Jlg 1500SJ Service Manual User Manual

Service and Maintenance ManualModel1500SJP/N - 3121262May 22, 2013

vi – JLG Lift – 3121262TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 3121262Figure 3-32. Reggiana Riduttori Hub - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-531. Screw2. Motor Support3. O-ring4. Inner Retention Ring5. Brake Spring Spacer6. Brake Spr

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 31212626. Loosen the M10x25 flathead socket screws andremove the planetary ring without damaging

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-5512. Disassemble the Ø160 inner snap ring and pull thespring holder spacer out. Remove the

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 31212624. Fit the brake sealing rings O-Ring and PARBAK(lubricated with grease) in the respective

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-579. Now check the unit roll torque and proceed in thefollowing order:10. By keeping the spi

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121262the spindle pins. Lock with a ÿ40 outer snap ring.Lubricate the bearings.14. Using a marki

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-5917. Prepare the closing cover fitting the O-ring 5-582suitably greased and lock it with th

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 31212621. Swing Drive2. Inner Race Bearing Bolt3. Swing Bearing4. Outer Race Bearing Bolt5. Turnt

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-613.13 SWING DRIVERoll and Leak TestingTorque-Hub units should always be roll and leak teste

3121262 – JLG Lift – vii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121262Motor Control Valve Disassembly1. Place unit on bench with the motor end up.2. Remove O-ri

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-63Motor and Brake Disassembly1. With unit resting on bench with Motor (10) end up,loosen Hex

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3121262Main Disassembly1. With the unit resting on the Output Shaft (Pinion)(1A), remove the eigh

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-65Hub-Shaft Disassembly1. Using retaining ring pliers, remove Retaining Ring(1I) from groove

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121262Carrier Disassembly1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G)which holds t

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-67Hub-Shaft Sub-Assembly1. Press Bearing Cone (1D) onto Shaft (1A).2. Press Bearing Cup (1C)

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 3121262Carrier Sub-Assembly1. Apply a liberal coat of grease to the bore of ClusterGear (3F). Thi

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-693A. Carrier 3B. Tanged Thrust Washer3C. Ne edle Bearing3D. Thrust Washer3

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 31212623A. Carrier 3B. Tanged Thrust Washer3C. Ne edle Bearing3D. Thrust Washer3

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-71Main Assembly1. With the Hub Shaft Sub-Assembly resting on theShaft (1A) install Internal

viii – JLG Lift – 3121262TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 31212622. Interna l Gear4. Rin g Gear5. O-R ing6. Input Cover8. Hex Bo

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-73Motor and Brake Assembly1. Place O-ring (27) onto end of Brake (26) and locatebrake into p

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121262Motor Control Valve Assembly1. Lay assembly down with motor ports facing up.Remove the two

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-753.14 SWING BRAKEPre-Installation ChecksMECHANICALCheck, That in the handling prior to asse

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 3121262InstallationPosition 1-off gasket (5) over male pilot on brake housing(4).Locate brake sha

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-77To ensure correct brake operation, it is importantthat the backing rings are assembled opp

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 31212623.15 SWING MOTORDisassembly and inspection1. Place the Torqlink™ in a soft jawed vice, wit

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-795. If the end cover (2) is equipped with shuttle valvecomponents, remove the two previou

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 31212626. Thoroughly wash end cover (2) in proper solventand blow dry. Be sure the end cover valv

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-81NOTE: The manifold is constructed of plates bondedtogether to form an integral component n

3121262 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 312126212. Remove drive link (10) from coupling shaft (12) if itwas not removed with rotor set an

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-8317. Remove thrust bearing (15) and thrust washer (14)Inspect for wear, brinelling, corrosi

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3121262replaced. If the housing has passed this inspectionthe disassembly of the Torql i n k ™ is

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-85AssemblyReplace all seals and seal rings with new ones each timeyou reassemble the Torqlin

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 31212622. The Torqlink™ inner housing bearing/bushing (13)can now be pressed into its counterbore

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-874. Place housing (18) assembly into a soft jawed visewith the coupling shaft bore down, cl

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 3121262THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYS-TEM’S HYDRAULIC FLUID. BE SURE IT IS T

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-8911. Assemble wear plate (9) over the drive link (10) andalignment studs onto the housing (

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 312126216. Apply grease to a new seal ring (4) and insert it inthe seal ring groove exposed on t

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-91NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previousl

x – JLG Lift – 3121262LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3121262One Piece Stator ConstructionA disassembled rotor (8A) stator (8B) and vanes (8C) thatcann

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-933.16 PROCEDURE FOR SETTING GEAR BACKLASH1. Set backlash to 0.010 to 0.015" using the

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 31212628. Tighten the jam nut (shown below) with Loctite#271.9. Torque the capscrews shown in ste

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-953.18 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckTHE SWING BEARING IS ONE

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3121262Figure 3-51. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-97Figure 3-52. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3121262Wear Tolerance1. From the underside of the machine, at rear center,with the main boom full

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-99Turntable/Swing Bearing RemovalThe following procedure was accomplished using twooverhead

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3121262Figure 3-54. Swing Bearing Removal - Sheet 1 of 4

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-101Boom & Jib Assembly - 20,650 lbs. (9,370 kg)287” (729 cm)Main Boom PivotCENTEROFGRAVI

3121262 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3121262Boom Assembly - 10,791 lbs. (4,895 kg)Main Boom Pivot227” (576.5 cm)CENTEROFGRAVITYFigure

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-103CLROTATIONNote: Attach Lifting Device to Turntable Cutouts Closest toThis Side of Turntab

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 31212626. Lay the jib control valve aside on the jib. Secure it inplace so it does not fall.7. D

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-1059. Attach an adequate supporting device to the jib tosupport its weight. Remove the bolt

SECTION 3 - CHASSIS & TURNTABLE3-106 – JLG Lift – 312126213. Have a container or absorption material ready tocatch residual hydraulic fluid. Disco

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-10717. Using the Main Lift Crackpoint option under the Cali-brations menu on the JLG Analyze

SECTION 3 - CHASSIS & TURNTABLE3-108 – JLG Lift – 312126224. Disconnect the negative battery terminal from thebattery.25. Place a container under

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-10931. Tag and disconnect the hoses from the top of theswivel. Cap or plug all openings. Use

SECTION 3 - CHASSIS & TURNTABLE3-110 – JLG Lift – 3121262NOTE: The turntable assembly weighs approximately20,650 lbs. (9370 kg).35. Using the lift

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-11140. Install lifting eyes into the swing bearing for removal.NOTE: The swing bearing weigh

xii – JLG Lift – 3121262LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-112 – JLG Lift – 31212623. Locate the high spot on the swing bearing. This willbe marked by blue paint and two X’

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-11312. Lift the turntable into place on the bearing using thepreviously installed guide pins

SECTION 3 - CHASSIS & TURNTABLE3-114 – JLG Lift – 312126217. Position the swing drive mounting bolts and back-lash adjusting shim, JLG p/n 4071041

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-11520. While lifting the boom into position, begin to routethe hoses into position so they c

SECTION 3 - CHASSIS & TURNTABLE3-116 – JLG Lift – 312126225. Connect the hoses to the main valve and pressurefilter as tagged during removal. 26.

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-11731. Attach a lifting device to the front of the jib and alignthe jib level cylinder attac

SECTION 3 - CHASSIS & TURNTABLE3-118 – JLG Lift – 312126236. Position the hoods in place on the turntable andsecure in place with the mounting har

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-1193.19 SWING SPEED PROPORTIONINGSwing Speed Proportioning uses the boom length andangle sen

SECTION 3 - CHASSIS & TURNTABLE3-120 – JLG Lift – 31212623.21 GENERATOREvery 250 hoursEvery 250 hours of operation, check the drive belt forproper

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-121Overload ProtectionSTOP THE ENGINE WHENEVER CHECKING OR INSPECTING THECIRCUIT BREAKER.The

3121262 – JLG Lift – xiii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-122 – JLG Lift – 312126211/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must rideco

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-1233.22 AUXILIARY POWER SYSTEMThe auxiliary power system is intended as a secondarymeans of

SECTION 3 - CHASSIS & TURNTABLE3-124 – JLG Lift – 31212623.23 ENGINENOTE: Refer to the engine manufacturer’s manual fordetailed operating and main

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-125Changing Engine Oil1. Allow the engine to warm up. The engine oil shouldreach approximate

SECTION 3 - CHASSIS & TURNTABLE3-126 – JLG Lift – 31212622. Using a suitable oil filter removal tool, loosen thelube oil filter cartridge and spin

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-127Cleaning the Fuel StrainerWHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARENO OPEN FLA

SECTION 3 - CHASSIS & TURNTABLE3-128 – JLG Lift – 3121262Figure 3-63. EMR 2 Engine Side EquipmentGLOW PLUGPOWER SUPPLYCOOLANT TEMPERATURESENSORCO

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-129Deutz EMR2;Fails to Start/Runs AbnormallyDoes the machinehave fuel and acharged battery?Y

