JLG 1500SJ Service Maintenance Manual

Service and Maintenance Manual
Model
1500SJ
P/N - 3121262
March 7, 2016
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 FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
possible injury to themselves or others, or damage to the SAFETY VIOLATION.
equipment. A maintenance program must be followed to
ensure that the machine is safe to operate.
• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
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 ELEC-
TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
The specific precautions to be observed during maintenance SECURE AT ALL OTHER TIMES.
are inserted at the appropriate point in the manual. These pre-
cautions are, for the most part, those that apply when servic- • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
ing hydraulic and larger machine component parts. FORMING ANY MAINTENANCE.
Your safety, and that of others, is the first consideration when • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
engaging in the maintenance of equipment. Always be con- TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
scious of weight. Never attempt to move heavy parts without CAUGHT ON OR ENTANGLED IN EQUIPMENT.
the aid of a mechanical device. Do not allow heavy objects to
rest in an unstable position. When raising a portion of the • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
equipment, ensure that adequate support is provided. MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING

SURFACES AND HAND HOLDS.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL- • USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL-
ITY OF THE OWNER/OPERATOR. ANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

B HYDRAULIC SYSTEM SAFETY BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
It should be noted that the machines hydraulic systems oper- HAS BEEN ENGAGED.
ate at extremely high potentially dangerous pressures. Every
effort should be made to relieve any system pressure prior to • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-
disconnecting or removing any portion of the system. FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
POWER CONTROLS.
Do not use your hand to check for leaks. Use a piece of card-
board or paper to search for leaks. Wear gloves to help protect • BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING
hands from spraying fluid. REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS

STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

VENTS.
3121262 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
Original Issue - September 12, 2011

Revised - November 9, 2011
Revised - March 26, 2012
Revised - May 16, 2012
Revised - January 10, 2013
Revised - February 20, 2013
Revised - May 22, 2013
Revised - September 30, 2015
Revised - March 7, 2016
A-2 – JLG Lift – 3121262

TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do the Following When Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3121262 – JLG Lift – i

TABLE OF CONTENTS

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Extending Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Axle Limit Switch Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Drive/Steering Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.7 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.8 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Swing Envelope Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.9 Oscillating Axle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.10 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.11 Drive Hub - Bonfiglioli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hydraulic Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Installation of the Wheel Drive on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Start Up and Running In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Connecting the Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Filling-up the Gearbox with Lubricating Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Gearbox Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Changing the Lubricating oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disassembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Inspection of Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Final Test and Reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.12 Drive Hub - Reggiana Riduttori. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Symbol Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.13 Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Motor and Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Hub-Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Hub-Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
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3.14 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3.15 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Disassembly and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.16 Procedure For Setting Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.17 Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.18 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Turntable/Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Turntable/Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119
3.19 Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3.20 Chassis Tilt Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3.21 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
3.22 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3.23 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Changing the Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
Cleaning the Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.24 Deutz EMR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.25 Bio Fuel in Deutz Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
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3.26 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
List of Abbreviations in this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
CAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
MIL Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
DTC 117- ECT/CHT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
DTC 122- TPS1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153
DTC 123- TPS1 Signal Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
DTC 217- ECT Higher Than Expected 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
DTC 219- RPM Higher Than Max Allowed Governed Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-158
DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
DTC 337- Loss of Crank Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
DTC 521- Oil Pressure Sender/Switch High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162
DTC 524- Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
DTC 562- Battery Voltage (VBat) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165
DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-167
DTC 601- Microprocessor Failure - FLASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-169
DTC 604- Microprocessor Failure - RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-171
DTC 606- Microprocessor Failure - COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173
DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175
DTC 643- 5 Volt External High Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-176
DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177
DTC 1615- Microprocessor Failure - A/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-182
DTC 1616- Microprocessor Failure - interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-184
DTC 1625- CAN J1939 Shutdown Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-186
DTC 1626- CAN J1939 Transmit (Tx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-187
DTC 1627- CAN J1939 Receive (Rx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-188
DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-189
DTC 1629- J1939 TSC1 Message Reciept Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-191
DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-192
DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193
DTC 2112- Unable to Reach Higher TPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-195
DTC 9999- Throttle Actuator Failsafe Spring Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-196
DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-197
3.27 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198
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SECTION 4 - BOOM & PLATFORM
4.1 Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Broken Cable Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Beyond Transport - Drive Speed Cutback System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drive/Steer – Boom Function Interlock System (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Jib Stow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Envelope Tracking System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Moment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom Control System (BCS) Functional Check (Push to Test) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2 Boom/Jib System Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Main Lift/Jib Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Jib Leveling During Automatic/Manual Envelope Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Jib Lift Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Telescope Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Swing Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Swing Stow Sequence (Jib Pin Unlock). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Jib Swing Deploy Sequence (Jib Pin Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Jib Lock Pin Lamp Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Swing/Axle Extend Retract Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Dual Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Jib Control During Over/Under Moment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Boom Recovery Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.3 Boom Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.4 Boom Disassembly/Assembly & Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.5 Load Sensing Pin Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4.6 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4.7 Boom Lubrication Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4.8 Platform Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4.9 Jib Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4.10 Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
4.11 Jib Straight Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4.12 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.13 Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.14 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
One Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Two Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.15 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Eight Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4.16 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
3121262 – JLG Lift – v

TABLE OF CONTENTS

Boom Section Re-Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4.17 Broken Boom Cable Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Adjusting the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
4.18 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
4.19 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Greasing Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Installing Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Testing the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
4.20 Jib Rotator Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS
5.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tapered Thread Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Tube and Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straight Thread Types, Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Flange Connection Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Tightening Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Assembly And Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections.. . . . . . . . 5-6
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections. . . . . . . . . . . . 5-7
Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assembly Instructions for 45° SAE Flare Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . . . . . . . . . . . . . . . . . . . 5-15
Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends . . . . . . . . . . . . . . . . . . . . . 5-34
Assembly instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Assembly Instructions for Flange Connections: (FL61 and FL62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
FFWR and TFFT Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.3 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Axle Extension Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Jib Level Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Platform Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Jib Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Jib Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
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Jib Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Main Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
5.4 Cylinder Length Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
5.5 Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
5.6 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
Set Up of the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-117
Adjustments made at the Main Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118
Adjustments Made at the Frame Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118
Adjustments Made at the Platform Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-123
Adjustments Made at the Jib Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
5.7 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-130
Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133
Mechanical Centering of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
Hydraulic Centering of Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-134
High Pressure Relief Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
Removal and inspection of charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-136
Removal and Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-138
5.8 Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
Sealing the Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
Disassembly and Assembly of the Complete Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-141
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-144
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
Pump Control Disassembly For Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-147
5.9 Drive & Function Pump Start Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-149
Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-149
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SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2 Machine Personality Settings and Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.3 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Test Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.6 Control System Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Sensor #1 - Moment Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Sensor #2 - Main Boom Angle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Sensor #3 - Main Boom Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Sensor #4 - Main Boom Cylinder Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Sensor #5 - Main Boom Transport Length Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Sensor #6 - Jib Level Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Sensor #7 - Jib Lock Pin Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Sensor #8 - Jib Stow Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Sensor #9 - Jib Lift Cylinder Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Sensor #10 - Dual Capacity / Jib Transport Length Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Sensor #11 - Platform Level Cylinder Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Sensor #12 - Platform Level Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Sensor #13 - Rotary Turntable Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6.7 Jib Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6.8 CAN Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6.9 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6.10 Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
6.11 Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
6.12 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Platform Leveling Fault Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Fault Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6.13 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
STEP 1: SETTING THE PLATFORM VALVE MINIMUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
STEP 2: BLEEDING THE PLATFORM VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS . . . . . . . . . . . . . 6-70
6.14 Calibrating Lift Crack Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
6.15 Calibrating Telescope Crack point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
6.16 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
6.17 Jib Sensor Calibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Calibrating the Jib Level Up and Down Valve Crackpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
6.18 Calibrating the Boom Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Boom Control System Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
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SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 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
7.3 Applying Silicone Dielectric Compound to Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Installation of Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
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TABLE OF CONTENTS
This page left blank intentionally.
x – JLG Lift – 3121262

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-2. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
2-1. Engine Operating Temperature Specifications - Deutz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2. Engine Operating Temperature Specifications - Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1. Axle Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Conventional Two Wheel Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Crab Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Coordinated Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-5. Chassis Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-6. Chassis Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-7. Turntable Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-8. Turntable Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-9. Oscillating Axle - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-10. Oscillating Axle - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-11. Axle Loctite Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-12. Steering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-13. Drive Hub Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-14. Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-15. Gearbox engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-16. Gearbox Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-17. Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-18. Drive Hub Special Tools - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-22. Bearing Track Spacer Mounting C016117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3-23. Oil Seal Spacer Mounting C125049 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3-24. Bearing Spacer Mounting CO16117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3-25. Assembly Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3-26. Wrench For Ring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-27. Anti-rotation Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-28. Anti-rotation Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-29. Anti-rotation Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3-30. Assembly Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3-31. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-32. Reggiana Riduttori Hub - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-33. Reggiana Riduttori Hub - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
3-34. Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3-35. Swing Drive - Motor Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3-36. Swing Drive - Motor and Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3-37. Swing Drive - Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-38. Swing Drive - Hub Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-39. Swing Drive - Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-40. Swing Drive - Hub Shaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3-41. Swing Drive - Carrier Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3-42. Swing Drive - Carrier Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3-43. Swing Drive - Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3-44. Swing Drive - Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3-45. Swing Drive - Motor Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3-46. Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3-47. Swing Brake 8 Spring Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3-48. Swing Brake 12 Spring Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3121262 – JLG Lift – xi

LIST OF FIGURES

3-49. Swing Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3-50. Swing Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3-51. Swing Drive Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3-52. Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3-53. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3-54. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
3-55. Swing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
3-56. Swing Bearing Removal - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
3-60. Swing Bearing Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
3-61. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123
3-62. Auxiliary Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
3-63. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3-64. Engine Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
3-65. EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
3-66. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
3-67. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
3-68. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
3-69. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
3-70. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
3-71. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
3-72. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-136
3-77. 1st page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
3-78. 2nd Page of Diagnostic Information for a Given Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
3-79. Counterweight Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-198
4-1. Boom Component Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2. Boom Component Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-2. Boom Assembly - Sheet 1 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-7. Boom Assembly Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4-8. Locations for Threadlocker Application - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4-12. Load Pin Removal Tool, JLG P/N 4846765. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4-13. Jib Assembly - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4-16. Jib Straight Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4-17. Powertrack Hosing - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
4-20. Torque Sequence for Fly Extend Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4-21. Wire Rope Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4-22. Outer Mid Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
4-23. Fly Boom Extend/Retract Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
xii – JLG Lift – 3121262

LIST OF FIGURES

4-24. Wire Rope Adjustment Tools (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
4-25. Broken Boom Cable Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
4-26. Actuator Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
4-27. Rotary Actuator - Assembly Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
4-28. Rotary Actuator - Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
4-29. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102
4-30. JIb Rotator Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
4-31. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
5-1. NPTF Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2. BSPT Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-3. JIC Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-4. SAE Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-5. ORFS Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-6. MTBL-MBTS Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-7. Bulkhead Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-8. ORB-MPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-9. MFF-BSPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-10. ORB-MPP Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-11. Torque Wrench Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-12. Double Wrench Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-13. FFWR Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5-14. Adjustable Stud End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-15. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-16. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-17. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-18. Axle Extension Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5-19. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5-20. Composite Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-21. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-22. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-23. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-24. Installation of Head Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-25. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-26. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-27. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5-28. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5-32. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5-41. Hydrolock Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5-42. Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5-47. Jib Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
3121262 – JLG Lift – xiii

LIST OF FIGURES

5-50. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-51. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-52. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-53. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-54. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-55. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5-56. Hydrolock Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-57. Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-59. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-60. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-61. Platform Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5-62. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5-75. Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
5-90. Jib Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5-102. Jib Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
xiv – JLG Lift – 3121262

LIST OF FIGURES

5-107. Cylinder Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
5-109. Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5-114. Jib Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
5-115. Jib Telescope Cylinder Head Gland Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5-116. Jib Telescope Piston Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5-120. Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98
5-131. Cylinder Length Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103
5-132. Platform Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
5-133. Platform Valve Torque and Resistance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5-134. Platform Valve Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
5-135. Jib Control Valve Identification - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
5-136. Jib Control Valve Identification - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110
5-137. Jib Control Valve Torque and Resistance Specifications - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
5-138. Jib Control Valve Torque and Resistance Specifications - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5-139. Jib Control Valve Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
5-140. Main Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
5-141. Main Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5-141. Oil Sampling Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116
5-142. Steer Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120
5-143. Function Pump - Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139
5-144. Function Pump, Pressure and Flow Control - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-146
5-147. Hydraulic Schematic - Sheet 1 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-152
5-156. Hydraulic Schematic - Sheet 10 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-161
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Control System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-3. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-4. Analyzer Flow Chart - Personalities (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6-6. Analyzer Flow Chart - Calibrations (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
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LIST OF FIGURES

6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-10. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-11. Ground Control Module - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6-14. Chassis Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6-15. BLAM Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-16. Jib Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6-17. Analyzer Connecting Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-18. Control System Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-19. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
6-20. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
6-21. Boom Sensor Calibration Position 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
6-30. Boom Sensor Calibration Position 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
6-31. Fault Code Light Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. Application to Female Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-7. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-8. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-12. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-13. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-14. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-15. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-16. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-17. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-18. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-19. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-20. Jib Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-21. Chassis Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-22. Chassis Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-23. Turntable Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-24. Turntable Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7-25. Console Box Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-26. Console Box Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-27. Platform Valve Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-28. Platform Valve Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7-29. Jib Valve Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-32. Boom Length and Angle Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
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7-33. Boom Length and Angle Harness - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7-34. Main Terminal Box Harness - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7-38. Turntable Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7-41. Pump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7-42. Chassis Harness - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7-45. Ground Control Box Wiring Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-46. Ground Control Box Wiring Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7-47. Electrical Schematic - Sheet 1 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7-56. Electrical Schematic - Sheet 10 of 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
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LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-5 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-6 Caterpillar 3.4T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-9 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-10 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-11 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-12 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-13 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-14 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2 Steering Assembly Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-2 Brake Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-3 Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade . . . . . . . . . . . . . . . . . . . . . . 3-19
3-4 Drive Hub Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-6 J1939 Diagnostic Lamp Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147
4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
5-1 NPTF Pipe Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-2 BSPT Pipe Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-3 37° Flare (JIC)Thread - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-4 37° Flare (JIC)Thread - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-5 45° Flare (SAE) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6 45° Flare (SAE) - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7 O-ring Face Seal (ORFS) - Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-8 O-ring Face Seal (ORFS) - Aluminum/Brass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-9 DIN 24°Cone (MBTL & MBTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-10 Bulkhead Fittings (BH) - INCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-11 Bulkhead Fittings (BH) - METRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-12 O-ring Boss (ORB) - Table 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-18 Metric Flat Face Port (MFF) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-21 Metric Flat Face Port (MFF) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-22 Metric Flat Face Port (MFF) - S Series - Table 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-24 Metric Pipe Parallel O-Ring Boss (MPP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
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5-25 British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-28 British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-31 Flange Code (FL61 & FL62) -Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-32 Flange Code (FL61 & FL62) - Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-33 Platform Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5-2 Fitting Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
5-33 Platform Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
5-4 Fitting Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
5-5 Cartridge Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
5-6 Torque Specs for Relief Valves into Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135
5-7 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
6-1 Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-3 Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-4 Machine Personality Settings and Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-6 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6-7 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
6-8 Diagnostic Trouble Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
3121262 – JLG Lift – xix

LIST OF TABLES
xx – JLG Lift – 3121262

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA
Table 1-1. Operating Specifications Table 1-2. Dimensional Data
Capacity - ANSI Turning Radius (Axles Retracted)

Unrestricted 500 lbs (227 kg) Outside 22 ft. 6 in. (6.8 m)
Restricted 1000 lbs (454 kg) Inside 14 ft. 5 in. (4.4 m)
Capacity - CE & Australia Turning Radius (Axles Extended)

Unrestricted 500 lbs (230 kg) Inside 8 ft. (2.4 m)
Restricted 1000 lbs (450 kg) Outside 19 ft. 4 in. (5.9 m)
Maximum Travel Grade, stowed 40% Machine Height (stowed) 9 ft. 11 in. (3.04 m)
Position (Gradeability)
Machine Length (stowed) 61 ft. 8-5/8 in. (18.81 m)
Maximum Travel Grade, stowed 5%
Position (Side Slope) Platform Height
Unrestricted Capacity 150 ft. 1 in. (45.75 m)
Maximum Drive Speed 3.0 mph (4.8 kph) Restricted Capacity 130 ft. 2 in. (39.67 m)
Gross Machine Weight - Approximate 48000 lbs. (21772 kg) Horizontal Reach from centerline of rota-
tion
Ground Bearing Pressure - Maximum 113 psi (7.94 kgcm2) Unrestricted Capacity 80 ft. (24.38 m)
Restricted Capacity 64 ft. 11 in. (19.79 m)
Maximum Wind Speed 28 mph (12.5 m/s)
Horizontal Reach over end
Maximum Manual Force 400 N Unrestricted Capacity 72 ft. 4 in. (24.38 m)
Maximum System Voltage 12 volts
Horizontal Reach over side
Maximum Main Relief Hyd. Pressure 4600 psi (317 Bar)
Unrestricted Capacity 73 ft. 9 in. (22.48 m)
Overall Width
Axles Retracted 8ft. 2in. (2.49 m)
Axles Extended 12ft. 6in. (3.8 m)
Wheelbase 12ft. 6in. (3.81 m)
Tailswing 5ft. 5-7/8 in. (1.6 m)
Ground Clearance (Axle) 12 in. (30.4 cm)
Ground Clearance (Chassis) 25.5 in. (64.7 cm)
3121262 – JLG Lift – 1-1

1.3 CAPACITIES 1.5 ENGINE DATA

Table 1-3. Capacities
Deutz
Hydraulic Oil Tank 55 gal. (208 L) Table 1-5. Deutz TD2011L4 Specifications
Fuel Tank - Standard 31 gal. (117 L) Type Liquid Cooled
Fuel Tank - Optional 52.8 gal. (200 L) Number of Cylinders 4
Bore 3.7 in. (94 mm)
Drive Hub
Stroke 4.4 in. (112 mm)
Bonfiglioli 2.1 quarts (2 liters) ± 10%
Reggiana Riduttori 0.5 quarts (0.5 liters) ± 10% Total Displacement 190 cu. in. (3108 cm3)
Compression Ratio 17.5:1
Firing Order 1-3-4-2
1.4 TIRES
Output 75hp (56 kW)
Table 1-4. Tire Specifications Oil Capacity
Cooling System 5 Quarts (4.5 L)
Size 445/50D710
w/Filter 11 Quarts (10.5 L)
Load Range J Total Capacity 16 Quarts (15 L)
Ply Rating 18 Average Fuel Consumption 1.2 gph (4.1 lph)
Foam Fill Polyurethane HD (55 Durometer) Foam Idle Engine RPM 1200
Diameter 46.45 in. (117.9 cm) Mid Engine RPM 1800
Width 18 in. (45.7 cm) High Engine RPM 2475
Rim Size 15x28
Tire & Wheel Weight 867 lbs. (393 kg)
Max Tire Load 28600 lbs. (12973 kg) Caterpillar
Size 445/65-24 Table 1-6. Caterpillar 3.4T
Type Solid Type Liquid Cooled, Antifreeze
Diameter 45.3 in. (115.1 cm) Number of Cylinders 4
Width 17.3 in. (43.9 cm) Bore 3.7 in. (94 mm)
Rim Size 12.00-24 Stroke 4.7 in. (120 mm)
Tire & Wheel Weight 960 lbs. (435.4 kg) Total Displacement 201 cu. in. (3294 cm3)
Max Tire Load 28600 lbs. (12973 kg) Compression Ratio 19.5:1
Firing Order 1-3-4-2
Output 73.7hp (55 kW)
Oil Capacity 10.5 Quarts (10 L)
Average Fuel Consumption 1.36 gph (5.14 lph)
Idle Engine RPM 1200
Mid Engine RPM 1800
High Engine RPM 2475
1-2 – JLG Lift – 3121262

1.6 HYDRAULIC OIL

Table 1-9. Mobil DTE 13M Specs
Table 1-7. Hydraulic Oil ISO Viscosity Grade #32

Specific Gravity 0.877
Hydraulic System
S.A.E. Viscosity Pour Point, Max -40°F (-40°C)
Operating
Grade
Temperature Range Flash Point, Min. 330°F (166°C)
+0° to + 180° F 10W Viscosity
(-18° to +83° C) at 40° C 33cSt
+0° to + 210° F 10W-20, 10W30 at 100° C 6.6 cSt
(-18° to +99° C)
at 100° F 169 SUS
+50° to + 210° F 20W-20
(+10° to +99° C at 210° F 48 SUS
cp at -20° F 6,200
NOTE: Hydraulic oils require anti-wear qualities at least API Ser- Viscosity Index 140
vice Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service.
Table 1-10. UCon Hydrolube HP-5046
NOTE: Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not con- Type Synthetic Biodegradable
tain the same required additives or be of comparable vis- Specific Gravity 1.082
cosities. If use of hydraulic oil other than Mobil 424 is Pour Point, Max -58°F (-50°C)
desired, contact JLG Industries for proper recommenda-
pH 9.1
tions.
Viscosity
Table 1-8. Mobilfluid 424 Specs at 0° C (32° F) 340 cSt (1600SUS)
at 40° C (104° F) 46 cSt (215SUS)
SAE Grade 10W30
at 65° C (150° F) 22 cSt (106SUS)
Gravity, API 29.0 Viscosity Index 170
Density, Lb/Gal. 60°F 7.35
Pour Point, Max -46°F (-43°C)
Flash Point, Min. 442°F (228°C)
Viscosity
Brookfield, cP at -18°C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
3121262 – JLG Lift – 1-3

1.7 MAJOR COMPONENT WEIGHTS

Table 1-11. Mobil EAL H 46 Specs
Type Synthetic Biodegradable

ISO Viscosity Grade 46 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT
Specific Gravity .910 WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT-
FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Pour Point -44°F (-42°C)
Flash Point 500°F (260°C) Table 1-13. Component Weights
Operating Temp. 0 to 180°F (-17 to 162°C) Components LBS. KG.

Weight 7.64 lb. per gal.
(0.9 kg per liter) Counterweight 9500 4309
Viscosity Tire and Wheel 867 393
at 40° C 45 cSt
Drive Hub & Motor 275.5 123
at 100° C 8.0 cSt
Viscosity Index 153 Swing Drive 290 132
Engine Assembly 1275 579

Table 1-12. Exxon Univis HVI 26 Specs
Complete Boom (including jib) 20,650 9370
Specific Gravity 32.1
Pour Point -76°F (-60°C) Platform 36 x 96 245 111
Flash Point 217°F (103°C) Platform 36 x 72 195 89

Viscosity
Axle Extension Cylinder 92 42
at 40° C 25.8 cSt
at 100° C 9.3 cSt Axle Lockout Cylinder 74 33.75
Viscosity Index 376 Jib Level Cylinder 148.5 67.5
NOTE: Mobil/Exxon recommends that this oil be
Platform Level 76 34
checked on a yearly basis for viscosity.
Boom Lift Cylinder 787 357
Jib Lift Cylinder 186 84
Jib Lock Cylinder 21 9.5
Steer Cylinder 49 22
Jib Telescope Cylinder 130.5 59
Boom Telescope Cylinder 1432 650
1-4 – JLG Lift – 3121262

13
16
14
5
4
4
7 10,11
8
9,12
15
2,3
1
4 4
16
Figure 1-1. Maintenance and Lubrication Diagram
3121262 – JLG Lift – 1-5

1.8 OPERATOR MAINTENANCE 2. Swing Gearbox
NOTE: The following numbers correspond to those in Figure 1-1.,

Maintenance and Lubrication Diagram.
Table 1-14. 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-L-2104. Diesel - API
CC/CD class, MIL-L-2104B/MIL-L-2104C
Lube Point(s) - Fill Plug
Capacity - 79 ounces (2.3 L)
Lube - GL-5
Interval - Check level every 150 hrs/Change every
1200 hours of operation. Fill to cover ring gear.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-
MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ 3. Swing Brake
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.
1. Swing Bearing - Remote Lube
Lube Point(s) - Fill Plug

Capacity - 2.7 ounces (80 ml)
Lube - DTE24
Lube Point(s) - 2 Grease Fitting Interval - Check level every 150 hrs/Change every
Capacity - A/R 1200 hours of operation.
Lube - MPG
Interval - Every 3 months or 150 hours of operation
1-6 – JLG Lift – 3121262

4. A. Wheel Drive Hub - Bonfiglioli 5. Hydraulic Return Filter
Lube Point(s) - Replaceable Element

Lube Point(s) - Level/Fill Plug Interval - Change after first 50 hours and every 300
Capacity - 2.1 quarts (2 liters) ± 10% hours thereafter or as indicated by condition
Lube - EPGL indicator
Interval - Change after first 150 hours then every 1200 6. Hydraulic Charge Filter
hours of operation
Comments - Place Fill port at 12 o’clock position and
Check port at 8 o’clock position. Pour lubricant into
fill port until it just starts to flow out of check port.
B: Wheel Drive Hub - Reggiana Riduttori

Interval - Change after first 50 hours and every 300
hours thereafter or as indicated by condition
indicator.
Lube Point(s) - Level/Fill Plug

Capacity - 0.5 quarts (0.5 liters) ± 10%
Lube - EPGL
Interval - Change after first 150 hours then every 1200
hours of operation
Comments - Place Fill port at 12 o’clock position and
Check port at 3 o’clock position. Pour lubricant into
fill port until it just starts to flow out of check port.
3121262 – JLG Lift – 1-7

7. Hydraulic Oil 9. Oil Change w/Filter - Deutz
FULL LEVEL (HOT OIL)
FULL LEVEL (COLD OIL)
Lube Point(s) - Fill Cap/Spin-on Element

Capacity -
5 Quarts (4.5 L) Cooling System
11 Quarts (10.5 L) w/Filter
Lube Point(s) - Fill Cap 16 Quarts (15 L) Total Capacity
Capacity - 55 gallons (208 liters) Tank Lube - EO
Lube - HO
Interval - Check level daily. Change every 2 years or Interval - Check level daily; change every 500 hours or
1200 hours of operation. six months, whichever comes first. Adjust final oil level
by mark on dipstick. Refer to Figure 1-2., Deutz Engine
8. Suction Strainers (In Tank) Dipstick.
MINIMUM OIL
LEVEL
MAXIMUM OIL
LEVEL
MINIMUM LEVEL,
OIL HOT
MAXIMUM LEVEL,
OIL HOT
Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation.
Remove and clean at time of hydraulic oil MINIMUM LEVEL,
OIL COLD
change. MAXIMUM LEVEL,
OIL COLD
NOTE: Hot oil checks should not be made until the engine
has been shut down for a period of 5 minutes.
Figure 1-2. Deutz Engine Dipstick
1-8 – JLG Lift – 3121262

10. Fuel Filter - Deutz 12. Oil Change w/Filter - CAT

Interval - Every year or 600 hours of operation Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 10.5 Quarts (10 L)
11. Fuel Strainer - Deutz Lube - EO
Interval - Check level daily; change every 150 hours or
three months, whichever comes first. Adjust final oil
level by mark on dipstick.
13. Fuel Filter - CAT

Interval - Every year or 600 hours of operation
3121262 – JLG Lift – 1-9

14. Air Filter 16. Boom

Lube Point(s) - Apply to wear pad contact paths
Lube - Super Lube®
Interval - Every year or 600 hours of operation. Refer to
the Section 4 - Boom for detailed procedures

Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator
15. Platform Filter

Interval - Change after first 50 hours and then every year
or 600 hours of operation thereafter
1-10 – JLG Lift – 3121262

Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-3. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
3121262 – JLG Lift – 1-11

To rqu e
Torqu e
Torq ue
Tor que
Torq ue
1-12 – JLG Lift – 3121262

Torq ue
Tor que
Torqu e
Cl amp L oa d
Torq ue
To rqu e
To rque
3121262 – JLG Lift – 1-13

To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
Figure 1-6. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
1-14 – JLG Lift – 3121262

To rq ue
To rqu e
To rqu e
Tor qu e
To rqu e
Torq ue
Figure 1-7. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
3121262 – JLG Lift – 1-15

NOTES:
1-16 – JLG Lift – 3121262

SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND inspections. Reference the appropriate areas of this manual for
servicing and maintenance procedures.
MAINTENANCE
General Annual Machine Inspection
This section provides the necessary information needed by The Annual Machine Inspection must be performed on an
those personnel that are responsible to place the machine in annual basis, no later than thirteen (13) months from the date
operation readiness and maintain its safe operating condition. of the prior Annual Machine Inspection. JLG Industries recom-
For maximum service life and safe operation, ensure that all mends this task be performed by a Factory-Trained Service
the necessary inspections and maintenance have been com- Technician. JLG Industries, Inc. recognizes a Factory-Trained
pleted before placing the machine into service. Service Technician as a person who has successfully com-
pleted the JLG Service Training School for the subject JLG
Preparation, Inspection, and Maintenance product model. Reference the machine Service and Mainte-
It is important to establish and conform to a comprehensive nance Manual and appropriate JLG inspection form for perfor-
inspection and preventive maintenance program. The follow- mance of this inspection.
ing table outlines the periodic machine inspections and main-
tenance recommended by JLG Industries, Inc. Consult your Reference the JLG Annual Machine Inspection Form and the
national, regional, or local regulations for further requirements Inspection and Preventive Maintenance Schedule for items
for aerial work platforms. The frequency of inspections and requiring inspection during the performance of this inspec-
maintenance must be increased as environment, severity and tion. Reference the appropriate areas of this manual for servic-
frequency of usage requires. ing and maintenance procedures.
Pre-Start Inspection For the purpose of receiving safety-related bulletins, it is

important that JLG Industries, Inc. has updated ownership
It is the User’s or Operator’s primary responsibility to perform a
information for each machine. When performing each Annual
Pre-Start Inspection of the machine prior to use daily or at
each change of operator. Reference the Operator’s and Safety Machine Inspection, notify JLG Industries, Inc. of the current
Manual for completion procedures for the Pre-Start Inspec- machine ownership.
tion. The Operator and Safety Manual must be read in its
entirety and understood prior to performing the Pre-Start Preventive Maintenance
Inspection.
In conjunction with the specified inspections, maintenance
Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
The Pre-Delivery Inspection and Frequent Inspection shall be
performed by a qualified JLG equipment mechanic. JLG Indus- mechanic as a person who, by possession of a recognized
tries, Inc. recognizes a qualified JLG equipment mechanic as a degree, certificate, extensive knowledge, training, or experi-
person who, by possession of a recognized degree, certificate, ence, has successfully demonstrated the ability and profi-
extensive knowledge, training, or experience, has successfully ciency to service, repair, and maintain the subject JLG product
demonstrated the ability and proficiency to service, repair, and model.
maintain the subject JLG product model.
Reference the Preventive Maintenance Schedule and the
The Pre-Delivery Inspection and Frequent Inspection proce-
appropriate areas of this manual for servicing and mainte-
dures are performed in the same manner, but at different
times. The Pre-Delivery Inspection shall be performed prior to nance procedures. The frequency of service and maintenance
each sale, lease, or rental delivery. The Frequent Inspection must be increased as environment, severity and frequency of
shall be accomplished for each machine in service for 3 usage requires.
months or 150 hours (whichever comes first); out of service for
a period of more than 3 months; or when purchased used. The
frequency of this inspection must be increased as environ-
ment, severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection Form

and the Inspection and Preventive Maintenance Schedule for
items requiring inspection during the performance of these
3121262 – JLG Lift – 2-1

SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual
At each Operator change.
Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.
Annual Machine Inspec- Annually, no later than 13 months from the date of Owner, Dealer, or User Factory-Trained Service Service and Maintenance Manual
tion the prior inspection. Technician and applicable JLG inspection form.
(Recommended)
Preventive At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.
2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are disconnected,
clear adjacent areas as well as the openings and fittings
themselves. As soon as a line or component is discon-
General nected, cap or cover all openings to prevent entry of for-
The following information is provided to assist you in the use eign matter.
and application of servicing and maintenance procedures
contained in this book. 3. Clean and inspect all parts during servicing or mainte-
nance, and assure that all passages and openings are
unobstructed. Cover all parts to keep them clean. Be
Safety and Workmanship sure all parts are clean before they are installed. New
parts should remain in their containers until they are
Your safety, and that of others, is the first consideration when
ready to be used.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without
the aid of a mechanical device. Do not allow heavy objects to Components Removal and Installation
rest in an unstable position. When raising a portion of the
equipment, ensure that adequate support is provided. 1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
Cleanliness cables, etc.) should be parallel to each other and as near
perpendicular as possible to top of part being lifted.
1. The most important single item in preserving the long
service life of a machine is to keep dirt and foreign mate- 2. Should it be necessary to remove a component on an
rials out of the vital components. Precautions have been angle, keep in mind that the capacity of an eyebolt or
taken to safeguard against this. Shields, covers, seals, similar bracket lessens, as the angle between the sup-
and filters are provided to keep air, fuel, and oil supplies porting structure and the component becomes less
clean; however, these items must be maintained on a than 90 degrees.
scheduled basis in order to function properly.
3. If a part resists removal, check to see whether all nuts,
bolts, cables, brackets, wiring, etc., have been removed
and that no adjacent parts are interfering.
2-2 – JLG Lift – 3121262

SECTION 2 - GENERAL
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the
text, standard torque values should be used on heat-
When disassembling or reassembling a component, complete treated bolts, studs, and steel nuts, in accordance with
the procedural steps in sequence. Do not partially disassemble recommended shop practices. (See Torque Chart Sec-
or assemble one part, then start on another. Always recheck tion 1.)
your work to assure that nothing has been overlooked. Do not
make any adjustments, other than those recommended, with- Hydraulic Lines and Electrical Wiring
out obtaining proper approval.
Clearly mark or tag hydraulic lines and electrical wiring, as well
Pressure-Fit Parts as their receptacles, when disconnecting or removing them
from the unit. This will assure that they are correctly rein-
When assembling pressure-fit parts, use a molybdenum disul- stalled.
fide base compound or equivalent to lubricate the mating sur-
face. Hydraulic System
Bearings 1. Keep the system clean. If evidence of metal or rubber
particles are found in the hydraulic system, drain and
1. When a bearing is removed, cover it to keep out dirt and flush the entire system.
abrasives. Clean bearings in nonflammable cleaning sol-
2. Disassemble and reassemble parts on clean work sur-
vent and allow to drip dry. Compressed air can be used
face. Clean all metal parts with non-flammable cleaning
but do not spin the bearing.
solvent. Lubricate components, as required, to aid
2. Discard bearings if the races and balls (or rollers) are pit- assembly.
ted, scored, or burned.
Lubrication
3. If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap Service applicable components with the amount, type, and
reusable or new bearings until they are ready to install. grade of lubricant recommended in this manual, at the speci-
fied intervals. When recommended lubricants are not avail-
4. Lubricate new or used serviceable bearings before
able, consult your local supplier for an equivalent that meets
installation. When pressing a bearing into a retainer or
or exceeds the specifications listed.
bore, apply pressure to the outer race. If the bearing is to
be installed on a shaft, apply pressure to the inner race.
Battery
Gaskets Clean battery using a non-metallic brush and a solution of
Check that holes in gaskets align with openings in the mating baking soda and water. Rinse with clean water. After cleaning,
parts. If it becomes necessary to hand-fabricate a gasket, use thoroughly dry battery and coat terminals with an anti corro-
gasket material or stock of equivalent material and thickness. sion compound.
Be sure to cut holes in the right location, as blank gaskets can
cause serious system damage. Lubrication and Servicing
Components and assemblies requiring lubrication and servic-
Bolt Usage and Torque Application ing are shown in the Lubrication Chart in Section 1.
2.3 LUBRICATION AND INFORMATION

SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL. Hydraulic System
1. Always use new replacement hardware when installing 1. The primary enemy of a hydraulic system is contamina-
locking fasteners. Use bolts of proper length. A bolt tion. Contaminants enter the system by various means,
which is too long will bottom before the head is tight e.g., using inadequate hydraulic oil, allowing moisture,
against its related part. If a bolt is too short, there will grease, filings, sealing components, sand, etc., to enter
not be enough thread area to engage and hold the part when performing maintenance, or by permitting the
properly. When replacing bolts, use only those having pump to cavitate due to insufficient system warm-up or
the same specifications of the original, or one which is leaks in the pump supply (suction) lines.
equivalent.
3121262 – JLG Lift – 2-3

SECTION 2 - GENERAL
2. The design and manufacturing tolerances of the compo- Changing Hydraulic Oil
nent working parts are very close, therefore, even the
smallest amount of dirt or foreign matter entering a sys- 1. Filter elements must be changed after the first 50 hours
tem can cause wear or damage to the components and of operation and every 300 hours (unless specified oth-
generally results in faulty operation. Every precaution erwise) thereafter. If it is necessary to change the oil, use
must be taken to keep hydraulic oil clean, including only those oils meeting or exceeding the specifications
reserve oil in storage. Hydraulic system filters should be appearing in this manual. If unable to obtain the same
checked, cleaned, and/or replaced as necessary, at the type of oil supplied with the machine, consult local sup-
specified intervals required in the Lubrication Chart in plier for assistance in selecting the proper equivalent.
Section 1. Always examine filters for evidence of metal Avoid mixing petroleum and synthetic base oils.
particles.
2. Use every precaution to keep the hydraulic oil clean. If
3. Cloudy oils indicate a high moisture content which per- the oil must be poured from the original container into
mits organic growth, resulting in oxidation or corrosion. another, be sure to clean all possible contaminants from
the service container. Always clean the mesh element of
If this condition occurs, the system must be drained,
the filter and replace the cartridge any time the system
flushed, and refilled with clean oil.
oil is changed.
4. It is not advisable to mix oils of different brands or types, 3. While the unit is shut down, a good preventive mainte-
as they may not contain the same required additives or nance measure is to make a thorough inspection of all
be of comparable viscosities. Good grade mineral oils, hydraulic components, lines, fittings, etc., as well as a
with viscosities suited to the ambient temperatures in functional check of each system, before placing the
which the machine is operating, are recommended for machine back in service.
use.
Lubrication Specifications
NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing components. Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however, multi-pur-
pose greases usually have the qualities which meet a variety of
Hydraulic Oil single purpose grease requirements. Should any question
arise, regarding the use of greases in maintenance stock, con-
1. Refer to Section 1 for recommendations for viscosity
sult your local supplier for evaluation. Refer to Section 1 for an
ranges. explanation of the lubricant key designations appearing in the
Lubrication Chart.
2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured using
the following methods.
Platform Drift
Measure the drift of the platform to the ground. Lower booms
(if equipped) slightly elevated, main boom fully extended with
the rated load in the platform and power off. Maximum allow-
able drift is 2 inches (5 cm) in 10 minutes. If the machine does
not pass this test, proceed with the following.
2-4 – JLG Lift – 3121262

SECTION 2 - GENERAL
Cylinder Drift 4. Re-assembly of pinned joints using filament wound

bearings.
Table 2-2. Cylinder Drift a. Housing should be blown out to remove all dirt and
debris...bearings and bearing housings must be free
Max. Acceptable Drift
Cylinder Bore Diameter of all contamination.
in 10 Minutes
b. Bearing / pins should be cleaned with a solvent to
inches mm inches mm remove all grease and oil...filament wound bearing
3 76.2 0.026 0.66 are a dry joint and should not be lubricated unless
3.5 89 0.019 0.48 otherwise instructed (i.e. sheave pins).
4 101.6 0.015 0.38 c. Pins should be inspected to ensure it is free of burrs,
nicks, and scratches which would damage the bear-
5 127 0.009 0.22 ing during installation and operation.
6 152.4 0.006 0.15
7 177.8 0.005 0.13 2.6 WELDING ON JLG EQUIPMENT
8 203.2 0.0038 0.10 NOTE: This instruction applies to repairs, or modifications to the
9 228.6 0.0030 0.08 machine and to welding performed from the machine on
an external structure, or component,
Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temperature Do the Following When Welding on JLG Equipment
and temperature stabilized.
• Disconnect the battery.
The cylinder must have the normal load, which is the normal • Disconnect the moment pin connection (where fitted)
platform load applied.
• Ground only to structure being welded.
If the cylinder passes this test, it is acceptable.
Do NOT Do the Following When Welding on JLG
NOTE: This information is based on 6 drops per minute cylinder Equipment
leakage.
• Ground on frame and weld on any other area than the
2.5 PINS AND COMPOSITE BEARING REPAIR chassis.
GUIDELINES • Ground on turntable and weld on any other area than the
turntable.
Filament wound bearings. • Ground on the platform/support and weld on any other
1. Pinned joints should be disassembled and inspected if area than the platform/support.
the following occurs: • Ground on a specific boom section and weld on any other
area than that specific boom section.
a. Excessive sloppiness in joints.
b. Noise originating from the joint during operation. • Allow pins, wear pads, wire ropes, bearings, gearing, seals,
valves, electrical wiring, or hoses to be between the
2. Filament wound bearings should be replaced if any of grounding position and the welded area.
the following is observed:
a. Frayed or separated fibers on the liner surface.
FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COM-
b. Cracked or damaged liner backing.
PONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
c. Bearings that have moved or spun in their housing. RING, BOOM WIRE ROPES ETC.)
d. Debris embedded in liner surface.
3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inspection):
a. Detectable wear in the bearing area.
b. Flaking, pealing, scoring, or scratches on the pin sur-
face.
c. Rusting of the pin in the bearing area.
3121262 – JLG Lift – 2-5

SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Weekly Monthly Pre-Delivery2 Annual4 Every 2

Preventive Preventive or Frequent3 (Yearly) Years
Maintenance Maintenance Inspection Inspection
Boom Assembly
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 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
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Boom Assembly 14
Platform Assembly
Platform 1,2
Railing 1 1,2
Gate 5 1 1,5
Floor 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly
Tires 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15 15
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 11 11
2-6 – JLG Lift – 3121262

SECTION 2 - GENERAL
INTERVAL

Functions/Controls
Platform Controls 5 6 6
Ground Controls 5 6 6
Function Control Locks, Guards, or Detents 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
Power System
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 2 1,5 1,5
Hydraulic/Electric System
Hydraulic Pumps 1,9 1,2,9
Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2
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 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 1 20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operation and Safety Manuals in Storage Box 21 21
ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only) 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
3121262 – JLG Lift – 2-7

SECTION 2 - GENERAL
INTERVAL

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
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 – 3121262

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
SUMMER
GRADE 70 F(21 C)
ENGINE FUEL
60 F(16 C)
SPECIFICATIONS 50 F(10 C)
40 F(4 C)
30 F(-1 C)
WINTER 20 F(-7 C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10 F(-12 C)
FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10 F(-23 C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20 F(-29 C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR
KEROSENE -30 F(-34 C)
GLOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER) ADDED
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
EXTENDED DRIVING WITH HYDRAULIC OIL TANK

TEMPERATURES OF 180°F (82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE
120° F (49° C)
NO OPERATION ABOVE THIS PROLONGED OPERATION IN NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F (38°C) OR ABOVE. 1) RECOMMENDATIONSAREFORAMBIENTTEMPERATURES
100° F (38° C)
CONSISTANTLYWITHIN SHOWN LIMITS
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C) 2) ALLVALUESAREASSUMED TO BEATSEA LEVEL.
EXXON UNIVIS HVI 26
70° F (21° C)
SUMMER-GRADE WINTER-GRADE
60° F (16° C) FUEL FUEL
50° F (10° C) HYDRAULIC F C
MOBIL DTE 13
SPECIFICATIONS + 32 0
40° F (4° C)
30° F (-1° C)
AMBIENTTEMPERATURE
+ 23 -5
20° F (-7° C)
10° F (-12° C) + 14 -10
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424 +5 -15
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) -4 -20
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -13 -25
-40° F (-40° C)
AMBIENT TEMPERATURE -22 -30
0 10 20 30 40 50 60
% OFADDED KEROSENE
4150548 E
Figure 2-1. Engine Operating Temperature Specifications - Deutz
3121262 – JLG Lift – 2-9

SECTION 2 - GENERAL
AMBIENT AIR
TEMPERATURE
120 F(49 C)
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
30 F(-1 C)
20 F(-7 C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10 F(-12 C)
FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE
EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE
OIL COOLER (CONSULT JLG SERVICE
120° F (49° C) PROLONGED OPERATION IN

110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F (38°C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26
70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC
SPECIFICATIONS
MOBIL DTE 13
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) NOTE:
DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS
-30° F (-34° C) AND COLD WEATHERHYDRAULIC OIL BELOW THIS TEMPERATURE 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
-40° F (-40° C) CONSISTENTLY WITHIN SHOWN LIMITS
AMBIENT TEMPERATURE 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
4150548 E
Figure 2-2. Engine Operating Temperature Specifications - Caterpillar
2-10 – JLG Lift – 3121262

SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES AND WHEELS ers. If you do not have a torque wrench, tighten the fasteners
with a lug wrench, then immediately have a service garage or
Tire Inflation dealer tighten the lug nuts to the proper torque. Over-tighten-
ing will result in breaking the studs or permanently deforming
The air pressure for pneumatic tires must be equal to the air
the mounting stud holes in the wheels.
pressure that is stenciled on the side of the JLG product or rim
decal for safe and proper operational characteristics. The proper procedure for attaching wheels is as follows:
Tire Damage 1. Start all nuts by hand to prevent cross threading. DO

For pneumatic tires, JLG Industries, Inc. recommends that NOT use a lubricant on threads or nuts.
when any cut, rip, or tear is discovered that exposes sidewall or
tread area cords in the tire, measures must be taken to remove 2. Tighten nuts in the following sequence:
the JLG product from service immediately. Arrangements
must be made for replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. recom-

mends that when any of the following are discovered, mea-
sures must be taken to remove the JLG product from service
immediately and arrangements must be made for replace-
ment of the tire or tire assembly.
• a smooth, even cut through the cord plies which exceeds 3

inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies which
exceeds 1 inch (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter
• any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the

tire must be inspected on a daily basis to insure the damage
hasn’t propagated beyond the allowable criteria.
Wheel and Tire Replacement

The rims installed on each product model have been designed 3. The tightening of the nuts should be done in stages. Fol-
for stability requirements which consist of track width, tire lowing the recommended sequence, tighten nuts per
pressure, and load capacity. Size changes such as rim width, wheel torque chart.
center piece location, larger or smaller diameter, etc., without
written factory recommendations, may result in an unsafe
condition regarding stability.
Table 3-1. Wheel Torque Chart
Wheel Installation TORQUE SEQUENCE

It is extremely important to apply and maintain proper wheel 1st Stage 2nd Stage 3rd Stage
mounting torque. 45 ft. lbs. 100 ft. lbs. 180 ft. lbs.
(60 Nm) (140 Nm) (252 Nm)
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE

4. Wheel nuts should be torqued before first road use and
TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS
after each wheel removal. Check and torque every 3
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS
months or 150 hours of operation.
MATCHED TO THE CONE ANGLE OF THE WHEEL.
Tighten the lug nuts to the proper torque to prevent wheels
from coming loose. Use a torque wrench to tighten the fasten-
3121262 – JLG Lift – 3-1

3.2 EXTENDING AXLES control system will automatically reduce the wheel angle to 25
degrees during axle retraction.
NOTE: The boom must be oriented between the rear wheels to NOTE: For more detailed information concerning system adjust-
extend or retract the axles. ment and operation, refer to Section 6 - JLG Control Sys-
tem.
The Axle Extension System allows each of the four axles to be
extended and retracted together while maintaining full steer-
ing control as the machine is driven. The system allows the 3.3 AXLE LIMIT SWITCH ADJUSTMENT PROCEDURE
axles to extend or retract only while the boom is in the trans-
1. Fully extend the axles.
port position and in order to minimize wheel scrubbing during
axle movement, a minimum drive speed must be attained 2. Initially position the limit switch arm straight.
before axle extension/retraction will be permitted. The system
3. Select the mounting plate bolt pattern to position the
uses four limit switches (one at each axle) to sense when the
switch roller within 0.125 inches (3.1 mm) from the edge
axles are fully extended. If any of the switches are not made,
of the axle cutout. It may be necessary to reposition the
the control system considers the axles retracted. To extend/
switch arm ±10° to accomplish this.
retract the axles, the user engages the axle extend/retract
switch on the platform console and the drive control at the 4. Ensure the arm will clear the axle (without bottoming
same time. The axle set indicator will be off when the axles are out to 70° stroke of the switch) in the retracted position.
not fully extended and the axle extend/retract switch is not
engaged. It will flash while the axles are extending or retract- 5. Check for proper operation. Axle set light is to deacti-
ing and will be on constantly when the axles are fully vate when the axle is retracted 0.625 inches (16 mm)
extended. With the axles not fully extended, the boom is maximum from fully extended.
restricted to operation within the transport position. If a signal
from any axle extend sensing switch is lost when the boom
beyond the transport position, the axle set indicator will flash
and drive/steer functions will be disabled until the boom is
brought back into the transport position. The steering angle
will be automatically limited to +/- 25 degrees anytime the
axles are not fully extended. If the wheel angle is more than +/
- 25 degrees when the axle retract command is engaged, the
Figure 3-1. Axle Limit Switch Adjustment
3-2 – JLG Lift – 3121262

3.4 DRIVE SYSTEM

The drive system utilizes 2 traction pumps so each side is pow-
ered individually. This produces maximum tractive effort to
wheels by minimizing flow divider losses. The maximum drive
speed is modulated with the steered angle of the wheels to
eliminate the whiplash effect of driving at full speed and maxi-
mum steering lock.
3.5 STEERING CONTROL SYSTEM

Each wheel is individually steered by means of a closed circuit
control system utilizing a steer sensor on each wheel, 4 steer
Figure 3-4. Coordinated Steer Mode
cylinders, and proportional valves.
Each wheel has its own steer cylinder, wheel angle sensor, and
The control system senses the wheel position in relation to the proportional valve, allowing the control system to position
steering command (direction and steering mode) and auto- each wheel to the ideal angle for all steering modes and all
matically synchronizes the movement of all 4 wheels to the steering commands. Changes in steering modes while the
desired position. footswitch is depressed causes the wheels to automatically
adjust to the appropriate angle for the selected steering mode
There are three different modes of steering selectable by the
based on the position of the inside front wheel. If the steer
position of the steer select switch on the platform control
select switch is changed without the footswitch depressed or
panel: conventional two wheel steering, crab and coordinated.
the EMS is off, the wheels will not move until the footswitch is
These are shown below.
depressed and a steering or drive command has been initi-
ated. The steering angles are limited to +/- 25 degrees anytime
the axles are not fully extended. If a wheel cannot achieve its
commanded angle within a specified time, it is considered
jammed. When a wheel is considered jammed during steering,
a fault is reported and the remaining wheels will continue to
their commanded position. The fault is cleared when the foot-
switch is cycled. If a wheel is jammed making it significantly
out of position, with regard to the other wheels, the drive
motors are restricted to their maximum displacement (slow
speed). Wheel angle sensor failures will result in an approxi-
mated steering control logic that will allow the operator to
move the machine until it can be repaired. The wheel at the
failed sensor will be driven based on the information available
Figure 3-2. Conventional Two Wheel Steer Mode from the other sensors. This wheel will not track perfectly and
will become farther out of position over time. When the wheel
becomes prohibitively out of position, the wheels can be re
synchronized by fully steering against the mechanical stops.
NOTE: For more detailed information concerning system adjust-

ment and operation, refer to Section 6 - JLG Control Sys-
tem.
Figure 3-3. Crab Steer Mode
3121262 – JLG Lift – 3-3

3.6 DRIVE/STEERING SPEED CONTROL enabled, the DOS indicator will be illuminated continuously
and a 3-second enable timer will be started and will continue
The Drive/Steering Speed Control system uses the steering for 3 seconds after the end the last drive/steer command. If the
sensors from the steering control system to increase operator timer expires, the DOS override switch must be re-engaged to
control and comfort by reducing the effect of turning the enable drive/steer.
chassis on the resulting lateral platform speed. The system
proportionally varies the drive speed based on the predicted Swing Envelope Service Mode
turning radius of the chassis for both coordinated and conven-
tional two wheel steer modes. The tighter the turn the slower NOTE: If the axles are in the retracted position, boom swing is
the allowable drive speed. As crab steer does not steer on a restricted to between the rear wheels (40 degrees).
radius, full drive speed is maintained regardless of steer angle.
The Swing Envelope Service Mode is used if the boom is
NOTE: For more detailed information concerning system adjust- swung past the rear tires with the axles retracted, there is a dis-
ment and operation, refer to Section 6 - JLG Control Sys- agreement fault between the DOS proximity switch and the
tem. turntable angle sensors, or there is a failed turntable angle
sensor. (Drive and swing are disabled during these events.)
This allows swing and drive functions to enable turntable
3.7 TRACTION CONTROL SYSTEM swing in the correct direction to return the boom between the
The traction control system uses the steering sensors from the rear wheels in the event the boom is beyond the swing enve-
steering control system to optimize the performance of the lope when the axles are retracted.
drive system. This is especially important due to the disparity Swing Envelope override is accessible in Access Level 1. Using
of wheel speeds generated between the inside and outside
wheels of the extended axle chassis with large steering angle
capability. The steering sensors are used to predict the rolling the Left and Right arrow keys until the screen
path and therefore the required wheel speed of each wheel as shown below is reached.
the steering angles change and steering modes change. The
control system can then command the ideal flow from each of
the two drive pumps, one for the right side of the machine and
one for he left side. Two flow dividers, one for the right side
front to back and one for the left side front to back absorb the
variation in wheel speed front to back.

tem.
3.8 DRIVE ORIENTATION SYSTEM

The Drive Orientation System (DOS) is intended to indicate to
the operator conditions that could make the direction of
movement of the chassis different than the direction of move-
ment of the drive/steer control handle. The system indicates to
the operator the need to match the black and white direc-
tional arrows on the platform control panel to the arrows on
the chassis. The system uses a proximity switch mounted on
the hydraulic swivel, an indicator light and an override switch
on the platform display panel. The proximity switch trips when
the turntable is swung +/- 40 degrees off center of the normal
driving position. This occurs roughly when the boom is swung
past a rear tire. When the turntable is in the normal drive posi-
tion with the boom between the rear tires, no indications or
interlocks are made. When the machine is actively driving
when the turntable is swung past the switch point, the system
is ignored until drive/steer is released. When drive is initiated
with the boom swung past the switch point, the DOS indicator
will flash and the drive/steer functions will be disabled. The
operator must engage the DOS override switch to enable
Drive/steer (high drive will remain disabled). When the DOS is
3-4 – JLG Lift – 3121262

Press ENTER , the screen should read: Use the Left or Right arrow key until you see:
To enable the override mode 58237 must be entered as the

code. When the code is entered, the screen will show: Press ENTER , the screen should read:
Swing and drive functions can now be used to swing the turn-
table in the correct direction to return the boom between the
rear wheels in the event the boom is beyond the swing enve-
lope when the axles are retracted.

tem.
3121262 – JLG Lift – 3-5

Figure 3-5. Chassis Component Location - Sheet 1 of 2
3-6 – JLG Lift – 3121262

1. Axle Limit Switch (Right Front) 10. Steer Angle Sensor (Left Rear)
2. Steer Angle Sensor (Right Front) 11. Chassis Module
3. Steer Valve (Front) 12. Swivel/Collector Ring
4. Axle Lockout Valve 13. Axle Lockout Pressure Switch
5. Traction Valve 14. Steer Angle Sensor (Left Front)
6. Steer Valve (Rear) 15. Axle Limit Switch (Left Front)
7. Steer Angle Sensor (Right Rear) 16. Brake Valve
8. Axle Limit Switch (Right Rear) 17. Two Speed Valve
9. Axle Limit Switch (Left Rear)
Figure 3-6. Chassis Component Location - Sheet 2 of 2
3121262 – JLG Lift – 3-7

Figure 3-7. Turntable Component Location - Sheet 1 of 2
3-8 – JLG Lift – 3121262

1. Ground Control Box 15. Starter Relay

2. Headlight 16. Glow Plug Relay
3. Deutz EMR2 Module & Diagnostic Connector 17. Swivel
4. 110V / 220V Generator 18. Alarm
5. 110V / 220V Generator Control Box 19. Main Control Valve
6. Alternator 20. Auxiliary Power Pump
7. Throttle Actuator 21. Auxiliary Power Relay
8. Oil Temperature Switch 22. Horn
9. Oil Pressure Switch 23. Head & Tail Light Relay
10. Intake Heaters 24. Ignition Relay
11. In-Head Glow Plugs 25. Lift Cylinder Pivot Pin
12. Engine Speed Sensor 26. Fuel Level Sensor
13. Starter 27. Strobe
14. Drive Pumps 28. Headlight
Figure 3-8. Turntable Component Location - Sheet 2 of 2
3121262 – JLG Lift – 3-9

3
1 DETAIL A
6 * AXLE STOP SHIMMING PROCEDURE:

2 1. ALL FOUR WHEELS OF THE MACHINE SHOULD BE ON A LEVEL
SURFACE WITH THE TURNTABLE SQUARE TO THE FRAME.
2. SHIM AXLE STOPS TO WITHIN THE THICKNESS OF THE THINNEST
SHIM.
DETAIL B
Figure 3-9. Oscillating Axle - Sheet 1 of 2
3-10 – JLG Lift – 3121262

9
3
11,12,B,G
6
11,12,A,G
8
10
11,12,C,G DETAIL A
11,12,D,G
11,12,E,G
11,12,F,G
2
4
A - Assemble to Axle Box Mid Plate; Typical 8 Places
B- Assemble to Top Plate of Axle Boxes; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5 ±0.062 DETAIL B
inches (12.7 ± 1.587 mm) thread engagement.
C - Assemble to Side Plates of Axle Weldments; Typical 16 Places.
D - Assemble to Front and Rear Plates of Axle Boxes; Typical 8 Places.
E - Assemble to Top Plate of Axle Weldment; Typical 4 Places; Torque; Select appropriate bolt to ensure 0.5
±0.062 inches (12.7 ± 1.587 mm) thread engagement.
F - Assemble to Bottom Plate of Axle Box Weldment; Typical 8 Places.
G - See Axle Stop Shimming Procedure on Sheet 1
1. Axle Oscillation Cylinder 5. Axle Pivot Pin 9. Hose Clamp

2. Axle 6. Axle Limit Switch 10. Stop Block
3. Axle Powertrack 7. Axle Stop Pin 11. Wear Pad
4. Extension Cylinder 8. Rubber Pad 12. Shim
Figure 3-10. Oscillating Axle - Sheet 2 of 2
3121262 – JLG Lift – 3-11

Figure 3-11. Axle Loctite Application
3-12 – JLG Lift – 3121262

Table 3-2. Steering Assembly Notes
A Apply JLG Threadlocker P/N 0100011
B Apply JLG Threadlocker P/N 0100019
C Apply Loctite #222
D Preload Torque 100-300 ft. lb. (140-420 Nm)

on Slot Nut
1. Spindle 4. Steer Cylinder Pivot Pin

2. Angle Sensor Assembly 5. King Pin
3. Steer Cylinder 6. Axle
Figure 3-12. Steering Installation
3121262 – JLG Lift – 3-13

