of the side
swing rotator. The control system will prevent swinging the jib
past the 90 degree position unless the axles are retracted, the
boom is in the transport position, and the jib stow override
button on the platform control panel is held in combination
with the jib swing function switch. When the jib is stowed,
automatic platform leveling is disabled, the boom is restricted
to the transport position, and axle extension is disabled. This
system is functional only in the 500 lb. (230 kg) mode of the
Dual Capacity System.

tem.
4-2 – JLG Lift – 3121142

Moment Control System Boom Control System (BCS) Functional Check

The Moment Control System is the secondary means of con- (Push to Test) System
trolling the stability of the machine. This system uses a load
The machine is equipped with a system for the operator to
moment pin to attach the lift cylinder of the boom to the turn-
daily verify the proper functioning of the Boom Control Sys-
table. This pin is instrumented with gauges allowing the forces
tem (Envelope Control System and the Moment Control Sys-
in the pin to be monitored. These forces are used to compare
tem). The operator is instructed to position the boom in the
the actual boom moment (force at a distance) to a predeter-
position described by the instruction decal and to then verify
mined allowable boom moment. In controlling the boom
the control system cut out the telescope movement at the cor-
moment, the position and load of the boom is controlled. The
rect length. When the operator pushes the push button
moment control system will detect moments larger than
mounted on the ground control panel, the control system
expected as well as those smaller than expected. This effec-
compares the current moment reading in the moment system
tively controls the forward and rearward positions of the
and compares it to the moment expected for this position. If
boom. The moment control system varies the maximum
the current moment is within allowable tolerance for the test
allowable moment based on ground slope. On level ground
position, the green BCS indicator will illuminate indicating the
and with rated load in the platform, the allowable moments
system is working properly. If the current moment is not
establish a working envelope slightly larger than the Envelope
within the allowable tolerance for the test position, the red
Control System’s envelope to minimize interaction of the sys-
BCS indicator will illuminate indicating the machine requires
tems. With increasing ground slopes and rated load in the
service by JLG authorized service personnel before the system
platform, the allowable moments may establish a working
is used. Failure of this test will not restrict the functionality of
envelope smaller than the Envelope Control System’s enve-
the machine and will not cause a system fault. It is the opera-
lope and may result in moment violations at the extreme plat-
tors responsibility to take proper action. The machine can be
form positions. Violations of the moment control systems
in either capacity mode of the dual capacity system for this
allowable moment will result in reduced function speeds, BCS
system check.
warning light illumination, restriction of functions, and sound-
ing of the platform alarm and the flashing of the BCS light with NOTE: For more detailed information concerning system adjust-
attempts to operate restricted functions. The restricted func- ment and operation, refer to Section 6 - JLG Control Sys-
tions due to moment system violations related to forward tem.
reach are disallowing jib functions, lift down, telescope out,
swing, drive, and steer. The restricted functions due to Controlled Arc System
moment system violations related to backward reach are disal-
The Controlled Arc System uses the envelope control sensors
lowing jib functions, lift up, telescope in, swing, drive, and
to enhance the control of the boom within the working enve-
steer. Recognized failures within this system will result in con-
lope. The purpose of the controlled arc system is to minimize
trol by the Envelope Control System, reduced function speeds,
the interaction of lift functions with envelope edges and to
BCS warning light illumination. The boom will be restricted
increase user efficiency. This minimizes the effect of a long
from leaving the transport position until the failure is resolved.
boom working in a comparatively narrow envelope. Because
NOTE: For more detailed information concerning system adjust- the boom is permitted to extend to longer lengths at high
ment and operation, refer to Section 6 - JLG Control Sys- angles than at it is low angles, lift commands would normally
tem. cause the boom to violate the permitted envelope while lifting
down or conversely require the operator to frequently com-
mand telescope out while lifting to high heights. The con-
trolled arc system optimizes the envelope shape by
automatically introducing telescope in or out during "lift only"
commands. Telescope flow is regulated during lift commands
to maintain a constant percentage of available boom length
(0% is always fully retracted, 100% is variable as the permitted
length changes when the boom is raised). The target percent-
age will be maintained throughout the lift command whether
it is maintaining 0%, 100%, or any percentage in between. The
target percentage is established at the start of lift command or
end of manual telescope commands when using multiple
functions with lift. The telescope command can be used inde-
pendently or in combination with other functions. Manual
introduction of telescope will override the controlled arc sys-
tem and result in conventional control. Controlled arc will be
disabled with any sensor failure, any moment violation, any
envelope violation, or with auxiliary power functions. The con-
trolled arc functionality and be turned off using the manual
3121142 – JLG Lift – 4-3

position of the boom control select switch. Refer to Boom Envelope Tracking
Control Select.
The Envelope Tracking System uses the envelope control sen-
sors to enhance the control of the boom within the working
envelope. Due to the shape of the working envelope, the max-
imum boom angle varies with telescope length. To maintain
unrestricted operation of the boom, the lift down function is
automatically introduced while telescoping in only when the
boom is on the rearward edge of the envelope. This only
occurs when telescoping in along the rearward edge and is
not used elsewhere within the envelope or when telescoping
out. Envelope tracking is disabled with any envelope or
moment violations or failures. The envelope tracking function-
ality and be turned off using the manual position of the boom
control select switch. Refer to Boom Control Select.

Controlled Arc Boom tem.
Movement
Slow Down System
When the boom approaches the edges of the working enve-
lope, all functions (except jib and platform functions, tele-
tem.
scope in or out on the rearward edge and telescope in on the
forward edge) are automatically slowed down by the control
Controlled Boom Angle System system to reduce the machine dynamics and improve opera-
The Controlled Boom Angle System uses the envelope control tor control. The slow down starts within 4 feet of all edges and
sensors to enhance the control of the boom by minimizing the is at the fully reduced speeds 2 feet from all edges. The control
interaction of swing and drive functions with the envelope system indicates to the operator this automatic introduction
edges. This interaction is due to two factors. First, the envelope of slow down by flashing the creep light on the platform dis-
is controlled relative to gravity regardless of ground slope and play panel. This feature applies to both platform and ground
second, the turntable/boom mounting is effected by swing controls, however, no indication is made on the ground con-
and drive functions when the ground slope varies. This can trol panel.
cause the boom position to vary within the envelope or even
violate the envelope edges when swinging or driving without NOTE: For more detailed information concerning system adjust-
intentionally moving the boom. The controlled boom angle ment and operation, refer to Section 6 - JLG Control Sys-
system minimizes this effect by automatically introducing lift tem.
up or down during swing and drive commands to maintain a
constant boom angle relative to gravity for all boom angles
greater than 9 degrees. Controlled boom angle is disabled
with any envelope or moment violations or failures. The con-
trolled boom angle functionality and be turned off using the
manual position of the boom control select switch. Refer to
Boom Control Select.

tem.
4-4 – JLG Lift – 3121142

Dual Capacity System Electronic Platform Leveling

The Dual Capacity System on this machine is a multiple enve- The electronic platform leveling system uses two tilt sensors
lope control system as opposed to an indication system. The (mounted on either side of the pivot weldment), a control
control system changes the working envelope and moment valve (mounted to the platform support), a level cylinder, and
limits to match the capacity select mode to either the 500 lb. the platform control module (mounted in the platform control
(230 kg) mode or the 1000 lb. (450 kg) mode. It then displays box) to automatically measure and control the incline of the
the capacity mode on the platform and ground display panel platform with respect to gravity. While in the automatic posi-
and controls the positions of the boom within the allowable tion of the boom control select (item 33) platform leveling is
envelope for that mode. This mode is selectable by the opera- active while operating drive, telescope, lift or swing and is not
tor with the dual capacity select switch on the platform con- active while operating any other function (e.g. rotate, jib, or
trol panel. The 500 lb. (230 kg) mode has the largest envelope steer). While in the manual position of the boom control
and allows the use of the side swing jib. The 1000 lb. (450 kg) select, platform leveling is active while operating lift only. The
mode has a smaller envelope and requires the jib to be fixed in system controls the platform angle relative to gravity using a
the centered position. To select the 1000 lb. (450 kg) mode the set point established during power-up (cycling of the EMS) or
boom must already be in the smaller 1000 lb. (450 kg) enve- at the conclusion of a manual platform level override by the
lope and the jib must be centered (+/-10 degrees) verified to operator using the platform level override switch from either
the control system by the jib centered limit switch mounted the platform or the ground control. In other words the opera-
on the side swing rotator. When the operator selects the 1000 tor can chose a platform incline other than level with gravity
lb. (450 kg) mode and these conditions are met, the capacity and the system will maintain that incline automatically.
light changes from 500 lb. (230 kg) to 1000#, jib swing is disal-
If a fault occurs in the platform leveling system the following
lowed, and the envelope and permitted moment values are
will occur:
changed accordingly. When the operator selects the 1000 lb.
(450 kg) mode and these conditions are not met, both capac- • Automatic platform leveling will stop (except when there is
ity lights will flash, the platform alarm will sound, and all func- a fault in only one sensor)
tions except jib swing will be disabled until the capacity select
• The platform level fault indicator will flash
switch is put back into the 500 lb. (230 kg) position. Operation
of jib swing in this condition can be used to find the center • The platform alarm will sound
position of the jib as the jib swing function will stop when the
• All functions will default to creep speed if in platform mode
center position is reached.
and the boom is out of the transport position. Refer to
NOTE: For more detailed information concerning system adjust- Transport Position Sensing System.
ment and operation, refer to Section 6 - JLG Control Sys- To reset the fault the emergency stop switch should be recy-
tem. cled.

tem.
3121142 – JLG Lift – 4-5

Boom Control Select In addition, when the boom control is selected to the auto-
matic position, the automatic platform leveling feature is
The boom control select switch is mounted on the platform
active during lift, telescope, swing, and drive movements as
control panel and allows the operator the ability to select
described in the Electronic Platform Leveling System descrip-
between two different modes of boom control functionality:
tion.
automatic and manual. While in either mode, the Envelope
Control System and Moment Control System remains active. When the boom control is selected to the manual position, lift
and telescope movements are controlled separately by the
When the boom control is selected to the automatic boom
operator effectively turning off the controlled arc, controlled
control position, lift and telescope movements are coordi-
boom angle, and envelope tracking systems. Without these
nated by the control system as described in the Controlled Arc,
systems being active, the control system will stop the move-
Controlled Boom Angle, and Envelope Tracking descriptions.
ments of the boom when the envelope boundaries are
These systems will remain active to automatically assist the
reached and the functions that could violate the envelope will
operator in keeping the boom within the envelope boundar-
be restricted. The platform alarm will sound and the BCS light
ies.
will flash with attempts to operate a restricted function. In
When operating in the automatic mode, the following func- addition, when the boom control is selected to the manual
tionality characteristics should be noted. position, the automatic platform leveling feature is active only
during lift movements.
• While operating Lift Up, the boom may also telescope out
(Controlled Arc) NOTE: For more detailed information concerning system adjust-
• While operating Lift Down, the boom may also telescope in ment and operation, refer to Section 6 - JLG Control Sys-
(Controlled Arc) tem.
• While operating Swing or Drive, the boom may lift up or lift

down (Controlled Boom Angle)
• While operating Telescope In, the boom may lift down
when at high boom angles and the creep light is flashing
(Envelope Tracking)
4-6 – JLG Lift – 3121142

4.2 BOOM REMOVAL, DISASSEMBLY/ASSEMBLY, & 6. Tag and disconnect the telescope, tank, and pressure
hoses as indicated below from the main valve and cap
CABLE REPLACEMENT ends.
Removal
1. Place machine on firm, level ground.
2. Slightly elevate the boom and support the fly boom
with a crane or an adequate lifting device capable of
handling 6 - 7 tons.
3. Place blocking under lift cylinder to hold it in place.

4. Remove lift cylinder pin securing the lift cylinder rod to
the boom.
1. Pivot Pin
2. Bolt
3. Keeper Pin
5. Remove the boom end cover.
3121142 – JLG Lift – 4-7

4-8
– JLG Lift –
1. Boom Base 5. Jib Rotator
2. Boom Inner Mid 6. Jib Assembly
3. Boom Outer Mid 7. Platform Rotator
4. Boom Fly
Figure 4-1. Boom Assembly - Sheet 1 of 7
3121142
3121142
1
9
– JLG Lift –
3
7
4
6
5 8
SECTION A-A SECTION B-B
1. Outer Mid Extend Block 4. Retract Rope Retainer Plate 7. Retract Rope Retainer Plate
2. Outer Mid Retract Sheave 5. Rope Retainer Block 8. Lock Plate
3. Rope Retainer Block 6. Fly Retract Sheave 9. Tele Cylinder Wear Pad
4-9
4-10
– JLG Lift –
1. Upper Rear Wear Pad 6. Shim
2. Shim 7. Tele Cylinder Pulley Assembly
3. Telescope Cylinder 8. Bottom Rear Wear Pad
4. Trunnion Keeper Block 9. Shim
5. Lower Rear Wear Pad
3121142
3121142
– JLG Lift –
1. Sheave Deflector 6. Rope Retainer Block
2. Sheave Deflector 7. Level Cylinder
3. Rope Retainer Block 8. Front Lower Wear Pad
4. Fly Extension Sheave 9. Lock Plate
5. Rope Retainer Block
4-11
4-12
– JLG Lift –
1. Front Upper Wear Pad 7. Jib Rotator
2. Shim 8. Jib Rotator Cam
3. Pivot Assembly 9. Front Side Wear Pad
4. Platform Rotator 10. Shim
5. Jib Cylinder 11. Shim
6. Lower Jib Link 12. Lock Plate
3121142
3121142
– JLG Lift –
1. Outer Mid Extend Rope 4. Outer Mid Retract Rope
2. Fly Extend Rope 5. Proximity Switch Spring
3. Fly Retract Rope 6. Switch Adjustment Block
4-13
4-14 – JLG Lift – 3121142

7. Tag and disconnect the three electrical wires that run to 10. Using the lifting device, support the rear of the boom to
the power track and the wire that goes to the proximity remove the load from the pivot pin.
switch.
11. Remove the boom pivot pin.

12. Move all of the hydraulic hoses and electrical wires so
8. Unbolt the power track. they are free from chassis.
9. Remove the bolt securing the keeper pin and remove

the keeper pin from boom pivot pin.
3121142 – JLG Lift – 4-15

13. Using the lifting device, remove boom from chassis. 6. Remove the bolt and keeper pin securing the jib pivot
pin and remove the pin.
14. Place boom on saw horses or other adequate supports.

7. Remove the jib and platform assembly from the boom.
Disassembly
It is not necessary to completely remove the entire boom
assembly from the machine to replace the cables. In the fol-
lowing procedure, the base boom section will remain on the
machine.
NEVER HANDLE WIRE ROPE WITH BARE HANDS.
1. Position the boom so that it is horizontal. If the boom is

below horizontal, ensure that the boom is not on the
boom rest.
2. Use an adequate lifting device to support the weight of
the jib and platform assembly.
3. Tag and disconnect the hoses and electrical harnesses
that run to the platform. Cap or plug all openings.
4. Pull the hoses and harnesses through the jib and lay
them off to the side of the boom.
5. Remove the bolt and keeper pin securing the platform
level pivot pin and remove the pin.
4-16 – JLG Lift – 3121142

8. Attach a lifting device to the powertrack for support and 9. Unbolt the lower powertrack tube from the outer mid
unbolt the upper powertrack tube from the fly boom. boom section and the mounting bracket from the inner
Pull the disconnected tube back to allow room to dis- mid boom section..
connect the lower tube.
10. Attach a strap or other similar device around the pow-

ertrack and boom to keep the powertrack secure
throughout the cable replacement procedure.
3121142 – JLG Lift – 4-17

11. Remove the bolts securing the side wear pads to the 13. Remove the cover over the boom length limit switch at
front of the base boom and remove the pads and shims. the front of the boom base section. Remove the switch.
12. Remove the boom length plate.
14. Remove the rear boom cover.
4-18 – JLG Lift – 3121142

15. Tag and disconnect the wiring harness running to the 18. Remove the keepers for the outer mid retract cable
boom length sensor. Remove all the bolts and washers adjustment nuts at the front of the boom base section.
securing the sensor, including those that secure the
measuring cable to the telescope cylinder, and remove
the length sensor.
19. Loosen and remove the outer mid retract cable adjust-
16. Tag and disconnect the hydraulic hoses from the tele-
ment nuts.
scope cylinder. Cap or plug all openings.
20. Remove the adjustment bolt keepers for the outer mid
extend cable adjustment nuts at the rear of the boom.
17. Remove the front side, top, and lower wear pads from
the boom base section.
3121142 – JLG Lift – 4-19

21. Remove the adjustment nuts for the for the outer mid 23. Remove the cover plate from the bottom of the boom
extend cables along with the Broken Cable proximity and remove the sheave blocks.
switch, spring, and adjustment plate.
22. Remove the cable mounting plate.
24. Remove the trunnion blocks that secure the telescope

cylinder rod to the boom base section.
4-20 – JLG Lift – 3121142

25. Remove the outer mid retract cables from the attach- 27. Pull the inner mid, outer mid, and fly boom sections out
ment fixtures at the front of the boom base section. of the base boom section. Use additional lifting devices
and reposition any lifting straps as necessary as the sec-
tions are withdrawn. It will be helpful during this step to
pull the outer mid retract cable out from the front of the
base section as the other sections are being pulled out.
This will prevent the cables from tangling as the sections
are withdrawn.
26. Attach an auxiliary hydraulic power source to the tele-

scope cylinder and extend the cylinder rod enough to
turn the trunnion in a vertical position.
3121142 – JLG Lift – 4-21

28. Remove the trunnion blocks that secure the telescope 30. Remove the hardware attaching the outer mid extend
cylinder barrel to the inner mid boom section. block and remove the block and outer mid extend
cables.
29. Attach a lifting device to the telescope cylinder and pull

the cylinder, along with the outer mid extend cables out 31. Remove the cable retainer plate, cable retainer block,
of the inner mid boom section. Reposition the lifting bushing, and sheave.
device as necessary to balance the cylinder.
4-22 – JLG Lift – 3121142

32. Remove the rear bottom wear pad. 34. Pull the fly boom extend cables from their mounting
receptacles.
33. Remove the lock plates from the fly boom retract cable
adjustment nuts and remove the adjustment nuts from
the fly boom retract cables and from the fly boom
extend cables at the front of the inner mid boom sec-
tion.
35. Remove the top, side, and bottom wear pads from the
front of the inner mid boom sections.
3121142 – JLG Lift – 4-23

36. Attach a strap to pull the outer mid and fly boom sec- NOTE: When pulling the outer mid and fly boom sections out of
tions out of the inner mid boom section. Secure the rear the inner mid boom section, make sure the outer mid
of the inner mid boom section so it doesn’t move as the retract cables do not catch at the rear of the boom section.
other sections are withdrawn.
38. Pull the sections the rest of the way out of the inner mid
boom section, pulling the fly boom retract cables out at
the same time.
39. Remove the outer mid retract cables from the rear of the
inner mid boom section.
37. Pull the sections out enough to allow easy removal of

the cable retainer blocks and sheave blocks for the fly
boom retract cables at the front of the inner mid boom
section.
4-24 – JLG Lift – 3121142

40. Remove the cable retract retainer plates, cable retainer 42. Remove the upper rear wear pads from the fly boom
blocks, sheaves, and bushings from the rear of the outer section.
mid boom section.
43. Remove the cable retainer blocks and shims.
41. Remove the front wear pads from the outer mid boom
section.
3121142 – JLG Lift – 4-25

44. Pull the fly boom extend cables out enough to have NOTE: When pulling the fly boom section out of the outer mid
clearance to remove the sheave, and remove the retain- boom section, make sure the fly boom retract cables do not
ing bolt, keeper pin, pin, bushings, and sheave from the catch at the rear of the boom section.
front of the outer mid boom section.
45. Attach a lifting device to the fly boom section and pull
the section and fly boom extend cables from the outer
mid boom section. Secure the rear of the outer mid
boom section so it doesn’t move when the fly boom sec-
tion is withdrawn.
4-26 – JLG Lift – 3121142

46. Remove the tape from the fly boom section and remove Assembly
the fly boom retract cables.
NEVER HANDLE WIRE ROPE WITH BARE HANDS.
NOTE: Moderately apply Super Lube JLG Part No. 3020042 to all
four inner surfaces of both ends of each boom section to a
minimum depth of 3 to 4 feet (1 to 1.25 m). The fly boom
section only needs Super Lube applied to the insertion end.
Super Lube is also to be moderately applied to all outer sur-

faces of interior wear pads after they are installed to the
insertion end of boom sections. Care should be taken to
avoid application on exposed painted surfaces of the fully
extended boom. Refer to Section 4.3 - Boom Lubrication
Application.
47. Remove the fly boom extend cables from the bottom of
the fly boom section.
WIRE ROPE NUTS ARE CLOSE IN SIZE AND CAN BE SWITCHED. REFER TO THE
JLG PARTS MANUAL. OUTER MID RETRACT NUTS, LOCATED ON BOTTOM OF
BASE BOOM, WILL BE BLACK IN COLOR.
48. Thoroughly clean the boom sections.
3121142 – JLG Lift – 4-27

wire rope and place them into the fly boom, tape the
slots to keep the rope from jumping out.
TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURING THE ASSEMBLY
PROCEDURE.
1. Install the fly extend wire rope button ends into the slots
on the bottom of the fly boom section. Place tape over
the wire ends to keep them in place during assembly.
2. Fabricate a special fixture as shown below to keep four

extend wire ropes from crossing over each other.
3. Install the fly retract wire rope button ends into the slots
in the side of the fly boom, coil the remaining lengths of
4-28 – JLG Lift – 3121142

Ft-Lbs. Nm
A 165 224
B 165 224
C 35 49
D 50 70
Figure 4-8. Boom Assembly Torque Values - Sheet 1 of 2
3121142 – JLG Lift – 4-29

E F
NOTE: If any rotator bolts are replaced, all bolts

on the rotator should be retorqued. Check
torque on the bolts every 150 hours of
operation.
Ft-Lbs. Nm
E 340 460
F 480 672
G 190 260
Figure 4-9. Boom Assembly Torque Values - Sheet 2 of 2
4-30 – JLG Lift – 3121142

4. Install the fly boom section partially into the outer mid 7. Install the sheave, bushings, pin, keeper pin, and retain-
boom section. ing bolt to the front of the outer mid boom section.
DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND WIRE ROPES
8. Install the cable retainer blocks and shims.
WHILE INSERTING IT INTO THE OUTER MID BOOM.
5. Apply JLG Threadlocker P/N 0100011 to the bolts and

install the front lower wear pads and shims to the outer
mid boom as marked during disassembly. Torque the
bolts to 50 ft.lbs. (68 Nm).

install the front upper, and side wear pads on the outer
mid boom section as marked during disassembly.
Torque the bolts to 50 ft.lbs. (68 Nm).
6. Install the fly boom section most of the way into the
outer mid boom section, leaving enough of the fly out
so there is adequate slack in the fly boom extend cables
to allow for installation of the front sheave.
3121142 – JLG Lift – 4-31

10. Apply JLG Threadlocker P/N 0100011 to the bolts and 12. Apply a thin coat of moly paste lubricant to the inside
install the rear upper and side wear pads on the outer diameter of the sheave composite bearings. Install the
mid boom section as marked during disassembly. fly retract sheaves and bushings while guiding the wire
Torque the bolts to 50 ft.lbs. (68 Nm). ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
P/N 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retract retainer
plates and cable retainer blocks.
11. Uncoil the fly retract wire ropes from the fly boom.
Route the threaded ends of the wire ropes through the
holes in the outer mid boom plates at the retract sheave
locations.

install the lower rear wear pad onto the outer mid boom
section. Torque the bolts to 50 ft.lbs. (68 Nm).

install the side and upper wear pads on the rear of the
inner mid boom section. Torque the bolts to 50 ft.lbs. (68
Nm).
15. Lubricate the wear surfaces on the inside of the inner
mid boom section with Super Lube.
4-32 – JLG Lift – 3121142

16. Feed the fly boom retract cable into the inner mid boom 18. Attach the fly boom retract cables in the inner mid
section from the front. boom section to the receptacles at the rear of the outer
mid boom section.
19. Put tape over the holes to keep the cable ends from
jumping out.
17. Using an adequate lifting device, align the outer mid

boom section with the inner mid boom section.
20. Push the outer mid assembly part way into the inner
mid boom section. Apply JLG Threadlocker P/N 0100011
to the bolts and install the front bottom wear pad into
the inner mid boom section. Torque the bolts to 50
ft.lbs. (68 Nm).
3121142 – JLG Lift – 4-33

21. Push the outer mid assembly into the inner mid while 23. Push the outer mid assembly almost completely into the
pulling the boom cables out the back fo the inner mid inner mid boom section.
section at the same time. Leave 3 to 4 feet of the outer
mid section sticking out of the inner mid section.
24. Install the cable retainer blocks over the fly boom retract
cables and insert the fly boom extend cable into the
22. Push the retract cable ends into the mounting recepta- mounting receptacles.
cles and install the cable sheaves and adjustment nuts.
4-34 – JLG Lift – 3121142

25. Apply JLG Threadlocker P/N 0100011 to the bolts and 27. Apply a thin coat of moly paste lubricant to the inside
install the side and top wear pads into the inner mid diameter of the sheave composite bearings. Install the
boom section. Torque the bolts to 50 ft.lbs. (68 Nm). retract sheaves and bushings while guiding the wire
ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
P/N 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retainer blocks and
cable retainer plates.
26. Put moly paste on the sheave mounts at the rear of the
inner mid boom section and install the sheaves.

install the rear bottom wear pad on the rear of the inner
mid boom section. Torque the bolts to 50 ft.lbs. (68 Nm).
3121142 – JLG Lift – 4-35

29. Install a new sheave on the telescope cylinder. 32. Route the cables around the sheave on the cylinder and
install the cable retainer block.
30. Install the outer mid extend cables into the cable pulley
at the rod end of the telescope cylinder. 33. Using an adequate lifting device, insert the cylinder and
cables part way into the inner mid boom.
31. Install the other end of the outer mid extend cables into
the cable guide block.
4-36 – JLG Lift – 3121142

34. Apply JLG Threadlocker P/N 0100019 to the bolts and 37. Using Super Lube®, lubricate all wear surfaces on the
attach the cable guide to the inner mid boom section inside of the boom base section and the outside of the
with the mounting hardware. Torque the bolts to 165 inner mid boom section.
ft.lbs. (224 Nm).
38. Insert the inner mid boom section part way into the
boom base section enough to be able to pull the outer
mid retract cables out through the hole at the bottom
front of the boom base section.
35. Push the cylinder the rest of the way into the inner mid
boom assembly.
36. Install the cylinder trunnion blocks and shims. 39. Apply JLG Threadlocker P/N 0100011 to the bolts and
install the front lower wear pads into the boom base
40. Push the inner mid boom assembly the rest of the way
into the boom base section, adjusting the lifting device
as necessary to keep the weight balanced.
3121142 – JLG Lift – 4-37

41. Apply JLG Threadlocker P/N 0100011 to the bolts and 46. Install the outer mid retract cable adjustment nuts at the
install the side and upper wear pads into the boom base front of the boom base section.
42. Install the boom transport length sensor on the side of
the boom base section.
43. Attach the powertrack tubes.
44. If necessary, attach a source of auxiliary hydraulic power
and retract the boom enough to allow installation of the
cable adjustment plate at the rear of the base boom sec-
tion and install the plate.
47. Install the boom length sensors and angle sensors as

tagged during removal.
45. Install the broken cable sensor and the outer mid extend
cable adjustment nuts.
48. Connect the hydraulic hoses to the telescope cylinder as

tagged during removal.
49. Adjust the boom cables. Refer to Section 4.11 - Wire
Rope Tensioning Adjustment.
50. Perform a boom calibration as described in Section 6
under Calibrating the Boom Sensors.
4-38 – JLG Lift – 3121142

#271
#0100011
#0100011
#0100019
#0100019
#0100011
A
A
#0100011
SECTION A-A
Figure 4-10. Locations for Threadlocker Application - Sheet 1 of 4
3121142 – JLG Lift – 4-39

#0100011
#0100011
#0100011
#0100011
#0100011
4-40 – JLG Lift – 3121142

#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
3121142 – JLG Lift – 4-41

#0100011
#0100011
#0100011
#0100011
#0100011
#0100019
#0100011
#0100011
#0100011
#0100011
4-42 – JLG Lift – 3121142

4.3 BOOM LUBRICATION APPLICATION 4.4 BOOM SHIMMING PROCEDURE

This procedure applies to booms after assembly or during 1. Measure and record the dimension and direction of any
annual application using Super Lube® lubricant (JLG p/n sweep found in the fly boom section. Measure and
3020042). record the inside width and inside height of the outer
mid boom opening.
1. Position the boom on the boom rest using the 500lb
capacity setting.
2. Telescope main boom section as far as it will extend at
this position, approximately 3 ft. (0.9 m).
3. From the front of the machine (boom pivot end), moder-
ately apply lubricant to the interior surfaces of the base
boom, inner mid boom, and outer mid boom. To pre-
vent misdiagnosis of hydraulic leaks, take care to pre-
vent excessive application of lubrication.
4. At the rear of the machine, apply lubricant to the side,
top and bottom surfaces of the fly boom, outer mid, and
inner mid specifically to wear pad contact paths. To pre- SWEEP
vent misdiagnosis of hydraulic leaks, take care to pre- MEASUREMENT
vent excessive application of lubrication.
5. After application of the lubricant is complete, cycle the
boom through its full range of travel 2 times.
TOP VIEW OF BOOM SECTION
Figure 4-14. Measuring Boom Section Sweep
NOTE: Wear Pad bolt lengths should be flush to one thread below
the surface of the insert. When installing wear pads in the
following steps, the wear pad bolt lengths may need to be
adjusted as shim thicknesses are adjusted.
2. Install the side wear pads on the fly boom sides. Shim as
necessary to match the outer mid boom dimension
recorded in step 1 ± 1/32” (± 0.8 mm). Shims should be
divided as evenly as possible between the side pads
unless corrections are needed to compensate for sweep
recorded in step 1. If the sweep is to the left the internal
side pads on the left should have more shims than the
right side pads and vise versa.
3. Install the bottom wear pad(s) and shims if applicable
on the fly boom.
3121142 – JLG Lift – 4-43

4. Install the top wear pad(s) on the fly boom and shim as 4.5 JIB ROTATOR ORIENTATION
necessary to obtain 0 - 1/16” (0 - 1.6 mm) less than the
corresponding dimension recorded in step 2. In order for the Jib Rotator to rotate properly, it must be
installed with the timing marks running parallel to the flat
5. Slide the fly into the outer mid boom leaving 2 - 6 feet rotator mounting plate as shown below.
(0.6-1.8 m) exposed.
6. Install the bottom wear pad(s) and shims if necessary
into the end of the outer mid boom.
7. Temporarily insert the side pads on one side and slide
the fly boom to that side. Insert the other side pads and
using shims, measure how many will be required to fill
the remaining space. Install the total amount of shims
as evenly as possible between the two sides unless cor-
rections are needed to compensate for out-of-square
booms or for corrections due to sweep recorded in step
1. Care should be taken to keep the bottom pads evenly
loaded while shimming the side pads.
NOTE: Do not install more shims than will fit because this may
result in a boom being shimmed too tight. The use of pry
bars or wedges should only be used to finish installing a
shim that can be installed by hand more than ½ of its
length. Figure 4-15. Jib Rotator Orientation
8. Install the top wear pads and shims into the end of the
outer mid boom leaving a gap of 0” to 1/16” between
the top of the fly boom and inside of the outer mid 4.6 JIB LIFT END OF STROKE DAMPENING
boom.
The jib lift cylinder is constructed in a way that causes the jib
9. Repeat steps 1-7 to install the fly/outer mid assembly lift cylinder oil flow to be restricted by an orifice while raising
into the inner mid boom. the jib within 5 degrees of maximum elevation. This restriction
slows the jib lift speed while raising the jib. The oil flow is not
10. Repeat steps 1-7 to assemble the fly/out mid/inner mid
restricted while lowering the jib and therefore the speed is not
assembly into the base boom.
altered.
11. Complete the boom assembly. The boom should be
functionally tested and evaluated for boom sweep.
Boom sweep should be limited to no more than 5/16" (8 4.7 LOAD SENSING PIN REMOVAL AND
mm). If necessary, the boom may be re-shimmed by INSTALLATION
moving shims from one side to the other to further cor-
rect any remaining boom sweep. There may be some 1. Place the machine on a firm, level surface.
instances where no shims are used under a given side
pad to pass the criteria for boom sweep at final inspec- NOTE: Replacing the load sensing pin requires the boom sensors
tion of machine. be re-calibrated. Make sure the machine is in an area
where this can be accomplished after installation of the
new pin.
2. Swing the engine tray out to gain access to the sensing

pin and retaining pin.
NOTE: The lift cylinder weighs 787 lbs. (357 kg.)
4-44 – JLG Lift – 3121142