SECTION 3 - CHASSIS & TURNTABLE3-130 – JLG Lift – 3121262Figure 3-65. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-131Figure 3-66. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

xiv – JLG Lift – 3121262LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-132 – JLG Lift – 3121262Figure 3-67. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-133Figure 3-68. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-134 – JLG Lift – 3121262Figure 3-69. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-135Figure 3-70. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3-136 – JLG Lift – 3121262Figure 3-71. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-137Figure 3-72. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3-138 – JLG Lift – 3121262Figure 3-73. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-139Figure 3-74. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS & TURNTABLE3-140 – JLG Lift – 31212623.25 BIO FUEL IN DEUTZ ENGINESGeneralUse of bio fuels is permitted for the compact engine

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-141PLANT OILPURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARENOT CLASSIFIED AS BIO

3121262 – JLG Lift – xv LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-142 – JLG Lift – 31212623.26 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONSThis section defines the diag

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-143 DTC XXXX- Diagnostic Condition Note: Helpful tips used to aid troubleshooting Yes

SECTION 3 - CHASSIS & TURNTABLE3-144 – JLG Lift – 3121262List of Abbreviations in this SectionAL Adaptive Learn LED Light Emitting DiodeBP Baromet

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-145FP Fuel Pressure UEGOUniversal Exhaust Gas Oxygen Sensor(also called wide-range EGO)FPP F

SECTION 3 - CHASSIS & TURNTABLE3-146 – JLG Lift – 3121262Diagnostic Trouble CodesThe numeric diagnostic trouble codes assigned to thefaults in thi

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-147DTC 116- ECT Higher Than Expected Stage 1• Engine Coolant Temperature Sensor• Check Condi

SECTION 3 - CHASSIS & TURNTABLE3-148 – JLG Lift – 3121262DTC 117- ECT/CHT Low Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine R

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-149Does DST display ECTvoltage of 4.9 VDC orgreater?·Key Off·Disconnect ECT sensor from harn

SECTION 3 - CHASSIS & TURNTABLE3-150 – JLG Lift – 3121262DTC 118- ECT/CHT High Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-151

xvi – JLG Lift – 3121262LIST OF TABLES TABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-152 – JLG Lift – 3121262DTC 122- TPS1 Signal Voltage Low• Throttle Position Sensor 1• Check Condition-Key On, Eng

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-153

SECTION 3 - CHASSIS & TURNTABLE3-154 – JLG Lift – 3121262DTC 123- TPS1 Signal Voltage High• Throttle Position Sensor 1• Check Condition-Key On, En

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-155

SECTION 3 - CHASSIS & TURNTABLE3-156 – JLG Lift – 3121262DTC 217- ECT Higher Than Expected 2• Engine Coolant Temperature Sensor• Check Condition-E

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-157DTC 219- RPM Higher Than Max Allowed Governed Speed• Max Govern Speed Override- Crankshaf

SECTION 3 - CHASSIS & TURNTABLE3-158 – JLG Lift – 3121262DTC 336- Crank Signal Input Noise• Crankshaft Position sensor• Check Condition- Key On, E

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-159• Key On, Engine Running• System Mode= “Running”Does DTC 336 reset ?Intermittent faultNoY

SECTION 3 - CHASSIS & TURNTABLE3-160 – JLG Lift – 3121262DTC 337- Loss of Crank Input Signal• Crankshaft Position sensor• Check Condition- Key On,

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-161DTC 521- Oil Pressure Sender/Switch High Pressure• Engine Oil Pressure• Check Condition-

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATATable 1-1. Operating Spec

SECTION 3 - CHASSIS & TURNTABLE3-162 – JLG Lift – 3121262DTC 524- Oil Pressure Low• Engine Oil Pressure• Check Condition- Key on, Engine on• Fault

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-163Normally Closed Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to

SECTION 3 - CHASSIS & TURNTABLE3-164 – JLG Lift – 3121262DTC 562- Battery Voltage (VBat) Low• System voltage to ECM• Check Condition- Key on, Engi

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-165

SECTION 3 - CHASSIS & TURNTABLE3-166 – JLG Lift – 3121262DTC 563- Battery Voltage (VBat) High• System voltage to ECM• Check Condition- Key on, Eng

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-167

SECTION 3 - CHASSIS & TURNTABLE3-168 – JLG Lift – 3121262DTC 601- Microprocessor Failure - FLASH• Engine Control Module- Flash Memory• Check Condi

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-169

SECTION 3 - CHASSIS & TURNTABLE3-170 – JLG Lift – 3121262DTC 604- Microprocessor Failure - RAM• Engine Control Module- Random Access Memory• Check

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-171

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31212621.3 CAPACITIES1.4 TIRES1.5 ENGINE DATADeutz Caterpillar Table 1-3. CapacitiesHydraulic Oil Tank 55 g

SECTION 3 - CHASSIS & TURNTABLE3-172 – JLG Lift – 3121262DTC 606- Microprocessor Failure - COP• Engine Control Module• Check Condition- Key on• Fa

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-173

SECTION 3 - CHASSIS & TURNTABLE3-174 – JLG Lift – 3121262DTC 642- 5 Volt External Low Voltage• Engine Control Module• Check Condition- Key on• Fau

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-175DTC 643- 5 Volt External High Voltage• Engine Control Module• Check Condition- Key on• Fa

SECTION 3 - CHASSIS & TURNTABLE3-176 – JLG Lift – 3121262DTC 1612- Microprocessor Failure - RTI 1• Engine Control Module• Check Condition- Key on•

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-177DTC 1613- Microprocessor Failure - RTI 2• Engine Control Module• Check Condition- Key on•

SECTION 3 - CHASSIS & TURNTABLE3-178 – JLG Lift – 3121262SFC 555- RTI 2 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 555

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-179DTC 1614- Microprocessor Failure - RTI 3• Engine Control Module• Check Condition- Key on•

SECTION 3 - CHASSIS & TURNTABLE3-180 – JLG Lift – 3121262SFC 556- RTI 3 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 556

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-181DTC 1615- Microprocessor Failure - A/D• Engine Control Module• Check Condition- Key on• F

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-31.6 HYDRAULIC OILNOTE: Hydraulic oils require anti-wear qualities at least APIService Classification

SECTION 3 - CHASSIS & TURNTABLE3-182 – JLG Lift – 3121262SFC 513- A/D LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 513 re

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-183DTC 1616- Microprocessor Failure - interrupt• Engine Control Module• Check Condition- Key

SECTION 3 - CHASSIS & TURNTABLE3-184 – JLG Lift – 3121262SFC 512- Invalid InterruptKey On - Engine RunningSystem Data ModeClear System FaultDoes S

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-185DTC 1625- CAN J1939 Shutdown Request• Controller Area Network• Check Condition- Key On, E

SECTION 3 - CHASSIS & TURNTABLE3-186 – JLG Lift – 3121262DTC 1626- CAN J1939 Transmit (Tx) Fault• Controller Area Network• Check Condition- Key On

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-187DTC 1627- CAN J1939 Receive (Rx) Fault• Controller Area Network• Check Condition- Key On,

SECTION 3 - CHASSIS & TURNTABLE3-188 – JLG Lift – 3121262DTC 1628- CAN Address Conflict Failure•CAN device(s)• Check Condition- Key On, Engine on•

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-189

SECTION 3 - CHASSIS & TURNTABLE3-190 – JLG Lift – 3121262DTC 1629- J1939 TSC1 Message Reciept Loss• Controller Area Network• Check Condition- Key

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-191DTC 1652- TPS1 Loss of Communications• Throttle Actuator (with serial/digital position fe

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31212621.7 MAJOR COMPONENT WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMSOF DIFFERENT WEIGHT

SECTION 3 - CHASSIS & TURNTABLE3-192 – JLG Lift – 3121262DTC 2111- Unable to Reach Lower TPS• Throttle Position Sensor• Check Condition-Cranking o

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-193

SECTION 3 - CHASSIS & TURNTABLE3-194 – JLG Lift – 3121262DTC 2112- Unable to Reach Higher TPS• Throttle Position Sensor• Check Condition-Cranking

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-195DTC 9999- Throttle Actuator Failsafe Spring Failure• Throttle Actuator• Check Condition-

SECTION 3 - CHASSIS & TURNTABLE3-196 – JLG Lift – 3121262DTC to SPN/FMI TableFAULTINDEXDESCRIPTIONDTC SETSPN FMI2 DTC 118: ECT voltage high 110 33

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-1973.27 COUNTERWEIGHTIf the counterweight has been removed, ensure the retain-ing bolts are

SECTION 3 - CHASSIS & TURNTABLE3-198 – JLG Lift – 3121262APPLY THREADLOCKER P/N 0100019 TO BOLT AND THREADS IN COUNTERWEIGHT.TORQUE TO 400 FT LBS

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM SYSTEMSNOTE: For more detailed information concerning s

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31212621615141312108119765134 2Figure 4-1. Boom Component Location - Sheet 1 of 2

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-31. Boom Cable Proximity Sensor2. Boom Length Sensor3. Boom Angle Sensor #14. Boom Angle Sensor

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-544415451378110,119,12142,361616Figure 1-1. Maintenance and Lubrication Diagram

