Jlg 510AJ Service Manual User Manual

Service and Maintenance ManualModel510AJP/N - 3121181August, 2014

viLIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-58 – JLG Lift – 31211813.6 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE1. With the turntable centered, adjust the bracket

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-59Lockout Cylinder Bleeding (Ram Cylinders)NOTE: The following procedure is to be used on mach

SECTION 3 - CHASSIS AND TURNTABLE3-60 – JLG Lift – 31211813.8 SWING BEARINGDescriptionThe swing bearing has five major components. They are thehousing

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-61Figure 3-48. Swing Bearing Installation

SECTION 3 - CHASSIS AND TURNTABLE3-62 – JLG Lift – 312118137467911251,22022828341,223,24,25,2651516173810302131,32,3335,3618131912,142739329Figure 3-4

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-638. Remove bearing (14) and Nilos Ring (13) from pinon (18)using an external bearing puller o

SECTION 3 - CHASSIS AND TURNTABLE3-64 – JLG Lift – 31211815. Using suitable lifting equipment, install bearing/rota-tion box assembly to frame with so

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-653. Lower the boom to horizontal and fully extend boom.4. At position indicated on Figure 2-3

SECTION 3 - CHASSIS AND TURNTABLE3-66 – JLG Lift – 3121181ABCDCEFigure 3-53. Auxiliary Pump - Sheet 1 of 2

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-671. Motor2. Adapter3. Setscrew4. Mounting Gasket5. Coupling6. Shaft Seal7. Stator8. Cap Assem

3121181 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-68 – JLG Lift – 31211813.9 GENERATOREvery 250 hoursEvery 250 hours of operation, check the drive belt for properten

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-6911/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must ridecompl

SECTION 3 - CHASSIS AND TURNTABLE3-70 – JLG Lift – 31211813.10 DEUTZ ENGINENOTE: Refer to the engine manufacturer’s manual for detailedoperating and m

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-715. Lightly oil the rubber gasket on the new oil filter.6. Manually screw in the new filter u

SECTION 3 - CHASSIS AND TURNTABLE3-72 – JLG Lift – 31211813.11 DEUTZ EMR 2 (S/N 1300000981 TO PRESENT)The EMR2 consists of sensors, control unit, and

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-73Figure 3-57. Deutz EMR 2 Troubleshooting Flow Chart

SECTION 3 - CHASSIS AND TURNTABLE3-74 – JLG Lift – 3121181Figure 3-58. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-75Figure 3-59. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS AND TURNTABLE3-76 – JLG Lift – 3121181Figure 3-60. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-77Figure 3-61. EMR 2 Engine Plug Pin Identification

viiiLIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-78 – JLG Lift – 3121181Figure 3-62. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-79Figure 3-63. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS AND TURNTABLE3-80 – JLG Lift – 3121181Figure 3-64. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-81Figure 3-65. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS AND TURNTABLE3-82 – JLG Lift – 3121181Figure 3-66. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-83Figure 3-67. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS AND TURNTABLE3-84 – JLG Lift – 31211813.12 PERKINS ENGINE GENERAL MAINTENANCEReplacing the Engine Crankcase BreatherKEEP ALL PARTS

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-85***234567811. Dipstick2. Crankcase Breather3. Coolant Sensor4. Oil Pressure Sensor5. Oil Dra

SECTION 3 - CHASSIS AND TURNTABLE3-86 – JLG Lift – 3121181NOTE: Do not drain oil when engine is cold. As oil cools, sus-pended waste particles settle

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-87Setting the Actuator1. Remove bolt from control linkage2. With control linkage pushed agains

3121181 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-88 – JLG Lift – 3121181Speed Sensor InstallationNOTE: A new speed sensor comes with two hex nuts.1. Remove one hex

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-896. Remove fill cap and fill coolant recovery reservoir to coldlevel line. Put fill cap back

SECTION 3 - CHASSIS AND TURNTABLE3-90 – JLG Lift – 31211813.14 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONSThis section defines the diagnostics

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-91List of Abbreviations in this SectionAL Adaptive Learn LED Light Emitting DiodeBP Barometric

SECTION 3 - CHASSIS AND TURNTABLE3-92 – JLG Lift – 3121181Fault Code BroadcastAll diagnostic trouble codes are broadcast through EDIS fordisplay on a

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-93Diagnostic Calibration Configuration and Corrective ActionsEach fault within the DGC is capa

SECTION 3 - CHASSIS AND TURNTABLE3-94 – JLG Lift – 3121181Fault/Diagnostic Trouble Code InteractionAll fault and diagnostic information is managed thr

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-95Once an active fault has occurred two sets of data arerecorded, fault snapshot and flight da

SECTION 3 - CHASSIS AND TURNTABLE3-96 – JLG Lift – 3121181Accessing fault information is accomplished through a doubleleft-click of the fault LED in t

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-97Figure 3-74. Historic Fault Information InterfaceTable 3-12. Historic Fault Information I

xLIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-98 – JLG Lift – 3121181Figure 3-75. Snapshot Data InterfaceFigure 3-76. Flight Data Recorder Interface

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-99DBW Diagnostic TestThe DGC engine control module incorporates a diagnostic testthat may be u

SECTION 3 - CHASSIS AND TURNTABLE3-100 – JLG Lift – 31211813.15 DIAGNOSTIC TROUBLE CODE FAULT DESCRIPTIONSDTC 116- ECT Higher Than Expected Stage 1• E

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-101DTC 117- ECT/CHT Low Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine Run

SECTION 3 - CHASSIS AND TURNTABLE3-102 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-103DTC 118- ECT/CHT High Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine Ru

SECTION 3 - CHASSIS AND TURNTABLE3-104 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-105DTC 122- TPS1 Signal Voltage Low• Throttle Position Sensor 1• Check Condition-Key On, Engin

SECTION 3 - CHASSIS AND TURNTABLE3-106 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-107DTC 123- TPS1 Signal Voltage High• Throttle Position Sensor 1• Check Condition-Key On, Engi

