1298 JLG 600 Service Manual

User Manual: JLG 600 Service Manual

Open the PDF directly: View PDF .
Page Count: 328

Download
Open PDF In Browser	View PDF

Service and Maintenance Manual

Model
600S
660SJ
S/N 0300171769
to Present
P/N - 3121298
February 26, 2014

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A

GENERAL

C

MAINTENANCE

This section contains the general safety precautions which
must be observed during maintenance of the aerial platform.
It is of utmost importance that maintenance personnel pay
strict attention to these warnings and precautions to avoid
possible injury to themselves or others, or damage to the
equipment. A maintenance program must be followed to
ensure that the machine is safe to operate.

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
SECURE AT ALL OTHER TIMES.

The specific precautions to be observed during maintenance
are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

Your safety, and that of others, is the first consideration when
engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the
equipment, ensure that adequate support is provided.

• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
CAUGHT ON OR ENTANGLED IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

B

HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every
effort should be made to relieve any system pressure prior to
disconnecting or removing any portion of the system.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
HAS BEEN ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING
REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3121298

– JLG Lift –

A-1

INTRODUCTION

REVISON LOG
Original Issue
Revised
Revised
Revised

A-2

- August 7, 2013
- October 10, 2013
- November 25, 2013
- February 26, 2014

– JLG Lift –

3121298

TABLE OF CONTENTS

SECTION NO.
SECTION
A
B
C

SECTION
1.1
1.2
1.3
1.4
1.5
1.6

1.7
1.8
1.9
1.10

SECTION
2.1

2.2

2.3

2.4

2.5
2.6

3121298

TITLE

PAGE NO.

A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

1 - SPECIFICATIONS
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1
1-1
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-4
1-5
1-6

2 - GENERAL
Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do NOT Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– JLG Lift –

2-1
2-1
2-1
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-4
2-5
2-5
2-5
2-5

i

TABLE OF CONTENTS

SECTION NO.
SECTION
3.1

3.2

3.3

3.4

3.5

3.6
3.7

ii

TITLE

PAGE NO.

3 - CHASSIS & TURNTABLE
Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Hub-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Spindle-Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Spindle - Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Hub-Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Output Planet Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Integral Brake Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Disengage Drive Motors & Brakes for Towing, etc. (Free Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Engage Drive Motors & Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Oscillating Axle Bleed Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Steer Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Motor and Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Hub-Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Hub-Shaft Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Carrier Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

– JLG Lift –

3121298

TABLE OF CONTENTS

SECTION NO.
3.8

3.9
3.10

3.11

3.12

3.13
3.14
3.15
3.16

3.17

3.18

3.19

3121298

TITLE

PAGE NO.

Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz D2.9 L4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz D2011 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replace Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz EMR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bio Fuel in Deutz Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GM Engine General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Fill Procedure - Dual Fuel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GM Engine Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Electronic Pressure Regulator (DEPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Throttle Control (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heated Exhaust Gas Oxygen Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline Multi Point Fuel Injection System (MPFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasoline Pressure And Temperature Sensor Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection . . . . . . . . . . . . . . . . . . . . . . .
Check/Drain Oil Build-Up In 2-Stage Vaporizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Fuel Mixer/Throttle Control Device Maintenance And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System And Catalytic Converter Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature Manifold Absolute Pressure (TMAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– JLG Lift –

3-44
3-44
3-44
3-46
3-47
3-48
3-52
3-52
3-52
3-53
3-53
3-55
3-57
3-57
3-58
3-58
3-59
3-61
3-61
3-62
3-62
3-63
3-63
3-63
3-64
3-76
3-76
3-76
3-77
3-78
3-78
3-78
3-78
3-79
3-79
3-80
3-80
3-82
3-82
3-83
3-83
3-83
3-84
3-84
3-84
3-84
3-85
3-85
3-85
3-85
3-85
3-85
3-86
3-86
3-87
3-87
3-88
3-88

iii

TABLE OF CONTENTS

SECTION NO.

3.20

SECTION
4.1
4.2
4.3
4.4

4.5

4.6

4.7
4.8
4.9

4.10
4.11

4.12

iv

TITLE

PAGE NO.

Throttle Body (ETC) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Mixer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Electronic Pressure Regulator (EPR) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Regulator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Coolant Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Vapor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Engine Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
GM Engine LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91

4 - BOOM & PLATFORM
Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Boom Disassembly/Assembly & Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boom Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Eight Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Wire Rope Tensioning Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Articulating Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Limit Switches and Cam Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Installing Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Testing Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Testing Actuator for Internal LeakS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Platform Support Torque Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Replace Platform Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Install New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Replace Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Replace Moving End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

– JLG Lift –

3121298

TABLE OF CONTENTS

SECTION NO.
SECTION
5.1

5.2

5.3

5.4

5.5

5.6

5.7

3121298

TITLE

PAGE NO.

5 - HYDRAULICS
O-Ring Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brush-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Systems With Double Acting Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Systems With Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder. . . . . . . . . . . . . . . . . .
Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinders With Dual Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Level (Slave) Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jib Lift Cylinder (SJ Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Parts For Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing Pump Back Into Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ports and Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NFPE Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove and Install FNR and NFPE Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove and Install FNR and NFPE Control Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– JLG Lift –

5-1
5-1
5-2
5-2
5-2
5-3
5-3
5-3
5-3
5-3
5-4
5-4
5-5
5-5
5-5
5-6
5-6
5-6
5-6
5-7
5-8
5-10
5-11
5-13
5-15
5-16
5-18
5-20
5-21
5-23
5-25
5-26
5-28
5-30
5-31
5-33
5-35
5-36
5-37
5-39
5-39
5-41
5-42
5-42
5-42
5-45
5-45
5-45
5-45
5-46
5-46
5-46
5-49
5-50
5-51

v

TABLE OF CONTENTS

SECTION NO.
5.8
5.9

SECTION
6.1

6.2
6.3
6.4

SECTION
7.1
7.2

7.3

7.4

7.5

vi

TITLE

PAGE NO.

Hydraulic Component Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Main Relief, Steer, Swing, and Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Articulating Jib Boom (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
4 Wheel Steer (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

6 - JLG CONTROL SYSTEM
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Connect JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Using Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Changing Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Adjust Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Test Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Exclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

– JLG Lift –

3121298

LIST OF FIGURES

FIGURE NO.
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
2-1.
2-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3-19.
3-20.
3-21.
3-22.
3-23.
3-24.
3-25.
3-26.
3-27.
3-28.
3-29.
3-30.
3-31.
3-32.
3-33.
3-34.
3-35.
3-36.
3-37.
3-38.
3-39.
3-40.
3-41.
3-42.
3-43.
3-44.
3-45.
3-46.
3-47.
3-48.
3-49.
3-50.

3121298

TITLE

PAGE NO.

Operator Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Chart (SAE Fasteners - Sheet 1 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Chart (SAE Fasteners - Sheet 2 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Chart (SAE Fasteners - Sheet 3 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Chart (SAE Fasteners - Sheet 4 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Chart (METRIC Fasteners - Sheet 5 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Chart (METRIC Fasteners - Sheet 6 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Chart (METRIC Fasteners - Sheet 7 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz Engine and Hydraulic Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GM Engine and Hydraulic Operating Temperature Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Hub Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Hub Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle-Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Planet Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drift Pin for Lining Up Thrust Washers with Output Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disengaging Drive Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft & Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Kit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swash Plate and Journal Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeder Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive Shim Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive Pivot and Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive Jam Nut and Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– JLG Lift –

1-6
1-11
1-12
1-13
1-14
1-15
1-16
1-17
2-9
2-10
3-1
3-2
3-3
3-4
3-5
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-15
3-16
3-16
3-17
3-17
3-18
3-19
3-21
3-21
3-22
3-22
3-23
3-23
3-24
3-24
3-25
3-27
3-28
3-29
3-29
3-29
3-30
3-30
3-31
3-31
3-31
3-32
3-33
3-34
3-35
3-36
3-36
3-36
3-36

vii

LIST OF FIGURES

FIGURE NO.
3-51.
3-52.
3-53.
3-54.
3-55.
3-56.
3-57.
3-58.
3-59.
3-60.
3-61.
3-62.
3-63.
3-64.
3-65.
3-66.
3-67.
3-68.
3-69.
3-70.
3-71.
3-72.
3-73.
3-74.
3-75.
3-76.
3-77.
3-78.
3-79.
3-80.
3-81.
3-82.
3-83.
3-84.
3-85.
3-86.
3-87.
3-88.
3-89.
3-90.
3-91.
3-92.
3-93.
3-94.
3-95.
3-96.
3-97.
3-98.
3-99.
3-100.
3-101.
3-102.
3-103.
3-104.
3-105.
4-1.
4-2.
4-3.
4-4.
4-5.

viii

TITLE

PAGE NO.

Main Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Motor and Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Hub-Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Hub-Shaft Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Carrier Subassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Swing Bearing Tolerance Measurement Location & Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Swing Bearing Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Rotary Coupling - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Rotary Coupling - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Rotary Coupling Port Location - 2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Rotary Coupling Port Location - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Generator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Generator Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Generator Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Generator Circuit Breaker Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Deutz D2.9 L4 Engine Installation - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Deutz D2.9 L4 Engine Installation - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Deutz 2.9 T4F Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Deutz D2011 Engine Installation - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Deutz D2011 Engine Installation - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Deutz Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
GM Engine Oil Dip Stick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
GM 3.0 Dual Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Direct Electronic Pressure Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
ELectronic Throttle Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Electric Lock Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
ECM Input-Output Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Filter Lock Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
DEPR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Location of Components - Platform Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Rotator and Leveling Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Boom Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Clamping Wire Ropes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

– JLG Lift –

3121298

LIST OF FIGURES

FIGURE NO.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14.
4-15.
4-16.
4-17.
4-18.
4-19.
4-20.
4-21.
4-22.
4-23.
4-24.
4-25.
4-26.
4-27.
4-28.
4-29.
4-30.
4-31.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
5-13.
5-14.
5-15.
5-16.
5-17.
5-18.
5-19.
5-20.
5-21.
5-22.
5-23.
5-24.
5-25.
5-26.
5-27.
5-28.
5-29.
5-30.
5-31.
5-32.
5-33.
5-34.

3121298

TITLE

PAGE NO.

Proximity Switch Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Wire Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Kink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sheave Groove Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Assembly Cutaway - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Assembly Cutaway - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Assembly Cutaway - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Rope Routing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proximity Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Articulating Jib Boom Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal Limit and Dual Capacity Limit Switches Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport Switch Adjustments - CE Machines Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotary Actuator - Assembly Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Bleed Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Section Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– JLG Lift –

4-3
4-4
4-4
4-4
4-5
4-5
4-6
4-7
4-8
4-8
4-9
4-9
4-10
4-11
4-12
4-13
4-14
4-16
4-17
4-19
4-20
4-30
4-31
4-33
4-33
4-33
5-3
5-7
5-8
5-8
5-8
5-9
5-10
5-10
5-11
5-11
5-11
5-11
5-12
5-12
5-12
5-13
5-13
5-13
5-14
5-15
5-15
5-16
5-16
5-16
5-16
5-17
5-17
5-17
5-18
5-18
5-18
5-19
5-20
5-20

ix

LIST OF FIGURES

FIGURE NO.
5-35.
5-36.
5-37.
5-38.
5-39.
5-40.
5-41.
5-42.
5-43.
5-44.
5-45.
5-46.
5-47.
5-48.
5-49.
5-50.
5-51.
5-52.
5-53.
5-54.
5-55.
5-56.
5-57.
5-58.
5-59.
5-60.
5-61.
5-62.
5-63.
5-64.
5-65.
5-66.
5-67.
5-68.
5-69.
5-70.
5-71.
5-72.
5-73.
5-74.
5-75.
5-76.
5-77.
5-78.
5-79.
5-80.
5-81.
5-82.
5-83.
5-84.
5-85.
5-86.
5-87.
5-88.
5-89.
5-90.
6-1.
6-2.
6-3.
6-4.

x

TITLE

PAGE NO.

Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Platform Level (Slave) Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Jib Lift Cylinder Assembly(600SJ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Removing Spanner Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Steer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Spanner Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Shim Adjustable Charge Relief Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Gauge Port Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Plugs/Fittings Size & Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Shaft Seal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Charge Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Articulating Jib Boom Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Main Control Valve - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Main Control Valve - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Location of Components - Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Hand-Held Analyzer (WANALYZER Controls and Display Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Controller Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Analyzer Platform Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Analyzer Ground Control Box Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

– JLG Lift –

3121298

LIST OF FIGURES

FIGURE NO.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13.
6-14.
6-15.
6-16.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7-11.
7-12.
7-13.
7-14.
7-15.
7-16.
7-17.
7-18.
7-19.
7-20.
7-21.
7-22.
7-23.
7-24.
7-25.
7-26.
7-27.
7-28.
7-29.
7-30.
7-31.
7-32.
7-33.
7-34.
7-35.
7-36.
7-37.
7-38.
7-39.
7-40.
7-41.

3121298

TITLE

PAGE NO.

Analyzer Software Version 6.8 - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzer Software Version 6.8 - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Module Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Control Module Pin Connections 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Control Module Pin Connections 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Control Module Pin Connections 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Control Module Pin Connections 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform Control Module Pin Connections 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applying Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutsch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dielectric Grease On Female Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Mate-N-Lok Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brad Harrison/Phoenix Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Junior Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Contact Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Close Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seating Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMP Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DT/DTP Contact Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Locking Contacts Into Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Components 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Components 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform and Ground Control Electrical Schematic - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform and Ground Control Electrical Schematic - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Wiring Schematic 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Wiring Schematic 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz Engine Harness Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GM/PSI Engine Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz Tier 4 Final Engine Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Deutz Tier 4 Final Engine Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 2-Wheel Drive - 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 2-Wheel Drive - 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 4-Wheel Drive - 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 4-Wheel Drive - 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– JLG Lift –

6-9
6-10
6-11
6-12
6-13
6-14
6-48
6-49
6-50
6-51
6-52
6-53
7-1
7-2
7-2
7-3
7-4
7-4
7-4
7-4
7-5
7-5
7-5
7-5
7-6
7-6
7-6
7-6
7-7
7-7
7-7
7-8
7-8
7-9
7-9
7-9
7-9
7-10
7-11
7-12
7-13
7-14
7-15
7-16
7-17
7-18
7-19
7-20
7-21
7-22
7-23
7-24
7-25

xi

LIST OF TABLES

TABLE NO.
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
2-1
2-2
2-3
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
4-1
5-1
5-2
6-1
6-2
6-3
6-4
6-5
6-6

xii

TITLE

PAGE NO.

Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Deutz TD 2.9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Deutz D2011L04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Mobilfluid 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Mobil DTE 13M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Mobil EAL H 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Exxon Univis HVI 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Torque Hub Brake Release Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Coupling Port Information Table - 2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
Coupling Port Information Table - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
LP Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94
DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-102
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
Hydraulic Pump Bolt Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44
Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45
Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Help Message/Fault Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
Fault Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-39

– JLG Lift –

3121298

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS

1.2 DIMENSIONAL DATA
Table 1-2. Dimensional Data

Table 1-1. Operating Specifications
Ground Bearing Pressure
600S 
660SJ
Maximum Drive Speed
Electrical System
Gross Machine Weight 
(Approximate)
600S - 2WS
600S - 4WS
660SJ - 2WD
660SJ - 4WS
Ground Bearing Pressure
600S 
660SJ
Maximum Drive Speed
Electrical System
Gross Machine Weight 
(Approximate)
600S - 2WS
600S - 4WS
660SJ - 2WD
660SJ - 4WS
Ground Bearing Pressure
600S 
660SJ
Maximum Drive Speed
Electrical System

3121298

Machine Height (Stowed)

8 ft. 5 in. (2.57 m)

2

67 psi (4.7 kg/cm )
75 psi (5.3 kg/cm2)
4.25 MPH (6.8 Km/hr.)
12VDC

21,425 lbs. (9718 kg)
21,800 lbs. (9888 kg)
26,275 lbs. (11918 kg)
25,910 lbs. (12088 kg)
67 psi (4.7 kg/cm2)
75 psi (5.3 kg/cm2)
4.25 MPH (6.8 Km/hr.)

Machine Length (Stowed)
600S
660SJ
Machine Width (by tire size)
39x15 - 22.5 
15x19.5 tire (non-marking)
41/18LLx22.5X625 (turf )
Wheelbase
Ground Clearance

28 ft. 4.6 in. (8.65 m)
35ft. 8 in. (10.88 m)
97 in. (2.46 m)
98 in. (2.49 m)
100 in. (2.54 m)
8 ft. 1 in. (2.46 m)
12 in. (0.3 m)

Platform Height
600S
660SJ

60 ft. 3 in. (18.36 m)
66 ft. 8 in. (20.32 m)

Horizontal Reach
600S
660SJ

49 ft. 6 in. (15.08 m)
56 ft. 9 in. (17.30 m)

12VDC
Tail Swing
Capacity (Unrestricted)

3 ft. 9 in. (1.14 m)
500 lbs (227 kg)

21,425 lbs. (9718 kg)
21,800 lbs. (9888 kg)
26,275 lbs. (11918 kg)
25,910 lbs. (12088 kg)
67 psi (4.7 kg/cm2)
75 psi (5.3 kg/cm2)
4.25 MPH (6.8 Km/hr.)
12VDC

– JLG Lift –

1-1

SECTION 1 - SPECIFICATIONS

1.3 CAPACITIES

1.5 ENGINE DATA
Table 1-3. Capacities

Table 1-5. Deutz TD 2.9 Specifications

Fuel Tank

40 Gallons (151 L)

Fuel

Hydraulic Oil Tank

32 Gallons (98.4 L)

Output

67 hp (50 kW)

Hydraulic System (Including Tank)

40 Gallons (121 L)

Torque

173 ft.lbs. (234 Nm) @ 1800rpm

Torque Hub, Drive*

17 ounces (0.5 L)

Oil Capacity (Crankcase)

Engine Crankcase
Deutz D2011L04
GM


11 quarts (10.5 L)
4.5 qts. (4.25 L) w/Filter

Cooling System

3.3 gal (12.5 L)

Low RPM

1200 ±50 rpm

High RPM

2600±50 rpm

Alternator

95 Amp

*Fill torque hubs half (1/2) full of lubricant.

Ultra Low Sulfur Diesel (15 ppm)

2.4 gal (8.9 L) w/Filter

Fuel Consumption

0.65 GPH (2.48 lph)

1.4 TIRES
Table 1-4. Tire Specifications

Table 1-6. Deutz D2011L04

Size

39 x 15-22.5

Fuel

Load Range

G

Ply Rating

14

Foam Fill (Optional)

Foam/Crumb

Diameter

38.5

Oil Capacity
Cooling System
Crankcase
Total Capacity

Width

15.5

Rim Size

11.75 x 22.5

Tire & Wheel Weight

128T, 262FF,

Max Tire Load

16,000 lb (7257 kg) @ 95 psi (6.5 bar)

Size

15 x 19.5 Non-Marking

Load Range

G

Ply Rating

14

Fuel Consumption

Foam Fill

Foam/Crumb

Horsepower

Diameter

40

Width

15.3

Rim Size

11.75 x 19.5

Tire & Wheel Weight

585 lb

Max Tire Load

20,000 lb @ 95 psi (6.5 bar)

Size

41/18LL x 22.5 Turf/Sand

Load Range
Ply Rating

Diesel
5 Quarts (4.5 L)
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L)

Idle RPM

1000

Low RPM

1800

High RPM

2500

Alternator

60 Amp, belt drive

Battery

950 Cold Cranking Amps, 205
Minutes Reserve Capacity, 12
VDC
0.65 GPH (2.46 lph)
49
Table 1-7. GM 3.0L

Fuel
No. of Cylinders

Gasoline or Gasoline/LP Gas
4

H

BHP
Gasoline
LP

83 hp @ 3000 rpm
75 hp @ 3000 rpm

16

Bore

4.0 in. (101.6 mm)

Foam Fill

Soft

Stroke

3.6 in. (91.44 mm)

Diameter

41

Displacement

Width

18.4

Oil Capacity w/filter

Rim Size

14 x 22.5

Tire & Wheel Weight

724 lb (329 kg)

Max Tire Load

15,500 lb @ 70 psi/5 bar

Minimum Oil Pressure
at idle
Hot
Compression Ratio
Firing Order
Max. RPM
Fuel Consumption

1-2

– JLG Lift –

181 cu.in. (3.0 L, 2966 cc)
4.5 qts. (4.25 L)
6 psi (0.4 Bar) @ 1000 rpm
18 psi (1.2 Bar) @ 2000 rpm
9.2:1
1-3-4-2
2800
N/A

3121298

SECTION 1 - SPECIFICATIONS

Platform Rotate: Platform level and completely rotated one
direction. Rotate opposite direction, record time. Rotate other
direction, record time.

1.6 FUNCTION SPEEDS
Table 1-8. Function Speeds (In Seconds)
Function

600S

600SJ

Lift Up

46 - 60

46 -60

Lift Down

33 - 43

33 - 43

Swing Right & Left*

79 - 101

79 - 101

Telescope In

25 - 33

25 - 33

Telescope Out

50 - 67

50 - 67

Platform Rotate Right & Left**

16 - 25

25-32

Jib Up

N/A

22 - 34

Jib Down

N/A

16 - 26

Drive (2WD & 4WD GM Engine)

30-34
(4.25 MPH)

Drive (2WD & 4WD Deutz Engines)
Drive above Horizontal
(50 ft.)

Jib: Platform level and centered with boom. Start with Jib
down. Jib up, record time. Jib down, record time.

Test Notes
1.

Start stop watch with function, not with controller or
switch.

2.

Drive test results reflect 12x16.5 or 33/1550x16.5 air or
foam-filled tires.

3.

All speed tests are run from platform. Speeds do not
reflect ground control operation.

30-34
(4.25 MPH)

4.

Platform speed knob control must be at full speed
(turned clockwise completely).

34-38
(4.02 MPH)

34-38
(4.02 MPH)

5.

46-54
(0.68 MPH)

46-54
(0.68 MPH)

Test with oil temperature above 100° F (38° C). Function
speeds vary if hydraulic oil is cold and thick.

6.

Some flow control functions may not work with speed
knob clicked into creep position.

*Max 10% Difference Between Left & Right
**Max 15% Difference Between Left & Right

1.7 TORQUE REQUIREMENTS

Machine Orientation When Doing Speed Tests

Table 1-9. Torque Requirements

Lift: Boom retracted. Telescope retracted. Lift up, record time,
Lift down, record time.
Swing: Boom at full elevation. Telescope retracted. Swing
turntable off center and stop. Swing opposite direction and
start test when centered. This eliminates controller ramp up
and ramp down affecting times.

Description

Torque Value (Dry)

Interval
Hours

Bearing To Chassis

190 ft. lbs.
(258 Nm)

50/600*

Bearing To Turntable

190 ft. lbs.
(258 Nm)

50/600*

Wire Rope

15 ft. lbs (20 Nm)

150

Drive: Test to be done on a smooth level surface. Set Drive
Select Switch to 2WD High Engine. Start approximately 25 ft
(7.62 m) from starting point so unit is at maximum speed
when starting test. Record results for a 200 ft. (60.96 m) course.
Drive forward, record time. Drive reverse, record time.

Wheel Lugs

170 ft. lbs (231 Nm)

150

Engine Mounting Bolts

165 ft. lbs. (231 Nm)

A/R

30 ft. lbs. (42 Nm)

A/R

Drive (Above Horizontal): Test should be done on a smooth
level surface. Set Drive Select Switch to 2WD High Engine.
Select Platform Speed Knob out of creep speed. This verifies
switches are working when boom is above horizontal. Results
should be recorded for a 50 ft course. Drive forward, record
time. Drive reverse, record time.

*Check swing bearing bolts after first 50 hours of operation and every 600 hours thereafter.
(See Swing Bearing in Section 3.)

Telescope: Boom at full elevation; Telescope retracted; Telescope out, record time. Telescope In, record time.

3121298

Engine Manifold Mounting Bolts

– JLG Lift –

1-3

SECTION 1 - SPECIFICATIONS

1.8 HYDRAULIC OIL

Table 1-12. Mobil DTE 13M

Table 1-10. Hydraulic Oil
Hydraulic System
Operating
Temperature Range

S.A.E. Viscosity
Grade

+0° to + 180° F
(-18° to +83° C)

10W

+0° to + 210° F
(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F
(+10° to +99° C

20W-20

ISO Viscosity Grade

#32

Specific Gravity

0.877

Pour Point, Max

-40°F (-40°C)

Flash Point, Min.

330°F (166°C)
Viscosity

NOTE:

Hydraulic oils require anti-wear qualities at least API Service Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service.

NOTE:

Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types. They may not contain
required additives or be of comparable viscosities. If
hydraulic oil other than Mobil 424 is desired, contact JLG
Industries for proper recommendations.

at 40° C

33cSt

at 100° C

6.6 cSt

at 100° F

169 SUS

at 210° F

48 SUS

cp at -20° F

6,200

Viscosity Index

140

Table 1-13. UCon Hydrolube HP-5046
Type

Synthetic Biodegradable

Specific Gravity

1.082

Pour Point, Max

-58°F (-50°C)

pH

9.1
Viscosity

Table 1-11. Mobilfluid 424

at 0° C (32° F)

340 cSt (1600SUS)

SAE Grade

10W30

at 40° C (104° F)

46 cSt (215SUS)

Gravity, API

29.0

at 65° C (150° F)

22 cSt (106SUS)

Density, Lb/Gal. 60°F

7.35

Viscosity Index

170

Pour Point, Max

-46°F (-43°C)

Flash Point, Min.

442°F (228°C)
Viscosity

1-4

Brookfield, cP at -18°C

2700

at 40° C

55 cSt

at 100° C

9.3 cSt

Viscosity Index

152

– JLG Lift –

3121298

SECTION 1 - SPECIFICATIONS

Table 1-14. Mobil EAL H 46

1.9 MAJOR COMPONENT WEIGHTS

Type

Synthetic Biodegradable

ISO Viscosity Grade

46

Specific Gravity

.910

Pour Point

-44°F (-42°C)

Flash Point

500°F (260°C)

Operating Temp.

0 to 180°F (-17 to 162°C)

600S Components

LBS.

KG.

Weight

7.64 lb. per gal.
(0.9 kg per liter)

Tire and Wheel (Ballasted Only) 15 - 19.5

253

115

Engine - Deutz

534

242

Counterweight

2900

1315

Platform - 6 ft. (1.83 M)

205

93

Platform - 8 ft. (2.44 M)

230

105

Viscosity
at 40° C

45 cSt

at 100° C

8.0 cSt

Viscosity Index

153

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT
WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Table 1-16. Component Weights

Table 1-15. Exxon Univis HVI 26
Specific Gravity

32.1

Pour Point

-76°F (-60°C)

600SJ Components

LBS.

KG.

Flash Point

217°F (103°C)

Tire and Wheel (Ballasted Only) 15 - 19.5

253

115

Engine - Deutz

534

242

Counterweight

4650

2109

Platform - 6 ft. (1.83 M)

205

93

Platform - 8 ft. (2.44 M)

230

105

Viscosity
at 40° C

25.8 cSt

at 100° C

9.3 cSt

Viscosity Index

376

NOTE:

3121298

ExxonMobil recommends checking oil viscosity
yearly.

– JLG Lift –

1-5

SECTION 1 - SPECIFICATIONS
















  




Figure 1-1. Operator Maintenance and Lubrication
1. Swing Bearing

1.10 OPERATOR MAINTENANCE
NOTE:

The following numbers correspond to those in Figure 1-1.,
Operator Maintenance and Lubrication.
Table 1-17. Lubrication Specifications.

KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping
point of 350° F (177° C). Excellent water resistance and
adhesive qualities, and being of extreme pressure type. 
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105
HO

Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424

EO

Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L2104C

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.

1-6

– JLG Lift –

Lube Point(s) - 1 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access. Apply grease and rotate
in 90 degree intervals until bearing is completely
lubricated.

3121298

SECTION 1 - SPECIFICATIONS

2. Wheel Bearings (If equipped)

5. Wheel Drive Hub

Lube Point(s) - Repack
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation

Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (1/2 Full)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation

3. Swing Drive Hub

6. Hydraulic Return Filter

4. Lube Point(s) - Level/Fill Plug
Capacity - 43 oz. (1.3 L)
Lube - 90w80 Gear Oil
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation

Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter or as shown by Condition Indicator.

3121298

– JLG Lift –

1-7

SECTION 1 - SPECIFICATIONS

7. Hydraulic Charge Filter

9. Oil Change w/Filter - Deutz D2011

Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter, or as shown by Condition Indicator.
8. Hydraulic TankLube Point(s) - Fill Cap

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 11 Quarts Crankcase; 5 Quarts Cooler
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in accordance
with engine manual..

NORMAL OPERATING
RANGE WITH BOOM
IN STOWED POSITION

Capacity - 26 gal. Tank; 40 gal. System
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation

1-8

– JLG Lift –

3121298

SECTION 1 - SPECIFICATIONS

10. Oil Change w/Filter - Deutz D2.9

11. Air Filter - Deutz D2.9

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 8.45 Qt (8 L) Crankcase and Filter
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance
with engine manual..

Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation or
as shown by condition indicator

MINIMUM OIL
LEVEL

MAXIMUM OIL
LEVEL

3121298

– JLG Lift –

1-9

SECTION 1 - SPECIFICATIONS

12. Oil Change w/Filter - GM

15. Air Filter

Lube Point(s) - Fill Cap/Spin-on Element 
(JLG P/N 7027965)
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.

Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator
16. 2-Stage Vaporizer (LP only)

13. Fuel Filter - Deutz

Interval - 3 Months or 150 hours of operation, or
whenever fuel is contaminated.
Comments - Drain oil build up or contamination.

Lube Point(s) - Replaceable Element
Interval - Every Year or 600 hours of operation
14. Fuel Filter (Gasoline) - GM

17. Fuel Filter (Propane) - GM Engine

Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation

Interval - 3 Months or 150 hours of operation
Comments - Replace filter.

1-10

– JLG Lift –

3121298

SECTION 1 - SPECIFICATIONS

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Lubricated

Torque
(Dry)

Tensile
Clamp Load
Stress Area

Torque
Torque
(Loctite® 242TM or 271TM
(Loctite® 262TM or VibraTM
OR Vibra-TITE 111 or
TITETM 131)
140)

Size

TPI

Bolt Dia

In

Sq In

LB

IN-LB

[N.m]

IN-LB

[N.m]

IN-LB

[N.m]

4

40
48
32
40
32
36
24
32
20
28

0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500

0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364

380
420
580
610
900
940
1120
1285
2020
2320

8
9
16
18
30
31
43
49
96
120

0.9
1.0
1.8
2.0
3.4
3.5
4.8
5.5
10.8
13.5

6
7
12
13
22
23
32
36
75
86

0.7
0.8
1.4
1.5
2.5
2.6
3.5
4
9
10

105
135

12
15

18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12

In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000

Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800

LB
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700

FT-LB
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200

[N.m]
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983

FT-LB
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640

[N.m]
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224

FT-LB
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300

[N.m]
26
29
48
54
75
82
116
136
163
184
224
258
388
449
646
707
918
1000
1142
1258
1598
1768
2074
2380
2754
3128

6
8
10
1/4

5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2

NOTES:

1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

IN-LB

[N.m]

FT-LB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974

[N.m]
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676

NO. 5000059 REV. J

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
JLG P/N

Loctite® P/N

ND Industries P/N

0100011
0100019
0100071

242TM
271TM
262TM

Vibra-TITE TM 121
Vibra-TITE TM 140
Vibra-TITE TM 131

Description
Medium Strength (Blue)
High Strength (Red)
Medium - High Strength (Red)

Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)

3121298

– JLG Lift –

1-11

SECTION 1 - SPECIFICATIONS

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Tensile
Clamp Load
Stress Area

Torque
(Dry or Loctite® 263)
K= 0.20

Torque
Torque
(Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or
TITETM 131)
140)
K=.18
K=0.15

Size

TPI

Bolt Dia

In

Sq In

LB

IN-LB

[N.m]

IN-LB

[N.m]

4

40
48
32
40
32
36
24
32
20
28

0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500

0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364

1320
1580
1800
2860
3280

43
60
68
143
164

5
7
8
16
19

129
148

15
17

18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12

In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000

Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800

LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200

FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555

[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835

FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
770
895
1160
1300
1635
1810
2145
2435
2845
3200

[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1045
1215
1580
1770
2225
2460
2915
3310
3870
4350

6
8
10
1/4

5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2

NOTES:

IN-LB

[N.m]

FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665

[N.m
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625

NO. 5000059

REV. J

1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)

1-12

– JLG Lift –

3121298

SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS
Magni Coating (Ref 4150701)*
Tensile
Stress Area

Clamp Load
See Note 4

Torque
(Dry) K = .17

Torque
(Loctite® 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85®
K=0.16

Size

TPI

Bolt Dia

In

Sq In

LB

IN-LB

[N.m]

IN-LB

[N.m]

4

40
48
32
40
32
36
24
32
20
28

0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500

0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364

2860
3280

122
139

14
16

114
131

13
15

18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12

In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000

Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800

LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200

FT-LB
20
25
35
40
60
65
90
100
130
145
180
205
320
355
515
570
730
845
1095
1225
1545
1710
2025
2300
2690
3020

[N.m]
25
35
50
55
80
90
120
135
175
195
245
280
435
485
700
775
995
1150
1490
1665
2100
2325
2755
3130
3660
4105

FT-LB
20
20
35
40
55
60
85
95
125
135
170
190
300
335
485
535
685
795
1030
1155
1455
1610
1905
2165
2530
2845

[N.m]
25
25
50
55
75
80
115
130
170
185
230
260
410
455
660
730
930
1080
1400
1570
1980
2190
2590
2945
3440
3870

6
8
10
1/4

5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2

Torque
(Loctite® 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB

[N.m]

FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665

[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625

NO. 5000059

REV. J

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)

3121298

– JLG Lift –

1-13

SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS
Zinc Yellow Chromate Fasteners (Ref 4150707)*
Tensile
Stress Area

Clamp Load
See Note 4

Torque
(Loctite® 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85®
K=0.18

Torque
(Dry)
K = .20

Size

TPI

Bolt Dia

In

Sq In

LB

IN-LB

[N.m]

IN-LB

[N.m]

4

40
48
32
40
32
36
24
32
20
28

0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500

0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364

2860
3280

143
164

16
19

129
148

15
17

18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12

In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000

Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800

LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200

FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555

[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835

FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
775
895
1160
1300
1635
1810
2145
2435
2845
3200

[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1055
1215
1580
1770
2225
2460
2915
3310
3870
4350

6
8
10
1/4

5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2

Torque
(Loctite® 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB

[N.m]

FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665

[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625

NO. 5000059 REV. J

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)

1-14

– JLG Lift –

3121298

SECTION 1 - SPECIFICATIONS

CLASS 8.8 METRIC BOLTS
CLASS 8 METRIC NUTS

Size

PITCH

Tensile
Stress
Area

Sq mm

Clamp
Load

Torque
(Dry or Loctite®
263TM)

Torque
(Lub)

KN

[N.m]

[N.m]

Torque
Torque
(Loctite®
(Loctite® 262TM 242TM or 271TM
OR VibraOR VibraTITETM 131)
TITETM 111 or
140)
[N.m]

[N.m]

3

0.5

5.03

2.19

1.3

1.0

1.2

1.4

3.5

0.6

6.78

2.95

2.1

1.6

1.9

2.3

4

0.7

8.78

3.82

3.1

2.3

2.8

3.4

5

0.8

14.20

6.18

6.2

4.6

5.6

6.8

6

1

20.10

8.74

11

7.9

9.4

12

7

1

28.90

12.6

18

13

16

19

8

1.25

36.60

15.9

26

19

23

28

10

1.5

58.00

25.2

50

38

45

55

12

1.75

84.30

36.7

88

66

79

97

14
16

2
2

115
157

50.0
68.3

140

105

126

154

219

164

197

241

18

2.5

192

83.5

301

226

271

331

20

2.5

245

106.5

426

320

383

469

22

2.5

303

132.0

581

436

523

639

24

3

353

153.5

737

553

663

811

27

3

459

199.5

1080

810

970

1130

30

3.5

561

244.0

1460

1100

1320

1530

33

3.5

694

302.0

1990

1490

1790

2090

36

4

817

355.5

2560

1920

2300

2690

42

4.5

1120

487.0

4090

3070

3680

4290

NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)

3121298

– JLG Lift –

1-15

SECTION 1 - SPECIFICATIONS

CLASS 10.9 METRIC BOLTS
CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

Size

PITCH

Tensile
Stress
Area

Clamp
Load

Torque
(Dry or Loctite®
263TM)
K = 0.20

Sq mm

KN

[N.m]

Torque
(Lub OR Loctite®
242TM or 271TM OR
Vibra-TITE TM 111 or
140)
K= 0.18

Torque
(Loctite® 262TM OR
Vibra-TITE TM 131)
K=0.15

[N.m]

[N.m]

3

0.5

5.03

3.13

3.5

0.6

6.78

4.22

4

0.7

8.78

5.47

5

0.8

14.20

8.85

6

1

20.10

12.5

7

1

28.90

18.0

25.2

22.7

18.9

8

1.25

36.60

22.8

36.5

32.8

27.4

10

1.5

58.00

36.1

70

65

55

12

1.75

84.30

52.5

125

115

95

14
16

2
2

115
157

71.6
97.8

200

180

150

315

280

235

18

2.5

192

119.5

430

385

325

20

2.5

245

152.5

610

550

460

22

2.5

303

189.0

830

750

625

24

3

353

222.0

1065

960

800

27

3

459

286.0

1545

1390

1160

30

3.5

561

349.5

2095

1885

1575

33

3.5

694

432.5

2855

2570

2140

36

4

817

509.0

3665

3300

2750

42

4.5

1120

698.0

5865

5275

4395

NO. 5000059

REV. J

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

1-16

– JLG Lift –

3121298

SECTION 1 - SPECIFICATIONS

Magni Coating (Ref 4150701)*
CLASS 12.9 SOCKET HEAD CAP SCREWS
M6 AND ABOVE*

Size

PITCH

Tensile
Stress
Area

Sq mm

Torque
Torque
(Lub OR Loctite®
Torque
(Loctite® 262TM
Clamp Load (Dry or Loctite® 242TM or 271TM
OR Vibra-TITE TM
See Note 4
263TM)
OR Vibra-TITE TM
131)
K = .17
111 or 140)
K = .15
K = .16
kN

[N.m]

[N.m]

[N.m]

11

3

0.5

5.03

3.5

0.6

6.78

4

0.7

8.78

5

0.8

14.20

6

1

20.10

12.5

13

12

7

1

28.90

18.0

21

20

19

8

1.25

36.60

22.8

31

29

27

10

1.5

58.00

36.1

61

58

54

12

1.75

84.30

52.5

105

100

95

14
16

2
2

115
157

71.6

170

160

150

97.8

265

250

235

18

2.5

192

119.5

365

345

325

20

2.5

245

152.5

520

490

460

22

2.5

303

189.0

705

665

625

24

3

353

220.0

900

845

790

27

3

459

286.0

1315

1235

1160

30

3.5

561

349.5

1780

1680

1575

33

3.5

694

432.5

2425

2285

2140

36

4

817

509.0

3115

2930

2750

42

4.5

1120

698.0

4985

4690

4395

NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

3121298

– JLG Lift –

1-17

SECTION 1 - SPECIFICATIONS

NOTES:

1-18

– JLG Lift –

3121298

SECTION 2 - GENERAL

SECTION 2. GENERAL
2.1

MACHINE PREPARATION, INSPECTION, AND
MAINTENANCE

Annual Machine Inspection

General
This section provides information needed by personnel
responsible to place machine in operation readiness and
maintain its safe operating condition. For maximum service
life and safe operation, ensure all necessary inspections and
maintenance have been completed before placing machine in
service.

Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive
inspection and preventive maintenance program. The following table outlines periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your
national, regional, or local regulations for further requirements
for aerial work platforms. Frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

The Annual Machine Inspection must be performed on an
annual basis, no later than thirteen (13) months from the date
of the prior Annual Machine Inspection. JLG Industries recommends this task be performed by a Factory-Trained Service
Technician. JLG Industries, Inc. recognizes a Factory-Trained
Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG
product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this inspection.
Reference the JLG Annual Machine Inspection Form and
Inspection and Preventive Maintenance Schedule for items
requiring inspection. Reference appropriate areas of this manual for servicing and maintenance procedures.
For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each Annual
Machine Inspection, notify JLG Industries, Inc. of current
machine ownership.

Preventive Maintenance

Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to perform a
Pre-Start Inspection of the machine before use daily or at each
change of operator. Reference the Operator’s and Safety Manual for Pre-Start Inspection procedures. The Operator and
Safety Manual must be read and understood in its entirety
before performing the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection
The Pre-Delivery Inspection and Frequent Inspection shall be
performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a
person who, by possession of a recognized degree, certificate,
extensive knowledge, training, or experience, has successfully
demonstrated the ability and proficiency to service, repair, and
maintain the subject JLG product model.

In conjunction with specified inspections, maintenance shall
be performed by a qualified JLG equipment mechanic. JLG
Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized
degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product
model.
Reference the Preventive Maintenance Schedule and appropriate areas of this manual for servicing and maintenance procedures. Frequency of service and maintenance must be
increased as environment, severity and frequency of usage
requires.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different
times. The Pre-Delivery Inspection shall be performed prior to
each sale, lease, or rental delivery. The Frequent Inspection
shall be accomplished for each machine in service for 3
months or 150 hours (whichever comes first); out of service for
a period of more than 3 months; or when purchased used. Frequency of this inspection must be increased as environment,
severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection Form
and Inspection and Preventive Maintenance Schedule for
items requiring inspection. Reference appropriate areas of this
manual for servicing and maintenance procedures.

3121298

– JLG Lift –

2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance
Primary
Responsibility

Service
Qualification

Reference

Prior to use each day; or
at each Operator change.

User or Operator

User or Operator

Operation and Safety Manual

Pre-Delivery Inspection

Prior to each sale, lease, or
rental delivery.

Owner, Dealer, or User

Qualified JLG Mechanic

Service and Maintenance Manual
and applicable JLG inspection form.

Frequent Inspection

In service for 3 months or 150 hours, whichever
comes first; or
out of service for a period of more than 3 months; or
purchased used.

Owner, Dealer, or User

Qualified JLG Mechanic

Service and Maintenance Manual
and applicable JLG inspection form.

Annual Machine Inspection

Annually, no later than 13 months from date of
prior inspection.

Owner, Dealer, or User

Factory-Trained Service
Technician
(Recommended)

Service and Maintenance Manual
and applicable JLG inspection form.

Preventive
Maintenance

At intervals as specified in Service and Maintenance Manual.

Owner, Dealer, or User

Qualified JLG Mechanic

Service and Maintenance Manual

Type

Frequency

Pre-Start Inspection

2.2

3.

SERVICE AND GUIDELINES

General
Following information is provided to assist you in using servicing and maintenance procedures in this manual.

Components Removal and Installation

Safety and Workmanship
Your safety, and that of others, is the first consideration in
maintenance of equipment. Always be conscious of weight.
Never attempt to move heavy parts without aid of a mechanical device. Do not allow heavy objects to rest in an unstable
position. Ensure adequate support is provided when raising a
portion of the equipment.

1.

Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.

2.

Should it be necessary to remove a component on an
angle, keep in mind the capacity of an eyebolt or similar
bracket lessens, as the angle between the supporting
structure and component becomes less than 90
degrees.

3.

If a part resists removal, check to see if all nuts, bolts,
cables, brackets, wiring, etc., have been removed and no
adjacent parts are interfering.

Cleanliness

2-2

1.

The most important single item in preserving the long
service life of a machine is to keep dirt and contamination out of vital components. Shields, covers, seals, and
filters are provided to keep air, fuel, and oil supplies
clean; however, these items must be maintained on a
schedule to function properly.

2.

Any time air, fuel, or oil lines are disconnected, clean
adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected,
cap or cover all openings to prevent contamination.

Clean and inspect all parts during servicing or maintenance. Ensure all passages and openings are unobstructed. Cover all parts to keep them clean. Make sure
all parts are clean before they are installed. New parts
should remain in their containers until ready to be used.

– JLG Lift –

3121298

SECTION 2 - GENERAL

2.

Component Disassembly and Reassembly
Complete procedural steps in sequence when disassembling
or reassembling a component. Do not partially disassemble or
assemble one part, then start on another. Always recheck your
work to ensure nothing is overlooked. Do not make any
adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

Hydraulic Lines and Electrical Wiring
Clearly mark or tag hydraulic lines and electrical wiring, and
their receptacles, when disconnecting or removing them from
the unit. This ensures correct reinstallation.

Hydraulic System

When assembling pressure-fit parts, use a molybdenum disulfide base compound or equivalent to lubricate the mating surface.

Bearings
1.

Unless specific torque requirements are given within the
text, use standard torque values on heat-treated bolts,
studs, and steel nuts, in accordance with recommended
shop practices. (See Torque Chart in Section 1.)

When a bearing is removed, cover it to keep out dirt and
abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used,
but do not spin the bearing.

2.

Discard bearings if races and balls (or rollers) are pitted,
scored, or burned.

3.

If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap
reusable or new bearings until ready to install.

4.

Lubricate new or used serviceable bearings before
installation. Apply pressure to the outer race when
pressing a bearing into a retainer or bore. Apply pressure to the inner race If bearing is installed on a shaft.

Gaskets

1.

Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
flush the entire system.

2.

Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning
solvent. Lubricate components as needed to aid assembly.

Lubrication
Service applicable components with the amount, type, and
grade of lubricant recommended in this manual at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets
or exceeds the specifications listed.

Battery
Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corrosion compound.

Lubrication and Servicing

Check holes in gaskets align with openings in mating parts. If
it is necessary to hand-fabricate a gasket, use gasket material
or stock of equivalent material and thickness. Be sure to cut
holes in the correct location. Blank gaskets can cause serious
system damage.

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.

Bolt Usage and Torque Application

SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
1.

Always use new replacement hardware when installing
locking fasteners. Use bolts of proper length. A bolt
which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will
not be enough thread area to engage and hold the part
properly. When replacing bolts, use only those having
the same specifications of the original, or one which is
equivalent.

3121298

– JLG Lift –

2-3

SECTION 2 - GENERAL

2.3

functional check of each system, before placing
machine back in service.

LUBRICATION AND INFORMATION

Hydraulic System

Lubrication Specifications

1.

The primary enemy of a hydraulic system is contamination. Contaminants can enter the system by using inadequate hydraulic oil; allowing moisture, grease, filings,
sealing components, sand, etc., to enter when performing maintenance; or allowing the pump to cavitate due
to insufficient system warm-up or leaks in pump supply
(suction) lines.

2.

Design and manufacturing tolerances of component
working parts are very close. The smallest amount of dirt
or other contamination entering a system can cause
wear or damage to components and faulty operation.
Take every precaution to keep hydraulic oil clean including reserve oil in storage. Check, clean, and
replace hydraulic system filters as at intervals specified
in the Lubrication Chart in Section 1. Always examine filters for metal particles.

3.

Cloudy oils indicate high moisture content which permits organic growth and causes oxidation or corrosion.
If this condition occurs, the system must be drained,
flushed, and refilled with clean oil.

4.

It is not advisable to mix oils of different brands or types.
They may not contain required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to ambient temperatures in which the
machine is operating, are recommended for use.

Specified lubricants, as recommended by component manufacturers, are always the best choice. However, multi-purpose
greases usually have qualities which meet a variety of single
purpose grease requirements. Should questions arise regarding use of greases in maintenance stock, consult your local
supplier for evaluation. Refer to Section 1 for an explanation of
lubricant key designations in the Lubrication Chart.

2.4

Measure maximum acceptable cylinder drift using the following methods.

Platform Drift
Measure platform drift to ground. Lower booms (if equipped)
slightly elevated, main boom fully extended with rated load in
platform and power off. Maximum allowable drift is 2 inches (5
cm) in 10 minutes. If machine does not pass this test, proceed
with the following.

Cylinder Drift
Table 2-2. Cylinder Drift
Cylinder Bore Diameter

NOTE: Metal particles may appear in oil or filters of new machines
due to wear-in of meshing components.

Hydraulic Oil
1.

Refer to Section 1 for viscosity ranges.

Changing Hydraulic Oil
1.

2-4

Filter elements must be changed after the first 50 hours
of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use
only those oils meeting or exceeding specifications in
this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing
petroleum and synthetic base oils.

2.

Keep hydraulic oil clean. If oil must be poured from original container into another, clean all possible contaminants from the service container. Always clean filter
mesh element and replace cartridge any time system oil
is changed.

3.

While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a

CYLINDER DRIFT TEST

Max. Acceptable Drift
in 10 Minutes*

inches

mm

inches

mm

3

76.2

0.026

0.66

3.5

89

0.019

0.48

4

101.6

0.015

0.38

5

127

0.009

0.22

6

152.4

0.006

0.15

7

177.8

0.005

0.13

8

203.2

0.0038

0.10

9

228.6

0.0030

0.08

*Based on 6 drops per minute cylinder leakage.
Measure drift at cylinder rod with a calibrated dial indicator.
Cylinder oil must be at stabilized ambient temperature.

Cylinder must have normal platform load applied.

Cylinder is acceptable if it passes this test.

– JLG Lift –

3121298

SECTION 2 - GENERAL

2.5

PINS AND COMPOSITE BEARING REPAIR
GUIDELINES

2.6

NOTE: This instruction applies to repairs, or modifications to the
machine and to welding performed from the machine on
an external structure, or component,

Filament wound bearings.
1.

Pinned joints should be disassembled and inspected if
the following occurs:

Do the Following When Welding on JLG Equipment:

a. Excessive sloppiness in joints.

• Disconnect battery.

b. Noise originating from joint during operation.
2.

WELDING ON JLG EQUIPMENT

• Disconnect moment pin connection (where fitted)

Filament wound bearings should be replaced if any of
the following is observed:

• Ground only to structure being welded.

Do NOT Do the Following When Welding on JLG
Equipment:

a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing.
d. Debris embedded in liner surface.
3.

Pins should be replaced if any of the following is
observed (Clean pin before inspection):
a. Detectable bearing area wear.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
RING, BOOM WIRE ROPES ETC.

b. Flaking, peeling, scoring, or scratches on pin surface.

4.

c. Rusting of pin in bearing area.

• Do NOT ground on frame and weld on any other area than
chassis.

Re-assembly of pinned joints using filament wound
bearings:

• Do NOT ground on turntable and weld on any other area
than turntable.

a. Blow out housing using compressed air to remove
all dirt and debris. Bearings and bearing housings
must be free of all contamination.
b. Clean bearings and pins with solvent to remove all
grease and oil.
NOTE: Filament wound bearings are a dry joint and should not be
lubricated unless otherwise instructed (i.e. sheave pins).

• Do NOT ground on platform/support and weld on any
other area than platform/support.
• Do NOT ground on a specific boom section and weld on
any other area than that specific boom section.
• Do NOT allow pins, wear pads, wire ropes, bearings, gearing, seals, valves, electrical wiring, or hoses to be between
grounding position and welded area.

c. Inspect pin to ensure it is free of burrs, nicks, and
scratches which can damage bearing during installation and operation.

3121298

– JLG Lift –

2-5

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
Pre-Delivery2
or Frequent3
Inspection

Annual4
(Yearly)
Inspection

1,2,4

1,2,4

1,2,9,12

1,2,9,12

Pivot Pins and Pin Retainers

1,2

1,2

Sheaves, Sheave Pins

1,2

1,2

Bearings

1,2

1,2

Wear Pads

1,2

1,2

Covers or Shields

1,2

1,2

1,2,3

1,2,3

AREA

Weekly
Preventive
Maintenance

Monthly
Preventive
Maintenance

Every 2
Years

Boom Assembly
Boom Weldments
Hose/Cable Carrier Installations

Extend/Retract Chain or Cable Systems
Boom Assembly

14

Platform Assembly
Platform

1,2

Railing
Gate

5

Floor
Rotator

9,5

Lanyard Anchorage Point

1

1,2

1

1,5

1

1,2

15
1,2,10

1,2,10

1,2,14

1,2,3,13,14

11

11

1,2,5

1,2,5

5

1,2,5

16,17

16,17,18

16,17,18

15

15

15

Turntable Assembly
Swing Bearing
Oil Coupling

9

Swing Drive System
Turntable Lock
Hood, Hood Props, Hood Latches

Chassis Assembly
Tires
Wheel Nuts/Bolts
Wheel Bearings

14,24

Oscillating Axle/Lockout Cylinder Systems

5,8

Extendable Axle Systems

5,8

5,8

Steer Components
Spindle Thrust Bearing/Washers

1,2

Drive Hubs

2-6

11

– JLG Lift –

11

3121298

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA

Weekly
Preventive
Maintenance

Monthly
Preventive
Maintenance

Pre-Delivery2
or Frequent3
Inspection

Annual4
(Yearly)
Inspection

Every 2
Years

Functions/Controls
Platform Controls

5

6

6

Ground Controls

5

6

6

1,5

5

5

Footswitch

5

5

Emergency Stop Switches (Ground & Platform)

5

5

Function Limit or Cutout Switch Systems

5

5

Drive Brakes

5

Swing Brakes

5

Auxiliary Power

5

5

3

3

Function Control Locks, Guards, or Detents

Power System
Engine Idle, Throttle, and RPM
Engine Fluids (Oil, Coolant, Fuel)

9,11

11

11

Air/Fuel Filter

1,7

7

7

9

9

Exhaust System

1,9

Batteries

1,9

Battery Fluid

11

Battery Charger

5

Fuel Reservoir, Cap, and Breather

19
11

11
5

2

1,5

1,5

Hydraulic/Electric System
Hydraulic Pumps
Hydraulic Cylinders

1,9
1,9,7

1,2,9
2

1,2,9

1,2,9

1,2

1,2

Cylinder Attachment Pins and Pin Retainers

1,9

Hydraulic Hoses, Lines, and Fittings

1,9

12

1,2,9,12

1,2,9,12

Hydraulic Reservoir, Cap, and Breather

1,9

2

1,5

1,5

Hydraulic Filter

1,9

7

7

7,11

7,11

20

20

Hydraulic Fluid
Electrical Connections

1

Instruments, Gauges, Switches, Lights, Horn

1

24

5,23

General
Operation and Safety Manuals in Storage Box

21

ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only)

21
21

Capacity Decals Installed, Secure, Legible

21

21

All Decals/Placards Installed, Secure, Legible

21

21

3121298

– JLG Lift –

2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA

Weekly
Preventive
Maintenance

Monthly
Preventive
Maintenance

Pre-Delivery2
or Frequent3
Inspection

Annual4
(Yearly)
Inspection

Annual Machine Inspection Due

21

No Unauthorized Modifications or Additions

21

21

All Relevant Safety Publications Incorporated

21

21

General Structural Condition and Welds

2,4

2,4

All Fasteners, Pins, Shields, and Covers

1,2

1,2

Grease and Lubricate to Specifications

22

22

Function Test of All Systems

21

21, 22

Paint and Appearance

7

7

Stamp Inspection Date on Frame

22

Notify JLG of Machine Ownership

22

Every 2
Years

Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill

2-8

– JLG Lift –

3121298

SECTION 2 - GENERAL

 
 

  


     
  

 
 
 

  

 





 





 





 


   



 




 

        

        
   

      
  
     
   

  
         
              
   
         





 
 






!"




  
 
  
    


 

  
&

!  


     
  

!! 



!! 

! 
  
 
 

  """$%
 "&  "

 
      
          %"%
       

&  
'    
 '
     '&

 &   '
  &






$%

 %

 !

# 

!" 

"#




 
&  



! 

 

      
   
 ! #!   

'"$'(



$! 



%!% 

!'

!" 

#! 



$        
 
 ! "!   

 ! "! 
   

