JLG 1200SJP Service Maintenance Manual
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JLG 1200SJP Service Maintenance Manual

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Table of Contents

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Service and Maintenance Manual
Models
1200SJP
1350SJP
P/N - 3121142
November 8, 2016
AS/NZS

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Summary of Contents for JLG 1200SJP

  • Page 1 Service and Maintenance Manual Models 1200SJP 1350SJP P/N - 3121142 November 8, 2016 AS/NZS...

  • Page 3: General

    • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS disconnecting or removing any portion of the system. STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL- VENTS. 3121142 – JLG Lift –...
  • Page 4 Revised - January 22, 2009 Revised - October 27, 2011 Revised - March 28, 2012 Revised - January 23, 2013 Revised - July 22, 2014 Revised - June 17, 2015 Revised - November 8, 2016 – JLG Lift – 3121142...

  • Page 5: Table Of Contents

    Cylinder Drift................. . 2-5 3121142 – JLG Lift –...
  • Page 6 Do NOT Do the Following When Welding on JLG Equipment....... .
  • Page 7 Cleaning the Fuel Strainer ..............3-118 3121142 – JLG Lift –...
  • Page 8 DTC to SPN/FMI Table ............... . 3-188 – JLG Lift –...
  • Page 9 Bleeding After Installation ..............4-88 3121142 – JLG Lift –...
  • Page 10 Start-Up Procedure ................5-51 – JLG Lift –...
  • Page 11 To Connect the JLG Control System Analyzer........
  • Page 12 HD30/HDP20 Series Disassembly............. . 7-9 viii – JLG Lift – 3121142...
  • Page 13 Swing Brake 8 Spring Orientation ..............3-80 3121142 – JLG Lift –...
  • Page 14 Load Pin Removal Tool, JLG P/N 4846765........
  • Page 15 Platform Valve Identification - JLG P/N 4641266 ........
  • Page 16 Electrical Schematic - Sheet 5 of 13..............7-27 – JLG Lift –...
  • Page 17 Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 2 of 2 ......7-43 3121142 – JLG Lift –...
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. This page left blank intentionally. – JLG Lift – 3121142...
  • Page 19 Load Moment Pin Troubleshooting: New Moment Pin Detected Fault....... . 6-131 3121142 – JLG Lift – xiii...
  • Page 20 LIST OF TABLES TABLE NO. TITLE PAGE NO. This page left blank intentionally. – JLG Lift – 3121142...

  • Page 21: Specifications

    5 Quarts (4.5 L) 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 –...

  • Page 22: Specifications And Performance Data

    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) – JLG Lift – 3121142...
  • Page 23 F. (-7 degrees C.), JLG Industries recommends the use of torque value. Mobil DTE13. Aside from JLG recommendations, it is not advisable to mix oils of Table 1-10. Engine Torque Requirements different brands or types, as they may not contain the same required additives or be of comparable viscosities.

  • Page 24: Mobil Dte 13M Specs

    9.3 cSt at 40° C (104° F) 46 cSt (215SUS) Viscosity Index at 65° C (150° F) 22 cSt (106SUS) NOTE: Mobil/Exxon recommends that this oil be checked on Viscosity Index a yearly basis for viscosity. – JLG Lift – 3121142...

  • Page 25: Major Component Weights

    Platform Level Up 2500 172.3 1350 Counterweight 8500 3856 Platform Level Down 1500 103.4 1200 Counterweight 5494 2492 Jib Up 2750 189.6 T/T Assy. (less Cwt) 9450 4286 Jib Down 2750 189.6 Extendable Axles 2500 172.3 3121142 – JLG Lift –...
  • Page 26 SECTION 1 - SPECIFICATIONS 10,11 Figure 1-1. Lubrication and Operator Maintenance Diagram – JLG Lift – 3121142...

  • Page 27: Lubrication And Operator Maintenance

    Capacity - 2.7 ounces (80 ml) Capacity - A/R Lube - DTE24 Lube - MPG Interval - Check level every 150 hrs/Change every 1200 Interval - Every 3 months or 150 hours of operation hours of operation. 3121142 – JLG Lift –...
  • Page 28 Comments - Place Fill port at 12 o’clock position and thereafter or as indicated by condition indicator. Check port at 8 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port. – JLG Lift – 3121142...
  • Page 29 Remove and clean at time of hydraulic oil change. 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 –...
  • Page 30 13. Fuel Filter - CAT Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation 1-10 – JLG Lift – 3121142...
  • Page 31 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...
  • Page 32 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 1-12 – JLG Lift – 3121142...
  • Page 33 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121142 – JLG Lift – 1-13...
  • Page 34 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-14 – JLG Lift – 3121142...
  • Page 35 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121142 – JLG Lift – 1-15...
  • Page 36 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-16 – JLG Lift – 3121142...

  • Page 37: General

    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-...

  • Page 38: Service And Guidelines

    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;...

  • Page 39: Component Disassembly And Reassembly

    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 –...

  • Page 40: Hydraulic Oil

    1. Refer to Section 1 for recommendations for viscosity machine back in service. ranges. 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...

  • Page 41: Cylinder Drift

    • Disconnect the moment pin connection (where fitted) GUIDELINES • Ground only to structure being welded. Filament wound bearings. Do NOT Do the Following When Welding on JLG 1. Pinned joints should be disassembled and inspected if Equipment the following occurs: •...

  • Page 42: Inspection And Preventive Maintenance Schedule

    Hood, Hood Props, Hood Latches 1,2,5 Chassis Assembly Tires 16,17 16,17,18 16,17,18 Wheel Nuts/Bolts Wheel Bearings 14,24 Oscillating Axle/Lockout Cylinder Systems Outrigger or Extendable Axle Systems Steer Components Drive Motors Drive Hubs Functions/Controls Platform Controls – JLG Lift – 3121142...
  • Page 43 Hydraulic Fluid 7,11 7,11 Electrical Connections Instruments, Gauges, Switches, Lights, Horn 5,23 General Operators and Safety Manuals in Storage Box ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible 3121142 – JLG Lift –...
  • Page 44 Function Test of All Systems 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to use each day; or at each Operator change Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...
  • Page 45 F U E L A N D T H E A ID O F A C O M P LE T E JLG S P E C IF IE D C O LD W E A T H E R...
  • Page 46 W IT H T H E R E C O M M E N D E D F LU ID S , A F U LL Y C H A R G E D B A TT E R Y A N D T H E A ID O F A C O M P LE T E JLG S P E C IF IE D C O LD W E A T H E R -20 F(-29 C) P A C K A G E (IE .

  • Page 47: Chassis & Turntable

    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.

  • Page 48: Extending Axles

    SECTION 3 - CHASSIS & TURNTABLE NOTE: For more detailed information concerning system adjust- 3.2 EXTENDING AXLES ment and operation, refer to Section 6 - JLG Control Sys- The Axle Extension System allows each of the four axles to be tem.

  • Page 49: Drive System

    NOTE: For more detailed information concerning system adjust- ment and operation, refer to Section 6 - JLG Control Sys- tem. Figure 3-3. Crab Steer Mode 3121142 –...

  • Page 50: Drive/Steering Speed Control

    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.
  • Page 51 SECTION 3 - CHASSIS & TURNTABLE This page left blank intentionally. 3121142 – JLG Lift –...
  • Page 52 SECTION 3 - CHASSIS & TURNTABLE Figure 3-5. Chassis Component Location - Sheet 1 of 2 – JLG Lift – 3121142...
  • Page 53 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 –...
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE Figure 3-7. Turntable and Boom Component Location - Sheet 1 of 2 – JLG Lift – 3121142...
  • Page 55 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 –...
  • Page 56 SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME. 2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST SHIM. D E T A IL B Figure 3-9. Oscillating Axle - Sheet 1 of 2 3-10 – JLG Lift – 3121142...
  • Page 57 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...
  • Page 58 SECTION 3 - CHASSIS & TURNTABLE Figure 3-11. Axle Loctite Application 3-12 – JLG Lift – 3121142...

  • Page 59: Steering Assembly Notes

    Apply Loctite #242 Apply Loctite #271 Apply Loctite #222 Preload Torque 100-300 ft. lb. (140-420 Nm) on Slot Nut Spindle Steer Cylinder Pivot Pin Angle Sensor Assembly King Pin Steer Cylinder Axle Figure 3-12. Steering Installation 3121142 – JLG Lift – 3-13...

