Jlg 450A_AJ Series II Service Manual User Manual

Service and Maintenance ManualModels450A/AJSeries IIPrior To S/N 0300160835P/N - 3121180December 3, 2012

vi – JLG Lift – 3121180TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121180DisassemblyNOTE: Removal of endcap voids warranty.During assembly, coat all moving parts w

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-5113. Using an 8 mm internal hex wrench, remove endcapscrews (22).14. Remove endcap (23). Re

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 312118018. Remove minimum angle stop (29) and servo spring (30)from housing.19. Turn housing on i

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-5323. Turn housing over and remove swashplate (39) bylifting on end opposite servo lever.24.

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121180RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRINGREQUIRES FORCE OF ABOUT 80 TO 90 LBF (350

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-55BALL GUIDE AND SLIPPER RETAINERInspect ball guide and slipper retainer for damage, discol-

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3121180SHAFTInspect motor shaft. Look for damage or excessive wearon output and block splines. In

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-573. Install inner block spring washer (4), block spring(5), and outer washer (6) in cylinde

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 31211808. Press front shaft bearing (15) onto shaft (16). Pressbearing onto shaft with lettering

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-5912. Press rear shaft bearing (22) into endcap. Installbearing with letters facing out. Pre

3121180 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 312118018. Cover shaft splines with an installation sleeve. Installa new shaft seal (27) with cup

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-6120. Install orifice poppet (30).21. Install shift spool (31).22. Install spring retaining

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121180Ta b l e 3 - 9 . Ch ass i s To r q u e Val u esFt-Lb NmA 120 163B 240 325C 170 230D 14

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-63EABCDTable 3-10. Chassis Torque ValuesFt-Lbs. NmA 120 163B 240 325C 170 230D 85 115E 165 2

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 31211803.7 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE11. With turntable centered, adjust bracket with

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-65Oscillating Axle Lockout TestLOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,ANY TIME A SY

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121180TOREMOTE12Inner RaceOuter RaceMotor HydraulicLines Not Shown9834675Figure 3-48. Swing Bea

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-67DisassemblyRefer to Figure 3-49., Swing Bearing Drive.1. Clean area around swing motor (1)

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 312118034467911252022, 3382812651617, 341030, 322135,3618131914333292121527Figure 3-49. Swing Be

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-69AssemblyRefer to Figure 3-49., Swing Bearing Drive.1. Press bearing cup (17) in cap (12).2

viii – JLG Lift – 3121180LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3121180IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACTWRENCH IS USED TO TIGHTEN BEARING ATTACHM

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-71Check Turntable To Bearing Bolts1. Fully retract boom and elevate to 70 degrees (fulleleva

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 31211803.10 SWING MOTORIF HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [INEXCESS OF 200°F (93.3°C)],

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-73Table 3-11. Swing Motor TroubleshootingTrouble Cause RemedyOil Leakage 1. Hose fittings lo

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121180RemovalRefer to Figure 3-55., Swing Motor Removal and Installation.1. Thoroughly clean are

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-75Disassembly and InspectionRefer to Figure 3-56., Swing Motor - Exploded View.1. Place moto

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 3121180free of contamination. Inspect end cover for cracksand bolt head recesses for good bolt he

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-772. Remove rotor set (8) and wearplate (9), together toretain rotor set in its assembled fo

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 31211805. Remove thrust bearing (11) from top of couplingshaft (12). Inspect for wear, brinelling

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-792. Remove thrust bearing (15) and thrust washer (14).Inspect for wear, brinelling, corrosi

3121180 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 31211807. Measure and note depth or location of bearing/bush-ing (13) in relation to housing wear

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-81123444888E8A8C8B48D9445761012131414151625171819201. Bolt2. End Cover3. Seal Ring4. Seal Ri

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 3121180AssemblyRefer to Figure 3-56., Swing Motor - Exploded View.Replace seals and seal rings wi

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-833. Press new dirt and water seal (20) into housing (18)outer bearing counterbore. Press in

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 31211808. Apply a generous amount of clean, corrosion resis-tant grease to lower (outer) housing

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-8511. Assemble wear plate (9) over drive link (10) andalignment studs onto housing (18). 12.

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 312118015. Place manifold (7) over alignment studs and drivelink (10) and onto rotor set. Be sure

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-87NOTE: If end cover has a valve (24) or five bolt holes, useline scribed on cover to radial

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 3121180One Piece Stator AssemblyA disassembled rotor stator and vanes that cannot bereadily assem

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-89Two Piece Stator AssemblyA disassembled rotor set (8) that cannot be easily by handand has

x – JLG Lift – 3121180LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 31211803.11 SEMI-TRACKThe semi-track option is available in soft or hard tracksand provides incre

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-91Figure 3-57. Track Adjustment and Installation

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3121180ABCDCEFigure 3-58. Auxiliary Pump - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-93Figure 3-59. Auxiliary Pump - Sheet 2 of 21. Motor2. Adapter3. Setscrew4. Mounting Gasket

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 31211803.12 GENERATOREvery 250 hoursCheck drive belt for proper tension every 250 hours ofoperati

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-9511/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must ridecom

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 31211803.13 FORD EFI ENGINEPerforming Diagnostics1. Verify complaint and determine if it is a dev

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-97Table 3-13. ECM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription0,11All Systems OK

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3121180ENGINE COOLANT TEMPERATURE (ECT) SENSORThe Engine Coolant Temperature (ECT) sensor is a th

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-99Figure 3-61. EFI Component Location

3121180 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3121180Intake Air Temperature (IAT) SensorThe intake air temperature (IAT)sensor is a thermistor

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-101ECM Inputs/OutputsInputs—Operating Conditions• Engine Coolant Temperature• Crankshaft Pos

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 31211803.14 CIRCUIT TESTING TOOLSDO NOT USE A TEST LIGHT TO DIAGNOSE ENGINE ELECTRICALSYSTEMS UN

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-103Figure 3-62. Typical Fuel System HIGH PRESSURE CIRCUIT - OPERATING PRESSURE 65 PSI.

