Jlg 601S ANSI Service Manual User Manual

Service and Maintenance ManualModel601SP/N - 3120746February 26, 2014

iv – JLG Lift – 3120746TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.General . . . . . . . .

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3120746Check-Out and Initial Start-Up ProceduresBefore proceeding, familiarize yourself with the

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-611. Turn ignition switch on. Do not start engine. Actuatorshould kick toward max. fuel once

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 31207462. Incorrect Linkage - Re-check linkage as discussedon page 40 and 41. Freedom of movement

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-63b. Governor is unstable at light-load or no-load.See “Linkage” for carbureted engines.c. G

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3120746ProcedureNOTE: Never run fuel tank dry. Diesel engines cannot berestarted after running ou

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-65Green and either Amber light followed by a red lightorthenAction:1. Inspect and clean wiri

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3120746c. Readjust for ambient temperature by rotating thecover one (1) mark per 5°F from 70°F. R

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-67a. Loosen jam nut b. Screw the adjustment screw all the way in, thenback out 1/2 turn.c. T

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 31207463.23 FORD EFI ENGINE (MACHINES AFTER S/N 58209)Performing Diagnostics1. Verify the complai

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-69When reading Diagnostic Trouble Codes thru the MIL, thefollowing conditions apply:• The fl

3120746 – JLG Lift – v TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.Cleaning and Inspection . . .

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3120746Table 3-9. ECM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription11All Systems OK12T

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-71Table 3-10. EPM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription Cause for Setting

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3120746145Adaptive Learn High (Natural Gas) This fault will set if the adaptive multiplier excee

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-73232 MAP Low Voltage This fault will set when the MAP reading is lower than the sensor sho

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3120746321Injector Driver #4 Open (2.5L) This fault will set if the EPM detects 10 injector firi

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-75513FPP 1 H ig he r Th an IV S Li m it Th is fa ul t wi l l s et i f t h e I V S i

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 3120746535TPS1 Higher Than TPS2 This fault will set if TPS1 is 20% (or more) higher than TPS2. At

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-77612Invalid Interrupt Several different things can happen within the microprocessor that w

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 3120746ENGINE COOLANT TEMPERATURE (ECT) SENSORThe engine coolant temperature (ECT) sensor is a gt

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-79Figure 3-46. EFI Component Location

vi – JLG Lift – 3120746TABLE OF CONTENTS (Continued) LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. Serial Number Locations. . . . . . . . . . . .

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 3120746INTAKE AIR TEMPERATURE (IAT) SENSORThe intake air temperature (IAT) sensor is a thermistor

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-81The Engine Module is designed to maintain exhaust emis-sion levels to government mandated

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 3120746Figure 3-47. ECM/EPM IdentificationECMEPM

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-83ELECTROSTATIC DISCHARGE DAMAGEElectronic components used in the Engine Module areoften des

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3120746FUEL METERING SYSTEM PURPOSEThe basic function of the air/fuel metering system is tocontro

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-85FUEL PRESSURE REGULATORThe fuel pressure regulator is a relief valve mounted in thefuel fi

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 3120746The electronic governor also acts as an idle air control(IAC) valve. Changes in engine loa

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-87ELECTRONIC IGNITIONThe electronic ignition system controls fuel combustion byproviding a s

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SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCERemoval1. Remove the platform/support as fol

3120746 – JLG Lift – vii TABLE OF CONTENTSLIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.3-45. Malfunction Indicator Light and Test

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3120746h. With powertrack support and using all applica-ble safety precautions, remove bolts #3 and #4

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-3WHEN REMOVING THE TELESCOPE CYLINDER FROM THEBOOM, IT MAY BE NECESSARY AT SOME POINT IN ORDER T

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3120746Figure 4-5. Boom Assembly Cutaway - Sheet 1 of 2

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-5Figure 4-6. Boom Assembly Cutaway - Sheet 2 of 2

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 312074612. Remove hardware which secures the sheave guardsand sheave assemblies to mid boom section,re

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-77. Inspect upper lift cylinder attach pin for wear, scor-ing, tapering and ovality, or other da

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 312074610. Install sheave guards to aft end of mid boom sectionand secure with mounting hardware.11. S

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-9Installation1. Using a suitable lifting device, position boomassembly on turntable so that the

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 31207463. Install adjusting nuts (or remove nylon collar lock-nuts if re-adjusting) to both retract a

