Jlg 1850SJ Service Manual User Manual

Service and Maintenance ManualModel1850SJP/N - 3121619September 25, 2014

vi – JLG Lift – 3121619TABLE OF CONTENTS SECTION NO. TITLE

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3121619Figure 4-7. Boom Assembly - Sheet 6 of 9

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-15Figure 4-8. Boom Assembly - Sheet 7 of 9

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3121619Figure 4-9. Boom Assembly - Sheet 8 of 9

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-17Figure 4-10. Boom Assembly - Sheet 9 of 9

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3121619Figure 4-11. Locations for Threadlocker Application - Sheet 1 of 5

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-19Figure 4-12. Locations for Threadlocker Application - Sheet 2 of 5

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3121619Figure 4-13. Locations for Threadlocker Application - Sheet 3 of 5

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-21Figure 4-14. Locations for Threadlocker Application - Sheet 4 of 5

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3121619Figure 4-15. Locations for Threadlocker Application - Sheet 5 of 5

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-23Figure 4-16. Boom Assembly Torque Values - Sheet 1 of 4

3121619 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3121619Figure 4-17. Boom Assembly Torque Values - Sheet 2 of 4

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-25Figure 4-18. Boom Assembly Torque Values - Sheet 3 of 4

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121619Figure 4-19. Boom Assembly Torque Values - Sheet 4 of 4

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-276. Place boom section 4 on a proper supporting device.7. Apply Super Lube® lubricant (JLG p/n

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 312161919. Install the rear bottom wear pads to the outside of sec-tion 4. Coat the retaining bolts w

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-2925. Install the fixed sheave shields, and deflector sheavesusing the retaining bolts and washe

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 312161929. Apply a thin coat of moly paste on I.D. of sheave bear-ings. Coat the bolts with JLG Threa

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-3133. Coat the bolts with JLG Threadlocker P/N 0100011.Install the rear upper wear pads to secti

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 312161951. Apply moly paste to the I.D. of the sheave bearings.Install the sheaves to section 2 boom.

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-334.4 TELESCOPE CYLINDERRemoval1. Remove the boom from the machine. Refer to Section4.2 - Boom R

viii – JLG Lift – 3121619LIST OF FIGURES FIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 31216196. Remove the bolts securing the extend rope support anddisconnect the support from boom secti

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-359. Repeat steps 1-7 above to install the Section 5/4 assem-bly into boom Section 3.10. Repeat

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 31216194.8 HOSE ADJUSTMENT PROCEDURE1. Load the hoses and cables into the powertracks andpush tubes a

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-37Figure 4-20. Hose Adjustment

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 3121619Figure 4-21. Section 3 Boom Cables

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-39Figure 4-22. Section 4 Boom Cables

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 3121619Figure 4-23. Section 5 Boom Cables

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-41Figure 4-24. Jib Hydraulics - Sheet 1 of 7

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 3121619XJBTBJATAT3T2P2SASBLALBFRONT VIEW JIB CONTROL VALVEV1TV2JIB STOW ROTATORPL2L1T2R1R2S1 S2T1FRON

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-43PLATFORM LEVEL CYLINDERPL ATF OR M VA LV EJIB LOCK CYLINDERJIB CONTR OL VALVEJIB TELE CYLIND

3121619 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 3121619PLATFOR M VALVEJIB LOCK CYLINDERJIB CONTROL VALVEFigure 4-27. Jib Hydraulics - Sheet 4 of 7

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-45PLATFORM VALVE1001157243-CFigure 4-28. Jib Hydraulics - Sheet 5 of 7

SECTION 4 - BOOM & PLATFORM4-46 – JLG Lift – 31216190.75 " AIR LINE0.815" GEN CABLE0.7" CONTROL CABLE0.75" AIR LINE0 .81 5&qu

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-47AA1001157243-C31 9195271313382423324362382300 MAI NTAI N H OSE LO OPAT T HIS DIM E NS I ON

SECTION 4 - BOOM & PLATFORM4-48 – JLG Lift – 31216194.9 JIBRemoval1. Lower the platform to the ground or onto blocking tosupport the weight of the

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-499. Attach an adequate supporting device to the jib to sup-port its weight. Remove the bolt and

SECTION 4 - BOOM & PLATFORM4-50 – JLG Lift – 3121619***JLG Threadlocker PN# 0100011Adhesive PN# 0100081JLG Threadlocker PN# 0100019HOSE CLAMPRUBBE

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-51***JLG Threadlocker PN# 0100011JLG Threadlocker PN# 0100019BOLTBOLTBOLTSHIMSJIB PIVOTJIB LIFT

SECTION 4 - BOOM & PLATFORM4-52 – JLG Lift – 3121619A1001158944-E***ALIGN HOLES IN LOCK CYLWIT H PROTRUSIONSIN CAP AS SHOWNINTERNALS OF ACTUATORNO

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-53*JLG Threadlocker PN# 0100011Loctite RC 609 ThreadlockerORIENT PORT ON LOCKCYL AS SHOWNJIB PI

x – JLG Lift – 3121619LIST OF FIGURES FIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-54 – JLG Lift – 3121619Stowed Jib Shimming Procedure1. Rotate the jib to the appropriate position as shownbelow.2. In

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-554.11 WIRE ROPEInspectionNOTE: The pictures in this paragraph are just samples to show therepla

SECTION 4 - BOOM & PLATFORM4-56 – JLG Lift – 31216194.12 WIRE ROPE TENSIONING ADJUSTMENTIf new wire ropes are installed, there is a general starti

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-57Figure 4-37. Initial Exposed Thread Length for Wire Rope Adjustment

SECTION 4 - BOOM & PLATFORM4-58 – JLG Lift – 3121619BOOM SECTION #3 REPOSITIONING:1. If Boom Section #3 falls within the dimension and toler-ance

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-59e. Retract the boom assembly such that the platformmoves 2 to 3 feet (0.6m-0.9m) from the prev

SECTION 4 - BOOM & PLATFORM4-60 – JLG Lift – 3121619g. To remove slack resulting from the adjustment in c,tighten the Section #4 Extend Adjustment

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-61BOOM SECTION #5 REPOSITIONING:1. If Boom Section #5 falls within the dimension and toler-ance