"# 



 

  


     
  

  



)



)



)



)





 



 



 














*"!"

4150548 E

Figure 2-1. Deutz Engine and Hydraulic Operating Temperature Specifications

3121298

– JLG Lift –

2-9

SECTION 2 - GENERAL

   
 

 !" 

      
    

 ! 
 !# 
" ! 

  
    



# !$ 


   
   

& !& 
% ! 
 ! 

  "     
     
"        

 $     "  
  
  "       
 "    

$ !  

 ! 
 !$ 
 ! 



 !# 
%

  "       
     "    %
  
%     &    "   
     %
" %    
 

 ! 
 !" 
 ! 
 ! 

   "  
    


  
       
  
    

!  
"    
   


 
 

  
 
  
    


 

  
&

!  

      
    

!! 

! 

 !

# 



$! 
 

 %

%!% 

    
     
  

 
&  





#! 



"# 

!'

!" 
  



!! 
!" 
! 
  
 
 

       
"  
 "  ##
    "    

&  
'    
 '
     '&

 &
  '
  &

4150548 E

Figure 2-2. GM Engine and Hydraulic Operating Temperature Specifications

2-10

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES & WHEELS
Tire Inflation
Pneumatic tire air pressure must be equal to air pressure stenciled on side of JLG product or rim decal for safe and proper
machine operation.

Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire,
ensure all tires are inflated to pressure recommended by JLG.
Due to size variations between tire brands, both tires on the
same axle should be identical.

Wheel Replacement

Tire Damage
PNEUMATIC TIRES
JLG Industries, Inc. recommends when any cut, rip, or tear is
discovered that exposes sidewall or tread area cords in the tire,
measures must be taken to remove the JLG product from service immediately. Arrangements must be made for replacement of the tire or tire assembly.

Rims installed on each product model are designed for stability requirements which consist of track width, tire pressure,
and load capacity. Size changes such as rim width, center
piece location, larger or smaller diameter, etc., without written
factory recommendations, may result in unsafe stability conditions.

Wheel Installation

POLYURETHANE FOAM FILLED TIRES
JLG Industries, Inc. recommends when any of the following are
discovered, measures must be taken to remove the JLG product from service immediately and arrangements made for
replacement of tire or tire assembly:
• Smooth, even cut through cord plies which exceeds
3" (7.5 cm) in total length.
• Tears or rips (ragged edges) in cord plies which
exceeds 1" (2.5 cm) in any direction.
• Punctures which exceed 1" in diameter.
• Damage to bead area cords.
NOTE: If a tire is damaged but within above criteria, it must be
inspected daily to ensure damage does not exceed allowable criteria.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT PROPER TORQUE TO
PREVENT LOOSE WHEELS, BROKEN STUDS, AND DANGEROUS SEPARATION OF
WHEEL FROM AXLE. USE ONLY NUTS MATCHED TO CONE ANGLE OF WHEEL.
Tighten lug nuts to proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten fasteners. If you
do not have a torque wrench, tighten fasteners with a lug
wrench, then immediately have a service garage or dealer
tighten lug nuts to proper torque.
Over-tightening will break studs or permanently deform
mounting stud holes in wheels.

Tire Replacement

1.

Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.

2.

Tighten nuts in the following sequence:

JLG recommends a replacement tire be the same size, ply, and
brand as originally installed on the machine. Please refer to the
JLG Parts Manual for part number of approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend replacement tires have the
following characteristics:
• Equal or greater ply/load rating and size of original
• Tire tread contact width equal or greater than original
• Wheel diameter, width, and offset dimensions equal to the
original
• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)

Figure 3-1. Wheel Lug Nut Tightening Sequence

3121298

– JLG Lift –

3-1

SECTION 3 - CHASSIS & TURNTABLE

3.

Torque to specifications shown in Table 3-1 below.

LEAK TEST
The purpose of a leak test is to make sure unit is air tight. You
can tell if your unit has a leak if pressure gauge test reading
starts to fall once you have pressurized the unit.

Table 3-1. Wheel Torque Chart
TORQUE SEQUENCE

4.

1st Stage

2nd Stage

3rd Stage

40 ft-lb
(55 Nm)

100 ft-lb
(130 Nm)

170 ft-lb
(255 Nm)

Torque wheel nuts after first 50 hours of operation and
after each wheel removal. Check torque every 3 months
or 150 hours of operation.

Leaks usually occur at the main seal or wherever O-rings or
gaskets are located. You can usually detect location of a leak by
brushing a soap and water solution around main seal and
where O-rings or gaskets meet unit exterior, then checking for
air bubbles. Replace part immediately if you detect a leak in a
seal, O-ring, or gasket.

Tightening and Torquing Bolts

3.2 TORQUE HUB
Oil Information
1.

1. TYPE – EP90 
Use EP90 for normal applications. For applications where
lubricant must meet special requirements, the O.E.M can
recommend a suitable substitute.

USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN
BOLTS BEYOND THEIR TORQUE SPECIFICATION. NEVER USE AN IMPACT
WRENCH TO TIGHTEN SHOULDER BOLTS. TIGHTEN ALL SHOULDER BOLTS BY
HAND.
1.

Tighten (but do not torque) bolt ”A” until snug.

2.

OIL TEMPERATURE 
Continuous – 160° F (70° C) Intermittent – 200° F (95° C).

2.

Go to opposite side of bolt circle and tighten bolt ”B”
until equally snug.

3.

OIL CHANGE 
Initial – After 50 hours or 50,000 revolutions of operation. Subsequent – After 1000 hours or (1) year, whichever comes first.

3.

Continue around bolt circle and tighten remaining bolts.

4.

Use a torque wrench to apply specified torque to bolt ”A”.

5.

Continue around bolt circle and apply equal torque to
remaining bolts.

NOTE: Higher temperatures make it necessary to change oil more
frequently.
4.



OIL FILL LEVEL AND VOLUME 
Unit mounted horizontal – half full. (See Diagram A.)
Approximate volume - 17 oz. (0.5 1tr).

Roll and Leak Testing
Always roll and leak test Torque-Hubs after assembly to make
sure that the unit’s gears and sealants are working properly.
The following information briefly outlines what to look for
when performing these tests.



ROLL TEST
The roll test determines if the unit’s gears rotate freely and
properly. You should be able to rotate gears by applying a constant force to the roll checker. If you feel more drag in gears
only at certain points, gears are not rolling freely. Examine
them for improper installation or defects.

Figure 3-2. Bolt Tightening Sequence

Some gear packages roll with more difficulty than others. Do
not be concerned if gears seem to roll hard as long as they roll
with consistency.

3-2

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

3B

19

3F
3C

11

3B

4G

20
5 9

3E

1E

17

2

6A

6E

3A

6D

6B
6C

6F

15

16

1B
6G

1C
1H

1G
1D
8C

18
8B

8L

1G

1C
8E
8D

8K
8J

8A
8F
8H

1F

12 21

7
1L

1M 1K

4H
4B
4C
4F

4D

1A
4G

4C

4E

4B
2780269

1A. Spindle
1B. Seal
1C. Bearing
1D. Housing
1E. Ring Gear
1F. Bearing Nut
1G. Setscrew
1H. Wheel Stud
1K. Retaining Ring

1L. Spring
1M. Thrustwasher
2. Thrustwasher
3A. Carrier
3B. Thrustwasher
3C. Needle Bearing
3E. Planet Shaft
3F. Planet Gear
4B. Thrustwasher

4C. Needle Bearing
4D. Thrust Spacer
4E. Planet Shaft
4F. Planet Gear
4G. Roll Pin
4H. Thrustwasher
5. Retaining Ring
6A. Cover Plate
6B. Disengage Cap

6C. Bolt
6D. Dowel Pin
6E. O-Ring
6F. Pipe Plug
6G. Retaining Ring
7. Coupling
8A. Brake Piston
8B. Pressure Plate
8C. Retaining Ring

8D. O-Ring
8E. Back-up Ring
8F. O-Ring
8H. Back-up Ring
8J. Brake Rotor
8K. Brake Stator
8L. Brake Spring
9. Input Shaft
11. Sun Gear

12. Plug
15. I.D. Plate
16. Drive Screw
17. O-Ring
18. O-Ring
19. Countersunk Screw
20. Retaining Ring
21. Plug

Figure 3-3. Torque Hub

3121298

– JLG Lift –

3-3

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Carefully pressurize unit with air to pop cover off.

Main Disassembly
1.

Perform Roll Check, Leak Check, and Brake Check if
applicable before disassembly.

2.

Drain oil from unit. Note condition and volume of oil.

3.

Remove Retaining Ring (6G) by prying open end of
Retaining Ring out of groove in Ring Gear (1E) with a
screwdriver. Grasp loose end with pliers and pull out
Retaining Ring.

4.

Remove Cover Subassembly (6).

5.

Remove Input Carrier Subassembly (3).

6.

Remove Input Shaft (9).

7.

Remove Second Stage Sun Gear (11).

8.

Loosen and remove three Flat Head Bolts (19) that retain
Ring Gear (1E) to Housing (1G).

9.

Lift Ring Gear (1E) off Housing (1D).

10.

Remove O-ring (18) from Housing (1D.

19

18

3

6

6A

11

9
1D

1E

Figure 3-4. Torque Hub Main Disassembly

3-4

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Output Carrier Disassembly
1.

Use a 1/8” diameter punch to drive Roll Pin (4G) in Planet
Shaft (4E) until it bottoms against Spindle (1A).

2.

Grasp Roll Pin (4G) with needle nosed pliers or a hooked
tool and pull Planet Shaft (4E) out of Spindle (1A).

3.

Drive Roll Pin (4G) out of Planet Shaft (4E). Discard roll
pin.

4.

Slide Planet Gear Subassembly (4) out of Spindle (1A).
Do not drop Needle Bearings (4C).

5.

Remove four Thrust Washers (4B), 28 Needle Rollers (4C),
and Thrust Spacer (4D) from Second Stage Planet Gear
(4F).

6.

Repeat Steps 12-15 for remaining Planet Gears (4F).

7.

Remove Thrust Washer (4H) from Spindle (1A) counterbore.

1A

4B
4C
4F
4D
4E
4G

4B

4H

Figure 3-5. Output Carrier Disassembly

Input Carrier Disassembly
1.

Using a 1/8” diameter punch, drive Roll Pin (4G) in Planet
Shaft (3E) until it bottoms against Carrier (3A).

2.

Using a soft face hammer, tap Planet Shaft (3E) out of
Carrier (3A).

3.

Using a 1/8” diameter punch, drive Roll Pin (4G) out of
Planet Shaft (3E). Discard roll pin.

4.

Slide Planet Gear (3F) and two Thrust Washers (3B) out
of Carrier (3A).

5.

Remove 14 needle Bearings (3C) from bore of Planet
Gear (3F).

6.

Repeat steps 1 through 5 for remaining planet gears.

3F

3B

3C

4G
3B

3A

Figure 3-6. Input Carrier Disassembly

3121298

– JLG Lift –

3-5

SECTION 3 - CHASSIS & TURNTABLE

Hub-Spindle Disassembly

5.

Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q)
from Hub (1D) if applicable.

1.

Place unit on bench with Spindle (1A) end down.

6.

2.

Remove 2 Set Screws (1G) and Bearing Nut (1F) using T206569.

If necessary, press nine Studs (1H) out of Hub (1D).
Locate Hub (1D) on Seal (1B) end.

7.

Remove Seal (1B) from Hub (1D). Discard seal.

8.

Remove “B” position Bearing Cone (1C) from Bearing
Cup (1C) in Hub (1D).

9.

Remove “B” position Bearing Cone (1C) from Hub (1D).

NOTE: Holes in Bearing Nut (1F) for Set Screws (1G) are staked for
retention of Set Screws (1G). Clean holes before removing
Set Screws.
3.

Remove “A” position Bearing Cone (1C) from Bearing
Cup (1C) in Hub (1D).

4.

While supporting unit on Hub (1D) flange, press Spindle
(1A) out of Hub (1D).

10.

Using a soft steel rod, knock both Bearing Cups (1C) out
of Hub (1D).

1A
1G

1B
1C

1H

1D
1C
1F

Figure 3-7. Hub Spindle Disassembly

3-6

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

(8B). Remove Flat Head Cap Screws (22) and Pressure
Plate (8B) from brake cavity in Spindle (1A).

Spindle-Brake Disassembly
NOTE: Units with integral Input Brake (8) only.

COMPRESSED SPRINGS CAN FLY OUT AND CAUSE SEVERE EYE DAMAGE OR
OTHER INJURIES. WEAR EYE PROTECTION WHEN PERFORMING THESE PROCEDURES.
1.

Install two 1/4"-20 x 5/8" Flat Head Cap Screws (22)
through Pressure Plate (8B) into Piston (8A). Tighten
incrementally until spring force is taken off Retaining
Ring (8C).

NOTE: Flat Head Cap Screws (22) are for transit and service only
and are removed before shipping new units. They are
included in most brake repair kits.

4.

Remove Compression Springs (8L) from Piston (8A).

5.

Using an air hose, slowly and carefully pressurize brake
port in Spindle (1A) until Piston (8A) comes out of piston
bore of Spindle (1A). Pull Piston (8A) out of Spindle (1A)
by hand.

6.

Remove Backup Rings (8E and 8H) and O-rings (8D and
8F) from grooves in Piston (8A).

7.

Remove Rotors (8J) and Stators (8K) from brake cavity in
Spindle (1A).

8.

Remove Coupling Subassembly (7) from brake cavity in
Spindle (1A).

9.

Remove Retaining Ring (1K) from internal groove using
appropriate tool.

2.

Using retaining ring pliers, remove Retaining Ring (8C)
from groove in Spindle (1A).

10.

Remove Spacer (1M) and Spring (1L) from bore of Coupling (7).

3.

Back Flat Head Cap Screws (22) incrementally out of Piston (8A) until spring force is relieved from Pressure Plate

11.

Remove Plastic Plug (12) and Pipe Plug (21) from Spindle
(1A) if applicable.

8C
8B
8L
8E
8A
8F

Figure 3-8. Spindle Brake Disassembly

3121298

– JLG Lift –

3-7

SECTION 3 - CHASSIS & TURNTABLE

Cover Disassembly

Cover Assembly

1.

Remove O-Ring (17) from groove in Cover (6A).

2.

Remove Thrust Washer (2) from Cover (6A) pockets.

3.

Unscrew two Hex Head Bolts (6C) and remove Disengage Cap (6B) from Cover (6A).

4.

Pull Disengage Rod (6D) out from Cover (6A).

5.

Use appropriate tool to remove O-ring (6E) from internal
groove in Cover (6A).

6.

Remove two O-Ring Pipe Plugs (6F) from Cover (6A).

1.

Grease O-Ring (6E) and insert in internal groove in Cover
(6A).

2.

Assemble Disengage Cap (6B) on Cover (6A) using two
Hex Head Bolts (6C). Torque bolts to 70-80 in-lbs.

3.

Insert Disengage Rod (6D) in hole in Cover (6A) until it
touches inside of Disengage Cap (6B).

NOTE: Disengage Rod can be inserted either end first.
4.

Grease face of Thrust Washer (2) and place in Cover (6A).
Make sure tangs on washer seat into pockets in cover.

5.

Install O-Ring Pipe Plugs (6F) in Cover (6A). Plugs should
be hand tight.
17

2

6A

6E

6D

6B
6C

6F
6G

Figure 3-9. Torque Hub Cover

3-8

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

8.

Input Carrier Assembly
1.

Apply a liberal coat of grease to bore of one Input Planet
Gear (3F).

2.

Line inside of Planet Gear (3F) with 14 Needle Rollers
(3C).

NOTE: The last roller installed must be installed end wise. That is,
the end of the last roller must be placed in between ends of
the two rollers which form the space, and then slid, parallel
to the other rollers, into place.
3.

Now insert Planet Shaft (3E) through opposite planet
shaft hole on Carrier (3A). Use an alignment punch or
similar tool to align roll pin holes on Carrier (3A) and
Planet Shaft (3E).

DO NOT TO HIT PLANET GEARS (3F) WHEN DRIVING IN ROLL PINS (4G).

Set Carrier (3A) in an upright position.

9.

Drive Roll Pin (4G) down into aligned roll pin holes. Pin
should be flush with flat of carrier.

10.

Repeat Steps 1-9 for installation of two remaining Planet
Gears (3F).

NOTE: Some grease may need to be applied to Thrust Washers
(3B) to hold them in place while installing planet gears.
INSERT END OF PLANET SHAFT THAT DOES NOT HAVE ROLL PIN HOLE IN CARRIER FIRST.

3F

3B

4.

Insert a Planet Shaft (3E) in planet shaft hole in end of
Carrier (3A) opposite splined end.

5.

Place one Thrust Washer (3B) on end of Planet Shaft (3E).
Make sure the flat faces towards inside of carrier and
make sure button fits in the pocket on inside of Carrier
(3A) towards the OD.

6.

Following the thrust washer, place Planet Gear (3F) with
needle rollers, on Planet Shaft (3E).

7.

Following the planet gear, place one more Thrust
Washer (3B) onto Planet Shaft (3E). Align Thrust Washer
(3B) in same manner described in Step 5.

3C

4G
3B

3A

Figure 3-10. Input Carrier Assembly

3121298

– JLG Lift –

3-9

SECTION 3 - CHASSIS & TURNTABLE

Spindle - Brake Assembly

10.

Insert Piston (8A) in Spindle (1A) until it contacts Stator
(8K).

11.

Insert appropriate number of Springs (8L), based on
assembly print, into Piston (8A)counterbore.

1.

Place Spindle (1A) with flange side up.

2.

Place Stator (8K) in Spindle (1A) scallop cuts.

3.

Place Rotor (8J) on top of Stator (8K).

12.

4.

Repeat steps 2 & 3 until there are a total of 9 Stators (8K)
and 8 Rotors (8J) installed.

Place Spring (1L) in Coupling (7) counterbore. Place Pressure plate (1M) on top of Spring (1L).

13.

Place Piston (8A) with smaller O.D. end facing up. Grease
two O-Rings and two Backup Rings.

Use appropriate tool to install Retaining Ring (1K) in
retaining ring groove in coupling (7) counterbore.

14.

Insert Coupling subassembly (7) through Rotors (8J).

15.

Place Pressure Plate (8B) on top of Springs (8L).

16.

Use two ¼ -20 x 0.625 Flat Head Cap Screws (22) by bolting Pressure Plate (8B) and Piston (8A) together or some
other appropriate tools to install Retaining Ring on top
of Pressure Plate (8B) until Retaining Ring (8C) is seated.

5.
6.

Install large Backup Ring (8E) in large-diameter groove at
bottom of Piston (8A).

7.

Install large O-Ring (8D) in large-diameter groove at bottom of Piston (8A), on top of large Backup Ring (8E).

8.

Install small O-Ring (8F) in small-diameter groove near
top of Piston (8A). Make sure O-Ring is seated on the
bottom of the groove.

9.

NOTE: Remove two screws from units when done or brake will not
function.

Install small Backup Ring (8H) in small-diameter groove
near top of Piston (8A), on top of small O-Ring (8F).

17.

Install Pipe Plug (21) if applicable.

8C
8B
8L
8E
8A
8F

Figure 3-11. Spindle-Brake Assembly

3-10

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Hub-Spindle Assembly
NOTE: Spray a light film of oil on all component parts during
assembly. Spray a generous amount of oil on bearings during installation.
1.

Press Bearing Cup of part (1C), position "A", into Hub
using T-158422 pressing tool.

2.

Turn hub over and press Bearing Cup of part (1C), position "B", into hub using T-158422 pressing tool.(T).

3.

Place Bearing Cone of part (1C), into Bearing Cup of part
(1C), position "B".

4.

Grease Seal (1B) lip and press seal into Hub (1D) using
appropriate tool until seal is flush with end of hub.(T).

DO NOT USE EXCESSIVELY HIGH PRESSURE TO PRESS IN STUDS OR HUB MAY
CRACK.
5.

6.

Set Spindle assembly (1A) on bench with flange down.
Turn Hub (1D) over and lower onto Spindle (5). Install
boot (21) if applicable.

7.

Install Bearing Cone of part (1C) in Bearing Cup, position
"A".

8.

Apply Loctite 243 or equivalent on Bearing Nut (1F)
thread. Screw Nut (1F) on top of Bearing Cone of part
(1C). Leave 0.003-0.005 inches end play to check initial
rolling torque with unit tied down. Torque Bearing Nut
(1F) until rolling torque is 40 - 50 in-lb (4.5 - 5.6 Nm)
greater than initial rolling torque. Using tool T-206569
for Bearing Nut.

NOTE: Final torque is initial rolling torque plus 40-50 in-lb E.g., if
initial rolling torque is 30 in-lb, final rolling torque is
between 70-80 in-lb. Be sure to rotate hub as torque is
applied to properly seat bearing. Be sure torque wrench is
tangent to the Hub (1D) OD.
9.

Place Hub (1D) into pressing base. Press nine Studs (1H)
in Hub.

Install two Set Screws (1G) in Bearing Nut (1F) threaded
holes. Make sure Set Screw is driven in spindle thread.
Tighten set screws to damage thread and stake edge of
nut around Set Screws (1G) so nut will not loosen.

1A
1B

1G
1C

1H

1D
1C
1F

Figure 3-12. Hub Spindle Assembly

3121298

– JLG Lift –

3-11

SECTION 3 - CHASSIS & TURNTABLE

8.

Output Planet Gear Assembly
1.

Apply a liberal coat of grease to the bore of one Output
Planet Gear (4F).

2.

Line inside of Planet Gear (4F) with 14 Needle Rollers
(4C).

NOTE: Last roller installed must be installed end wise. That is, the
end of the last roller must be placed in between the ends of
the two rollers which form the space, and then slid, parallel
to the other rollers, into place.
3.

Place Spacer (4D) in bore of Output Planet (4F).

4.

Repeat Step 2 to put in second roll of Needle Rollers (4C).

5.

Apply grease to hold two Thrust Washers (4B) together
and on Output Planet Gear (4F) counterbore. Repeat on
other side.

6.

Repeat Steps 1-5 for remaining Output Planet Gears (4F).

7.

Place Thrust Washer (4H) in counterbore of Spindle (1A).

Place Planet Gear Subassembly (4) in Spindle (1A)
through gap between two Studs (1H). Align planet gear
bore with one of the planet shaft holes on spindle (1A)
assembly using special tool T-209919.

INSERT END OF PLANET SHAFT THAT DOES NOT HAVE ROLL PIN HOLE IN SPINDLE FIRST.
9.

Insert Planet Shaft (4E) in Spindle (1A) through first set of
Thrust Washers (4B), Planet gear, and second set of
Washers (4B).

10.

Use an alignment punch or similar tool to align roll pin
holes on Spindle (1A) and Planet Shaft (4E).

DO NOT HIT PLANET GEARS (4F) WHEN DRIVING IN ROLL PINS (4G).
11.

Drive new Roll Pin (4G) in aligned roll pin holes. Pin
should be flush with OD of spindle.

12.

Repeat Steps (11-14) for remaining Planet Gears (4F).

1A

4B
4C
4F
4D
4E
4B

4G

4H

Figure 3-13. Output Planet Gear Assembly

3-12

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Main Assembly

6.

Using appropriate tool to install Retaining Ring (20) in
groove on Output Sun (11).

NOTE: Coat all components with a generous amount of lubricant
oil as they are being assembled.

7.

Place Input Shaft (9) spline end into mesh with Internal
Coupling (7) splines.

8.

With modified spline end facing up, place Output Gear
(11) in mesh with planet gears from Hub-Spindle Subassembly.

1.

Place Hub-Spindle Subassembly on bench.

2.

Grease O-Ring (18) and place it in groove of Hub (1D).

3.

Place Ring Gear (1E) on Hub (1D). Align three shipping
Cap Screw Holes on Hub (1D) and Ring Gear (1E).

9.

Place Input Carrier Subassembly (3) on Output Sun Gear
(11) splines.

4.

Install three shipping Cap Screws (19) in ring gear and
hub. Torque to 15-20 ft-lb.

10.

Grease O-Ring (17) and insert in groove in Cover Subassembly (6).

5.

Place External Retaining Ring (5) over 13T spline to the
retaining groove on Input Shaft (9).

11.

Install Cover Subassembly (6) in Ring Gear (1E) counterbore and install Retaining Ring (6G) in groove in Ring
Gear (1E).

12.

Check disconnect, roll and air check unit, leak check
brake, and record release pressure.

NOTE: For ratio 48:1, assemble Output Sun Gear (11) over Input
Shaft (9) first, then install External Retaining Ring (5).

19

18

3

6

6A

11

9
1D

1E

Figure 3-14. Main Assembly
Table 3-2. Torque Hub Brake Release Pressure

Integral Brake Check
1.

Using appropriate fittings, connect hydraulic line from
hand pump to brake port.

2.

Check brake is set by trying to rotate Input Shaft (9). This
can be accomplished by installing an appropriate tool
(any tool that can locate on splines of Input Coupling (7),
such as a mating splined shaft) into Input Coupling
(7).Bleed brake.

3.

Increase hydraulic pressure gradually while trying to
rotate input until brake just starts to release. Note this
pressure. Make sure pressure falls into appropriate range
in Table 3-2.

BRAKE
CODE
A
B
C
D
E
4.

JUST RELEASE
PRESSURE RANGE
PSI
200-260
170-220
140-185
130-155
115-145

BAR
13.7-17.9
11.7-15.1
9.6-12.7
8.9-10.6
7.9-9.9

Increase pressure to 1,000 psi and hold for 30 seconds to
check for leaks. Repair leaks if necessary.

NOTE: Make sure brake re-engages when pressure is released.
NOTE: When done, make sure Input Coupling (7) is centered in
Spindle (1A) to make installation of motor possible without
release of brake.

3121298

– JLG Lift –

3-13

SECTION 3 - CHASSIS & TURNTABLE

1A. Spindle
1B. Lip Seal
1C. Tapered Bearing
1D. Housing
1E. Ring Gear
1F. Bearing Nut
1G. Setscrew
1H. Stud
1K. Retaining Ring
1L. Spring

1M. Thrust Washer
1Q. Seal Boot
2. Thrust Spacer
3A. Carrier
3B. Thrust Washer
3C. Needle Bearing
3E. Planet Shaft
3F. Planet Gear
4B. Thrust Washer

4C. Needle Bearing
4D. Thrust Spacer
4E. Planet Shaft
4F. Planet Gear
4G. Roll Pin
4H. Thrust Washer
5. Retaining Ring
6A. Cover
6B. Disengage Cap

6C. Bolt
6D. Dowel Pin
6E. O-Ring
6F. Pipe Plug
6G. Retaining Ring
7. Coupling
8A. Brake Piston
8B. Pressure Plate
8C. Retaining Ring

8D. O-Ring
8E. Backup Ring
8F. O-Ring
8H. Backup Ring
8J. Brake Rotor
8K. Brake Stator
8L. Spring
9. Input Shaft
10. Sun Gear

11. Sun Gear
12. Plastic Plug
15. ID Plate
16. Drive Screw
17. O-Ring
18. O-Ring
19. Bolt
20. Retaining Ring
21. O-Ring Plug

Figure 3-15. Hub Assembly

3-14

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-16. Bearing Cup Pressing Tool

Figure 3-17. Seal Pressing Tool

3121298

– JLG Lift –

3-15

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-18. Bearing Cup Pressing Tool

Figure 3-19. Drift Pin for Lining Up Thrust Washers with Output Planet Gear

3-16

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

3.3 FREE WHEELING OPTION

3.4 DRIVE MOTOR

Disengage Drive Motors & Brakes for Towing, etc.
(Free Wheel)

Description

1.

Chock wheels securely if not on flat level surface.

2.

Disconnect both drive hubs by inverting disconnect
caps in center of hubs.

3.

If equipped, move steer/tow selector valve to float (tow)
position by pulling valve knob out.

Engage Drive Motors & Brakes (Normal Operation)
1.

If equipped, move steer/tow valve to steer position by
pushing valve knob in.

2.

Connect both drive hubs by inverting disconnect cap in
center of hub.

3.

Drive motors are low to medium power, two-position axial piston motors incorporating an integral servo piston. They are
designed for operation in open and closed circuit applications.
The standard control is a direct acting single line hydraulic
control. The integral servo piston controls motor displacement.
Motors are spring biased to maximum displacement and
hydraulically shifted to minimum displacement. Minimum and
maximum displacement can be set with fixed internal stops.
The large diameter servo piston allows smooth acceleration
and deceleration with relatively large circuit orificing.

1

2

Remove chocks from wheels as required.
12

3

11
4
DISCONNECT
CAP

10
5
DRIVE
HUB

Drive Hub Engaged

9

1.
2.
3.
4.

DISCONNECT CAP
(REVERSED)

DRIVE
HUB

Bias Spring
Servo Piston
Swashplate
Output Shaft

8

5.
6.
7.
8.

Shaft Seal
Bearing
Slipper
Piston

6

7

9.
10.
11.
12.

Valve Plate
End Cap
Cylinder Block
Minimum Angle Stop

Figure 3-21. Drive Motor Cross Section

Drive Hub Disengaged

Figure 3-20. Disengaging Drive Hubs

3121298

– JLG Lift –

3-17

SECTION 3 - CHASSIS & TURNTABLE

INSPECTION

Shaft Seal Replacement

Inspect new seal, motor housing seal bore, and sealing area on
shaft for rust, wear, and contamination. Polish shaft and clean
housing if necessary.

REMOVAL
1.

Remove snap ring (1) retaining shaft seal, and support
washer.

1

2

INSTALLATION
1.

Cover shaft splines with an installation sleeve to protect
shaft seal during installation.

2.

Install new shaft seal with cupped side facing motor.
Press seal into housing until it bottoms out. Press evenly
to avoid binding and damaging the seal.

3.

Install seal support washer.

4.

Install snap ring.

5.

Remove installation sleeve.

3

1.
2.
3.

Snap Ring
Support Washer
Shaft Seal

Figure 3-22. Removing Shaft Seal
2.

Remove support washer (2).

3.

Carefully pry out shaft seal (3).

NOTE: To avoid damaging shaft during removal, install a large
sheet metal screw in chuck of a slide hammer. Drive screw
in seal surface and use slide hammer to pull seal.
4.

3-18

Discard seal.

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

INSPECTION

Loop Flushing Valve

Inspect new O-rings and the sealing area for rust, wear, or contamination. Check springs and poppet for wear.

REMOVAL
1.

Using a 11/16 in internal hex wrench remove plug (1)
and (2).

INSTALLATION

6
9
11

2
11/16 in
27 ft-lb
(37 Nm)

12

10
8
4
1

11/16 in
27 ft-lb
(37 Nm)

1.

Install orifice poppet (13).

2.

Install shift spool (12).

3.

Install spring retaining washers on springs (10 and 11).

4.

Carefully install centering springs (7, 8, and 9).

5.

Install new O-rings (6, 4, and 5).

6.

Using a 1/4 in hex wrench torque plug (3) to 20 ft. lbs.
(27 Nm).

7.

Using a 11/16 in internal hex, torque plugs (2 and 1) to
27 ft.lbs. (37 Nm).

13
7

5

1.
2.
3.
4.
5.

Plug
Plug
Plug
O-ring
O-ring

3

6.
7.
8.
9.
10.

5/8 in
20 ft-lb (27 Nm)

O-ring
Spring
Spring
Spring
Washer

11. Washer
12. Shift Spool
13. Orifice Poppet

Figure 3-23. Loop Flushing Spool
2.

Using a 1/4 in hex wrench remove plug (3).

3.

Remove O-rings (4, 5, and 6).

4.

Using pliers, remove centering springs (7, 8, and 9).

5.

Remove spring retaining washers (10 and 11).

6.

Remove shift spool (12).

7.

Remove orifice poppet (13).

3121298

– JLG Lift –

3-19

SECTION 3 - CHASSIS & TURNTABLE

Troubleshooting
Table 3-3. Excessive Noise and/or Vibration
Item

Description

Action

Check oil level in reservoir and oil
supply to motor.

Insufficient hydraulic fluid could lead to cavitation that would cause system noise.

Fill reservoir to proper level. Ensure oil supply to motor is adequate and
lines are unobstructed.

Check for air in system.

Air trapped in system lines or motor could result in cavitation that would
cause system noise.

Ensure all system lines and components are purged of air.

Inspect output shaft couplings.

A loose or incorrect shaft coupling will produce vibrations that could result Ensure correct coupling is used and that it fits properly on shaft.
in system noise.

Inspect output shaft alignment.

Misaligned shafts create excessive frictional vibration that could result in
system noise.

Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation that would lead
to system noise.

Ensure shafts are properly aligned.
Replace hydraulic oil with appropriate fluid for operating conditions.

Table 3-4. System Operating Hot
Item

Description

Action

Check oil level in reservoir and oil
supply to pump.

Insufficient amount of hydraulic fluid will not meet system cooling
demands.

Fill reservoir to proper level.

Inspect heat exchanger, (if
equipped).

If heat exchanger fails, or becomes obstructed, it may not meet system
cooling demands.

Ensure heat exchanger is receiving adequate air flow and is in good operating condition. Repair or replace as necessary.

Check system relief valves.

If a system relief valve becomes unseated for an extended period of time or Repair or replace any malfunctioning relief valves as applicable and verify
fails for any other reason, system could become overheated.
loads on machine are not excessive.

Table 3-5. Won’t Shift or Slow to Start
Item
Check signal line to servo control
port.

Description

Action

Obstructed or restricted flow through servo control signal lines could
result in slow shift or no shift motor conditions.

Check correct supply and drain ori- Supply and drain orifices determine motor shift. The smaller the orifice,
fices are properly installed and not the longer the time it takes to shift the motor. Obstruction also increases
obstructed.
shift times.

3-20

– JLG Lift –

Ensure signal lines are not obstructed or restricted and signal pressure is
adequate to shift motor.
Ensure proper control orifices are installed in motor and not obstructed.
Clean or replace as necessary.

3121298

SECTION 3 - CHASSIS & TURNTABLE

Disassembly
NOTE: Removal of endcap voids warranty.



19

During assembly, coat all moving parts with a film of clean
hydraulic oil. This ensures parts will be lubricated during
start-up.

17



Replace all O-Rings and gaskets.

15



It is recommended that all O-rings be replaced. Lightly
lubricate all O-rings with clean petroleum jelly prior to
assembly.

14

6

21

9
11

5
7

2

13

18

3

12

10
8
4

16
16

1
20

14.
15.
16.
17.
1.
2.
3.
4.

Plug
Plug
Plug
O-ring

5.
6.
7.
8.

O-ring
O-ring
Spring
Spring

9. Spring
10. Washer
11. Washer

12. Shift Spool
13. Orifice Poppet

Using a 11/16 in wrench remove plug (1) and (2).

2.

Using a 5/8 in hex wrench remove plug (3).

3.

Remove O-rings (4, 5, and 6).

4.

Using pliers, remove centering springs (7, 8, and 9).

5.

Remove spring retaining washers (10 and 11).

6.

Remove shift spool (12).

7.

Remove orifice poppet (13).

3121298

18.
19.
20.
21.

Cavity Plug
Drain Plug
Drain Plug
Work Port Plug

Figure 3-25. Plugs, Fittings, and Speed Sensor
8.

Remove all fittings from unit. Discard any O-rings on fittings.

9.

Using an 11/16 inch hex wrench, loosen speed sensor
lock nut (14) if equipped. Remove speed sensor using a
Vi inch hex wrench. Units without speed sensor have an
O-ring plug (15) installed in that location; remove it with
a Va inch internal hex wrench.

10.

Using a 1/4 inch internal hex wrench, remove control
line plugs (16, 17). Discard O-rings. Using a 3 mm hex
wrench, remove cavity plug (18, if equipped with twoline control) from X2 cavity.

11.

Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.

12.

Using a 9/16 inch internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard Orings.

Figure 3-24. Loop Flushing Spool
1.

Lock Nut
O-ring Plug
Control Line Plug
Control Line Plug

– JLG Lift –

3-21

SECTION 3 - CHASSIS & TURNTABLE

25

22

27

30

29
29

23

26
28

24

25. Valve Plate
26. End Cap
27. O-ring
22. Screw
23. End Cap
24. O-ring

28. O-ring
29. Angle Stop
30. Servo Spring

Figure 3-27. Valve Plate & Rear Shaft Bearing

Figure 3-26. End Cap
13.

Using an 8 mm internal hex wrench, remove endcap
screws (22).

14.

Remove endcap (23). Remove O-ring (24) from housing
or endcap. When endcap screws are removed, pressure
from servo spring will cause endcap to bind on shaft.
Press down on portion of endcap covering servo piston
and hold endcap level while removing.

3-22

DO NOT SCRATCH VALVE PLATE SURFACE. DO NOT DRIVE BEARING PAST REAR
SHAFT JOURNAL. BEARING MAY BECOME TRAPPED ON SHAFT AND DAMAGED.

– JLG Lift –

15.

Remove valve plate (25) and timing pin (26) from endcap. Each displacement has a unique valve plate. For
identification, the last two digits of the valve plate part
number are stamped on its surface.

16.

Remove and discard O-rings (27, 28).

17.

Remove rear shaft bearing (29) from endcap with a bearing puller. Bearing may be difficult to remove with a
puller. Try this as an alternative: Pack bearing cavity with
heavy grease. After shaft is removed, insert it into bearing cavity and tap splined end lightly with a soft mallet.
Grease will force the bearing out. Remove minimum
angle stop (29) and servo spring (30) from housing.

3121298

SECTION 3 - CHASSIS & TURNTABLE

34

33

32

31

32. Snap Ring
33. Support Washer
34. Shaft Seal

31. Cylinder Kit Assembly
Figure 3-28. Cylinder Kit
18.

Turn housing on its side and remove cylinder kit assembly (31). Set assembly aside. Do not to scratch running
surface.

NOTE: Grooves on surface of cylinder kit identify its displacement:

Figure 3-29. Shaft Seal

TO AVOID DAMAGING SHAFT DURING SEAL REMOVAL, INSTALL A LARGE
SHEET METAL SCREW IN CHUCK OF SLIDE HAMMER. DRIVE SCREW INTO SEAL
SURFACE AND USE SLIDE HAMMER TO PULL SEAL.

Table 3-6. Displacement Identifiers

3121298

# of Grooves

Frame L

Frame K

1

25

38

2

30

45

3

35

--

1.

– JLG Lift –

Turn housing over and remove snap ring (32) retaining
shaft seal and support washer. Remove support washer
(33) and carefully pry out shaft seal (34). Discard seal.

3-23

SECTION 3 - CHASSIS & TURNTABLE

.

Lift Here
39

36
35
37

38

40
43
42

41

35. Inner Snap Ring
36. Snap Ring

37. Bearing
38. Shaft

Figure 3-30. Shaft & Front Bearing
2. Remove inner snap ring (35) and shaft/bearing assembly.
3.

Remove snap-ring (36) retaining shaft front bearing. Pull
bearing (37) off shaft (38).

39. Swashplate
40. Servo Piston
41. Piston Seal

42. O-ring
43. Journal Bearings

Figure 3-31. Swash Plate & Servo Piston

3-24

– JLG Lift –

4.

Turn housing over and remove swashplate (39) by lifting
on end opposite servo lever.

5.

Remove servo piston (40). Remove piston seal (41) and
O-ring (42) from servo piston. Discard seal and O-ring.

6.

Remove journal bearings (43) from housing. Note location and orientation of each bearing for reassembly.

3121298

SECTION 3 - CHASSIS & TURNTABLE

9.

44

Turn block over. Using a press, apply pressure on block
spring washer (50) to compress block spring. Compress
spring enough to safely remove spiral retaining ring
(51). While maintaining pressure, unwind spiral retaining
ring (51). Carefully release pressure and remove outer
block spring washer (50), block spring (52), and inner
block spring washer (53) from cylinder block.

45

Inspection
After disassembly, wash all parts (including end-cap and housing) thoroughly with clean solvent and allow to air dry. Blow
out oil passages in housing and endcap with compressed air.
Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or
resurfacing.

47

48

53

49

PISTON

52

Inspect pistons for damage and discoloration. Discolored pistons may indicate excessive heat; do not reuse.

50

46

51

Slipper

Maximum End Play

44.
45.
46.
47.
48.

Piston
Slipper Retainer
Cylinder Block
Ball Guide
Holddown Pins

49.
50.
51.
52.
53.

Retaining Ring
Block Spring Washer
Spiral Retaining Ring
Block Spring
Inner Block Spring Washer

Minimum Slipper Foot Thickness

SLIPPERS

Figure 3-32. Cylinder Kit Disassembly
7.

Remove pistons (44) and slipper retainer (45) from cylinder block (46).

Inspect slipper running surfaces. Replace piston assemblies
with scored or excessively rounded slipper edges. Measure
slipper foot thickness. Replace piston assemblies with excessively worn slippers. Check slipper axial end-play. Replace piston assemblies with excessive end-play.

NOTE: Pistons are not selectively fitted. However, units with high
hourly usage may develop wear patterns. Number pistons
and bores for reassembly if they are to be reused.
8.

Remove ball guide (47), hold-down pins (48), and retaining ring (49) from cylinder block.

Table 3-7. Slipper Foot Thickness & End Play
Measurement
Slipper Foot Thickness
Piston/Slipper End Play

L Frame

K Frame

2.71 mm (0.11 in.)

4.07 mm (0.16 in.)

0.15 mm (0.006 in.)

NOTE: Most repairs do not require block spring removal. Perform
this procedure only if you suspect problems with the block
spring.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES
FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS
SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED.

3121298

– JLG Lift –

3-25

SECTION 3 - CHASSIS & TURNTABLE

CYLINDER BLOCK
Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface.
Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing
will not reduce block height below minimum specification. Table 3-8, Cylinder Block Measurements.
Table 3-8. Cylinder Block Measurements
Measurement
Minimum Cylinder Block Height (A)
Cylinder Block Surface Flatness

L25

L30

L35

K38

K45

50.8 (2.00)

50.8 (2.00)

50.8 (2.00)

54.4 (2.14)

54.4 (2.14)

0.002 (0.0000079)

0.002 (0.0000079)

0.002 (0.0000079)

0.002 (0.0000079)

0.002 (0.0000079)

A

BALL GUIDE AND SLIPPER RETAINER

SWASHPLATE AND JOURNAL BEARINGS

Inspect ball guide and slipper retainer for damage, discoloration, or excessive wear. A discolored ball guide or slipper
retainer indicates excessive heat. Do not reuse.

Inspect running face, servo ball-joint, and swashplate journal
surfaces for damage or excessive wear. Some material transfer
may appear on these surfaces and is acceptable if surface condition meets specifications shown. Measure swashplate thickness from journals running face. Replace swashplate if
damaged or worn beyond minimum specification. Replace
swashplate if difference in thickness from one side to the other
exceeds specification.

Slipper Retainer

Ball Guide

VALVE PLATE
0.0025 mm
(0.0001 in)

Valve Plate condition is critical to efficiency of the motor.
Inspect valve plate surfaces carefully for excessive wear,
grooves, or scratches. Replace or resurface grooved or
scratched valve plates. Measure valve plate thickness and
replace if worn beyond minimum specification. Valve plates
may be resurfaced, provided resurfacing will not reduce thickness below minimum specification.

LV

25.8 mm
24.6 mm

KV (0.969 in)

3.83 mm (0.151 in) Min

Thickness equality side to side:
0.05 mm (0.002 in)

0.025 mm
(0.001 in)

0.0076 mm
(0.00030 in)
Convex Max

Inspect journal bearings for damage or excessive wear.
Replace journal bearings if scratched, warped, or excessively
worn. Polymer wear layer must be smooth and intact.

3-26

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

SHAFT BEARINGS

Assembly

Inspect bearings for excessive wear or contamination. Rotate
bearings while feeling for uneven movement. Bearings should
spin smoothly and freely. Replace bearings that appear worn
or do not rotate smoothly.

1.

Install new O-ring (1) and piston seal (2) to servo piston
(3). Install piston seal over O-ring.

NOTE: Installing piston seal stretches it, making it difficult to
install servo piston in its bore. Allow 30 minutes for seal to
relax after installation. To speed up seal relaxation, compress seal by installing piston head in end-cap servo cavity
and let it stand for at least five minutes.

3

SHAFT
Inspect motor shaft for damage or excessive wear on output
and block splines. Inspect bearing surfaces and sealing surface. Replace shafts with damaged or excessively worn splines,
bearing surfaces, or sealing surfaces.
2

SERVO PISTON AND MINIMUM ANGLE STOP
Inspect minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. Replace as
required.

1

1.
2.
3.

LOOP FLUSHING SPOOL
Inspect loop flushing spool for cracks or damage. Replace as
required.

– JLG Lift –

O-ring
Piston Seal
Servo Piston

Figure 3-33. Servo Piston
2.

3121298

3

After piston seal has relaxed, lubricate and install servo
piston in housing bore. Align piston with ball socket facing inside of housing.

3-27

SECTION 3 - CHASSIS & TURNTABLE

6.
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES
ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS
SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING.
RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS INSTALLED.
3.

Install journal bearings (13) in housing seats. Use assembly grease to keep bearings seated during assembly.
Ensure locating nubs drop into seat cavities. If reusing
bearings, install in original location and orientation.
Lubricate journal bearings.

14

Install inner block spring washer (4), block spring (5), and
outer washer (6) in cylinder block (6A). Using a press,
compress block spring enough to expose retaining ring
groove. Wind spiral retaining ring (7) in cylinder block
groove.

13

11

13
12

10

9

4

8

13. Journal Bearings
14. Swash Plate
5

Figure 3-34. Swash Plate and Journal Bearing
7.

6

6A

7

4.
5.
6.
6A.
7.

Block Spring Washer
Block Spring
Outer Washer
Cylinder Block
Spiral Retaining Ring

8.
9.
10.
11.
12.

Retaining Ring
Holddown Pins
Ball Guide
Piston
Slipper Retainer

4.

Turn block over and install retaining ring (8), hold-down
pins (9), and ball guide (10) to cylinder block.

5.

Install pistons (11) to slipper retainer (12). Install piston/
retainer assembly in cylinder block. Ensure concave surface of retainer seats on ball guide. If reusing pistons,
install them in original block bores. Lubricate pistons,
slippers, retainer, and ball guide before assembly. Set
cylinder kit aside on a clean surface until needed.

3-28

Install swashplate (14) in housing. Tilt swashplate and
guide servo lever ball into its socket in the servo piston
rod. Ensure swashplate seats into journal bearings and
moves freely. Lubricate running surface of swashplate.

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

8.

Press front shaft bearing (15) on shaft (16). Press bearing
on shaft with lettering facing out. Lubricate bearing rollers. Install snap-ring (17) on shaft.

11.

Lubricate and install servo spring (20) and minimum
angle stop (21) in housing bore.

21

20
15

16

17
18

15. Front Shaft Bearing
16. Shaft

17. Snap Ring
18. Snap Ring

Figure 3-35. Shaft and Front Bearing
9.

While holding swashplate in place, turn housing on its
side. Install the install shaft/bearing assembly into housing from flange end. Install snap-ring (18).

10.

Verify swashplate and bearings are properly seated.
Install cylinder kit (19) on shaft. Install with slippers facing swashplate. Rock the shaft to align block splines and
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate,
journal bearings, and servo piston are properly installed.
19

20. Servo Spring
21. Minimum Angle Stop
Figure 3-37. Servo Spring and Minimum Angle Stop

19. Cylinder Kit
Figure 3-36. Cylinder Kit Installation

3121298

– JLG Lift –

3-29

SECTION 3 - CHASSIS & TURNTABLE

12.

Press rear shaft bearing (22) in endcap. Install bearing
with letters facing out. Press until bearing surface is 0.08
±0.01 in (2 ±0.25 mm) above endcap surface.

0.08 in

22

23

15.

Install endcap (25) on housing with endcap screws (26).
Ensure endcap will properly seat to housing without
interference. Improper assembly of internal components
may prevent endcap from seating properly. Ensure Orings seat properly when installing endcap.

0.12 in
(3 mm)

26
8 mm
35-45 ft-lbs
(47-61 Nm)

23
22
24

25

23

22. Rear Shaft Bearing
23. Timing Pin
24. Valve Plate
Figure 3-38. Valve Plate and Rear Bearing
13.

14.

3-30

25. End Cap
26. Screw

Install timing pin (23) into its bore in the endcap. Install
pin with groove facing toward or away from shaft. Press
pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm)
above endcap surface.

16.

Install valve plate (24) on endcap. Install valve plate with
yellow surface toward cylinder block. Align slot in valve
plate with timing pin. Apply a liberal coat of assembly
grease to endcap side of valve plate to keep it in place
during installation.

Using an 8 mm internal hex wrench, tighten endcap
screws. Tighten screws in opposite corners slowly and
evenly to compress the servo spring and properly seat
the endcap. Torque endcap screws 35-45 ft-lb (47-61
Nm).

17.

Before installing shaft seal, ensure shaft turns smoothly
with less than 120 in-lb (13.5 Nm) of force. If shaft does
not turn smoothly within specified maximum force, disassemble and check unit.

– JLG Lift –

Figure 3-39. End Cap

3121298

SECTION 3 - CHASSIS & TURNTABLE

18.

Cover shaft splines with an installation sleeve. Install a
new shaft seal (27) with cup side facing motor. Press seal
in housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer
(28) and snap ring (29).

20.

Install orifice poppet (30).

39

37
36
33
34

30

40

27

28

5/8 in
20 ft-lb
(27 Nm)

29

32
35
38

41
11/16 in
27 ft-lb
(37 Nm)

31

42
11/16 in
27 ft-lb
(37 Nm)

27. Shaft Seal
28. Seal Support Washer
29. Snap Ring

30.
31.
32.
33.

Figure 3-40. Shaft Seal
19.

Install remaining plugs and fittings to housing. Refer to
drawing below for wrench sizes and installation torques.
5/16 in
63 ft-lb (85 Nm)
1/4 in
33 ft-lb (45 Nm)

Orifice Poppet
Shift Spool
Spring
Spring

34. Spring
35. Spring
36. Spring

37. O-ring
38. O-ring
39. O-ring

40. Plug
41. Plug
42. Plug

Figure 3-42. Loop Flushing Spool
21.

Install shift spool (31).

22.

Install spring retaining washers on springs (32 and 33).

23.

Carefully install centering springs (34, 35, and 36).

24.

Install new O-rings (37, 38, and 39).

25.

Using a 5/8 in wrench torque plug (40) to 20 ft-lb (27
Nm).

26.

Using a 11/16 in wrench, torque plugs (41 and 42) to 27
ft-lb (37 Nm).

9/16 in
125 ft-lb
(170 Nm)

3 mm
1.5 - 2.5 ft-lb
(2 - 3 Nm)

1/4 in
33 ft-lb (45 Nm)
5/16 in
63 ft-lb (85 Nm)

Figure 3-41. Plugs and Fittings Installation

3121298

– JLG Lift –

3-31

SECTION 3 - CHASSIS & TURNTABLE

Initial Start-up Procedures
Follow this procedure when starting-up a new motor or when
installing a motor that has been removed.
Prior to installing the motor, inspect for damage incurred during shipping. Make certain all system components (reservoir,
hoses, valves, fittings, heat exchanger, etc.) are clean prior to
filling with fluid.
1.

Fill reservoir with recommended hydraulic fluid. Always
filter fluid through a 10 micron filter when pouring into
the reservoir. Never reuse hydraulic fluid.

2.

Fill inlet line leading from pump to reservoir. Check inlet
line for properly tightened fittings and be certain it is
free of restrictions and air leaks.

3.

Fill pump and motor housing with clean hydraulic fluid.
Pour filtered oil directly in upper most case drain port.

4.

To ensure pump and motor stay filled with oil, install
case drain lines in upper most case drain ports.

5.

Install a 0 to 500 psi (0 to 35 bar) gauge in charge pressure gauge port of pump to monitor system pressure
during start up.

6.

Watching pressure gauge and run engine at lowest possible speed until system pressure builds to normal levels
(minimum 160 psi [11 bar]). Once system pressure is
established, increase to full operating speed. If system
pressure is not maintained, shut down engine, determine cause, and take corrective action.

7.

Operate hydraulic system for at least fifteen minutes
under light load conditions.

8.

Check and adjust control settings as necessary after
installation.

9.

Shut down engine and remove pressure gauge. Replace
plug at charge pressure gauge port.

10.

Check fluid level in reservoir. Add clean filtered fluid if
necessary. Motor is now ready for operation.

3.5 OSCILLATING AXLE BLEED PROCEDURE AND
LOCKOUT TEST
Lockout Cylinder Bleeding
ENSURE MACHINE IS ON A LEVEL SURFACE, REAR WHEELS ARE BLOCKED, AND
BRAKE WIRE IS DISCONNECTED. ENSURE PLATFORM IS FULLY LOWERED AND
BOOM IS CENTERED OVER REAR AXLE BEFORE STARTING BLEED PROCEDURE.
1.

Park machine on a level surface and block rear wheels.

2.

Center boom over rear axle to make sure oscillation
valve in rotary coupling is activated.

3.

Place suitable container under flow divider mounted on
inside of frame to catch hydraulic fluid.

4.

Remove Port 11 tee fitting from flow divider. Cap fitting
and plug hose.

5.

Place suitable containers under each lockout cylinder to
catch hydraulic fluid.

6.

Have helper start engine from platform. Turn function
control knob speed fully counter-clockwise to Turtle
position to set drive creep mode. Activate Low Drive In
Reverse creep mode.

7.

Open bleeder screw on one lockout cylinder.

NOTE: Open bleeder valve enough to get a fast stream of oil. A fast
stream of oil will exhaust air from hose and lockout cylinder better than a slow stream.

Figure 3-43. Bleeder Valve Location

3-32

– JLG Lift –

8.

Close bleeder valve when no more air in hydraulic oil.

9.

Repeat on opposite lockout cylinder.

10.

Shut down engine.

11.

Reconnect hose and tee fitting to Port 11 on flow
divider.

3121298

SECTION 3 - CHASSIS & TURNTABLE

15.

Oscillating Axle Lockout Test

If lockout cylinders do not function properly, have qualified personnel correct malfunction before further operation.

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
SUSPECTED.

3.6 STEER ADJUSTMENTS

NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels before starting lockout cylinder test.

NOTE: 2 Wheel Steering/2 Wheel Drive: Spindles do not stop on
cylinder stroke. Adjust steering stops as follows: Adjust item
#1 to achieve 44° inside turn angles. Steer full left and
adjust RH item #2 to contact axle. Steer full right and adjust
LH item #2 to contact axle. 

1.

Place a 6 inch (15.2 cm) high block with ascension ramp
in front of left front wheel.

2.

From platform control station, activate machine hydraulic system.

3.

Place FUNCTION SPEED CONTROL and DRIVE SPEED/
TORQUE SELECT control switches to their respective
LOW positions.

4.

Place DRIVE control lever to FORWARD position and
carefully drive machine up ascension ramp until left
front wheel is on top of block.

5.

Carefully activate SWING control lever and position
boom over right side of machine.

6.

With boom over right side of machine, place DRIVE control lever to REVERSE. Drive machine off block and ramp.

7.

Have an assistant check if left front wheel remains
locked in position off of ground.

8.

Carefully activate SWING control lever and return boom
to stowed position (centered between drive wheels).
When boom reaches center, stowed position, lockout
cylinders should release and allow wheel to rest on
ground. It may be necessary activate DRIVE to release
cylinders.

9.

Place 6 inch (15.2 cm) high block with ascension ramp in
front of right front wheel.

10.

Place DRIVE control lever to FORWARD and carefully
drive machine up ascension ramp until right front wheel
is on top of block.

11.

Carefully activate SWING control lever and position
boom over left side of machine.

12.