  • Page 60: Oscillating Axle System

    NOTE: For more detailed information concerning system adjust- form (on high engine) feather drive. Activate drive fully. ment and operation, refer to Section 6 - JLG Control Sys- 5. Close the bleeder when there is a steady stream of oil tem.

  • Page 61: Oscillating Axle Lockout Test

    12" [30.4 cm] on the1350SJP or 24" 13. Have an assistant check to see that right front wheel [60.9 cm] on the 1200SJP) and drive is selected. 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.

  • Page 62: Drive Hub (Prior To S/N 100131)

    18. The second stage planetary gears (1) must be changed as a complete set of four and JLG recommends changing 2. Remove all bolts holding the motor and Remove motor the sun gear (3) along with this set of planets.

  • Page 63: Assembly Of First Stage Planetary Assembly (7)

    4. Install “o” ring (33) in groove of ring gear (30). 2. Subsequent changes, every 1500 hours or annually, whichever occurs first. 5. Install seal rings (22) and screw plugs (21). NOTE: Flush the drive before filling with new oil. 3121142 – JLG Lift – 3-17...
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE 3-18 – JLG Lift – 3121142...
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-19...

  • Page 66: Drive Hub - Bonfiglioli (S/N 100128 To Present)

    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...

  • Page 67: General Information

    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...
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE 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...

  • Page 69: Gearbox Disengagement

    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...
  • Page 70 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...

  • Page 71: Maintenance Information

    The gearbox only requires the scheduled maintenance proce- THAT GOVERN LOCALLY. dures set out by the manufacturer (see Table 3-4). Good maintenance will ensure an ongoing functioning in time as well as maximum reliability. 3121142 – JLG Lift – 3-25...

  • Page 72: Troubleshooting

    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...
  • Page 73 (44). 2. Remove the circlip (47) and remove the special tool. 6. By using pliers remove the circlip (36) from its seat in the 3. Remove the spring retainer disc (46). brake shaft (35). 3121142 – JLG Lift – 3-27...
  • Page 74 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...
  • Page 75 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...
  • Page 76 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...
  • Page 77 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...
  • Page 78 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 in the flanged hub's pins (31). 27. Remove the 1st reduction assembly (16). 3-32 – JLG Lift – 3121142...
  • Page 79 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...

  • Page 80: Inspection Of Parts

    3. In the case of damaged gears, for example a planetary, do not proceed to replace the individual gear but the tually replace the lifetime seal (29), which means both the entire reduction assembly. metal rings parts and the O-ring seals. 3-34 – JLG Lift – 3121142...

  • Page 81: Assembly

    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...
  • Page 82 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...
  • Page 83 HUB (31) FROM COMING OUT OF THE GEARBOX HOUSING (23) DURING THE 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...
  • Page 84 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...
  • Page 85 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...
  • Page 86 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...
  • Page 87 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...
  • Page 88 38. Assemble the brake discs package according to the fol- 41. Fit the external O-ring seal (38) and the backup ring (37) lowing order: first, insert one sintered bronze disc with into their seats in the spacer (39). external teeth (33). 3-42 – JLG Lift – 3121142...
  • Page 89 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...
  • Page 90 48. Insert the spring retainer disc (46). 46. By using a rubber hammer and a metal stopper push the brake piston (44) against the flanged hub (31), paying attention not to damage the seals already fitted. 3-44 – JLG Lift – 3121142...

  • Page 91: Final Test And Reinstallation

    5. After having reassembled the gearbox, install the hydraulic motor. 6. Fill the gearmotor with the lubricant oil. 3121142 – JLG Lift – 3-45...
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE Figure 3-20. Drive Hub Special Tools - Sheet 1 of 4 3-46 – JLG Lift – 3121142...
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE Figure 3-21. Drive Hub Special Tools - Sheet 2 of 4 3121142 – JLG Lift – 3-47...
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE Figure 3-22. Drive Hub Special Tools - Sheet 3 of 4 3-48 – JLG Lift – 3121142...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE Figure 3-23. Drive Hub Special Tools - Sheet 4 of 4 3121142 – JLG Lift – 3-49...

  • Page 96: Drive Hub - Reggiana Riduttori (S/N 134389 To Present)

    2. Clamps for inner retention rings; Ø210 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...
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE Ø210 Ø130 Ø30 M- 1321 LOCTITE 2701 N° 4 Hole to 90° Ø40 M- 1320 Ø197.5 Ø210 Figure 3-26. Bearing Spacer Mountng CO16117 Figure 3-27. Assembly Diagram 1 3121142 – JLG Lift – 3-51...
  • Page 98 ) n°12 Hole to 30° n° 12 Hole to 30° Ø6.5 n° 12 Spot-facing to 30° Ø10.5 Figure 3-31. Anti-rotation Pin n° 4 Hole to 90° M10 Ø50 Ø275 Ø305 Figure 3-29. Anti-rotation Flange 3-52 – JLG Lift – 3121142...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 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...
  • Page 100 M- 1546 M- 1548 Ø105 Ø93.5 Ø48 +0.1 Ø20 +0.2 Ø46 Ø8.5 Ø13.5 Ø40.5 Ø46 M- 1547 Ø39.5 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...

  • Page 101: Disassembly

    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...
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE 3-56 – JLG Lift – 3121142...
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-57...
  • Page 104 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...

  • Page 105: Assembly

    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...
  • Page 106 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...
  • Page 107 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...
  • Page 108 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...
  • Page 109 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...
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE 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...

  • Page 111: Swing Drive

    Leak test at 10 psi (0.7 bar) for 20 min- utes. 3121142 – JLG Lift – 3-65...

  • Page 112: Motor Control Valve Disassembly

    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...

  • Page 113: Motor And Brake Disassembly

    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...

  • Page 114: Main Disassembly

    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...

  • Page 115: Hub-Shaft Disassembly

    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...

  • Page 116: Carrier Disassembly

    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...

  • Page 117: Hub-Shaft Sub-Assembly

    1D. Tapered Bearing Cone 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...

  • Page 118: Carrier Sub-Assembly

    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...
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE 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...

  • Page 120: Main Assembly

    Ring Gear (4) with an "X" or punch mark stamped on it with GEAROIL 80W90, to bottom of plug hole in cover at should be up. Pipe Plug (20). 18. Install Pipe Plug (20) into Cover (6) using thread sealant. 3-74 – JLG Lift – 3121142...
  • Page 121 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...

  • Page 122: Motor And Brake Assembly

    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...

  • Page 123: Motor Control Valve Assembly

    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...

  • Page 124: Swing Brake

    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...

  • Page 125: Installation

    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...
  • Page 126 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...
  • Page 127 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...

  • Page 128: Swing Motor

    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...
  • Page 129 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...
  • Page 130 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...
  • Page 131 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...
  • Page 132 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...
  • Page 133 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...
  • Page 134 (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...

  • Page 135: Assembly

    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...
  • Page 136 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...
  • Page 137 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...
  • Page 138 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...
  • Page 139 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...
  • Page 140 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...
  • Page 141 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...

  • Page 142: One Piece Stator Construction

    6. Remove the two assembled bolts (1) if used to retain sta- tor and wear plate. 3-96 – JLG Lift – 3121142...

  • Page 143: Procedure For Setting Gear Backlash

    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.

  • Page 144: 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. Brake Bleed Port Brake Fill Port Gearbox Fill Port Gearbox Drain Port Figure 3-52. Swing Drive Ports 3-98 – JLG Lift – 3121142...

  • Page 145: Swing Bearing

    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.
  • Page 146 M E A S U R IN G P O IN T M E A S U R IN G P O IN T Figure 3-54. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2 3-100 – JLG Lift – 3121142...
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-101...

  • Page 148: Wear Tolerance

    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...
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-103...

  • Page 150: Swing Bearing Installation

    (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.

  • Page 151: Swing Bearing Torque Values

    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...

  • Page 152: Swing Speed Proportioning

    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.