SECTION 4 - BOOM & PLATFORM4-62 – JLG Lift – 3121619e. Retract the boom assembly such that the platformmoves 2 to 3 feet (0.6m-0.9m) from the prev

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-63ing between the two ropes until both maintain therequired torque.6. Using tool, JLG p/n 100116

3121619 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-64 – JLG Lift – 312161914. Retract the boom 2-3 feet (.6m – 1.0m) Do NOT fullyretract the boom or bottom out any sect

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-654.13 BROKEN BOOM CABLE PROXIMITY SWITCHThis system uses a proximity switch to detect excessive

SECTION 4 - BOOM & PLATFORM4-66 – JLG Lift – 31216191. Powertrack2. Powertrack3. Clamp Plate4. Rubber Pad5. Powertrack6. Clamp Plate7. Rubber PadF

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-671. Clamp Plate2. Rubber Pad3. Clamp Plate4. Rubber Pad5. Clamp Plate6. Rubber PadFigure 4-41.

SECTION 4 - BOOM & PLATFORM4-68 – JLG Lift – 31216191. Clamp Bar2. Rubber Pad3. Spacer Tube4. Power Track Support5. Track Support Cover6. Spacer T

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-691. Support Bracket2. Push Tube Pad3. Push Tube Pad4. Upper Push Tube Assembly5. Adjusting Shim

SECTION 4 - BOOM & PLATFORM4-70 – JLG Lift – 3121619IS A 6MM±3MM CLEARANCE BETWEEN THE PU SH TUBE ANDPO WE R TRA CK RO LLERS. ADJ UST AT T HE RE

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-71#0100081Figure 4-45. Powertrack Locations for Threadlocker Application and Torque - Sheet 1 o

SECTION 4 - BOOM & PLATFORM4-72 – JLG Lift – 3121619#0100011#0100081#0100081#0100081Figure 4-46. Powertrack Locations for Threadlocker Applicatio

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-73Figure 4-47. Powertrack Locations for Threadlocker Application and Torque - Sheet 3 of 4

xii – JLG Lift – 3121619LIST OF FIGURES FIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-74 – JLG Lift – 312161949 ft.lbs.(66 Nm)#010001138 ft.lbs.(66 Nm)#010001138 ft.lbs.(66 Nm)#010001138 ft.lbs.(66 Nm)#0

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-75Figure 4-49. Powertrack Hose Installation - Sheet 1 of 4

SECTION 4 - BOOM & PLATFORM4-76 – JLG Lift – 3121619Figure 4-50. Powertrack Hose Installation - Sheet 2 of 4

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-77Figure 4-51. Powertrack Hose Installation - Sheet 3 of 4

SECTION 4 - BOOM & PLATFORM4-78 – JLG Lift – 3121619Figure 4-52. Powertrack Hose Installation - Sheet 4 of 4

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-794.14 POWERTRACK MAINTENANCEOne Piece Bracket Maintenance1. Place the powertrack on a workbench

SECTION 4 - BOOM & PLATFORM4-80 – JLG Lift – 31216195. Slide the poly roller off of the round bar.6. Hold the round bar to remove the other screw.

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-8110. Push down with slight pressure on the link and slide thebracket side up and over the extru

SECTION 4 - BOOM & PLATFORM4-82 – JLG Lift – 31216194. Hold the flat bar and remove the screws.5. Remove the snap rings and pins.6. Remove the scr

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-83Make sure that all snap rings are closed and seated. An open snap ring is shown below.A snap r

3121619 – JLG Lift – xiii LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-84 – JLG Lift – 3121619C,DEABCDETorque to 40 ft.lbs. (55 Nm)Loctite #242Torque to 480 ft. lbs. (650 Nm)Check torque e

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-1SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHE

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-2 – JLG Lift – 3121619Dip MethodNOTE: This method works best with Face Seal o-ring

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-3Figure 5-1. Turntable Hydraulic System

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-4 – JLG Lift – 3121619Figure 5-2. Hydraulic Hose Installation - Sheet 1 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-5Figure 5-3. Hydraulic Hose Installation - Sheet 2 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-6 – JLG Lift – 3121619Figure 5-4. Hydraulic Hose Installation - Sheet 3 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-7Figure 5-5. Hydraulic Hose Installation - Sheet 4 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-8 – JLG Lift – 3121619Figure 5-6. Hydraulic Hose Installation - Sheet 5 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-9Figure 5-7. Hydraulic Hose Installation - Sheet 6 of 8

xiv – JLG Lift – 3121619LIST OF TABLES TABLE NO. TITLE

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-10 – JLG Lift – 3121619Figure 5-8. Hydraulic Hose Installation - Sheet 7 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-11Figure 5-9. Hydraulic Hose Installation - Sheet 8 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-12 – JLG Lift – 31216195.2 HYDRAULIC CYLINDERSAxle Extend CylinderRefer to Figure

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-131. Bushing2. Barrel3. Counterbalance Valve4. Capscrew5. Was

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-14 – JLG Lift – 31216199. Loosen and remove bolts from tapered bushing and pis-ton

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-15d. Press bushing in barrel or rod bushing with correctsize

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-16 – JLG Lift – 31216199. Thread piston on cylinder rod hand tight. Ensure O-ringa

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-17Jib Level (Slave) CylinderRefer to Figure 5-24.DISASSEMBLYC

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-18 – JLG Lift – 312161910011558341123*3*46589710111213141318191817**1615202021*Tor

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-198. Using suitable protection, clamp cylinder rod in a vise

SECTION 1 - SPECIFICATIONS3121619 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS1.2 DIMENSIONAL DATA1.3 CAPACITIES1.4 TIRESTab

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-20 – JLG Lift – 3121619CLEANING AND INSPECTION1. Clean parts thoroughly with appro

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-21ASSEMBLYIMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-22 – JLG Lift – 3121619NOTE: Apply JLG Threadlocker (P/N 0100011) to tapered bushi

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-23Platform Level CylinderRefer to Figure 5-37.DISASSEMBLYCCON

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-24 – JLG Lift – 31216191001139999134567811**1242*13***141516171819182021222324****

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-25OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-26 – JLG Lift – 3121619CLEANING AND INSPECTION1. Clean parts thoroughly with appro