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121262Drive/Steer – Boom Function Interlock System (CE ONLY)The Drive/Steer – Boom Function Interlock

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-5Boom Control System (BCS) Functional Check (Push to Test) System The machine is equipped with a

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121262Press ENTER , the screen should read:To enable the level override mode 58237 must be enteredas

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-7Attempts to lift the main boom while this override is on willresult in a JIB LEVELING SYSTEM FA

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 3121262Jib Lock Pin override is accessible in Access Level 1.Using the Left and Right arrow keys u

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-9Use the Left or Right arrow key until you see:Press ENTER , the screen should read:Using t

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121262Swing/Axle Extend Retract RestrictionsIn addition to the Direction Of Steer proximity switch i

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-11To enable the override mode 58237 must be entered asthe code. When the code is entered, the sc

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 31212624.3 BOOM REMOVAL AND INSTALLATIONRemoval1. Remove the Jib Assembly. Refer to Section 4.6 - Jib

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-136. Remove the cover from the rear of the boom anddisconnect the wiring harnesses and hoses run

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31212621.8 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1-1., Maintenance

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 312126211. Remove the bolt and keeper pin securing the boomlift cylinder rod pivot pin and drive out

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-152. While lifting the boom into position, begin to routethe hoses into position so they can be

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 31212627. Connect the hoses to the main valve and pressurefilter as tagged during removal. 8. Reconne

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-174.4 BOOM DISASSEMBLY/ASSEMBLY & CABLE REPLACEMENTIt is not necessary to completely remove

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 31212628. Attach a lifting device to the powertrack for supportand unbolt the upper powertrack tube f

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-191. Boom Base2. Boom Inner Mid3. Boom Outer Mid4. Boom FlyFigure 4-3. Boom Assembly - Sheet 1

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 31212621. Outer Mid Extend Block2. Outer Mid Retract Sheave3. Rope Retainer Block4. Retract Rope Reta

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-211. Upper Rear Wear Pad2. Shim3. Telescope Cylinder4. Trunnion Keeper Block5. Lower Rear Wear P

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 31212621. Sheave Deflector2. Sheave Deflector3. Rope Retainer Block4. Fly Extension Sheave5. Rope Ret

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-231. Front Upper Wear Pad2. Shim3. Front Side Wear Pad4. Shim5. Lock PlateFigure 4-5. Boom Asse

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-74. A. Wheel Drive Hub - BonfiglioliLube Point(s) - Level/Fill PlugCapacity - 2.1 quarts (2 liters) ±

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 31212621. Outer Mid Extend Rope2. Fly Extend Rope3. Fly Retract Rope4. Outer Mid Retract Rope5. Proxi

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-25Figure 4-7. Boom Assembly - Sheet 7 of 7

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 312126211. Remove the bolts securing the side wear pads to thefront of the base boom and remove the p

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-2715. Tag and disconnect the wiring harness running tothe boom length sensor. Remove all the bol

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 312126221. Remove the adjustment nuts for the for the outer midextend cables along with the Broken Ca

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-2925. Remove the outer mid retract cables from the attach-ment fixtures at the front of the boom

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 312126228. Remove the trunnion blocks that secure the tele-scope cylinder barrel to the inner mid boo

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-3132. Remove the rear bottom wear pad.33. Remove the lock plates from the fly boom retractcable

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 312126236. Attach a strap to pull the outer mid and fly boomsections out of the inner mid boom sectio

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-3340. Remove the cable retract retainer plates, cableretainer blocks, sheaves, and bushings from

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31212627. Hydraulic OilLube Point(s) - Fill CapCapacity - 55 gallons (208 liters) TankLube - HOInterval - C

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 312126244. Pull the fly boom extend cables out enough to haveclearance to remove the sheave, and remo

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-3546. Remove the tape from the fly boom section andremove the fly boom retract cables.47. Remove

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 3121262TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURINGTHE ASSEMBLY PROCEDURE.1. Install the fly ex

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-37Ft-Lbs. NmA 165 224B 165 224C 35 49D 50 70Figure 4-8. Boom Assembly Torque Values

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 3121262SECTION A-A#0100011#0100011#0100019#0100011#0100011#0100019#0100019Figure 4-9. Locations for

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-39#0100011#0100011#0100011#0100011#0100011Figure 4-10. Locations for Threadlocker Application -

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 3121262#0100011#0100011#0100011#0100011#0100011#0100011#0100011#0100011#0100011#0100011#0100011Figure

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-41#0100011#0100011#0100011Figure 4-12. Locations for Threadlocker Application - Sheet 4 of 4

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 31212624. Install the fly boom section partially into the outermid boom section.DO NOT ALLOW THE FLY

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-4310. Apply JLG Threadlocker P/N 0100011 to the boltsand install the rear upper and side wear pa

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-910. Fuel Filter - DeutzLube Point(s) - Replaceable ElementInterval - Every year or 600 hours of oper

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 312126216. Feed the fly boom retract cable into the inner midboom section from the front. 17. Using a

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-4521. Push the outer mid assembly into the inner midwhile pulling the boom cables out the back f

SECTION 4 - BOOM & PLATFORM4-46 – JLG Lift – 312126225. Apply JLG Threadlocker P/N 0100011 to the boltsand install the side and top wear pads into

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-4729. Install a new sheave on the telescope cylinder. 30. Install the outer mid extend cables in

SECTION 4 - BOOM & PLATFORM4-48 – JLG Lift – 312126234. Apply JLG Threadlocker P/N 0100019 to the boltsand attach the cable guide to the inner mid

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-4940. Push the inner mid boom assembly the rest of theway into the boom base section, adjusting

SECTION 4 - BOOM & PLATFORM4-50 – JLG Lift – 31212624.5 LOAD SENSING PIN REMOVAL AND INSTALLATION1. Place the machine on a firm, level surface.NOT

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-51Figure 4-13. Load Pin Removal Tool, JLG P/N 4846765

SECTION 4 - BOOM & PLATFORM4-52 – JLG Lift – 31212624.6 JIBRemoval1. Lower the platform to the ground or onto blocking tosupport the weight of the

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-537. Disconnect the jib protractor sensor linkage from theboom.8. Remove the bolt and keeper pin

INTRODUCTION3121262 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 312126214. Air FilterLube Point(s) - Replaceable ElementInterval - Every 6 months or 300 hours of operatio

SECTION 4 - BOOM & PLATFORM4-54 – JLG Lift – 3121262Installation1. Attach an adequate lifting device to the jib and posi-tion it in front of the b

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-554. Attach a lifting device to the front of the jib and alignthe jib level cylinder attachment

SECTION 4 - BOOM & PLATFORM4-56 – JLG Lift – 31212621001118868-AJIBROTARYACTUATORJIB LIFT CYLINDERPLATFORM LEVEL CYLINDERJIB BASE BOOMJIB FLY BOOM

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-571001118868-AINSERT SHIMS BETWEEN JIB PIVOT ANDJIB ROTATE ACTUATORADJUST QTY OF SHIMS A/RTO MIN

SECTION 4 - BOOM & PLATFORM4-58 – JLG Lift – 31212621001118868-A***ALIGN HOLES IN LOCK CYLWITH PROTRUSIONSIN CAP AS SHOWNINTERNALS OF ACTUATORNOT

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-594.7 BOOM LUBRICATION APPLICATIONThis procedure applies to booms after assembly or duringannual

SECTION 4 - BOOM & PLATFORM4-60 – JLG Lift – 31212624. Lift the platform to allow enough room for removal ofthe cylinder. NOTE: The platform level

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-615. Secure the pivot pin in place with the keeper pin.Loosely install the bolt, but do not tigh

SECTION 4 - BOOM & PLATFORM4-62 – JLG Lift – 31212624. Remove the retaining rings securing the retainingpins on the powertrack side of the jib and

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-63Installation1. If installing a new cylinder, test fit the retaining pinsthat secure the jib te

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-11Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 4 - BOOM & PLATFORM4-64 – JLG Lift – 31212624.10 JIB LIFT CYLINDERRemoval1. Ensure the weight of the jib is fully supported. 2. Place a st

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-655. Remove the bolt and keeper pin that secure the jiblift cylinder rod pivot pin. Remove the j

SECTION 4 - BOOM & PLATFORM4-66 – JLG Lift – 31212624. Raise the cylinder into position to allow the jib liftbarrel pivot pin to be installed and

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-67SHIMS(NOMINAL QTY SHOWN)TORQUE 20 FT.LBS. (27 Nm)PIVOT PAD MOUNTJIB ROTATORBOTTOM PLATEWEAR PA

SECTION 4 - BOOM & PLATFORM4-68 – JLG Lift – 31212624.12 BOOM CLEANLINESS GUIDELINESThe following are guidelines for internal boom cleanlinessfor

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-69HARNESS BUNDLETELESCOPE RETRACT HOSE(OUTSIDE OF BEND RADIUS)TELESCOPE EXTEND HOSETELESCOPE TAN

SECTION 4 - BOOM & PLATFORM4-70 – JLG Lift – 3121262Figure 4-19. Powertrack Hosing - Sheet 2 of 3

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-71Figure 4-20. Powertrack Hosing - Sheet 3 of 3

SECTION 4 - BOOM & PLATFORM4-72 – JLG Lift – 31212624.14 POWERTRACK MAINTENANCEOne Piece Bracket Maintenance1. Place the powertrack on a workbench

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-735. Slide the poly roller off of the round bar.6. Hold the round bar to remove the other screw.