  • Page 153: Rotary Coupling

    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...
  • Page 154 SECTION 3 - CHASSIS & TURNTABLE Center Body Seal Seal Thrust Ring Housing Snap Ring O-ring Figure 3-60. Rotary Coupling Cutaway 3-108 – JLG Lift – 3121142...
  • Page 155 SECTION 3 - CHASSIS & TURNTABLE Loctite #242 5B. Rotary Circuit Contactor Bolt Locknut Bolt Not Used Swivel Bracket Flatwasher Rotary Coupling & Collector Ring Assembly 5A. Rotary Coupling Figure 3-61. Rotary Coupling Installation 3121142 – JLG Lift – 3-109...
  • Page 156 SECTION 3 - CHASSIS & TURNTABLE Figure 3-62. Rotary Coupling Port Location 3-110 – JLG Lift – 3121142...

  • Page 157: Generator

    If operating in a hostile environment, clean monthly. Case Drain 250 (17) 375 (26) 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...

  • Page 158: Overload Protection

    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...
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE 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...

  • Page 160: Auxiliary Power System

    Auxiliary Pump Power Relay Battery Figure 3-64. Auxiliary Pump Installation 3-114 – JLG Lift – 3121142...
  • Page 161 B A TT E R Y H E A T E R V IE W A -A T A N K H E A T E R VIEW B-B Figure 3-65. Cold Weather Package 3121142 – JLG Lift – 3-115...

  • Page 162: Cold Weather Package

    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, OIL HOT Control System.

  • Page 163: Changing The Oil Filter

    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...

  • Page 164: Replacing The Fuel Filter

    (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...

  • Page 165: Deutz Emr 2 (S/N 87579 To Present)

    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...
  • Page 166 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 TO CONTROL THE ENGINE & FAULT REPORTING. OIL PRESSURE SENSOR Figure 3-68.
  • Page 167 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-121...
  • Page 168 SECTION 3 - CHASSIS & TURNTABLE 3-122 – JLG Lift – 3121142...
  • Page 169 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-123...
  • Page 170 SECTION 3 - CHASSIS & TURNTABLE 3-124 – JLG Lift – 3121142...
  • Page 171 SECTION 3 - CHASSIS & TURNTABLE Figure 3-73. EMR 2 Engine Plug Pin Identification 3121142 – JLG Lift – 3-125...
  • Page 172 SECTION 3 - CHASSIS & TURNTABLE Figure 3-74. EMR 2 Vehicle Plug Pin Identification 3-126 – JLG Lift – 3121142...
  • Page 173 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-127...
  • Page 174 SECTION 3 - CHASSIS & TURNTABLE 3-128 – JLG Lift – 3121142...
  • Page 175 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-129...
  • Page 176 SECTION 3 - CHASSIS & TURNTABLE 3-130 – JLG Lift – 3121142...
  • Page 177 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-131...

  • Page 178: Bio Fuel In Deutz Engines

    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...

  • Page 179: Biological Contamination In Fuels

    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...
  • Page 180 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...
  • Page 181 SECTION 3 - CHASSIS & TURNTABLE DTC XXXX- Diagnostic Condition Note: Helpful tips used to aid troubleshooting Troubleshooting flow chart Figure 3-81. 2nd Page of Diagnostic Information for a Given Fault 3121142 – JLG Lift – 3-135...

  • Page 182: List Of Abbreviations In This Section

    ERWT Exhaust Manifold Riser Temperature Throttle Body Injection Electronic Throttle Body Top Dead Center Electronic Throttle Control Throttle Inlet Pressure Flight Data Recorder Throttle Position Sensor Failure Mode Indicator Torque/Speed Control Firing Order Transmit 3-136 – JLG Lift – 3121142...
  • Page 183 Heated Exhaust Gas Oxygen Sensor (same as HO2S) HO2S Heated Oxygen Sensor (same as HEGO) Idle Air Control Intake Air Temperature ICAV Instant Crank Angle Velocity Idle Validation Switch LDGCP Light-Duty Global Control Platform (Industrial, Smart/Logic Coil) 3121142 – JLG Lift – 3-137...

  • Page 184: Diagnostic Trouble Codes

    • 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...

  • Page 185: Dtc 116- Ect Higher Than Expected Stage 1

    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...

  • Page 186: Dtc 117- Ect/Cht Low Voltage

    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...
  • Page 187 D oes D S T display E C T S ensor voltage of 4.9 V D C or greater? · S ensor signal circuit shorted to ground, check w ire harness for ground short · F aulty E C M 3121142 – JLG Lift – 3-141...

  • Page 188: Dtc 118- Ect/Cht High Voltage

    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...
  • Page 189 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-143...

  • Page 190: Dtc 122- Tps1 Signal Voltage Low

    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...
  • Page 191 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-145...

  • Page 192: Dtc 123- Tps1 Signal Voltage High

    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...
  • Page 193 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-147...

  • Page 194: Dtc 217- Ect Higher Than Expected 2

    RPM for the latch time this fault will set. by debris and that the hose is tightly connected • Check that the thermostat is not stuck closed • Check that the raw water pump/impeller is tact and that it is not restricted 3-148 – JLG Lift – 3121142...

  • Page 195: Dtc 219- Rpm Higher Than Max Allowed Governed Speed

    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...

  • Page 196: Dtc 336- Crank Signal Input Noise

    (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...
  • Page 197 Check wiring and electrical connections between crankshaft position sensor and ECM Is the wiring OK? Repair wireharness • Poor system ground • Bad crankshaft position sensor • Bad ECM 3121142 – JLG Lift – 3-151...

  • Page 198: Dtc 337- Loss Of Crank Input Signal

    #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...

  • Page 199: Dtc 521- Oil Pressure Sender/Switch High Pressure

    • Check continuity through switch to ground. reset ? Intermittent Problem • Oil Pressure circuit shorted-to-ground in harness Is switch open? • Faulty ECM • Faulty Oil Pressure Switch (short circuit) • Faulty engine oiling system (verify with mechanical gauge) 3121142 – JLG Lift – 3-153...

  • Page 200: Dtc 524- Oil Pressure Low

    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...
  • Page 201 • Faulty Oil Pressure Switch (open circuit) • Faulty engine oiling system (verify with mechanical gauge) • Faulty connection at sensor Does DMM indicate a • Faulty ECM resistance < 5.0 ohms? • Faulty harness (open circuit) 3121142 – JLG Lift – 3-155...

  • Page 202: Dtc 562- Battery Voltage (Vbat) Low

    • 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 • Non-emissions related fault 3-156 – JLG Lift – 3121142...
  • Page 203 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-157...

  • Page 204: Dtc 563- Battery Voltage (Vbat) High

    • Corrective Action(s)- Illuminate MIL and/or sound audible warning or illuminate secondary warning lamp, disable adaptive fueling correction for remainder of key cycle • Non-emissions related fault 3-158 – JLG Lift – 3121142...
  • Page 205 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-159...

  • Page 206: Dtc 601- Microprocessor Failure - Flash

    A fault of flash memory can occur for any calibration vari- • Non-emissions related fault able set and thus could cause undesirable operation. 3-160 – JLG Lift – 3121142...
  • Page 207 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-161...

  • Page 208: Dtc 604- Microprocessor Failure - Ram

    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...
  • Page 209 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-163...

  • Page 210: Dtc 606- Microprocessor Failure - Cop

    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- tion. • Non-emissions related fault 3-164 – JLG Lift – 3121142...
  • Page 211 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-165...

  • Page 212: Dtc 642- 5 Volt External Low Voltage

    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...

  • Page 213: Dtc 643- 5 Volt External High Voltage

    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...

  • Page 214: Dtc 1612- Microprocessor Failure - Rti 1

    During this active fault, Power Derate (level 2) will be enforced. • Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. • Power Derate (level 2 until fault is cleared manually) 3-168 – JLG Lift – 3121142...

  • Page 215: Dtc 1613- Microprocessor Failure - Rti 2

    During this active fault, Power Derate (level 2) will be enforced. • Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. • Power Derate (level 2 until fault is cleared manually) 3121142 – JLG Lift – 3-169...
  • Page 216 Clear System Fault ground circuits to ECM Does SFC 555 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent Repair wiring to ECM and retest 3-170 – JLG Lift – 3121142...

  • Page 217: Dtc 1614- Microprocessor Failure - Rti 3

    During this active fault, Power Derate (level 2) will be enforced. • Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. • Power Derate (level 2 until fault is cleared manually) 3121142 – JLG Lift – 3-171...
  • Page 218 Clear System Fault ground circuits to ECM Does SFC 556 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent Repair wiring to ECM and retest 3-172 – JLG Lift – 3121142...