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-273. Install cylinder head assembly on rod. Do not damage ord

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-28 – JLG Lift – 312161914. If removed, install the cylinder length sensor. See Sec

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-29Boom Lift CylinderRefer to Figure 5-52.DISASSEMBLYCONTAMINA

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31216191.5 ENGINE DATA 1.6 MAJOR COMPONENT WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-30 – JLG Lift – 3121619100115885313*4*5678910111213141516172122**18192019182423231

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-318. Remove three bolts attaching tapered bushing to pis-ton.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-32 – JLG Lift – 312161911. Inspect seal and O-ring grooves in head for burrs andsh

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-333. Install backup ring (16), O-ring (15), and backup ring (

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-34 – JLG Lift – 312161910. Remove cylinder rod from holding fixture.11. Position c

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-35Jib Lift CylinderRefer to Figure 5-65.DISASSEMBLYCONTAMINAT

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-36 – JLG Lift – 312161912*100114010436119871032*12***13141516151417171819202122232

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-37PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARRE

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-38 – JLG Lift – 3121619CLEANING AND INSPECTION1. Clean parts thoroughly with appro

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-393. Install washer ring (27) on rod (29). Install cylinder h

SECTION 1 - SPECIFICATIONS3121619 – JLG Lift – 1-3Table 1-9. Mobil DTE 13M SpecsISO Viscosity Grade #32Specific Gravity 0.877Pour Point, Max-40°F (-4

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-40 – JLG Lift – 3121619INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BAR

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-41Jib Lock CylinderRefer to Figure 5-77.DISASSEMBLYCCONTAMINA

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-42 – JLG Lift – 3121619184326579111010011193131. Rod2. Seal3. Wear Ring4. Barrel5.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-43CLEANING AND INSPECTION1. Clean parts thoroughly with appro

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-44 – JLG Lift – 3121619Steer CylinderRefer to Figure 5-81.DISASSEMBLYCCONTAMINATIO

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-4510011559861. Bushing2. Barrel3. Wiper Seal4. Seal5. Head6.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-46 – JLG Lift – 312161910. Remove cylinder head assembly (5) from rod (17).Remove

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-4710. Install setscrew (13) in piston. Torque to 90 in-lb (10

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-48 – JLG Lift – 3121619Jib Telescope CylinderRefer to Figure 5-87.DISASSEMBLYCCONT

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-4910011589912**2**345667*89101211131416151718231920***2122218

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3121619Figure 1-1. Maintenance and Lubrication Diagram

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-50 – JLG Lift – 3121619REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-51ASSEMBLYNOTE: Use proper cylinder seal kit for cylinder as

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-52 – JLG Lift – 3121619NOTE: Apply locking primer and JLG Threadlocker (P/N 010001

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-53Boom Telescope CylinderRefer to Figure 5-98.DISASSEMBLYCONT

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-54 – JLG Lift – 3121619100117859210121514161718192021222324252627281. Capscrew2. V

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-5510. Remove three bolts attaching tapered bushing to pis-ton

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-56 – JLG Lift – 3121619CLEANING AND INSPECTION1. Clean parts thoroughly with appro

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-575. Install Spacer (16) on Rod (7) with screw hole facingtow

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-58 – JLG Lift – 3121619b. Tap each space once; this means the tapered bush-ing is

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-595.3 CYLINDER LENGTH SENSORBoth the jib lift cylinder and th

SECTION 1 - SPECIFICATIONS3121619 – JLG Lift – 1-51.8 MAINTENANCE AND LUBRICATIONNOTE: The following numbers correspond to those in Figure 1-1.,Mainte

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-60 – JLG Lift – 31216197. Using an allen wrench, remove the bolts securing thereta

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-61Installation1. Carefully insert the sensor into the cylinde

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-62 – JLG Lift – 31216195.4 OIL SAMPLINGSee Figure 5-109., Oil Sampling Valve Locat

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-63Figure 5-110. Main Valve Identification - Sheet 1 of 2

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-64 – JLG Lift – 3121619Figure 5-112. Main Valve Identification - Sheet 2 of 2

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-65Figure 5-113. Main Valve Torque Values - Sheet 1 of 2Item

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-66 – JLG Lift – 3121619Figure 5-114. Main Valve Torque Values - Sheet 2 of 2

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-675.5 PRESSURE SETTING PROCEDURECold temperatures have a sign

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-68 – JLG Lift – 31216194. The stand by adjustment is the outside adjustment.Using

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-694. Reconnect lift down coil. 5. Retighten locknuts. LIFT UP

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31216194. Hydraulic Return FilterLube Point(s) - Replaceable ElementInterval - Change after first 50 hours

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-70 – JLG Lift – 3121619LIFT DOWN 1. Install a high pressure gauge at the “M4” port

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-714. Install gauge at MS3, Activate swing left, the gaugeshou

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-72 – JLG Lift – 3121619TELESCOPE IN 1. Install a high pressure gauge at the “M7” p

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-733. Adjustments Made at the Frame Valve Bank AXLE EXTEND A

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-74 – JLG Lift – 3121619STEERING, FRONT AND REAR 1. The axles must be extended to s

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-752. Activate level down to the end of stroke, the gaugeshoul

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-76 – JLG Lift – 3121619JIB LEVEL DOWN 1. Install high pressure gauge at MLA. Using

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-77JIB TELESCOPE IN 1. Install high pressure gauge at MTA. 2.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-78 – JLG Lift – 3121619JIB LIFT DOWN 1. Install high pressure gauge at port MJA.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-795.6 DRIVE PUMPSTroubleshooting ProcedureTo aid in troublesh

SECTION 1 - SPECIFICATIONS3121619 – JLG Lift – 1-78. Hydraulic OilLube Point(s) - Fill CapCapacity - 75 Gallons (208 liters) Tank to Full Mark 82

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-80 – JLG Lift – 3121619h. Remove charge pressure relief valve from the mid-dle pum

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-815. Transmission Drives in one direction onlya. Are electric

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-82 – JLG Lift – 3121619f. Is a wheel drive hydraulic motor operating at exces-sive

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-83NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are av

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-84 – JLG Lift – 3121619trol spring are correctly located in the grooves near the e

