Jlg 600SC_660SJC Service Manual User Manual

Service and Maintenance ManualModels600SC660SJCS/N 74875 to PresentP/N - 3121157May 24, 2011

vi – JLG Lift – 3121157TABLE OF CONTENTS SECTION NO. TITLE

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-8 – JLG Lift – 3121157Two-Speed Changeover SystemStructure of two-speed changeover systemSwash pl

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-9If exertion of pilot pressure for changeover is stopped, the2-speed changeo

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-10 – JLG Lift – 3121157Working Principle of Parking BrakeParking brake is a negative brake consis

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-11Procedures for manually releasing parking brake (This mechanism is optiona

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-12 – JLG Lift – 3121157Figure 5-13. Procedures for Manually Releasing Parking Brake (step 1)Plug

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-13Reduction GearsReduction gears consist of a double stage planetary pin-ion

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-14 – JLG Lift – 31211575.4 PRECAUTIONS AND WARNINGSInspectionCheck the following points before in

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-15Hydraulic Fluid1. Hydraulic fluid is an important factor for transmissiono

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-16 – JLG Lift – 31211575.5 OPERATING STEPS AND PRECAUTIONSPrecautions at StartupAfter installatio

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-17Figure 5-19. Lubricant Change Lubricant discharge port Filling port Ga

3121157 – JLG Lift – vii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-18 – JLG Lift – 3121157Hydraulic Fluid Temperature during OperationTemperature control of the hyd

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-19Lubricating Oil for Reduction Gears1. Inspection of Contaminated Lubricati

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-20 – JLG Lift – 3121157Inspection for Hydraulic Fluid and Lubricant Leaks, and Torque of Bolts an

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-215.7 TROUBLESHOOTINGIn the event a failure occurs while in operation, refer

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-22 – JLG Lift – 3121157Troubleshooting for Parking BrakeTroubleshooting for High Pressure Relief

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-23Troubleshooting for Low Pressure Shuttle ValveTROUBLES (TYPE OF FAILURE)

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-24 – JLG Lift – 3121157Troubleshooting for 2-speed ControlsTROUBLES (TYPE OF FAILURE) POSSIBLE C

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-25Troubleshooting for Low Pressure Relief ValveTROUBLES (TYPE OF FAILURE) P

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-26 – JLG Lift – 31211575.8 MAINTENANCE AND REPAIR PROCEDURESTools for Disassembly and ReassemblyT

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-27Table 5-2. List of Special Purpose ToolsNo. Parts Name Standard Type an

viii – JLG Lift – 3121157TABLE OF CONTENTS SECTION NO. TITLE

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-28 – JLG Lift – 3121157Tool - Angular Bearing Disassembly

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-29Tool - Angular Bearing Outer Ring Press Fitting

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-30 – JLG Lift – 3121157Tool - Angular Bearing Inner Ring Press Fitting Ring Nut Disassembly and T

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-31Brake Piston Positioning Brake Piston Positioning (PLATE)

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-32 – JLG Lift – 3121157Brake Piston Positioning (PIN) Snap Ring Assembly

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-33Tool - Angular Bearing Outer Ring Press Fitting

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-34 – JLG Lift – 3121157Motor Bearing Assembly Floating Seal Assembly

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-35Floating Seal #1 - Assembly Floating Seal #2 - Assembly

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-36 – JLG Lift – 3121157Table 5-3. List of Subsidiary MaterialNo. Parts Name Standard Type and Dim

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-37Nut M12 1729 ft lb (± 3)39.2 N-m (±4.9)(38-16) Plug PF 1/2 1087 ft lb (±3

3121157 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-38 – JLG Lift – 31211575.9 PRECAUTIONS FOR DISASSEMBLY1. Since all parts are precisely machined,

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-39Figure 5-21. Exploded View of Motor

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-40 – JLG Lift – 3121157Figure 5-22. Exploded View of Reduction Gear Assembly

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-415.10 DISASSEMBLY INSTRUCTIONSPerform disassembly in accordance with the fo

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-42 – JLG Lift – 31211575. Remove brake piston (17) by blowing compressedair from oil passage of p

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-4310. Pull out plunger sub assembly (33).NOTE: Slowly pull it out while turn

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-44 – JLG Lift – 312115716. Remove planetary gear A (1-18) and needle bearing(1-1), and then remov

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-45Maintenance Standards For Disassembled PartsWash all parts disassembled in

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-46 – JLG Lift – 3121157Roller bearing (3) / Roller bearing (28) When flaking and abrasion develop

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-47Reduction Gear MaintenanceNOTE: Pitching in this instance refers to a case

x – JLG Lift – 3121157LIST OF FIGURES FIGURE NO. TITLE

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-48 – JLG Lift – 31211575.11 PRECAUTIONS FOR REASSEMBLY1. Wash all parts in treated oil, and remov

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-494. Install inner ring sub assembly of the second angu-lar bearing (1-3) on

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-50 – JLG Lift – 312115710. Assemble sun gear B (1-15) mounted with snap ring(1-16).11. Assemble h

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-5115. Apply Loctite #262 (16 locations) to bolt (1-29), andtighten it to spe

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-52 – JLG Lift – 312115721. Assemble steel ball (6), spring (25) and piston subassembly (24), and

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-5327. Grip base plate (32) with vise, and assemble plungersub assembly (33).

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-54 – JLG Lift – 312115733. Insert spool (39) and spring (40) into base plate, andassemble plugs (

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-1SECTION 6. TURNTABLE6.1 SWING HUBAdjustment Procedures1. Ensure swing drive is located on bearing gear m

SECTION 6 - TURNTABLE6-2 – JLG Lift – 3121157d. At the position indicated on figure 2-45. try andinsert the 0.0015" feeler gauge between the bolt

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-3Figure 6-4. Swing Bearing Tolerance Boom Placement

3121157 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 6 - TURNTABLE6-4 – JLG Lift – 3121157f. Use a suitable tool to scribe a line on the innerrace of the swing bearing and on the undersideof the

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-5e. Using suitable lifting equipment, carefully posi-tion the turntable assembly above the machineframe.f.