3121181 – JLG Lift – xi LIST OF TABLESTABLE NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-108 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-109DTC 217- ECT Higher Than Expected 2• Engine Coolant Temperature Sensor• Check Condition-Eng

SECTION 3 - CHASSIS AND TURNTABLE3-110 – JLG Lift – 3121181DTC 219- RPM Higher Than Max Allowed Governed Speed• Max Govern Speed Override- Crankshaft

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-111DTC 336- Crank Signal Input Noise• Crankshaft Position sensor• Check Condition- Key On, Eng

SECTION 3 - CHASSIS AND TURNTABLE3-112 – JLG Lift – 3121181• Key On, Engine Running• System Mode= “Running”Does DTC 336 reset ?Intermittent faultNoYes

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-113DTC 337- Loss of Crank Input Signal• Crankshaft Position sensor• Check Condition- Key On, E

SECTION 3 - CHASSIS AND TURNTABLE3-114 – JLG Lift – 3121181DTC 521- Oil Pressure Sender/Switch High Pressure• Engine Oil Pressure• Check Condition- Ke

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-115Normally Open SwitchNormally Closed Switch• Key-On, Engine Off• System Mode= “Stopped”Does

SECTION 3 - CHASSIS AND TURNTABLE3-116 – JLG Lift – 3121181Sensor/Transducer Type

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-117DTC 524- Oil Pressure Low• Engine Oil Pressure• Check Condition- Key on, Engine on• Fault C

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SECTION 3 - CHASSIS AND TURNTABLE3-118 – JLG Lift – 3121181Normally Open Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to nor

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-119Normally Closed Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to n

SECTION 3 - CHASSIS AND TURNTABLE3-120 – JLG Lift – 3121181Sensor/Transducer Type

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-121DTC 562- Battery Voltage (VBat) Low• System voltage to ECM• Check Condition- Key on, Engine

SECTION 3 - CHASSIS AND TURNTABLE3-122 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-123DTC 563- Battery Voltage (VBat) High• System voltage to ECM• Check Condition- Key on, Engin

SECTION 3 - CHASSIS AND TURNTABLE3-124 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-125DTC 601- Microprocessor Failure - FLASH• Engine Control Module- Flash Memory• Check Conditi

SECTION 3 - CHASSIS AND TURNTABLE3-126 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-127DTC 604- Microprocessor Failure - RAM• Engine Control Module- Random Access Memory• Check C

SECTION 1 - SPECIFICATIONS3121181 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIES1.2 TIRES1.3 ENGINENOTE: RPM Tolerances are ± 100. 1.4 SPECI

SECTION 3 - CHASSIS AND TURNTABLE3-128 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-129DTC 606- Microprocessor Failure - COP• Engine Control Module• Check Condition- Key on• Faul

SECTION 3 - CHASSIS AND TURNTABLE3-130 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-131DTC 642- 5 Volt External Low Voltage• Engine Control Module• Check Condition- Key on• Fault

SECTION 3 - CHASSIS AND TURNTABLE3-132 – JLG Lift – 3121181DTC 643- 5 Volt External High Voltage• Engine Control Module• Check Condition- Key on• Faul

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-133DTC 1612- Microprocessor Failure - RTI 1• Engine Control Module• Check Condition- Key on• F

SECTION 3 - CHASSIS AND TURNTABLE3-134 – JLG Lift – 3121181DTC 1613- Microprocessor Failure - RTI 2• Engine Control Module• Check Condition- Key on• F

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-135SFC 555- RTI 2 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 555 re

SECTION 3 - CHASSIS AND TURNTABLE3-136 – JLG Lift – 3121181DTC 1614- Microprocessor Failure - RTI 3• Engine Control Module• Check Condition- Key on• F

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-137SFC 556- RTI 3 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 556 re

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3121181Reach SpecificationsChassis1.5 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsLift: Boom R

SECTION 3 - CHASSIS AND TURNTABLE3-138 – JLG Lift – 3121181DTC 1615- Microprocessor Failure - A/D• Engine Control Module• Check Condition- Key on• Fau

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-139SFC 513- A/D LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 513 rese

SECTION 3 - CHASSIS AND TURNTABLE3-140 – JLG Lift – 3121181DTC 1616- Microprocessor Failure - interrupt• Engine Control Module• Check Condition- Key o

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-141SFC 512- Invalid InterruptKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC

SECTION 3 - CHASSIS AND TURNTABLE3-142 – JLG Lift – 3121181DTC 1625- CAN J1939 Shutdown Request• Controller Area Network• Check Condition- Key On, Eng

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-143DTC 1626- CAN J1939 Transmit (Tx) Fault• Controller Area Network• Check Condition- Key On,

SECTION 3 - CHASSIS AND TURNTABLE3-144 – JLG Lift – 3121181DTC 1627- CAN J1939 Receive (Rx) Fault• Controller Area Network• Check Condition- Key On, E

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-145DTC 1628- CAN Address Conflict Failure• CAN device(s)• Check Condition- Key On, Engine on•

SECTION 3 - CHASSIS AND TURNTABLE3-146 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-147DTC 1629- J1939 TSC1 Message Reciept Loss• Controller Area Network• Check Condition- Key On

SECTION 1 - SPECIFICATIONS3121181 – JLG Lift – 1-31.6 TORQUE REQUIREMENTS 1.7 LUBRICATIONHydraulic OilNOTE: Hydraulic oils must have anti-wear qualiti

SECTION 3 - CHASSIS AND TURNTABLE3-148 – JLG Lift – 3121181DTC 1652- TPS1 Loss of Communications• Throttle Actuator (with serial/digital position feed

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-149DTC 2111- Unable to Reach Lower TPS• Throttle Position Sensor• Check Condition-Cranking or

SECTION 3 - CHASSIS AND TURNTABLE3-150 – JLG Lift – 3121181

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-151DTC 2112- Unable to Reach Higher TPS• Throttle Position Sensor• Check Condition-Cranking or

SECTION 3 - CHASSIS AND TURNTABLE3-152 – JLG Lift – 3121181DTC 9999- Throttle Actuator Failsafe Spring Failure• Throttle Actuator• Check Condition- Ke

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-153DTC to SPN/FMI TableFAULTINDEXDESCRIPTIONDTC SETSPN FMI2 DTC 118: ECT voltage high 110 33 D

SECTION 3 - CHASSIS AND TURNTABLE3-154 – JLG Lift – 3121181ABCDA. Exh au st Vent uriB. 1/4" (6.35 mm) minimum clearance all around.C.