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-85sembly. Make sure 0-rings are completely seated in theirgro

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-86 – JLG Lift – 3121619g. Under application conditions with a heavy occur-rence of

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-87Removal and Installation of Shaft SealRemove the retaining

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-88 – JLG Lift – 31216195.7 FUNCTION PUMPPump OperationThe variable pump converts i

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-89Control AdjustmentESCAPING HYDRAULIC FLUID UNDER PRESSURE C

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 312161912. Fuel Pre-Filter Lube Point(s) - Replaceable ElementInterval - Every year or 500 hours of operati

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-90 – JLG Lift – 3121619LS CONTROL SETTING5. Install pressure gauge in port M1 to m

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-91TroubleshootingEXCESSIVE NOISE OR VIBRATIONSLOW ACTUATOR RE

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-92 – JLG Lift – 3121619SYSTEM OPERATING HOTLOW PUMP OUTPUTUNSTABLE PRESSURE OR FLO

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-93SYSTEM PRESSURE NOT REACHING PC SETTINGHIGH INLET VACUUMHIG

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-94 – JLG Lift – 31216191001169892123456789121113141617181920212223241012*Torque to

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-95Disassemble Pump1. Remove coupling (11) from endcap (34).2.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-96 – JLG Lift – 312161916. Remove tapered roller bearing cup (10) and cone (9).17.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-97DISASSEMBLE CYLINDER BLOCK1. Pull to remove slipper retaine

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-98 – JLG Lift – 3121619CYLINDER BLOCKExamine cylinder block running face. Surface

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-99ENDCAP1. Inspect endcap (34). Remove poppet (30) and spring

SECTION 1 - SPECIFICATIONS3121619 – JLG Lift – 1-9Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)Tor q ueTo r qu eTor q ueTo r qu eTorque T

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-100 – JLG Lift – 31216198. Insert input shaft (8) through bearing into housing (11

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-101VALVE PLATE AND ENDCAP1. Clean valve plate (26) and endcap

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-102 – JLG Lift – 3121619LS CONTROL ASSEMBLY1. Hold control in a horizontal positio

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-1035.8 DRIVE & FUNCTION PUMP START UP PROCEDURESStart-Up

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-104 – JLG Lift – 312161912. Switch drive mode speed control from "turtle"

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-105Figure 5-139. Hydraulic Schematic - Sheet 1 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-106 – JLG Lift – 3121619Figure 5-140. Hydraulic Schematic - Sheet 2 of 8100114970

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-107Figure 5-141. Hydraulic Schematic - Sheet 3 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-108 – JLG Lift – 3121619Figure 5-142. Hydraulic Schematic - Sheet 4 of 8100114970

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-109Figure 5-143. Hydraulic Schematic - Sheet 5 of 8

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121619Figure 1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)Torq ueTor queTorq ueTorqu eTo rqu e

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-110 – JLG Lift – 3121619Figure 5-144. Hydraulic Schematic - Sheet 6 of 8100114970

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS3121619 – JLG Lift – 5-111Figure 5-145. Hydraulic Schematic - Sheet 7 of 8

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS5-112 – JLG Lift – 3121619Figure 5-146. Hydraulic Schematic - Sheet 8 of 8100114970

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN I

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121619To Connect the JLG Control System Analyzer1. Connect the four pin end of the cable supplied with

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-3The top level menus are as follows:HELPDIAGNOSTICSACTIVATE TESTACCESS LEVELPERSONALITIESMACHINE

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121619Press ENTER to select the ACCESS LEVEL menu.Using the UP or DOWN arrow keys, enter the firs

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-5Machine SetupWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121619Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERATEACT ACTIVEA/D ANALOG DIGITA

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-7S/C SHORT CIRCUITSEL SELECTORSN SERIAL NUMBERSPD SPEEDSTOW STOWEDSTOWD STOWEDSW SWITCH or SOFTWA

SECTION 1 - SPECIFICATIONS3121619 – JLG Lift – 1-11Figure 1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)Clamp LoadTo rque To r qu e Torq ue Tor

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121619Table 6-2. Machine Configuration Programming InformationConfiguration Digit Number DescriptionDe

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-9ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant temperatur

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121619DRIVE:12012WD drive mode enabled.4WD drive mode enabled.1STOUCH/SKYGUARD:130123None: No soft to

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-11FUNCTION CUTOUT:18*0123NO: No drive cutout.BOOM CUTOUT: Boom function cutout while driving abov

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121619LANGUAGE:26012345678910ENGLISHSPANISHEURO PORTUGUESEBRAZILIAN PORTUGUESEFRENCHGERMANDUTCHITALIA

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-13Table 6-3. Machine Configuration Programming Settings1850SJANSI USAANSI ExportCSACEAustraliaJap

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 31216196.2 MACHINE PERSONALITY SETTINGS AND FUNCTION SPEEDSNOTE: Personality settings can be adjusted

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-15SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 3DECEL X.Xs Displays/adjus

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121619PLATFORMROTATE:ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1DECEL X.X

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-17JIB LEVEL: ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec 1.5DECEL X.Xs Disp

INTRODUCTION3121619 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121619Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)To r qu eTo rqu eTorqueTo rq ueTo r qu

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 31216196.3 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDSLIFT UP, from platform control, lowest elev

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-196.4 CANBUS COMMUNICATIONSCANbus: CAN (Control Area Network) is a two wire differentialserial li

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121619 J7-24YEL Ca n HighGRN C an LoMS833X4 B uss BarBe lo w U GM624Shie ldC hassi sGround X468C an 2

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-21 J12-4J12-7J12-6120 OHMMS 8 33X4 Buss BarBelow UGM12106Whit eYEL Can HighGRN Can LoUGM MODULE

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 31216196.5 CALIBRATION INSTRUCTIONSThis machine incorporates a variety of sensors and a highdegree of

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-23MENU:HELP:PRESS ENTERHELP:GROUND MODE OKACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONAL

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121619Figure 6-5. Analyzer Flow Chart - Personalities (Software Version 7.X)NOTE: The layout shown i

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-25Figure 6-6. Analyzer Flow Chart - Machine Setup (Software Version 7.X)NOTE: The layout shown i

