Jlg 18RS Service Manual User Manual

Service and Maintenance ManualModel18RSP/N - 3121284October 22, 2013

vi – JLG Lift – 3121284LIST OF FIGURES FIGURE NO. TITLE

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31212841612141413158311456791011819172020220201. Barrel2. Rod3. Head4. Wiper5. Retaining Ring6. Rod Seal7. Bac

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-11Main Boom Telescope CylinderDISASSEMBLYDISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMEDON A CLEAN WORK S

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31212849. Loosen and remove the capscrews which attach thetapered bushing to the piston.10. Insert the capscre

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-1312. Inspect cylinder head outside diameter for scoring orother damage and ovality and tapering. Replace

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31212842. Use a soft mallet to tap a new wiper seal into the cylin-der head gland groove. Install a new wear r

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-1513. Remove the cylinder rod from the holding fixture.14. Place a new t-seal and wear rings in the outer

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31212841. Threadlocker2. Bolt3. Bolt4. Tapered Bushing5. Barrel6. Rod7. Backup Ring8. Plug9. Not Used10. Pad11

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-17Figure 5-24. Main Hydraulic Valve - Sheet 1 of 5

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3121284Figure 5-25. Main Hydraulic Valve - Sheet 2 of 5

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-19Figure 5-26. Main Hydraulic Valve - Sheet 3 of 5

3121284 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 3121284Figure 5-27. Main Hydraulic Valve - Sheet 4 of 5

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-21Figure 5-28. Main Hydraulic Valve - Sheet 5 of 5

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121284Figure 5-29. Main Hydraulic Valve Schematic

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-23Figure 5-30. Flow Divider Valve - Sheet 1 of 2

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3121284Figure 5-31. Flow Divider Valve - Sheet 2 of 2Torque 18- 23.5 lb.ft. (24-32 Nm)Tor que 2 5 l b. ft. (

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-25Figure 5-32. Hydraulic Oil Tank - Sheet 1 of 3

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121284Figure 5-33. Hydraulic Oil Tank - Sheet 2 of 31. Breather Assembly2. Wing Nut3. Cover4. Fitler5. Filte

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-27Figure 5-34. Hydraulic Oil Tank - Sheet 3 of 3Torque to 8 lb.ft. (11 Nm)Finger Tight

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 3121284Figure 5-35. Filter LocationMAIN VALVE FILTERCHARGE FILTER

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-29Figure 5-36. Hose Routing - Sheet 1 of 2

viii – JLG Lift – 3121284LIST OF TABLES TABLE NO. TITLE

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 3121284Figure 5-37. Hose Routing - Sheet 2 of 2

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-315.3 SAUER DANFOSS PUMPNew Pump Startup ProcedureBefore installing the pump, inspect for damage that may

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 3121284TroubleshootingTable 5-1. Electrical TroubleshootingItem Description ActionControl operates pump in one

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-33Table 5-3. Transmission Operates Normally in One Direction OnlyItem Description ActionOpen bypass valve

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 3121284Table 5-5. System Noise or VibrationItem Description ActionReservoir oil level Low oil level leads to

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-35General Adjustment PracticesThis section offers instruction on inspection and adjustment ofpump compone

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 3121284Pressure Limiter AdjustmentsLock motor output shaft to adjust the pressure limiter setting.Lock the veh

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-372. Start the prime mover and operate at normal speed.3. Use a 17mm wrench to loosen the locking nut (L0

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 3121284Engaging the Bypass FunctionUse this procedure to bypass the pump to allow moving thevehicle/machine sh

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-39Control Neutral AdjustmentNOTE: Adjustment of the EDC is very sensitive. Be sure to hold thehex wrench

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONSOperating SpecificationsDimensional DataCapaci

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 3121284NOTE: A small pressure differential of 1.5 bar [22 psi] or less isacceptable. Zero differential is usua

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-417. Remove all gauges and replace gauge port plugs.SERVO ADJUSTMENT SIDE M41. Run prime mover at 1800 rp

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 3121284electrical connections when using straps or chains tosupport the pump.INSPECTION1. Ensure the work surf