SECTION 6 - TURNTABLE6-6 – JLG Lift – 3121157Figure 6-6. Swing Brake Assembly (Mico)

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-7AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulicoil prior to assembly.1. Press new rota

SECTION 6 - TURNTABLE6-8 – JLG Lift – 3121157Overload ProtectionSTOP THE ENGINE WHENEVER CHECKING OR INSPECTING THECIRCUIT BREAKER.The circuit breaker

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-91. Battery2. Battery Holddown3. Gear Pump4. Piston Pump5. Air Cleaner6. Fan7. Motor Mount8. Muffler9. Fro

SECTION 6 - TURNTABLE6-10 – JLG Lift – 312115717. Engine Tray18. Engine Mounting Plate19. Hayes Coupling20. Pump Adapter Plate21. Dipstick22. Filler C

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-116.6 DEUTZ EMR 2 (S/N 85110 TO PRESENT)The EMR2 consists of the sensors, the control unit and theactuator

SECTION 6 - TURNTABLE6-12 – JLG Lift – 3121157Figure 6-9. EMR 2 Engine Side EquipmentGLOW PLUGPOWER SUPPLYCOOLANT TEMPERATURESENSORCONTROL ROD POSITI

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-13Figure 6-10. Deutz EMR 2 Troubleshooting Flow Chart

xii – JLG Lift – 3121157LIST OF FIGURES FIGURE NO. TITLE

SECTION 6 - TURNTABLE6-14 – JLG Lift – 3121157Figure 6-11. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-15Figure 6-12. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 6 - TURNTABLE6-16 – JLG Lift – 3121157Figure 6-13. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-17Figure 6-14. EMR 2 Engine Plug Pin Identification

SECTION 6 - TURNTABLE6-18 – JLG Lift – 3121157Figure 6-15. EMR 2 Vehicle Plug Pin Identification

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-19Figure 6-16. EMR2 Fault Codes - Sheet 1 of 5

SECTION 6 - TURNTABLE6-20 – JLG Lift – 3121157Figure 6-17. EMR2 Fault Codes - Sheet 2 of 5

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-21Figure 6-18. EMR2 Fault Codes - Sheet 3 of 5

SECTION 6 - TURNTABLE6-22 – JLG Lift – 3121157Figure 6-19. EMR2 Fault Codes - Sheet 4 of 5

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-23Figure 6-20. EMR2 Fault Codes - Sheet 5 of 5

3121157 – JLG Lift – xiii LIST OF TABLESTABLE NO. TITLE

SECTION 6 - TURNTABLE6-24 – JLG Lift – 31211571. Battery Hold-down2. Battery3. Air Cleaner4. Coolant Overflow Container5. Pump Coupling6. Fan7. Engine

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-2515. Engine Tray16. Piston Pump17. Gear Pump18. Fuel Filter19. Alternator20. Oil Pressure Switch21. Oil F

SECTION 6 - TURNTABLE6-26 – JLG Lift – 31211576.7 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONSThis section defines the diagnostics and reco

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-27 DTC XXXX- Diagnostic Condition Note: Helpful tips used to aid troubleshooting Yes No Troubles

SECTION 6 - TURNTABLE6-28 – JLG Lift – 3121157List of Abbreviations in this SectionAL Adaptive Learn LED Light Emitting DiodeBP Barometric Pressure LP

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-29FP Fuel Pressure UEGOUniversal Exhaust Gas Oxygen Sensor(also called wide-range EGO)FPP Foot Pedal Posit

SECTION 6 - TURNTABLE6-30 – JLG Lift – 3121157Diagnostic Trouble CodesThe numeric diagnostic trouble codes assigned to thefaults in this section are c

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-31DTC 116- ECT Higher Than Expected Stage 1• Engine Coolant Temperature Sensor• Check Condition-Engine Run

SECTION 6 - TURNTABLE6-32 – JLG Lift – 3121157DTC 117- ECT/CHT Low Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine Running• Fault C

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-33Does DST display ECTvoltage of 4.9 VDC orgreater?·Key Off·Disconnect ECT sensor from harness·Key On, Eng

xiv – JLG Lift – 3121157LIST OF TABLES TABLE NO. TITLE

SECTION 6 - TURNTABLE6-34 – JLG Lift – 3121157DTC 118- ECT/CHT High Voltage• Engine Coolant Temperature Sensor• Check Condition-Engine Running• Fault

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-35

SECTION 6 - TURNTABLE6-36 – JLG Lift – 3121157DTC 122- TPS1 Signal Voltage Low• Throttle Position Sensor 1• Check Condition-Key On, Engine Off• Fault

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-37

SECTION 6 - TURNTABLE6-38 – JLG Lift – 3121157DTC 123- TPS1 Signal Voltage High• Throttle Position Sensor 1• Check Condition-Key On, Engine Off• Fault

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-39

SECTION 6 - TURNTABLE6-40 – JLG Lift – 3121157DTC 217- ECT Higher Than Expected 2• Engine Coolant Temperature Sensor• Check Condition-Engine Running•

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-41DTC 219- RPM Higher Than Max Allowed Governed Speed• Max Govern Speed Override- Crankshaft Position Sen-

SECTION 6 - TURNTABLE6-42 – JLG Lift – 3121157DTC 336- Crank Signal Input Noise• Crankshaft Position sensor• Check Condition- Key On, Engine On• Fault

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-43• Key On, Engine Running• System Mode= “Running”Does DTC 336 reset ?Intermittent faultNoYesCheck wiring

SECTION 1 - SPECIFICATIONS3121157 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS1.2 CAPACITIES1.3 ENGINE DATA Table 1-1. Opera

SECTION 6 - TURNTABLE6-44 – JLG Lift – 3121157DTC 337- Loss of Crank Input Signal• Crankshaft Position sensor• Check Condition- Key On, Engine On• Fau

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-45DTC 521- Oil Pressure Sender/Switch High Pressure• Engine Oil Pressure• Check Condition- Key on, Engine

SECTION 6 - TURNTABLE6-46 – JLG Lift – 3121157DTC 524- Oil Pressure Low• Engine Oil Pressure• Check Condition- Key on, Engine on• Fault Condition- Eng

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-47Normally Closed Switch• Key-On, Engine On• System Mode= “Running”• Warm engine at idle to normal operati

SECTION 6 - TURNTABLE6-48 – JLG Lift – 3121157DTC 562- Battery Voltage (VBat) Low• System voltage to ECM• Check Condition- Key on, Engine on• Fault Co

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-49

SECTION 6 - TURNTABLE6-50 – JLG Lift – 3121157DTC 563- Battery Voltage (VBat) High• System voltage to ECM• Check Condition- Key on, Engine Cranking or