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121262Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 4 - BOOM & PLATFORM4-74 – JLG Lift – 312126210. Push down with slight pressure on the link and slidethe bracket side up and over the extru

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-754. Hold the flat bar and remove the screws.5. Remove the snap rings and pins.6. Remove the scr

SECTION 4 - BOOM & PLATFORM4-76 – JLG Lift – 3121262Make sure that all snap rings are closed and seated. An open snap ring is shown below.A snap r

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-774.15 WIRE ROPEInspectionNOTE: The pictures in this paragraph are just samples toshow the repla

SECTION 4 - BOOM & PLATFORM4-78 – JLG Lift – 31212624.16 WIRE ROPE TENSIONING ADJUSTMENTANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED,BOOM C

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-793. Remove the lock plates and nylon collar locknutsfrom the wire rope adjustment nuts.4. If th

SECTION 4 - BOOM & PLATFORM4-80 – JLG Lift – 31212624. If the Fly Boom needs extended: a. Loosen the Fly Boom Retract Adjustment Nutsby an amount

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-816. Using tool JLG p/n 4120043, torque the Outer MidBoom Retract Adjustment Nuts to 80 ft-lb (1

SECTION 4 - BOOM & PLATFORM4-82 – JLG Lift – 312126211. Repeat the following boom movement steps threetimes. This is to ensure that the wire rope

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-83BASE BOOMINNER MID BOOMNOTE: Boom shown in fully retracted position.OUTER MID BOOMFLY BOOM9.5

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-13Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 4 - BOOM & PLATFORM4-84 – JLG Lift – 3121262Figure 4-23. Outer Mid Boom Extend/Retract Cables

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-85Figure 4-24. Fly Boom Extend/Retract Cables

SECTION 4 - BOOM & PLATFORM4-86 – JLG Lift – 31212621. 2" Socket2. 3/4” Socket3. Retaining BoltFigure 4-25. Wire Rope Adjustment

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-874.17 BROKEN BOOM CABLE PROXIMITY SWITCHThis system uses a proximity switch to detect excessive

SECTION 4 - BOOM & PLATFORM4-88 – JLG Lift – 3121262PLATFORM VALVESThe platform specific valves are located in a manifold atthe platform. There ar

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-894.19 ROTARY ACTUATOREach actuator is individually serial numbered. The serialnumber is a five

SECTION 4 - BOOM & PLATFORM4-90 – JLG Lift – 3121262Tools RequiredSeveral basic tools are required for the disassembly andreassembly of the actuat

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-91DisassemblyInspect the actuator for corrosion prior to disassembly.Severe corrosion can make i

SECTION 4 - BOOM & PLATFORM4-92 – JLG Lift – 3121262PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-93PARTS1. Ho usi ng 2. Sh af t 3. Pi sto n Sleeve4. En d CapHARDWARE103.1.

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121262Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 4 - BOOM & PLATFORM4-94 – JLG Lift – 31212627. Remove the end cap (4) and carefully set aside forlater inspection.8. Remove the stop tube

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-9511. Remove the shaft (2) by rotating counterclockwise.As the shaft is rotated, it will disenga

SECTION 4 - BOOM & PLATFORM4-96 – JLG Lift – 312126217. Remove the main pressure seal (205).18. Remove the thrust washer (304) from the end cap(4)

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-97Assembly1. Gather all the components and tools into one loca-tion prior to re-assembly. Use th

SECTION 4 - BOOM & PLATFORM4-98 – JLG Lift – 31212627. Install the inner T-seal (200) into the appropriategroove in the piston (3). Use a circular

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-9910. Looking into the bore from the opposite end of thehousing (1) be sure the timing marks ali

SECTION 4 - BOOM & PLATFORM4-100 – JLG Lift – 312126214. Install the stop tube (400) onto the shaft end if nec-essary. Stop tubes are an available

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-101Greasing Thrust Washers1. After the actuator is assembled but before it is putinto service, t

SECTION 4 - BOOM & PLATFORM4-102 – JLG Lift – 3121262Figure 4-30. Rotator Counterbalance Valve

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-103Installation and BleedingAfter installation of the actuator on the equipment, it isimportant

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-15Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 4 - BOOM & PLATFORM4-104 – JLG Lift – 3121262TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM3121262 – JLG Lift – 4-1054.20 JIB ROTATOR TORQUING PROCEDURESee Figure 4-31., JIb Rotator Torque1. Torque the center b

SECTION 4 - BOOM & PLATFORM4-106 – JLG Lift – 3121262NOTES:

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121262Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-35.2 HYDRAULIC CYLINDERSAxle Extension CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31212621,2,212,3,16445678911121314151718181920222323221. Thread Locker2. Locking Primer3. Loctite RC 6094. Bolt

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-59. Loosen and remove the capscrew which attach thetapered bushing to the piston.10. Insert the capscrews

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 312126212. Inspect cylinder head outside diameter for scoringor other damage and ovality and tapering. Replacea

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-72. Use a soft mallet to tap a new wiper seal into the cyl-inder head gland groove. Install a new wear ri

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121262Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 312126212. Remove the cylinder rod from the holding fixture.13. Place a new t-seal and wear rings in the outer

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-9Axle Lockout CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK SURFACE I

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31212621234567,8,138,9,21101011111215161717181920222324242511111. Barrel2. Rod3. Piston4. Bushing5. Head6. Cou

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-119. Using suitable protection, clamp the cylinder rod ina vise or holding fixture as close to the piston

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 312126212. Inspect cylinder head outside diameter for scoringor other damage and ovality and tapering. Replace

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-132. Use a soft mallet to tap a new wiper seal into the cyl-inder head gland groove. Install a new wear r

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 312126212. Remove the cylinder rod from the holding fixture.WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE SEA

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-15Jib Level CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK SURFACE IN

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31212621410610512101109104102103102108107131071081,6***2*34578**9**10111. Threadlocker2. Bolt3. Tapered Bushin

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-178. Using suitable protection, clamp the cylinder rod ina vise or holding fixture as close to the piston

SECTION 1 - SPECIFICATIONS3121262 – JLG Lift – 1-17Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 312126212. Inspect cylinder head outside diameter for scoringor other damage and ovality and tapering. Replace

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-192. Use a soft mallet to tap a new wiper seal into the cyl-inder head gland groove. Install a new wear r

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 312126213. Remove the cylinder rod from the holding fixture.WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE SEAL

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-21Platform Level CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK SURFAC

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 312126210104106104101108710810132**15109110103614***105107102418****46,9*18****4132002012022036,16171,81. Thre

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-2310. Using suitable protection, clamp the cylinder rod ina vise or holding fixture as close to the pisto

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 312126212. Inspect cylinder head outside diameter for scoringor other damage and ovality and tapering. Replace

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-252. Use a soft mallet to tap a new wiper seal into the cyl-inder head gland groove. Install a new wear r

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 312126213. If removed, install the spacer sleeve, sensor magnet,and retaining ring.14. Remove the cylinder rod

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-27Boom Lift CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK SURFACE IN

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3121262NOTES:

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 312126220830301,2,25****232,171872119152614151413121622121354**10927***29*3028***301. Threadlocker2. Locking P

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-298. Using suitable protection, clamp the cylinder rod ina vise or holding fixture as close to the piston

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 312126212. Inspect cylinder head outside diameter for scoringor other damage and ovality and tapering. Replace

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-312. Use a soft mallet to tap a new wiper seal into the cyl-inder head gland groove. Install a new wear r

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 312126213. Remove the cylinder rod from the holding fixture.WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE SEAL

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-33Jib Lift CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK SURFACE IN A

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 31212621. Threadlocker2. Bolt3. Screw4. Tapered Bushing5. Cable Clamp6. Cylinder Head7. Plug8. Plug9. Plug10.

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-359. Using suitable protection, clamp the cylinder rod ina vise or holding fixture as close to the piston

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 312126212. Inspect cylinder head outside diameter for scoringor other damage and ovality and tapering. Replace

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-372. Use a soft mallet to tap a new wiper seal into the cyl-inder head gland groove. Install a new wear r

SECTION 2 - GENERAL3121262 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 312126213. Remove the cylinder rod from the holding fixture.WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE SEAL

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-39Jib Lock CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK SURFACE IN A

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 31212621,2341011021031041051061071081. Head2. Lubricant3. Barrel4. Rod101.Wear Ring102.Backup Ring103.Wear Rin

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-41ASSEMBLYNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 3121262Steer CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK SURFACE IN A DI

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-432143121397118101465*1684314-D1. Cylinder Cap2. Rod3. Head4. Barrel5. Nut6. Piston7. Backup Ring8. W

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 31212628. Using suitable protection, clamp the cylinder rod ina vise or holding fixture as close to the piston

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-45WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLEDPROPERLY. IMPROPER SEAL INSTALLATION COULD RESULT

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 3121262Jib Telescope CylinderUSE CARE IN REMOVAL OF ANY, AND ALL, COMPONENTS ASCOUNTERBALANCE VALVES MAY RETAI

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-471. Barrel2. Rod3. Gland4. Piston5. Stop Tube6. Wear Pad7. Pad Support8. O-ring9. O-ring10. Rod Seal11.