With boom over left side of machine, place DRIVE control lever to REVERSE. Drive machine off block and ramp.

13.

Have an assistant check if right front wheel remains
locked in position off of ground.

14.

Carefully activate SWING control lever and return boom
to stowed position (centered between drive wheels).
When boom reaches center, stowed position, lockout
cylinders should release and allow wheel to rest on
ground. It may be necessary activate DRIVE to release
cylinders.

3121298

– JLG Lift –



2 Wheel Steering/Four Wheel Drive: Spindles do not stop
on cylinder stroke. Adjust steering stops as follows: Adjust
item #1 to achieve 39° inside turn angles. Steer full left and
adjust RH item #2 to contact axle. Steer full right and adjust
LH item #2 to contact axle.

Figure 3-44. Steer Adjustments

3-33

SECTION 3 - CHASSIS & TURNTABLE

3.7 SWING DRIVE

20
12

2

6
1I
1H
5A

1E
4
13
5
1G
11

1J
3

1C

11
44

8

1A

1A. Output Shaft
1B. Lip Seal
1C. Bearing
1E. Bearing

1G. Housing
1H. Thrust Washer
1I. Retaining Ring
1J. Pipe Plug

2. Internal Gear
3. Carrier Assembly
4. Ring Gear
5. O-Ring

5A. O-Ring
6. Brake Housing
8. Sun Gear
11. Thrust Washer

12. Bolt
13. Dowel Pin
20. Pipe Plug
44. Internal Retaining Ring

Figure 3-45. Swing Drive Assembly

3-34

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

101

102
104

105

103
106
104
107
104
108
104

8K

109
110

8K

104
8K

112

29
28

23

32

113
115
114
116
125
117

8K
118

8K
29
6

28
22
21
30
35

6. Brake Housing
8A. Piston
8D. O-Ring
8E.Back-Up Ring
8F. O-Ring
8H. Back-up Ring
8J. Rotor Disc
8K. Stator Disc

8L. Spring
21. Bolt
22. Lockwasher
23. Pipe Plug
26. O-Ring
28. Lifting Lug
29. Bolt
30. Elbow

35. Tube
101. Bolt
102. End Cover
103. Commutator Seal
104. Ring Seal
105. Commutator and Ring Assy
106. Ring
107. Manifold

108. Rotor Set
109. Wear Plate
110. Drive Link
112. Coupling Shaft
113. Inner Bearing
114. Thrust Washer
115. Thrust Bearing
116. Inner Seal

117. Back-up Washer
118. Housing
119. Outer Bearing
120. Seal
125. Back-up Washer

Figure 3-46. Swing Motor and Brake Assembly

3121298

– JLG Lift –

3-35

SECTION 3 - CHASSIS & TURNTABLE

Gear Backlash
Set backlash to .010 - .015 in (0.254 to 0.381mm).
1.

Insert shim (JLG P/N 4071009) between pinion and bearing on the bearing high spot. The bearing high spot
should be stamped with an "X" on the surface below the
teeth and marked with yellow paint in the tooth space.

5.

Loosen jam nut.

6.

Tighten jack bolt until pinion is snug against shim and
bearing, then loosen jack bolt.

7.

Apply JLG Thread locking compound P/N 0100019 to
jack bolt threads. Torque jack bolt to 50 ft-lb (68 Nm).

8.

Tighten jam nut.

9.

Torque four mounting bolts to 340 ft-lb (461 Nm).

Shim

Jam Nut
Jack Bolt

Figure 3-47. Swing Drive Shim Placement
2.

Apply JLG Thread locking compound P/N 0100019 to
pivot bolt. Torque pivot bolt to 205 ft-lb (280 Nm).

3.

Remove turntable lock pin.

4.

Apply JLG Thread locking compound P/N 0100019 to
four mounting bolts. Torque mounting bolts to 30 ft-lb
(40 Nm).

Mounting Bolt

Figure 3-49. Swing Drive Jam Nut and Mounting Bolt
10.

Remove and discard swing drive shim.

Swing Drive Lubrication
Fill Swing Drive Gearbox with 43 oz (1.27L) 90w80 gear oil with
EP additives. Oil should cover the ring gear. Torque pipe plug
23 - 24 ft-lb (31 - 32.5 Nm).

Fill Plug

Pivot Bolt

Mounting Bolt

Figure 3-48. Swing Drive Pivot and Mounting Bolts

Drain Plug

Figure 3-50. Swing Drive Lubrication

3-36

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Motor Control Valve Disassembly

Motor and Brake Disassembly

1.

Place unit on bench with motor end up.

2.

Remove Drain Plug (1P) and drain oil from gearbox.

3.

Remove Hydraulic Tubing Assembly (35).

4.

Loosen jam nuts on Elbow Fittings (30). Remove fittings
from Brake (6) and Motor Control Valve (32).

5.

Remove O-ring Plugs (23) from Motor Control Valve (32).

6.

Remove four bolts (21), washers (22), and Motor Control
Valve (32) from Motor (31).

7.

Reinstall Drain Plug (1P). Torque to 23 - 24 ft-lb (31 - 32.5
Nm).

1.

With unit resting on bench with Motor (31) end up,
remove Hex Bolts (29) and Lift Lugs (28) from Motor (31).

2.

Pull Motor (31) straight up and remove Motor (31) from
Brake Housing (6).

3.

Remove O-ring (26) between Motor (31) and Brake
Housing (6).

4.

Remove Springs (8L) from piston.

PISTON (8A) MAY MOVE QUICKLY. WEAR EYE PROTECTION.
5.

Apply less than 50 psi air to brake port to remove Brake
Piston (8A).

6.

Remove Rotors (8J) and Stators (8K) from Brake Housing
(6).

32
31
23
22
21
6

1P
6
8K

35

8J 8K
8J 8K
8J 8K
8J 8K

Figure 3-51. Main Control Valve Disassembly

8A

28
8L

29

26
31

Figure 3-52. Motor and Brake Disassembly

3121298

– JLG Lift –

3-37

SECTION 3 - CHASSIS & TURNTABLE

Main Disassembly

Hub-Shaft Disassembly

1.

Remove Sun Gear (8) with Retaining Ring (44) inside.

2.

With unit resting on Output Shaft (Pinion) (1A), remove
Bolts (12) from Brake Housing (6).

3.

Remove Brake Housing (6) from main assembly.

11.

4.

Remove O-ring (5A) from Brake Housing (6) and Ring
Gear (4).

Using retaining ring pliers, remove and discard Retaining
Ring (11) from groove in Output Shaft (1A).

12.

Remove Thrust Washer (1H).

13.

Support Housing (1G) on Output Shaft (1A) end. Press
Output Shaft (1A) out of Housing (IG).

WEAR EYE PROTECTION DURING THIS PROCEDURE.

5.

Remove Thrust Washer (11) from Brake Housing (6) and
Carrier Subassembly.

6.

Remove Ring Gear (4) from Housing (1G).

7.

Remove O-ring (5) from Ring Gear (4) and Housing (1G).

8.

Remove Carrier Subassembly.

14.

Remove Bearing Cone (IE) from Housing (IG).

9.

Remove Thrust Washer (11) between Carrier Subassembly and Internal Gear (2).

15.

Use a bearing puller to remove Bearing Cone (1D) from
Shaft (1A). Bearing Cups (1C & 1F) will remain in Housing
(1G).

10.

NOTE: Lip Seal (1B) will be pressed out of Housing (1G) by Bearing
Cone(1D) during this step.

Remove Internal Gear (2).

NOTE: If bearing replacement is necessary, Bearing Cups (1C & 1F)
can be removed with a slide hammer puller or driven out
with a punch.

44
8
20

1I
1H
1E

6

1F

11
5A

1G

4

5

1C

3F

1D

11

1B

2
13

1A

Figure 3-54. Hub-Shaft Disassembly

1A

Figure 3-53. Main Disassembly

3-38

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Carrier Disassembly
1.

Using a 3/16" punch drive Roll Pin (3G) holding Planet
Shaft (3E) in Carrier (3A) in Planet Shaft (3E) until it bottoms.

3B

3F

3G
3C

3D

3C

3B

MAKE SURE ROLL PIN HAS BOTTOMED OR CARRIER MAY BE DAMAGED WHEN
PLANET SHAFT IS REMOVED.
2.

Remove Planet Shaft (3E) from Carrier (3A). Use a small
punch to remove Roll Pin (3G) from Planet Shaft (3E).

3.

Slide Planet Gear (3F) and two Thrust Washers (3B) out
of Carrier (3A).

4.

Remove both rows of Needle Bearings (3C) and Spacer
(3D) from bore of Planet Gear (3F).

5.

Repeat Steps 1 thru 4 for remaining Cluster Gears (3F).

3E

3A
Figure 3-55. Carrier Disassembly

3121298

– JLG Lift –

3-39

SECTION 3 - CHASSIS & TURNTABLE

Hub-Shaft Subassembly
1.

Press Bearing Cup (1C) in Housing (1G). Make sure cup
starts square with bore of Hub (1G).

2.

Place Bearing Cone (1D) in Bearing Cup (1C) in Housing
(1G).

1I

3.

Apply grease to rubber portion of Seal (1B). Press or tap
Seal (1B) with smooth face up, in counterbore of Housing (1G) until it is flush with Housing (1G) face bore.

4.

Invert Hub (1G) and press Bearing Cup (1E) in counterbore of Housing (1G).

5.

Carefully lower Housing (1G) on Output Shaft (1A) until
Bearing Cone (1D) contacts Output Shaft (1A).

6.

Press on small end of Bearing Cone (1D), being careful
not to contact the bearing cage, until Bearing Cone (1D)
seats on Output Shaft (1A) shoulder.

7.

Start Bearing Cone (1F) on Output Shaft (1A).

8.

Press or tap Bearing Cone (1F) on Output Shaft (1A) until
it is just seated in Bearing Cup (1E), while rotating the
Housing (1G).

9.

1H
1E

1F

1G

1C

Install Bearing Spacer (1H) on Output Shaft (1A) against
Bearing Cone (1F).

1D
1B

RINGS UNDER TENSION CAN FLY OUT AND CAUSE SERIOUS INJURY. WEAR EYE
PROTECTION WHEN INSTALLING RINGS.
1A

NEVER REUSE A RETAINING RING IN REBUILD OR REPAIR.
10.

Install new Retaining Ring (1I) in groove of Output Shaft
(1A).

11.

Tap Retaining Ring (1I) with a soft metal punch to ensure
it is completely seated in groove of Output Shaft (1A).

3-40

– JLG Lift –

Figure 3-56. Hub-Shaft Subassembly
12.

Reinstall Drain Plug if not already installed (1P from Fig.
3-45). Torque to 23 - 24 ft-lb (31 - 32 Nm).

3121298

SECTION 3 - CHASSIS & TURNTABLE

Carrier Subassembly
1.

Apply a liberal coat of grease to bore of Cluster Gear
(3F). This holds Needle Rollers (3C) in place during
assembly.

2.

Install first row of Needle Rollers (3C) in bore of Cluster
Gear (3F).

3.
4.

Insert Spacer (3D) in bore of Cluster Gear (3F) on top of
Needle Rollers (3C).
Place second row of Needle Rollers (3C) in bore of Cluster Gear (3F) against Spacer(3D).

5.

Place Carrier (3A) with one roll pin hole straight up.

6.

Start Planet Shaft (3E) through hole in Carrier (3A). Using
ample grease to hold it in position, slide one Thrust
Washer (3B) over Planet Shaft (3E) with tang resting in
cast slot of Carrier (3A).

7.

With large end of Cluster Gear (3F) facing roll pin hole in
Carrier, place Cluster Gear in position in Carrier (3A).
Push Planet Shaft (3E) through Cluster Gear (3F) without
going all the way through.

8.

Slide second Thrust Washer (3B) between Cluster Gear
(3F) and Carrier (3A) with washer tang located in cast
slot of Carrier (3A). Finish sliding Planet Shaft (3E)
through Thrust Washer (3B) into Carrier (3A).

9.

Position non-chamfered side on Planet Shaft (3E) Roll
Pin hole in line with hole in Carrier (3A) using a 1/8 inch
diameter punch.

3121298

– JLG Lift –

10.

Use a 3/16" punch to align two roll pin holes. Drive roll
pin (3G) through Carrier (3A) and into Planet Shaft (3E)
until Roll Pin (3G) is flush with bottom of cast slot in Carrier (3A) outside diameter at Thrust Washer (3B) tang.
Use a 1/4" pin punch to make sure roll pin (3G) is flush in
slot.

11.

Repeat Steps 1 thru 10 for remaining Cluster Gears (3F).
3B

3F

3G
3C

3D

3C

3B

3E

3A
Figure 3-57. Carrier Subassembly

3-41

SECTION 3 - CHASSIS & TURNTABLE

Main Assembly
1.

With Hub Shaft Subassembly resting on Shaft (1A) install
Internal Gear (2). The spline of Internal Gear (2) bore will
mesh with spline of Output Shaft (1A). This will be a tight
fit.

2.

Inspect location of Internal Gear (2) on Output Shaft
(1A). A portion of Output Shaft (1A) should protrude
through Internal Gear (2) bore.

3.

Install 4 Dowel Pins (13) into counter bore holes in Hub
(1G).

4.

Install Thrust Washer (11) in counter bore of Carrier Subassembly (Small Cluster-Gear end) Use grease to hold in
place.

5.

SHARP EDGES OF COUNTER-BORE CAN CAUSE SERIOUS INJURY. BE CAREFUL
WHEN SEATING O-RING.

Place O-ring (5) into Hub counter-bore. Use grease to
hold O-ring in place.

11.

Install Brake Housing (6). Align Pipe Plug hole (20) with
those in the Hub (1G).

12.

Install Bolts (12) through Brake Housing (6) into Hub
(1G). Torque to 23 - 27 ft-lb (31-36 Nm).

13.

With gearbox standing on pinion end, fill gearbox with
43 oz of ISO VG150 / VG220 gear oil.

14.

Install Retaining Ring (44) in groove of Sun Gear (8).

15.

Install Sun Gear (8) into mesh with Planet Gears (3F).

16.

Install Pipe Plug (20) in Cover (6). Torque to 23 to 24 ft-lb
(31 - 32 Nm).
44
8

SHARP EDGES OF COUNTER-BORE CAN CAUSE SERIOUS INJURY. BE CAREFUL
WHEN SEATING O-RING.
6.

7.

8.

Place Carrier Subassembly on bench with large end of
Cluster Gears (3F) facing up with one at 12 o’clock position. Find punch marked tooth on each gear at large end
and locate at 12 o'clock (straight up) from each planet
pin. Marked tooth will be located just under Carrier on
upper two gears. Check timing through slots in carrier.
(See Carrier Subassembly)
With longer shoulder side of Ring Gear (4) facing down,
place Ring Gear (4) over (into mesh with) cluster gears
(3F). Be sure cluster gear timing marks (punch marks)
remain in correct location during Ring Gear (4) installation. Ring Gear (4) side with an "X" or punch mark
stamped on it should be up.
While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
with Internal Gear (2). On Ring Gear (4), locate hole
marked "X" or punch marked over one of the marked
counter-bored holes (Step 5) in Hub (1G). Check timing
through slots in carrier. Rotate carrier in assembly to
check freedom of rotation.

20

6
11
5A

4

5

3F
11
2
13

NOTE: If gears do not mesh easily or Carrier Assembly does not
rotate freely, remove Carrier and Ring Gear. Check Cluster
Gear timing.
9.
10.

3-42

Install Thrust Washer (11) in counter bore on face of carrier. Use grease to hold in place.
Place O-ring (5A) into counter bore of Brake Housing (6).
Use grease to hold O-Ring in place.

– JLG Lift –

1A

Figure 3-58. Main Assembly

3121298

SECTION 3 - CHASSIS & TURNTABLE

Motor and Brake Assembly

Motor Control Valve Assembly

1.

Insert Stator (8K) (O.D. lobes) in bore of Brake Housing
(6). Alternate Rotors (8J) (I.D. splines) and Stators, ending
with a Stator (8K).

2.

Grease O-rings (8F) & (8D) and Back-up rings (8H) & (8E).
Place them in their respective grooves in Brake Housing
(6) and Piston (8A). Make sure Back-up rings are correctly
positioned.

3.

1.

NOTE: Align holes in control valve with motor ports.

Apply grease sparingly to Piston O.D. (8A) and bore of
Brake Housing (6). Insert Piston (8A) in Brake Housing
(6). Do not damage O-rings.

4.

Install Springs (8L) in Piston (8A) spring pockets.

5.

Test brake and perform roll test. Remove Brake Test
Plate.

6.

Install O-ring (26) on pilot of Motor (31). Use grease to
keep O-ring in place.

7.

Place Motor (31) in Brake pilot and line up holes. Check
timing sheet.

8.

Assemble Lift Lugs (28) on Hex Bolts (29). Assemble Hex
Bolts (29) with Lift Lugs (28) through Motor (31) and
Brake (6) against Motor flange. Torque to 80-100 ft-lb
(108-135 Nm).

Lay assembly down with motor ports facing up. Remove
two plastic plugs in the motor ports. Do not to lose Oring in each port. Assemble Motor control Valve (32) on
Motor (31) with Bolt (21) and Lock Washers (22). Torque
Bolts (21) to 23-27 ft-lb (31-36 Nm).

2.

Install Elbow Fittings (30) in Brake (6). Do not tighten
jam nuts.

3.

Install Elbow Fittings (30) in Motor Control Valve (32). Do
not tighten jam nuts.

4.

Assemble Tube (35) in Elbow Fittings (30). Torque jam
nuts to 13-15 ft-lb (17-20 Nm).

5.

Install one O-ring Plug (23) in Motor Control Valve (32).
Torque to 30-31 ft-lb (40-42 Nm).

6.

Pressure test brake, tube, and control valve connections
by applying 3000 psi (207 bar) pressure to open port in
Motor Control Valve (32) and holding for one minute.
Check for leaks at control-valve-motor interface and
tube connections. Release pressure and install remaining O-ring Plug (23) in Motor Control Valve (32). Torque
to 30-31 ft-lb (40-42 Nm).
31

O-Ring

32
23

6

8K
8J

22
8K
8J

8K
8J

6
8K
8J

21

8K
8H

1P
Brake Port
8F

8D
8E

8A

28

8L
26

Figure 3-60. Motor Control Valve Assembly
29

31

Figure 3-59. Motor and Brake Assembly

3121298

– JLG Lift –

3-43

SECTION 3 - CHASSIS & TURNTABLE

3.8 SWING BEARING

Wear Tolerance

Turntable Bearing Mounting Bolt Condition Check
NOTE: This check is designed to replace existing bearing bolt
torque checks on JLG Lifts in service. This check must be
performed after first 50 hours of machine operation and
every 600 hours of machine operation thereafter. If any
bolts are missing or loose, replace missing or loose bolts
with new bolts and torque to value specified in torque
chart after lubricating bolt threads with loctite #271. After
replacing and retorquing bolt or bolts, recheck all bolts for
looseness.
1.

SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT. IT
IS HERE STRESSES OF LIFTING ARE CONCENTRATED, AT CENTER OF ROTATION.
BECAUSE OF THIS, PROPER MAINTENANCE OF SWING BEARING BOLTS IS A
MUST FOR SAFE OPERATION.
1.

From underside of machine, at rear center, with boom
fully elevated and fully retracted, as shown in Figure 363., Swing Bearing Tolerance Measurement Location &
Boom Placement A, using a magnetic base dial indicator,
measure and record distance between swing bearing
and turntable as shown in Figure 3-62., Swing Bearing
Tolerance Measuring Point.

2.

At the same point, with boom horizontal and fully
extended, and tower boom fully elevated as shown in Swing Bearing Tolerance Boom Placement B, using a
magnetic base dial indicator, measure and record distance between swing bearing and turntable as shown in
Figure 3-62., Swing Bearing Tolerance Measuring Point.

d. Swing turntable 90° and check some selected bolts
at new position.

3.

If difference is greater than 0.079 in. (2.00 mm), replace
swing bearing.

e. Continue rotating turntable at 90° intervals until a
sampling of bolts are checked in all quadrants.

4.

If difference is less than 0.079 in. (2.00 mm) and any of
the following conditions exist:

Check frame to bearing. Attach bolts as follows:
a. Elevate fully retracted boom to 70° (full elevation).
b. Try and insert a 0.0015" feeler gauge between bolt
head and hardened washer at position shown in Figure 3-61.
c. Make sure 0.0015" feeler gauge will not fit under
bolt head to bolt shank.

2.

Check turntable to bearing. Attach bolts as follows:

a. Metal particles in grease.

a. Elevate fully retracted boom to 70° (full elevation).

b. Increased drive power required.

b. try and insert a 0.0015" feeler gauge between bolt
head and hardened washer at positions shown in
Figure 3-61.

c. Noise.

c. Lower boom to horizontal and fully extend boom.
d. Try and insert the 0.0015" feeler gauge between bolt
head and hardened washer at position shown in Figure 3-61.

d. Rough rotation.
5.

Remove, disassemble, and inspect bearing. If bearing
inspection shows no defects, reassemble and return to
service.

   

 




 









Figure 3-62. Swing Bearing Tolerance Measuring Point
Figure 3-61. Swing Bearing Bolt Feeler Gauge Check

3-44

– JLG Lift –

3121298

3121298

– JLG Lift –
Figure 3-63. Swing Bearing Tolerance Measurement Location & Boom Placement

a. Boom fully elevated and fully retracted.

Measuring Point

b. Boom horizontal and fully extended.

Measuring Point

SECTION 3 - CHASSIS & TURNTABLE

3-45

SECTION 3 - CHASSIS & TURNTABLE

INSTALLATION

Swing Bearing Replacement

1.

REMOVAL
1.

Operate boom from Ground Control station to provide
access to frame opening or rotary coupling.

NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING.
2.

Attach an adequate support sling to boom and draw all
slack from sling. Prop or block boom if feasible.

3.

From inside turntable, remove mounting hardware
attaching rotary coupling retaining yoke brackets to
turntable.

JLG INDUSTRIES RECOMMENDS ALL REMOVED BEARING BOLTS BE DISCARDED
AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY
STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPERATIVE
SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.

CHECK TORQUE SETTING ACCURACY OF TOOL IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED TO TIGHTEN BEARING ATTACHMENT BOLTS.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM.
4.

Tag and disconnect hydraulic lines from fittings on top
of rotary coupling. Use a suitable container to retain any
residual hydraulic fluid. Immediately cap lines and ports.

5.

Attach suitable overhead lifting equipment to base of
turntable weldment.

6.

Use a suitable tool to scribe a line on swing bearing
inner race an underside of turntable. This will aid in
aligning bearing upon installation. Remove bolts and
washers which attach turntable to bearing inner race.
Discard bolts.

7.

Use lifting equipment to carefully lift complete turntable
assembly from bearing. Ensure no damage occurs to
turntable, bearing, or frame-mounted components.

8.

Carefully place turntable on a suitably supported trestle.

9.

Use a suitable tool to scribe a line on outer swing bearing race and frame. This line will aid in aligning bearing
upon installation. Remove bolts and washers which
attach outer race of bearing to frame. Discard bolts. Use
suitable lifting equipment to remove bearing from
frame, then move bearing to a clean, suitably supported
work area.

3-46

Using suitable lifting equipment, carefully lower swing
bearing in position on frame. Ensure scribed line of outer
bearing race aligns with scribed line on frame. If a new
swing bearing is used, ensure filler plug fitting is 90°
from fore and aft center line of frame.

– JLG Lift –

2.

Refer to Torque Sequence diagram as shown in Figure 364., Swing Bearing Torque Sequence. Clean residue off
new bearing bolts and apply a light coating of Thread
Locking Compound JLG P/N 0100019. Install bolts and
washers through frame and outer bearing race. Torque
bolts to 190 ft-lb (258 Nm). Remove lifting equipment
from bearing.

3.

Using suitable lifting equipment, carefully position turntable assembly above machine frame.

4.

Carefully lower turntable onto swing bearing. Ensure
scribed line of inner bearing race aligns with scribed line
on turntable. If a new swing bearing is used, ensure filler
plug fitting is 90° fore and aft center line of turntable.

5.

Clean residue off new bearing bolts and apply a light
coating of Thread Locking Compound JLG P/N 0100019.
Install bolts and washers through turntable and bearing
inner race.

3121298

SECTION 3 - CHASSIS & TURNTABLE






























































Figure 3-64. Swing Bearing Torque Sequence
6.

Following Torque Sequence diagram shown in Figure 364., Swing Bearing Torque Sequence, torque bolts to 190
ft-lb (258 Nm) w/Loctite.

Swing Bearing Torque Values
1.

Outer Race - 190 ft-lb (258 Nm) w/Loctite.

7.

Remove lifting equipment.

2.

Inner Race - 190 ft-lb (258 Nm) w/Loctite.

8.

Install rotary coupling retaining yoke brackets. Apply a
light coating of Thread Locking Compound, JLG P/N
0100011 to attaching bolts. Secure yoke to turntable
with mounting hardware.

3.

See Figure 3-64. Swing Bearing Torque Sequence.

9.

Connect hydraulic lines to rotary coupling as tagged
prior to removal.

10.

At ground control station, use boom lift control to lower
boom to stowed position.

11.

Using all applicable safety precautions, activate hydraulic system and check swing system for proper and safe
operation.

3121298

CHECK OR MISSING OR LOOSE INNER AND OUTER SWING BEARING BOLTS
AFTER FIRST 50 HOURS OF OPERATION AND EVERY 600 HOURS THEREAFTER.

– JLG Lift –

3-47

SECTION 3 - CHASSIS & TURNTABLE

3.9 ROTARY COUPLING
Use the following procedure to install the seal kit.

6.

Assemble lip seals (14) in direction shown in Figure 3-66.,
Rotary Coupling - Sheet 2 of 2.

7.

Reassemble O-ring (18).

1.

If not already removed, remove axle oscillation valve
from cylinder barrel. The valve spool protrudes into the
barrel and will damage spool and seals if left in place.

8.

Heat cap seals (17) in hydraulic oil for 5 minutes at 300° F
(149° C).

2.

Remove snap ring (12) from end.

9.

Assemble cap seals over O-rings

3.

Remove thrust ring (13) from same end.

10.

Reinsert center body in housing (lube with hydraulic oil).

4.

Remove center body (10) from housing (11).

11.

Replace thrust ring and snap ring.

5.

Cut off old seals (14,15,17,18).

5

4

1

4
6

2

3
4
3
7

4

4

4

5

5

Detail A

1. Rotary Coupling
2. Torque Lug

3. Locknut
4. Flat Washer

5. Bolt
6. Nut
7. Bracket

Figure 3-65. Rotary Coupling - Sheet 1 of 2

3-48

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

12
13

10

15
16
2

3

1

17, 18
4

5

17, 18

11

6

16
15

9

14

7
8

13

DETAIL A
12

1.
2.
3.
4.
5.

O-ring
Plug
Check Valve
Screw
Plug

6. Spring
7. Valve Block Plunger
8. Valve Block
9. O-ring
10. Body

11. Housing
12. Retaining Ring
13. Ring
14. Oil Seal
15. O-ring

16. Bearing
17. Cap Seal
18. O-ring

Figure 3-66. Rotary Coupling - Sheet 2 of 2

3121298

– JLG Lift –

3-49

SECTION 3 - CHASSIS & TURNTABLE

7

5

1,5

2
5

6

6

2

1
7
2,7

3
4

4

7

3

3

1
2
2

2
4

1

3

3
4
5

6
7

7
7

7

Figure 3-67. Rotary Coupling Port Location - 2WS

3-50

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

7

5

1,5,9
2,8
5

6

6
2

1
7

2,7

3
4

4

9

8

7

3

8

3

1
2

2

2

1

3

3
4

4

5
6

7

7

7
8

7
8

9

Figure 3-68. Rotary Coupling Port Location - 4WS

3121298

– JLG Lift –

3-51

SECTION 3 - CHASSIS & TURNTABLE

Table 3-9. Coupling Port Information Table - 2WS

3.10 GENERATOR

Port
No.

Outlet

Port
Size

Description

Operating
Pressure
PSI (Bar)

Proof
Pressure
PSI (Bar)

1

1

-8

Brake

450 (31)

675 (47)

2

2

-6

2 Speed

4500 (310)

6750 (465)

3

1

-6

Steer

2500 (172)

3750 (259)

4

1

-6

Steer

2500 (172)

3750 (259)

5

2

-6, -16

Drive Reverse

4500 (310)

6750 (465)

6

1

-16

Drive Forward

4500 (310)

6750 (465)

7

3

-8, -6

Case Drain

250 (17)

375 (26)

Every 250 hours
Check drive belt tension every 250 hours of operation,.

1/2 in.
(13 mm)

Table 3-10. Coupling Port Information Table - 4WS
Operating
Pressure
PSI (Bar)

Proof
Pressure
PSI (Bar)

Port
No.

Outlet

Port
Size

1

1

-8

Brake

450 (31)

675 (47)

2

2

-6

2 Speed

4500 (310)

6750 (465)

3

1

-6

Steer

2500 (172)

3750 (259)

4

1

-6

Steer

2500 (172)

3750 (259)

5

2

-6, -16

Drive Reverse

4500 (310)

6750 (465)

6

1

-16

Drive Forward

4500 (310)

6750 (465)

7

3

-8, -6

Case Drain

250 (17)

375 (26)

8

1

-6

Steer

2500 (172)

3750 (259)

9

1

-6

Steer

2500 (172)

3750 (259)

Description

Figure 3-69. Generator Belt Tension

Every 500 hours
Service generator brushes and slip rings every 500 hours of
operation. Hostile environments may require more frequent
service.

Figure 3-70. Generator Brushes and Slip Rings
Blow out inside of generator every 500 hours of service. If
operating in a hostile environment, clean monthly.

Figure 3-71. Generator Cleaning

3-52

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Overload Protection

Inspecting Brushes, Replacing Brushes, and
Cleaning Slip Rings

STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER.

Refer to Figure 3-73., Inspecting Generator Brushes, Replacing
Brushes, and Cleaning Slip Rings.

The circuit breaker protects generator windings from overload. Generator output stops if circuit breaker opens.

INSPECTING BRUSH POSITION

If circuit breaker continues to open, check for faulty equipment connected to platform receptacles.

Inspect brush alignment with slip rings. View alignment
through air vents in stator barrel. Brushes must ride completely on slip rings.

INSPECTING BRUSHES

Circuit
Breaker

Remove end panel. Inspect wires.

2.

Remove brush holder assembly. Pull brushes from holders.

3.

Replace brushes if damaged, or if brush is at or near minimum length.

CLEANING SLIP RINGS

Figure 3-72. Generator Circuit Breaker Location

3121298

1.

– JLG Lift –

1.

Visually inspect the slip rings. Under normal use, the
rings turn dark brown.

2.

If slip rings are corroded or their surface is uneven,
remove belt to turn shaft by hand for cleaning.

3.

Clean rings with 220 grit emery paper. Remove as little
material as possible. If rings are deeply pitted and do not
clean up, consult generator factory service.

4.

Reinstall belt, brush holder assembly, and end panel.

3-53

SECTION 3 - CHASSIS & TURNTABLE

Brush Position on Slip Rings

2

3

Acceptable

Unacceptable

Note: Brushes must ride completely on slip rings.

1
1/4 in (6 mm)
or Less - Replace
2

7/16 in - 1/2 in
(11 - 12 mm ) New

3

1.
2.
3.

Brush Holder Assembly
Brushes
Slip Rings

Figure 3-73. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings

3-54

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

3.11 DEUTZ D2.9 L4 ENGINE

1
13

7

2

8

6
4

14
5

3

10, 11

12
15

17

36

38
37

16

35
34
33

32
18

31

19

30
29
20
28

25
24

21
23
27

26

1.
2.
3.
4.
5.
6.
7.
8.

Fan
Adapter
Drive Belt
Water Pump
Fuel Injector
Thermostat
Oil Fill Cap
Temperature Sender

22

9.
10.
11.
12.
13.
14.
15.
16.

Turbocharger
Exhaust Pipe
Spark Arrester
Pressure Sensor
Front Engine Mount
Motor Mount
Shuttle Valve
Catalytic Converter/Muffler

17.
18.
19.
20.
21.
22.
23.
24.

Rear Engine Mount
Coupling
Pump Adapter Plate
Pump Assembly
Gear Pump Assembly
Oil Drain Hose
Oil Drain Valve
Pump Coupler

25.
26.
27.
28.
29.
30.
31.
32.

Flywheel
Fuel Filter
Pressure Sensor
Rear Engine Mount
Oil Pan Drain Plug
Front Engine/Generator Mount
Oil Fill Cap
Oil Cooler

33.
34.
35.
36.
37.
38.

Oil Filter
Belt Tensioner
Plug
Alternator
Adapter
Pulley

Figure 3-74. Deutz D2.9 L4 Engine Installation - Sheet 1 of 2

3121298

– JLG Lift –

3-55

SECTION 3 - CHASSIS & TURNTABLE

Vent

1
Return
Supply

5
2

4

3
15

7
6

To Engine

9
14

10

8

12

13

1.
2.
3.

Coolant Recovery Tank
Radiator Assembly
Air Filter Service Indicator

11

4.
5.
6.

Coolant Overflow Hose
Coolant Level Sensor
Fuel Pump

7.
8.
9.

Fuel Pre-Filter
Battery
Power Module Relay

10. Relay
11. Lanyard
12. Hitch Pin

13. Engine Tray
14. Air Filter Assembly
15. Engine Control Unit (ECU)

Figure 3-75. Deutz D2.9 L4 Engine Installation - Sheet 2 of 2

3-56

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions.

Change Engine Oil

Check Oil Level

1.

Allow engine to warm up. Engine oil should reach
approximately 176° F (80° C).

1.

Make sure machine and engine are level and switch
engine OFF before checking oil level.

2.

Make sure machine and engine are level and switch off
engine.

2.

Remove oil dipstick and wipe with clean cloth.

3.

Place oil tray under engine.

3.

Insert dipstick to the stop and remove again.

4.

Check oil level. Top oil level as shown in figure below
with an approved grade and type of oil outlined in
engine manufacturer’s operator’s manual.

MINIMUM OIL
LEVEL

HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
DRAINING.

COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.
DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.

MAXIMUM OIL
LEVEL

4.

Open oil drain valve and drain oil.

5.

Close oil drain valve.

6.

Pour in new engine oil. Refer to Section 1 for capacity
and Figure 3-81., Engine Oil Viscosity.

Figure 3-76. Deutz 2.9 T4F Dipstick Markings
5.

Replace dipstick until fully seated.

Figure 3-77. Engine Oil Viscosity

3121298

– JLG Lift –

3-57

SECTION 3 - CHASSIS & TURNTABLE

Change Oil Filter

Change Fuel Filters

1.

Wipe area around filter to clean any dirt from area.

2.

Using a suitable oil filter removal tool, loosen lube oil filter cartridge and spin off.

3.

Catch any escaping oil.

4.

Clean any dirt from filter carrier sealing surface.

5.

Lightly coat new oil filter rubber gasket with clean oil

6.

Screw in new filter by hand until gasket is flush.

7.

Hand-tighten filter another half-turn.

8.

Check oil level.

9.

Check oil pressure.

10.

3-58

FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1.

Wipe area around filter to clean any dirt from area.

2.

Disconnect water sensor connector (Pre-filter Only).

3.

Remove fuel filter cartridge. Catch any escaping fuel.

4.

Clean dirt from filter carrier sealing surface.

5.

Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.

6.

Screw in new filter by hand until gasket is flush. Handtighten filter another half-turn.

7.

Connect water sensor connector (Pre-filter Only).

8.

Open fuel shut-off valve.

9.

Check for leaks.

Check oil filter cartridge for leaks.

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

3.12 DEUTZ D2011 ENGINE

1
5

6
24

7

3

2

9

8

4

10

23

11
22

21

12

19
20
OR

13

18
14
15
16

17

1.
2.
3.
4.
5.
6.

Radiator Mounting Plate
Fan
Dipstick
Oil Filler Cap
Control Module
Fuel Injector

7.
8.
9.
10.
11.
12.

Oil Cooler Hose
Exhaust Pipe Extension
Air Cleaner
Right Rear Engine Mounting Plate
Exhaust Pipe
Coupling

13.
14.
15.
16.
17.
18.

Pump Adapter Plate
Piston Pump
Gear Pump
Left Rear Engine Mounting Plate
Engine Mount
Left Front Engine Support

19.
20.
21.
22.
23.
24.

Left Front Engine/Generator Support
Starter
Muffler
Alternator
Radiator Hose
Radiator

Figure 3-78. Deutz D2011 Engine Installation - Sheet 1 of 2

3121298

– JLG Lift –

3-59

SECTION 3 - CHASSIS & TURNTABLE

5

9

1

10

2
16
6

8

7
3
14
4

13
15
11

12

18

1.
2.
3.
4.

Battery
Battery Hold-Down
J-Bolt
Battery Hold-Down Plate

5.
6.
7.
8.

Temperature Sensor
Oil Filter
Fuel Filter
Oil Pressure Sensor

9.
10.
11.
12.

Throttle Actuator
Temperature Sensor
Starter
Oil Lube Pump

17

13. Oil Filler Cap
14. Fuel Supply Pump
15. Relay

16. Speed Sensor
17. Hitch Pin
18. Engine Tray

Figure 3-79. Deutz D2011 Engine Installation - Sheet 2 of 2

3-60

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

NOTE: Refer to engine manufacturer’s manual for detailed operating and maintenance instructions.

Changing Engine Oil

Checking Oil Level

1.

Allow engine to warm up. Engine oil should reach
approximately 176° F (80° C).

1.

Make sure machine and engine are level and switch
engine OFF before checking oil level.

2.

Make sure machine and engine are level and switch off
engine.

2.

Remove oil dipstick and wipe with clean cloth.

3.

Place oil tray under engine.

3.

Insert dipstick to the stop and remove again.

4.

Check oil level. Top oil level as shown in figure below
with an approved grade and type of oil outlined in
engine manufacturer’s operator’s manual.

HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
DRAINING.

COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.
DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
4.

Open oil drain valve and drain oil.

5.

Close oil drain valve.

6.

Pour in new engine oil. Refer to Section 1 for capacity
and Figure 3-81., Engine Oil Viscosity.

Figure 3-80. Deutz Dipstick Markings
5.

Replace dipstick until fully seated.

Figure 3-81. Engine Oil Viscosity

3121298

– JLG Lift –

3-61

SECTION 3 - CHASSIS & TURNTABLE

Changing Oil Filter
1.

Wipe area around filter to clean any dirt from area.

2.

Using a suitable oil filter removal tool, loosen lube oil filter cartridge and spin off.

3.

Catch any escaping oil.

4.

Clean any dirt from filter carrier sealing surface.

5.

Lightly coat new oil filter rubber gasket with clean oil.

6.

Screw in new filter by hand until gasket is flush.

7.

Hand-tighten filter another half-turn.

8.

Check oil level.

9.

Check oil pressure.

10.

Check oil filter cartridge for leaks.

Replace Fuel Filter
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.

3-62

– JLG Lift –

1.

Wipe area around filter to clean any dirt from area.

2.

Remove fuel filter cartridge. Catch any escaping fuel.

3.

Clean dirt from filter carrier sealing surface.

4.

Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.

5.

Screw in new filter by hand until gasket is flush. Handtighten filter another half-turn.

6.

Open fuel shut-off valve.

7.

Check for leaks.

3121298

SECTION 3 - CHASSIS & TURNTABLE

Clean Fuel Strainer

3.13 SPARK ARRESTER CLEANING INSTRUCTIONS

FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1.

Unscrew hexagonal nut (1).

1.

Remove cleanout plug in bottom of spark arrester (muffler).

2.

Without causing deformation (or any type of damage to
spark arrester) repeatedly tap on arrester near cleanout
plug. This may be enough to begin spark trap drainage.

3.

An industrial vacuum cleaner can do a complete job at
this point.
a. Or, IN A SAFE AREA, start engine. Alternate between
low idle and high idle for two to three minutes.
b. Or, operate engine as required by application for
two to three minutes.

4.

Install cleanout plug.

3.14 GLOW PLUGS
If glow plug option is enabled in the JLG Control System, glow
plug and indicator lamp will be energized when Power/Emergency Stop switch is pulled on if ambient air temperature is
less than 50° F (10° C) and engine coolant temperature is less
than 140° F (60° C).

2.

Remove fuel strainer cover (2).

3.

Clean fuel strainer with diesel fuel and replace as
needed.

4.

Place seal (3) in position.

5.

Install fuel strainer cover (2). Tighten screw (1).

6.

Check for leaks.

3121298

This determination occurs one second after the Power/Emergency Stop switch has been pulled on. Lamp and glow plugs
remain energized for period of time specified by setting in the
JLG Control System. Engine start is disabled during this period.
On Deutz engines, glow plugs continue (post glow) after
engine has started three times the machine digit setting.

– JLG Lift –

3-63

SECTION 3 - CHASSIS & TURNTABLE

3.15 DEUTZ EMR 2
The EMR2 consists of sensors, control unit, and actuator.
Engine-side controls and the JLG Control System are connected by separate cable harnesses to the EMR control unit.
Sensors attached to the engine provide control unit electronics with all relevant physical parameters In accordance with
information of the current engine conditions and preconditions (throttle position etc.), the EMR2 controls an actuator
that operates the control rod of the injection pump and thus
doses the fuel quantity in accordance with the performance
requirements.
Exact position of the regulating rod is reported back and, if
necessary, is corrected, by means of the control rod travel sensor, situated together with the rotation magnets in a housing
of the actuator.

The EMR2 is equipped with safety devices and measures in the
hardware and software to ensure emergency running (Limp
home) functions. In order to switch the engine off, the EMR2 is
switched in a de-energized fashion over the ignition switch. A
strong spring in the actuator presses the control rod in the deenergized condition into the zero position. As a redundancy
measure, an additional solenoid serves for switching off and
this, independently of the actuator, also moves the control rod
in the de-energized condition into the zero position.
After programming over the ISO9141 interface, the EMR2 possesses a motor-specific data set which is permanently assigned
to the engine. Included in this are the various application cases
as well as the customer’s wishes regarding a particular scope
of function.
Each EMR2 module is matched by serial number to the engine.
Modules cannot be swapped between engines.

 !" #!$% &'!(



   
   

   
 

!()#*!+ ,-!" #!$% &'!(
  

 

 
 

         
       

 

        

 
 

       
         
     

Figure 3-82. EMR 2 Engine Side Equipment

3-64

– JLG Lift –

3121298

Figure 3-83. Deutz EMR 2 Troubleshooting Flow Chart

SECTION 3 - CHASSIS & TURNTABLE

3121298

– JLG Lift –

3-65

Figure 3-84. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE

3-66

– JLG Lift –

3121298

Figure 3-85. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE

3121298

– JLG Lift –

3-67

Figure 3-86. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE

3-68

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-87. EMR 2 Engine Plug Pin Identification

3121298

– JLG Lift –

3-69

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-88. EMR 2 Vehicle Plug Pin Identification

3-70

– JLG Lift –

3121298

Figure 3-89. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE

3121298

– JLG Lift –

3-71

Figure 3-90. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE

3-72

– JLG Lift –

3121298

Figure 3-91. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE

3121298

– JLG Lift –

3-73

Figure 3-92. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE

3-74

– JLG Lift –

3121298

Figure 3-93. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS & TURNTABLE

3121298

– JLG Lift –

3-75

SECTION 3 - CHASSIS & TURNTABLE

3.16 BIO FUEL IN DEUTZ ENGINES

APPROVED ENGINES

General

912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and 513
series are approved for bio-diesel from year of manufacture
1993 under compliance with basic conditions specified below.

Use of bio fuels is permitted for the compact engines made by
DEUTZ.

BASIC CONDITIONS TO BE OBSERVED
• A power loss of 5-9% in relation to diesel fuel in accordance
with EN 590 is possible due to the lower heating value.
Blocking of fuel injector is not allowed.

Distillate fuels with residue oil percentages or mixed fuels may
not be used in DEUTZ compact engines.
DEUTZ vehicle engines are designed for diesel fuels in accordance with EN 590 with a cetane number of at least 51. DEUTZ
engines for mobile machinery are designed for a cetane number of at least 45. When using fuels of a low cetane number, disturbing white smoke and ignition misfires are to be expected
under some circumstances.

• Lubricating oil quality must correspond to TR 0199-993002. Lubricating oil change interval must be halved in
relation to operation with diesel fuel in accordance with EN
590.
• Standstills of longer than 4 to 6 weeks must be avoided with
bio-diesel. Otherwise, engine must be started and stopped
with diesel fuel.

A cetane number of at least 40 is permissible for the US market,
therefore special engine models have been developed to
avoid starting difficulties, extreme white smoke or increased
hydrocarbon emissions (EPA specification - US EPA REGULATIONS FOR LARGE NONROAD COMPRESSION-IGNITION
ENGINES).

• Bio-diesels can be mixed with normal diesel fuel but basic
conditions described in this subsection apply for mixtures.
Mixtures with up to 5% (m/m) bio-diesel (B5) which have
recently been on sale at European fuel stations are
excepted. These fuels must be treated like normal diesel
fuels because EN 590 expressly permits adding up to 5%
(m/m) bio-diesel in accordance with EN 14214.

If white smoke is unacceptable when using a very low cetane
number, use of ignition improvers is to be recommended as a
later remedial measure.

• Approximately 30-50 hours after changing from diesel fuel to
bio-diesel, the fuel filter should be changed as a preventive
measure to avoid a drop in performance due to clogged fuel
filters. Deposited fuel ageing products are dissolved by biodiesel and transported into the fuel filter. They should not
be changed immediately, but after 30 to 50 hours because
that is the time it takes for most dirt to be dissolved.

Certification measurements for compliance with legal emission
limits are carried out with test fuels prescribed by law. These
correspond to diesel fuels in accordance with EN 590 and
ASTM D 975. No emission values are guaranteed with other
fuels described. It is the obligation of the owner to check permission for use of fuels in accordance with regional regulations.

PLANT OIL

Bio Fuel
PERMITTED BIO-DIESEL FUELS
Originally only rape seed oil methylester (RME) was sold as a
bio-diesel fuel in Europe but fatty acid methylester (FAME)
based on other oils have come onto the market increasingly in
recent years. However, with the latter there is a risk that the limit
values of EN 14214 are not kept in the field. Anyone who uses
bio-diesel fuel in DEUTZ engines must therefore choose his
supplier very carefully and have him guarantee compliance
with the EN 14214 limit values. Since experience has shown
that rape seed oil methylester (RME) exceeds the limit values
less often that other esters, it is expressly recommended to use
only rape seed oil methyester. DEUTZ customers in Germany
can additionally ensure the quality by buying bio-diesel fuel
with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Management Biodiesel e.V.).

PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS
BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPERATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH
VISCOSITY, AND POOR EVAPORATION BEHAVIOR).
The conversion of DEUTZ engines to rape seed oil fuel operation with conversion kits and modified tanks systems of various
manufacturers is not allowed and leads to loss of warranty
rights.

The use of US bio-diesel based on soy oil methylester is only
permissible in mixtures with diesel fuel with a bio-diesel part of
a max. 20 weight-%. The US bio-diesel used for the mixture must
comply with the ASTM D6751-07a (B100) standard.

3-76

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

PREVENTIVE MEASURES

Biological Contamination In Fuels

• Keep storage tank clean. Perform regular cleaning of the
tank by specialist companies

SYMPTOMS
The following symptoms may indicate a fuel tank is contaminated by micro-organisms:

• Installation of fuel pre-filters with water traps, especially in
countries with frequently fluctuating fuel qualities and high
percentage of water.

• Internal tank corrosion,
• Filter blockage and associated loss of power due to gel-like
deposits on the fuel filter (especially after long standstills)

If the fuel system and storage tank have already been attacked
by micro-organisms. Biocide must be dosed according to the
manufacturer's specifications.

CAUSE

• Avoid direct exposure of the storage tank to sunlight

Micro-organisms (bacteria, yeasts, funguses) can form biosludge under unfavorable conditions (favoured particularly by
heat and water).
Penetration by water is usually caused by condensation of water
in the air. Water does not dissolve in fuel so penetrating water
collects at bottom of the tank. Bacteria and funguses grow in the
watery phase, at phase boundary to the fuel phase, from which
they draw their nutrition. There is an increased risk especially
with bio-diesel (FAME).

3121298

• Use smaller storage tanks with corresponding low dwell
times of the stored fuel

FUEL ADDITIVES
The use of fuel additives is not permitted. The flow improvers
mentioned above are an exception. Use of unsuitable additives
will result in loss of warranty.

– JLG Lift –

3-77

SECTION 3 - CHASSIS & TURNTABLE

3.17 GM ENGINE GENERAL MAINTENANCE

Checking/Filling Engine Oil Level

Drive Belt Maintenance
The serpentine drive belt utilizes a spring loaded tensioner
which keeps the belt properly adjusted. The drive belt is an
integral part of the cooling and charging systems and should
be inspected frequently.

AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED FULL MARK) CAN
CAUSE AN OIL LEAK, FLUCTUATION OR DROP IN OIL PRESSURE, AND ROCKER
ARM "CLATTER".

When inspecting belts check for:
CARE MUST BE TAKEN WHEN CHECKING ENGINE OIL LEVEL. OIL LEVEL MUST
BE MAINTAINED BETWEEN "ADD" MARK AND "FULL" MARK ON DIPSTICK.

• Cracks or breaks
• Chunking of the belt

To ensure you are not getting a false reading, make sure the
following steps are taken before checking oil level.

• Splits
• Material hanging from belt
• Glazing and hardening

1.

Stop engine if in use.

2.

Allow sufficient time (approximately 5 minutes) for oil to
drain back into oil pan.

3.

Remove dipstick. Wipe with a clean cloth or paper towel
and reinstall. Push dipstick all the way in dipstick tube.

4.

Remove dipstick and note oil level.

5.

Oil level must be between "FULL" and "ADD" marks.

• Damaged or improperly aligned pulleys
• Improperly performing tensioner
Check belt tensioner by pressing down on the midway point of
the longest stretch between pulleys. The belt should not
depress beyond 1/2 inch (13mm). If depression is more than
allowable, adjust tension.

ENGINE MANUFACTURER DOES NOT RECOMMEND USE OF "BELT DRESSING"
OR "ANTI SLIPPING AGENTS" ON DRIVE BELT.

Engine Electrical System Maintenance
The engine electrical system incorporates computers and
microprocessors to control engine ignition, fuel control, and
emissions. Periodic inspection of electrical wiring is necessary
due to sensitivity of computers to good electrical connections.
When inspecting the electrical system use the following:
• Check and clean battery terminal connections and ensure
connections are tight
• Check battery for any cracks or damage to case
• Check Positive and Negative battery cables for corrosion
build up, or rubbing and chafing. Check connections on
chassis are tight.
• Check entire engine wire harness for rubbing chafing, cuts
or damaged connections. Repair as needed.

Figure 3-94. GM Engine Oil Dip Stick
6.

If oil level is below "ADD" mark, proceed to Step 7 and 8
and reinstall dipstick in dipstick tube.

7.

Remove oil filter cap from valve rocker arm cover.

8.

Add required amount of oil to bring level up to, but not
over, "FULL" mark on dipstick.

9.

Reinstall oil fill cap to valve rocker cover and wipe away
any excess oil.

• Check all wire harness connectors to ensure they are fully
seated and locked.
• Check ignition coil and spark plug cables for hardening,
cracking, chafing, separation, split boot covers, and fit
• Replace spark plugs at the proper intervals as prescribed in
the engine manufacturer’s manual
• Make sure all electrical components are fitted securely.
• Check ground and platform control stations to ensure all
warning indicator lights are functioning.

3-78

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Changing Engine Oil

1.

Loosen worm gear clamp on coolant line running to EPR
as shown below. Remove hose from EPR. Place a rag
under hose to prevent coolant from running onto
engine/machine.

2.

Remove radiator cap. Fill radiator with coolant until
coolant starts to appear from previously removed hose
at the EPR. Reinstall hose back on EPR and continue to
fill radiator with coolant.

3.

With radiator cap still removed, start engine and run
until thermostat opens at 170° F (77° C), which can be
checked using the JLG handheld analyzer.

ALWAYS CHANGE OIL FILTER WHEN CHANGING OIL. CHANGE OIL WHEN
ENGINE IS WARM FROM OPERATION. OILS WILL FLOW FREELY AND CARRY
AWAY MORE IMPURITIES.
To change oil use the following steps:
1.

Start engine and run until it reaches normal operating
temperature.

2.

Stop engine.

3.

Remove drain plug and allow oil to drain.

4.

Remove and discard oil filter and sealing ring.

5.

Coat sealing ring on new filter with clean engine oil and
wipe engine filter mounting surface to remove contamination. Tighten filter securely (follow filter manufacturers instructions). Do not over tighten.

6.

Check sealing ring on drain plug for damage. Replace if
necessary. Pipe plug and oil pan sealing surface with a
clean rag. Reinstall plug. Do not over tighten.

7.

Fill crankcase with oil.

8.

Start engine and check for oil leaks.

9.

Stop engine and check oil level is at "FULL".

10.

Dispose of oil and filter in a safe manner as required by
local regulations.

Coolant Fill Procedure - Dual Fuel Engine

HOT ENGINE AND COMPONENTS CAN CAUSE SEVERE BURNS. MAKE SURE
ENGINE IS COOL BEFORE PERFORMING MAINTENANCE.

DAMAGE TO ENGINE CAN OCCUR IF NOT PROPERLY FILLED WITH COOLANT.
LPG FUELED ENGINES ARE MOST PRONE TO CREATING AN AIR LOCK DURING A
COOLANT FILL OPERATION DUE TO ELECTRONIC PRESSURE REGULATOR (EPR)
BEING THE HIGHEST POINT IN THE COOLING SYSTEM. AN EPR THAT APPEARS
TO HAVE FROST FORMING ON IT IS A SIGN THE ENGINE COOLING SYSTEM CONTAINS AIR. APPEARANCE AND TEMPERATURE OF THE EPR SHOULD BE MONITORED DURING COOLANT FILL OPERATION. A WARM EPR IS AN INDICATION
THAT THE COOLING SYSTEM IS PROPERLY FILLED AND FUNCTIONING.

WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRESENT COMING
FROM THE RADIATOR. THIS IS NORMAL.
4.

3121298

– JLG Lift –

Run engine for five minutes after it has reached operating temperature. Shut off engine and continue to step 5.

3-79

SECTION 3 - CHASSIS & TURNTABLE

3.18 GM ENGINE DUAL FUEL SYSTEM
WITH ENGINE RUNNING OR WHEN SHUTTING OFF ENGINE, SOME HEATED
COOLANT MAY SPILL OUT DUE TO AIR "BURPING" OUT OF THE SYSTEM WITH
RADIATOR CAP OFF.
5.

Verify the two coolant hoses on the EPR are warm. If they
are not warm repeat step 3 and 4, otherwise continue to
step 6.

A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIATOR HOSE AND A WARM EPR HOSE. IF UPPER RADIATOR AND EPR HOSES ARE
NOT WARM TO THE TOUCH AFTER ENGINE HAS RUN FOR 5-8 MINUTES AFTER
REACHING OPERATING TEMPERATURE, THE SYSTEM MAY STILL CONTAIN AIR.
IT MAY BE NECESSARY TO REPEAT ABOVE STEPS.

6.

Fill radiator with coolant as needed and install radiator
cap.

7.

Remove coolant recovery bottle cap and fill to just
below HOT FULL line. Reinstall cap.