3. Run a nylon strap capable of supporting the weight of 6. Use the Load Pin Removal Tool (JLG P/N 4846765) to pre-
the lift cylinder around the bottom of the cylinder. Lift vent the pin from being damaged, and use a hammer to
up on the strap to relieve the weight of the lift cylinder remove the pin. To make the tool refer to Figure 4-16.,
on the load sensing pin. Load Pin Removal Tool, JLG P/N 4846765. If the Load Pin
Removal Tool is not available, use an arbor of the proper
size (as shown below). If excessive force is necessary to
move the pin, it may be necessary to carefully activate
lift using the auxiliary power switch to relieve lift cylin-
der weight from the load sensing pin.
7. When installing a new pin, make sure all of the holes in

4. Loosen and remove the bolt that secures the retaining the turntable and lift cylinder are aligned. If the new
pin and remove the retaining pin. load sensing pin does not push 1/2 to 3/4 of the way in
by hand, remove the pin and align the holes better. Also
make sure the pin is installed with the strain relief con-
nector opposing the pin orientation bar as shown. Refer
to Figure 4-22., Pivot Pin Installation.
5. Disconnect the wiring harness from the strain relief con-

nector at the opposite side of the load sensing pin.
8. Using an oak block, carefully tap the pin until it is fully

installed. Secure the pin in place with the retaining pin
and retaining pin bolt.
DO NOT TAP ON THE CENTER OF THE PIVOT PIN.
9. Connect the wiring harness to the strain relief connector

and re-calibrate the boom sensors.
3121142 – JLG Lift – 4-45

Figure 4-16. Load Pin Removal Tool, JLG P/N 4846765
4-46 – JLG Lift – 3121142

Figure 4-17. Boom/Jib Sensors and Switches Installation - Sheet 1 of 4
3121142 – JLG Lift – 4-47

4-48 – JLG Lift – 3121142

3121142 – JLG Lift – 4-49

4-50 – JLG Lift – 3121142

0271875 D
1. Bar
2. Blade
3. Mount
A Adjust top blades 0.000 to 0.063" (0 to 1.6 mm) from top boom plate
B Adjust side blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate
C Apply Loctite #242 & torque to 50 ft.lbs. (70 Nm)
Figure 4-21. Boom Wiper Installation
3121142 – JLG Lift – 4-51

1 Pivot Pin
2 Bolt
3 Keeper Rod
4 Load Sensing Pin
5 Pin Orientation Bar
* Position the Load Sensing Pin with the strain relief connector opposite the pin
orientation bar as shown
CAUTION: Pounding on the Load Sensing Pin for removal can destroy the internal
strain gauge. Use care when removing the pin.
Figure 4-22. Pivot Pin Installation
4-52 – JLG Lift – 3121142

4.8 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of
the powertrack.
One Piece Bracket Maintenance

1. Place the powertrack on a workbench.
4. Pull up on the loose side of the round bar to allow the

poly roller to slide off.
2. Remove the screws from the bars on one side of the

powertrack on the first link.
3121142 – JLG Lift – 4-53

5. Slide the poly roller off of the round bar. 7. Slide the flat bar out.
6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
4-54 – JLG Lift – 3121142

10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance
bracket side up and over the extrusion on the link.
1. Loosen the screw.
11. Repeat the previous step on the other side.
2. Slide the roller off the bar.
12. Slide the bracket off of the powertrack.
3. Hold the bar tightly and remove the other screw.
3121142 – JLG Lift – 4-55

4. Hold the flat bar and remove the screws. 7. Slide the link out.
5. Remove the snap rings and pins. Snap Rings and Screws
WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO

DISCARD AND REPLACE ALL OLD SCREWS.
Make sure screws are tight and installed properly.
6. Remove the screws from the bar. Remove the snap ring
and pin. LOOSE SCREW TIGHT SCREW
4-56 – JLG Lift – 3121142

Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below.
CLOSED
OPEN
10-24 x 0.812 button torx socket head with blue locking patch:
An open snap ring is shown below. • Tighten to 45-50 in.lbs. (5-5.6 Nm).
• Use T-25 torx bit.
• Do not reuse this screw. After removing replace with a new
one.
A snap ring that is not seated is shown below.
3121142 – JLG Lift – 4-57

4-58
– JLG Lift –
0271570-K
0271800-J
Figure 4-23. Powertrack Installation - Sheet 1 of 6
3121142
3121142
– JLG Lift –
0271570-K
0271800-J
4-59
4-60
– JLG Lift –
0271570-K
0271800-J
3121142
3121142
– JLG Lift –
0271570-K
0271800-J
4-61
4-62
Table 4-1. Hose/Cable Pull Chart
LETTER DESCRIPTION DIM "X"
IN. CM
P LEVEL UP HOSE (PORT L1) 64 162.5
Q LEVEL DOWN HOSE (PORT L2) 64 162.5
R SWING RIGHT HOSE (PORT S1) 64 162.5
S SWING LEFT HOSE (PORT S2) 64 162.5
T JIB LIFT UP HOSE (PORT J1) 64 162.5
U JIB LIFT DOWN HOSE (PORT J2) 64 162.5
NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm)
Table 4-1. Hose/Cable Pull Chart
– JLG Lift –
LETTER DESCRIPTION DIM "X"
FT. (IN.) CM
A HARNESS, TRANSPORT LIMIT SWITCH (18/3 CABLE) 6 (72) 182.8
B HARNESS, BOOM ANGLE SENSOR (LEFT) (18/3 CABLE) 1.5 (18) 45.8
C HARNESS, BOOM ANGLE SENSOR (RIGHT) (18/3 CABLE) 1.5 (18) 45.8
D HARNESS, BOOM LENGTH SENSOR (18/3 CABLE) 1.5 (18) 45.8
E BROKEN CABLE PROXIMITY SENSOR (YELLOW CABLE) 5 (60) 152.4
F AC CABLE (10/3) 13 (156) 396.2
G CONTROL CABLE (18/8) 6 (72) 182.8
H TELESCOPE EXTEND HOSE (5/8 10M3K) 7 (84) 213.3
I TELESCOPE RETRACT HOSE (1/2 8M3K) 7 (84) 213.3
J PRESSURE HOSE TO PLATFORM VALVE (3/8 6M4K) 6 (72) 182.8
K RETURN HOSE TO PLATFORM VALVE (1/2 8M3K) 6 (72) 182.8
L AIR LINE (1/2 8LOLA) OPTIONAL 10 (120) 304.8
M WELD LEAD (3/0 CABLE) OPTIONAL 10 (120) 304.8
N 7500W GENERATOR (8/5 CABLE) OPTIONAL 10 (120) 304.8
NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm)
0271570-K
0271800-J
3121142
3121142
– JLG Lift –
0271800-J
4-63
4.9 HOSE ROUTING PROCEDURE 6. Inspect sheaves with a groove wearout gauge for exces-
sive wear.
For proper hose routing and cable wrap placement and
clamping, refer to Figure 4-23., Figure 4-24., Figure 4-25., Fig-
ure 4-26., Figure 4-27., and Figure 4-28. It is important to peri-
odically inspect hoses, wraps and clamps for proper slack
adjustments and clamping integrity (pull check). Any
changes as a result of inspection should be verified by per-
forming full strokes of boom functions especially lift, tele-
scope, jib, and platform rotate.
4.10 WIRE ROPE Observe the groove so that it may be clearly seen
Each day before using the machine: whether the contour of the gauge matches the
contour of the bottom of the groove.
1. Raise the main boom to approximately horizontal.
7. Ropes passing inspection should be lubricated with wire
2. Extend and retract the boom sections. rope lubricant before reassembly.
3. Check for delayed movement of the fly section, which
indicates loose wire ropes. Three Month Inspection
1. Remove boom covers and visually (with flashlight)
Inspection inspect the ropes for rust, broken wires, frays, abuse, or
any signs of abnormalities.
NOTE: The pictures in this paragraph are just samples to show the
replacement criteria of the rope. 2. Check rope tension by deflecting the ropes by
hand...properly tensioned ropes should have little or no
1. Inspect ropes for broken wires, particularly valley wire movement.
breaks and breaks at end terminations.
Eight Year Inspection
1. Mandatory wire rope and sheave replacement.
Additional inspection required if:

a. Machine is exposed to hostile environment or con-
Flexing a wire rope can often expose broken wires hid-
ditions.
den in valleys between strands.
b. Erratic boom operation or unusual noise exists.
c. Machine is idle for an extended period.
2. Inspect ropes for corrosion.
d. Boom is overloaded or sustained a shock load.
3. Inspect ropes for kinks or abuse. e. Boom exposed to electrical arc...wires may be fused
internally.
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, 3. Kinked, “bird caged”, or crushed ropes.
installation, or operation.
4. Ropes at end of adjustment range.
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.) 5. Sheaves failing wearout gage inspection.
5. Inspect sheaves for condition of flanges. (See Dimension 6. Ropes with 6 total broken wires in one rope lay, 3 in one
Of Sheaves for proper dimension.) strand in one rope lay, 1 valley break, or 1 break at any
end termination.
4-64 – JLG Lift – 3121142

4.11 WIRE ROPE TENSIONING ADJUSTMENT INNER MID BOOM SECTION REPOSITIONING
The inner mid section of the boom is positioned by the
hydraulic cylinder. No adjustments can be made to this sec-
tion. The wire ropes within the assembly only control the
ANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED, BOOM CALI- movement of the Outer Mid Boom and Fly Boom sections.
BRATION SHOULD BE PERFORMED IMMEDIATELY AFTERWARD.
OUTER MID BOOM SECTION REPOSITIONING
Before adjusting wire rope tension, the boom sections must If the Outer Mid Boom falls within the dimension and toler-
be in the proper position as shown in Figure 4-30., Wire Rope ance of Figure 4-30., Wire Rope Tensioning, proceed to the Fly
Tensioning. This is so the wire ropes are equalized on both Boom Section Positioning procedure in this section. If the
sides of the sheaves and are seated properly in the sheave Outer Mid Boom section is outside of the tolerance as shown,
grooves. This is necessary for proper tensioning of the wire perform the following procedure.
ropes.
1. Extend the boom assembly so the platform moves 5 to 6
This section covers the two major operations in tensioning the feet (1.5 to 1.8 m) from the fully retracted position.
wire ropes which are as follows:
2. Remove any covers necessary to access the wire rope
• Positioning the boom sections (so that proper tensioning adjustment nuts.
can be achieved).
• Tensioning the wire rope.
Boom Section Re-Positioning

NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom section will also affect the position of the Fly Boom
section. Correctly position the Outer Mid Boom before
repositioning the Fly Boom.
NOTE: Use the Telescope function of the machine to position the

boom sections. Do not use the wire rope adjustment nuts
to position the booms. This may cause damage to the wire
rope adjustment threads.
1. Ensure the machine is placed on firm, level ground.

2. Before making any adjustments, position the boom
assembly in the fully retracted position.
3. Take preliminary measurements of the position of each
boom section and compare them to Figure 4-30., Wire
Rope Tensioning. If the measurements fall within the tol-
erances in the figure, proceed to Wire Rope Tensioning
in this section.
PROPER BOOM POSITIONS DO NOT MEAN THAT THE WIRE ROPE TENSIONS
ARE CORRECT.
If the measurements do not fall within the tolerances in Figure

4-30., Wire Rope Tensioning, adjust the booms using the re-
positioning procedures that follow.
3121142 – JLG Lift – 4-65

3. Remove the lock plates and nylon collar locknuts from a. If the Outer Mid Boom still does not fall within the
the wire rope adjustment nuts. dimension and tolerance of Figure 4-30., repeat the
Outer Mid Boom positioning procedure.
b. If the Outer Mid Boom falls within the dimension
and tolerance of Figure 4-30., proceed to the Fly
Boom Section Positioning procedure in this section.
NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom Section will also affect the position of the Fly Boom
section. After repositioning the Outer Mid Boom, always
check the Fly Boom position per Figure 4-30.
FLY BOOM SECTION REPOSITIONING

If the Fly Boom section location and the Outer Mid Boom sec-
tion location are both within the dimensions and tolerances in
Figure 4-30., proceed to the Wire Rope Tensioning Procedure
Outer Mid Retract Adjusting in this section.
Nuts and Lock Plates
If the Fly Boom section is outside of the tolerance as shown in
Figure 4-30. while the boom assembly is fully retracted, per-
form the following procedure:
1. Extend the boom assembly such that the platform
moves 5 to 6 feet (1.5-1.8 m) from the fully retracted
position.
2. Remove the lock plates and nylon collar locknuts from
the wire rope adjustment nuts.
3. If the Fly Boom needs to be retracted farther in:
a. Loosen the Fly Boom Extend Adjustment Nuts by an
Outer Mid Extend Adjusting amount equal to twice the distance the boom needs
Nuts and Lock Plates to move to be in tolerance.
4. If the Outer Mid Boom needs to be retracted:

a. Loosen the Outer Mid Boom Extend Adjustment
Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance.
b. Fully retract the boom.
c. To remove the slack caused by the previous step,
tighten the Outer Mid Boom Extend Adjustment
Nuts until they just contact the plate.
5. If the Outer Mid Boom needs to be extended out:
a. Loosen the Outer Mid Boom Retract Adjustment Fly Boom Extend Adjusting
Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance
b. Fully retract the boom.
b. Extend the boom 3-4 feet (1-1.5m).
c. To remove the slack caused by the previous step, tighten the Fly Boom Extend Adjustment Nuts until
tighten the Outer Mid Boom Retract Adjustment they just contact the plate.
Nuts until they just contact the plate.
6. Fully retract the boom sections.
7. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-30., Wire
Rope Tensioning.
4-66 – JLG Lift – 3121142

4. If the Fly Boom needs extended: 1. Remove any covers necessary to access the wire rope
adjustment nuts.
a. Loosen the Fly Boom Retract Adjustment Nuts by an
amount equal to twice the distance the boom needs
to move to be in tolerance.
Fly Boom Retract Adjusting

b. Extend the boom 3-4 feet (1-1.5m).
tighten the Fly Boom Retract Adjustment Nuts until
they just contact the plate.
d. Fully retract the boom sections.
5. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-30., Wire
Rope Tensioning.
a. If the Fly Boom still does not fall within the dimen-
sion and tolerance of Figure 4-30., repeat the Fly 2. If not already done, remove the lock plates and nylon
Boom Section Repositioning procedure. collar locknuts from the wire rope adjustment nuts.
b. If the Fly Boom falls within the dimension and toler- 3. Position the boom so that it is horizontal within ±5°. If
ance of Figure 4-30., proceed to the Wire Rope Ten- the boom is below horizontal, ensure that the boom is
sioning Procedure. not on the boom rest.
Wire Rope Tensioning Procedure 4. Extend the boom so the platform moves 5 to 6 feet (1.5-
1.8 m) from the fully retracted position. This is done to
NOTE: Verification of the rope tension should be determined by position the boom so the ropes to be tensioned are not
proper function of the boom assembly and by the dimen- under load.
sions and tolerances of Figure 4-30., Wire Rope Tensioning. 5. When extending the boom in the previous step, if the
boom reaches the end of travel and then automatically
retracts a small amount, the ropes may still be under
load. If so, perform the following steps:
REPEAT WIRE ROPE TENSIONING PROCEDURE ONLY AS NECESSARY TO
ACHIEVE PROPER TENSION. a. Note where the boom hits the end of stroke.
b. Retract 3-4 feet (1-1.3 m).
c. Extend the boom and stop just before the boom
IF THE BOOMS HAVE BEEN PROPERLY POSITIONED AND THERE IS NOT hits the end of stroke.
ENOUGH ADJUSTMENT REMAINING ON THE WIRE ROPES TO ACHIEVE TORQUE,
THE SERVICE LIFE OF THE WIRE ROPES HAS BEEN CONSUMED. DO NOT PRO-
CEED WITH THE REMAINDER OF THIS PROCEDURE. REPLACE THE WIRE ROPES
AND SHEAVES.
3121142 – JLG Lift – 4-67

6. Using tool JLG p/n 4120043, torque the Outer Mid Boom 9. Using tool JLG p/n 4120043, torque the Outer Mid Boom
Retract Adjustment Nuts to 80 ft-lb (108 Nm), alternat- Extend Adjustment Nuts to 80 ft-lb (108 Newton
ing between the two ropes until both maintain the meters), alternating between the two ropes until both
required torque. maintain the required torque.
Outer Mid Extend Adjusting

Outer Mid Retract Adjusting
Nuts and Lock Plates 10. Using tool JLG p/n 4120040, torque the Fly Extend
Adjustment Nuts to 10 ft-lb (13.5 Nm), starting with the
inside ropes and doing the outside ropes last. Refer to
7. Using tool JLG p/n 4120043, torque the Fly Boom Retract
Figure 4-29., Torque Sequence for Fly Extend Rope.
Adjuster Nuts to 80 ft-lb (108 Nm), alternating between
Alternate between the four ropes until all maintain the
the two ropes until both maintain the required torque.
required torque.
Fly Boom Retract Adjusting Fly Boom Extend Adjusting

Nuts and Lock Plates Nuts and Lock Plates
8. Retract the boom 2-3 feet (0.6-1.0 m). Do not fully retract
or bottom out the booms.
3 1 2 4
Figure 4-29. Torque Sequence for Fly Extend Rope
4-68 – JLG Lift – 3121142

11. Repeat the following boom movement steps three 18. Install all covers.
times. This is to ensure that the wire rope tension has
equalized on both sides of the sheaves and the ropes are
seated properly in the sheave grooves.
a. Fully retract the boom.
b. Extend the boom such that the platform moves 5 to
6 feet (1.5-1.8 m) from fully retracted position.
12. Verify the Fly Boom and Outer Mid Boom Retract wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
13. Retract the boom 2-3 feet (0.5-1 m). Do not fully retract
or bottom out the boom.
14. Verify the Fly Boom and Outer Mid Boom Extend wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
15. Check for proper function of the boom assembly. When
properly torqued and positioned, all three moving
boom sections will move simultaneously.
16. Install new nylon collar locknuts to the Fly Boom Extend
wire rope fittings. Do not re-use the old nylon collar lock
nuts. Torque the locknuts to 10 ft-lb (13.5 Nm)
17. Reinstall the lock plates to the remaining adjuster nuts.
3121142 – JLG Lift – 4-69

9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
FLY BOOM
BASE BOOM OUTER MID BOOM
INNER MID BOOM
NOTE: Boom shown in fully retracted position.
Figure 4-30. Wire Rope Tensioning
4-70 – JLG Lift – 3121142

Figure 4-31. Outer Mid Boom Extend/Retract Cables
3121142 – JLG Lift – 4-71

Figure 4-32. Fly Boom Extend/Retract Cables
4-72 – JLG Lift – 3121142

1. 2" Socket
2. 3/4” Socket
3. Retaining Bolt
Figure 4-33. Wire Rope Adjustment Tools (Optional)
3121142 – JLG Lift – 4-73

4.12 BROKEN BOOM CABLE PROXIMITY SWITCH To avoid damaging the proximity switch, install and adjust
after assembling the switch block, compression spring, and
This system uses a proximity switch to detect excessive move- torquing the wire ropes.
ment of the cable block. If movement is detected the Cable
Break indicator will illuminate in the platform control panel.
No restrictions are made to the functionality of the control sys-
Adjusting the Proximity Switch
tem. It is the responsibility of the operator to take immediate 1. Thread the switch in until it contacts the adjuster block.
action.
2. Thread the switch out 1/8 to 1/2 turn to achieve proper
sensing range.
3. Tighten the jam nut.
Figure 4-34. Broken Boom Cable Proximity Switch Location
4.13 ELECTRONIC PLATFORM LEVELING PRIMARY AND SECONDARY TILT SENSOR INTERACTION
The secondary tilt sensor is used as a backup to the primary tilt
sensor. Any time a tilt set point is reset, a value from each sen-
sor shall be set.
tem.
If a fault occurs with the primary sensor, control will revert to
Description the secondary sensor. (This is discussed in more detail in the
error response section.)
Electronic platform leveling replaces the conventional hydrau-
lic method of platform leveling. Because of the mounting orientation of the tilt sensors, the
primary tilt sensor will output ascending voltage values with
To control electronic platform leveling the platform is
increases in positive platform tilt angle. The backup or second-
equipped with a pair of tilt sensors, one primary and one sec-
ary tilt sensor will output descending voltage values with
ondary, mounted to the non-rotating portion of the platform
increases in positive platform angle.
rotator. The tilt sensors are monitored regularly and the plat-
form level up and down valves are automatically controlled to
maintain set point as the machine is operated.
4-74 – JLG Lift – 3121142

PLATFORM VALVES In order to obtain acceptable performance while performing

all hydraulic functions, five sets of parameters are used. These
The platform specific valves are located in a manifold at the
“zones” allow compensation for differences in how the basket
platform.
level changes when doing different functions. These zones are
There are individual proportional control valves that control as follows:
each of the four platform functions; Platform Level, Platform
1. Lift up
Rotate, Jib Lift, and Jib Swing.
2. Lift down
There is also a Platform Dump Valve, located in the platform
valve manifold, which is used to hydraulically isolate the con- 3. Other boom functions
trol valves and to improve hydraulic response.
4. Drive
The Ground Module controls this valve to provide manual
5. Auxiliary
platform leveling in the event that the Platform Module is
inoperable. The other boom functions zone includes Swing, Telescope, Jib
swing (It is not necessary to level with jib lift, since the
In ground mode, the platform dump valve is turned on when-
mechanical linkage keeps the basket level).
ever any platform or jib valve output is turned on. Whenever
all platform and jib valves are turned off, the platform dump These zones are prioritized when multiple functions are active.
valve is turned off. The priorities are as follows.
In platform mode, the platform dump valve is turned on 1. Auxiliary power and any other function, zone = auxiliary
whenever the footswitch is depressed. power
2. Drive and any other function, zone = Drive
Normal Operation
AUTOMATIC LEVELING 3. Lift up and any other function, zone = Lift up
Two tilt sensors, mounted on either side of the platform sup- 4. Lift down and any other function, zone = Lift down
port, are used to measure the incline of the platform with 5. Other boom functions, zone = Other boom functions
respect to gravity and control the automatic leveling function,
one is used as the primary sensor and one as a secondary back During the power-up procedure, function enable, in both Plat-
up sensor. form and Ground Mode, is delayed during the 1.5 second
startup lamp test. During this 1.5 second startup period, the
The level system shall assume a new fixed set point (fixed basket level up valve will be energized at 100% duty cycle for
incline of the platform with respect to gravity) each time the 0.5 second, and then the basket level down valve energized at
control system is powered up (cycling of the EMS). 100% duty cycle for 0.5 second. This will help to keep the
Automatic platform leveling only functions while operating valves from sticking.
drive, telescope, lift or swing. It does not operate while operat- PLATFORM LEVEL MANUAL OVERRIDE
ing any other function (e.g. rotate, jib, or steer).
In addition to automatic leveling the operator is able to manu-
The proportional control for these valves varies. This is depen- ally adjust the platform level position by means of the level
dant on the tilt variance from target as well as on the impact override switches located at the platform and ground control
coil temperature is having on the current to the valves. positions (similar to a Master/Slave hydraulic system).
If a command from the Platform Level Up and Down toggle The level system assumes a new set point after a level over-
switch on either the platform or the ground is received, auto- ride switch is operated. In other words the operator can chose
matic platform leveling will cease and the appropriate output a platform level incline other than level with gravity and the
will be commanded to turn on. system will maintain this set point during automatic leveling.
When the toggle switch is released, after ¼ second, the current
filtered value of tilt angle will be taken as the new set point.
3121142 – JLG Lift – 4-75

4.14 ROTARY ACTUATOR Required Tools

Upon assembly and disassembly of the actuator there are
Theory of Operation basic tools required. The tools and their intended functions are
The L20 Series rotary actuator is a simple mechanism that uses as follows:
the sliding spline operating concept to convert linear piston
motion into powerful shaft rotation. Each actuator is com-
posed of a housing with integrated gear teeth (01) and only
two moving parts: the central shaft with integrated 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 diameter of the piston. The
outside diameter of the piston carries a second set of splines,
of opposite hand, which engage with matching splines in the
housing. As hydraulic pressure is applied, the piston is dis-
placed axially within the housing - similar to the operation of a
hydraulic cylinder - while the splines cause the shaft to rotate.
When the control valve is closed, oil is trapped inside the actu-
ator, preventing piston movement and locking the shaft in
position.
1. Flashlight - helps examine timing marks, component

failure and overall condition.
2. Felt Marker - match mark the timing marks and outline
troubled areas.
3. Allen wrench - removal of port plugs and set screws.
4. Box knife - removal of seals.
5. Seal tool - assembly and disassembly of seals and wear
guides.
6. Pry bar - removal of end cap and manual rotation of
shaft.
7. Rubber mallet- removal and installation of shaft and pis-
ton 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 screw-
Bars indicate starting positions As fluid pressure is applied, the driver. To make this tool you will need to heat the flat end with
of piston and shaft. Arrows indi- piston is displaced axially while
a torch. Secure the heated end of the screwdriver in a vice and
cate direction they will rotate. the helical gearing causes the
The housing with integral ring piston and shaft to rotate simul-
physically bend the heated end to a slight radius. Once the
gear remains stationary. taneously. The double helix radius is achieved round off all sharp edges of the heated end
design compounds rotation: by using a grinder. There may be some slight modifications for
shaft rotation is about twice that your own personal preference.
of the piston.
The shaft is supported radially by the large upper radial bear-

ing and the lower radial bearing. Axially, the shaft is separated
from the housing by the upper and lower thrust washers. The
end cap is adjusted for axial clearance and locked in position
by set screws or pins.
4-76 – JLG Lift – 3121142

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-35. Rotary Actuator - Exploded View
3121142 – JLG Lift – 4-77

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-36. Rotary Actuator - Assembly Drawing
4-78 – JLG Lift – 3121142

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

entire pin.
1. Remove the cap screws (113) over end cap lock pins
4. Install the end cap (4) removal tools provided with the
(109).
Helac seal kit.
2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center

of each lock pin to a depth of approximately 3/16” 5. Using a metal bar, or something similar, unscrew the end
(4.76mm). 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 5/1
3121142 – JLG Lift – 4-79

6. Remove the end cap (4) and set aside for later inspec- 8. Every actuator has timing marks for proper engage-
tion. ment.
7. Remove the stop tube if included. The stop tube is an

available option to limit the rotation of the actuator.
9. Prior to removing the shaft, (2), use a felt marker to

clearly indicate the timing marks between shaft and pis-
ton. This will greatly simplify timing during assembly.
4-80 – JLG Lift – 3121142

10. Remove the shaft (2). It may be necessary to strike the 13. At the point when the piston gear teeth come out of
threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis-
ton 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 should 14. Remove the o-ring (204) and backup ring (207) from end
now be timing marks on the housing (1) ring gear, the cap (4) and set aside for inspection.
piston (3) and the shaft (2).
15. Remove the wear guides (302) from the end cap (4) and
12. To remove the piston (3) use a rubber mallet and a plas- shaft (2).
tic mandrel so the piston is not damaged.
3121142 – JLG Lift – 4-81

16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202).
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 proceed
to the inspection process.
17. Remove the thrust washers (304), from the end cap (4)
and shaft (2).
18. Remove the wiper seal (304.1) from its groove in the end
cap (4) and shaft (2).
4-82 – JLG Lift – 3121142

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 criti-
cal 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 location
prior to re-assembly. Use the cut away drawing to refer-
2. Inspect the thrust washers (304) for rough or worn ence the seal orientations.
edges and surfaces. Measure it’s thickness to make sure
it is within specifications (Not less than 0.092” or 2.34
mm).
3121142 – JLG Lift – 4-83

2. Install the thrust washer (304) onto shaft (2) and end cap 4. Using a seal tool install the main pressure seal (205) onto
(4). 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 groove 5. Install the wear guide (302) on the end cap (4) and shaft
on the shaft (2) and end cap (4) around the outside edge (2).
of the thrust washer (304).
6. Install the inner T-seal (200) into the piston (3) using a
circular motion.
Install the outer T-seal (202) by stretching it around the

groove in a circular motion.
4-84 – JLG Lift – 3121142

Each T-seal has 2 back-up rings (see drawing for orienta- 7. Insert the piston (3) into the housing (1) as shown, until
tion). the outer piston seal (202) is touching inside the hous-
ing bore.
Beginning with the inner seal (200) insert one end of b/u
ring in the lower groove and feed the rest in using a cir- 8. Looking from the angle shown, rotate the piston (3) until
cular motion. Make sure the wedged ends overlap cor- the marks you put on the piston and the housing (1)
rectly. during disassembly line up as shown. Using a rubber
Repeat this step for the outer seal (202). mallet, tap the piston into the housing up to the point
where the gear teeth meet.
3121142 – JLG Lift – 4-85

9. Looking from the opposite end of the housing (1) you 11. Looking from the view shown, use the existing timing
can see if your timing marks are lining up. When they do, marks to line up the gear teeth on the shaft (2) with the
tap the piston (3) in until the gear teeth mesh together. gear teeth on the inside of the piston (3). Now tap the
Tap the piston into the housing the rest of the way until flange end of the shaft with a rubber mallet until the
it bottoms out. gear teeth engage.
10. Install the shaft (2) into the piston (3). Be careful not to 12. Install 2 bolts in the threaded holes in the flange. Using a
damage the seals. Do not engage the piston gear teeth bar, rotate the shaft in a clockwise direction until the
yet. 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 actuator.
4-86 – JLG Lift – 3121142

14. Coat the threads on the end of the shaft with anti-seize 17. Tighten the end cap (4). In most cases the original holes
grease to prevent galling. for the lock pins will line up.
18. Place the lock pins (109) provided in the Helac seal kit in
15. Install the 0-ring (204) and back-up ring (207) into the
the holes with the dimple side up. Then, using a punch,
inner seal groove on the end cap (4).
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 it is 19. Insert the set screws (113) over the lock pins. Tighten
threaded into the housing (1). them to 25 in. lbs. (2.825 Nm).
3121142 – JLG Lift – 4-87

Installing Counterbalance Valve Bleeding After Installation

Refer to Figure 4-37., Rotator Counterbalance Valve. NOTE: Bleeding will be necessary if excessive backlash is displayed
1. Make sure the surface of the actuator is clean, free of any after the actuator is installed. To do this, bleeder valves
contamination and foreign debris including old Loctite. must be installed in the actuator at the locations shown
below. The following steps are recommended when a mini-
2. Make sure the new valve has the O-rings in the counter- mum of two gallons (8 liters) is purged.
bores of the valve to seal it to the actuator housing.
3. The bolts that come with the valve are grade 8 bolts.
New bolts should be installed with a new valve. Loctite
#242 should be applied to the shank of the three bolts at
the time of installation.
4. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4
to 13.5 Nm). Do not torque over 125 inch pounds (14.1
Nm). Torque the 5/16-inch bolts 140 inch pounds (15.8
Nm). Do not torque over 145 inch pounds (16.3 Nm).
Testing the Actuator

If the equipment is available, the actuator should be tested on
a hydraulic test bench. The breakaway pressure — the pres-
sure at which the shaft begins to rotate — should be approxi-
mately 400 psi (28 bar). Cycle the actuator at least 25 times at
3000 psi (210 bar) pressure. After the 25 rotations, increase the
pressure to 4500 psi (315 bar) to check for leaks and cracks. 1. Connect a 5 foot (1.5 m) long 3/16" inside diameter, 5/
Perform the test again at the end of the rotation in the oppo- 16" outside diameter clear vinyl drain tube to each of
site direction. the two bleeder valves. Secure the tubes in place with
hose clamps.
TESTING THE ACTUATOR FOR INTERNAL LEAKAGE
2. Place the end of the tubes in a clean 5 gallon (19 L) con-
If the actuator is equipped with with a counterbalance valve,
tainer to collect the purged oil. The oil can be returned
plug the valve ports. Connect the hydraulic lines to the hous-
to the reservoir when the procedure is complete.
ing ports. Bleed all air from the actuator (see Installation and
Bleeding) Rotate the shaft to the end of rotation at 3000 psi 3. Open both bleeder valves 1/4 turn. Using the hydraulic
(210 bar) and maintain pressure. Remove the hydraulic line system, rotate the platform to the end of rotation and
from the non-pressurized side. maintain hydraulic pressure. Oil with small air bubbles
should be seen flowing through the tubes. Allow 1/2
Continuous oil flow from the open housing port indicates
gallon (2 L) of oil to be purged from the actuator.
internal leakage across the piston. Replace the line and rotate
the shaft to the end of rotation in the opposite direction. 4. Keep the bleeder valves open and rotate the platform in
Repeat the test procedure outlined above for the other port. If the opposite direction to the end of rotation. Maintain
there is an internal leak, disassemble, inspect and repair. hydraulic pressure until an additional 1/2 gallon (2 L) of
oil is pumped out.
5. Repeat steps 3 and 4. After the last 1/2 gallon (2 L) of oil
is purged, close both bleed nipples before rotating away
from the end of rotation.
4-88 – JLG Lift – 3121142

Figure 4-37. Rotator Counterbalance Valve
3121142 – JLG Lift – 4-89

A,B,D
C,D
A Torque to 50 ft.lbs. (68 Nm)