  • Page 219: Dtc 1615- Microprocessor Failure - A/D

    During this active fault, Power Derate (level 2) will be enforced. • Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. • Power Derate (level 2 until fault is cleared manually) 3121142 – JLG Lift – 3-173...
  • Page 220 Clear System Fault ground circuits to ECM Does SFC 513 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent Repair wiring to ECM and retest 3-174 – JLG Lift – 3121142...

  • Page 221: Dtc 1616- Microprocessor Failure - Interrupt

    During this active fault, Power Derate (level 2) will be enforced. • Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%. This is enforced until the fault is manually cleared. • Power Derate (level 2 until fault is cleared manually) 3121142 – JLG Lift – 3-175...
  • Page 222 Clear System Fault ground circuits to ECM Does SFC 512 reset with engine idling? Replace ECM with known Are all circuits ok? good part and retest Fault is intermittent Repair wiring to ECM and retest 3-176 – JLG Lift – 3121142...

  • Page 223: Dtc 1625- Can J1939 Shutdown Request

    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...

  • Page 224: Dtc 1626- Can J1939 Transmit (Tx) Fault

    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...

  • Page 225: Dtc 1627- Can J1939 Receive (Rx) Fault

    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...

  • Page 226: Dtc 1628- Can Address Conflict Failure

    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...
  • Page 227 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-181...

  • Page 228: Dtc 1629- J1939 Tsc1 Message Reciept Loss

    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...

  • Page 229: Dtc 1652- Tps1 Loss Of Communications

    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...

  • Page 230: Dtc 2111- Unable To Reach Lower Tps

    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. 3-184 – JLG Lift – 3121142...
  • Page 231 SECTION 3 - CHASSIS & TURNTABLE 3121142 – JLG Lift – 3-185...

  • Page 232: Dtc 2112- Unable To Reach Higher Tps

    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. 3-186 – JLG Lift – 3121142...

  • Page 233: Dtc 9999- Throttle Actuator Failsafe Spring Failure

    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...

  • Page 234: Dtc To Spn/Fmi Table

    DTC 1628: J1939 CAN address / engine-number conflict DTC 521: Oil pressure high DTC 1652: TPS1 loss of communications DTC 1629: CAN-J1939 TSC1 Parameter Rx Fault DTC 1113: Unable to achieve lower RPM DTC 9999: TPS1 failsafe spring failure 3-188 – JLG Lift – 3121142...

  • Page 235: Boom & Platform

    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.

  • Page 236: Drive/Steer - Boom Function Interlock System (Ce Only)

    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.

  • Page 237: Moment Control System

    BCS light with 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.

  • Page 238: Controlled Boom Angle System

    Refer to Boom Control Select. NOTE: For more detailed information concerning system adjust- ment and operation, refer to Section 6 - JLG Control Sys- Controlled Arc Boom tem.

  • Page 239: Dual Capacity System

    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.

  • Page 240: Boom Control Select

    • While operating Lift Up, the boom may also telescope out NOTE: For more detailed information concerning system adjust- (Controlled Arc) ment and operation, refer to Section 6 - JLG Control Sys- • While operating Lift Down, the boom may also telescope in tem.

  • Page 241: Removal

    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 –...
  • Page 242 SECTION 4 - BOOM & PLATFORM – JLG Lift – 3121142...
  • Page 243 SECTION 4 - BOOM & PLATFORM 3121142 – JLG Lift –...
  • Page 244 SECTION 4 - BOOM & PLATFORM 4-10 – JLG Lift – 3121142...
  • Page 245 SECTION 4 - BOOM & PLATFORM 3121142 – JLG Lift – 4-11...
  • Page 246 SECTION 4 - BOOM & PLATFORM 4-12 – JLG Lift – 3121142...
  • Page 247 SECTION 4 - BOOM & PLATFORM 3121142 – JLG Lift – 4-13...
  • Page 248 SECTION 4 - BOOM & PLATFORM 4-14 – JLG Lift – 3121142...
  • Page 249 12. Move all of the hydraulic hoses and electrical wires so they are free from chassis. 8. Unbolt the power track. 9. Remove the bolt securing the keeper pin and remove the keeper pin from boom pivot pin. 3121142 – JLG Lift – 4-15...

  • Page 250: Disassembly

    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...
  • Page 251 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...
  • Page 252 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...
  • Page 253 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...
  • Page 254 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...
  • Page 255 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...
  • Page 256 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...
  • Page 257 35. Remove the top, side, and bottom wear pads from the front of the inner mid boom sections. 3121142 – JLG Lift – 4-23...
  • Page 258 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...
  • Page 259 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...
  • Page 260 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...

  • Page 261: Assembly

    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.
  • Page 262 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...
  • Page 263 SECTION 4 - BOOM & PLATFORM Ft-Lbs. Figure 4-8. Boom Assembly Torque Values - Sheet 1 of 2 3121142 – JLG Lift – 4-29...
  • Page 264 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. Figure 4-9. Boom Assembly Torque Values - Sheet 2 of 2 4-30 – JLG Lift – 3121142...
  • Page 265 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.
  • Page 266 SECTION 4 - BOOM & PLATFORM 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.
  • Page 267 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.
  • Page 268 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...
  • Page 269 SECTION 4 - BOOM & PLATFORM 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.
  • Page 270 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...
  • Page 271 SECTION 4 - BOOM & PLATFORM 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.
  • Page 272 SECTION 4 - BOOM & PLATFORM 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.
  • Page 273 SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100019 #0100019 #0100011 #0100011 S E C T IO N A -A Figure 4-10. Locations for Threadlocker Application - Sheet 1 of 4 3121142 – JLG Lift – 4-39...
  • Page 274 SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-11. Locations for Threadlocker Application - Sheet 2 of 4 4-40 – JLG Lift – 3121142...
  • Page 275 SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 #0100011 Figure 4-12. Locations for Threadlocker Application - Sheet 3 of 4 3121142 – JLG Lift – 4-41...
  • Page 276 SECTION 4 - BOOM & PLATFORM #0100011 #0100011 #0100011 #0100011 #0100011 #0100019 #0100011 #0100011 #0100011 #0100011 Figure 4-13. Locations for Threadlocker Application - Sheet 4 of 4 4-42 – JLG Lift – 3121142...

  • Page 277: 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).

  • Page 278: Jib Rotator Orientation

    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...
  • Page 279 SECTION 4 - BOOM & PLATFORM 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.
  • Page 280 SECTION 4 - BOOM & PLATFORM Figure 4-16. Load Pin Removal Tool, JLG P/N 4846765 4-46 – JLG Lift – 3121142...
  • Page 281 SECTION 4 - BOOM & PLATFORM Figure 4-17. Boom/Jib Sensors and Switches Installation - Sheet 1 of 4 3121142 – JLG Lift – 4-47...
  • Page 282 SECTION 4 - BOOM & PLATFORM Figure 4-18. Boom/Jib Sensors and Switches Installation - Sheet 2 of 4 4-48 – JLG Lift – 3121142...
  • Page 283 SECTION 4 - BOOM & PLATFORM Figure 4-19. Boom/Jib Sensors and Switches Installation - Sheet 3 of 4 3121142 – JLG Lift – 4-49...
  • Page 284 SECTION 4 - BOOM & PLATFORM Figure 4-20. Boom/Jib Sensors and Switches Installation - Sheet 4 of 4 4-50 – JLG Lift – 3121142...
  • Page 285 Adjust top blades 0.000 to 0.063" (0 to 1.6 mm) from top boom plate Adjust side blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate Apply Loctite #242 & torque to 50 ft.lbs. (70 Nm) Figure 4-21. Boom Wiper Installation 3121142 – JLG Lift – 4-51...
  • Page 286 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...

  • Page 287: Powertrack Maintenance

    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...
  • Page 288 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...

  • Page 289: Two Piece Bracket Maintenance

    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...