The fuel system installed on this engine is designed to meet
mobile engine emission standards applicable for 2010 and
later model years. The Dual Fuel system allows the vehicle to
operate on gasoline or LPG by positioning a selector switch in
the operator's platform. When the operator places the selector
switch in gasoline mode, the gasoline fuel pump is energized.
In gasoline mode the LPG fuel lock-off is isolated and will not
energize. In addition, the gasoline injector circuit is enabled
and injector pulses are provided to each injector. ECM calibration for gasoline is also enabled.
When LPG mode is selected the Low Pressure LPG lock-off is
energized and fuel from the LPG tank flows to the Electronic
Pressure Regulator (EPR). The EPR receives an electronic signal
to position the secondary lever for start or run positions. When
the engine begins to crank, the mixer air valve will rise and fuel
begins flowing to engine. During this mode the gasoline fuel
pump is isolated and is not activated.
Primary components of the gasoline dual fuel system are the
gasoline tank, electric fuel pump and filter, fuel supply line,
injector rail and injectors and the fuel pressure regulator.
Primary components of the LPG dual fuel system are the LPG
fuel tank, in-fuel filter, LPG Low Pressure lock-off, Electronic
Pressure Regulator (EPR) and the fuel mixer module. The LPG
fuel system operates at pressures which range from 14.0
inches (355.60 mm) of water column up to 312 psi (21.5 BAR).
Components shared by both systems include the Electronic
Throttle Control and ECM. The ECM contains a dual calibration;
one controls the gasoline fuel system during gasoline operation and one controls the LPG fuel system during LPG operation.

Fuel Filter
Propane fuel, like all other motor fuels, is subject to contamination from outside sources. Refueling and removal of the tank
from the equipment can contaminate the fuel system. It is necessary to filter fuel before it enters fuel system components
downstream of the tank.
An in-line fuel filter is installed in the fuel system to remove
fuel contamination. The in-line filter is replaceable as a unit
only. Filter maintenance is critical to proper operation of the
fuel system and should be replaced as listed in Section 1. More
frequent replacement of the filter may be necessary in severe
operating conditions.

3-80

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

1

2

8

3
7

4

6

5

1.
2.

T-MAP Sensor
Lock-Off Valve

3.
4.

Mixer
Adapter

5.
6.

Regulator
Direct Electronic Pressure Regulator (DEPR)

7.
8.

Throttle Body
Intake Manifold

Figure 3-95. GM 3.0 Dual Fuel System Components

3121298

– JLG Lift –

3-81

SECTION 3 - CHASSIS & TURNTABLE

Direct Electronic Pressure Regulator (DEPR)

Air Fuel Mixer

THE DEPR IS AN EMISSION CONTROL DEVICE AND SHOULD ONLY BE SERVICED
BY QUALIFIED TECHNICIANS.

THE AIR/FUEL MIXER IS AN EMISSION CONTROL DEVICE. COMPONENTS INSIDE
THE MIXER ARE SPECIFICALLY CALIBRATED TO MEET THE ENGINE’S EMISSIONS
REQUIREMENTS AND SHOULD NEVER BE DISASSEMBLED OR REBUILT. IF THE
MIXER FAILS TO FUNCTION CORRECTLY, REPLACE WITH AN OEM REPLACEMENT PART.

The ECI engine management system uses the DEPR to control
fuel delivery for precise fuel metering needed for optimum
combustion, fuel economy, and transient response.
The DEPR is a single-stage microprocessor based electromechanical fuel pressure regulator that incorporates a high
speed/fast acting actuator. It communicates with the Engine
Control Module (ECM) over a Controller Area Network (CAN)
link, receiving fuel pressure commands and broadcasting
DEPR operating parameters back to the ECM.
The DEPR can regulate fuel pressure from -18 to +13 inches of
water column above the Mixer air inlet pressure, providing sufficient control authority to stall an engine either rich or lean.
When the DEPR receives an output pressure command from
the ECM, the valve is internally driven to attain targeted fuel
pressure, the DEPR then closes the loop internally using a built
in fuel pressure sensor to maintain target fuel pressure/fuel
flow rate, until another external command from the ECM is
received (intervals < 10 ms).
The DEPR has an integral fuel temperature sensor that is used
by the ECM to correct for variations in fuel density. This provides an extremely accurate method for open loop fuel control. Then with the addition of the pre- and post-cat oxygen
sensors, the pressure command transmitted form the ECM can
be further adjusted using closed loop feedback.

The air valve mixer is a self-contained air-fuel metering device.
The mixer is an air valve design, utilizing a relatively constant
pressure drop to draw fuel into the mixer from cranking
speeds to full load.
The mixer is mounted in the air stream ahead of the throttle
control device. When the engine begins to crank it draws in air
with the air valve covering the inlet, and negative pressure
begins to build. This negative pressure signal is communicated
to the top of the air valve chamber through vacuum ports in
the air valve assembly. A pressure/force imbalance begins to
build across the air valve diaphragm between the air valve vacuum chamber and the atmospheric pressure below the diaphragm.
The vacuum being created is referred to as Air Valve Vacuum
(AVV). As the air valve vacuum reaches the imbalance point,
the air valve begins to lift against the air valve spring. The
amount of AVV generated is a direct result of throttle position.
At low engine speed the air valve vacuum and the air valve
position is low, creating a small venturi for the fuel to flow. As
engine speed increases, AVV increases and the air valve is lifted
higher creating a much larger venturi. Air valve vacuum is
communicated from the mixer venturi to the IEPR via the fuel
supply hose.







   
 

 

Figure 3-96. Direct Electronic Pressure Regulator
   

Figure 3-97. Air Fuel Mixer

3-82

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Electronic Throttle Control (ETC)

Engine Control Module (ECM)

The Electronic Throttle Control device or "Throttle Body
Assembly" is connected to the intake manifold of the engine.
The electronic throttle control device utilizes an electric motor
connected to the throttle shaft.
When the engine is running, electrical signals are sent from
equipment controls to the engine ECM. The ECM then sends
an electrical signal to the motor on the electronic throttle control to increase or decrease the angle of the throttle blade thus
increasing or decreasing the air/fuel flow to the engine.

NOTE: The ECM may also be referred to as the Engine Control Unit
(ECU) in some applications.
To obtain maximum effect from the catalyst and accurate control of air fuel ratio, the emission certified engine is equipped
with an onboard computer or Engine Control Module (ECM).
The ECM is a 32 bit controller which receives input data from
sensors fitted to the engine and fuel system and then outputs
various signals to control engine operation.

Two internal Throttle Position Sensors (TPS) provide throttle
shaft and blade position output signals to the ECM. TPS information is used by the ECM to correct speed and load control,
as well as emission control.

Figure 3-100. ECM Assembly
One specific function of the controller is to maintain "closed
loop fuel control". Closed loop fuel control is accomplished
when the exhaust gas oxygen sensor (HEGO) mounted in the
exhaust system sends a voltage signal to the controller. The
controller calculates corrections for the air fuel ratio. and outputs signals to the DEPR to correct the amount of fuel supplied
to the mixer. At the same time the ECM may correct throttle
blade position to correct engine speed and load.

Figure 3-98. ELectronic Throttle Control Device

Electric Lock Off
The Electric Lock Off device is an integrated assembly consisting of a 12 volt solenoid and normally closed valve. When
energized, the solenoid opens the valve and allows propane
fuel to flow through the device. The valve opens during
engine cranking and run cycles. Lock Off supply voltage is controlled by the Engine Control Module (ECM).

The controller also performs fuel system diagnostic functions
and notifies the operator of malfunctions by turning on a Malfunction Indicator Light (MIL) mounted in the Ground Control
Station and Platform Control Station. System malfunctions are
identified by a Diagnostic Code number. In addition to notifying the operator of the system malfunction, the controller also
stores information about the malfunction in its memory.

Figure 3-101. ECM Input-Output Diagram
Figure 3-99. Electric Lock Off Assembly

3121298

– JLG Lift –

3-83

SECTION 3 - CHASSIS & TURNTABLE

Heated Exhaust Gas Oxygen Sensor

Gasoline Fuel Pump

There are two Heated Exhaust Gas Oxygen Sensors (HEGO).
The first HEGO is mounted in the exhaust system downstream
of the engine. It is used to measure the amount of oxygen
present in the exhaust stream and communicate that to the
ECM via an electrical signal. The amount of oxygen present in
the exhaust stream indicates whether the fuel/air ratio is too
rich or too lean. If the HEGO sensor signal indicates exhaust
stream is too rich, the ECM will decrease or lean the fuel mixture during engine operation. If mixture is too lean the ECM
will richen the mixture. The ECM continuously monitors the
HEGO sensor output. If a rich or lean condition is present for an
extended period of time, and the ECM cannot correct the condition, the ECM sets a diagnostic code and turns on the MIL
light in control box.
The second HEGO is mounted in the exhaust system after the
muffler. It measures the amount of oxygen in the exhaust system after the catalyst treatment has been completed in the
muffler. If the ECM detects that the catalytic action in the muffler is not sufficient and fuel correction cannot correct the malfunction the MIL light is illuminated in the control box and a
DTC code will stored in the computer.

THE HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION CONTROL
DEVICE. IF THE HEGO FAILS TO OPERATE, REPLACE IT WITH AN OEM REPLACEMENT PART. THE HEGO SENSOR IS SENSITIVE TO SILICONE OR SILICONE BASED
PRODUCTS AND CAN BECOME CONTAMINATED. AVOID USING SILICONE SEALERS OR HOSES TREATED WITH SILICONE LUBRICANTS IN THE AIR STREAM OR
FUEL LINES.

Gasoline is stored as a liquid in the fuel tank and in drawn into
the fuel system by an electric fuel pump. The fuel pump
receives a signal from the ECM to prime the fuel system for
approximately two seconds before start. Priming the fuel system provides for a quicker start when engine begins to crank.

Gasoline Pressure And Temperature Sensor
Manifold
This engine is equipped with a fuel injector rail that does not
have a pressure regulator or a return circuit to the fuel tank.
Fuel pressure for this engine is regulated by the engine’s ECM.
The ECM receive fuel pressure and temperature feedback from
the gasoline fuel sensor manifold and uses this information to
control the ground side of the fuel pump. Fuel pressure is regulated by the ECM pulse width modulating (PWM) the fuel
pump. The fuel pressure and temperature sensor manifold has
a return or "bleed" circuit that connects back to the fuel tank.
This circuit is used to bleed off any vapor that develops in the
line and return a small amount of fuel to the tank.
Fuel comes from the fuel tank and passes through the fuel
pump. Fuel exits the fuel pump, passes through the filter and
then enters the fuel pressure and temperature manifold
assembly. Fuel flows through the feed circuit and is delivered
to the fuel injector rail. Fuel that enters the bleed circuits
through the bypass valve in the manifold is returned to the
fuel tank.

Figure 3-102. Heated Exhaust Gas Oxygen Sensor

Gasoline Multi Point Fuel Injection System (MPFI)
The primary components of the Gasoline Multi Point Fuel
Injection (MPFI) fuel system are the fuel tank, electric fuel
pump, fuel pressure and temperature sensor manifold, fuel filter, and fuel rail.

Figure 3-103. Gasoline Fuel Pressure and Temperature
Manifold Assembly

3-84

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Fuel Filter

3.19 GM ENGINE FUEL SYSTEM REPAIR

After fuel is drawn into the fuel pump, the fuel flows through
the gasoline fuel filter. The fuel filter traps small particles as
fuel passes through the filter to remove debris and prevents
fuel pressure and temperature manifold and fuel injectors
from becoming damaged. Fuel filter maintenance is required
as shown in Section 1.

Fuel Injector Rail
Fuel flows from the fuel pressure and temperature manifold
assembly to the fuel rails where fuel is delivered to the fuel
injectors. The fuel rail also contains a Schrader valve which is
used to test regulated pressure of the fuel system.

Propane Fuel System Pressure Relief

THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5
BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE
PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING
THE PROPANE FUEL SYSTEM COMPONENTS.
To relieve propane fuel system pressure:

Fuel Injector
The fuel supply is maintained on the top of the injector from
the injector rail. The injector is fed a "pulse" signal through the
wire harness which causes the injector to open. During regular
operating conditions the ECM controls the opening and duration of opening of the injector. During lower RPM operation
the injector signals or "pulses" are less frequent then when the
engine is operating at higher RPMs. The engine has been calibrated to deliver the precise amount of fuel for optimum performance and emission control.

1.

Close manual shut-off valve on propane fuel tank.

2.

Start and run vehicle until engine stalls.

3.

Turn ignition switch OFF.

RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE
WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE.

Propane Fuel System Leak Test

PROPANE IS HIGHLY FLAMMABLE AND CAN EASILY IGNITE AND CAUSE BURNS
AND SERIOUS INJURIES. NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK
FOR PROPANE FUEL SYSTEM LEAKS.
Always inspect propane fuel system for leaks after performing
service. Check for leaks at fittings of the serviced or replaced
component. Use a commercially available liquid leak detector
or an electronic leak detector. When using both methods, use
electronic leak detector first to avoid contamination by liquid
leak detector.

3121298

– JLG Lift –

3-85

SECTION 3 - CHASSIS & TURNTABLE

INSTALLATION

Propane Fuel Filter Replacement

REINSTALL FILTER MAGNET IN HOUSING BEFORE INSTALLING NEW SEAL.

1.
2.
3.
4.
5.
6.

Electric Lock Off Solenoid
Mounting Plate
Housing Seal
Filter Magnet
Filter Housing
Seal

7.
8.
9.
10.
11.
12.

Electrical Connector
Fuel Outlet
O-ring
Filter
Fuel Inlet
Retaining Bolt

1.

Install mounting plate to lock off O-ring seal.

2.

Install retaining bolt seal.

3.

Install housing seal.

4.

Drop magnet in bottom of filter housing.

5.

Install filter in housing.

6.

Install retaining bolt in filter housing.

7.

Install filter up to bottom of electric lock off.

8.

Tighten filter retaining bolt to 106 in-lb (12 Nm).

9.

Open manual shut-off valve. Start vehicle and leak check
propane fuel system at each serviced fitting. Refer to
Propane Fuel System Leak Test.

Direct Electronic Pressure Regulator (DEPR)
Maintenance And Inspection
Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.

Figure 3-104. Filter Lock Assembly
REMOVAL

DEPR COMPONENTS ARE SPECIFICALLY DESIGNED AND CALIBRATED TO MEET
FUEL SYSTEM REQUIREMENTS OF THE EMISSION CERTIFIED ENGINE. IF THE
DEPR FAILS TO OPERATE OR DEVELOPS A LEAK, IT SHOULD BE REPAIRED OR
REPLACED WITH OEM RECOMMENDED REPLACEMENT PARTS.

1.

Relieve propane fuel system pressure. Refer to Propane
Fuel System Pressure Relief.

2.

Disconnect the negative battery cable.

3.

Slowly loosen the filter housing retaining bolt and
remove it.

1.

Check for any fuel leaks at inlet and outlet fittings.

2.

Check for any fuel leaks in DEPR body.

4.

Pull filter housing from electric lock off assembly.

3.

5.

Locate and remove filter magnet.

Check inlet and outlet fittings of coolant supply lines for
water leaks if applicable.

6.

Remove the filter from housing.

4.

7.

Remove and discard housing seal.

Check DEPR is securely mounted and mounting bolts are
tight.

8.

Remove and discard retaining bolt seal.

5.

Check DEPR for external damage.

9.

Remove and discard mounting plate to lock off O-ring
seal.

6.

Check DEPR electrical connections are seated and
locked.

3-86

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Check/Drain Oil Build-Up In 2-Stage Vaporizer
Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.
During normal operation for LPG engines oil or “heavy ends”
may build inside the Vaporizer secondary chamber. These oil
and heavy ends may be a result of poor fuel quality, fuel contamination, or regional variation of the fuel make up. A significant build up of oil can affect performance of the secondary
diaphragm response.

FUEL CYLINDER MANUAL VALVE CONTAINS AN “EXCESS FLOW CHECK VALVE”.
OPEN MANUAL VALVE SLOWLY TO PREVENT ACTIVATING THE “EXCESS FLOW
CHECK VALVE.”

FAILURE TO FOLLOW THIS RECOMMENDATION MAY BE USED TO DENY A WARRANTY CLAIM.
Drain oil periodically to maintain emission warranty. More frequent draining of the Vaporizer Regulator is recommended
where substandard fuel may be a problem. Drain Vaporizer
Regulator at every engine oil change if contaminated or substandard fuel is suspected or known to be have been used
with the emission compliant fuel system.
NOTE: Draining regulator when engine is warm will help oils to
flow freely from the regulator.

14.

Check for leaks at the inlet and outlet fittings using a
soapy solution or an electronic leak detector.

15.

Check coolant line connections for leaks.

16.

Start engine. Recheck regulator for leaks.

17.

Dispose of any drained material in safe and proper manner according to applicable regulations.

Air Fuel Mixer/Throttle Control Device Maintenance
And Inspection
Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.

AIR FUEL MIXER COMPONENTS HAVE BEEN SPECIFICALLY DESIGNED AND CALIBRATED TO MEET FUEL SYSTEM REQUIREMENTS OF THE EMISSION CERTIFIED
ENGINE. THE MIXER SHOULD NOT BE DISASSEMBLED OR REBUILT. IF MIXER
FAILS TO OPERATE OR DEVELOPS A LEAK, IT SHOULD BE REPLACED WITH OEM
RECOMMENDED REPLACEMENT PARTS.

1.

Move equipment well ventilated area and ensure no
external ignition sources are present.

2.

Start engine.

1.

Check for leaks at the inlet fitting.

3.

With engine running, close manual valve.

2.

4.

When engine runs out of fuel and stops, turn key OFF.

Inspect fuel inlet hose for cracking, splitting, or chaffing.
Replace if any of these condition exist.

5.

Disconnect negative battery cable.

3.

Ensure mixer is securely mounted and not leaking vacuum at the mounting gasket or surface.

4.

Inspect air inlet hose connection and clamp. Inspect
inlet hose for cracking, splitting, or chafing. Replace if
any of these conditions exist.

5.

Inspect air cleaner element.

6.

Check fuel lines for cracking, splitting, or chafing.
Replace if any of these conditions exist.

7.

Check for leaks at the throttle body and intake manifold.

A SMALL AMOUNT OF FUEL MAY STILL BE PRESENT IN THE FUEL LINE. USE
GLOVES TO PREVENT BURNS AND WEAR PROPER EYE PROTECTION.
NOTE: If fuel continues to flow from connections when loosened,
check manual valve is fully closed.
6.

Loosen hose clamps at inlet and outlet hoses. Remove
hoses.

7.

Remove regulator mounting bolts.

8.

Place a small receptacle in the engine compartment.

9.

Rotate regulator to 90° so outlet fitting is pointing down
into receptacle. Drain regulator.

10.

Inspect secondary chamber for any large dried particles
and remove.

11.

Remove receptacle and reinstall regulator retaining
bolts. Torque to specifications.

12.

Reinstall fuel hoses. Reconnect any other hoses
removed during this procedure.

13.

Slowly open manual service valve.

3121298

– JLG Lift –

3-87

SECTION 3 - CHASSIS & TURNTABLE

Exhaust System And Catalytic Converter Inspection
And Maintenance

Throttle Body (ETC) Replacement
Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.

REMOVAL
EXHAUST SYSTEM ON THIS EMISSION CERTIFIED ENGINE CONTAINS A HEATED
EXHAUST GAS OXYGEN SENSOR (HEGO) WHICH PROVIDES FEEDBACK TO THE
ECM ON AMOUNT OF OXYGEN PRESENT IN THE EXHAUST STREAM AFTER COMBUSTION. OXYGEN IN THE EXHAUST STREAM IS MEASURED IN VOLTAGE AND
SENT TO THE ECM. THE ECM THEN MAKES CORRECTIONS TO THE FUEL AIR
RATIO TO ENSURE PROPER FUEL CHARGE AND OPTIMUM CATALYTIC PERFORMANCE. EXHAUST CONNECTIONS MUST REMAIN SECURE AND AIR TIGHT.

THE HEGO SENSOR IS SENSITIVE TO SILICONE BASED PRODUCTS. DO NOT USE
SILICONE SPRAYS OR HOSES WHICH ARE ASSEMBLED USING SILICONE LUBRICANTS. SILICONE CONTAMINATION CAN CAUSE SEVERE DAMAGE TO THE
HEGO.

1.

Disconnect negative battery cable.

2.

Remove Mixer (See “Mixer Replacement” on page 88).

3.

Disconnect TMAP electrical connector.

4.

Disconnect electronic throttle control connector.

5.

Remove bolts (208), adapter (204), and throttle body
(201) from manifold.

6.

Remove spacer (205).

7.

Remove and discard gasket (202) and O-ring (203).

INSTALLATION
NOTE: Lightly lubricate O-ring.

1.
2.

Check exhaust manifold at cylinder head for leaks and all
retaining bolts and shields (if used) are in place.

1.

Check manifold to exhaust pipe fasteners are tight and
there are no exhaust leaks. Repair if necessary.

Install O-ring (203) and spacer (205) on throttle body
(201).

2.

Align new gasket (202) and throttle body on manifold.

3.

Slide adapter (204) on throttle body and secure with four
bolts (208).

4.

Reinstall Mixer (See “Mixer Replacement” on page 88).

3.

Inspect HEGO electrical connector is seated and locked.
Check wires for cracking, splits, chafing or “burn
through.” Repair if necessary.

4.

Check exhaust pipe extension connector for leaks.
Tighten if necessary.

5.

Check catalyst muffler is securely mounted. Check for
leaks at inlet and outlet.

Mixer Replacement
Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.
REMOVAL

Temperature Manifold Absolute Pressure (TMAP)
Sensor
Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.

REMOVAL
1.

Disconnect TMAP (402) electrical connector.

2.

Remove retaining bolt (403), washer (404), and TMAP
(402).

Remove EPR. (See Electronic Pressure Regulator Replacement on next page).

2.

Remove Air Intake hose from Mixer.

3.

Remove four bolts (206) and washers (207) securing
mixer (104) to adapter (204). Remove Mixer.

INSTALLATION

COVER THROTTLE BODY ADAPTER OPENING TO PREVENT DEBRIS FROM
ENTERING ENGINE.

INSTALLATION
NOTE: Apply a small amount of O-ring lubricant before installation.
1.

Install TMAP (402). Secure with washer (404) and bolt
(403).

2.

Torque retaining bolt to 62 in-lb (7 Nm).

3.

Start vehicle and check for proper operation.

3-88

1.

– JLG Lift –

1.

Install Mixer (104) to Adapter (204). Secure with four
washers (207) and bolts (206). Torque to 80 in-lb (9 Nm)

2.

Install EPR (See Electronic Pressure Regulator Replacement on next page).

3.

Reinstall Air Intake Hose.

4.

Start engine and leak check all fittings and connections.

3121298

SECTION 3 - CHASSIS & TURNTABLE

Electronic Pressure Regulator (EPR) Replacement
REMOVAL

Coolant Hose Replacement
REMOVAL

Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.
1.

Unplug EPR (102) electrical connector.

2.

Remove hoses from EPR.

3.

Remove four flange nuts (107) and EPR from Mixer (104).

4.

If new EPR is being installed, remove and retain hose
adapter (103) and four bolts (105).

If new EPR is being installed, install adapter (103) and
four bolts (105) to EPR.

2.

Install EPR (102) on Mixer (104). Secure with four flange
nuts (107).

3.

Reattach all hoses.

4.

Start engine and leak check all fittings and connections.

Drain coolant.

2.

Using hose clamp pliers, disconnect both hose clamps
on each hose.

3.

Remove hose from fittings.

INSTALLATION
NOTE: Use hose material and lengths specified by JLG.

INSTALLATION
1.

1.

1.

Install hose clamps to each hose and set clamp back on
each hose to make installation easier.

2.

Fit hose to fittings.

3.

Secure by positioning each of the clamps.

Vapor Hose Replacement
REMOVAL

Regulator Replacement
Refer to Figure 3-95. GM 3.0 Dual Fuel System Components.

1.

Disconnect both hose clamps using hose clamp pliers.

2.

Remove vapor hose from each fitting.

INSTALLATION

REMOVAL
1.

Disconnect and remove Lock-Off Valve (12) from Regulator (16).

2.

Remove hoses from regulator.

3.

Remove regulator from engine.

VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED FOR THIS EQUIPMENT. DO
NOT USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED PARTS.

INSTALLATION

1.

Install hose clamps and set back on each hose.

2.

Reinstall vapor hose to each fitting.

1.

Install Regulator (16) on engine.

3.

Reset clamps.

2.

Install hoses on regulator.

4.

Start engine and check for leaks.

3.

Install Lock-Off Valve (12) to Regulator. Reconnect LockOff Valve.

4.

Start engine and leak check all fittings and connections.

3121298

– JLG Lift –

3-89

SECTION 3 - CHASSIS & TURNTABLE

Engine Control Module Replacement

Heated Exhaust Gas Oxygen Sensor Replacement
REMOVAL

REMOVAL
1.

Disconnect Negative battery cable.

2.

Remove controller from mounting bracket.

3.

Push connector lock back to unlock connector.

4.

Unplug and remove controller.

1.

Disconnect negative (-) battery cable.

2.

Disconnect O2 sensor electrical connector.

3.

Using an O2 Sensor socket, remove and discard Sensor.

INSTALLATION

INSTALLATION

CONTROLLER IS CALIBRATED FOR EACH ENGINE. VERIFY YOU HAVE CORRECT
CONTROLLER.

LUBRICATE O2 SENSOR THREADS WITH ANTI-SEIZE COMPOUND GM P/N
5613695 OR EQUIVALENT BEFORE INSTALLATION. DO NOT GET COMPOUND
ON SENSOR TIP.
1.

Install O2 sensor. Tighten to 30 lb-ft (41 Nm).

1.

Plug connector into controller.

2.

Start engine.

2.

Push lock into place.

3.

Check and clear any DTC codes.

3.

Mount controller into mounting bracket.

4.

4.

Reconnect the battery cable.

Verify engine is in closed loop and no warning lights are
illuminated.

5.

Start engine.

6.

Check and clear any DTC codes.

7.

Verify engine is in closed loop and no warning lights are
illuminated.

3-90

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

3.20 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS

Diagnostic Aids
This procedure is intended to diagnose a vehicle operating on
LPG. If vehicle will not continue to run on LPG, refer to Hard
Start for preliminary checks.

Fuel System Description

NOTE: Before proceeding with this procedure, verify vehicle has a
sufficient quantity of fuel and that liquid fuel is being delivered to the LPR. Ensure the LPG tank manual shut off valve
is fully opened and excess flow valve has not been activated.
Tools Required:
• 7/16 Open end wrench (for test port plugs)
• DVOM (GM J 39200, Fluke 88 or equivalent).
• 12 volt test light
Diagnostic Scan Tool
• Diagnostic Display tool.
Pressure Gauges
Figure 3-105. DEPR

• IMPCO ITK-2 Test kit
• Water Column Gauge / Manometer (GM 7333-6 or equivalent).

The Engine Control Module (ECM) receives information from
various engine sensors to control the Direct Electronic Pressure Regulator (DEPR) and lock-off Valve.

• 0-10 PSI Gauge

The lock-off Valve solenoid prevents fuel flow unless the
engine is cranking or running.

Test Description

At Key ON, the DEPR valve receives a two (2) second prime
pulse from the ECM, allowing time for the fuel to flow through
the fuel filter and fuel lines to the DEPR.

5. This step determines if the LPR requires replacement

Fuel travels from the lock-off to the light duty 2- stage regulator into the DEPR.
Engine cranking generates vacuum which provided lift for the
mixer air valve and is commonly referred to as air valve vacuum. Once in the mixer, fuel is combined with air and drawn
into the engine for combustion.

3121298

Numbers below refer to step numbers on the diagnostic table.

6. This step determines if the problems are in the mechanical
side of the Pressure Regulator or the Electronic Voice Coil
10. This step determines if the Mixer requires replacement
14. This step determines if the Lock Off requires replacement
17. This step determines if the Fuel Filter requires replacement.

– JLG Lift –

3-91

SECTION 3 - CHASSIS & TURNTABLE

Table 3-11. LP Fuel System Diagnosis
STEP

ACTION

VALUE(S)

YES

NO

1

Were you referred to this procedure by a DTC diagnostic chart?

--

Go to Step 3

Go to Step 2

2

Perform the On Board Diagnostic (OBD) System Check.
Are any DTCs present in the ECM?

--

Go to the
applicable DTC Table

Go to Step 3

3

Verify that the LPG fuel tank has a minimum of 1/4 tank of fuel, that the manual valve is open
and the tank quick connect is fully engaged
Does the vehicle have fuel?

--

Go to Step 4

--

4

1. Connect a water column gauge or a manometer to the secondary test port of the low pressure
regulator (LPR).
2. Start the engine and allow it to reach operating temperature.
Does the engine start and run?

--

Go to Step 5

Go to Step 8

5

With the engine idling, observe the pressure reading for the LPR secondary pressure.
Does the fuel pressure fluctuate rhythmically OUTSIDE the specified range?

-1.0" to
-2.0" w.c

Go to Step 25

Go to Step 6

6

1. Disconnect the EPR electrical connectors. NOTE: This action will cause a DTC to be set by the
ECM
2. With the engine idling observe the pressure reading on the secondary test port.
Is the fuel pressure WITHIN the specified range?

-1.0" to
-2.0" w.c

Go to Fuel Control System
Diagnosis

Go to Step 7

7

1. Inspect the air intake stream between the mixer assembly and the throttle body for leaks.
2. Inspect the fuel hose connection between the LPR and mixer assembly for damage or leakage.
3. Inspect any vacuum hoses for leaks
Was a problem found and corrected?

--

Go to Step 26

Go to Step 22

8

1. Connect a water column gauge or a manometer to the secondary test port of the low pressure
regulator (LPR).
2. Crank the engine and observe the pressure reading for the LPR secondary pressure.
Does the fuel pressure indicate a vacuum is present?

--

Go to Step 12

Go to Step 9

9

1. Remove Air induction hose to the mixer
2. Observe the air valve for movement while the engine is cranking. Note: Movement of the air
valve will be minimal at cranking speeds.
Does the air valve move when the engine is cranked?

--

Go to Step 11

Go to Step 10

10

1. Inspect the air intake stream to the mixer assembly and the throttle body for vacuum leaks.
2. Inspect the vacuum hoses from the mixer for proper connection and condition.
Was a problem found and repaired?

--

Go to Step 26

Go to Step 24

11

Inspect the fuel hose connection between the LPR and the mixer assembly for damage or leakage.
Was a problem found and repaired?

--

Go to Step 26

Go to Step 12

12

1. Connect a 0-10 psi gauge to the primary test port of the low pressure regulator (LPR).
2. Crank the engine and observe the pressure reading for the LPR primary pressure.
Is the fuel pressure ABOVE the specified value?

1- 3 PSI

Go to Step 22

Go to Step 13

13

1. Turn OFF the ignition.
2. Disconnect the LPL connector.
3. Install a test light between the pins of the LPL connector.
4. Crank the engine. The test light should illuminate.
Does the test light illuminate?

--

Go to Step 14

Go to Step 16

14

Using a DVOM, check the resistance of the low pressure lock-off (LPL).
Is the resistance within the specified range?

12W - 16W

Go to Step 15

Go to Step 23

3-92

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Table 3-11. LP Fuel System Diagnosis
STEP

ACTION

VALUE(S)

YES

NO

15

1. Turn the ignition OFF.
2. Close the manual shut-off valve on the LPG tank.
CAUTION: When disconnecting LPG fuel lines, liquid LPG may be present. Perform this step in a
well ventilated area.
3. Loosen the fuel inlet hose fitting at the inlet of the LPL.
Was fuel present when the fitting was loosened?

--

Go to Step 23

Go to Step 17

16

1. Turn OFF the ignition.
2. Connect the test light to chassis ground and probe pin A of the LPL connector.
3. Crank the engine. The test light should illuminate.
Does the test light illuminate?

--

Go to Step 20

Go to Step 21

17

1. Remove the LPG fuel filter / LPL.
2. Remove the filter from the LPL.
3. Empty the contents of the inlet side of the LPG fuel filter onto a clean surface.
4. Inspect the contents of the LPG fuel filter for an excessive amount of foreign material or
water. If necessary, locate and repair the source of contamination.
5. Verify the LPG fuel filter is not restricted or plugged.
Was a problem found?

--

Go to Step 19

Go to Step 18

18

The fuel supply system or hoses are plugged or restricted, locate and repair the problem.
Is the action complete?

--

Go to Step 26

--

19

Replace the fuel filter. Refer to Fuel Filter Replacement.
Is the action complete?

--

Go to Step 26

--

20

Repair the open in the lock-off ground circuit.
Is the action complete?

--

Go to Step 26

--

21

Repair the open in the lock-off power circuit.
Is the action complete?

--

Go to Step 26

--

22

Replace the low pressure regulator (LPR). Refer to Low Pressure Regulator Replacement.
Is the action complete?

--

Go to Step 26

--

23

Replace the lock-off. Refer to Lock-off Replacement.
Is the action complete?

--

Go to Step 26

--

24

Replace the mixer assembly. Refer to Fuel Mixer Replacement.
Is the action complete?

--

Go to Step 26

--

25

The fuel supply system is operating normally, if a failure of the control solenoids is suspected.
Refer to Fuel Control System Diagnosis.

--

System OK

--

--

System OK

--

1. Install the test plug in the LPR secondary chamber.
2. If you were sent to this routine by another diagnostic chart, return to the previous diagnostic
procedure.
Is the action complete?
26

1. Disconnect all test equipment
2. Install the primary and secondary test port plugs.
3. Start the engine.
4. Using SNOOP or equivalent, leak check the test port plugs.
Is the action complete?

3121298

– JLG Lift –

3-93

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks

Action
Important Preliminary Checks

Before Using This Section

Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful visual and physical check. The visual and physical checks are very important. The
checks can lead to correcting a problem without further checks that may save valuable time.

LPG Fuel System Check

1. Verify the customer complaint.
2. Locate the correct symptom table.
3. Check the items indicated under that symptom.
4. Operate the vehicle under the conditions the symptom occurs. Verify HEGO switching between lean and rich.
IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operating correctly at that time.

Visual and Physical Checks

2 Check all ECM system fuses and circuit breakers.
2 Check the ECM ground for being clean, tight and in its proper location.
2 Check the vacuum hoses for splits, kinks and proper connections.
2 Check thoroughly for any type of leak or restriction.
2 Check for air leaks at all the mounting areas of the intake manifold sealing surfaces.
2 Check for proper installation of the mixer module assembly.
2 Check for air leaks at the mixer assembly.
2 Check the ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
2 Check the wiring for the following items:
- Proper connections, pinches or cuts.
2 The following symptom tables contain groups of possible causes for each symptom. The order of these procedures is not important. If the scan
tool readings do not indicate the problems, then proceed in a logical order, easiest to check or most likely to cause first.
Intermittent

DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks

2 Refer to Important Preliminary Checks.
2 Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good parts.

Faulty Electrical Connections or Wiring

2 Faulty electrical connections or wiring can cause most intermittent problems.
2 Check the suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient.
2 Carefully remove all the connector terminals in the problem circuit in order to ensure the proper contact tension. If necessary, replace all the
connector terminals in the problem circuit in order to ensure the proper contact tension.
2 Checking for poor terminal to wire connections requires removing the terminal from the connector body.

Operational Test

If a visual and physical check does not locate the cause of the problem, drive the vehicle with a scan tool. When the problem occurs, an abnormal
voltage or scan reading indicates the problem may be in that circuit.

3-94

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks

Action

Intermittent Malfunction Indicator Lamp
(MIL)

The following components can cause intermittent MIL and no DTC(s):
2 A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interference. Normally, the problem will occur
when the faulty component is operating.
2 The improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
2 The ignition secondary voltage shorted to a ground.
2 The Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to ground.
2 The Control Module grounds.

Loss of DTC Memory

To check for the loss of the DTC Memory:
1. Disconnect the TMAP sensor.
2. Idle the engine until the Malfunction Indicator Lamp illuminates.

The ECM should store a TMAP DTC. The TMAP DTC should remain in the memory when the ignition is turned OFF. If the TMAP DTC does not store
and remain, the ECM is faulty

Additional Checks
No Start
DEFINITION: The engine cranks OK22but does not start.
Preliminary Checks

Refer to Important Preliminary Checks.

Control Module Checks

If a scan tool is available:
2 Check for proper communication with both the ECM
2 Check the fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
2 Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schematics. Verify voltage and/or continuity for
each circuit.

Sensor Checks

2 Check the TMAP sensor.
2 Check the Magnetic pickup sensor (RPM).

Fuel System Checks

Important: A closed LPG manual fuel shut off valve will create a no start condition.
2 Check for air intake system leakage between the mixer and the throttle body.
2 Verify proper operation of the low pressure lock-off solenoids.
2 Check the fuel system pressures. Refer to the LPG Fuel System Diagnosis.
2 Check for proper mixer air valve operation.

Ignition System Checks

Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions.
2 Check for the proper ignition voltage output with J 26792 or the equivalent.
2 Verify that the spark plugs are correct for use with LPG (R42LTS)
2 Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
2 Check for bare or shorted ignition wires.
2 Check for loose ignition coil connections at the coil.

Engine Mechanical Checks

Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than
the gasoline fuel supply system.
2 Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.

3121298

– JLG Lift –

3-95

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks
Exhaust System Checks

Action
2 Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure.
2 Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis
Hard Start

DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
Preliminary Checks

2 Refer to Important Preliminary Checks.
2 Make sure the vehicle's operator is using the correct starting procedure.

Sensor Checks

2Check the Engine Coolant Temperature sensor with the scan tool. Compare the engine coolant temperature with the ambient air temperature
on a cold engine. IF the coolant temperature reading is more than 5 degrees greater or less than the ambient air temperature on a cold engine,
check for high resistance in the coolant sensor circuit. Refer to DTC 111
2 Check the Crankshaft Position (CKP) sensor.
2Check the Throttle position (TPS) sensor.

Fuel System Checks

Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition.
2 Verify the excess flow valve in the LPG manual shut-off valve is not tripped.
2 Check mixer module assembly for proper installation and leakage.
2 Verify proper operation of the low pressure lock-off solenoids.
2 Verify proper operation of the EPR
2 Check for air intake system leakage between the mixer and the throttle body.
2 Check the fuel system pressures. Refer to the Fuel System Diagnosis.

Ignition System Checks

Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions.
2 Check for the proper ignition voltage output with J 26792 or the equivalent.
2 Verify that the spark plugs are correct for use with LPG (R42LTS)
2 Check the spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
2 Check for bare or shorted ignition wires.
2 Check for moisture in the distributor cap if applicable.
2 Check for loose ignition coil connections.
Important:
1. If the engine starts but then immediately stalls, Check the Crankshaft Position (CKP).
2. Check for improper gap, debris or faulty connections.

Engine Mechanical Checks

Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than the
gasoline fuel supply system.
2 Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.
2 Check the intake and exhaust manifolds for casting flash.

Exhaust System Checks

2 Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure.
2 Check for possible plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System in the GM Base Engine Service
Manual

3-96

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks
Additional Checks

Action
2
Cuts Out, Misses

DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases which is not normally felt above 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Checks

2 Refer to Important Preliminary Checks.

Ignition System Checks

2 Start the engine.
2 Wet down the secondary ignition system with water from a spray bottle, and look/listen for arcing or misfiring as you apply water.
2 Check for proper ignition output voltage with spark tester J 26792.
2 Check for a cylinder misfire.
2 Verify that the spark plugs are correct for use with LPG (R42LTS)
2 Remove the spark plugs in these cylinders and check for the following conditions:
2 Insulation cracks
2 Wear
2 Improper gap
2 Burned electrodes
2 Heavy deposits
2 Visually/Physically inspect the secondary ignition for the following:
2 Ignition wires for arcing, cross-firing and proper routing
2 Ignition coils for cracks or carbon tracking

Engine Mechanical Checks

2 Perform a cylinder compression check.
2 Check the engine for the following:
- Improper valve timing
- Bent pushrods
- Worn rocker arms
- Worn camshaft lobes.
- Broken or weak valve springs.
2 Check the intake and exhaust manifold passages for casting flash.

Fuel System Checks

2 Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
2 Check the condition of the wiring to the low pressure lock-off solenoid.

Additional Check

Check for Electromagnetic Interference (EMI).
2 EMI on the reference circuit can cause a missing condition.
2 Monitoring the engine RPM with a scan tool can detect an EMI.
2 A sudden increase in the RPM with little change in the actual engine RPM, indicates EMI is present.
2 If the problem exists, check the routing of the secondary wires and the ground circuit.
Hesitation, Sag, Stumble

DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it's
severe enough.
Preliminary Checks

Refer to Important Preliminary Checks.

Fuel System Checks

2 Check the fuel pressure. Refer to LPG Fuel System Diagnosis.
2 Check for low fuel pressure during a moderate or full throttle acceleration. If the fuel pressure drops below specification, there is possibly a
faulty low pressure regulator or a restriction in the fuel system.
2 Check the Manifold Absolute Pressure (MAP) sensor response and accuracy.
2 Check LPL electrical connection
2 Check the mixer air valve for sticking or binding.
2 Check the mixer module assembly for proper installation and leakage.
2 Check the EPR electrical connections.

3121298

– JLG Lift –

3-97

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks

Action

Ignition System Checks

Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. If a problem is reported on LPG and not gasoline, do not discount the possibility of a LPG only ignition system failure and test the system accordingly.
2 Check for the proper ignition voltage output with J 26792 or the equivalent.
2 Verify that the spark plugs are correct for use with LPG (R42LTS)
2 Check for faulty spark plug wires
2 Check for fouled spark plugs.

Additional Check

2 Check for manifold vacuum or air induction system leaks
2 Check the generator output voltage.
Backfire

DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Preliminary Check

2 Refer to Important Preliminary Checks.

Ignition System Checks

Important! LPG, being a gaseous fuel, requires higher secondary ignition system voltages for the equivalent gasoline operating conditions. The ignition system must be maintained in peak condition to prevent backfire.
2 Check for the proper ignition coil output voltage using the spark tester J26792 or the equivalent.
2 Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the
wires.
2 Check the connection at each ignition coil.
2 Check for deteriorated spark plug wire insulation.
2 Check the spark plugs. The correct spark plugs for LPG are (R42LTS)
2 Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits

Engine Mechanical Check

Important! The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than a
gasoline fuel supply system.
2 Check the engine for the following:
- Improper valve timing
- Engine compression
- Manifold vacuum leaks
- Intake manifold gaskets
- Sticking or leaking valves
- Exhaust system leakage
2 Check the intake and exhaust system for casting flash or other restrictions.

Fuel System Checks

2 Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
Lack of Power, Sluggishness, or Sponginess

DEFINITION: The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator pedal.
Preliminary Checks

3-98

2 Refer to Important Preliminary Checks.
2 Refer to the LPG Fuel system OBD System Check
2 Compare the customer's vehicle with a similar unit. Make sure the customer has an actual problem. Do not compare the power output of the
vehicle operating on LPG to a vehicle operating on gasoline as the fuels do have different drive feel characteristics
2 Remove the air filter and check for dirt or restriction.
2 Check the vehicle transmission Refer to the OEM transmission diagnostics.

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks

Action

Fuel System Checks

2 Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System Diagnosis.
2 Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
2 Check for proper installation of the mixer module assembly.
2 Check all air inlet ducts for condition and proper installation.
2 Check for fuel leaks between the LPR and the mixer.
2 Verify that the LPG tank manual shut-off valve is fully open.
2 Verify that liquid fuel (not vapor) is being delivered to the LPR.

Sensor Checks

2 Check the Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance. Check for proper operation of the MAP sensor.
2 Check for proper operation of the TPS sensor.

Exhaust System Checks

2 Check the exhaust system for a possible restriction:
- Inspect the exhaust system for damaged or collapsed pipes
- Inspect the muffler for signs of heat distress or for possible internal failure.
- Check for possible plugged catalytic converter.

Engine Mechanical Check

Check the engine for the following:
2 Engine compression
2 Valve timing
2 Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.

Additional Check

2 Check the ECM grounds for being clean, tight, and in their proper locations.
2 Check the generator output voltage.
2 If all procedures have been completed and no malfunction has been found, review and inspect the following items:
2 Visually and physically, inspect all electrical connections within the suspected circuit and/or systems.
2 Check the scan tool data.
Poor Fuel Economy

DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this vehicle at one time, as previously
shown by an by refueling records.
Preliminary Checks

2 Refer to Important Preliminary Checks.
2 Check the air cleaner element (filter) for dirt or being plugged.
2 Visually (Physically) check the vacuum hoses for splits, kinks, and proper connections.
2 Check the operators driving habits for the following items:
- Is there excessive idling or stop and go driving?
- Are the tires at the correct air pressure?
- Are excessively heavy loads being carried?
- Is their often rapid acceleration?
2 Suggest to the owner to fill the fuel tank and to recheck the fuel economy.
2 Suggest that a different operator use the equipment and record the results.

Fuel System Checks

2 Check the LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
2 Check the fuel system for leakage.

Sensor Checks

2 Check the Temperature Manifold Absolute Pressure (TMAP) sensor.

Ignition System Checks

2 Verify that the spark plugs are correct for use with LPG (R42LTS)
2 Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
2 Check the ignition wires for the following items:
- Cracking
- Hardness
- Proper connections

Cooling System Checks

2 Check the engine thermostat for always being open or for the wrong heat range

3121298

– JLG Lift –

3-99

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks
Additional Check

Action
2 Check the transmission shift pattern. Refer to the OEM Transmission Controls section the Service Manual.
2 Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling

DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPM. Either condition may be severe enough to stall the
engine.
Preliminary Check

Refer to Important Preliminary Checks.

Sensor Checks

2Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white powdery coating. The sensor will result in a
high but false signal voltage (rich exhaust indication). The ECM will reduce the amount of fuel delivered to the engine causing a severe driveability problem.
2Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
2Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.

Fuel System Checks

2Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will
help identify the problem.
2Check for a sticking mixer air valve.
2Verify proper operation of the EPR.
2Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
2Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
2Check mixer module assembly for proper installation and connection.

Ignition System Checks

2Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
2 Verify that the spark plugs are correct for use with LPG (R42LTS)
2Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
2Check the spark plug wires by connecting an ohmmeter to the ends of each wire in question. If the meter reads over 30,000 ohms, replace the
wires.

Additional Checks

Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to intake manifold leakage than
the gasoline fuel supply system.
2Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle control command.
2Check the ECM grounds for being clean, tight, and in their proper locations.
2Check the battery cables and ground straps. They should be clean and secure. Erratic voltage may cause all sensor readings to be skewed
resulting in poor idle quality.

Engine Mechanical Check

2 Check the engine for the following:
- Broken motor mounts
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
Surges/Chuggles

DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal.
Preliminary Checks

Refer to Important Preliminary Checks.

Sensor Checks

2 Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.

3-100

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Table 3-12. Symptom Diagnosis
Checks

Action

Fuel System Checks

2 Check for Rich or Lean symptom that causes the condition. Drive the vehicle at the speed of the complaint. Monitoring the oxygen sensors will
help identify the problem.
2 Check the fuel pressure while the condition exists. Refer to LPG Fuel System Diagnosis.
2 Verify proper fuel control solenoid operation.
2 Verify that the LPG manual shut-off valve is fully open.
2 Check the in-line fuel filter for restrictions.

Ignition System Checks

2 Check for the proper ignition output voltage using the spark tester J26792 or the equivalent.
2 Verify that the spark plugs are correct for use with LPG (R42LTS)
2 Check the spark plugs. Remove the plugs and inspect them for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
- Check the Crankshaft Position (CKP) sensor.

Additional Check

2 Check the ECM grounds for being clean, tight, and in their proper locations.
2 Check the generator output voltage.
2 Check the vacuum hoses for kinks or leaks.
2 Check Transmission

3121298

– JLG Lift –

3-101

SECTION 3 - CHASSIS & TURNTABLE

Table 3-13. DTC to SPN/FMI Cross Reference Chart
DTC

3-102

SPN Code

FMI Code

16

Crank Never Synced at Start

Description

636

8

91

Fuel Pump Low Voltage

94

4

92

Fuel Pump High Voltage

94

3

107

MAP Low Voltage

106

4

108

MAP High Pressure

106

16

111

IAT Higher Than Expected 1

105

15

112

IAT Low Voltage

105

4

113

IAT High Voltage

105

3

116

ECT Higher Than Expected 1

110

15

117

ECT Low Voltage

110

4

118

ECT High Voltage

110

3

121

TPS 1 Lower Than TPS 2

51

1

122

TPS 1 Signal Voltage Low

51

4

123

TPS 1 Signal Voltage High

51

3

127

IAT Higher Than Expected 2

105

0

129

BP Low Pressure

108

1

134

EGO 1 Open/Inactive

724

10

154

EGO 2 Open/Inactive

520208

10

171

Adaptive Learn High Gasoline

520200

0

172

Adaptive Learn Low Gasoline

520200

1

182

Fuel Temp Gasoline Low Voltage

174

4

183

Fuel Temp Gasoline High Voltage

174

3

187

Fuel Temp LPG Low Voltage

520240

4

188

Fuel Temp LPG High Voltage

520240

3

217

ECT Higher Than Expected 2

110

0

219

Max Govern Speed Override

515

15

221

TPS 2 Signal Voltage Low

51

0

222

TPS 2 Signal Low Voltage

520251

4

223

TPS 2 Signal High Voltage

520251

3

261

Injector Driver 1 Open

651

5

262

Injector Driver 1 Shorted

651

6

264

Injector Driver 2 Open

652

5

265

Injector Driver 2 Shorted

652

6

267

Injector Driver 3 Open

653

5

268

Injector Driver 3 Shorted

653

6

270

Injector Driver 4 Open

654

5

271

Injector Driver 4 Shorted

654

6

336

Crank Sync Noise

636

2

337

Crank Loss

636

4

341

Cam Sync Noise

723

2

342

Cam Sensor Loss

723

4

420

Gasoline Cat Monitor

520211

10

524

Oil Pressure Low

100

1

– JLG Lift –

3121298

SECTION 3 - CHASSIS & TURNTABLE

Table 3-13. DTC to SPN/FMI Cross Reference Chart
DTC

3121298

Description

SPN Code

FMI Code

562

System Voltage Low

168

17

563

System Voltage High

168

15

601

Flash Checksum Invalid

628

13

604

RAM Failure

630

12

606

COP Failure

629

31

642

External 5V Reference Low

1079

4

643

External 5V Reference High

1079

3

685

Power Relay Open

1485

5

686

Power Relay Shorted

1485

4

687

Power Relay Short to Power

1485

3

1111

Fuel Rev Limit

515

16

1112

Spark Rev Limit

515

0

1151

Closed Loop Multiplier High LPG

520206

0

1152

Closed Loop Multiplier Low LPG

520206

1

1155

Closed Loop Multiplier High Gasoline

520204

0

1156

Closed Loop Multiplier Low Gasoline

520204

1

1161

Adaptive Learn High LPG

520202

0

1162

Adaptive Learn Low LPG

520202

1

1165

LPG Cat Monitor

520213

10

1171

LPG Pressure Higher Than Expected

520260

0

1172

LPG Pressure Lower Than Expected

520260

1

1173

EPR Comm Lost

520260

31

1174

EPR Voltage Supply High

520260

3

1175

EPR Voltage Supply Low

520260

4

1176

EPR Internal Actuator Fault

520260

12

1177

EPR Internal Circuitry Fault

520260

12

1178

EPR Internal Comm Fault

520260

12

1612

RTI 1 loss

629

31

1613

RTI 2 Loss

629

31

1614

RTI 3 Loss

629

31

1615

A/D Loss

629

31

1616

Invalid Interrupt

629

31

1625

Shutdown Request

1384

31

1626

CAN Tx Failure

639

12

1627

CAN Rx Failure

639

12

1628

CAN Address Conflict Failure

639

13

1629

Loss of TSC 1

639

31

2111

Unable to Reach Lower TPS

51

7

2112

Unable to Reach Higher TPS

51

2135

TPS 1/2 Simultaneous Voltages

51

31

2229

BP Pressure High

108

0

– JLG Lift –

3-103

SECTION 3 - CHASSIS & TURNTABLE

NOTES:

3-104

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM
f. Tag and disconnect hydraulic lines to slave leveling
cylinder. Use a suitable container for residual
hydraulic fluid. Cap hydraulic lines and ports.
Remove slave cylinder.

4.1 BOOM SYSTEMS
Removal
1.

Remove platform/support as follows:
a. Disconnect electrical cable from control console.
b. Remove eight bolts securing platform to platform
support and remove the platform.


c. Using an overhead crane or suitable lifting device,
strap support platform support.
d. Remove six bolts and locknuts securing support to
rotator.
e. Using a suitable brass drift and hammer, remove
rotator shaft, then remove support from rotator.




Figure 4-2. Rotator and Leveling Cylinder Locations
3.

Remove powertrack from boom as follows:
a. Disconnect wiring harness from ground control box.

Figure 4-1. Location of Components - Platform Support
2.

Remove rotator and slave level cylinder from fly boom
as follows:

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

a. Tag and disconnect hydraulic lines to rotator. Use
suitable container for residual hydraulic fluid. Cap
hydraulic lines and ports.

b. Tag and disconnect hydraulic lines from boom to
control valve. Use a suitable container for residual
hydraulic fluid. Cap hydraulic lines and ports.

b. Remove hardware from pin #1. Remove pin #1 from
fly boom with a suitable brass drift and hammer.

c. Disconnect dual capacity indicator limit switch from
side of boom section.

c. Support rotator. Remove hardware from pin #2.
Remove pin #2 from fly boom with a suitable brass
drift and hammer. Remove rotator.

d. Remove hydraulic lines and electrical cables from
powertrack.

d. Telescope fly section out approximately 20 inches
(50.8 cm) to access slave leveling cylinder.
e. Support slave cylinder. Remove hardware from pin
#3. Remove pin #3 from fly boom with a suitable
brass drift and hammer.

3121298

– JLG Lift –

e. Using a suitable lifting equipment, adequately support powertrack weight along entire length.
f. Remove bolts #1 securing push tube on fly boom
section.
g. Remove bolts #2 securing push tube on mid boom
section.

4-1

SECTION 4 - BOOM & PLATFORM

h. With powertrack support and using all applicable
safety precautions, remove bolts #3 and #4 securing
rail to the base boom section. Remove powertrack
from boom section.

4.2 WEAR PADS
Wear pads are made of polyethylene. Pads move on polyurethene painted surfaces. No paint is removed and no lubrication
is applied.

     !
   "
#"     

    
   
     






Figure 4-3. Boom Powertrack Components
4.





Remove boom assembly from machine as follows:
a. Using suitable lifting equipment, adequately support boom assembly weight along entire length.



CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING
LINES TO PREVENT ENTRY OF CONTAMINANTS INTO SYSTEM.







b. Tag and disconnect hydraulic lines from telescope
cylinder. Use a suitable container for residual
hydraulic fluid. Cap hydraulic lines and ports.

PAD

c. Remove hardware securing lift cylinder rod end to
base boom section.

A

5/8"

9/16"

B, C, D

3/4"

5/8"

d. Using a suitable brass drift and hammer, remove lift
cylinder pin from base boom.

THICKNESS
OF NEW PAD

REPLACE WHEN
WORN TO:

Figure 4-4. Location and Thickness of Wear Pads

e. Remove hardware securing master cylinder rod end
to base boom section.

1.

Shim wear pads to within 1/32 inch (.79 mm) tolerance
between wear pad and adjacent surface.

f. Using a suitable brass drift and hammer, remove the
master cylinder pin from the base boom.

2.

Replace wear pads when worn within 1/16 inch (1.59
mm) and 1/8 inch (3.18 mm) - B, C, D of threaded insert.
See Location and Thickness Of Wear Pads.

3.