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-51

SECTION 6 - TURNTABLE6-52 – JLG Lift – 3121157DTC 601- Microprocessor Failure - FLASH• Engine Control Module- Flash Memory• Check Condition- Key on• F

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-53

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31211571.4 COMPONENT DATASwing SystemAuxiliary Power PumpHydraulic Filters1.5 PERFORMANCE DATAFunction Spee

SECTION 6 - TURNTABLE6-54 – JLG Lift – 3121157DTC 604- Microprocessor Failure - RAM• Engine Control Module- Random Access Memory• Check Condition- Key

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-55

SECTION 6 - TURNTABLE6-56 – JLG Lift – 3121157DTC 606- Microprocessor Failure - COP• Engine Control Module• Check Condition- Key on• Fault Condition-

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-57

SECTION 6 - TURNTABLE6-58 – JLG Lift – 3121157DTC 642- 5 Volt External Low Voltage• Engine Control Module• Check Condition- Key on• Fault Condition- E

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-59DTC 643- 5 Volt External High Voltage• Engine Control Module• Check Condition- Key on• Fault Condition-

SECTION 6 - TURNTABLE6-60 – JLG Lift – 3121157DTC 1612- Microprocessor Failure - RTI 1• Engine Control Module• Check Condition- Key on• Fault Conditio

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-61DTC 1613- Microprocessor Failure - RTI 2• Engine Control Module• Check Condition- Key on• Fault Conditio

SECTION 6 - TURNTABLE6-62 – JLG Lift – 3121157SFC 555- RTI 2 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 555 resetwith engin

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-63DTC 1614- Microprocessor Failure - RTI 3• Engine Control Module• Check Condition- Key on• Fault Conditio

SECTION 1 - SPECIFICATIONS3121157 – JLG Lift – 1-3Dimensions1.6 TORQUE REQUIREMENTS1.7 PRESSURE SETTINGS1.8 CYLINDER SPECIFICATIONS1.9 MAJOR COMPONENT

SECTION 6 - TURNTABLE6-64 – JLG Lift – 3121157SFC 556- RTI 3 LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 556 resetwith engin

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-65DTC 1615- Microprocessor Failure - A/D• Engine Control Module• Check Condition- Key on• Fault Condition-

SECTION 6 - TURNTABLE6-66 – JLG Lift – 3121157SFC 513- A/D LossKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 513 resetwith engine

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-67DTC 1616- Microprocessor Failure - interrupt• Engine Control Module• Check Condition- Key on• Fault Cond

SECTION 6 - TURNTABLE6-68 – JLG Lift – 3121157SFC 512- Invalid InterruptKey On - Engine RunningSystem Data ModeClear System FaultDoes SFC 512 resetwit

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-69DTC 1625- CAN J1939 Shutdown Request• Controller Area Network• Check Condition- Key On, Engine Off and/o

SECTION 6 - TURNTABLE6-70 – JLG Lift – 3121157DTC 1626- CAN J1939 Transmit (Tx) Fault• Controller Area Network• Check Condition- Key On, Engine Off an

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-71DTC 1627- CAN J1939 Receive (Rx) Fault• Controller Area Network• Check Condition- Key On, Engine Off and

SECTION 6 - TURNTABLE6-72 – JLG Lift – 3121157DTC 1628- CAN Address Conflict Failure• CAN device(s)• Check Condition- Key On, Engine on• Fault Conditi

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-73

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31211571.10 SERIAL NUMBER LOCATIONSA serial number plate is affixed to the left rear side of theframe. If t

SECTION 6 - TURNTABLE6-74 – JLG Lift – 3121157DTC 1629- J1939 TSC1 Message Reciept Loss• Controller Area Network• Check Condition- Key On, Engine Runn

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-75DTC 1652- TPS1 Loss of Communications• Throttle Actuator (with serial/digital position feedback)• Check

SECTION 6 - TURNTABLE6-76 – JLG Lift – 3121157DTC 2111- Unable to Reach Lower TPS• Throttle Position Sensor• Check Condition-Cranking or Running• Faul

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-77

SECTION 6 - TURNTABLE6-78 – JLG Lift – 3121157DTC 2112- Unable to Reach Higher TPS• Throttle Position Sensor• Check Condition-Cranking or Running• Fau

SECTION 6 - TURNTABLE3121157 – JLG Lift – 6-79DTC 9999- Throttle Actuator Failsafe Spring Failure• Throttle Actuator• Check Condition- Key Off, Engine

SECTION 6 - TURNTABLE6-80 – JLG Lift – 3121157DTC to SPN/FMI TableFAULTINDEXDESCRIPTIONDTC SETSPN FMI2 DTC 118: ECT voltage high 110 33 DTC 117: ECT v

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-1SECTION 7. BOOM & PLATFORM7.1 PLATFORMPlatform Sections ReplacementThe platform is made up

SECTION 7 - BOOM & PLATFORM7-2 – JLG Lift – 31211575. Repeat the torque procedure in step #4 to theextend wire ropes (turntable end).6. Extend the

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-37.4 WIRE ROPENOTE: The pictures in this paragraph are just samples toshow the replacement crite

SECTION 1 - SPECIFICATIONS3121157 – JLG Lift – 1-51.12 OPERATOR MAINTENANCE AND LUBRICATIONNOTE: The following numbers correspond to those in Figure1-

SECTION 7 - BOOM & PLATFORM7-4 – JLG Lift – 3121157Figure 7-5. Boom Assembly Cutaway - Sheet 1 of 3

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-5Figure 7-6. Boom Assembly Cutaway - Sheet 2 of 3

SECTION 7 - BOOM & PLATFORM7-6 – JLG Lift – 3121157e. Using a suitable brass drift and hammer, removethe rotator shaft, then remove the support fr

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-7retain any residual hydraulic fluid. Cap hydrauliclines and ports. Remove the slave cylinder.3.

SECTION 7 - BOOM & PLATFORM7-8 – JLG Lift – 3121157Disassembly of Boom Sections1. Remove hardware securing the push bar to aft endof the telescope

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-916. When removing wire rope from fly boom section,push the cable into fly boom. Route wire rope

SECTION 7 - BOOM & PLATFORM7-10 – JLG Lift – 312115710. Inspect extend and retract wire rope attach pointcomponents for cracks, stretching, distor

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-1110. Install sheave guards to aft end of mid boom sectionand secure with mounting hardware.11.