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-43Control SolenoidsREMOVAL1. Disconnect electrical connection and remove the threecap screws (D050) using

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 3121284Shaft Seal, Roller Bearing and Shaft ReplacementThe shaft assembly is serviceable without disassembling

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-45Charge PumpIf the pump has an auxiliary pump attached, remove the auxil-iary pump and connecting shaft

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 31212846. Install the thrust washer (K500). Coated side goestoward charge pump coupling (K200).7. Install a ne

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-47Charge Pressure Relief ValveReplace the charge pressure relief valve (V010) as a completeunit. Do not a

SECTION 5 - HYDRAULICS5-48 – JLG Lift – 3121284Table 5-12. Fastener Size and Torque ChartItem Fastener Wrench Size TorqueD015 Neutral adjust screw 4 m

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-49Figure 5-56. Fasteners and Plugs - Sheet 1 of 2

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3121284Hydraulic OilNOTE: Hydraulic oils require anti-wear qualities at least APIService Classification GL-

SECTION 5 - HYDRAULICS5-50 – JLG Lift – 3121284Figure 5-57. Fasteners and Plugs - Sheet 2 of 2

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-515.4 HYDRAULIC DRIVE PUMP PRE-FILL PROCEDUREThe case of the hydraulic drive pump, MUST be pre-filledbefo

SECTION 5 - HYDRAULICS5-52 – JLG Lift – 31212844. P2 MAIN RELIEF VALVE. Pressure gauge at the MP2port. Locate the Platform level up relief valve locat

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN I

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121284The JLG Control System controller has a built in LED to indicateany faults. The system stores re

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-36.3 USING THE HAND HELD ANALYZERTo Connect the JLG Control System Analyzer1. Connect the four pi

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121284The top level menus are as follows:HELPDIAGNOSTICSSYSTEM TESTOPERATOR ACCESSPERSONALITIESMACHINE

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-5Press ENTER to select the ACCESS LEVEL menu.Using the UP or DOWN arrow keys, enter the first dig

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121284Machine SetupWhen a machine digit item is selected, press the UP or DOWNarrow keys to adjust its

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-7Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERATEACT ACTIVEA/D ANALOG DIGITA

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-3Table 1-8. Machine Orientation When Performing Speed TestDrive;(Max Speed)Te st sh ou ld be do ne

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121284ROT. ROTATERT RIGHTS/C SHORT CIRCUITSEL SELECTORSN SERIAL NUMBERSPD SPEEDSTOW STOWEDSTOWD STOWED

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-9MENU:SYSTEM TESTMENU:HELP: PRESS ENTERHELPLOG: (xxx):EVERYTHING OKx: xxxxxxxxxxxSYSTEM TEST:ACTI

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121284MENU:PERSONALITIESPERSONALITIES:DRIVEDRIVE MAX SPEEDACCEL 275mA/sDRIVE MAX SPEEDDECEL 175mA/SDR

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-11MENU:MACHINE SETUPMODELNO MODEL340AJENGINE SHUTDOWNDISABLEDENABLEDSTART LOCKOUTDISABLEDENABLEDE

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121284MENU:DIAGNOSTICSDRIVE/STEERDRIVE DEMANDFORWARD /REVERSE XXX%DRIVE OUTPUTFORWARD /REVERSE XXX%DR

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-13MENU:DIAGNOSTICSPLATFORM LOADPLATFORM LOADSTATE : OK/OVERLOADPLATFORM LOADACTUAL: XXX.XKGPLATFO

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121284Figure 6-7. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-15Figure 6-8. Ground Module - Sheet 1 of 3

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121284Figure 6-9. Ground Module - Sheet 2 of 3

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-17Figure 6-10. Ground Module - Sheet 3 of 3

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3121284Table 1-9. Function SpeedsFunctionAdjustment RangesDefaultSettingTime RangeIn SecondsDRIVEMax Speed

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121284Figure 6-11. Platform Module - Sheet 1 of 2

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-19Figure 6-12. Platform Module - Sheet 2 of 2

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 31212846.4 SYSTEM FAULT MESSAGESThe Help Message display on the JLG Analyzer provides diag-nostic feed

