Jlg T500J Service Manual User Manual

Service & Maintenance ManualModelT500J3121200January 9, 2013

vi – JLG Lift – 3121200TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 31212003. On the right front outrigger cylinder, remove theelectrical connector from the electric

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-653. If the board has been replaced or the tilt sensor isnot calibrated, connect an analyzer

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 31212003.20 DRIVE & SETThe Drive & Set Option is used to position the machineafter it has

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-67In order to use Drive & Set, the following conditions mustbe met: • The machine must b

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 31212001934510811267108*1. Flow Divider2. Drive Enable Valve3. Proximity Sensor4. Propulsion Modu

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-691132591Figure 3-22. Drive and Set - Sheet 2 of 2Adjust the limit switch so clearance betw

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3121200Figure 3-23. Drive and Set CircuitDRIVE ENGAGECYLINDERBRAKE RELEASECYLINDERDRIVE ENGAGEME

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-713.21 DRIVE MOTORDisassembly and inspection1. Place the Torqlink™ in a soft jawed vice, wit

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 31212005. If the end cover (2) is equipped with shuttle valvecomponents, remove the two previous

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-736. Thoroughly wash end cover (2) in proper solventand blow dry. Be sure the end cover valv

3121200 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121200NOTE: The manifold is constructed of plates bondedtogether to form an integral component n

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-7512. Remove drive link (10) from coupling shaft (12) if itwas not removed with rotor set an

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 312120017. Remove thrust bearing (15) and thrust washer (14)Inspect for wear, brinelling, corrosi

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-7721. If the housing (18) assembly has passed inspectionto this point, inspect the housing b

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 3121200AssemblyReplace all seals and seal rings with new ones each timeyou reassemble the Torqlin

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-792. The Torqlink™ inner housing bearing/bushing (13)can now be pressed into its counterbore

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 31212004. Place housing (18) assembly into a soft jawed visewith the coupling shaft bore down, cl

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-81THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYS-TEM’S HYDRAULIC FLUID. BE SURE IT IS T

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 312120011. Assemble wear plate (9) over the drive link (10) andalignment studs onto the housing (

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-8316. Apply grease to a new seal ring (4) and insert it inthe seal ring groove exposed on th

viii – JLG Lift – 3121200LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3121200NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previousl

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-85One Piece Stator ConstructionA disassembled rotor (8A) stator (8B) and vanes (8C) thatcann

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 31212003.22 BATTERIES (ELECTRIC MACHINES)The electrical system is a 24 volt system, supplied by f

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-871. Contactor Assembly2. Fuse3. Clamping Bar4. Relay5. Battery6. Battery Pad7. Tie Down Str

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 31212009. Sevcon Controller10. Relay11. Ground Control ModuleA Apply Dielectric GreaseB Torque M6

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-89Figure 3-25. Battery Cable Routing

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 31212003.23 BATTERY CHARGER(Prior to S/N 030000236)OPENING THE BATTERY CHARGER WHILE THE MACHINE

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-91Printed Circuit Board Replacement1. Disconnect the wide wiring connector from the endof th

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3121200AC Circuit Breaker Replacement1. Disconnect wiring connected to the breaker poles.2. Remov

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-93Figure 3-26. Battery Charger Schematic

3121200 – JLG Lift – ix LIST OF TABLESTABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 31212001. Selector Switch 2. AC Ci rcuit Breake r3. Inte rlock Relay4. Varistor5.

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-953.24 BATTERY CHARGER(S/N 030000199 to 030000225 & S/N 030000236 to Pres-ent)LEAD ACID

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3121200NOTES:

SECTION 4 - BOOM & PLATFORM3121200 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM AND CYLINDER ASSEMBLYRemoval1. Using an adequate suppor

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31212004.2 MAIN BOOMRemovalNOTE: Prior to removing the boom, it will be helpful toextend the boom fly

SECTION 4 - BOOM & PLATFORM3121200 – JLG Lift – 4-32. Remove the bolt, keeper pin, and upper pivot pinsecuring the platform pivot.3. Remove the pi

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121200NOTE: The telescope cylinder weighs approximately 140lbs. (64 kg).8. Remove the wear pads from

SECTION 4 - BOOM & PLATFORM3121200 – JLG Lift – 4-54. Push the telescope cylinder into the rear of theboom.NOTE: The telescope cylinder weighs app

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31212009. Install the bolt, keeper pin, and upper pivot pinsecuring the platform pivot to the boom.10.