Bolt length must be changed when adjusting wear pads
and removing or adding shims.

g. Remove hardware securing push bar to turntable
upright.

WHEN REMOVING PIN FROM PUSHBAR DO NOT DROP PUSHBAR ON WIRE
ROPE ADJUSTMENT THREADS. FAILURE TO DO SO WILL DAMAGE THREADS.
h. Using a suitable brass drift and hammer, remove
push bar pin from turntable upright.

a. Longer bolts must be used when adding shims to
ensure proper thread engagement in insert.
b. Shorter bolts must be used when shims are
removed so bolt does not protrude from insert and
contact boom surface.

i. Remove hardware securing boom pivot pin to turntable upright.
j. Using a suitable brass drift and hammer, remove
pivot pin from turntable upright.
k. Using all applicable safety precautions, carefully lift
boom assembly clear of turntable and lower to
ground or suitably supported work surface.

4-2

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

4.

4.3 BOOM DISASSEMBLY/ASSEMBLY & CABLE
REPLACEMENT

Remove spring mounting plate, spring, and proximity
switch from aft end of base section.

Boom Section Disassembly
1.

Remove hardware securing push bar to aft end of telescope cylinder. Remove pin from cylinder.

2.

Remove hardware securing cover plate on bottom front
of base boom section.

DO NOT ALLOW WIRE ROPE TO ROTATE. THIS MAY DAMAGE THE WIRE ROPE.
3.

Clamp both threaded ends of wire rope to prevent rotation. Note: Do not clamp on threads. Remove jam nuts
and nuts which secure wire rope adjustments to bottom
front of base boom section.

Figure 4-6. Proximity Switch Assembly Disassembly

Figure 4-5. Clamping Wire Ropes
NOTE: CE specification machines go to Step 4. All other machines
go to Step 5.

3121298

5.

Remove hardware securing wire rope adjustment block
to aft end of base boom section and remove block.

6.

Remove hardware securing telescope cylinder to aft end
of mid boom section.

WHEN REMOVING TELESCOPE CYLINDER FROM BOOM, IT MAY BE NECESSARY
TO TURN CYLINDER SLIGHTLY TO CLEAR ASSEMBLIES MOUNTED IN BOOM.
MOVE CYLINDER SLOWLY OUT OF POSITION. DAMAGE TO COMPONENTS MAY
RESULT FROM FORCIBLE IMPACT WITH ASSEMBLIES.

– JLG Lift –

7.

Remove bolts securing wire rope attach bar to top of fly
boom section.

8.

Pull telescope cylinder and wire ropes partially from aft
end of base boom section. Secure cylinder with a suitable sling and lifting device at center of gravity.

4-3

SECTION 4 - BOOM & PLATFORM

NOTE: Check groove so that it may be clearly seen if gauge contour matches sheave groove contour.

4.4 WIRE ROPE

WIRE ROPE CAN HAVE SHARP EDGES AND CAUSE SERIOUS INJURY. NEVER
HANDLE WIRE ROPE WITH BARE HANDS.
Each day before using machine:
1.

Raise main boom approximately horizontal.

2.

Extend and retract the boom sections.

3.

Check for delayed movement of fly section which indicates loose wire ropes.

Figure 4-9. Sheave Groove Wear
7.

Inspection
NOTE: Pictures in this paragraph are samples to show rope
replacement criteria.
1.

Ropes passing inspection should be lubricated with wire
rope lubricant before reassembly.

Three Month Inspection
1.

Remove boom covers and visually (with flashlight)
inspect the ropes for rust, broken wires, frays, abuse, or
any signs of abnormalities.

2.

Check wire rope tension by deflecting wire ropes by
hand. Properly tensioned ropes should have little or no
movement.

Inspect ropes for broken wires, particularly valley wire
breaks and breaks at end terminations.

NOTE: Flexing a wire rope can often expose broken wires hidden
in valleys between strands.

Eight Year Inspection
1.

Figure 4-7. Wire Rope Wire Breaks
2.

Inspect ropes for corrosion.

3.

Inspect ropes for kinks or abuse.

Mandatory wire rope and sheave replacement.

Additional inspection required if:
a. Machine is exposed to hostile environment or conditions.
b. Erratic boom operation or unusual noise exists.
c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.

NOTE: A kink is caused by pulling down a loop in a slack line during improper handling, installation, or operation.

e. Boom exposed to electrical arc. Wires may be fused
internally.

Replacement Criteria
NOTE: Sheaves and wire rope must be replaced as sets.

Figure 4-8. Wire Rope Kink
4.

5.

4-4

Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)Inspect
sheaves for condition of flanges. (See Dimension Of
Sheaves for proper dimension.)
Inspect sheaves with a groove wearout gauge for excessive wear.

– JLG Lift –

1.

Rusted or corroded wire ropes.

2.

Kinked, “bird caged”, or crushed ropes.

3.

Ropes at end of adjustment range.

4.

Sheaves failing wearout gage inspection.

5.

Ropes with 6 total broken wires in one rope lay, 3 in one
strand in one rope lay, 1 valley break, or 1 break at any
end termination.

3121298

SECTION 4 - BOOM & PLATFORM

4.5 WIRE ROPE TENSIONING ADJUSTMENT
Wire Rope Tensioning Procedure
1.

2.

Install adjusting nuts (or remove nylon collar locknuts if
re-adjusting) to both retract and extend wire ropes.

3.

Torque retract adjusting nuts (platform end) to 15 ft-lb
(20 Nm) alternating between the two wire ropes and
keeping approximately the same amount of thread
beyond the adjusting nut.

4.

Repeat torque procedure in step #4 to extend wire ropes
(turntable end).

5.

Extend boom 2 - 3 feet using telescope function. Repeat
step #4.

6.

Retract boom 1 - 2 feet using telescope function. Do not
bottom out telescope cylinder. Repeat step #5.

7.

Extend boom approximately 2 - 3 feet again and check
torque on retract wire ropes.

8.

Retract boom without bottoming out telescope cylinder. Check torque on extend wire ropes.

Position boom in fully down and retracted position.

NOTE: Step #8 and #9 may need to be repeated to equalize the
torque on all 4 wire ropes.
Figure 4-10. Dimensions of Boom Sections
9.
DO NOT CLAMP ON THREADS OR THREADS MAY BE DAMAGED.

DO NOT ALLOW WIRE ROPE TO ROTATE OR WIRE ROPE MAY BE DAMAGED.
CLAMP THREADED ENDS OF WIRE ROPE TO PREVENT ROTATION.

After all wire ropes are properly torqued, install nylon
collar locknuts. Remove all clamping devices and install
all covers and guards. Check boom for proper function.

Figure 4-11. Clamping Wire Ropes

3121298

– JLG Lift –

4-5

SECTION 4 - BOOM & PLATFORM

Figure 4-12. Boom Assembly Cutaway - Sheet 1 of 3

4-6

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

Figure 4-13. Boom Assembly Cutaway - Sheet 2 of 3

3121298

– JLG Lift –

4-7

SECTION 4 - BOOM & PLATFORM

 



  



 
  

 



Figure 4-14. Boom Assembly Cutaway - Sheet 3 of 3
10.

Carefully remove telescope cylinder and sheave assembly. Place telescope cylinder on a suitable trestle.

Figure 4-15. Disassembly of Sheave Assembly
11.

Remove hardware securing wear pads to front of base
boom section. Remove wear pads from top, sides, and
bottom of base boom section.

12.

Using an overhead crane or suitable lifting device,
remove mid and fly boom sections from base section.
Note: When removing mid and fly boom sections from
base boom section, retract wire rope must be dragged
along with boom sections.

13.

Remove hardware which secures wear pads to aft end of
mid boom section. Remove wear pads from top, sides,
and bottom of mid boom section.

14.

Remove hardware which secures sheave guards and
sheave assemblies to mid boom section. Remove sheave
assemblies from mid boom section.

15.

Remove hardware which secures wear pads to front of
mid boom section. Remove wear pads from top, sides,
and bottom of the mid boom section.

a. Remove hardware from wear pads. Remove wear
pads from cylinder.
b. Remove hardware from wire rope guard. Remove
guard from cylinder.
c. Remove hardware from sheave pin. Remove pin and
sheave from cylinder.

4-8

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

16.

Remove fly boom section from mid section using an
overhead crane or suitable lifting device.

NOTE: When removing fly boom section from mid boom section,
retract wire rope must be dragged along with fly boom section.
17.

18.

Remove hardware which secures wear pads to aft end of
fly boom section. Remove wear pads from top, sides,
and bottom of fly boom section.
When removing wire rope from fly boom section, push
cable into fly boom. Route wire rope back through holes
in side of fly boom section.

Inspection
NOTE: Refer to guidelines established in Section 2 - General when
inspecting pins and bearings.
1.

Inspect all sheaves (extend and retract wire ropes and
telescope cylinder) for excessive groove wear, burrs, or
other damage. Replace sheaves as necessary.

NOTE: Use a groove gauge to check size, contour, and amount of
wear. Replace sheave if worn as shown in the following
drawing.

Figure 4-17. Dimension of Sheaves When New

Figure 4-16. Wire Rope Routing Disassembly

3121298

– JLG Lift –

4-9

SECTION 4 - BOOM & PLATFORM

2.

Inspect extend and retract wire rope sheave bearings for
wear, scoring or other damage, and ovality.

2.

Measure inside dimensions of mid section to determine
number of shims required for proper lift.

3.

Inspect extend wire rope and retract wire rope sheave
pins for scoring, tapering and ovality. Replace pins as
necessary.

3.

Install side, top, and bottom wear pads to aft end of fly
section. Shim evenly to inside measurements of mid section.

4.

Inspect telescope cylinder sheave pin for scoring, tapering and ovality. Replace pins as necessary.

4.

5.

Inspect boom pivot pin for wear, scoring, tapering and
ovality, or other damage. Replace pins as necessary.

Install retract wire ropes in aft end of fly section. Route
wire ropes through holes in side of fly boom section and
pull into slot.

6.

Inspect telescope cylinder attach point for scoring,
tapering and ovality. Replace pins as necessary.

7.

Inspect upper lift cylinder attach pin for wear, scoring,
tapering and ovality, or other damage. Ensure pin surfaces are protected prior to installation. Replace pins as
necessary.

8.

Inspect inner diameter of boom pivot bushing for scoring, distortion, wear, or other damage. Replace bearing
as necessary.

9.

Inspect all wear pads for excessive wear or other damage. Replace pads when worn to within 1/8 inch (3.2
mm) of threaded insert.

10.

Inspect extend and retract wire rope attach point components for cracks, stretching, distortion, or other damage. Replace components as necessary.

11.

Inspect all threaded components for damage such as
stretching, thread deformation, or twisting. Replace as
necessary.

12.

Inspect structural units of boom assembly for bending,
cracking, separation of welds, or other damage. Replace
boom sections as necessary.

Assembly

Figure 4-18. Routing Installation of Retract Wire Ropes
5.

NOTE: Install same number and thickness of shims removed during disassembly when installing fly section wear pads.
1.

Install side, top, and bottom wear pads to aft end of mid
section. Shim evenly to mid section inside measurements.

Measure inside dimensions of base and mid sections to
determine number of shims required for proper lift.
WHEN ASSEMBLING BOOM SECTIONS, ENSURE BOOM SLIDING TRAJECTORIES
ARE CLEAR OF CHAINS, TOOLS, AND OTHER OBSTRUCTIONS.
6.

4-10

– JLG Lift –

Shim insides of boom sections for a total of 1/16 inch
(0.062) clearance (if action is centered, there will be 1/32
inch clearance on each side).

3121298

SECTION 4 - BOOM & PLATFORM

Figure 4-19. Boom Powertrack Installation

3121298

– JLG Lift –

4-11

SECTION 4 - BOOM & PLATFORM

7.

Slide fly boom section into mid boom section. Shim
boom, if necessary, for a total of 1/16 inch (0.062) clearance.

8.

Install wear pads in forward position of the mid boom
section. Shim boom, if necessary, for a total of 2/10 inch
(0.20) clearance.

9.

Properly position retraction wire rope sheaves assemblies at aft end of mid boom section. Ensure all sheaveto-mounting block attachment holes align. Install
sheave pins and secure them with mounting hardware.
Position retract wire ropes onto sheaves.

10.

Install sheave guards to aft end of mid boom section
and secure with mounting hardware.

11.

Slide mid boom section into base boom section. Allow
retraction wire ropes to trail between bottom surfaces
of boom sections. Shim boom, if necessary, for a total of
1/16 inch (0.062) clearance.

12.

Install wear pads into the forward position of base boom
section. Shim boom, if necessary, for a total of 2/10 inch
(0.20) clearance.

13.

Install sheave block to bottom of base boom section
and adjust block so that retract wire ropes do not come
into contact with boom surfaces.

14.

Install wire rope threaded ends thru attachment holes in
bottom of base boom section. Loosely install nuts and
jam nuts on threaded ends of wire ropes.

15.

16.

Route extend wire ropes around extend sheave and
secure wire ropes to the telescope cylinder.

17.

Install extend wire rope mounting blocks to threaded
ends of wire ropes. Loosely install nuts and jam nuts on
threaded ends of wire ropes.

NOTE: Do not twist or cross wire ropes during installation.
NOTE: For non CE specification machines, skip step 18 and proceed to step 19.
18.

Install extend wire rope mounting blocks, proximity
mounting plate and spring to threaded ends of wire
ropes. Loosely install nuts and jam nuts on threaded
ends of wire ropes. Refer to Figure 4-20., Proximity
Switch Installation.

19.

Secure sling and lifting device at telescope cylinder’s
approximate center of gravity, and lift cylinder to aft end
of boom assembly.

WHEN INSERTING TELESCOPE CYLINDER IN BOOM, IT MAY BE NECESSARY TO
TURN CYLINDER SLIGHTLY TO CLEAR ASSEMBLIES MOUNTED IN BOOM. CARE
MUST BE TAKEN TO MOVE CYLINDER SLOWLY INTO POSITION. DAMAGE TO
COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH ASSEMBLIES.

Align telescope cylinder barrel-to-sheave attachment
point. Install extend sheave pin through telescope cylinder barrel and sheave assembly; secure pin with mounting hardware.

20.

Align cylinder with slots at aft end of mid boom section,
then secure cylinder with mounting hardware.

21.

Align holes in aft end of fly boom section with holes in
wire rope mounting block. Secure with mounting hardware.

Figure 4-20. Proximity Switch Installation

4-12

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

22.

Align holes in aft end of mid boom section with holes in
wire rope mounting block. Secure with mounting hardware.

Installation
1.

Using a suitable lifting device, position boom assembly
on turntable so pivot holes in both boom and turntable
are aligned.

2.

Install boom pivot pin. Ensure location of hole in pin is
aligned with attach point on turntable.

3.

If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.

4.

Align push bar pivot hole with pivot holes in turntable.
Install push bar pivot pin, Ensure location of hole in pin
is aligned with attach point on turntable.

5.

If necessary, gently tap pin into position with soft
headed mallet. Secure pin mounting hardware.

6.

Connect all wiring to ground control box.

b. Install powertrack to rail with mounting hardware.

7.

Connect all hydraulic lines running along side of boom
assembly.

c. Attach push tube bracket to side of mid boom section with mounting hardware.

8.

Using all applicable safety precautions, operate lifting
device to position boom lift cylinder so holes in cylinder
rod end and boom structure are aligned. Insert lift cylinder pin. Ensure location of hole in pin is aligned with
attach point on boom.

9.

Align holes in boom structure with hole in master cylinder. Insert master cylinder pin. Ensuring hole in pin is
aligned with attach point on boom.

10.

Adjust retract and extend cables to proper torque. Refer
to paragraph 2-6, boom cable torque procedures.

f. Carefully feed hoses and electrical cables through
aft end of powertrack rail, powertrack, and push
tube.

11.

Using all applicable safety precautions, operate machine
systems and raise and extend boom fully. Note extension cycle performance.

g. Ensure all hoses and cables are properly routed
through powertrack rail, powertrack, and push tube.
Tighten or install all clamping or securing apparatus
to hoses or cables, as necessary.

12.

Retract and lower boom. Note retraction cycle performance.

NOTE: Boom wire ropes must be torqued after installation of
boom assembly.
23.

Align holes in rod end of telescope cylinder with holes in
push bar. Install push bar pin and secure with mounting
hardware.

23.

Install hydraulic lines and electrical cables, and harnessing powertrack components as follows:
a. Align holes in powertrack rail with attachment holes
in side of base boom section. Secure rail with
mounting hardware.

NOTE: Do not over tighten attach bolt on push tube bracket. It
should pivot freely.
d. Install slide block and wear pads to powertrack rail
with mounting hardware.
e. Install powertrack to push tube with mounting
hardware.

h. Install powertrack cover and push tube rods with
mounting hardware.

Figure 4-21. Boom Powertrack Assembly

3121298

– JLG Lift –

4-13

SECTION 4 - BOOM & PLATFORM

4.6 ARTICULATING JIB BOOM

Disassembly

Removal
1.

For platform/support removal see platform/support
removal diagram. See Section 4-1., Location of Components - Platform Support.

2.

Position articulating jib boom level with ground.

3.

Remove mounting hardware from slave leveling cylinder pin #1. Using a suitable brass drift and hammer,
remove cylinder pin from articulating jib boom.

1.

Remove mounting hardware from articulating jib boom
pivot pins #3 and #4. Using a suitable brass drift and
hammer, remove the pins from articulating jib boom
pivot weldment.

2.

Remove mounting hardware from rotator support pins
#5 and #6. Using a suitable brass drift and hammer,
remove pins from rotator support.

3.

Remove mounting hardware from lift cylinder pin #7.
Using a suitable brass drift and hammer, remove the cylinder pin from articulating jib boom.

Inspection
NOTE: Refer to Section 2 - General, when inspecting pins and
bearings.

Figure 4-22. Articulating Jib Boom Components
4.

4-14

Remove mounting hardware from articulating jib boom
pivot pin #2. Using a suitable brass drift and hammer,
remove pivot pin from boom assembly.

– JLG Lift –

1.

Inspect articulating fly boom pivot pin for wear, scoring,
tapering and ovality, or other damage. Replace pins as
necessary.

2.

Inspect articulating fly boom pivot attach points for
scoring, tapering and ovality, or other damage. Replace
pins as necessary.

3.

Inspect inner diameter of articulating fly boom pivot
bearings for scoring, distortion, wear, or other damage.
Replace bearings as necessary.

4.

Inspect lift cylinder attach pin for wear, scoring, tapering
and ovality, or other damage. Ensure pin surfaces are
protected prior to installation. Replace pins as necessary.

5.

Inspect inner diameter of rotator attach point bearings
for scoring, distortion, wear, or other damage. Replace
bearing as necessary.

6.

Inspect all threaded components for damage such as
stretching, thread deformation, or twisting. Replace as
necessary.

7.

Inspect structural units of articulating jib boom assembly for bending, cracking, separation of welds, or other
damage. Replace boom sections as necessary.

3121298

SECTION 4 - BOOM & PLATFORM

Assembly

4.8 BOOM CLEANLINESS GUIDELINES

NOTE: For location of components See Section 4-22., Articulating
Jib Boom Components.
1.

Align lift cylinder with attach holes in articulating jib
boom. Using a soft head mallet, install cylinder pin #7
into articulating jib boom and secure with mounting
hardware.

2.

Align rotator support with attach hole in articulating jib
boom. Using a soft head mallet, install rotator support
pin #6 into articulating jib boom and secure with
mounting hardware.

3.

Align bottom tubes with attach holes in rotator support.
Using a soft head mallet, install rotator support pin #5
into articulating jib boom and secure with mounting
hardware.

4.

Align articulating jib boom with attach hole in articulating jib boom pivot weldment. Using a soft head mallet,
install rotator support pin #4 into articulating jib boom
and secure with mounting hardware.

5.

Align bottom tubes with attach holes in articulating jib
boom pivot weldment. Using a soft head mallet, install
rotator support pin #3 into articulating jib boom pivot
weldment. Secure with mounting hardware.

6.

Align articulating jib boom pivot weldment with attach
holes in fly boom assembly. Using a soft head mallet,
install pivot pin #2 into fly boom assembly. Secure with
mounting hardware.

7.

Align slave leveling cylinder with attach holes in articulating jib boom pivot weldment. Using a soft head mallet, install slave leveling cylinder pin #1 into articulating
jib boom pivot weldment. Secure with mounting hardware.

The following are guidelines for internal boom cleanliness for
machines used in excessively dirty environments.
1.

JLG recommends use of JLG Hostile Environment Package to keep internal portions of a boom cleaner and
help prevent dirt and debris from entering the boom.
This package reduces the amount of contamination
which can enter the boom, but does not eliminate the
need for more frequent inspections and maintenance
when used in these types of environments.

2.

JLG recommends you follow all guidelines for servicing
your equipment in accordance with instruction in the
JLG Service & Maintenance Manual for your machine.
Periodic maintenance and inspection is vital to proper
operation of the machine. Frequency of service and
maintenance must be increased as environment, severity, and frequency of usage requires.

3.

Debris and contamination inside the boom can cause
premature failure of components and should be
removed. Methods to remove debris should always be
done using all applicable safety precautions outlined in
the JLG Operation & Safety Manual and the JLG Service
& Maintenance Manuals.

4.

The first attempt to remove debris from inside the boom
must be to utilize pressurized air to blow the debris
toward the nearest exiting point from the boom. Make
sure that all debris is removed before operating the
machine.

5.

If pressurized air cannot dislodge debris, then water
with mild solvents applied with a pressure washer can
be used. Wash debris toward the nearest exiting point
from the boom. Make sure all debris is removed, no
“puddling” of water has occurred, and boom internal
components are dry before operating machine. Make
sure you comply with all federal and local laws for disposing of wash water and debris.

6.

If pressurized air or washing boom does not dislodge
and remove debris, disassemble boom following
instructions outlined in the JLG Service & Maintenance
Manual to remove debris.

4.7 LIMIT SWITCHES AND CAM VALVE ADJUSTMENT
Adjust switches and cam valve as shown in Figure 4-23., Horizontal Limit and Dual Capacity Limit Switches Adjustments
and Figure 4-24., Transport Switch Adjustments - CE Machines
Only.

3121298

– JLG Lift –

4-15

SECTION 4 - BOOM & PLATFORM

Figure 4-23. Horizontal Limit and Dual Capacity Limit Switches Adjustments

4-16

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

Figure 4-24. Transport Switch Adjustments - CE Machines Only

3121298

– JLG Lift –

4-17

SECTION 4 - BOOM & PLATFORM

4.9 ROTARY ACTUATOR

Required Tools

Theory of Operation
The L20 Series rotary actuator is a simple mechanism that uses
the sliding spline operating concept to convert linear piston
motion into powerful shaft rotation.
Each actuator is composed of a housing with integrated gear
teeth (01) and only two moving parts: the central shaft with
integrated bearing tube and mounting flange (02), and the
annular piston sleeve (03). Helical spline teeth machined on
the shaft engage matching splines on the piston inside diameter. The piston outside diameter carries a second set of opposite direction splines which engage with matching splines in
the housing.
As hydraulic pressure is applied, piston is displaced axially
within the housing - similar to operation of a hydraulic cylinder - while splines cause shaft to rotate. When control valve is
closed, oil is trapped inside the actuator, preventing piston
movement and locking the shaft in position. The shaft is sup-

1.

Flashlight - Examine timing marks, component failure,
and overall condition.

2.

Felt Marker - Match mark timing marks and outline troubled areas.

3.

Allen wrench - Remove port plugs and set screws.

4.

Box knife - removal of seals.

5.

Seal tool - assembly and disassembly of seals and wear
guides.

6.

Pry bar - End cap removal and manual rotation of shaft.

7.

Rubber mallet- Removal and installation of shaft and
piston sleeve assembly.

8.

Nylon drift - Piston sleeve installation.

9.

End cap dowel pins - removal and installation of end cap
(sold with Helac seal kit).

The seal tool is a customized standard flat head screwdriver. To
make this tool, heat flat end with a torch. Secure heated end of
screwdriver in a vice and bend to a slight radius. Once radius is
achieved, round off all sharp edges using a grinder. There may
be some slight modifications for your personal preference.
Bars indicate starting positions
of piston and shaft. Arrows indicate direction they will rotate.
The housing with integral ring
gear remains stationary.

As fluid pressure is applied, the
piston is displaced axially while
helical gearing causes the piston
and shaft to rotate simultaneously. The double helix design
compounds rotation: shaft rotation is about twice of the piston.

ported radially by the large upper radial bearing and lower
radial bearing. Axially, the shaft is separated from the housing
by upper and lower thrust washers. End cap is adjusted for
axial clearance and locked in position by set screws or pins.

4-18

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

PARTS
1. Housing 
2. Shaft 
3. Piston Sleeve
4. End Cap

HARDWARE
103.1. Screw
103.2 . Washer
106.1. Port Plug
106.2. Port Plug
109 . Lock Pin
113. Capscrew

SEALS
200. T-Seal
202. T-Seal
204. O-ring
205. Cup Seal
207. Backup Ring
304.1. Wiper Seal

BEARINGS
302. Wear Guide
304. Thrust Washer

ACCESSORIES
400. Stop Tube
420.1 Bushing
420.2 Bushing
421.1 Bushing

Figure 4-25. Rotary Actuator - Exploded View

3121298

– JLG Lift –

4-19

SECTION 4 - BOOM & PLATFORM

PARTS
1. Housing 
2. Shaft 
3. Piston Sleeve
4. End Cap

HARDWARE
103.1. Screw
103.2 . Washer
106.1. Port Plug
106.2. Port Plug
109 . Lock Pin
113. Capscrew

SEALS
200. T-Seal
202. T-Seal
204. O-ring
205. Cup Seal
207. Backup Ring
304.1. Wiper Seal

BEARINGS
302. Wear Guide
304. Thrust Washer

ACCESSORIES
400. Stop Tube
420.1 Bushing
420.2 Bushing
421.1 Bushing

Figure 4-26. Rotary Actuator - Assembly Drawing

4-20

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

Disassembly
1.

Remove capscrews (113) over end cap lock pins (109).

2.

Using a 1/8” (3.18mm) drill bit, drill a hole in center of
each lock pin approximately 3/16" (4.76mm) deep.

3.

Remove lock pins using an ”Easy Out” (Size #2 shown. If
pin will not come out, use 5/16" drill bit 1/2" (12.7mm)
deep to drill out entire pin.

3121298

– JLG Lift –

4.

Remove end cap (4) using tools provided with Helac seal
kit.

5.

Using a metal bar or similar tool, unscrew end cap (4) by
turning it counter clockwise.

6.

Remove end cap (4) and set aside for later inspection.

4-21

SECTION 4 - BOOM & PLATFORM

7.

Remove stop tube if installed.

8.

Actuator has timing marks for proper engagement.

4-22

– JLG Lift –

9.

Before removing shaft, (2), use a felt marker to clearly
indicate timing marks between shaft and piston. This
simplifies timing during assembly.

10.

Remove shaft (2). It may be necessary to strike threaded
end of shaft with a rubber mallet.

3121298

SECTION 4 - BOOM & PLATFORM

11.

Before removing piston (3), mark housing (1) ring gear in
relation to piston O.D. gear. There should be timing
marks on housing (1) ring gear, piston (3), and shaft (2).

13.

At the point when piston gear teeth come out of
engagement with housing gear teeth, mark piston and
housing with a marker as shown.

12.

To remove piston (3), use a rubber mallet and plastic
mandrel so piston is not damaged.

14.

Remove O-ring (204) and backup ring (207) from end
cap (4) and set aside for inspection.

3121298

– JLG Lift –

4-23

SECTION 4 - BOOM & PLATFORM

15.

Remove wear guides (302) from end cap (4) and shaft
(2).

17.

Remove thrust washers (304) from end cap (4) and shaft
(2).

16.

To remove main pressure seals (205), cut them with a
sharp razor blade. Do not to damage seal groove.

18.

Remove wiper seal (304.1) from end cap (4) and shaft (2).

19.

Remove piston O.D. seal (202).

4-24

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

20.

Remove piston I.D. seal (200).

2.

Inspect thrust washers (304) for rough or worn edges
and surfaces. Measure thickness is within specifications
(Not less than 0.092” or 2.34 mm).

3.

Inspect wear guide condition and measure thickness
(not less than 0.123” or 3.12 mm).

Inspection
1.

Clean all parts in a solvent tank and dry with compressed air before inspecting. Carefully inspect all critical areas for any surface finish abnormalities: Seal
grooves, bearing grooves, thrust surfaces, rod surface,
housing bore, and gear teeth.

3121298

– JLG Lift –

4-25

SECTION 4 - BOOM & PLATFORM

Assembly
1.

Gather all components and tools to one location. Use
cut away drawing to reference seal orientations.

2.

Install thrust washer (304) on shaft (2) and end cap (4).

4-26

– JLG Lift –

3.

Install wiper seal (304.1/green 0-ring) in groove on shaft
(2) and end cap (4) - around outside edge of thrust
washer (304).

4.

Use a seal tool install main pressure seal (205) on shaft
(2) and end cap (4). Use seal tool in a circular motion.

5.

Install wear guide (302) on end cap (4) and shaft (2).

3121298

SECTION 4 - BOOM & PLATFORM

6.

7.

Install inner T-seal (200) in piston (3) using a circular
motion. Install outer T-seal (202) by stretching it around
the groove in a circular motion. Each T-seal has two
back-up rings (see drawing for orientation).

Beginning with inner seal (200) insert one end of b/u
ring in lower groove and feed the rest in using a circular
motion. Make sure wedged ends overlap correctly.

8.

Insert piston (3) in housing (1) as shown, until outer piston seal (202) touches inside housing bore.

9.

Looking from angle shown, rotate piston (3) until marks
you put on piston and housing (1) during disassembly
line up as shown. Using a rubber mallet, tap piston in
housing to point where gear teeth meet. 

Repeat for outer seal (202).

3121298

– JLG Lift –

4-27

SECTION 4 - BOOM & PLATFORM

10.

Looking from opposite end of housing (1) when timing
marks line up, tap piston (3) in until gear teeth mesh
together. Tap piston in housing until it bottoms out.

13.

Install 2 bolts in threaded holes in flange. Using a bar,
rotate shaft clockwise until wear guides are seated in
housing bore.

11.

Install shaft (2) in piston (3). Do not damage seals. Do
not engage piston gear teeth.

14.

Install stop tube on shaft end. Stop tube is an available
option to limit actuator rotation.

15.

Coat threads on end of shaft with anti-seize grease to
prevent galling.

12.

4-28

Looking from view shown, use existing timing marks to
line up gear teeth on shaft (2) with gear teeth on inside
of piston (3). Tap flange end of shaft with rubber mallet
until gear teeth engage.

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

16.

Install 0-ring (204) and back-up ring (207) in inner seal
groove on end cap (4).

17.

Thread end cap (4) on shaft (2) end. Ensure wear guide
stays in place on end cap as it is threaded in housing (1).

18.

19.

Place lock pins (109) provided in Helac seal kit in holes
with dimple side up. Using a punch, tap lock pins to bottom of hole.

20.

Insert set screws (113) over lock pins. Tighten to 25 in-lb
(2.825 Nm).

Tighten end cap (4). Ensure holes for lock pins line up.

3121298

– JLG Lift –

4-29

SECTION 4 - BOOM & PLATFORM

Installing Counterbalance Valve

3.

Bolts that come with valve are Grade 8 bolts. Install new
bolts with a new valve. Apply Loctite #242 to shanks of
the three bolts at time of installation.

4.

Torque 1/4-inch bolts 110-120 in-lb (12.4-13.5 Nm). Do
not torque over 125 in-lb (14.1 Nm). Torque 5/16-inch
bolts to 140 in-lb (15.8 Nm). Do not torque over 145 in-lb
(16.3 Nm).

Refer to Figure 4-27., Rotator Counterbalance Valve.
1.

Make sure surface of actuator is clean and free of any
contamination and debris, including old Loctite.

2.

Make sure new valve has the O-rings in counterbores of
valve to seal it to the actuator housing.

Figure 4-27. Rotator Counterbalance Valve

4-30

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

Testing Actuator

1.

If equipment is available, test actuator on a hydraulic test
bench. Breakaway pressure — the pressure at which the shaft
begins to rotate — should be approximately 400 psi (28 bar).
Cycle actuator at least 25 times at 3000 psi (210 bar) pressure.
After 25 rotations, increase pressure to 4500 psi (315 bar).
Check for leaks and cracks. Perform test again at end of rotation in the opposite direction.

Connect a 3/16" inside diameter x 5/16" outside diameter x 5 foot clear, vinyl drain tube to each of the two
bleed nipples. Secure with hose clamps. Place vinyl
tubes in a clean 5-gallon container to collect purged oil.

2.

Oil can be returned to reservoir after procedure is completed.

Testing Actuator for Internal LeakS
If actuator is equipped with a counterbalance valve, plug valve
ports, connect hydraulic lines to housing ports. Bleed all air
from actuator (see Installation and Bleeding). Rotate shaft to
end of rotation at 3000 psi (210 bar) and maintain pressure.
Remove hydraulic line from non-pressurized side.



Continuous oil flow from open housing port indicates internal
leakage across the piston. Replace line and rotate shaft to end
of rotation in opposite direction. Repeat test procedure outlined above for other port. If there is an internal leak, disassemble, inspect, and repair.

Installation and Bleeding


     

AFTER INSTALLING ACTUATOR, IT IS IMPORTANT THAT ALL SAFETY DEVICES
SUCH AS TIE RODS OR SAFETY CABLES ARE PROPERLY REATTACHED.
Figure 4-28. Actuator Bleed Ports
To purge air from hydraulic lines, connect them together to
create a closed loop and pump hydraulic fluid through them.
Review hydraulic schematic to determine which hydraulic
lines to connect. The linear feet and inside diameter of hydraulic supply lines together with pump capacity determine
amount of pumping time required to fully purge the hydraulic
system.
Bleeding may be necessary if excessive backlash is exhibited
after actuator is connected to hydraulic system. The following
steps are recommended when a minimum of two gal (8L) is
purged.

3121298

– JLG Lift –

3.

With an operator in the platform, open both bleed nipples 1/4 turn. Hydraulically rotate platform to end of
rotation (clockwise or counterclockwise), and maintain
hydraulic pressure. Oil with small air bubbles will be
seen flowing through the tubes. Allow 1/2 gallon of fluid
to be purged from actuator.

4.

Keep fittings open and rotate platform in opposite
direction to end position. Maintain hydraulic pressure
until an additional 1/4 gallon of fluid is pumped into the
container.

5.

Repeat steps 2 & 3. After last 1/2 gallon is purged, close
both bleed nipples before rotating away from end position.

4-31

SECTION 4 - BOOM & PLATFORM

Table 4-1. Troubleshooting
Troubleshooting
Problem
1.

Shaft rotates slowly or not at all

Cause

Solution

a. Insufficient torque output



a. Verify correct operating pressure. Do not exceed OEM’s
pressure specifications. Load may be above maximum
capacity of the actuator.

b. Low rate of fluid flow


b. Inspect ports for obstructions and hydraulic lines for
restrictions and leaks.

c. Control or counterbalance valve has internal leak





c. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate actuator through housing ports (do
not exceed OEM’s operating pressure). Valve must be
replaced if a steady flow of fluid is seen coming from valve
ports.

d. Piston and/or shaft seal leak



d. Remove plug and housing’s valve ports. Operate actuator
through housing ports. Conduct internal leakage test.

e. Corrosion build-up on the thrust surfaces

e. Rebuild actuator. Remove all rust then polish. Replacement parts may be needed.

f. Rebuild actuator. Use fluid compatible with all seals and
f. Swollen seals and composite bearings caused by incom- bearings.
patible hydraulic fluid
2.

Operation is erratic or not responsive

a. Air in actuator

a. Purge air from actuator. See bleeding procedures.

3.

Shaft will not fully rotate

a. Twisted or chipped gear teeth



a. Check for gear binding. Actuator may not be able to be
rebuilt and may need to be replaced. Damage could be a
result of overload or shock.

b. Port fittings are obstructing the piston

b. Check thread length of port fittings. Fittings should during stroke not reach inside housing bore.

a. Control or counterbalance valve has internal leak





a. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate actuator through housing ports (do
not exceed OEM’s operating pressure). Valve must be
replaced if a steady flow of fluid is seen coming from valve
ports.

b. Piston and/or shaft seal leak



b. Remove plug and housing’s valve ports. Operate actuator
through housing ports. Conduct internal leakage test.

4.

Selected position cannot be maintained

c. Purge air from actuator. See bleeding procedures
c. Air in actuator

4-32

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

4.10 FOOT SWITCH ADJUSTMENT

4.11 PLATFORM

Adjust foot switch to operate functions when pedal is at center
of travel. Adjust if switch operates within last 1/2 in. (6.35 mm)
of top or bottom travel.

Platform Support Torque Settings
NOTE: If any rotator bolts are replaced, re-torque all rotator bolts.


ELECTRIC SHOCK OR UNCONTROLLED MACHINE MOVEMENT CAN CAUSE
DEATH OR SERIOUS INJURY. DISCONNECT INPUT POWER BEFORE PERFORMING INSTALLATION OR MAINTENANCE.



NOTE: For models with two switches, both switches can be independently adjusted.
1.

Remove four socket head cap screws and cover from
foot switch assembly.

2.

To increase travel before switch is activated, turn Adjustment Screw clockwise.

3.

To decrease travel before switch is activated, turn
Adjustment Screw counter-clockwise.




 

  
 

 "#
 




 
!
! 
$ %&"  '  ( ) *
 &&

Figure 4-30. Platform Support Torque Values

Replace Platform Sections
The platform is made up of five sections: floor, right side, left
side, back (console box mounting.), and gate. Sections are
secured with Huck magna grip fastener and collars.
1.

Support Huck collar with a suitable support.

2.

Using a hammer and chisel, remove collar from fastener.

Figure 4-29. Foot Switch Adjustment
4.

Install cover and secure with four socket head caps
crews. Torque to 18-22 in-lb (2-3 Nm).

Figure 4-31. Platform Section Replacement

3121298

– JLG Lift –

3.

Replace Huck fasteners with 1/4 x 20 NC x 2 1/4" grade 5
bolts, flat washers, and locknuts when installing new
section of platform.

4.

Replace rivets with 1/4 x 20 NC x 2 “grade 5 bolts, flat
washers, and locknuts when installing a new gate to
platform.

4-33

SECTION 4 - BOOM & PLATFORM

2.

4.12 POWERTRACK MAINTENANCE

Repeat step 1 and remove screw from other side of
track. Remove bar/poly roller from powertrack.

Remove Link
NOTE: Hoses shown in powertrack are for example only. Actual
hose and cable arrangements are different.

1.

4-34

Clamp bar and poly roller tightly so they do not spin
when removing screw. With a small ¼” ratchet and a T20 Torx bit, remove 8-32 x 0.500 screw from one side.

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

5.
REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT
DAMAGE.
3.

To remove a link, rivets holding links together must be
removed. Use a right-angle pneumatic die grinder with
a ¼” ball double cut bur attachment.

4.

insert tool into rolled over end of rivet. Grind out middle
of rivet until rolled over part of rivet falls off. Repeat for
all rivets to be removed.

3121298

After grinding it may be necessary to use a center punch
with a hammer to remove rivet.

NOTE: It may be necessary to loosen fixed end brackets from
machine to move track section enough to disconnect links.

– JLG Lift –

4-35

SECTION 4 - BOOM & PLATFORM

6.

4-36

Insert flat head screwdriver between links. Twist and pull
links apart.

– JLG Lift –

7.

Remove link from other section of powertrack using
screwdriver.

3121298

SECTION 4 - BOOM & PLATFORM

Install New Link
1.

2.

Spread half-shear (female) end of new link and slide cutout end of track section into it. Use screwdriver if necessary.

3.

Round half-shears will not fit properly in cut-outs after
new link is installed .

Squeeze cut-out end of new link into half-shear (female)
end of track section.

3121298

– JLG Lift –

4-37

SECTION 4 - BOOM & PLATFORM

4.

5.

4-38

Pull moving end over track so new connection is positioned in curve of powertrack. Round half-shears will
rotate into cut-outs.

6.

Push pin through center hole. Slide washer on pin.

7.

Install snap ring in groove on pin. Repeat pin installation
steps for all center holes with rivets removed.

Parts shown below connect new link to powertrack.

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

NOTE: Make sure snap rings are seated in pin groove and closed
properly.

Correct

1.

2.

Pull up on other end of round bar. Slide new poly roller
on bar.

Incorrect

Install new 8-32 x 0.500 self-threading Torx head screw
in end of new aluminum round bar. Torque to 18-20 inlb (2-2.25 Nm).

3121298

– JLG Lift –

4-39

SECTION 4 - BOOM & PLATFORM

3.

Install new 8-32 x 0.500 self threading screw on other
side. Torque to 18-20 in-lb (2-2.25 Nm).

Replace Fixed End Brackets

REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT
DAMAGE.
1.

Remove rivets as shown in link removal instructions..

NOTE: When tightening screws make sure screw head is seated
against link with no space in between link and underside of
screw head.

4-40

– JLG Lift –

3121298

SECTION 4 - BOOM & PLATFORM

2.

Parts used: Bracket Center Pin and Center Pin Snap Ring.

3.

Take new bracket and install bracket center pin and
snap ring. Repeat on other bracket if replacing it.

Replace Moving End Brackets

REPOSITION CABLES AND HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE.
1.

Remove existing pins and center rivet. Remove rivet as
shown in link removal instructions on page 4-20. Repeat
on other bracket if replaced.

NOTE: Ensure snap rings are seated in pin groove and closed
properly.

Correct

3121298

Incorrect

– JLG Lift –

4-41

SECTION 4 - BOOM & PLATFORM

2.

Install center pin with snap ring in new bracket.

NOTE: Ensure snap rings are seated in pin groove and closed
properly.

Correct

3.

4-42

Install radius pins and snap rings in original locations.
Repeat with other moving end if replaced.

– JLG Lift –

1.

Incorrect

Make sure both brackets rotate correctly.

3121298

SECTION 5 - HYDRAULICS

SECTION 5. HYDRAULICS
5.1 O-RING LUBRICATION

2.

Hold fitting over hydraulic oil container and brush an
even film of oil around entire O-ring in fitting. Make sure
O-ring is completely saturated.

3.

Turn fitting over and repeat previous step to O-ring on
other side of fitting. Make sure entire O-ring is coated
with hydraulic oil.

When assembling connectors, all fittings with O-rings must be
lubricated with hydraulic oil before assembly. There are four
methods of lubricating O-rings:
1. Cup and Brush
2. Dip
3. Spray
4. Brush-On

Cup and Brush
Tools needed:
• Small container for hydraulic oil
• Small paint brush

1.

Hold fitting in one hand and dip brush into container
with other hand. Remove excess hydraulic oil from
brush so an even film of oil is applied to O-ring.

3121298

– JLG Lift –

5-1

SECTION 5 - HYDRAULICS

Dip

Spray

NOTE: This method works best with Face Seal O-rings, but will
work for all O-ring fitting types.

This method requires a pump or trigger spray bottle.

Tools needed:
• Small leak proof container

1.

Fill spray bottle with hydraulic oil.

2.

Hold fitting over suitable catch can.

3.

Spray entire O-ring surface with medium coat of oil.

• Sponge cut to fit inside container
• Small amount of hydraulic oil to saturate sponge.
1.

Place sponge inside container and add hydraulic oil to
sponge until fully saturated.

2.

Dip fitting into sponge using firm pressure.

Brush-On
This method requires a sealed bottle brush.

3.

After lifting fitting, a small droplet should form and drip
from bottom of fitting. This indicates an even coating of
oil.

1.

Fill bottle with hydraulic oil.

2.

Using slight pressure to body of spray bottle, invert bottle so brush end faces down.

3.

Brush an even coat of hydraulic oil on entire O-ring.

NOTE: O-ring boss-type fittings require more pressure to immerse
more of fitting into saturated sponge. This also causes
more oil to be dispersed from sponge.

5-2

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

5.2 CYLINDERS - THEORY OF OPERATION

Cylinders Without Counterbalance Valves - Master
Cylinder and Steer Cylinder

Systems With Double Acting Cylinders
Systems with double acting cylinders are the Slave Level, Master Level, Lift, Telescope, Articulating Jib Boom Lift, Axle Lockout, and Steer. A double acting cylinder is one that requires oil
flow to operate the cylinder rod in both directions. Directing
oil (by actuating the corresponding control valve to piston
side of cylinder) forces the piston to travel toward the rod end
of the barrel, extending the cylinder rod (piston attached to
rod). When oil flow is stopped, movement of rod stops. By
directing oil to the rod side of the cylinder, the piston is forced
in the opposite direction and the cylinder rod retracts.

1.

Using all applicable safety precautions, activate engine
and fully extend cylinder to be checked. Shut down
engine.

2.

Carefully disconnect hydraulic hoses from retract port of
cylinder. There will be some initial weeping of hydraulic
fluid which can be caught in a suitable container. After
initial discharge, there should be no further drainage
from the retract port.

3.

Activate engine and extend cylinder.

4.

If cylinder retract port leakage is less than 6-8 drops per
minute, carefully reconnect hose to port and retract cylinder. If leakage continues at a rate of 6-8 drops per minute or more, repair cylinder.

5.

With cylinder fully retracted, shut down engine and
carefully disconnect hydraulic hose from cylinder
extend port.

6.

Activate engine and retract cylinder. Check extend port
for leakage.

7.

If extend port leakage is less than 6-8 drops per minute,
carefully reconnect hose to extend port, then activate
cylinder through one complete cycle and check for
leaks. If leakage continues at a rate of 6-8 drops per minute or more, repair cylinder.

Systems With Holding Valves
Holding valves are used in the Lift, Telescope, Lockout, Slave
Level, and Articulating Jib Boom Lift circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or a
leak develop between the cylinder and its control valve.

5.3 CYLINDER CHECKING PROCEDURE
NOTE: Cylinder check must be performed anytime a system component is replaced or when improper system operation is
suspected.



 

Figure 5-1. Boom Positioning and Support, Cylinder Repair

3121298

– JLG Lift –

5-3

SECTION 5 - HYDRAULICS

Cylinders With Single Counterbalance Valve

Cylinders With Dual Counterbalance Valves

(Upper Lift Cylinder)

(Articulating Jib Boom Lift, and Slave), Slave Level, Lower Lift,
Upright level, Main Telescope and Tower Telescope)

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.
1.

Using all applicable safety precautions, activate hydraulic system.

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.
1.

Using all applicable safety precautions, activate hydraulic system.

WHEN WORKING ON MAIN LIFT CYLINDER, RAISE BOOM TO HORIZONTAL AND
PLACE A BOOM PROP APPROXIMATELY 1 INCH (2.54 CM) BELOW THE MAIN
BOOM. DO NOT WORK ON CYLINDER WITHOUT A SUITABLE PROP IN PLACE.

5-4

2.

Shut down hydraulic system and allow machine to sit for
10-15 minutes. If machine is equipped with proportional
control valves, turn IGNITION SWITCH to ON, move control switch or lever for applicable cylinder in each direction, then turn IGNITION SWITCH to OFF. If machine is
equipped with hydraulic control valves, move control
lever for applicable cylinder in each direction. This is
done to relieve hydraulic line pressure. Carefully remove
hydraulic hoses from appropriate cylinder port block.

3.

There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After initial discharge, there should be no further leakage from the
ports. If leakage continues at a rate of 6-8 drops per minute or more, counterbalance valve is defective and must
be replaced.

4.

To check piston seals, carefully remove counterbalance
valve from the retract port. After initial discharge, there
should be no further leakage from the ports. If leakage
occurs at a rate of 6-8 drops per minute or more, piston
seals are defective and must be replaced.

5.

If no repairs are necessary or when repairs have been
made, replace counterbalance valve and connect
hydraulic hoses to cylinder port block.

6.

If used, remove lifting device from upright or remove
prop from below main boom. Activate hydraulic system
and run cylinder through one complete cycle to check
for leaks.

IF WORKING ON TOWER BOOM LIFT CYLINDER, RAISE TOWER BOOM HALFWAY, FULLY ELEVATE MAIN BOOM WITH TELESCOPE C YLINDER FULLY
RETRACTED. ATTACH AN OVERHEAD CRANE TO THE UPRIGHT FOR SUPPORT,
LEAVING APPROXIMATELY 1 INCH (2.54 CM) OF SLACK IN CHAIN OR SLING FOR
TEST PURPOSES. IF WORKING ON THE UPRIGHT LEVEL, RAISE TOWER BOOM
HALFWAY, THEN RAISE MAIN BOOM TO HORIZONTAL AND POSITION A SUITABLE BOOM PROP APPROXIMATELY 1 INCH (2.54 CM) BELOW MAIN BOOM. IF
WORKING ON PLATFORM LEVEL CYLINDER, STROKE PLATFORM LEVEL CYLINDER FORWARD UNTIL PLATFORM SITS AT A 45 DEGREES ANGLE.

– JLG Lift –

2.

Shut down hydraulic system and allow machine to sit for
10-15 minutes. If machine is equipped with proportional
control valves, turn IGNITION SWITCH to ON, move control switch or lever for applicable cylinder in each direction, then turn IGNITION SWITCH to OFF. If machine is
equipped with hydraulic control valves, move control
lever for applicable cylinder in each direction. This is
done to relieve hydraulic line pressure. Carefully remove
hydraulic hoses from appropriate cylinder port block.

3.

There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After initial discharge, there should be no further leakage from the
ports. If leakage continues at a rate of 6-8 drops per minute or more, counterbalance valve is defective and must
be replaced.

4.

To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge,
there should be no further leakage from the ports. If
leakage occurs at a rate of 6-8 drops per minute or more,
the piston seals are defective and must be replaced.

5.

If no repairs are necessary or when repairs have been
made, replace counterbalance valve and carefully connect hydraulic hoses to cylinder port block.

6.

Remove lifting device from upright or remove prop from
below main boom. Activate hydraulic system and run
cylinder through one complete cycle to check for leaks.

3121298

SECTION 5 - HYDRAULICS

5.4 CYLINDER REMOVAL AND INSTALLATION

Main Boom Telescope Cylinder Installation

Main Boom Telescope Cylinder Removal
1.

Place machine on a flat and level surface, with main
boom in the horizontal position.

2.

Shut down engine. Support main boom basket end with
a prop. (See Figure 5-1., Boom Positioning and Support,
Cylinder Repair).

1.

Route extend cables around extend sheave and secure
cables to the telescope cylinder.

2.

Install extend cables mounting blocks to threaded ends
of cables. Loosely install nuts and jam nuts on threaded
end of cables.

DO NOT TO TWIST OR CROSS CABLES DURING INSTALLATION.
3.

Secure sling and lifting device at telescope cylinder’s
center of gravity. Lift cylinder to aft end of boom assembly.

4.

Install extend cable mounting blocks to threaded ends
of cables. Loosely install nuts and jam nuts on threaded
ends of cables.

CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING
LINES TO PREVENT ENTRY OF CONTAMINANTS INTO THE SYSTEM.
3.

Tag and disconnect hydraulic lines to telescope cylinder.
Use a suitable container to retain residual hydraulic fluid.
Cap hydraulic lines and ports.

4.

Remove hardware securing cover plate on bottom of
base boom section and remove cover.

DO NOT ALLOW CABLE TO ROTATE. THIS MAY DAMAGE THE CABLE.
5.

6.
7.
8.
9.

WHEN INSERTING TELESCOPE CYLINDER INTO BOOM, IT MAY BE NECESSARY
TO TURN C YLINDER SLIGHTLY TO CLEAR ASSEMBLIES MOUNTED IN THE
BOOM. MOVE CYLINDER SLOWLY INTO POSITION OR DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES.
5.

Carefully install telescope cylinder barrel end support
into slots in mid boom and secure with blocks and bolts.
Use Loctite #242 on bolts.

6.

Remove hardware securing push bar to turntable and
telescope cylinder.

Align holes in aft end of fly boom section with holes in
cable mounting block. Secure with mounting hardware.

7.

Using a suitable brass drift, carefully drive push bar pins
from telescope cylinder rod and turntable.

Align holes in aft end of base boom section with holes in
cable mounting block. Secure with mounting hardware.

8.

Remove cylinder port plugs and hydraulic line caps. Correctly attach lines to cylinder ports.

Remove hardware securing cable adjustment block to
aft end of the base boom section and remove block.

9.

Align holes in rod end of telescope cylinder with holes in
push bar. Install push bar pin and secure with mounting
hardware.

10.

Align holes in push bar with holes in turntable. Install
push bar pin and secure with mounting hardware.

Clamp both threaded ends of cable to prevent rotation.
Note: Do not clamp on threads. Remove jam nuts and
loosen adjustment nuts so there is slack in the cables.
(See Section 4 - Boom & Platform).

Remove hardware securing telescope cylinder to aft end
of mid boom section.

WHEN REMOVING TELESCOPE CYLINDER FROM BOOM, IT MAY BE NECESSARY
AT SOME POINT TO TURN CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED IN THE BOOM. MOVE CYLINDER SLOWLY INTO POSITION OR
DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE
ASSEMBLIES.
10.

Remove bolts securing cable attach bar to top of fly
boom section.

11.

Pull telescope cylinder and cables partially from aft end
of base boom section. Secure cylinder with a suitable
sling and lifting device at center of gravity.

12.

Carefully remove telescope cylinder and sheave assembly. Place telescope cylinder on a suitable trestle.

3121298

NOTE: Boom cables must be torqued after telescope cylinder installation. (See Section 4.1, Boom Rope Torquing Procedures)

– JLG Lift –

5-5

SECTION 5 - HYDRAULICS

5.5 CYLINDER REPAIR

Main Boom Lift Cylinder Removal
1.

Place machine on a flat and level surface. Start engine
and place main boom in horizontal position. Shut down
engine and prop boom. (See Figure 5-1., Boom Positioning and Support, Cylinder Repair)

2.

Remove hardware retaining cylinder rod attach pin to
boom. Using a suitable brass drift, drive out cylinder rod
pin.

3.

Using auxiliary power, retract the lift cylinder rod completely.

4.

Disconnect, cap and tag the main boom lift cylinder
hydraulic lines and ports.

5.

Remove barrel end attach pin retaining hardware. Using
a suitable brass drift drive out the barrel end attach pin
from the turntable.

6.

Remove the cylinder from the turntable and place in a
suitable work area.

NOTE: Following are general procedures that apply to all cylinders on this machine. Procedures that apply to a specific
cylinder are noted.

Disassembly
CYLINDER DISASSEMBLYSHOULD BE PERFORMED ON A CLEAN WORK SURFACE
IN A DIRT FREE WORK AREA TO PREVENT CONTAMINATION.
1.

DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2.

Operate hydraulic power source and extend the cylinder. Shut down and disconnect power source. Adequately support cylinder rod, if applicable.

3.

If applicable, remove cartridge-type holding valve and
fittings from cylinder port block. Discard O-rings.

Main Boom Lift Cylinder Installation

5-6

1.

Install lift cylinder in place using suitable slings or supports, aligning attach pin mounting holes on the turntable.

2.

Using a suitable drift, drive barrel end attach pin
through mounting holes in lift cylinder and turntable.
Secure in place with pin retaining hardware.

3.

Remove cylinder port plugs and hydraulic line caps and
correctly attach lines to cylinder ports.

4.

Using auxiliary power, extend cylinder rod until attach
pin hole aligns with those in the boom. Using a suitable
soft mallet, drive cylinder rod attach pin through the
boom and lift cylinder. Secure pin in place with attaching hardware.

5.

Remove boom prop and overhead crane. Activate
hydraulic system.

6.

