Jlg M400 ANSI Service Manual User Manual

Service and Maintenance ManualModelE400A/AJPE400A/AJPnarrowM400A/AJPM400A/AJPnarrowP/N - 3121125March 20, 2014

vi – JLG Lift – 3121125TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121125Figure 3-23. Generator System Analyzer Flow Chart

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-59• Over SpeedIf the engine speed exceeds the overspeed limit, theengine will stop immediate

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3121125Priming the Fuel LineThe following procedure is for re-priming the fuel line onthe generat

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-613.12 GENERATOR (S/N 88539 TO PRESENT)NOTE: Throughout the Generator section, the abbreviat

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 31211257131012118971211105412631314Figure 3-24. Generator8. Temperature Sensor9. Voltage Regulat

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-63Start BatteryThe RBS requires a 12V lead-acid start battery (not sup-plied with the system

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3121125Fuel Control RelayThe fuel control relay energizes the hold coil of the fuelsolenoid.The

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-65Fuel PumpThe fuel pump runs in parallel with the fuel solenoid holdcoil which is run by th

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121125engine. The signal is also used in determining if the airglow plug should be energized.The

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-67Warnings and Safety PrecautionsTHE RBS MAY START WITHOUT WARNING.MORE THAN ONE LIVE CIRCUI

3121125 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 3121125RBS Start RBS shutdownCall to start Manual 48V DC applied to the inputAutomatic 1 Low

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-69RBS Alarms and Flash CodesIn the event of an RBS alarm, a flash code will be issuedand an

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3121125TroubleshootingTable 3-11. TroubleshootingFlash Code Problem Solution- Unit Off / Disable

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-71APU Engine Start Battery BoostingAlways connect the POSITIVE (+) of the booster batteryto

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 31211253.13 SUPPLEMENTARY FUSE FOR APUThe purpose of this section is to describe the procedure to

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-73conductors of the harness.5. Cut wire 106 going to the Engine/Generator Control-ler after

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121125NOTES:

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCERemoval1. Remove the platform/support as fol

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31211254. Remove hardware securing telescope cylinder #1 tothe fly boom section, then remove pin from

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-36. Using suitable lifting equipment, slide fly boom sec-tion out to gain access to telescope cy

viii – JLG Lift – 3121125LIST OF FIGURES FIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31211254.2 UPPER (MAIN) BOOM LIFT CYLINDERRemoval1. Place the machine on a flat and level surface. Pla

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-5InstallationNOTE: Coat I.D. of bushings with specified lubricant prior toinstalling pins.1. Wit

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31211254.5 UPPER BOOM TELESCOPE CYLINDER Removal1. Place machine on flat and level surface, with Upper

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-76. Carefully install the telescope cylinder barrel end tobase, securing cylinder to the base bo

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31211254.8 BOOM SYNCHRONIZING PROCEDURENOTE: If the Lower Boom assembly does not fully lower:1. Remove

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-9Figure 4-8. Jib/Platform Components and Attaching Hardware

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121125AssemblyNOTE: For location of components See Section 4-7., Loca-tion of Components - Articulat

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-11Figure 4-10. Boom Limit Switches

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 31211254.12 HELAC ROTARY ACTUATORTheory Of OperationThe rotary actuator is a simple mechanism that us

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-131. Housi ng2. Shaft3. Piston Sleeve4. End Ca p109. Lock Pin113. Cap Sc

3121125 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 31211251. Housing2. Shaft3. Piston Sleeve4. End Cap109. Lock Pin113. Cap Scre

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-15Tools Required for Assembly/DisassemblyUpon assembly and disassembly of the actuator there are

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 31211254. Install the end cap (4) removal tools provided withthe Helac seal kit.5. Using a metal bar,

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-179. Prior to removing the shaft, (2), use a felt marker toclearly indicate the timing marks bet

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 312112515. Remove the wear guides (302) from the end cap (4)and shaft (2).16. To remove the main pres

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-19Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 31211254. Using a seal tool install the main pressure seal (205)onto shaft (2) and end cap (4). Use t