SECTION 4 - BOOM & PLATFORM3121200 – JLG Lift – 4-74.3 MASTER CYLINDERRemoval1. Swing the boom away from the tongue.2. Place a suitable support or

x – JLG Lift – 3121200LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31212004.4 SLAVE CYLINDERRemoval1. Swing the boom away from the tongue.2. Place a suitable support or

SECTION 4 - BOOM & PLATFORM3121200 – JLG Lift – 4-94.5 JIB CYLINDERRemoval1. Swing the boom away from the tongue.2. Place a suitable support or bl

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 31212006152,32,341148711101312594161. Boom & Cylinders Assembly 2. Keeper Bolt3. Reta

SECTION 4 - BOOM & PLATFORM3121200 – JLG Lift – 4-114.6 BOOM SENSORSThere are two mechanical sensors that are standard onthe machine which sense t

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 3121200NOTES:

SECTION 5 - HYDRAULICS3121200 – 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 – 3121200Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-35.2 CYLINDER REPAIRDisassemblyDO NOT ATTEMPT TO SERVICE A HYDRAULIC CYLINDER WHILEIT IS INSTALLED. THE C

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31212001. Cylinder Head2. Cylinder Rod3. Piston4. Barrel5. O-ring6. O-ring7. Rod Seal8. Backup Ring9. Wiper10.

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-51. Cylinder Head2. Cylinder Rod3. Piston4. Barrel5. O-ring6. O-ring7. Rod Seal8. Backup Ring9. Wiper10.

SECTION 1 - SPECIFICATIONS3121200 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS 1.2 CAPACITIES1.3 ELECTRIC POWER UNIT1.4 TIRE

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31212001. Cylinder Head2. Cylinder Rod3. Piston4. Barrel5. O-ring6. O-ring7. Rod Seal8. Backup Ring9. Wiper10.

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-71234589101111121314151617171717181919ORIENT SOLENOID VALVEAS SHOWN1. Cylinder Rod2. Cylinder Head3. Barr

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 31212001. Cylinder Head2. Cylinder Rod3. Piston4. Barrel5. O-ring6. O-ring7. O-ring8. Rod Seal9. Backup Ring10.

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-91. Cylinder Head2. Cylinder Rod3. Piston4. Barrel5. O-ring6. O-ring7. Rod Seal8. Backup Ring9. Wiper10.

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 3121200AssemblyINSPECT ALL COMPONENTS AS DESCRIBED UNDER INSPEC-TION. CLEAN ALL COMPONENTS WITH A LINT-FREE CL

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-115.3 PRESSURE SETTING PROCEDURECold temperatures have a significant impact on pressurereadings. JLG Indu

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3121200Figure 5-7. Hydraulic Test Ports

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-13Outrigger Up1. Install a pressure gauge at the port marked "G"located on top of the block. 2.

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3121200Table 5-1. Control Valve Torque ValuesFt-Lbs. Nm Ft-Lbs. Nm Ft-Lbs. Nm1 23-24 31-32.5 5 17-19 23-26 9 4

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-15Table 5-2. Control Valve Torque ValuesFt-Lbs. Nm Ft-Lbs. Nm Ft-Lbs. Nm1 23-24 31-32.5 5 17-19 23-26 9 4

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31212001.5 ENGINEBattery1.6 DIMENSIONAL DATA1.7 LUBRICATIONHydraulic OilNOTE: Hydraulic oils must have anti

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31212001. Lef t Dr iv e Va lv e2. Shuttle Valve (LS2)3. Ri gh t D ri ve Valve4. EP 25. EP

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-17Ft-Lbs. NmA 18-20 24-27B 30-35 41-47C 35-40 47-54Figure 5-9. Drive Directional Valve Torque Values - D