  • Page 290: 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 LOOSE SCREW TIGHT SCREW and pin. 4-56 – JLG Lift – 3121142...
  • Page 291 An open snap ring is shown below. • 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...
  • Page 292 SECTION 4 - BOOM & PLATFORM 4-58 – JLG Lift – 3121142...
  • Page 293 SECTION 4 - BOOM & PLATFORM 3121142 – JLG Lift – 4-59...
  • Page 294 SECTION 4 - BOOM & PLATFORM 4-60 – JLG Lift – 3121142...
  • Page 295 SECTION 4 - BOOM & PLATFORM 3121142 – JLG Lift – 4-61...
  • Page 296 SECTION 4 - BOOM & PLATFORM 4-62 – JLG Lift – 3121142...
  • Page 297 SECTION 4 - BOOM & PLATFORM 3121142 – JLG Lift – 4-63...

  • Page 298: Hose Routing Procedure

    6. Ropes with 6 total broken wires in one rope lay, 3 in one 5. Inspect sheaves for condition of flanges. (See Dimension strand in one rope lay, 1 valley break, or 1 break at any Of Sheaves for proper dimension.) end termination. 4-64 – JLG Lift – 3121142...

  • Page 299: Wire Rope Tensioning Adjustment

    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...
  • Page 300 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...

  • Page 301: Wire Rope Tensioning Procedure

    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...
  • Page 302 SECTION 4 - BOOM & PLATFORM 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...
  • Page 303 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...
  • Page 304 O U T E R M ID BO O M BA S E BO O M IN N E R M ID BO O M N O T E : Boom shown in fully retracted position. Figure 4-30. Wire Rope Tensioning 4-70 – JLG Lift – 3121142...
  • Page 305 SECTION 4 - BOOM & PLATFORM 3121142 – JLG Lift – 4-71...
  • Page 306 SECTION 4 - BOOM & PLATFORM 4-72 – JLG Lift – 3121142...
  • Page 307 SECTION 4 - BOOM & PLATFORM 2" Socket 3/4” Socket Retaining Bolt Figure 4-33. Wire Rope Adjustment Tools (Optional) 3121142 – JLG Lift – 4-73...

  • Page 308: Broken Boom Cable Proximity Switch

    The secondary tilt sensor is used as a backup to the primary tilt NOTE: For more detailed information concerning system adjust- sensor. Any time a tilt set point is reset, a value from each sen- ment and operation, refer to Section 6 - JLG Control Sys- sor shall be set. tem.

  • Page 309: Normal Operation

    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...

  • Page 310: Rotary Actuator

    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...
  • Page 311 204. 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...
  • Page 312 204. 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...

  • Page 313: Disassembly

    (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...
  • Page 314 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...
  • Page 315 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...
  • Page 316 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...

  • Page 317: Inspection

    2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within specifications (Not less than 0.092” or 2.34 mm). 3121142 – JLG Lift – 4-83...
  • Page 318 (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...
  • Page 319 Using a rubber mallet, tap the piston into the housing up to the point Repeat this step for the outer seal (202). where the gear teeth meet. 3121142 – JLG Lift – 4-85...
  • Page 320 Do not engage the piston gear teeth wear guides are seated inside the housing bore. yet. 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...
  • Page 321 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...

  • Page 322: Installing Counterbalance Valve

    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...
  • Page 323 SECTION 4 - BOOM & PLATFORM Figure 4-37. Rotator Counterbalance Valve 3121142 – JLG Lift – 4-89...
  • Page 324 Torque to 50 ft.lbs. (68 Nm) Loctite #242 Torque to 480 ft. lbs. (650 Nm) Check torque every 150 hours of operation Torque to 75 ft. lbs. (102 Nm) Figure 4-38. Platform Support Torque Values 4-90 – JLG Lift – 3121142...

  • Page 325: Hydraulics

    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 –...

  • Page 326: Dip Method

    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. – JLG Lift – 3121142...

  • Page 327: Cylinder Repair

    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 –...
  • Page 328 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 – JLG Lift – 3121142...
  • Page 329 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 –...
  • Page 330 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 – JLG Lift – 3121142...
  • Page 331 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 –...
  • Page 332 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 – JLG Lift – 3121142...
  • Page 333 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 –...
  • Page 334 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...
  • Page 335 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...

  • Page 336: Cleaning And Inspection

    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...
  • Page 337 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...

  • Page 338: Assembly

    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.
  • Page 339 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...
  • Page 340 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.

  • Page 341: Holding Valve Torque 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.
  • Page 342 SECTION 5 - HYDRAULICS 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...
  • Page 343 SECTION 5 - HYDRAULICS 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...
  • Page 344 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...
  • Page 345 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...
  • Page 346 10. Lift Down Relief 14. Tele In Relief Lift Up Swing Left 11. Lift Flow 15. Tele Flow Swing Right Lift Down 12. Tele In 16. Lift Down/Aux Select Figure 5-26. Main Valve Identification 5-22 – JLG Lift – 3121142...

  • Page 347: Cartridge Torque Values

    33.9-40.6 30-35 40.6-47.4 25-30 33.9-40.6 30-35 40.6-47.4 30-35 40.6-47.4 40.6 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.4 30-35 40.6-47.5 30-35 40.6-47.4 30-35 40.6-47.5 40.6 Figure 5-27. Main Valve Cartridge Torque Values 3121142 – JLG Lift – 5-23...

  • Page 348: Plug Torque Values

    SECTION 5 - HYDRAULICS Table 5-4. Plug Torque Values Ft-Lbs. 135.5 17.5 Figure 5-27. Main Valve Plug Torque Values 5-24 – JLG Lift – 3121142...

  • Page 349: Hydraulic Tank

    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...

  • Page 350: Adjustments Made At The Main Valve Bank

    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...

  • Page 351: Adjustments Made At The Frame Valve Bank

    Section 6 - JLG TELESCOPE OUT - 3000 PSI (206.8 Bar) Control System. The purpose of these measuring tools is to 1.
  • Page 352 SECTION 5 - HYDRAULICS Figure 5-28. Steer Pressure Adjustments 5-28 – JLG Lift – 3121142...
  • Page 353 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.
  • Page 354 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...

  • Page 355: Adjustments Made At The Platform Valve Bank

    If decrease. the pressure is not 2600 psi (179 Bar), adjust the relief valve mounted next to the MS3 port CW to increase or CCW to decrease. 3121142 – JLG Lift – 5-31...

  • Page 356: Drive Pumps

    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...
  • Page 357 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...
  • Page 358 No - Proceed to step 8.f 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...

  • Page 359: Charge Pressure Relief Valve Adjustment

    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...

  • Page 360: Mechanical Centering Of Pump

    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 X and X 5-36 – JLG Lift – 3121142...

  • Page 361: High Pressure Relief Valve Adjustments

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

  • Page 362: Routine Maintenance

    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.
  • Page 363 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.

  • Page 364: 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...

  • Page 365: Function Pump

    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...

  • Page 366: Sealing The Drive Shaft

    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...

  • Page 367: Disassembly And Assembly Of The Complete Unit

    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...
  • Page 368 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...
  • Page 369 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...

  • Page 370: Assembly

    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...

  • Page 371: Adjustments

    For all other parts, use Loctite #242. Table 5-6. Tightening Torques M8 M10 M12 M14 M16 M18 M20 M24 1220 10.9 1670 12.9 14.5 2000 3121142 – JLG Lift – 5-47...
  • Page 372 SECTION 5 - HYDRAULICS Figure 5-30. Function Pump, Pressure and Flow Control - Sheet 1 Figure 5-31. Function Pump, Pressure and Flow Control - Sheet 2 5-48 – JLG Lift – 3121142...

  • Page 373: Pump Control Disassembly For Cleaning

    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...
  • Page 374 24. Re-assemble in reverse order. 18. The spools are identical. 25. Bench set the pressure adjustments as described in ”C. 19. Wash the housing and all parts in a clean JLG approved 4” of the Operating Instructions. solvent such as non-chlorinated brake cleaner, Stoddard solvent, etc.

  • Page 375: Drive & Function Pump Start Up Procedures

    1. Insure all electrical checks have been performed & the 3. The third or rear pump is the function pump. It is cou- machine is set up correctly with the JLG Analyzer. pled to the back of the middle pump and provides oil flow to operate the boom, axle, steer and platform func- 2.
  • Page 376 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...

  • Page 377: Jlg Control System

    AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- The JLG Control System controller has a built in LED to indicate TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A any faults.