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-2110. Looking from the opposite end of the housing (1)you can see if your timing marks are linin

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 312112516. Install the O-ring (204) and back-up ring (207) intothe inner seal groove on the end cap (

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-23Installing Counterbalance ValveRefer to Figure 4-13., Rotator Counterbalance Valve.1. Make sur

x – JLG Lift –LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3121125Figure 4-13. Rotator Counterbalance Valve

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-25Installation and BleedingAfter installation of the actuator on the equipment, it isimportant t

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121125TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-274.13 POWERTRACK MAINTENANCERemoving a LinkNOTE: Hoses shown in the powertrack are for example

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 31211253. To remove a link, the rivets holding the links togethermust be removed. Use a right-angle p

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-295. After grinding it may be neccesary to help the rivetout by using a center punch with a hamm

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 31211257. Remove the link from the other section of the pow-ertrack using a screwdriver. Installing a

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-312. Spread apart the half-shear (female) end of the newlink and slide the peanut end of the tra

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 31211254. Pull the moving end out over the track so that thenew connection is positioned in the curve

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-337. Install the snap ring in the groove on the pin. Repeatthe pin installation steps for all ce

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS1.2 CAPACITIES1.3 BATTERY CHARGER1.4 DRIVE SYS

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 3121125NOTE: Maximum tightening torque is 18-20 in-lbs. 9. Pull up on the other end of the round bar

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-3510. Install a new 8-32 x 0.500 self threading screw onthe other side. NOTE: When tightening sc

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 31211252. Parts used: Bracket Center Pin and Center Pin SnapRing. 3. Take the new bracket and install

SECTION 4 - BOOM & PLATFORM3121125 – JLG Lift – 4-37Replacing Moving End Brackets1. Remove existing pins and center rivet. Remove therivet the sam

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 31211253. Install radius pins into their original locations andinstall snap rings. Repeat with other

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121125Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-35.2 CYLINDERS - THEORY OF OPERATIONDouble Acting Cylinder(Upper Boom Lift, Mid Boom Lift, Lower Boom Lif

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3121125121126618 195192518 1410162022179233*,4*,242127131388771683779-E*Prior to S/N 03001065181. Loctite #2422

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-51. Barrel2. Cylinder Rod3. Retainer4. Piston5. Cylinder Head6. Hex Nut7. Tube Spacer8. Holding Valve9. S

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31211251.8 DIMENSIONAL DATA 1.9 FUNCTION SPEEDSTable 1-8. Dimensional DataMachine Height (stowed) E/M4 00

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31211251. Loctite #2422. Primer #74713. Socket Head Bolt4. Tapered Bushing5. Bushing6. Cylinder Head7. Cylinder

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-71. Barrel2. Cylinder Rod3. Retainer4. Piston5. Cylinder Head6. Hex Nut7. Tube Spacer8. Holding Valve9. H

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31211251. Barrel2. Cylinder Rod3. Retainer4. Piston5. Cylinder Head6. Hex Nut7. Washer8. Spacer9. Holding Valve

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-91. Barrel2. Cylinder Rod3. End Cap4. Piston5. Cylinder Head6. Hex Nut7. Tube Spacer8. Not Used9. Holding

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31211251. Barrel2. Cylinder Rod3. Retainer4. Piston5. Cylinder Head6. Hex Nut7. Tube Spacer8. Setscrew9. T-Sea

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-111. Loctite #2422. Locking Primer3. Bolt4. Tapered Bushing5. Bushing6. Piston7. Washer8. Head9. Barrel10

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 31211251. Wiper2. Spanner Nut3. Retaining Ring4. Lip Seal5. Wear Ring6. Backup Ring7. O-ring8. Guide9. Barrel1

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-131. Barrel 2. Rod3. Piston4. Head5. Spacer6. Counterbalance Valve7. Bolt8. Plug 9. Setscrew10. Locknut11

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3121125Cylinders With Dual Counterbalance Valve(Lower Lift, Mid Lift, Telescope, and Slave Cylinders)OPERATE A

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-15cap screws from cylinder barrel.NOTE: Steps 6 applies only to the lower lift and telescopecylinders.6.