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-155B,CB, CB, CB,CB,CAAA. Pa rt Number\ Act ual Wei ght S tampingB. A pply Loc tit e #2

SECTION 3 - CHASSIS AND TURNTABLE3-156 – JLG Lift – 3121181NOTES:

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-1SECTION 4. BOOM AND PLATFORM4.1 BOOM MAINTENANCEDO NOT USE A LIFTING DEVICE TO LIFT BOOMS UNLESS

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3121181Table 1-14. Mobil DTE 13M SpecsISO Viscosity Grade #32Specific Gravity 0.877Pour Point, Max -40°F (

SECTION 4 - BOOM AND PLATFORM4-2 – JLG Lift – 3121181Disassemble Main Boom1. Loosen jam nuts on aft end of fly boom wear pad adjust-ment and loosen ad

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-3Assemble Main Boom1. Install power track to the attach point on the base boomsection. Secure powe

SECTION 4 - BOOM AND PLATFORM4-4 – JLG Lift – 31211811. Upper Boom2. Tower Link3. Upper Upright4. Upper Lift Cylinder5. Upper Towe

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-5Figure 4-2. Boom Limit Switches

SECTION 4 - BOOM AND PLATFORM4-6 – JLG Lift – 3121181Figure 4-3. Main Boom

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-74.2 ROTATORSee Figure 4-5., Rotator Assembly - CutawayDisassembly and Inspection 1. Place on a cl

SECTION 4 - BOOM AND PLATFORM4-8 – JLG Lift – 31211811. Housing & Ring Gear2A. Shaft2B. Flange2C. Bearing Tube3. Piston Sleeve4. Piston5.

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-94.3 ROTARY ACTUATOR (S/N 1300006433 TO PRESENT)Theory of OperationThe L20 Series rotary actuator

SECTION 4 - BOOM AND PLATFORM4-10 – JLG Lift – 3121181PAR TS1. Housing 2. Shaf t 3. Pi ston Slee ve4. End CapHARDWARE103.1. Sc

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-11PARTS1. Ho usi ng 2. Sha ft 3. Pi ston Sle eve4. End CapHARDWARE103.1. Sc

SECTION 1 - SPECIFICATIONS3121181 – JLG Lift – 1-51.8 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Figure 1-1.,Operator Main

SECTION 4 - BOOM AND PLATFORM4-12 – JLG Lift – 3121181Disassembly1. Remove capscrews (113) over end cap lock pins (109). 2. Using a 1/8” (3.18mm) dril

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-137. Remove stop tube if included. Stop tube is an availableoption to limit rotation of the actuat

SECTION 4 - BOOM AND PLATFORM4-14 – JLG Lift – 312118111. Before removing piston (3), mark housing (1) ring gear inrelation to piston O.D. gear. There

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-1515. Remove wear guides (302) from end cap (4) and shaft (2). 16. To remove main pressure seals (

SECTION 4 - BOOM AND PLATFORM4-16 – JLG Lift – 3121181Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspecting.

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-172. Install thrust washer (304) on shaft (2) and end cap (4). 3. Install wiper seal (304.1/green

SECTION 4 - BOOM AND PLATFORM4-18 – JLG Lift – 3121181Each T-seal has two back-up rings (see drawing for ori-entation). Beginning with inner seal (200

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-199. Looking from opposite end of housing (1) you can see iftiming marks line up. When they do, ta

SECTION 4 - BOOM AND PLATFORM4-20 – JLG Lift – 312118114. Coat threads on end of shaft with anti-seize grease toprevent galling. 15. Install 0-ring (2

SECTION 4 - BOOM AND PLATFORM3121181 – JLG Lift – 4-21Installing Counterbalance ValveRefer to Figure 4-8., Rotator Counterbalance Valve.1. Make sure a

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3121181*If necessary install grease fittings into worm gearhousing and grease bearings.DO NOT OVER-GREASE E

SECTION 4 - BOOM AND PLATFORM4-22 – JLG Lift – 3121181A,B,DC,DEABCDETorque to 50 ft-lb (68 Nm)Thread Locking Compound - JLG P/N 0100011Torque to 480 f

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-1SECTION 5. HYDRAULICS AND HYDRAULIC SCHEMATICSNOTE: Hydraulic Schematics locat

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-2 – JLG Lift – 3121181DipNOTE: This method works best with Face Seal O-rings, but willwork for all O-

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-35.2 HYDRAULIC CYLINDERSFigure 5-1. Hydraulic Cylinder Locations 12345678 or 98

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-4 – JLG Lift – 3121181Tower Lift CylinderRefer to Figure 5-5.DISASSEMBLYCONTAMINATION MAY DAMAGE EQUI

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-5111119161715142*2*320111098**7126541318***1684239* Torque to 33 ft-lb (45 Nm)**

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-6 – JLG Lift – 31211817. Using suitable protection, clamp cylinder rod (20) in avise or similar holdi

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-7ASSEMBLYNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-8 – JLG Lift – 3121181Main Lift CylinderRefer to Figure 5-15.DISASSEMBLYCONTAMINATION MAY DAMAGE EQUI

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-91191816***1715143*13210911712654168424420111* Torque to 33 ft-lb (45 Nm)** Torq

SECTION 1 - SPECIFICATIONS3121181 – JLG Lift – 1-7Lube Point(s) - Fill CapCapacity - 27 gallons (102 liters); 23.6 gal. (89 liters) to the Full l

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-10 – JLG Lift – 31211817. Using suitable protection, clamp cylinder rod (20) in avise or similar hold

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-11ASSEMBLYNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-12 – JLG Lift – 3121181Master CylinderRefer to Figure 5-25.DISASSEMBLYCONTAMINATION MAY DAMAGE EQUIPM

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-1321141213**11157*985106431684241111* 442 ft-lb (600 Nm)** 295 ft-lb (400 Nm)1.