  • Page 378: Canbus Communications

    SECTION 6 - JLG CONTROL SYSTEM 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 Platform Level: The GROUND MODULE stores the default val- serial link between the Platform Module, Ground Module, ues and handles interlocks.
  • Page 379 SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. Control System Block Diagram 3121142 – JLG Lift –...

  • Page 380: Calibration Instructions

    SECTION 6 - JLG CONTROL SYSTEM 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...
  • Page 381 SECTION 6 - JLG CONTROL SYSTEM 3121142 – JLG Lift –...
  • Page 382 SECTION 6 - JLG CONTROL SYSTEM – JLG Lift – 3121142...
  • Page 383 SECTION 6 - JLG CONTROL SYSTEM 3121142 – JLG Lift –...
  • Page 384 SECTION 6 - JLG CONTROL SYSTEM – JLG Lift – 3121142...
  • Page 385 SECTION 6 - JLG CONTROL SYSTEM 3121142 – JLG Lift –...
  • Page 386 SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3121142...
  • Page 387 SECTION 6 - JLG CONTROL SYSTEM 3121142 – JLG Lift – 6-11...
  • Page 388 SECTION 6 - JLG CONTROL SYSTEM 6-12 – JLG Lift – 3121142...
  • Page 389 SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-11. Analyzer Connecting Points 3121142 – JLG Lift – 6-13...

  • Page 390: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM 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...
  • Page 391 SECTION 6 - JLG CONTROL SYSTEM 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.

  • Page 392: Adjusting Parameters Using The Hand Held Analyzer

    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.

  • Page 393: Machine Configuration Programming Information - Version P7.X To Present

    SECTION 6 - JLG CONTROL SYSTEM 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-...
  • Page 394 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P7.X to Present Default Configuration Digit Number Description Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. AIR INTAKE: Glow plugs installed in the air intake on the manifold.
  • Page 395 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P7.X to Present Default Configuration Digit Number Description Number GEN SET/WELDER: NO: No generator installed. BELT DRIVE: Belt driven setup. HYDRAULIC DRIVE: Hydraulic driven setup. GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON.
  • Page 396 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Machine Configuration Programming Information - Version P7.X to Present Default Configuration Digit Number Description Number FUNCTION CUTOUT: NO: No drive cutout. BOOM CUTOUT: Boom function cutout while driving above elevation. DRIVE CUTOUT: Drive cutout above elevation.
  • Page 397 SECTION 6 - JLG CONTROL SYSTEM 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 ANSI USA ANSI EXPORT AUSTRALIA...
  • Page 398 SECTION 6 - JLG CONTROL SYSTEM 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 ANSI USA ANSI EXPORT AUSTRALIA...

  • Page 399: Personality Ranges/Defaults

    SECTION 6 - JLG CONTROL SYSTEM NOTE: Personality settings can be adjusted within the adjustment 6.9 MACHINE PERSONALITY SETTINGS/FUNCTION range in order to achieve optimum machine performance. SPEEDS Table 6-3. Personality Ranges/Defaults TIME RANGE (SEC) (SEE SECTION 6.10 FOR PARAMETER...
  • Page 400 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults TIME RANGE (SEC) (SEE SECTION 6.10 FOR PARAMETER SUBMENU DEFAULT VALUES MACHINE ORIENTATION (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 WHEN SETTING SPEEDS) ANALYZER 1ST LINE) LINE) 1200 1350...
  • Page 401 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults TIME RANGE (SEC) (SEE SECTION 6.10 FOR PARAMETER SUBMENU DEFAULT VALUES MACHINE ORIENTATION (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 WHEN SETTING SPEEDS) ANALYZER 1ST LINE) LINE) 1200 1350...
  • Page 402 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Personality Ranges/Defaults TIME RANGE (SEC) (SEE SECTION 6.10 FOR PARAMETER SUBMENU DEFAULT VALUES MACHINE ORIENTATION (DISPLAYED ON DESCRIPTION RANGE (DISPLAYED ON ANALYZER 2 WHEN SETTING SPEEDS) ANALYZER 1ST LINE) LINE) 1200 1350...

  • Page 403: Machine Personality Settings/Function Speeds

    SECTION 6 - JLG CONTROL SYSTEM 6.10 MACHINE ORIENTATION WHEN SETTING Test Notes FUNCTION SPEEDS 1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum Lift Up: From platform control, lowest elevation up to maxi- machine performance.

  • Page 404: System Test

    SECTION 6 - JLG CONTROL SYSTEM 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 a. Drive speed switch is in the Middle position. (Turtle check the system components and functions.
  • Page 405 SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 406 SECTION 6 - JLG CONTROL SYSTEM 6-30 – JLG Lift – 3121142...

  • Page 407: Test From The Ground Station

    SECTION 6 - JLG CONTROL SYSTEM 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. 4. The analyzer screen should read: 2. Plug the analyzer into the connector inside the Ground control box.
  • Page 408 SECTION 6 - JLG CONTROL SYSTEM 6-32 – JLG Lift – 3121142...

  • Page 409: System Test Messages

    SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 410 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Message Displayed on 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.
  • Page 411 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.
  • Page 412 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) DRIVE: DRIVE FOR/REV XXX% Displays drive joystick direction & demand...
  • Page 413 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) BOOM: U LIFT UP/DOWN XXX% Displays main lift joystick direction & demand...
  • Page 414 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) ENGINE: START ACTIVE/NOT ACTIVE Displays status of the engine start circuit...
  • Page 415 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) SYSTEM: GM BATTERY XX.XV Ground module battery voltage PM BATTERY XX.XV...

  • Page 416: Machine Diagnostics Parameters

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is configured)
  • Page 417 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING...
  • Page 418 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) MOMENT: Displayed if MODEL NUMBER = 7 or 8...
  • Page 419 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) ENVELOPE: Displayed if MODEL NUMBER = 7 or 8 LENGTH XXXX.X...
  • Page 420 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) CALIBRATION DATA BASKET UP Displays the basket up calibration point...
  • Page 421 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Diagnostics Parameters Diagnostics Submenu Parameter (Displayed on Parameter Value (Displayed on Analyzer Description Analyzer 2 Line) (Displayed on Analyzer 2 Line) Line) DATALOG: XXXXhXXm Displays total controller on (EMS) time ENGINE...

  • Page 422: Calibrating Steer

    SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 423 SECTION 6 - JLG CONTROL SYSTEM 3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Steer. The screen will read: engine. 4. The analyzer screen should read: 9. Hit Enter. The screen will read: 5.
  • Page 424 SECTION 6 - JLG CONTROL SYSTEM 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.

  • Page 425: Calibrating Drive

    SECTION 6 - JLG CONTROL SYSTEM 6.13 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the engine. 1. Position the Platform/Ground select switch to the Plat- form position. 4. The analyzer screen should read: 2. Plug the analyzer into the connector at the base of the platform control box.
  • Page 426 SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 427 SECTION 6 - JLG CONTROL SYSTEM 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.

  • Page 428: Electronic Platform Leveling

    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.

  • Page 429: Can Errors

    SECTION 6 - JLG CONTROL SYSTEM TILT SENSOR ERRORS CAN Errors The Ground Module has two direct outputs dedicated to over- If the secondary tilt sensor is faulty, the control system will riding the Platform Module’s control of the leveling valves. The continue to utilize information from the primary sensor.

  • Page 430: Platform Leveling Calibration Procedure

    5. Go to the "Personalities" menu and adjust the following menu. personalities. Refer to the Personality Ranges/Defaults table in Section 6 - JLG Control System for proper setting 7. Hit ENTER. values. 8. Using the UP/DOWN arrows, adjust the following per- sonalities to 100%.

  • Page 431: Calibrating Platform Level

    SECTION 6 - JLG CONTROL SYSTEM 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.

  • Page 432: Step 2: Calibrating The Platform Level Sensors

    SECTION 6 - JLG CONTROL SYSTEM 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.

  • Page 433: Step 3: Bleeding The Platform Valves

    SECTION 6 - JLG CONTROL SYSTEM 10. Hit ENTER. The screen should read: STEP 3: BLEEDING THE PLATFORM VALVES 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box.

  • Page 434: Step 4: Calibrating The Platform Level Up And Down Valve Crackpoints

    SECTION 6 - JLG CONTROL SYSTEM 4. The analyzer screen should read: STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box.