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31212001. Pre ss ur e Re gu la to r ( PR 1)2. Check Valve (CV1)3. Rel ie f Val ve (RV1)4. Rel i

SECTION 5 - HYDRAULICS3121200 – JLG Lift – 5-19Figure 5-11. Hydraulic Diagram

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 3121200NOTES:

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING ANY NEW MODULE CONTROLLER ON THEMA

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 31212006.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the cable supplied with the analyzer, t

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-3If ENTER is pressed again, the display moves to the fol-lowing display: LOGGED HELP1: POWER CYCL

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121200Once the correct password is displayed, press ENTER.The access level should display the followin

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-56.6 MACHINE SETUPWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust

SECTION 1 - SPECIFICATIONS3121200 – JLG Lift – 1-31.8 MAJOR COMPONENT WEIGHTS 1.9 PRESSURE SETTINGSCold temperatures have a significant impact on pres

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121200Figure 6-2. Analyzer Flow ChartNOTE: The layout shown includes all possible analyzer screens. P

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-7Figure 6-3. Analyzer Flow Chart - DiagnosticsNOTE: The layout shown includes all possible analy

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121200Figure 6-4. Analyzer Flow Chart - PersonaltiesNOTE: The layout shown includes all possible anal

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-96.7 SYSTEM TESTThe Control System Incorporates a built-in system test tocheck the system compone

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121200Figure 6-5. System Test Flow Chart - Platform Tests

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-11Ground Test1. Position the Platform/Ground select switch to theGround position.2. Plug the anal

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 31212006.8 USER FAULT CODESA single digit fault code blinks on the Platform and theGround control pane

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-13Figure 6-6. System Test Flow Chart - Ground Station Tests

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121200J1NATURAL 35 PINJ7BLACK 35 PINJ4BLUE 35 PINJ3BLACK 14 PINJ2GREY 35 PINFigure 6-7. Ground Modul

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-15Figure 6-8. Ground Module - Sheet 2 of 5

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31212001.10 OPERATOR MAINTENANCE & LUBRICATIONNOTE: Lubrication intervals are based on machine opera-ti

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121200Figure 6-9. Ground Module - Sheet 3 of 5

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-17Figure 6-10. Ground Module - Sheet 4 of 5

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121200Figure 6-11. Ground Module - Sheet 5 of 5

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-19Table 6-2. Machine Model Adjustments and Speeds - ANSI & CSAFUNCTIONADJUSTMENT1,4MODEL DEFA

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121200PLATFORM LEVELACCEL 0.1 to 5.0 sec 0.1 0.1 0.1 0.1DECEL 0.1 to 3.0 sec 0.1 0.1 0.1 0.1MIN UP 0

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-21Table 6-3. Machine Model Adjustments and Speeds - CE OnlyFUNCTIONADJUSTMENT1,4MODEL DEFAULTSMOD

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121200PLATFORM LEVELACCEL 0.1 to 5.0 sec 0.1 0.1 0.1 0.1DECEL 0.1 to 3.0 sec 0.1 0.1 0.1 0.1MIN UP 0

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-236.9 MACHINE ORIENTATION WHEN SETTING SPEEDSLIFT: Telescope retracted, lift up, and record time.

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121200Table 6-4. Machine Configuration Programming InformationConfiguration DigitSetting Description

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-25Table 6-5. Help MessagesHelp Message IndexService Flash CodeUser Flash CodeFunction in Creep Mo

SECTION 1 - SPECIFICATIONS3121200 – JLG Lift – 1-52. Hydraulic OilLube Point(s) - Fill CapCapacity - 4 gal. (15.1 L)Lube - HOInterval - Check oil dail

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121200JOYSTICK FAULTY -- Y-AXIS WIPER OUT OF RANGE12 2-2 9Lift Up, Lift Down, Jib Up, Jib Down, Level

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-27FUNCTION PROBLEM – LIFT UP AND DOWN BOTH SELECTED22 2-3 9 Lift Up, Lift DownFUNCTION PROBLEM –