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-21 Table 6-2. Machine Configuration Programing InformationConfiguration Label/Digit Number Descri

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121284FUEL CUTOUT:8*1234ONE RESTART: One restart with limited run time when near Empty.ENG IN E S

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-23H & T LIGHTS: 15*12NO: No head and tail lights installed. YES: Head and tail lights install

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121284* Certain market selections will alter default setting.LEVELING MODE:22* 12ALL FUNCTIONS: Platf

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-25Table 6-3. Machine Configuration Programming Settings18RSANSI USAANSI ExportCSAJapanModel Numbe

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121284Table 6-4. Fault Code ListDTC Text001 EVERYTHING OK0010 RUNNING AT CUTBACK - OUT OF TRANSPORT P

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-272371 FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED2372 FUNCTION PROBLEM - SWING LEFT PE

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-51.3 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1-1., Operator Ma

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 31212843374 GEN SET/WELDER - OPEN CIRCUIT3375 GEN SET/WELDER - SHORT TO BATTERY3376 HEAD TAIL LIGHT -

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-2933281 GLOWPLUG - SHORT TO GROUND33287 LIFT - CURRENT FEEDBACK READING TOO LOW33295 SWING LEFT V

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 31212843419 JIB LIFT DOWN VALVE - SHORT TO BATTERY3420 JIB LIFT DOWN VALVE - SHORT TO GROUND431 FUEL S

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-318211 LSS READING UNDER WEIGHT8639 FRONT LEFT STEER VALVE - OPEN CIRCUIT8640 FRONT LEFT STEER VA

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121284Table 6-5. Fault Code Troubleshooting InformationHelp Message DTC Condition Producing DTCContro

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-33FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED225 The machine is in Platform mode and the

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121284L/S JOY. CENTER TAP BAD 2220 The Platform Module detects that the Lift/Swing center tap voltage

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-35FUNCTION PROBLEM - TELE-SCOPE IN PERMANENTLY SELECTED2251 The machine is in Platform mode and t

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121284FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH236 The Ground Module detects one of the

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-37FUNCTION PROBLEM - LIFT UP PERMANENTLY SELECTED23 10 7 Th e m ac hi ne is in Grou nd mo de

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31212842. Swing Bearing/Worm Gear TeethLube Point(s) - Grease FittingCapacity - A/RLube - Lubriplate 930-AA

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121284FUNCTION PROBLEM - PLAT-FORM ROTATE LEFT PERMA-NENTLY SELECTED23113 The machine is in Ground mo

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-39FUNCTIONS LOCKED OUT – CONSTANT DATA VERSION IMPROPER2520 The Ground Module detects a mismatch

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3121284MAIN DUMP VALVE – OPEN CIRCUIT3359 The Ground Module detects an open circuit at the Main Dump V

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-41STEER DUMP VALVE – SHORT TO BATTERY3367 The Ground Module detects a short to battery at the Ste

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 3121284PLATFORM LEVEL UP VALVE – OPEN CIRCUIT3383 The Ground Module detects an open circuit at the Pla

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-43SWING LEFT VALVE – SHORT TO GROUND33122 The Ground Module detects a short to ground at the Swin

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 3121284GLOWPLUG – SHORT TO BAT-TERY33280 The Ground Module detects a short to battery at the Glow Plug

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-45DRIVE FORWARD VALVE – OPEN CIRCUIT33317 The Ground Module detects an open circuit at the Drive

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121284LIFT UP VALVE – SHORT TO GROUND33406 The Ground Module detects a short to ground at the Lift Up

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-47SWING – CURRENT FEEDBACK READING LOST33418 Measured feedback current is less than 225mA while G

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-75. King PinsLube Point(s) - 2 Grease FittingsCapacity - As RequiredLube - MPGInterval - Every 3 mont

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 3121284PLATFORM ROTATE LEFT VALVE – SHORT TO GROUND3411 The Platform Module detects a short to ground

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-49JIB LIFT DOWN VALVE – SHORT TO BATTERY3419 The Platform Module detects a short to battery at th