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 3121180FUEL METERING SYSTEM PURPOSEThe basic function of the air/fuel metering system is tocontr

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-105ELECTRONIC GOVERNOR AND THROTTLE BODYIn the 2.5L EFI industrial engine, throttle control

SECTION 3 - CHASSIS & TURNTABLE3-106 – JLG Lift – 3121180CRANKSHAFT POSITION (CKP) SENSORThe crankshaft position (CKP) sensor provides a signal us

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-107Changing Oil Filter1. Wipe area around filter to clean any dirt from area.2. Using a suit

SECTION 3 - CHASSIS & TURNTABLE3-108 – JLG Lift – 31211803.16 DEUTZ EMR 2 (S/N 85332 TO PRESENT)The EMR2 system consists of sensors, control unit,

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-109Figure 3-65. Deutz EMR 2 Troubleshooting Flow Chart

LIST OF TABLESTABLE NO. TITLE PAGE NO.xii

SECTION 3 - CHASSIS & TURNTABLE3-110 – JLG Lift – 3121180Figure 3-66. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-111Figure 3-67. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3-112 – JLG Lift – 3121180Figure 3-68. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-113Figure 3-69. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-114 – JLG Lift – 3121180Figure 3-70. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-115Figure 3-71. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3-116 – JLG Lift – 3121180Figure 3-72. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-117Figure 3-73. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3-118 – JLG Lift – 3121180Figure 3-74. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-119Figure 3-75. EMR2 Fault Codes - Sheet 5 of 5

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 TIRES1.3 ENGINENOTE: RPM Tolerances are ± 100. Table 1-1

SECTION 3 - CHASSIS & TURNTABLE3-120 – JLG Lift – 31211803.17 GM ENGINE GENERAL MAINTENANCEDrive Belt MaintenanceThe serpentine drive belt utilize

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-121Changing Engine OilALWAYS CHANGE OIL FILTER WHEN CHANGING OIL. CHANGEOIL WHEN ENGINE IS W

SECTION 3 - CHASSIS & TURNTABLE3-122 – JLG Lift – 3121180HEATED COOLANT MAY SPILL OUT DUE TO AIR “BURPING” OUTOF SYSTEM WITH RADIATOR CAP OFF WITH

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-123EPR AssemblyThe EPR assembly is a combination Low Pressure Regu-lator and a Voice Coil As

SECTION 3 - CHASSIS & TURNTABLE3-124 – JLG Lift – 3121180Air Fuel MixerThe air valve mixer is an air-fuel metering device and iscompletely self-co

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-125Engine Control ModuleTo obtain maximum effect from the catalyst and accuratecontrol of th

SECTION 3 - CHASSIS & TURNTABLE3-126 – JLG Lift – 3121180Gasoline Fuel PumpThe Gasoline is stored as a liquid in the fuel tank and indrawn into th

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-127Propane Fuel System Leak TestPROPANE IS EXTREMELY FLAMMABLE. NEVER USE AN OPEN FLAMEOF AN

SECTION 3 - CHASSIS & TURNTABLE3-128 – JLG Lift – 3121180Electronic Pressure Regulator (EPR) Assembly ReplacementThe EPR assembly consists of two

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-129PRESSURE REGULATOR SECTION REMOVAL1. Remove EPR. Refer to EPR Removal Procedure. 2. Remov

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31212591.4 SPECIFICATIONS AND PERFORMANCE DATAReach SpecificationsDimensional DataChassisTable 1-6. Caterpi

SECTION 3 - CHASSIS & TURNTABLE3-130 – JLG Lift – 31211802. Install two quad seals one seal at a time so sealdoes not roll. Seal must sit flat on

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-131 Vapor Hose ReplacementREMOVAL1. Disconnect hose clamps using hose clamp pliers.2. Remove

SECTION 3 - CHASSIS & TURNTABLE3-132 – JLG Lift – 31211803.20 GM ENGINE LPG FUEL SYSTEM DIAGNOSISFuel System DescriptionThe LPG fuel system Engine

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-133Table 3-14. LPF Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to th

SECTION 3 - CHASSIS & TURNTABLE3-134 – JLG Lift – 312118015 1. Turn ignition OFF. 2. Close LPG tank manual shut-off valve.LIQUID LPG MAY BE PRESE

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-135Table 3-15. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using This S

SECTION 3 - CHASSIS & TURNTABLE3-136 – JLG Lift – 3121180Intermittent Malfunction Indicator Lamp (MIL)The following components can cause intermitt

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-137Exhaust System Checks 1. Check exhaust system for a possible restriction:

SECTION 3 - CHASSIS & TURNTABLE3-138 – JLG Lift – 3121180Exhaust System Checks 1. Check exhaust system for a restriction: - Inspect exh

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-139Hesitation, Sag, StumbleDEFINITION: The vehicle has a momentary lack of response when dep

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-31.5 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsLift: Boom retracted. Telescope retract

SECTION 3 - CHASSIS & TURNTABLE3-140 – JLG Lift – 3121180Lack of Power, Sluggishness, or SponginessDEFINITION: Engine delivers less than expecte

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-141Ignition System Checks 1. Verify that the spark plugs are correct for use with LPG (R42LT

SECTION 3 - CHASSIS & TURNTABLE3-142 – JLG Lift – 3121180Engine Mec hanical Check Check engine f or the following:

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-143Table 3-16. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 Crank

SECTION 3 - CHASSIS & TURNTABLE3-144 – JLG Lift – 3121180562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid 628

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-145 1. Battery2. Coolant Overflow3. Air Cleaner4. Radiator5. Alternator6. O2 Sensor7. Cranks

SECTION 3 - CHASSIS & TURNTABLE3-146 – JLG Lift – 312118016. O2 Sensor17. Dipstick18. Control Module19. Starter20. Distributor21. Oil Filter22. Wa

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-1473.21 PERKINS ENGINE GENERAL MAINTENANCEReplacing the Engine Crankcase BreatherKEEP PARTS

SECTION 3 - CHASSIS & TURNTABLE3-148 – JLG Lift – 3121180***234567811. Dipstick2. Crankcase Breather3. Coolant Sensor4. Oil Pressure Sensor5. Oil

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-149NOTE: Do not drain oil when engine is cold. As oil cools,suspended waste particles settle

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3121259Table 1-14. Engine Torque Requirements - FordDescriptionTorque Value ft. lb.To rqu e Va l u e NmOi

SECTION 3 - CHASSIS & TURNTABLE3-150 – JLG Lift – 3121180Setting Actuator1. Remove bolt from control linkage2. With control linkage pushed against

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-151Speed Sensor InstallationNOTE: A new speed sensor comes with two hex nuts.1. Remove one h

SECTION 3 - CHASSIS & TURNTABLE3-152 – JLG Lift – 31211806. Remove fill cap and fill coolant recovery reservoir tocold level line. Put fill cap ba

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-1533.23 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONSThis section defines diagnostics

SECTION 3 - CHASSIS & TURNTABLE3-154 – JLG Lift – 3121180List of Abbreviations in this SectionAL Adaptive Learn LED Light Emitting DiodeBP Baromet

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-155Fault Code BroadcastAll diagnostic trouble codes are broadcast through EDISfor display on