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-3Machine Orientation When Doing Function Tests1. LIFT: Boom retracted, telescope retracted. Lift up,

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31211256. Inspect piston surface for damage and scoring andfor distortion. Dress piston surface or replace pis

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-17wear ring into the applicable cylinder head glandgroove.3. Place a new o-ring and back-up seal in the a

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 3121125 12. Tighten the cap screws evenly and progressively inrotation to the specified torque value. (See Tab

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-1922. If applicable, install the cartridge-type holding valveand fittings in the rod port block, using ne

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31211255.5 PRESSURE SETTING PROCEDURESCold temperatures have a significant impact on pressurereadings.JLG Indu

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-21Platform Level Down Relief1. On machines prior to S/N 0300062642, install thepressure gauge at the “G”

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121125Table 5-4. Pressure Settings - Prior to S/N 0300062642Circuit PSI BarMain Control ValveLift Down Relie

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-23GAUGE PORTSTEER RELIEFMAIN RELIEFSHUTTLECARTRIDGEHYDRAULICFILTERCHECKCARTRIDGEBRAKE RELEASECARTRIDGESTE

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3121125Figure 5-26. HydraForce Cartridge Torque Value Chart

SECTION 5 - HYDRAULICS3121125 – JLG Lift – 5-25Figure 5-27. Main Valve Components Prior to S/N 62642

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31211251.11 CYLINDER SPECIFICATIONSNOTE: All dimensions are given in inches (in.), with the met-ric equival

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121125EMERGENCY DESCENT HAND PUMPEMERGENCY DESCENT VALVELOWER LIFTDOWN RELIEFRELEVELING RELIEFRELEVELINGVALVE

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 JLG CONTROL SYSTEM ANALYZER KIT INSTRUCTIONSIntroductionWHEN I

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121125The JLG Control System controller has a built in LED toindicate any faults. The system stores re

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-3Using the AnalyzerWith the machine power on and the analyzer connectedproperly, the analyzer wil

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121125Changing the Access Level of the Hand Held AnalyzerWhen the analyzer is first connected, you wil

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-5Adjusting Parameters Using the Hand Held AnalyzerOnce you have gained access to level 1, and a p

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121125The effect of the machine digit value is displayed alongwith its value. The above display would

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-7Table 6-1. Personality Ranges/DefaultsFUNCTION PERSONALITY RANGE DEFAULTSDRIVE ACCELeration 0.5s

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121125TELEscope ACCELeration 0.5 to 5.0 1.0DECELeration 0.1 to 3.0 0.5MINimum IN speed 0 to 20 8MAXimu

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-9GROUND MODE Lower LIFT UP speed 0 to 100 73Lower LIFT DOWN speed 0 to 100 36UPPER LIFT speed 0 t

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-51.14 PRESSURE SETTINGSTable 1-14. Pressure Settings - Prior to S/N 0300062642Circuit PSI BarMain Co

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121125Machine Configuration Programming Information4150286-9NOTE: The following information is to be

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-113= Motion Alarm - Sounds when any function isactive (Option)6. PLATFORM ALARM0= Sounds continuo

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121125Table 6-4. Help Descriptions and Fault Flash CodesFlash Code DescriptionNo flash code is indica

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-132/2Flash code 2/2 indicates problems with drive & steer selection.DRIVE JOYSTICK FAULTYThe

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 31211252/5Flash code 2/5 indicates that a function is prevented due to a cutout.BOOM PREVENTED - DRIVE

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-153/3Flash code 3/3 indicates that a contactor coil is short-circuited.OVERLOADED VALVE SUPPLY-CH

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 31211256/6Flash code 6/6 indicates problems with the CANbus.48V PROTECTION TRIPPED - CHECK INTER-MODUL

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-179/9Flash code 9/9 indicates problems with the controller.POWER MODULE FAILURE: CONTACTOR DRIVE

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121125MENU: HELP:PRESS ENTERHELP: (001) SYSTEM OKLOG: (XXX)XX:XXXXXXXXXXXXXMENU:

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-19MENU:ACTIVATE TESTSACTIVATE TESTS: YES:ENTER,NO:ESCMENU:ACCESS LEVEL 1ACCESS LEVEL: CODE 0000

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31211251.15 SERIAL NUMBER LOCATIONSFor machine identification, a serial number plate is affixedto the left

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121125MENU: MACHINE SETUPMODEL NUMBER: 1=3002TILT: 1=5Deg2DRIVE CUTOUT: 0=CHA

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-21Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item i

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121125System Self TestThe system self test is utilized to locate typical problems.See Table 6-6, Syst

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-23Table 6-6. System Test DescriptionsACTIVATE TESTSYES:ENTER, NO:ESCNot available once tests are

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121125Table 6-7. System Test MessagesRUNNING Initial display when system test is run; certain “criti

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-25TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121125CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure t

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-27TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121125 Table 6-8. Diagnostic Fault CodesDTCFlash CodeFault Message Description 001 00 EVERYTHING OK T

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-292252 22 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTEDInput was CLOSED during startup225

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-7Figure 1-2. Operator Maintenance & Lubrication Diagram

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 31211252514 25 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is be

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-3133364 33 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward co

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 312112577 6 77 STALLED PUMP M OTOR O R PO WER WIRING ERROR Th e po wer mo dul e pu mp MOSFET protecti

SECTION 6 - JLG CONTROL SYSTEM3121125 – JLG Lift – 6-3399133 99 POWER MODULE FAILURE - HWFS CODE 15 Hardware failsafe tests failed because the hardwar

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121125NOTES:

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-1SECTION 7. BASIC TROUBLESHOOTING, ELECTRICAL INFOR

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-2 – JLG Lift – 3121125.Table 7-1. Platform Assembly - TroubleshootingTRO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-3Proportional Flow Regulator not powered. Check wiri

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-4 – JLG Lift – 3121125Table 7-2. Boom Assembly - TroubleshootingTROUBLE

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-5Restricted or broken supply line on valve bank or h

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31211251.17 OPERATOR MAINTENANCE & LUBRICATIONNOTE: The following numbers correspond to those in Fig-ur

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-6 – JLG Lift – 3121125Function Speed and Drive Speed does not operate bel

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-7Boom extends and retracts erratically.Hydraulic sys

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-8 – JLG Lift – 3121125Boom swings erratically in either direction.Hydraul

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-9Table 7-3. Turntable Assembly - TroubleshootingTRO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-10 – JLG Lift – 3121125Table 7-4. Chassis Assembly - TroubleshootingTROU

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-11FRONT FRAME AXLE AREA.One or both wheels will not

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-12 – JLG Lift – 3121125Joystick not functioning properly. Replace joystic

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-13Proportional Flow Valve not functioning properly.

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-14 – JLG Lift – 3121125Brake Drags or runs hot.Low actuation pressure. Pl

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-15Table 7-5. Hydraulic System - TroubleshootingTROU

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-94. Hydraulic Return FilterInterval - Change after first 50 hrs. and every 6months or 300 hrs. therea

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-16 – JLG Lift – 3121125Function sluggish during operation. (System pressu

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-17Table 7-6. Electrical System - TroubleshootingTRO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-18 – JLG Lift – 3121125Hourmeter inoperative.Damaged wiring in hourmeter

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-197.3 MULTIMETER BASICSA wide variety of multimeters

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-20 – JLG Lift – 3121125Resistance Measurement• First test meter and leads

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-21Current Measurement• Set up the meter for the expe

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-22 – JLG Lift – 3121125Automatic SwitchesIf the switch is actuated automa

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-237.6 AMP CONNECTORApplying Silicone Dielectric Comp

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-24 – JLG Lift – 31211253. After all required contacts have been inserted,

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-25Disassembly1. Insert a 4.8 mm (3/16") wide sc

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 31211259. EngineLube Point(s) - Fill CapCapacity - Refer to Engine ManualLube - EOInterval - 3 Months or 1

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-26 – JLG Lift – 3121125Figure 7-11. Connector Installation

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-277.7 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Gra

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-28 – JLG Lift – 3121125HD30/HDP20 Series Assembly1. Grasp contact about 2

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-29This page left blank intentionally.