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-14 – JLG Lift – 31211816. Using suitable protection, clamp cylinder rod (15) in avise or similar hold

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-15ASSEMBLYNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-16 – JLG Lift – 3121181Telescope CylinderRefer to Figure 5-35.DISASSEMBLYCONTAMINATION MAY DAMAGE EQU

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-172*4**51920***17****1816151210***139148763121111684235* Torque to 18 ft-lb (24

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-18 – JLG Lift – 31211819. Remove seal (19) from piston (20).10. Unscrew and remove piston assembly.11

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-19ASSEMBLYNOTE: Apply a light film of hydraulic oil to all components beforeasse

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 312118115. Air FilterLube Point(s) - Replaceable ElementInterval - Every 6 months or 300 hours of operation

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-20 – JLG Lift – 3121181Platform Level (Slave) CylinderRefer to Figure 5-44.DISASSEMBLYCONTAMINATION M

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-21111513***14123162*2*1098**117654111116842401001094789* Torque to 33 ft-lb (45N

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-22 – JLG Lift – 31211817. Using suitable protection, clamp cylinder rod (20) in avise or similar hold

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-23ASSEMBLYNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-24 – JLG Lift – 3121181Jib Lift CylinderRefer to Figure 5-54.DISASSEMBLYCONTAMINATION MAY DAMAGE EQUI

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-2545671210**8911233*13151416171819***201111211684242* Torque to 33 ft-lb (45 Nm)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-26 – JLG Lift – 31211817. Using suitable protection, clamp cylinder rod (21) in avise or similar hold

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-27ASSEMBLYNOTE: Apply a light film of hydraulic oil to all components beforeass

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-28 – JLG Lift – 3121181Steer CylinderDISASSEMBLYRefer to Figure 5-64.CONTAMINATION MAY DAMAGE EQUIPME

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-2916*6*22334455998877121010111684246* Torque to 295 ft-lb (400 Nm)1. Barrel2. O-

SECTION 1 - SPECIFICATIONS3121181 – JLG Lift – 1-9Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-30 – JLG Lift – 31211818. Remove two wear rings (10) from piston/rod assembly(12). 9. Remove seal (11

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-31ASSEMBLY NOTE: Apply a light film of hydraulic oil to all components beforeas

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-32 – JLG Lift – 3121181Axle Lockout Cylinder (Outside Frame)NOTE: Refer to Figure 5-70., Axle Lockout

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-331. Barrel2. Rod3. Plug4. Pilot Piston5. Wear Ring6. Wiper7. Rod Seal8. Bleeder

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-34 – JLG Lift – 3121181Axle Lockout Cylinder (Inside Frame)Refer to Figure 5-74.DISASSEMBLYCONTAMINAT

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-353571289**11 1021915161417**1114*4*6181684243* Torque to 33 ft-lb (45 Nm)** Tor

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-36 – JLG Lift – 31211818. Using suitable protection, clamp cylinder rod (21) in avise or similar hold

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-37ASSEMBLYNOTE: Apply a light film of hydraulic oil to all components beforeass

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-38 – JLG Lift – 31211815.3 HYDRAULIC PUMP (GEAR)DisassemblyNOTE: The following general instructions a

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-3910. Remove rear bearing block from drive and idler shafts.11. Remove idler sha

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121181Figure 1-4. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-40 – JLG Lift – 3121181Inspect Parts For Wear1. Clean and dry all parts thoroughly prior to inspectio

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-41General InformationIt is important that the relationship of the mounting flang

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-42 – JLG Lift – 31211816. Apply a light coating of petroleum jelly to the exposedface of the front be

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-43is the case, remove the gear housing and check forproper seal installation.15.

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-44 – JLG Lift – 3121181Placing Pump Back Into Service1. If shop test stand is available, the followin

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-45Removal and Installation of FNR and NFPE Modules1. Clean pump and module housi

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-46 – JLG Lift – 3121181Figure 5-82. Gauge Port Locations1. System Pressure Gauge Port M22. System Pr

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-47

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-48 – JLG Lift – 3121181Figure 5-83. Plugs/Fittings Size & Torque#Plug/FittingTorquelb. ft. Nm1 S

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-495. Install a new O-ring on the valve plug. Reinstall the pop-pet, spring, and

SECTION 1 - SPECIFICATIONS3121181 – JLG Lift – 1-11Figure 1-5. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-50 – JLG Lift – 31211811. Position the pump with shaft facing up.NOTE: If the unit is positioned hori

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-51Charge PumpNOTE: Charge pump may be disassembled to inspect and clean,or to ch

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-52 – JLG Lift – 31211815.5 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONSThe goal at sys

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-535.6 PRESSURE SETTING PROCEDURECold temperatures have a significant impact on p

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-54 – JLG Lift – 31211811. Check Valve2. Load Shuttle3. Load Shuttle4. Main Dump5.

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-55ABC18-20 ft. lbs. (24.5 - 27.2 Nm)4-5 ft. lbs. (5.4 - 6.8 Nm)25-27 ft. lbs. (3

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-56 – JLG Lift – 31211811. Jib Up2. Jib Down3. Jib Up/Down Relief4. Rotate - Left5.