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121200FUNCTION PROBLEM – LIFT UP PERMANENTLY SELECTED34 2-3 1 Lift UpFUNCTION PROBLEM – LIFT DOWN PER

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-29MODEL CHANGED – HYDRAULICS SUSPENDED – CYCLE EMS49 2-5 2Lift Up, Lift Down, Swing Left, Swing R

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121200SWING RIGHT SOLENOID - SHORT TO GROUND65 3-3 9 Swing Right Swing RightSWING RIGHT SOLENOID - OP

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-31R-L L/J SOLENOID - OPEN CIRCUIT86 3-3 9 Rear Left L/J Rear Left L/JR-R L/J SOLENOID - SHORT TO

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121200THROTTLE PULL RELAY - SHORT TO GROUND106 3-3 9 Engine Throttle Pull Engine Throttle PullTHROTTL

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-33DRIVE LEFT FWD SOLENOID - SHORT TO BATTERY120 3-3 9DRIVE LEFT FWD SOLENOID - SHORT TO GROUND121

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121200FUNCTIONS AT CUTBACK -- POWER MODULE CURRENT LIMIT136 4-2 4NO CHARGE SYSTEM OUT-PUT137 4-3 3Lif

SECTION 6 - JLG CONTROL SYSTEM3121200 – JLG Lift – 6-35ACCESSORY FAULT 144 6-7 9CHASSIS TILT SENSOR NOT CALIBRATED145 8-1 9POWER MODULE FAILURE: PERSO

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31212007. EngineCapacity - See Engine Manual.Lube - EO, 10W30 API SJInterval - Check level daily; change pe

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121200FUNCTIONS LOCKED OUT – DRIVE MODULE SOFTWARE VERSION IMPROPER152 9-9 9Lift Up, Lift Down, Swing

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121200Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 3121200Automatic SwitchesIf the switch is actuated automatically, by tempera

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-57.5 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 31212003. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-7Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 3121200Figure 7-11. Connector Installation

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-97.6 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 1 - SPECIFICATIONS3121200 – JLG Lift – 1-7Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANEROBIC THREAD LOCKING COMPOU

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121200HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the con

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-11This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121200STROBELIGHTMOTIONALARMBATTERY(ENGINE POWERED)STARTER(ENGINE POWERED)

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-13PLATFORM CONSOLERIGHTTAILLIGHTLEFTTAILLIGHTLEFT SIDEMARKER LIGHTRIG

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121200Figure 7-20. Controller and Valve Body Connector Locations

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-15Table 7-1. Connector IdentificationCONNECTOR DESCRIPTIONX001 Ground

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121200X095 Engine Mag PickupX096 Engine RectifierX097 Engine Throttle Coil

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-17This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121200Figure 7-21. Electrical Schematic (Boom Operations) - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-19Figure 7-22. Electrical Schematic (Boom Operations) - Sheet 2 of 21

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3121200Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121200CE SPECSWITH ELECTRIC BRAKESANSI & ANSI EXPORT SPECSWITH ELECTRI

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-21ANSI & ANSI EXPORT SPECSWITH HYDRAULIC BRAKESFigure 7-24. Elect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 31212001870185 CAUSTRALIAN & SOUTH AFRICA SPECSWITH ELECTRIC BRAKESAUST

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-23This page left blank intentionally.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121200Figure 7-26. Hydraulic Schematic - Electric Machines - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-25Figure 7-27. Hydraulic Schematic - Electric Machines - Sheet 2 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3121200Figure 7-28. Hydraulic Schematic - Gas Machines - Sheet 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-27Figure 7-29. Hydraulic Schematic - Gas Machines - Sheet 2 of 227926

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3121200Figure 7-30. Hydraulic Schematic - Drive Option (Gas) - Sheet 1 of

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-29Figure 7-31. Hydraulic Schematic - Drive Option (Gas) - Sheet 2 of

SECTION 1 - SPECIFICATIONS3121200 – JLG Lift – 1-9Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp Lo

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-30 – JLG Lift – 3121200Figure 7-32. Hydraulic Schematic - Drive Option (Electric) - Sheet

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121200 – JLG Lift – 7-31Figure 7-33. Hydraulic Schematic - Drive Option (Electric) - Sheet

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-32 – JLG Lift – 3121200This page left blank intentionally.