B Loctite #242
C Torque to 480 ft. lbs. (650 Nm)
D Check torque every 150 hours of operation
E Torque to 75 ft. lbs. (102 Nm)
Figure 4-38. Platform Support Torque Values
4-90 – JLG Lift – 3121142

SECTION 5. HYDRAULICS
5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in the
SYSTEM fitting, making sure the entire o-ring is completely satu-
When assembling connectors in the hydraulic that use o-ring rated.
fittings, it is necessary to lubricate all fittings with hydraulic oil
prior to assembly. To lubricate the fittings, use one of the fol-
lowing procedures.
NOTE: All O-ring fittings must be pre-lubricated with hydraulic oil

prior to assembly.
Cup and Brush

The following is needed to correctly oil the o-ring in this man-
ner:
• 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.
3121142 – JLG Lift – 5-1

Dip Method Spray Method

NOTE: This method works best with Face Seal o-rings, but will This method requires a pump or trigger spray bottle.
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 man- 2. Hold the fitting over a suitable catch can.
ner:
3. Spray the entire o-ring surface with a medium coat of
• A small leak proof container 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 in even coat of oil.
able to immerse more of the fitting into the saturated
sponge. This will also cause more oil to be dispersed
from the sponge.
5-2 – JLG Lift – 3121142

5.2 CYLINDER REPAIR

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 5-2. Cap Screw Removal
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER 4. Place the cylinder barrel into a suitable holding fixture.
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate the hydraulic power source and extend the cyl-

inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. If applicable, remove the cartridge-type holding valve
and fittings from the cylinder port block. Discard o-
rings.
Figure 5-1. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch for

easy realignment. Using an allen wrench, loosen the
eight (8) cylinder head retainer cap screws, and remove
cap screws from cylinder barrel.
6. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.
3121142 – JLG Lift – 5-3

1. Loctite #242 (Not Shown) 7. Barrel 13. Back-Up Ring 19. T-Seal
2. Locking Primer (Not Shown) 8. Rod 14. O-Ring 20. Washer Ring
3. Loctite #RC 609 (Not Shown) 9. Piston 15. O-Ring 21. Bolt
4. Capscrew 10. Not Used 16. Rod Wiper 22. Holding Valve
5. Tapered Bushing 11. Wear Ring 17. Seal 23. O-Ring Plug
6. Head 12. Back-Up Ring 18. Wear Ring
Figure 5-3. Axle Extension Cylinder
5-4 – JLG Lift – 3121142

11
6
24
24
11
1
12
10 4
3
10 19
20
16
5
18
17 15
23
22
17 21
25
13
2
11
11
1684081-C
1. Barrel 8. Locking Primer (Not Shown) 14. Not Used 20. O-ring
2. Rod 9. Loctite #RC 609 (Not Shown) 15. Wear Ring 21. Wiper
3. Piston 10. Bolt 16. Backup Ring 22. Seal
4. Bushing 11. Bearing 17. Lock Ring 23. Rod Seal
5. Head 12. O-ring Plug 18. Backup Ring 24. Bleeder Valve
6. Counterbalance Valve 13. Socket Head Bolt 19. O-ring 25. Washer Ring
7. Loctite #242 (Not Shown)
Figure 5-4. Axle Lockout Cylinder
3121142 – JLG Lift – 5-5

8
1A
1 11
10
12 4
17
22
3
22
17
18
19
18
6
20
16
15
15
5 2
23
21, 25
9
13, 24
2A
1684149-D
1. Barrel 8. Cartridge, Holding Valve 17. Ring, Lock

1A. Bushing 9. Washer Ring 18. Ring, Back-Up
2. Rod 10. Capscrew 19. O-Ring
2A. Bushing 11. O-Ring Plug 20. O-Ring
3. Piston 12. O-Ring Plug 21. Wiper, Rod
4. Tapered Bushing 13. Capscrew 22. Ring, Guide
5. Head 14. Not Used 23. Seal, Rod
6. Spacer 15. Wear Ring 24. Loctite #242 (Not Shown)
7. Holding Valve 16. Back-Up Ring 25. Loctite #RC 609 (Not Shown)
Figure 5-5. Level Cylinder
5-6 – JLG Lift – 3121142

30
28
29
27
4
5
10
13
1,2,24 12
22
16
12
13
14
15
14
26
20
19
21
7
18
2,3,17 8
23
25
30
1684162-D
1. Loctite #242 7. Head 13. Lock Ring 19. Backup Ring 25. Capscrew
2. Locking Primer 8. Rod 14. Back Up Ring 20. O-ring 26. Spacer
3. Not Used 9. Barrel 15. O-Ring 21. Wear Ring 27. Check Valve Cartridge
4. Capscrew 10. O-ring Plug 16. Wear Ring 22. Piston 28. Holding Valve Cartridge
5. Tapered Bushing 11. Not Used 17. Rod Wiper 23. Washer Ring 29. Pressure Regulator Valve
6. Not Used 12. Guide Ring 18. Rod Seal 24. Not Used 30. Bushing
Figure 5-6. Lift Cylinder
3121142 – JLG Lift – 5-7

7 13
13
1A
1A
1
13
13 8**
11
14
3
11 104
6
105 12*
106
109
101 102
110 103 4
101 5
107
16*,108
9
2
10
2A
2A
* Prior to S/N 79667

** Torque to 20 ft.lbs. (27 Nm) Max
1684173-D
1. Barrel 5. Spacer 11. Capscrew 101. Wear Ring 107. Seal

1A. Bushing 6. Tapered Bushing 12. Not Used 102. Wear Ring 108. Rod Wiper
2. Rod 7. Counterbalance Cartridge 13. O-ring Plug 103. Backup Ring 109. Backup Ring
2A. Bushing 8. Check Valve Cartridge 14. O-ring Plug 104. Seal 110. Seal
3. Piston 9. Washer Ring 15. Loctite #242 105. O-ring
4. Head 10. Capscrew 16. Not Used 106. O-ring
Figure 5-7. Jib Cylinder
5-8 – JLG Lift – 3121142

1. Barrel 7. Not Used 13. Wear Ring

2. Rod 8. Rod End Bushing 14. Piston Seal
3. Head 9. Barrel End Bushing 15. Wear Ring
4. Piston 10. Not Used 16. O-ring
5. Nut 11. Wiper 17. Back Up Ring
6. Loctite #222 (not shown) 12. Rod Seal 18. O-ring
Figure 5-8. Steer Cylinder - Prior to S/N 73367
3121142 – JLG Lift – 5-9

14
6
9
5* 12
10
8 3
11
7 13
1
* Torque to 400 ft.lbs. (542 Nm) Max

1684314-D
1. Cylinder Cap 6. Piston 11. O-ring

2. Rod 7. Backup Ring 12. Wiper
3. Head 8. Wear Ring 13. Piston Seal
4. Barrel 9. Wear Ring 14. Loctite #222 (not shown)
5. Nut 10. O-ring
Figure 5-9. Steer Cylinder - S/N 73367 to Present
5-10 – JLG Lift – 3121142

28 5
21
30
21
28
5
7 8
22
4 14 24
26
11
18 16
11
13
30
31
15 6
12
25**
19
17
20
29
27
23*
* Torque to 13 ft.lbs. (17.5 Nm)

** Torque to 120 ft.lbs. (163 Nm) 1684108 J
1. Loctite #242 8. Barrel 15. O-Ring 22. Piston 29. Flatwasher

2. Locking Primer 9. Rod 16. Backup Ring 23. Capscrew 30. O-Ring Plug
3. Not Used 10. Not Used 17. Rod Wiper 24. Capscrew 31. Head
4. Capscrew 11. Wear Ring 18. T-Seal 25. Capscrew
5. Bolt 12. Backup Ring 19. Rod Seal 26. Spacer
6. Bracket 13. Wear Ring 20. Retaining Ring 27. Valve Assembly
7. Tapered Bushing 14. O-Ring 21. Wear Pad 28. Flatwasher
Figure 5-10. Telescope Cylinder
3121142 – JLG Lift – 5-11

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,

HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
7. With the barrel clamped securely, apply pressure to the

rod pulling device and carefully withdraw the complete
rod assembly from the cylinder barrel.
Figure 5-12. Tapered Bushing Removal
13. Screw the piston CCW, by hand, and remove the piston
from cylinder rod.
14. Remove and discard the piston o-rings, seal rings, and
backup rings.
15. Remove piston spacer, if applicable, from the rod.
16. Remove the rod from the holding fixture. Remove the
Figure 5-11. Cylinder Rod Support cylinder head gland and retainer plate, if applicable. Dis-
card the o-rings, back-up rings, rod seals, and wiper
8. Using suitable protection, clamp the cylinder rod in a seals.
vise or similar holding fixture as close to the piston as
possible. Cleaning and Inspection
NOTE: Step 9 applies only to the steer cylinder. 1. Clean all parts thoroughly in an approved cleaning sol-
vent.
9. Loosen and remove nut which attaches the piston to the
2. Inspect the cylinder rod for scoring, tapering, ovality, or
rod, and remove the piston.
other damage. If necessary, dress rod with Scotch Brite
10. Loosen and remove the cap screw(s), if applicable, or equivalent. Replace rod if necessary.
which attach the tapered bushing to the piston.
3. Inspect threaded portion of rod for excessive damage.
11. Insert the cap screw(s) in the threaded holes in the outer Dress threads as necessary.
piece of the tapered bushing. Progressively tighten the
cap screw(s) until the bushing is loose on the piston.
12. Remove the bushing from the piston.
5-12 – JLG Lift – 3121142

4. Inspect inner surface of cylinder barrel tube for scoring 13. If applicable, inspect rod and barrel bearings for signs of
or other damage. Check inside diameter for tapering or correct excessive wear or damage. Replace as necessary.
ovality. Replace if necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
5. Inspect threaded portion of barrel for damage. Dress etc. to facilitate bearing installation.
threads as necessary. b. Inspect steel bushing for wear or other damage. If
6. Inspect piston surface for damage and scoring and for steel bushing is worn or damaged, rod/barrel must
distortion. Dress piston surface or replace piston as nec- be replaced.
essary. c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
7. Inspect threaded portion of piston for damage. Dress
threads as necessary. d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary. NOTE: Install pin into the composite bearing dry. Lubrication is
not required with nickel plated pins and bearings.
9. Inspect cylinder head inside diameter for scoring or
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 necessary.
12. Inspect cylinder head outside diameter for scoring or
other damage and ovality and tapering. Replace as nec-
essary.
Figure 5-13. Composite Bearing Installation
14. Inspect travel limiting collar or spacer for burrs and

sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
3121142 – JLG Lift – 5-13

Assembly 2. Use a soft mallet to tap a new wiper seal into the appli-
cable cylinder head gland groove. Install a new wear
NOTE: Prior to cylinder assembly, ensure that the proper cylinder ring into the applicable cylinder head gland groove.
seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components prior to

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

applicable cylinder head gland groove.
Figure 5-15. Poly-Pak Piston Seal Installation
Figure 5-14. Rod Seal Installation
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS ARE INSTALLED Figure 5-16. Wiper Seal Installation
PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAK-
AGE AND IMPROPER CYLINDER OPERATION.
5-14 – JLG Lift – 3121142

3. Place a new “O-ring and back-up seal in the applicable NOTE: The backup rings for the solid seal have a radius on one
outside diameter groove of the cylinder head. side. This side faces the solid seal.(See magnified insert in
Figure 5-18.)The split of seals and backup rings are to be
positioned so as not to be in alignment with each other.
Figure 5-17. 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: Main telescope cylinder piston has an o-ring installed

inside the spacer.
6. If applicable, correctly place new o-ring in the inner pis-

ton diameter groove. (The backup ring side facing the
O-ring is grooved.)
Figure 5-18. Piston Seal Kit Installation
7. If applicable, correctly place new seals and guide lock
rings in the outer piston diameter groove. (A tube, with
I.D. slightly larger than the O.D.of the piston is recom- 8. Using suitable protection, clamp the cylinder rod in a
mended to install the solid seal.) vise or similar holding fixture as close to piston as possi-
ble.
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.
3121142 – JLG Lift – 5-15

10. Thread piston onto rod until it abuts the spacer end and b. Tap each space once; this means the tapered bush-
install the tapered bushing. ing is tapped 3 times as there are 3 spaces between
the capscrews.
NOTE: When installing the tapered bushing, piston and mating
end of rod must be free of oil.
WHEN REBUILDING THE TELESCOPE, LIFT, JIB, LEVEL, AXLE LOCKOUT OR AXLE
EXTENSION CYLINDERS, TIGHTEN SECURELY. (SEE TABLE 5-1)
11. Assemble the tapered bushing loosely into the piston

and insert JLG capscrews (not vendor capscrews)
through the drilled holes in the bushing and into the
tapped holes in the piston.
Figure 5-20. Seating the Tapered Bearing
14. Retorque the capscrews evenly and progressively in

rotation to the specified torque value. (See Table 5-1,
Cylinder Head and Tapered Bushing Torque Specifica-
tions).
15. Remove the cylinder rod from the holding fixture.
16. Place new guide locks and seals in the applicable out-
side diameter grooves of the cylinder piston. (See Figure
5-18., Piston Seal Kit Installation)
17. Position the cylinder barrel in a suitable holding fixture.
Figure 5-19. Tapered Bushing Installation
12. Tighten the capscrews evenly and progressively in rota-

tion to the specified torque value. (See Table 5-1, Cylin- EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
der Head and Tapered Bushing Torque Specifications). HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft 18. With barrel clamped securely, and while adequately sup-
(approximately 3/4" in diameter) as follows; porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston loading o-ring and seal ring
a. Place the shaft against the cylinder rod and in con-
are not damaged or dislodged.
tact with the bushing in the spaces between the
capscrews. 19. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
5-16 – JLG Lift – 3121142

20. Secure the cylinder head gland using the washer ring Table 5-1. Cylinder Head and Tapered Bushing Torque
and socket head bolts. (See Table 5-1, Cylinder Head and Specifications
Tapered Bushing Torque Specifications and Table 5-2,
Holding Valve Torque Specifications) Tapered
Head Torque Value
Description Bushing Torque
(Wet)
Value (Wet)
Tele Cylinder (1200SJP) 120 ft. lbs. 30 ft. lbs.

(163 Nm) (40.5 Nm)
Tele Cylinder (1350SJP) 120 ft. lbs. 45 ft. lbs.

(163 Nm) (63 Nm)
Level Cylinder 120 ft. lbs. 9 ft. lb.s

(163 Nm) (12.6 Nm)
Jib Cylinder 30 ft. lbs. 5 ft. lbs.

(41 Nm) (9 Nm)
Figure 5-21. Rod Assembly Installation
Lift Cylinder 300 ft. lbs. 120 ft. lbs.
(410 Nm) (168 Nm)
21. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the Axle Oscillation 120 ft. lbs. 9 ft. lb.s
reinstallation of any holding valve or valves. Cylinder (163 Nm) (12.6 Nm)
22. If applicable, install the cartridge-type holding valve and
Axle Extend 50 ft. lbs. 9 ft. lb.s
fittings in the rod port block, using new o-rings as appli-
Cylinder (70 Nm) (12.6 Nm)
cable. (See Table 5-2, Holding Valve Torque Specifica-
tions).
Table 5-2. 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)
3121142 – JLG Lift – 5-17

1. Return Filter
2. Vented Fill Cap
3. Sight/Temperature Gauge
4. Suction Strainer
5. Magnetic Drain Plug
Figure 5-22. Hydraulic Tank
5-18 – JLG Lift – 3121142

A. Front Steer Valve/Axle Extend

B. Traction Valve
C. Rear Steer Valve/Axle Extend
D. Chassis Module Controller
E. Junction Manifold Valve
F. Axle Oscillation Valve
Figure 5-23. Chassis Control Valve Locations
3121142 – JLG Lift – 5-19

1. Level Up 6. Jib Swing Left 10. Level Up Relief 14. Main Pressure Check Port
2. Rotate Right 7. Jib Up 11. Jib Up/Down Relief 15. Level Up Test Port
3. Level Down 8. Jib Swing Right 12. Level Down Relief 16. Level Down Test Port
4. Rotate Left 9. Platform Dump 13. Filter or Plug 17. Jib Up/Down Test Port
5. Jib Down
Figure 5-24. Platform Valve Identification - JLG P/N 4641266
5-20 – JLG Lift – 3121142

1. Level Up 5. Jib Down 9. Platform Dump 13. Main Pressure Check Port
2. Rotate Right 6. Jib Swing Left 10. Level Up Relief 14. Level Up Test Port
3. Level Down 7. Jib Up 11. Jib Up/Down Relief 15. Level Down Test Port
4. Rotate Left 8. Jib Swing Right 12. Level Down Relief 16. Jib Up/Down Test Port
Figure 5-25. Platform Valve Identification - JLG P/N 4641460
3121142 – JLG Lift – 5-21

1. Aux Lift Down 5. Dump 9. Lift Up Relief 13. Tele Out Relief
2. Tele Out 6. Swing Relief 10. Lift Down Relief 14. Tele In Relief
3. Lift Up 7. Swing Left 11. Lift Flow 15. Tele Flow
4. Swing Right 8. Lift Down 12. Tele In 16. Lift Down/Aux Select
Figure 5-26. Main Valve Identification
5-22 – JLG Lift – 3121142

Table 5-3. Cartridge Torque Values
Ft-Lbs. Nm Ft-Lbs. Nm
1 25-30 33.9-40.6 9 30-35 40.6-47.4
2 25-30 33.9-40.6 10 30-35 40.6-47.4
3 30-35 40.6-47.4 11 30 40.6
4 30-35 40.6-47.4 12 30-35 40.6-47.4
5 30-35 40.6-47.4 13 30-35 40.6-47.4
6 30-35 40.6-47.4 14 30-35 40.6-47.5
7 30-35 40.6-47.4 15 30-35 40.6-47.5
8 30 40.6
Figure 5-27. Main Valve Cartridge Torque Values
3121142 – JLG Lift – 5-23

4 3
Table 5-4. Plug Torque Values
Ft-Lbs. Nm
1 115 156
2 100 135.5
3 40 54
4 13 17.5
Figure 5-27. Main Valve Plug Torque Values
5-24 – JLG Lift – 3121142

5.3 HYDRAULIC TANK 5.4 PRESSURE SETTING PROCEDURE

The hydraulic tank has a capacity of 55 gallons (208 liters) and Cold temperatures have a significant impact on pressure read-
includes the hydraulic return filter and two suction strainers. It ings. JLG Industries Inc. recommends operating the machine
is normal for the oil level to appear low when the boom is until the hydraulic system has warmed to normal operating
raised and should only be checked with the machine on level temperatures prior to checking pressures. JLG Industries Inc.
ground and with the boom fully retracted and lowered. The also recommends the use of a calibrated gauge. Pressure read-
hydraulic oil should be maintained at the full level as shown by ings are acceptable if they are within ± 5% of specified pres-
the decal and hydraulic oil level gauge located on the side of sures.
the tank as shown in Figure 5-27., Hydraulic Oil Level Gauge.
This decal shows the proper full level for both hot and cold oil. To ensure all pressures are set correctly, the following proce-
Do not fill the hydraulic tank past the appropriate full mark. dures must be followed in order.
Overfilling can cause the oil to overflow from the top of the
1. All applicable steps in Section 5.7, Drive & Function
hydraulic tank during emergency lowering operations.
Pump Start Up Procedures must be followed.
2. Set up of the function pump.
3. Adjustments made at the main valve bank.
4. Adjustments made at the platform valve.
Set Up of the Function Pump

HIGH PRESSURE RELIEF - 3400 PSI (234.4 BAR)
1. Install a high pressure gauge at the MP port of the main
valve block.
2. Using a screwdriver, remove the Din connector from the
lift down coil.
FULL LEVEL (HOT OIL)

3. Activate lift down. The gauge should read 3400 psi (234
bar).
FULL LEVEL (COLD OIL)
Figure 5-27. Hydraulic Oil Level Gauge
3121142 – JLG Lift – 5-25

4. To make an adjustment to this pressure, go back to the 3. To make an adjustment to this pressure, go to the
engine compartment to the function pump which is the engine compartment, locate the function pump. The
back pump. The high pressure relief adjustment is the stand by adjustment is the adjustment outside adjust-
adjustment closest to the pump. Using a 17 mm wrench, ment, closest to the turntable. Use the same tools that
remove the cover nut. Be careful not to lose the O-ring were used in the Hi pressure adjustment procedure.
washer inside the cover nut.
5. Loosen the jam nut at the setscrew with the 17 mm Adjustments made at the Main Valve Bank
wrench. Using a 3 mm allen wrench, adjust clockwise to LIFT UP - 2750 PSI (189.6 BAR)
increase, or counterclockwise to decrease. 1. Install a high pressure gauge at the M5 port of the main
6. After adjusting the pressure, tighten the jam nut and the valve block. Plug and cap the hose on port 5.
cover nut. This is the maximum relief pressure for all the 2. Activate lift up. The gauge should read 2750 psi (189.6
functions governed by this pump. Bar).
STAND BY PRESSURE OR LOW PRESSURE RELIEF - 300 PSI 3. The adjustment cartridge is located below the M5
(20.6 BAR) gauge port. Turn clockwise to increase, counterclock-
1. Install a low pressure gauge at port MP of the main valve wise to decrease.
block capable of reading 300 psi (20.6 bar). LIFT DOWN - 1500 PSI (103.4 BAR)
2. Start the engine, the gauge should read 300 psi (20.6 1. Install a high pressure gauge at the M4 port of the main
bar). valve block.
2. Activate lift down to the end of the stroke. The gauge
should read 1500 psi (103.4 bar).
3. The adjustment cartridge is located to the left of the M4
gauge port. Turn clockwise to increase, counterclock-
wise to decrease.
5-26 – JLG Lift – 3121142

SWING - 1500 PSI (103.4 BAR) STEERING, FRONT AND REAR

NOTE: Left and right are done with one adjustment. NOTE: The following procedure requires 2 people to perform. One
is needed for verifying / adjusting pressure readings and
1. Install a high pressure gauge at port MS. wheel spindle alignment the other for operating the steer
functions and using the Analyzer from the platform.
2. Lock the turntable pin.
3. Activate swing, the gauge should read 1500 psi (103.4 The Analyzer is required to perform the pressure check proce-
Bar). The adjustment cartridge is located below the MS dure through access of the calibration menu. The calibration
gauge port. menu will allow for extending and retracting the steer cylin-
ders individually, verifying pressures, and proper steer sensor
4. Turn clockwise to increase, counterclockwise to calibration. Verification of the steer sensor calibration will
decrease. require one of two types of measuring methods; using a
TELESCOPE OUT - 3000 PSI (206.8 Bar) square and ruler or using string as explained in Section 6 - JLG
Control System. The purpose of these measuring tools is to
1. Install a high pressure gauge at the M8 port of the main assure that the wheel spindle is aligned “straight” with the
valve bank. Plug the telescope out hose either at the extended axle weldment.
valve bank (port #8) or at the inlet of the telescope cylin-
der (V1). 1. Position the machine with both front and rear axles fully
extended.
2. Activate telescope out. The gauge should read 3000 psi
(206.8 Bar). 2. Install the Analyzer in the platform control box and scroll
menu’s to Access Level 2 and insert password (33271) to
3. The adjustment cartridge is located below the M8 get into Access Level 1.
wise to decrease.
TELESCOPE IN - 3200 PSI (220.6 BAR)
1. Install a high pressure gauge at the M7 port of the main
valve block.
2. Activate Telescope In. The gauge should read 3200 psi
(220.6 Bar).
3. The adjustment cartridge is located to the left of the M7
wise to decrease.
Adjustments Made at the Frame Valve Bank

AXLE EXTEND AND RETRACT, FRONT AND REAR - 2500 PSI
(172.3 BAR)
1. To extend the axles, drive the machine back and forth
3. Scroll to the calibration mode. Once in the calibration
until extended. A machine that cannot be driven must
mode, press “ENTER” and scroll to steer. Once in the
be jacked up.
steer calibration mode, the Analyzer is going to ask to
2. On both the front and rear frame valve banks, install a calibrate the steer sensors, this is going to allow extend-
high pressure gauge on ports MA1 for extend and MA2 ing and retracting each steer cylinder individually dur-
for retract. The gauge should read 2500 psi (172.3 Bar) in ing this process. The JLG control system will ask to
both directions. calibrate the left front sensor, the left rear sensor, the
right front sensor and finally the right rear sensor in that
3. The axle extend/retract cylinders are connected hydrau- order. During this calibration mode each individual steer
lically in parallel. In order to get the correct pressure of cylinder will be extended and retracted to verify correct
the circuit being adjusted, unscrew the solenoid coil pressures with the marked MS (Measure Steer) ports on
from the circuit not being adjusted and pull it away from the steer / axle valve that pertains to that steer cylinder.
the valve. Refer to the Hydraulic Schematic in Section 7 - Schemat-
4. Turn clockwise to increase, counterclockwise to ics.
decrease.
3121142 – JLG Lift – 5-27

Figure 5-28. Steer Pressure Adjustments
5-28 – JLG Lift – 3121142

4. Remove the front circular steer/axle access covers at the mounted next to the MS2 port, CW to increase or CCW
front of the chassis, and the rear square cover at the top to decrease.
rear of the chassis to gain access to the axle/steer valves.
6. Remove the pressure gauge from MS2 port and install

on the MS1 port, which is on the right side of the front
axle/steer valve, closest to the right front wheel spindle.
Position the steer switch to activate the left front steer
cylinder until the rod is in the fully retracted position
and hold the switch for a few seconds after the rod has
stopped. The MS1 port should read 2600 psi (179 Bar). If
the pressure is not correct, adjust relief valve next to
MS1 port, CW to increase or CCW to decrease.
5. Install a pressure gauge at the front axle/steer valve at

MS2 port. This should be located on the left side of the
valve closest to the left front wheel spindle. Position the
steer switch to activate the left front steer cylinder until
the rod is in the fully extended position and hold the
switch for a few seconds after the rod has been fully
extended. The MS2 port should read 2000 psi (138 Bar).
If the pressure is not 2000 psi (138 Bar) adjust relief valve
7. This step involves aligning the left front wheel spindle

with the axle weldment. Position the left front wheel
spindle “straight” using a square and rule or string for
proper alignment (Refer to Section 6 - JLG Control Sys-
tem). Once the left front wheel spindle has been prop-
erly measured, press “ENTER” on the Analyzer. This is
calibrating data to the JLG Control System that the left
front steer sensor is centered.
3121142 – JLG Lift – 5-29

8. Checking the left rear steer cylinder is identical to the mounted next to MS2 port CW to increase or CCW to
procedure for left front steer cylinder, except now we are decrease.
checking pressures at the rear axle/steer valve location.
Install pressure gauge at MS1 port. This should be
located on the left side of the valve closest to the left
rear wheel spindle. MS1 port should read 2600 psi (179
Bar) when the left rear steer cylinder is activated with
the rod in the fully retracted position. If the pressure is
not 2600 psi (179 Bar) adjust relief valve mounted next
to MS1 port CW to increase or CCW to decrease.
10. The next step is identical to the left front step men-
tioned above. Make sure the left rear wheel spindle is
straight and press “ENTER” to accept the new calibration
settings, now press “ESC” (escape) and scroll to the right
front steer calibration step.
11. Checking the right front steer cylinder is identical to the
procedure laid out for the left front steer cylinder, except
the pressures are now checked at MS3 port of the front
9. Remove the gauge from MS1 port and install on MS2
axle/steer valve. This should be at the right side of the
port, which is on the right side of the rear axle/steer
valve closest to the right front wheel spindle. Install the
valve, closest to the right rear wheel spindle. Position
gauge at MS3 port. Position the steer switch to activate
the steer switch to activate the left rear steer cylinder
the right front steer cylinder until the rod is in the fully
until the rod is in the fully extended position and hold
retracted position and hold the steer switch for a few
the steer switch for a few seconds after the rod has been
seconds after the rod has been fully retracted. If the
fully extended. The MS2 port should read 2000 psi (179
pressure is not 2600 psi (179 Bar), adjust the relief valve
Bar). If the pressure is not correct, adjust the relief valve
mounted next to the MS3 port CW to increase or CCW to
decrease.
5-30 – JLG Lift – 3121142

12. Remove the gauge from MS3 port and install on MS4 16. The next step is identical to the left front step men-
port, which is on the left side of the front axle/steer tioned above, make sure the right rear wheel spindle is
valve, closest to the left front wheel spindle. Position the straight and press “ENTER” to accept the new calibration
steer switch to activate the right front steer cylinder settings, now escape out of the calibration menu and
until the rod is in the fully extended position and hold remove the Analyzer and pressure gauge.
the steer switch for a few seconds after the rod has
stopped extending. The MS4 port should read 2000 psi Adjustments Made at the Platform Valve Bank
(138 Bar). If the pressure is not correct, adjust relief valve
PLATFORM LEVEL UP - 2500 PSI (172.3 BAR)
mounted next to the MS4 port CW to increase or CCW to
decrease. 1. Install a high pressure gauge at the gauge port M1.
13. The next step is identical to the left front step men- 2. Activate level up to the end of stroke, it should read
tioned above. Make sure the right front wheel spindle is 2500 psi (172.3 Bar).
straight and press “ENTER” to accept the new calibration
3. All the relief valves are located on the same face. The
settings. Scroll over to right rear steer calibration step.
level up relief valve is located closest to the M1 gauge
14. Checking the right rear steer cylinder is identical to the port. Turn clockwise to increase, counterclockwise to
procedure laid out for the left rear steer cylinder. Install decrease.
gauge at MS4 port of the rear axle/steer valve. This
PLATFORM LEVEL DOWN - 1500 PSI (103.4 BAR)
should be at the right side of the valve closest to the
right rear wheel spindle. Position the steer switch to acti- 1. Install a high pressure gauge at gauge port M2.
vate the right rear steer cylinder until the rod is in the
fully extended position and hold the steer switch for a 2. Activate level down to the end of stroke, it should read
few seconds after the rod has stopped extending. The 1500 psi (103.4 Bar).
MS4 port should read 2000 psi (138 Bar. If the pressure is 3. The level down relief valve is located to the left of the
not correct, adjust relief valve next to the MS4 port CCW level up relief valve. Turn clockwise to increase, counter-
to increase or CCW to decrease. clockwise to decrease.
15. Remove gauge from MS4 port and install on MS3 port, ARTICULATING JIB UP AND DOWN - 2750 PSI (189.6 BAR)
which is on the left side of the rear axle/steer valve, clos-
est to the left rear wheel spindle. Position the steer 1. Install a high pressure gauge on gauge port M3. The jib
switch to activate the right rear steer cylinder until the relief valve is located below the level down relief valve.
rod is in the fully retracted position and hold the steer Activate jib up or down, it should read 2750 psi (189.6
switch for a few seconds after the rod stops retracting. If Bar). Turn clockwise to increase, counterclockwise to
the pressure is not 2600 psi (179 Bar), adjust the relief decrease.
valve mounted next to the MS3 port CW to increase or
CCW to decrease.
3121142 – JLG Lift – 5-31