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-57Figure 5-91. Hydraulic Schematic - Sheet 2 of 62792780 C

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-58 – JLG Lift – 3121181Figure 5-92. Hydraulic Schematic - Sheet 3 of 6

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-59Figure 5-93. Hydraulic Schematic - Sheet 4 of 62792780 C

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121181Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-60 – JLG Lift – 3121181Figure 5-94. Hydraulic Schematic - Sheet 5 of 6

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS3121181 – JLG Lift – 5-61Figure 5-95. Hydraulic Schematic - Sheet 6 of 62792780 C

SECTION 5 - HYDRAULICS AND HYDRAULIC SCHEMATICS5-62 – JLG Lift – 3121181NOTES:

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121181Figure 6-2. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-3Figure 6-3. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 31211816.4 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the four pin end of the cable supplied

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-5DRIVEBOOMSYSTEMDATALOGVERSIONSPressing ENTER with any of the above displayed menus, willdisplay

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121181Figure 6-4. ADE Control System Block Diagram

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-76.7 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZEROnce you have gained access to level 1, and

SECTION 1 - SPECIFICATIONS3121181 – JLG Lift – 1-13Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121181ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTOMENU:MACHINE SETUPPERSONALITIES:DR

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-9FROMPERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:UPPER TELESCOPEPERSONALITIES:BASKET

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121181FROMMENU:PERSONALITIESMENU:MACHINE SETUPTOMENU:CALIBRATIONSMODEL NUMBER:1=400ENGINE:1=FORD EFI

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-11Figure 6-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121181Figure 6-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4NOTE: Some screens may not

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-13Figure 6-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121181FROM:MENU:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL NUMBER:400SENGINE:FORD EFI G

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-15MENU:HELP:PRESS ENTERHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU:CALIBRATIONSMENU:DIAGNOSTIC

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121181 MENU: HELP:PRESS ENTER HELP: (001) EVERYTHING OK LOG:(xxx) x:xxxxxxxxxxx MENU: DIAGNOSTIC

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-17FromDIAGNOSTICS:BOOM FUNCTIONSTODIAGNOSTICS:LOAD DIAGNOSTICS: ENGINE START SEQUENCE: NOT ACTIVE

INTRODUCTION3121181 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121181NOTES:

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121181 CALIBRATION DATA LOAD 500LB: CALIBRATION DATA PLATFORM UP:FROM DIAGNOSTICS:UMS DIAGNOSTICS: LO

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-19FROM MENU:DIAGNOSTICSTO PERSONALITIES:MAIN LIFT MENU: SYSTEM TEST SYSTEM TEST: ACTIVATE? MENU:

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121181FROM PERSONALITIES:RIGHT TRACK PERSONALITIES: MAIN LIFT MAIN LIFT: ACCEL X.XS MAIN LIFT: DECEL

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-21FROMMENU:PERSONALITIES MENU: MACHINE SETUP MODEL NUMBER: 600S MARKET: CE ENGINE: PERKINS ECM FL

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121181Table 6-1. Machine Set-Up ParametersConfigurationDigitParameterDisplayed onAnalyzer Line 1Descr

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-235JOYSTICK TYPE:Displays/adjusts joystick type0=LIFT LOCK LIFT LOCK refers to the OEM controls p

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 312118110 EXT. AXLES: Displays/adjusts extendable axle presence. NOTE: Not Displayed0=NO No Extendable

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-2519 LOAD TYPE Selects if we are using the LSS Module, built in load cell or the BPE module (if s

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 312118125 TILT SENSOR:Displays/adjusts type of tilt sensorNOTE: Only Dis-played in Access Level 00=EXT

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-276.9 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustme

SECTION 2 - GENERAL3121181 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121181SWING 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 SYSTEM3121181 – JLG Lift – 6-29JIB 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 SYSTEM6-30 – JLG Lift – 3121181Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3Configur

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-31GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: Automatic pre-glow time

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121181GEN SET CUTOUT:12* * On ly visib le if Gen S et / Welder Menu selection is not 0.01MOTION E

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-33GROUND ALARM:18* * Certain market selec-tions will alter default set-ting.0123NO: No ground ala

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121181Table 6-4. Machine Configuration Programming Information Prior to Software Version P5.3Configur

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-35GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: Automatic pre-glow time

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121181GEN SET CUTOUT:12* * On ly visib le if Gen Set / Welder Menu selection is not 0.01MOTION ENA

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-37GROUND ALARM:18* * Certain market selec-tions will alter default set-ting.0123NO: No ground ala

SECTION 2 - GENERAL2-2 – JLG Lift – 31211812.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in the useand applicat

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121181Table 6-5. Machine Configuration Programming Information Software Version P5.3 to P6.1Configur

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-39ENGINE:3* * Engine selections vary depending on model selection.12345678910111213FORD EFI GAS:

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3121181ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant temperatu

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-41GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED:

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 3121181FUNCTION CUTOUT:18* * Only visible under cer-tain market selections. * Certain market selec-tio

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-43Table 6-6. Machine Configuration Programming Information Software Version P6.1 to PresentConfig

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 3121181ENGINE:3*12345678910111213141516FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1)FORD EFI D/F: Ford LR

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-45STARTER LOCKOUT:601DISABLED: Automatic pre-glow time determined by ambient air temperature; eng

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121181JIB:10*01NO: No jib installed.YES: Jib installed which has up and down movements only. 0 * Only

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-47LOAD SYSTEM:17*01234NO: No load sensor installed.WARN ONLY: Functions in creep, overload lamp l

SECTION 2 - GENERAL3121181 – JLG Lift – 2-3Pressure-Fit PartsWhen assembling pressure-fit parts, use an anti-seize ormolybdenum disulfide base compoun

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 3121181DRIVE:21*0124WD: Four wheel drive.2WD: Two wheel drive.2WD W/ 2-SPEED: Two wheel drive with 2-s

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-49CLEARSKY:2801NO: ClearSky (telematics) options is disabled.YES: ClearSky (telematics) option is

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121181510AJHEAD & TAIL LIGHTSLOAD SYSTEMLOAD SENSORFUNCTION CUTOUTGROUND ALARMDRIVE TYPEDISPLAY U

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-516.10 SYSTEM TESTThe Control System Incorporates a built-in system test tocheck the system compo

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121181Figure 6-19. System Test Flow Chart - Platform Tests

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-53Test from the Ground Station1. Position the Platform/Ground select switch to theGround position

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121181Figure 6-20. System Test Flow Chart - Ground Station Tests

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-55Table 6-7. System Test MessagesMessage Displayed onAnalyzerMessage Displayed onAnalyzerDescript