SECTION 7 - BOOM & PLATFORM7-12 – JLG Lift – 3121157Figure 7-16. Boom Powertrack Installation

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-13Installation1. Using a suitable lifting device, position boomassembly on turntable so that the

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31211572. Swing Drive HubLube Point(s) - Level/Fill PlugCapacity - 17 oz. (1/2 Full)Lube - EPGLInterval - C

SECTION 7 - BOOM & PLATFORM7-14 – JLG Lift – 31211575. Inspect inner diameter of rotator attach point bear-ings for scoring, distortion, wear, or

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-15Figure 7-18. Limit Switches Adjustments

SECTION 7 - BOOM & PLATFORM7-16 – JLG Lift – 31211577.8 ROTATOR - HELAC (PRIOR TO S/N 0300132437) Disassembly1. Place actuator on a clean workbenc

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-17Figure 7-19. Rotator Assembly (Helac)

SECTION 7 - BOOM & PLATFORM7-18 – JLG Lift – 31211577. Remove the shaft (2) from piston sleeve (3) and theactuator housing (1).8. Remove piston sl

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-198. The end cap must be secured against the shaft byinstalling axial set screws (4). 7.9 ROTARY

SECTION 7 - BOOM & PLATFORM7-20 – JLG Lift – 3121157Required ToolsUpon assembly and disassembly of the actuator there arebasic tools required. The

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-21PARTS1. Housing 2. Sh aft 3. Piston Sleeve4. En d Ca pHARDWARE103.1. Screw10

SECTION 7 - BOOM & PLATFORM7-22 – JLG Lift – 3121157PARTS1. Housing 2. Sh aft 3. Piston Sleeve4. En d CapHARDWARE103.1. Screw103

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-23Disassembly1. Remove the capscrews (113) over end cap lock pins(109). 2. Using a 1/8” (3.18mm)

SECTION 1 - SPECIFICATIONS3121157 – JLG Lift – 1-77. Suction Strainers (in tank)Lube Point(s) - 2Interval - Every 2 years or 1200 hours of operation,r

SECTION 7 - BOOM & PLATFORM7-24 – JLG Lift – 31211576. Remove the end cap (4) and set aside for laterinspection. 7. Remove the stop tube if includ

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-2510. Remove the shaft (2). It may be necessary to strikethe threaded end of the shaft with a ru

SECTION 7 - BOOM & PLATFORM7-26 – JLG Lift – 312115716. To remove the main pressure seals (205), it is easi-est to cut them using a sharp razor bl

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-27Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 7 - BOOM & PLATFORM7-28 – JLG Lift – 31211572. Install the thrust washer (304) onto shaft (2) and endcap (4). 3. Install the wiper seal (3

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-29Each T-seal has 2 back-up rings (see drawing for ori-entation). Beginning with the inner seal

SECTION 7 - BOOM & PLATFORM7-30 – JLG Lift – 31211579. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-3114. Coat the threads on the end of the shaft with anti-seize grease to prevent galling. 15. In

SECTION 7 - BOOM & PLATFORM7-32 – JLG Lift – 3121157Installing Counterbalance ValveRefer to Figure 7-29., Rotator Counterbalance Valve.1. Make sur

SECTION 7 - BOOM & PLATFORM3121157 – JLG Lift – 7-337.10 FOOT SWITCH ADJUSTMENTAdjust so that functions will operate when pedal is at cen-ter of t

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3121157Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPOU

SECTION 7 - BOOM & PLATFORM7-34 – JLG Lift – 3121157NOTES:

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-1SECTION 8. HYDRAULICS8.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 8 - HYDRAULICS8-2 – JLG Lift – 3121157Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-38.2 VALVES - THEORY OF OPERATIONSolenoid Control ValveControl valves used are four-way three-position so

SECTION 8 - HYDRAULICS8-4 – JLG Lift – 31211577. If extend port leakage is less than 6-8 drops perminute, carefully reconnect hose to extend port,than

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-58.5 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

SECTION 8 - HYDRAULICS8-6 – JLG Lift – 31211579. Loosen and remove the cap screw(s), if applicable,which attach the tapered bushing to the piston.10.

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-717. If applicable, inspect piston rings for cracks or otherdamage. Replace as necessary.AssemblyNOTE: Pr

SECTION 8 - HYDRAULICS8-8 – JLG Lift – 31211576. If applicable, correctly place new o-ring in the innerpiston diameter groove. (The backup ring side f

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-9b. Tap each space once; this means the taperedbushing is tapped 3 times as there are 3 spacesbetween the

SECTION 1 - SPECIFICATIONS3121157 – JLG Lift – 1-9Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 8 - HYDRAULICS8-10 – JLG Lift – 3121157IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ONTHE MACHINE, EXTREME CARE SHOULD BE USED TO INS

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-118.6 CYLINDER REMOVAL AND INSTALLATIONMain Boom Telescope Cylinder Removal1. Place machine on a flat and

SECTION 8 - HYDRAULICS8-12 – JLG Lift – 31211574. Install extend cable mounting blocks to threadedends of cables. Loosely install nuts and jam nutsont

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-138.7 PRESSURE SETTING PROCEDURESCold temperatures have a significant impact on pressurereadings. JLG Ind

SECTION 8 - HYDRAULICS8-14 – JLG Lift – 3121157Figure 8-15. Pressure Setting Adjustments - Sheet 1 of 2

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-15Figure 8-16. Pressure Setting Adjustments - Sheet 2 of 2

SECTION 8 - HYDRAULICS8-16 – JLG Lift – 3121157Figure 8-17. Location of Components - Main Control Valve (Sheet 1 of 2)

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-17Figure 8-18. Location of Components - Main Control Valve (Sheet 2 of 2)

SECTION 8 - HYDRAULICS8-18 – JLG Lift – 3121157Figure 8-19. Main Control Valve Torque ValuesA. 18-20 ft.lbs. (24.5-27 Nm)B. 25-27 ft.lbs. (34

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-19Figure 8-20. Platform Valve Identification1. Flow Control Cartridge2. Directional Control Valv

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121157Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 8 - HYDRAULICS8-20 – JLG Lift – 31211578.8 HYDRAULIC PUMP (GEAR)DisassemblyNOTE: The following general instructions also apply to mul-tiple se

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-2110. Remove rear bearing block from drive and idlershafts.11. Remove idler shaft from bearing block.12.