Using all applicable safety precautions, operate boom
functions. Check for correct operation and hydraulic
leaks. Secure as necessary.

7.

Check fluid level of hydraulic tank. Adjust as necessary.

Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

Cylinder Locations

Item
1
2
3
4
5
6
7

Cylinder
Main Lift
Master
Telescope
Slave (Platform Level)
Jib Lift
Steer
Axle Lockout

Figure 5-2. Hydraulic Cylinder Locations

3121298

– JLG Lift –

5-7

SECTION 5 - HYDRAULICS

5.

Main Lift Cylinder

Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).

DISASSEMBLY
NOTE: Refer to Figure 5-6.

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.



Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.



DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.



2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.
Figure 5-4. Marking Cylinder for Alignment

3. If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.

Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.





 

 




6.

Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.

7.

Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.





Figure 5-3. Cylinder Barrel Support

Figure 5-5. Cylinder Rod Support

5-8

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS






































 






1.
1a.
2.
2a.
3.
4.

Barrel
Composite Bushing
Rod
Composite Bushing
Head
Piston

5.
6.
7.
8.
9.
10.

Tapered Bushing
Spacer
Cartridge Valve
O-Ring Plug
5/16"-11x2 Bolt
O-Ring Plug

11.
12.
13.
14.
15.
16.

Lock Ring
Hydrolock Seal
O-Ring
Back-Up Ring
Wear Ring
O-Ring

17.
18.
19.
20.
21.
22.

Back-Up Ring
Rod Seal
Wiper
Locking Compound
Locking Primer
Ring Washer

23. Not Used
24. Socket Head Screw
25. O-Ring Plug

Figure 5-6. Main Lift Cylinder Assembly

3121298

– JLG Lift –

5-9

SECTION 5 - HYDRAULICS

8.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

7.

Inspect threaded portion of piston for damage. Dress
threads as necessary.

9.

Loosen and remove nut attaching piston to rod. Remove
piston.

8.

Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.

10.

Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.

9.

11.

Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.

Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.

10.

Inspect threaded portion of head for damage. Dress
threads as necessary.

11.

Inspect seal and O-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.

12.

Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary.

13.

If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.

12.

Remove tapered bushing from piston.

13.

Screw piston counter-clockwise by hand and remove
from cylinder rod.

 






a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.

 
 

NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-7. Tapered Bushing Removal
14.

Remove and discard piston O-rings, seal rings, and
backup rings.

15.

Remove piston spacer, if applicable, from rod.

16.

Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.

d. Press composite bushing into barrel or rod bushing
with correct size arbor.

 

 
  


 

Cleaning and Inspection
1.

Clean parts thoroughly with approved cleaning solvent.

2.

Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.

Figure 5-8. Composite Bushing Installation
14.

Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.

15.

If applicable, inspect port block fittings and holding
valve. Replace as necessary.

Inspect threaded portion of barrel for damage. Dress
threads as necessary.

16.

Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.

Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.

17.

If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

3.

Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.

4.

Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

5.
6.

5-10



– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

Assembly
NOTE:

Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.



Apply a light film of hydraulic oil to all components before
assembly.
1.

Use seal tool to install new rod seal into applicable cylinder head gland groove.

Figure 5-11. Wiper Seal Installation
3.

Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.

Figure 5-9. Rod Seal Installation

IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.

Figure 5-12. Head Seal Kit Installation

Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.

4.

Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.

5.

Carefully slide piston spacer on rod.

NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.

Figure 5-10. Poly-Pak Piston Seal Installation

3121298

– JLG Lift –

5-11

SECTION 5 - HYDRAULICS

6.

If applicable, place new O-ring and back-up rings in
inner piston diameter groove.

11.

Remove cylinder rod from holding fixture.

12.

Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)

13.

Position cylinder barrel in a suitable holding fixture.

INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.

Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.

15.

Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.

16.

Secure cylinder head gland using washer ring and
socket head bolts.

Figure 5-13. Piston Seal Kit Installation
7.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

8.

Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.

NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.

Thread piston onto rod until it aligns with spacer end
and install tapered bushing.

NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.

Install bolts in tapered bushing using loctite #242
Figure 5-15. Rod Assembly Installation
 






 
 

Figure 5-14. Tapered Bushing Installation

5-12

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

5.

Master Cylinder

Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).

DISASSEMBLY
NOTE: Refer to Figure 5-19. Master Cylinder.

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.



Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.



DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2.

Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.

3.

If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.

4.

Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.



Figure 5-17. Marking Cylinder for Alignment

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.





 

 




6.

Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.

7.

Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.





Figure 5-16. Cylinder Barrel Support

Figure 5-18. Cylinder Rod Support

3121298

– JLG Lift –

5-13

SECTION 5 - HYDRAULICS





































 




1.
1a.
2.
2a.
3.

Barrel
Composite Bushing
Rod
Composite Bushing
Piston

4.
5.
6.
7.
8.

Head
Tapered Bushing
Spacer
Capscrew
Ring Washer

9.
10.
11.
12.
13.

Locking Compound
Locking Primer
Seal
Lock Ring
O-Ring

14.
15.
16.
17.
18.

Back-Up Ring
Wear Ring
O-Ring
Back-Up Ring
Rod Seal




19. Wiper
20. Not Used
21. Capscrew

Figure 5-19. Master Cylinder Assembly

5-14

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

8.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

7.

Inspect threaded portion of piston for damage. Dress
threads as necessary.

9.

Loosen and remove nut attaching piston to rod. Remove
piston.

8.

Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.

10.

Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.

9.

11.

Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.

Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.

10.

Inspect threaded portion of head for damage. Dress
threads as necessary.

11.

Inspect seal and O-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.

12.

Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary.

13.

If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.

12.

Remove tapered bushing from piston.

13.

Screw piston counter-clockwise by hand and remove
from cylinder rod.

 






a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.

 
 

NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-20. Tapered Bushing Removal
14.

Remove and discard piston O-rings, seal rings, and
backup rings.

15.

Remove piston spacer, if applicable, from rod.

16.

Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.

d. Press composite bushing into barrel or rod bushing
with correct size arbor.

 

 
  


 

Cleaning and Inspection
1.

Clean parts thoroughly with approved cleaning solvent.

2.

Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.



Figure 5-21. Composite Bushing Installation
14.

Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.

15.

If applicable, inspect port block fittings and holding
valve. Replace as necessary.

Inspect threaded portion of barrel for damage. Dress
threads as necessary.

16.

Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.

Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.

17.

If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

3.

Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.

4.

Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

5.
6.

3121298

– JLG Lift –

5-15

SECTION 5 - HYDRAULICS

Assembly
NOTE:

Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.



Apply a light film of hydraulic oil to all components before
assembly.
1.

Use seal tool to install new rod seal into applicable cylinder head gland groove.

Figure 5-24. Wiper Seal Installation
3.

Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.

Figure 5-22. Rod Seal Installation

IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.

Figure 5-25. Head Seal Kit Installation

Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.

4.

Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.

5.

Carefully slide piston spacer on rod.

NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.

Figure 5-23. Poly-Pak Piston Seal Installation

5-16

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

6.

If applicable, place new O-ring and back-up rings in
inner piston diameter groove.

11.

Remove cylinder rod from holding fixture.

12.

Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)

13.

Position cylinder barrel in a suitable holding fixture.

INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.

Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.

15.

Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.

16.

Secure cylinder head gland using washer ring and
socket head bolts.

Figure 5-26. Piston Seal Kit Installation
7.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

8.

Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.

NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.

Thread piston onto rod until it aligns with spacer end
and install tapered bushing.

NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.

Install bolts in tapered bushing using loctite #242
Figure 5-28. Rod Assembly Installation
 






 
 

Figure 5-27. Tapered Bushing Installation

3121298

– JLG Lift –

5-17

SECTION 5 - HYDRAULICS

5.

Telescope Cylinder

Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).

DISASSEMBLY

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.


1.

Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.


DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.



2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.



3. If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.

Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.

Figure 5-30. Marking Cylinder for Alignment

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.





 

 

6.

Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.

7.

Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.








Figure 5-29. Cylinder Barrel Support

Figure 5-31. Cylinder Rod Support

5-18

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS












































     



1.
2.
3.
4.
5.

Barrel
Rod
Head
Piston
Tapered Bushing

6.
7.
8.
9.
10.

Spacer
Valve Assembly
O-Ring Plug
Capscrew
Ring Washer

11.
12.
13.
14.
15.

Capscrew
Capscrew
Wiper
Rod Seal
O-Ring

16.
17.
18.
19.
20.

Back-Up Ring
Wear Ring
O-Ring
Back-Up Ring
T-Seal

21.
22.
23.
24.
25.

  

Wear Ring
Locking Compound
Locking primer
Not Used
Bolt

Figure 5-32. Telescope Cylinder Assembly

3121298

– JLG Lift –

5-19

SECTION 5 - HYDRAULICS

8.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

7.

Inspect threaded portion of piston for damage. Dress
threads as necessary.

9.

Loosen and remove nut attaching piston to rod. Remove
piston.

8.

Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.

10.

Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.

9.

11.

Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.

Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.

10.

Inspect threaded portion of head for damage. Dress
threads as necessary.

11.

Inspect seal and O-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.

12.

Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary.

13.

If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.

12.

Remove tapered bushing from piston.

13.

Screw piston counter-clockwise by hand and remove
from cylinder rod.

 






a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.

 
 

NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-33. Tapered Bushing Removal
14.

Remove and discard piston O-rings, seal rings, and
backup rings.

15.

Remove piston spacer, if applicable, from rod.

16.

Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.

d. Press composite bushing into barrel or rod bushing
with correct size arbor.

 

 
  


 

Cleaning and Inspection
1.

Clean parts thoroughly with approved cleaning solvent.

2.

Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.

Figure 5-34. Composite Bushing Installation
14.

Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.

15.

If applicable, inspect port block fittings and holding
valve. Replace as necessary.

Inspect threaded portion of barrel for damage. Dress
threads as necessary.

16.

Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.

Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.

17.

If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

3.

Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.

4.

Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

5.
6.

5-20



– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

Assembly
NOTE:

Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.



Apply a light film of hydraulic oil to all components before
assembly.
1.

Use seal tool to install new rod seal into applicable cylinder head gland groove.

Figure 5-37. Wiper Seal Installation
3.

Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.

Figure 5-35. Rod Seal Installation

IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.

Figure 5-38. Head Seal Kit Installation

Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.

4.

Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.

5.

Carefully slide piston spacer on rod.

NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.

Figure 5-36. Poly-Pak Piston Seal Installation

3121298

– JLG Lift –

5-21

SECTION 5 - HYDRAULICS

6.

If applicable, place new O-ring and back-up rings in
inner piston diameter groove.

11.

Remove cylinder rod from holding fixture.

12.

Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)

13.

Position cylinder barrel in a suitable holding fixture.

INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.

Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.

15.

Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.

16.

Secure cylinder head gland using washer ring and
socket head bolts.

Figure 5-39. Piston Seal Kit Installation
7.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

8.

Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.

NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.

Thread piston onto rod until it aligns with spacer end
and install tapered bushing.

NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.

Install bolts in tapered bushing using loctite #242
Figure 5-41. Rod Assembly Installation
 






 
 

Figure 5-40. Tapered Bushing Installation

5-22

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

5.

Platform Level (Slave) Cylinder

Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).

DISASSEMBLY

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.


1.

Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.


DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2.

Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.

3.

If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.

4.

Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.




Figure 5-43. Marking Cylinder for Alignment

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.





 

 






6.

Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.

7.

Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.



Figure 5-42. Cylinder Barrel Support

Figure 5-44. Cylinder Rod Support

3121298

– JLG Lift –

5-23

SECTION 5 - HYDRAULICS






































 
  


 
  

1.
1a.
2.
2a.
3.
4.

Barrel
Composite Bushing
Rod
Composite Bushing
Piston
Head

5.
6.
7.
8.
9.
10.

Tapered Bushing
Spacer
Cartridge Valve
O-Ring Plug
Capscrew
Ring Washer

11.
12.
13.
14.
15.
16.

Locking Compound
Locking Primer
Seal
Ring Lock
O-Ring
Back-Up Ring

17.
18.
19.
20.
21.

Wear Ring
O-Ring
Back-Up Ring
Rod Seal
Wiper

22.
23.
24.
25.

Not Used
Cartridge Valve
O-Ring Plug
Bolt

Figure 5-45. Platform Level (Slave) Cylinder Assembly

5-24

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

8.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

7.

Inspect threaded portion of piston for damage. Dress
threads as necessary.

9.

Loosen and remove nut attaching piston to rod. Remove
piston.

8.

Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.

10.

Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.

9.

11.

Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.

Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.

10.

Inspect threaded portion of head for damage. Dress
threads as necessary.

11.

Inspect seal and O-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.

12.

Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary.

13.

If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.

12.

Remove tapered bushing from piston.

13.

Screw piston counter-clockwise by hand and remove
from cylinder rod.

 






a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.

 
 

NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-46. Tapered Bushing Removal
14.

Remove and discard piston O-rings, seal rings, and
backup rings.

15.

Remove piston spacer, if applicable, from rod.

16.

Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.

d. Press composite bushing into barrel or rod bushing
with correct size arbor.

 

 
  


 

Cleaning and Inspection
1.

Clean parts thoroughly with approved cleaning solvent.

2.

Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.



Figure 5-47. Composite Bushing Installation
14.

Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.

15.

If applicable, inspect port block fittings and holding
valve. Replace as necessary.

Inspect threaded portion of barrel for damage. Dress
threads as necessary.

16.

Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.

Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.

17.

If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

3.

Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.

4.

Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

5.
6.

3121298

– JLG Lift –

5-25

SECTION 5 - HYDRAULICS

Assembly
NOTE:

Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.



Apply a light film of hydraulic oil to all components before
assembly.
1.

Use seal tool to install new rod seal into applicable cylinder head gland groove.

Figure 5-50. Wiper Seal Installation
3.

Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.

Figure 5-48. Rod Seal Installation

IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.

Figure 5-51. Head Seal Kit Installation

Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.

4.

Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.

5.

Carefully slide piston spacer on rod.

NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.

Figure 5-49. Poly-Pak Piston Seal Installation

5-26

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

6.

If applicable, place new O-ring and back-up rings in
inner piston diameter groove.

11.

Remove cylinder rod from holding fixture.

12.

Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)

13.

Position cylinder barrel in a suitable holding fixture.

INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.

Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.

15.

Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.

16.

Secure cylinder head gland using washer ring and
socket head bolts.

Figure 5-52. Piston Seal Kit Installation
7.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

8.

Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.

NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.

Thread piston onto rod until it aligns with spacer end
and install tapered bushing.

NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.

Install bolts in tapered bushing using loctite #242
Figure 5-54. Rod Assembly Installation
 






 
 

Figure 5-53. Tapered Bushing Installation

3121298

– JLG Lift –

5-27

SECTION 5 - HYDRAULICS

5.

Jib Lift Cylinder (SJ Only)

Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
head cap screws (4).

DISASSEMBLY

CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.


1.

Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.


DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.



2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.



3. If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard Orings.
4.

Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.

Figure 5-56. Marking Cylinder for Alignment

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.





 

 






6.

Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.

7.

Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.



Figure 5-55. Cylinder Barrel Support

Figure 5-57. Cylinder Rod Support

5-28

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS













































  
 







1.
1a.
2.
3.
4.

Barrel
Bushing
Head
Ring Washer
Capscrew

5.
5a.
6.
7.
8.

Rod
Bushing
Cartridge Valve
Not Used
O-Ring Plug

9.
10.
11.
12.
13.

  

O-Ring Plug
Piston
Tapered Bushing
Spacer
Not Used

14.
15.
16.
17.
18.

Seal
Lock Ring
O-Ring
Back-Up Ring
Rod Seal

19.
20.
21.
22.
23.

Wiper
Wear Ring
Wiper
Wear Ring
Locking Compound

24. Locking Primer
25. Not Used
26. Bolt

Figure 5-58. Jib Lift Cylinder Assembly(600SJ)

3121298

– JLG Lift –

5-29

SECTION 5 - HYDRAULICS

8.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

7.

Inspect threaded portion of piston for damage. Dress
threads as necessary.

9.

Loosen and remove nut attaching piston to rod. Remove
piston.

8.

Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.

10.

Loosen and remove cap screw(s), if applicable, attaching
tapered bushing to piston.

9.

11.

Insert cap screw(s) in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.

Inspect cylinder head inside diameter for scoring or
other damage, and for ovality and tapering. Replace as
necessary.

10.

Inspect threaded portion of head for damage. Dress
threads as necessary.

11.

Inspect seal and O-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.

12.

Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary.

13.

If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.

12.

Remove tapered bushing from piston.

13.

Screw piston counter-clockwise by hand and remove
from cylinder rod.

 






a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.

 
 

NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
Figure 5-59. Tapered Bushing Removal
14.

Remove and discard piston O-rings, seal rings, and
backup rings.

15.

Remove piston spacer, if applicable, from rod.

16.

Remove rod from holding fixture. Remove cylinder head
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.

d. Press composite bushing into barrel or rod bushing
with correct size arbor.

 

 
  


 

Cleaning and Inspection
1.

Clean parts thoroughly with approved cleaning solvent.

2.

Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.

Figure 5-60. Composite Bushing Installation
14.

Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.

15.

If applicable, inspect port block fittings and holding
valve. Replace as necessary.

Inspect threaded portion of barrel for damage. Dress
threads as necessary.

16.

Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.

Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.

17.

If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

3.

Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.

4.

Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

5.
6.

5-30



– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

Assembly
NOTE:

Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.



Apply a light film of hydraulic oil to all components before
assembly.
1.

Use seal tool to install new rod seal into applicable cylinder head gland groove.

Figure 5-63. Wiper Seal Installation
3.

Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.

Figure 5-61. Rod Seal Installation

IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION.
2.

Figure 5-64. Head Seal Kit Installation

Use a soft mallet to tap new wiper seal into applicable
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove.

4.

Install washer ring on rod. Carefully install head gland
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.

5.

Carefully slide piston spacer on rod.

NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.

Figure 5-62. Poly-Pak Piston Seal Installation

3121298

– JLG Lift –

5-31

SECTION 5 - HYDRAULICS

6.

If applicable, place new O-ring and back-up rings in
inner piston diameter groove.

11.

Remove cylinder rod from holding fixture.

12.

Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)

13.

Position cylinder barrel in a suitable holding fixture.

INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
14.

Clamp barrel clamped securely and support rod. Insert
piston end into barrel cylinder. Do not damage or dislodge piston loading O-ring and seal ring.

15.

Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.

16.

Secure cylinder head gland using washer ring and
socket head bolts.

Figure 5-65. Piston Seal Kit Installation
7.

Using suitable protection, clamp cylinder rod in a vise or
similar holding fixture as close to piston as possible.

8.

Carefully thread piston on cylinder rod hand tight,
Ensure O-ring and back-up rings are not damaged or
dislodged.

NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9.

Thread piston onto rod until it aligns with spacer end
and install tapered bushing.

NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts
when rebuilding master, slave, lift, and telescope cylinders.
10.

Install bolts in tapered bushing using loctite #242
Figure 5-67. Rod Assembly Installation
 






 
 

Figure 5-66. Tapered Bushing Installation

5-32

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

5.

Steer Cylinder

Unscrew Spanner Nut (13) with hook spanner.

DISASSEMBLY
NOTE: Refer to Figure 5-71.

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1.

Connect a suitable auxiliary hydraulic power source to
cylinder port block fitting.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
2.

Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.

3.

Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound.

Figure 5-69. Removing Spanner Nut

PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD AND PISTON.
6.






Clamp barrel securely. Apply pressure to rod pulling
device and carefully withdraw complete rod assembly
from cylinder barrel.


 

 






 



Figure 5-68. Cylinder Barrel Support
4.

Remove burrs and contamination from cylinder before
disassembly.
Figure 5-70. Cylinder Rod Support

3121298

– JLG Lift –

5-33

SECTION 5 - HYDRAULICS























     
      




1.
2.
3.
4.

Piston
Seal
O-Ring
Setscrew

5.
6.
7.
8.

Barrel
Rod
Head
O-Ring

9. Back-Up Ring
10. Seal
11. O-Ring



 

12. Wiper
13. Spanner Nut
14. Composite Bushing

Figure 5-71. Steer Cylinder Assembly

5-34

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

7.

Remove two Seals (2) and O-Ring (3) from Piston (1).

8.

Loosen two Setscrews (4) in Piston (1). Unscrew and
remove Piston (1) from Rod (6) with strap wrench.

Cleaning and Inspection
1.

Clean all parts in an approved cleaning solvent.

2.

Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite™
or equivalent. Replace rod if necessary.

3.

Inspect inner surface of cylinder barrel tube for scoring,
tapering, ovality, or other damage. Replace if necessary.

4.

Inspect threaded portion of barrel for damage. Dress
threads as necessary.

5.

Inspect piston surface for damage and scoring and for
distortion. Inspect seal and O-ring grooves in piston for
burrs and sharp edges. Dress piston surfaces or replace
rod assembly as necessary.

6.

Inspect rod bushings for excessive wear or damage.
Replace as necessary.











Figure 5-72. Piston Seal and Wear Ring
9.
10.

a. Thoroughly clean rod bushing of burrs, dirt, etc.

Remove Cylinder Head (7) from Rod (6).

b. Inspect rod bushing for wear or other damage. If rod
bushing is worn or damaged, rod must be replaced.

Remove O-Ring (11), O-Ring (9), and Backup Ring (8)
from Cylinder Head (7).

11.

Remove Wiper (12) and Rod Seal (10). Do not damage
cylinder head groove.

12.

Remove Spanner Nut (13) from Rod (6).

c. Lubricate inside of rod bushing with WD40 before
installing composite bushing.
d. Press composite bushing in rod bushing using correct size arbor.
NOTE: Pin is installed in composite bushing dry. Lubrication is not
required with nickel plated pins and bearings.






 




 
  


 



Figure 5-74. Composite Bushing Installation



7.

Inspect cylinder head inside diameter for scoring, tapering, ovality, or other damage. Replace as necessary.

8.

Inspect threads, and seal and O-Ring grooves in head for
burrs, sharp edges, and other damage. Dress surfaces as
necessary.

9.

Inspect oil ports for blockage or contamination. Repair
as necessary.



Figure 5-73. Cylinder Head Disassembly

3121298

– JLG Lift –

5-35

SECTION 5 - HYDRAULICS

Assembly
NOTE:

Apply a light film of hydraulic oil to all components before
assembly.

5.

Install wear ring (11) in piston groove.

6.

Install seal (10) in piston groove.


1.

Position cylinder barrel in a suitable holding fixture.



IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
CYLINDER OPERATION.
2.

Install Spanner Nut (3) on Rod (6).

3.

Install Rod Seal (5) and Wiper () in Cylinder Head (3).

4.

Install O-Ring (7), Backup Ring (8), and O-Ring (9).












Figure 5-76. Piston Seal and Wear Ring



INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
SURFACES. USE EXTREME CARE INSTALLING CYLINDER ROD AND PISTON.




7.

Insert Rod Assembly in Barrel (1).

8.

Apply Locking Primer and Loctite 242 (or equivalent) to
threads of Spanner Nut (3). Tighten spanner nut (3) with
hook spanner to 57-63 ft-lb (77-85 Nm).



Figure 5-75. Cylinder Head Assembly

    

Figure 5-77. Spanner Nut Torque

5-36

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

ASSEMBLY

Axle Lockout Cylinder

Refer to Figure 5-78., Axle Lockout Cylinder.

NOTE: Refer to Figure 5-78., Axle Lockout Cylinder.

1.

Install two new wear rings (5) and rod seal (7) in piston
bore grooves. Make sure they are not twisted.

2.

Install new wiper (6) in housing.

3.

Lubricate piston bore with clean hydraulic fluid.

DISASSEMBLY

CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
INSERTING PISTON OFF-CENTER CAN DAMAGE PISTON AND PISTON BORE
SURFACES. USE EXTREME CARE WHEN INSTALLING PISTON.
PISTON CAN FALL OUT OF HOUSING AND CAUSE INJURY OR DAMAGE TO
EQUIPMENT. BE CAREFUL WHEN REMOVING AXLE CYLINDER. OPENING BLEED
VALVE CAN CAUSE PISTON TO FALL OUT OF HOUSING.
1.

Open bleed valve (8). Rotate piston (2) and remove from
housing (1).

2.

Remove wiper (6). Do not scratch housing bore.

3.

Remove two wear rings (5) and rod seal (7) from grooves
in piston bore. Do not scratch housing bore.

4.

Remove check valve (9), if required.

5.

Inspect bore and piston for scoring, pitting, or excessive
wear.

6.

Remove minor surface blemishes with wet 2000-grit
sandpaper. Pitting requires replacement of housing or
piston.

7.

Clean all parts with approved solvent and dry with compressed air.

3121298

– JLG Lift –

4.

Install piston (2) in bore and push to top of bore.

5.

Install check valve (9). Torque to 25 - 27 ft-lb (33 - 36 Nm).

6.

Bleed system.

5-37

SECTION 5 - HYDRAULICS

FALLING PARTS CAN CAUSE INJURY AND EQUIPMENT DAMAGE. CYLINDER
ROD CAN FALL OUT WHEN BLEEDER VALVE IS OPENED.

1.
2.
3.
4.
5.

Barrel
Rod
Plug
Pilot Piston
Wear Ring

6.
7.
8.
9.

Wiper
Rod Seal
Bleeder
Cartridge Valve

Figure 5-78. Axle Lockout Cylinder

5-38

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

7.

Remove pump from vise and place on clean work bench.
Remove four hex head bolts and spacers if applicable.

8.

Lift and remove end cover.

9.

Carefully remove gear housing and place on work
bench. Make sure rear bearing block remains on drive
and idler shafts.

5.6 HYDRAULIC PUMP (GEAR)
Disassembly
NOTE: The following general instructions also apply to multiple
section gear pumps. The only extra parts are the coupling
between drive shafts and center distance plate which
divides the two pump sections. This repair procedure also
applies to ”W” series Gear Motors.
1.

Always work in a clean work area when repairing
hydraulic products. Plug ports and wash exterior of
pump with approved cleaning solvent.

2.

Remove port plugs and drain oil from pump.

3.

Use a permanent marker pen to mark a line across
mounting flange, gear housing and end cover. This will
assure proper reassembly and rotation of pump.

4.

Remove key from drive shaft if applicable.

5.

Clamp mounting flange in a protected jaw vise with
pump shaft facing down.

6.

Loosen four metric hex head bolts.

3121298

– JLG Lift –

5-39

SECTION 5 - HYDRAULICS

10.

Remove rear bearing block from drive and idler shafts.

13.

Remove front bearing block.

11.

Remove idler shaft from bearing block.

14.

Turn mounting flange over, with shaft seal up. Remove
retaining ring with snap ring pliers.

12.

Remove drive shaft from mounting flange.
15.

Remove oil seal from mounting flange. Do not mar or
scratch seal bore.

16.

Remove dowel pins from gear housing. Do not lose pins.

17.

Remove and discard seals from both bearing blocks.

NOTE: Shaft seal will be replaced.

5-40

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

Inspect Parts For Wear
1.

2.

3.

4.

Inspect gear face for scoring or excessive wear. If face
edge of gear teeth are sharp, they will mill into the bearing blocks. If wear has occurred, parts are unusable.

5.

Inspect bearing blocks for excessive wear or scoring on
surfaces in contact with gears. Inspect bearings for
excessive wear or scoring.

6.

Inspect area inside gear housing. A clean ”wipe” on
inside surface of intake side is normal. There should not
be excessive wear, deep scratches, or gouges.

Clean and dry all parts thoroughly before inspection. It
is not necessary to inspect seals. They will be placed as
new items.

Check drive shaft spine for twisted or broken teeth,
check keyed drive shaft for broken or chipped keyway.
No marks or grooves on shaft in seal area, some discoloration of shaft is allowable.
Inspect drive gear shaft and idler gear shafts at bearing
points and seal area for rough surfaces and excessive wear.

3121298

– JLG Lift –

5-41

SECTION 5 - HYDRAULICS

General Information

2.

Install retaining ring in groove in seal bore of mounting
flange.

3.

Place front and back bearing blocks on a clean surface
with E-seal grooves facing up. Apply a light coating of
petroleum jelly in the grooves. Coat E-seal and backup
with petroleum jelly. This helps keep seals in place during reassembly

4.

Place E-seals, flat side out, into grooves in both bearing
blocks. Carefully place backup ring, flat side out, in
groove made by E-seal and groove in bearing block.
(Note: W900 series pump - In center of backup ring and Eseal there is a notch. Make sure notches line up so backup
ring will set flush with E-seal). Backup ring in W1500
pump is symmetrical.

FAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT WITH LITTLE OR
NO FLOW AT RATED PRESSURE. RELATIONSHIP OF MOUNTING FLANGE, BEARING BLOCKS, AND GEAR HOUSING MUST BE CORRECT.

Reverse Shaft Rotation of Pump
NOTE: Pump is not bi-rotational. Use the following procedure if
shaft rotation direction is changed.
Reverse shaft rotation of ”W” series gear pump by rotating, as
a group, two bearing blocks and gear housing 180° in relationship to remaining parts of pump. This places pressure port
opposite from original position.

Assembly
NOTE: Install new seals when reassembling pump or motor. Go to
page 8 for kit part numbers for W-600, W-900, and W-1500
pumps and motors.

1.

5-42

Install new shaft seal in mounting flange with part number side facing out. Press seal into seal bore until seal
reaches bottom of bore. Use uniform pressure to prevent seal misalignment or damage.

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

5.

Place mounting flange, with shaft seal side down, on a
clean flat surface.

10.

Place rear bearing block over drive and idler gear shafts
with seal side up and open end of E-seal 
facing intake side of pump.

6.

Apply a light coating of petroleum jelly to exposed face
of front bearing block.

11.

Install two dowel pins in mounting flange holes or two
long dowel pins through gear housing if pump is a multiple section pump.

7.

Insert drive end of drive shaft through bearing block
with seal side down and open side of E-seal pointing to
intake side of pump.

12.

Apply a light coating of petroleum jelly in grooves on
both sides of gear housing. Coat new O-rings and install
in grooves.

8.

Install seal sleeve over drive shaft. Carefully slide drive
shaft through shaft seal. Remove seal sleeve from shaft.

9.

Install idler gear shaft in remaining position in bearing
block. Apply a light coat of clean oil to face of drive and
idler gears.

3121298

– JLG Lift –

5-43

SECTION 5 - HYDRAULICS

13.

Gently slide gear housing over rear bearing block
assembly. Slide housing down until it engages dowel
pins. Press firmly in place with hands, do not force or use
any tool. Check intake port in housing is on same side as
open end of E-seal, and marked lines on mounting
flange and gear housing are aligned.

15.

Install four spacers (if applicable) and hex head bolts
through bolt holes in end cover. Hand tighten.

16.

Place mounting flange of pump in protected jawed vise
and alternately torque bolts to torque chart specifications. All torque figures are for ”dry torque” bolts.

NOTE: Rear bearing block surface should be slightly below gear
housing face. If bearing block is higher than rear face of
gear housing, E-seal or O-ring have shifted out of groove.
Remove gear housing and check for proper seal installation.

Table 5-1.Hydraulic Pump Bolt Torque Chart

14.

5-44

Install two remaining dowel pins in rear of gear housing,
if applicable. Place end cover over back of pump.

Torque Values,
Black Oxide
End Cover

Torque Values,
Zinc Plated End
Cover

M 8 x 1.25

18-21 ft.lb.
24-30 Nm

16-18 ft.lb.
21.7-24.4 Nm

W-900

M 10 x 1.5

50-55 ft.lb.
68-75 Nm

38-43 ft.lb.
51.5-58.3 Nm

W-1500

M 12 x 1.75

80-85 ft.lb.
108-115 Nm

68-73 ft.lb.
92.2-99 Nm

Pump Series

Thread Size

W-600

17.

Remove pump from vise.

18.

Place a small amount of clean oil in pump inlet and
rotate drive shaft away from inlet one revolution. If drive
shaft binds, disassemble pump and check for assembly
problems. Reassemble pump.

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

Placing Pump Back Into Service
1.

5.7 VARIABLE PUMP

If shop test stand is available, use the following procedure for testing rebuilt pumps:
a. Mount pump on test stand. Make sure proper level
of clean oil is available in reservoir. Check suction
line for leaks and obstructions.
b. Start pump and run for three minutes at zero pressure.

Ports and Pressure Gauges
Proper servicing of pumps and motors requires pressure measured and monitored at various hydraulic circuit points. The
Series 42 pump has several locations at which to take these
measurements. The following outlines show gauge port locations, and gauge and fitting size for each port.
Table 5-2. Recommended Gauge Size

c. Intermittently load pump to 500 P.S.I. for three minutes.
d. Intermittently load pump to 1000 P.S.I. for three
minutes.
e. Intermittently load pump to 2000 P.S.I. for three
minutes.
f. Remove pump from test stand and check for freeness of drive shaft. Check pump for signs of external
leakage.
2.

If shop test stand is not available, use the following procedure for testing rebuilt pumps:
a. For engine driven pumps, mount pump on equipment and run pump at 1/2 engine speed at zero
pressure for three minutes.

Gauge
Port
Name

d. Stop engine and check pump for external leaks.

Recommended Gauge
Size
PSI

Bar

Fitting

M1 & M2

System
Pressure
Ports A & B

10000

600

9/16-18 ORF

M3

Charge

1000

60

3/4-16 ORF

M4 & M5

Servo

1000

60

9/16-18 ORF

L1 & L2

Case

500

35

1-1/16-12 ORF

S

Charge Pump
Inlet Vacuum

30 in. Hg Vac.

1

1-1/16-12 ORF

b. Operate control valve and build pressure intermittently for three minutes.
c. Increase engine speed to full throttle and build
pressure intermittently for three minutes.

Pressure
Measured

NFPE Control
The 3-position FNR control, and electric and hydraulic nonfeedback proportional (NFPE and NFPH) controls are nonfeedback type controls. FNR and NFPE controls consist of
pump housing mounted modules. Hydraulic input for NFPH is
received through ports on top of pump [9/16–18 SAE O-ring
fitting].
Non-feedback controls are factory set. Control modules can be
removed to clean ports and change O-rings.
FNR and NFPE orifice plugs are located inside the servo piston
covers. NFPH orifice plugs are located in the NFPH ports. Orifice plugs may be cleaned or replaced.

3121298

– JLG Lift –

5-45

SECTION 5 - HYDRAULICS

SHIM ADJUSTABLE STYLE

Remove and Install FNR and NFPE Modules
1.

Clean pump and module housings.

2.

Remove four screws retaining module to pump housing (4
mm Int. Hex). Remove module from housing.

3.

Remove O-rings from the control ports. Examine ports
for cleanliness.

4.

Clean sealing surfaces.

5.

Replace locator pin.

6.

Install new O-rings.

7. Replace screws. Torque to 3.5 - 4.5 ft-lb (4.7-6.1 Nm).

Remove and Install FNR and NFPE Control Orifices
NOTE: Future models may contain an orifice plate between module and pump housing. This will take the place of the orifice
plugs beneath the servo piston cover.
1.

Remove servo piston cover.

2.

Remove orifice plug (1/8" Int. Hex).

3.

Examine orifice and port for cleanliness.

4.

Install orifice plug. Torque to 1.5 - 2.5 ft-lb (2.0-3.4 Nm).

1.
2.
3.

Plug
O-Ring
Shims

4.
5.

Spring T-Seal
Poppet

Figure 5-79. Shim Adjustable Charge Relief Valve
Components

Charge Relief Valve
Charge relief valve may be removed for cleaning and installation of new O-rings. Pressure setting may be changed for different charge flows depending on charge pump size and
pump speed. 

Factory setting is set relative to case pressure at 1800 rpm.
Actual charge pressure varies at different speeds.

5-46

– JLG Lift –

1.

Remove shim adjustable charge relief valve plug (1" Hex)
from pump housing. Remove O-ring from plug.

2.

Remove spring and poppet from housing.

3.

Do not alter shims which may be installed between
spring and valve plug, or interchange parts with another
valve. Inspect poppet and mating seat in housing for
damage or foreign material.

4.

If desired, change charge relief valve setting. An approximate rule of thumb is 4 bar / 1.25 mm (58 psi / 0.050 in).
Effective setting will vary.

To confirm charge relief valve setting, measure charge
pressure (port M3) with pump in stroke. Charge pressure
should level off when relief setting is reached.

3121298

SECTION 5 - HYDRAULICS

1.

System Pressure Gauge Port M2

7.

Case Drain Port L2

2.

System Pressure Port B

8.

Servo Pressure Gauge Port L4

3.

System Pressure Port A

9.

Case Drain Port L1

4.

System Pressure Gauge Port M1

10.

Case Drain Port L1 (non-feedback)

5.

Servo Pressure Gauge Port M5

11.

Charge Pressure Gauge

6.

Case Drain Port L2 (non-feedback)

12.

Charge Pump Inlet Port S

Figure 5-80. Gauge Port Locations

3121298

– JLG Lift –

5-47

SECTION 5 - HYDRAULICS

Torque

#

Plug/
Fitting

lb. ft.

Nm

1

Servo Gauge Port M4

N/A

N/A

2

11/16

20-35

27-47

3

9/16

70-100

95-135

4

Case Drain Port L1

N/A

N/A

5

Charge Pressure Gauge M3

N/A

N/A

6

Charge Pump Inlet Port S

85

115

7

Case Drain Port L2

N/A

N/A

8

Port N

N/A

N/A

9

System Gauge M1 & M2

N/A

N/A

10

System Ports A&B

85

115

11

11/16

20-35

27-47

12

9/16

70-100

95-135

13

11/16

20-35

27-47

14

Servo Gauge M5

15

11/16

N/A

N/A

20-35

27-47

Figure 5-81. Plugs/Fittings Size & Torque

5-48

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

5.

Install new O-ring on valve plug. Reinstall poppet,
spring, and plug (with shims and O-ring) into pump
housing. Torque to 40-100 ft-lb (55-135 Nm).

Shaft Seal and Shaft Replacement

SCREW ADJUSTABLE STYLE

1. Lock Nut 
2. O-Ring 
3. Plug

1. Retaining Ring
4. Spring T-Seal
5. Poppet

2. Seal Carrier Assembly

Figure 5-83. Shaft Seal Components

Figure 5-82. Screw Adjustable Charge Relief Valve
Components

A lip type shaft seal is used in Series 42 pumps. Seal and shaft
can be replaced without major unit disassembly. Replacement
generally requires removing pump from machine.

1.

Mark plug, lock nut, and housing to maintain original
adjustment before removing screw adjustable relief valve
plug. Loosen lock nut (1-1/16" Hex) and remove plug (8
mm Int. Hex). Remove O-ring from plug.

2.

Remove spring and poppet from housing.

3.

Inspect poppet and mating seat in housing for damage
or foreign material.

4.

Install new O-ring on valve plug. Reinstall poppet and
spring. Reinstall plug and lock nut. Torque to 34 - 42 ft-lb
(47-57 Nm), aligning marks made at disassembly.

5.

Check and adjust charge pressure if necessary. For screw
adjustable “anti-stall” charge relief valves, an approximate rule of thumb is 2.8 bar/quarter turn (40 psi/quarter turn).

6.

Measure charge pressure (port M3) with pump in stroke.
Charge pressure should level off when relief setting is
reached.

1. O-Ring
2. Seal 
3. Seal Carrier

4. Sealant may be used on outside diameter
5. Inside Lip (face down)
6. Press Seal to Bottom of Seal Carrier

Figure 5-84. Installation of Shaft Seal

3121298

– JLG Lift –

5-49

SECTION 5 - HYDRAULICS

1.

Position pump with shaft facing up.

NOTE: If unit is positioned horizontally when shaft is removed, cylinder block could move out of place, making shaft installation difficult.
2.

Remove retaining ring from housing.

3.

Pull out seal carrier assembly.

4.

Remove O-ring from seal carrier. To install a new shaft
only, go to step 8.

5.

Place seal carrier in an arbor press with shaft bearing
side down and press out old seal. An appropriately sized
pipe spacer or socket wrench can be used as a press
tool. Seal is not reusable.

6.

Inspect seal carrier and new seal for damage. Inspect
sealing area on shaft for rust, wear, or contamination.
Polish sealing area on shaft if necessary.

7.

Press new seal in shaft bearing side of seal carrier. Seal
lip must face outside of pump. Do not damage seal. Outside diameter of seal may be coated with a sealant (e.g.
Loctite High Performance Sealant #59231) before installation. This helps prevent leaks caused by damage to
seal bore in seal carrier. If shaft is not being replaced go
to step 11.

8.

Remove shaft and roller bearing assembly from pump or
motor.

9. Remove retaining ring from roller bearing assembly with
snap ring pliers. Remove roller bearing assembly.
10.

Place roller bearing assembly on new shaft and secure
with retaining ring.

11. Wrap spline or key end of shaft with thin plastic to prevent damage to seal lip during installation. Lubricate
inside diameter of shaft seal with petroleum jelly.
12.
13.

Place O-ring on shaft bearing and lubricate with petroleum jelly.
Slide seal carrier assembly over shaft and into housing
bore. Press against O-ring. Hold inward pressure against
shaft to compress cylinder block spring while pressing seal
carrier into place.

14. Install retaining ring.

5-50

1. Key 
2. Shaft Assembly 
3. Retaining Ring

4. Roller Bearing
5. Shaft

Figure 5-85. Shaft Components

Hydraulic Pump W/Hayes Pump Drive Coupling
Lubrication
Coat pump and drive coupling splines with Lithium Soap
Base Grease (TEXACO CODE 1912 OR EQUIVALENT)
whenever pump or pump drive coupling is removed. Coupling is greased prior to assembly.

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

Charge Pump
NOTE: Disassemble charge pump to inspect and clean, or change
auxiliary shaft drive coupling.
1.

Remove auxiliary pump if necessary.

2.

Remove screws retaining charge pump cover to pump
housing (Torx T). Seven screws are used with “no pad” or
SAE “A” auxiliary mounting pad charge pump cover, and
six screws are used with SAE “B” auxiliary mounting pad
charge pump cover. Remove charge pump cover, gasket, and cover locating pins.

3.

Remove gerotor cover assembly from charge pump
cover or back of pump housing. Remove gerotor cover
O-rings. Two O-rings are used on gerotor cover of all
pumps.

4.

Remove gerotor assembly from gerotor cover or pump
housing.

5.

Remove gerotor drive pin and drive coupling. Remove
gerotor cover locating pin from pump housing.

6.

Inspect each part if they are to be reused. If either gerotor
assembly parts needs to be replaced, they must both be
replaced. Always replace O-rings and charge pump cover
gasket. Inspect journal bearing in gerotor cover for excessive wear.

7.

Lubricate gerotor assembly with clean hydraulic oil
before assembly.

8.

Install gerotor drive pin into hole in drive coupling.
Apply grease or petroleum jelly to keep in place.

9.

Install drive coupling on pump shaft with smaller outside diameter facing away from shaft.

10.

Install gerotor assembly onto coupling.

11.

Install gerotor cover locating pin into pump housing.
Install gerotor cover assembly over gerotor. Locating pin
must engage slot in gerotor cover.

NOTE: Charge pump rotation is determined by location of gerotor
recess and pressure balance hole in gerotor cover. Different
gerotor covers are used for clockwise and counterclockwise
rotation pumps.

1.

Cover Retaining Screw

6.

Gerotor Cover Locating Pin

2.

O-Ring

7.

Charge Pump Cover
Locating Pin

Install new pressure balance O-rings to gerotor cover
and retain with petroleum jelly or grease.

3.

Gerotor Cover

4.

Gerotor Assembly

8.

Gerotor Drive Pin

13.

Install charge pump cover locating pins and new charge
pump cover gasket.

5.

Drive Coupling

9.

Gasket

14.

Install charge pump cover. Cover must engage gerotor
cover and locating pins. Install charge pump cover
screws. Torque evenly to 26 - 32 ft-lb (36-43 Nm).

15.

Reinstall auxiliary pump if necessary.

12.

3121298

– JLG Lift –

Figure 5-86. Charge Pump Components

5-51

SECTION 5 - HYDRAULICS

NOTE: Oil used to fill component housing must be clean. Store fill
container properly to prevent contamination.

5.8 HYDRAULIC COMPONENT START-UP
The goal at hydrostatic system start up is to preserve the
designed life span of the system. Use the following start-up
procedure when a new pump or motor is installed or a system
is restarted after a pump or motor has been removed and reinstalled.

THE FOLLOWING PROCEDURE MAY REQUIRE MACHINE TO BE DISABLED
(WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DISCONNECTED, ETC.)
WHILE PERFORMING PROCEDURE. TO PREVENT INJURY. TAKE NECESSARY
SAFETY PRECAUTIONS BEFORE MOVING VEHICLE/MACHINE.
Inspect pumps or motors for damage that may have been
incurred during shipping and handling before installation.
Make sure all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean before filling with fluid.
Fill reservoir with recommended hydraulic fluid. This fluid
should be passed through a 10 micron (nominal, no bypass)
filter before entering reservoir. Using contaminated fluid can
damage components and may cause unexpected vehicle/
machine movement.

INSPECT ALL PUMPS OR MOTORS FOR DAMAGE AND CONTAMINATION IF ANY
PUMP OR MOTOR IS REPLACED DUE TO INTERNAL DAMAGE. FLUSH AND
REPLACE ALL HYDRAULIC SYSTEM FLUID OR DAMAGE TO ENTIRE SYSTEM MAY
RESULT.
Inlet line from reservoir to pump must be filled prior to startup. Check inlet line for properly tightened fittings, restrictions,
and air leaks.
NOTE: Reservoir is usually above pump inlet. Pressure head created by higher oil level helps keep inlet pressures within
acceptable range and prevent high vacuum levels. However, air may be trapped due to hose routing or low reservoir locations. Bleed air by loosening hose at fitting closest
to pump. When oil begins to flow, line is full and air has
been purged. Tighten fitting to specified torque. If tank
needs to be pressurized to start oil flow, take a vacuum
reading at pump inlet during operation to verify pump is
not trying to draw an inlet vacuum higher than its capability.

Install 1000 psi (60 bar) pressure gauge in charge pressure
gauge port to monitor charge pressure during start-up.
It is recommended external control input signal, (electrical
connections for EDC), be disconnected at pump control until
after initial start-up. This ensures pump remains in its neutral
position.

DO NOT START ENGINE UNLESS PUMP IS IN NEUTRAL POSITION (0° SWASHPLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN
CASE PUMP IS ACTUATED DURING INITIAL START-UP.
”Jog” or slowly rotate engine until charge pressure starts to
rise. Start engine and run at lowest possible RPM until charge
pressure is established. Excess air should be bled from system
lines as close to motors as possible.
NOTE: With engine on low idle loosen, do not remove, system lines
at motor(s). Continue to run engine at low idle and tighten
system lines as soon as oil is observed to leak from them.
When oil is observed to ”leak” at motor, line is full and air is
purged. Tighten system hoses to specified torque.
Once charge pressure is established, increase speed to normal
operating RPM. Charge pressure should be as indicated in the
pump model code. If charge pressure is inadequate, shut
down and determine cause.

INADEQUATE CHARGE PRESSURE WILL AFFECT OPERATOR'S ABILITY TO CONTROL MACHINE.
Shut down engine and connect external control input signal.
Reconnect machine function(s), if disconnected earlier. Start
engine, checking pump remains in neutral. With engine at normal operating RPM, slowly check forward and reverse machine
operation.
Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between forward
and reverse for at least five minutes.
Shut down engine, remove gauges, and plug ports. Check reservoir level and add filtered fluid if needed.
Machine is ready for operation.

Fill pump and motor housing with clean hydraulic fluid before
start up. Fill housing by pouring filtered oil in upper case drain
port.
NOTE:

Use highest possible case drain port. This ensures housing contains as much oil as possible and offers the greatest amount of
lubrication to internal components.

NOTE:

It may be easier to fill housing before installing the case drain
line. Component (especially motor) location may prevent case
drain port access after installation.

5-52

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

5.9 PRESSURE SETTING PROCEDURES

Articulating Jib Boom (If Equipped)

COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS.
JLG INDUSTRIES, INC. RECOMMENDS OPERATING THE MACHINE UNTIL THE
HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES
PRIOR TO CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CALIBRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF WITHIN +/- 5% OF
SPECIFIED PRESSURES.

Main Relief, Steer, Swing, and Lift Down
1.

Install pressure gauge at quick disconnect on port MP
on main valve.

2.

With aid of an assistant, activate telescope in.

3.

Monitor pressure gauge and adjust main relief valve to
3000 PSI (206.85 Bar).

4.

With the aid of an assistant, activate steer left.

5.

Monitoring pressure gauge and adjust steer left relief
valve to 1800 PSI (124.1 Bar).

1.

Install pressure gauge at quick disconnect on articulating valve.

2.

With aid of an assistant, activate articulating jib up.

3.

Monitor pressure gauge and adjust articulating jib up
relief valve to 1500 PSI (103 Bar).

4.

With aid of an assistant, activate articulating jib down.

5.

Monitor pressure gauge and adjust activate articulating
jib down relief valve to 1200 PSI (83 Bar).

 
 

6.

With aid of an assistant, activate steer right.

7.

Monitor pressure gauge and adjust steer right relief
valve to 1800 PSI (124.1 Bar).

8.

With aid of an assistant, activate swing left or right.

Figure 5-87. Articulating Jib Boom Pressure Adjustment

9.

Monitor pressure gauge and adjust swing relief valve to
1700 PSI (117.2 Bar).

4 Wheel Steer (If Equipped)

 
  

10.

With aid of an assistant, activate lift down.

1. Activate "2 wheel steer" at platform console using
steer select switch.

11.

Monitoring pressure gauge and adjust lift down relief
valve to 1500 PSI (103.4 Bar).

2. Install pressure gauge in port MP on main control valve.
3. With aid of an assistant, activate steer left and right.
Adjust front steer relief valve to 2500 PSI (172.4 Bar).
This pressure only affects the front axle.

Platform Level
1.

Install pressure gauge at quick disconnect on port M3
on main valve.

4. Activate “crab” or “coordinated” steer at platform
console using steer select switch

2.

With aid of an assistant, activate platform level forward.

3.

While monitoring pressure gauge, adjust platform level
relief to 2800 PSI (193.06 Bar).

4.

Install pressure gauge at quick disconnect on port M4
on main valve.

5.

With aid of an assistant, activate platform level backward.

7. With aid of an assistant, activate steer left and right.
Adjust rear steer relief valve to 2500 PSI (172.4 Bar).
2500 PSI (172.4 Bar) at valve bank will give 2000PSI
(137.9 Bar) at cylinders.

6.

Monitor pressure gauge and adjust platform level relief
valve to 1800 PSI (124.11 Bar).

8. Reconnect front steer DIN connectors at valve bank.

3121298

– JLG Lift –

5. Disconnect wire DIN connectors on front steer valve
at main control valve block. When steer is activated
only rear steer will work.
6. Install pressure gauge in port MP on main control valve.

5-53

SECTION 5 - HYDRAULICS

"  
#$%&'(#)

 


 

  ! 
 


 

  
 


 

  


 

 


 
  


 



       !"#

Figure 5-88. Main Control Valve - Sheet 1 of 2

5-54

– JLG Lift –

3121298

SECTION 5 - HYDRAULICS

     
 
 
 

   
   
 
 
 

"  #
$ %&'()*' +'$,' -




   
   !
 
 
 





       !"#

Figure 5-89. Main Control Valve - Sheet 1 of 2

3121298

– JLG Lift –

5-55

SECTION 5 - HYDRAULICS





 










































        !     
"    
  !#$     %  !
&"  '   (  %   $      
%  !)   *+,  !

1.

Solenoid Operated 2-Way valve

10.

Directional Control Valve (Platform Rotator)

19.

Directional Control Valve (Upper Lift)

2.

Pressure Control Load Sense Cartridge

11.

Directional Control Valve (Upper Telescope)

20.

Directional Control Valve (Swing)

3.

Direct Operated Relief Valve (Main Relief)

12.

Directional Control Valve (Flow Control)

21.

Direct Operated Relief Valve

4.

Directional Control Valve (Platform Level)

13.

Load Shuttle Valve

22.

Directional Control Valve (Steer)

5.

Pilot Operated Check Valve

14.

Load Shuttle Valve

23.

Direct Operated Relief Valve

6.

Pilot Operated Check Valve

15.

Load Shuttle Valve

24.

Direct Operated Relief Valve

7.

Direct Operated Relief Valve

16.

Load Shuttle Valve

25.

Directional Control Valve (Lower Telescope)

8.

Direct Operated Relief Valve

17.

Load Shuttle Valve

26.

Directional Control Valve (Lower Lift)

9.

Pressure Compensated Flow Control (Fixed 0.2 GPM)

18.

Direct Operated Relief Valve

27.

Check Valve

Figure 5-90. Location of Components - Main Control Valve
1.

5-56

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

SECTION 6. JLG CONTROL SYSTEM
speed, and max.-speed for all boom, drive, and steering functions.

6.1 INTRODUCTION

WHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT IS NECESSARY
TO PROGRAM THE CONTROLLER FOR PROPER MACHINE CONFIGURATION,
INCLUDING OPTIONS.

AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF
PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/
ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5
CM) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
The JLG designed Control System is a 12 volt based motor control unit installed on the boom lift.
The JLG Control System has reduced the need for exposed terminal strips, diodes and trimpots and provides simplicity in
viewing and adjusting the various personality settings for
smooth control of: acceleration, deceleration, creep, min





 

Upper lift, swing, and drive are controlled by individual joysticks. Steering is controlled by a rocker switch built in the top
of the drive joystick. To activate Drive, Lift, and Swing; pull up
the slide lock on the joystick and move the handle in the
desired direction.
The control system provides voltage output to the valves and
pump, as programmed, for smooth operation and maximum
cycle time. Ground control speeds for all boom functions can
also be programmed in the control system.
The JLG Control System controller has a built in LED to indicate
any faults. The system stores recent faults which may be
accessed for troubleshooting. Optional equipment includes a
soft touch system, head and tail lights, and ground alarm.
These options may be added later but must be programmed
into the control system when installed.
The Control System may be accessed with a custom designed,
direct connect hand held analyzer or wireless adapter using an
app on your Android or iPhone/iPad device. The analyzer or
wireless output displays two lines of information at a time, by
scrolling through the program.
Each module has a label with JLG part number and a serial number
containing a date code.



 
     
!   " #

  
   
   

   
 

$   %   
# !  
!   " #

Figure 6-1. Hand-Held Analyzer (WANALYZER Controls and Display Similar)

3121298

– JLG Lift –

6-1

SECTION 6 - JLG CONTROL SYSTEM

  
 

 
 




&"(
)*







   

# !"
 

 

# 
 

   





  
 

!"  

 
  
 





$


 

   

-./0

$ #  
%&  #'

+,  

Figure 6-2. Controller Block Diagram

6-2

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Connect JLG Control System Analyzer
1.

Using Analyzer

Connect four pin end of cable supplied with hand-held
or wireless analyzer to controller module on platform
box or at controller module inside ground control box.
Connect other end of cable to analyzer.

NOTE: Cable has a keyed four pin connector at each end. It cannot
be connected backwards.

1.

Power up Control System by turning lower key to platform or ground position and pulling both emergency
stop buttons out.

Analyzer displays the following with machine power on and
analyzer connected properly:

Figure 6-3. Analyzer Platform Connector

MENU:
HELP:PRESS ENTER
Move between top level menu items using 

RIGHT

and LEFT

arrow keys. To select a dis-

played menu item, press ENTER

. To cancel a selected

Figure 6-4. Analyzer Ground Control Box Connector
NOTE: Follow instructions provided with Wireless Analyzer (WANALYZER) kit. JLG Analyzer application must be downloaded
and installed to your smartphone or tablet device.

menu item press ESC
. Scroll using right and left arrow
keys to select a different menu item.
Top level menus:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)

3121298

– JLG Lift –

6-3

SECTION 6 - JLG CONTROL SYSTEM

If ENTER
is selected at the HELP: PRESS ENTER display,
and a fault is present, the analyzer display scrolls the fault
across the screen. If no fault is detected, the display shows:
HELP: EVERYTHING OK. If powered up at the ground station,
the display shows: GROUND OK.