3.9 OSCILLATING AXLE SYSTEM 3.10 OSCILLATING AXLE BLEEDING PROCEDURE AND
The oscillating front axle is attached to the frame by a pivot
LOCKOUT TEST
pin, which allows all four wheels to remain on the ground
when traveling on rough terrain. The oscillating axle also Lockout Cylinder Bleeding
incorporates two lockout cylinders connected between the To start the test, the axle must be fully oscillated in one direc-
frame and the axle. The lockout cylinders permit axle oscillation. Start with oscillating the axle so that the left lock-out cyl-
tion when the boom is in the transport position and drive is inder is fully retracted (left front tire up), and the right lock-out
commanded. The lockout cylinders will lock and hold the axle cylinder Is fully extended (right front tire down).
when drive is not commanded or when the boom is outside
the transport position. The cylinders unlock when pilot pres-
sure is applied to the holding valves mounted on the cylinders
and lock when pilot pressure is removed. Pilot pressure is avail- ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CENTERED OVER REAR
able from brake pressure and is controlled by a solenoid oper- AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE. MAKING SURE MACHINE
IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED, BRAKE WIRE IS
ated NC lockout valve mounted in the frame. To ensure the
DISCONNECTED.
lockout valve is functioning correctly, a NO pressure switch is
mounted between the lockout valve and the holding valves.
The system is “healthy” when pressure trips the pressure 1. Making sure machine is on a level surface and rear
switch when the lockout valve is commanded to be open and wheels are blocked, machine is in transport mode.
conversely is healthy when the lack of pressure resets the pres-
2. Disengage the drive hubs.
sure switch when the lockout valve is commanded to be
closed. Failures in the oscillating axle system will cause the 3. Use suitable container to catch any residual hydraulic
control system to disallow lift up and telescope out when the fluid, place container under the lockout cylinder.
boom is within the transport position and will disallow drive/
steer, lift up and telescope out when the boom is beyond the 4. With the left lock-out cylinder retracted, open the
bleeder on top of the cylinder, then have an operator
transport position.
from the platform (on high engine) feather drive. Acti-
vate drive fully.
ment and operation, refer to Section 6 - JLG Control Sys- 5. Close the bleeder when there is a steady stream of oil
tem. and not air.
6. With the axle in the same position, go to the right lock-

out cylinder and open the bleeder at the rod end. Acti-
vate drive in the same manner and close when all air has
been purged.
7. Close the bleeder when there is a steady stream of oil

and not air.
8. Oscillate the axle the other direction, left lock-out cylin-

der extended (tire down), right lock-out cylinder
retracted (tire up). Use the same procedure for the
bleeder in the rod end of the left lock-out cylinder, Then
the piston end of the right lock-out cylinder then close.
9. Repeat this process one more time to ensure that all air
has been purged from the system.
10. Perform oscillating axle lockout test.
11. If necessary, repeat steps 1 thru 9.
NOTE: Bleeding of the oscillating axles is an infrequent operation

performed after hydraulic line failure and or lock-out cylin-
der repair.
3-14 – JLG Lift – 3121262

Oscillating Axle Lockout Test 11. Telescope the boom out of the transport position.
The front axles will oscillate when the boom is in the transport 12. Drive machine off of block and ramp back onto the level
position (i.e. when the boom is less than 6° above horizontal surface.
and not extended beyond 12" [30.4 cm] and drive is selected.
13. Have an assistant check to see that right front wheel
remains locked in position off of ground.
14. Retract the boom back in to the transport position. Acti-
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- vate drive and the lockout cylinders should release.
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
SUSPECTED. 15. If lockout cylinders do not function properly, have quali-
fied personnel correct the malfunction prior to any fur-
ther operation.
NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels prior to beginning lockout cylinder
test. The axles must also be fully extended.
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 hydrau-

lic 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. Telescope the boom out of the transport position.
6. Drive machine off of block and ramp back onto the level
surface.
7. Have an assistant check to see that left front wheel

remains locked in position off of ground.
8. Retract the boom back in to the transport position. Acti-

vate drive and the lockout cylinders should release.
9. Place the 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.
3121262 – JLG Lift – 3-15

3.11 DRIVE HUB - BONFIGLIOLI Installation of the Wheel Drive on the Machine
NOTE: Machines may be built with either Bonfiglioli or Reggiana 1. Clean the mating surfaces from oils or paint and fit the
Riduttori wheel drive hubs. See Section 3.12, Drive Hub - wheel drive on the machine frame.
Reggiana Riduttori. Do not use different hubs on the same
2. Attach the gearbox to the machine frame with the
machine.
mounting bolts and torque to 178 ft.lbs. (241 Nm).
Product Identification Start Up and Running In

The identification data of the hub is shown on a name plates on
the hub. Figure 3-13., Drive Hub Identification Plate shows If new hubs are being installed, it is advised to follow the
how the information is displayed. measures given below:
1. Bleed air from every part of the hydraulic and add oil in
The informations stamped on the name plates must always be the tank if necessary.
readable. Use the identification data (at least serial number)
for spare part enquiries, information and service, etc.
THE PRESENCE OF RESIDUAL AIR IN THE HYDRAULIC CIRCUIT WILL BE REC-
Hydraulic Motor Installation OGNIZED BY THE PRESENCE OF FOAM IN THE TANK AND WILL LEAD TO A
The mating areas and the pilot diameter of the gearbox JERKING OF THE MOTOR AS WELL AS EXCESSIVE NOISE COMING FROM THE
where the motor is to be mounted must be clean and without MOTOR AND THE VALVES.
burrs.
2. Start the gearmotor at a low speed and gradually
Before assembling the hydraulic motor, verify by a depth slide increase it after having verified that it is functioning cor-
gauge the correct assembly of the unit checking the axial dis- rectly without any noises or vibrations.
tance as shown in the scheme below as shown in the scheme
below.
1. Fit the O-ring seal, supplied with the gearbox, in its seat DO NOT REACH MAXIMUM PRESSURE UNLESS THE ENTIRE SYSTEM HAS BEEN
in the hydraulic motor, and assemble it to the gearbox FILTERED TO ELIMINATE ANY PARTICLES OF DIRT THAT MAY BE PRESENT.
being careful not to damage the seal already fitted.
NOTE: During the running-in stage follow the steps given
2. Torque the bolts to 63.5 ft.lbs. (86 Nm) torque.
below.
3. Check the correct revolution and direction of rota-

tion.
4. Make sure that the functioning is regular and without

any excessive noises and vibrations.
5. Make sure that the oil temperature does not exceed

values listed previously.
Figure 3-13. Drive Hub Identification Plate
3-16 – JLG Lift – 3121262

After having finished running-in the gearbox, follow the steps Connecting the Brake
given below. The gearbox is fitted with a negative multi disk safety brake
6. Check that there are no oil leaks. If leaks are present, with hydraulic control release (parking brake). For information
fix them before proceeding. regarding the characteristics of the brake refer to the installa-
tion drawing.
7. Check the level of oil in the gearmotor.
Table 3-2. Brake Technical Data
8. It possible that the presence of air in the system
during the first start up could cause the application of Brake Release Pressure 232 psi (16 bar)
the brake to be slowed down. It is advised to Maximum Operating Pressure Brake 725 psi (50 bar)
repeat the application and release functions of the
Braking Torque 195 ft.lbs. (265 Nm) ± 10%
brake to purge air from the brake.
9. Check that there are no other problems in general.
Filling-up the Gearbox with Lubricating Oil
The motor and the gearbox have separate lubrication. The
General Information gearbox is lubricated by oil splashing. The recommended type
The gearbox is designed and built for wheel drive. of oil is SAE 80W/90 or SAE 85W/140 with EP features comply-
ing with MIL-L-2105 C & API GL5. Refer to Table 3-3, Suggested
The unit includes planetary gearbox, 3 stages, rotating hous-
Lubricants According SAE 80W/90 and SAE 85W/140 API GL5
ing type.
Grade.
The illustrations show the parts and the main functions of the
NOTE: During operation the oil temperature must not exceed 185-
gearbox.
194° F (85-90° C) intermittent.
A strict and consistent compliance with the specifications of
this technical manual ensure the minimum operating costs
and a longer unit life.
Photographic documentation and drawings are supplied for
educational purposes, so as to safely and properly carry out
maintenance operations.
Minor deviations from pictures of this manual may appear on
the actual gearbox. However, these discrepancies are not rele-
vant to the main parameters, or maintenance functions.
3121262 – JLG Lift – 3-17

1= M18x1,5..........................Filling, draining and oil level plugs

2= 7/16" - 20 UNF - 2B..........Brake port
Figure 3-14. Hub Assembly
3-18 – JLG Lift – 3121262

Table 3-3. Suggested Lubricants According SAE 80W/90 and SAE 85W/140 API GL5 Grade
Ambient temperature -20°C / +30°C +10°C / +45°C

Oil viscosity SAE 80W/90 SAE 85W/140
Manufacturer Oil Brand
SHELL SPIRAX HD SPIRAX HD
AGIP ROTRA MP ROTRA MP
ARAL GETRIEBEOL HYP GETRIEBEOL HYP
BP-MACH HYPOGEAR EP HYPOGEAR EP
CASTROL HYPOY HYPOY
CHEVRON UNIVERSAL GEAR LUBRICANT UNIVERSAL GEAR LUBRICANT
ELF TRANSELF B TRANSELF B
ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP
I.P. PONTIAX HD PONTIAX HD
MOBIL MOBILUBE HD MOBILUBE HD
TOTAL TRASMISSION TM TRASMISSION TM
NOTE: Do not mix together oils of different brands or characteris- 4. Tighten the fill and level oil plug (B) and let the gearbox
tics. run. After a few minutes, stop and check the oil level.
5. If necessary, refill with lubricant oil. Approximate oil
NOTE: The gearbox is supplied without oil; before putting the
capacity = 2 liters ±10%
gearbox into operation, it is necessary to fill it with oil.
This procedure is undertaken following the indications given

Gearbox Disengagement
below. The gearbox is supplied with mechanical disengagement.
1. Check that the gearbox axis is horizontal. Rotate the

gearbox housing until the drain plug (A) is on the bot-
tom on the vertical axis of the end cover. THE DISENGAGEMENT OPTION MUST BE CONNECTED OR DISCONNECTED ONLY
WHEN THE GEARBOX IS STOPPED ON FLAT GROUND.
2. Unscrew the fill and level oil plug (B).
3. Fill from the hole until the lubricant flows out.
3121262 – JLG Lift – 3-19

3. Take out the cap nut (5).
THE MAX WHEEL SPEED WITH DISENGAGED GEARBOX MUST NOT EXCEED 25
REV/MIN.
4. Turn the cap nut (5) upside down. As result the pin (3)
will be pushed inside in order to permit disengagement
of the gearbox.
Figure 3-15. Gearbox engaged
1. Unscrew the 2 socket head screws M8x16 (4), grade 8.8,

of the end cover (7) with a male hex head wrench.
5. Rotate the cap nut (5).
2. Rotate the cap nut (5).
3-20 – JLG Lift – 3121262

6. Tighten the 2 socket head screws M8x16 (4) with a male Should irregularities in function arise, it will be necessary to
hex head torque wrench at 18.4 ft.lbs. (25 Nm) torque. consult the troubleshooting checklist to find the most ade-
quate solution.
If unsuccessful, it may be necessary to partially or completely

disassemble the gearbox.
Table 3-4. Drive Hub Maintenance Schedule
Inspection Frequency Action

Tightening bolts After the first 50 operating hours Bolt tightening torque
of the gearbox check
Oil level Every 150 operating hours of the Refill oil if necessary
gearbox
1st oil change At 150 operating hours of the Oil replacement
gearbox
Next oil change Every 1200 operating hours Oil replacement
Changing the Lubricating oil

1. Check that the gearbox axis is horizontal. Rotate the
gearbox housing until the drain plug is on the bottom of
the vertical axis of the end cover.
Figure 3-16. Gearbox Disengaged
7. Repeat the above steps to engage the gearbox again.
Operation:
a. Engaged gearbox
At this condition the motion is transmitted from the 2. Unscrew the both plugs (Fill and Drain) and let the oil
hydraulic motor to the gearbox. flow in a large enough container; in order to facilitate
draining the oil must still be warm.
b. Disengaged gearbox
3. Wait a few minutes until all the oil is drained and then
proceed to screw on the plugs.
AT THIS CONDITION THE HYDRAULIC MOTOR AND THE BRAKE ARE DISCON-
NECTED TO THE GEARBOX: THE WHEEL IS IDLE. 4. Proceed with the oil fill-up. Refer to Filling-up the Gear-
box with Lubricating Oil.
Maintenance Information NOTE: Never mix mineral oils with synthetic oils and vice versa.
PERIODIC MAINTENANCE
The gearbox only requires the scheduled maintenance proce-

dures set out by the manufacturer (see Table 3-4).
DO NOT DISPOSE OF THE OIL IN THE NATURAL ENVIRONMENT. BE CAREFUL TO
Good maintenance will ensure an ongoing functioning in time ELIMINATE IT IN COMPLIANCE WITH THE RELATIVE RULES AND REGULATIONS
as well as maximum reliability. THAT GOVERN LOCALLY.
3121262 – JLG Lift – 3-21

Troubleshooting
The following table is provided to help locate problems in the
gearbox.
Table 3-5. Troubleshooting
Symptom Causes Remedies

External oil leakage:
From the lifetime seal a) Lifetime seal damaged a) Replace lifetime seal
From the end cover a) O-ring seal damaged a) Replace O-ring seals
From the plugs a) Plug seal damaged a) Replace plug seal
b) Plugs or screws loose b) Tighten the plugs/screws
Too much noise:
Hydraulic noise (during the slowing down a) Hydraulic circuit malfunctioning a) Verify hydraulic circuit
of the motor speed)
Inside the gearmotor (reductions) a) Internal damage a) Check the gearbox
Other:
Overheating a) Insufficient oil level a) Check the oil level and refill if necessary
b) Hydraulic oil too warm b) Check the hydraulic circuit
c) Brake not fully released c) Check brake release pressure
Parking brake malfunctioning
Insufficient braking torque a) Brake discs worn a) Replace brake disc pack
b) Damaged parts b) Check brake components
Wheel Locked a) Parking brake locked a) Check the complete brake release
b) Mechanical components damaged b) Replace damaged parts
Disassembly Information 2. Making sure that the coupling surfaces are not dam-
aged.
It is also important that this procedure is undertaken in a
workshop that is equipped with the proper tools. As well as 3. Handle with care so as to be sure that there are no risks
normal workshop tools it will be necessary to use special tools for personnel safety and to guarantee the reliability of
that can be made (see special tools attachment) or may be the gearbox.
requested from the manufacturer.
4. Making available a work area that is in line with work
Special Tools: and health safety in the workplace guidelines.
Puller...............................................Code/: 6689960240 Disassembly Procedure

Tool for lifetime seal assembly........Code/: 6689960300
NOTE: Below are all the steps to follow during Disassembly and
Puller for brake disassembly..........Code/: 6689960310 Assembly. Numbers in brackets in the text correspond to
the references in the exploded view.
Torque multiplier............................Code/: ATZ.09.016.0
Initial inspection can be made without disassembling the hub
To be able to produce these special tools refer to Figure 3-18. from the machine. Before wheel drive disassembling, make
thru Figure 3-21. sure that the oil is drained from the hub.
It is important to strictly adhere to all the procedures for disas- Unscrew and remove the nos. 2 screws M12, grade 8,8, and
sembling and reassembling the gearbox. Proceed with these remove the hydraulic motor and its O-ring seal (48).
instructions using all the necessary safety measures, for exam-
ple:
1. Plug all the Hydraulic ports on the gearbox to avoid the

introduction of any foreign particles in the circuit and
the gearbox.
3-22 – JLG Lift – 3121262

1. Install the special tool (6689960310) on the flanged hub 4. Mark the position of the springs (45) as a reference for
(31) and turn the screw until it compresses the springs the reassembly.
(45).
5. Remove the springs (45) from their seats in the brake

2. Remove the circlip (47) and remove the special tool. piston (44).
3. Remove the spring retainer disc (46). 6. By using pliers remove the circlip (36) from its seat in the
brake shaft (35).
3121262 – JLG Lift – 3-23

1. Screw 11. Elastic Ring 21. Spacer 31. Flanged Hub 41. O-ring
2. O-ring 12. Washers 22. Ring Nut 32. Disc (Internal Teeth 42. O-ring
3. Pin 13. Spring 23. Gearbox Housing 33. Disc (External Teeth) 43. Backup Ring
4. Screw 14. Splined Shaft 24. Bearing 34. Spacer 44. Brake Piston
5. Cap Nut 15. Disengagement Shaft 25. Spacer 35. Brake Shaft 45. Springs
6. Oil Plug 16. 1st Reduction Assembly 26. Spacer 36. Circlip 46. Retainer Disc
7. End Cover 17. 2nd Stage Sun Gear 27. O-ring 37. Backup Ring 47. Circlip
8. Pad 18. 2nd Reduction Assembly 28. Spacer 38. O-ring
9. O-ring 19. Circlip 29. Half Seal 39. Spacer
10. 1st Stage Sun Gear 20. 3rd Reduction Assembly 30. Seal Ring 40. Backup Ring
Figure 3-17. Drive Hub
3-24 – JLG Lift – 3121262

7. By using a puller remove, at the same time, the brake 10. Remove the external O-Ring seal (38) and the backup
piston (44), the spacer (39) and the brake shaft (35). ring (37) from their seat in the spacer (39).
11. Remove the O-ring seal (42) and the backup ring (43)
from their seats in the flanged hub (31).
8. Remove the spacer (39) from the brake piston (44).
12. Remove brake discs pack (32-33).

9. Remove the internal O-Ring seal (41) and the backup
ring (40) from their seat in the spacer (39).
3121262 – JLG Lift – 3-25

13. Remove the disengagement shaft kit (15). 16. By using pliers remove the elastic ring (11) from the
splined shaft (14).
14. Place the disengagement shaft kit (15) inside the special
tool (6689960240). 17. Remove the special tool and remove the spring (13) and
the washers (12).
15. Tighten the 2 screws M5x16, grade 8.8, of the cover by a

torque wrench to 18.4 ft.lbs. (25 Nm). 18. Turn the gearbox upside down and unscrew the 2
screws M8x16 (4), grade 8.8, of the end cover (7).
3-26 – JLG Lift – 3121262

19. Remove the cap nut (5). 22. Unscrew the draining-filling-level oil plugs (6) by a male
hex head wrench.
20. Remove the pin (3).

23. Unscrew the 10 screws M10X25 (1), grade 12,9, from the
end cover (7).
21. Remove the O-ring seal (2) from its seat in the end cover
(7).
24. Remove the end cover (7).
3121262 – JLG Lift – 3-27

25. Remove the O-ring seal (9) from its seat in the end cover 28. Remove the 2nd stage sun gear (17).
(7).
29. Remove the 2nd reduction assembly (18).

26. Remove the 1st stage sun gear (10).
30. By using pliers remove the circlips (19) from their seats
27. Remove the 1st reduction assembly (16). in the flanged hub's pins (31).
3-28 – JLG Lift – 3121262

31. By using a puller remove the planet assemblies of the 34. By using a tackle place the torque multiplier
3rd reduction (20). (ATZ.09.016.0) on the ring nut (22).
35. By using the torque multiplier (ATZ.09.016.0) loosen the

32. Remove the spacer (21) from their seats in the pins of
ring nut (22).
the flanged hub (31).
36. Take out the ring nut (22).

NOTE: In order to proceed with the gearbox disassembly, it is now
necessary to remove it from the machine and bring it to a
properly equipped workshop.
33. By using a drill remove the caulkings on the ring nut

(22).
3121262 – JLG Lift – 3-29

37. By using a puller and a metal stopper, remove the 40. By using a screwdriver, remove the 1st half-seal (29)
flanged hub (31) from the gearbox housing (23). from the flanged hub (31).
38. By using a tackle remove the gearbox housing (23) from 41. By using a screwdriver, remove the 2nd half-seal (29)
the flanged hub (31). from the gearbox housing (23).
39. Remove the seal ring (30) from its seat in the flanged
hub (31). NOTE: The gearbox disassembly ends with the above operation.
All items are now available for the necessary inspections.
Inspection of Parts
The pieces that are subject to general wear and tear are the
following:
- Gears.
- Bearings.
- All the seals
Replace the used or irregular parts using the following steps:
1. Remove dirt, and in particular properly clean the seals,

bearings and locking rings seating.
NOTE: In case of oil leaks, it may be necessary to check and even- 2. Lubricate the parts before connecting them.
tually replace the lifetime seal (29), which means both the
metal rings parts and the O-ring seals. 3. In the case of damaged gears, for example a planetary,
do not proceed to replace the individual gear but the
entire reduction assembly.
3-30 – JLG Lift – 3121262

4. When reassembling a part always replace all the seals c. Carefully clean the lapped surface (D) of metal rings
involved. Add some grease on the seats and on the new (E) and remove dust or fingerprints. Then lubricate
seals to make reassembly easier. them with a thin oil film, taking care not to oil the
other components.
5. Replace all the damaged parts with original spare parts.
2. Assemble the half seal (29) on the tool (6689960300).
Assembly
Apply grease TECNOLUBE SEAL GS730 on the gearbox hous-
ing (23).
3. Assemble the 1st half seal (29) on the gearbox housing

(23).
1. Follow the steps below to prepare the lifetime seal for

assembly:
a. Carefully clean the seats (A and B) using, if neces-

sary, metallic brushes or solvent (surfaces in contact
with or (C) must be perfectly clean and dry).
4. Using the same tool (6689960300), assemble the 2nd

half seal (29) on the flanged hub (31).
b. Make sure that sealing surfaces (D) of metal rings (E)

are free from scratches, dinges or foreign sub-
stances; metallic ring surfaces must be perfectly
clean and dry. We suggest to dip the metallic rings
in volatile solvent or industrial degreasing alcohol.
3121262 – JLG Lift – 3-31

5. Carefully clean the metallic faces of the lifetime seal (29) 8. By using a hoist, place the gearbox housing (23) on the
and lube the surfaces with oil. flanged hub (31).
6. Insert the seal ring (30) in its seat in the flanged hub (31). 9. By using a press and a metallic stopper, push the gear-
box housing (23) against the shoulder on the flanged
hub (31) until assembling of the unit is complete.
7. Apply grease TECNOLUBE SEAL GS730 on the seal ring

(30).
SCREW THE NUT (22) ON PARTIALLY IN ORDER TO PREVENT THE FLANGED

HUB (31) FROM COMING OUT OF THE GEARBOX HOUSING (23) DURING THE
FOLLOWING STEPS.
AVOID GETTING GREASE IN CONTACT WITH THE LIFETIME SEAL (29)
3-32 – JLG Lift – 3121262

10. By using a hoist place the torque multiplier NOTE: Stake Ø 4+5 mm (depth 1+1,5 mm).
(ATZ.09.016.0) on the ring nut (22).
13. Assemble correctly the spacers (21) on the pins of the

11. By using the multiplier (ATZ.09.016.0), tighten the ring
flanged hub (31).
nut (22), using a torque wrench with an input multiplier
torque of 71 ± 3 ft.lbs.(96,5 ± 4, 5 Nm) corresponding to
an output multiplier torque of 3688 ± 184 ft.lbs. (5000 ±
250 Nm).
14. Place the 5 planet assemblies of the 3rd reduction (20) in

the flanged hub's pin (31).
12. Stake the ring nut (22) near 2 seats at 180° of the flanged
hub (31) on the right side.
3121262 – JLG Lift – 3-33

15. By using a rubber hammer and a metal stopper push the 18. Insert the 2nd stage sun gear (17).
planet assemblies of the 3rd reduction (20) against the
shoulder until assembly is complete.
19. Assemble the 1st reduction assembly (16).
16. By using pliers, assemble the circlips (19) in the flanged

hub pin seats (31).
20. Insert the 1st stage sun gear (10).
17. Assemble the 2nd reduction assembly (18).
3-34 – JLG Lift – 3121262

21. Assemble the O-ring seal (9) into its seat in the end 24. Insert the plugs (6) into the oil draining-filling holes of
cover (7). the end cover (7). Torque the plugs to 52 ± 7 ft.lbs.
(70±10 Nm).
22. Place the end cover (7) on the gearbox housing (23).
25. Assemble the O-ring seal (2) into its seat in the end
cover (7).
23. Tighten the 10 socket head screws M10x25 (1),grade

12,9, by a torque wrench at 62.7 ft.lbs. torque (85 Nm).
26. Protect the seat and the pin (3) with grease type
MOLYKOTE G6000. Wait 15 minutes for it to completely
dry. Insert the pin (3) in its seat in the end cover (7).
3121262 – JLG Lift – 3-35

27. Assemble the cap nut (5). 30. Insert the spring (13) in the splined shaft (14).
28. Torque the 2 screws M8x16 (4) grade 8.8, to 18.4 ft.lbs. 31. Insert the splined shaft (14) in the equipment
(25 Nm). (6689960240).
29. Insert the 1st washer (12) in the splined shaft (14). 32. Insert the 2nd washer (12) correctly in the splined shaft
(14).
3-36 – JLG Lift – 3121262

33. Torque the 2 screws M5x16, grade 8.8, of the cover to 35. Insert the disengagement shaft kit (15) in the flanged
18.4 ft.lbs. (25 Nm). hub (31).
34. By using pliers, assemble the elastic ring (11) into its seat 36. By using pliers assemble the circlip (36) into its seat in
in the splined shaft (14). the brake shaft (35).
37. Turn the gearbox upside down and assemble the brake
shaft (35) inside the flanged hub (31).
3121262 – JLG Lift – 3-37

38. Assemble the brake discs package according to the fol- 41. Fit the external O-ring seal (38) and the backup ring (37)
lowing order: first, insert one sintered bronze disc with into their seats in the spacer (39).
external teeth (33).
42. Insert the spacer (39) inside the flanged hub (31), paying
39. Then insert an internally toothed steel disc (32). Repeat attention not to damage the seals already fitted.
the operation until all 5 sintered bronze discs and 4 steel
discs have been assembled.
43. By using a rubber hammer and a metal stopper push the

spacer (39) against the flanged hub (31), paying atten-
40. Fit the internal O-ring seal (41) and the backup ring (40) tion not to damage the seals already fitted.
into their seats in the spacer (39).
3-38 – JLG Lift – 3121262

44. Lube the seal seats into the flanged hub (31) and assem- 45. Insert the brake piston (44) inside the flanged hub (31),
ble the O-ring seal (42) and the backup ring (43). paying attention not to damage the seals already fitted.
NOTE: The O-ring seals (A) and backup rings (B) must be fitted in 46. By using a rubber hammer and a metal stopper push the
the seats according the mutual position as shown in the brake piston (44) against the flanged hub (31), paying
scheme. attention not to damage the seals already fitted.
3121262 – JLG Lift – 3-39

47. Insert the springs (45) into the holes in the brake piston 49. Install the special tool (6689960310) on the flanged hub
(44) marked previously. (31) and turn the screw until it compresses the springs
(45).
48. Insert the spring retainer disc (46).