  • Page 435: Calibrating Lift Crack Point

    SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 436 SECTION 6 - JLG CONTROL SYSTEM 2. Plug the analyzer into the connector at the base of the 4. The analyzer screen should read: platform control box. 3. Pull out the Emergency Stop switch and Start the engine. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.
  • Page 437 SECTION 6 - JLG CONTROL SYSTEM 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.

  • Page 438: Calibrating Telescope Crack Point

    SECTION 6 - JLG CONTROL SYSTEM 13. Hit enter. The number displayed will be the value that 6.17 CALIBRATING TELESCOPE CRACK POINT the crack point is set to. The screen will show: 1. Position the Platform/Ground select switch to the Plat- form position.
  • Page 439 SECTION 6 - JLG CONTROL SYSTEM 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: 4. The analyzer screen should read: 9.
  • Page 440 SECTION 6 - JLG CONTROL SYSTEM 10. Hit Enter. The screen will read: 13. Hit enter. The number displayed will be the value that the crack point is set to. The screen will show: 11. Hit enter again. The screen will read: 14.

  • Page 441: Calibrating Tilt Sensor

    SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 442 SECTION 6 - JLG CONTROL SYSTEM 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: 4. Pull out the Emergency Stop switch and start the engine.

  • Page 443: Calibrating The Boom Sensors

    SECTION 6 - JLG CONTROL SYSTEM 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).
  • Page 444 SECTION 6 - JLG CONTROL SYSTEM 5. The analyzer screen should read: 9. Use the arrow keys to reach BOOM SENSORS. The screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 10. Hit Enter. The screen will read: 7.
  • Page 445 SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 446 SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 447 SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 448 SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 449 SECTION 6 - JLG CONTROL SYSTEM 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: Figure 6-16. Boom Sensor Calibration Position 3 When the machine is in the proper position, hit Enter.
  • Page 450 SECTION 6 - JLG CONTROL SYSTEM 26. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The screen will read: 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.
  • Page 451 SECTION 6 - JLG CONTROL SYSTEM 27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The screen will read: Telescope out to stop (boom must be fully extended) for Calibration Position 5.
  • Page 452 SECTION 6 - JLG CONTROL SYSTEM 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. Figure 6-20. Boom Sensor Calibration Position 7 When the machine is in the proper position, hit Enter.
  • Page 453 SECTION 6 - JLG CONTROL SYSTEM 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. Figure 6-21. Boom Sensor Calibration Position 8 When the machine is in the proper position, hit Enter.
  • Page 454 SECTION 6 - JLG CONTROL SYSTEM 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"...
  • Page 455 SECTION 6 - JLG CONTROL SYSTEM 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).

  • Page 456: Boom Control System Check Procedure

    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 –...
  • Page 457 SECTION 6 - JLG CONTROL SYSTEM Figure 6-24. Fault Code Light Location 3121142 – JLG Lift – 6-81...

  • Page 458: Diagnostic Trouble Code Chart

    SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code EVERYTHING OK The normal help message in Platform Mode. GROUND MODE OK The normal help message in Ground Mode. 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELE-...
  • Page 459 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 2211 FSW INTERLOCK TRIPPED The Footswitch was closed for - Can be reported during power- more then seven seconds. 2212...
  • Page 460 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH A boom function was selected before engine start. START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH The Start Switch was closed dur- ing power-up.
  • Page 461 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code <<< GROUND OUTPUT DRIVER >>> BRAKE - SHORT TO BATTERY There is a Short to Battery to the Brake Valve.
  • Page 462 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 3339 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the Alternator 3340 AUX POWER - SHORT TO GROUND There is a Short to Ground to the Auxiliary Power Pump Relay.
  • Page 463 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 3372 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the - Ground Alarm equipped vehicles Ground Alarm.
  • Page 464 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 3397 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the Platform Rotate Right Valve.
  • Page 465 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 33135 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system Platform Control Valve.
  • Page 466 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 33154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi- Lift Down Auxiliary Valve.
  • Page 467 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 33175 JIB ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the JIB Rotate Left Valve. 33176...
  • Page 468 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 33306 SWING LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the Swing Left Valve. 33307...
  • Page 469 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 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.
  • Page 470 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code MAIN LIFT PVG VALVE - HIGH VOLTAGE The Main Lift PVG Valve supply - 1250AJP only. voltage is high. TOWER LIFT PVG VALVE - HIGH VOLTAGE The Tower Lift PVG Valve supply - 1250AJP only.
  • Page 471 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 4524 TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER The Tower Telescope PVG Valve - 1250AJP only. command is improper. 4525...
  • Page 472 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code <<< COMMUNICATION >>> CANBUS FAILURE - PLATFORM MODULE Platform Module CAN commu- nication lost. CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only.
  • Page 473 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 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.
  • Page 474 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8313 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.
  • Page 475 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 commu- - Envelope Control equipped vehi- nications lost. cles only.
  • Page 476 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8426 TOWER LENGTH SENSOR #2 - OUT OF RANGE HIGH Tower Boom Angle Sensor #2 - Envelope Control equipped vehi- out of range high.
  • Page 477 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8441 TOWER CYLINDER ANGLE MOVEMENT WITHOUT COMMAND The Tower Cylinder Angle Sensor - Envelope Control equipped vehi- is changing without a tower lift cles only.
  • Page 478 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8484 BCS VIOLATION - BOOM LOCKED 8485 BCS - HYDRAULIC RETRIEVAL ACTIVE 8486 BCS - ELECTRICAL RETRIEVAL ACTIVE 8487 BCS - MULTIPLE FAILURES ACTIVE <<<...
  • Page 479 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an Open Circuit to the Axle Retract Valve.
  • Page 480 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8618 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.
  • Page 481 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 8634 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.
  • Page 482 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has reported that its high side driver cutout failed.
  • Page 483 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Diagnostic Trouble Code Chart Flash Fault Message Fault Description Check Sequence Code 9941 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply volt- age is low. 9942 BLAM BACKUP COMMUNICATIONS LINK FAULTY The BLAM backup communica- - BLAM equipped vehicles only.

  • Page 484: Canbus Troubleshooting

    SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 485 SECTION 6 - JLG CONTROL SYSTEM PLATFORM MODULE CANbus Link Figure 6-26. CANbus Connections - Sheet 1 of 5 3121142 – JLG Lift – 6-109...
  • Page 486 SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 487 SECTION 6 - JLG CONTROL SYSTEM Remove Ground Module J7 plug and measure the A & B pin of the T Boom Length & f i t t i n g . T h i s s h o u l d m e a s u r e...
  • Page 488 SECTION 6 - JLG CONTROL SYSTEM "BEFORE" Slip Ring Connection "AFTER" Slip Ring Connection Figure 6-29. CANbus Connections - Sheet 4 of 5 6-112 – JLG Lift – 3121142...
  • Page 489 SECTION 6 - JLG CONTROL SYSTEM Chassis Module J1 (Gray) Plug Chassis Module CANbus Link Figure 6-30. CANbus Connections - Sheet 5 of 5 3121142 – JLG Lift – 6-113...
  • Page 490 SECTION 6 - JLG CONTROL SYSTEM Figure 6-31. CANbus Circuit 6-114 – JLG Lift – 3121142...

  • Page 491: Canbus Communication Failure

    SECTION 6 - JLG CONTROL SYSTEM 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.

  • Page 492: Troubleshooting: Platform Can Communications Lost

    SECTION 6 - JLG CONTROL SYSTEM 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...
  • Page 493 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Troubleshooting: Platform Can Communications Lost STEP ACTION REQUIRED SPEC 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”...
  • Page 494 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Troubleshooting: Platform Can Communications Lost STEP ACTION REQUIRED SPEC 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.
  • Page 495 SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE GROUND MODULE LOST 4. The analyzer screen should read: 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box.
  • Page 496 SECTION 6 - JLG CONTROL SYSTEM 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...
  • Page 497 SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE BOOM LENGTH & ANGLE MOD- 4. The analyzer screen should read: ULE (BLAM) LOST 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box.
  • Page 498 SECTION 6 - JLG CONTROL SYSTEM 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, NOTE: BLAM CAN COMMUNICATIONS LOST (6/6) (Help Fault Code...