SECTION 8 - HYDRAULICS8-22 – JLG Lift – 3121157Inspect Parts For Wear18. Clean and dry all parts thoroughly prior to inspec-tion. It is not necessary

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-23General InformationIt is important that the relationship of the mounting flange,bearing blocks and gear

SECTION 8 - HYDRAULICS8-24 – JLG Lift – 31211575. Place mounting flange, with shaft seal side down, ona clean flat surface.6. Apply a light coating of

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-25out of the groove. If this is the case, remove the gearhousing and check for proper seal installation.1

SECTION 8 - HYDRAULICS8-26 – JLG Lift – 3121157Placing Pump Back Into Service1. If shop test stand is available, the following proce-dure for testing

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-27Removal and Installation of FNR and NFPE Modules1. Clean pump and module housings.2. Remove four (4) sc

SECTION 8 - HYDRAULICS8-28 – JLG Lift – 3121157Figure 8-23. Gauge Port Locations1. System Pressure Gauge Port M22. System Pressure Port B3. System Pr

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-29Figure 8-24. Plugs/Fittings Size & Torque#Plug/FittingTorquelb. ft. Nm1 Servo Gauge Port M4N/A N/A

SECTION 1 - SPECIFICATIONS3121157 – JLG Lift – 1-11Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 8 - HYDRAULICS8-30 – JLG Lift – 31211575. Install a new O-ring on the valve plug. Reinstall thepoppet, spring, and plug (with shims and O-ring

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-311. Position the pump with the shaft facing up.NOTE: If the unit is positioned horizontally when the sha

SECTION 8 - HYDRAULICS8-32 – JLG Lift – 312115712. Place the O-ring onto the shaft bearing and lubricatewith petroleum jelly.13. Slide the seal carrie

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-33Figure 8-29. Charge Pump Components1. Cover Retaining Screw2. O-ring3. Gerotor Cover4. Gerotor Assembl

SECTION 8 - HYDRAULICS8-34 – JLG Lift – 31211578.10 HYDRAULIC PUMP W/HAYES PUMP DRIVE COUPLING LUBRICATIONAny time pump or pump drive coupling is remo

SECTION 8 - HYDRAULICS3121157 – JLG Lift – 8-35NOTE: With the engine on low idle, "crack", (loosen-don'tremove), the system lines at th

SECTION 8 - HYDRAULICS8-36 – JLG Lift – 3121157NOTES:

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-1SECTION 9. JLG CONTROL SYSTEM9.1 INTRODUCTIONWHEN INSTALLING A NEW GROUND MODULE CONTROLLER ONT

SECTION 9 - JLG CONTROL SYSTEM9-2 – JLG Lift – 3121157Figure 9-2. ADE Block Diagram

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-39.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the four pin end of the cable supplied

INTRODUCTION3121157 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121157Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 9 - JLG CONTROL SYSTEM9-4 – JLG Lift – 3121157Figure 9-3. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-5When a top level menu is selected, a new set of menuitems may be offered: for example: DRIVEBOOM

SECTION 9 - JLG CONTROL SYSTEM9-6 – JLG Lift – 3121157Figure 9-4. Control Module Location

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-7Once the correct password is displayed, press ENTER.The access level should display the followin

SECTION 9 - JLG CONTROL SYSTEM9-8 – JLG Lift – 31211579.6 MACHINE SETUPWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-9ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTOMENU:MACHINE SETUPPERSONALITIES:DR

SECTION 9 - JLG CONTROL SYSTEM9-10 – JLG Lift – 3121157FROMPERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:UPPER TELESCOPEPERSONALITIES:BASKE

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-11FROMMENU:PERSONALITIESMENU:MACHINE SETUPTOMENU:CALIBRATIONSMODEL NUMBER:1=400ENGINE:1=FORD EFI

SECTION 9 - JLG CONTROL SYSTEM9-12 – JLG Lift – 3121157Figure 9-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-13Figure 9-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4NOTE: Some screens may not

SECTION 1 - SPECIFICATIONS3121157 – JLG Lift – 1-13Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 9 - JLG CONTROL SYSTEM9-14 – JLG Lift – 3121157Figure 9-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-15FROM:MENU:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL NUMBER:400SENGINE:FORD EFI G

SECTION 9 - JLG CONTROL SYSTEM9-16 – JLG Lift – 3121157MENU:HELP:PRESS ENTERHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU:CALIBRATIONSMENU:DIAGNOSTIC

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-17ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTO:MENU:MACHINE SETUPPERSONALITIES:

SECTION 9 - JLG CONTROL SYSTEM9-18 – JLG Lift – 3121157FROM:PERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:MAIN TELESCOPEPERSONALITIES:PLATF

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-19FROM:MENU:TOTILT:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL NUMBER:400SENGINE:FOR

SECTION 9 - JLG CONTROL SYSTEM9-20 – JLG Lift – 3121157FROM:ENGINE SHUTDOWN:TOLOAD SENSOR:TILT:5 DEGREESJIB:NO4 WHEEL STEER:NOSOFT TOUCH:NOGEN SET/WEL

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-21FROMLOAD SYSTEM:LOAD SENSOR:4 UNDER PLATFORMFUNCTION CUTOUT:NOGROUND ALARM:NODRIVE:4WDLOAD SENS

SECTION 9 - JLG CONTROL SYSTEM9-22 – JLG Lift – 3121157MENU:MENU:HELP:PRESS ENTERSERVICE MODEHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU:CALIBRATIO

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-239.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within theadjustmen

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121157Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 9 - JLG CONTROL SYSTEM9-24 – JLG Lift – 3121157RIGHT TRACK Accel 0.1 to 5.0 sec 2.0Decel 0.1 to 3.0 sec 0.7For. Min. 0 to 100% 12For. Max. 0

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-25SWING Accel 0.1 to 5.0 sec 2.0Deceleration 0.1 to 3.0 sec 1.8Minimum Left Speed 0 to 50% 30Maxi

SECTION 9 - JLG CONTROL SYSTEM9-26 – JLG Lift – 3121157BASKET ROTATE Acceleration 0.1 to 5.0 sec 1.8Deceleration 0.1 to 3.0 sec 0.7Mlnimum Left Speed

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-27Table 9-2. Help Fault Codes, Displayed Faults, and DescriptionsFault FlashCodeCommunicated (Dis

SECTION 9 - JLG CONTROL SYSTEM9-28 – JLG Lift – 3121157D/S JOY. OUT OF RANGE HIGHResistive joysticks: These faults do not occur if the Vref voltage is

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-29l/s joy. center tap bad Resistive joysticks: These faults occur when the center tap voltage is