SECTION 3 - CHASSIS & TURNTABLE3-156 – JLG Lift – 3121180Diagnostic Calibration Configuration and Corrective ActionsEach fault within the DGC is c

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-157Fault/Diagnostic Trouble Code InteractionAll fault and diagnostic information is managed

SECTION 3 - CHASSIS & TURNTABLE3-158 – JLG Lift – 3121180Once an active fault has occurred, two sets of data arerecorded; fault snapshot and fligh

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-159Accessing fault information is accomplished through adouble left-click of the fault LED i

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-51.7 LUBRICATIONHydraulic OilNOTE: Hydraulic oils must have anti-wear qualities at least toAPI Servic

SECTION 3 - CHASSIS & TURNTABLE3-160 – JLG Lift – 3121180Figure 3-100. Historic Fault Information InterfaceTable 3-19. Historic Fault Informati

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-161Figure 3-101. Snapshot Data InterfaceFigure 3-102. Flight Data Recorder Interface

SECTION 3 - CHASSIS & TURNTABLE3-162 – JLG Lift – 31211803.24 DIAGNOSTIC TROUBLE CODE FAULT DESCRIPTIONSDTC 116- ECT Higher Than Expected Stage 1•

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-163DTC 117- ECT/CHT Low Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine R

SECTION 3 - CHASSIS & TURNTABLE3-164 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-165DTC 118- ECT/CHT High Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine

SECTION 3 - CHASSIS & TURNTABLE3-166 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-167DTC 122- TPS1 Signal Voltage Low• Throttle Position Sensor 1.• Check Condition-Key On, En

SECTION 3 - CHASSIS & TURNTABLE3-168 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-169DTC 123- TPS1 Signal Voltage High• Throttle Position Sensor 1.• Check Condition-Key On, E

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31212591.8 MAJOR COMPONENT WEIGHTS1.9 PRESSURE SETTINGS - PSI (BAR)1.10 SERIAL NUMBER LOCATIONA serial numb

SECTION 3 - CHASSIS & TURNTABLE3-170 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-171DTC 217- ECT Higher Than Expected 2• Engine Coolant Temperature Sensor.• Check Condition-

SECTION 3 - CHASSIS & TURNTABLE3-172 – JLG Lift – 3121180DTC 219- RPM Higher Than Max Allowed Governed Speed• Max Govern Speed Override- Crankshaf

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-173DTC 336- Crank Signal Input Noise• Crankshaft Position sensor.• Check Condition- Key On,

SECTION 3 - CHASSIS & TURNTABLE3-174 – JLG Lift – 3121180• Key On, Engine Running• System Mode= “Running”Does DTC 336 reset ?Intermittent faultNoY

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-175DTC 337- Loss of Crank Input Signal• Crankshaft Position sensor.• Check Condition- Key On

SECTION 3 - CHASSIS & TURNTABLE3-176 – JLG Lift – 3121180DTC 521- Oil Pressure Sender/Switch High Pressure• Engine Oil Pressure• Check Condition-

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-177Normally Open SwitchNormally Closed Switch• Key-On, Engine Off• System Mode= “Stopped”Doe

SECTION 3 - CHASSIS & TURNTABLE3-178 – JLG Lift – 3121180Sensor/Transducer Type

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-179DTC 524- Oil Pressure Low• Engine Oil Pressure.• Check Condition- Key on, Engine on.• Fau

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-71.11 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Figure1-2., Operator Mai

SECTION 3 - CHASSIS & TURNTABLE3-180 – JLG Lift – 3121180Normally Open Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to n

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-181Normally Closed Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to

SECTION 3 - CHASSIS & TURNTABLE3-182 – JLG Lift – 3121180Sensor/Transducer Type

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-183DTC 562- Battery Voltage (VBat) Low• System voltage to ECM.• Check Condition- Key on, Eng

SECTION 3 - CHASSIS & TURNTABLE3-184 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-185DTC 563- Battery Voltage (VBat) High• System voltage to ECM.• Check Condition-Key on, Eng

SECTION 3 - CHASSIS & TURNTABLE3-186 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-187DTC 601- Microprocessor Failure - FLASH• Engine Control Module- Flash Memory.• Check Cond

SECTION 3 - CHASSIS & TURNTABLE3-188 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-189DTC 604- Microprocessor Failure - RAM• Engine Control Module- Random Access Memory.• Chec

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3121259DO NOT OVERGREASE END BEARINGS OR HOUSING OUTER SEALMAY BLOW AND CAUSE DAMAGE TO EQUIPMENT.3. Wheel

SECTION 3 - CHASSIS & TURNTABLE3-190 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-191DTC 606- Microprocessor Failure - COP• Engine Control Module.• Check Condition- Key on.•

SECTION 3 - CHASSIS & TURNTABLE3-192 – JLG Lift – 3121180

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-193DTC 642- 5 Volt External Low Voltage• Engine Control Module.• Check Condition- Key on.• F

SECTION 3 - CHASSIS & TURNTABLE3-194 – JLG Lift – 3121180DTC 643- 5 Volt External High Voltage• Engine Control Module.• Check Condition- Key on.•

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-195DTC 1612- Microprocessor Failure - RTI 1• Engine Control Module.• Check Condition- Key on

SECTION 3 - CHASSIS & TURNTABLE3-196 – JLG Lift – 3121180SFC 555- RTI 2 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 555

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-197DTC 1614- Microprocessor Failure - RTI 3• Engine Control Module• Check Condition- Key on•

SECTION 3 - CHASSIS & TURNTABLE3-198 – JLG Lift – 3121180SFC 556- RTI 3 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 556

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-199DTC 1615- Microprocessor Failure - A/D• Engine Control Module.• Check Condition- Key on.•

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-98. Suction StrainersLube Point(s) - 2Interval - Every 2 years or 1200 hours of operation,remove and

SECTION 3 - CHASSIS & TURNTABLE3-200 – JLG Lift – 3121180SFC 513- A/D LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 513 re

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-201DTC 1616- Microprocessor Failure - interrupt• Engine Control Module• Check Condition- Key

SECTION 3 - CHASSIS & TURNTABLE3-202 – JLG Lift – 3121180SFC 512- Invalid InterruptKey On - Engine RunningSystem Data ModeClear System FaultDoes S

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-203DTC 1625- CAN J1939 Shutdown Request• Controller Area Network• Check Condition- Key On, E

SECTION 3 - CHASSIS & TURNTABLE3-204 – JLG Lift – 3121180DTC 1626- CAN J1939 Transmit (Tx) Fault• Controller Area Network.• Check Condition- Key O