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-114.4 WIRE ROPEEach day before using the machine:1. Raise the main boom to approximately horizon

viii – JLG Lift – 3120746TABLE OF CONTENTS (Continued) LIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.7-1. Electrical Components Installati

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 31207464.5 LIMIT SWITCHES AND CAM VALVE ADJUSTMENTAdjust switches and cam valve as shown in Limit Swi

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-13Limit Switch Functional CheckTO AVOID COLLISION AND INJURY IF PLATFORM DOES NOTSTOP WHEN A CON

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3120746minate, return the machine to a level surface, shutdown the machine, and contact a qualified t

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-157. Remove the shaft (2) from piston sleeve (3) and theactuator housing (1).8. Remove piston sl

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3120746AssemblyNOTE: Lubricate all seals and o-rings with clean hydraulicoil prior to assembly.1. Ins

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-17Figure 4-22. Rotator Assembly (Helac)

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 31207464.7 DRIVE CARD SETUP PROCEDURESNOTE: The following procedures are to be used as a begin-ning b

SECTION 4 - BOOM & PLATFORM3120746 – JLG Lift – 4-192. Rotating the adjustment potentiometer clockwisewill increase the ramp time.4.8 FOOT SWITCH

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SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 CYLINDERS - THEORY OF OPERATIONSystems Incorporating Double Acting CylindersCy

3120746 – JLG Lift – ix TABLE OF CONTENTSLIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Function Speeds (In Seconds) . . . . . . . . . . . .

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3120746Cylinders With Dual Counterbalance ValvesSlave Level, Lift, and Telescope.OPERATE ALL FUNCTIONS FROM GRO

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-3NOTE: Steps 6 and 7 apply only to the steer cylinder.6. Using a spanner wrench, loosen the spanner nutre

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 312074615. Screw the piston CCW, by hand, and remove thepiston from cylinder rod.16. Remove and discard the pis

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-5AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31207465. Using suitable protection, clamp the cylinder rod ina vise or similar holding fixture as close to pis

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-7Head and Tapered Bushing Torque Specifications.)15. After the cylinder has been reassembled, the rodshou

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31207465.5 CYLINDER REMOVAL AND INSTALLATIONIF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ONTHE MACHINE

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-95. Secure the sling and lifting device at the telescopecylinder’s approximate center of gravity, and lif

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31207465.6 VARIABLE DISPLACEMENT PUMP (M46 SERIES)TroubleshootingGAUGE INSTALLATIONIt will be necessary to ins

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-11Figure 5-14. Troubleshooting - System Operating HotFigure 5-15. Troubleshooting - Transmission Operat

x – JLG Lift – 3120746TABLE OF CONTENTS (Continued) This page left blank intentionally.

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3120746Figure 5-16. Troubleshooting - System Response is Sluggish

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-13Inspections and AdjustmentsCHECK/HIGH PRESSURE RELIEF VALVESThe system check/relief valves have the dua

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3120746ELECTRICAL DISPLACEMENT CONTROL ORIFICESNOTE: The pump should have two control orifices locatedunder th

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-15SWASHPLATE NEUTRAL ADJUSTMENT1. Using a low pressure line (500 psi [35 Bar] min.),cross port servo port

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3120746Minor Repair and ReplacementMinor repairs may be performed, following the proceduresin this section.Cle

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-17NOTE: The outside diameter of the seal may be lightlycoated with sealant (such as Loctite High Perfor-m

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3120746The appropriate check valve kit and/ or check andrelief valve kit should be used. Refer to appropriateS

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-193. Remove the control sleeve from the pump.4. Remove the control inlet screen plug from the inletpassag

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31207469. Align the control sleeve so its slot will engage theswash plate feedback pin (slot) positioned towar

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-211. Front Steer Right Relief2. Swing Left & Right3. Front Steering Right4. Swing Rig

SECTION 1 - SPECIFICATIONS3120746 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESFuel Tank26 US. Gallons (98.4 L).Hydraulic Oil TankApprox. 3

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 31207461. Front Steer Left Relief2. Front Steering Left3. Swing Left4. Upper Lift Down Relief5

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-23A. 18-20 ft.lbs. (24.5-27.2 Nm)B. 25-27 ft.lbs. (34-36.7 Nm)* Torque Valve Bolts to 60 in. lb

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 31207465.8 DIRECTIONAL CONTROL VALVEWhen removing the directional control valves from themain valve block, it