50. Assemble the circlip (47) in its seat and remove the spe-
cial tool.
NOTE: Before assembling the hydraulic motor, verify by a depth

slide gauge the correct assembly of the unit checking the
axial distance as shown below.
3-40 – JLG Lift – 3121262

Final Test and Reinstallation 2. Open the flow valve and release the brake with the pilot
pressure of 50 bar.
Check the product by remounting it to the machine.
3. Close the flow valve and keep the brake released 3 min-
Check the function of the drive hub following all the checks utes or longer.
shown in Startup and Running In. 4. Using the manometer, check that the pressure remains
constant.
If work on the brake was undertaken, it is important to check
that there are no oil leaks. Follow the procedure below: NOTE: If the pressure drops it may mean that the brake seals are
not tight and consequently they must be replaced or it may
1. Connect the pressure pilot line with the manometer mean that the reassembling was not completed properly.
(with a base scale of 100 bars) to the brake release port.
5. After having reassembled the gearbox, install the
hydraulic motor.
6. Fill the gearmotor with the lubricant oil.
3121262 – JLG Lift – 3-41

Figure 3-18. Drive Hub Special Tools - Sheet 1 of 4
3-42 – JLG Lift – 3121262

3121262 – JLG Lift – 3-43

3-44 – JLG Lift – 3121262

3121262 – JLG Lift – 3-45

3.12 DRIVE HUB - REGGIANA RIDUTTORI 9. Socket wrench for M6 hexagonal screw.
NOTE: After S/N 0300134389 machines may be built with either

Bonfiglioli or Reggiana Riduttori wheel drive hubs. See Sec-
tion 3.11, Drive Hub - Bonfiglioli. Do not use different hubs M- 1326
on the same machine.
Ø240
Symbol Nomenclature Ø130
Ø30 5x45°
35
°
15
R5
= ADHESIVE
10
5
Ø224
Ø233
Ø240
60°
= LUBRICANT
60
60
°
A A
= GREASE
N° 6 Hole to 120° Ø30
Figure 3-22. Bearing Track Spacer Mounting C016117

= TORQUE WRENCH
M- 1537
Ø249
= DISPOSAL Ø130
Ø30
Tools N° 4 Hole to 90° Ø30
Tools required for assembling and disassembling the wheel

29.5
gear RRTD1701TB
1. Hammer;
Ø210
14.5
10
2. Clamps for inner retention rings; Ø219

3. Clamps for outer retention rings;
4. Electric or pneumatic screwdriver; Figure 3-23. Oil Seal Spacer Mounting C125049
5. Special spacer mounting;
6. Torque wrench;
7. Hydraulic press;
8. Wrench for M6, M8, M10 socket head screws and
1/4" G plug.
3-46 – JLG Lift – 3121262

Ø210
5x45°
Ø130
25
Ø30
M- 1321
LOCTITE 2701
N° 4 Hole to 90° Ø40
110
M- 1320
Ø197.5
Ø210
Figure 3-24. Bearing Spacer Mounting CO16117
Figure 3-25. Assembly Diagram 1
3121262 – JLG Lift – 3-47

M- 1316 M- 1020
30
Ø34 35 35
10
10 10
M- 1317
45°
45°
8 M- 1317
N° 4 R
35
45°
45°
70
A A
35
50
M- 1317
50
216.5 70
Ø
12
10
Ø11
Ø230
20
M- 1316 10x45°
60
90
Ø16
70
Ø17
55
38
11
M- 1317
M- 1317
M- 1317 Figure 3-28. Anti-rotation Block
16 n° 8 Routing to 45°
Ø205
Figure 3-26. Wrench For Ring Nut

M- 1126
Ø20
Ø12
M- 1125
T.U.9
Ø180
n° 12 Fori a 30° Ø35
Ø80
30
50
Ø20 H7 (+0.021) n°12 Hole to 30°

10.5
0
20
n° 12 Hole to 30° Ø6.5

M6
32
n° 12 Spot-facing to 30° Ø10.5

T.U.15
Figure 3-29. Anti-rotation Pin

6.5
n° 4 Hole to 90° M10

Ø50
Ø275
Ø305
30° 30°
0
°
30
3
°
30°
30°
A A
Figure 3-27. Anti-rotation Flange
3-48 – JLG Lift – 3121262

M- 1126 M- 1126
M- 1125 VTCEI M6X12 n°12
M- 1020
VTCEI M10X60 n°4
Figure 3-30. Assembly Diagram 2
3121262 – JLG Lift – 3-49

Ø105 M- 1546 M- 1548

Ø93.5
+0.1
Ø48
Ø20+0.2 Ø46
5
5
9
80
70
50
8.5
20
Ø8.5
Ø13.5 Ø40.5
5
Ø46
2.5x15° M- 1547
Ø39.5
t.u. 12
88.5
3.5
0 M8
Ø20 -0.1
VTCEI M8X16 n°1
Figure 3-31. Tools For Assembling Bearing 3rd Stage Planetary Gear Assembly Diagram
3-50 – JLG Lift – 3121262

Disassembly 3. Release the screws from the release cover and pull the
pin out.
1. Remove the plugs and pour the lubricant in a container.
4. Remove the BR250 ring and pull the cover out avoiding
to damage the O-Ring.
2. Release the screws to disassemble the motor flange tak-

ing care not to damage the O-Ring.
5. Pull the reduction gears out.
3121262 – JLG Lift – 3-51

Figure 3-32. Reggiana Riduttori Hub - Sheet 1 of 2
3-52 – JLG Lift – 3121262

3121262
1. Screw 13. Iron Brake Disc 25. Tapered Roller Bearing 37. O-ring
2. Motor Support 14. Plastic Plug 26. Bearing Support 38. Crown Gear
3. O-ring 15. Spindle 27. Ring Nut 39. Crown Gear Screw
4. Inner Retention Ring 16. Planet Wheel 28. Sphere 40. O-ring
5. Brake Spring Spacer 17. Bearing 29. Screw 41. Support Tablet
6. Brake Spring 18. Outer Retention Ring 30. Pinion 42. O-ring
7. Brake Piston 19. Input Shaft 31. Reduction Gears 43. Cover
8. Parbak 20. Input Shaft Bearing 32. Outer Retention Ring 44. Steel Plug
9. O-ring 21. Ring 33. Pinion 45. Cover Retaining Ring
– JLG Lift –
10. O-ring 22. Disengagement Spring 34. Reduction Gears 46. Disengagement Stud
11. Parbak 23. Disengagement Shaft 35. Outer Retention Ring 47. Disengagement Cap
12. Sintered Brake Disc 24. Spindle Oil Seal 36. Pinion 48. Disengagement Screw
Figure 3-33. Reggiana Riduttori Hub - Sheet 2 of 2
3-53
6. Loosen the M10x25 flathead socket screws and remove 9. Loosen the M6x6 socket headless screws and also
the planetary ring without damaging the O-Ring. remove the 3/16" balls.
7. Remove the release joint together with the spring. 10. Loosen the ring nut using the special wrench.
8. Disassemble the Ø40 outer snap rings and using an 11. Remove the hub support together with the roller bear-
extractor remove the planetary gears from the spindle ing inner track.
pins.
3-54 – JLG Lift – 3121262

12. Disassemble the Ø160 inner snap ring and pull the Assembly
spring holder spacer out. Remove the springs and using
a compressed air jet in the brake control hole pull the 1. Make sure all the component parts of the wheel gear are
piston out of the spindle. devoid of burrs, machining residues and that they are
correctly washed.
2. Fit the ball bearing in the input shaft and lock with a Ø40
outer snap ring.
13. Remove the brake discs and seals.

3. Mount the motor shaft in the spindle and lock with BR68
ring. Lubricate the bearing.
14. Fit the ball bearing into the input shaft and lock it with a
Ø40 outer snap ring. Then mount the motor shaft in the
spindle and lock with a BR68 ring. Lubricate the bearing.
3121262 – JLG Lift – 3-55

4. Fit the brake sealing rings O-Ring and PARBAK (lubri- 6. Prepare the hub support, mounting on it the two roller
cated with grease) in the respective spindle seats. Place bearing outer tracks. Place the first roller bearing inner
the brake discs making sure to centre them on the spin- track.
dle and on the input shaft.
7. Fit the oil seal lubricated with grease onto the support
5. Insert the brake piston and place the springs into the
with the special spacer mounting (see figure A).
piston holes. Close the brake fitting the spring holder
plate, then lock with the Ø160 inner snap ring. Check the
brake leakage, if any, as well as the static torque and Fig.A
minimum opening pressure.
8. Place the hub support already assembled on the spindle

making sure that the first roller bearing inner track goes
correctly against it; then fit the second roller bearing
inner track by means of the spacer mounting. Tighten
the ring nut.
3-56 – JLG Lift – 3121262

9. Now check the unit roll torque and proceed in the fol- 11. Using the special tool and hammer make four dents on
lowing order: the spindle thread by the M6 holes of the ring nut.
10. By keeping the spindle locked, apply a setting preload
by tightening the ring nut at 40daNm, turn completely
the hub support twice using the special wrench to
recover any bearing cage misalignments. Release and
tighten the ring nut at the final torque of 30daNm (alter-
nate tightening and some setting turns). Check the roll
torque with seal which must be within 1÷1,5 daNm.
12. Fit the 4 3/16" balls and tighten with LOCTITE 243 the 4
M6x6 socket headless screws at the torque of 1daNm.
NOTE: Place the ring nut with its convex part facing the roller
bearing as shown below.
13. Fit the bearings onto the 3rd stage planetary gears and
using a spacer mounting mount everything on the spin-
3121262 – JLG Lift – 3-57

dle pins. Lock with a ÿ40 outer snap ring. Lubricate the 15. Place the hub onto the support making the two holes
bearings. coincide for tightening the M10x25 flathead socket
screws at the torque of 5daNm.
16. Fit the reduction gears and the pinion in the unit.
14. Using a marking pen, make a mark between the snap

ring and the bearing. Fit the greased spring and the
release joint. Use grease to fit the O-Ring 2-275 in the
hub support seat.
3-58 – JLG Lift – 3121262

17. Prepare the closing cover fitting the O-ring 5-582 suit- 19. Fit the O-Ring 2-163 suitably greased, onto the motor
ably greased and lock it with the shimming ring. Lubri- coupling flange S-D LC/KC. Mount the flange on the
cate the bearings. spindle with 6 M8x25 socket cap screws at the torque of
2.4daNm with LOCTITE 243 Insert the pin and carry out
the rotation test according to PGQ-22 standard.
18. Fit the O-Ring 2-177 suitably greased, mount the cover
locking it with the BR250 ring.
20. Mount the release cover fastening it with 2 M6x20 hex-
agonal screws at the torque of 1daNm. Mount the 1/
4"GAS plugs on the cover at the torque of 1daNm.
3121262 – JLG Lift – 3-59

1. Swing Drive 4. Outer Race Bearing Bolt

2. Inner Race Bearing Bolt 5. Turntable Lock Pin
3. Swing Bearing 6. Remote Bearing Lubrication Fittings
Figure 3-34. Swing System
3-60 – JLG Lift – 3121262

3.13 SWING DRIVE Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
should be taken to ensure that the bolts are not tightened
Roll and Leak Testing beyond their specified torque.
Torque-Hub units should always be roll and leak tested before
The following steps describe how to tighten and torque bolts
disassembly and after assembly to make sure that the unit's
or socket head cap screws in a bolt circle.
gears, bearings and seals are working properly. The following
information briefly outlines what to look for when performing
these tests.
NOTE: The brake must be released before performing the roll test.
This can be accomplished by either pressure testing using
the Brake Leak Test procedure below or by tightening the
12 bolts into the piston through the end plate (See Brake
Disassembly Procedure)
NOTE: Bolts must be removed while performing brake release test
Roll Test
The purpose of the roll test is to determine if the unit's gears

are rotating freely and properly. You should be able to rotate
the gears in your unit by applying constant force to the roll
checker. If you feel more drag in the gears only at certain
points, then the gears are not rolling freely and should be
examined for improper installation or defects. Some gear
packages roll with more difficulty than others. Do not be con-
cerned if the gears in your unit seem to roll hard as long as
they roll with consistency. 1. Tighten (but do not torque) bolt “A" until snug.
LEAK TEST (MAIN UNIT) 2. Go to the opposite side of the bolt circle and tighten
bolt "B" until equally snug.
The purpose of a leak test is to make sure the unit is air tight.
You can tell if your unit has a leak if the pressure gauge read- 3. Crisscross around the bolt circle and tighten remaining
ing on your air checker starts to fall after the unit has been bolts.
pressurized and allowed to equalize. Leaks will most likely 4. Now use a torque wrench to apply the specified torque
occur at the pipe plugs, the main seal or wherever o-rings or to bolt "A".
gaskets are located. The exact location of a leak can usually be
detected by brushing a soap and water solution around the 5. Using the same sequence, crisscross around the bolt cir-
main seal and where the o-rings or gaskets meet on the exte- cle and apply an equal torque to the remaining bolts.
rior of the unit, then checking for air bubbles. If a leak is
detected in a seal, o-ring or gasket, the part must be replaced,
and the unit rechecked. Leak test at 10 psi (0.7 bar) for 20 min-
utes.
3121262 – JLG Lift – 3-61

Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on Elbow Fittings (36)
and remove fittings from Brake (26) and Motor Control
1. Place unit on bench with the motor end up. Valve (32).
2. Remove O-ring Plug (1J) and drain the oil from the gear- 5. Remove O-ring Plugs (21) from Motor Control Valve (32).
box.
6. Remove Motor Control Valve (32) from Motor (10) by
3. Remove Hydraulic Tubing Assembly (35) by loosening removing the four Bolts (34) and washers (33).
fittings on both ends of tube with a wrench.
1J. O-Ring Plug 32. Motor Control Valve

10. Hydraulic Motor 33. Lockwasher
21. Plug 34. Hex Bolt
24. ID Plate 35. Hydraulic Tubing
25. Drive Screw 36. Elbow
26. Hydraulic Brake
Figure 3-35. Swing Drive - Motor Control Valve Disassembly
3-62 – JLG Lift – 3121262

Motor and Brake Disassembly 3. Remove Gasket (31) from between Brake (26) and Motor
(10).
1. With unit resting on bench with Motor (10) end up, 4. Remove Brake (26) from Main Torque-Hub Assembly
loosen Hex Bolts (29) and remove Lift Lugs (28) from the and dump oil out of Brake (26).
Motor (10).
5. Remove O-ring (27) from between Motor (10) and Brake
2. Pull Motor (10) straight up and remove Motor (10) from (26).
Brake (26).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-36. Swing Drive - Motor and Brake Disassembly
3121262 – JLG Lift – 3-63

Main Disassembly 6. Remove Thrust Washers (16) and Thrust Bearing (15)
from between Input Cover (6) and Carrier (3A) Subas-
1. With the unit resting on the Output Shaft (Pinion) (1A), sembly.
remove the eight Bolts (17), four Shoulder Bolts (18) and
7. Remove Ring Gear (4) from Housing (1G).
four Lock Washers (19) from the Input Cover (6).
8. Remove O-ring (5) from between Ring Gear (4) and
2. Thread either 1/2-13 UNC eye bolts or motor mounting Housing (1G).
Bolts (29) into threaded holes in Input Cover (6) and pull
Input Cover (6) off on the main assembly. 9. Remove Carrier (3A) Subassembly.
3. Remove O-ring (5) from between Input Cover (6) and 10. Remove Thrust Washers (16) and Thrust Bearing (15)
Ring Gear (4). from between Carrier (3A) Subassembly and Internal
Gear (2).
4. Remove Thrust Washer (8) from end of Sun Gear (13).
11. Remove Internal Gear (2).
5. Remove Sun Gear (13).
2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-37. Swing Drive - Main Disassembly
3-64 – JLG Lift – 3121262

Hub-Shaft Disassembly 4. Remove the Bearing Cone (1F) from the Housing (1G).
5. Invert the Housing (1G) and remove the Lip Seal (1B) if
1. Using retaining ring pliers, remove Retaining Ring (1I)
not already removed when Output Shaft (1A) was
from groove in Output Shaft (1A) and discard.
pressed out of Housing (1G).
6. Remove the Bearing Cone (1D).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE. 7. Bearing Cups (1C & 1E) will remain in Housing (1G).
2. Remove Thrust Washer (1H). NOTE: If bearing replacement is necessary, the Bearing Cups (1C &
1E) can be removed with a slide hammer puller or driven
3. While supporting the Housing (1G) on the Output Shaft out with a punch.
(1A) end, press the Output Shaft (1A) out of the Housing
(1G).
NOTE: The Lip Seal (1B) may or may not be pressed out of the
Housing (1G) by the Bearing Cone (1D) during this step.
1A. Output Shaft 1F. Tapered Bearing Cone

1B. Lip Seal 1G. Housing
1C. Tapered Bearing Cup 1H. Thrust Washer
1D. Tapered Bearing Cone 1I. Retaining Ring
1E. Tapered Bearing Cup 1J. O-Ring Plug
Figure 3-38. Swing Drive - Hub Shaft Disassembly
3121262 – JLG Lift – 3-65

Carrier Disassembly 3. Slide the Planet Gear (3F), two Ball-Indented Thrust
Washers (3H) and the two Thrust Washers (3B) out of the
1. Using a 3/16" (5 mm) punch drive the Roll Pin (3G) which Carrier (3A).
holds the Planet Shaft (3E) in the Carrier (3A) down into
4. Remove both rows of Needle Bearings (3C) and the
the Planet Shaft (3E) until it bottoms.
Spacer (3D) from the bore of the Planet Gear (3F).
NOTE: Make sure that the Roll Pin has bottomed. Otherwise, dam-
5. Repeat Steps 1 thru 4 for the remaining two Cluster
age to the carrier could occur when the Planet Shaft is
Gears(3F).
removed.
2. Remove the Planet Shaft (3E) from the Carrier (3A). Use a
small punch to remove the Roll Pin (3G) from the Planet
Shaft (3E).
3A. Carrier 3E. Planet Shaft

3B. Tanged Thrust Washer 3F. Cluster Gear
3C. Needle Bearing 3G. Roll Pin
3D. Thrust Washer 3H. Ball Indented Washer
Figure 3-39. Swing Drive - Carrier Disassembly
3-66 – JLG Lift – 3121262

Hub-Shaft Sub-Assembly 9. Install Bearing Spacer (1H) onto Output Shaft (1A) and
against Bearing Cone (1F).
1. Press Bearing Cone (1D) onto Shaft (1A).
10. Install Retaining Ring (1I) into the groove in the Output
2. Press Bearing Cup (1C) into Housing (1G), take care to Shaft (1A). This Retaining Ring (1I) should never be
insure cup starts square with bore of Hub (1G). reused in a repair or rebuild.
3. Place Bearing Cone (1D) in Bearing Cup (1C) in Housing

1G).
EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
4. Press or tap Seal (1B) into the counterbore of Housing
(1G) to the point where it becomes flush with the Hous-
11. Tap the Retaining Ring (1I) with a soft metal punch to
ing (1G) face. Care should be taken to insure Seal (1B) is
ensure that the Retaining Ring (1I) is completely seated
being correctly installed (smooth face up).
in the groove of the Output Shaft (1A).
5. Invert Hub (1G) and press Bearing Cup (1E) into counter-
bore of Housing (1G).
6. Carefully lower Housing (1G) onto the Output Shaft (1A). EYE PROTECTION SHOULD BE WORN DURING THIS PROCEDURE.
7. Start the Bearing Cone (1F) onto the Output Shaft (1A). 12. Install O-ring Plug (1J) and torque 23 to 24 ft-lbs.(32 -
33.5 Nm).
8. Press or tap the Bearing Cone (1F) onto the Output Shaft
(1A) until it is seated in the Bearing Cup (1E).
1A. Output Shaft 1D. Tapered Bearing Cone 1G. Housing 1I. Retaining Ring
1B. Lip Seal 1E. Tapered Bearing Cup 1H. Thrust Washer 1J. O-Ring Plug
1C. Tapered Bearing Cup 1F. Tapered Bearing Cone
Figure 3-40. Swing Drive - Hub Shaft Sub-Assembly
3121262 – JLG Lift – 3-67

Carrier Sub-Assembly 8. Slide the second Thrust Washer (3E) between the Cluster
Gear (3F) and the Carrier (3A) with the tang of the
1. Apply a liberal coat of grease to the bore of Cluster Gear washer located in the cast slot of the Carrier (3A). Slide
(3F). This will enable the Needle Rollers (3C) to be held in ball-indented Thrust Washer (3H) onto the end of the
place during assembly. Planet Shaft with the indents against the second thrust
Washer. Finish sliding the Planet Shaft (3E) through the
2. Install the first row of 14 Needle Rollers (3C) into the Thrust Washers (3H) & (3B) and into the Carrier (3A).
bore of Cluster Gear (3F).
9. Position the non-chamfered side on the Planet Shaft (3E)
3. Insert Spacer (3D) into bore of Cluster Gear (3F) on top of roll pin hole so that it is in line with the hole in the Car-
the Needle Rollers (3C). rier (3A) using a 1/8" (3 mm) diameter punch.
4. Place second row of Needle Rollers (3C) into bore of 10. After using a 3/16" (5 mm) punch to align the two roll
Cluster Gear (3F) against Spacer (3D) and remove Planet pin holes. Drive the Roll Pin (3G) through Carrier (3A)
Shaft (3E). and into the Planet Shaft (3E) until the Roll Pin (3G) is
flush with the bottom of the cast tang slot in the Carrier
5. Place Carrier (3A) into tool fixture so that one of the roll (3A). Use a 1/4" (6 mm) pin punch to make sure the Roll
pin holes is straight up. Pin (3G) is flush in the slot.
6. Start Planet Shaft (3E) through the hole in Carrier (3A). 11. Repeat Steps 1 thru 10 for the remaining two Cluster
Using ample grease to hold it in position, slide one Gears(3F).
Thrust Washer (3B) over the Planet Shaft (3E) with the
tang resting in the cast slot of the Carrier (3A). Place Ball-
Indented Thrust Washer (3H) on the Planet Shaft (3E)
with the indents against the first washer.
7. With large end of Cluster Gear (3F) facing the roll pin
hole in the carrier, place the cluster gear into position in
Carrier (3A) and push Planet Shaft (3E) through the Clus-
ter Gear (3F) without going all the way through.
3-68 – JLG Lift – 3121262


Figure 3-41. Swing Drive - Carrier Sub-Assembly
3121262 – JLG Lift – 3-69


Figure 3-42. Swing Drive - Carrier Sub-Assembly
3-70 – JLG Lift – 3121262

Main Assembly 9. While holding Ring Gear (4) and Cluster Gears (3F) in
mesh, place small end of Cluster Gears (3F) into mesh
1. With the Hub Shaft Sub-Assembly resting on the Shaft with the Internal Gear (2) and Input Gear (13). On the
(1A) install Internal Gear (2). The spline of the Internal Ring Gear (4) locate the hole marked "X", or punch
Gear (2) bore will mesh with the spline of the Output marked, over one of the marked counter-bored holes
Shaft (1A). (Step 5) in Hub (1G). Check timing through the slots in
the carrier. Rotate carrier in assembly to check for free-
2. Inspect the location of the Internal Gear (2) on the Out- dom of rotation.
put Shaft (1A). The portion of the Output Shaft (1A),
which does not have full spline, should protrude NOTE: If gears do not mesh easily or Carrier Assembly does not
through the Internal Gear (2) bore. rotate freely, then remove the Carrier and Ring Gear and
check the Cluster Gear timing
3. Install two Thrust Washers (15) and one Thrust Bearing
(16) on the portion of Output Shaft (1A) which protrudes 10. Install Thrust Washer (15)/Thrust Bearing (16) set into
through Internal Gear (2). the counter-bore in the face of the carrier. Use grease to
hold in place.
4. Center the Input Gear (13) on the end of the Output
Shaft (1A) opposite the gear with the large diameter 11. Place O-ring (5) into Cover (6) counter-bore. Use grease
down. to hold O-Ring in place.
5. Place O-ring (5) into Hub counter-bore. Use grease to

hold O-ring in place.
CAUTION: BEWARE OF SHARP EDGES OF THE COUNTER-BORE WHILE SEATING
THIS O-RING.
BEWARE OF SHARP EDGES OF THE COUNTER BORE WHILE SEATING THIS O- 12. Using sufficient grease to hold in place, install Thrust
RING. Washer (8) into the counter-bore of the interface of the
Cover (6).
6. Also at this time locate and mark the four counter 13. The Cover (6) is now installed, taking care to correctly
reamed holes in the face of the Hub (1G). This is for iden- align Pipe Plug hole (20) with those in the Hub (1J).
tification later in the assembly. Check timing sheet.
7. Place Carrier (3A) Subassembly on bench with the large 14. Locate the 4 counter-bored holes in Hub (1G) [marked in
end of Cluster Gears (3F) up with one at the 12 o clock Step 5] and install 4 Shoulder Bolts (18) with Lockwash-
position. Find the punch marked tooth on each gear at ers (19). Start the shoulder bolts by hand.
the large end and locate at 12 o'clock (straight up) from
each planet pin. Marked tooth will be located just under 15. Install Grade 8 Bolts (17) with Lockwashers (19) into
the Carrier on upper two gears. Check the timing remaining holes.
through the slots in the carrier.
16. Torque Shoulder Bolts (18) 43 to 47 ft.-lbs. (60 to 65 Nm)
8. With large shoulder side of Ring Gear (4) facing down, and Grade 8 Bolts (17) to 43 to 47 ft.-lbs. (60 to 65 Nm).
place Ring Gear (4) over (into mesh with) large end of Roll and leak test the assembly.
gears. Be sure that punch marks remain in correct loca- 17. With gearbox standing on the pinion end fill gearbox
tion during Ring Gear (4) installation. The side of the with GEAROIL 80W90, to bottom of plug hole in cover at
Ring Gear (4) with an "X" or punch mark stamped on it Pipe Plug (20).
should be up.
18. Install Pipe Plug (20) into Cover (6) using thread sealant.
3121262 – JLG Lift – 3-71

2. Internal Gear 15. Thrust Bearing

4. Ring Gear 16. Thrust Washer
5. O-Ring 17. Hex Bolt
6. Input Cover 18. Shoulder Bolt
8. Hex Bolt 19. Lockwasher
13. Sun Gear 20. Pipe Plug
Figure 3-43. Swing Drive - Main Assembly
3-72 – JLG Lift – 3121262

Motor and Brake Assembly 4. Assemble Lift Lugs (28) onto Hex Bolts (29). Assemble
Hex Bolts (29) with Lift Lugs through the Motor (10) and
1. Place O-ring (27) onto end of Brake (26) and locate brake Brake (26) against the motor flange. Torque to 35 ft-lbs.
into pilot of cover.
5. Fill Brake (26) with 2.7 oz. (80cc) of BRAKOILVG32
2. Place Gasket (31) onto the brake face and line up the
holes. (DTE24).
3. Place Motor (10) into Brake pilot against the Gasket (31).
10. Hydraulic Motor 28. Lift Lug

26. Hydraulic Brake 29. Bolt
27. O-Ring 31. Gasket
Figure 3-44. Swing Drive - Motor and Brake Assembly
3121262 – JLG Lift – 3-73

Motor Control Valve Assembly 4. Assemble Tube (35) into Elbow Fittings (36) and torque
13 to 15 ft-lbs. (18 to 21 Nm).
1. Lay assembly down with motor ports facing up. Remove
the two plastic plugs in the motor ports, being careful 5. Install O-ring Plugs (21) into Motor Control Valve (32)
not to loose the O-ring in each port. Assemble the Motor and torque 30 to 31 ft-lbs. (42 to 43 Nm).
control Valve (32) onto the Motor (10) with Bolt (34) and
6. Pressure test brake, tube and control valve connections
Lock Washers (33). Torque Bolts (33) 23 to 27 ft-lbs. (32 to
by applying 3000 psi (207 bar) pressure to the brake
38 Nm).
bleed port and holding for 1 minute. Check for leaks at
NOTE: Be sure to align the holes in the control valve with the the control-valve-motor interface and the tube connec-
motor ports. tions. Release pressure.
2. Install Elbow Fittings (36) into Brake (26) and torque 13 7. Place I.D. Plate (24) onto Housing (1G) with two Drive
to 15 ft-lbs. (18 to 21 Nm). Screws (25). I.D. Plate (24) is to be inline with O-ring Plug
(1J) as shown on assembly print.
3. Install Elbow Fittings (36) into Motor Control Valve (32)
and torque to 13 to 15 ft-lbs. (18 to 21 Nm).
1J. O-Ring Plug 25. Drive Screw 34. Hex Bolt

10. Hydraulic Motor 26. Hydraulic Brake 35. Hydraulic Tubing
21. Plug 32. Motor Control Valve 36. Elbow
24. ID Plate 33. Lockwasher
Figure 3-45. Swing Drive - Motor Control Valve Assembly
3-74 – JLG Lift – 3121262

3.14 SWING BRAKE HYDRAULIC/MECHANICAL
To check brake release, connect an appropriate hydraulic pres-

Pre-Installation Checks sure supply set to the required level up to a maximum of 3000
MECHANICAL psi (200bar) and check that brake shaft (1) is free to rotate.
Check, That in the handling prior to assembly, the mounting

Remove hydraulic supply from brake, checking to ensure that
features and other parts of the brake are undamaged. Ensure
the friction plates (3 & 6) have engaged thus preventing rota-
that the shaft to which the brake is mounted are clean and free
tion of brake shaft (1)
from burrs and swellings.
RELEASE PRESSURE DURING BENCH TESTING SHOULD BE LIMITED TO 2000

PSI (138 BAR) UNLESS BRAKE IS FULLY INSTALLED USING 2-OFF 1/2” UNC
MOUNTING BOLTS IN THE THROUGH (MOUNTING) HOLES.
1. Brake Shaft 9. Piston 17. O-Ring

2. Housing 10. Deep Groove Ball Bearing 18. Backing Ring
3. Inner Friction Plate 11. Internal Retaining Ring 19. Dowel Pin
4. Pressure Plate 12. Rotary Shaft Seal 20. Hexagon Plug
5. Gasket 13. Socket Head Cap Screw 21. Plastic Plug
6. Outer Plate 14. Shakeproof Washer 21A. Socket Pressure Plug
7. Gasket 15. O-Ring 22. Spring (Natural)
8. Cylinder 16. Backing Ring 23. Spring (Blue)
Figure 3-46. Swing Brake
3121262 – JLG Lift – 3-75

Installation 6. Remove springs (8). Take note of quantity and orien-

tation of springs.
Position 1-off gasket (5) over male pilot on brake housing (4).
Locate brake shaft (1) and secure brake in position using 2-off 7. Should it be necessary to replace ball bearing (10)
1/2” UNC mounting bolts in the through mounting (fixing) or shaft seal (12), reverse remainder of brake sub-
holes provided. assembly, supporting on face “c” of housing (2).
Connect hydraulic pressure supply to brake pressure inlet
port. Ensure that the hydraulic pressure is set to the required 8. Remove internal retaining ring (11).
level up to a maximum of 3000 psi (200 bar) and check that the 9. Using arbor press or similar to break Loctite seal,
brake disengages and re-engages correctly. remove brake shaft (1) from housing (2) and lay
aside.
Maintenance
10. Reverse housing (2) and press out ball bearing (10).
The brake is required to be kept in good working order and Shaft seal (12) can also be removed if necessary.
must be included in the planned maintenance program for the
equipment to which the brake is installed.
This must include torque testing together with inspection and Examination
replacement of the working parts such as friction plates (3 & 6) All components can now be examined and inspected,
and, springs (22 & 23). The frequency of inspection depends paying particular attention to the following.
on the duty demanded of the brake.
1. Inspect friction plates (3 & 6) and friction surface on
Disassembly pressure plate (4) for wear or damage.
To remove brake from its installed position, reverse procedure 2. Examine friction plates (3) and brake shaft (1) for
previously described in the installation instructions. wear or damage to splines.
Place the complete brake assembly on a clean, dry work
bench. 3. Examine input and output splines of brake shaft (1)
for wear or damage.
Remove external gasket (5) as necessary. 4. Examine compression springs (22 & 23) for damage
or fatigue.
NOTE: Refer to Diagrams for the following.
5. Check ball bearing (10) for axial float or wear.
1. Supporting brake face “A”, remove the six socket head
6. Examine O-ring seals (15 & 17) and backing rings
cap screws and washers (items 13 & 14) in equal incre-
(16 & 18) for damage.
ments to ensure the spring pressure within the brake is
reduced gradually and evenly. 7. Obtain replacement parts as required.
Alternatively, if press is available, the cylinder housing
(8) can be restrained on face “B” while removing the six
socket head cap screws and washers (13 & 14).
Assembly
The brake assembly can now be fully dismantled and Clean all parts thoroughly.
parts examined. Reverse procedure previously outlined in Dismantling
instructions taking particular care with.
2. Remove cylinder housing (8) and piston (9) subassembly
and dismantle if required, removing O-ring seals (15 & a. Assembly of shaft seal (12).
17) and backing rings (16 & 18) as necessary.
b. Assembly of bearing (10).
3. Remove gasket (7) from housing (2). c. Quantity and orientation of springs (8).
4. Remove friction plates (3 & 6) and pressure plate (4). d. Assembly sequence of friction plates (3 & 6).
5. Remove 2-off dowel pins (19). 1. Lightly lubricate rotary shaft seal (12) and assemble
to housing (2) taking care not to damage seal lip.
3-76 – JLG Lift – 3121262