SECTION 9 - JLG CONTROL SYSTEM9-30 – JLG Lift – 3121157HOUR METER SHORT TO BATTERYHORN SHORT TO GROUNDHORN OPEN CIRCUITHORN SHORT TO BATTERYAUX POWER

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-31STEER DUMP OPEN CIRCUITSTEER DUMP SHORT TO BATTERYTWO SPEED SHORT TO GROUNDTWO SPEED OPEN CIRCU

SECTION 9 - JLG CONTROL SYSTEM9-32 – JLG Lift – 3121157BASKET DOWN SHORT TO BATTERYBASKET DOWN OVERRIDE SHORT TO GROUNDOnly occurs on machines with el

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-33TOWER DOWN OPEN CIR-CUITTOWER DOWN SHORT TO BATTERYTOWER IN SHORT TO GROUNDTOWER IN OPEN CIRCUI

SECTION 2 - GENERAL3121157 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 9 - JLG CONTROL SYSTEM9-34 – JLG Lift – 31211573/4 Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All drive

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-35JIB LEFT OPEN CIRCUITJIB RIGHT SHORT TO BAT-TERYJIB RIGHT SHORT TO GROUNDJIB RIGHT OPEN CIRCUIT

SECTION 9 - JLG CONTROL SYSTEM9-36 – JLG Lift – 31211574/4 Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second pow

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-37CHASSIS TILT SENSOR NOT GAIN CALIBRATEDIndicates that the chassis tilt sensor calibration infor

SECTION 9 - JLG CONTROL SYSTEM9-38 – JLG Lift – 3121157Table 9-3. Machine Configuration Programming Information Prior to Software Version P5.3Configur

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-39GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: Automatic pre-glow time

SECTION 9 - JLG CONTROL SYSTEM9-40 – JLG Lift – 3121157GEN SET CUTOUT:12* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-41GROUND ALARM:18* * Certain market selections will alter default setting.0123NO: No ground alarm

SECTION 9 - JLG CONTROL SYSTEM9-42 – JLG Lift – 3121157Table 9-4. Machine Configuration Programming Information Software Version P5.3 to P6.1Configura

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-43ENGINE:3* * Engine selections vary depending on model selec-tion.12345678910111213FORD EFI GAS

SECTION 2 - GENERAL2-2 – JLG Lift – 31211572.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 9 - JLG CONTROL SYSTEM9-44 – JLG Lift – 3121157ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant temperatu

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-45GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 9 - JLG CONTROL SYSTEM9-46 – JLG Lift – 3121157FUNCTION CUTOUT:18* * Only visible under certain market selections. * Certain market selectio

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-47Table 9-5. Machine Configuration Programming Information Software Version P6.1 to PresentConfig

SECTION 9 - JLG CONTROL SYSTEM9-48 – JLG Lift – 3121157ENGINE:3* * Engine selections vary depending on model selec-tion.123456789101112131415FORD EFI

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-49STARTER LOCKOUT:601DISABLED: Automatic pre-glow time determined by ambient air temperature; eng

SECTION 9 - JLG CONTROL SYSTEM9-50 – JLG Lift – 3121157GEN SET/WELDER:1201NO: No generator installed.BELT DRIVE: Belt driven setup.0GEN SET CUTOUT:13*

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-51LOAD SENSOR:17* * Only visible if Load Sen-sor Menu selection is not 0 and under certain marke

SECTION 9 - JLG CONTROL SYSTEM9-52 – JLG Lift – 3121157LEVELING MODE:22* * Only visible on 800S models.01ALL FUNCTIONS: Platform level with all funct

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-53NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available

SECTION 2 - GENERAL3121157 – JLG Lift – 2-3Components Removal and Installation1. Use adjustable lifting devices, whenever possible, ifmechanical assis

SECTION 9 - JLG CONTROL SYSTEM9-54 – JLG Lift – 3121157600SCLOAD SYSTEMLOAD SENSORFUNCTION CUTOUTGROUND ALARMDRIVE TYPETEMPERATURELEVELING MODEANSI US

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-55600SJCMODEL NUMBERMARKETENGINEGLOW PLUGSENGINE SHUTDOWNTILTJIB4 WHEEL STEERSOFT TOUCHGEN SET /

SECTION 9 - JLG CONTROL SYSTEM9-56 – JLG Lift – 3121157660SJCCABLE BREAK SWITCHLOAD SYSTEMLOAD SENSORFUNCTION CUTOUTGROUND ALARMDRIVE TYPETEMPERATUREL

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-57Table 9-6. Fault Code ListingHELP MESSAGE FAULT FAULT REMOVALOK 0 0 CLEARS WHEN FAULT IS REMOVE

SECTION 9 - JLG CONTROL SYSTEM9-58 – JLG Lift – 3121157FORD ECM POWER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTHORN SHORT TO GROU

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-59ALARM SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTGENERATOR SHORT TO GROUND

SECTION 9 - JLG CONTROL SYSTEM9-60 – JLG Lift – 3121157TOWER UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTTOWER UP OPEN CIRCUIT 3

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-61FORD FAULT CODE 31 4 3 CLEARS WHEN FAULT IS REMOVEDFORD FAULT CODE 32 4 3 CLEARS WHEN FAULT IS

SECTION 9 - JLG CONTROL SYSTEM9-62 – JLG Lift – 3121157NO ALTERNATOR OUTPUT 4 3 CLEARS WHEN FAULT IS REMOVEDOIL PRESSURE LOW 4 3 CLEARS WHEN FAULT IS

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-639.9 ANALYZER DIAGNOSTICS MENU STRUCTURE In the following structure descriptions, an intended it

SECTION 2 - GENERAL2-4 – JLG Lift – 3121157LubricationService applicable components with the amount, type,and grade of lubricant recommended in this m

SECTION 9 - JLG CONTROL SYSTEM9-64 – JLG Lift – 3121157SWINGACCEL … Displays/adjusts swing accelerationDECEL … Displays/adjusts swing decelerationMIN

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-65JIB LIFT Not displayed if JIB = NOACCEL … Displays/adjusts jib accelerationDECEL … Displays/adj

SECTION 9 - JLG CONTROL SYSTEM9-66 – JLG Lift – 3121157Table 9-8. Diagnostic Menu DescriptionsDRIVEDRIVE FOR … Displays drive joystick direction &

SECTION 9 - JLG CONTROL SYSTEM3121157 – JLG Lift – 9-67PM BATTERY … Displays battery voltage at platform moduleTEMP ... Displays ground module temper