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121619Figure 6-7. Analyzer Flow Chart - Calibrations (Software Version 7.X)NOTE: The layout shown in

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-27Figure 6-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3NOTE: The l

SECTION 1 - SPECIFICATIONS3121619 – JLG Lift – 1-13Figure 1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)Torque TorqueTor qu eTo rqu eTo rqu eT

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121619Figure 6-9. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 2 of 3NOTE: The l

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-29Figure 6-10. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 3 of 3NOTE: The

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 31216191001119509AConnector Pin Function TypeJ1(Natural)1THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPU

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-311001119509AConnector Pin Function TypeJ7(Black)1PLATFORM EMSDIGITAL INPUT2PLATFORM MODEDIGITAL

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 31216191001119509AConnector Pin Function TypeJ4(Blue)1AXLES SET LAMP DIGITAL OUTPUT2500# CAPACITY LAMP

SECTION 6 - JLG CONTROL SYSTEM3121619 – 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 – 31216191001112757-CConnector PinFUNCTIONTypeJ1 (Grey)1 Power Feed Thru to J2-1 Power I/O2 Power Feed T

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-351001119262-AConnectorPinFUNCTIONTypeJ2 (Black)1Power Feed Thru to J1-1Power I/O2Power Feed Thru

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121619Figure 6-17. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-376.6 CONTROL SYSTEM BOOM SENSORSThe Boom Control System (BCS) requires the use of multiplesensor

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121619NOTES:

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121619Figure 6-18. Main Boom Angle Sensors

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-39Sensor #4 - Main Boom Cylinder Angle Sensor (1)See (See Figure 6-19.)This sensor's functio

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 312161990°+1°-10°BLACKREDWHITEBLACKREDWHITE1321 2214TRANSPORT LIMIT SWITCH WIRINGTORQUE BOLT TO 55 NMS

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-41Sensor #6 - Jib Level Angle Sensor (1)See (See Figure 6-22.)This sensor is used to measure Jib

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 3121619SHOWN IN PHAN TOM FOR CLARITYDETAIL B INSTALL BETWEEN LINK AND ARMTORQUE UNTIL SNUG5 NM MAXB

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-43Sensor #8 - Jib Stow Angle Sensor (1)See (See Figure 6-23.)This sensor is used to measure Jib s

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 3121619Sensor #10 - Dual Capacity / Jib Transport Length Switches (2)See (See Figure 6-24.)These switc

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-45Sensor #12 - Platform Level Angle Gravity Sensors (2)See (See Figure 6-25.)These sensors are lo

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121619Sensor #21 - Main Lift Cylinder Pressure Transducer (1)This pressure transducer is located on t

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-475. Pull out the Emergency Stop switch and Start theengine.6. The analyzer screen should read: 7

SECTION 2 - GENERAL3121619 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 3121619Figure 6-26. System Test Flow Chart - Platform Tests - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-49Figure 6-27. System Test Flow Chart - Platform Tests - Sheet 2 of 2

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121619Test from the Ground Station1. Position the Platform/Ground select switch to theGround position

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-51Figure 6-28. System Test Flow Chart - Ground Station Tests

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121619Table 6-6. System Test MessagesMessage Displayed onAnalyzerMessage Displayed onAnalyzerDescript

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-53CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure t

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121619TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, t

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-556.8 CALIBRATION PROCEDURESAxle CalibrationThe axle angle sensors need to be calibrated to ensur

SECTION 6 - JLG CONTROL SYSTEM6-56 – JLG Lift – 31216193. If the initial conditions are not met, the controller willprompt the operator with analyzer

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-5711. The controller will disable telescope out, enable tele-scope in and display “CAL POSITION 6

SECTION 2 - GENERAL2-2 – JLG Lift – 31216192.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in the useand applicat

SECTION 6 - JLG CONTROL SYSTEM6-58 – JLG Lift – 31216196.9 ELECTRONIC PLATFORM LEVELINGPlatform Leveling Fault WarningThe JLG Control System takes a s

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-59TILT SENSOR ERRORSIf the secondary tilt sensor is faulty, the control system willcontinue to ut

SECTION 6 - JLG CONTROL SYSTEM6-60 – JLG Lift – 3121619Table 6-7. Diagnostic Fault Code ChartFault Text Flash 1 Flash 2 DTC 1350 1200 1250 1500 1850EV

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-61FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM 2 3 234✔ ✔ ✔ ✔ ✔FUNCTION SWITCHES LOCKED - SE

SECTION 6 - JLG CONTROL SYSTEM6-62 – JLG Lift – 3121619REAR RIGHT AXLE SWING SENSOR - VOLTAGE OUT OF RANGE LOW 2 6 267- - - - - - - - ✔REAR RIGHT AXLE

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-63MAIN DUMP VALVE - SHORT TO GROUND 3 3 3358✔ ✔ ✔ ✔ ✔MAIN DUMP VALVE - OPEN CIRCUIT 3 3 3359✔ ✔ ✔

SECTION 6 - JLG CONTROL SYSTEM6-64 – JLG Lift – 3121619JIB LIFT UP VALVE - SHORT TO BATTERY 3 3 33102✔ ✔ ✔ - - - -JIB LIFT DOWN VALVE - SHORT TO GROUN

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-65LIFT DOWN AUX VALVE - SHORT TO BATTERY 3 3 33155✔ ✔ - - ✔ ✔TOWER LIFT APU VALVE - SHORT TO GROU

SECTION 6 - JLG CONTROL SYSTEM6-66 – JLG Lift – 3121619HORN - SHORT TO GROUND 3 3 33209✔ ✔ ✔ ✔ ✔GLOWPLUG - OPEN CIRCUIT 3 3 33279✔ ✔ ✔ ✔ ✔GLOWPLUG - S

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-67CHASSIS ENABLE VALVE - OPEN CIRCUIT 3 3 33466- - - - - - - - ✔CHASSIS ENABLE VALVE - SHORT TO G

SECTION 2 - GENERAL3121619 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, completethe procedural

SECTION 6 - JLG CONTROL SYSTEM6-68 – JLG Lift – 3121619JIB TELESCOPE OUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT 3 5 3516- - - - - - ✔ ✔FRONT AXLE EX