5.5 DRIVE PUMPS 2. Transmission does not propel the machine, diesel
engine running properly - Charge Pump/Relief Valve
Troubleshooting Procedure a. Is there any charge pressure at port G or indicated

by measuring pressure at Ma and Mb?
To aid in troubleshooting, refer also to the pressure measuring No - Proceed to step 2.d
port connections for test gauge installation information as Yes - Proceed to step 2.b
shown on the hydraulic circuit diagram. Procedure assumes
b. Is the charge pressure at least 500 psi while running
proper gauges are installed. (Minimum gauges required: (2) 0-
at high engine speed?
6000 psi, (1) 0-3000 psi & (1) 0-1000 psi [{2} 0-415 bar, {1} 0-210
No - Proceed to step 2.c
bar & {1} 0-70 bar]). This procedure was written to aid the trou-
Yes - Proceed to step 3.a
bleshooter in following a logical approach to a hydraulic sys-
tem fault. c. Can the charge pressure be raised by removing dirt/
debris from charge relief poppet or by adding or
1. Transmission does not propel the machine, diesel removing shims from the charge pressure relief
engine running properly valve mounted in the second pump of the triple?
a. Is there oil in the reservoir? No - Proceed to step 2.d
No - Fill reservoir Yes - Adjust pressure to 500 psi +50 psi, -0 psi (34.4
Yes - If yes, proceed to step 1.b bar +3.4 bar, -0 bar)
b. Is the pump input shaft connected to the engine NOTE: The propulsion circuit uses a hot oil flushing valve to
flex plate or rear of forward pump? obtain brake release pressure. The hot oil flushing valve
No - Connect pump input shaft cartridge (#120) is mounted in the Traction Control Mani-
Yes - If yes, proceed to step 1.c fold. The flushing valve receives its oil from the "left side"
c. Are the hydraulic hoses and tubing connected in wheel drive pump; the middle pump of the triple. With the
accordance with the hydraulic circuit diagram? engine running and propelling the machine forward or
reverse, the "hot oil flushing valve" and the brake release
No - Correct the hoses/tubing pressure must be adjusted to 475 psi, +25 psi, -0 psi (32.7
Yes - If yes, proceed to step 1.d bar, +1.7 bar, -0 bar), as set by adjusting pressure relief car-
d. Is the pump direction of rotation correct? (clockwise tridge (#130). The brake release pressure must be 25 psi less
as looking at the shaft) than the charge pump pressure. Measure pressure at port
"MP" using a 0-1000 psi (0 - 70 bar) pressure gauge.
No - Fit pump having the correct direction of rota-
d. Is the transmission pumps suction hose pinched
tion
shut?
Yes - If yes, proceed to step 1.e
No - Proceed to step 2e
e. Are there "O"-rings missing from fittings (as exam- Yes - Repair damaged hose
ple - suction leak), pinched hoses, broken tubing,
e. Is the charge pump suction pressure/vacuum within
etc?
recommended limits? (0.8 bar absolute or 6.3 inches
of mercury)
No - Proceed to step 1.f
Yes - Repair damage or fault
Yes - Proceed to step 2.g
f. Are the electrical connectors/wiring intact and
f. Is the suction strainer inside the reservoir blocked,
secure to the pump control solenoids?
clogged, restricted?
No - Repair damage or fault
No - Proceed to step 2.g
Yes - If yes, proceed to step 1.g
Yes - Repair/replace with a clean suction strainer
g. Does the engine "labor" when attempting drive, are
g. Is the reservoir air breather blocked or restricted?
the brakes released?
No - Proceed to step 2.h
No - Proceed to step 1.h
Yes - Clean or replace air breather
Yes - Check brake release circuit, measure pressure
at port "MP" on Traction Control manifold
h. Are all four wheel drive planetary reduction gear-
boxes engaged?
No - Engage wheel drive(s)
Yes - If yes, proceed to step 2.a
5-32 – JLG Lift – 3121142

h. Remove charge pressure relief valve from the mid- to step 3.a
dle pump and inspect. Is it damaged? Yes - Proceed to step 3.g
No - Refit cartridge and proceed to step 2.i g. Is it possible to adjust high pressure relief valves
Yes - Clean & inspect cartridge, poppet, springs, using 0-6000 psi (0 - 415 bar) gauges to monitor
seals to determine cause of damage. Repair or fit a pressure at Ma & Mb? (Refer to relief valve adjust-
new cartridge and return to step 2.a ment)
i. Remove and inspect charge pump assemblies. Are No - Replace high pressure relief valve and return to
they damaged? step 3.c
No - Proceed to step 2.j Yes - Adjust high pressure relief valves to 5000 psi
Yes - Repair and/or replace damaged components +50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
and return to step 2.a h. Actuate control in both directions. Does transmis-
j. Is the charge pump installed for the clockwise rota- sion operate?
tion? No - Check that minimum displacement stops on
No - Refit charge pump. Return to step 2.a the wheel drive motors are adjusted properly, check
Yes - With proper charge pressure and transmission that the motors stroke between maximum to mini-
still does not operate, proceed to step 3.a mum.
3. Transmission does not propel the machine, diesel Yes - Operate the transmission
engine running properly - Pump Control: (Insure Gener- 4. Transmission Drive is Sluggish or Erratic
ator Drive option is not turned "on")
a. Does the "EP" proportional pump control current
a. Are the electrical connectors & wiring connected vary with joystick movement?
properly to the pump control solenoids? No - Rectify the problem - broken wires, electrical
No - Connect a ammeter in series with solenoid wir- connector, open solenoid coil, etc.
ing. Is a current of 400 mA to 1060 mA being Yes - Proceed to step 4.b
applied. (Current signal varies with joystick position)
b. Are all four (4) brakes fully released?
Yes - Proceed to step 3.b
No - Check brake release pressure and insure each
b. Are all four of the two-speed motors, mounted in wheel receives correct release pressure.
the wheel drive planetary reduction gearboxes, Yes - Proceed to step 4.c
shifted to maximum displacement (high torque -
c. Are the pumps stroking time orifices installed tight
low speed)?
and clean?
No - Select maximum displacement
No - Remove the Plugs in ports X1 and X2. Remove
Yes - Proceed to step 3.c
orifices with a 3mm allen wrench. Check that orifices
c. Actuate the pump control in both directions. Do the
are clean & re-install.
pumps stroke? Do they go to full stroke?
Yes - Proceed to step 4.d
No - Refer to the pump service manual and then
proceed to step 3.d d. Is an motor displacement stroking time orifice
Yes - Operate the transmission plugged or is the two-speed shift hose pinched?
Yes - Inspect and clean stroking orifice, check two-
d. Remove stroking orifices in X1 and X2. Install pres-
speed hose routing
sure gauges in X 1 and X 2 (0-500 psi [0 - 35 bar]).
e. Is a flow divider/combiner cartridge stuck in the
Stroke the pump in both directions. Do the pres- Traction Control Manifold? Flow divider/combiner
sures at X1 and X2 alternate between 30 & 250 psi (2 cartridge # 111 controls the right side wheels, # 112
& 17 bar)? controls the left side wheels. Also check to insure
No - Remove the EP control module & replace it with bypass orifices #151 (right side) and # 152 (left side
a new unit. Repeat step 3.c are not plugged.
Yes - Proceed to step 3.e.
e. Is the pressure at port "R", case pressure, less than 15
psi (1 bar) gauge pressure?
No - Correct problem restricting case drain oil flow
(oil cooler blockage, pinched hoses, etc)
Yes - Proceed to step 3.f
f. Stroke pump in both directions, while measuring
pressure at Ma & Mb ports of the pump. Does any
pressure greater than charge pressure alternate
between ports Ma & Mb?
No - Verify that loading the pump will cause system
pressure to increase above charge pressure. Proceed
3121142 – JLG Lift – 5-33

5. Transmission Drives in one direction only 7. Transmission Does Not Find or Hold Neutral
a. Are electrical connections to pump control propor- a. Does pump remain in neutral with electrical con-
tional solenoids correct, intact and without defects? nectors removed?
Yes - Proceed to step 5.b No - proceed to step 7.b
No - Rectify the problem Yes - Check electrical system for signal problem
b. Check hot oil flushing valve cartridge #120 located b. With electrical connectors removed and machines
in the Traction Control Manifold. wheels jacked off the ground and engine running,
Remove and inspect flushing valve cartridge for momentarily apply 12 volt DC signal (battery volt-
stuck spool or damaged cartridge "O"-ring seals & age) to a pump control solenoid. Does the pump
backup rings. return to neutral after the 12 volt signal is removed?
c. Inspect "Make-Up" check valve cartridges, #190.1- No - Apply 12 volts to opposite solenoid & recheck.
190.4, installed in the Traction Control Manifold. Is a No - Replace pump control module, repeat step 7.a
cartridge "stuck" open with debris or is an "O"-ring Yes - Possibly dirt was dislodged from control mod-
failed? ule, re-check thoroughly to determine problem has
No - Proceed to step 5.d definitely been resolved.
Yes - Clean/repair or replace Make-Up check car- c. Check mechanical centering of the pumps
tridge. 8. Transmission Drives at a High Noise Level
d. Swap high pressure relief valves in the transmission. a. Are the wheel drive planetary reduction gearboxes
Does the transmission drive in the other direction? filled to the correct level and do they have the
No - Proceed to step 5.e proper lubricant?
Yes - Repair/clean/adjust or replace high pressure No - Fill gearbox with correct grade of oil to the pre-
relief valve on the non-driving side scribed level.
e. Replace "EP" control module. Does pump operate Yes - Proceed to step 8.b
properly? b. Is the engine flex plate and drive coupling correctly
No - Replace or repair pump installed and aligned with the transmission pump?
Yes - Operate the transmission No - Install flex plate and bell housing per manufac-
6. Transmission Drives in Wrong Direction turer's instructions
Yes - proceed to step 8.c
a. Check to see if electrical connectors or wiring have
been swapped on the pump. c. Is a rigid item or object contacting the resilient
mounted engine/pump assembly?
b. Check to determine want end of the machine the No - Proceed to step 8.d
boom is swung over. Yes - Insure no item is contacting the unit, transmit-
ting air borne noise.
d. Is the suction pressure/vacuum at the charge
pumps inlets within recommended limits?
No - Return to step 1.h
Yes - Proceed to step 8.e
e. Is there air in the hydraulic fluid? This may be indi-
cated by foaming or milky colored oil.
Yes - Deaerate the oil and inspect system for cause
of air induction. Check for loose or missing "O"-rings
on face seal connections.
5-34 – JLG Lift – 3121142

f. Is a wheel drive hydraulic motor operating at exces- 11. Transmission Pump(s) Do Not Develop Maximum Horse-
sive speed? power (Flow & Pressure)
Yes - Check minimum displacement stop screw
adjustments on the motors. Should be 0.433" or a. Does the charge pump pressure meet specification?
11mm above the stop screw lock nut. Is one or more No - Return to step 2.a
motors "stuck" at minimum displacement, check for Yes - Proceed to step 11.b
plugged/blocked two-speed stroking orifice(s). b. Does the pump case pressure exceed 15 psi gauge
pressure?
9. Transmission Operates at a Higher than Normal Temper-
ature
Yes - Check case drain hoses, oil cooler, etc. for
a. Is the reservoir temperature above 195oF (90.5° C)? pinched or restricted oil flow
No - 195oF (90.5° C) is the upper limit. If temperature c. Are the pump(s) high pressure cross port relief
is over 195oF (90.5° C), the oil cooler may need to be valves adjusted to the required pressure (5000 psi)
cleaned. so they do not bypass prematurely?
Yes - Proceed to step 9.c No - Inspect/clean/adjust and or replace valve car-
tridge
b. Are the hydraulic motor(s) stalling (wheels not turn-
Yes - Replace the pump, after blocking the "A" & "B"
ing) intermittently?
ports, running the pump and measuring pressure
developed at "A" & "B". This must be done to insure
Yes - Hydraulic fluid is being heated through system
that flow & pressure loss in not elsewhere in the sys-
pressure relief valves. Shut down system and rectify
tem. (motors, swivel coupling, etc)
the cause of motor stall.
d. Is the diesel engine capable of developing horse-
c. Does oil temperature remain above 195oF (90.5° C), power at design rpm?
after cleaning the oil cooler? Follow recommended troubleshooting procedures
No - Operate transmission. Check oil cooler more to insure the engine is developing full power at
often. specified rpms.
Yes - Proceed to step 8.a
10. Transmission Operates at a Higher than Normal Temper- Charge Pressure Relief Valve Adjustment
ature
a. Check for differential temperature across the oil
cooler. Is there a temperature difference?
No - Check to determine if the bypass check valve
(10 psi [0.7 bar] crack pressure) is stuck open. Check
to determine if the oil cooler is restricted internally,
causing oil flow to pass across the bypass check
valve.
Yes - Proceed to step 8.b
NOTE: Oil cooler flow is received from the transmission pumps

cases, max. continuous pump case pressure is 15 psi gauge
pressure. Higher pressure will prematurely damage pump
shaft seals CHARGE RELIEF
b. Disconnect pump case drain from oil cooler & check With a low pressure (0 – 1000 psi [0 - 70 bar]) pressure gauge
flow rate from charge pumps. Is the flow rate 3.8 tee’d into the ”G” port or two (2) low pressure gauges installed
GPM (14.4 LPM) with diesel idle speed of 1200 rpm? into ”Ma” and ”Mb”, run pump at engine idle speed. Do not
No - Refer to charge pump removal & inspection place the pump on stroke – low pressure gauges installed in
procedure ”Ma” & ”Mb” will be damaged! Prior to adjusting pressure,
insure charge pressure relief valve is clean of any dirt or debris.
The charge pressure relief valve does not wear appreciably
over time. If charge pressure was normal and then has
decayed, check for other causes of low charge pressure. If pres-
sure is low, remove relief valve and add shim(s). If pressure is
high, remove relief valve and take out shim(s).
3121142 – JLG Lift – 5-35

NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules
able in 0.3, 0.5, and 1.0 mm thickness.
PREPARATION FOR ADJUSTMENT
When control modules are exchanged or replaced, it is gener-
ally necessary to center the new module. This is done by run-
ning the pump with gauges installed at ports X1, X2, MA, and
MB Release the jam nut and turn the adjustment screw on top
of the control module valve body.
Mechanical Centering of Pump

PREPARATION FOR ADJUSTMENT
The control piston has strong centering springs to ensure that
once the pump is adjusted for the neutral position it will
always return to neutral. If an adjustment is necessary follow
the steps listed below.
To ensure there is equal pressure on both sides of the control
module during the centering operation, it is necessary to con-
nect the X1 and X2 ports together by means of hose or tubing.
(No less than a 1/4 inch ID) The port sizes are:
Pump Size Allen Wrench Wrench
28 5 mm 17 mm
With pressure gages installed at MA, and MB, and with A and B
ports blocked (or motor stalled), and with the pump running, The adjustment screw is an eccentric, therefore, turning more
loosen the jam nut. Turn the mechanical centering adjusting than 90’ in either direction will have no further centering
screw until 1000 psi is read on MA, or MB then turn screw effect, and could cause damage to the eccentric pin.
opposite direction until 1000 psi is read on other pressure Pump Size Tool Required Wrench
port. Turn the screw back, splitting the distance between the
28 Screwdriver 10 mm
previous two positions. This should be the neutral position.
Pressure on MA, and MB should be equal.
CENTERING THE EP CONTROL MODULE
With no electrical signal to solenoids A and B, (remove both
plug-in connectors), the EP control module is correctly
adjusted when any or all of the following conditions exist:
1. Approximately, when equal control pressures are
obtained at control pressure ports X1 and X2.
2. The hydraulic motor does not turn when the brake is
released.
3. Charge pressure is registered equally at ports MA and
MB, when the flow output of the pump is deadheaded
against a locked motor or a valve.
If difficulties are encountered in obtaining neutral position of
the HD or EP control modules, check that the ends of the con-
Tighten jam nut, stop the pump drive, remove the hose con-
necting ports X1 and X2.
5-36 – JLG Lift – 3121142

trol spring are correctly located in the grooves near the end of Removal and inspection of charge pump
the feedback lever arms.
Before removing cap screws, mark the position of the charge
pump housing and separator plate in relation to the port
block.
High Pressure Relief Valve Adjustments

1. Remove relief valve cover from pump (ref. item 1).
Loosen screws with metric allen wrench.
Pump Size Allen Wrench
28 8 mm
2. Loosen jam screw (ref. item 2).

3. Holding spring loading nut (ref. item 4) rotate valve
spindle (ref. item 3). For high range relief valve, one turn
equals approximately 630 psi (44 bar). For low range
relief valve, one turn equals approximately 377 psi (26
bar).
4. After adjustment is completed torque jam screw (ref.
item 4) to 5 ft.lb. (7 Nm). Remove charge pump housing and inspect for wear or dam-
age to gear set and 0-ring seals. Grease 0-rings prior to reas-
5. Install relief valve assembly into pump, reinstall cover
(ref. item 1) to proper torque.
Table 5-5. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque

28 32 mm 66 ft.lb. (90 Nm)
3121142 – JLG Lift – 5-37

sembly. Make sure 0-rings are completely seated in their Routine Maintenance
grooves.
The Variable Displacement Hydrostatic Transmission Pumps
are relatively maintenance free. Maintenance work is confined
to the system, by way of maintaining hydraulic fluid condition,
the "life blood" of the machine. Oil monitoring, changes and
filter renewal promote system cleanliness. This will prevent
premature breakdown and repairs. Under normal application
conditions, the following maintenance intervals are sug-
gested:
1. Renewal of Filter Elements
a. After commissioning or re-build.
b. At every 500 operating hours or when filter indica-
tor shows a dirty element.
c. With the suction strainer, the strainer should be
renewed as soon as charge pump inlet pressure is
less than -3.2 psi, 6.3"Hg or 0.8 bar absolute.
d. Only JLG recommended filter elements are to be
used. Paper elements cannot be cleaned; use throw-
away cartridges.
Withdraw pinion shaft and inspect gear teeth and bearing sur-
faces for abnormal wear. 2. Hydraulic Fluid Change
When reassembling, make sure chamfer (on outer edge of
a. After 2000 operating hours (1st oil change)
driven gear and drive gear) is installed into housing per illus-
tration. b. Thereafter, every 2000 operating hours or annually,
irrespective of operating hours achieved.
c. Oil change should be performed with the system in
warm running condition. Before re-filling, the reser-
voir interior should be inspected and cleaned to
remove any sludge.
d. Rags or threaded material must not be used.
e. This machine has been designed & manufactured to
operate on an Exxon-Mobil Oil Co. hydraulic fluid,
Mobilfluid #424, Product #52233-4. Consult JLG
Industries prior to introducing any other type of
fluid to prevent interaction or possible contamina-
tion.
f. The recommended interval between oil changes is
based on various factors and should be carried out
Torque value for bolts when replacing charge pump. according to the degree of aging, contamination
Pump Size Torque and water content.
28 18 ft.lb. (24 Nm)
NOTE: If serious wear or damage has occurred to one component,

the complete charge pump assembly must be replaced
because they are matched components.
5-38 – JLG Lift – 3121142

g. Under application conditions with a heavy occur- b. The air/oil cooler surfaces and engine radiator
rence of dust or severe temperature fluctuations, should be cleaned at the same time.
the intervals between fluid maintenance should be c. If hose connections are disassembled, it is impera-
shortened accordingly. tive that the utmost care be taken that no foreign
bodies infiltrate the oil circuit. Catastrophic compo-
nent failure may occur.
PRACTICAL EXPERIENCE SHOWS THAT MOST FLUID MAINTENANCE ERRORS 5. Oil Level Inspection
OCCUR DURING AN OIL CHANGE DUE TO:
a. Inspect oil level in the reservoir daily.
• USE OF AN UNSUITABLE HYDRAULIC FLUID b. If "topping off" is required, use only the same Mobil-
fluid #424, Product #52233-4.
• USE OF OIL CONTAMINATED DUE TO POOR STORAGE PRACTICES
c. Do Not Mix Fluids.
• FAILURE TO CLEAN THE RESERVOIR
6. Hydraulic Fluid - The "Life Blood" of the Machine
• INADEQUATE CLEANLINESS WHEN FILLING THE RESERVOIR (DIRTY
a. The type of hydraulic fluid supplied in the machine
DRUMS, CONTAINERS, WATER, ETC)
from the factory was selected after extensive testing
3. Leakage Inspection and development. The fluid was selected to perform
a. After commissioning under "most" applications and conditions. Should
this machine be in service for extended time peri-
b. The complete transmission drive system (pumps, ods at the extremes (hot or cold), JLG should be con-
motors, hosing, filters, valves, etc) should be sulted for assistance in selection of the most
checked for leakage at regular intervals. suitable fluid type and grade for your application.
c. Leaking joints & connections must only be tight-
b. When operating at temperatures below 0oF, allow a
ened when pressureless.
warm-up period, if at all possible, to a temperature
4. Cleanliness Inspection
of 40oF.
a. The oil tank breather should be regularly cleaned of c. When beginning motion of a "cold" machine, oper-
dirt and dust to prevent clogging. With each cylin- ate all functions at reduced speeds until the "cold"
der movement, gallons of oil pumped, an equal oil has circulated out of the drive loop.
amount of air exchange occurs across the reservoir
breather. A dirty or clogged breather will affect all
machine functions!
3121142 – JLG Lift – 5-39

Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap
ring.
Remove the retaining ring with snap ring pliers.
Screw in sheet metal screw into the holes fitted with rubber.
Pull out shaft seal with pliers.
5-40 – JLG Lift – 3121142

5.6 FUNCTION PUMP
Figure 5-29. Function Pump - Sectional View
Spare Parts 2. Drive Shaft
1. Sealing kit, existing spare parts: shaft sealing ring, o-

rings, and a circlip.
3. Bearing set, miscellaneous parts.
3121142 – JLG Lift – 5-41

4. Rotary Group complete: 9 pistons, cylinder subassem- Sealing the Drive Shaft
bly, valve plate, retaining plate, and retaining ball.
BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED DURING THE

REMOVAL OF THE SHAFT SEALING RING.
1. Remove the snap ring.
5. Swash Plate.
2. Change the shaft seal and check its’ sliding surface

(drive shaft) and housing. Grease the sealing ring.
6. Parts of the control valve: control piston, piston rod,

plug, spring stopper max flow, hex nut, and hex head
nut.
3. Be careful while you seal the drive shaft. Use an adhesive

tape to prevent the shaft splines from damaging the
seal.
7. DFR pilot valve.
5-42 – JLG Lift – 3121142

4. Assemble the sealing ring, fitting tool holds the correct 2. Mark the position of the port plate and remove the
position of the sealing ring in the pump housing. socket screw of the port plate.
5. Assemble the snap ring. 3. Remove the port plate together with the valve plate
(hold the valve plate so the plate can’t fall down).
6. Assemble the snap ring in the correct position.

4. Remove the o-ring.
Disassembly and Assembly of the Complete Unit 5. Disassemble the taper roller bearing (nearby port plate).
1. Disassemble the pilot valve.
3121142 – JLG Lift – 5-43

6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position.
7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow.
8. Loosen the fixing nut of the stopper max flow and disas- 12. Remove the threaded pin.
semble it.
13. Disassemble the plug.

9. Turn in the stopper max flow to get swivel angle zero.
5-44 – JLG Lift – 3121142

14. Disassemble the control piston while moving the swash 18. Remove both bearing shells.
plate.
19. Remove the drive shaft.

15. The swash plate must be lifted a little bit to disassemble
the piston rod.
20. Disassemble the snap ring.
16. Remove the swash plate.
21. Disassemble the sealing ring.
17. Remove the spring.
3121142 – JLG Lift – 5-45

22. The external front bearing ring is pulled out of the pump 25. The spring has additional pretension while you disas-
housing. semble the three pressure pins inside the cylinder.
23. Remove the o-ring. Lifting of the valve plate isn’t shown.
Assembly
1. Measurement of the taper roller bearing pretention.
24. A bearing puller is used to disassemble the external

bearing ring of the taper roller bearing inside the port
plate. Take care of the surface of the port plate. 2. Ensure there is a correct connection of the piston rod
and the swash plate.
5-46 – JLG Lift – 3121142

3. Pumps clockwise driven must have a position of the Adjustments

valve plate 4 degrees out of center in the same direction
TAPER ROLLER BEARING INITIAL TENSION
decentered like drive direction.
Cast Iron pump housing must have initial tension of the bear-
ings: 0 to 0.05 mm.
4. Pumps counterclockwise driven must have a position of

the valve plate 4 degrees decentered in the ccw posi-
tion.
MECHANICAL FLOW LIMITER

Differential volume if you are rotating the threaded pin - each
rotation is approximately 3.1 cm3.
5. Note the correct position of the drilling that connects
high pressure to the control valve. Check control valve Tightening Torques
drilling position at the pump housing and fit together. For break-off plugs, use Loctite #601.
For all other parts, use Loctite #242.
Table 5-6. Tightening Torques
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8.8 2.3 5.0 8.5 21 41 72 115 176 240 350 600 1220
10.9 3.2 7.2 12 29 58 100 165 250 350 490 840 1670
12.9 4.1 8.5 14.5 35 70 121 195 300 410 590 990 2000
3121142 – JLG Lift – 5-47

Figure 5-30. Function Pump, Pressure and Flow Control - Sheet 1
5-48 – JLG Lift – 3121142

Pump Control Disassembly For Cleaning 3. Hydraulic fluid may drip from the pump. Wiping the sur-
face clean and installing some adhesive tape should pre-
NOTE: If the Function Pump does not perform correctly after
vent oil from seeping from the pump control.
following the pre-start start-up procedures, it is possible that a
contaminate particle has lodged in the pump control prevent- 4. Work on a clean, lint free area.
ing proper operation. The pump control’s internal parts are
not provided as spare parts due to the close tolerances NOTE: The pump control can be equipped with either O-rings or a
required between the mating parts. However, the control can sealing plate. These components are NOT interchangeable.
be disassembled, cleaned and placed back in service should 5. Remove the three (3) ”0”-rings (Parker # 2-011, Viton 90
the only problem prove to be contamination. Disassembly, shore)
inspection, cleaning and reassembly MUST BE done in a clean
well-illuminated area. 6. Remove both the adjustment hex caps and bonded seal
rings. (17 mm wrench)
Pump Control removal:
7. Remove both the adjustment lock nuts and bonded seal
1. Disconnect plug the hose attached to the pump control rings. (17 mm wrench)
Port ”X”.
8. Remove both the adjusting screws. (3-mm Allen
2. Remove the four (4) socket head cap screws that attach wrench)
the control to the pump. Insure that the three (3) ”0”-
rings are also removed with the control.
3121142 – JLG Lift – 5-49

9. Remove the spring cover hex cap for the ”outer” flow 21. Inspect the housing for contamination or plugged ori-
regulation adjustment this requires a 19-mm wrench. fices. Clean orifices carefully with a dead soft steel wire
to insure they are open. Inspect all parts for burrs, scor-
10. Remove the spring disc.
ing, debris, etc.
11. Remove the adjusting springs (two springs, one
NOTE: On the mounting surface of the control housing, between
”nested” inside the other) and spring follower.
the oil ports is what appears to be a slotted head screw. IT
12. The flow regulation spool should slide from the control IS NOT A SCREW. This is a bleed orifice, which must be ori-
housing, (a magnet should aid in removal). If it does not, entated to allow proper control operation. The slot in the
remove the hollow hex head plug at the rear of the flow head should be oriented to fall in-line with the oil ports,
regulation spool and carefully push the spool from the NOT PERPENDICULAR to the oil ports. If the slot is oriented
housing - do not scratch/mar the spool’s bore. perpendicular to the three ports, the pump pressure will
not return from load pressure to stand-by pressure at the
13. Remove the spring cover hex cap for the ”inner” pres-
end of operating a function! The pump pressure will
sure compensation adjustment – this requires a 30-mm
remain at the last highest pressure generated.)
wrench.
14. Remove the spring disc. 22. After all parts are clean and dry, lightly oil a control
spool and install in its bore. The spool must slide
15. Remove the adjusting springs (two springs, one smoothly and easily within the housing. If it does not,
”nested” inside the other). check for contamination. If contamination cannot be
16. Remove the spring follower. found check for ”scoring” or ”burring” of the control
housing. If the spool does not slide smoothly & freely,
17. The pressure compensation spool should slide from the the control must be replaced with a new unit.
control housing, (a magnet should aid in removal). If it
does not, remove the hollow hex head plug at the rear 23. Lightly oil and check operation of the second spool. The
of the flow regulation spool and carefully push the spool spools are installed correctly when there ”pointed” end
from the housing - do not scratch/mar the spool’s bore. faces the spring followers
18. The spools are identical. 24. Re-assemble in reverse order.
19. Wash the housing and all parts in a clean JLG approved 25. Bench set the pressure adjustments as described in ”C.
solvent such as non-chlorinated brake cleaner, Stoddard 4” of the Operating Instructions.
solvent, etc.
NOTE: The pump control can be equipped with either O-rings or a
20. Blow off all the parts with clean, dry compressed air. sealing plate. These components are NOT interchangeable.
26. Re-install on the Function Pump, insure the ”0”-rings are

installed properly and tighten the four (4) M6 socket
head cap screws to 105 inch pounds.
5-50 – JLG Lift – 3121142

5.7 DRIVE & FUNCTION PUMP START UP The middle transmission pump also supplies oil to a hot oil
flushing valve cartridge, #120, in the Traction Control Mani-
PROCEDURES fold. This cartridge provides a means to obtain brake release
oil pressure. The brake release pressure is controlled by a pres-
Start-Up Procedure sure relief valve cartridge # 130 and a solenoid operated brake
release directional control cartridge, #170, also located in the
The 1200/1350 Boom Lift utilizes a Triple Combination Pump Traction Control Manifold. This is important to note as the
coupled to the Deutz diesel engine. The pumps are connected brake release oil pressure must be set 25 psi (1.7 bar) below
in-line to each other as follows: the boost oil pressure relief valve. If the brake release pressure
1. The front hydrostatic transmission pump, or drive pump, is set too low, brake drag and pump control will be affected. If
is coupled directly to the diesel engine and provides oil set too high, damage to the wheel drive parking brakes could
flow to operate the machine's right side wheels. result. Prior to start, connect appropriate pressure gauges to
2. The middle hydrostatic transmission pump, or drive the unit.
pump, is coupled to the back of the front pump and pro- FOR THE START-UP OF NEW OR OVERHAULED INSTALLA-
vides oil flow to operate the machine's left side wheels. TIONS:
3. The third or rear pump is the function pump. It is cou- 1. Insure all electrical checks have been performed & the
pled to the back of the middle pump and provides oil machine is set up correctly with the JLG Analyzer.
flow to operate the boom, axle, steer and platform func- 2. Insure the machine has all four wheels jacked & blocked
tions. off the ground per JLG procedures.
The transmission pumps share some common connections. 3. Insure the triple pump assembly is installed and con-
Each pumps charge oil suction ports are connected by steel nected correctly per the hydraulic circuit diagram.
tubing, the charge pumps discharge oil flows are connected
and flow to a common charge pump inline oil filter, cleaned & 4. Disconnect the electrical connector from the diesel's
filtered oil flows back to the transmission pumps "G" ports. The throttle actuator, to prevent engine start.
pumps case drain ports are connected (T1 & T2), oil flow from 5. Crank the engine until charge pressure reaches 50 psi or
the middle pumps T1 port also provides flows to the oil cooler. more.
The charge pumps oil pressure is regulated by a single boost 6. Re-connect throttle actuator electrical connector and
oil pressure relief valve installed in the middle pump. The front start engine. Allow engine to run at idle speed only for at
pump has an orifice cartridge (0.047" diameter) installed in least 5 minutes. This will allow the hydrostatic system to
place of a charge oil pressure relief cartridge. This insures that filled.
only one valve controls charge pressure & provides an amount
of charge oil flow to the front pump's case to insure flushing & 7. Listen for any abnormal noises.
removal of hot oil. 8. Check for oil leaks.
Each pump has its own separate electrical proportional direc- 9. Check charge pressure (500 psi +50psi, - 0 psi [34.4 bar
tional control valve to control oil flow and direction. The sig- +3.4 bar, - 0 bar]). Pressure can be measured a pump
nals or command values to each pump are similar except ports Ma & Mb or by "teeing" into the inlet for the
when steering. During steering and propel of the machine the charge oil filter. Charge pressure is checked with the joy-
pump supplying oil to the "inside turning radius" has a com- stick in neutral. A 0-1000 psi (0-70 bar) pressure gauge
mand less than the pump supplying oil flow to the "outside must be used. (If pressure gauges were installed in Ma &
turning radius" pump. Mb to check charge pressure, disconnect the gauges
"Posi-Traction" control, front to rear on a given side of the installed in Ma & Mb, as they will be damaged if loop
machine, is accomplished by a flow divider/combiner car- pressure rises above 1000 psi [34.4 bar].)
tridge installed in the Traction Control Manifold. There is a flow
divider/combiner for each side. Each flow divider/combiner
also has a "bleed orifice" to limit the amount of flow splitting
or combining.
3121142 – JLG Lift – 5-51

10. Operate the drive system in the "turtle mode", forward 17. Check oil level & temperature.
and reverse. 18. Remove and inspect charge pressure oil filter, replace
11. De-aerate the system by bleeding fluid from the Ma & with new element.
Mb ports. 19. Operate the transmission under no load conditions for
12. Switch the drive mode speed control from "turtle" to about 15 minutes to stabilize the temperature and
"rabbit". Gradually increase drive speed forward & remove any residual air from the fluid.
reverse, still with no load - wheels off the ground. 20. Set the machine back on the ground. Operate the trans-
13. With the joystick in neutral, check for creep in neutral. If missions under full and normal conditions.
evident, most likely dirt is present in the proportional 21. Erratic operation may indicate there is still air trapped in
pump control, an incorrect electrical signal is present on the system. By working the pump controls forward and
the pump's electrical control(s) or the control was not reverse the remaining air can be eliminated. The system
centered properly when overhauled. See service manual is free of air when all functions can be operated
for centering instructions. smoothly and when the oil in the reservoir is no longer
14. Check that the controls are connected so that the trans- aerated. (Usually less than one hour of operation)
missions operate in the correct direction related to con-
trol input. NOTE: If the transmissions do not perform correctly after follow-
ing the pre-start & start-up procedures, refer to the relevant
15. Continue to monitor all pressure gauges & correct any sections of the trouble-shooting procedures.
irregularities.
16. Remove the brake coil (leaving the electrical connection
intact) from the brake release solenoid cartridge located
on the Traction Manifold. This disables the machine's
ability to release the brakes! Stroke the transmission
pumps slightly (less than 20%) and check the setting of
the high pressure cross port relief valves. Setting should
be 5000 psi +50 psi, - 0 psi (344.7 bar +3.4 bar, -0 bar).
Install 0-6000 psi (0 - 415 bar) gauges on Pump ports Ma
& Mb.
5-52 – JLG Lift – 3121142