If ENTER

Pressing ENTER
with any of the above displayed menus,
displays additional sub-menus within the selected menu. In
some cases, such as DRIVE, the next level is the parameter or
information to be changed. Refer to the flow chart for what
menus are available within the top level menus. You may only
view the personality settings for selected menus while in
access level 2. Remember, you may always cancel a selected

is pressed again, display shows the following:
menu item by pressing the ESCAPE

key.

Changing Access Level
When analyzer is first connected, you will be in access level 2
which enables you to only view most settings which cannot be
changed until you enter a password to advance to a lower
level. This ensures that a setting cannot be accidentally
altered. To change access level, the correct password must be
entered. To enter password, scroll to ACCESS LEVEL menu. For
example:

LOGGED HELP
1: POWER CYCLE (0/0)
Analyzer displays last system fault if any are present. Use right
and left arrow keys to scroll through fault logs and view last 25

faults. Press ESC
two times to return to MENU screen.
POWER CYCLE (0/0) indicates a power up.
When a top level menu is selected, a new set of menu items
may be offered: for example:
ACCESS LEVEL:
CODE 00000

DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS

6-4

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Adjust Parameters
Press ENTER

to select the ACCESS LEVEL menu.

Using the UP
or DOWN
digit of the password, 3.

Once you have gained access to level 1, and a personality item

arrow keys, enter first

is selected, press the UP
adjust its value, for example:

or DOWN

arrow keys to

Then using the RIGHT
arrow key, position cursor right
one space to enter the second digit of the password.
Use the UP
or DOWN
arrow key to enter the second digit of the password which is 33271.
When correct password is displayed, press ENTER
. The
access level displays the following if password was entered
correctly:

DRIVE:
ACCEL 1.0S
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if the UP
arrow is pressed at maximum value or decrease if the
DOWN
arrow is pressed at minimum value for any personality. If value does not change when pressing up and down
arrows, check access level is at access level 1.
MENU: 
ACCESS LEVEL 1
Repeat above steps if correct access level is not displayed or
you can not adjust personality settings.

3121298

– JLG Lift –

6-5

SECTION 6 - JLG CONTROL SYSTEM

There is a setting that JLG strongly recommends that you do
not change. This setting is so noted below:

Machine Setup
When a machine digit item is selected, press UP
DOWN

ELEVATION CUTBACK

or

arrow keys to adjust its value, for example:
CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFORMANCE OF YOUR MACHINE.

AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF
PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/
ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOMMENDS A MAXIMUM
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES
(30.5CM) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND FOR BRIEF TIME
PERIODS TO AVOID HEAVY SATURATION.

Level Vehicle Description

DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.

GROUND ALARM:
2 = DRIVE
The effect of the machine digit value is displayed along with
its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when driving. There are certain settings allowed to
install optional features or select the machine model.
When selection the machine model to match the size of the
machine, the personality settings will all default to the factory
recommended setting.
NOTE: Refer to Personality Ranges/Defaults for the recommended
factory settings.
NOTE: Password 33271 allows access to level 1 to change
machine personality settings.

LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2. ENTER
cle is current.

6-6

– JLG Lift –

confirms vehi-

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-1. Analyzer Abbreviations

Table 6-1. Analyzer Abbreviations
ABBREVIATION

ABBREVIATION

MEANING

MEANING

ACCELERATE

GND

ACTIVE

GRN

GREEN

A/D

ANALOG DIGITAL CONVERTER COUNT

GM

GROUND MODULE

AMB.

AMBIENT

ACCEL
ACT

ANG

ANGLE

AUX

AUXILIARY

H
HW
HWFS
I

GROUND

HOURS
HARDWARE
HARDWARE FAILSAFE
IN or CURRENT

BCS

BOOM CONTROL SYSTEM

BM

BOOM LENGTH ANGLE MODULE

JOY

BOOM LENGTH ANGLE MODULE

L

BROKEN

LB

POUND

BSK

BASKET

LEN

LENGTH

CAL

CALIBRATION

LIM

LIMIT
LEFT

BLAM
BR

CL

CLOSED

LT

CM

CHASSIS MODULE

LVL

JOYSTICK
LEFT

LEVEL

CNTL

CONTROL

M

CNTRL

CONTROL

MIN

MINIMUM

CUT OUT

MAX

MAXIMUM

C/O
CONT(S)

CONTRACTOR(S)

MINUTES

M

MAIN
MAIN

COOR

COORDINATED

MN

CRK PT

CRACK POINT

NO

NORMALLY OPEN or NO

CRP

CREEP

NC

NORMALLY CLOSED

CUT

CUTOUT

O

OUT

CYLINDER

O/C

DECELERATE

OP

OPEN

D

DOWN

O/R

OVERRIDE or OUTRIGGER

DN

DOWN

O//R

OVERRIDE

DWN

DOWN

OSC

OSCILLATING

DEG.

DEGREE

OVRD

OVERRIDE
PLATFORM

CYL
DECEL

OPEN CIRCUIT

DOS

DRIVE ORIENTATION SYSTEM

P

DRV

DRIVE

P

ERROR

PCV

PROPORTIONAL CONTROL VALVE

ELEVATED & TILTED

PLAT

PLATFORM
PLATFORM

E
E&T

PRESSURE

ELEV

ELEVATION

PLT

ENG

ENGINE

PM

PLATFORM MODULE

EXT

EXTEND

POT

POTENTIOMETER

F

FRONT

PRES

PRESSURE

FL

FLOW

PRS

PRESSURE

FNT

FRONT

PT

POINT

FOR

FORWARD

R

REAR or RIGHT

FWD

FORWARD

REV

REVERSE or REVISION

FSW

FOOT SWITCH

RET

RETRACT

FUNC

FUNCTION

ROT.

ROTATE

RT

RIGHT

G

3121298

GROUND

– JLG Lift –

6-7

SECTION 6 - JLG CONTROL SYSTEM

Table 6-1. Analyzer Abbreviations
ABBREVIATION
S/C

MEANING
SHORT CIRCUIT

SEL

SELECTOR

SN

SERIAL NUMBER

SPD
STOW
STOWD
SW

SPEED
STOWED
STOWED
SWITCH or SOFTWARE

TELE

TELESCOPE

TEMP

TEMPERATURE

TORQ.

TORQUE

TRN

TRANSPORT

T/T

TURNTABLE

T
TURNTBL
TWR

TOWER
TURNTABLE
TOWER

U

UPPER or UP

V

VOLT

VER

VERSION

VLV

VALVE

WIT

WITNESS

YEL

YELLOW

6-8

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

MENU:
HELP:PRESS ENTER

HELP:
(001)
EVERYTHING OK
LOG:(xxx)
x:xxxxxxxxxxx

MENU:
DIAGNOSTICS

TO
MENU:
SYSTEM TEST

DIAGNOSTICS:
DRIVE/STEER

DIAGNOSTICS:
BOOM FUNCTIONS

JOYSTICK DRIVE:
FORWARD XXX%

JOYSTICK LIFT:
MAIN UP XXX%

JOYSTICK STEER:
LEFT XXX%

LIFT OUTPUT:
MAIN UP XXX%

DRIVE OUTPUT:
FORWARD XXX%

LIFT UP
COMMANDED:XXXXMA

TO
DIAGNOSTICS:
ENGINE

DRIVE FORWARD:
COMMANDED:XXXXMA

BRAKES STATUS:
LOCKED

LIFT DOWN
COMMANDED:XXXXMA

DRIVE REVERSE:
COMMANDED:XXXXMA

CREEP:
SWITCH: CLOSED

LIFT OUTPUT
ACTUAL:XXXXMA

DRIVE OUTPUT:
ACTUAL: XXXXMA

CREEP MODE:
OFF

JOYSTICK SWING:
LEFT XXX%

STEER OUTPUT:
LEFT XXX%

2-SPEED:
SWITCH: OPEN

SWING OUTPUT:
LEFT XXX%

LEFT TRACK
OUTPUT: FWD XXX%

2-SPEED VALVE
OUTPUT: OFF

SWING LEFT
COMMANDED:XXXXMA

STEER TYPE:
NORMAL

HIGH ENGINE
SWITCH: OPEN

SWING RIGHT
COMMANDED:XXXXMA

RIGHT TRACK
ACTUAL: XXXXMA

DRIVE MODE:
MID ENGINE

SWING OUTPUT
ACTUAL:XXXXMA

LEFT TRACK FWD
COMMANDED:XXXXMA

DRV. ORIENTATION
FEATURE:DISABLED

PLATFORM LEVEL:
UP XXX%

FLOW VALVE
COMMANDED:XXXXMA

LEFT TRACK REV
COMMANDED:XXXXMA

DRV. ORIENTATION
SWITCH: OPEN

PLATFORM ROTATE:
LEFT XXX%

FLOW VALVE
ACTUAL:XXXXMA

LEFT TRACK
ACTUAL: XXXXMA

DRV. ORIENTATION
OVERRIDE: OPEN

MAIN TELESCOPE:
IN XXX%

PLATFORM CONTROL
VALVE: OFF

RIGHT TRACK
OUTPUT: FWD XXX%

DRV. ORIENTATION
STATUS:CONFIRMED

TOWER TELESCOPE:
IN XXX%

FUNCTION SPEED:
PUMP POT XXX%

RIGHT TRACK FWD
COMMANDED:XXXXMA

DRIVE CONTROL:
NORMAL

TOWER LIFT:
UP XXX%

CREEP
SWITCH: CLOSED

RIGHT TRACK REV
COMMANDED:XXXXMA

CRIBBING MODE:
DISABLED

JIB LIFT:
UP XXX%

CREEP MODE:
OFF

Figure 6-5. Analyzer Software Version 6.8 - Sheet 1 of 6

3121298

– JLG Lift –

6-9

SECTION 6 - JLG CONTROL SYSTEM

From
DIAGNOSTICS:
BOOM FUNCTIONS

DIAGNOSTICS:
ENGINE

DIAGNOSTICS:
SYSTEM

DIAGNOSTICS:
UMS

START SEQUENCE:
NOT ACTIVE

GROUND MODULE:
BATTERY: XX.XV

CHASSIS TILT
ANGLE: XX.X

BATTERY VOLTAGE:
XX.XV

PLATFORM MODULE:
BATTERY: XX.XV

UMS TO TURNTABLE
ANGLE: XX.X

COOLANT
TEMPERATURE:XXXF

AMBIENT
TEMPERATURE:XXXF

UMS INCLINATION
ANGLE: XX.X

ELECTRIC FAN
OUTPUT: OFF

PLATFORM SELECT
KEYSWITCH: OPEN

CHASSIS TILT
X-AXIS: XX.X

ELECTRIC FUEL
PUMP OUTPUT: OFF

GROUND SELECT
KEYSWITCH: OPEN

CHASSIS TILT
Y-AXIS: XX.X

ENGINE OIL
PRESSURE:XXX PSI

STATION CONTROL:
GROUND

AUXILIARY POWER
SWITCH: OPEN

FUEL SELECTION
SWITCH: GAS

FOOTSWITCH INPUT
GROUND: OPEN

HORN
SWITCH: OPEN

FUEL SELECTION
STATUS: GAS

FOOTSWITCH INPUT
PLATFORM: OPEN

RETURN HYDRAULIC
FILTER: OPEN

AMBIENT
TEMPERATURE:XXXF

TRANSPORT
SWITCHES: OPEN

CHARGE PUMP
FILTER: OPEN

FUEL LEVEL
SENSOR: OK

TRANSPORT MODE:
OUT OF TRANSPORT

SOFT TOUCH LIMIT
SWITCH: OPEN

STARTER
CRANK TIME: XX S

END OF STROKE
PROXIMITY:CLOSED

STOUCH OR SKYGRD
RELAYS: OPEN

ENGINE SPEED
ACTUAL: XXXX RPM

TOWER LIFT
PROXIMITY:CLOSED

ST/SG OVERRIDE
OVERRIDE: OPEN

ENGINE SPEED
TARGET: XXXX RPM

TOWER TELESCOPE
PROXIMITY:CLOSED

GENSET.WELDER
SWITCH: OPEN

TOWER POSITION:
RETRACTED

LIGHTS
SWITCH: OPEN

CABLE BREAK
SWITCH: CLOSED

PLATFORM TILT1
ANGLE: XX.X

CREEP
SWITCH: CLOSED

PLATFORM TILT2
ANGLE: XX.X

CREEP MODE:
OFF

PLATFORM TILT1
VOLTAGE: XX MV

CHASSIS TILT:
XX.X DEGREES

PLATFORM TILT2
VOLTAGE: XX MV

TO
DIAGNOSTICS:
LOAD

UMS STATUS:
NORMAL

Figure 6-6. Analyzer Software Version 6.8 - Sheet 2 of 6

6-10

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

FROM
DIAGNOSTICS:
UMS

DIAGNOSTICS:
LOAD

DIAGNOSTICS:
CAN STATISTICS

DIAGNOSTICS:
1
CALIBRATION DATA

DIAGNOSTICS:
DATALOG

DIAGNOSTICS:
VERSIONS

CAPACITY LENGTH
SWITCH: CLOSED

CAN STATISTICS
RX/SEC: X

CALIBRATION DATA 1
LOAD ZERO:

DATALOG:
ON: XXXh XXm

GROUND MODULE
SOFTWARE: XX.XX

CAPACITY ANGLE
SWITCH: CLOSED

CAN STATISTICS
TX/SEC: X

CALIBRATION DATA 1
LOAD 500LB:

DATALOG:
ENGINE: XXXh XXm

GROUND MODULE
COST. DATA:XX.XX

PERCENT OF MAX
LOAD: XXX%

CAN STATISTICS
BUS OFF: X

CALIBRATION DATA 1
PLATFORM UP:

DATALOG:
DRIVE: XXXh XXm

GROUND MODULE
HARDWARE: REV XX

PLATFORM LOAD
STATE: OK

CAN STATISTICS
PASSIVE: X

CALIBRATION DATA 1
1
PLATFORM DN:

DATALOG:
LIFT: XXXh XXm

GROUND MODULE
S/N: XXXXXX

DATALOG:
SWING: XXXh XXm

PLATFORM MODULE
SOFTWARE: XX.XX

DATALOG:
TELE: XXXh XXm

PLATFORM MODULE
HARDWARE: REV XX

DATALOG:
MAX TEMP: XXXF

PLATFORM MODULE
S/N: XXXXXX

DATALOG:
MIN TEMP: XXXF

PROPULSION MOD
SOFTWARE: XX.XX

DATALOG:
MAX VOLTS: XX.XV

TCU MODULE
SOFTWARE: XX.XX

DATALOG:
RENTAL: XXXh XXm

TCU MODULE
HARDWARE: REV XX

CAN STATISTICS
MSG ERROR: XXXX

CLEAR RENTAL:
1
YES:ENTER,NO:ESC

DATALOG:
ERASE RENTAL?

1

TCU MODULE
S/N: XXXXXX
GATEWAY MODULE
SOFTWARE: XX.XX
GATEWAY MODULE
HARDWARE: REV XX
ANALYZER:
ANALYZER XX.XX

Figure 6-7. Analyzer Software Version 6.8 - Sheet 3 of 6

3121298

– JLG Lift –

6-11

SECTION 6 - JLG CONTROL SYSTEM

FROM
MENU:
DIAGNOSTICS

MENU:
SYSTEM TEST

SYSTEM TEST:
ACTIVATE?

MENU:
ACCESS LEVEL

ACCESS LEVEL:
CODE XXXXXX

MENU:
PERSONALITIES

PERSONALITIES:
DRIVE

PERSONALITIES:
STEER

PERSONALITIES:
LEFT TRACK

PERSONALITIES:
RIGHT TRACK

DRIVE:
ACCEL X.XS

STEER:
MAX SPEED XXX%

LEFT TRACK:
ACCEL X.XS

RIGHT TRACK:
ACCEL X.XS

DRIVE:
DECEL X.XS

LEFT TRACK:
DECEL X.XS

RIGHT TRACK:
DECEL X.XS

DRIVE:
MIN FORWARD XXX%

LEFT TRACK:
MIN FORWARD XXX%

RIGHT TRACK:
MIN FORWARD XXX%

DRIVE:
MAX FORWARD XXX%

LEFT TRACK:
MAX FORWARD XXX%

RIGHT TRACK:
MAX FORWARD XXX%

DRIVE:
MIN REVERSE XXX%

LEFT TRACK:
MIN REVERSE XXX%

RIGHT TRACK:
MIN REVERSE XXX%

DRIVE:
MAX REVERSE XXX%

LEFT TRACK:
MAX REVERSE XXX%

RIGHT TRACK:
MAX REVERSE XXX%

DRIVE:
ELEV. MAX XXX%

LEFT TRACK:
ELEV F MAX XXX%

RIGHT TRACK:
ELEV F MAX XXX%

DRIVE:
CREEP MAX XXX%

LEFT TRACK:
ELEV R MAX XXX%

RIGHT TRACK:
ELEV R MAX XXX%

LEFT TRACK:
CREEP F MAX XXX%

RIGHT TRACK:
CREEP F MAX XXX%

LEFT TRACK:
CREEP R MAX XXX%

RIGHT TRACK:
CREEP R MAX XXX%

TO
MENU:
MACHINE SETUP

TO
PERSONALITIES:
MAIN LIFT

TRACK COUNTER
ROTATE MAX XXX%

Figure 6-8. Analyzer Software Version 6.8 - Sheet 4 of 6

6-12

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

FROM
PERSONALITIES:
RIGHT TRACK

PERSONALITIES:
MAIN LIFT

PERSONALITIES:
SWING

PERSONALITIES:
TOWER LIFT

PERSONALITIES:
MAIN TELESCOPE

PERSONALITIES:
TOWER TELESCOPE

MAIN LIFT:
ACCEL X.XS

SWING:
ACCEL X.XS

TOWER LIFT:
ACCEL X.XS

MAIN TELESCOPE:
ACCEL X.XS

TOWER TELESCOPE:
ACCEL X.XS

MAIN LIFT:
DECEL X.XS

SWING:
DECEL X.XS

TOWER LIFT:
DECEL X.XS

MAIN TELESCOPE:
DECEL X.XS

TOWER TELESCOPE:
DECEL X.XS

MAIN LIFT:
MIN UP XXX%

SWING:
MIN LEFT XXX%

TOWER LIFT:
MIN UP XXX%

MAIN TELESCOPE:
MIN IN XXX%

TOWER TELESCOPE:
MIN IN XXX%

MAIN LIFT:
MAX UP XXX%

SWING:
MAX LEFT XXX%

TOWER LIFT:
MAX UP XXX%

MAIN TELESCOPE:
MAX IN XXX%

TOWER TELESCOPE:
MAX IN XXX%

MAIN LIFT:
CREEP UP XXX%

SWING:
CREEP LEFT XXX%

TOWER LIFT:
MIN DOWN XXX%

MAIN TELESCOPE:
MIN OUT XXX%

TOWER TELESCOPE:
MIN OUT XXX%

MAIN LIFT:
MIN DOWN XXX%

SWING:
MIN RIGHT XXX%

TOWER LIFT:
MAX DOWN XXX%

MAIN TELESCOPE:
MAX OUT XXX%

TOWER TELESCOPE:
MAX OUT XXX%

MAIN LIFT:
MAX DOWN XXX%

SWING:
MAX RIGHT XXX%

MAIN LIFT:
CREEP DOWN XXX%

SWING:
CREEP RIGHT XXX%

PERSONALITIES:
PLATFORM LEVEL

PERSONALITIES:
PLATFORM ROTATE

PERSONALITIES:
JIB LIFT

PERSONALITIES:
GROUND MODE

PERSONALITIES:
GEN SET/WELDER

PLATFORM LEVEL:
ACCEL X.XS

PLATFORM ROTATE:
ACCEL X.XS

JIB LIFT:
ACCEL X.XS

GROUND MODE:
MAIN UP: XXX%

GEN SET/WELDER:
ENGINE XXXX RPM

PLATFORM LEVEL:
DECEL X.XS

PLATFORM ROTATE:
DECEL X.XS

JIB LIFT:
DECEL X.XS

GROUND MODE:
MAIN DOWN: XXX%

PLATFORM LEVEL:
MIN IN XXX%

PLATFORM ROTATE:
MIN LEFT XXX%

JIB LIFT:
MIN UP XXX%

GROUND MODE:
SWING: XXX%

PLATFORM LEVEL:
MAX IN XXX%

PLATFORM ROTATE:
MAX LEFT XXX%

JIB LIFT:
MAX UP XXX%

GROUND MODE:
PLT LEVEL: XXX%

PLATFORM LEVEL:
MIN OUT XXX%

PLATFORM ROTATE:
MIN RIGHT XXX%

JIB LIFT:
MIN DOWN XXX%

GROUND MODE:
PLT ROTATE: XXX%

PLATFORM LEVEL:
MAX OUT XXX%

PLATFORM ROTATE:
MAX RIGHT XXX%

JIB LIFT:
MAX DOWN XXX%

GROUND MODE:
MAIN TELE: XXX%
GROUND MODE:
TOWER TELE: XXX%
GROUND MODE:
TOWER UP: XXX%
GROUND MODE:
TOWER DOWN: XXX%
GROUND MODE:
JIB LIFT: XXX%
GROUND MODE:
JIB SWING: XXX%

Figure 6-9. Analyzer Software Version 6.8 - Sheet 5 of 6

3121298

– JLG Lift –

6-13

SECTION 6 - JLG CONTROL SYSTEM

FROM
MENU:
PERSONALITIES

MENU:
MACHINE SETUP

MENU:
CALIBRATIONS

1

MODEL NUMBER:
600S

MARKET:
CE

ENGINE:
PERKINS ECM

FLYWHEEL TEETH:
133 TEETH

GLOW PLUG:
IN-CYLINDER

STARTER LOCKOUT:
DISABLED

ENGINE SHUTDOWN:
ENABLED

TILT:
5 DEGREES

JIB:
NO

4 WHEEL STEER:
NO

STOUCH/SKYGUARD:
NO

GEN SET/WELDER:
NO

GEN SET CUTOUT:
MOTION ENABLED

H & T LIGHTS:
NO

CABLE SWITCH:
NO

LOAD SYSTEM:
NO

LOAD SENSOR:
4 UNDER PLATFORM

FUNCTION CUTOUT:
NO

GROUND ALARM:
MOTION

DRIVE:
4WD

TEMPERATURE:
FAHRENHEIT

LEVELING MODE:
ALL FUNCTIONS

DRIVE CONTROL:
ENHANCED

BOOM CONTROL:
NORMAL

CLEARSKY:
NO

CRIBBING OPTION:
NO

FUEL TANK SIZE:
31 GALLON

ALARM / HORN:
SEPARATE

CALIBRATIONS:
TILT SENSOR

1

CALIBRATIONS:
UMS SENSOR

1

CALIBRATIONS:
FORD ENGINE

1

CALIBRATIONS:
LOAD SENSOR

1

CALIBRATIONS:
DEUTZ SETUP

1

TILT SENSOR:
CALIBRATE?

1

UMS SENSOR:
CALIBRATE?

1

FORD ENGINE:
DISABLE RS-485?

1

LOAD SENSOR:
CALIBRATE?

1

DEUTZ SETUP
SETUP X

1

UMS SENSOR:
RAW: XX.X

1

CALIBRATIONS:
LEVEL UP CRKPT

1

1
CALIBRATIONS:
LEVEL DOWN CRKPT

CALIBRATIONS:
PROP MODULE

1

PROP MODULE:
J1-7 MIN: XXX

1

PROP MODULE:
J1-7 MAX: XXX

1

1
PROP MODULE:
DEADBAND: XXXXX

PROP MODULE:
J1-8 MIN: XXX

1

PROP MODULE:
FF NUM: XXXXX

1

PROP MODULE:
J1-8 MAX: XXX

1

PROP MODULE:
FF DEN: XXXXX

1

PROP MODULE:
J1-9 MIN: XXX

1

PROP MODULE:
I NUM: XXXXX

1

PROP MODULE:
J1-9 MAX: XXX

1

PROP MODULE:
I DEN: XXXXX

1

PROP MODULE:
J1-10 MIN: XXX

1

PROP MODULE:
NEG ERR: XXXXX

1

PROP MODULE:
J1-10 MAX: XXX

1

PROP MODULE:
GAIN FLAG: XXXXX

1

CALIBRATIONS:
PLAT. LEVELING

1

Figure 6-10. Analyzer Software Version 6.8 - Sheet 6 of 6

6-14

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

NOTE: Personality settings can be adjusted within the adjustment
range for optimum machine performance.

6.2 MACHINE PERSONALITY SETTINGS

Table 6-2. Personality Ranges/Defaults
FUNCTION
DRIVE

PERSONALITY

RANGE

DEFAULTS - 600S

ACCELeration

0.1s to 5.0s

2.0

DECELeration

0.1s to 3.0s

2.0

Forward MINimum speed

0 to 35%

4

Forward MAXimum speed

0 to 100%

35

REVerse MINimum speed

0 to 35%

4

REVerse MAXimum speed

0 to 100%

35

ELEVATED MAXimum speed

0 to 50%

15

CREEP MAXimum speed

0 to 50%

25

800 to 2900

1800

ACCELeration

0.1 to 5.0

N/A

DECELeration

0.1 to 3.0

N/A

MlNimum UP speed

0 to 60%

N/A

MAXimum UP speed

0 to 100%

N/A

MINimum DOWN speed

0 to 60%

N/A

MAXimum DOWN speed

0 to 100%

N/A

800 to 2900

N/A

ACCELeration

0.1 to 5.0

2.0

DECELeration

0.1 to 3.0

0.7

MlNimum UP speed

0 to 60%

40

MAXimum UP speed

0 to 100%

80

CREEP Maximum UP speed

0 to 65%

55

MINimum DOWN speed

0 to 60%

40

MAXimum DOWN speed

0 to 100%

70

CREEP maximum DOWN speed

0 to 75%

55

800 to 2900

1800

Engine RPM
TOWER LIFT

Engine RPM
UPPER LIFT

Engine RPM

3121298

– JLG Lift –

6-15

SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Personality Ranges/Defaults
FUNCTION
SWING

PERSONALITY

RANGE

DEFAULTS - 600S

ACCELeration

0.1 to 5.0s

2.0

DECELeration

0.1 to 3.0s

1.8

MINimum LEFT speed

0 to 50%

30

MAXimum LEFT speed

0 to 100%

65

CREEP maximum LEFT speed

0 to 65%

45

MINimum RIGHT speed

0 to 50%

30

MAXimum RIGHT speed

0 to 100%

65

CREEP maximum RIGHT speed

0 to 65%

45

800 to 2900

1400

ACCELeration

0.1 to 5.0

3.5

DECELeration

0.1 to 3.0

0.8

MINimum IN speed

0 to 65%

45

MAXimum IN speed

0 to 100%

75

MINimum OUT speed

0 to 65%

45

MAXimum OUT speed

0 to 100%

70

800 to 2900

1800

ACCELeration

0.1 to 5.0

N/A

DECELeration

0.1 to 3.0

N/A

MINimum IN speed

0 to 65%

N/A

MAXimum IN speed

0 to 100%

N/A

MINimum OUT speed

0 to 65%

N/A

MAXimum OUT speed

0 to 100%

N/A

800 to 2900

N/A

ACCELeration

0.1 to 5.0

2.5

DECELeration

0.1 to 3.0

0.5

MINimum UP speed

0 to 65%

48

MAXimum UP speed

0 to 100%

52

MlNimum DOWN speed

0 to 65%

45

MAXimum DOWN speed

0 to 100%

50

800 to 2900

1500

Engine RPM
TELESCOPE UPPER

Engine RPM
TELESCOPE TOWER

Engine RPM
BASKET LEVEL

Engine RPM

6-16

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Personality Ranges/Defaults
FUNCTION
BASKET ROTATE

PERSONALITY

RANGE

DEFAULTS - 600S

ACCELeration

0.1 to 5.0

1.8

DECELeration

0.1 to 3.0

0.7

MlNimum LEFT speed

0 to 65%

46

MAXimum LEFT speed

0 to 100%

50

MINimum RIGHT speed

0 to 65%

46

MAXimum RIGHT speed

0 to 100%

50

800 to 2900

1500

ACCELeration

0.1 to 5.0

5.0

DECELeration

0.1 to 3.0

1.0

MINimum UP speed

0 to 65%

46

MAXimum UP speed

0 to 100%

52

MINimum DOWN speed

0 to 65%

45

MAXimum DOWN speed

0 to 100%

52

800 to 2900

1800

0 to 100%

100

800 to 2900

1800

Tower LIFT UP speed

0 to 100%

N/A

Tower LIFT DOWN speed

0 to 100%

N/A

Upper LIFT UP

0 to 100%

60

Upper LIFT DOWN

0 to 100%

60

SWING speed

0 to 100%

60

Upper TELEscope speed

0 to 100%

70

Tower TELEscope speed

0 to 100%

N/A

BASKET ROTATE speed

0 to 100%

50

BASKET LEVEL speed

0 to 100%

50

JIB LIFT speed

0 to 100%

50

Engine RPM
JIB LIFT

Engine RPM
STEER

MAXimum speed
Engine RPM

GROUND MODE

NOTE:

Personality settings can be adjusted anywhere within the adjustment range for optimum machine performance.
4150365B

3121298

– JLG Lift –

6-17

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

None

Priority

No flash code is indicated for the following help messages. They are intended to
hint at a possible problem if vehicle is not behaving as expected.

1

EVERYTHING OK

The “normal” help message in platform mode

GROUND MODE OK

The “normal” help message in ground mode

FSW OPEN

A drive or boom function has been selected but footswitch is open.

RUNNING AT CREEP – CREEP
SWITCH OPEN

All function speeds are limited to creep because creep switch is open.

RUNNING AT CREEP – TILTED
AND ABOVE ELEVATION

All boom function speeds are limited to creep because vehicle is tilted and
above elevation.

RUNNING AT CUTBACK – ABOVE
ELEVATION

Drive speed is limited to “ELEVATED MAX” because vehicle is above elevation.

TILT SENSOR OUT OF RANGE

The tilt sensor has indicated a tilt angle greater than 19 degrees for more than 4
seconds. Not reported during 2 second power-up.

LOAD SENSOR READING UNDER
WEIGHT

The load sensor is reading 20% or more under the calibrated zero point. This
fault may occur if platform is resting on the ground. Not reported during 2 second power-up.

1/1

Flash code 1/1 indicates a “sleep” mode.
NOT REQUIRED

2/1

Flash code 2/1 indicates problems with footswitch.
FSW FAULTY

The two footswitch inputs have read the same state for more than one second.

KEYSWITCH FAULTY

Both platform and ground modes are selected simultaneously

2/2

6-18

Description

Flash code 2/2 indicates problems with drive & steer selection. Except where
noted, these faults are not reported during 2 second power-up sequence.
DRIVE LOCKED – JOYSTICK
MOVED BEFORE FOOTSWITCH

Drive was selected before and during footswitch closure. Can be reported during power-up sequence.

FSW INTERLOCK TRIPPED

Footswitch was closed for seven seconds with no function selected. Can be
reported during power-up sequence.

STEER LOCKED – SELECTED
BEFORE FOOTSWITCH

Steer was selected before and during footswitch closure.

STEER SWITCHES FAULTY

Both steer switches are active together.

DRIVE / STEER WITH NO QPROX

This fault only occurs with inductive joysticks. It occurs if the joystick is moved
out of the neutral position with no Qprox sensors active.

D/S JOY. QPROX BAD

These faults only occur with inductive joysticks. They indicate that the Q-Prox
sensor is reading above 3.18 volts.

D/S JOY. OUT OF RANGE LOW

Resistive joysticks: These faults do not occur.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage is
less than the centertap voltage minus half the center tap voltage minus 0.3
volts. If the centertap is at the high end of the range, these faults will be triggered below 1.05 volts. If the centertap is at the low end of the range, these
faults will be triggered below 0.79 volts.

– JLG Lift –

2

3

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

Description

D/S JOY. OUT OF RANGE HIGH

Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1 volts.
If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to battery
has occurred.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage is
more than the centertap voltage plus half the centertap voltage plus 0.3 volts. If
the centertap is at the high end of the range, these faults will be triggered above
4.35 volts. If the centertap is at the low end of the range, these faults will be triggered above 3.8 volts.

D/S JOY. CENTER TAP BAD

Resistive joysticks: These faults occur when the center tap voltage is not
between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt
range around these values where the fault may be indicated.
Inductive joysticks: These faults occur when the center tap voltage is not
between 2.18 volts and 2.70 volts. Due to resistor tolerances there is a +/-.1 volt
range around these values where the fault may be indicated.

WAITING FOR FSW TO BE OPEN

Footswitch was closed when platform mode was selected. Can be reported
during power-up sequence.

2/3

Flash code 2/3 indicates problems with boom function selection.

Priority

3

LIFT/SWING LOCKED – JOYSTICK Platform upper lift or swing was selected before and during footswitch closure.
MOVED BEFORE FOOTSWITCH
PUMP SWITCHES FAULTY –
CHECK DIAGNOSTICS/BOOM

A boom function (lower lift, telescope, basket level, basket rotate, jib) has both
directions selected together.

PUMP SWITCHES LOCKED –
A platform boom function (lower lift, telescope, basket level, basket rotate, jib)
SELECTED BEFORE FOOTSWITCH was selected before key switch or footswitch closure.

3121298

PUMP SWITCHES LOCKED –
SELECTED BEFORE AUX POWER

A ground boom function (lower lift, telescope, basket level, basket rotate, jib)
was selected before aux power.

LIFT / SWING WITH NO QPROX

This fault only occurs with inductive joysticks. It occurs if the joystick is moved
out of the neutral position with no Qprox sensors active.

l/S JOY. QPROX BAD

These faults only occur with inductive joysticks. They indicate the Q-Prox sensor
is reading above 3.18 volts.

l/S JOY. OUT OF RANGE LOW

Resistive joysticks: These faults do not occur.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when voltage is less
than centertap voltage minus half the center tap voltage minus 0.3 volts. If centertap is at high end of the range, these faults will be triggered below 1.05 volts.
If centertap is at low end of the range, these faults will be triggered below 0.79
volts.

l/S JOY. OUT OF RANGE HIGH

Resistive joysticks: These faults do not occur if Vref voltage is below 8.1 volts. If
Vref is above 7.7 volts, Vref is operating out of tolerance or a short to battery has
occurred.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when voltage is more
than centertap voltage plus half the centertap voltage plus 0.3 volts. If centertap is at high end of the range, these faults will be triggered above 4.35 volts. If
centertap is at low end of the range, these faults will be triggered above 3.8
volts.

– JLG Lift –

6-19

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

Description

l/S JOY. CENTER TAP BAD

Resistive joysticks: These faults occur when center tap voltage is not between
3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt range
around these values where the fault may be indicated.
Inductive joysticks: These faults occur when center tap voltage is not between
2.18 volts and 2.70 volts. Due to resistor tolerances there is a +/-.1 volt range
around these values where the fault may be indicated.

PUMP SWITCHES LOCKED –
SELECTED BEFORE START
SWTICH

This fault occurs when a hydraulic function switch is closed before start switch is
closed.

Priority

FOOTSWITCH SELECTED BEFORE User attempted to start machine with footswitch engaged.
START
2/4

Flash code 2/4 indicates steering digital inputs are faulty.
NOT REQUIRED

2/5

Flash code 2/5 indicates a function is prevented due to a cutout.
BOOM PREVENTED – DRIVE
SELECTED

A boom function is selected while a drive function is selected and drive cutout is
configured to prevent simultaneous drive & boom operation.

DRIVE PREVENTED – ABOVE 
ELEVATION

Drive is selected while above elevation and drive cutout is configured to prevent drive.

DRIVE PREVENTED – BOOM
SELECTED

Drive is selected while a boom function is selected and drive cutout is configured to prevent simultaneous drive & boom operation.

DRIVE PREVENTED – TILTED &
ABOVE ELEVATION

Drive is selected while tilted and above elevation and tilt is configured to cutout
drive.

MODEL CHANGED – HYDRAULICS SUSPENDED – CYCLE EMS

User changed model number using the analyzer. User must cycle power before
hydraulics system will be active again.

2/7

Flash code 2/7 indicates accelerator input is faulty.
NOT REQUIRED

2/8

Flash code 2/8 indicates a problem with a hydraulic filter. Not reported during 2
second power-up.
RETURN FILTER BYPASSED

4

11

5

Hydraulic return filter clogged

CHARGE PUMP FILTER BYPASSED Charge pump filter clogged
3/1

Flash code 3/1 indicates a contactor did not close when energized.
NOT REQUIRED

3/2

Flash code 3/2 indicates a contactor did not open when energized.
NOT REQUIRED

3/3

Flash code 3/3 indicates a driver problem. All driver faults are detected in a similar manner. Open circuit faults are detected when analog feedback reads too
high and the output is commanded off. Short to ground is detected when analog feedback reads low and the output is commanded on. Short to battery is
detected when analog feedback reads Vbat and the output is commanded off.
Not reported during 2 second power-up.

6

ALTERNATOR/ECM POWER
SHORT TO GROUND
HOUR METER SHORT TO
GROUND
HOUR METER SHORT TO 
BATTERY
HORN SHORT TO GROUND
HORN OPEN CIRCUIT

6-20

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

Description

Priority

HORN SHORT TO BATTERY
AUX POWER SHORT TO GROUND
AUX POWER OPEN CIRCUIT
AUX POWER SHORT TO 
BATTERY
GLOW PLUG SHORT TO GROUND
GLOW PLUG OPEN CIRCUIT
GLOW PLUG SHORT TO 
BATTERY
LP LOCK SHORT TO GROUND
LP LOCK OPEN CIRCUIT
LP LOCK SHORT TO BATTERY
LP START ASSIST SHORT TO
GROUND
LP START ASSIST OPEN 
CIRCUIT
LP START ASSIST SHORT TO BATTERY
MAIN DUMP SHORT TO GROUND
MAIN DUMP OPEN CIRCUIT
MAIN DUMP SHORT TO 
BATTERY
PARKING BRAKE SHORT TO
GROUND
PARKING BRAKE OPEN 
CIRCUIT
PARKING BRAKE SHORT TO BATTERY
START SOLENOID SHORT TO
GROUND
START SOLENOID OPEN 
CIRCUIT
START SOLENOID SHORT TO BATTERY
STEER DUMP SHORT TO
GROUND
STEER DUMP OPEN CIRCUIT
STEER DUMP SHORT TO 
BATTERY
TWO SPEED SHORT TO GROUND
TWO SPEED OPEN CIRCUIT
TWO SPEED SHORT TO 
BATTERY
GROUND ALARM SHORT TO
GROUND

3121298

– JLG Lift –

6-21

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

Description

Priority

GROUND ALARM OPEN 
CIRCUIT
GROUND ALARM SHORT TO 
BATTERY
GENERATOR SHORT TO GROUND
GENERATOR OPEN CIRCUIT
GENERATOR SHORT TO 
BATTERY
WELDER SHORT TO GROUND
WELDER OPEN CIRCUIT
WELDER SHORT TO BATTERY
HEAD TAIL LIGHT SHORT TO
GROUND
HEAD TAIL LIGHT OPEN 
CIRCUIT
HEAD TAIL LIGHT SHORT TO 
BATTERY
BASKET UP OVERRIDE SHORT TO Only occurs on machines with electronic leveling systems.
GROUND
BASKET UP OVERRIDE OPEN 
CIRCUIT

Only occurs on machines with electronic leveling systems.

BASKET UP OVERRIDE SHORT TO Only occurs on machines with electronic leveling systems.
BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO 
BATTERY
BASKET DOWN SHORT TO
GROUND
BASKET DOWN OPEN 
CIRCUIT
BASKET DOWN SHORT TO BATTERY
BASKET DOWN OVERRIDE
SHORT TO GROUND

Only occurs on machines with electronic leveling systems.

BASKET DOWN OVERRIDE OPEN Only occurs on machines with electronic leveling systems.
CIRCUIT
BASKET DOWN OVERRIDE
SHORT TO BATTERY

Only occurs on machines with electronic leveling systems.

BASKET LEFT OPEN CIRCUIT
BASKET LEFT SHORT TO 
BATTERY
BASKET LEFT SHORT TO
GROUND
BASKET RIGHT SHORT TO
GROUND

6-22

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

Description

Priority

BASKET RIGHT OPEN CIRCUIT
BASKET RIGHT SHORT TO 
BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB DOWN SHORT TO GROUND
JIB DOWN OPEN CIRCUIT
JIB DOWN SHORT TO 
BATTERY
JIB LEFT SHORT TO GROUND
JIB LEFT OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB RIGHT SHORT TO GROUND
JIB RIGHT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
TOWER UP SHORT TO GROUND
TOWER UP OPEN CIRCUIT
TOWER UP SHORT TO 
BATTERY
TOWER DOWN SHORT TO
GROUND
TOWER DOWN OPEN CIRCUIT
TOWER DOWN SHORT TO BATTERY
TOWER IN SHORT TO GROUND
TOWER IN OPEN CIRCUIT
TOWER IN SHORT TO 
BATTERY
TOWER OUT SHORT TO GROUND
TOWER OUT OPEN CIRCUIT
TOWER OUT SHORT TO 
BATTERY
UPPER IN SHORT TO GROUND
UPPER IN OPEN CIRCUIT
UPPER IN SHORT TO BATTERY
UPPER OUT SHORT TO GROUND
UPPER OUT OPEN CIRCUIT
UPPER OUT SHORT TO 
BATTERY
LIFT UP DUMP SHORT TO
GROUND
LIFT UP DUMP OPEN CIRCUIT

3121298

– JLG Lift –

6-23

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

Description

Priority

LIFT UP DUMP SHORT TO 
BATTERY
LIFT DOWN HOLDING SHORT TO
GROUND
LIFT DOWN HOLDING OPEN CIRCUIT
LIFT DOWN SHORT TO BATTERY
HOUR METER OPEN CIRCUIT

This fault cannot be detected during normal operation. It may be reported during self test.

FORD ECM POWER OPEN 
CIRCUIT

This fault cannot be detected during normal operation. It may be reported during self test.

FORD ECM POWER SHORT TO
BATTERY

This fault cannot be detected during normal operation. It may be reported during self test.

3/4

Flash code 3/4 indicates a driver problem on a platform valve block valve driver.
All driver faults are detected in a similar manner. Open circuit faults are detected
when analog feedback reads too high and the output is commanded off. Short
to ground is detected when analog feedback reads low and the output is commanded on. Short to battery is detected when analog feedback reads Vbat and
the output is commanded off. Not reported during 2 second power-up.

6

BASKET UP SHORT TO 
BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO 
BATTERY OR OPEN CIRCUIT

Only occurs on machines with electronic basket leveling

BASKET DOWN SHORT TO BATTERY
BASKET DOWN SHORT TO
GROUND
BASKET DOWN OPEN 
CIRCUIT
BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT

Only occurs on machines with electronic basket leveling.

BASKET LEFT SHORT TO 
BATTERY
BASKER LEFT SHORT TO
GROUND
BASKET LEFT OPEN CIRCUIT
BASKET RIGHT SHORT TO BATTERY
BASKET RIGHT SHORT TO
GROUND
BASKET RIGHT OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT

6-24

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault

Description

Priority

JIB DOWN SHORT TO 
BATTERY
JIB DOWN SHORT TO GROUND
JIB DOWN OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB LEFT SHORT TO GROUND
JIB LEFT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
JIB RIGHT SHORT TO GROUND
JIB RIGHT OPEN CIRCUIT
PLATFORM CONTROL VALVE
SHORT TO BATTERY

Only occurs on machines with electronic basket leveling

PLATFORM CONTROL VALVE
SHORT TO GROUND

Only occurs on machines with electronic basket leveling

PLATFORM CONTROL VALVE
OPEN CIRCUIT

Only occurs on machines with electronic basket leveling

3/5

Flash code 3/5 indicates a brake pressure problem.
NOT REQUIRED

4/2

Flash code 4/2 indicates engine is over temperature. NOT REQUIRED

4/3

Flash code 4/3 indicates problems with the engine. Except where noted, these
faults are not reported during 2 second power-up sequence.

3121298

HIGH ENGINE TEMP

Occurs when engine temperature is above 117° Celsius for Ford engines, and
above 130° Celsius for Deutz engines.

AIR FILTER BYPASSED

Air filter clogged

NO ALTERNATOR OUTPUT

Engine has been running for 15 seconds or more and battery voltage is still
below 12.5 volts.

LOW OIL PRESSURE

If a Deutz engine is installed, oil pressure is below 8 PSI and the engine has been
running for at least 10 seconds. If a Ford engine is installed, the Ford ECM has
reported a low oil pressure fault.

OIL PRESSURE SHORT TO 
BATTERY

If a Deutz engine is installed, this indicates oil pressure sensor is reading above
6.6 volts.

OIL PRESSURE SHORT TO
GROUND

If a Deutz engine is installed, this indicates oil pressure sensor is reading below
0.1 volts for more than 5 seconds. This fault is not detected during crank.

COOLANT TEMPERATURE
SHORT TO GROUND

If a Deutz engine is installed, this indicates coolant temperature is reading
below 0.1 volts.

FORD FAULT CODE ##

All Ford fault codes except 63 are simply passed through from the FORD ECM.
They only occur if a Ford engine is selected in machine configuration digits. Can
be reported during power-up sequence.

FORD FAULT CODE UNKNOWN

An unrecognized Ford ECM fault code has been received. Can be reported during power-up sequence.

485 COMMUNICATIONS LOST

This fault only occurs with a Ford engine. It occurs when no responses are
received from the ECM for 2.5 seconds. Can be reported during power-up
sequence.

FUEL SENSOR SHORT TO
BATTERY

Indicates fuel sensor is reading above 4.3 volts.

– JLG Lift –

9

6-25

SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code

Communicated (Displayed on
Analyzer) Fault
FUEL SENSOR SHORT TO
GROUND

4/4

Description
Indicates fuel sensor is reading below 0.2 volts.
Flash code 4/4 indicates problems with the battery supply. Not reported during
2 second power-up.

BATTERY LOW

Battery voltage is below 11V for more than 5 seconds. This fault is not detected
during crank. This is a warning – controller does not shut down.

BATTERY TOO HIGH – 
SYSTEM SHUT DOWN

Battery voltage is above 16V. EMS recycle required.

BATTERY TOO LOW – 
SYSTEM SHUT DOWN

Battery voltage is below 9V.

5/5

Flash code 5/5 indicates problems with vehicle engine RPM or the encoder. Not
reported during 2 second power-up.
SPEED SENSOR READING
INVALID SPEED

This fault is detected with diesel engines only. The RPM pickup is indicating a
speed that greater than 4000 RPM or approximately 8875 Hz.

SPEED INPUT LOST

This fault is detected with diesel engines only. It occurs if there is no RPM
detected and the oil pressure input is reading above 8 PSI for more than three
seconds. This is probably due to wiring problems at the ground module or a
faulty speed sensor.

6/6

Flash code 6/6 indicates problems with the CAN bus.
CAN BUS FAILURE:

Priority

7

8

10

Ground module or platform module is not receiving CAN messages. This is
probably due to wiring problems between the platform and ground modules.

7/7

Flash code 7/7 indicates problems with a motor.
NOT REQUIRED

9/9

Flash code 9/9 indicates problems with the controller.
PLATFORM MODULE 
SOFTWARE UPDATE REQUIRED

Platform module code is too old to support the EIM or BPE load sensor and the
machine is configured to use one of these two sensors. The PM code must be
updated to a newer version.

HIGH RESOLUTION A2D 
FAILURE –INTERRUPT LOST

The ADS1213 chip in the platform module has stopped asserting its interrupt
(DRDY) line for some reason. An EMS cycle is required.

HIGH RESOLUTION A2D 
FAILURE-REINIT LIMIT

The ADS1213 has needed to be reset 3 or more times.

PLATFORM MODULE FAILURE:
HWFS CODE 1

Platform module V(Low) FET has failed

GROUND MODULE FAILURE:
HWFS CODE 1

Ground module V(Low) FET has failed

GROUND SENSOR REF
VOLTAGE OUT OF RANGE

These faults occur when the seven volt reference voltage used for joysticks, sensors, etc. goes out of range. Not reported during 2 second power-up.

PLATFORM SENSOR REF VOLTAGE OUT OF RANGE

These faults occur when the seven volt reference voltage used for the joysticks,
sensors, etc. goes out of range. Not reported during 2 second power-up.

EEPROM FAILURE – CHECK ALL
SETTINGS

A critical failure occurred with the EEPROM. Personalities, machine configuration digits, etc. may be reset to default values and should be checked.

11

CHASSIS TILT SENSOR NOT GAIN Indicates that chassis tilt sensor calibration information has been lost. Machine
CALIBRATED
will indicate it is tilted at all times. This calibration data is programmed into the
unit at the factory.
CHASSIS TILT SENSOR GAIN OUT Indicates chassis tilt sensor calibration is corrupted.
OF RANGE

6-26

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Help Message/Fault Listing
HELP MESSAGE

FAULT

FAULT REMOVAL

OK

0

0

CLEARS WHEN FAULT IS REMOVED

DRIVING AT CREEP - TILTED

0

0

CLEARS WHEN FAULT IS REMOVED

FSW OPEN

0

0

CLEARS WHEN FAULT IS REMOVED

RUNNING AT CREEP - CREEP SWITCH OPEN

0

0

CLEARS WHEN FAULT IS REMOVED

RUNNING AT CREEP - TILTED AND ABOVE ELEVATION

0

0

CLEARS WHEN FAULT IS REMOVED

RUNNING AT CUTBACK - ABOVE ELEVATION

0

0

CLEARS WHEN FAULT IS REMOVED

TILT SENSOR OUT OF RANGE

0

0

CLEARS WHEN FAULT IS REMOVED

LOAD SENSOR READING UNDER WEIGHT

0

0

CLEARS WHEN FAULT IS REMOVED

FSW FAULTY

2

1

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

KEYSWITCH FAULTY

2

1

CLEARS WHEN FAULT IS REMOVED

DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH

2

2

CLEARS WHEN FAULT IS REMOVED

FSW INTERLOCK TRIPPED

2

2

CLEARS WHEN FAULT IS REMOVED

STEER LOCKED - SELECTED BEFORE FOOTSWITCH

2

2

CLEARS WHEN FAULT IS REMOVED

STEER SWITCHES FAULTY

2

2

CLEARS WHEN FAULT IS REMOVED

D/S JOY. QPROX BAD

2

2

CLEARS WHEN FAULT IS REMOVED

L/S JOY. QPROX BAD

2

3

CLEARS WHEN FAULT IS REMOVED

D/S JOY. OUT OF RANGE LOW

2

2

CLEARS WHEN FAULT IS REMOVED

D/S JOY. OUT OF RANGE HIGH

2

2

CLEARS WHEN FAULT IS REMOVED

L/S JOY. OUT OF RANGE LOW

2

3

CLEARS WHEN FAULT IS REMOVED

L/S JOY. OUT OF RANGE HIGH

2

3

CLEARS WHEN FAULT IS REMOVED

D/S JOY. CENTER TAP BAD

2

2

CLEARS WHEN FAULT IS REMOVED

L/S JOY. CENTER TAP BAD

2

3

CLEARS WHEN FAULT IS REMOVED

WAITING FOR FSW TO BE OPEN

2

2

CLEARS WHEN FAULT IS REMOVED

PUMP POT FAULTY

2

3

CLEARS WHEN FAULT IS REMOVED

PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM

2

3

CLEARS WHEN FAULT IS REMOVED

PUMP SWITCHES LOCKED - SELECTED BEFORE FOOTSWITCH

2

3

CLEARS WHEN FAULT IS REMOVED

PUMP SWITCHES LOCKED - SELECTED BEFORE START SWITCH

2

3

CLEARS WHEN FAULT IS REMOVED

FOOTSWITCH SELECTED BEFORE START

2

3

CLEARS WHEN FAULT IS REMOVED

BOOM PREVENTED - DRIVE SELECTED

2

5

CLEARS WHEN FAULT IS REMOVED

DRIVE PREVENTED - ABOVE ELEVATION

2

5

CLEARS WHEN FAULT IS REMOVED

DRIVE PREVENTED - TILTED & ABOVE ELEVATION

2

5

CLEARS WHEN FAULT IS REMOVED

DRIVE PREVENTED - BOOM SELECTED

2

5

CLEARS WHEN FAULT IS REMOVED

3121298

– JLG Lift –

6-27

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Help Message/Fault Listing
HELP MESSAGE

FAULT

FAULT REMOVAL

FORD ECM POWER SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HORN SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HORN OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HORN SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

AUX POWER SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

AUX POWER OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

AUX POWER SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

GLOW PLUG SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

GLOW PLUG OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

GLOW PLUG SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

LP LOCK SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

LP LOCK OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

LP LOCK SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

LP START ASSIST SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

LP START ASSIST OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

LP START ASSIST SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

MAIN DUMP SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

MAIN DUMP OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

MAIN DUMP SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

PARKING BRAKE SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

PARKING BRAKE OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

PARKING BRAKE SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

START SOLENOID SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

START SOLENOID OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

START SOLENOID SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

STEER DUMP SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

STEER DUMP OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

STEER DUMP SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TWO SPEED SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TWO SPEED OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TWO SPEED SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

ALARM SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

ALARM OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

6-28

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Help Message/Fault Listing
HELP MESSAGE

FAULT

FAULT REMOVAL

ALARM SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

GENERATOR SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

GENERATOR OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

GENERATOR SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HEAD TAIL LIGHT SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HEAD TAIL LIGHT OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HEAD TAIL LIGHT SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HOUR METER SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

HOUR METER SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET UP SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET UP OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET UP SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET DOWN SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET DOWN OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET DOWN SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET LEFT SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET LEFT OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET LEFT SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET RIGHT SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET RIGHT OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BASKET RIGHT SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB UP SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB UP OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB UP SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB DOWN SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB DOWN OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB DOWN SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB LEFT SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB LEFT OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB LEFT SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB RIGHT SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB RIGHT OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

JIB RIGHT SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

3121298

– JLG Lift –

6-29

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Help Message/Fault Listing
HELP MESSAGE

FAULT

FAULT REMOVAL

TOWER UP SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER UP OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER UP SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER DOWN SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER DOWN OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER DOWN SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER IN SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER IN OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER IN SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER OUT SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER OUT OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

TOWER OUT SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

UPPER IN SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

UPPER IN OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

UPPER IN SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

UPPER OUT SHORT TO GROUND

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

UPPER OUT OPEN CIRCUIT

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

UPPER OUT SHORT TO BATTERY

3

3

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

FUEL SENSOR SHORT TO BATTERY

3

3

CLEARS WHEN FAULT IS REMOVED

FUEL SENSOR SHORT TO GROUND

3

3

CLEARS WHEN FAULT IS REMOVED

OIL PRESSURE SHORT TO BATTERY

4

3

CLEARS WHEN FAULT IS REMOVED

OIL PRESSURE SHORT TO GROUND

4

3

CLEARS WHEN FAULT IS REMOVED

COOLANT TEMPERATURE SHORT TO GROUND

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 12

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 13

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 14

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 15

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 21

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 22

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 23

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 24

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 25

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 26

4

3

CLEARS WHEN FAULT IS REMOVED

6-30

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Help Message/Fault Listing
HELP MESSAGE

FAULT

FAULT REMOVAL

FORD FAULT CODE 31

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 32

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 33

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 34

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 35

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 36

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 41

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 42

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 43

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 44

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 45

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 46

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 51

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 52

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 53

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 54

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 55

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 56

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 57

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 61

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 62

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 63

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE 64

4

3

CLEARS WHEN FAULT IS REMOVED

FORD FAULT CODE UNKNOWN

4

3

CLEARS WHEN FAULT IS REMOVED

RETURN FILTER BYPASSED

2

8

CLEARS WHEN FAULT IS REMOVED

CHARGE PUMP FILTER BYPASSED

2

8

CLEARS WHEN FAULT IS REMOVED

BATTERY LOW

4

4

CLEARS WHEN FAULT IS REMOVED

BATTERY TOO HIGH - SYSTEM SHUT DOWN

4

4

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

BATTERY TOO LOW - SYSTEM SHUT DOWN

4

4

CLEARS WHEN FAULT IS REMOVED

SPEED SENSOR READING INVALID SPEED

5

5

CLEARS WHEN FAULT IS REMOVED

SPEED INPUT LOST

5

5

CLEARS WHEN FAULT IS REMOVED

ENGINE TEMP HIGH

4

3

CLEARS WHEN FAULT IS REMOVED

AIR FILTER BYPASSED

4

3

CLEARS WHEN FAULT IS REMOVED

3121298

– JLG Lift –

6-31

SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. Help Message/Fault Listing
HELP MESSAGE

FAULT

FAULT REMOVAL

NO ALTERNATOR OUTPUT

4

3

CLEARS WHEN FAULT IS REMOVED

OIL PRESSURE LOW

4

3

CLEARS WHEN FAULT IS REMOVED

485 COMMUNICATIONS LOST

4

3

CLEARS WHEN FAULT IS REMOVED

CAN BUS FAILURE

6

6

CLEARS WHEN FAULT IS REMOVED

LOAD SENSOR NOT CALIBRATED

9

9

CLEARS WHEN FAULT IS REMOVED

TILT SENSOR NOT CALIBRATED

9

9

CLEARS WHEN FAULT IS REMOVED

EEPROM FAILURE - CHECK ALL SETTINGS

9

9

REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT

PLATFORM MODULE FAILURE: HWFS CODE 1

9

9

CLEARS WHEN FAULT IS REMOVED

GROUND MODULE FAILURE: HWFS CODE 1

9

9

CLEARS WHEN FAULT IS REMOVED

6-32

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information
Configuration Digit

Number

Description

Default
Number

NOTE: Machine configuration must be completed before any personality settings can be changed. Changing personality settings first and then changing the model number of the machine configuration will cause personality settings to return to
default
MODEL NUMBER:
1

0
4

No Model
600S

0
1

MARKET:
2

0
1
2
3
4
5

ANSI USA
ANSI EXPORT
CSA
CE
AUSTRALIA
JAPAN

0

ENGINE:
3

8
9
12
13

DEUTZ F4 TIER1: Deutz BF4M1011 Diesel (Tier 1)
DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
DEUTZ ECM: Engine Control Module
CAT Engine

14

FLYWHEEL TEETH:
4

0
1

133 TEETH: 133 flywheel teeth.
110 TEETH: 110 flywheel teeth.

1

GLOW PLUG:
5

0
1
2

NO GLOW PLUGS: No glow plugs installed.
AIR INTAKE: Glow plugs installed in the air intake on the manifold.
IN-CYLINDER: Glow plugs installed in each cylinder.