2. Apply ring of Loctite 641 or equivalent adhesive to 4. Lubricate O-ring seals (15 & 17) with Molykote 55M
full circumference of housing (2) bearing recess (or equivalent) silicone grease and assemble
adjacent to shoulder. together with backing rings (16 & 18) to piston (9).
Apply complete coverage of Loctite 641 to outside To ensure correct brake operation, it is important
diameter of bearing (10) and assemble fully in hous- that the backing rings are assembled opposite ti the
ing (2), retaining with internal retaining ring (11). pressurized side of piston (9).
Remove excess adhesive with clean cloth. 5. Correctly orientate piston (9) aligning spaces with
Press shaft (1) through bearing (10), ensuring bear- the two dowel pin holes and, assemble into cylinder
ing inner ring is adequately supported. housing (2) taking care not to damage seals and
carefully lay aside.
3. Assemble correct quantity of springs (8) in orienta-
6. Loctite 2-off pins (19) in housing (2) followed by pres-
tion required. Refer to (See Figure 3-47.) and (See
sure plate (4) and friction plates i.e. an inner (3) followed
Figure 3-48.).
by an outer (6) in correct sequence.
7. Position gasket (7) in correct orientation.
8. Align two holes in cylinder with dowel pins (19) and
assemble piston & cylinder sub-assembly to remainder
of brake securing with 6-off socket head cap screws and
washers (13 & 14). Torque to 55ft/lbs. (75 Nm).
NOTE: The use of a suitable press (hydraulic or arbor) Pressing

down on cylinder end face “B” will ease assembly of the
socket head cap screws (13).
Figure 3-47. Swing Brake 8 Spring Orientation
Figure 3-48. Swing Brake 12 Spring Orientation
3121262 – JLG Lift – 3-77

1. Brake Shaft 8. Cylinder 15. O-Ring

2. Housing 9. Piston 16. Backing Ring
3. Inner Friction Plate 10. Deep Groove Ball Bearing 17. O-Ring
4. Pressure Plate 11. Internal Retaining Ring 18. Backing Ring
5. Gasket 12. Rotary Shaft Seal 19. Dowel Pin
6. Outer Plate 13. Socket Head Cap Screw 20. Hexagon Plug
7. Gasket 14. Shakeproof Washer 21. Plastic Plug
21A. Socket Pressure Plug
Figure 3-49. Swing Brake Assembly
3-78 – JLG Lift – 3121262

3.15 SWING MOTOR
Disassembly and inspection

1. Place the Torqlink™ in a soft jawed vice, with coupling
shaft (12) pointed down and the vise jaws clamping
firmly on the sides of the housing (18) mounting flange
or port bosses. Remove manifold port O-Rings (18A) if
applicable.
3. Remove the five, six, or seven special ring head bolts (1)
using an appropriate 1/2 or 9/16 inch size socket.
Inspect bolts for damaged threads, or sealing rings,
under the bolt head. Replace damaged bolts.
IFTHETORQLINK™ IS NOT FIRMLY HELD IN THE VISE, IT COULD BE DISLODGED

DURINGTHE SERVICE PROCEDURES, CAUSING INJURY.
2. Scribe an alignment mark down and across the Torq-

link™ components from end cover (2) to housing (18) to
facilitate reassembly orientation where required. Loosen
two shuttle or relief valve plugs (21) for disassembly
later if included in end cover. 3/16 or 3/8 inch Allen 4. Remove end cover assembly (2) and seal ring (4). Discard
wrench or 1 inch hex socket required. seal ring.
NOTE: Refer to the appropriate “alternate cover construction” on

the exploded view to determine the end cover construction
being serviced.
3121262 – JLG Lift – 3-79

1. Special Bolts 8B. Stator or Stator Vane 15. Thrust Bearing

2. End Cover 8C. Vane 16. Seal
3. Seal Ring-Commutator 8D. Stator Half 17. Back-up Washer
4. Seal Ring 9. Wear Plate 18. Housing
5. Commutator Ring 10. Drive Link 18A. O-Ring
6. Commutator Ring 11. Not Used 19. Bearing/Bushing, Outer
7. Manifold 12. Coupling Shaft 20. Dirt & Water Seal
8. Rotor Set 13. Bearing/Bushing, Inner 21. Plug
8A. Rotor 14. Thrust Washer
Figure 3-50. Swing Drive Motor
5. If the end cover (2) is equipped with shuttle valve com-

ponents, remove the two previously loosened plugs
(21). BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS
THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE
REMOVED.
NOTE: The insert and if included the orifice plug in the end cover
(2) must not be removed as they are serviced as an integral
part of the end cover.
3-80 – JLG Lift – 3121262

6. Thoroughly wash end cover (2) in proper solvent and 8. Remove commutator (5) and seal ring (3) Remove seal
blow dry. Be sure the end cover valve apertures, includ- ring from commutator, using an air hose to blow air into
ing the internal orifice plug, are free of contamination. ring groove until seal ring is lifted out and discard seal
Inspect end cover for cracks and the bolt head recesses ring. Inspect commutator for cracks or burrs, wear, scor-
for good bolt head sealing surfaces. Replace end cover ing, spalling or brinelling. If any of these conditions exist,
as necessary. replace commutator and commutator ring as a matched
set.
NOTE: A polished pattern (not scratches) on the cover from rota-

tion of the commutator (5) is normal. Discoloration would
indicate excess fluid temperature, thermal shock, or excess
speed and require system investigation for cause and close
inspection of end cover, commutator, manifold, and rotor
set.
7. Remove commutator ring (6). Inspect commutator ring

for cracks, or burrs.
9. Remove manifold (7) and inspect for cracks surface scor-

ing, brinelling or spalling. Replace manifold if any of
these conditions exist. A polished pattern on the ground
surface from commutator or rotor rotation is normal.
Remove and discard the seal rings (4) that are on both
sides of the manifold.
3121262 – JLG Lift – 3-81

NOTE: The manifold is constructed of plates bonded together to

form an integral component not subject to further disas-
sembly for service. Compare configuration of both sides oft
hem an if old to ensure that same surface is reassembled
against the rotor set.
10. Remove rotor set (8) and warplane (9), together to retain
the rotor set in its assembled form, maintaining the
same rotor vane (8C) to stator (8B) contact surfaces. The
drive link (10) may come away from the coupling shaft
(12) with the rotor set, and wearplate.You may have to
shift the rotor set on the warplane to work the drive link
out of the rotor (8A) and warplane. Inspect the rotor set
in its assembled form for nicks, scoring, or spalling on
any surface and for broken or worn splines. If the rotor
NOTE: Series TG Torqlinks™ may have a rotor set with two stator
set component requires replacement, the complete
halves (8B) with a seal ring (4) between them and two sets
rotor set must be replaced as it is a matched set. Inspect
of seven vanes (8C). Discard seal ring only if stator halves
the warplane for cracks, brinelling, or scoring. Discard
become disassembled during the service procedures.
seal ring (4) that is between the rotor set and wearplate.
NOTE: A polished pattern on the wear plate from rotor rotation is

normal.
11. Place rotor set (8) and wear plate (9) on a flat surface
and center rotor (8A) in stator (8B) such that two
rotor lobes (180 degrees apart) and a roller vane
(8C) centerline are on the same stator centerline.
Check the rotor lobe to roller vane clearance with a
feeler gage at this common centerline. If there is
more than 0.005 inches (0.13 mm) of clearance,
replace rotor set.
NOTE: The rotor set (8) components may become disassembled

during service procedures. Marking the surface of the rotor
and stator that is facing UP, with etching ink or grease pen-
cil before removal from Torqlink™ will ensure correct reas-
sembly of rotor into stator and rotor set
intoTorqlink™.Marking all rotor components and mating
spline components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set
andTorqlink™.
NOTE: If rotor set (8) has two stator halves (8B & 8D) and two sets
of seven vanes (8C & 8E) as shown in the alternate con-
struction TG rotor set assembly view, check the rotor lobe
to roller vane clearance at both ends of rotor.
3-82 – JLG Lift – 3121262

12. Remove drive link (10) from coupling shaft (12) if it was 15. Remove coupling shaft (12), by pushing on the output
not removed with rotor set and wear plate. Inspect drive end of shaft. Inspect coupling shaft bearing and seal sur-
link for cracks and worn or damaged splines. No percep- faces for spalling, nicks, grooves, severe wear or corro-
tible lash (play) should be noted between mating spline sion and discoloration. Inspect for damaged or worn
parts. Remove and discard seal ring (4) from housing internal and external splines or keyway. Replace cou-
(18). pling shaft if any of these conditions exist.
13. Remove thrust bearing (11) from top of coupling shaft

(12). Inspect for wear, brinelling, corrosion and a full
complement of retained rollers.
NOTE: Minor shaft wear in seal area is permissible. If wear

exceeds 0.020 inches (0.51 mm) diametrically, replace cou-
pling shaft.
14. Check exposed portion of coupling shaft (12) to be sure
you have removed all signs of rust and corrosion which
might prevent its withdrawal through the seal and bear- NOTE: A slight “polish” is permissible in the shaft bearing areas.
ing. Crocus cloth or fine emery paper may be used. Anything more would require coupling shaft replacement.
16. 16. Remove and discard seal ring (4) from housing (18).
3121262 – JLG Lift – 3-83

17. Remove thrust bearing (15) and thrust washer (14) 19. Remove housing (18) from vise, invert it and remove and
Inspect for wear, brinelling, corrosion and a full comple- discard seal (20). A blind hole bearing or seal puller is
ment of retained rollers. required.
18. Remove seal (16) and back up washer (17) from Small 20. Inspect housing (18) assembly for cracks, the machined
Frame, housing (18). Discard both. surfaces for nicks, burrs, brinelling or corrosion. Remove
burrs that can be removed without changing dimen-
sional characteristics. Inspect tapped holes for thread
damage. If the housing is defective in these areas, dis-
card the housing assembly.
21. If the housing (18) assembly has passed inspection to

this point, inspect the housing bearings/bushings (19)
and (13) and if they are captured in the housing cavity
the two thrust washers (14) and thrust bearing (15). The
bearing rollers must be firmly retained in the bearing
cages, but must rotate and orbit freely. All rollers and
thrust washers must be free of brinelling and corrosion.
The bushing (19) or (13) to coupling shaft diameter
clearance must not exceed 0.010 inch (0.025 mm). A
bearing, bushing, or thrust washer that does not pass
inspection must be replaced. If the housing has passed
3-84 – JLG Lift – 3121262

this inspection the disassembly of the Torqlink™ is com- NOTE: The depth or location of bearing/bushing (13) in relation to
pleted. the housing wear plate surface and the depth or location
of bearing/bushing (19) in relation to the beginning of
bearing/bushing counter bore should be measured and
noted before removing the bearings/ bushings. This will
facilitate the correct reassembly of new bearings/bushings.
22. If the bearings, bushing or thrust washers must be

replaced use a suitable size bearing puller to remove
bearing/bushings (19) and (13) from housing (18) with-
out damaging the housing. Remove thrust washers (14)
and thrust bearing (15) if they were previously retained
in the housing by bearing (13).
3121262 – JLG Lift – 3-85

Assembly
Replace all seals and seal rings with new ones each time you
reassemble the Torqlink™ unit. Lubricate all seals and seal rings
with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal

kit are available. The parts should be available through
most OEM parts distributors or Parker approved Torqlink™
distributors. (Contact your local dealer for availability).
NOTE: Unless otherwise indicated, do not oil or grease parts

before assembly.
NOTE: Bearing mandrel must be pressed against the lettered end
Wash all parts in clean petroleum-based solvents before of bearing shell. Take care that the housing bore is square
assembly. Blow them dry with compressed air. Remove any with the press base and the bearing/bushing is not cocked
paint chips from mating surfaces of the end cover, commuta- when pressing a bearing/bushing into the housing.
tor set, manifold rotor set, wear plate and housing and from
port and sealing areas.
IF THE BEARING MANDREL SPECIFIED IN THE “TOOLS AND MATERIALS

REQUIRED FOR SERVICING” SECTION IS NOT AVAILABLE AND ALTERNATE
METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND (19) THE
SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN USING ANY
BEARING/BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADE-
SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR
QUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJACENT COM-
DEATH.
PONENTS WHEN ASSEMBLED.
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX- BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO THE
IMUM AIR PRESSURE REQUIREMENTS. HOUSING THEY MUST BE DISCARDED WHEN REMOVED. THEY MUST NOT BE
REUSED.
1. If the housing (18) bearing components were removed
for replacement, thoroughly coat and pack a new outer
bearing/bushing (19) with clean corrosion resistant
grease recommended in the material section. Press the
new bearing/bushing into the counterbore at the
mounting flange end of the housing, using the appro-
priate sized bearing mandrel, which will control the
bearing/ bushing depth.
Torqlink™ housings require the use of bearing mandrel

to press bearing/ bushing (19) into the housing to a
required depth of 0.151/0.161 inches (3.84/4.09 mm)
from the end of the bearing counterbore.
3-86 – JLG Lift – 3121262

2. The Torqlink™ inner housing bearing/bushing (13) can

now be pressed into its counterbore in housing (18)
flush to 0.03 inch (.76 mm) below the housing wear
plate contact face. Use the opposite end of the bearing
mandrel that was used to press in the outer bearing/
bushing (19).
3. Press a new dirt and water seal (20) into the housing (18)
outer bearing counterbore.
The Torqlink™ dirt and water seal (20) must be pressed in

until its flange is flush against the housing.
3121262 – JLG Lift – 3-87

4. Place housing (18) assembly into a soft jawed vise with 6. Assemble thrust washer (14) then thrust bearing (15)
the coupling shaft bore down, clamping against the that was removed from the Torqlink™.
mounting flange.
NOTE: Torqlinks™ require one thrust washer (14) with thrust bear-
5. On the Torqlinks™ assemble a new backup washer (17)
ing (15).The coupling shaft will be seated directly against
and new seal (16) with the seal lip facing toward the
inside of Torqlink™, into their respective counterbores in the thrust
housing (18) if they were not assembled in procedure 2.
7. Apply masking tape around splines or keyway on shaft
(12) to prevent damage to seal.
8. Be sure that a generous amount of clean corrosion resis-

tant grease has been applied to the lower (outer) hous-
ing bearing/bushing (19). Install the coupling shaft (12)
into housing (18), seating it against the thrust bearing
(15) in the housings.
ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE

BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A
NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16).
3-88 – JLG Lift – 3121262

9. Apply a small amount of clean grease to a new seal ring

(4) and insert it into the housing (18) seal ring groove.
THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYSTEM’S HYDRAULIC
FLUID. BE SURE IT IS THOROUGHLY PACKED WITH THE RECOMMENDED
GREASE, PARKER GEAR GREASE SPECIFICATION #045236, E/M LUBRICANT
#K-70M.
NOTE: Mobil Mobilith SHC ® 460
NOTE: A 102Tube (P/N 406010) is included in each seal kit.
NOTE: The coupling shaft (12) will be flush or just below the hous-
ing wear plate surface on Torqlinks™ when properly
seated. The coupling shaft must rotate smoothly on the
thrust bearing package.
NOTE: One or two alignment studs screwed finger tight into

housing (18) bolt holes, approximately 180 degrees apart,
will facilitate the assembly and alignment of components
as required in the following procedures.The studs can be
made by cutting off the heads of either 3/8-24 UNF 2A or 5/
16-24 UNF 2A bolts as required that are over 0.5 inch (12.7
mm) longer than the bolts (1) used in the Torqlink™.
10. Install drive link (10) the long splined end down into the
coupling shaft (12) and engage the drive link splines
into mesh with the coupling shaft splines.
NOTE: Use any alignment marks put on the coupling shaft and
drive link before disassembly to assemble the drive link
splines in their original position in the mating coupling
shaft splines.
3121262 – JLG Lift – 3-89

11. Assemble wear plate (9) over the drive link (10) and original rotor-drive link spline contact. A rotor set without
alignment studs onto the housing (18). a counterbore and that was not etched before disassembly
can be reinstalled using the drive link spline pattern on the
rotor splines if apparent, to determine which side was
down.The rotor set seal ring groove faces toward the wear
plate (9).
14. Apply clean grease to a new seal ring (4) and assemble it
in the seal ring groove in the rotor set contact side of
manifold (7).
12. Apply a small amount of clean grease to a new seal ring

(4) and assemble it into the seal ring groove on the wear
plate side of the rotor set stator (8B).
NOTE: The manifold (7) is made up of several plates bonded

together permanently to form an integral component.The
manifold surface that must contact the rotor set has it’s
series of irregular shaped cavities on the largest circumfer-
ence or circle around the inside diameter.The polished
impression left on the manifold by the rotor set is another
indication of which surface must contact the rotor set.
15. Assemble the manifold (7) over the alignment studs and
13. Install the assembled rotor set (8) onto wear plate (9) drive link (10) and onto the rotor set. Be sure the correct
with rotor (8A) counterbore and seal ring side down and manifold surface is against the rotor set.
the splines into mesh with the drive link splines.
NOTE: It may be necessary to turn one alignment stud out of the

housing (18) temporarily to assemble rotor set (8) or mani-
fold (7) over the drive link.
NOTE: If necessary, go to the appropriate, “Rotor Set Component

Assembly Procedure.”
NOTE: The rotor set rotor counterbore side must be down against
wear plate for drive link clearance and to maintain the
3-90 – JLG Lift – 3121262

16. Apply grease to a new seal ring (4) and insert it in the
seal ring groove exposed on the manifold.
19. If shuttle valve components items #21, were removed

17. Assemble the commutator ring (6) over alignment studs from the end cover (2) turn a plug (21), loosely into one
onto the manifold. end of the valve cavity in the end cover. A 3/16 inch
Allen wrench is required.
20. Assemble a new seal ring (4) into end cover (2) and
assemble end cover over the alignment studs and onto
the commutator set. If the end cover has only 5 bolt
holes be sure the cover holes are aligned with the 5
threaded holes in housing (18).The correct 5 bolt end
cover bolt hole relationship to housing port bosses.
18. Assemble a new seal ring (3) flat side up, into commuta-
tor (5) and assemble commutator over the end of drive
link (10) onto manifold (7) with seal ring side up.
3121262 – JLG Lift – 3-91

NOTE: If the end cover has a valve (24) or has five bolt holes, use
the line you previously scribed on the cover to radially align
the end cover into its original position.
21. Assemble the 5 or 7 special bolts (1) and screw in finger

tight. Remove and replace the two alignment studs with
bolts after the other bolts are in place. Alternately and
progressively tighten the bolts to pull the end cover and NOTE: The special bolts required for use with the relief or shuttle
other components into place with a final torque of 22-26 valve (24) end cover assembly (2) are longer than the bolts
ft. lbs. 45-55 ft. lbs.(61-75 N m) for the seven 3/8-24 required with standard and cover assembly. Refer to the
threaded bolts. individual service parts lists or parts list charts for correct
service part number if replacement is required.
22. Torque the two shuttle valve plug assemblies (21) in end
cover assembly to 9-12 ft. lbs. (12-16 Nm) if cover is so
equipped.
Torque the two relief valve plug assemblies (21) in end

cover assembly to 45-55 ft. lbs.(61-75 Nm) if cover is so
equipped.
3-92 – JLG Lift – 3121262

One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read-
A disassembled rotor (8A) stator (8B) and vanes (8C) that can- ily assemble into the stator vane pockets.
not be readily assembled by hand can be assembled by the
following procedures.
1. Place stator (8B) onto wear plate (9) with seal ring (4)
side down, after following Torqlink™ assembly proce-
dures 1 through 13. Be sure the seal ring is in place.
EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD
SHEAR OFF THE COATING APPLIED TO THE STATOR VANE POCKETS.
2. If assembly alignment studs are not being utilized, align 5. Grasp the output end of coupling shaft (12) with locking
stator bolt holes with wear plate and housing bolt holes pliers or other appropriate turning device and rotate
and turn two bolts (1) finger tight into bolt holes coupling shaft, drive link and rotor to seat the rotor and
approximately 180 degrees apart to retain stator and the assembled vanes (8C) into stator (8B), creating the
wear plate stationary. necessary clearance to assemble the seventh or full
complement of seven vanes. Assemble the seven vanes
3. Assemble the rotor (8A), counterbore down if applica-
ble, into stator (8B), and onto wear plate (9) with rotor using minimum force.
splines into mesh with drive link (10) splines.
NOTE: If the manifold side of the rotor was etched during Torqlink
disassembly, this side should be up. If the rotor is not
etched and does not have a counterbore, use the drive link
spline contact pattern apparent on the rotor splines to
determine the rotor side that must be against the wear
plate.
6. Remove the two assembled bolts (1) if used to retain sta-

tor and wear plate.
3121262 – JLG Lift – 3-93

3.16 PROCEDURE FOR SETTING GEAR BACKLASH 5. Pre-torque the capscrews (shown below) to 90 foot-
pounds (122 Nm) with Loctite #271.
1. Set backlash to 0.010 to 0.015" using the following pro-
cedure.
2. Place shim (JLG p/n 4071041) between pinion and bear-
ing 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.
3. Torque the shoulder screw (shown below) to 660 foot- 6. Tighten the setscrew (shown below) until the pinion is
pounds (896 Nm) with Loctite #271. completely snug against the shim and bearing and then
back off the setscrew.
4. Remove the turntable lock pin.

7. Torque the setscrew to 50 foot-pounds (68 Nm).
3-94 – JLG Lift – 3121262

8. Tighten the jam nut (shown below) with Loctite #271. The Swing Gearbox is to be filled with 79 ounces (2.3 L) of API
Service Classification GL-5 Extreme Pressure Gear Lube. Fill to
cover the ring gear.
1.195 IN. (30.35 mm) TOP OF HOUSING TO TOP

OF RING GEAR. TO BE FILLED TO COVER RING
GEAR.
9. Torque the capscrews shown in step 5 to 660 foot-

pounds (896 Nm).
10. Remove shim and discard.
3.17 SWING DRIVE LUBRICATION Figure 3-52. Swing Drive Lubrication
The Swing Brake is to be filled half full, 2.7 ounces (80 ml), with
DTE24 oil.
1 Brake Bleed Port

2 Brake Fill Port
3 Gearbox Fill Port
4 Gearbox Drain Port
Figure 3-51. Swing Drive Ports
3121262 – JLG Lift – 3-95

3.18 SWING BEARING c. Ensure that the 0.0015” feeler gauge will not pene-
trate under the bolt head to the bolt shank.
d. Swing the turntable 90 degrees, and check some
Turntable Bearing Mounting Bolt Condition selected bolts at the new position.
Check e. Continue rotating the turntable at 90 degrees inter-
vals until a sampling of bolts have been checked in
all quadrants.
THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL 2. Check the turntable to bearing attach bolts as follows:
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE a. Elevate the fully retracted main boom to full eleva-
SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION. tion.
b. At the position indicated on Figure 3-55. try to insert
NOTE: This check is designed to replace the existing bearing bolt the 0.0015” feeler gauge between the bolt head and
torque checks on JLG Lifts in service. This check must be hardened washer at the arrow indicated position.
performed after the first 50 hours of machine operation c. Lower the boom to horizontal and fully extend the
and every 600 hours of machine operation thereafter. If boom.
during this check any bolts are found to be missing or d. At the position indicated on Figure 3-54., try and
loose, replace missing or loose bolts with new bolts and insert the 0.0015” feeler gauge between the bolt
torque to the value specified in the torque chart, after head and hardened washer at the arrow indicated
applying loctite #271 to the bolt threads. After replacing position.
and retorquing bolt or bolts recheck all existing bolts for
looseness.
1. Check the frame to bearing attach bolts as follows:
a. Fully elevate the main boom. (See Figure 3-53.)

b. At the position indicated on Figure 3-53., try to
insert a 0.0015" feeler gauge between the bolt and
hardened washer at the arrow indicated position.
3-96 – JLG Lift – 3121262

Figure 3-53. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2
3121262 – JLG Lift – 3-97

3-98
– JLG Lift –
Figure 3-54. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2
3121262
3. If the measurement is greater than 0.094 in. (2.387 mm),

the swing bearing should be replaced.
4. If the measurement is less than 0.094 in. (2.387 mm), and
any of the following conditions exist, the bearing should
be removed, disassembled, and inspected for the fol-
lowing:
a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.
5. If bearing inspection shows no defects, reassemble and
Figure 3-55. Swing Bolt Feeler Gauge Check return to service.
Wear Tolerance
1. From the underside of the machine, at rear center, with

the main boom fully elevated and fully retracted, as
shown in Figure 3-53., Swing Bearing Tolerance Boom
Placement - Sheet 1 of 2, set up a magnetic base dial
indicator as shown below and set the indicator to 0
(zero).
2. Next, position the main boom fully extended and hori-

zontal as shown in Figure 3-54., Swing Bearing Tolerance
Boom Placement - Sheet 2 of 2. Read the measurement
recorded on the dial indicator gauge.
3121262 – JLG Lift – 3-99

Turntable/Swing Bearing Removal It may be necessary to disconnect additional lines to

gain access to certain fittings. Cap or plug all openings.
The following procedure was accomplished using two over-
head cranes with the jib assembly and the boom removed
prior to un-decking the turntable. For un-decking information
concerning lifting the entire upperstructure as a unit, or
removing the boom and jib assembly together refer to Section
4 - Boom & Platform.
1. Lower the platform to the ground or onto blocking to
support the weight of the jib.
2. Tag and disconnect the electrical harnesses that run to
the jib. If necessary, loosen the guide block to allow the
harnesses and hoses to move more freely.
5. Unbolt the valve from the boom.
3. Remove the jib valve protection plate.
4. Have a container or absorption material ready to catch

residual hydraulic fluid. Tag and disconnect the hydrau-
lic hoses that run from the boom to the jib control valve.
3-100 – JLG Lift – 3121262

Figure 3-56. Swing Bearing Removal - Sheet 1 of 4
3121262 – JLG Lift – 3-101

3-102
287” (729 cm)
CENTER
OF
GRAVITY
– JLG Lift –
Boom & Jib Assembly - 20,650 lbs. (9,370 kg)
Main Boom Pivot
3121262
3121262
Boom Assembly - 10,791 lbs. (4,895 kg)
227” (576.5 cm)
– JLG Lift –
CENTER
OF
GRAVITY
Main Boom Pivot
3-103
3-104
Turntable - 12,850 lbs. (5,825 kg)
Note: Attach Lifting Device to

Turntable Cutouts Closest to
This Side of Turntable
– JLG Lift –
C
L ROTATION
3121262
6. Lay the jib control valve aside on the jib. Secure it in 8. Remove the bolt and keeper pin securing the jib level
place so it does not fall. cylinder pivot pin and remove the pin. Place blocking or
a soft material under the cylinder rod to protect the rod
surface from being scratched.
7. Disconnect the jib protractor sensor linkage from the

boom.
NOTE: The jib and platform assembly weighs approximately 2100

lbs. (953 kg.).
3121262 – JLG Lift – 3-105

9. Attach an adequate supporting device to the jib to sup- 11. At the rear of the turntable, tag and disconnect all wir-
port its weight. Remove the bolt and keeper pin securing harnesses that run from the powertrack to the
ing the jib pivot pin and remove the pin. ground control station. The connector inside the ground
control box will have to be removed from the wires to
allow the harness to be pulled out of the control box. It
will simplify installation if a diagram of the wiring run-
ning into the connector is made at this time.
10. Remove the jib and platform assembly from the boom.

residual hydraulic fluid. Disconnect the pressure line
going into the platform filter, taking care to slowly bleed
off hydraulic pressure. Cap or plug all openings..
3-106 – JLG Lift – 3121262

13. Have a container or absorption material ready to catch 15. Remove the cover from the rear of the boom and dis-
residual hydraulic fluid. Disconnect the telescope hoses connect the wiring harnesses and hoses running from
from the bottom of the hydraulic control valve. Cap or the turntable to the boom.
plug all openings. Pull the hoses out so the can be lifted
away from the machine with the boom.
16. Disassemble the end of the turntable-to-boom pow-

ertrack from the turntable. Use a lifting device to pull
14. Have a container or absorption material ready to catch the powertrack up so the hydraulic hoses and wiring
residual hydraulic fluid. Disconnect the pressure hose harnesses can be pulled out from the turntable.
from the end of the main control valve. Cap or plug all
openings.
3121262 – JLG Lift – 3-107

17. Using the Main Lift Crackpoint option under the Calibra- NOTE: To assist in determining when the lift cylinder is properly
tions menu on the JLG Analyzer, lift the boom enough to supported, use the JLG Analyzer and select Diagnostics >
access the boom lift cylinder rod pivot pin. Refer to Sec- Moment > Actual Moment and get a reading as close to
tion 6 - JLG Control System for additional analyzer zero (0) as possible.
instructions.
20. Remove the bolt and keeper pin securing the boom lift
cylinder rod pivot pin and drive out the pivot pin.
NOTE: The boom assembly weighs approximately 10,800 lbs.

(4,900 kg.). 21. Lower the lift cylinder until it rests on the turntable.
18. Using an adequate lifting device, support the weight of 22. Attach an adequate lifting device to support the pivot
the boom. end of the boom.
19. Attach a lifting device to support the weight of the

boom lift cylinder.
23. Remove the bolt and keeper pin securing the boom
pivot pin and remove the pivot pin. Remove the boom
from the machine and place it on adequate supports.
3-108 – JLG Lift – 3121262

24. Disconnect the negative battery terminal from the bat- 27. Remove the attaching hardware securing the side of the
tery. hood.
25. Place a container under the machine to catch escaping 28. Remove the attaching hardware securing the top of the
hydraulic fluid. hood.
NOTE: The hood assembly weighs approximately 72 lbs. (33 kg). 29. Remove the front hood from the machine.
26. Attach an adequate lifting device to the rear hood

assembly.
30. Repeat steps 4, 5, and 6 for the front hood on the other
side of the machine.
3121262 – JLG Lift – 3-109

31. Tag and disconnect the hoses from the top of the swivel. NOTE: The complete swing drive assembly weighs approximately
Cap or plug all openings. Use a tie strap to secure the 290 lbs. (132 kg).
hoses together.
34. Remove the hardware securing the swing drive to the
turntable and remove the swing drive.
32. Tie off the bundle of hydraulic hoses to the center sup-
port to prevent any damage to the hoses during the
remainder of the procedure.
NOTE: Remove the shoulder/pivot bolt last.
33. Remove the hardware securing the swing brake to the

swing drive and lay the swing brake and motor to the
side.
3-110 – JLG Lift – 3121262

NOTE: The turntable assembly weighs approximately 20,650 lbs. 37. Lift the turntable assembly off of the swing bearing and
(9370 kg). place it on adequate supports.
35. Using the lifting lugs and the center support, attach a
lifting device to the front and rear of the turntable to
support its weight.
36. Remove the swing bearing inner race bolts. Remove the
bolts on the inside of the turntable first, leaving 3-4
bolts on both sides of the outside of the turntable to be
removed last.
38. Remove the remote grease lines from the bearing.
NOTE: The turntable assembly weighs approximately 20,650 lbs.