  • Page 499: Troubleshooting: Blam Can Communications Lost

    SECTION 6 - JLG CONTROL SYSTEM Table 6-8. Troubleshooting: BLAM Can Communications Lost STEP ACTION REQUIRED SPEC 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”...
  • Page 500 SECTION 6 - JLG CONTROL SYSTEM CANBUS LINK FROM THE CHASSIS MODULE LOST 4. The analyzer screen should read: 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box.
  • Page 501 SECTION 6 - JLG CONTROL SYSTEM 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 &...

  • Page 502: Troubleshooting: Chassis Can Communications Lost

    SECTION 6 - JLG CONTROL SYSTEM 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.
  • Page 503 SECTION 6 - JLG CONTROL SYSTEM Table 6-9. Troubleshooting: Chassis Can Communications Lost STEP ACTION REQUIRED SPEC 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”...

  • Page 504: Load Moment Pin Troubleshooting

    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...

  • Page 505: Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out Of Range

    SECTION 6 - JLG CONTROL SYSTEM Table 6-11. Load Moment Pin Troubleshooting: Moment Pin Horizontal Force Out of Range STEP FAULT CODE/SYMPTOM REPAIR 8/6 MOMENT PIN HORIZONTAL FORCE OUT OF RANGE The Check to see if the platform is over-...

  • Page 506: Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out Of Range

    SECTION 6 - JLG CONTROL SYSTEM Table 6-12. Load Moment Pin Troubleshooting: Moment Pin Vertical Force Out of Range STEP FAULT CODE/SYMPTOM REPAIR 8/6 MOMENT PIN VERTICAL FORCE OUT OF RANGE The vertical Check to see if the platform is over-...

  • Page 507: Load Moment Pin Troubleshooting: Moment Pin Sensor Fault

    SECTION 6 - JLG CONTROL SYSTEM Table 6-13. Load Moment Pin Troubleshooting: Moment Pin Sensor Fault STEP FAULT CODE/SYMPTOM REPAIR 8/6 MOMENT PIN SENSOR FAULT The moment pin has Use the Analyzer, scroll to the DIAGNOS- Replace load moment pin &...
  • Page 508 SECTION 6 - JLG CONTROL SYSTEM 6-132 – JLG Lift – 3121142...

  • Page 509: Basic Electrical Information, Electrical & Hydraulic Schematics

    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 –...

  • Page 510: Resistance Measurement

    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) • Use firm contact with meter leads – JLG Lift – 3121142...

  • Page 511: Current Measurement

    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 –...

  • Page 512: Amp Connector

    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 – JLG Lift – 3121142...
  • Page 513 (See Figure 7-9.). Release the locking latches by squeezing them inward (See Figure 7-8.). Figure 7-9. Connector Assembly Figure 4 Figure 7-8. Connector Assembly Figure 3 3121142 – JLG Lift –...

  • Page 514: Disassembly

    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. – JLG Lift – 3121142...
  • Page 515 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-11. Connector Installation 3121142 – JLG Lift –...

  • Page 516: Deutsch Connectors

    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. – JLG Lift – 3121142...

  • Page 517: Hd30/Hdp20 Series Assembly

    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 –...
  • Page 518 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-18. Chassis Electrical Components - Sheet 1 of 2 7-10 – JLG Lift – 3121142...
  • Page 519 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 0274660 D Figure 7-19. Chassis Electrical Components - Sheet 2 of 2 3121142 – JLG Lift – 7-11...
  • Page 520 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-20. Turntable Electrical Components - Prior to S/N 87579 - Sheet 1 of 2 7-12 – JLG Lift – 3121142...
  • Page 521 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 0272445-E Figure 7-21. Turntable Electrical Components - Prior to S/N 87579 - Sheet 2 of 2 3121142 – JLG Lift – 7-13...
  • Page 522 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-22. Turntable Electrical Components - S/N 87579 to Present - Sheet 1 of 2 7-14 – JLG Lift – 3121142...
  • Page 523 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 0274660-D Figure 7-23. Turntable Electrical Components - S/N 87579 to Present - Sheet 2 of 2 3121142 – JLG Lift – 7-15...
  • Page 524 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-24. Electrical Schematic - Deutz EMR2 - Sheet 1 of 6 7-16 – JLG Lift – 3121142...
  • Page 525 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1870214 H Figure 7-25. Electrical Schematic - Deutz EMR2 - Sheet 2 of 6 3121142 – JLG Lift – 7-17...
  • Page 526 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-26. Electrical Schematic - Deutz EMR2 - Sheet 3 of 6 7-18 – JLG Lift – 3121142...
  • Page 527 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1870214 H Figure 7-27. Electrical Schematic - Deutz EMR2 - Sheet 4 of 6 3121142 – JLG Lift – 7-19...
  • Page 528 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-28. Electrical Schematic - Deutz EMR2 - Sheet 5 of 6 7-20 – JLG Lift – 3121142...
  • Page 529 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1870214 H Figure 7-29. Electrical Schematic - Deutz EMR2 - Sheet 6 of 6 3121142 – JLG Lift – 7-21...
  • Page 530 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS This page left blank intentionally. 7-22 – JLG Lift – 3121142...
  • Page 531 (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...
  • Page 532 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 2 Figure 7-31. Electrical Schematic - Sheet 2 of 13 7-24 – JLG Lift – 3121142...
  • Page 533 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 2 1001119860-G Figure 7-32. Electrical Schematic - Sheet 3 of 13 3121142 – JLG Lift – 7-25...
  • Page 534 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 3 Figure 7-33. Electrical Schematic - Sheet 4 of 13 7-26 – JLG Lift – 3121142...
  • Page 535 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001119860-G SHEET 3 Figure 7-34. Electrical Schematic - Sheet 5 of 13 3121142 – JLG Lift – 7-27...
  • Page 536 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 4 Figure 7-35. Electrical Schematic - Sheet 6 of 13 7-28 – JLG Lift – 3121142...
  • Page 537 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 4 1001119860-G Figure 7-36. Electrical Schematic - Sheet 7 of 13 3121142 – JLG Lift – 7-29...
  • Page 538 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 5 Figure 7-37. Electrical Schematic - Sheet 8 of 13 7-30 – JLG Lift – 3121142...
  • Page 539 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 5 1001119860-G Figure 7-38. Electrical Schematic - Sheet 9 of 13 3121142 – JLG Lift – 7-31...
  • Page 540 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 6 Figure 7-39. Electrical Schematic - Sheet 10 of 13 7-32 – JLG Lift – 3121142...
  • Page 541 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 6 1001119860-G Figure 7-40. Electrical Schematic - Sheet 11 of 13 3121142 – JLG Lift – 7-33...
  • Page 542 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 7 Figure 7-41. Electrical Schematic - Sheet 12 of 13 7-34 – JLG Lift – 3121142...
  • Page 543 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS SHEET 7 1001119860-G Figure 7-42. Electrical Schematic - Sheet 13 of 13 3121142 – JLG Lift – 7-35...
  • Page 544 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-43. Hydraulic Schematic - Boom Functions - Sheet 1 of 2 7-36 – JLG Lift – 3121142...
  • Page 545 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-44. Hydraulic Schematic - Boom Functions - Sheet 2 of 2 3121142 – JLG Lift – 7-37...
  • Page 546 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-45. Hydraulic Schematic - Axle/Steer Control - Sheet 1 of 2 7-38 – JLG Lift – 3121142...
  • Page 547 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-46. Hydraulic Schematic - Axle/Steer Control - Sheet 2 of 2 3121142 – JLG Lift – 7-39...
  • Page 548 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-47. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 1 of 2 7-40 – JLG Lift – 3121142...
  • Page 549 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-48. Hydraulic Schematic - Drive System Bosch/Rexroth Pumps - Sheet 2 of 2 3121142 – JLG Lift – 7-41...
  • Page 550 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS Figure 7-49. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 1 of 2 7-42 – JLG Lift – 3121142...
  • Page 551 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS 1001110749-C Figure 7-50. Hydraulic Schematic - Drive System Sauer/Danfoss Pumps - Sheet 2 of 2 3121142 – JLG Lift – 7-43...
  • Page 552 SECTION 7 - BASIC ELECTRICAL INFORMATION, ELECTRICAL & HYDRAULIC SCHEMATICS NOTES: 7-44 – JLG Lift – 3121142...
  • Page 554 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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