SECTION 9 - JLG CONTROL SYSTEM9-68 – JLG Lift – 3121157NOTES:

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-1SECTION 10. BASIC ELECTRICAL INFORMATION & SCHEMATICS10.1 GENE

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-2 – JLG Lift – 3121157Resistance Measurement• First test meter and leads by touching lead

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-3Current Measurement• Set up the meter for the expected current rang

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-4 – JLG Lift – 31211573. Anderson connectors for the battery boxes and bat-tery chargers

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-5AMP Mate-N-LokFollow the installation instructions.DIN ConnectorsTh

SECTION 2 - GENERAL3121157 – JLG Lift – 2-5Changing Hydraulic Oil1. Use of any of the recommended crankcase orhydraulic oils eliminates the need for c

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-6 – JLG Lift – 3121157BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gold contact

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-7MIL-C-5015 SPEC CONNECTORSCrown Connector Inc's recommendation

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-8 – JLG Lift – 31211572. Pull back on the contact wire with a force of 1 or 2lbs. to be s

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-9Release the locking latches by squeezing theminward (See Figure 10-

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-10 – JLG Lift – 3121157Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladeb

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-11Figure 10-13. Connector Installation

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-12 – JLG Lift – 312115710.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped cont

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-13HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the c

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-14 – JLG Lift – 3121157Figure 10-20. Electrical Components - Sheet 1 of 2

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-15Figure 10-21. Electrical Components - Sheet 2 of 2

SECTION 2 - GENERAL2-6 – JLG Lift – 31211572.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINESFilament wound bearings.1. Pinned joints should be disassem

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-16 – JLG Lift – 3121157Figure 10-22. Electrical Schematic - Pre EMR2 Deutz, Caterpillar

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-17Figure 10-23. Electrical Schematic - Pre EMR2 Deutz, Caterpillar

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-18 – JLG Lift – 3121157Figure 10-24. Electrical Schematic - Pre EMR2 Deutz, Caterpillar

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-19Figure 10-25. Electrical Schematic - Pre EMR2 Deutz, Caterpillar

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-20 – JLG Lift – 3121157Figure 10-26. Electrical Schematic - Deutz EMR2/Gradall - Sheet 1

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-21Figure 10-27. Electrical Schematic - Deutz EMR2/Gradall - Sheet 2

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-22 – JLG Lift – 3121157Figure 10-28. Electrical Schematic - Deutz EMR2/Gradall - Sheet 3

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-23Figure 10-29. Electrical Schematic - Deutz EMR2/Gradall - Sheet 4

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-24 – JLG Lift – 3121157REDBLACKBLACKREDPLATFORM WORK LIGHTSALARMMAIN TELE INMAIN TELE OUT

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-25AUXILIARY POWERPUMPMOTORMUP LEVELDOWN LEVELRIGHT ROTATE LEFT ROTAT

SECTION 2 - GENERAL3121157 – JLG Lift – 2-7Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-26 – JLG Lift – 312115721ENGINECONNECTORYEL/RED 2-1-99 (16)WHT/YEL 48-33456RED CAN HIBLK

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-278685873087aBLU/ORN 52-57500 WGENERATOR8685873087aRED5 AMPREDBLU/OR

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-28 – JLG Lift – 3121157211ANA RTNEPC_1F1T-14A624-AA-004 CONNGTS_0330-930009 TERM (18-29)G

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-29PINK 18DEUTSCH_DT06-6S CONNDEUTSCH_0462-201-16141 TERMINALDEUTSCH_

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-30 – JLG Lift – 3121157B+FUSIBLELINKRECTIFERREGULATORALTERNATORSTATORSENSING ANDSWITCHING

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-31This page left blank intentionally.

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-32 – JLG Lift – 3121157Figure 10-37. Hydraulic Schematic - Gradall Chassis - Sheet 1 of

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-33Figure 10-38. Hydraulic Schematic - Gradall Chassis - Sheet 2 of

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-34 – JLG Lift – 3121157Figure 10-39. Hydraulic Schematic - Gradall Chassis - Sheet 3 of

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-35Figure 10-40. Hydraulic Schematic - Gradall Chassis - Sheet 4 of

INTRODUCTIONA-2 – JLG Lift – 3121157REVISON LOGOriginal Issue - December 4, 2003Revised - November 14, 2005Revised - July 28, 2009Revised - January 20

SECTION 2 - GENERAL2-8 – JLG Lift – 3121157Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-36 – JLG Lift – 3121157Figure 10-41. Hydraulic Schematic - CAT Chassis - Sheet 1 of 4

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-37Figure 10-42. Hydraulic Schematic - CAT Chassis - Sheet 2 of 4100

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-38 – JLG Lift – 3121157Figure 10-43. Hydraulic Schematic - CAT Chassis - Sheet 3 of 4

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121157 – JLG Lift – 10-39Figure 10-44. Hydraulic Schematic - CAT Chassis - Sheet 4 of 4100

SECTION 10 - BASIC ELECTRICAL INFORMATION & SCHEMATICS10-40 – JLG Lift – 3121157NOTES:

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

SECTION 2 - GENERAL3121157 – JLG Lift – 2-9Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 2 - GENERAL2-10 – JLG Lift – 3121157-40° F(-40° C)-30° F(-34° C)-20°F(- 29°C)-10°F(- 23°C) 0°F(- 18°C) 10°F(- 12°C) 20°F( - 7°C) 30°F( - 1°C)

SECTION 2 - GENERAL3121157 – 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 2 - GENERAL2-12 – JLG Lift – 3121157NOTES:

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-1SECTION 3. GRADALL CHASSIS3.1 ASSEMBLY1. Place frame into upside down position.2. Make sure roller

SECTION 3 - GRADALL CHASSIS3-2 – JLG Lift – 3121157Figure 3-1. Chassis Service Notes - Sheet 1 of 2

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-31Track tension adjustment to be made between the idler and carrier roller - 0.781 inches (19.8 mm)2

SECTION 3 - GRADALL CHASSIS3-4 – JLG Lift – 312115712. Repeat process to opposite side:13. Assemble fitting and fitting seal into the end of eachshock

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-519. Reference offset in idler spring from centerline ofidler (to be oriented down). Using gantry cr

3121157 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - GRADALL CHASSIS3-6 – JLG Lift – 31211571. Guide Roller2. Shaft3. Plug4. Bearing5. Ring6. Seal7. Mounting Bracket8. O-ring9. Roll PinFigure

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-71. Guide Roller2. Shaft3. Internal Cover4. Bolt5. Washer6. Roller Bearing7. Not Used8. Seal Ring9.