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121284ENGINE TROUBLE CODE 437 The engine controller reports a J1939 fault Engine will operate at 18

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-51FUEL ACTUATOR – OPEN CIR-CUIT4327 The Ground Module detects an open circuit at the fuel actuato

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121284LSS BATTERY VOLTAGE TOO LOW444 The machine is configured with and Load Sensing System and the G

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-53CANBUS FAILURE – EXCESSIVE CANBUS ERRORS6613 More than 22 error frames per second for 4 seconds

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121284DRIVE & BOOM PREVENTED – PLATFORM OVERLOADED827 The Platform is Overloaded and Machine Setu

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-55LSS INTERNAL ERROR – DRDY MISSING FROM A/D994 The Ground Module detects an LSS report of an ano

SECTION 6 - JLG CONTROL SYSTEM6-56 – JLG Lift – 3121284FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED9924 The machine is powered up and no model has be

SECTION 6 - JLG CONTROL SYSTEM3121284 – JLG Lift – 6-57Table 6-6. Overload VariationsBROADCAST ONLY3WARN ONLY CUTOUT ALLSPECIAL 1(Access Industries)CU

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31212849. Air FilterLube Point(s) - Replaceable ElementInterval - Every 6 months or 300 hours of operation1

SECTION 6 - JLG CONTROL SYSTEM6-58 – JLG Lift – 3121284NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121284Resistance Measurement• First test meter and leads by touching leads

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31212843. Anderson connectors for the battery boxes and batterychargers shou

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-5AMP Mate-N-LokFollow the installation instructions.DIN ConnectorsThis

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3121284AMP JUNIOR TIMERThis type of connector uses back-seals for moisture i

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-7Figure 7-7. Electrical System Installation - Sheet 1 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 3121284Figure 7-8. Electrical System Installation - Sheet 2 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-9Figure 7-9. Electrical System Installation - Sheet 3 of 7

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-9Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPOU

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121284Figure 7-10. Electrical System Installation - Sheet 4 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-11Figure 7-11. Electrical System Installation - Sheet 5 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121284Figure 7-12. Electrical System Installation - Sheet 6 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-13Figure 7-13. Electrical System Installation - Sheet 7 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121284This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-15ELECTRICAL SCHEMATICFigure 7-14. Electrical Schematic - Sheet 1 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121284Figure 7-15. Electrical Schematic - Sheet 2 of 11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-17Figure 7-16. Electrical Schematic - Sheet 3 of 111001129238-B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121284Figure 7-17. Electrical Schematic - Sheet 4 of 11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-19Figure 7-18. Electrical Schematic - Sheet 5 of 111001129238-B

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121284Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121284Figure 7-19. Electrical Schematic - Sheet 6 of 11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-21Figure 7-20. Electrical Schematic - Sheet 7 of 111001129238-B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121284Figure 7-21. Electrical Schematic - Sheet 8 of 11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-23Figure 7-22. Electrical Schematic - Sheet 9 of 111001129238-B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121284Figure 7-23. Electrical Schematic - Sheet 10 of 11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-25Figure 7-24. Electrical Schematic - Sheet 11 of 111001129238-B

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3121284Figure 7-25. Hydraulic Schematic - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121284 – JLG Lift – 7-27Figure 7-26. Hydraulic Schematic - Sheet 2 of 21001131499-A

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3121284NOTES:

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-11Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

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

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121284Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-13Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121284Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3121284 – JLG Lift – 1-15Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121284NOTES:

SECTION 2 - GENERAL3121284 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

INTRODUCTION3121284 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 2 - GENERAL2-2 – JLG Lift – 31212842.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121284 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 31212842. The design and manufacturing tolerances of thecomponent working parts are very close, therefore,even the

SECTION 2 - GENERAL3121284 – JLG Lift – 2-5Cylinder DriftDrift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil

SECTION 2 - GENERAL2-6 – JLG Lift – 3121284NOTE: Reference the Operation and Safety Manual for com-pletion procedures for the Pre-Start Inspection.Tab

SECTION 2 - GENERAL3121284 – JLG Lift – 2-7Functions/ControlsPlatform Controls 566Ground Controls 566Function Control Locks, Guards, or Detents 1,5 5