INTRODUCTIONA-2 – JLG Lift – 3121262REVISON LOGOriginal Issue - September 12, 2011Revised - November 9, 2011Revised - March 26, 2012Revised - May 16,

SECTION 2 - GENERAL2-2 – JLG Lift – 31212622.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 5 - HYDRAULICS5-48 – JLG Lift – 3121262ASSEMBLYNOTE: Refer to the Seal Detail provided at the end of thisService Manual for the particular mod

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-49Figure 5-101. Jib Telescope Cylinder Head Gland DetailFigure 5-102. Jib Telescope Piston Detail

SECTION 5 - HYDRAULICS5-50 – JLG Lift – 3121262Main Boom Telescope CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON ACLEAN WORK S

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-511. Loctite #2422. Locking Primer3. Not Used4. Capscrew5. Bolt6. Bracket7. Tapered Bushing8. Barrel9. Ro

SECTION 5 - HYDRAULICS5-52 – JLG Lift – 31212628. Using suitable protection, clamp the cylinder rod ina vise or holding fixture as close to the piston

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-5312. Inspect cylinder head outside diameter for scoringor other damage and ovality and tapering. Replace

SECTION 5 - HYDRAULICS5-54 – JLG Lift – 31212622. Use a soft mallet to tap a new wiper seal into the cyl-inder head gland groove. Install a new wear r

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-5513. Remove the cylinder rod from the holding fixture.14. Place a new t-seal and wear rings in the outer

SECTION 5 - HYDRAULICS5-56 – JLG Lift – 31212625.3 CYLINDER LENGTH SENSORBoth the jib lift cylinder and the platform level cylinder uti-lize a cylinde

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-577. Using an allen wrench, remove the bolts securingthe retaining cap and remove the cap.8. Pull sensor

SECTION 2 - GENERAL3121262 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 5 - HYDRAULICS5-58 – JLG Lift – 3121262Installation1. Carefully insert the sensor into the cylinder. It maybe necessary to gently tap the end

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-59Figure 5-118. Platform Valve Identification

SECTION 5 - HYDRAULICS5-60 – JLG Lift – 3121262Figure 5-119. Platform Valve Torque and Resistance SpecificationsTable 5-1. Platform Valve Specificati

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-61Figure 5-120. Platform Valve Fitting Torque SpecificationsTable 5-2. Fitting Torque Specifications#Tor

SECTION 5 - HYDRAULICS5-62 – JLG Lift – 3121262Figure 5-121. Jib Control Valve Identification - Sheet 1 of 2

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-63Figure 5-122. Jib Control Valve Identification - Sheet 2 of 2

SECTION 5 - HYDRAULICS5-64 – JLG Lift – 3121262Figure 5-123. Jib Control Valve Torque and Resistance Specifications - Sheet 1 of 2

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-65Figure 5-124. Jib Control Valve Torque and Resistance Specifications - Sheet 2 of 2Table 5-1. Platform

SECTION 5 - HYDRAULICS5-66 – JLG Lift – 3121262Figure 5-125. Jib Control Valve Fitting Torque SpecificationsTable 5-4. Fitting Torque#Torqueft.lbs. N

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-671. Aux Lift Down2. Tele Out3. Lift Up4. Swing Right5. Dump6. Swing Relief7. Swing Left8. Lift Down9. L

SECTION 2 - GENERAL2-4 – JLG Lift – 31212622. The design and manufacturing tolerances of thecomponent working parts are very close, therefore,even the

SECTION 5 - HYDRAULICS5-68 – JLG Lift – 3121262Table 5-5. Cartridge Torque ValuesFt-Lbs. Nm Ft-Lbs. Nm1 25-30 33.9-40.6 9 30-35 40.6-47.42 25-30 33.9-

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-695.4 OIL SAMPLINGSee Figure 5-127., Oil Sampling Port.This machine is equipped with an oil sampling valv

SECTION 5 - HYDRAULICS5-70 – JLG Lift – 31212625.5 PRESSURE SETTING PROCEDURECold temperatures have a significant impact on pressurereadings. JLG Indu

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-713. To make an adjustment to this pressure, go to theengine compartment, locate the function pump. Thest

SECTION 5 - HYDRAULICS5-72 – JLG Lift – 3121262STEERING, FRONT AND REARNOTE: The following procedure requires 2 people to per-form. One is needed for

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-73Figure 5-128. Steer Pressure Adjustments

SECTION 5 - HYDRAULICS5-74 – JLG Lift – 31212624. Remove the front circular steer/axle access coversat the front of the chassis, and the rear square c

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-758. Checking the left rear steer cylinder is identical tothe procedure for left front steer cylinder, ex

SECTION 5 - HYDRAULICS5-76 – JLG Lift – 312126212. Remove the gauge from MS3 port and install onMS4 port, which is on the left side of the front axle/

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-77Adjustments Made at the Jib ValveJIB LEVEL UP1. Install a high pressure gauge at the MLB port. 2. Using

SECTION 2 - GENERAL3121262 – JLG Lift – 2-5Cylinder DriftDrift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil

SECTION 5 - HYDRAULICS5-78 – JLG Lift – 3121262JIB TELESCOPE OUT1. Install a high pressure gauge at the MTB port. 2. Fully extend the jib boom. 3. Set

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-79JIB LIFT UP1. Install a high pressure gauge at the MJB port. 2. Fully extend the jib lift cylinder or c

SECTION 5 - HYDRAULICS5-80 – JLG Lift – 31212625.6 DRIVE PUMPSTroubleshooting ProcedureTo aid in troubleshooting, refer also to the pressure mea-surin

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-81h. Remove charge pressure relief valve from themiddle pump and inspect. Is it damaged?No - Refit cartri

SECTION 5 - HYDRAULICS5-82 – JLG Lift – 31212625. Transmission Drives in one direction onlya. Are electrical connections to pump control pro-portional

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-83f. Is a wheel drive hydraulic motor operating atexcessive speed?Yes - Check minimum displacement stop s

SECTION 5 - HYDRAULICS5-84 – JLG Lift – 3121262NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims areavailable in 0.3, 0.5, and 1.0 mm thickness.Mec

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-85If difficulties are encountered in obtaining neutral positionof the HD or EP control modules, check tha

SECTION 5 - HYDRAULICS5-86 – JLG Lift – 3121262to reassembly. Make sure 0-rings are completely seated intheir grooves. Withdraw pinion shaft and inspe

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-87g. Under application conditions with a heavyoccurrence of dust or severe temperature fluctu-ations, the

SECTION 2 - GENERAL2-6 – JLG Lift – 3121262Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALWeeklyPreventiveMaintenanceMonthlyPrev

SECTION 5 - HYDRAULICS5-88 – JLG Lift – 3121262Removal and Installation of Shaft SealRemove the retaining ring with snap ring pliers.Screw in sheet me

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-895.7 FUNCTION PUMPSpare Parts1. Sealing kit, existing spare parts: shaft sealing ring,o-rings, and a cir

SECTION 5 - HYDRAULICS5-90 – JLG Lift – 31212624. Rotary Group complete: 9 pistons, cylinder subas-sembly, valve plate, retaining plate, and retaining

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-914. Assemble the sealing ring, fitting tool holds the cor-rect position of the sealing ring in the pump

SECTION 5 - HYDRAULICS5-92 – JLG Lift – 31212626. Remove the adjustment shim.7. Unscrew the cap nut and remove it.8. Loosen the fixing nut of the stop

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-9314. Disassemble the control piston while moving theswash plate.15. The swash plate must be lifted a lit

SECTION 5 - HYDRAULICS5-94 – JLG Lift – 312126222. The external front bearing ring is pulled out of thepump housing.23. Remove the o-ring. Lifting of

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-953. Pumps clockwise driven must have a position of thevalve plate 4 degrees out of center in the samedir

SECTION 5 - HYDRAULICS5-96 – JLG Lift – 3121262Figure 5-130. Function Pump, Pressure and Flow Control - Sheet 1Figure 5-131. Function Pump, Pressure

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-97Pump Control Disassembly For Cleaning NOTE: If the Function Pump does not perform correctlyafter follow

SECTION 2 - GENERAL3121262 – JLG Lift – 2-7Functions/ControlsPlatform Controls 566Ground Controls 566Function Control Locks, Guards, or Detents 1,5 5

SECTION 5 - HYDRAULICS5-98 – JLG Lift – 31212629. Remove the spring cover hex cap for the ”outer”flow regulation adjustment this requires a 19-mmwrenc

SECTION 5 - HYDRAULICS3121262 – JLG Lift – 5-995.8 DRIVE & FUNCTION PUMP START UP PROCEDURESStart-Up ProcedureThe Boom Lift utilizes a Triple Comb