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-205DTC 1627- CAN J1939 Receive (Rx) Fault• Controller Area Network.• Check Condition- Key On

SECTION 3 - CHASSIS & TURNTABLE3-206 – JLG Lift – 3121180DTC 1628- CAN Address Conflict Failure•CAN device(s).• Check Condition- Key On, Engine on

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-207

SECTION 3 - CHASSIS & TURNTABLE3-208 – JLG Lift – 3121180DTC 1629- J1939 TSC1 Message Receipt Loss• Controller Area Network.• Check Condition- Key

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-209DTC 1652- TPS1 Loss of Communications• Throttle Actuator (with serial/digital position fe

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 312125913. Oil Change w/Filter - PerkinsLube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7026855)Capa

SECTION 3 - CHASSIS & TURNTABLE3-210 – JLG Lift – 3121180DTC 2111- Unable to Reach Lower TPS• Throttle Position Sensor• Check Condition-Cranking o

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-211

SECTION 3 - CHASSIS & TURNTABLE3-212 – JLG Lift – 3121180DTC 2112- Unable to Reach Higher TPS• Throttle Position Sensor.• Check Condition-Cranking

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-213DTC 9999- Throttle Actuator Failsafe Spring Failure• Throttle Actuator• Check Condition-

SECTION 3 - CHASSIS & TURNTABLE3-214 – JLG Lift – 3121180DTC to SPN/FMI TableFAULTINDEXDESCRIPTIONDTC SETSPN FMI2 DTC 118: ECT voltage high 110 33

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-215ABCDA. Exhaust VenturiB. 1/4" (6.35 mm) minimum clearance all around.C. 3

SECTION 3 - CHASSIS & TURNTABLE3-216 – JLG Lift – 3121180B,CB,CB,CB,CB,CAAA. Part Number\Actual Weight StampingB. Apply Loctite #271 to Bo

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCEDO NOT USE A LIFTING DEVICE TO LIFT BOOMS UN

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121180Disassembly of Main Boom1. Loosen jam nuts on aft end of fly boom wear padadjustment and loosen

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-3Assembly of Main Boom1. Install power track to the attach point on the baseboom section. Secure

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-1121. Fuel Filter (Propane) - GM EngineInterval - 3 Months or 150 hours of operationComments - Replac

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31211801. Upper Boom2. Tower Link3. Upper Upright4. Upper Lift Cylinder5. Upper Tower Boom6. Tower Lin

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-5Figure 4-2. Boom Limit Switches - US Manufactured

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121180Figure 4-3. Boom Limit Switches - Euro Manufactured

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-7Figure 4-4. Main Boom

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31211804.2 ROTATORTheory of Operation See Figure 4-6., Rotator Assembly - CutawayFluid entering Port P

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-91. Housing & Ring Gear2A. Shaft2B. Flange2C. Bearing Tube3. Piston Sleeve4. Piston5.

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121180If actuator is not equipped with grease fittings, coat thrustbearings (20) with grease before

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-114.3 ROTARY ACTUATOR (S/N 0300130812 AND 1300006433 TO PRESENT)Theory of OperationThe L20 Serie

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3121180PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-13PARTS1. Housing 2. Shaft 3. Piston Sleeve4. End CapHARDWARE103.1. Screw103.2

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 31212591.13 PROPANE FUEL FILTER REPLACEMENTRemoval1. Relieve propane fuel system pressure. Refer to 1.14Pr

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3121180Disassembly1. Remove capscrews (113) over end cap lock pins (109).2. Using a 1/8" (3.18mm

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-157. Remove stop tube if included. Stop tube is an avail-able option to limit actuator rotation.

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 312118011. Mark housing (1) ring gear in relation to piston O.D.gear before removing piston (3). Ther

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-1716. To remove main pressure seals (205), it is easiest tocut them using a sharp razor blade be

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3121180Inspection1. Clean all parts in a solvent tank and dry with com-pressed air before inspecting.

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-192. Install thrust washer (304) on shaft (2) and end cap (4).3. Install wiper seal (304.1/green

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 31211809. Repeat for outer seal (202).10. Insert piston (3) into housing (1) as shown, untilouter pis

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-2113. Look from opposite end of housing (1) to see if tim-ing marks are lining up. When they do,

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 312118018. Coat threads on end of shaft with anti-seize greaseto prevent galling. 19. Install 0-ring

SECTION 4 - BOOM & PLATFORM3121180 – JLG Lift – 4-23Installing Counterbalance ValveRefer to Figure 4-9., Rotator Counterbalance Valve.1. Clean act

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-13Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3121180A,B,DC,DEABCDETorque to 50 ft-lb (68 Nm)Loctite #242Torque to 480 ft-lb (650 Nm)Check torque e

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 CYLINDER REPAIR -USA MANUFACTURED ONLYNOTE: Following are general procedures t

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121180201933861016713141251817111,2,15741. Loctite #2422. Locking Primer3. Bushing4. Bushing5. Head6. Barrel7.

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-3162291910413 12121120245617171714142571. Barrel2. Rod3. Not Used4. Head5. Piston6. Locknut7. Retaining R

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31211801349856572 1. Barrel2. Rod3. Plug4. Pilot Piston5. Wear Ring6. Wiper7. Rod Seal8. Bleeder9. Valve Cartri

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-545122413131518252016191772,3,2223141,2,211026278669661. Loctite #2422. Locking Primer3. Loctite RC6094.

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 312118011132312220201215141437891019161764222155181. Loctite #2422. Locking Primer #74713. Bolt4. Tapered Bushi

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-788214910121718121352014152922881. Barrel2. Rod3. Not Used4. Piston5. Head6. Not Used7. Not Used8. Bearin

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 312118012111,3,26618 195192518 1410162022179233,4,242127131377881. Loctite #2422. Not Used3. Locking Primer4. L

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-99922431181920621222311111147282914151617881. Barrel2. Rod3. Not Used4. Not Used5. Not Used6. Head7. Pist

INTRODUCTION3121180 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA. GENERALThis section contains general safety precaution

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121259Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 312118017154613111014132021161819752322923231232312201. Barrel2. Rod3. End Cap4. Piston5. Head6. Hex Nut7. Tub

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-1166661097111214252612821221920232429271. Barrel2. Rod3. Not Used4. Not Used5. Not Used6. Bearing7. Pisto

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3121180862566231554156910111,2,122221171671318191924241. Loctite #2422. Locking Primer3. Loctite RC6094. Bolt5

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-136666121671514101012191718820212430262311 1. Barrel2. Rod3. Not Used4. Not Used5. Not Used6. Bearing7. P

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31211801, 2, 2114717192, 3, 22231620 251518151310241213459666681. Loctite #242 2. Locking Primer3. Loctite RC6

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-155126755101221121416191381817141520209312451. Loctite #2422. Locking Primer3. Bolt4. Tapered Bushing5. C

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31211801888819941025121315181423211. Barrel2. Rod3. Not Used4. Piston5. Head6. Not Used7. Not Used8. Bearing9.