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-30 – JLG Lift – 3121125Figure 7-18. Electrical Components Installation -

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-31Figure 7-19. Electrical Components Installation -

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-32 – JLG Lift – 3121125Figure 7-20. Electrical Schematic - Sheet 1 of 4

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-33Figure 7-21. Electrical Schematic - Sheet 2 of 41

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-34 – JLG Lift – 3121125Figure 7-22. Electrical Schematic - Sheet 3 of 4

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-35Figure 7-23. Electrical Schematic - Sheet 4 of 41

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-11Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPO

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-36 – JLG Lift – 3121125Figure 7-24. Hydraulic Schematic - M400A/E400A -

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-372792505DFigure 7-25. Hydraulic Schematic - M400A/

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-38 – JLG Lift – 3121125Figure 7-26. Hydraulic Schematic - M400AJ/E400AJ

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS3121125 – JLG Lift – 7-392792505DFigure 7-27. Hydraulic Schematic - M400AJ

SECTION 7 - BASIC TROUBLESHOOTING, ELECTRICAL INFORMATION, & SCHEMATICS7-40 – JLG Lift – 3121125Figure 7-28. Hydraulic Schematic Component List

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

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121125Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-13Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121125Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-15Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

INTRODUCTION3121125 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121125Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3121125 – JLG Lift – 1-17Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3121125NOTES:

SECTION 2 - GENERAL3121125 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31211252.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121125 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 3121125components and generally results in faulty opera-tion. Every precaution must be taken to keephydraulic oil

SECTION 2 - GENERAL3121125 – JLG Lift – 2-52.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINESFilament wound bearings.1. Pinned joints should be disassem

SECTION 2 - GENERAL2-6 – JLG Lift – 3121125Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3121125 – JLG Lift – 2-7Functions/Controls9Platform Controls 55 66Ground Controls 55 66Function Control Locks, Guards, or Detents 1

INTRODUCTIONA-2 – JLG Lift – 3121125REVISON LOGOriginal Issue - August 15, 2000Revised - March 26, 2001Revised - October 1, 2001Revised - December 18,

SECTION 2 - GENERAL2-8 – JLG Lift – 3121125Capacity Decals Installed, Secure, Legible 21 21 21All Decals/Placards Installed, Secure, Legible 21 21 21W

SECTION 2 - GENERAL3121125 – JLG Lift – 2-9 -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) 40 F(4 C) 5

SECTION 2 - GENERAL2-10 – JLG Lift – 3121125NOTES:

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31211252. Tighten nuts in the following sequence:3. The tightening of the nuts should be done in s

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-31. Dust Cap2. Cotter Pin3. Spindle Nut4. Spindle Washer5. Stud Nut6. Bearing Cone7. Hub8. B

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31211253.3 DRIVE HUB (PART NO. 2780236)The final drive consists of two planetary stages with anint

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-5Disassembly1. Loosen and remove hex head bolts (53) to removecover (51).2. Remove shaft rod

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121125Final Assembly1. Install thrust washer (29) in spindle (60).2. Install “o” ring (19) into g

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-71. Planet Gear2. Planet Gear 3. Sun Gear4. Shaft Nut5. Planet Bolt6. Support Ring7. Planet

3121125 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 31211253.4 DRIVE BRAKE - MICODisassembly1. Remove pressure plate (3) from cover (21) byremoving th

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-92322192118171615201211109876542331131421. Capscrew2. Washer3. Pressure Plate4. Case Seal5.