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-69SPEED SENSOR READING INVALID SPEED 4 3 4323✔ ✔ ✔ ✔ ✔SOOT LOAD WARNING - LOW 4 3 4331✔ ✔ ✔ ✔ ✔SO

SECTION 6 - JLG CONTROL SYSTEM6-70 – JLG Lift – 3121619TOWER TELESCOPE PVG VALVE - COMMAND IMPROPER 4 5 4524- - - - ✔ - - - -MAIN LIFT PVG VALVE - TIM

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-71CANBUS FAILURE - CHASSIS MODULE 6 6 6611✔ ✔ ✔ ✔ ✔CANBUS FAILURE - CYLINDER LOAD PIN 6 6 6612✔ ✔

SECTION 6 - JLG CONTROL SYSTEM6-72 – JLG Lift – 3121619PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST 8 3 8317✔ ✔ ✔ ✔ ✔PLATFORM LEVELING SYSTEM TIMEOU

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-73BOOM ANGLE SENSOR #1 - INVALID ANGLE 8 4 8411✔ ✔ - - ✔ ✔BOOM ANGLE SENSOR #2 - INVALID ANGLE 8

SECTION 6 - JLG CONTROL SYSTEM6-74 – JLG Lift – 3121619MAIN TRANSPORT LENGTH SWITCH DISAGREEMENT 8 4 8446- - - - ✔ - - - -MAIN DUAL CAPACITY LENGTH SW

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-75MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE 8 5 851✔ ✔ - - ✔ ✔MOMENT PIN - VERTICAL FORCE OUT OF

SECTION 6 - JLG CONTROL SYSTEM6-76 – JLG Lift – 3121619FRONT LEFT STEER SENSOR - DECOUPLED 8 6 8623✔ ✔ ✔ ✔ ✔REAR RIGHT STEER SENSOR - DECOUPLED 8 6 86

SECTION 6 - JLG CONTROL SYSTEM3121619 – JLG Lift – 6-77REAR LEFT AXLE - MOVEMENT WITHOUT COMMAND 8 6 8689- - - - - - - - ✔MACHINE SAFTEY SYSTEM OVERRI

SECTION 2 - GENERAL2-4 – JLG Lift – 31216192. The design and manufacturing tolerances of the compo-nent working parts are very close, therefore, even

SECTION 6 - JLG CONTROL SYSTEM6-78 – JLG Lift – 3121619BLAM HIGH RES A/D FAILURE 9 9 9939✔ ✔ ✔ ✔ ✔CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH 9 99940✔ ✔ ✔

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-2 – JLG Lift – 3121619Resistance Measurement• First test meter and leads by touc

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected cur

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-4 – JLG Lift – 31216193. Anderson connectors for the battery boxes and batterych

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-5AMP Mate-N-LokFollow the installation instructions.DIN Con

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-6 – JLG Lift – 3121619BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gol

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-77.4 AMP CONNECTORAssemblyCheck to be sure the wedge lock i

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-8 – JLG Lift – 31216193. After all required contacts have been inserted, thewedg

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-9Disassembly1. Insert a 4.8 mm (3/16") wide screwdrive

SECTION 2 - GENERAL3121619 – JLG Lift – 2-5Cylinder DriftDrift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-10 – JLG Lift – 3121619Figure 7-13. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-117.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crim

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-12 – JLG Lift – 3121619HD30/HDP20 Series Assembly1. Grasp contact about 25mm beh

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-137.6 WIRING HARNESS CONNECTOR LABELSConnector LabelsConnec

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-14 – JLG Lift – 3121619Other Switches Disconnect SWEMSFootHVAC WH Key SWPark bra

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-15DRIV E ORIENTSW26CAPACITY SELSW25STRT/AU X PWRSW35-1ASW35

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-16 – JLG Lift – 3121619CONNPO SWI R ECOLORWI R ELABELG AU G E J AC KET TO1 WHT 5

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-17CONNPOSWIRECOLORWIRELABE LGAUGE JACKET TO1YEL 2-6-1 18AWG

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-18 – JLG Lift – 3121619SN273MS 43 7X36BHV281PLTFM ENABLEHV275P-LVL UPHV278P- ROT

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-19X36BCONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1REDCABLE 18

SECTION 2 - GENERAL2-6 – JLG Lift – 3121619Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALWeeklyPreventiveMaintenanceMonthlyPrev

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-20 – JLG Lift – 3121619CONNPOSWIRECO L O RWIRELA BELGAUGE JACKET TO1WHT2 7 -5-1

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-21MS262-3CONNPO SWI R ECOLORWI R ELABELG AU G E J AC KET T

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-22 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1 S HLD SHIE LD 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-23C O1 28-J5CO128 -J3X411SN130CO12 8-J1CO1 28-J2X4 06AMS148

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-24 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABE LGAUGE JACKET TO1 WHT 5V 18 AWG

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-25CONNPOSWIRECOLORWIRELABELGAUGE JACKETA RED +B PWR SUP 22

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-26 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKETA YELLOW #2 ANGLE PW

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-27CONNPOSWIRECOLORWIRELABELGAUGE J ACKET1 RED B LNTH PWR 18

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-28 – JLG Lift – 3121619CO NNPOSWIRECO L O RWIRELABELGAUGE JACKET1 RED B LNTH PWR

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-29X407BA C B1 4 3 21 4 3 2SN221 SN401SN131S409S410B

SECTION 2 - GENERAL3121619 – JLG Lift – 2-7Functions/ControlsPlatform Controls 5 6 6Ground Controls 5 6 6Function Control Locks, Guards, or Detents 1,

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-30 – JLG Lift – 3121619CO NNPOSWIRECO L O RWIRELABELGAUGE JACKET TO1 WHT BECON P

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-31CONNPOSWIRECOLORWIRELABELGAUG E J ACKET TO1 BLK 000-48-1

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-32 – JLG Lift – 3121619PIN 2 = ANODEIP90, IP91 DIODE DETAILSRL360-85RL360-86RL12

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-33CONNPOSWI RECOLORWI RELABELGAUGE JACKET TO1RED1-15 18 AWG

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-34 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1BLK00-11 10 AWG

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-35CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1WHT27-3 JIB DN O

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-36 – JLG Lift – 3121619X81SN123LB417X84X327BX412CO0 2-J7X88CO0 2- J1IP85S89X440B