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-17111131012121023889934774551. Barrel2. Rod3. Cap4. Ring Washer5. Bolt6. Not Used7. Wiper8. Backup Ring9.

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 312118013621112397108181079312111. Barrel2. Rod3. Cylinder Head4. Anti-Seize5. Not Used6. Wear Ring7. Backup R

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-19133151518186677141413131212299101. Barrel2. Rod3. Head4. Not Used5. Not Used6. Wiper7. Seal8. Not Used9

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-15Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31211801. Barrel2. Rod3. Piston4. Head5. Tube Spacer6. Valve7. Bolt8. O-Ring Plug9. Setscrew10. Locknut11. Ret

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-211855A17625892021342614191627231. Barrel2. Rod3. Not Used4. Head5. Valve Block6. Piston7. Seal8. O-Ring9

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121180USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD,AND PISTON. PULLING ROD OFF-CENTER CAN DAMAGE PISTONA

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-2310. Inspect threaded portion of head for damage. Dressthreads as necessary.11. Inspect seal and O-ring

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 31211802. Use a soft mallet to tap a new wiper seal into appli-cable cylinder head gland groove. Install new w

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-2511. Remove cylinder rod from holding fixture.12. Place new guide locks and seals in applicable out-side

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121180IF CYLINDER IS TEST PRIOR TO INSTALLATION ON MACHINE,USE EXTREME CARE TO INSURE OUTER END OF ROD IS SUP

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-2710. Remove rear bearing block from drive and idlershafts.11. Remove idler shaft from bearing block.12.

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 3121180Inspect Parts For Wear1. Clean and dry all parts thoroughly before inspection.It is not necessary to in

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-29General InformationFAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULTWITH LITTLE OR NO FLOW AT RATED PR

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121259Figure 1-7. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 31211806. Apply a light coating of petroleum jelly to exposedface of front bearing block.7. Insert drive end o

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-3114. Install two remaining dowel pins in rear of gearhousing, if applicable, and place end cover overbac

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 3121180Placing Pump Back Into Service1. If shop test stand is available, the following proce-dure for testing

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-33Removal and Installation of FNR and NFPE Modules1. Clean pump and module housings.2. Remove four screws

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 3121180Figure 5-34. Gauge Port Locations1. System Pressure Gauge Port M22. System Pressure Port B3. System Pr

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-35Figure 5-35. Plugs/Fittings Size & Torque#Plug/FittingTorquelb. ft. Nm1 Servo Gauge Port M4N/A N/A

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 31211805. Install new O-ring on valve plug. Reinstall poppet,spring, and plug (with shims and O-ring) into pum

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-371. Position pump with shaft facing up.NOTE: If the unit is positioned horizontally when the shaft isrem

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 3121180Charge PumpDisassemble charge pump to inspect and clean, orchange auxiliary shaft drive coupling.1. Rem

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-39Figure 5-40. Charge Pump Components1. Cover Retaining Screw2. O-Ring3. Geroter Cover4. Geroter Assembl

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-17Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 31211805.4 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSFrom a hydrostatic component standpoint,

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-41Install a 1000 psi (60 bar) pressure gauge in charge pres-sure gauge port to monitor charge pressure du

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 31211805.5 PRESSURE SETTING PROCEDURECold temperatures have a significant impact on pressurereadings. JLG Indu

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-43.1. Check Valve2. Load Shuttle3. Load Shuttle4. Main Dump5. Swing6. Steer7. Upper Lift8. Proportional D

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 3121180ABC18-20 ft. lbs. (24.5 - 27.2 Nm)4-5 ft. lbs. (5.4 - 6.8 Nm)25-27 ft. lbs. (34 - 36.7 Nm)Figure 5-42.

SECTION 5 - HYDRAULICS3121180 – JLG Lift – 5-451. Jib Up2. Jib Down3. Jib Up/Down Relief4. Rotate - Left5. Rotate - Right6. Level Up7. Level Down8. Le

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 3121180NOTES:

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING ANY NEW MODULE CONTROLLER ON THEMA

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121180Figure 6-2. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-36.2 CONNECT JLG CONTROL SYSTEM ANALYZER1. Connect four pin end of cable supplied with analyzerto

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3121259Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121180Figure 6-3. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-5When a top level menu is selected, a new set of menuitems may be offered: for example: DRIVEBOOM

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121180Figure 6-4. ADE Control System Block Diagram

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-76.5 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZEROnce you have gained access to level 1, and

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121180 ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTOMENU:MACHINE SETUPPERSONA

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-9 FROMPERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:UPPER TELESCOPEPERSONALITIES:BA

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121180FROMMENU:PERSONALITIESMENU:MACHINE SETUPTOMENU:CALIBRATIONSMODEL NUMBER:1=400ENGINE:1=FORD EFI

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-11Figure 6-6. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121180Figure 6-7. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4NOTE: Some screens may not

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-13Figure 6-8. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4

SECTION 1 - SPECIFICATIONS3121259 – JLG Lift – 1-19Figure 1-10. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121180FROM:MENU:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL NUMBER:400SENGINE:FORD EFI G

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-15 MENU:HELP:PRESS ENTERHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU:CALIBRATIONSMENU:DIA

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121180DIAGNOSTICS:VERSIONSGROUND MODULESOFTWARE: XX.XXGROUND MODULECOST. DATA:XX.XXGROUND MODULEHARDW

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-17 DIAGNOSTICS:VERSIONSGROUND MODULESOFTWARE: XX.XXGROUND MODULECOST. DATA:XX.XXGROUND MODULE

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121180TOWER LIFT:ACCEL X.XSTOWER LIFT:DECEL X.XSTOWER LIFT:MIN UP XXX%TOWER LIFT:MAX UP XXX%TOWER LIF

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-196.7 MACHINE PERSONALITY SETTINGS NOTE: Adjust personality settings within range for optimummach

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121180SWING ACCELeration 0.1 to 5.0s 2.0DECELeration 0.1 to 3.0s 1.5MINimum LEFT speed 0 to 50% 32MAX

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-21JIB LIFT ACCELeration 0.1 to 5.0 3.0DECELeration 0.1 to 3.0 0.5MINimum UP speed 0 to 65% 16MAX

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121180Table 6-2. Machine Configuration Programming Information Prior to Software Version P5.3Configur