SECTION 6. JLG CONTROL SYSTEM
6.1 INTRODUCTION smooth control of: acceleration, deceleration, creep, min

speed, and max.-speed for all boom, drive, and steering func-
tions.
WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THE MACHINE, IT The main lift, swing, and drive are controlled by individual joy-
WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER sticks, with steering being controlled by a rocker switch built
MACHINE CONFIGURATION, INCLUDING OPTIONS AND PROPERLY CALIBRATE into the top the drive joystick. To activate Drive, Lift, and Swing
THE TILT SENSOR. simply pull up on the slide lock location on the joystick and
move the handle into the direction desired.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation and
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- maximum cycle time. Ground control speeds for all boom
TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH functions can also be programmed into the control system.
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS-
TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A The JLG Control System controller has a built in LED to indicate
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO- any faults. The system stores recent faults which may be
NENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING accessed for troubleshooting. Optional equipment includes a
MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SAT- soft touch system, head and tail lights, and ground alarm.
URATION. These options may be added later but must be programmed
into the control system when installed.
The JLG designed Control System is a 12 volt based control The Control System may be accessed utilizing a custom
unit installed on the boom lift. designed, hand held analyzer (Analyzer Kit, JLG part no.
The JLG Control System has reduced the need for exposed ter- 2901443) which will display two lines of information at a time,
minal strips, diodes and trimpots and provides simplicity in by scrolling through the program.
viewing and adjusting the various personality settings for
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub Level,
To return home or access previ-
and item menus
ous menu
Left & Right Arrow Keys

Up & Down Arrow Keys Used to move between Top Level, Sub
Value Selector Level, and item menus
Figure 6-1. Hand Held Analyzer
3121142 – JLG Lift – 6-1

6.2 CANBUS COMMUNICATIONS Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc;)
CANbus: CAN (Control Area Network) is a two wire differential
serial link between the Platform Module, Ground Module, Platform Level: The GROUND MODULE stores the default val-
Boom Length Angle Module and the Chassis Module provid- ues and handles interlocks. The PLATFORM MODULE reads the
ing bi-directional communications. sensors mounted on the platform assembly and controls the
Level Up / Down valves to maintain setpoint sent from the
Two-wire: One wire (red) is driven high (5v) and the other low GROUND MODULE.
(black) (0v) to send a signal; both wires ”float” (2.5v) when no
signal is being sent. Steer: The GROUND MODULE stores crack points, sends
desired drive direction, sends steering mode and sends axle
Differential: Any electrical line noise can affect the high or the extend / retract commands. The PLATFORM MODULE reports
low wires but never both, so communications is not corrupted. the steering switch position to the GROUND MODULE. The
CHASSIS MODULE modulates each steer left / right valve to
Serial Link: Messages are being sent bit by bit along the wires; maintain commanded wheel position.
the high bus speed allow all modules to be constantly Drive: The GROUND MODULE stores crack points, sends com-
updated around 20 times per second. Typical traffic is 300 - mands for each drive pump to the BLAM. (Command is com-
500 messages per second. puted from drive joystick input, interlocks, wheel angle, etc).
BLAM maintains proper current for the drive pumps by modu-
A complete CANbus circuit is approximately 60 ohms, which lating PWM outputs.
can be verified at the ”T” fitting inside the ground station or
below the BLAM. Each individual circuit from the modules is Lift, Tele, & Swing: The GROUND MODULE stores default val-
approximately 120 ohms. ues, handles interlocks and calibration information. Lift, Tele-
scope and Swing commands are dependent upon interlocks
The GROUND MODULE is the master system controller. Most through out the machine. Boom angle, length and swing are
functions are dispatched and coordinated from this module, controlled by the GROUND MODULE. The BLAM monitors and
all other system modules (PLATFORM, BLAM L CHASSIS) han- communicates (CANbus) to the GROUND MODULE boom
dle sub-tasks. All characterized information (values) are stored angle and boom length via two angle sensors, a length sensor
into the ground module (i.e., Personalities or Calibrations). and a load moment pin.
6-2 – JLG Lift – 3121142

Figure 6-2. Control System Block Diagram
3121142 – JLG Lift – 6-3

6.3 CALIBRATION INSTRUCTIONS Table 6-1. Calibration Instructions
This machine incorporates a variety of sensors and a high Telescope Crack Point Cali- Ground module replacement
degree of function interaction. For safety and proper machine bration Telescope proportional valve replacement
functionality, the calibration procedures must be repeated for Erratic controlled arc operation
any control module replacement, system calibration related Erratic controlled boom angle operation
fault, or removal or replacement of any sensors, valves, coils,
motors, or pumps. The chart below lists the calibrations Chassis Tilt Ground module removal or replacement
required and potential reasons for re-calibration. All calibra- Calibration Main terminal box removal or replacement
tion procedures are menu driven through the use of the stan- Tilt indication inaccuracy
dard analyzer. With the exception of steering calibration, no
Boom Sensors Ground module removal or replacement
external tools are required to complete the calibration proce-
Calibration BLAM module removal or replacement
dures. The user is prompted to exercise the machine in a spe-
Boom angle sensor removal or replacement
cific order to use the machines physical properties to
Boom length sensor removal or replacement
consistently establish sensor response and the interaction of
Moment pin removal or replacement
valves, pumps, and motors. Steering calibration also uses the
Boom angle sensor calibration fault
analyzer and is performed on one side of the machine at a
Boom length sensor calibration fault
time requiring the use of a string or other means to determine
Moment pin fault
when the tires are in line with each other. With the exception
Failed BCS functional check
of the load control calibration, all calibrations are accessed by
Boom control system inaccuracies
connecting the analyzer into the control system inside the
Installing or removing approved accessories
main terminal box or on the bottom of the platform control
Changing Platform Size
box.
Table 6-1. Calibration Instructions
Calibration Reasons for Re-calibration

Procedure
Steering Calibration Ground module replacement
Chassis module replacement
Steer sensor removal or replacement
Persistent wheel misalignment
Drive Calibration Ground module replacement

BLAM module replacement
Drive pump/coil replacement
Drive pulls to one side
Drive lugs engine
Poor slow speed control
Platform Leveling Ground module replacement

Calibration Platform module replacement
Platform level sensor removal or replacement
Platform level sensor calibration fault
Platform Level Crack Point Platform module replacement

Calibration Ground module replacement
Platform level valve/coil replacement
Erratic platform leveling
Lift Crack Point Ground module replacement

Calibration Lift proportional valve/coil replacement
Erratic controlled arc operation
Erratic controlled boom angle operation
6-4 – JLG Lift – 3121142

3121142
(See Figure 6-4.) (See Figure 6-5.) (See Figure 6-6.) (See Figure 6-7.)
or
(See Figure 6-8.)
or
(See Figure 6-9.)
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine con-
figuration.
Figure 6-3. Analyzer Flow Chart
6-5
6-6
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some
screens may not be available depending upon machine configuration.
Figure 6-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present)
3121142
3121142
NOTE: The layout shown includes all possible ana-
lyzer screens. Please note that some screens
may not be available depending upon
machine configuration.
– JLG Lift –
Figure 6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present)
6-7
6-8
FROM:
MACHINE SETUP
MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

CALIBRATIONS STEER DRIVE BOOM VALVES LEVEL UP CRKPT LEVEL DOWN CRKPT MAIN LIFT CRKPT MAIN TELE CRKPT
CALIBRATE CALIBRATE CALIBRATE CALIBRATE LEVEL CALIBRATE LEVEL CALIBRATE MAIN CALIBRATE MAIN
STEER? DRIVE? BOOM VALVES? UP CRACKPOINT? DOWN CRACKPOINT? LIFT CRACKPOINT? TELE CRACKPOINT?
CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:

TILT SENSOR BOOM SENSORS DEUTZ SETUP: UNLOCK BOOM NONE AVAILABLE
POSITION 1: POSITION 1: DEUTZ SETUP: CALIBRATE

CHECK SYSTEM? CHECK SYSTEM? SETUP 1 UNLOCK BOOM?
– JLG Lift –
DEUTZ SETUP:
SETUP 2
DEUTZ SETUP:
SETUP 3
DEUTZ SETUP:
SETUP 4
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
Figure 6-6. Analyzer Flow Chart - Calibrations (Software Version 7.X to Present)
3121142
3121142
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens
may not be available depending upon machine configuration.
Figure 6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3
6-9
6-10
– JLG Lift –
3121142
3121142
– JLG Lift –
6-11
Figure 6-10. Control Module Location
6-12 – JLG Lift – 3121142

PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-11. Analyzer Connecting Points
3121142 – JLG Lift – 6-13

6.4 TO CONNECT THE JLG CONTROL SYSTEM The top level menus are as follows:
ANALYZER HELP
DIAGNOSTICS
1. Connect the cable supplied with the analyzer, to the SYSTEM TEST
controller module located in the platform box or at the ACCESS LEVEL
controller module in the ground control box and con- PERSONALITIES
nect the remaining end of the cable to the analyzer. MACHINE SETUP
CALIBRATIONS (view only)
NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards. If you press ENTER, at the HELP: PRESS ENTER display, and a
fault is present, the analyzer display will scroll the fault across
2. Power up the Control System by turning the key to the the screen. If there was no fault detected, the display will read:
platform or ground position and pulling both emer- HELP: EVERYTHING OK. If powered up at the ground station,
gency stop buttons on. the display will read: GROUND OK.
If ENTER is pressed again, the display moves to the following
6.5 USING THE ANALYZER display:
With the machine power on and the analyzer connected prop-

erly, the analyzer will display the following:
LOGGED HELP
1: POWER CYCLE (0/0)
HELP: At this point, the analyzer will display the last fault the system
PRESS ENTER has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
At this point, using the RIGHT and LEFT arrow keys, you can arrow keys to scroll through the fault logs. To return to the
move between the top level menu items. To select a displayed beginning, press ESC. two times. POWER CYCLE (0/0) indi-
menu item, press ENTER. To cancel a selected menu item, cates a power up.
press ESC.; then you will be able to scroll using the right and
left arrow keys to select a different menu item.
6-14 – JLG Lift – 3121142

When a top level menu is selected, a new set of menu items Then using the RIGHT arrow key, position the cursor to the
may be offered: for example: right one space to enter the second digit of the password.
DRIVE Use the UP or DOWN arrow key to enter the second digit of
BOOM the password which is 33271.
SYSTEM
Continue using the arrow keys until all the remaining digits of
DATALOG
the password is shown.
VERSIONS
Pressing ENTER with any of the above displayed menus, will
Once the correct password is displayed, press ENTER. The
display additional sub-menus within the selected menu. In
access level should display the following, if the password was
some cases, such as DRIVE, the next level is the parameter or
entered correctly:
information to be changed. Refer to the flow chart for what
menus are available within the top level menus. You may only
view the personality settings for selected menus while in
access level 2. Remember, you may always cancel a selected
menu item by pressing the ESC. key.
6.6 CHANGING THE ACCESS LEVEL OF THE HAND

HELD ANALYZER
When the analyzer is first connected, you will be in access level
2 which enables you to only view most settings which cannot
be changed until you enter a password to advance to a lower
level. This ensures that a setting cannot be accidentally
altered. To change the access level, the correct password must
be entered. To enter the password, scroll to the ACCESS LEVEL
menu. For example:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings.
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of the
password, 3.
3121142 – JLG Lift – 6-15

6.7 ADJUSTING PARAMETERS USING THE HAND 6.8 MACHINE SETUP

HELD ANALYZER When a machine digit item is selected, press the UP or DOWN
arrow keys to adjust its value, for example:
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:
GROUND ALARM:
2 = LIFT DOWN
PERSONALITIES: The effect of the machine digit value is displayed along with
DRIVE ACCEL 1.0s its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
There will be a minimum and maximum for the value to
sound when lifting down. There are certain settings allowed to
ensure efficient operation. The Value will not increase if the UP
install optional features or select the machine model.
arrow is pressed when at the maximum value nor will the
value decrease if the DOWN arrow is pressed and the value is When selection the machine model to match the size of the
at the minimum value for any particular personality. If the machine, the personality settings will all default to the factory
value does not change when pressing the up and down recommended setting.
arrows, check the access level to ensure you are at access level
1. NOTE: Refer to Table 6-3, 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 personality settings.
There is a setting that JLG strongly recommends that you do

not change. This setting is so noted below:
ELEVATION CUTBACK
CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF

YOUR MACHINE.
6-16 – JLG Lift – 3121142

Table 6-2. Machine Configuration Programming Information - Version P7.X to Present
Default
Configuration Digit Number Description
Number
NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal-
ity settings first and then changing the model number of the machine configuration will cause the personality settings
to return to default
MODEL NUMBER: 1 1200S 1

1
2 1250A
3 1350S
ENVELOPE HEIGHT: 1 1350S: 135' MAX 5

2
2 1350S: 125' MAX
3 1350S: 120' MAX
4 1350S: 110' MAX
5 1200S: 120' MAX
6 1200S: 110' MAX
7 1250A: 125' MAX
8 1250A: 100' MAX
9 1250A: 80' MAX
Note: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial default setting.
MARKET: 0 ANSI USA 0

3
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
ENGINE: 1 DEUTZ F4 TIER1: Deutz BF4M1011 Diesel (Tier 1) 3

4
2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
3 DEUTZ ECM: Engine Control Module
3121142 – JLG Lift – 6-17

Default
Number
GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start 0
6 can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permit-
ted until pre-glow is finished.
ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil
pressure is less than 8 PSI.
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more 1
8 than 5 degrees and above elevation; also reduces drive speed to creep.
2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees
and above elevation; also reduces drive speed to creep.
3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees
and above elevation; also reduces drive speed to creep.
4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 3
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is also above elevation.
SOFT TOUCH: 0 NO: No soft touch system installed. 0

9
1 YES: Soft touch system installed.
6-18 – JLG Lift – 3121142

Default
Number
GEN SET/WELDER: 0 NO: No generator installed. 1

10
1 BELT DRIVE: Belt driven setup.
2 HYDRAULIC DRIVE: Hydraulic driven setup.
GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
11*
1 MOTION CUTOUT: Motion cutout in platform mode only.
* Only visible if Gen Set / Welder Menu selection is not 0.
H & T LIGHTS: 0 NO: No head and tail lights installed. 0

12
1 YES: Head and tail lights installed.
LOAD SYSTEM: 0 0
NO: No load sensor installed.
13*
1
WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
2
CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
3
SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
alarm beeps (5 sec ON, 2 sec OFF).
4
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
3121142 – JLG Lift – 6-19

Default
Number
FUNCTION CUTOUT: 0 NO: No drive cutout. 0

14*
1 BOOM CUTOUT: Boom function cutout while driving above elevation.
2 DRIVE CUTOUT: Drive cutout above elevation.
3 DRIVE CUT E&T: Drive cutout above elevation and tilted.
* Only visible under certain market selections.
* Certain market selections will limit function cutout options or alter default setting.
GROUND ALARM: 0 NO: No ground alarm installed. 0

15*
1 DRIVE: Travel alarm sounds when the drive function is active (Option).
2 DESCENT: Descent alarm sounds when lift down is active (Option).
3 MOTION: Motion alarm sounds when any function is active (Option).
* Certain market selections will alter default setting.
OSCILLATING AXLE: 0 NO: No oscillating axle system installed. 1

16
1 YES: Oscillating axle system installed.
TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1

17*
1 FAHRENHEIT: Fahrenheit unit selection.
* Certain market selections will alter default setting.
4150364-17
6-20 – JLG Lift – 3121142

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined num-
bers indicate the default when the option is factory installed.
1200SJP
HEAD & TAIL LIGHTS

ENGINE SHUTDOWN
GEN SET / WELDER

ENVELOPE HEIGHT
MODEL NUMBER
GEN SET CUTOUT

GLOW PLUGS
SOFT TOUCH
MARKET
ENGINE
TILT
ANSI USA 1 5 0 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
ANSI EXPORT 1 5 1 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CSA 1 5 2 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CE 1 5 3 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
AUSTRALIA 1 5 4 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
JAPAN 1 5 5 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
1200SJP
FUNCTION CUTOUT
OSCILLATING AXLE
GROUND ALARM
TEMPERATURE
LOAD SYSTEM
ANSI USA 0 X X X X 0 X X X 0 1 2 3 0 1 0 1
ANSI EXPORT 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
CSA 0 X X X X 0 1 2 3 0 1 2 3 0 1 0 1
CE 0 X 2 3 X 0 1 X X 0 1 2 3 0 1 0 1
AUSTRALIA 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
JAPAN 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
3121142 – JLG Lift – 6-21

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined num-
bers indicate the default when the option is factory installed.
1350SJP
HEAD & TAIL LIGHTS

ENGINE SHUTDOWN
GEN SET / WELDER

ENVELOPE HEIGHT
MODEL NUMBER
GEN SET CUTOUT

GLOW PLUGS
SOFT TOUCH
MARKET
ENGINE
TILT
ANSI USA 3 1 0 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
ANSI EXPORT 3 1 1 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CSA 3 1 2 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CE 3 1 3 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
AUSTRALIA 3 1 4 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
JAPAN 3 1 5 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
1350SJP
FUNCTION CUTOUT
OSCILLATING AXLE
GROUND ALARM
TEMPERATURE
LOAD SYSTEM
ANSI USA 0 X X X X 0 X X X 0 1 2 3 0 1 0 1
ANSI EXPORT 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
CSA 0 X X X X 0 1 2 3 0 1 2 3 0 1 0 1
CE 0 X 2 3 X 0 1 X X 0 1 2 3 0 1 0 1
AUSTRALIA 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
JAPAN 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
6-22 – JLG Lift – 3121142

6.9 MACHINE PERSONALITY SETTINGS/FUNCTION NOTE: Personality settings can be adjusted within the adjustment
range in order to achieve optimum machine performance.
SPEEDS
Table 6-3. Personality Ranges/Defaults
TIME RANGE (SEC) (SEE

SUBMENU PARAMETER SECTION 6.10 FOR
DEFAULT VALUES
(DISPLAYED ON (DISPLAYED ON ANALYZER 2ND DESCRIPTION RANGE MACHINE ORIENTATION
ANALYZER 1ST LINE) LINE) WHEN SETTING SPEEDS)
1200 1350 1200S 1350S
DRIVE: ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2.0 2.0
DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3 1.3
MIN forward XX% Displays/adjusts minimum forward drive 0 to 35% 1 1
speed
MAX forward XXX% Displays/adjusts maximum forward drive 0 to 100% 100 100 44-48 44-48
speed
MIN reverse XX% Displays/adjusts minimum reverse drive speed 0 to 35% 1 1
MAX reverse XXX% Displays/adjusts maximum reverse drive speed 0 to 100% 100 100 44-48 44-48
ELEV. MAX XX% Displays/adjusts maximum drive speed 0 to 50% 25 25 93-104 93-104
NOTE: used when elevation cutout switches are
limiting maximum speed
CREEP MAX XX% Displays/adjusts maximum drive speed 0 to 50% 35 35 79-87 79-87
NOTE: used when creep switch on pump pot is
active
STEER: max SPEED XXX% Displays/adjusts maximum steer speed. 0 to 100% 100 100
MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1.0 1.0
DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1.0 1.0
MIN Up XX% Displays/adjusts minimum main lift up speed 0 to 60% 20 20
MAX UP XX% Displays/adjusts maximum main lift up speed 0 to 100% 50 50 75-100 75-100
MIN DOWN XX% Displays/adjusts minimum main lift down 0 to 60% 10 10
speed
MAX DOWN XXX% Displays/adjusts maximum main lift down 0 to 100% 50 50 85-110 85-110
speed
CREEP UP XX% Displays/adjusts maximum main lift up speed 0 to 65% 50 50
active
CREEP DOWN XX% Displays/adjusts maximum main lift down 0 to 75% 45 45
speed
active
3121142 – JLG Lift – 6-23


DEFAULT VALUES
1200 1350 1200S 1350S
SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 2.0
DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5 1.5
MIN LEFT XX% Displays/adjusts minimum swing left speed 0 to 50% 40 40
MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 100% 65 65 115-125 115-125
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 40 40
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 100% 65 65 115-125 115-125
CREEP LEFT XX% Displays/adjusts maximum swing left speed 0 to 65% 50 50
active
CREEP RIGHT XX% Displays/adjusts maximum swing right speed 0 to 65% 50 50
active
MAIN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 1.0 1.0
MIN IN XX% Displays/adjusts minimum main telescope in 0 to 65% 15 15
speed. Same as Creep speed
MAX IN XXX% Displays/adjusts maximum main telescope in 0 to 100% 65 65 58-68 65-75
speed
MIN OUT XX% Displays/adjusts minimum main telescope out 0 to 65% 15 15
MAX OUT XXX% Displays/adjusts maximum main telescope out 0 to 100% 60 60 45-55 50-60
speed
BASKET LEVEL: ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5 0.5
MIN UP XX% Displays/adjusts minimum basket level up 0 to 65% 40 40
MAX UP XXX% Displays/adjusts maximum basket level up 0 to 100% 70 70
speed
MIN DOWN XX% Displays/adjusts minimum basket level down 0 to 65% 40 40
MAX DOWN XXX% Displays/adjusts maximum basket level down 0 to 100% 70 70
speed
6-24 – JLG Lift – 3121142


DEFAULT VALUES
1200 1350 1200S 1350S
BASKET ROTATE: ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1.0 1.0
DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5 0.5
MIN LEFT XX% Displays/adjusts minimum basket rotate left 0 to 100% 60 60
MAX LEFT XXX% Displays/adjusts maximum basket rotate left 0 to 100% 60 60 24-30 24-30
speed (180°) (180°)
MIN RIGHT XX% Displays/adjusts minimum basket rotate right 0 to 100% 60 60
MAX RIGHT XXX% Displays/adjusts maximum basket rotate right 0 to 100% 60 60 24-30 24-30
speed (180°) (180°)
JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1.0 1.0
MIN UP XX% Displays/adjusts minimum jib up speed. Same 0 to 65% 40 40
as Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 65 65 30-36 30-36
MIN DOWN XX% Displays/adjusts minimum jib down speed. 0 to 65% 40 40
Same as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 60 60 30-36 30-36
JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5 0.5
MIN LEFT XX% Displays/adjusts minimum jib left speed. Same 0 to 65% 40 40
as Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 70 60-68 60-68
(180°) (180°)
MIN RIGHT XX% Displays/adjusts minimum jib right speed. 0 to 65% 40 40
Same as Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 70 60-68 60-68
(180°) (180°)
3121142 – JLG Lift – 6-25


DEFAULT VALUES
1200 1350 1200S 1350S
GROUND U. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 100% 60 60
MODE: U. LIFT DN XXX% Displays/adjusts main lift down speed 0 to 100% 60 60
SWING XXX% Displays/adjusts fixed swing speed 0 to 100% 60 60
BASKET LVL XXX% Displays/adjusts fixed basket level speed 0 to 100% 75 75
BASKET ROT XXX% Displays/adjusts fixed basket rotate speed 0 to 100% 75 75
MAIN TELE XXX% Displays/adjusts fixed main telescope speed 0 to 100% 60 60
TOWER TELE XXX% Displays/adjusts fixed tower telescope speed 0 to 100% 100 100
Not displayed if TOWER TELE=NO
T. LIFT UP XXX% Displays/adjusts fixed tower lift up speed 0 to 100% 100 100
Not displayed if TOWER LIFT=NO
T. LIFT DN XXX% Displays/adjusts fixed tower lift down speed 0 to 100% 100 100
Not displayed if TOWER LIFT=NO
JIB (U/D) XXX% Displays/adjusts jib lift speed 0 to 100% 60 60
Not displayed if JIB = 0
JIB (L/R) XXX% Displays/adjusts jib swing speed 0 to 100% 70 70
Displayed if JIB = 2
GEN SET/WELDER: ENGINE XXXX RPM Control generator/welder RPM. Not displayed if 1200-2800 1800 1800
GEN SET/WELDER = 0
4150453-F
6-26 – JLG Lift – 3121142

6.10 MACHINE ORIENTATION WHEN SETTING Test Notes

FUNCTION SPEEDS 1. Personality settings can be adjusted anywhere within
Lift Up: From platform control, lowest elevation up to maxi- the adjustment range in order to achieve optimum
mum elevation, boom retracted. machine performance.
2. Stop watch should be started when the function is acti-
Lift Down: From platform control, maximum elevation down vated.
to minimum elevation, boom retracted.
3. Unless noted, all speed tests are run from the platform.
Swing Right (Max): 360 Degrees, from platform control, boom These speeds do not reflect the ground control opera-
approximately 45° elevation, boom retracted. tion.
Swing Left (Max): 360 Degrees, from platform control, boom 4. The platform speed knob control must be at full speed
approximately 45° elevation, boom retracted. (turned clockwise completely).
Telescope Out: From platform control, boom horizontal, 500 5. Function speeds may vary due to cold, thick hydraulic
lb. (230 kg) capacity selected. oil. Test should be run with the oil temperature above
100° F (38° C).
Telescope In: From platform control, boom horizontal, 500 lb.
(230 kg) capacity selected.
Drive Forward (Max): Test should be done on a smooth level
surface. High Speed - Low Torque setting, drive 200 ft. (61 m)
front wheels to front wheels. Timed after machine has
obtained maximum speed.
Drive Reverse (Max): Test should be done on a smooth level

surface. High Speed - Low Torque setting, drive 200 ft. (61 m)
front wheels to front wheels. Timed after machine has
obtained maximum speed.
Drive Forward (Creep Max): Test should be done on a

smooth level surface. High Torque - Low Speed setting, plat-
form speed knob at full creep.
Drive Reverse (Creep Max): Test should be done on a smooth

level surface. High Torque - Low Speed setting, platform speed
knob at full creep.
Drive Forward (Elevated Max - Boom Beyond Transport):

Test should be done on a smooth level surface. High speed -
Low Torque setting, platform speed knob out of creep, Lift
boom above transport, drive forward 50 ft. (15.2 m).
Drive Reverse (Elevated Max - Boom Beyond Transport):

Test should be done on a smooth level surface. High speed -
Low Torque setting, platform speed knob out of creep, Lift
boom above transport, drive forward 50 ft. (15.2 m).
Platform Rotate: Platform level and completely rotated one

direction. Rotate the opposite direction, Record Time. Rotate
the other direction, Record Time.
Articulating Jib: Platform level and centered with the boom.
Start with the Jib down. Jib Up, Record Time. Jib Down, Record
Time.
3121142 – JLG Lift – 6-27

6.11 SYSTEM TEST 3. Before proceeding, ensure that the switches on the plat-
form console are in the following positions:
The Control System Incorporates a built-in system test to
check the system components and functions. To use this func- a. Drive speed switch is in the Middle position. (Turtle
tion, use the following procedures. Icon)
b. 4WS switch is in the Middle position. (2WS mode)
Test from the Platform c. Capacity select switch in the 1000 lb. (450 kg) mode.
d. Function speed potentiometer out of creep mode
1. Position the Platform/Ground select switch to the Plat-
switch.
form position.
e. Generator (if equipped) switched to the off position.
f. Head and Tail lights (if equipped) switched to the off
position.
2. Plug the analyzer into the connector at the base of the

platform control box.
6-28 – JLG Lift – 3121142

4. Pull out the Emergency Stop switch and Start the 6. Use the arrow button to reach SYSTEM TEST. Hit Enter.
engine. The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
7. Follow the flow path in Figure 6-12., System Test Flow
Chart - Platform Tests and go through the component
tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
5. The analyzer screen should read:
3121142 – JLG Lift – 6-29

Figure 6-12. System Test Flow Chart - Platform Tests
6-30 – JLG Lift – 3121142

Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the
engine.
1. Position the Platform/Ground select switch to the
Ground position.
2. Plug the analyzer into the connector inside the Ground

control box.
5. Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
6. Follow the flow path in Figure 6-13., System Test Flow
Chart - Ground Station Tests and go through the compo-
nent tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
3121142 – JLG Lift – 6-31

6-32
– JLG Lift –
Figure 6-13. System Test Flow Chart - Ground Station Tests
3121142
Table 6-4. System Test Messages
Message Displayed on Message Displayed on

Description
Analyzer Analyzer
RUNNING Initial display when system test is run; certain “critical” checks are made. Problems that can be
reported include below messages.
ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V).
CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from the platform and
ground modules. The system test cannot run in ground mode unless data is being received from
the platform module.
CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed encoder.
BAD GROUND MODULE An internal problem was detected in the ground module.
HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt sensor.
HOT ENGINE The engine temperature exceeds 100°C. This is only a warning.
BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other problems are also
detected, the controller may need replacing.
SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at switch on.
Check and, if necessary correct, all personality settings.
OPEN FSW In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW In platform mode, the footswitch must be closed when this message is displayed; the footswitch
MUST BE KEPT CLOSED during the valve & contactor tests.
BAD FSW The two footswitch signals are not changing together, probably because one is open-circuit. One
footswitch signal (“FSW1”) is routed to the power module, the other (“FSW2”) is routed to the
platform module. Check footswitch and wiring.
3121142 – JLG Lift – 6-33


Description
Analyzer Analyzer
TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized;
checks are made for open- and short- circuit valve coils.
NOTE: In platform mode, the footswitch must be closed.
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if
TOWER TELE=NO. Jib valves are not tested if JIB = NO. Extendable axle valves are not tested if EXT
AXLES=NO. Four wheel steer valves are not tested if 4WS=NO.
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.
Problems that can be reported include below messages.
CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning correctly. Check valve
wiring. Check ground alarm & hour meter wiring.
XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-circuited. Check valve
wiring.
XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit. Check valve wir-
ing.
CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “nor-
mal” position; function switches should be open, cutout switches should be closed, joysticks
should be in neutral.
In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are
reported.
In ground mode any non-neutral ground switches is reported; any active cutouts are reported.
NOTE: Switches, which are not in use (due to the settings of machine digits), are not checked.
NOTE: The pump pot is checked only for a wire-off condition; it can be at any demand from creep
to maximum.
Problems that can be reported include below messages.
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.
TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a prompt asks for con-
firmation that the lamp is lit.
ENTER must be pressed or clicked to continue the test.
NOTE: Lamps, which are not in use (due to the settings of machine digits), are not checked.
NOTE: Platform Lamps are only tested in platform mode.
NOTE: The GM overload lamp and 500# capacity lamp are not tested.
NOTE: Head and tail lamps are tested in both platform and ground mode if enabled by a machine
digit.
TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a prompt asks for con-
firmation that the alarm is sounding.
ENTER must be pressed or clicked to continue the test.
NOTE: The platform alarm and the horn are only tested in platform mode.
NOTE: The ground alarm is not tested if GROUND ALARM = NO.
6-34 – JLG Lift – 3121142


Description
Analyzer Analyzer
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.
If ENTER is pressed or clicked, each operator input is prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not
tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are
not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX The named switch should be closed.
OPEN XXXXXXX The named switch should be opened.
XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction.
XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX The pump pot should be turned to maximum.
PUMP POT TO MIN The pump pot should be turned to minimum.
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short
between two inputs.
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and
should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu.
3121142 – JLG Lift – 6-35

Table 6-5. Machine Diagnostics Parameters
Diagnostics Submenu
Parameter (Displayed on Parameter Value
(Displayed on Analyzer Description
Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
1st Line)
DRIVE:
DRIVE FOR/REV XXX% Displays drive joystick direction & demand
STEER RIGHT/LEFT XXX% Displays steer switch direction & demand
4WS NORMAL/COOR/CRAB Displays status of four wheel steer input (Displayed if 4WS = 1)
BRAKES LOCKED/RELEASED Displays brake control system status
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
CRP MODE ACTIVE/NOT ACT Displays creep mode status
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
TWO SPEED OP/CL Displays status of two speed switch input if selected model has two speed.
2 speed mode ON/OFF Displays status of two speed valve if selected model has two speed
high engine OP/CL Displays status of high engine switch
LT F ANG XX.X Displays status of left front steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT F ANG XX.X Displays status of right front steer angle (Displayed if MODEL NUMBER = 7 or
8)
LT R ANG XX.X Displays status of left rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT R ANG XX.X Displays status of right rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
DOS LIM sw OP/CL Displays status of Drive Orientation System limit switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R sw OP/CL Displays status of Drive Orientation Limit System override switch. (Displayed if
MODEL NUMBER = 7 or 8)
6-36 – JLG Lift – 3121142

Diagnostics Submenu
1st Line)
BOOM:
U LIFT UP/DOWN XXX% Displays main lift joystick direction & demand
SWING RIGHT/LEFT XXX% Displays swing joystick direction & demand
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
LEVEL UP/DOWN XXX% Displays basket level switch direction & demand. NOTE: demand is controlled
by the pump pot
ROT. RIGHT/LEFT XXX% Displays basket rotate switch direction & demand. NOTE: demand is con-
trolled by the pump pot
U TELE IN/OUT XXX% Displays main telescope switch direction & demand. NOTE: demand is con-
T TELE IN/OUT XXX% Displays tower telescope switch direction & demand. NOTE: demand is con-
Not displayed if TOWER TELE=NO (machine digit = 0)
T LIFT UP/DOWN XXX% Displays tower lift switch direction & demand. NOTE: demand is controlled by
the pump pot
Not displayed if TOWER LIFT=NO (machine digit = 0)
JIB UP/DOWN XXX% Displays jib lift switch direction & demand. NOTE: demand is controlled by the
pump pot
Not displayed if JIB = NO (machine digit = 0)
JIB RIGHT/LEFT XXX% Displays jib swing switch direction & demand. NOTE: demand is controlled by
the pump pot
Displayed if JIB = SIDESWING (machine digit = 2)
JIB INLINE OP/CL Displays status of jib inline limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIMIT OP/CL Displays status of jib right limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIM OVRD OP/CL Displays status of jib limit override switch. Displayed on models equipped
with the Jib Stow System
PCV ON/OFF Displays status of Platform Control Valve. Displayed on models equipped with
Electronic Platform Leveling.
PUMP POT XXX% Displays pump pot demand. Not displayed if MODEL = 601 (machine digit =
4)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
3121142 – JLG Lift – 6-37