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

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3121200Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 1 - SPECIFICATIONS3121200 – JLG Lift – 1-11Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121200Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 1 - SPECIFICATIONS3121200 – JLG Lift – 1-13Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121200NOTES:

SECTION 2 - GENERAL3121200 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

INTRODUCTION3121200 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 2 - GENERAL2-2 – JLG Lift – 31212002.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3121200 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 31212002.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3121200 – 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 – 31212002.6 WELDING ON JLG EQUIPMENTNOTE: This instruction applies to repairs, or modifications tothe machine and t

SECTION 2 - GENERAL3121200 – JLG Lift – 2-7.Table 2-3. Maintenance ScheduleINTERVALItem/Function Method Break-InEvery 3000 Miles or 3 MonthsEvery 60

SECTION 2 - GENERAL2-8 – JLG Lift – 3121200NOTES:

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 BREAKING-IN A NEW TRAILERRetighten Lug Nuts at First

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 3121200pressure of the linings against the drum produces aslight drag.5. Remount the wheel and bra

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-3reverse is significantly less effective than in the forwarddirection.The hydraulic braking

INTRODUCTIONA-2 – JLG Lift – 3121200REVISON LOGOriginal Issue - January 15, 2005Revised - July 15, 2005Revised - August 26, 2005Revised - December 12,

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31212002. Remove the adjusting hole cover from the adjustingslot on the bottom of the brake backin

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-53. After cleaning the hub bore area, replace the cup bytapping in with the brass drift punc

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 31212001. Gr ease Seal 2. Inner Bearing Cone3. Inner Bearing Cup4. Brake Assembly5

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-7WHEEL CYLINDERSInspect for leaks and smooth operation. Clean with brakecleaner and flush wi

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121200Wheel and Tire ReplacementReplacement wheels must have the same diameter, width,and profile

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-9Figure 3-4. Spare Tire (Optional)PLACE THE SPARE ON THE HOOK PROVIDED ON THE MOUNTING FIXT

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 31212003.7 HYDRAULIC BRAKE COUPLERTroubleshootingIF ANY OF THE FOLLOWING CONDITIONS DEVELOP, TRAI

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-11Bleeding the Brake SystemDO NOT USE BRAKE FLUID DRAINED FROM THE BRAKE SYS-TEM IN REFILLIN

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31212004. Close the release handle. The release handle willclose freely with finger pressure when

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-13travel. Plush the lever knob down to engage thelocking notch.4. Back the trailer up.AVOID

3121200 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 31212003.8 COMBINATION COUPLERTHE WEIGHT RATING OF THE COUPLER IS DEPENDENT UPONTHE CORRECT BOLTS

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-151. Not Used2. Not Used3. Pus h Rod4. Shock Absorber5. Release Handle6.

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 31212001. Not Used2. Not Used3. Not Used4. Pin5. Not Used6. Damper Shock7

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-173.9 HITCH COUPLER & AXLE (CE ONLY)To insure continuing reliability and road safety in

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121200IF THE INDICATOR IS IN THE RED "-" ZONE, THE COUPLING ISNOT PROPERLY CLOSED, AND

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-19Coupling Head MaintenanceREPLACINGPrior to replacing the coupling head, it is essential to

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121200Damper MaintenanceThe dampers assembled within the overrun coupling ispressurized. During

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-21Brake MaintenanceWHEEL BRAKESThe linings of the wheel brakes are wearing parts, so theirco

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31212001. Flanged Nut 2. Lockwasher3. Hub/Drum Assembly4. Co tter Pin5. Dust

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-237. Undo the locknut on the brake rod (front to rear)adjacent to the compensator. Slacken t

ii – JLG Lift – 3121200TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121200Adjustment and Readjustment of the Overrun Braking SystemADJUSTING THE BRAKING SYSTEMPrepa

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-25d. The compression spring may only be lightly pre-tensioned and must not become fully com-