SECTION 5 - HYDRAULICS3120746 – JLG Lift – 5-25DO NOT START THE ENGINE UNLESS PUMP IS IN THE NEUTRALPOSITION (0 DEGREES SWASHPLATE ANGLE). TAKE PRECAU

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SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM (ADE)This section is applicable to machines from S/N 60188

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-2 – JLG Lift – 3120746Figure 6-1. EPBCS Block Diagram

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-36.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the four pin end of the cable sup

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-4 – JLG Lift – 3120746Figure 6-2. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-5When a top level menu is selected, a new set of menuitems may be offered: for example: DRI

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120746Swing SystemSwing Motor Displacement - 4.62 cu. in. (75 cm[3]).Swing Brake - Automatic spring applie

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-6 – JLG Lift – 3120746Figure 6-3. Control Module and Fault Code Indicator Location

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-7Once the correct password is displayed, press ENTER.The access level should display the fo

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-8 – JLG Lift – 31207466.6 MACHINE SETUPWhen a machine digit item is selected, press the UP orDOWN arrow keys to

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-9Figure 6-4. Analyzer Flow Chart - Sheet 1 of 3

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-10 – JLG Lift – 3120746Figure 6-5. Analyzer Flow Chart - Sheet 2 of 3

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-11Figure 6-6. Analyzer Flow Chart - Sheet 3 of 3

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-12 – JLG Lift – 31207466.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within theadj

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-13TELESCOPE Engine RPM 800 to 2900 1800BASKET LEVEL Engine RPM 800 to 2900 1500BASKET ROTAT

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-14 – JLG Lift – 3120746Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66939Fault

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-152/3 Flash code 2/3 indicates problems with boom function selection. 3LIFT/SWING JOYSTICK

SECTION 1 - SPECIFICATIONS3120746 – JLG Lift – 1-3Te s t N o t e s1. Stop watch should be started with the function, notwith the controller or switch

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-16 – JLG Lift – 31207463/2 Flash code 3/2 indicates that a contactor did not open when energized.NOT REQUIRED3/3

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-179/9 Flash code 9/9 indicates problems with the controller. 11PLATFORM MODULE FAILURE: hwf

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-18 – JLG Lift – 3120746Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66939 to PresentFau

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-19D/S JOY. OUT OF RANGE HIGHResistive joysticks: These faults do not occur if the Vref volt

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-20 – JLG Lift – 3120746l/s joy. center tap bad Resistive joysticks: These faults occur when the center tap volta

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-21HOUR METER SHORT TO BATTERYHORN SHORT TO GROUNDHORN OPEN CIRCUITHORN SHORT TO BATTERYAUX

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-22 – JLG Lift – 3120746STEER DUMP OPEN CIRCUITSTEER DUMP SHORT TO BATTERYTWO SPEED SHORT TO GROUNDTWO SPEED OPEN

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-23BASKET DOWN SHORT TO BATTERYBASKET DOWN OVERRIDE SHORT TO GROUNDOnly occurs on machines w

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-24 – JLG Lift – 3120746TOWER DOWN OPEN CIR-CUITTOWER DOWN SHORT TO BATTERYTOWER IN SHORT TO GROUNDTOWER IN OPEN

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-253/4 Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31207461.6 LUBRICATIONFord LRG425 EngineSingle Viscosity Oils (SF, SF-SE, SF-CC, SF-CD).NOTE: Crankcase oil

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-26 – JLG Lift – 3120746JIB LEFT OPEN CIRCUITJIB RIGHT SHORT TO BAT-TERYJIB RIGHT SHORT TO GROUNDJIB RIGHT OPEN C

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-274/4 Flash code 4/4 indicates problems with the battery supply. Not reported during 2 seco

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-28 – JLG Lift – 3120746CHASSIS TILT SENSOR NOT GAIN CALIBRATEDIndicates that the chassis tilt sensor calibration

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-29Table 6-4. Machine Configuration Programming Information Prior to Software Version P5.3Co

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-30 – JLG Lift – 3120746GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: Automatic pre-glow

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-31GEN SET CUTOUT:12* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION E

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-32 – JLG Lift – 3120746GROUND ALARM:18* * Certain market selections will alter default setting.0123NO: No ground

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-33Table 6-5. Machine Configuration Programming Information Software Version P5.3 to Present

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-34 – JLG Lift – 3120746ENGINE:3* * Engine selections vary depending on model selec-tion.123456789101112FORD EFI

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-35ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant tem

SECTION 1 - SPECIFICATIONS3120746 – JLG Lift – 1-5Hydraulic OilNOTE: Hydraulic oils must have anti-wear qualities at leastto API Service Classificatio