SECTION 6 - JLG CONTROL SYSTEM6-56 – JLG Lift – 3121181CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure t

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-57TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, t

SECTION 2 - GENERAL2-4 – JLG Lift – 3121181Hydraulic Oil1. Refer to Section 1 for recommendations for viscosityranges.2. JLG recommends Mobilfluid 424

SECTION 6 - JLG CONTROL SYSTEM6-58 – JLG Lift – 3121181Table 6-8. Machine Diagnostics ParametersDiagnostics Submenu(Displayed on Analyzer 1st Line)Par

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-59BOOM:U LIFT UP/DOWN XXX% Displays upper lift joystick direction & demandSWING RIGHT/LEFT XX

SECTION 6 - JLG CONTROL SYSTEM6-60 – JLG Lift – 3121181ENGINE:START ACTIVE/NOT ACTIVE Displays status of the engine start circuitAIR FILTER OP/CL Disp

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-61SYSTEM:GM BATTERY XX.XV Ground module battery voltagePM BATTERY XX.XV Platform module battery v

SECTION 6 - JLG CONTROL SYSTEM6-62 – JLG Lift – 3121181h i T I LT E D - N O / Y E S D i s p l a y s s t a t u s o f hi t i l t i n p u t . ( D

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-63osc axle p sw OP/CL Displays status of oscillating axle pressure switch. (Dis-played if OSCILLA

SECTION 6 - JLG CONTROL SYSTEM6-64 – JLG Lift – 3121181MOMENT: Displayed if MODEL NUMBER = 7 or 8(LB-IN) ACTUAL XXXXXXXX Displays current moment value

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-65CALIBRATION DATABASKET UP XXX Displays the basket up calibration pointBasket DOWN XXX Displays

SECTION 6 - JLG CONTROL SYSTEM6-66 – JLG Lift – 3121181VERSIONS:GM SW PX.X Displays ground module software versionGM HW REV XXXX Displays ground modul

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-67Table 6-9. Help Fault Codes, Displayed Faults, and DescriptionsFault Flash CodeAnalyzer Displa

SECTION 2 - GENERAL3121181 – JLG Lift – 2-52.4 PINS AND COMPOSITE BEARING REPAIR GUIDELINESFilament wound bearings.1. Pinned joints should be disassem

SECTION 6 - JLG CONTROL SYSTEM6-68 – JLG Lift – 31211812/2 Flash code 2/2 indicates problems with drive & steer selection. Except where noted, the

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-692/3 Flash code 2/3 indicates problems with boom function selec-tion.3LIFT/SWING LOCKED – JOYSTI

SECTION 6 - JLG CONTROL SYSTEM6-70 – JLG Lift – 31211812/5 Flash code 2/5 indicates that a function is prevented due to a cutout.4BOOM PREVENTED – DRI

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-713/3 Flash code 3/3 indicates a driver problem. All driver faults are detected in a similar mann

SECTION 6 - JLG CONTROL SYSTEM6-72 – JLG Lift – 3121181LP LO CK S HOR T TO BAT TE RY Only occ urs on ma chi nes w ith dual -fu el en gine s.LP STAR

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-73HEAD TAIL LIGHT OPEN CIRCUIT Only occurs on machines with the headlights option configured.HEAD

SECTION 6 - JLG CONTROL SYSTEM6-74 – JLG Lift – 3121181JIB DOWN OPEN CIRCUITJIB DOWN SHORT TO BATTERYJIB LEFT SHORT TO GROUNDJIB LEFT OPEN CIRCUITJIB

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-75LIFT DOWN AUX VALVE OPEN CIRCUIT Only occurs on machines with gravity lift down.TOWER LIFT APU

SECTION 6 - JLG CONTROL SYSTEM6-76 – JLG Lift – 31211813/4 Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All drive

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-774/2 Flash code 4/2 indicates that the engine is over temperature. NOT REQUIRED4/3 Flash code 4/

SECTION 2 - GENERAL2-6 – JLG Lift – 3121181Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 6 - JLG CONTROL SYSTEM6-78 – JLG Lift – 31211814/4 Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second pow

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-794/5 Flash code 4/5 indicates problems with the S-D CAN based PVG valves currently used on the 1

SECTION 6 - JLG CONTROL SYSTEM6-80 – JLG Lift – 3121181MAIN LIFT PVG VALVE COMMAND IMPROPERMain boom lift pvg valve received an invalid command from t

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-815/5 Flash code 5/5 indicates problems with vehicle engine RPM or the encoder. Not reported duri

SECTION 6 - JLG CONTROL SYSTEM6-82 – JLG Lift – 31211818/3 Flash code 8/3 indicates problems with the Basket Leveling sys-tem.10BASKET LEVELING CRACKP

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-838/4 Flash code 8/4 indicates problems with the envelope system. On ly o cc ur on m achi nes w

SECTION 6 - JLG CONTROL SYSTEM6-84 – JLG Lift – 3121181TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOWThis fault is repo rte d by th e Gro und modu le

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-858/5 Flash code 8/5 indicates problems with the moment or load pin system. Only occur on machine

SECTION 6 - JLG CONTROL SYSTEM6-86 – JLG Lift – 31211818/6 Flash code 8/6 indicates problems with the steering system. Except as noted, an EMS cycle i

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-87REAR LEFT WHEEL BLOCKED The wheel is not responding to steer commands. Fault clears when condit

SECTION 2 - GENERAL3121181 – JLG Lift – 2-7Platform Controls 55 66Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitc

SECTION 6 - JLG CONTROL SYSTEM6-88 – JLG Lift – 31211819/9 Flash code 9/9 indicates problems with the controller or the user disabling safety systems

SECTION 6 - JLG CONTROL SYSTEM3121181 – JLG Lift – 6-89BL AM SENSOR SUPP LY OU T O F RA NGE HIGHIndicates that the supply voltage for the boom angle

SECTION 6 - JLG CONTROL SYSTEM6-90 – JLG Lift – 3121181NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHE

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-2 – JLG Lift – 3121181Resistance Measurement• First test meter and leads by touchi

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected curre

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-4 – JLG Lift – 31211817.4 AMP CONNECTORApplying Silicone Dielectric Compound to AM

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-53. After all required contacts have been inserted, thewedge

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-6 – JLG Lift – 3121181Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-7Figure 7-11. Connector Installation

SECTION 2 - GENERAL2-8 – JLG Lift – 3121181Capacity Decals Installed, Secure, Legible 21 21 21All Decals/Placards Installed, Secure, Legible 21 21 21W

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-8 – JLG Lift – 31211817.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-10 – JLG Lift – 3121181Figure 7-18. Electrical Components Installation - Sheet 1

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-11Figure 7-19. Electrical Components Installation - Sheet 2

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-12 – JLG Lift – 3121181Figure 7-20. Electrical Schematic - Sheet 1 of 4NOTE: This

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-13Figure 7-21. Electrical Schematic - Sheet 2 of 41870144G

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-14 – JLG Lift – 3121181Figure 7-22. Electrical Schematic - Sheet 3 of 4NOTE: This

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-15Figure 7-23. Electrical Schematic - Sheet 4 of 41870144G

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-16 – JLG Lift – 3121181Figure 7-24. Electrical Schematic - Deutz EMR2 & GM En

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-17Figure 7-25. Electrical Schematic - Deutz EMR2 & GM En

SECTION 2 - GENERAL3121181 – JLG Lift – 2-9Footnotes:1 Prior to use each day; or at each Operator change2 Prior to each sale, lease, or delivery3 In s

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-18 – JLG Lift – 3121181Figure 7-26. Electrical Schematic - Deutz EMR2 & GM En

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-19Figure 7-27. Electrical Schematic - Deutz EMR2 & GM En

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-20 – JLG Lift – 3121181Figure 7-28. Electrical Schematic - Deutz EMR2 & GM En

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-21Figure 7-29. Electrical Schematic - Deutz EMR2 & GM En

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-22 – JLG Lift – 3121181Figure 7-30. Electrical Schematic - Deutz, GM, & CAT E

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-23Figure 7-31. Electrical Schematic - Deutz, GM, & CAT E

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-24 – JLG Lift – 3121181Figure 7-32. Electrical Schematic - Deutz, GM, & CAT E

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-25Figure 7-33. Electrical Schematic - Deutz, GM, & CAT E

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-26 – JLG Lift – 3121181Figure 7-34. Electrical Schematic - Deutz, GM, & CAT E

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS3121181 – JLG Lift – 7-27Figure 7-35. Electrical Schematic - Deutz, GM, & CAT E

INTRODUCTIONA-2 – JLG Lift – 3121181REVISON LOGOriginal Issue - January 24, 2003Revised - March 12, 2003Revised - September 20, 2005Revised - March 16

SECTION 2 - GENERAL2-10 – JLG Lift – 3121181Figure 2-1. Engine Operating Temperature Specifications - Deutz4150548 D

SECTION 7 - BASIC ELECTRICAL INFORMATION AND ELECTRICAL SCHEMATICS7-28 – JLG Lift – 3121181NOTES:

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

SECTION 2 - GENERAL3121181 – JLG Lift – 2-11AMBIENT AIRTEMPERATUREFigure 2-2. Engine Operating Temperature Specifications - Perkins4150548 D

SECTION 2 - GENERAL2-12 – JLG Lift – 3121181NOTES:

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-1SECTION 3. CHASSIS AND TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for pne

SECTION 3 - CHASSIS AND TURNTABLE3-2 – JLG Lift – 31211813.2 TORQUE HUB (MACHINES BUILT BEFORE S/N 1300000064)Roll, Leak and Brake TestingTorque-Hub u

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-3Main Disassembly1. Perform Roll Check, Leak Check and Brake Check if appli-cable before disas

SECTION 3 - CHASSIS AND TURNTABLE3-4 – JLG Lift – 31211817. Input Shaft 17. Input Sun Gear8. Output Sun GearFigure 3-2. Main Disassembly Drawing

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-5Input Carrier Disassembly1. Place Carrier (3A) on a press with spline end up. DrivePlanet Sha

SECTION 3 - CHASSIS AND TURNTABLE3-6 – JLG Lift – 3121181Output Carrier Disassembly1. Using a small diameter punch, Drive Roll Pin (4G) whichholds Pla

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-7Housing-Spindle Disassembly1. Place unit on bench with Spindle (1A) end down.EYE PROTECTION M

3121181 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-8 – JLG Lift – 3121181Spindle-Brake DisassemblyNOTE: This procedure applies only to units with integral inputbrake

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-9EYE PROTECTION MUST BE WORN WHILE PERFORMING THE STEPS 1-3 IN THISPROCEDURE.1. Compress the C

SECTION 3 - CHASSIS AND TURNTABLE3-10 – JLG Lift – 31211813A. Carrier 3E. Planet Shaft3B. Thrust Washers 3F. Planet Gear3C. Needl

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-11Output Carrier Sub-Assembly1. Place Spring (4I) into the deep counterbore of the Out-put Car

SECTION 3 - CHASSIS AND TURNTABLE3-12 – JLG Lift – 31211814A. Output Carrier 4E. Planet Shaft 4H. Thrust Washer 4K. Retaining Ring4B. Thrust

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-13Spindle-Brake Sub-AssemblyNOTE: This procedure applies only to units with integral inputbrak

SECTION 3 - CHASSIS AND TURNTABLE3-14 – JLG Lift – 31211811-A. Spindle 2-3. Back-up Ring 2-7. End Plate 2-11. Capscrew12. Pressure P

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-15Housing-Spindle Sub-AssemblyNOTE: Spray a light film of oil on all component parts duringass

SECTION 3 - CHASSIS AND TURNTABLE3-16 – JLG Lift – 31211811B. Seal 1D. Bearing Cone 1F. Bearing Spacer 1H. Wheel Stud1C. Bearing