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-23GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: Automatic pre-glow time

SECTION 1 - SPECIFICATIONS1-20 – JLG Lift – 3121259NOTES:

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121180GEN SET CUTOUT:12* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-25GROUND ALARM:18* * Certain market selections will alter default setting.0123NO: No ground alarm

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121180Table 6-3. Machine Configuration Programming Information Software Version P5.3 to P6.1Configura

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-27ENGINE:3* * Engine selections vary depending on model selec-tion.12345678910111213FORD EFI GAS

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121180ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant temperatu

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-29GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121180FUNCTION CUTOUT:18* * Only visible under certain market selections. * Certain market selectio

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-31Table 6-4. Machine Configuration Programming Information Software Version P6.1 to PresentConfig

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121180ENGINE:3* * Engine selections vary depending on model selec-tion.123456789101112131415FORD EFI

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-33STARTER LOCKOUT:601DISABLED: Automatic pre-glow time determined by ambient air temperature; eng

SECTION 2 - GENERAL3121180 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides informa

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121180GEN SET/WELDER:1201NO: No generator installed.BELT DRIVE: Belt driven setup.0GEN SET CUTOUT:13*

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-35LOAD SENSOR:17* * Only visible if Load Sen-sor Menu selection is not 0 and under certain marke

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121180LEVELING MODE:22* * Only visible on 800S models.01ALL FUNCTIONS: Platform level with all funct

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-37450A Series IIMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUTENGINE SHUTDOWNTIL

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121180450AJ Series IIMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUTENGINE SHUTDOWNTI

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-396.8 SYSTEM TESTThe Control System Incorporates a built-in system test tocheck system components

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3121180Figure 6-14. System Test Flow Chart - Platform Tests

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-41Test from the Ground Station1. Set Platform/Ground select switch to Ground.2. Plug analyzer int

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 3121180Figure 6-15. System Test Flow Chart - Ground Station Tests

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-43Table 6-5. System Test MessagesMessage Displayed onAnalyzerMessage Displayed onAnalyzerDescript

SECTION 2 - GENERAL2-2 – JLG Lift – 31211802.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 3121180TESTING VALVES Indicates valve test is beginning. Each valve is alternately energized and de-en

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-45TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, s

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121180Table 6-6. Machine Diagnostics ParametersDiagnostics Submenu(Displayed on Analyzer 1st Line)Par

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-47BOOM:U LIFT UP/DOWN XXX% Displays upper lift joystick direction & demandSWING RIGHT/LEFT XX

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 3121180ENGINE:START ACTIVE/NOT ACTIVE Displays status of the engine start circuitAIR FILTER OP/CL Disp

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-49SYSTEM:GM BATTERY XX.XV Ground module battery voltagePM BATTERY XX.XV Platform module battery v

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121180HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is conf

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-51osc axle p sw OP/CL Oscillating axle pressure switch status. (Displayed if OSCILLATING AXLE = 1

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121180MOMENT: Displayed if MODEL NUMBER = 7 or 8(LB-IN) ACTUAL XXXXXXXX Current moment value(LB-IN)OV

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-53ENVELOPE: Displayed if MODEL NUMBER = 7 or 8LENGTH XXXX.X Current indicated boom length in inch

SECTION 2 - GENERAL3121180 – JLG Lift – 2-3Component Disassembly and ReassemblyComplete steps in sequence when disassembling or reas-sembling a compon

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121180CALIBRATION DATABASKET UP XXX Basket up calibration pointBasket DOWN XXX Basket down calibratio

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-55DATALOG:ON XXXXhXXm Total controller on (EMS) timeENGINE XXXXhXXm Engine run timeDRIVE XXXXhXXm

SECTION 6 - JLG CONTROL SYSTEM6-56 – JLG Lift – 3121180Table 6-7. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 0300066949Fault

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-572/3 Flash code 2/3 indicates problems with boom function selection. 3LIFT/SWING JOYSTICK FAULTY

SECTION 6 - JLG CONTROL SYSTEM6-58 – JLG Lift – 31211803/2 Flash code 3/2 indicates that a contactor did not open when energized.NOT REQUIRED3/3 Flash

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-59Table 6-8. Help Fault Codes, Displayed Faults, and Descriptions - S/N 0300066949 & S/N 130

SECTION 6 - JLG CONTROL SYSTEM6-60 – JLG Lift – 31211802/2 Flash code 2/2 indicates problems with drive & steer selection. Except where noted, the

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-612/5 Flash code 2/5 indicates a function is prevented due to a cutout. 4BOOM PREVENTED – DRIVE S

SECTION 6 - JLG CONTROL SYSTEM6-62 – JLG Lift – 31211803/3 Flash code 3/3 indicates a driver problem. All driver faults are detected in a similar mann

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-63LP LOCK SHORT TO BATTERY Machines with dual-fuel engines ONLY.LP START ASSIST SHORT TO GROUNDMa

INTRODUCTIONA-2 – JLG Lift – 3121180REVISON LOGOriginal Issue - January 24, 2003Revised - March 14, 2003Revised - August 26, 2005Revised - February 15

SECTION 2 - GENERAL2-4 – JLG Lift – 31211802.3 LUBRICATION AND INFORMATIONHydraulic System1. Contamination is the primary enemy of a hydraulicsystem.

SECTION 6 - JLG CONTROL SYSTEM6-64 – JLG Lift – 3121180HEAD TAIL LIGHT OPEN CIRCUIT Machines with headlights option configured ONLYHEAD TAIL LIGHT SHO

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-65JIB DOWN OPEN CIRCUITJIB DOWN SHORT TO BATTERYJIB LEFT SHORT TO GROUNDJIB LEFT OPEN CIRCUITJIB

SECTION 6 - JLG CONTROL SYSTEM6-66 – JLG Lift – 3121180LIFT DOWN AUX VALVE OPEN CIR-CUITMachines with gravity lift down ONLY.TOWER LIFT APU SHORT TO G

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-673/4 Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All drive

SECTION 6 - JLG CONTROL SYSTEM6-68 – JLG Lift – 31211804/3 Flash code 4/3 indicates engine problems. These faults are not reported during 2 second pow

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-694/5 Flash code 4/5 indicates problems with the S-D CAN based PVG valves currently used on the 1

SECTION 6 - JLG CONTROL SYSTEM6-70 – JLG Lift – 3121180MAIN LIFT PVG VALVE COMMAND IMPROPERMain boom lift pvg valve received invalid control system co

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-716/6 Flash code 6/6 indicates problems with the CAN bus. 10PLATFORM CAN COMMUNICATIONS LOSTGroun

SECTION 6 - JLG CONTROL SYSTEM6-72 – JLG Lift – 31211808/3 Flash code 8/3 indicates problems with the Basket Leveling system. 10BASKET LEVELING CRACKP

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-738/4 Flash code 8/4 indicates problems with the envelope system. Only occur on machines with env

SECTION 2 - GENERAL3121180 – JLG Lift – 2-52.4 CYLINDER DRIFT TESTMeasure maximum acceptable cylinder drift using the fol-lowing methods.Platform Drif

SECTION 6 - JLG CONTROL SYSTEM6-74 – JLG Lift – 3121180TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOWThis fault is reported by the Ground module when th

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-758/5 Flash code 8/5 indicates problems with the moment or load pin system. Only occur on machine

SECTION 6 - JLG CONTROL SYSTEM6-76 – JLG Lift – 31211808/6 Flash code 8/6 indicates steering system problem. An EMS cycle is required except as noted.