(9370 kg).
39. Remove the outer race bearing bolts from the underside
of the frame.
3121262 – JLG Lift – 3-111

40. Install lifting eyes into the swing bearing for removal. Turntable/Swing Bearing Installation
1. Remove the attaching hardware securing the swivel and
lay it off to the side.
NOTE: The swing bearing weighs approximately 300 lbs. (136 kg).
41. Attach an adequate lifting device to the swing bearing

and remove it from the frame.
2. Thoroughly clean the bearing mounting surface and

mounting holes.
3-112 – JLG Lift – 3121262

3. Locate the high spot on the swing bearing. This will be 7. Install grease fittings into the bearing and also install
marked by blue paint and two X’s on the bearing teeth. two pins to facilitate turning the bearing by hand and
for alignment of the turntable.
4. Place the new bearing onto the frame orienting the high
spot as close as possible to where the swing drive gear 8. Using the pins, turn the bearing slowly by hand while an
will be. assistant applies grease to the fitting. Apply grease until
the bearing is adequately greased around the entire cir-
cumference of the bearing.
9. Place the swivel back into position and secure in place
with the mounting hardware.
10. Line up the two grease holes in the bearing perpendicu-
lar to the chassis and install the remote grease lines.
5. Once the bearing is positioned on the frame, start the

outer race bolts by hand until they are all installed.
6. Tighten all the outer race bearing bolts until snug and
then torque them according to the torquing procedures
in this section.
11. Clean the bearing mounting surface on the bottom of

the turntable. If necessary, run a tap through the swing
drive mounting holes to clean the threads.
3121262 – JLG Lift – 3-113

12. Lift the turntable into place on the bearing using the 15. Connect the hoses to the top of the swivel as tagged
previously installed guide pins for alignment. during removal. Secure the hoses together with a tie
strap as shown.
13. Install all of the inner race bearing bolts hand tight.
Remove the guide pins to install the last two bolts. After
all of the bolts are installed, tighten them until snug. Dis-
connect the front lifting device at the front of the turnta-
ble (leaving the rear lifting device in place) to gain full
access to all bolts and torque the bolts according to the
torquing procedures in this section.
16. Using an adequate lifting device, set the swing drive in

place on the turntable. Make sure the swing bearing
high spot is still aligned with the swing drive gear. If nec-
essary, swing the turntable slightly to align the mark
with the gear.
14. After all swing bearing bolts are torqued, the rear lifting
device can be disconnected.
3-114 – JLG Lift – 3121262

17. Position the swing drive mounting bolts and backlash 19. Lift the boom from its supports.
adjusting shim, JLG p/n 4071041. Set backlash following
the procedures in this section.
18. Attach the swing bearing remote lubrication lines to the

turntable.
3121262 – JLG Lift – 3-115

20. While lifting the boom into position, begin to route the 22. Raise the boom enough to gain access to the lift cylin-
hoses into position so they can be inserted into the der rod pivot fitting.
powertrack.
23. Attach a lifting device to the lift cylinder barrel. Lift the
lift cylinder up to align the lift cylinder rod pivot fittings.
21. Line up the boom pivot fittings and install the boom
pivot pin. Apply JLG Threadlocker P/N 0100019 to the
bolt threads and secure the pin in place with the keeper
pin and bolt. Torque the bolt to 285 ft.lbs. (388 Nm). 24. Install the lift cylinder rod pivot pin. Apply JLG Thread-
locker P/N 0100019 to the bolt and secure the pivot pin
in place with the keeper pin and bolt. Torque the bolt to
285 ft.lbs. (388 Nm).
3-116 – JLG Lift – 3121262

25. Connect the hoses to the main valve and pressure filter 29. Place something under the front of the jib that will allow
as tagged during removal. it to slide or move along the ground easily. Attach a lift-
ing device to the rear of the jib, allowing the front to
pivot on the ground.
26. Reconnect the negative battery terminal.
30. Lift the jib into position on the boom fly section and
install the jib pivot pin. Apply JLG Threadlocker P/N
0100019 to the bolt and secure the pivot pin in place
with the keeper pin and bolt. Torque the bolt to 165
ft.lbs. (224 Nm).
27. Using auxiliary power, lower the boom to horizontal.

28. Attach an adequate lifting device to the jib and position
it in front of the boom.
3121262 – JLG Lift – 3-117

31. Attach a lifting device to the front of the jib and align 33. Install the wiring harnesses and hydraulic hoses on the
the jib level cylinder attachment fittings. Install the pivot jib valve as tagged during removal.
pin. Apply JLG Threadlocker P/N 0100019 to the bolt and
secure the pivot pin in place with the keeper pin and
bolt. Torque the bolt to 165 ft.lbs. (224 Nm).
34. Install the jib valve protection plate.

35. Connect all electrical harnesses as tagged during
removal. Reinstall the wiring into the connector plug in
the ground control box as tagged during removal.
32. Place the mounting bracket on the jib valve and bolt the
jib valve to the fly boom section.
3-118 – JLG Lift – 3121262

36. Position the hoods in place on the turntable and secure Swing Bearing Torque Values
in place with the mounting hardware.
1. Outer Race - 190 ft. lbs. (258 Nm) w/Loctite.
2. Inner Race - 190 ft. lbs. (258 Nm) w/Loctite.
3. See Swing Bearing Torquing Sequence.
CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR
LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS
THEREAFTER.
37. Cycle test the machine and check for leakage and
proper operation.
38. Perform a boom calibration as described in Section 6

under Calibrating the Boom Sensors.
3121262 – JLG Lift – 3-119

NOTE: Swing Bearing Torque Sequence is typical for both inner and outer races.
Figure 3-60. Swing Bearing Torque Sequence
3.19 SWING SPEED PROPORTIONING Beyond Transport - Drive Speed Cutback System, the tilt sen-
sor will cause an alarm to sound, and automatically put all
Swing Speed Proportioning uses the boom length and angle functions in the creep speed mode. With the exception of the
sensors to improve the comfort, speed and control of the turn- speed cutback, this is a warning system only. The machine will
table swing function. Turntable swing speed is increased as continue to function. The operator is responsible to prevent
the distance of the platform to the center of rotation is the machine from attaining an unstable position. The 8.0
decreased. This results in approximately constant platform degree angle is used exclusively for the purpose of automati-
speeds regardless of boom position. Swing speed proportion- cally shifting the drive motors to the maximum displacement
ing is disabled with any envelope sensors failure. Disabling of position (slow speed). The control system responds to indi-
swing speed proportioning will default to the slowest swing cated angle readings 0.5 degrees smaller than the required
speed setting. angles to account for calibration and sensor variation.
NOTE: For more detailed information concerning system adjust- NOTE: For more detailed information concerning system adjust-
ment and operation, refer to Section 6 - JLG Control Sys- ment and operation, refer to Section 6 - JLG Control Sys-
tem. tem.
3.20 CHASSIS TILT INDICATOR SYSTEM

The Chassis Tilt Indicator System measures the turntable angle
with respect to level ground. The tilt sensor (which is an inte-
gral part of the ground module) has two settings; 5.0 and 8.0
degrees. The smaller angle is used for the purpose of warning
the operator by means of the chassis tilt light in the platform
display panel. Additionally when used in conjunction with the
3-120 – JLG Lift – 3121262

3.21 GENERATOR Every 500 hours

Every 500 hours of operation, service the generator brushes
Every 250 hours and slip rings. Hostile environments may require more fre-
Every 250 hours of operation, check the drive belt for proper quent service.
tension.
1/2 in.
(13 mm)
Every 500 hours of service, blow out the inside of the genera-
tor. If operating in a hostile environment, clean monthly.
3121262 – JLG Lift – 3-121

Overload Protection Inspecting Brushes, Replacing Brushes, and

Cleaning Slip Rings
Refer to Figure 3-61., Inspecting Generator Brushes, Replacing
STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Brushes, and Cleaning Slip Rings.
BREAKER.
INSPECTING BRUSH POSITION
The circuit breaker protects the generator windings from over- Inspect brush alignment with slip rings. View alignment
load. If the circuit breaker opens, generator output stops. If the through the air vents in the stator barrel. The brushes must
circuit breaker continues to open, check for faulty equipment ride completely on the slip rings.
connected to the platform receptacles.
INSPECTING BRUSHES
Remove the end panel. Inspect the wires. Remove the brush
holder assembly. Pull the brushes from the holders.
Replace the brushes if damaged, or if the brush is at or near

minimum length.
CLEANING SLIP RINGS
CIRCUIT Visually inspect the slip rings. Under normal use, the rings turn
BREAKER dark brown.
If the slip rings are corroded or their surface is uneven, remove

the belt to turn the shaft by hand for cleaning.
Clean the rings with 220 grit emery paper. Remove as little
material as possible. If the rings are deeply pitted and do not
clean up, consult generator factory service.
Reinstall the belt, brush holder assembly, and end panel.
3-122 – JLG Lift – 3121262

Brush Position On Slip Rings
2
3
Acceptable Unacceptable
Brushes must ride
completely on slip
rings
1/4 in (6 mm)
Or Less - Replace
7/16 in - 1/2 in
2 (11 - 12 mm) New
1. Brush Holder Assembly

2. Brushes
3. Slip Rings
Figure 3-61. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3121262 – JLG Lift – 3-123

3.22 AUXILIARY POWER SYSTEM ity. The auxiliary power lift down function supplies pilot pres-
sure to the lift cylinder allowing gravity to lower the boom.
The auxiliary power system is intended as a secondary means The system redirects discharge oil from the lift cylinder to
of moving the boom in the event of primary power loss. This retract the telescope cylinder. When the boom is retracted to
system uses an electric motor/pump unit powered by a 12V the transport length, the telescope in valve is dropped out and
battery capable of operating all functions except drive, con- lift down is operated alone allowing the platform to reach the
trolled arc, controlled boom angle, and envelope tracking. ground. This not only greatly reduces the power required for
During lift up or down functions, no other functions are per- these functions but also lowers the boom within the envelope
mitted and during lift up functions, automatic platform level- regardless of starting position. Envelope control and moment
ing is not active. To reduce the demand on the battery and control remain active during the auxiliary power function.
therefore extend the run time of the system, the auxiliary
power functionality differs from the primary power functional-
1. Auxiliary Pump
2. Power Relay
3. Battery
Figure 3-62. Auxiliary Pump Installation
3-124 – JLG Lift – 3121262

3.23 ENGINE Check the oil level, and if necessary, top the oil level up
to the MAX mark with an approved grade and type of oil
NOTE: Refer to the engine manufacturer’s manual for detailed as outlined in the engine manufacturer’s operator’s
operating and maintenance instructions. manual. Refer to Figure 3-63., Deutz Engine Dipstick.
Glow Plugs MINIMUM OIL

LEVEL
If the glow plug option is enabled in the JLG Control System,
the glow plug and indicator lamp will be energized when the
Power/Emergency Stop switch is pulled on if the ambient air
temperature is less than 50° F (10° C) and the engine coolant
temperature is less than 140° F (60° C). This determination will
occur one second after the Power/Emergency Stop switch has MAXIMUM OIL
LEVEL
been pulled on. The lamp and glow plugs will remain ener-
gized for the period of time specified by the setting in the JLG
Control System. Engine start shall be disabled during this
period. On Deutz engines, the glow plugs will continue (post
glow) after the engine has started for three times the machine
digit setting.
MINIMUM LEVEL,
Checking Oil Level OIL HOT
MAXIMUM LEVEL,
OIL HOT
1. Switch the engine off before checking oil level.
2. Make sure the machine and engine are level.

MINIMUM LEVEL,
3. Remove the oil dipstick. OIL COLD
MAXIMUM LEVEL,
OIL COLD
4. Wipe the dipstick with non-fibrous, clean cloth.
NOTE: Hot oil checks should not be made until the engine
5. Insert the dipstick to the stop and remove again. has been shut down for a period of 5 minutes.
Figure 3-63. Deutz Engine Dipstick

6. Replace the dipstick making sure that it is fully seated in
the dipstick tube to seal off the crankcase.
3121262 – JLG Lift – 3-125

Changing Engine Oil 8. Pour in new engine oil. Refer to Section 1 for capacity
and refer to Figure 3-64., Engine Oil Viscosity for the
1. Allow the engine to warm up. The engine oil should proper grade.
reach approximately 176° F (80° C).
2. Make sure the machine and engine are level.
3. Switch off the engine.
4. Place an oil tray under the engine.
5. Open the oil drain valve.
Figure 3-64. Engine Oil Viscosity
Changing the Oil Filter
WHEN DRAINING HOT ENGINE OIL THERE IS A RISK OF SCALDING.
DO NOT LET USED OIL RUN INTO THE SOIL; COLLECT THE USED OIL IN A CON-
TAINER SUITABLE FOR DISPOSAL OR RECYCLING. DISPOSE OF THE USED
ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGULATIONS.
6. Drain the oil.

7. Close the oil drain valve.
1. Wipe the area around the filter to clean any dirt from the
area.
3-126 – JLG Lift – 3121262

2. Using a suitable oil filter removal tool, loosen the lube oil Replacing the Fuel Filter
filter cartridge and spin off.
3. Catch any escaping oil.
4. Clean any dirt from the filter carrier sealing surface.
5. Lightly oil the rubber gasket on the new oil filter. WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE
FUEL SYSTEM.
1. Wipe the area around the filter to clean any dirt from the
area.
2. Undo the fuel filter cartridge and spin off.
3. Catch any escaping fuel.
4. Clean any dirt from the filter carrier sealing surface.
5. Apply a light film of oil or diesel fuel to the rubber gas-
ket of the new filter cartridge.
6. Manually screw in the new filter until the gasket is flush.
6. Manually screw in the new filter until the gasket is flush. 7. Tighten the fuel filter cartridge with a final half-turn.
8. Open the fuel shut-off valve.
9. Check for leaks.
7. Tighten the filter another half-turn.
8. Check the oil level.
9. Check the oil pressure.
10. Check the oil filter cartridge and make sure there are no
leaks.
3121262 – JLG Lift – 3-127

Cleaning the Fuel Strainer 3.24 DEUTZ EMR 2

The EMR2 consists of the sensors, the control unit and the
actuator. Engine-side controls as well as the JLG Control Sys-
tem are connected by means of separate cable harnesses to
the EMR control unit.
The sensors attached to the engine provide the electronics in
the control unit with all the relevant physical parameters In
accordance with the information of the current condition of
the engine and the 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.
The 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 hous-
ing of the actuator.
The EMR2 is equipped with safety devices and measures in the
hardware and software in order to ensure emergency running
WHEN WORKING ON THE FUEL SYSTEM, MAKE SURE THERE ARE NO OPEN (Limp home) functions.
FLAMES OR SPARKS IN THE AREA. DO NOT SMOKE WHEN WORKING ON THE
FUEL SYSTEM. In order to switch the engine off, the EMR2 is switched in a de-
energized fashion over the ignition switch. A strong spring in
1. Unscrew the hexagonal nut (1). the actuator presses the control rod in the de-energized con-
dition into the zero position. As a redundancy measure, an
additional solenoid serves for switching off and this, indepen-
dently of the actuator, also moves the control rod in the de-
energized condition into the zero position.
After the programming, that is carried out over the ISO9141
interface, the EMR2 is possesses a motor-specific data set and
this is then fixedly 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.
2. Remove the fuel strainer cover (2).
3. Clean the fuel strainer with diesel fuel, replace if neces-

sary.
4. Place the seal (3) in position.
5. Install the fuel strainer cover (2) in position and tighten

the hexagonal screw (1).
6. Check for leaks.
3-128 – JLG Lift – 3121262

CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE FLYWHEEL SPEED

SENSOR SENSOR
JLG SYSTEM HANDLES ENGINE START/STOP; EMR2

TAKES CONTROL OF THE ENGINE AT 700RPM
GLOW PLUG
JLG SYSTEM USES JLG ANALYZER TO REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS; JLG SYSTEM USES THIS

OIL PRESSURE TO CONTROL THE ENGINE & FAULT REPORTING.
SENSOR
Figure 3-65. EMR 2 Engine Side Equipment
3121262 – JLG Lift – 3-129

3-130
Deutz EMR2;
Fails to Start/
Runs Abnormally
Does the machine Add fuel or

have fuel and a NO replace/
charged battery? recharge
battery.
YES
The starter and/
Connect or starter solenoid
Verify the needs replaced
JLG starter relay
Analyzer is getting
12V when
the start
Cycle Power YES switch is YES
engaged.
Unplug the vehicle NO
side engine module
Are there any Does the fault connector. Verify On the analyzer, are
faults listed since indicate the engine there is 12V across Can you start there faults indicating Does the
the power was YES module is not YES pins 1 (Ground) & 14 the engine? NO Cycle Power NO starter crank?
(Battery +). Verify an open circuit on
cycled? detected? the starter relay?
there is 60 Ohms
across pins 12 & 13
NO (CAN High & Low)
YES
NO
Does the
engine operate YES
– JLG Lift –
correctly?
The EMR2 needs
NO replaced.
Contact
Deutz
Service
Department
Connect Does the fault

Laptop to Replace/Repair
use Deutz indicate a Deutz the faulty
Diagnostic NO fault code YES wiring/
Software number? component(s)
YES
Does the
diagnostic software
indicate a problem?
Figure 3-66. Deutz EMR 2 Troubleshooting Flow Chart
3121262
3121262
– JLG Lift –
Figure 3-67. Deutz EMR 2 Vehicle Side Connection Diagram
3-131
3-132
– JLG Lift –
Figure 3-68. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3121262
3121262
– JLG Lift –
Figure 3-69. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3-133
Figure 3-70. EMR 2 Engine Plug Pin Identification
3-134 – JLG Lift – 3121262

Figure 3-71. EMR 2 Vehicle Plug Pin Identification
3121262 – JLG Lift – 3-135

Figure 3-72. EMR2 Fault Codes - Sheet 1 of 5
3-136 – JLG Lift – 3121262

3121262 – JLG Lift – 3-137

3-138 – JLG Lift – 3121262

3121262 – JLG Lift – 3-139

3-140 – JLG Lift – 3121262

3.25 BIO FUEL IN DEUTZ ENGINES 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
General
comply with the ASTM D6751-07a (B100) standard.
Use of bio fuels is permitted for the compact engines made by
DEUTZ. APPROVED ENGINES
The 912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and
Distillate fuels with residue oil percentages or mixed fuels may
513 series are approved for bio-diesel from year of manufac-
not be used in DEUTZ compact engines.
ture 1993 under compliance with the basic conditions speci-
The DEUTZ vehicle engines are designed for diesel fuels in fied below.
accordance with EN 590 with a cetane number of at least 51.
DEUTZ engines for mobile machinery are designed for a cetane BASIC CONDITIONS TO BE OBSERVED
number of at least 45. When using fuels of a low cetane num- • A power loss of 5-9 % in relation to diesel fuel in accor-
ber, disturbing white smoke and ignition misfires are to be dance with EN 590 is possible due to the lower heating
expected under some circumstances. value. Blocking of the fuel injector is not allowed.
A cetane number of at least 40 is permissible for the US market, • The lubricating oil quality must correspond to TR 0199-
therefore special engine models have been developed to 99-3002. The lubricating oil change interval must be
avoid starting difficulties, extreme white smoke or increased halved in relation to operation with diesel fuel in accor-
hydrocarbon emissions (EPA specification - US EPA REGULA- dance with EN 590.
TIONS FOR LARGE NONROAD COMPRESSION-IGNITION
ENGINES). • Standstills of longer than 4 to 6 weeks must be avoided
with bio-diesel. Otherwise the engine must be started and
If the white smoke behavior is unacceptable when using a very
stopped with diesel fuel.
low cetane number, the use of ignition improvers is to be rec-
ommended as a later remedial measure. • Bio-diesels can be mixed with normal diesel fuel but the
basic conditions described in this subsection apply for mix-
The certification measurements for compliance with the legal
tures. Mixtures with up to 5 % (m/m) bio-diesel (B5) which
emission limits are carried out with the test fuels prescribed by
have recently been on sale at European fuel stations are
law. These correspond to the diesel fuels in accordance with
excepted. These fuels must be treated like normal diesel
EN 590 and ASTM D 975. No emission values are guaranteed
fuels because EN 590 expressly permits adding up to 5 %
with the other fuels described. It is the obligation of the owner
(m/m) bio-diesel in accordance with EN 14214.
to check the permission for use of the fuels in accordance with
regional regulations. • Approx. 30-50 hours after changing over from diesel fuel to
bio-diesel, the fuel filter should be changed as a preventive
Bio Fuel measure to avoid a drop in performance due to clogged fuel
filters. Deposited fuel ageing products are dissolved by bio-
PERMITTED BIO-DIESEL FUELS diesel and transported into the fuel filter. They should not
Originally only rape seed oil methylester (RME) was sold as a be changed immediately but after approx. 30 to 50 hours
bio-diesel fuel in Europe but fatty acid methylester (FAME) because the dissolving of dirt takes a certain amount of
based on other oils have come onto the market increasingly in time.
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-Man-
agement Biodiesel e.V.).
3121262 – JLG Lift – 3-141

PLANT OIL PREVENTIVE MEASURES

• Keep the storage tank clean, regular cleaning of the tank
by specialist companies
PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS • Installation of fuel pre-filters with water traps, especially in
BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPER- countries with frequently fluctuating fuel qualities and high
ATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH percentage of water.
VISCOSITY, POOR EVAPORATION BEHAVIOR.
If the fuel system and storage tank have already been attacked
by micro-organisms. The biocide must be dosed according to
The conversion of DEUTZ engines to rape seed oil fuel opera-
the manufacturer's specifications.
tion with conversion kits and modified tanks systems of vari-
ous manufacturers is not allowed and leads to loss of warranty • Avoid direct exposure of the storage tank to sunlight
rights.
• Use smaller storage tanks with corresponding low dwell
times of the stored fuel
Biological Contamination In Fuels
FUEL ADDITIVES
SYMPTOMS The use of fuel additives is not permitted. The flow improvers
The following symptoms may indicate that a fuel tank is con- mentioned above are an exception. Use of unsuitable additives
taminated by micro-organisms: will result in loss of warranty.
• Internal tank corrosion,

• Filter blockage and the associated loss of power due to gel-
like deposits on the fuel filter (especially after long stand-
stills)
CAUSE
Micro-organisms (bacteria, yeasts, funguses) can form bio-
sludge under unfavorable conditions (favoured particularly by
heat and water).
Penetration by water is usually caused by condensation of the

water in the air. Water does not dissolve in fuel so that the pene-
trating water collects at the bottom of the tank. The bacteria and
funguses grow in the watery phase, at the phase boundary to
the fuel phase, from which they draw their nutrition. There is an
increased risk especially with bio-diesel (FAME).
3-142 – JLG Lift – 3121262

3.26 CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE This section is organized in the following manner:
CODE DEFINITIONS 1st page of Diagnostic Information for a Given Fault (See Fig-
ure 3-77.) then:
This section defines the diagnostics and recommended trou-
bleshooting procedures associated with the engine control 2nd Page of Diagnostic Information for a Given Fault (See Fig-
module (ECM) on the CAT 3.4 engine. ure 3-78.)
DTC XXXX- Diagnostic Condition
Block Diagram of Circuit
External Hardware Input/Output- This identifies the hardware that either sends an input
to the ECM or is driven by and ECM output.
Check Condition- This defines what condition to troubleshoot the fault condition.
Fault Condition(s)- This identifies the condition(s) that set the fault.
Corrective Action(s)- This identifies the RECOMMENED corrective action(s) that the
ECM is generally programmed to perform. In some instances, the calibration
engineer(s) may choose to perform a different action.
Emissions or Non-emissions related fault
Text to identify the circuit of interest and its use for control.
Text to describe t he conditions that cause the fault to set.
Figure 3-77. 1st page of Diagnostic Information for a Given Fault
3121262 – JLG Lift – 3-143

DTC XXXX- Diagnostic Condition
Note: Helpful tips used to aid troubleshooting
Yes
Troubleshooting flow
chart
No
Figure 3-78. 2nd Page of Diagnostic Information for a Given Fault
3-144 – JLG Lift – 3121262

List of Abbreviations in this Section

AL Adaptive Learn LED Light Emitting Diode
BP Barometric Pressure LPG Liquefied Propane Gas
CAN Controller Area Network MAP Manifold Absolute Pressure
CCP CAN Calibration Protocol MGCP Marine Global Control Platform
CHT Cylinder Head Temperature μP Microprocessor
CL Closed Loop Mfg Manufacture
CNG Compressed Natural Gas MIL Malfunction Indicator Lamp
DBW Drive-By-Wire NG Natural Gas
DGC Diesel Governor Control OBD On-Board Diagnostics
DM Diagnostic Message OEM Original Equipment Manufacture
DMM Digital Multi-Meter (high impedance) PC Personal Computer
DST Diagnostic Scan Tool PCU Powertrain Control Unit
DTC Diagnostic Trouble Code PFI Port Fuel Injection
DVOM Digital Voltage and Ohm Meter (high impedance) PGN Parameter Group Number
ECI EControls Inc. PWM Pulse Width Modulated
ECIPP EControls Inc. Proprietary Protocol RAM Random Access Memory
ECM Engine Control Module RPM Revolutions Per Minute
ECT Engine Coolant Temperature Rx Receive
ECU Engine Control Unit SAE Society of Automotive Engineering
EDIS EControls Display and Interface Software SA Source Address
EGO Exhaust Gas Oxygen Sensor, typically heated SPFI Sequential Port Fuel Injection
EMWT Exhaust Manifold Water Temperature SPN Suspect Parameter Number
EPR Electronic Pressure Regulator Tach Tachometer
ERWT Exhaust Manifold Riser Temperature TBI Throttle Body Injection
ETB Electronic Throttle Body TDC Top Dead Center
ETC Electronic Throttle Control TIP Throttle Inlet Pressure
FDR Flight Data Recorder TPS Throttle Position Sensor
FMI Failure Mode Indicator TSC Torque/Speed Control
FO Firing Order Tx Transmit
3121262 – JLG Lift – 3-145

Universal Exhaust Gas Oxygen Sensor

FP Fuel Pressure UEGO
(also called wide-range EGO)
FPP Foot Pedal Position VDC Voltage, Direct Current
FRP Fuel Rail Pressure VR Variable Reluctance
FRT Fuel Rail Temperature Vsw Switched, Ignition Voltage
FSS Fault Snapshot WGP Waste-Gate Pressure
FT Fuel Temperature
GCP Global Control Platform
Heavy-Duty Global Control Platform

HDGCP
(On-Road Heavy-Duty)
HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S)
HO2S Heated Oxygen Sensor (same as HEGO)
IAC Idle Air Control
IAT Intake Air Temperature
ICAV Instant Crank Angle Velocity
IVS Idle Validation Switch
LDGCP Light-Duty Global Control Platform (Industrial, Smart/Logic Coil)
3-146 – JLG Lift – 3121262

Diagnostic Trouble Codes Resetting active and previously active DTCs is handled
through DM11 and DM3, respectively DM1 and DM2 lamp
The numeric diagnostic trouble codes assigned to the faults in
indicators are assigned to each fault based on the fault.s diag-
this section are cross-referenced to SAE’s "Recommended
nostic action as defined in the calibration. The lamps are
Practice for Diagnostic Trouble Code Definitions" (SAE J2012).
assigned based on the configuration outlined in Table 3-6.
While these codes are recommended, the manufacturer may
define their own codes by assigning a new number to the flash
code in the diagnostic calibration. This will assign both the Table 3-6. J1939 Diagnostic Lamp Configuration
DTC as displayed in EDIS as well as the flash code output on
the MIL output pin. EDIS may be used to connect to the DGC ECI DIAGNOSTIC ACTION J1939 LAMP
ECM via CAN.
MIL MIL
CAN Soft Warning Amber
The DGC supports SAE J1939 CAN based diagnostic support.
This includes: Hard Warning, Low Rev Limit, Shutdown Red Stop
• DM1: Active Diagnostic Trouble Codes Power Derate 1 & 2 Protect
• DM2: Previously Active Diagnostic Trouble Codes
None (use in combination with other
• DM3: Diagnostic Data Clear/Reset of Previously Active Forced Idle
action)
DTCs
• DM4: Freeze Frame Parameters MIL Output
• DM5: Diagnostic Readiness (bytes 1, 2, and 3 are sup- The MIL output is used to convey fault information to the
ported) equipment operator. The MIL is always on (grounded) when
the system is in a key-on (Vsw), engine-off state. This provides
• DM11: Diagnostic Data Clear/Reset For Active DTCs
assurance that the output is functional. If a DTC is logged as
• DM12: Emissions-Related Active Diagnostic Trouble Codes previously-active (historic), the MIL will send a single flash for
the “Blink on-time” every “Blink off-time.”
• DM19: Calibration Information
All diagnostic trouble codes broadcast over CAN will be SAE
J1939 DM1 and DM2 formatted messages. DGC ECMs are com-
pliant with J1939 OBD-M, supporting the Diagnostic Messages
above as well as user indicators and CAN data defined in the
OBD-M protocol. Faults available for broadcast and their
respective SPN/FMI numbers are dependent on the applica-
tion and engine calibration. There are 4 CAN SPN/FMI lists
available in the DGC software set, contact EControls Inc. for a
list of CAN SPN/FMIs.
The data capture at the occurrence of a fault, known in the