SECTION 2 - GENERAL2-8 – JLG Lift – 3121284All Decals/Placards Installed, Secure, Legible 21 21Walk-Around Inspection PerformedAnnual Machine Inspecti

SECTION 2 - GENERAL3121284 – JLG Lift – 2-9Figure 2-1. Hydraulic Oil Operation Chart1001151189-AFigure 2-2. Engine Oil Operation Chart1001151190-A

SECTION 2 - GENERAL2-10 – JLG Lift – 3121284NOTES:

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES AND WHEELSTire ReplacementJLG recommends a rep

INTRODUCTIONA-2 – JLG Lift – 3121284REVISON LOGOriginal Issue - October 22, 2013

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31212843.2 DRIVE ORIENTATION SYSTEM The Drive Orientation System (DOS) indicates to the operatorco

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-33.4 STEER CYLINDERRemoval1. Place the machine on a firm, level surface.2. Place a container

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3121284FLOW DIVIDER BOTTOM VIEWPORT REVPORT FWDFLOW DIVIDERDRIVE PUMPPORT APORT BPORT APORT BRIGHT

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-53.5 DRIVE HUBRemoval1. Place the machine on a firm, level surface.2. Use an adequate jack t

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121284FLOW DIVIDER BOTTOM VIEWFLOW DIVIDERHYD TANK(SOME COMPONENTS NOTSHOWN FOR CLARITY)DRIVE PUM

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-7119±5DISTANCE FROM HOSE GUIDETO INNER HOSE EDGE356±26FRONT AXLE ROUTING - RIGHT SIDEROUTE T

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121284Installation1. Position the hub onto the axle or spindle.2. Coat the retaining bolts with J

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-9Figure 3-5. Drive Motor

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 31212849. Remove cardan shaft from the splines of output shaft.10. Separate Intermediate Plate fr

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-119. Lubricate the roll-gerotor set surface and place on it thechannel plate.10. Lubricate a

3121284 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31212844. Place the balance plate (set) inside the end cover withthe pin orientated to fall in wi

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-13Figure 3-6. Swing Motor - Cutaway

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121284Table 3-3. Swing Motor TroubleshootingTrouble Cause RemedyOil Leakage 1. Hose fittings loo

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-15RemovalRefer to Figure 3-7., Swing Motor Removal and Installation.1. Thoroughly clean the

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121284WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-IMUM AIR PRESSURE REQUIRE

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-17123444888E8A8C8B48D9445761012131414151625171819201. Bolt2. End Cover3. Seal Ring4. Seal Ri

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 31212844. Remove end cover assembly (2) and seal ring (4). Discardseal ring.5. Thoroughly wash en

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-198. Remove manifold (7) and inspect for cracks surface scor-ing, brinelling or spalling. Re

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 312128410. Place rotor set (8) and wear plate (9) on a flat surface andcenter rotor in stator suc

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-2114. Remove coupling shaft (12), by pushing on the outputend of shaft. Inspect coupling sha

ii – JLG Lift – 3121284TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 312128419. Inspect housing (18) assembly for cracks, the machinedsurfaces for nicks, burrs, brine

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-2321. If the bearings, bushing or thrust washers must bereplaced use a suitable size bearing

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121284IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE METHODS AREUSED TO PRESS IN BEARING/BU

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-256. Assemble thrust washer (14) then thrust bearing (15)that was removed from the motor. NO

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 31212849. Apply a small amount of clean grease to a new seal ring(4) and insert it into the housi

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-27NOTE: It may be necessary to turn one alignment stud out of thehousing (18) temporarily to

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 312128418. Assemble a new seal ring (3) flat side up, into commuta-tor (5) and assemble commutato

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-2920. Assemble the bolts (1) and screw in finger tight. Removeand replace the two alignment

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 31212844. Assemble six vanes, or as many vanes that will readilyassemble into the stator vane poc

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-318. Assemble six vanes, or as many vanes that will readilyassemble into the stator vane poc

3121284 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31212843.8 SWING BEARINGDescriptionThe swing bearing has five major components: housing,worm, wor