2

STARTER LOCKOUT:
6

0


DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.

0

1

ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-glow is finished.

0

DISABLED: No engine shutdown.

1

ENABLED: Shutdown engine when coolant temperature is greater than
110°C or oil pressure is less than 8 PSI.

ENGINE SHUTDOWN:
7

3121298

– JLG Lift –

1

6-33

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information
Configuration Digit
TILT:
8

Number

Description

1



5 DEGREES: Reduces the maximum speed of all boom functions to creep
when tilted more than 5 degrees and above elevation; also reduces drive
speed to creep.

2


4 DEGREES: Reduces the maximum speed of all boom functions to creep
when tilted more than 4 degrees and above elevation; also reduces drive
speed to creep.

3

4


5

Default
Number
1

3 DEGREES: Reduces the maximum speed of all boom functions to creep
when tilted more than 3 degrees and above elevation; also reduces drive
speed to creep.
4 DEGREES + CUT: Reduces the maximum speed of all boom functions to
creep when tilted more than 4 degrees and above elevation; also disallows
tower lift up, tower telescope out, drive, main telescope out and main lift up.
3 DEGREES + CUT: Reduces the maximum speed of all boom functions to
creep when tilted more than 3 degrees and above elevation; also disallows
tower lift up, tower telescope out, drive, main telescope out and main lift up.

Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when
the machine is also above elevation.

JIB:
9

0
1

NO: No Jib installed.
YES: Jib installed which has up and down movements only.

0

4 WHEEL STEER:
10

0
1

NO: No four-wheel steer installed.
YES: Four wheel steer installed

0

STOUCH/SKYGUARD:

0
1
2
3

NO: No soft touch or SkyGuard system installed.
SOFT TOUCH: Soft touch only installed.
SKYGUARD: SkyGuard only installed.
BOTH (CUTOUT) - Soft touch and SkyGuard installed.

0

GEN SET/WELDER:
12

0
1

NO: No generator installed.
BELT DRIVE: Belt driven setup

0

GEN SET CUTOUT:
13*

0
1

MOTION ENABLED: Motion enabled when generator is ON.
MOTION CUTOUT: Motion cutout in platform mode only.

0

11

* Only visible if Gen Set / Welder Menu selection is not 0.

6-34

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information
Configuration Digit

Number

Description

Default
Number

H & T LIGHTS:
14

0
1

NO: No head and tail lights installed.
YES: Head and tail lights installed.

0

CABLE SWITCH:
15*

0
1

NO: No broken cable switch installed.
YES: Broken cable switch installed.

0

* Certain market selections will alter default setting.

LOAD SYSTEM:
16*

0

NO: No load sensor installed.

1


WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5
sec ON, 2 sec OFF).

2


CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm
beeps (5 sec ON, 2 sec OFF).

3


CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS
off ), platform alarm beeps (5 sec ON, 2 sec OFF).

4

SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out
& main lift up, platform alarm beeps (5 sec ON, 2 sec OFF).

0

* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.

LOAD SENSOR:
17*

0


1 ON ROTATOR: Use the on-board load sensor for all models except those
which use the Leveling Platform Module.

1

4 UNDER PLATFORM: Use the EIM for load sensing.

1

* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.

3121298

– JLG Lift –

6-35

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information
Configuration Digit
FUNCTION CUTOUT:
18*

Number
0
1
2
3

Description
NO: No drive cutout.
BOOM CUTOUT: Boom function cutout while driving above elevation.
DRIVE CUTOUT: Drive cutout above elevation.
DRIVE CUT E&T: Drive cutout above elevation and tilted.

Default
Number
0

* Only visible under certain market selections.
* Certain market selections will limit function cutout options or alter default setting.

GROUND ALARM:
19*

0
1
2
3

NO: No ground alarm installed.
DRIVE: Travel alarm sounds when the drive function is active (Option).
DESCENT: Descent alarm sounds when lift down is active (Option).
MOTION: Motion alarm sounds when any function is active (Option).

3

* Certain market selections will alter default setting.

DRIVE:
20*

0
1
2

4 WD: Four wheel drive.
2WD: Two wheel drive.
2WD W/2-SPEED: Two wheel drive with two-speed valve.

0

* Only visible under certain market selections.

DISPLAY UNITS:
21*

0
1

IMPERIAL: DEG F, PSI, LBS
METRIC: DEG C, KPA, KGS.

0

* Certain market selections will alter default setting.

LEVELING MODE:
22*

0
1

ALL: Platform level with all functions.
LEVEL LIFT /TELESCOPE: Platform level on lift and telescope only.

0

* Only visible on 800S models.

6-36

DRIVE CONTROL:
23

0
1
2

NORMAL: Drive coils are energized from the Ground Module.
PROPULSION: Drive coils are energized from the Propulsion Module.
ENHANCED: Drive coils are energized from the Ground Module and the
ground side of the drive coils are brought back to current feedback returns.

2

BOOM CONTROL:
24

0
1

NORMAL: Boom control coils are energized from the Ground Module.
ENHANCED: Boom control coils are energized from the Ground Module and
the ground side of the drive coils are brought back to current feedback
returns.

0

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-5. Machine Configuration Programming Information
Configuration Digit

Number

Description

Default
Number

CLEARSKY:
25

0
1

NO: ClearSky Telematics system not installed.
YES: ClearSky Telematics system installed.

0

CRIBBING OPTION:
26

0
1

NO: Cribbing Option is disabled.
YES: Cribbing Option is enabled.

0

FUEL TANK SIZE:
27

0
1

31 Gallon tank.
52 Gallon tank.

0

ALARM/HORN:
28

0
1

SEPERATE: Separate alarm and horn.
COMBINED: combination alarm/horn.

0

4150364 F

DRIVE FORWARD (Max): high speed - low torque setting,
drive 200 ft (61 m) front wheels to front wheels. Timed after
machine has obtained maximum speed.

6.3 MACHINE ORIENTATION WHEN SETTING
FUNCTION SPEEDS
LIFT UP: from platform control, lowest elevation up to maximum elevation, boom retracted, jib retracted.
LIFT DOWN: from platform control, maximum elevation down
to minimum elevation, boom retracted, jib retracted.

DRIVE REVERSE (Max): high speed - low torque setting, drive
200 ft (61 m) front wheels to front wheels Timed after machine
has obtained maximum speed.
DRIVE FORWARD (Creep Max): high torque - low speed setting, platform speed knob at full creep

JIB LIFT UP: from platform control, lowest jib elevation up to
maximum jib elevation, boom retracted, jib retracted.

DRIVE REVERSE (Creep Max): high torque - low speed setting, platform speed knob at full creep

JIB LIFT DOWN: from platform control, maximum jib elevation
down to minimum jib elevation, boom retracted, jib retracted.

DRIVE FORWARD (Elevated Max - Boom Beyond Transport): high speed - low torque setting, platform speed knob
out of creep, Lift boom above transport, drive forward 50 ft (15
m).

SWING RIGHT(Max): 360°, from platform control, boom
approximately 45° elevation, boom retracted, jib retracted.
SWING LEFT(Max): 360°, from platform control, boom
approximately 45° elevation, boom retracted, jib retracted.

DRIVE REVERSE (Elevated Max - Boom Beyond Transport):
high speed - low torque setting, platform speed knob out of
creep, Lift boom above transport, drive backward 50 ft (15 m).

TELESCOPE OUT: from platform control, boom 20°, 500 lb
(226 kg) capacity selected.
TELESCOPE IN: from platform control, boom 20°, 500 lb (226
kg) capacity selected.
JIB TELESCOPE IN: from platform control, boom horizontal, jib
horizontal, 500 lb (226 kg) capacity selected.
JIB TELESCOPE OUT: from platform control, boom horizontal,
jib horizontal, 500 lb (226 kg) capacity selected.

3121298

– JLG Lift –

6-37

SECTION 6 - JLG CONTROL SYSTEM

Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc;)

Test Notes
1.

Personality settings can be adjusted anywhere within
the adjustment range for optimum machine performance.

2.

Stop watch should start when function is activated - not
controller or switch.

3.

Unless noted, measure function speeds from platform.

4.

Platform speed knob must be at full speed (fully clockwise).

5.

Perform all tests with oil temperature above 100° F (38°
C).

6.4 CANBUS COMMUNICATIONS
CANbus: CAN (Control Area Network) is a two wire differential
serial link between the Platform and Ground Modules providing bi-directional communications.
Two-wire: One wire (red) is driven high (5v) and the other low
(black) (0v) to send a signal. Both wires ”float” (2.5v) when no
signal is being sent. 

Differential: Any electrical line noise can affect the high or the
low wires but never both, so communications is not corrupted. 

Serial Link: Messages are being sent bit by bit along the wires;
the high bus speed allow all modules to be constantly
updated around 20 times per second. Typical traffic is 300 500 messages per second. 

A complete CANbus circuit is approximately 60 ohms, which
can be verified at the ”T” fitting inside the ground station. Individual circuits are approximately 120 ohms.

Platform Level: The GROUND MODULE stores default values
and handles interlocks. The PLATFORM MODULE reads sensors
mounted on the platform assembly and controls Level Up /
Down valves to maintain setpoint sent from the GROUND
MODULE.
Steer: The GROUND MODULE stores crack points, and sends
desired drive direction, steering mode, and axle extend/retract
commands. The PLATFORM MODULE reports steering switch
position to the GROUND MODULE.
Drive: The GROUND MODULE stores crack points and sends
commands for each drive pump. (Command is computed from
drive joystick input, interlocks, wheel angle, etc).
Lift, Tele, & Swing: The GROUND MODULE stores default values, and handles interlocks and calibration information. Lift,
Telescope, and Swing commands depend on interlocks
through out the machine. Boom angle, length, and swing are
controlled by the GROUND MODULE

The GROUND MODULE (UGM) is the master system controller.
Most functions are dispatched and coordinated from this
module. The PLATFORM MODULE handles sub-tasks. All characterized information (values) are stored in the ground module (i.e., Personalities or Calibrations).

6-38

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

.
Table 6-6. Fault Code List
DTC

3121298

Text

001

EVERYTHING OK

0010

RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION

0011

FSW OPEN

0012

RUNNING AT CREEP - CREEP SWITCH OPEN

0013

RUNNING AT CREEP - TILTED AND ABOVE ELEVATION

0014

CHASSIS TILT SENSOR OUT OF RANGE

0030

RUNNING AT CREEP - PLATFORM STOWED

0031

FUEL LEVEL LOW - ENGINE SHUTDOWN

211

POWER CYCLE

212

KEYSWITCH FAULTY

213

FSW FAULTY

224

FUNCTION PROBLEM - STEER LEFT PERMANENTLY SELECTED

225

FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED

227

STEER SWITCHES FAULTY

2211

FSW INTERLOCK TRIPPED

2212

DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH

2213

STEER LOCKED - SELECTED BEFORE FOOTSWITCH

2216

D/S JOY. OUT OF RANGE HIGH

2217

D/S JOY. CENTER TAP BAD

2219

L/S JOY. OUT OF RANGE HIGH

2220

L/S JOY. CENTER TAP BAD

2221

LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH

2222

WAITING FOR FSW TO BE OPEN

2223

FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE

2224

FOOTSWITCH SELECTED BEFORE START

2247

FUNCTION PROBLEM - PLATFORM ROTATE LEFT PERMANENTLY SELECTED

2248

FUNCTION PROBLEM - PLATFORM ROTATE RIGHT PERMANENTLY SELECTED

2249

FUNCTION PROBLEM - JIB LIFT UP PERMANENTLY SELECTED

2250

FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED

2251

FUNCTION PROBLEM - TELESCOPE IN PERMANENTLY SELECTED

2252

FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTED

2257

FUNCTION PROBLEM - TOWER LIFT UP PERMANENTLY SELECTED

2258

FUNCTION PROBLEM - TOWER LIFT DOWN PERMANENTLY SELECTED

2262

FUNCTION PROBLEM - PLATFORM LEVEL UP PERMANENTLY SELECTED

2263

FUNCTION PROBLEM - PLATFORM LEVEL DOWN PERMANENTLY SELECTED

234

FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM

235

FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER

236

FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH

237

START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH

2310

FUNCTION PROBLEM - GROUND ENABLE PERMANENTLY SELECTED

2370

FUNCTION PROBLEM - JIB LIFT UP PERMANENTLY SELECTED

– JLG Lift –

6-39

SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. Fault Code List
DTC

6-40

Text

2371

FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED

2372

FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED

2373

FUNCTION PROBLEM - SWING RIGHT PERMANENTLY SELECTED

23104

BOOM TRANSPORT SWITCH DISAGREEMENT

23105

FUNCTION PROBLEM - TOWER LIFT UP PERMANENTLY SELECTED

23106

FUNCTION PROBLEM - TOWER LIFT DOWN PERMANENTLY SELECTED

23107

FUNCTION PROBLEM - LIFT UP PERMANENTLY SELECTED

23108

FUNCTION PROBLEM - LIFT DOWN PERMANENTLY SELECTED

23109

FUNCTION PROBLEM - TELESCOPE IN PERMANENTLY SELECTED

23110

FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTED

23111

FUNCTION PROBLEM - PLATFORM LEVEL UP PERMANENTLY SELECTED

23112

FUNCTION PROBLEM - PLATFORM LEVEL DOWN PERMANENTLY SELECTED

23113

FUNCTION PROBLEM - PLATFORM ROTATE LEFT PERMANENTLY SELECTED

23114

FUNCTION PROBLEM - PLATFORM ROTATE RIGHT PERMANENTLY SELECTED

259

MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS

2513

GENERATOR MOTION CUTOUT ACTIVE

2514

BOOM PREVENTED - DRIVE SELECTED

2516

DRIVE PREVENTED - ABOVE ELEVATION

2517

DRIVE PREVENTED - TILTED & ABOVE ELEVATION

2518

DRIVE PREVENTED - BOOM SELECTED

331

BRAKE - SHORT TO BATTERY

332

BRAKE - OPEN CIRCUIT

334

LIFT UP VALVE - OPEN CIRCUIT

335

LIFT DOWN VALVE - SHORT TO BATTERY

336

LIFT DOWN VALVE - OPEN CIRCUIT

3311

GROUND ALARM - SHORT TO BATTERY

3352

LP LOCK - SHORT TO GROUND

3353

LP LOCK - OPEN CIRCUIT

3354

LP LOCK - SHORT TO BATTERY

3355

LP START ASSIST - SHORT TO GROUND

3356

LP START ASSIST - OPEN CIRCUIT

3357

LP START ASSIST - SHORT TO BATTERY

3358

MAIN DUMP VALVE - SHORT TO GROUND

3359

MAIN DUMP VALVE - OPEN CIRCUIT

3360

MAIN DUMP VALVE - SHORT TO BATTERY

3361

BRAKE - SHORT TO GROUND

3362

START SOLENOID - SHORT TO GROUND

3363

START SOLENOID - OPEN CIRCUIT

3364

START SOLENOID - SHORT TO BATTERY

3365

STEER DUMP VALVE - SHORT TO GROUND

3366

STEER DUMP VALVE - OPEN CIRCUIT

3367

STEER DUMP VALVE - SHORT TO BATTERY

3373

GEN SET/WELDER - SHORT TO GROUND

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. Fault Code List
DTC

3121298

Text

3374

GEN SET/WELDER - OPEN CIRCUIT

3375

GEN SET/WELDER - SHORT TO BATTERY

3376

HEAD TAIL LIGHT - SHORT TO GROUND

3377

HEAD TAIL LIGHT - OPEN CIRCUIT

3378

HEAD TAIL LIGHT - SHORT TO BATTERY

3379

HOUR METER - SHORT TO GROUND

3382

PLATFORM LEVEL UP VALVE - SHORT TO GROUND

3383

PLATFORM LEVEL UP VALVE - OPEN CIRCUIT

3384

PLATFORM LEVEL UP VALVE - SHORT TO BATTERY

3388

PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND

3389

PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT

3390

PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY

3394

PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND

3395

PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT

3396

PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY

3397

PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND

3398

PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT

3399

PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY

33100

JIB LIFT UP VALVE - SHORT TO GROUND

33101

JIB LIFT UP VALVE - OPEN CIRCUIT

33102

JIB LIFT UP VALVE - SHORT TO BATTERY

33103

JIB LIFT DOWN VALVE - SHORT TO GROUND

33104

JIB LIFT DOWN VALVE - OPEN CIRCUIT

33105

JIB LIFT DOWN VALVE - SHORT TO BATTERY

33106

TOWER LIFT UP VALVE - SHORT TO GROUND

33107

TOWER LIFT UP VALVE - OPEN CIRCUIT

33109

TOWER LIFT DOWN VALVE - SHORT TO GROUND

33110

TOWER LIFT DOWN VALVE - OPEN CIRCUIT

33118

SWING RIGHT VALVE - SHORT TO GROUND

33119

SWING RIGHT VALVE - OPEN CIRCUIT

33120

TELESCOPE IN VALVE - SHORT TO BATTERY

33122

SWING LEFT VALVE - SHORT TO GROUND

33123

TELESCOPE OUT VALVE - SHORT TO BATTERY

33130

THROTTLE ACTUATOR - SHORT TO GROUND

33131

THROTTLE ACTUATOR - OPEN CIRCUIT

33132

THROTTLE ACTUATOR - SHORT TO BATTERY

33182

LIFT VALVES - SHORT TO BATTERY

33186

TELESCOPE OUT VALVE - OPEN CIRCUIT

33188

TELESCOPE OUT VALVE - SHORT TO GROUND

33189

TELESCOPE IN VALVE - OPEN CIRCUIT

33190

TELESCOPE IN VALVE - SHORT TO GROUND

33279

GLOWPLUG - OPEN CIRCUIT

33280

GLOWPLUG - SHORT TO BATTERY

– JLG Lift –

6-41

SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. Fault Code List
DTC

6-42

Text

33281

GLOWPLUG - SHORT TO GROUND

33287

LIFT - CURRENT FEEDBACK READING TOO LOW

33295

SWING LEFT VALVE - OPEN CIRCUIT

33314

FLOW CONTROL VALVE - OPEN CIRCUIT

33315

FLOW CONTROL VALVE - SHORT TO BATTERY

33316

FLOW CONTROL VALVE - SHORT TO GROUND

33317

DRIVE FORWARD VALVE - OPEN CIRCUIT

33318

DRIVE FORWARD VALVE - SHORT TO BATTERY

33319

DRIVE FORWARD VALVE - SHORT TO GROUND

33320

DRIVE REVERSE VALVE - OPEN CIRCUIT

33322

DRIVE REVERSE VALVE - SHORT TO GROUND

33331

DRIVE - CURRENT FEEDBACK READING TOO LOW

33406

LIFT UP VALVE - SHORT TO GROUND

33410

DRIVE - CURRENT FEEDBACK READING LOST

33412

SWING VALVES - SHORT TO BATTERY

33413

TOWER LIFT - CURRENT FEEDBACK READING TOO LOW

33414

SWING - CURRENT FEEDBACK READING TOO LOW

33415

FLOW CONTROL VALVE - CURRENT FEEDBACK READING TOO LOW

33416

TOWER LIFT - CURRENT FEEDBACK READING LOST

33417

LIFT - CURRENT FEEDBACK READING LOST

33418

SWING - CURRENT FEEDBACK READING LOST

33419

FLOW CONTROL VALVE - CURRENT FEEDBACK READING LOST

33420

TRACTION LOCK VALVE - SHORT TO BATTERY

33421

TRACTION LOCK VALVE - OPEN CIRCUIT

33422

TRACTION LOCK VALVE - SHORT TO GROUND

33423

OSCILLATING AXLE VALVES - SHORT TO BATTERY

33424

OSCILLATING AXLE VALVES - SHORT TO GROUND

33425

TOWER LIFT VALVES - SHORT TO BATTERY

342

PLATFORM LEVEL UP VALVE - SHORT TO BATTERY

343

PLATFORM LEVEL UP VALVE - SHORT TO GROUND

345

PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT

346

PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY

347

PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND

349

PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT

3410

PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY

3411

PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND

3412

PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT

3413

PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY

3414

PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND

3415

JIB LIFT UP VALVE - OPEN CIRCUIT

3416

JIB LIFT UP VALVE - SHORT TO BATTERY

3417

JIB LIFT UP VALVE - SHORT TO GROUND

3418

JIB LIFT DOWN VALVE - OPEN CIRCUIT

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. Fault Code List
DTC

3121298

Text

3419

JIB LIFT DOWN VALVE - SHORT TO BATTERY

3420

JIB LIFT DOWN VALVE - SHORT TO GROUND

431

FUEL SENSOR - SHORT TO BATTERY

432

FUEL SENSOR - SHORT TO GROUND

433

OIL PRESSURE - SHORT TO BATTERY

434

OIL PRESSURE - SHORT TO GROUND

435

COOLANT TEMPERATURE - SHORT TO GROUND

437

ENGINE TROUBLE CODE

438

HIGH ENGINE TEMP

4310

NO ALTERNATOR OUTPUT

4311

LOW OIL PRESSURE

4313

THROTTLE ACTUATOR FAILURE

4314

WRONG ENGINE SELECTED - ECM DETECTED

4322

LOSS OF ENGINE SPEED SENSOR

4323

SPEED SENSOR READING INVALID SPEED

4326

FUEL ACTUATOR - SHORT TO GROUND

4327

FUEL ACTUATOR - OPEN CIRCUIT

4328

FUEL ACTUATOR - SHORT TO BATTERY

4329

FUEL ACTUATOR - CURRENT FEEDBACK READING TOO LOW

4330

FUEL ACTUATOR - CURRENT FEEDBACK READING LOST

441

BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN

442

BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN

443

LSS BATTERY VOLTAGE TOO HIGH

444

LSS BATTERY VOLTAGE TOO LOW

445

BATTERY VOLTAGE LOW

662

CANBUS FAILURE - PLATFORM MODULE

663

CANBUS FAILURE - LOAD SENSING SYSTEM MODULE

666

CANBUS FAILURE - ENGINE CONTROLLER

6613

CANBUS FAILURE - EXCESSIVE CANBUS ERRORS

6622

CANBUS FAILURE - TCU MODULE

6629

CANBUS FAILURE - TELEMATICS CANBUS LOADING TOO HIGH

681

REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP

813

CHASSIS TILT SENSOR NOT CALIBRATED

814

CHASSIS TILT SENSOR OUT OF RANGE

815

CHASSIS TILT SENSOR DISAGREEMENT

821

LSS CELL #1 ERROR

822

LSS CELL #2 ERROR

823

LSS CELL #3 ERROR

824

LSS CELL #4 ERROR

825

LSS HAS NOT BEEN CALIBRATED

826

RUNNING AT CREEP - PLATFORM OVERLOADED

827

DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED

828

LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED

– JLG Lift –

6-43

SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. Fault Code List
DTC

6-44

Text

8211

LSS READING UNDER WEIGHT

8639

FRONT LEFT STEER VALVE - OPEN CIRCUIT

8640

FRONT LEFT STEER VALVE - SHORT TO BATTERY

8641

FRONT LEFT STEER VALVE - SHORT TO GROUND

8642

FRONT RIGHT STEER VALVE - OPEN CIRCUIT

8643

FRONT RIGHT STEER VALVE - SHORT TO BATTERY

8644

FRONT RIGHT STEER VALVE - SHORT TO GROUND

8669

OSCILLATING AXLE SWITCH DISAGREEMENT

991

LSS WATCHDOG RESET

992

LSS EEPROM ERROR

993

LSS INTERNAL ERROR - PIN EXCITATION

994

LSS INTERNAL ERROR - DRDY MISSING FROM A/D

998

EEPROM FAILURE - CHECK ALL SETTINGS

9910

FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION
IMPROPER

9911

FUNCTIONS LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER

9915

CHASSIS TILT SENSOR NOT GAIN CALIBRATED

9919

GROUND SENSOR REF VOLTAGE OUT OF RANGE

9920

PLATFORM SENSOR REF VOLTAGE OUT OF RANGE

9921

GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY

9922

PLATFORM MODULE FAILURE - HWFS CODE 1

9924

FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED

9927

GROUND MODULE CONSTANT DATA UPDATE REQUIRED

9944

CURRENT FEEDBACK GAINS OUT OF RANGE

9945

CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT

9949

MACHINE CONFIGURATION OUT OF RANGE - CHECK ALL SETTINGS

9977

LSS CORRUPT EEPROM

9979

FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER

9986

GROUND MODULE VLOW FET FAILURE

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.

4 WHEEL STEER

4

0

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

0

0

0

1

2

3

ANSI EXPORT

4

1

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

0

0

0

1

2

3

CSA

4

2

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

0

0

0

1

2

3

CE

4

3

12

0

1

0

1

2

0

1

0

1

X

X

3

X

5

0

0

0

1

2

3

AUSTRALIA

4

4

12

0

1

0

1

2

0

1

0

1

X

X

3

X

5

0

0

0

1

2

3

JAPAN

4

5

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

0

0

0

1

2

3

X

X

0

1

0

X

2

X

0

1

2

3

TILT

JIB

STOUCH/SKYGUARD

ENGINE SHUTDOWN

ENGINE

STARTER LOCKOUT

MARKET

ANSI USA

GLOW PLUG

MODEL NUMBER

FLYWHEEL TEETH

600S

X

GROUND ALARM

ANSI USA

0

1

0

1

0

1

0

1

0

ANSI EXPORT

0

1

0

1

0

1

0

1

0

1

2

3

4

0

1

0

1

2

3

0

1

2

3

CSA

0

1

0

1

0

1

0

1

0

X

X

X

X

0

1

0

1

2

3

0

1

2

3

CE

0

1

0

1

0

1

0

1

0

X

2

3

X

0

1

0

1

X

X

0

1

2

3

AUSTRALIA

0

1

0

1

0

1

0

1

0

X

2

X

X

0

1

0

1

2

3

0

1

2

3

JAPAN

0

1

0

1

0

1

0

1

0

1

2

3

4

0

1

0

1

2

3

0

1

2

3

3121298

X

FUNCTION CUTOUT

LOAD SENSOR

LOAD SYSTEM

CABLE BREAK SWITCH

HEAD & TAIL LIGHTS

GEN SET CUTOUT

GEN SET / WELDER

600S

– JLG Lift –

6-45

SECTION 6 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.

ALARM/HORN

FUEL TANK SIZE

CRIBBING OP

CLEARSKY

BOOM CONTROL

DRIVE CONTROL

DRIVE TYPE

DISPLAY UNITS

LEVELING MODE

600S

ANSI USA

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

ANSI EXPORT

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

CSA

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

CE

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

AUSTRALIA

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

JAPAN

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed.

4 WHEEL STEER

4

0

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

1

0

0

1

2

3

ANSI EXPORT

4

1

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

1

0

0

1

2

3

CSA

4

2

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

1

0

0

1

2

3

CE

4

3

12

0

1

0

1

2

0

1

0

1

X

X

3

X

5

1

0

0

1

2

3

AUSTRALIA

4

4

12

0

1

0

1

2

0

1

0

1

X

X

3

X

5

1

0

0

1

2

3

JAPAN

4

5

12

0

1

0

1

2

0

1

0

1

1

2

3

4

5

1

0

0

1

2

3

6-46

– JLG Lift –

TILT

JIB

STOUCH/SKYGUARD

ENGINE SHUTDOWN

ENGINE

STARTER LOCKOUT

MARKET

ANSI USA

GLOW PLUG

MODEL NUMBER

FLYWHEEL TEETH

600SJ

3121298

SECTION 6 - JLG CONTROL SYSTEM

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers
indicate the default when the option is factory installed.

ANSI USA

0

1

0

1

0

1

0

1

0

X

X

ANSI EXPORT

0

1

0

1

0

1

0

1

0

1

2

CSA

0

1

0

1

0

1

0

1

0

X

X

CE

0

1

0

1

0

1

0

1

0

X

2

AUSTRALIA

0

1

0

1

0

1

0

1

0

X

JAPAN

0

1

0

1

0

1

0

1

0

1

X

GROUND ALARM

FUNCTION CUTOUT

LOAD SENSOR

LOAD SYSTEM

CABLE BREAK SWITCH

HEAD & TAIL LIGHTS

GEN SET CUTOUT

GEN SET / WELDER

600SJ

X

0

1

0

X

2

X

0

1

2

3

3

4

0

1

0

1

2

3

0

1

2

3

X

X

0

1

0

1

2

3

0

1

2

3

3

X

0

1

0

1

X

X

0

1

2

3

2

X

X

0

1

0

1

2

3

0

1

2

3

2

3

4

0

1

0

1

2

3

0

1

2

3

NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers
indicate the default when the option is factory installed.

ALARM/HORN

FUEL TANK SIZE

CRIBBING OP

CLEARSKY

BOOM CONTROL

DRIVE CONTROL

DRIVE TYPE

DISPLAY UNITS

LEVELING MODE

600SJ

ANSI USA

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

ANSI EXPORT

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

CSA

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

CE

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

AUSTRALIA

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

JAPAN

0

1

2

0

1

0

1

0

1

2

0

1

0

1

0

1

0

1

0

1

3121298

– JLG Lift –

6-47

SECTION 6 - JLG CONTROL SYSTEM



 
 















 
 


 


 
 


Figure 6-11. Control Module Locations

6-48

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM




 



"




$
27



"
$
)
*
+
,
.
/

"
$
)
*
+
,
.
"/
"
""
"$
")
"*
"+
",
"".
$/
$
$"
$$
$)
$*

 
   
 # ###
!% &   ' (! 
 !
 !
!% &   ' %# 
 ' &   !%
 !
 !
  0 &  1 &

  #!

# #!
 (  #

2 0
  3  
  ## 
 # !
 !
 !
 !
"5# ! %%

3
 205 ##
 2 0
2' %%
 !
#5)-* 
#5)-* (
 !
06 (
06 #5"$" 1
06 #5"$" 1
06  !
 1
#5)-*  !
  205 ##
 !



"
$
)
*
+
,
.
/

"
$
)
*
+
,
.
"/
"
""
"$
")
"*
"+
",
"".
$/
$
$"
$$
$)
$*

# ! 3 %%
   
( #   #!
3 #   #!
 3 %
#!
 !
 3 % !( #!
 ' %# 
 !
 3    #!
3  
#!
2
#!
3 ! 3 %%
 !
( #    #!
3 #    #!
 !
 !
 ' (! 
 !
 3   #!
3   !( #!
2 !( #!
   205 ##
 % ##
! &   2 0
3   
 !
 !
 !
(  %%
(   !( #!
(  
#!
#(   #!
#(  #!

 



"
$
)
*
+
,
.
/

"
$
)

!% &   '   !2'
 '   !2'
 !
#(   !2'
 !
(    !2'
20 %
3#  ##
22  #(
 !
 !
 !
 !
    !2'


!
!
!
 !
 !
!
!
 !
 !
!
!
!
!


4 0
 !
 !
 !
!
!
!
!
&
#
#
 !
%
#
#
 !
!
 !
!
!


!
!
!
!
!
 !
!
!
!
!
!
!
!
 !
!
!
 !
 !
!
!
!
!
!
!

!
!
 !
 !
 !
!
!
!
!
!

 

  
  
  
 
 
  
  
 
 
  
  
  
  
 
 
 
 
 
 
  
 
  
  
&
&
&
 
  
 
  
 
  
 
 
 

 
 
 
 
 

 
 
 
 
 
 
 

 
 


 
 
 
 
 


 
 



 
 
 
 
 






































 !
 !
 !
 !
 !
 !
%2
!
!
!
!
%

 !







 




 




















Figure 6-12. Ground Control Module Pin Connections 1 of 3

3121298

– JLG Lift –

6-49

SECTION 6 - JLG CONTROL SYSTEM








&




&
'
(
,
/

1
2
3

&
'
(
,
/

1
2
&3
&
&&
&'
&(
&,
&/
&
&1
&2
'3
'
'&
''
'(
',

 



  
  !
#%$! !
 ") $# *"+
-, .
$ "$
 ") $#+ *"+
$ $$!
#%$!
#%$!
"$ 0 %  $  *"+
4$  *"+
$ +"#+
#%$! ! *   
 *"+
-, .
$ "$
$ +"!
#%$!
$ $$!
*    5"") 133 $) !". "$"$

* "  5"") 133 $)
#%$! %$"$ $ ."
$ *
#%$!
-, .
-, .
#%$!
) .#
) .#
) .#
) .#
) .#
) .#   % "$ !%
 $# 5"") 133 $) !". "$"$



&
'
(
,
/

1

 
$ $$!
$ $$!
$& +"#+ " 
$& * " 
$& +"! " 
$& "$
$& "$
$ $$!

!"#"
!"#"
!"#"
$#
.#

$#
$#
#%$!
#%$!
!"#"
!"#"
"
!"#"
!"#"
.#

#%$!
#%$!
$#
!"#"
!"#"
!"#"
"
#%$!
.#
.#
#%$!
.
.
.
.
.
.
!"#"

"$ %
"$ %
"$ %
"$ %
% %
"0
"$ %
"$ %
"$ %
"$ %
"$ %
"$ %
"0
"$ %
"$ %
% %
"0
"$ %
"$ %
"$ %
"$ %
"$ %
"$ %
"0
"$ %
% %
% %
"$ %
% %
% %
% %
% %
% %
% %
"$ %


6%$)
6%$)
"
"
#%$!


!"#"

"$ %
"$ %
"0
"0
"$ %
"0
"0
"$ %



Figure 6-13. Ground Control Module Pin Connections 2 of 3

6-50

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM







)
 



#
(
)
*
.
/

0
+

#
(
)
*
.
/

0
#+
#
##
#(
#)
#*
#.
#/
#
#0
(+
(
(#
((
()
(*



#
(
)

 



 !"
 $!
!"  & ! 
$!  & ! 

!"
%&
!"
%&

 
!''" " &  '"'&!
*++  & &', &
$  '"'&!
" '" -&!
& ! % $"
& ! !&  
&'" -  '"
' 
'  
$! '  
$! -  '"
1!!
!!" '! ,2 &-- &
& ! %!& '"'&!
 & "'" '"'&!
&3''&!, $! 4 "'" "&
& ! % 
& ! !& !' 1
' 
' !' 1
$! '  $"
$! -  
&'" '  
&!, %& 
&!, %&   !" "& !-"
&!, $ 4 " 1&! '" '"'&!
1&!  
'! ,2 &-- &
" '" 1' 1 &"  !&! '"'&!
" '" $ ' !--! '"'&!
&'" -  
&
!"
!"
&'" '  $"
-$'"  
-$'" !' 1

 
'" 
'" 
 


' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
' '&
%&
%&
' '&
' '&
' '&
' '&
' '&
!"
!"
' '&
' '&
' '&

 
 
 
'" 
'" 
'" 
'" 
'" 
'" 
'" 
'" 
 
 
 
 
'" 
'" 
'" 
'" 
'" 
'" 
'" 
'" 
 
 
 
 
 
 
'" 
'" 
'" 
'" 
'" 
'" 



Figure 6-14. Ground Control Module Pin Connections 3 of 3

3121298

– JLG Lift –

6-51

SECTION 6 - JLG CONTROL SYSTEM



"
 




 



"
#
%
&
(
)
+
,
.

"
#
%
&
(
)
+
,
".
"
""
"#
"%
"&
"(
")
"+
",
#.
#
#"
##
#%
#&

 
 
/!1 -! 
- ! $1$' - $*
 
*!$$$  !
 !/ !
-* $1$' $$$ !
 $  !
/6 !/ !
! ' -! !
&.. / ! !1 !
... / ! !1 !
- ! $1$' !
!  !
$  * 
 !
   !  !
!' 
- $!/ !
  *  !
  !
3%  - !
#3%  - !
3"  - !
 - !$ 
!!17 
!!17 
!!17 0
!!17 0
/!1 -! 
/!1 -! 
/!1 -! 
/!1 -! 
$* 
  - !

 



"
#
%
&
(
)
+
,
.

"
#
%
&
(
)
+
,
".
"
""
"#
"%
"&
"(
")
"+
",
#.
#
#"
##
#%
#&

   
   
 $  
 $  
'! $  
'! $  
! ' !  *
! ' !  
! ' - 
! ' - 
/ 
/ 
$  '
' 
  $!
!0!1 
!/ $ $
! $ $
$* 
 
 
 
- ! $1$' ! !/
 
 
 
 
 $  -!- * *  
2 '
$  * -
*! 3 !  *
*
 '
!4  $
$  '
'   -! 
$  '
'

 


 !
 !
*$  !
*$  !
!'
!'
!'
!'
!'
!'
!'
!'
!'
!'
!'
!'
!'

!'
!'
!'
!'
!'
!'

!!

 !
 !
/!1
/!1
/!1
/!1
/!1
!'

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
-! 
-! 
-! 
-! 
-! 
 


 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !

 !
 !
 !
 !
/!1
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
 !
5)
 !

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
-! 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
-! 
 



Figure 6-15. Platform Control Module Pin Connections 1 of 2

6-52

– JLG Lift –

3121298

SECTION 6 - JLG CONTROL SYSTEM






.
$& &%(



/
$ %&'(



#
$ %&'(




*
+
.
/
#


  4 )" -)"0 ) - !
"   !
"  )"!
)" )"!
)"  !
 
"  4 )" -)"0 
 

 




*
+
.
/
#


" 4 ) -)"0 ) - !
"  !
" )"!
) )"!
)  
) ",
" 4 ) -)"0 
 

 


 
  
!  )

!  )   
*
)", $ " !  )",( 
+
. ! )", 
/ " 0 "" )", 
# )  , "" )", 
)", )"!

1 !  )"!
2 3#   !
 !  "  
 !  "  
*  
+  
. !    !
/ !  
# " 0 "" )",
 )  , "" )",
1 !  !!
2 !! 
  
  
*  
+  
.  
/  
#  
  
1  
*2 ! 
* ! ,",
* ! ),"
**  
*+  
*.  





 
 
 



 !

 
" 


) ""!
""!
""!
""!
""!



!
" 
" 
" 
" 
" 
" 
" 


) ""!
""!
""!
""!
""!



!
" 
" 
" 
" 
" 
" 
" 


""!
""!
""!
!!!!""!
""!
3#
!!
!!
!!

3#

,) ""!
,) ""!
!

""!
""!


 ""!
 ""!
 ""!
 ""!

""!
""!
""!
 ""!
 ""!


" 
 
 
!
!
!
!
" 
" 
!
" 
" 
" 
" 
!
" 
" 
" 
 
" 
 
 
" 
" 
 
 
 
 
" 
 
 
 
 
 
" 



Figure 6-16. Platform Control Module Pin Connections 2 of 2

3121298

– JLG Lift –

6-53

SECTION 6 - JLG CONTROL SYSTEM

NOTES:

6-54

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS
7.1

GENERAL

Polarity

This section contains basic electrical information and schematics for locating and correcting most electrical problems. If
a problem develops which is not presented in this section or
corrected by listed corrective actions, obtain technically qualified guidance before proceeding with any additional maintenance.

Getting a negative Voltage or current reading when expecting
a positive reading frequently means the leads are reversed.
Check what reading is expected, location of the signal and
leads are correctly connected to the device under test. Also
check the lead on the "COM" port goes to the ground or negative side of the signal and lead on the other port goes to the
positive side of the signal.

Scale

NOTE: Some procedures/connectors shown in this section may
not apply to all models.

M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)

7.2 MULTIMETER BASICS

m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM) can
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM
may vary. Please consult the meter operator’s manual for more
information.

μ = micro = (Displayed Number) / 1,000,000
Example: 1.2 k = 1200 
Example: 50 mA = 0.05 A

Voltage Measurement

Grounding
"Grounding the meter" means to take the black lead (which is
connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the Voltage source.

Backprobing
To "backprobe" means to take the measurement by accessing
a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connector such that the test also checks both terminals of the connection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector.

Min/Max

Figure 7-1. Voltage Measurement (DC)
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads

"Min/Max" recording feature of some meters can help when
taking measurements of intermittent conditions while alone.
For example, you can read voltage applied to a solenoid when
it is only operational while a switch, far from the solenoid and
meter, is held down.

3121298

– JLG Lift –

7-1

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Resistance Measurement

Continuity Measurement

Figure 7-3. Continuity Measurement
• Some meters require a separate button press to enable
audible continuity testing
• Circuit power must be turned OFF before testing continuity

Figure 7-2. Resistance Measurement
• First test meter and leads by touching leads together.
Resistance should read a short circuit (very low resistance)
• Circuit power must be turned OFF before testing resistance

• Disconnect component from circuit before testing
• Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity

• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads

7-2

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

• To prevent oxidation at mechanical joint between male
and female pins.

Current Measurement

• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. This procedure applies to
all plug connections not enclosed in a box. Silicone grease
should not be applied to connectors with external seals.
1.

To prevent oxidation, silicone grease must be packed
completely around male and female pins on the inside
of the connector prior to assembly. This is most easily
achieved by using a syringe.

NOTE: Over a period of time, oxidation increases electrical resistance at the connection, eventually causing circuit failure.
2.

To prevent shorting, silicone grease must be packed
around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connectors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.

NOTE: This condition is especially common when machines are
pressure washed since the washing solution is much more
conductive than water.

Figure 7-4. Current Measurement (DC)
• Set up meter for expected current range

3.

• Be sure to connect meter leads to correct jacks for
selected current range
• If meter is not auto ranging, set it to correct range (See
multi meter’s operation manual)

Anderson connectors for battery boxes and battery
chargers should have silicone grease applied to contacts
only.

NOTE: Curing-type sealants can also be used to prevent shorting
and would be less messy, but make future pin removal difficult.

• Use firm contact with meter leads

7.3

APPLYING SILICONE DIELECTRIC COMPOUND
TO ELECTRICAL CONNECTIONS

NOTE: This section is not applicable for battery terminals.

When applied to electrical connections, dielectric grease helps
prevent corrosion of electrical contacts and improper conductivity between contacts from moisture intrusion. Open and
sealed connectors benefit from application of dielectric
grease.
Dielectric grease shall be applied to all electrical connectors at
the time of connection (except those noted under Exclusions).

JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATERIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
NOTE: Do NOT apply dielectric grease to the following connections:
• Main Boom Rotary sensor connections (on Celesco Sensor),
• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical
connections except for those mentioned above for the following reasons:

3121298

– JLG Lift –

7-3

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Dielectric Grease Application

AMP Seal

Before following these instructions, refer to excluded connector types (See Exclusions below).
1.

Use dielectric grease in a tube for larger connection
points or apply with a syringe for small connectors.

2.

Apply dielectric grease to the female contact (fill it
approximately ½ full; see example below)

3.

Leave a thin layer of dielectric grease on connector face.

4.

Assemble connector system immediately to prevent
moisture or dust contamination

5.

Pierce one of the unused wire seals before assembly if
the connector system tends to trap air (i.e. AMP Seal)
and then install a seal plug.

The AMP Seal connector system is used on Control ADE Platform and Ground Modules.
Apply dielectric grease to the female contact. If trapped air
prevents connector from latching, pierce one of the unused
wire seals.





 
 
   
   
   

Figure 7-7. Dielectric Grease On Female Contacts

 

After assembly, install a seal plug (JLG #4460905) to keep out
moisture. Seal plugs may also be installed by the wire harness
manufacturer if an unused wire seal was damaged during
assembly.

Figure 7-5. Applying Dielectric Grease

Deutsch HD, DT, DTM, DRC Series
The Deutsch connector system is commonly used for harsh
environments. Follow installation instructions.

Figure 7-8. Seal Plugs

Figure 7-6. Deutsch Connector

7-4

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

BRAD HARRISON/PHOENIX CONTACT M12

AMP Mate-N-Lok

This connector uses gold contact material to resist corrosion
and an O-ring seal for moisture integrity. Low-force contacts
cannot displace dielectric grease to achieve electrical contact.
Once contaminated, replacement of female contacts is
required. The JLG Load Sensing System and 1250AJP Rotary
Angle Sensors are examples of components with the M12 connector system.

Follow manufacturer installation instructions.

Figure 7-9. AMP Mate-N-Lok Connector

DIN Connectors
This connector is typically used on hydraulic valves. Follow
manufacturer installation instructions.

Figure 7-11. Brad Harrison/Phoenix Connectors

AMP JUNIOR TIMER
This type of connector uses back-seals to keep out moisture.
Low-force contacts cannot displace dielectric grease and create electrical contact. Use solvents (i.e. contact cleaner or mineral spirits) to remove dielectric grease. The Deutz EMR2
engine control module uses this connector.

Figure 7-10. DIN Connector

Exclusions
Some connectors do not require or may be permanently damaged by application of dielectric grease. Dielectric grease may
not be required in properly sealed enclosures.

DO NOT USE DIELECTRIC GREASE ON BRAD HARRISON/PHOENIX CONTACT
M12 OR AMP JUNIOR TIMER CONNECTORS. LOW-FORCE CONTACTS CANNOT
DISPLACE DIELECTRIC GREASE AND CREATE ELECTRICAL CONTACT.

3121298

– JLG Lift –

Figure 7-12. AMP Junior Timer

7-5

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.4 AMP CONNECTOR

Connector Assembly

Plug and header assembly colors are mechanically keyed to
mate only with identical colors.

1.




 





Check wedge lock is in the open, or as-shipped, position.







   

  








 






Figure 7-13. AMP Connector
Figure 7-15. AMP Connector Assembly

Contact Assembly
1.

Strip wire and install in crimp end of connector as
shown in Figure 7-14.

2.

Crimp connector. Do not damage cutoff tab.

2.

Push contact straight into circuit cavity as far as it will go.

3.

Pull on contact wire with a force of 1 - 2 lb to be sure
retention fingers are holding contact.






  

    

 

   




    
  

Figure 7-16. AMP Contact Installation

  



Figure 7-14. AMP Contact Assembly

7-6

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

4.

After all contacts are inserted, close wedge lock to its
locked position. Release locking latches by squeezing
them inward.

NOTE: Wedge lock should never be removed from housing for
insertion or removal of contacts.





 
 
  

Figure 7-17. Close Wedge Lock
5.

Slide wedge lock in housing until flush with housing.

 

 
 

Figure 7-19. AMP Connector Disassembly

Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.

Service - Voltage Reading
Figure 7-18. Seating Wedge Lock
HOLES IN WIRE INSULATION CAN LET IN MOISTURE AND CAUSE SYSTEM FAILURE. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

Disassembly
1.

Insert a 4.8 mm (3/16") wide screwdriver blade between
mating seal and one of red wedge lock tabs.

2.

Pry wedge lock open.

3.

While rotating wire back and forth over a half turn (1/4
turn in each direction), gently pull wire until contact is
removed.

3121298

It has been common practice in electrical troubleshooting to
probe wires by piercing insulation with a sharp point. This
practice should be discouraged when dealing with an
AMPSEAL plug assembly or any other sealed connector system. Resulting pinholes in the insulation allows moisture to
enter by traveling along wire strands and could result in system failure.

– JLG Lift –

7-7

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.5 DEUTSCH CONNECTORS

DT/DTP Series Disassembly

DT/DTP Series Assembly
1.

Grasp crimped contact (1) about 25mm behind contact
barrel.

2.

Hold connector with rear grommet (2) facing you.

3.

Push contact straight into connector grommet (3) until a
click is felt. A slight tug confirms it is locked in place.

4.

1.

Remove wedgelock (1) using needle-nose pliers or a
hook shaped wire to pull wedge straight out.

2.

To remove contacts, gently pull wire backwards at the
same time releasing the locking finger (2) by moving it
away from contact with a screwdriver.

3.

Hold rear seal (3) in place. Removing contact may displace seal.

Once all contacts are in place, insert wedgelock (4) with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. They may go in either way.

NOTE: Receptacle shown - use same procedure for plug.

1

1

2

2

3
Figure 7-21. DT/DTP Contact Removal
3

4

Figure 7-20. DT/DTP Contact Installation

7-8

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

HD30/HDP20 Series Assembly

HD30/HDP20 Series Disassembly

1.

Grasp contact (1) about 25mm behind contact crimp
barrel.

1.

With rear insert toward you, snap appropriate size
extractor tool (1) over wire of contact to be removed.

2.

Hold connector with rear grommet (2) facing you.

2.

Push tool in the insert cavity (2) until it engages contact
and resistance is felt.

1

2
1

Figure 7-22. HD/HDP Contact Installation
3.

2

Figure 7-24. HD/HDP Contact Removal

Push contact straight into connector grommet until a
positive stop is felt. A slight tug will confirm it is locked
in place.

3.

Pull contact-wire assembly out of connector

NOTE: Do Not twist or insert tool at an angle.

Figure 7-23. HD/HDP Locking Contacts Into Position

Figure 7-25. HD/HDP Unlocking Contacts

NOTE: Insert sealing plugs in unused wire cavities for full environmental sealing.

3121298

– JLG Lift –

7-9

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-26. Electrical Components 1 of 2

7-10

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-27. Electrical Components 2 of 2

3121298

– JLG Lift –

7-11

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 2

Figure 7-28. Platform and Ground Control Electrical Schematic - 1 of 2

7-12

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 2

Figure 7-29. Platform and Ground Control Electrical Schematic - 2 of 2

3121298

– JLG Lift –

7-13

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 3

Figure 7-30. Generator Wiring Schematic 1 of 2

7-14

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 3

Figure 7-31. Generator Wiring Schematic 2 of 2

3121298

– JLG Lift –

7-15

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 5

Figure 7-32. Deutz Engine Harness Electrical Schematic

7-16

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 5

Figure 7-33. GM/PSI Engine Harness Electrical Schematic

3121298

– JLG Lift –

7-17

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 6

Figure 7-34. Deutz Tier 4 Final Engine Harness Electrical Schematic

7-18

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001110345D - Sheet 6

Figure 7-35. Deutz Tier 4 Final Engine Harness Electrical Schematic

3121298

– JLG Lift –

7-19

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792605D - Sheet 1

Figure 7-36. Hydraulic Schematic

7-20

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792605D - Sheet 1

Figure 7-37. Hydraulic Schematic

3121298

– JLG Lift –

7-21

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792605D - Sheet 3

Figure 7-38. Hydraulic Schematic 2-Wheel Drive - 1 of 2

7-22

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792605D - Sheet 3

Figure 7-39. Hydraulic Schematic 2-Wheel Drive - 2 of 2

3121298

– JLG Lift –

7-23

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792605D - Sheet 4

Figure 7-40. Hydraulic Schematic 4-Wheel Drive - 1 of 2

7-24

– JLG Lift –

3121298

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

2792605D - Sheet 4

Figure 7-41. Hydraulic Schematic 4-Wheel Drive - 2 of 2

3121298

– JLG Lift –

7-25

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

7-26

– JLG Lift –

3121298

Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417

JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
+61 2 65 811111
+61 2 65813058
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+55 19 3295 0407

JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England

+55 19 3295 1025

+44 (0)161 654 1000
+44 (0)161 654 1001

JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong

JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy

(852) 2639 5783

+39 029 359 5210
+39 029 359 5845

(852) 2639 5797

+33 (0)5 53 88 31 70
+33 (0)5 53 88 31 79

Oshkosh-JLG Singapore
Technology Equipment Pte Ltd
29 Tuas Ave 4,
Jurong Industrial Estate
Singapore, 639379
+65-6591 9030
+65-6591 9031

Plataformas Elevadoras 
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain
+34 93 772 4700
+34 93 771 1762

JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France

JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0)850 659 500
+46 (0)850 659 534

www.jlg.com



---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.6
Linearized                      : Yes
Encryption                      : Standard V2.3 (128-bit)
User Access                     : Print, Extract
Author                          : DFORD
Create Date                     : 2014:02:26 07:41:48Z
Modify Date                     : 2014:02:26 14:10:29-05:00
Tagged PDF                      : Yes
XMP Toolkit                     : Adobe XMP Core 4.2.1-c043 52.372728, 2009/01/18-15:08:04
Creator Tool                    : FrameMaker 10.0.2
Metadata Date                   : 2014:02:26 14:10:29-05:00
Format                          : application/pdf
Title                           : 1298.book
Creator                         : DFORD
Producer                        : Acrobat Distiller 9.3.0 (Windows)
Document ID                     : uuid:6438f20e-dcc2-4c60-8041-f40f7db5a28c
Instance ID                     : uuid:b282f35b-dced-4ba2-ad70-8da17fb51632
Page Mode                       : UseOutlines
Page Count                      : 328

EXIF Metadata provided by EXIF.tools