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-77REAR LEFT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condition cle

SECTION 6 - JLG CONTROL SYSTEM6-78 – JLG Lift – 31211809/9 Flash code 9/9 indicates problems with the controller or the user dis-abling safety systems

SECTION 6 - JLG CONTROL SYSTEM3121180 – JLG Lift – 6-79BLAM SENSOR SUPPLY OUT OF RANGE HIGHSupply voltage for boom angle sensors is above expected ran

SECTION 6 - JLG CONTROL SYSTEM6-80 – JLG Lift – 3121180NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121180Resistance Measurement• Test meter and leads by touching leads togeth

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-3Current Measurement• Set up meter for expected current range.• Connec

SECTION 2 - GENERAL2-6 – JLG Lift – 31211802.6 WELDING ON JLG EQUIPMENTNOTE: This instruction applies to repairs, or modifications tothe machine and t

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31211807.3 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-53. After all required contacts are inserted, close wedgelock to its l

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3121180Disassembly1. Insert a 3/16" (4.8 mm) wide screwdriver blade bet

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-7Figure 7-11. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31211807.4 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121180Figure 7-18. Electrical Components Installation - Sheet 1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-11Figure 7-19. Electrical Components Installation - Sheet 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121180Figure 7-20. Electrical Schematic - Sheet 1 of 4NOTE: This Schemati

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-13Figure 7-21. Electrical Schematic - Sheet 2 of 41870144G

SECTION 2 - GENERAL3121180 – JLG Lift – 2-7Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121180Figure 7-22. Electrical Schematic - Sheet 3 of 4NOTE: This Schemati

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-15Figure 7-23. Electrical Schematic - Sheet 4 of 41870144G

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121180Figure 7-24. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-17Figure 7-25. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121180Figure 7-26. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-19Figure 7-27. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121180Figure 7-28. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-21Figure 7-29. Electrical Schematic - Deutz EMR2 & GM Engine - Sh

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121180ALARMFUEL GAGEFULL3/41/21/4MAIN TELE INMAIN TELE OUTROTATE RIGHTROAT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-23AUXILIARY POWERPUMPMOTORMUP LEVELDOWN LEVELRIGHT ROTATE LEFT ROTATED

SECTION 2 - GENERAL2-8 – JLG Lift – 3121180Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 31211808685873087aYEL/RED 2-4-1 (12)BPLATFORMGROUNDSELECTSWITCHBLACK 0-6YEL

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-25B+FUSIBLELINKRECTIFERREGULATORALTERNATORSTATORSENSING ANDSWITCHINGCI

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3121180EGO 1EGO 2EGO 3EGO 4TPS 1TPS 2MAPAUX ANA PDIFPP 1FPP2/1VSAUX ANA PD2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-27DCBADCBAEGO 2EGO 1BLK/LT GRNDR GRN/WHTPNK/DK GRN4321BOSCHTMAPECTBLK/

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3121180Figure 7-36. Electrical Schematic 1001141989 - Sheet 1of 4 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-29Figure 7-37. Electrical Schematic 1001141989 - Sheet 1of 4 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-30 – JLG Lift – 3121180Figure 7-38. CAT/Perkins Engine Electrical Schematic 1001141989 - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-31Figure 7-39. CAT/Perkins Engine Electrical Schematic 1001141989 - S

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-32 – JLG Lift – 3121180Figure 7-40. Deutz Engine Electrical Schematic 1001141989 - Sheet 3

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-33Figure 7-41. GM/PSI Engine Electrical Schematic 1001141989 - Sheet

SECTION 2 - GENERAL3121180 – JLG Lift – 2-9Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-34 – JLG Lift – 3121180Figure 7-42. Electrical Schematic 1001102901(LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-35Figure 7-43. GM/PSI Engine Electrical Schematic 1001102901 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-36 – JLG Lift – 3121180Figure 7-44. Hydraulic Schematic 2792780 D - Sheet 1 of 3 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-37Figure 7-45. Hydraulic Schematic 2792780 D - Sheet 1 of 3 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-38 – JLG Lift – 3121180Figure 7-46. Hydraulic Schematic 2792780 D - Sheet 2 of 3 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-39Figure 7-47. Hydraulic Schematic 2792780 D - Sheet 2 of 3 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-40 – JLG Lift – 3121180Figure 7-48. Hydraulic Schematic 2792780 D - Sheet 3 of 3 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-41Figure 7-49. Hydraulic Schematic 2792780 D - Sheet 3 of 3 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-42 – JLG Lift – 3121180+Hydraulic Drawing 1283460 DescriptionFigure 7-50. Hydraulic Schema

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-43Figure 7-51. Hydraulic Schematic 1283460 - Sheet 1 of 7 (RH)

SECTION 2 - GENERAL2-10 – JLG Lift – 3121180(HYD. OIL TANK TEMP.)IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHLY RECOMMENDSTHE ADDITION OF A HYDRAULICOIL

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-44 – JLG Lift – 3121180Figure 7-52. Hydraulic Schematic 1283460 - Sheet 2 of 7 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-45Figure 7-53. Hydraulic Schematic 1283460 - Sheet 2 of 7 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-46 – JLG Lift – 3121180Figure 7-54. Hydraulic Schematic 1283460 - Sheet 3 of 7 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-47Figure 7-55. Hydraulic Schematic 1283460 - Sheet 3 of 7 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-48 – JLG Lift – 3121180Figure 7-56. Hydraulic Schematic 1283460 - Sheet 4 of 7 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-49Figure 7-57. Hydraulic Schematic 1283460 - Sheet 4 of 7 (RH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-50 – JLG Lift – 3121180Figure 7-58. Hydraulic Schematic 1283460 - Sheet 5 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-51Figure 7-59. Hydraulic Schematic 1283460 - Sheet 6 of 7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-52 – JLG Lift – 3121180Figure 7-60. Hydraulic Schematic 1283460 - Sheet 7 of 7 (LH)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121180 – JLG Lift – 7-53Figure 7-61. Hydraulic Schematic 1283460 - Sheet 7 of 7 (RH)