ECM as fault snapshot (FSS), is available upon DM4 request.
The following bytes are supported for DM4 if configured in the
ECM software:
• Byte 1: Freeze Frame Length

• Byte 2-6: SPN, FMI, SPN Conversion Method, and Occur-
rence
• Byte 7: Manifold Absolute Pressure
• Byte 8-9: Engine Speed
• Byte 10: Engine Load (MAP based estimate)
• Byte 11: Engine Coolant Temperature
• Byte 14: # of starts since fault was last active
• Byte 15: Index into FSS_storage table for Fault Snap Shot
retrieval
3121262 – JLG Lift – 3-147

DTC 116- ECT Higher Than Expected Stage 1
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor Diagnostic Aids

• Check Condition-Engine Running If the "ECT High Voltage" fault is also present, follow the trou-
• Fault Condition-Engine Coolant Temperature reading or bleshooting procedures for that fault as it may have caused
estimate greater than the stage 1 limit when operating at a "ECT Higher Than Expected 1."
speed greater than defined in the diagnostic calibration If the cooling system utilizes an air-to-water heat exchanger
• Corrective Action(s): Sound audible warning or illuminate (radiator) and fan:
secondary warning lamp, disable adaptive learn fueling
• Check that the radiator has a proper amount of ethylene
correction during active fault. Recommend a power derate
glycol/water and that the radiator is not leaking
1/2 and/or a low rev limit to protect engine from possible
damage. • Ensure that there is no trapped air in the cooling path
• Non-emissions related fault • Inspect the cooling system (radiator and hoses) for cracks
and ensure connections are leak free
The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in the engine coolant. • Check that the fan is operating properly
Some engines use a CHT sensor that is located in the coolant • Check that the thermostat is not stuck closed
in the cylinder head. Some engines use an ECT (Engine Cool-
ant Temperature) sensor that is located in the coolant near the If the cooling system utilizes a water-to-water heat exchanger:
thermostat. If the engine is equipped with a CHT sensor then • Check that the heat exchanger has a proper amount of eth-
the ECT value is estimated. If equipped with an ECT sensor ylene glycol/water and that the heat exchanger is not leak-
then the CHT value is estimated. They are used for engine air- ing
flow calculation, ignition timing control, to enable certain fea-
tures, and for engine protection. The ECM provides a voltage • Ensure that there is no trapped air in the cooling path
divider circuit so when the sensor reading is cool the sensor • Inspect the cooling system (radiator and hoses) for cracks
reads higher voltage, and lower when warm. and ensure connections are leak free
This fault will help protect the engine in the event of over tem- • Check that the raw water pickup is not blocked/restricted
perature. When the coolant exceeds x deg. F and engine RPM by debris and that the hose is tightly connected
exceeds y RPM for the latch time this fault will set.
• Check that the thermostat is not stuck closed
• Check that the raw water pump/impeller is tact and that it
is not restricted
3-148 – JLG Lift – 3121262

DTC 117- ECT/CHT Low Voltage
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor This fault will set if the signal voltage is less than the limit
defined in the diagnostic calibration anytime the engine is
• Check Condition-Engine Running running. The limit is generally set to 0.10 VDC. The ECM will
• Fault Condition-CHT/ECT sensor voltage less than the limit use a default value for the CHT/ECT sensor in the event of this
fault.
defined in the diagnostic calibration
• Corrective Action(s)- Sound audible warning or illuminate

correction during active fault, or any combination thereof
as defined in calibration. Recommend a power derate 1/2
to reduce the possibility of engine damage due to the
inability to sense temperature.
• Non-emissions related fault

perature sensitive resistor) located in the engine coolant.
Some engines use an ECT sensor that is located in the coolant
near the thermostat. Some engines use a CHT (Cylinder Head
Temperature) sensor that is located in the coolant in the cylin-
der head. If the engine is equipped with an ECT sensor then
the CHT value is estimated. If equipped with a CHT sensor then
the ECT value is estimated. The ECM provides a voltage divider
circuit so that when the coolant is cool, the signal reads higher
voltage, and lower when warm.
3121262 – JLG Lift – 3-149

· Key On, Engine Running

· System Mode = “Running”
· Key Off
Does DST display an ECT Yes · Disconnect ECT sensor from harness
voltage less the limit
defined in calibration? · Key On, Engine Off
· System Mode = “Stopped”
No
· Intermittent Problem Yes

Does DST display ECT · Faulty ECT
voltage of 4.9 VDC or Sensor
greater?
No
· Sensor signal circuit shorted to ground,

check wire harness for ground short
· Faulty ECM
3-150 – JLG Lift – 3121262

DTC 118- ECT/CHT High Voltage
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor This fault will set if the signal voltage is higher than the high
voltage limit as defined in the diagnostic calibration anytime
• Check Condition-Engine Running the engine is running. The limit is generally set to 4.90 VDC. In
many cases, this condition is caused by the CHT/ECT sensor
• Fault Condition-CHT/ECT sensor voltage higher than the being disconnected from the engine harness, an open-circuit
limit defined in the diagnostic calibration or short-to-power of the CHT/ECT circuit in the wire harness,
• Corrective Action(s)- Sound audible warning or illuminate or a failure of the sensor. The ECM will use a default value for
secondary warning lamp, disable adaptive learn fueling the CHT/ECT sensor in the event of this fault.
correction during active fault, or any combination thereof
as defined in calibration. Recommend a power derate 1/2
to reduce the possibility of engine damage due to the
inability to sense temperature.

perature sensitive resistor) located in the engine coolant.
Some engines use an ECT sensor that is located in the coolant
near the thermostat. Some engines use a CHT (Cylinder Head
Temperature) sensor that is located in the coolant in the cylin-
der head. If the engine is equipped with an ECT sensor then
the CHT value is estimated. If equipped with a CHT sensor then
the ECT value is estimated. The ECM provides a voltage divider
circuit so that when the coolant is cool, the signal reads higher
voltage, and lower when warm.
3121262 – JLG Lift – 3-151

3-152 – JLG Lift – 3121262

DTC 122- TPS1 Signal Voltage Low
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor 1 condition while the engine is cranking or running. The limit is
generally set to 4.90 VDC. In many cases, this condition is
• Check Condition-Key On, Engine Off
caused by the TPS sensor being disconnected from the engine
• Fault Condition-TPS1 sensor voltage lower than the limit harness, an open-circuit or short-to-ground of the TPS circuit
defined in the diagnostic calibration in the wire harness, or a failure of the sensor. This fault should
• Corrective Action(s): Sound audible warning or illuminate be configured to trigger an engine shutdown and the engine
secondary warning lamp, shutdown engine will not start with this fault active.

In the case of a diesel engine, an actuator controls a fuel injec-
tion pump, directly affecting the fueling level into the cylin-
ders. This may be by direct manipulation of the fuel injection
pump rack or by manipulation of the mechanical governor
control level or "throttle arm." In the DGC ECM and EDIS, refer-
ences to the throttle and throttle position sensor refer to these
fuel injection pump control actuators and their position feed-
back sensors. When the fuel injection pump is electronically
controlled it can be used to control the idle stability and limit
engine speed based on operating conditions.
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit or
2) a non-contact hall-effect sensor to determine throttle actu-
ator position, and is located within the throttle actuator.
There are two types of throttle actuators;
1) actuator with analog position feedback and
2) actuator with digital position feedback
The first type, with analog position feedback, provides an ana-
log return signal between 0 and 5 volts that is proportional to
the throttle actuator position. The second type, with digital
position feedback, provides a serial data signal to the ECM
with the throttle actuator position voltage level encoded in
the data stream.
This fault will set if TPS1 voltage is lower than the low voltage
limit as defined in the diagnostic calibration at any operating
3121262 – JLG Lift – 3-153

3-154 – JLG Lift – 3121262

DTC 123- TPS1 Signal Voltage High
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor 1 There are two types of throttle actuators, 1) actuator with ana-
log position feedback and 2) actuator with digital position
• Check Condition-Key On, Engine Off
feedback. The first type, with analog position feedback, pro-
• Fault Condition-TPS1 sensor voltage higher than the limit vides an analog return signal between 0 and 5 volts that is pro-
defined in the diagnostic calibration portional to the throttle actuator position. The second type,
• Corrective Action(s): Sound audible warning or illuminate with digital position feedback, provides a serial data signal to
secondary warning lamp, shutdown engine the ECM with the throttle actuator position voltage level
encoded in the data stream.
This fault will set if TPS1 voltage is higher than the limit set in
In the case of a diesel engine, an actuator controls a fuel injec- the diagnostic calibration at any operating condition while the
tion pump, directly affecting the fueling level into the cylin- engine is cranking or running. The limit is generally set to 4.90
ders. This may be by direct manipulation of the fuel injection VDC. In many cases, this condition is caused by a short-to-
pump rack or by manipulation of the mechanical governor power of the TPS circuit in the wire harness or a failure of the
control level or "throttle arm." In the DGC ECM and EDIS, refer- sensor. This fault should be configured to trigger an engine
ences to the throttle and throttle position sensor refer to these shutdown and the engine will not start with this fault active.
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit or
2) a non-contact hall-effect sensor to determine throttle actu-
ator position, and is located within the throttle actuator.
3121262 – JLG Lift – 3-155

3-156 – JLG Lift – 3121262

DTC 217- ECT Higher Than Expected 2
TAN/WHITE
BLACK/GREEN
• Engine Coolant Temperature Sensor Diagnostic Aids

• Check Condition-Engine Running
If the "ECT High Voltage" fault is also present, follow the trou-
• Fault Condition-Engine Coolant Temperature reading or bleshooting procedures for that fault as it may have caused
estimate greater than the stage 2 limit when operating at a "ECT Higher Than Expected 2."
speed greater than defined in the diagnostic calibration
If the cooling system utilizes an air-to-water heat exchanger
• Corrective Action(s)- Sound audible warning or illuminate
(radiator) and fan:
correction during active fault. Recommend a power derate • Check that the radiator has a proper amount of ethylene
2 and/or a forced idle or engine shutdown to protect glycol/water and that the radiator is not leaking
engine from possible damage. • Ensure that there is no trapped air in the cooling path
• Non-emissions related fault • Inspect the cooling system (radiator and hoses) for cracks
The Engine Coolant Temperature sensor is a thermistor (tem- and ensure connections are leak free
perature sensitive resistor) located in the engine coolant. • Check that the fan is operating properly
Some engines use a CHT sensor that is located in the coolant
in the cylinder head. Some engines use an ECT (Engine Cool-
ant Temperature) sensor that is located in the coolant near the If the cooling system utilizes a water-to-water heat exchanger:
thermostat. If the engine is equipped with a CHT sensor then • Check that the heat exchanger has a proper amount of eth-
the ECT value is estimated. If equipped with an ECT sensor ylene glycol/water and that the heat exchanger is not leak-
then the CHT value is estimated. The ECM provides a voltage ing
divider circuit so when the sensor reading is cool the sensor
reads higher voltage, and lower when warm. • Ensure that there is no trapped air in the cooling path
• Inspect the cooling system (radiator and hoses) for cracks
This fault will help protect the engine in the event of over tem- and ensure connections are leak free
perature. When the coolant exceeds x deg. F and engine RPM
exceeds y RPM for the latch time this fault will set. • Check that the raw water pickup is not blocked/restricted
by debris and that the hose is tightly connected
• Check that the raw water pump/impeller is tact and that it
is not restricted
3121262 – JLG Lift – 3-157

DTC 219- RPM Higher Than Max Allowed Governed

Speed
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Max Govern Speed Override- Crankshaft Position Sensor Diagnostic Aids

• Check Condition-Engine Running NOTE: If any other DTCs are present, diagnose those first.
• Fault Condition-Engine speed greater than the max gover-
• Ensure that no programmed governor speeds exceed the
nor override speed as defined in the diagnostic calibration
limit set in the diagnostic calibration for Max Gov Override
• Corrective Action(s): Sound audible warning or illuminate Speed
secondary warning lamp, reduce throttle to limit speed.
• Check mechanical operation of the throttle actuator
Recommend closed loop and adaptive learn fueling correc-
tion remains active during fault.
This fault will set anytime the engine RPM exceeds the limit set
in the diagnostic calibration for the latch time or more. This
speed overrides any higher max governor speeds pro-
grammed by the user. This fault is designed to help prevent
engine or equipment damage.
The throttle will be lowered in order to govern the engine to
the speed set in the diagnostic calibration.
DTC 219- RPM Higher Than Max Allowed Governed Speed
(continued)
3-158 – JLG Lift – 3121262

DTC 336- Crank Signal Input Noise
2 WHITE/PURPLE PURPLE/WHITE
WHITE/PURPLE
1 PURPLE/WHITE
• Crankshaft Position sensor The ECM must see a valid crankshaft position signal while run-
ning. If no signal is present, the signal amplitude is too high
• Check Condition- Key On, Engine On
(due to improper air gap with respect to trigger wheel), or an
• Fault Condition- Electrical noise or irregular crank pattern irregular crank pattern is detected causing the ECM to resyn-
detected causing x number of crank resynchronization chronize x times for y ms or longer as defined in the diagnostic
events as defined in the diagnostic calibration calibration, this fault will set. Irregular crank patterns can be
• Corrective Action(s)- Illuminate MIL and/or sound audible detected by the ECM due to electrical noise, poor machining
warning or illuminate secondary warning lamp and disable of trigger wheel, or trigger wheel runout and/or gear lash.
adaptive fueling correction for remainder of key-cycle. Ensure crank circuit used with VR/magnetic pick-up sensors
• Emissions related fault are properly twisted.
The crankshaft position sensor is a magnetic sensor (variable

reluctant/magnetic pick-up or halleffect) installed in the
engine block adjacent to a "coded" trigger wheel located on
the crankshaft. The sensor-trigger wheel combination is used
to determine crankshaft position (with respect to TDC cylinder
#1 compression) and the rotational engine speed. Determina-
tion of the crankshaft position and speed is necessary to prop-
erly activate the ignition, fuel injection, and throttle governing
systems for precise engine control.
3121262 – JLG Lift – 3-159

• Key On, Engine Running

• System Mode= “Running”
Operate engine at condition

that set fault based on fault
snapshot
Yes Is crank sensor a VR/ No Check wiring and electrical connections

Does DTC 336 reset ?
magnetic pick-up? between crankshaft position sensor and ECM
No Yes
No
Is the wiring OK? Repair wireharness
Intermittent fault
Yes
Faulty wireharness No Is wiring between sensor
(twist circuit) and ECM properly twisted?
• Poor system ground
• Bad crankshaft position sensor
• Bad ECM
Yes
Yes
Increase the air gap between Does fault only occur at
sensor and trigger wheel high operating speeds?
No
Check wiring and electrical connections

between crankshaft position sensor and ECM
No
Repair wireharness Is the wiring OK?
Yes
• Poor system ground

• Bad crankshaft position sensor
• Bad ECM
3-160 – JLG Lift – 3121262

DTC 337- Loss of Crank Input Signal
2 WHITE/PURPLE PURPLE/WHITE
WHITE/PURPLE
1 PURPLE/WHITE
• Crankshaft Position sensor The ECM must see a valid crankshaft position signal while run-
ning. If no signal is present while x cam pulses continue the
• Check Condition- Key On, Engine On
fault will set. The engine typically stalls or dies as a result of
• Fault Condition- Loss of crankshaft position signal while this fault condition due to the lack of crankshaft speed input
valid camshaft position signals continue for x number of resulting in the inability to control ignition timing.
cam pulses as defined in the diagnostic calibration
DTC 337- Loss of Crank Input Signal (continued)
• Corrective Action(s)- Illuminate MIL and/or sound audible
warning or illuminate secondary warning lamp Diagnostic Aids
• Emissions related fault • Check that crankshaft position sensor is securely con-
nected to harness
The crankshaft position sensor is a magnetic sensor (variable
• Check that crankshaft position sensor is securely installed
reluctant/magnetic pick-up or halleffect) installed in the
into engine block
engine block adjacent to a ¡§coded¡¨ trigger wheel located on
the crankshaft. The sensor-trigger wheel combination is used • Check crankshaft position sensor circuit wiring for open cir-
to determine crankshaft position (with respect to TDC cylinder cuit
#1 compression) and the rotational engine speed. Determina-
tion of the crankshaft position and speed is necessary to prop-
erly activate the ignition, fuel injection, and throttle governing
systems for precise engine control.
3121262 – JLG Lift – 3-161

DTC 521- Oil Pressure Sender/Switch High The ECM can be configured to monitor oil pressure through a
proportional transducer or through a switch. Oil pressure
Pressure monitoring is important to prevent engine damage due to low
oil pressure resulting in higher friction and lack of lubrication.
19
In addition, high oil pressure can be undesirable because it
BLACK/GREEN can cause oil to leak past seals and rings, can be a result of a
2 1 BLUE restriction in the oil flow path, or can be a sign of a malfunc-
tioning oiling system.
Additionally for normally-open type oil pressure switches, a
high pressure indication while the engine is off is a symptom
of a failed oil pressure switch. The ECM can monitor oil pres-
• Engine Oil Pressure sure indication when the engine is stopped for this failure
mode.
• Check Condition- Key on, Engine on (or Engine off )
For sender types, this fault sets if the engine oil pressure is
• Fault Condition- For sender types, oil pressure higher than higher than x psia and engine speed greater than y RPM as
x psia while engine speed is greater that y RPM. For switch defined in the diagnostic calibration. For switch types, this
types, oil pressure is indicating high when the engine has fault sets if the engine oil pressure is indicating high when the
been stopped for more than n seconds. engine is stopped for more than n seconds. Recommend a
• Corrective Action(s)- Illuminate MIL and/or sound audible power derate and/or low rev limit to help prevent possible
warning or illuminate secondary warning lamp, possibly engine damage and reduce oil pressure.
configure for power derate 1 or low rev limit Normally Closed Switch
• Key-On, Engine Off

• System Mode= “Stopped”
• Key Off
No • Disconnect harness from Oil Pressure switch
Does DTC 524 • Check continuity through switch to ground.
reset ?
Yes
Intermittent Problem
No • Oil Pressure circuit shorted-to-ground in harness

Is switch open?
• Faulty ECM
Yes
• Faulty Oil Pressure Switch (short circuit)

• Faulty engine oiling system (verify with
mechanical gauge)
3-162 – JLG Lift – 3121262

DTC 524- Oil Pressure Low For systems that use a transducer, this fault sets if the engine
oil pressure is less than x psia and engine speed is greater than
y RPM after the engine has been running for z seconds as
19 defined in the diagnostic calibration. For systems that use a
BLACK/GREEN
2 1
switch this fault can be configured two different ways. It may
BLUE
use a normally closed switch or a normally open switch. If the
switch is normally open, the fault will set if the circuit becomes
grounded. If the switch is normally closed, the fault will set if
the circuit becomes open. Go to the Faults page in EDIS to
determine how the input is configured. ("Open=OK" is nor-
mally open and "Ground=OK" is normally closed). The engine
• Engine Oil Pressure will should be configured to derate or force idle and/or shut
down in the event of this fault to help prevent possible dam-
• Check Condition- Key on, Engine on
age.
• Fault Condition- Engine oil pressure lower than expected
while engine has been running for a minimum amount of
time while engine speed is above some limit as defined in
the diagnostic calibration

warning or illuminate secondary warning lamp, generally
configured to derate the engine and trigger an engine
shutdown
The ECM can be configured to monitor oil pressure through a

proportional transducer or through a switch. Oil pressure
monitoring is important to prevent engine damage due to low
oil pressure resulting in higher friction and lack of lubrication.
In addition, high oil pressure can be undesirable because it
can cause oil to leak past seals and rings, can be a result of a
restriction in the oil flow path, or can be a sign of a malfunc-
tioning oiling system.
3121262 – JLG Lift – 3-163

Normally Closed Switch
• Key-On, Engine On
• System Mode= “Running”
• Key Off
• Disconnect harness from Oil Pressure switch
• Jumper Oil Pressure signal wire to ground
• Warm engine at idle to normal • Clear DTC 524
operating temperature • Key On, Engine On
• Increase RPM above limit set • System Mode= “Running”
in diagnostic calibration • Operate engine et idle for at least one minute
• Increase RPM above limit set in diagnostic calibration
• Disconnect wireharness header from ECM

• Carefully remove yellow lock from header
Yes at device output terminal
Does DTC 524 • CAREFULLY check resistance between
reset ? Oil Pressure signal at ECM header and
Does DTC 524 Yes signal at sensor. NOTE: DO NOT
reset? INSERT probe or object into terminals
No as this will cause the terminal to
spread and may no longer make
No contact with ECM pin. Spread pins will
void warranty! Probe on the side of
Intermittent Problem terminal.
• Faulty Oil Pressure Switch (open circuit)
• Faulty engine oiling system (verify with
mechanical gauge)
• Faulty connection at sensor Yes Does DMM indicate a

• Faulty ECM resistance < 5.0 ohms?
No
• Faulty harness
(open circuit)
3-164 – JLG Lift – 3121262

DTC 562- Battery Voltage (VBat) Low
BLACK
RED/TAN
• System voltage to ECM The battery voltage powers the ECM and must be within limits
to correctly operate throttle actuator, power supplies, and
• Check Condition- Key on, Engine on other powered devices that the ECM controls.
• Fault Condition- Battery voltage to ECM less than x volts This fault will set if the ECM detects system voltage less than x
while the engine is operating at y RPM or greater as volts while the engine is operating at y RPM as defined in the
defined in the diagnostic calibration diagnostic calibration as the alternator should be charging the
system.
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle
3121262 – JLG Lift – 3-165

3-166 – JLG Lift – 3121262

DTC 563- Battery Voltage (VBat) High
BLACK
RED/TAN
• System voltage to ECM The battery voltage powers the ECM and must be within limits
to correctly operate throttle acutator, power supplies, and
• Check Condition- Key on, Engine Cranking or Running other powered devices that the ECM controls.
• Fault Condition- Battery voltage to ECM greater than x This fault will set if the ECM detects system voltage greater
volts while the engine is running as defined in the diagnos- than x volts while the engine is running or cranking as defined
tic calibration in the diagnostic calibration.
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle
3121262 – JLG Lift – 3-167

3-168 – JLG Lift – 3121262

DTC 601- Microprocessor Failure - FLASH
ECM
Microprocessor
RAM
• Engine Control Module- Flash Memory The ECM has checks that must be satisfied each time an
instruction is executed. Several different things can happen
• Check Condition- Key on within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error If this fault sets, the ECM will reset itself and log the code. The
fault should be configured to never forget and will not self-
• Corrective Action(s)- Illuminate MIL and/or sound audible erase and will not clear until a technician performs diagnostics
warning or illuminate secondary warning lamp, disable and manually clears the code. This fault should be configured
adaptive fueling correction for remainder of key cycle, rec- to set a power derate 2 and low rev limit to reduce possible
ommend power derate 2 and low rev limit to reduce possi- engine damage and reduce possibility of an overspeed condi-
ble engine damage and/or overspeed condition tion. A fault of flash memory can occur for any calibration vari-
able set and thus could cause undesirable operation.
3121262 – JLG Lift – 3-169

3-170 – JLG Lift – 3121262

DTC 604- Microprocessor Failure - RAM
ECM
Microprocessor
RAM
• Engine Control Module- Random Access Memory This fault will set if the ECM detects a problem accessing or
writing information to RAM and should be configured to set a
• Check Condition- Key on power derate 2 and low rev limit to reduce possible engine
damage and reduce possibility of an overspeed condition. If
• Fault Condition- Internal ECM microprocessor memory
this fault sets, the ECM will reset itself and log the code. This
access failure
fault should be erased by a technician after diagnostics are
• Corrective Action(s)- Illuminate MIL and/or sound audible performed. The fault should be configured to never forget and
warning or illuminate secondary warning lamp, disable will not self-erase.
adaptive fueling correction for remainder of key cycle, rec-
ommend power derate 2 and low rev limit to reduce possi-
ble engine damage and/or overspeed condition
Random Access Memory is located within the microprocessor

and can be read from or written to at any time. Data stored in
RAM include DTCs (when fault configuration is set to "Battery
Power Retained"), adaptive fuel learn tables, octane adapta-
tion table, misfire adaption tables, and closed loop fuel multi-
pliers. The ECM has checks that must be satisfied each time an
instruction is executed.
3121262 – JLG Lift – 3-171

3-172 – JLG Lift – 3121262

DTC 606- Microprocessor Failure - COP
ECM
Microprocessor
RAM
• Engine Control Module The ECM has checks that must be satisfied each time an
• Check Condition- Key on within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error If this fault sets, the ECM will reset itself and log the code. The
fault should be configured to never forget and will not self-
• Corrective Action(s) - Illuminate MIL and/or sound audible erase and will not clear until a technician performs diagnostics
warning or illuminate secondary warning lamp, disable and manually clears the code. This fault should be configured
adaptive fueling correction for remainder of key cycle, rec- to set a power derate 2 and low rev limit to reduce possible
ommend power derate 2 and low rev limit to reduce possi- engine damage and reduce possibility of an overspeed condi-
ble engine damage and/or overspeed condition tion.
3121262 – JLG Lift – 3-173

3-174 – JLG Lift – 3121262

DTC 642- 5 Volt External Low Voltage
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Engine Control Module Diagnostic Aids

• Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key
• Fault Condition- ECM 5-volt output is below the acceptable on and the engine stopped. Verify that the output is lower
limit than the fault thresholds configured in the diagnostic cali-
bration.
warning or illuminate secondary warning lamp • Inspect the 5-Volt output circuit in the wire harness and
look for shorts to ground or other harness circuits.
• Disconnect each device powered by the 5-volt output of
The ECM supplies 5-volt power to sensors, switches, and actu- the ECM one-at-a-time. Powered devices may include the
ators external to the ECM. By supplying the power to these throttle actuator, smart sensors, smart actuators, etc. After
devices, the ECM can accurately measure their output relative disconnecting device, observe the system fault and deter-
to its own ground reference. The ECM can also control when mine if the fault has cleared. If the fault clears, troubleshoot
the devices are active and put the devices in a low or no power the disconnected device for failures.
state based on the current operating condition of the engine
or vehicle. • With all 5-volt powered devices disconnected, look for a
change in the fault state and measure the 5-volt output of
If this fault sets, something other than the ECM is drawing the the ECM and verify it is within acceptable limits.
5-volt power output of the ECM below an acceptable thresh-
old. This may be due to a short in the wire harness, malfunc-
tioning device, or failure of the ECM power output circuitry.
3121262 – JLG Lift – 3-175

DTC 643- 5 Volt External High Voltage
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Engine Control Module Diagnostic Aids

• Check Condition- Key on • Measure the 5-volt output of the ECM while cycling the key
• Fault Condition- ECM 5-volt output is above the acceptable on and the engine stopped. Verify that the output is lower
limit than the fault thresholds configured in the diagnostic cali-
bration.
• Inspect the 5-Volt output circuit in the wire harness and
warning or illuminate secondary warning lamp
look for shorts to ground or other harness circuits.
• Disconnect each device powered by the 5-volt output of
The ECM supplies 5-volt power to sensors, switches, and actu- the ECM one-at-a-time. Powered devices may include the
ators external to the ECM. By supplying the power to these throttle actuator, smart sensors, smart actuators, etc. After
devices, the ECM can accurately measure their output relative disconnecting device, observe the system fault and deter-
to its own ground reference. The ECM can also control when mine if the fault has cleared. If the fault clears, troubleshoot
the devices are active and put the devices in a low or no power the disconnected device for failures.
state based on the current operating condition of the engine
• With all 5-volt powered devices disconnected, look for a
or vehicle.
change in the fault state and measure the 5-volt output of
If this fault sets, something other than the ECM is drawing the the ECM and verify it is within acceptable limits.
5-volt power output of the ECM above an acceptable thresh-
old. This may be due to a short in the wire harness, malfunc-
tioning device, or failure of the ECM power output circuitry.
3-176 – JLG Lift – 3121262

DTC 1612- Microprocessor Failure - RTI 1
ECM
Microprocessor
RAM
• Check Condition- Key on within the microprocessor that will cause this fault. The ECM
• Fault Condition- Internal microprocessor error will reset itself in the event this fault is set, and the MIL will be
on until the code is cleared. This fault should be erased after
• MIL- On until code is cleared by technician diagnosis by removing battery power. It will not self-erase.
• Adaptive- Disabled for the remainder of the key-on cycle During this active fault, Power Derate (level 2) will be enforced.
When this is enforced, maximum throttle position will be 20%.
• Closed Loop- Enabled This is enforced until the fault is manually cleared.
• Power Derate (level 2 until fault is cleared manually)
3121262 – JLG Lift – 3-177

ECM
Microprocessor
RAM
3-178 – JLG Lift – 3121262

SFC 555- RTI 2 Loss
Key On - Engine Running

System Data Mode
Check all power and

Clear System Fault
ground circuits to ECM
Does SFC 555 reset Yes

with engine idling?
Yes Replace ECM with known
Are all circuits ok?
good part and retest
No
No
Fault is intermittent
Repair wiring to
ECM and retest
3121262 – JLG Lift – 3-179

ECM
Microprocessor
RAM
3-180 – JLG Lift – 3121262

SFC 556- RTI 3 Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 556 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3121262 – JLG Lift – 3-181

DTC 1615- Microprocessor Failure - A/D
ECM
Microprocessor
RAM
3-182 – JLG Lift – 3121262

SFC 513- A/D Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 513 reset

with engine idling?
Yes
Replace ECM with known
No
No
Repair wiring to
ECM and retest
3121262 – JLG Lift – 3-183

DTC 1616- Microprocessor Failure - interrupt
ECM
Microprocessor
RAM
3-184 – JLG Lift – 3121262

SFC 512- Invalid Interrupt

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 512 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3121262 – JLG Lift – 3-185