Diagnostics Submenu
1st Line)
ENGINE:
START ACTIVE/NOT ACTIVE Displays status of the engine start circuit
AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not displayed if MODEL
NUMBER = 7 or 8)
BATTERY XX.XV Displays measured battery voltage
COOLANT XXXC Displays measured coolant temperature
OIL PRS LOW / OK or XXPSI Displays measured oil pressure
FUEL SELECT GAS/LP Displays status of fuel select switch. (Displayed if MODEL NUMBER = 2)
AMB. TEMP XXXC Displays measured ambient air temperature
FUEL LEVEL ¼ / ½ / ¾ / FULL or LOW / OK Displays measured fuel level
XXXx rpm Engine RPM
6-38 – JLG Lift – 3121142

Diagnostics Submenu
1st Line)
SYSTEM:
GM BATTERY XX.XV Ground module battery voltage
PM BATTERY XX.XV Platform module battery voltage
AMB. TEMP XXXC Ambient temperature
FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground module.
FSW2 OP/CL Displays footswitch status. NOTE: FSW2 is wired to the platform module.
ABOVE ELEV. OP/CL/YES/NO Displays above elevation cutout switch status or above angle status
LEN SW 1 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
LEN SW 2 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
RETRACTED YES/NO Displays status of boom length retracted (Displayed if MODEL NUMBER = 7 or
8)
TRANSPORT YES/NO Displays status of transport position
U LIFT CUTOUT OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 6)
T LIFT PROX OP/CL Displays status of tower lift proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
T TELE PROX OP/CL Displays status of tower telescope proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
BR CABLE CUT. OP/CL Displays status of broken cable switch (Displayed if BROKEN CABLE SWITCH =
1)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status. Not displayed if MODEL = 601
(machine digit = 4)
SUPER CREEP ON/OFF Displays super creep mode status (Displayed if MODEL NUMBER = 7 or 8)
TILT XX.X DEG Displays measured vehicle tilt. (Displayed if internal tilt sensor is configured)
LO TILTED - NO/YES Displays status of lo tilt input. (Displayed if external tilt sensor is configured)
3121142 – JLG Lift – 6-39

Diagnostics Submenu
1st Line)
HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is configured)
AUX POWER OP/CL Displays the status of the auxiliary power switch input
HORN OP/CL Displays the status of the horn input
R FILTER OP/CL Displays the status of the return hydraulic filter by-pass switch. Displayed
ONLY if MODEL = 600 (Configuration digit = 3)
C FILTER OP/CL Displays measured status of charge pump filter bypass switch. Displayed ONLY
if MODEL = 600 (Configuration digit = 3)
JIB BLOCK OP/CL Displays jib block limit switch status. Not displayed if associated configuration
digit = 0
BASKET STOWD YES/NO Displays status of basket stowed mode. (Displayed if MODEL NUMBER = 7 or 8)
SOFT LIMIT OP/CL Displays status of soft touch limit switch. Not displayed if associated configu-
ration digit = 0
SOFT O/R OP/CL Displays status of soft touch override switch. Not displayed if associated con-
figuration digit = 0
GEN SET/WELDER OP/CL Displays generator/welder switch input status. Not displayed if associated
configuration digit = 0
LIGHTS OP/CL Displays head and tail light switch input status. Not displayed if associated
configuration digit = 0
BSK TILT1 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
BSK TILT2 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
AXLE RET SW OP/CL Displays status of axle extension user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE EXT SW OP/CL Displays status of axle retraction user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE LIM SW RET/EXT Displays status of axle extension limit switches. (Displayed if MODEL NUMBER
= 7 or 8)
DOS LIM SW OP/CL Displays status of Drive Orientation System Limit Switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R SW OP/CL Displays status of Drive Orientation System Override switch. (Displayed if
MODEL NUMBER = 7 or 8)
CAPACITY SW 500/1000 Displays status of capacity selection switch. (Displayed if MODEL NUMBER = 7
or 8)
6-40 – JLG Lift – 3121142

Diagnostics Submenu
1st Line)
OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING
AXLE = 1)
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
(Displayed if MODEL NUMBER = 7 or 8)
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
LOAD: Not displayed if LOAD=NO, LENGTH=NO, and ANGLE=NO (machine digits =

0)
LENGTH OP /CL Displays measured length, NOTE: Not displayed if MODEL NUMBER = 7 or 8
ANGLE OP / CL Displays measured angle, NOTE: Not displayed if MODEL NUMBER = 7 or 8
WEIGHT XXXX% Percentage of maximum calibrated weight on the platform. An uncalibrated

load cell will read 1000% Displayed if LOAD is not 0 and LOAD TYPE is 0.
OK/OVERLOADED Displayed if LOAD is not 0 and LOAD TYPE is 1.
3121142 – JLG Lift – 6-41

Diagnostics Submenu
1st Line)
MOMENT: Displayed if MODEL NUMBER = 7 or 8
(LB-IN) ACTUAL XXXXXXXX Displays current moment value
(LB-IN) XXXXXXXX Displays current over moment setpoint.

OVER
(LB-IN) XXXXXXXX Displays current under moment setpoint.

UNDER
CAL PT XXXXXXXX Displays the under moment value recorded during boom sensor calibration.
UNDER
CAL PT XXXXXXXX Displays the yellow witness mark moment value recorded during boom sen-
WIT YEL sor calibration.
CAL PT XXXXXXXX Displays the green witness mark moment value recorded during boom sensor
WIT GRN calibration.
CYL PIN X.XXX Displays the current cylinder moment pin ratio of X and Y forces.
RATIO
PIN 0xXXXX Displays the current error flag status of the cylinder moment pin.
E FLAGS
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
6-42 – JLG Lift – 3121142

Diagnostics Submenu
1st Line)
ENVELOPE: Displayed if MODEL NUMBER = 7 or 8
LENGTH XXXX.X Displays the current indicated boom length in inches.
ANGLE 1 XX.X Displays the current indicated boom angle 1 in degrees.
ANGLE 2 XX.X Displays the current indicated boom angle 2 in degrees.
A/D LNGTH XXXXX Displays the current indicated boom length in A/D counts.
A/D ANG1 XXXXX Displays the current indicated boom angle 1 in A/D counts or raw angle if cali-
brated.
A/D ANG2 XXXXX Displays the current indicated boom angle 2 in A/D counts or raw angel if cali-
brated.
CAN STATISTICS: CAN Statistics as detected by the Ground Module
RX/SEC XXX Displays the number of received messages per second
TX/SEC XXX Displays the number of transmitted messages per second
BUS OFF XX Displays the number of bus off occurrences
PASSIVE XX Displays the number of bus passive occurrences
3121142 – JLG Lift – 6-43

Diagnostics Submenu
1st Line)
CALIBRATION DATA
BASKET UP XXX Displays the basket up calibration point
BASKET DOWN XXX Displays the basket down calibration point
L FWD DRIVE XXX Displays the left forward drive calibration point
R FWD DRIVE XXX Displays the right forward drive calibration point
L REV DRIVE XXX Displays the left reverse drive calibration point
R REV DRIVE XXX Displays the right reverse drive calibration point
F LT STEER XXX Displays the forward left steer calibration point
F RT STEER XXX Displays the forward right steer calibration point
R LT STEER XXX Displays the reverse left steer calibration point
R RT STEER XXX Displays the reverse right steer calibration point
U LIFT UP XXX Displays the main lift up calibration point
U LIFT DOWN XXX Displays the main lift down calibration point
U TELE IN XXX Displays the main telescope in calibration point
U TELE OUT XXX Displays the main telescope out calibration point
BM ANG 1 LO XXX Displays the boom angle 1 low calibration point
BM ANG 1 HI XXX Displays the boom angle 1 high calibration point
BM ANG 2 LO XXX Displays the boom angle 2 low calibration point
BM ANG 2 HI XXX Displays the boom angle 2 high calibration point
LEN RETRACT XXX Displays the length sensor retracted calibration point
LEN EXTEND XXXXX Displays the length sensor extended calibration point
LEN WIT XXXXX Displays the witness mark calibration point
LEN SWITCH XXXX Displays the length switch calibration point
6-44 – JLG Lift – 3121142

Diagnostics Submenu
1st Line)
DATALOG:
ON XXXXhXXm Displays total controller on (EMS) time
ENGINE XXXXhXXm Display engine run time
DRIVE XXXXhXXm Displays total controller drive operation time
LIFT XXXXhXXm Displays total controller lift operation time
SWING XXXXhXXm Displays total controller swing operation time
TELE XXXXhXXm Displays total controller telescope operation time
MAX TEMP XXC Displays maximum measured ambient temp.
MIN TEMP XXC Displays minimum measured ambient temp.
MAX VOLTS XX.XV Displays maximum measured battery voltage
RENTAL XXXXhXXm Displays total controller operation time. NOTE: can be reset
ERASE RENTAL? Not available at Access Level 2.

ENTER resets rental data log time to zero.
VERSIONS:
GM SW PX.X Displays ground module software version
GM HW REV XXXX Displays ground module hardware revision
GM SN XXXXXX Displays ground module serial number
PM SW PX.X Displays platform module software version
PM HW REV XXXX Displays platform module hardware revision
PM SN XXXXXX Displays platform module serial number
CM SW PX.X Displays chassis module software version
BM SW PX.X Displays BLAM module software version
C PIN SW Displayed if cylinder moment load pin transmits software version.
C PIN SN Displayed if cylinder moment load pin transmits serial number.
ANALYZER VX.XXXX Displays Analyzer software version
3121142 – JLG Lift – 6-45

6.12 CALIBRATING STEER 1. Position the Platform/Ground select switch to the Plat-
form position.
When calibrating steering, each individual wheel must be cali-
brated in order to make the tire and wheel parallel with the
frame. Two methods to help ensure proper calibration are the
use of a carpenter’s square to square the spindle to the axle or
aligning the two wheels on one side using a stretched string.

6-46 – JLG Lift – 3121142

3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Steer. The screen will read:
engine.
9. Hit Enter. The screen will read:
5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.

6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
3121142 – JLG Lift – 6-47

10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer.
15. Left Rear Steer Calibration will be followed by Right For-
ward Steer Calibration which will be followed by Right
Rear Steer Calibration.
16. After completing all the Steer Calibrations, hit ESC twice
to go back to CALIBRATIONS.
12. Activate the steer control until the tire and wheel are
straight in relationship with the chassis, then leave off
the control. The display will read FRT LEFT = and show
the numeric calibration value for that wheel.
6-48 – JLG Lift – 3121142

6.13 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the
engine.
form position.


Enter.
3121142 – JLG Lift – 6-49

8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read:
9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read:
12. Activate the Drive Joystick forward full stroke until the
machine just begins to move, then leave off the joystick
immediately. The display will read CRK PT = and show
the numeric crack point value.
6-50 – JLG Lift – 3121142

13. Hit Enter. The number displayed will be the value that 14. Hit Enter. The screen will read:
the crack point is set to. The screen will show:
15. Repeat steps 10 thru 12 for left reverse drive.

16. Left Reverse Drive Calibration will be followed by Right
Forward Drive Calibration which will be followed by
Right Reverse Calibration.
17. After completing all the Drive Calibrations, hit ESC twice
3121142 – JLG Lift – 6-51

6.14 ELECTRONIC PLATFORM LEVELING allow the operator to operate the machine as a new level set-
point is taken.
Platform Leveling Fault Warning VALVE DRIVER ERRORS

The JLG Control System takes a snapshot of the two sensor val- There are three possible level valve driver errors, short to bat-
ues and records the difference once on each power up. The tery, short to ground, and open circuit.
Control system allows a ±5 degree difference from those val-
ues. For example, if Sensor 1 is at 5 degrees and Sensor 2 is at 1. In the case of a short to ground or an open circuit, the
11 degrees, the difference is 6 degrees and the DTC is trig- platform valve cannot be turned on and the following
gered when the sensors are 1 degree (or less) apart or 11 will occur:
degrees (or more) apart. a. All interactions with platform leveling shall cease
If a fault occurs in the platform leveling system the following b. The Electronic Leveling System Fault Lamp shall
will occur: flash (to indicate that the leveling function has been
lost).
1. Automatic platform leveling will stop (except when
there is a fault in only one sensor automatic leveling will c. The platform alarm will sound.
remain active as the control system will use the other d. A system fault will be logged.
sensor to control leveling) e. All function speeds (lift, swing, telescope and drive)
2. The level fault lamp will flash will be placed in creep mode (except when the plat-
form is in the transport position).
3. The audible alarm will sound
2. In the case of a short to battery on one of the platform
4. All functions will default to creep speed if the platform is leveling valves, the valve cannot be turned off and the
out of the transport position (extended more than 12” following will occur:
[51 cm] 1350SJP; 24" [60.9 cm] 1200SJP, or elevated
above the horizontal position). a. The platform dump valve will be turned off to pre-
vent unintended tilting of the platform.
To reset the fault the emergency stop switch should be recy-
b. All interactions with platform leveling shall cease.
cled.
c. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has been
lost).
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE GROUND POSITION,
d. The platform alarm will sound.
SWITCH THE MACHINE OFF AND CONTACT A QUALIFIED SERVICE REPRESEN-
TATIVE TO INVESTIGATE THE FAULT. e. A system fault will be logged.
f. All function speeds (lift, swing, telescope and drive)
Fault Response will be placed in creep mode (except when the plat-
ERROR RESPONSE form is in the transport position)
If basket level varies from the current setpoint by ± 5.5º for 3. In the case of a short to battery on the platform dump
more than 1.5 seconds when the platform is not in the trans- valve, the valve cannot be turned off. The controllability
port position, the following events will occur: of the platform leveling function will be impaired and
the following will occur:
1. The platform dump valve will be disabled (level, rotate
and jib functions disabled). a. All interactions with platform leveling shall cease.
b. The Electronic Leveling System Fault Lamp shall
2. The level system fault lamp will flash (to indicate that flash (to indicate that the leveling function has been
the leveling function has been lost). lost).
3. The platform alarm will sound. c. The platform alarm will sound.
4. A system fault will be logged. d. A system fault will be logged.
e. All function speeds (lift, swing, telescope and drive)
5. All function speeds (lift, swing, telescope and drive) will
will be placed in creep mode (except when the plat-
be placed in creep mode (except when the platform is in
form is in the transport position).
the transport position see below).
Lift, swing, drive and telescope will continue to operate
When the unit is in the transport position and driving and the
current setpoint varies by ± 5.5º for more than 8 seconds the In each of the cases above it shall be necessary to re-cycle the
events 1,2,3 & 4 above will occur. (note function speeds will EMS to clear the fault. Operable functions shall be in the creep
operate normally). Cycling the EMS will clear the fault and mode except while below elevation.
6-52 – JLG Lift – 3121142

TILT SENSOR ERRORS CAN Errors

If the secondary tilt sensor is faulty, the control system will The Ground Module has two direct outputs dedicated to over-
continue to utilize information from the primary sensor. riding the Platform Module’s control of the leveling valves. The
Ground Module “Platform Level Up/Down” outputs are used
If the primary sensor is faulty, the control system will switch to to control the platform level up and down valves.
the backup sensor for control.
When in ground mode, if the Ground Module reads a platform
In both cases above the following will occur: leveling switch command, the switch command is communi-
1. The Electronic Leveling System Fault Lamp will flash (to cated over CAN to the Platform Module where it is handled
indicate that there is a leveling fault). normally.
2. The platform alarm will sound. If Ground Module determines that CAN communication is
inoperable, it turns on the platform control valve and the
3. A system fault will be logged. appropriate platform leveling override outputs while the
4. All function speeds (lift, swing, telescope, jib and drive) switch is engaged.
will be placed in creep mode (except when the platform If the Platform Module is still running when CAN is down noth-
is in the transport position). ing will operate when in platform mode. When the operator
5. Automatic leveling remains active. switches to ground mode, the platform will not control any of
its valve outputs and a CAN error message is signaled.
Lift, swing, drive and telescope will continue to operate.
In each of the cases above it will be necessary to re-cycle the Additional Platform and Jib Valves
EMS to clear the fault. Operable functions shall be in the creep The high side drivers for the platform left and right and the jib
mode except while below elevation. up and down valves are be located in the Platform Module and
are proportional. Flow through the valves is individually con-
When both sensors appear to be working but have measure-
trollable. The individually controlled duty cycle will be the
ments that disagree by ±5.5º The following will occur:
same as would otherwise have been commanded to the flow
1. All interactions with platform leveling shall cease. control valve.
2. The Electronic Leveling System Fault Lamp shall flash (to Only one platform or jib function is allowed at one time to
indicate that the leveling function has been lost). limit the amount of current draw, minimizing the voltage drop
on the supply to the Platform Module.
3. The platform alarm will sound.
The function is enabled first shall remain active until it is
4. A system fault will be logged.
released. Any other function commanded while another func-
5. All function speeds (lift, swing, telescope and drive) will tion is active is ignored.
be placed in creep mode (except when the platform is in
the transport position)
At this point, the operator must use the level up and down
toggle switch to manually level during descent. It shall be nec-
essary to re-cycle the EMS to clear the fault.
3121142 – JLG Lift – 6-53

Platform Leveling Calibration Procedure STEP 3: BLEEDING THE PLATFORM VALVES

STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 1. Put machine into “Ground Mode”.
1. Put machine into “Ground Mode”. 2. Start machine and plug in Analyzer.
2. Start machine and plug in Analyzer. 3. Go to the “Access Level 2” screen.
3. Go to the “Access Level 2” screen. 4. Enter “33271” to get into Access Level 1 mode.
4. Enter “33271” to get into Access Level 1 mode. 5. Go to the "Personalities" menu.
5. Go to the "Personalities" menu and adjust the following 6. Using the left arrow button, go to the "Ground Mode"
personalities. Refer to the Personality Ranges/Defaults menu.
table in Section 6 - JLG Control System for proper setting 7. Hit ENTER.
values.
8. Using the UP/DOWN arrows, adjust the following per-
Basket Level Up Min sonalities to 100%.
Basket Level Up Max
Basket Level Down Max Basket Rotate
Jib Up Min Basket Level
Jib Down Min Jib U/D (if configured)
6. Recycle EMS. Start up the machine and exercise each above platform
STEP 2: CALIBRATING THE PLATFORM LEVEL function (from the ground) eight (8) to ten (10) times for
SENSORS 5 seconds in each direction.
1. Put machine into “Ground Mode”. 9. Return the personality settings back to the values as
shown in the Personality Ranges/Defaults table in Sec-
2. Start machine and plug in Analyzer. tion 6 - JLG Control System.
3. Manually level the platform with the switch on the MTB. 10. Recycle EMS.
4. Go to the “Access Level 2” screen. STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND
DOWN VALVE CRACKPOINTS
5. Enter “33271” to get into Access Level 1 mode.
1. Put machine into “Ground Mode”.
6. Go to the “Calibrations” menu and hit ENTER.
2. Start machine and plug in Analyzer.
7. Use RIGHT ARROW go to “Plat. Leveling” screen.
3. Go to the “Access Level 2” screen.
8. Hit ENTER. “Calibrate?” prompt should appear.
4. Enter “33271” to get into Access Level 1 mode.
9. Hit ENTER again to calibrate level sensors.
5. Go to the “Calibrations” menu and hit ENTER.
10. When calibration has been successful “Cal. Complete”
should appear. 6. Go to the “Basket U Crkpt” Screen. Hit ENTER.
11. Cycle power to the machine. 7. “Calibrate?” prompt should appear. Hit ENTER again.
8. You will hear engine go to 1800 rpm.
9. Using UP ARROW, increase the value until you see the
basket up movement.
6-54 – JLG Lift – 3121142

10. Hit ENTER again. “Cal. Complete” message should 2. Plug the analyzer into the connector inside the Ground
appear control box.
11. Engine should again return to idle.
12. Hit ESC should return to “Basket U Crkpt” screen.
13. Hit RIGHT ARROW to get to the “Basket D Crkpt” screen.
Hit ENTER.
14. “Calibrate?” prompt should appear. Hit ENTER again.
Using UP ARROW, decrease the value until you see the basket
down movement.
Hit ENTER again. “Cal. Complete” message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
3. Pull out the Emergency Stop switch and start the
engine.
6.15 CALIBRATING PLATFORM LEVEL
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS

Ground position.

3121142 – JLG Lift – 6-55

7. Use the arrow button to reach PERSONALITIES adjust 4. Manually level the platform with the switch on the Main
the following personalities. Refer to the Personality Terminal Box.
Ranges/Defaults table for proper setting values.
Basket Level Up Min
Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
8. Recycle EMS.
STEP 2: CALIBRATING THE PLATFORM LEVEL

SENSORS
Ground position.

8. Use the arrow button to reach CALIBRATIONS menu and
hit ENTER.
2. Plug the analyzer into the connector inside the Ground 9. Use right arrow go to PLAT. LEVELING screen.
control box.

engine.
6-56 – JLG Lift – 3121142

10. Hit ENTER. The screen should read: STEP 3: BLEEDING THE PLATFORM VALVES
Ground position.

control box.
11. Hit ENTER again to calibrate level sensors.

12. When calibration has been successful CAL. COMPLETE
should appear.
13. Cycle power to the machine.

engine.
3121142 – JLG Lift – 6-57

4. The analyzer screen should read: STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND
DOWN VALVE CRACKPOINTS
Ground position.

control box.

7. Go to the PERSONALITIES menu.
8. Using the left arrow button, go to the GROUND MODE
menu.
9. Hit ENTER.
10. Using the UP/DOWN arrows, adjust the following per-
sonalities to 100%.
Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform

function (from the ground) eight (8) to ten (10) times for 3. Pull out the Emergency Stop switch and start the
5 seconds in each direction. engine.
11. Return the personality settings back to the values as

shown in the Personality Ranges/Defaults table in Sec-
tion 6 - JLG Control System.
12. Recycle EMS.
6-58 – JLG Lift – 3121142

4. The analyzer screen should read: 11. Using UP ARROW, increase the value until you see the
basket up movement.
12. Hit ENTER again. CAL. COMPLETE message should
appear
13. Engine should again return to idle.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”
screen. Hit ENTER.
16. CALIBRATE? prompt should appear. Hit ENTER again.
Using UP ARROW, increase the value until you see the basket
down movement.
Hit ENTER again. CAL. COMPLETE message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
6.16 CALIBRATING LIFT CRACK POINT

form position.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the BASKET U CRKPT Screen. Hit ENTER.
9. CALIBRATE? prompt should appear. Hit ENTER again.
3121142 – JLG Lift – 6-59

2. Plug the analyzer into the connector at the base of the 4. The analyzer screen should read:
3. Pull out the Emergency Stop switch and Start the

engine.

Enter.
6-60 – JLG Lift – 3121142

8. Use the arrow keys to reach Upper Lift Crack Point 10. Hit Enter. The screen will read:
(UPPER LIFT CRKPT). The screen will read:
11. Hit Enter again. The screen will read:

9. Hit enter. The screen will read:
12. Activate the Lift Up function by fully stroking the joy-

stick until the boom starts to move, then leave off imme-
diately. The display will read CRK PT = and show the
numeric crack point value.
3121142 – JLG Lift – 6-61

13. Hit enter. The number displayed will be the value that 6.17 CALIBRATING TELESCOPE CRACK POINT
form position.

15. Repeat steps 10 thru 12 for the Lift Down function.

16. After completing all the Tele Calibrations, hit ESC twice
6-62 – JLG Lift – 3121142

3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Upper Telescope Crack Point
engine. (UPPER TELE CRKPT). The screen will read:

Enter.
3121142 – JLG Lift – 6-63

10. Hit Enter. The screen will read: 13. Hit enter. The number displayed will be the value that
11. Hit enter again. The screen will read:

12. Activate the Tele Out function until the boom starts to
move, then leave off immediately. The display will read
CRK PT = and show the numeric crack point value.
6-64 – JLG Lift – 3121142

15. Hit Enter. The screen will read: 6.18 CALIBRATING TILT SENSOR
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.
1. Use the following procedure to calibrate the tilt sensor.
Before the tilt sensor can be calibrated, the following

conditions must be met:
a. Steering previously calibrated.
b. Axles extended.
c. Wheels straight.
d. Turntable centered.
e. Boom fully retracted.
f. Boom angle is less than 45°.
g. Machine on firm, level ground.
16. Repeat steps 10 thru 12 for the Tele In function. Ground position.
17. After completing all the Tele Calibrations, hit ESC twice
3121142 – JLG Lift – 6-65

3. Plug the analyzer into the connector inside the Ground 9. Use the arrow keys to reach the TILT SENSOR. The screen
control box. should read:

engine.
10. Press ENTER.

11. When prompted, swing turntable 180° to opposite end
of chassis.
12. Press ENTER. The screen should read:

Enter.
13. Upon completing swing calibration, swing turntable

180° back to the stowed position.
14. Hit ESC twice to go back to CALIBRATIONS.
6-66 – JLG Lift – 3121142

6.19 CALIBRATING THE BOOM SENSORS 2. Position the Platform/Ground select switch to the
Ground position.
DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS NORMAL FOR

THE REAR WHEEL TO LIFT FROM THE GROUND APPROXIMATELY 1 INCH (2.5
CM). IF THE WHEEL RAISES APPRECIABLY MORE THAN THIS (I.E. 4 INCHES [10
CM] OR MORE), CHECK THE AXLE OSCILLATION SYSTEM FOR PROPER OPERA-
TION OR THE NEED FOR BLEEDING, THEN PROCEED WITH THE BOOM SENSOR
CALIBRATION PROCEDURE.
Use the following step-by-step procedure to calibrate the

boom sensors.
1. Before the boom sensors can be calibrated, the follow-

ing conditions must be met:
a. Steering, telescope crack points, and tilt previously
calibrated
b. Axles Extended
c. Wheels Straight control box.
d. Platform Unloaded
e. Jib Horizontal
f. Jib Swing Centered
g. Platform Level
h. Platform Centered
i. Turntable Centered
j. Boom Fully Retracted
k. Level Ground (within 1.5°)
Figure 6-14. Boom Sensor Calibration Position 1

engine.
3121142 – JLG Lift – 6-67

5. The analyzer screen should read: 9. Use the arrow keys to reach BOOM SENSORS. The screen
should read:

Enter.
6-68 – JLG Lift – 3121142

11. After verifying all the conditions listed in step 1 are met, 13. After visually verifying that the jib is horizontal, hit Enter.
hit Enter. The screen will read: The screen will read:
12. After verifying all load (personnel or material) is 14. After visually verifying the platform is level, hit Enter. The
removed from the platform, hit Enter. The screen will screen will read:
read:
3121142 – JLG Lift – 6-69

15. After visually verifying the platform is centered, hit 17. Use the up/down arrows to select YES if the accessory is
Enter. The screen will read: installed, NO if it is not installed and hit enter. The screen
will read:
16. After operating telescope in to verify the boom is fully

retracted, hit Enter. The screen will read: 18. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen
will read:
6-70 – JLG Lift – 3121142

19. Use the up/down arrows to select YES if the accessory is 21. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, NO if it is not installed and hit enter. The screen
will read: will read:
20. Use the up/down arrows to select YES if the accessory is 22. Use the up/down arrows to select yes if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, no if it is not installed and hit Enter. The screen
will read: will read:
3121142 – JLG Lift – 6-71

23. After making sure the machine is in Calibration Position The screen will read:
1, hit Enter. The screen will read:
24. Lift up to stop (full stroke of cylinder) for Calibration

Position 2. When the machine is in that position, hit
Enter.
6-72 – JLG Lift – 3121142

25. Swing 180 degrees (centered over opposite end of chas- When Position 3 calibrating is complete the screen will
sis) for Calibration Position 3. read:
When the machine is in the proper position, hit Enter.

The screen will read:
3121142 – JLG Lift – 6-73

26. Press Enter. The screen will read: When the machine is in the proper position, hit Enter.
Swing the machine back 180 degrees (centered over When Position 4 calibrating is complete, the screen will
original end of chassis) for Calibration Position 4. read:
6-74 – JLG Lift – 3121142

27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter.
Telescope out to stop (boom must be fully extended) for

Calibration Position 5.
3121142 – JLG Lift – 6-75

28. Retract to stop (boom must be fully retracted) for Cali- 29. Lift down to stop (boom must be on boom rest) for Cali-
bration Position 6. bration Position 7.

The screen will read as follows:

6-76 – JLG Lift – 3121142

When Position 7 Calibrating is complete, the screen will 30. Lift until the function stops (controller will stop at 5
read: degrees above horizontal) for Calibration Position 8.