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-36 – JLG Lift – 3120746GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION E

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-37FUNCTION CUTOUT:18* * Only visible under certain market selections. * Certain market se

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-38 – JLG Lift – 3120746‘Table 6-6. Fault Code ListingHELP MESSAGE FAULT FAULT REMOVALOK 0 0 CLEARS WHEN FAULT IS

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-39FORD ECM POWER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTHORN SHORT T

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-40 – JLG Lift – 3120746ALARM SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTGENERATOR SHORT TO G

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-41TOWER UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTTOWER UP OPEN CIRC

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-42 – JLG Lift – 3120746FORD FAULT CODE 31 4 3 CLEARS WHEN FAULT IS REMOVEDFORD FAULT CODE 32 4 3 CLEARS WHEN FAU

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-43NO ALTERNATOR OUTPUT 4 3 CLEARS WHEN FAULT IS REMOVEDOIL PRESSURE LOW 4 3 CLEARS WHEN FAU

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-44 – JLG Lift – 31207466.9 ANALYZER DIAGNOSTICS MENU STRUCTURE In the following structure descriptions, an inten

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-45SWINGACCEL … Displays/adjusts swing accelerationDECEL … Displays/adjusts swing decelerati

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31207461.8 CYLINDER SPECIFICATIONS1.9 MAJOR COMPONENT WEIGHTS1.10 CRITICAL STABILITY WEIGHTSDO NOT REPLACE

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-46 – JLG Lift – 3120746JIB LIFT Not displayed if JIB = NOACCEL … Displays/adjusts jib accelerationDECEL … Displa

SECTION 6 - JLG CONTROL SYSTEM (ADE)3120746 – JLG Lift – 6-47Table 6-8. Diagnostic Menu DescriptionsDRIVEDRIVE FOR … Displays drive joystick direction

SECTION 6 - JLG CONTROL SYSTEM (ADE)6-48 – JLG Lift – 3120746PM BATTERY … Displays battery voltage at platform moduleTEMP... Displays ground module t

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-1SECTION 7. SCHEMATICS7.1 GENERALThis section contains schematics to be used for locatingand correcting

SECTION 7 - SCHEMATICS7-2 – JLG Lift – 3120746Figure 7-1. Electrical Components Installation (Prior to S/N 62137) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-3Figure 7-2. Electrical Components Installation (Prior to S/N 62137)- Sheet 2 of 2

SECTION 7 - SCHEMATICS7-4 – JLG Lift – 3120746Figure 7-3. Electrical Components Installation (S/N 62137 to Present)-Sheet 1 of 2

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-5Figure 7-4. Electrical Components Installation (S/N 62137 to Present)-Sheet 2 of 2

SECTION 7 - SCHEMATICS7-6 – JLG Lift – 3120746Figure 7-5. Electrical Schematic - Deutz Engine - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-7Figure 7-6. Electrical Schematic - Deutz Engine - Sheet 2 of 21870074-C

SECTION 1 - SPECIFICATIONS3120746 – JLG Lift – 1-71.11 SERIAL NUMBER LOCATIONSA serial number plate is affixed to the left rear side of theframe. If t

SECTION 7 - SCHEMATICS7-8 – JLG Lift – 3120746Figure 7-7. Electrical Schematic - Ford Dual Fuel Engine - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-9Figure 7-8. Electrical Schematic - Ford Dual Fuel Engine - Sheet 2 of 21870077-A

SECTION 7 - SCHEMATICS7-10 – JLG Lift – 3120746Figure 7-9. Electrical Schematic - Ford EFI Engine - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-11Figure 7-10. Electrical Schematic - Ford EFI Engine - Sheet 2 of 21870127-A

SECTION 7 - SCHEMATICS7-12 – JLG Lift – 3120746Figure 7-11. Electrical Schematic - ADE Machines - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-13Figure 7-12. Electrical Schematic - ADE Machines - Sheet 2 of 41870132-G

SECTION 7 - SCHEMATICS7-14 – JLG Lift – 3120746Figure 7-13. Electrical Schematic - ADE Machines - Sheet 3 of 4

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-15Figure 7-14. Electrical Schematic - ADE Machines - Sheet 4 of 41870132-G

SECTION 7 - SCHEMATICS7-16 – JLG Lift – 3120746Figure 7-15. Hydraulic Schematic - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-17Figure 7-16. Hydraulic Schematic - Sheet 2 of 42792338-A