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-33INNER RACEBEARING BOLTOUTER RACEBEARING BOLTCAPSCREWWASHERGREASE FITTINGSWINGMOTORGASKETWA

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 3121284DisassemblyRefer to Figure 3-10., Swing Bearing Drive.1. Clean area around swing motor (1)

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-35Figure 3-10. Swing Bearing Drive

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 31212848. Install worm (29), hex end first, into housing (4).IF COMPRESSED AIR OR ELECTRICALLY OP

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-373.9 CHASSIS TILT INDICATOR SYSTEM The Chassis Tilt Indicator System measures the relation

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121284ENGINESTOPPEDENGINERUNNINGENGINECRANKINGENGINESTARTING(RPM greater than 800 for 1/4 second

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-393.12 ENGINE START CONDITIONSEngine starting is controlled by the Ground Module. TheGround

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121284Mid Engine RPMMid Engine RPM occurs when all of the following conditionsexist;1. The Engin

SECTION 3 - CHASSIS & TURNTABLE3121284 – JLG Lift – 3-41Glow PlugsThe diesel engine has glow plugs, controlled by the groundmodule to assist in co

iv – JLG Lift – 3121284TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121284Figure 3-14. Counterweight Bolt Torque

SECTION 4 - BOOM & PLATFORM3121284 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 PLATFORM CONTROL ENABLE SYSTEM The platform controls use a t

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31212842. Pull the telescope cylinder rod out and turn the trunnionplate at the end of the rod 90 degr

SECTION 4 - BOOM & PLATFORM3121284 – JLG Lift – 4-34.8 LOWER BOOMDisassembly1. Remove the main boom.2. Support the weight of the lower boom assemb

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121284EESEE DETAIL A SEE DETAIL B SEE DETAIL C 75±5405±5DETAIL B ROUTE THROUGHHOSE GUIDEINCLUDE R

SECTION 4 - BOOM & PLATFORM3121284 – JLG Lift – 4-5GGFF50±5TIE STRAP ROTATOR HOSES,AIRLINE AND CABLES.ROUTE AIR HOSE AND CABLES ON LEFT,HYDRAULIC

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31212844.9 HOSE ADJUSTMENT PROCEDURE1. Starting at the front of the machine, pull the hosesand cables

SECTION 4 - BOOM & PLATFORM3121284 – JLG Lift – 4-7lengths set, tighten the hose clamp at position “B”until hoses are tight and unable to be moved

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31212847. Attach all hydraulic hoses and cables and start upthe machine. Raise the boom a minimum of 5

SECTION 4 - BOOM & PLATFORM3121284 – JLG Lift – 4-9and cables are pushed to the outside of the curve inthe power track. Adjust the loop of hoses b

3121284 – JLG Lift – v LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121284NOTES:

SECTION 5 - HYDRAULICS3121284 – 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 – 3121284Dip MethodNOTE: This method works best with Face Seal o-rings, but willwork for all o-ring fitting types

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-35.2 HYDRAULIC CYLINDERSPlatform Slave Level CylinderDISASSEMBLY1. Remove the lockwire.2. Remove the cyli

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31212841. Barrel2. Rod3. Piston4. Head5. Lock Wire6. Locknut7. Bearing8. Rod Seal9. Piston Seal10. Wiper11. Wea

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-5Master CylinderDISASSEMBLY1. Remove the lockwire.2. Remove the rod (with piston, head, and locknut) from

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31212841. Rod2. Wiper Seal3. Rod Seal4. O-ring5. Backup Ring6. Gland7. Tube Weldment8. Piston9. Piston Seal10.

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-7Steer CylinderDISASSEMBLY1. Unscrew the heads from both ends.2. Remove the piston rod from the tube weld

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31212841. Rod2. Head3. Wiper Seal4. Retaining Ring5. Rod Seal6. Wear Ring7. O-ring8. Backup Ring9. Piston10. We

SECTION 5 - HYDRAULICS3121284 – JLG Lift – 5-9Lift CylinderDISASSEMBLY1. Remove all valve cartridges and plugs. 2. Unscrew the cylinder head from the