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-37CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1RED1-7-2 WK LT P

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-38 – JLG Lift – 3121619CO NNPOSWIRECO L O RWIRELABELGAUGE JACKET TO1 RED 1- 5 16

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-39CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1YEL2-4-4 18 AWG

INTRODUCTIONA-2 – JLG Lift – 3121619REVISON LOGOriginal Issue - June 18, 2014Revised - September 25, 2014

SECTION 2 - GENERAL2-8 – JLG Lift – 3121619Annual Machine Inspection Due 21No Unauthorized Modifications or Additions 21 21All Relevant Safety Publica

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-40 – JLG Lift – 3121619MS148-2MS83 MS 82X395Figure 7-45. Turntable Wiring Harne

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-41ZIP TIE AS SHOWNSW 58TURNTABLE SWINGSW 60MAIN TELESW 61JI

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-42 – JLG Lift – 3121619CONNPO SWIR ECOLORWI R EL ABELG AU G E J AC KET T O1WH T3

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-43CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1WHT48-4 STRT 18

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-44 – JLG Lift – 3121619CO03-J3CO03 -J2X147B445AX3 37AX33 9A448BX340AX3 38A442AHV

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-45CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1WHT61-1-3 5V 18

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-46 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1 W HT 61-1-4 5V

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-47CONNPOSWIRECOLORWIRELABELGAUGE JACKET TOA BLK 00-14 18 AW

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-48 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1 YEL CAN HI 18 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-49Figure 7-54. Chassis Harness - Sheet 6of 6

SECTION 2 - GENERAL3121619 – JLG Lift – 2-9Figure 2-1. Engine Operating Temperature Specifications - Deutz1001159163 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-50 – JLG Lift – 3121619HYD OIL TEMPHV1 01MAIN LIFT DNHV1 07LIFT PILOTHV1 05LIFT

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-51LIFT DN AUXCO NNPOSWIRECO L O RWIRELABELGAUGE JACKET TO1

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-52 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1 WHT 50-3 JIB D

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-53CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1WHT7-4 RDRV PFWD

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-54 – JLG Lift – 3121619SN939RL930T920RL931-85RL931-86RL 93 1 -8 7RL930-1RL930-2F

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-55CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1RED148-1ECM PWR

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-56 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO1SHLD248-38ENGINE

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-57CONNPOSWIRECOLORWIRELABELGAUGE JACKET TO12BLK248-2 INJECT

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-58 – JLG Lift – 3121619CONNPOSWIRECOLORWIRELABELGAUGE JACKET TOA YEL CAN HI 20 A

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-59MS1000-2X1005MS1002-1MS999-3MS999-2Figure 7-64. CAN Engi

SECTION 2 - GENERAL2-10 – JLG Lift – 3121619MACHINE OPERATION USING NON-JLG APPROVEDHYDRAULIC FLUIDS OR OPERATION OUTSIDE OFTHE TEMPERATURE BOUNDARIES

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-60 – JLG Lift – 3121619Figure 7-65. Electrical Installation - Sheet 1 of 100011

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-61Figure 7-66. Electrical Installation - Sheet 2 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-62 – JLG Lift – 3121619Figure 7-67. Electrical Installation - Sheet 3 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-63Figure 7-68. Electrical Installation - Sheet 4 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-64 – JLG Lift – 3121619Figure 7-69. Electrical Installation - Sheet 5 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-65Figure 7-70. Electrical Installation - Sheet 6 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-66 – JLG Lift – 3121619Figure 7-71. Electrical Installation - Sheet 7 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-67Figure 7-72. Electrical Installation - Sheet 8 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-68 – JLG Lift – 3121619Figure 7-73. Electrical Installation - Sheet 9 of 101001

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-69Figure 7-74. Electrical Installation - Sheet 10 of 10100

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES AND WHEELSTire DamageFor pneumatic tires, JLG

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-70 – JLG Lift – 3121619Figure 7-75. Battery Jump-Start HookupTHIS MACHINE UTILI

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-71Figure 7-76. Battery Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-72 – JLG Lift – 3121619This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-73SHEET 2: PLATFORM BOXSHEET 3: PLATFORM AND JIB COMPONENTS

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-74 – JLG Lift – 31216194321GHEFCDAB1234RRRRGYRYGGGGYYYGYGGGPLTF LEVELBCS AXLE SE

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-75BCDEFGH8765445678BOOM CABLECONNECTI ONSEE SHEET 3ZONE C-1

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-76 – JLG Lift – 31216194321GHEFCDAB12345+-+-GNDCANHCANLCANSGRAPHIC DISPLAYMOUNTE

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-77BCDEFGH87655678+-+-+-PWRGNDCANHCANLCANSCAN SHDCAN LOCAN H

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-78 – JLG Lift – 31216194321GHEFCDAB1234587308685PWRGNDCANHCANLPOWERCOMMONOUTPUTC

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-79BCDEFGH8765445 6 7 8M8730868587308685GROUND STUD87308685T

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31216193.2 AXLE EXTENSION SYSTEMNOTE: The boom must be oriented between the rear wheels toextend o

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-80 – JLG Lift – 31216194321GHEFCDAB12345DIAGNOSTIC DISPLAYHO URME TE RGN DSHIELD

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-81BCDEFGH8765445 6 7 8DRAWING NUMBER REV.ENGINECONNECT OR #

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-82 – JLG Lift – 31216194321GHEFCDAB12345CHASSIS MODULECANTCANTBRK RELEASE FROM U

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-83BCDEFGH876556 78TURNTABLE ANGGNDGNDLFT FRNT AXLE SWGRIG

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-84 – JLG Lift – 31216194321GHEFCDAB12345HEAD & TAIL LIGHTSIGNALCONNECTION TO

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-85BCDEFGH87655678PWRSI GGNDPWRSI GGNDRIGHTSWINGHV 99 12LE F

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-86 – JLG Lift – 3121619K [J1]2.5M M (1-6)1.5MM (7,29,51,73)1.5MM (7,29,51,73)1.5

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-87308685PWRSI GGNDFUEL PUMPWATER IN FUELDEUTZ DIAGNOSTICENG

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-88 – JLG Lift – 31216194321GHEFCDAB12345DRAWING NUMBER873087 a8586CONNECTS TO X1

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS3121619 – JLG Lift – 7-89BCDEFGH87655678ENGINECONNECTOR #2REFERENCE O NLYREFERENCE

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-33.4 STEERING CONTROL SYSTEMThere are three different modes of steering selectable by thepos

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS7-90 – JLG Lift – 3121619NOTES:

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

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3121619will be driven based on the information available from theother sensors. This axle will not

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-5This page left blank intentionally.