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31207461, 632, 4578, 109, 12 THRU 17 ENGINE LOCATED ON OPPOSITESIDE OF MACHINE FROM VIEW SHOWN.11Remove fi

SECTION 7 - SCHEMATICS7-18 – JLG Lift – 3120746Figure 7-17. Hydraulic Schematic - Sheet 3 of 4

SECTION 7 - SCHEMATICS3120746 – JLG Lift – 7-19Figure 7-18. Hydraulic Schematic - Sheet 4 of 42792338-A

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

SECTION 1 - SPECIFICATIONS3120746 – JLG Lift – 1-9Table 1-9. Lubrication ChartComponentsNumber/TypeLube PointsCapacity LubeInterval HoursComments3 Mon

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3120746Figure 1-3. Torque Chart

SECTION 2 - GENERAL3120746 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31207462.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3120746 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

– JLG Lift –A Machine that incorporates theADE (Advanced Design Elec-tronics) system can be out-wardly identified by the analyzerconnection at the b

SECTION 2 - GENERAL2-4 – JLG Lift – 31207462.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3120746 – JLG Lift – 2-52.4 CYLINDER DRIFT TESTMaximum acceptable cylinder drift is to be measuredusing the following methods.Platf

SECTION 2 - GENERAL2-6 – JLG Lift – 31207462.6 WELDING ON JLG EQUIPMENTNOTE: This instruction applies to repairs, or modifications tothe machine and t

SECTION 2 - GENERAL3120746 – JLG Lift – 2-72.8 AMP CONNECTORApplying Silicone Dielectric Compound to AMP ConnectorsSilicone Dielectric Compound must b

SECTION 2 - GENERAL2-8 – JLG Lift – 31207463. After all required contacts have been inserted, thewedge lock must be closed to its locked position.Rele

SECTION 2 - GENERAL3120746 – JLG Lift – 2-9Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetween the mating seal and one of the red

SECTION 2 - GENERAL2-10 – JLG Lift – 3120746Figure 2-7. Connector Installation

SECTION 2 - GENERAL3120746 – JLG Lift – 2-11Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveM

SECTION 2 - GENERAL2-12 – JLG Lift – 3120746Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Sto

SECTION 2 - GENERAL3120746 – JLG Lift – 2-13Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additi

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SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TORQUE HUB, DRIVE Disassembly1. Position hub over su

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 3120746k. Turn cover over and push disconnect rod intocover cap. Rod will be held in place by fric

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-3l. Apply grease or petroleum jelly to tang side oftwo thrust washers. Place thrust washers

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3120746e. Install retaining ring into input shaft groove tosecure spacers and spring to shaft.Asse

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-56. Place bearing shim (8) over end of spindle andagainst bearing cone.EYE PROTECTION SHOULD

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 312074612. Place thrust spacer (36) over input shaft (35) withcounter bore side facing spindle.13.

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-717. While holding ring gear, input gear, and clustergears in mesh, place small side of clus

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 312074621. Place o-ring (22) into cover assembly counter bore.Use petroleum jelly or grease to hol

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-9Figure 3-1. Torque Hub, Drive (Fairfield)

INTRODUCTION3120746 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 31207463.2 TORQUE HUB, DRIVE (AUBURN GEAR)Disassembly1. Position hub over suitable container and

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-11Figure 3-2. Torque Hub, Drive (Auburn Gear)

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31207463.3 DRIVE BRAKE - AUSCODisassembly1. With the shaft protrusion downward, disassemblethe pa

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-13Figure 3-3. Drive Brake Assembly (Ausco)

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31207463.4 DRIVE BRAKE - MICODisassembly1. Remove pressure plate (3) from cover plate (16) byremo

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-151. Capscrew2. Washer3. Pressure Plate4. Case Seal5. O-ring6. Backup Ring7. Piston8. O-ring

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3120746Bleeding1. Install brake in system and connect pressure lines.2. Bleed pressure release se

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-173.5 DRIVE MOTOR (PRIOR TO S/N 85132)Spare Parts KitsSealing kit, existing spare parts: sha

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3120746Bearing set/miscellaneous parts Rotary group complete 9 pistons, cylinder sub-assembly,val

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-194. Assemble the sealing ring. The fitting tool will holdthe sealing ring in the correct po

INTRODUCTIONA-2 – JLG Lift – 3120746REVISON LOGMarch, 1998 - Original IssueFebruary 1, 1999 - RevisedFebruary 14, 2001 - RevisedAugust 24, 2001 - Revi