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3121200Troubleshooting Table 3-5. Malfunctions and RemediesMalfunction Cause RemedyInsufficient

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-273.10 COUPLER ASSEMBLY (S/N 0030002099 TO PRESENT)Engaging Manual Lockout Lever The manual

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3121200165432429212087231415221311121310181917161. Cover2. Master Cylinder3. Gasket4. Cap5. Capsc

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-29Actuator Maintenance1.Frequently check brake fluid level (fluid must be DOT3 or 4 approved

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 31212003.11 TRAILER JACK (SOLID WHEELS)Installation1. Place the jack against the trailer tongue a

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-31AssemblyHANDLE1. Place one spacer over the bolt. 2. Lightly grease the split tube spacer.

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31212006. Remove the rotor assembly and wear plate. Removethe body seals from the rotor and housi

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-337. Install the high pressure seal into the groove in thehousing. 8. Install the metal back

3121200 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312120011. Lower the rotor onto the drive link making sure thetiming mark on the drive link is al

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-351. Du st Seal 2. Re tainer Ring3. Backup Shim4. Housing Seal5. Bod y S

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 31212003.13 SWING MOTOR (S/N 0030001050 TO PRESENT)NOTE: This motor may also be used on some mach

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-374. Remove end cover assembly (2) and seal ring (4).Discard seal ring.NOTE: Refer to the a

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 31212005. If the end cover (2) is equipped with shuttle valvecomponents, remove the two previous

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-399. Remove manifold (7) and inspect for cracks surfacescoring, brinelling or spalling. Repl

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 312120012. Remove drive link (10) from coupling shaft (12) if itwas not removed with rotor set an

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-4117. Remove thrust bearing (15) and thrust washer (14)Inspect for wear, brinelling, corrosi

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 312120021. If the housing (18) assembly has passed inspectionto this point, inspect the housing b

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-43AssemblyReplace all seals and seal rings with new ones each timeyou reassemble the Torqlin

iv – JLG Lift – 3121200TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 31212002. The Torqlink™ inner housing bearing/bushing (13)can now be pressed into its counterbore

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-454. Place housing (18) assembly into a soft jawed visewith the coupling shaft bore down, cl

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121200THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYS-TEM’S HYDRAULIC FLUID. BE SURE IT IS T

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-4711. Assemble wear plate (9) over the drive link (10) andalignment studs onto the housing (

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 312120016. Apply grease to a new seal ring (4) and insert it inthe seal ring groove exposed on th

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-49NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previousl

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121200One Piece Stator ConstructionA disassembled rotor (8A) stator (8B) and vanes (8C) thatcann

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-51Installation1.Connect the two hydraulic lines to the motor as tagged during Removal.2.Posi

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 31212001. Inn er Race Bolt2. Out er Race Bolt3. Inner Bearing Cup4. Swing Motor5.

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-53Wear Tolerance1. From the underside of the machine, at rear center,with the main boom full

3121200 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121200Swing Bearing Installation1. Place the swing drive on a table.2. Place the bearing on the

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-55and washers through the turntable and inner race ofthe bearing.14. Following the Torque Se

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 31212003.15 ENGINENOTE: Refer to the engine manufacturer’s manual fordetailed operating and maint

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-575. From ENGINE, use the down arrow key toscroll to the SPEED display, which will display

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121200Choke ActuatorIf a new carburetor is needed, the choke detent must beremoved from the new

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-591. Engine Assembly2. Fuel Tank3. Heat Shield4. St arter5. Air Filter6

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 31212003.16 OUTRIGGER CYLINDER AND STABILIZERRemoval1. Using the analyzer and service mode, lower

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-61Installation1. If removed, position the stabilizer in place on theframe and install the pi

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 31212001. Outrigger Pad 2. Stabilizer3. Cylinder Cover4. Cylinder5. Pad Rod6

SECTION 3 - CHASSIS & TURNTABLE3121200 – JLG Lift – 3-633.17 OUTRIGGER LIMIT SWITCHESA mechanical limit switch at each outrigger senses theoutrigg