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121125Table 3-2. Drive Brake DiagnosisProblem Cause ExplanationCorrectiveActionBrake slips Exces

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-113.5 SPEED SENSOR ADJUSTMENTFor proper drive operation, the speed sensors must beproperly i

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121125Figure 3-3. Speed Sensor Orientation

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-13Figure 3-4. Frame Mounted Electrical Components - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121125Figure 3-5. Frame Mounted Electrical Components - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-15Should read 0-7 Volts. Anything over 7 volts should flash Error Code 7-7, Open Pump Circui

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121125Speed Sensor Installation VerificationThe motor controller averages the readings from the

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-1718. While watching the analyzer display, select drive for-ward. Be ready to remove your fo

ii – JLG Lift – 3121125TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121125Figure 3-7. Steering Components and Spindles

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-193.6 POSITRAC/TILT MODULEWhen installing a new positrac/tilt module, always ensurethat it i

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121125Figure 3-9. Tilt Sensor Location

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-213.7 SWING MOTOR - S/N 0300135649 TO PRESENTIF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATE

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 3121125Table 3-3. Swing Motor TroubleshootingTrouble Cause RemedyOil Leakage 1. Hose fittings loo

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-23123444888E8A8C8B48D9445761012131414151625171819201. Bolt2. End Cover3. Seal Ring4. Seal Ri

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121125Preparation Before Disassembly• Before you disassemble the motor unit or any of itscompone

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-253. Remove the special ring head bolts (1) using anappropriate 1/2 or 9/16 inch size socket

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 31211257. Remove commutator (5) and seal ring (3) Removeseal ring from commutator, using an air h

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-279. Remove rotor set (8) and wearplate (9), together toretain the rotor set in its assemble

3121125 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 312112512. Check exposed portion of coupling shaft (12) to besure you have removed all signs of r

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-2915. Remove thrust bearing (15) and thrust washer (14).Inspect for wear, brinelling, corros

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121125replaced. If the housing has passed this inspectionthe disassembly of the motor is complet

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-31SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHENUSING ANY SOLVENT. EVEN A SMALL EXPLOSI

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31211253. Press a new dirt and water seal (20) into the housing(18) outer bearing counterbore. Th

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-338. Be sure that a generous amount of clean corrosionresistant grease has been applied to t

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312112511. Assemble wear plate (9) over the drive link (10) andalignment studs onto the housing (

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-3515. Assemble the manifold (7) over the alignment studsand drive link (10) and onto the rot

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121125NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previously

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-37One Piece Stator ConstructionA disassembled rotor stator and vanes that cannot bereadily a

iv – JLG Lift – 3121125TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121125Two Piece Stator ConstructionA disassembled rotor set (8) that cannot be readily assem-ble

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-393.8 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is design

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 31211253. If a difference greater than 0.057 in. (1.40 mm) isdetermined, the swing bearing should

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-41Replacement of Swing Bearing1. Removal.a. Attach an adequate support sling to the boomand

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 31211252. Installation.a. Install bearing to rotation box with two cap-screws, so that fill plug

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-43i. Use suitable lifting equipment to carefully posi-tion the turntable assembly above the

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121125Figure 3-16. Swing Components

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-453.9 BATTERY MAINTENANCE AND CHARGINGBattery Maintenance, Quarterly1. Open battery compartm

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121125Figure 3-18. Battery Cable Connections

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-47Battery Charging (On Board Charger)1. For maximum battery life:a. Avoid completely dischar

3121125 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3121125Figure 3-20. On Board Generator

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-493.10 BATTERY CHARGER (S/N 0300059350 TO PRESENT)LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 312112512341. AC Voltage - Input Cable2. Charger Interlock Cable3. DC Power Cable to Batteries4.

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-51NO LIGHTS AT ALLNo Lights at all indicate that AC power to the charger isnot connected or

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 3121125[5 Flashes] - Over TemperatureThis fault indicates the charger has become too hot duringop

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-53Checking/Changing the Battery Charger AlgorithmThe charger is pre-loaded with programming

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 31211253.11 GENERATOR (PRIOR TO S/N 88539)NOTE: Throughout the Generator section, the abbreviatio

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-55Figure 3-22. Generator Components

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 31211252. Time Delay Pre-Heat (TDPH)TDPH, if enabled, occurs after TDES has elapsedand the engine

SECTION 3 - CHASSIS & TURNTABLE3121125 – JLG Lift – 3-57To Connect the JLG Control System Analyzer to the GeneratorThe JLG Control System Analyzer