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 31207464. Remove the O-ring. 5. Disassemble the taper roller bearing.6. Remove the adjustment shi

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-2112. Remove the threaded pin (stopper - max.flow) 13. Disassemble the plug. 14. Disassemble

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 312074620. Remove the snap ring. 21. Disassemble the sealing ring.22. The external front bearing

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-23Assembly Notes1. Measurement of the taper roller bearing pretension. 2. Note that there is

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3120746NOTE: Differential volume if you are rotating the threaded pin -each rotation is appr. 3,1

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-25Te s t i n g a n d S e t u pDR: When pressure line is closed adjust the pressure ofthe c

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 31207463.6 DRIVE MOTOR ADJUSTMENT PROCEDURE (PRIOR TO S/N 85132)1. Remove the cap nut from adjust

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-273.7 DRIVE MOTOR (S/N 85132 TO PRESENT)DescriptionThe drive motors are low to medium power,

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3120746Loop Flushing ValveREMOVAL1. Using a 11/16 in internal hex wrench remove plug(1) and (2).2

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-29TroubleshootingTable 3-2. Excessive Noise and/or VibrationItem Description ActionCheck o

3120746 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3120746DisassemblyNOTE: Removal of the endcap voids warranty.During assembly, coat all moving par

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-3113. Using an 8 mm internal hex wrench, remove theendcap screws (22).14. Remove the endcap

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 312074619. Turn the housing on its side and remove the cylinderkit assembly (31). Set the assembl

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-3323. Turn housing over and remove the swashplate (39)by lifting on the end opposite the ser

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312074628. Turn the block over. Using a press, apply pressureon the block spring washer (50) to c

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-35BALL GUIDE AND SLIPPER RETAINERInspect the ball guide and slipper retainer for damage,disc

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3120746SERVO PISTON AND MINIMUM ANGLE STOPInspect the minimum angle stop, servo piston head, ands

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-37enough to expose the retaining ring groove. Windthe spiral retaining ring (7) into the gro

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 31207468. Press front shaft bearing (15) onto shaft (16). Pressbearing onto shaft with lettering

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-3912. Press the rear shaft bearing (22) into the endcap.Install the bearing with letters fac

ii – JLG Lift – 3120746TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.General . . . . . . . .

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 312074618. Cover shaft splines with an installation sleeve. Installa new shaft seal (27) with the

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-4120. Install orifice poppet (30).21. Install shift spool (31).22. Install spring retaining

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 31207462. Disconnect both drive hubs by inverting disconnectcaps in center of hubs.3. If equipped

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-433.9 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TESTLockout Cylinder BleedingENSURE PL

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 31207466. With boom over right side of machine, place DRIVEcontrol lever to REVERSE and drive mac

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-453.11 SWING HUBAdjustment Procedures1. Ensure swing drive is located on bearing gear maxecc

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 31207464. At the position indicated on Figure 3-36. try andinsert the 0.0015" feeler gauge b

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-47e. Attach suitable overhead lifting equipment to thebase of the turntable weldment.f. Use

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3120746Figure 3-38. Swing Bearing Tolerance Boom Placement

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-49Swing Bearing Torque Value1. Outer Race - 240 ft. lbs. (326 Nm) w/Loctite.2. Inner Race -

3120746 – JLG Lift – iii TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.Disassembly and Assembly .

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 31207464. Remove the piston (15) from the power plate (21) byintroducing low pressure air into th

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-51Figure 3-40. Swing Brake Assembly (Ausco)

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31207463.14 SWING MOTORCleanliness is extremely important when repairing hydrau-lic motors. Work

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-53If the Loctite is holding the screws too tightly, heat themotor housing, with a propane to

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3120746BE SURE THE EXCLUSION SEAL AND PRESSURE SEAL AREUNDAMAGED AND PROPERLY SEATED.5. Clamp the

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-551. Capscrew2. Exclusion Seal3. Mounting Flange4. Backup Ring5. Pressur

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 31207463.15 TILT ALARM SWITCH (MACHINES WITH EXTERNAL TILT SENSOR)PERFORM TILT ALARM SWITCH LEVEL

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-57Changing from LP Gas to Gasoline1. With engine operating on LP under a no load condi-tion,

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3120746with good linkages. Remember, the Actuator can beturned 180 degrees on its mounting to “re

SECTION 3 - CHASSIS & TURNTABLE3120746 – JLG Lift – 3-59