SECTION 2 - GENERAL3121180 – JLG Lift – 2-11-40 F(-40 C)-30 F(-34 C)-20 F(-29 C)-10 F(-23 C) 0F(-18C) 10 F(-12 C) 20 F(-7 C) 30 F(-1 C) 40 F(4 C) 50

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-54 – JLG Lift – 3121180NOTES:

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

SECTION 2 - GENERAL2-12 – JLG Lift – 3121180(HYD. OIL TANK TEMP.)IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHLY RECOMMENDSTHE ADDITION OF A HYDRAULICOIL

SECTION 2 - GENERAL3121180 – JLG Lift – 2-13-40 F(-40 C)-30 F(-34 C)-20 F(-29 C)-10 F(-23 C) 0F(-18C) 10 F(-12 C) 20 F(-7 C) 30 F(-1 C) 40 F(4 C) 50

3121180 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 2 - GENERAL2-14 – JLG Lift – 3121180(HYD. OIL TANK TEMP.)IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHLY RECOMMENDSTHE ADDITION OF A HYDRAULICOIL

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationPneumatic tire air p

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 3121180Wheel InstallationIt is extremely important to apply and maintain properwheel mounting torq

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-33.2 TORQUE HUB (MACHINES BUILT BEFORE S/N 0300071527)Roll, Leak, and Brake TestingAlways ro

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3121180Main Disassembly1. Perform Roll Check, Leak Check and Brake Check ifapplicable prior to dis

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-5Figure 3-2. Main Disassembly Drawing 27. Input Shaft8. Output Sun Gear17. Input

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121180Input Carrier Disassembly1. Place Carrier (3A) on a press with spline end up.Drive Planet S

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-7Output Carrier Disassembly1. Using a small diameter punch, drive Roll Pin (4G)which holds P

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121180Housing-Spindle Disassembly1. Place unit on bench with Spindle (1A) end down.EYE PROTECTION

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-9Spindle-Brake DisassemblyNOTE: This procedure applies only to units with integralinput brak

ii – JLG Lift – 3121180TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121180SPRINGS AND COMPRESSED AIR CAN CAUSE EYE DAMAGE ORSERIOUS INJURY. ALWAYS WEAR EYE PROTECTI

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-11Figure 3-7. Input Carrier Sub-Assembly3A. Carrier3B. Thrust Washers3C. Needle

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121180Output Carrier Sub-AssemblyUNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI-OUS INJURY. A

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-134A. Output Carrier4B. Thrust Washer4C. Needle Rollers4E. Planet Shaft4F.

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121180Spindle-Brake Sub-AssemblyUNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI-OUS INJURY. AL

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-15Figure 3-8. Spindle Brake Sub-Assembly1-A. Spindle12. Pressure Plug2-1. Inter

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121180Housing-Spindle Sub-AssemblyNOTE: Spray a light film of oil on all component parts duringa

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-17Figure 3-9. Housing-Spindle Disassembly1B. Seal1C. Bearing Cups1D. Bearing Co

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121180Main AssemblyNOTE: All components should receive a generous amountof lubricant oil as they

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-19Figure 3-11. Figure 3-11. Main Assembly Drawing 26. Cover9. Input Coupling10. T

3121180 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121180Figure 3-12. Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-211A Spindle1G Retaining Ring - Ext12 Pressure Plug16 O-ring Pipe Plug1F Thrust Washer1E Hou

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 3121180Figure 3-14. Assembly Drawing - With Integral Input Brake - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-231A Spindle2 Input Brake1G Retaining Ring - Ext12 Pressure Plug16 O-ring Pipe Plug1F Thrust

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121180Figure 3-16. Assembly Tools - Bearing Cone Pressing - “B” Bearing

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-25Figure 3-17. Assembly Tools - Bearing Cone Pressing - “A” Bearing

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121180Figure 3-18. Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-27Figure 3-19. Assembly Tools - Seal Pressing

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3121180Figure 3-20. Assembly Tools - Spacer - Brake Disc Installation

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-29Figure 3-21. Assembly Tools - Brake Retaining Ring Installation

iv – JLG Lift – 3121180TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 31211803.3 TORQUE HUB (MACHINES BUILT AFTER S/N 0300071527)Roll and Leak Testing Always roll and

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-31UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERI-OUS INJURY. ALWAYS WEAR EYE PROTECTION.1

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31211807. Repeat steps 1-6 to remove and disassemble tworemaining cluster gears.8. At this point

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-337. Following cluster gear, place one more thrustwasher (3B) onto planet shaft (3E) through

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 3121180Cover Sub-Assembly1. Using disconnect rod, push O-ring (6F) into grooveinside cover cap (6

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-357. With large end down, place disconnect cap (6D) oncover cap (6B), aligning pipe plug hol

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 31211803. Apply a light coat of “Never-Seize” to two pipe plugs(1J) and tighten them in two pipe

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-379. Place spacer (1H) on spindle (1A) in hub (1G).NOTE: Make sure retaining ring is securel

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 31211803. Place internal gear (2) in hub (1G) so its internalsplines mesh with external splines o

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-399. With large splined end down, place input shaft sub-assembly (7) into spindle (1A). 10.

3121180 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 312118015. Oil all exposed surfaces inside hub (1G). Placethrust washer (11) into counterbore in

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-4121. Place 12 bolts in remaining bolt holes in cover (6)and tighten.22. Torque shoulder bol

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121180Tool List The following specialized tools are used to assemble thisunit. Tool diagrams in

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-433.4 RE-ALIGNING TORQUE HUB INPUT COUPLINGThe following procedure applies to torque hubs wi

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121180Inspection1. Wash all parts thoroughly in a suitable solvent.2. Examine needle bearings (8

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-451. Snap Ring2. Shaft Seal3. Washer4. Snap Ring5. Thrust Washer6. Thrust Bearin

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121180Assembly1. Use filtered system oil to lubricate all critical movingparts before assembly.2

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-473.6 DRIVE MOTORNOTE: This procedure covers:2WD motors used on GM powered machines.2WD moto

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3121180Loop Flushing ValveREMOVAL1. Use an 11/16" internal hex wrench to remove plug(1) and

SECTION 3 - CHASSIS & TURNTABLE3121180 – JLG Lift – 3-49TroubleshootingTable 3-3. Excessive Noise and/or VibrationItem Description ActionCheck o