SECTION 5 - HYDRAULICS5-100 – JLG Lift – 312126210. Operate the drive system in the "turtle mode", for-ward and reverse.11. De-aerate the sy

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN I

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121262To Connect the JLG Control System Analyzer1. Connect the four pin end of the cable supplied with

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-3The top level menus are as follows:HELPDIAGNOSTICSACTIVATE TESTACCESS LEVELPERSONALITIESMACHINE

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121262Press ENTER to select the ACCESS LEVEL menu.Using the UP or DOWN arrow keys, enter thefirst

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-5Machine SetupWhen a machine digit item is selected, press the UP or DOWN arrow keys to adjust

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121262Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERATEACT ACTIVEA/D ANALOG DIGITA

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-7S/C SHORT CIRCUITSEL SELECTORSN SERIAL NUMBERSPD SPEEDSTOW STOWEDSTOWD STOWEDSW SWITCH or SOFTWA

SECTION 2 - GENERAL2-8 – JLG Lift – 3121262Annual Machine Inspection Due 21No Unauthorized Modifications or Additions 21 21All Relevant Safety Publica

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121262Table 6-2. Machine Configuration Programming InformationConfiguration Digit Number DescriptionDe

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-9ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant temperatur

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121262GEN SET/WELDER:13012NO: No generator installed.BELT DRIVE: Belt driven setup.HYDRAULIC DRIVE: H

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-11FUNCTION CUTOUT:17*0123NO: No drive cutout.BOOM CUTOUT: Boom function cutout while driving abov

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121262Table 6-3. Machine Configuration Programming Settings1500SJANSI USAANSI ExportCSACEAustraliaJap

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-136.2 MACHINE PERSONALITY SETTINGS AND FUNCTION SPEEDSNOTE: Personality settings can be adjusted

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121262MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1DECEL X.Xs Displa

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-15MAIN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceleration0.1 to 5.0 sec 1.5DECEL

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121262JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5DECEL X.Xs Displa

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-17JIB LEVEL: ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec 1.5DECEL X.Xs Disp

SECTION 2 - GENERAL3121262 – JLG Lift – 2-9-40 F(-40 C)-30 F(-34 C)-20 F(-29 C)-10 F(-23 C) 0F(-18C) 10 F(-12 C) 20 F(-7 C) 30 F(-1 C) 40 F(4 C) 50 F

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 31212626.3 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDSLIFT UP, from platform control, lowest elev

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-196.4 CANBUS COMMUNICATIONSCANbus: CAN (Control Area Network) is a two wire differ-ential serial

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121262 Figure 6-2. Control System Block Diagram

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-216.5 CALIBRATION INSTRUCTIONSThis machine incorporates a variety of sensors and a highdegree of

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121262MENU:HELP:PRESS ENTERHELP:GROUND MODE OKACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONAL

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-23MENU:FROM:PERSONALITIESACCESS LEVEL 1MENU:PERSONALITIESPERSONALITIES:DRIVEPERSONALITIES:STEERPE

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121262FROM:TO:PERSONALITIESCALIBRATIONSTILT:1=5 DEGTILT:2=4 DEGMENU:MACHINE SETUPMODEL NUMBER:???ENGI

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-25FROM:MACHINE SETUPMENU:CALIBRATIONSCALIBRATIONS:CALIBRATIONS:STEERUNLOCK BOOMCALIBRATIONS:DRIVE

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121262TO:SHEET 2FROM: HELP:TO:HELP:PRESS ENTER GROUND MODE OKSYSTEM TESTMENU:DIAGNOSTICSDIAGNOSTICS:D

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-27FROM:TO:SHEET 1SHEET 3FRONT AXLE:SWITCH: CLOSEDREAR AXLE:JIB LOCK PIN:JIB STATUS:JIB TRANSPORT:

SECTION 2 - GENERAL2-10 – JLG Lift – 3121262-40 F(-40 C)-30 F(-34 C)-20 F(-29 C)-10 F(-23 C) 0F(-18C) 10 F(-12 C) 20 F(-7 C) 30 F(-1 C) 40 F(4 C) 50

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121262FROM:SHEET 2DIAGNOSTICS:CAN STATISTICSDIAGNOSTICS:DATALOGDIAGNOSTICS:VERSIONSDIAGNOSTICS:CALIBR

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-29Figure 6-10. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 31212621001119509AConnector Pin Function TypeJ1(Natural)1THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPU

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-311001119509AConnector Pin Function TypeJ7(Black)1PLATFORM EMSDIGITAL INPUT2PLATFORM MODEDIGITAL

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 31212621001119509AConnector Pin Function TypeJ4(Blue)1AXLES SET LAMP DIGITAL OUTPUT2500# CAPACITY LAMP

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-331001112758-CConnector PinFUNCTIONTypeJ1 (Grey)1 Power Feed Thru to J2-1 Power I/O2 Power Feed T

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 31212621001112757-CConnector PinFUNCTIONTypeJ1 (Grey)1 Power Feed Thru to J2-1 Power I/O2 Power Feed T

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-351001119262-AConnectorPinFUNCTIONTypeJ2 (Black)1Power Feed Thru to J1-1Power I/O2Power Feed Thru

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121262Figure 6-17. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-376.6 CONTROL SYSTEM BOOM SENSORS NOTE: Note: The machine is defined as being in transportmode if

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES AND WHEELSTire InflationThe air pressure for p

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121262MAIN BOOM LIMIT SWITCH JIB TELESCOPEPROXIMITY SENSORSMAIN BOOM STRING POTMAIN BOOM PROTRACTOR S

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-39Sensor #3 - Main Boom Length SensorThis sensor measures total stroke of the Main Boom. It isloc

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3121262Sensor #6 - Jib Level Angle SensorThis sensor is used to measure Jib Level angle in relation-sh

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-41Sensor #10 - Dual Capacity / Jib Transport Length SwitchesThese switches are located on the Jib

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 31212626.7 JIB CONTROL MODULESee Figure 6-16., Jib Control Module.The Jib Control Module is mounted at

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-436.9 SYSTEM TESTThe Control System Incorporates a built-in system test tocheck the system compon

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 31212624. Pull out the Emergency Stop switch and Start theengine.5. The analyzer screen should read: 6

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-45Figure 6-19. System Test Flow Chart - Platform Tests

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121262Test from the Ground Station1. Position the Platform/Ground select switch to theGround position

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-47Figure 6-20. System Test Flow Chart - Ground Station Tests

3121262 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31212623.2 EXTENDING AXLESNOTE: The boom must be oriented between the rear wheelsto extend or retr

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 3121262Table 6-6. System Test MessagesMessage Displayed onAnalyzerMessage Displayed onAnalyzerDescript

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-49TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121262TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, t

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-51Table 6-7. Machine Diagnostics ParametersDiagnostics Submenu(Displayed on Analyzer 1st Line)Par

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121262BOOM:U LIFT UP/DOWN XXX% Displays main lift joystick direction & demandSWING RIGHT/LEFT XXX

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-53ENGINE:START ACTIVE/NOT ACTIVE Displays status of the engine start circuitAIR FILTER OP/CL Disp

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121262SYSTEM:GM BATTERY XX.XV Ground module battery voltagePM BATTERY XX.XV Platform module battery v

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-55HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is conf

SECTION 6 - JLG CONTROL SYSTEM6-56 – JLG Lift – 3121262OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLAT

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-57MOMENT: Displayed if MODEL NUMBER = 7 or 8(LB-IN) ACTUAL XXXXXXXX Displays current moment value

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-33.4 DRIVE SYSTEMThe drive system utilizes 2 traction pumps so each side ispowered individua

SECTION 6 - JLG CONTROL SYSTEM6-58 – JLG Lift – 3121262ENVELOPE: Displayed if MODEL NUMBER = 7 or 8LENGTH XXXX.X Displays the current indicated boom l

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-59CALIBRATION DATABASKET UP XXX Displays the basket up calibration pointBASKET DOWN XXX Displays

SECTION 6 - JLG CONTROL SYSTEM6-60 – JLG Lift – 3121262DATALOG:ON XXXXhXXm Displays total controller on (EMS) timeENGINE XXXXhXXm Display engine run t

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-616.10 CALIBRATING STEERWhen calibrating steering, each individual wheel must becalibrated in ord

SECTION 6 - JLG CONTROL SYSTEM6-62 – JLG Lift – 31212623. Pull out the Emergency Stop switch and Start theengine.4. The analyzer screen should read: 5

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-6310. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 12. Activate th

SECTION 6 - JLG CONTROL SYSTEM6-64 – JLG Lift – 31212626.11 CALIBRATING DRIVE1. Position the Platform/Ground select switch to thePlatform position.2.