Press Enter. The screen will read:
3121142 – JLG Lift – 6-77

Press Enter. The screen will read: When the boom is in the proper position, hit Enter. The
screen will read:
31. Telescope to the yellow witness mark (controller will be

close - operator must position the pointer to center line When Position 9 calibrating is complete, the screen will
on decal within 0.25" [6 mm]) for Calibration Position 9. read:
6-78 – JLG Lift – 3121142

Press Enter. The screen will read: When the boom is in the proper position, the screen will
read:
32. Telescope in to green witness mark (controller will find

the position - operator must visually verify the position). Press Enter. The screen will read:
33. After completing all the Boom Sensors Calibrations, hit

ESC twice to go back to Calibrations.
34. Cycle the emergency stop switch.
3121142 – JLG Lift – 6-79

Boom Control System Check Procedure 5. Push and hold the gray Boom Control System Test But-
ton on the ground control panel. The lighting of the
Perform the following check with no load (personnel or mate-
green Boom Control System Calibrated indicator indi-
rial) in the platform from the ground control station.
cates the system is functioning properly. No indicator
1. With the boom fully retracted, raise the boom off the light or the lighting of the red Boom Control System
boom rest to horizontal. Warning indicator indicates the system must be repaired
by JLG authorized Service Personnel before the machine
2. Position the jib horizontal, jib straight, and platform
can be used.
level.
3. Extend the boom until it stops.
4. Boom must stop on colored stripe matching the capac-
ity indicator. If the boom does not stop on the correct
stripe, the system must be repaired by JLG authorized
Service Personnel before the machine can be used.
6-80 – JLG Lift – 3121142

Figure 6-24. Fault Code Light Location
3121142 – JLG Lift – 6-81

Table 6-6. Diagnostic Trouble Code Chart
Flash
DTC Sequence Fault Message Fault Description Check
Code
001 00 1 EVERYTHING OK The normal help message in
Platform Mode.
002 00 2 GROUND MODE OK The normal help message in
Ground Mode.
0010 00 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELE-
VATED MAX" while the vehicle is
out of transport position.
000 00 0 <<< HELP COMMENT >>>
0011 00 11 FSW OPEN A drive / boom function was
selected with the Footswitch
open.
0012 00 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the
Creep Switch is open.
0013 00 13 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All functions at creep while the
Platform is elevated and the
Chassis is tilted.
0014 00 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 - Not reported during power-up.
degrees for more then 4 sec-
onds.
0015 00 15 LOAD SENSOR READING UNDER WEIGHT The Load Sensing System indi- - Not reported during power-up.
cates > 20% under calibrated - May occur if the Platform is rest-
zero point. ing on the ground.
0016 00 16 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is an envelope violation. - Envelope control system
equipped vehicle only.
0017 00 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment viola- - Envelope control system
tion. equipped vehicle only.
0018 00 18 UNDER MOMENT - HYDRAULICS SUSPENDED There is an under moment viola- - Envelope control system
0019 00 19 MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a main envelope viola- - Main envelope system equipped
tion. vehicle only.
0020 00 20 TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is a tower envelope viola- - Tower envelope system
210 21 0 <<< POWER-UP >>>
211 21 1 POWER CYCLE The normal help message is
issued at each power cycle.
212 21 2 KEYSWITCH FAULTY Both Platform and Ground
modes are selected simultane-
ously.
213 21 3 FSW FAULTY Both Footswitches are closed for
more then one second.
220 22 0 <<< PLATFORM CONTROLS >>>
227 22 7 STEER SWITCHES FAULTY Both Steer Left and Steer Right
inputs are closed simultane-
ously.
6-82 – JLG Lift – 3121142

Flash
Code
2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed for - Can be reported during power-
more then seven seconds. up.
2212 22 12 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected - Can be reported during power-
with Footswitch open. up.
2213 22 13 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected
with Footswitch open.
2215 22 15 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2216 22 16 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2217 22 17 D/S JOY. CENTER TAP BAD The D/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2218 22 18 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2219 22 19 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2220 22 20 L/S JOY. CENTER TAP BAD The L/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2221 22 21 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A lift / swing function was
selected with Footswitch open.
2222 22 22 WAITING FOR FSW TO BE OPEN The Footswitch was closed dur- - Can be reported during power-
ing Platform selection. up.
2223 22 23 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE A boom function was selected
with Footswitch open.
2224 22 24 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed dur-
ing engine start.
230 23 0 <<< GROUND CONTROLS >>>
234 23 4 FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM A boom function has both direc-
tions selected together.
235 23 5 FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER A boom function was selected
before aux power.
3121142 – JLG Lift – 6-83

Flash
Code
236 23 6 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH A boom function was selected
before engine start.
237 23 7 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed dur-
ing power-up.
250 25 0 <<< FUNCTION PREVENTED >>>
259 25 9 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been
changed.
2513 25 13 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the
vehicle generator is running
AND is configured to prevent
drive.
2514 25 14 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible
while the vehicle is being driven
AND is configured to not allow
simultaneous drive & boom
operation.
2515 25 15 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the
vehicle above elevation AND is
configured to prevent drive
while above elevation.
2516 25 16 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while
Boom functions are selected
AND is configured to not allow
simultaneous drive & boom
operation.
2517 25 17 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the
vehicle is tilted and above eleva-
tion AND is configured to pre-
vent drive while tilted and
above elevation.
2521 25 21 JIB SWING PREVENTED - IN 1000# MODE JIB Swing is not possible while
the vehicle is in 1000 LB Mode.
2522 25 22 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED CAN Dongle attached. Very lim-
ited restrictions for all hydrau-
lics systems.
2523 25 23 BACKUP BLAM COMMUNICATIONS ACTIVE RS232 serial backup communi-
cations link to the BLAM is
active.
2524 25 24 DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL RS232 serial backup communi-
cations link to the BLAM is
needed but an analyzer is con-
nected.
6-84 – JLG Lift – 3121142

Flash
Code
330 33 0 <<< GROUND OUTPUT DRIVER >>>
331 33 1 BRAKE - SHORT TO BATTERY There is a Short to Battery to the
Brake Valve.
332 33 2 BRAKE - OPEN CIRCUIT There is an Open Circuit to the
Brake Valve.
3311 33 11 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3316 33 16 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Forward Drive Valve. cles only.
3317 33 17 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3318 33 18 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3320 33 20 RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Reverse Drive Valve. cles only.
3321 33 21 RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3322 33 22 RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3324 33 24 LEFT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Forward Drive Valve. cles only.
3325 33 25 LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3326 33 26 LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3328 33 28 LEFT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Reverse Drive Valve. cles only.
3329 33 29 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3330 33 30 LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3336 33 36 ALTERNATOR/ECM POWER - SHORT TO GROUND There is a Short to Ground to the
Alternator/ECM.
3338 33 38 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
3121142 – JLG Lift – 6-85

Flash
Code
3339 33 39 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the
Alternator
3340 33 40 AUX POWER - SHORT TO GROUND There is a Short to Ground to the
Auxiliary Power Pump Relay.
3341 33 41 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the
3342 33 42 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the
3343 33 43 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Cold Start Advance Solenoid.
3344 33 44 COLD START ADVANCE SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
3345 33 45 COLD START ADVANCE SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
3349 33 49 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Pump Relay.
3350 33 50 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
Pump Relay.
3351 33 51 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
Pump Relay.
3358 33 58 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Dump Valve.
3359 33 59 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Dump Valve.
3360 33 60 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Dump Valve.
3361 33 61 BRAKE - SHORT TO GROUND There is a Short to Ground to the
Brake Valve.
3362 33 62 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the - Diesel engines only.
Start Relay.
3363 33 63 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - Diesel engines only.
Start Relay.
3364 33 64 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - Diesel engines only.
Start Relay.
3368 33 68 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the
Two Speed Valve.
3369 33 69 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the
Two Speed Valve.
3370 33 70 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the
Two Speed Valve.
3371 33 71 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the - Ground Alarm equipped vehicles
Ground Alarm. only.
6-86 – JLG Lift – 3121142

Flash
Code
3372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3373 33 73 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the - Generator / Welder equipped
Generator Relay. vehicles only.
3374 33 74 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the - Generator / Welder equipped
3375 33 75 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the - Generator / Welder equipped
3376 33 76 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the - Head Light equipped vehicles
Head Light Relay. only.
3377 33 77 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the - Head Light equipped vehicles
3378 33 78 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the - Head Light equipped vehicles
3379 33 79 HOUR METER - SHORT TO GROUND There is a Short to Ground to the
Hour Meter.
3380 33 80 HOUR METER - OPEN CIRCUIT There is an Open Circuit to the - Can be reported during power-
Hour Meter. up.
3381 33 81 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the
Hour Meter.
3385 33 85 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Up Override equipped vehicles only.
Valve.
3386 33 86 PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3387 33 87 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3391 33 91 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Down Override equipped vehicles only.
Valve.
3392 33 92 PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3393 33 93 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3394 33 94 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Left Valve.
3395 33 95 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3396 33 96 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
3121142 – JLG Lift – 6-87

Flash
Code
3397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Right Valve.
3398 33 98 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3399 33 99 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
33100 33 100 JIB LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Lift Up Valve.
33101 33 101 JIB LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Lift Up Valve.
33102 33 102 JIB LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Lift Up Valve.
33103 33 103 JIB LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Lift Down Valve.
33104 33 104 JIB LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Lift Down Valve.
33105 33 105 JIB LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Lift Down Valve.
33118 33 118 SWING RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Swing Right Valve.
33119 33 119 SWING RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
Swing Right Valve.
33120 33 120 MAIN TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope In Valve.
33121 33 121 SWING RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Swing Right Valve.
33122 33 122 SWING LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Swing Left Valve.
33123 33 123 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope Out Valve.
33130 33 130 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the
Throttle Actuator.
33131 33 131 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the
Throttle Actuator.
33132 33 132 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the
Throttle Actuator.
33133 33 133 PLATFORM CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Control Valve. equipped vehicles only.
33134 33 134 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
6-88 – JLG Lift – 3121142

Flash
Code
33135 33 135 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
33136 33 136 MAIN LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Main Lift APU Valve.
33137 33 137 MAIN LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33138 33 138 MAIN LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33139 33 139 MAIN LIFT PILOT - PRESSURE FAILURE The Main Lift Pilot has a Pressure - 1250AJP only.
Failure.
33140 33 140 MAIN LIFT PILOT - NO PRESSURE The Main Lift Pilot has No Pres- - 1250AJP only.
sure.
33141 33 141 MAIN LIFT PILOT - PRESSURE SWITCH FAILURE The Main Lift Pilot has a Pressure - 1250AJP only.
Switch Failure.
33142 33 142 TOWER LIFT APU VALVE - STUCK OPEN The Tower Lift APU Valve is Stuck - 1250AJP only.
Open
33143 33 143 TOWER LIFT ENABLE VALVE - STUCK OPEN The Tower Lift Enable Valve is - 1250AJP only.
Stuck Open
33144 33 144 TOWER LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Lift Enable Valve.
33145 33 145 TOWER LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33146 33 146 TOWER LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33147 33 147 TOWER TELESCOPE APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Telescope APU Valve.
33148 33 148 TOWER TELESCOPE APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33149 33 149 TOWER TELESCOPE APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33150 33 150 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Pilot Valve. cles only.
33151 33 151 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33152 33 152 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33153 33 153 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Down Auxiliary Valve. cles only.
3121142 – JLG Lift – 6-89

Flash
Code
33154 33 154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33155 33 155 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33156 33 156 TOWER LIFT APU VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Tower Lift APU Valve.
33157 33 157 TOWER LIFT APU VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33158 33 158 TOWER LIFT APU VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33159 33 159 MAIN LIFT ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
Main Lift Enable Valve.
33160 33 160 MAIN LIFT ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33161 33 161 MAIN LIFT ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33162 33 162 TOWER TELESCOPE APU VALVE - STUCK OPEN The Tower Telescope APU Valve - 1250AJP only.
is Stuck Open
33163 33 163 TOWER TELESCOPE ENABLE VALVE - STUCK OPEN The Tower Telescope Enable - 1250AJP only.
Valve is Stuck Open
33164 33 164 TOWER TELESCOPE ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
33165 33 165 TOWER TELESCOPE ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
33166 33 166 TOWER TELESCOPE ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
33167 33 167 PVG ENABLE VALVE - SHORT TO GROUND There is a Short to Ground to the - 1250AJP only.
PVG Valve.
33168 33 168 PVG ENABLE VALVE - OPEN CIRCUIT There is an Open Circuit to the - 1250AJP only.
PVG Valve.
33169 33 169 PVG ENABLE VALVE - SHORT TO BATTERY There is a Short to Battery to the - 1250AJP only.
PVG Valve.
33173 33 173 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY There is a Short to Battery or an
OR OPEN CIRCUIT Open Circuit to the Axle Lockout
Valve.
33174 33 174 RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIR- There is a Short to Battery or an
CUIT Open Circuit to the Brake.
6-90 – JLG Lift – 3121142

Flash
Code
33175 33 175 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Left Valve.
33176 33 176 JIB ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Rotate Left Valve.
33177 33 177 JIB ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Rotate Left Valve.
33178 33 178 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB
Rotate Right Valve.
33179 33 179 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
JIB Rotate Right Valve.
33180 33 180 JIB ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
JIB Rotate Right Valve.
33181 33 181 MAIN LIFT UP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Lift Up Valve.
33183 33 183 MAIN LIFT UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Up Valve.
33184 33 184 MAIN LIFT DOWN VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Lift Down Valve.
33185 33 185 MAIN LIFT DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
33186 33 186 MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the
33188 33 188 MAIN TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the
33189 33 189 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the
33190 33 190 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the
33207 33 207 HORN - OPEN CIRCUIT There is an Open Circuit to the
Horn.
33208 33 208 HORN - SHORT TO BATTERY There is a Short to Battery to the
Horn.
33209 33 209 HORN - SHORT TO GROUND There is a Short to Ground to the
Horn.
33279 33 279 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the - Glowplugs equipped vehicles
Glow Plugs. only.
33280 33 280 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the - Glowplugs equipped vehicles
Glow Plugs. only.
33281 33 281 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the - Glowplugs equipped vehicles
Glow Plugs. only.
33295 33 295 SWING LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
Swing Left Valve.
3121142 – JLG Lift – 6-91

Flash
Code
33306 33 306 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Swing Left Valve.
33307 33 307 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Telescope Flow Control
Valve.
33308 33 308 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
Valve.
33309 33 309 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
Valve.
33310 33 310 MAIN LIFT DOWN VALVE - SHORT TO BATTERY There is a Short to Battery to the
33311 33 311 MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Flow Control Valve.
33312 33 312 MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
33313 33 313 MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
33329 33 329 MAIN LIFT UP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Lift Up Valve.
340 34 0 <<< PLATFORM OUTPUT DRIVER >>>
343 34 3 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Up Valve.
344 34 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Open Circuit to the Platform equipped vehicles only.
Level Up Valve.
347 34 7 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Down Valve.
348 34 8 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Level Down Valve.
430 43 0 <<< ENGINE >>>
431 43 1 FUEL SENSOR SHORT TO BATTERY The Fuel Sensor reading is >
4.3V.
432 43 2 FUEL SENSOR SHORT TO GROUND The Fuel Sensor reading is <
0.2V.
433 43 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading - Deutz engine only.
is > 6.6V.
6-92 – JLG Lift – 3121142

Flash
Code
434 43 4 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading - Deutz engine only.
is < 0.1V for more then 5 sec- - Not reported during engine
onds. start.
435 43 5 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sen- - Deutz engine only.
sor reading is < 0.1V.
437 43 7 ENGINE TROUBLE CODE Displays engine SPN FMI code.
438 43 8 HIGH ENGINE TEMP (Ford engine only) The engine - Ford / Deutz engine only.
temperature is > 117 C.
(Deutz engine only) The engine
temperature is > 130 C.
439 43 9 AIR FILTER BYPASSED The Air Filter is clogged.
4310 43 10 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts
for more then 15 seconds after
engine start.
4311 43 11 LOW OIL PRESSURE (Ford engine only) The ECM has - Ford / Deutz engine only.
reported a low oil pressure fault.
(Deutz engine only) Oil pressure
is < 8 PSI for more then 10 sec-
onds after engine start.
4313 43 13 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for
more then XX seconds.
4314 43 14 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non-
ECM type engine selected.
4322 43 22 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indi- - Diesel engine only.
cates 0 RPM AND the Oil Pressure
Sensor indicates > 8 PSI for
three seconds.
4323 43 23 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indi- - Diesel engine only.
cates > 4000 RPM.
440 44 0 <<< BATTERY SUPPLY >>>
441 44 1 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Battery voltage is < 9V.
442 44 2 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Battery voltage is > 16V.
445 44 5 BATTERY VOLTAGE LOW Battery voltage is < 11V for
more then 5 seconds.
450 45 0 <<< CAN CONTROLLED VALVES >>>
451 45 1 MAIN LIFT PVG VALVE - INTERNAL FAULT The Main Lift PVG Valve has an - 1250AJP only.
internal fault.
452 45 2 TOWER LIFT PVG VALVE - INTERNAL FAULT The Tower Lift PVG Valve has an - 1250AJP only.
internal fault.
453 45 3 TOWER TELESCOPE PVG VALVE - INTERNAL FAULT The Tower Telescope PVG Valve - 1250AJP only.
has an internal fault.
3121142 – JLG Lift – 6-93

Flash
Code
454 45 4 MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply - 1250AJP only.
voltage is high.
455 45 5 TOWER LIFT PVG VALVE - HIGH VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only.
voltage is high.
456 45 6 TOWER TELESCOPE PVG VALVE - HIGH VOLTAGE The Tower Telescope PVG Valve - 1250AJP only.
supply voltage is high.
457 45 7 MAIN LIFT PVG VALVE - LOW VOLTAGE The Main Lift PVG Valve supply - 1250AJP only.
voltage is low.
458 45 8 TOWER LIFT PVG VALVE - LOW VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only.
voltage is low.
459 45 9 TOWER TELESCOPE PVG VALVE - LOW VOLTAGE The Tower Telescope PVG Valve - 1250AJP only.
supply voltage is low.
4510 45 10 MAIN LIFT PVG VALVE - STUCK NEUTRAL The Main Lift PVG Valve is stuck - 1250AJP only.
in its neutral position.
4511 45 11 TOWER LIFT PVG VALVE - STUCK NEUTRAL The Tower Lift PVG Valve is stuck - 1250AJP only.
in its neutral position.
4512 45 12 TOWER TELESCOPE PVG VALVE - STUCK NEUTRAL The Tower Telescope PVG Valve - 1250AJP only.
is stuck in its neutral position.
4513 45 13 MAIN LIFT PVG VALVE - STUCK EXTENDED The Main Lift PVG Valve is stuck - 1250AJP only.
in its extended position.
4514 45 14 TOWER LIFT PVG VALVE - STUCK EXTENDED The Tower Lift PVG Valve is stuck - 1250AJP only.
in its extended position.
4515 45 15 TOWER TELESCOPE PVG VALVE - STUCK EXTENDED The Tower Telescope PVG Valve - 1250AJP only.
is stuck in its extended position.
4516 45 16 MAIN LIFT PVG VALVE - STUCK RETRACTED The Main Lift PVG Valve is stuck - 1250AJP only.
in its retracted position.
4517 45 17 TOWER LIFT PVG VALVE - STUCK RETRACTED The Tower Lift PVG Valve is stuck - 1250AJP only.
in its retracted position.
4518 45 18 TOWER TELESCOPE PVG VALVE - STUCK RETRACTED The Tower Telescope PVG Valve - 1250AJP only.
is stuck in its retracted position.
4519 45 19 MAIN LIFT PVG VALVE - OBSTRUCTED The Main Lift PVG Valve is - 1250AJP only.
obstructed
4520 45 20 TOWER LIFT PVG VALVE - OBSTRUCTED The Tower Lift PVG Valve is - 1250AJP only.
obstructed
4521 45 21 TOWER TELESCOPE PVG VALVE - OBSTRUCTED The Tower Telescope PVG Valve - 1250AJP only.
is obstructed
4522 45 22 MAIN LIFT PVG VALVE - COMMAND IMPROPER The Main Lift PVG Valve com- - 1250AJP only.
mand is improper.
4523 45 23 TOWER LIFT PVG VALVE - COMMAND IMPROPER The Tower Lift PVG Valve com- - 1250AJP only.
mand is improper.
6-94 – JLG Lift – 3121142

Flash
Code
4524 45 24 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER The Tower Telescope PVG Valve - 1250AJP only.
command is improper.
4525 45 25 MAIN LIFT PVG VALVE - TIMEOUT The Main Lift PVG Valve has - 1250AJP only.
timed out.
4526 45 26 TOWER LIFT PVG VALVE - TIMEOUT The Tower Lift PVG Valve has - 1250AJP only.
timed out.
4527 45 27 TOWER TELESCOPE PVG VALVE - TIMEOUT The Tower Telescope PVG Valve - 1250AJP only.
has timed out.
4528 45 28 MAIN LIFT PVG VALVE - SETUP FAULT The Main Lift PVG Valve has a - 1250AJP only.
setup fault.
4529 45 29 TOWER LIFT PVG VALVE - SETUP FAULT The Tower Lift PVG Valve has a - 1250AJP only.
setup fault.
4530 45 30 TOWER TELESCOPE PVG VALVE - SETUP FAULT The Tower Telescope PVG Valve - 1250AJP only.
has a setup fault.
4531 45 31 MAIN LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Main Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
4532 45 32 TOWER LIFT PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Lift PVG Valve has an - 1250AJP only.
unrecognized fault.
4533 45 33 TOWER TELESCOPE PVG VALVE - SENT UNRECOGNIZED FAULT The Tower Telescope PVG Valve - 1250AJP only.
has an unrecognized fault.
4534 45 34 MAIN LIFT PVG VALVE - PARAMETERS INCORRECT The Main Lift PVG Valve parame- - 1250AJP only.
ters are incorrect.
4535 45 35 TOWER LIFT PVG VALVE - PARAMETERS INCORRECT The Tower Lift PVG Valve param- - 1250AJP only.
eters are incorrect.
4536 45 36 TOWER TELESCOPE PVG VALVE - PARAMETERS INCORRECT The Tower Telescope PVG Valve - 1250AJP only.
parameters are incorrect.
4537 45 37 MAIN LIFT PVG VALVE - LOCATION IMPROPER The Main Lift PVG Valve is in the - 1250AJP only.
wrong location.
4538 45 38 TOWER LIFT PVG VALVE - LOCATION IMPROPER The Tower Lift PVG Valve is in the - 1250AJP only.
wrong location.
4539 45 39 TOWER TELESCOPE PVG VALVE - LOCATION IMPROPER The Tower Telescope PVG Valve - 1250AJP only.
is in the wrong location.
4540 45 40 MAIN LIFT PVG VALVE - WIRING INCORRECT The Main Lift PVG Valve has - 1250AJP only.
incorrect wiring.
4541 45 41 TOWER LIFT PVG VALVE - WIRING INCORRECT The Tower Lift PVG Valve has - 1250AJP only.
incorrect wiring.
4542 45 42 TOWER TELESCOPE PVG VALVE - WIRING INCORRECT The Tower Telescope PVG Valve - 1250AJP only.
has incorrect wiring.
4543 45 43 MAIN LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4544 45 44 TOWER LIFT PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
4545 45 45 TOWER TELESCOPE PVG VALVE - SPOOL CANNOT REACH NEUTRAL X - 1250AJP only.
3121142 – JLG Lift – 6-95

Flash
Code
660 66 0 <<< COMMUNICATION >>>
662 66 2 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN commu-
nication lost.
666 66 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only.
communication lost.
667 66 7 CANBUS FAILURE - MAIN LIFT PVG Main Lift PVG CAN communica- - 1250AJP only.
tion lost.
668 66 8 CANBUS FAILURE - TOWER LIFT PVG Tower Lift PVG CAN communica- - 1250AJP only.
tion lost.
669 66 9 CANBUS FAILURE - TOWER TELESCOPE PVG Tower Telescope PVG CAN com- - 1250AJP only.
munication lost.
6610 66 10 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped vehicles only.
6611 66 11 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN - ECM equipped engine only.
communication lost.
6612 66 12 CANBUS FAILURE - CYLINDER LOAD PIN Cylinder Load Pin CAN commu- - Cylinder Load Pin equipped
nication lost. engine only.
6613 66 13 CANBUS FAILURE - EXCESSIVE CANBUS ERRORS There has been > 500 Bus Off
errors or >500 Bus Passive
Errors.
6614 66 14 CANBUS FAILURE - MAIN ANGLE SENSOR #1 Angle Sensor #1 CAN communi- - 1250AJP only.
cation lost.
6615 66 15 CANBUS FAILURE - MAIN ANGLE SENSOR #2 Angle Sensor #2 CAN communi- - 1250AJP only.
cation lost.
6622 66 22 CANBUS FAILURE - TCU MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6623 66 23 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6629 66 29 CANBUS FAILURE - TELEMATICS CANBUS LOADING X -Telematics only
TOO HIGH
680 68 0 <<< TELEMATICS >>>
681 68 1 REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP X -Telematics only
810 81 0 <<< TILT SENSOR >>>
813 81 3 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not
been calibrated.
815 81 5 CHASSIS TILT SENSOR DISAGREEMENT X
820 82 0 <<< PLATFORM LOAD SENSE >>>
825 82 5 LSS HAS NOT BEEN CALIBRATED The Load Sensing System Mod-
ule has not been calibrated.
6-96 – JLG Lift – 3121142

Flash
Code
826 82 6 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load
Sensing System indicates the
Platform is overloaded AND is
configured to warn only while
the Platform is overloaded.
827 82 7 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are
not possible while the Load
Sensing System indicates the
Platform is overloaded AND is
configured to prevent drive and
boom functions while the Plat-
form is overloaded.
828 82 8 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED Lift up and telescope out are not
possible while the Load Sensing
System indicates the Platform is
overloaded AND is configured to
prevent Lift up and telescope
out while the Platform is over-
loaded.
830 83 0 <<< PLATFORM LEVELING >>>
831 83 1 PLATFORM LEVELING OVERRIDE ON Platform Leveling forced on
with Access Level 0 selection.
832 83 2 PLATFORM LEVELING OVERRIDE OFF Platform Leveling forced off
with Access Level 0 selection.
833 83 3 PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED The Platform Level Up Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
834 83 4 PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED The Platform Level Down Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
837 83 7 PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #1. equipped vehicles only.
838 83 8 PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #1.
8311 83 11 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #2. equipped vehicles only.
8312 83 12 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #2.
3121142 – JLG Lift – 6-97

Flash
Code
8313 83 13 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
8314 83 14 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
8315 83 15 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the - Electronic leveling system
sensor values at power-up. The equipped vehicles only.
fault is triggered when there is a
± 5 degree difference from the
initial reading.
8316 83 16 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST Platform Level Sensor #1 serial - 1200S and 1350S only.
communication lost.
8317 83 17 PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST Platform Level Sensor #2 serial - 1200S and 1350S only.
communication lost.
8318 83 18 PLATFORM LEVELING SYSTEM TIMEOUT The Platform was unable to
maintain desired level within
range for the allotted time.
840 84 0 <<< ENVELOPE >>>
841 84 1 BOOM ANGLE SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Boom Angle Sen- cles only.
sors.
842 84 2 BOOM LENGTH SWITCH FAILED The Boom Length Switches are - Envelope Control equipped vehi-
reporting the same state. cles only.
843 84 3 BOOM LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Boom Length cles only.
Switch and the Boom Length
Sensor.
844 84 4 BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not - Envelope Control equipped vehi-
changing during a boom tele- cles only.
scope command.
845 84 5 BOOM LENGTH SENSOR - OUT OF RANGE HIGH Boom Length Sensor out of - Envelope Control equipped vehi-
range high. cles only.
-1200/1350 only
846 84 6 BOOM LENGTH SENSOR - OUT OF RANGE LOW Boom Length Sensor out of - Envelope Control equipped vehi-
range low. cles only.
-1200/1350 only
847 84 7 BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH Boom Length out of range high. - Envelope Control equipped vehi-
cles only.
-1200/1350 only
848 84 8 BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW Boom Length out of range low. - Envelope Control equipped vehi-
cles only.
-1200/1350 only
6-98 – JLG Lift – 3121142

Flash
Code
849 84 9 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8410 84 10 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8411 84 11 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of - Envelope Control equipped vehi-
range. cles only.
8412 84 12 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of - Envelope Control equipped vehi-
range. cles only.
8413 84 13 WRONG TELESCOPE RESPONSE Boom telescope is moving in the - Envelope Control equipped vehi-
opposite direction of the com- cles only.
mand.
8414 84 14 WRONG LIFT RESPONSE Boom lift is moving in the oppo- - Envelope Control equipped vehi-
site direction of the command. cles only.
8415 84 15 TOWER ANGLE SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Angle Sen- cles only.
sors. -1250
8416 84 16 TOWER LENGTH SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Length Sen- cles only.
sors. -1250
8417 84 17 MAIN ANGLE SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Angle cles only.
Sensors. -1250
8418 84 18 TOWER LENGTH SENSOR #1 - OUT OF RANGE HIGH Tower Boom Angle Sensor #1 - Envelope Control equipped vehi-
out of range high. cles only.
-1250
8419 84 19 TOWER LENGTH SENSOR #1 - OUT OF RANGE LOW Tower Boom Angle Sensor #1 - Envelope Control equipped vehi-
out of range low. cles only.
-1250
-1250
-1250
8422 84 22 TOWER LENGTH SENSOR - NOT DETECTING LENGTH CHANGE The Tower Length Sensor is not - Envelope Control equipped vehi-
changing during a tower tele- cles only.
scope command. -1250
8423 84 23 TOWER LENGTH MOVEMENT WITHOUT COMMAND The Tower Length Sensor is - Envelope Control equipped vehi-
changing without a tower tele- cles only.
scope command. -1250
-1250
-1250
3121142 – JLG Lift – 6-99

Flash
Code
-1250
-1250
8428 84 28 TOWER ANGLE SENSOR #1 - INVALID ANGLE Tower Boom Angle Sensor #1 - Envelope Control equipped vehi-
out of range. cles only.
-1250
8429 84 29 TOWER ANGLE SENSOR #2 - INVALID ANGLE Tower Boom Angle Sensor #2 - Envelope Control equipped vehi-
out of range. cles only.
-1250
8430 84 30 TOWER ANGLE SENSOR #1 - INVALID MODEL Wrong Tower Boom Angle Sen- - Envelope Control equipped vehi-
sor #1 installed. cles only.
- 1250AJP Only
- Must be a Rieker Sensor, not a
Spectron Sensor.
8431 84 31 TOWER ANGLE SENSOR #2 - INVALID MODEL Wrong Tower Boom Angle Sen- - Envelope Control equipped vehi-
sor #2 installed. cles only.
- 1250AJP Only
- Must be a Rieker Sensor, not a
Spectron Sensor.
8432 84 32 MAIN ANGLE SENSOR #1 - INVALID ANGLE Main Boom Angle Sensor #1 out - Envelope Control equipped vehi-
of range. cles only.
-1250
8433 84 33 MAIN ANGLE SENSOR #2 - INVALID ANGLE Main Boom Angle Sensor #2 out - Envelope Control equipped vehi-
of range. cles only.
-1250
8434 84 34 MAIN ANGLE SENSOR - NOT DETECTING ANGLE CHANGE The Main Boom Angle Sensor is - Envelope Control equipped vehi-
not changing during a main lift cles only.
command. -1250
8435 84 35 MAIN ANGLE MOVEMENT WITHOUT CMD The Main Boom Angle Sensor is - Envelope Control equipped vehi-
changing without a main lift cles only.
command. -1250
8436 84 36 WRONG TOWER TELESCOPE RESPONSE Tower telescope is moving in the - Envelope Control equipped vehi-
mand. -1250
8437 84 37 WRONG TOWER LIFT RESPONSE Tower lift is moving in the oppo- - Envelope Control equipped vehi-
-1250
8438 84 38 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE HIGH The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is < 4721 A/D counts. cles only.
-1250
8439 84 39 TOWER CYLINDER ANGLE SENSOR - OUT OF RANGE LOW The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is > 29535 A/D counts. cles only.
-1250
8440 84 40 TOWER CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is not changing during a tower cles only.
lift command. -1250
6-100 – JLG Lift – 3121142

Flash
Code
8441 84 41 TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND The Tower Cylinder Angle Sensor - Envelope Control equipped vehi-
is changing without a tower lift cles only.
command. -1250
8442 84 42 MAIN TRANSPORT ANGLE SWITCH FAILED The Main Boom Angle Switch is - Envelope Control equipped vehi-
bad. cles only.
-1250
8443 84 43 TWR TRANSPORT SWITCH DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Boom cles only.
Length Switch and the Tower -1250
Length Sensor.
8444 84 44 TRANSPORT DUAL CAPACITY SWITCHES BAD Both the Dual Capacity Switch - Envelope Control equipped vehi-
and the Transport Switch are cles only.
bad. -1250
8445 84 45 TRANSPORT DUAL CAPACITY BAD TRANSITION The Dual Capacity Switch and - Envelope Control equipped vehi-
the Transport Switch changed cles only.
state out of order. -1250
8446 84 46 MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Trans- cles only.
port Length Switches. -1250
8447 84 47 MAIN DUAL CAPACITY LENGTH SWITCH DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Dual cles only.
Capacity Length Switches. -1250
8448 84 48 MAIN TRANSPORT ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Main Boom Angle cles only.
Switch and the Main Boom -1250
Angle Sensor.
8449 84 49 TOWER CYLINDER ANGLE SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Boom Angle cles only.
Switch and the Tower Cylinder -1250
Angle Sensor.
8450 84 50 NEW MAIN ANGLE SENSOR #1 DETECTED A new Main Angle Sensor 1 has -1250
been detected.
8451 84 51 NEW MAIN ANGLE SENSOR #2 DETECTED A new Main Angle Sensor 2 has -1250
been detected.
8452 84 52 TOWER LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Tower Length cles only.
Switch and the Tower Length -1250
Sensor.
8453 84 53 WRONG MAIN TELE RESPONSE Main telescope is moving in the - Envelope Control equipped vehi-
mand. -1250
8454 84 54 WRONG MAIN LIFT RESPONSE Main lift is moving in the oppo- - Envelope Control equipped vehi-
-1250
8482 84 82 TOWER ENVELOPE MASSIVELY ENCROACHED X
8483 84 83 TOWER ENVELOPE MULTIPLE ENCROACHMENTS X
3121142 – JLG Lift – 6-101

Flash
Code
8484 84 84 BCS VIOLATION - BOOM LOCKED X
8485 84 85 BCS - HYDRAULIC RETRIEVAL ACTIVE X
8486 84 86 BCS - ELECTRICAL RETRIEVAL ACTIVE X
8487 84 87 BCS - MULTIPLE FAILURES ACTIVE X
850 85 0 <<< MOMENT / LOAD PINS >>>
851 85 1 MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE The Moment Pin horizontal
force is out of range.
852 85 2 MOMENT PIN - VERTICAL FORCE OUT OF RANGE The Moment Pin vertical force is
out of range.
853 85 3 LOAD PIN - HORIZONTAL FORCE OUT OF RANGE The Load Pin horizontal force is -1250
out of range.
854 85 4 LOAD PIN - VERTICAL FORCE OUT OF RANGE The Load Pin vertical force is out -1250
of range.
855 85 5 MOMENT PIN - SENSOR FAULT The Moment Pin has reported a
fault.
856 85 6 LOAD PIN - SENSOR FAULT The Load Pin has reported a -1250
fault.
857 85 7 NEW MOMENT PIN DETECTED A new Moment Pin has been
detected.
858 85 8 NEW LOAD PIN DETECTED A new Load Pin has been -1250
detected.
859 85 9 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT There is a disagreement -1250
between the Load Pin and the
Tower Lift cylinder Angle.
8510 85 10 LOAD PIN - FORCE VALUES NOT CHANGING The Load Pin is not changing. -1250
8511 85 11 LOAD PIN - FORCE TOO LOW OVER TOWER ANGLE CHANGE X -1250
8512 85 12 LOAD PIN - FORCE TOO LOW OVER MAIN ANGLE CHANGE X -1250
8513 85 13 LOAD PIN - FORCE TOO LOW OVER MAIN LENGTH TRANSITION X -1250
860 86 0 <<< STEERING / AXLE >>>
861 86 1 RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH DIS- The Oscillating Axle Pressure - Electrically released Oscillated
AGREEMENT Switch indicates pressure while Axles equipped vehicles only.
not driving or does not indicate
pressure while driving and
restricted to transport.
862 86 2 AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Extend
Valve.
863 86 3 AXLE EXTEND VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Extend Valve.
6-102 – JLG Lift – 3121142

Flash
Code
864 86 4 AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Retract
Valve.
865 86 5 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Retract Valve.
866 86 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Right Valve.
867 86 7 RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Right Valve.
868 86 8 RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Left Valve.
869 86 9 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Left Valve.
8610 86 10 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Right Valve.
8611 86 11 LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Right Valve.
8612 86 12 LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Left Valve.
8613 86 13 LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Left Valve.
8614 86 14 RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Right Valve.
8615 86 15 RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Right Valve.
8616 86 16 RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Left Valve.
8617 86 17 RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Left Valve.
3121142 – JLG Lift – 6-103