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-17Main AssemblyNOTE: All components should receive a generous amount of lubri-cant oil as they

ii – JLG Lift – 3121181TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-18 – JLG Lift – 31211816. Cover 10. Thrust Spacer 19. O-ring9. Input Coupling 14. Cover BoltsFigure 3-12. Main Ass

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-19Figure 3-13. Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2

SECTION 3 - CHASSIS AND TURNTABLE3-20 – JLG Lift – 31211811A Spindle1G Retaining Ring - Ext12 Pressure Plug16 O-ring Pipe Plug1F Thrust Washer1E Housi

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-21Figure 3-15. Assembly Drawing - With Integral Input Brake - Sheet 1 of 2

SECTION 3 - CHASSIS AND TURNTABLE3-22 – JLG Lift – 31211811A Spindle2 Input Brake1G Retaining Ring - Ext12 Pressure Plug16 O-ring Pipe Plug1F Thrust W

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-23Figure 3-17. Assembly Tools - Bearing Cone Pressing - “B” Bearing

SECTION 3 - CHASSIS AND TURNTABLE3-24 – JLG Lift – 3121181Figure 3-18. Assembly Tools - Bearing Cone Pressing - “A” Bearing

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-25Figure 3-19. Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings

SECTION 3 - CHASSIS AND TURNTABLE3-26 – JLG Lift – 3121181Figure 3-20. Assembly Tools - Seal Pressing

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-27Figure 3-21. Assembly Tools - Spacer - Brake Disc Installation

3121181 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-28 – JLG Lift – 3121181Figure 3-22. Assembly Tools - Brake Retaining Ring Installation

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-293.3 TORQUE HUB (MACHINES BUILT AFTER S/N 1300000064)Roll and Leak Testing Always roll and le

SECTION 3 - CHASSIS AND TURNTABLE3-30 – JLG Lift – 3121181WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE THAT SPRING ANDSPACERS COMPRESSED BY RETA

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-314. Remove 16 needle rollers (3C) from inside one end ofcluster gear (3F). Discard the needle

SECTION 3 - CHASSIS AND TURNTABLE3-32 – JLG Lift – 31211816. Following thrust washer, place cluster gear (3F), largeend toward roll pin hole in carrie

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-33Cover Sub-Assembly1. Using the disconnect rod, push O-ring (6F) in grooveinside cover cap (6

SECTION 3 - CHASSIS AND TURNTABLE3-34 – JLG Lift – 31211817. With large end down, place disconnect cap (6D) oncover cap (6B), aligning pipe plug hole

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-353. Apply a light coat of "Never-Seize" to two pipe plugs (1J)and tighten them into

SECTION 3 - CHASSIS AND TURNTABLE3-36 – JLG Lift – 31211819. Place spacer (1H) on spindle (1A) in hub (1G).NOTE: Make sure retaining ring is securely

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-373. Place thrust washer (11) around spindle (1A) so it restson bottom of internal gear (2). 4

iv – JLG Lift – 3121181TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-38 – JLG Lift – 31211819. Place thrust spacer (9) on input shaft (7).10. Set carrier sub-assembly (3) on a flat wor

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-39BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING O-RING.15. Set cover (6A) on table, int

SECTION 3 - CHASSIS AND TURNTABLE3-40 – JLG Lift – 312118121. Torque shoulder bolts (13) 18 to 25 ft-lb (25 to 34 Nm).Torque bolts (12) 18 to 25 ft-lb

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-41Tool List The following specialized tools are used to assemble this unit.Tool diagrams inclu

SECTION 3 - CHASSIS AND TURNTABLE3-42 – JLG Lift – 31211813.4 RE-ALIGNING TORQUE HUB INPUT COUPLINGThe following procedure applies to torque hubs with

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-43INSPECT COMPONENTSInspect the new seal, the motor housing seal bore, and thesealing area on

SECTION 3 - CHASSIS AND TURNTABLE3-44 – JLG Lift – 3121181TroubleshootingTable 3-2. Excessive Noise and/or VibrationItem Description ActionCheck oil

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-45DisassemblyNOTE: Removal of endcap voids warranty.During assembly, coat all moving parts wit

SECTION 3 - CHASSIS AND TURNTABLE3-46 – JLG Lift – 312118113. Using an 8 mm internal hex wrench, remove endcapscrews (22).14. Remove endcap (23). Remo

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-4719. Turn housing on its side and remove cylinder kit assem-bly (31). Set assembly aside. Do

3121181 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS AND TURNTABLE3-48 – JLG Lift – 312118124. Turn housing over and remove swashplate (39) by liftingon the end opposite the servo lev

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-49CYLINDER BLOCKMeasure the cylinder block height. Replace blocks wornbeyond the minimum heigh

SECTION 3 - CHASSIS AND TURNTABLE3-50 – JLG Lift – 3121181SWASHPLATE AND JOURNAL BEARINGSInspect the running face, servo ball-joint, and swashplate jo

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-51Assembly1. Install new O-ring (1) and piston seal (2) to the servo pis-ton (3). Install the

SECTION 3 - CHASSIS AND TURNTABLE3-52 – JLG Lift – 31211816. Install the journal bearings (13) into the housing seats.Use assembly grease to keep the

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-5310. Verify swashplate and bearings are properly seated.Install cylinder kit (19) on shaft. I

SECTION 3 - CHASSIS AND TURNTABLE3-54 – JLG Lift – 3121181NOTE: Improper assembly of internal components may preventendcap from seating properly.15. I

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-5520. Install orifice poppet (30).21. Install shift spool (31).22. Install spring retaining wa

SECTION 3 - CHASSIS AND TURNTABLE3-56 – JLG Lift – 3121181Table 3-8. Chassis Torque ValuesFt-Lbs. NmA 120 163B 240 325C 170 230D 140 190E 165 224F 35

SECTION 3 - CHASSIS AND TURNTABLE3121181 – JLG Lift – 3-57EABCDTable 3-9. Chassis Torque ValuesItem Ft-Lbs. NmA 120 163B 240 325C 170 230D 85 115E 165