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-658. Use the arrow keys to reach DRIVE.9. Hit Enter. The screen will read: 10. Hit Enter again. T

SECTION 6 - JLG CONTROL SYSTEM6-66 – JLG Lift – 312126213. Hit Enter. The number displayed will be the valuethat the crack point is set to. The screen

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-676.12 ELECTRONIC PLATFORM LEVELINGPlatform Leveling Fault WarningThe JLG Control System takes a

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31212623.6 DRIVE/STEERING SPEED CONTROLThe Drive/Steering Speed Control system uses the steer-ing

SECTION 6 - JLG CONTROL SYSTEM6-68 – JLG Lift – 3121262TILT SENSOR ERRORSIf the secondary tilt sensor is faulty, the control system willcontinue to ut

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-694. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. HitEnter.6

SECTION 6 - JLG CONTROL SYSTEM6-70 – JLG Lift – 31212624. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. HitEnter.6

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-714. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. HitEnter.6

SECTION 6 - JLG CONTROL SYSTEM6-72 – JLG Lift – 31212622. Plug the analyzer into the connector at the base ofthe platform control box.3. Pull out the

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-738. Use the arrow keys to reach Upper Lift Crack Point(UPPER LIFT CRKPT). The screen will read:

SECTION 6 - JLG CONTROL SYSTEM6-74 – JLG Lift – 312126213. Hit enter. The number displayed will be the valuethat the crack point is set to. The screen

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-753. Pull out the Emergency Stop switch and Start theengine.4. The analyzer screen should read: 5

SECTION 6 - JLG CONTROL SYSTEM6-76 – JLG Lift – 312126210. Hit Enter. The screen will read: 11. Hit enter again. The screen will read: NOTE: In the fo

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-7714. Hit Enter. The screen will read: 15. Hit Enter. The screen will read: 16. Repeat steps 10

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-5Press ENTER , the screen should read:To enable the override mode 58237 must be entered ast

SECTION 6 - JLG CONTROL SYSTEM6-78 – JLG Lift – 31212626.16 CALIBRATING TILT SENSORA NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THETIME UNTIL

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-799. Use the arrow keys to reach the TILT SENSOR. Thescreen should read: 10. Press ENTER.11. When

SECTION 6 - JLG CONTROL SYSTEM6-80 – JLG Lift – 31212626.17 JIB SENSOR CALIBRATIONSTo calibrate the jib sensors, the analyzer must be inaccess level 1

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-818. Use the arrow keys to reach the JIB SENSORS. Thescreen should read: 9. Press ENTER. The scre

SECTION 6 - JLG CONTROL SYSTEM6-82 – JLG Lift – 312126211. Press ENTER. The screen should read as shownbelow. When it does, the operator can either pr

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-8314. Once the jib is stopped the screen shown below willbe displayed. 15. Hitting the escape key

SECTION 6 - JLG CONTROL SYSTEM6-84 – JLG Lift – 312126218. Operate jib lift down until the jib stops. When the jibis at the mechanical stop the operat

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-8522. When the system completes this step, the nextscreen will show: 23. Press ENTER. The screen

SECTION 6 - JLG CONTROL SYSTEM6-86 – JLG Lift – 312126226. Hitting the ENTER key at this point will take the oper-ator to the next jib sensor calibrat

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-8730. Press Enter. The screen shown below will be dis-played. At this point, use the platform rot

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 31212621001119385-C6781191012316174135141512Figure 3-5. Chassis Component Location - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM6-88 – JLG Lift – 3121262NOTE: At this point the left or right arrow key may be used toskip to any of the other jib sens

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-8939. Press ENTER. The display will then show: 40. The control system will stop the platform leve

SECTION 6 - JLG CONTROL SYSTEM6-90 – JLG Lift – 31212622. Plug the analyzer into the connector inside theGround control box.3. Pull out the Emergency

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-916.18 CALIBRATING THE BOOM SENSORSDURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT ISNORMAL FOR

SECTION 6 - JLG CONTROL SYSTEM6-92 – JLG Lift – 31212625. The analyzer screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. HitEnter.7

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-9311. After verifying all the conditions listed in step 1 aremet, hit Enter. The screen will read

SECTION 6 - JLG CONTROL SYSTEM6-94 – JLG Lift – 312126215. After visually verifying the platform is centered, hitEnter. The screen will read: 16. Afte

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-9519. Use the up/down arrows to select YES if the acces-sory is installed, NO if it is not instal

SECTION 6 - JLG CONTROL SYSTEM6-96 – JLG Lift – 312126223. After making sure the machine is in Calibration Posi-tion 1, hit Enter. The screen will rea

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-9725. Swing 180 degrees (centered over opposite end ofchassis) for Calibration Position 3. When t

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-71. Axle Limit Switch (Right Front)2. Steer Angle Sensor (Right Front)3. Steer Valve (Front)

SECTION 6 - JLG CONTROL SYSTEM6-98 – JLG Lift – 312126226. Press Enter. The screen will read: Swing the machine back 180 degrees (centeredover origina

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-9927. Press Enter. The screen will read: Telescope out to stop (boom must be fullyextended) for C

SECTION 6 - JLG CONTROL SYSTEM6-100 – JLG Lift – 312126228. Retract to stop (boom must be fully retracted) forCalibration Position 6.When the machine

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-101When Position 7 Calibrating is complete, the screenwill read: Press Enter. The screen will rea

SECTION 6 - JLG CONTROL SYSTEM6-102 – JLG Lift – 3121262Press Enter. The screen will read: 31. Telescope to the yellow witness mark (controller willbe

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-103Press Enter. The screen will read: 32. Telescope in to green witness mark (controller willfind

SECTION 6 - JLG CONTROL SYSTEM6-104 – JLG Lift – 312126233. Operate the Lift Up function switch. The control sys-tem will stop the boom at the desired

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-10537. Operate the Jib Telescope In function switch untilthe jib is telescoped in to the mechanic

SECTION 6 - JLG CONTROL SYSTEM6-106 – JLG Lift – 312126241. Operate the Main Boom Telescope function until themain boom is telescoped in to the stop.

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-107Boom Control System Check ProcedurePerform the following check with no load (personnel ormater

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121262161001119385-C151489101112137654322728126252423222120191817Figure 3-7. Turntable Component

SECTION 6 - JLG CONTROL SYSTEM6-108 – JLG Lift – 31212621001125195 B1702566 B1702565 B1705170 A1705744 A1706741A1001125194 A1702938PLATFORMCONTROLMODU

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-109Table 6-8. Diagnostic Trouble Code ChartDTCFlash CodeSequenceFault Message Fault Description C

SECTION 6 - JLG CONTROL SYSTEM6-110 – JLG Lift – 3121262220 22 0 <<< PLATFORM CONTROLS >>>227 22 7 STEER SWITCHES FAULTY Both Steer

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-111240 24 0 <<< OTHER CONTROLS >>>250 25 0 <<< FUNCTION PREVENTED >

SECTION 6 - JLG CONTROL SYSTEM6-112 – JLG Lift – 31212623317 33 17 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the Right Forwa

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-1133343 33 43 COLD START ADVANCE SOLENOID - SHORT TO GROUNDThere is a Short to Ground to the Cold

SECTION 6 - JLG CONTROL SYSTEM6-114 – JLG Lift – 31212623377 33 77 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the Head Light Relay.- H

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-11533123 33 123 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the Ma

SECTION 6 - JLG CONTROL SYSTEM6-116 – JLG Lift – 312126233190 33 190 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the Main

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-117344 34 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUITThere is a Short to Battery

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-91. Ground Control Box2. Headlight3. Deutz EMR2 Module & Diagnostic Connector4. 110V / 2

SECTION 6 - JLG CONTROL SYSTEM6-118 – JLG Lift – 3121262433 43 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading is > 6.6V.- Deutz en

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-119663 66 3 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE666 66 6 CANBUS FAILURE - ENGINE CONTROLLE

SECTION 6 - JLG CONTROL SYSTEM6-120 – JLG Lift – 3121262827 82 7 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom func-tions are not

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-1218315 83 15 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the sensor values

SECTION 6 - JLG CONTROL SYSTEM6-122 – JLG Lift – 3121262844 84 4 BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGEThe Boom Length Sensor is not changing

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-12384102 84 102 MAIN CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE84103 84 103 JIB LEVEL ANGLE SEN

SECTION 6 - JLG CONTROL SYSTEM6-124 – JLG Lift – 3121262869 86 9 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the Righ

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-1258624 86 24 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sen-sor has become decou-p

SECTION 6 - JLG CONTROL SYSTEM6-126 – JLG Lift – 3121262993 99 3 LSS INTERNAL ERROR - PIN EXCITATION994 99 4 LSS INTERNAL ERROR - DRDY MISSING FROM A/

SECTION 6 - JLG CONTROL SYSTEM3121262 – JLG Lift – 6-1279925 99 25 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFT-WARE VERSION IMPROPERThe Chassis Module

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 31212623126DETAIL ADETAIL B54Figure 3-9. Oscillating Axle - Sheet 1 of 2* AXLE STOP SHIMMING PRO

SECTION 6 - JLG CONTROL SYSTEM6-128 – JLG Lift – 3121262NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121262Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31212623. Anderson connectors for the battery boxes and bat-tery chargers sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-5AMP Mate-N-LokFollow the installation instructions.DIN ConnectorsThis

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3121262BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gold contact m