SECTION 3 - GRADALL CHASSIS3-8 – JLG Lift – 3121157Figure 3-6. Hose Routing - Sheet 1 of 2

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-9Figure 3-7. Hose Routing - Sheet 2 of 2

SECTION 3 - GRADALL CHASSIS3-10 – JLG Lift – 312115729. Route reverse & forward hoses through frame one ata time. Lubricate o-rings, and hand tigh

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-111. Chain Assembly2. Left Link3. Right Link4. Bearing5. Hinge Pin6. Bearing Splice7. Splice Hinge P

SECTION 3 - GRADALL CHASSIS3-12 – JLG Lift – 31211571. Idler2. Shaft3. Bearing4. Roll Pin5. Mounting Bracket6. Seal7. Seal8. Seal Holder9. Not Used10.

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-131. Mounting Flange2. Spring3. Base Plate4. Locknut5. Roll Pin6. Piston/Rod7. Wiper8. Barrel9. Seal

SECTION 3 - GRADALL CHASSIS3-14 – JLG Lift – 31211571. Coupling2. Stabilizer3. Support4. Spacer5. KeeperFigure 3-11. Rotary Coupling Installation

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-1543. Get overhead crane and slings, then connect to thecarbody assembly. Have crane man lift up whi

ii – JLG Lift – 3121157TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - GRADALL CHASSIS3-16 – JLG Lift – 312115748. Repeat tracking process to opposite side of frame.49. Using overhead crane connect top of trac

SECTION 3 - GRADALL CHASSIS3121157 – JLG Lift – 3-173.3 RUBBER TRACK PAD INSTALLATION1. Seat the rubber track pad over the center rib of thesteel trac

SECTION 3 - GRADALL CHASSIS3-18 – JLG Lift – 3121157NOTES:

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-1SECTION 4. CAT CHASSIS (PRIOR TO S/N 0300128000)4.1 DUO-CONE CONVENTIONAL SE

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-2 – JLG Lift – 3121157NOTE: Be careful when you are working on the rubber toricring. Nicks, cuts or

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-37. Do not adjust the seal ring (1) by pushing on theseal ring or by pulling o

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-4 – JLG Lift – 312115711. Make sure that both seal ring housings (5) are incorrect alignment and th

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-5RESULT OF INCORRECT ASSEMBLYThe slipping of the rubber toric ring on the hous

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-6 – JLG Lift – 3121157Release Of Hydraulic Pressure From A Single Hydraulic CircuitPERSONAL INJURY

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-7Release Of Hydraulic Pressure From Multiple Hydraulic CircuitsPERSONAL INJURY

3121157 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-8 – JLG Lift – 31211574.3 TRACK CARRIER ROLLERRemovalPERSONAL INJURY OR DEATH CAN RESULT FROM GREAS

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-92. Position track carrier roller (2) in the mountingbracket. The weight of tr

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-10 – JLG Lift – 31211573. Lift the side of the machine. Install Tooling (A) underundercarriage (1),

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-112. Use Tooling (B) in order to position track roller (3) onthe undercarriage

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-12 – JLG Lift – 31211574. Remove bolts (1). Remove track shoes (2).5. Move the track assembly until

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-133. Install Tooling (D) between the first bushing in thetrack link and the sp

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-14 – JLG Lift – 31211574.6 FRONT IDLER AND RECOIL SPRING Removal1. Position the machine onto suitab

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-154.7 RECOIL SPRINGDisassemblyStart By:a. Remove the track adjuster. Refer to

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-16 – JLG Lift – 31211575. Adjust the spacing between reaction plate (2) andmovable plate (3) so tha

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-178. Close covers (6) on Tooling (A). Use Tooling (B) tocompress the recoil sp

iv – JLG Lift – 3121157TABLE OF CONTENTS SECTION NO. TITLE

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-18 – JLG Lift – 3121157Assembly1. Install backup ring (17) and O-ring seal (16) into cyl-inder (10)

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-195. Position two supports (1) of Tooling (A) in order tosupport the recoil sp

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-20 – JLG Lift – 312115710. Open the covers (6) on Tooling (A). Measure Dimen-sion (X). Dimension (X

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-213. Slide front idler (1) and the hydraulic track adjusterinto the undercarri

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-22 – JLG Lift – 31211573. Remove bolts (4), plate (5), and plate assembly (6)from piston assembly (

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-232. Replace O-ring seals (7) and (10) with new O-ringseals. Install O-ring se

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-24 – JLG Lift – 31211574.10 SPROCKETRemoval1. Position the machine onto suitable cribbing belowthe

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-254. Install bolts (1). Tighten bolts (1) to a torque of 270± 40 Nm (200 ± 30

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-26 – JLG Lift – 31211576. Disconnect hose assemblies (2). Remove fitting (3).7. Attach a suitable l

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-273. Install fitting (3). Connect hose assemblies (2).4. Install cover assembl

3121157 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-28 – JLG Lift – 31211573. Place a straight edge on top of the track grousersbetween the front carri

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)3121157 – JLG Lift – 4-29LOOSENING THE TRACK1. Loosen relief valve (2) carefully until the track begi

SECTION 4 - CAT CHASSIS (PRIOR TO S/N 0300128000)4-30 – JLG Lift – 3121157NOTES:

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-1SECTION 5. CAT CHASSIS (S/N 0300128000 TO PRESENT)5.1 PRECAUTIONS FOR USEG

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-2 – JLG Lift – 3121157GREATER THAN 10 µ M IN THE HYDRAULIC CIRCUIT.THE CONTAMINATION LEVEL OF HYD

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-3REFRAIN FROM EXERTING AXIAL LOAD. IF AXIAL LOAD ISEXERTED, PLEASE CONTACT U

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-4 – JLG Lift – 31211575.2 GENERALThis manual describes the specifications, structure andhandling

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-55.3 CONSTRUCTION AND FUNCTIONThe drive motor consists of swash plate type a

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)5-6 – JLG Lift – 3121157Working Principle of Shuttle ValveThe shuttle valve prevents the axial pist

SECTION 5 - CAT CHASSIS (S/N 0300128000 TO PRESENT)3121157 – JLG Lift – 5-7Working Principle of Relief ValveRelief valve which determines driving and