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121619Figure 3-4. Axle Hose Routing - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-7Figure 3-5. Axle Hose Routing - Sheet 2 of 2

3121619 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121619Figure 3-6. Steering/Axle Hydraulic Circuit

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-9HUB/DRIV E MOTORBOTTOM VIEW OFTRACTION VALVEB5B6A3B3DA5TOSW IVE L POR T 7TOSW IVEL P O RT

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121619TRACTION VALVEBRBRBRL1L1X1X1FRONTREARLEFTRIGHTTOSWIVEL PORT 7XXXXXXXXLEFT FRONT HU B /D R

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-11Figure 3-9. Turntable Hydraulic System

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31216193.7 DRIVE ASSEMBLYFigure 3-10. Drive Assembly12345671. Drive Hub2. O-Ring3. Drive motor4.

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-133.8 DRIVE HUBFigure 3-11. Drive Hub1. Ring2. Screw3. Cover4. Gasket5. Plug6. Cover7. O-Ri

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121619Disassembly1. Remove plugs (5) and pour lubricant in a container.Reinstall plugs.2. Remove

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-156. Remove two Screws (19), Planetary Ring (18) and O-Ring(26). Do not damage O-Ring. 7. Re

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 312161910. Remove Hub Support (30), Bearing (29), O-Ring (31),Bearing (32), and two Seals (33) fr

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-1714. Remove Split Ring (36), Input Shaft (42), and Bearing (37)from Axle (38).AssemblyNOTE:

ii – JLG Lift – 3121619TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 31216195. Install Flange (25) on Axle (38), with Plug (21) and sixscrews (20).NOTE: Flat surface

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-199. Install Spring (35) and Coupling (34). 10. Install O-Ring (26). Install Planetary Ring

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 312161913. Install O-Ring (54) and Motor Flange (55). Apply Loctite243 or equivalent to six Screw

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-213.9 FREE WHEELING OPTIONDisengage Drive Motors & Brakes for Towing, etc. (Free Wheel)1

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 3121619Figure 3-14. Drive Motor12334567891011121314151617202118192223242526272829303132333435363

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-233.11 DRIVE MOTORNOTE: Drive motor servicing is similar for all Series 45 hydraulicmotors.

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121619INSPECTIONInspect new seal, motor housing seal bore, and sealing area onshaft for rust, we

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-25TroubleshootingTable 3-2. Excessive Noise and/or VibrationItem Description ActionCheck o

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121619DisassemblyNOTE: Removal of endcap voids warranty.During assembly, coat all moving parts w

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-27Figure 3-20. End Cap13. Using an 8 mm internal hex wrench, remove endcapscrews (22).14. R

3121619 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3121619Figure 3-22. Cylinder Kit18. Turn housing on its side and remove cylinder kit assem-bly (

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-29.Figure 3-24. Shaft & Front Bearing20. Remove inner snap ring (35) and shaft/bearing

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121619Figure 3-26. Cylinder Kit Disassembly25. Remove pistons (44) and slipper retainer (45) fr

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-31CYLINDER BLOCKMeasure cylinder block height. Replace blocks worn beyond minimum height spe

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 3121619SHAFT BEARINGSInspect bearings for excessive wear or contamination. Rotatebearings while f

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-33RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRESABOUT 80 TO 90 LBF (350 TO 4

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 31216198. Press front shaft bearing (15) on shaft (16). Press bearingon shaft with lettering faci

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-3512. Press rear shaft bearing (22) in endcap. Install bearingwith letters facing out. Press

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 312161918. Cover shaft splines with an installation sleeve. Install anew shaft seal (27) with cup

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-37Initial Start-up ProceduresFollow this procedure when starting-up a new motor or wheninsta

iv – JLG Lift – 3121619TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 31216195. Apply JLG Thread locking compound P/N 0100019 tothe bolts and pre-torque the 5 bolts to

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-39CENTEROFGRAVITY31 .7 " (8 0 cm)Upperstructu re - 39, 000 lbs (17,690 kg)Figure 3-37.

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121619Figure 3-38. Swing Bearing Removal - Sheet 2 of 4

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-41Main Boom PivotCENTEROFGRAVITYBoom Assembly - 21,650 lbs (9,820 kg)Figure 3-39. Swing Bea

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121619Note: Attach Lifting Device toTurntable Cutouts Closest toThis Side of TurntableTurntable

SECTION 3 - CHASSIS & TURNTABLE3121619 – JLG Lift – 3-433.13 SWING CONTROL SYSTEMThe swing control system uses the turntable swing angle sen-sor i

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121619NOTES:

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM SYSTEMSBroken Cable Indicator SystemThe boom on this mo

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121619envelope. The two main boom angle sensors measure theangle of the main boom relative to gravity

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-3Controlled Boom Angle System The Controlled Boom Angle System uses the envelope controlsensors

3121619 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121619automatically. If a fault occurs in the platform leveling systemthe following will occur:• Auto

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-5Figure 4-1. Boom Hydraulic System

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31216194. Tag and disconnect all electrical lines from the limitswitches and generator that go to from

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-75. Raise the front of the boom enough to allow connectionof the lift cylinder.6. Attach a lifti

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31216192. Install the side rear wear pads and shims. Coat theretaining bolts with JLG threadlocking co

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-9Figure 4-2. Boom Assembly - Sheet 1 of 9

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121619Figure 4-3. Boom Assembly - Sheet 2 of 9

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-11Figure 4-4. Boom Assembly - Sheet 3 of 9

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3121619Figure 4-5. Boom Assembly - Sheet 4 of 9

SECTION 4 - BOOM & PLATFORM3121619 – JLG Lift – 4-13Figure 4-6. Boom Assembly - Sheet 5 of 9