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-77.4 AMP CONNECTORAssemblyCheck to be sure the wedge lock is in the op

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31212623. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-9Disassembly5. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-113987DETAIL ADETAIL B4611,12,A,G1011,12,B,G11,12,C,G11,12,E,G11,12,D,G11,12,F,G2A - Assembl

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121262Figure 7-13. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-117.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121262HD30/HDP20 Series Assembly8. Grasp contact about 25mm behind the con

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-13J4J2J1J5J3V41-JIB LEVEL UPV42-JIB LEVEL DOWNV87-JIB SWING LEFTV88-JI

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121262WHITE13142221BLACKWHITEBLACKAXLE LIMIT SWITCHWIRING - TYP.SWIVELSTEE

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-15CHASSISMODULESTEER VALVESWITCHAXLE LIMITSWITCHV124-RIGHT REAR STEER

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121262IN HEAD STYLEGLOW PLUGGLOW PLUGRELAY BROKEN CABLEPROXIMITYSWITCHHEAD

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-17WHITERED13142221BLACKWHITEBLACKREDTRANSPORT LIMIT SWITCH WIRING.SECT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121262CO239-J7123456789101112131415161718192021222324252627282930313233343

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-19CO239-J1123456789101112131415161718192021222324252627282930313233343

ii – JLG Lift – 3121262TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121262Figure 3-11. Axle Loctite Application

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121262This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-21Figure 7-27. Electrical Schematic - Sheet 1 of 14

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 31212624321GHEFCDAB1234DRAWING NUMBER1001119266J1 (WHITE)J7 (BLACK)J6 (BLAC

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-23ABCDEFGH87655678CO01-J11PROX2NC2192025PLVL126PLVL233PROX2NO131423242

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121262Figure 7-30. Electrical Schematic - Sheet 4 of 144321GHEFCDAB1234X6

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-25ABCDEFGH87655678Platform and JibX55 12345678910111213141516171819ENA

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 31212624321GHEFCDAB1234#1 Right SideBoom Angle SensorSN06 123#2 Left SideBo

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-27ABCDEFGH87655678Turntable & Boom165AH/1150CCA12V BATTERYBT200+1B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 31212624321GHEFCDAB1234J12 (BLACK)120120J7 (BLACK)CO239-J71PLTS2PLTE3GNDMOD

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-29ABCDEFGH87655678SEE SHEET 3 FOROTHER CONNECTIONSJ1 (WHITE)J2 (GRAY)J

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-131. Spindle2. Angle Sensor Assembly3. Steer Cylinder4. Steer Cylinder Pivot

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-30 – JLG Lift – 31212624321GHEFCDAB1234CHASSIS MODULEJ1 (GRAY)J3 (GREEN)J4 (GRAY)CO21-J1123

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-31ABCDEFGH87655678J2 (BLACK)J5 (RUST)CO21-J2123GND4FAXLS5RAXLS6DOS7AXL

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-32 – JLG Lift – 31212624321GHEFCDAB123414V, 95AALTERNATORB+D+WEC203-B+1EC203-D+1EC203-W1STA

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-33This Page Left Blank Intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-34 – JLG Lift – 31212624321GHEFCDAB1234LED WORKLIGHTSPOT BEAM PATTERNMOUNTED ON RAIL CORNER

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-35ABCDEFGH87655678AccessoriesLED WORKLIGHTSPOT BEAM PATTERNMOUNTED ON

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-36 – JLG Lift – 3121262Figure 7-41. Hydraulic Schematic - Sheet 1 of 10

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-37Figure 7-42. Hydraulic Schematic - Sheet 2 of 101001120628-F

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-38 – JLG Lift – 3121262Figure 7-43. Hydraulic Schematic - Sheet 3 of 10

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-39Figure 7-44. Hydraulic Schematic - Sheet 4 of 101001120628-F

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31212623.9 OSCILLATING AXLE SYSTEMThe oscillating front axle is attached to the frame by apivot p

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-40 – JLG Lift – 3121262DA4A3B2B5B6B12-SPEEDBRAKESTEERBBBRMBRP3P4P1P2TS A1A5A6A2B4B3MPGG1GG1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-41BAG1GG1GFRONT AXLEBAPVPVLL1LL1PORT# 7LEFTMOTOROil Cooler OptionPort

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-42 – JLG Lift – 3121262DA4A3B2B5B6B12-SPEEDBRAKESTEERBBBRMBRP3P4P1P2TS A1A5A6MLOPBAX1 X2MBM

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-43BAG1GG1GFRONT AXLEDRIVE SYSTEMREXROTH PUMPSLL1LL1PORT# 7LEFTMOTORFRO

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-44 – JLG Lift – 3121262V2V1JIB TELESCOPE CYLINDERBORE 2.5" 4.91 sq inROD 1.5&

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121262 – JLG Lift – 7-45JIB LOCK CYLINDERBORE 2.5" 4.91 sq inROD 1.75" 2.4

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-46 – JLG Lift – 3121262NOTES:

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

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-15Oscillating Axle Lockout TestThe front axles will oscillate when the boom is in the trans-

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 31212623.11 DRIVE HUB - BONFIGLIOLINOTE: Machines may be built with either Bonfiglioli or Reg-gia

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-174. Make sure that the functioning is regular and with-out any excessive noises and vibrati

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121262Figure 3-14. Hub Assembly1= M18x1,5...Filling, draining and oil le

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-19NOTE: Do not mix together oils of different brands or char-acteristics.NOTE: The gearbox i

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121262THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUSTNOT EXCEED 25 REV/MIN.1. Unscrew the 2 soc

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-216. Tighten the 2 socket head screws M8x16 (4) with amale hex head torque wrench at 18.4 ft

3121262 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 3121262TroubleshootingThe following table is provided to help locate problems inthe gearbox.Disas

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-231. Install the special tool (6689960310) on the flangedhub (31) and turn the screw until i

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 31212621. Screw2. O-ring3. Pin4. Screw5. Cap Nut6. Oil Plug7. End Cover8. Pad9. O-ring10. 1st Sta

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-257. By using a puller remove, at the same time, thebrake piston (44), the spacer (39) and t

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 312126213. Remove the disengagement shaft kit (15).14. Place the disengagement shaft kit (15) ins

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-2719. Remove the cap nut (5).20. Remove the pin (3).21. Remove the O-ring seal (2) from its

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 312126225. Remove the O-ring seal (9) from its seat in the endcover (7).26. Remove the 1st stage

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-2931. By using a puller remove the planet assemblies ofthe 3rd reduction (20).32. Remove the

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 312126237. By using a puller and a metal stopper, remove theflanged hub (31) from the gearbox hou

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-314. When reassembling a part always replace all theseals involved. Add some grease on the s

iv – JLG Lift – 3121262TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31212624. Using the same tool (6689960300), assemble the2nd half seal (29) on the flanged hub (31

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-33flanged hub (31) until assembling of the unit is com-plete.SCREW THE NUT (22) ON PARTIALLY

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312126213. Assemble correctly the spacers (21) on the pins ofthe flanged hub (31).14. Place the 5

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-3519. Assemble the 1st reduction assembly (16).20. Insert the 1st stage sun gear (10).21. As

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 312126225. Assemble the O-ring seal (2) into its seat in the endcover (7).26. Protect the seat an

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-3731. Insert the splined shaft (14) in the equipment(6689960240).32. Insert the 2nd washer (

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 312126236. By using pliers assemble the circlip (36) into its seatin the brake shaft (35).37. Tur

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-3942. Insert the spacer (39) inside the flanged hub (31),paying attention not to damage the

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 312126245. Insert the brake piston (44) inside the flanged hub(31), paying attention not to damag

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-4149. Install the special tool (6689960310) on the flangedhub (31) and turn the screw until

3121262 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121262Figure 3-18. Drive Hub Special Tools - Sheet 1 of 4

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-43Figure 3-19. Drive Hub Special Tools - Sheet 2 of 4

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121262Figure 3-20. Drive Hub Special Tools - Sheet 3 of 4

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-45Figure 3-21. Drive Hub Special Tools - Sheet 4 of 4

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 31212623.12 DRIVE HUB - REGGIANA RIDUTTORINOTE: After S/N 0300134389 machines may be built withei

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-47 LOCTITE 2701Ø197.5Ø210110Ø30Ø130Ø210N° 4 Hole to 90° Ø40255x45°M- 1320M- 1321Figure 3-24.

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3121262M- 1316M- 1317M- 1317M- 1317M- 1317M- 1317Ø230Ø20555703810x45°45°45°45°216.545°2090Ø343012

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-49M- 1020M- 1126M- 1125VTCEI M6X12 n°12VTCEI M10X60 n°4M- 1126Figure 3-30. Assembly Diagram

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121262Ø46Ø485705805088.53.5M8Ø20 0-0.1Ø20+0.1+0.2Ø93.5Ø105Ø8.5Ø13.59208.55t.u. 122.5x15°Ø39.5M-

SECTION 3 - CHASSIS & TURNTABLE3121262 – JLG Lift – 3-51Disassembly1. Remove the plugs and pour the lubricant in a con-tainer. 2. Release the scre