Flash
Code
8618 86 18 LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Right Valve.
8619 86 19 LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Right Valve.
8620 86 20 LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Left Valve.
8621 86 21 LEFT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Left Valve.
8622 86 22 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has
become decoupled.
8623 86 23 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has
become decoupled.
8624 86 24 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has
become decoupled.
8625 86 25 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has
become decoupled.
8626 86 26 FRONT LEFT STEER SENSOR - NOT RESPONDING The Front Right Steer Sensor is
not responding to steer com-
mands.
8627 86 27 FRONT RIGHT STEER SENSOR - NOT RESPONDING The Front Left Steer Sensor is not
responding to steer commands.
8628 86 28 REAR LEFT STEER SENSOR - NOT RESPONDING The Rear Right Steer Sensor is
not responding to steer com-
mands.
8629 86 29 REAR RIGHT STEER SENSOR - NOT RESPONDING The Rear Left Steer Sensor is not
responding to steer commands.
8630 86 30 FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Right
Steer Sensor.
8631 86 31 FRONT RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Right Steer Sensor.
8632 86 32 FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Left
Steer Sensor.
8633 86 33 FRONT LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Left Steer Sensor.
6-104 – JLG Lift – 3121142

Flash
Code
8634 86 34 REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Right
Steer Sensor.
8635 86 35 REAR RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Right Steer Sensor.
8636 86 36 REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Left
Steer Sensor.
8637 86 37 REAR LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Left Steer Sensor.
8651 86 51 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT Engine Start is prevented while
there is an Oscillating Axle fault
and vehicle is out of transport
position
990 99 0 <<< HARDWARE >>>
998 99 8 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has
reported an EEPROM failure.
9910 99 10 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION The Platform Module software
IMPROPER version is not compatible with
the rest of the system.
9914 99 14 PLATFORM MODULE SOFTWARE UPDATE REQUIRED The Platform Module software
requires an updated.
9915 99 15 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain cali-
bration has been lost.
9916 99 16 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain cali-
bration has become corrupted.
9917 99 17 HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST The Platform Module has
reported that its ADS1213 chip
has stopped asserting its inter-
rupt.
9918 99 18 HIGH RESOLUTION A2D FAILURE - REINIT LIMIT The Platform Module has
reported that its ADS1213 chip
had to be reset 3 or more times.
9919 99 19 GROUND SENSOR REF VOLTAGE OUT OF RANGE The Ground Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
9920 99 20 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
3121142 – JLG Lift – 6-105

Flash
Code
9921 99 21 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has
reported that its high side driver
cutout failed.
9922 99 22 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has
reported that the V(Low) FET
has failed.
9923 99 23 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has
reported that the V(Low) FET
has failed.
9925 99 25 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION The Chassis Module software
IMPROPER version is not compatible with
the rest of the system.
9926 99 26 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER The BLAM software version is
not compatible with the rest of
the system.
9927 99 27 GROUND MODULE CONSTANT DATA UPDATE REQUIRED The Ground Module constant
data requires an updated.
9928 99 28 ENVELOPE CONTROL DISABLED Envelope Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
9929 99 29 MOMENT CONTROL DISABLED Moment Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
9930 99 30 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been - Chassis Module equipped vehi-
calibrated. cles only.
9931 99 31 BOOM SENSORS NOT CALIBRATED The Boom Sensors have not - BLAM equipped vehicles only.
been calibrated.
9932 99 32 LIFT CRACKPOINTS NOT CALIBRATED The Lift Valves have not been - 1200S and 1350S only.
calibrated.
9933 99 33 TELESCOPE CRACKPOINTS NOT CALIBRATED The Telescope Valves have not - 1200S and 1350S only.
been calibrated.
9934 99 34 DRIVE CRACKPOINTS NOT CALIBRATED The Drive Valves have not been - 1200S and 1350S only.
calibrated.
9935 99 35 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is high.
9936 99 36 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is low.
9937 99 37 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors sup-
ply voltage is high.
9938 99 38 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors sup-
ply voltage is low.
9939 99 39 BLAM HIGH RES A/D FAILURE The BLAM high resolution ana- - BLAM equipped vehicles only.
log to digital converter has
failed.
9940 99 40 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH The Chassis Sensors supply volt-
age is high.
6-106 – JLG Lift – 3121142

Flash
Code
9941 99 41 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply volt-
age is low.
9942 99 42 BLAM BACKUP COMMUNICATIONS LINK FAULTY The BLAM backup communica- - BLAM equipped vehicles only.
tions link test was activated at -1250
startup, but no communication
connection established/main-
tained.
9943 99 43 BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED The BLAM backup communica- - BLAM equipped vehicles only.
tions link was activated, but no -1250
communication connection
established/maintained.
9944 99 44 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback
gains are out of range.
9945 99 45 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT The factory set current feedback
checksum is not correct.
9975 99 75 LOAD PIN NOT CALIBRATED The Load Pin has not been cali- -1250
brated.
9979 99 79 FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION Temporary fault for the telemat-
IMPROPER ics project. The model needs to
be a 600S or 1350S if not this
fault will be generated and Plat-
form controls will be prevented.
This fault was to insure that the
software will only work for
these two models.
3121142 – JLG Lift – 6-107

Figure 6-25. CANbus Connections Diagram
6.20 CANBUS TROUBLESHOOTING

The PLATFORM MODULE and the CHASSIS MODULE have ”Ter-
minator Resistors” located inside the modules, these resistors
squelch high speed signal reflections in the CANbus transmis-
sion lines. The value of the terminators is determined by wire
properties, this includes the type of insulation and geometry,
combined to determine the perfect value for bus termination.
Improper values or missing terminators allow bus ringing. A
complete CANbus circuit (wired in parallel) is approximately
60 Ohms at the ”T” fitting inside the Ground Station or at the
Boom Length & Angle Module. Each individual circuit from
their respective Module should read approximately 120 Ohm.
For CANbus connections, refer to Figure 6-25., Figure 6-26.,
Figure 6-27., Figure 6-28., Figure 6-29., and Figure 6-30.
6-108 – JLG Lift – 3121142

A B
PLATFORM MODULE
CANbus Link
C
Figure 6-26. CANbus Connections - Sheet 1 of 5
3121142 – JLG Lift – 6-109

1. Chassis Module CANbus Link

2. Ground Module CANbus Link
3. Boom Length & Angle Module
4. BLAM J1 (Gray) Plug
* Remove BLAM J1 Plug and measure the A & B pin of the T fitting.
This should measure approximately 60 Ohms for a complete CANbus
Circuit.
6-110 – JLG Lift – 3121142

Remove Ground Module J7 plug

and measure the A & B pin of the T
Boom Length &
fitting. This should measure
Angle Module
approximately 60 Ohms for a com-
CANbus Link
plete CANbus Circuit.
Ground Module J7 Platform Module J7

(Black) plug (Black) plug
3121142 – JLG Lift – 6-111

"BEFORE" Slip Ring

Connection
"AFTER" Slip Ring

Connection
6-112 – JLG Lift – 3121142

Chassis Module J1
(Gray) Plug
Chassis Module
CANbus Link
3121142 – JLG Lift – 6-113

Figure 6-31. CANbus Circuit
6-114 – JLG Lift – 3121142

CANbus Communication Failure 4. The analyzer screen should read:

If a problem in the CANbus system is suspected, use the fol-
lowing step-by-step procedure to verify which part of the
CANbus communication system has failed.
CANBUS LINK FROM THE PLATFORM MODULE LOST

Ground position.
2. Plug the analyzer into the connector inside the Ground 5. Press enter twice to reach Logged Help. The screen will
control box. read:
3. Pull out the Emergency Stop switch.
6. Hit ESC to get back to the HELP screen and then use the
arrow button to reach VERSIONS. Hit Enter.
3121142 – JLG Lift – 6-115

7. If the CANbus link from the platform module is lost, you TROUBLESHOOTING: PLATFORM CAN COMMUNICATIONS
will see the Ground Module SW version, Ground Module LOST
HW version, Ground Module SN, BM SW version, Chassis
SW version, Platform Module SN, but you will not see the NOTE: PLATFORM CAN COMMUNICATIONS LOST (6/6) (Help Fault
Platform Module SW version or the Platform Module HW Code 6-6) basically means all communication linked to the
version. The Analyzer screen will read: Platform Module is lost. This does not mean that the Plat-
form Module Link only is affected, this means the commu-
nication link between the Platform Module down to the
Chassis Module has been broken, therefore all Canbus links
have to be checked. Remember this link is wired in parallel,
so the Ground Module has lost all MSA communication.
8. Hit the right arrow button once. The screen will read:
6-116 – JLG Lift – 3121142

Table 6-7. Troubleshooting: Platform Can Communications Lost
STEP ACTION REQUIRED SPEC YES NO

1 Install the Analyzer at the ground station, scroll to the ”Diag- See Diagnostics / Version Chart See step 2 See step 2
nostics” sub level menu, press ”enter” then scroll to the ”Ver-
sions” menu item press ”enter” and view the screen,
reference the Diagnostics / Version Chart to assist you in
determining which module has lost it’s communication link.
In some cases the module that shows up with a question may
be defective if all other CANbus links check OK.
2 Disconnect the Ground Module J7 deutsche plug connection Approximately 60 ohms. CANbus circuit is Reconnect plug and go to step 3
at the "T" fitting inside of the ground control station. Perform complete. Platform
an ohms check at the ”A” and ”B” pins of the "T" fitting. Module suspected
Inspect the shield wire ”C” for shorts. defective
3 Make sure the CANbus link wires are installed correctly at the See Electrical Schematic in Section 7 Go to step 4 Wire per Electrical Schematic
Platform Module.
4 Disconnect the platform cannon plug and ground cannon Continuity Reconnect plug and go to step 5 Repair or replace platform har-
plug that holds the CANbus link. Red (3) Black (2) and Shield ness.
(1) perform a continuity test.
5 Disconnect the deutsche plug connection from the Platform Approximately 120 ohms. Reconnect plug and go to step 6 Suspected defective Platform
Module at the ”T” fitting inside of the ground station. Per- Module.
form an ohms check at the ”A” and ”B” sockets of the
deutsche plug. Inspect the shield wire ”C” for shorts.
6 Inspect the Platform Module harness connection at the Continuity Reconnect harness and go to Repair or replace harness inside
ground cannon plug and at the ”T”’ fitting inside of the step 7 the ground control station.
ground control station.
7 Disconnect the deutsche plug connection from the Boom Approximately 120 ohms Reconnect plug and go to step 8 Verify step 7, inspect the BLAM
Length & Angle Module at the ”T’ fitting inside of the ground to Ground Module harness con-
station. Perform an ohms check at the ”A” and ”B” sockets of nection s at both ”T" fitting con-
the deutsche plug. Inspect the shield wire ”C” for shorts. nections for proper continuity
and correct wiring per Electrical
schematic.
8 Disconnect all deutsche plug connections at the "T” fitting in Continuity (NO OHM VALUES) Reconnect all deutsche plugs at Replace defective ”T" fitting
the ground station and the BLAM, perform a continuity test the "T” fitting and go to step 9 plug.
on all ”A” ”B” and ”C” pins use the singular end of the fitting
and cross probe the corresponding letters of the other two
connections.
9 Disconnect the Chassis Module deutsche plug at the ”T’ fit- Approximately 120 ohms Reconnect deutsche plug and Inspect the harness from the
ting below the Boom Length & Angle Module. Perform an go to step 10 ”T” fitting at the BLAM to the
ohms check at the ”A” and ”B” sockets of the deutsche plug. Chassis Module plug connec-
Inspect the shield wire ”C” for shorts. tion at the battery. Assure
proper continuity and correct
wiring per Electrical Schematic.
3121142 – JLG Lift – 6-117

Table 6-7. Troubleshooting: Platform Can Communications Lost

10 Disconnect the Chassis Module connection at the right side of Approximately 120 ohms Reconnect plug and go to step Inspect the harness from the
the battery at the turntable lock pin. Perform an ohms check 11 slip ring connections at the top
at the #1 and #2 connections of the plug. Inspect shield wire and bottom plug connections of
#3 for possible short. the swivel. Assure proper conti-
nuity and correct wiring per
Electrical Schematic.
11 Disconnect the Chassis Module connection below the swivel Approximately 120 ohms Reconnect plug and go to step Inspect the harness from the
under the machine. Perform an ohms check at the #1 and #2 12 bottom of the swivel into the
connections of the plug that is routed to the Chassis Module. Chassis Module. Assure proper
Inspect shield wire #3 for possible short. continuity and wiring r sche-
matic 1870149A.
12 Make sure the Chassis Module CANbus link wires are installed Electrical Schematic Stop Replace the Chassis Module.
correctly at the plug near the battery, the plug below the
swivel and 31 plug at the Chassis Module.
6-118 – JLG Lift – 3121142

CANBUS LINK FROM THE GROUND MODULE LOST 4. The analyzer screen should read:
Ground position.

control box.
5. Press enter twice to reach Logged Help. The screen will

read:
3121142 – JLG Lift – 6-119

7. If the CANbus link from the ground module is lost, you 8. Hit the right arrow button once. The screen will read:
will see the Ground Module SW version, Ground Module
HW version, Ground Module SN, BM SW version, Chassis
SW version, Platform Module SN, but you will not see the
Platform Module SW version or the Platform Module HW
version. The Analyzer screen will read:
6-120 – JLG Lift – 3121142

CANBUS LINK FROM THE BOOM LENGTH & ANGLE MOD- 4. The analyzer screen should read:
ULE (BLAM) LOST
Ground position.

control box.

read:
3121142 – JLG Lift – 6-121

7. If the CANbus link from the Boom Length & Angle Mod- TROUBLESHOOTING: BLAM CAN COMMUNICATIONS LOST
ule is lost, you will see the Platform Module SW version,
Platform Module HW Rev, Platform Module SN, Ground NOTE: BLAM CAN COMMUNICATIONS LOST (6/6) (Help Fault Code
Module SW version, Ground Module HW Revision, 6-6) basically means all communication linked from the
Ground Module SN, Chassis SW version, but you will not Ground Module to the Boom Length &: Angle Module is
see the Boom Length & Angle Module SW revision. The lost. This also includes the lift cylinder load moment pin as
Analyzer screen will read: well.
6-122 – JLG Lift – 3121142

Table 6-8. Troubleshooting: BLAM Can Communications Lost

2 Disconnect the BLAM J 1 deutsche plug connection at the "T” Approximately 60 ohms. CANbus circuit is com- Reconnect plug and go to step 3
fitting just above the fuel tank. Perform an ohms check at the plete.
”A” and ”B” pins of the "T” fitting. Inspect the shield wire ”C” BLAM suspected defec-
for possible short. tive.
3 Disconnect the Ground Module deutsche plug from ”T” fit- Approximately 120 Ohms Reconnect harness and go to Repair or replace the Ground
ting at the BLAM above the fuel tank. Perform an ohm check step 4 Module to BLAM harness.
at the ”A” and ”B” sockets of the deutsche plug. Inspect the
shield wire ”C ” for possible short.
4 Verify the CANbus link signal wires are installed correctly at Electrical Schematic Reconnect plug and go to step 5 Wire per Electrical Schematic
the ’T” fitting at the Ground Module.
5 Verify the lift cylinder load moment harness has good conti- Continuity Reconnect plug and go to step 6 Repair or replace Chassis Mod-
nuity and wired correctly at the J4 plug on the BLAM. ule harness.
6 Disconnect the Chassis Module plug connection at the bat- Approximately l 20 Ohms Reconnect plug and stop Inspect harness and connec-
tery and perform an ohm check at the #1 and #2 socket of the tions to the Chassis Module.
deutsche plug. Inspect the shield wire #3 for possible short.
3121142 – JLG Lift – 6-123

CANBUS LINK FROM THE CHASSIS MODULE LOST 4. The analyzer screen should read:
Ground position.

control box.

read:
6-124 – JLG Lift – 3121142

7. If the CANbus link from the Chassis Module is lost, you 9. Hit the right arrow button once. The screen will read:
will NOT see the Platform Module SW version, Platform
Module HW rev, Platform Module SN, Chassis SW ver-
sion, Boom Length & Angle Module SW version, but you
WILL see the Ground Module SW version, Ground Mod-
ule HW rev, and the Ground Module SN. The analyzer
screen will read:
3121142 – JLG Lift – 6-125

11. Hit the right arrow button once. The screen will read: TROUBLESHOOTING: CHASSIS CAN COMMUNICATIONS
LOST
NOTE: CHASSIS CAN COMMUNICATIONS LOST (6/6) (Help Fault

Code 6-6) basically means all communication linked from
the Ground Module to the Chassis Module is lost.
6-126 – JLG Lift – 3121142

Table 6-9. Troubleshooting: Chassis Can Communications Lost

2 Disconnect the BLAM J1 deutsche plug connection at the "T" Approximately 60 ohms. CANbus circuit is com- Reconnect plug and go to step 3
fitting just above the fuel tank. Perform an ohms check at the plete. Chassis Module
”A” and ”B” pins of the ”T” fitting. Inspect the shield wire ”C” suspected defective.
for possible short.
3 Disconnect the Chassis Module communication harness from Continuity Reconnect harness and go to Repair or replace BLAM and
the BLAM ”T” fitting and Chassis Module plug connection at step 4 Chassis Module harness.
the battery. Perform a continuity test.
4 Verify the CANbus link signal wires are installed correctly at Electrical Schematic Reconnect plug and go to step 6 Wire per Electrical Schematic
the Chassis Module plug connection at the battery and at the
plug below the swivel.
5 Verify continuity at the Chassis Module harness from the plug Continuity Reconnect plug and go to step 6 Repair or replace Chassis Mod-
connection at the battery down to the plug connection ule harness.
below the swivel.
6 Disconnect the Chassis Module plug connection below the Approximately 120 Ohms Stop Replace Chassis Module
swivel and perform an ohms check at the #1 and #2 of the
plug. Inspect the shield wire #3 plug connection for possible
short.
3121142 – JLG Lift – 6-127

Load Moment Pin Troubleshooting refer to Section 4 for information concerning replacement of
the Load Moment Pin.
The following Troubleshooting Charts outline diagnostic mea-
sures to be taken to diagnose problems within the Load
Moment Pin portion of the JLG Control System. If necessary,
Table 6-10. Load Moment Pin Troubleshooting: Can Communications Lost
STEP FAULT CODE/SYMPTOM REPAIR YES NO

1 6/6 CYLINDER LOAD PIN CAN COMMUNICATIONS LOST Check for correct and tight wire connec- Go to step 2 Replace harness. (4922826)
tions at the deutsch and phoenix con-
nectors of the Load Sensing Pin harness
and perform a continuity check.
2 Check for loose pins in the potting of the Replace the BLAM & Go to step 3
Boom Length & Angle Module J4 con- Perform the Boom Sen-
nection. sor calibration process.
3 Inspect the CANbus link ”T” fitting con- Go to step 4 Replace ”T” fitting connector.
nections at the BLAM & Ground Module. (4460945)
Are the fittings dry?
4 Inspect the CANbus link ”T” fitting con- Go to step 5 Replace ”T” fitting connector.
nections at the BLAM & Ground Module. (4460945)
Perform a continuity check.
5 Check the J1 and J4 plug connections on Go to step 6 Position plug correctly.
the BLAM, make sure the notched plugs
line up with the plug sockets correctly.
6 Use the Analyzer, scroll – + to the DIAG- Go to step 6 Replace the load moment pin. &
NOSTICS menu, press ENTER, then scroll Perform the Boom Sensor cali-
to the MOMENT menu, and press ENTER, bration process.
check to see i f Actual / Over / Under
moment values are registering on the
screen display.
7 If they are, refer to Figure 6-32., If the problem still exists, verify Replace the load moment pin. &
Moment Chart for comparable values, if steps 1-7 again before contact- Perform the Boom Sensor cali-
the values are not close, try boom sen- ing the JLG Service Dept. bration process.
sor calibration to see if the values come
within the chart.
6-128 – JLG Lift – 3121142

Table 6-11. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range

1 8/6 MOMENT PIN HORIZONTAL FORCE OUT OF RANGE The Check to see if the platform is over- Remove excess weight Go to step 2
horizontal force is out of allowed range. loaded in the vertical position. Check
the rated capacity requirement.
2 Check to see if any additional accesso- Perform the Boom Sen- Go to step 3
ries have been added to the platform sor calibration process.
without proper calibration.
3 Perform the BCS daily check procedure Go to step 4 Perform the Boom Sensor cali-
to make sure the boom sections are bration process.
stopping correctly at the witness marks
matching their capacity selection.
4 Inspect the job the machine is perform- Go to step 5 Position machine correctly.
ing, making sure that there is no addi-
tional force applied when the boom
sections are in the horizontal position.
Also consider weather conditions
(Wind).
5 Use the Analyzer, scroll to the DIAGNOS- Go to step 6 Replace the load moment pin. &
TICS menu, press ENTER, then scroll to Perform the Boom Sensor cali-
the MOMENT menu, and press ENTER, bration process.
check to see if Actual / Over / Under
screen display.
within the chart.
3121142 – JLG Lift – 6-129

Table 6-12. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range

1 8/6 MOMENT PIN VERTICAL FORCE OUT OF RANGE The vertical Check to see if the platform is over- Remove excess weight Go to step 2
force is out of allowed range. loaded in the vertical position. Check
the rated capacity requirement.
2 Check to see if any additional accesso- Perform the Boom Sen- Go to step 3
ries have been added to the platform sor calibration process.
without proper calibration.
3 Perform the BCS daily check procedure Go to step 4 Perform the Boom Sensor cali-
to make sure the boom sections are bration process.
stopping correctly at the witness marks
matching their capacity selection.
4 Inspect the job the machine is perform- Go to step 5 Position machine correctly.
ing, making sure that there is no addi-
tional force applied when the boom
sections are in the horizontal position.
Also consider weather conditions
(Wind).
5 Use the Analyzer, scroll to the DIAGNOS- Go to step 6 Replace the load moment pin. &
TICS menu, press ENTER, then scroll to Perform the Boom Sensor cali-
the MOMENT menu, and press ENTER, bration process.
check to see if Actual / Over / Under
screen display.
within the chart.
6-130 – JLG Lift – 3121142

Table 6-13. Load Moment Pin Troubleshooting: Moment Pin Sensor Fault

1 8/6 MOMENT PIN SENSOR FAULT The moment pin has Use the Analyzer, scroll to the DIAGNOS- Replace load moment pin & Contact JLG Service Dept.
reported a fault flag TICS menu, press ENTER, then scroll to Perform the Boom Sensor cali-
the MOMENT menu, and press ENTER, bration process
check to see if PIN E FLAGS has any num-
bers on the screen display.
Table 6-14. Load Moment Pin Troubleshooting: New Moment Pin Detected Fault

1 8/6 NEW MOMENT PIN DETECTED FAULT A moment pin was Perform the Boom Sensor calibration Verify BCS check and review all Contact JLG Service Dept.
detected on the system different from the one used to cali- process to accept the new load moment faults prior to contacting JLG
brate the machine. pin. Service Dept.
3121142 – JLG Lift – 6-131

Figure 6-32. Moment Chart
6-132 – JLG Lift – 3121142

SECTION 7. BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS

7.1 GENERAL or negative side of the signal and the lead on the other port
goes to the positive side of the signal.
This section contains basic electrical information and sche-
matics to be used for locating and correcting most of the oper- Scale
ating problems which may develop. If a problem should
M = Mega = 1,000,000 * (Displayed Number)
develop which is not presented in this section or which is not
corrected by listed corrective actions, technically qualified k = kilo = 1,000 * (Displayed Number)
guidance should be obtained before proceeding with any
maintenance. m = milli = (Displayed Number) / 1,000
μ = micro = (Displayed Number) / 1,000,000
7.2 MULTIMETER BASICS
Example: 1.2 kW = 1200 W
A wide variety of multimeters or Volt Ohm Meters (VOM) can Example: 50 mA = 0.05 A
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for sev-
eral different circuit measurements. Instructions for your VOM
Voltage Measurement
may vary. Please consult the meter operator’s manual for more
information. This manual assumes reasonable measuring
device accuracy (at least 1%).
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 cir-
cuit continuity this way. If the connector 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 technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen- Figure 7-1. Voltage Measurement (DC)
tle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector. • If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
Min/Max • Use firm contact with meter leads
Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
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 location of the signal and
that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the Ground
3121142 – JLG Lift – 7-1

Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to enable

audible continuity testing
• Circuit power must be turned OFF before testing conti-
Figure 7-2. Resistance Measurement nuity
• First test meter and leads by touching leads together. • Disconnect component from circuit before testing
Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads
tance)
• First test meter and leads by touching leads together.
• Circuit power must be turned OFF before testing resis-
Meter should produce an audible alarm, indicating
tance
continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
7-2 – JLG Lift – 3121142

Current Measurement NOTE: Over a period of time, oxidation increases electrical resis-
tance at the connection, eventually causing circuit 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 connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
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.
3. Anderson connectors for the battery boxes and battery

chargers should have silicone grease applied to the con-
tacts only.
NOTE: Curing-type sealants might also be used to prevent short-

ing and would be less messy, but would make future pin
removal more difficult.
Figure 7-4. Current Measurement (DC)
• Set up the meter for the expected current range

• Be sure to connect the meter leads to the correct jacks
for the current range you have selected
• If meter is not auto ranging, set it to the correct range
(See multi meter’s operation manual)
7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO

ELECTRICAL CONNECTIONS
Silicone Dielectric Compound must be used on all electrical
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 con-
ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-
pound to the electrical connectors. This procedure applies to
all plug connections not enclosed in a box. Silicone 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.
3121142 – JLG Lift – 7-3

7.4 AMP CONNECTOR Assembly

Check to be sure the wedge lock is in the open, or as-shipped,
Applying Silicone Dielectric Compound to AMP position (See Figure 7-5.). Proceed as follows:
Connectors
Silicone Dielectric Compound must be used on the AMP con-
nections for the following reasons:
• To prevent oxidation at the mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level con-
ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-
pound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone
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 assem-
bling the housing to the header, it is possible that the
housing will become air locked, thus preventing the Figure 7-5. Connector Assembly Figure 1
housing latch from engaging.
2. Pierce one of the unused wire seals to allow the trapped
1. To insert a contact, push it straight into the appropriate
air inside the housing to escape.
circuit cavity as far as it will go (See Figure 7-7.).
3. Install a hole plug into this and/or any unused wire seal
2. Pull back on the contact wire with a force of 1 or 2 lbs. to
that has silicone dielectric compound escaping from it.
be sure the retention fingers are holding the contact
(See Figure 7-7.).
Figure 7-6. AMP Connector
7-4 – JLG Lift – 3121142

Figure 7-7. Connector Assembly Figure 2
3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-9.).
Release the locking latches by squeezing them inward
(See Figure 7-8.).
3121142 – JLG Lift – 7-5

Figure 7-10. Connector Disassembly
Disassembly Service - Voltage Reading

1. Insert a 4.8 mm (3/16") wide screwdriver blade between DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
the mating seal and one of the red wedge lock tabs.
It has been common practice in electrical troubleshooting to
2. Pry open the wedge lock to the open position.
probe wires by piercing the insulation with a sharp point. This
3. While rotating the wire back and forth over a half turn practice should be discouraged when dealing with the
(1/4 turn in each direction), gently pull the wire until the AMPSEAL plug assembly, or any other sealed connector sys-
contact is removed. tem. The resulting pinholes in the insulation will allow mois-
ture to invade the system by traveling along the wire strands.
NOTE: The wedge lock should never be removed from the housing This nullifies the effectiveness of the connector seals and
for insertion or removal of the contacts. could result in system failure.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.
7-6 – JLG Lift – 3121142

Figure 7-11. Connector Installation
3121142 – JLG Lift – 7-7

7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly
DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-13. DT/DTP Contact Removal
Figure 7-12. DT/DTP Contact Installation
1. Remove wedgelock using needlenose pliers or a hook
1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.
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 by
moving it away from the contact with a screwdriver.
3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly 3. Hold the rear seal in place, as removing the contact may
locked in place. displace the seal.
4. Once all contacts are in place, insert wedgelock with
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.
7-8 – JLG Lift – 3121142

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-14. HD/HDP Contact Installation Figure 7-16. HD/HDP Contact Removal
1. Grasp contact about 25mm behind the contact crimp

1. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
2. Hold connector with rear grommet facing you.
2. Slide tool along into the insert cavity until it engages
3. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
3. Pull contact-wire assembly out of connector.
properly locked in place.
Figure 7-17. HD/HDP Unlocking Contacts

Figure 7-15. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing
3121142 – JLG Lift – 7-9

Figure 7-18. Chassis Electrical Components - Sheet 1 of 2
7-10 – JLG Lift – 3121142

0274660 D
Figure 7-19. Chassis Electrical Components - Sheet 2 of 2
3121142 – JLG Lift – 7-11

Figure 7-20. Turntable Electrical Components - Prior to S/N 87579 - Sheet 1 of 2
7-12 – JLG Lift – 3121142

0272445-E
Figure 7-21. Turntable Electrical Components - Prior to S/N 87579 - Sheet 2 of 2
3121142 – JLG Lift – 7-13

Figure 7-22. Turntable Electrical Components - S/N 87579 to Present - Sheet 1 of 2
7-14 – JLG Lift – 3121142

0274660-D
Figure 7-23. Turntable Electrical Components - S/N 87579 to Present - Sheet 2 of 2
3121142 – JLG Lift – 7-15

Figure 7-24. Electrical Schematic - Deutz EMR2 - Sheet 1 of 6
7-16 – JLG Lift – 3121142

1870214 H
3121142 – JLG Lift – 7-17

7-18 – JLG Lift – 3121142

1870214 H
3121142 – JLG Lift – 7-19

7-20 – JLG Lift – 3121142

1870214 H
3121142 – JLG Lift – 7-21

7-22 – JLG Lift – 3121142

Page 1: TABLE OF CONTENTS
Page 2: GROUND CONTROL & BLAM

(Boom Length Angle Module)
Page 3: PLATFORM
Page 4: CHASSIS
Page 5: CAT ENGINE
Page 6: DEUTZ ENGINE
Page 7: DEUTZ TIER 4 FINAL ENGINE
1001119860-G
Figure 7-30. Electrical Schematic - Sheet 1 of 13
3121142 – JLG Lift – 7-23

SHEET 2
7-24 – JLG Lift – 3121142

SHEET 2 1001119860-G
3121142 – JLG Lift – 7-25

SHEET 3
7-26 – JLG Lift – 3121142

SHEET 3 1001119860-G
3121142 – JLG Lift – 7-27

SHEET 4
7-28 – JLG Lift – 3121142

SHEET 4 1001119860-G
3121142 – JLG Lift – 7-29

SHEET 5
7-30 – JLG Lift – 3121142

SHEET 5 1001119860-G
3121142 – JLG Lift – 7-31

SHEET 6
7-32 – JLG Lift – 3121142

SHEET 6 1001119860-G
3121142 – JLG Lift – 7-33

SHEET 7
7-34 – JLG Lift – 3121142

SHEET 7 1001119860-G
3121142 – JLG Lift – 7-35

Figure 7-43. Hydraulic Schematic - Boom Functions - Sheet 1 of 2
7-36 – JLG Lift – 3121142

1001110749-C
Figure 7-44. Hydraulic Schematic - Boom Functions - Sheet 2 of 2
3121142 – JLG Lift – 7-37

Figure 7-45. Hydraulic Schematic - Axle/Steer Control - Sheet 1 of 2
7-38 – JLG Lift – 3121142

1001110749-C
Figure 7-46. Hydraulic Schematic - Axle/Steer Control - Sheet 2 of 2
3121142 – JLG Lift – 7-39

Figure 7-47. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 1 of 2
7-40 – JLG Lift – 3121142

1001110749-C
Figure 7-48. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 2 of 2
3121142 – JLG Lift – 7-41

Figure 7-49. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 1 of 2
7-42 – JLG Lift – 3121142

1001110749-C
Figure 7-50. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 2 of 2
3121142 – JLG Lift – 7-43

NOTES:
7-44 – JLG Lift – 3121142

3121142
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

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Port Macquarie 13092-310 Campinas-SP Middleton France
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Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
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JLG 1200SJP 1350SJP Service Manual PDF

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What safety precautions should be observed during maintenance?

What safety precautions should be observed during maintenance?

What does the manual cover?

What does the manual cover?

Service and Maintenance Manual

July 22, 2014

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

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Original Issue - June 5, 2002

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1.1 CAPACITIES Deutz S/N 0300127698 to Present

Hydraulic Tank 55 gallons (208 liters) Type Liquid Cooled

Deutz Prior to S/N 0300127698 Type Liquid Cooled, Antifreeze

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1.4 SPECIFICATIONS AND PERFORMANCE DATA Dimensional Data

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1.5 TORQUE REQUIREMENTS 1.6 HYDRAULIC OIL

Cylinder Head Cover 6 8.5 Table 1-12. Mobilfluid 424 Specs

Rocker Arm Adjustment Screw 15 21 SAE Grade 10W30

Injection Valve Attachment 15 21