DTC 1625- CAN J1939 Shutdown Request
BLUE/RED or PINK
BLUE/WHITE
• Controller Area Network Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running • The ECM has shutdown the engine upon command by a
• Fault Condition- ECM has received shutdown message external controller. This is the requested and expected
from another CAN device and is shutdown on request. behavior.
• Corrective Action(s)- Illuminate MIL, sound audible warn-
ing or illuminate secondary warning lamp
In some situations, external controllers may send a request to
the ECM to shutdown engine operation and stop the engine.
This request may be sent in response to a safety related condi-
tion in the vehicle.
This fault will set if the ECM receives the J1939 shutdown
request via the CAN interface. This is the expected behavior.
3-186 – JLG Lift – 3121262

DTC 1626- CAN J1939 Transmit (Tx) Fault
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver transmit error grounded
counts greater than the limit defined in the diagnostic cali- • Verify that the CAN network is properly terminated
bration (must be < 125 failures)
• Check CAN wire routing with respect to noise sources (igni-
• Corrective Action(s)- Illuminate MIL, sound audible warn- tion coils, spark plug coil wires, etc.) and shield if necessary
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital data.
This fault will set if CAN communication is enabled and the
ECM transceiver broadcasts a number of packets (as defined in
the diagnostic calibration, must be set to less than 125 fail-
ures) to the network that are not received.
3121262 – JLG Lift – 3-187

DTC 1627- CAN J1939 Receive (Rx) Fault
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Off and/or Running • Verify that all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver receive error counts grounded
greater than the limit defined in the diagnostic calibration • Verify that the CAN network is properly terminated
(must be < 125 failures)
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital data.
This fault will set if CAN communication is enabled and the
ECM transceiver is expecting to see network traffic and either
does not see traffic (as defined in the diagnostic calibration,
must be set to less than 125 failures).
3-188 – JLG Lift – 3121262

DTC 1628- CAN Address Conflict Failure
BLUE/RED or PINK
BLUE/WHITE
• CAN device(s) The Controller Area Network serves as a communication portal

between intelligent devices. These devices may be but are not
• Check Condition- Key On, Engine on limited to other engine ECMs (slave), diagnostic tools, "smart"
gauges, "smart" sensors, powertrain control units, vehicle con-
• Fault Condition- two or more devices on the network that
trollers, actuators, etc. The network permits several devices to
contain the same SA
communicate with each other receiving and broadcasting
• Corrective Action(s)- Sound audible warning or illuminate commands as programmed. This type of network allows
secondary warning lamp devices to be added to an entire system through only two con-
ductors and permits all other devices to broadcast and receive
• Non-emissions related fault commands to and from the device when properly com-
manded.
This fault indicates that there are two (2) or more devices on
the network that use the same source address.
3121262 – JLG Lift – 3-189

3-190 – JLG Lift – 3121262

DTC 1629- J1939 TSC1 Message Reciept Loss
BLUE/RED or PINK
BLUE/WHITE

• Check Condition- Key On, Engine Running • Verify that that the CAN device generating the TSC1 mes-
• Fault Condition- ECM is expecting to receive J1939 TSC1 sage is powered and properly grounded
messages and has not received a message for more than n • Verify that the CAN network is properly terminated
seconds (as defined in the diagnostic calibration).
ing or illuminate secondary warning lamp. Govern engine
speed at a forced idle. • Check CAN (+) and (-) wires for short circuits

J1939 TSC1 may be used to send a commanded (or desired)
engine speed to the ECM. If configured, the ECM will govern
the engine speed to this commanded speed if possible. When
operating in this mode, the ECM expects to receive TSC1 mes-
sages on a regular interval. When this message is not received,
the ECM must operate the engine at a default idle speed until
commanded to do otherwise.
This fault will set if CAN communication is enabled, the engine
is running, and no TSC1 messages are received over the CAN
bus for more than n seconds (as determined by the diagnostic
calibration).
3121262 – JLG Lift – 3-191

DTC 1652- TPS1 Loss of Communications
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Actuator (with serial/digital position feedback) Diagnostic Aids

• Check Condition- Key On, Engine Running and/or Stopped • Verify that the throttle actuator 5V supply voltage is pres-
• Fault Condition- ECM is expecting to receive throttle posi- ent at the actuator.
tion information from the throttle actuator and is not. • Check for a all four TPS feedback wires for short circuits.
• Corrective Action(s)- Illuminate MIL, sound audible warn- • Check TPS SER+ and TPS SER- wire routing with respect to
ing or illuminate secondary warning lamp. Shutdown noise sources (ignition coils, spark plug coil wires, etc.) and
engine. shield if necessary.
In the case of a throttle actuator with serial/digital position
feedback, the ECM receives a constant data stream from the
throttle actuator. If the communication is absent or inter-
rupted, the ECM can no longer control the position of the
throttle.
This fault will set if the key is on, the throttle actuator is receiv-
ing power, and the ECM is not receiving digital information
from the actuator.
3-192 – JLG Lift – 3121262

DTC 2111- Unable to Reach Lower TPS
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable resistor
and voltage divider circuit or 2) a non-contact hall-effect sen-
• Check Condition-Cranking or Running sor to determine throttle actuator position, and is located
• Fault Condition-Throttle command is 20% less than throttle within the throttle actuator.
position for 200ms or longer There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault
feedback. The first type, with analog position feedback, pro-
• Engine Shut Down vides an analog return signal between 0 and 5 volts that is pro-
portional to the throttle actuator position. The second type,
In the case of a diesel engine, an actuator controls a fuel injec- with digital position feedback, provides a serial data signal to
tion pump, directly affecting the fueling level into the cylin- the ECM with the throttle actuator position voltage level
ders. This may be by direct manipulation of the fuel injection encoded in the data stream.
pump rack or by manipulation of the mechanical governor
control level or "throttle arm." In the DGC ECM and EDIS, refer- This fault will set if the throttle command is 20% less than the
ences to the throttle and throttle position sensor refer to these actual throttle position. During this active fault the MIL light
fuel injection pump control actuators and their position feed- will be on and the engine will shut down.
3121262 – JLG Lift – 3-193

3-194 – JLG Lift – 3121262

DTC 2112- Unable to Reach Higher TPS
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable resistor
and voltage divider circuit or 2) a non-contact hall-effect sen-
• Check Condition-Cranking or Running sor to determine throttle actuator position, and is located
within the throttle actuator.
• Fault Condition-Throttle command is 20% more than
actual throttle position There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault feedback. The first type, with analog position feedback, pro-
vides an analog return signal between 0 and 5 volts that is pro-
• Engine Shut Down portional to the throttle actuator position. The second type,
In the case of a diesel engine, an actuator controls a fuel injec- with digital position feedback, provides a serial data signal to
tion pump, directly affecting the fueling level into the cylin- the ECM with the throttle actuator position voltage level
ders. This may be by direct manipulation of the fuel injection encoded in the data stream.
pump rack or by manipulation of the mechanical governor This fault will set if the throttle command is 20% or more than
control level or "throttle arm." In the DGC ECM and EDIS, refer- the actual throttle position. During this active fault the MIL
ences to the throttle and throttle position sensor refer to these light will be on and the engine will shut down.
3121262 – JLG Lift – 3-195

DTC 9999- Throttle Actuator Failsafe Spring

Failure
4 PINK/WHITE
3 TAN/ORANGE
5 GREEN/RED
1 PURPLE/BLUE
2 BLACK/GREEN
• Throttle Actuator Diagnostic Aids

• Check Condition- Key Off, Engine Stopped
• Disconnect the throttle actuator from the wire harness.
• Fault Condition- When the key is off (or the actuator is Remove the throttle actuator from the engine and manu-
unpowered), the ECM is expecting the failsafe spring in the ally move it. Verify that the internal spring forces the throt-
actuator to return the throttle position to near 0%. If the tle back to near 0% position.
throttle does not reach this position when the actuator is
powered, a fault is generated. • Inspect the throttle arm or fuel rack on the fuel pump. Ver-
ify that it is not stuck.
• Corrective Action(s)- Illuminate MIL, sound audible warn-
ing or illuminate secondary warning lamp. Govern the
engine speed to a forced idle speed.
The throttle actuator has a return spring that causes the throt-
tle to move to a near 0% position when powered off. This
causes the engine to shutdown following a key off. If the ECM
detects the throttle position to be above x volts when the key
is off (as determined by the diagnostic calibration), it will
power up the actuator and attempt to drive it to a zero posi-
tion. This should ensure that the engine is stopped.
This fault will set if the throttle does not return to a near 0%
position with the key is off.
3-196 – JLG Lift – 3121262

DTC to SPN/FMI Table
FAULT DTC SET

DESCRIPTION
INDEX SPN FMI
2 DTC 118: ECT voltage high 110 3
3 DTC 117: ECT voltage low 110 4
4 DTC 116: ECT higher than expected stage 1 110 15
9 DTC 563: Vbat voltage high 168 15
10 DTC 562: Vbat voltage low 168 17
11 DTC 643: Sensor supply voltage 1 high 1079 3
12 DTC 642: Sensor supply voltage 1 low 1079 4
13 DTC 123: TPS1 voltage high 51 3
14 DTC 122: TPS1 voltage low 51 4
29 DTC 524: Oil pressure low 100 1
86 DTC 217: ECT higher than expected stage 2 110 0
89 DTC 2112: Unable to reach higher TPS 51 7
90 DTC 2111: Unable to reach lower TPS 51 7
96 DTC 336: CRANK input signal noise 636 2
98 DTC 606: Microprocessor failure - COP 629 31
99 DTC 1612: Microprocessor failure - RTI 1 629 31
102 DTC 1615: Microprocessor failure - A/D 629 31
103 DTC 1616: Microprocessor failure - Interrupt 629 31
104 DTC 601: Microprocessor failure - FLASH 628 13
105 DTC 604: Microprocessor failure - RAM 630 12
106 DTC 219: RPM higher than max allowed govern speed 515 15
144 DTC 337: Crank signal loss 636 4
145 DTC 1625: J1939 shutdown request 1384 31
146 DTC 1626: CAN-J1939 Tx fault 639 12
147 DTC 1627: CAN-J1939 Rx fault 639 12
175 DTC 1628: J1939 CAN address / engine-number conflict 639 13
188 DTC 521: Oil pressure high 100 0
189 DTC 1652: TPS1 loss of communications 51 9
190 DTC 1629: CAN-J1939 TSC1 Parameter Rx Fault 695 9
191 DTC 1113: Unable to achieve lower RPM 515 31
192 DTC 9999: TPS1 failsafe spring failure 51 7
3121262 – JLG Lift – 3-197

3.27 COUNTERWEIGHT
If the counterweight has been removed, ensure the retaining
bolts are torqued to the proper value as shown in Figure 3-79.,
Counterweight Bolt Torque.
APPLY THREADLOCKER P/N 0100019

TO BOLT AND THREADS IN COUNTERWEIGHT.
TORQUE TO 400 FT LBS (542 Nm).
Figure 3-79. Counterweight Bolt Torque
3-198 – JLG Lift – 3121262

SECTION 4. BOOM & PLATFORM
4.1 BOOM SYSTEMS Transport Position Sensing System

The transport position sensing system uses the main boom
NOTE: For more detailed information concerning system adjust- angle sensors, the main boom length sensor mounted in the
ment and operation, refer to Section 6 - JLG Control Sys- pivot end of the main base boom in addition to the boom
tem. length switch mounted on the platform end of the main base
boom and length switches mounted to the jib fly boom to
Broken Cable Indicator System sense when the main boom and jib boom are in the position
associated with high speed travel. Above transport angle is
The boom on this model is a 4 section proportionally driven recognized when one main boom angle sensor reads more
telescopic boom. The inner mid boom is driven directly by the than 6° in relationship to the turntable and resets to within
telescope cylinder. The outer mid and fly booms are each transport position when both main boom angle sensors read
driven by separate wire rope systems. Each rope system con- less than 4° in relationship to the turntable. Transport length is
tains redundant ropes that are capable of allowing the opera- recognized when the main boom length switch and main
tor to unknowingly continue use of the machine with a single boom length sensor read less than 1 ft (0.3 m) extension for
rope failure. These kinds of failures with the extend ropes are the main boom. In addition the jib boom length switches must
self revealing to the operator so proper action can be taken. indicate fully retracted and the jib boom must be locked in line
Failures within the fly extend ropes are self revealing as they with the main boom. During failures of either the main boom
are exposed on the exterior of the boom where a broken rope length switch or the main boom length sensor the main boom
would be obvious. Failures within the outer mid ropes require transport length will be determined by the remaining sensor
the addition of the Broken Cable Indicator System in order to or switch. In addition for a failure either jib boom length
be self-revealing to the operator. This system uses a proximity switch, jib length will be determined by the remaining switch.
sensor to detect excessive movement of the sensed rope as
would be expected with a rope failure. A broken rope detec- This system is used to control the following systems:
tion results in illuminating the Cable Break indicator on the
• Beyond Transport - Drive Speed Cutback System
platform control panel. No restrictions are made to the func-
tionality of the control system. It is the responsibility of the • Drive/Steer - Boom Function Interlock System (CE Only)
operator to take the appropriate action.
• Jib Stow System
Platform Control Enable System • Axle Extension System
The platform controls make use of a time dependent enable
• Oscillating Axle System
circuit to limit the time availability of “live” or enabled controls.
When the footswitch is depressed, the controls are enabled
and the operator has 7 seconds to operate any control. The Beyond Transport - Drive Speed Cutback System
controls will remain enabled as long as the operator continues
When boom is positioned beyond the Transport Position, the
to use any function and will remain enabled 7 seconds after
drive motors are automatically restricted to their maximum
the last function has been used. While the controls are “live”,
displacement position (slow speed).
the enabled light will be illuminated in the platform display
panel. When the time limit has been reached, the enabled
light will turn off and the controls will be “dead” or disabled. To
continue use of the machine the controls must be re-enabled
to start the timer system over again. This is done by releasing
all functions, then releasing and re-depressing the footswitch.
3121262 – JLG Lift – 4-1

1. Boom Angle Sensor #1 (Right)

2. Boom Cable Proximity Sensor
3. Boom Length Sensor
4. Boom Angle Sensor #2 (Left)
5. Boom Length & Angle Module
6. Lift Cylinder Pivot Pin
Figure 4-1. Boom Component Location - Sheet 1 of 2
4-2 – JLG Lift – 3121262

7. Jib Level Rotary Sensor 12. Platform Level Sensor #1 (Right-Primary)

8. Lock Pin Proximity Sensor (Bottom Side) 13. Jib Transport Proximity Sensors
9. Jib Control Module 14. Jib Swing Rotary Sensor (Bottom Side)
10. Platform Level Sensor #2 (Left-Secondary) 15. Jib Control Valve
11. Platform Control Valve 16. Main Boom Transport Limit Switch
Figure 4-2. Boom Component Location - Sheet 2 of 2
3121262 – JLG Lift – 4-3

Drive/Steer – Boom Function Interlock System (CE Envelope Tracking System

ONLY) The Envelope Tracking System uses the envelope control sen-
The Drive/Steer – Boom Function Interlock System uses the sors to enhance the control of the boom within the working
Transport Position Sensing System to sense when the boom is envelope. Due to the shape of the working envelope, the max-
out of the transport position. All controls are simultaneously imum boom angle varies with telescope length. To maintain
functional when the booms are within the transport position unrestricted operation of the boom, the lift down function is
as on the standard machine. When the boom is beyond the automatically introduced while telescoping in only when the
transport position, the control functions are interlocked to boom is on the rearward edge of the envelope. This only
prevent simultaneous operation of any boom function with occurs when telescoping in along the rearward edge and is
drive/steer. The first function set to be operated in this mode,
not used elsewhere within the envelope or when telescoping
becomes the master function set. In other words, while oper-
ating drive/steer functions the boom functions are inoperable. out. Envelope tracking is disabled with any envelope or
Likewise, while operating boom functions drive/steer func- moment violations or failures. The envelope tracking function-
tions are inoperable. ality and be turned off using the manual position of the boom
control select switch. Refer to Boom Control Select.
Jib Stow System
The stowed length of the machine can be reduced to enable
Moment Control System
transport on standard trailers by swinging the jib to the right The Moment Control System is the secondary means of con-
using the jib stow rotator. The control system will prevent trolling the stability of the machine. This system uses a load
swinging the jib unless the axles are retracted, the boom and moment pin to attach the lift cylinder of the boom to the turn-
jib are in the transport position (refer to Transport Position table. This pin is instrumented with gauges allowing the forces
Sensing System), and the jib stow override button on the plat-
in the pin to be monitored. These forces are used to compare
form control panel is held in combination with the jib stow
function switch. When the jib is stowed, automatic platform the actual boom moment (force at a distance) to a predeter-
leveling is disabled, the boom is restricted to the transport mined allowable boom moment. In controlling the boom
position, and axle extension is disabled. This system is func- moment, the position and load of the boom is controlled. The
tional only in the 500 lb (227 kg ANSI markets or 230 kg CE moment control system will detect moments larger than
market) mode of the Dual Capacity System. Jib telescope func- expected as well as those smaller than expected. This effec-
tion will resume when the jib is fully stowed along side the tively controls the forward and rearward positions of the
main boom. boom. The moment control system varies the maximum
allowable moment based on ground slope. On level ground
and with rated load in the platform, the allowable moments
establish a working envelope slightly larger than the Envelope
Control System’s envelope to minimize interaction of the sys-
tems. With increasing ground slopes and rated load in the
platform, the allowable moments may establish a working
envelope smaller than the Envelope Control System’s enve-
lope and may result in moment violations at the extreme plat-
form positions. Violations of the moment control systems
allowable moment will result in reduced function speeds, BCS
warning light illumination, restriction of functions, and sound-
ing of the platform alarm and the flashing of the BCS light with
attempts to operate restricted functions. The restricted func-
tions due to moment system violations related to forward
reach are disallowing jib functions, lift down, telescope out,
swing, drive, and steer. The restricted functions due to
moment system violations related to backward reach are disal-
lowing jib functions, lift up, telescope in, swing, drive, and
steer. Recognized failures within this system will result in con-
trol by the Envelope Control System, reduced function speeds,
BCS warning light illumination. The boom will be restricted
from leaving the transport position until the failure is resolved.
4-4 – JLG Lift – 3121262

Boom Control System (BCS) Functional Check Jib Leveling During Automatic/Manual Envelope
(Push to Test) System Control
The machine is equipped with a system for the operator to
There are no function switches in the platform or ground con-
daily verify the proper functioning of the Boom Control Sys-
trols to manually adjust the jib level function. During auto-
tem (Envelope Control System and the Moment Control Sys-
matic or manual main lift control, jib level maintains its angle
tem). The operator is instructed to position the boom in the
in relation to the main boom position.
position described by the instruction decal and to then verify
the control system cut out the telescope movement at the cor- Jib Level Up/Down can be manually overriden using the ana-
rect length. When the operator pushes the push button lyzer. The control system only allows this under certain condi-
mounted on the ground control panel, the control system tions and it should only be performed by an authorized JLG
compares the current moment reading in the moment system service technician. When accessed, jib level can be adjusted
and compares it to the moment expected for this position. If using the Jib Lift Up/Down function switch.
the current moment is within allowable tolerance for the test
Jib Level override is accessible in Access Level 1. Using the Left
position, the green BCS indicator will illuminate indicating the
system is working properly. If the current moment is not
within the allowable tolerance for the test position, the red and Right arrow keys until the screen shown
BCS indicator will illuminate indicating the machine requires below is reached.
service by JLG authorized service personnel before the system
is used. Failure of this test will not restrict the functionality of
the machine and will not cause a system fault. It is the opera-
tors responsibility to take proper action. The machine can be
in either capacity mode of the dual capacity system for this
system check.
4.2 BOOM/JIB SYSTEM FUNCTIONALITY

Main Lift/Jib Velocity Control
To improve the control of the main boom, platform leveling,
and main lift/jib functions' end of stroke dampening, the fol-
lowing angle sensors are utilized:
• Jib lift cylinder angle - CAN based in-cylinder length sen-
sor.
• Platform level cylinder angle - CAN based in-cylinder
length sensor.
• Jib level angle - Dual output analog angle sensor whose
signal is processed by the Jib Control Module.
• Jib rotate angle - Dual output analog angle sensor whose
signal is processed by the Jib Control Module.
• Main boom cylinder angle - Dual output analog angle sen-
sor (to be processed by the BLAM)
3121262 – JLG Lift – 4-5

Press ENTER , the screen should read: Press ENTER , the screen should read:
To enable the level override mode 58237 must be entered as

the code. When the code is entered, the screen will show:
Using the UP and DOWN arrow keys will toggle
the override from off to on. Once turned on, operating the jib
lift function will cause jib level to be activated.
NOTE: Using this override may set the JIB LEVELING SYSTEM FAULT
depending on how far out of level the jib is moved. (See Jib
Leveling section)
Escaping out of this override will not turn it off, reset is

achieved by cycling power to the machine or re-entering the
override code and manually turning it off.
4-6 – JLG Lift – 3121262

Attempts to lift the main boom while this override is on will Jib Telescope Functionality
result in a JIB LEVELING SYSTEM FAULT because during the
override automatic jib leveling is disabled. To adjust the jib Jib Telescope out will only be allowed if the axles are
back to level go into override mode for the jib leveling. Turn it extended, and the capacity control is in the 500# mode and
on, escape out of the Service Modes menu, and go to DIAG- the jib is locked inline with the main boom, or if the machine is
in the stowed state.
NOSTICS/BOOM SENSORS menu. Use the RIGHT arrow
key go until you get to the following screen. Jib Swing Functionality
The jib swing function is only used to stow the jib for trans-
port, and taking the jib out of the stowed position for use. This
function is only permitted when the main boom is in the trans-
port state.
Jib Swing Stow Sequence (Jib Pin Unlock)

If the machine is in the transport mode and the operator
attempts jib swing right, the control system attempts to
unlock the jib lock pin. If successful, (determined by the jib
lock pin proximity sensor) the control system continues to
command the jib lock pin unlock output on and control the jib
swing right function until the operator releases the jib swing
function, or the jib reaches the jib stowed position. Once the
operator releases the jib swing function the control system
shall command the jib lock pin unlock output to off. If the jib
lock pin does not unlock, the control system continues to try
to unlock the jib pin when the operator commands a jib swing
right function. The control system allows jib swing left to jog
the jib in the instance the pin is pinched by the jib structure.
Jib Lock Pin control can be manually overriden using the ana-
Adjust the jib level using the jib lift up and down function lyzer. The control system only allows this under certain condi-
switch until the jib level control angle reads zero. Cycle power tions and it should only be performed by an authorized JLG
and operate the main boom to verify that jib level is working. service technician. When accessed, the jib lock pin can be
manually extended or retracted. To use this service mode the
Jib Lift Functionality technician must be in platform and in platform mode because
the footswitch is required to activate the jib lock pin.
The ground module controls the jib control valve using an out-
put on the ground. Simultaneous main lift and jib lift function
is not possible. The first function activated will have priority
over the other. Manual override of the platform leveling func-
tion will be allowed during all functions. If there is a failure in
which the jib functions cannot be controlled from the Jib Con-
trol Module, the ground module will control the jib control
valve and also override the jib lift up and down valve with out-
puts out of the ground module.
3121262 – JLG Lift – 4-7

Jib Lock Pin override is accessible in Access Level 1. Using the

Press ENTER , the screen should read:
Left and Right arrow keys until the screen shown
below is reached.

code. When the code is entered, the screen will show:
4-8 – JLG Lift – 3121262

Use the Left or Right arrow key until you see: Using the Up and Down arrow keys will allow the
following modes:
• OFF
• EXTEND
• RETRACT
Once the desired mode is selected, stepping into the foot-

switch with the machine running will perform extension or
retraction of the jib lock pin. Reset or turning it off is achieved
by escaping out of the service mode, by cycling power to the
machine, or re-entering the service mode and manually turn-
ing it off. When the service mode is used to retract the jib lock
pin for servicing, attempts to lift or telescope out of transport
will result in a JIB UNLOCKED OUT OF TRANSPORT – HYDRAU-
LICS SUSPENDED fault and the boom will be trapped into
transport.
Jib Swing Deploy Sequence (Jib Pin Lock)

If the machine is in the stowed state and the operator
attempts to swing the jib left, the control system will first
check the position of the jib telescope. If the jib is in the trans-
port position, the control system will unlock the jib lock pin
and jib swing left until the jib is in line with the main boom
Press ENTER , the screen should read:
(determined by the jib swing angle sensor). If the jib is in line
the control system will attempt to lock the jib lock pin. If the
attempt fails, the control system will allow the operator to jib
swing right or left.
Jib Lock Pin Lamp Operation

On machine power-up the control system will energize the
lamp based on the current state of the jib lock pin as deter-
mined by the jib lock proximity sensor. While attempting to
stow or deploy the jib, the control system shall flash the jib
lock pin lamp while the operator is activating the jib swing
function switch. If the jib lock pin is in the locked position the
lamp will be energized. If the jib lock pin is in the unlocked
position the lamp will be de-energized. If the jib lock pin is in a
fault state (i.e. the jib is deployed and the jib lock pin is
unlocked) or the jib is in the stowed state and the jib lock pin is
in the locked state, attempts of disallowed functions results in
the jib lock pin lamp being flashed.
NOTE: Attempts to move the boom out of transport when the pin
is unlocked will be disallowed and a fault code will be regis-
tered.
3121262 – JLG Lift – 4-9

Swing/Axle Extend Retract Restrictions Boom Recovery override is accessible in Access Level 1. Using
In addition to the Direction Of Steer proximity switch in the the Left and Right arrow keys until the screen
chassis, a 360 degree dual rotary sensor is also used to calcu- shown below is reached.
late the turntable rotation angle. These sensors are used
together to restrict swing when the machine is in the trans-
port state. If the machine is in the transport state and the oper-
ator is attempting to swing the boom, the control system shall
allow swing until the angle is at approx. +/- 40 Degrees from
the transport position or the DOS proximity switch is tripped.
At this point the control system will use the turntable rotary
angle sensor to determine which swing function is allowed to
return the boom between the rear wheels. Attempts to con-
tinue swinging in the wrong direction causes the DOS indica-
tor light to flash. If the machine is in the transport state with
the exception of the axles being extended and the operator
has the boom outside of the rear wheels, the control system
disallows axle retract until the boom is again within the rear
wheels. Faults within this system override DOS functionality.
Dual Capacity
The position of the jib telescope is integrated into the dual
capacity logic and the logic relating to the jib swing control
and dual capacity will be removed since the jib is restricted
from swinging in all cases except when the machine is in the
transport state. In order to switch from the 500# capacity Press ENTER , the screen should read:
mode to 1000# capacity mode the jib will have to be fully
retracted, (determined by the two proximity switches
mounted on the side of the jib) and the operating envelope
will have to be in the 1000# envelope in order to switch capac-
ity modes. The jib transport/dual capacity proximity sensors
are mounted in line so one should switch before the other. The
control system monitors the proximity sensors changing state
in relation to jib telescope in versus jib telescope out.
Jib Control During Over/Under Moment

During an overmoment condition the control system limits
the jib functions to jib telescope in only. During an undermo-
ment condition the control system disables all jib functions.
Boom Recovery Mode

Boom Recovery Mode allows the boom to be lifted down and
telescoped in, in the event CAN bus communication is lost to
both the Jib Control Module and the Platform Module.
Boom Recovery Override is only available in the event the

ground module loses CAN communication with both the Jib
Control Module and the Platform module, in the case of a sev-
ered boom cable for example. This mode allows the boom to
be lifted down and telescoped in.
4-10 – JLG Lift – 3121262


code. When the code is entered, the screen will show:
Press Enter . Once Enter is pressed using the Up
or Down arrow key will turn the boom recovery

on or off. Once turned on, main boom lift down will be
enabled and main telescope in will be enabled to recover the
boom. After the boom is brought down it will be trapped into
transport. Reset or turning it off is achieved by escaping out of
the service mode, by cycling power to the machine, or re-
entering the service mode and manually turning it off.
Use the Left or Right arrow key until you see:
3121262 – JLG Lift – 4-11

4.3 BOOM REMOVAL AND INSTALLATION 4. Disconnect the telescope hoses from the bottom of the
hydraulic control valve. Pull the hoses out so the can be
lifted away from the machine with the boom.
Removal
1. Remove the Jib Assembly. Refer to Section 4.6 - Jib.
2. At the rear of the turntable, tag and disconnect all wir-
ing harnesses that run from the powertrack to the
ground control station. The connector inside the ground
control box will have to be removed from the wires to
allow the harness to be pulled out of the control box.

residual hydraulic fluid. Disconnect the pressure hose
from the end of the main control valve. Cap or plug all
openings.

residual hydraulic fluid. Disconnect the pressure line
going into the platform filter, taking care to slowly bleed
off hydraulic pressure. Cap or plug all openings.
4-12 – JLG Lift – 3121262

6. Remove the cover from the rear of the boom and dis- 8. Using the Main Lift Crackpoint option under the Calibra-
connect the wiring harnesses and hoses running from tions menu, lift the boom enough to access the boom
the turntable to the boom. lift cylinder rod pivot pin.
7. Disassemble the end of the turntable to boom pow- NOTE: The boom assembly weighs approximately 10,800 lbs.
ertrack from the turntable. Use a lifting device to pull (4,900 kg.).
the powertrack up so the hydraulic hoses and wiring
harnesses can be pulled out from the turntable. 9. Using an adequate lifting device, support the weight of
the boom.
10. Attach a lifting device to support the weight of the

boom lift cylinder.
NOTE: To assist in determining when the lift cylinder is properly

supported, use the JLG Analyzer and select Diagnostics >
Moment > Actual Moment and get a reading as close to
zero as possible.
3121262 – JLG Lift – 4-13

11. Remove the bolt and keeper pin securing the boom lift Installation
cylinder rod pivot pin and drive out the pivot pin.
1. Lift the boom from its supports.
12. Lower the lift cylinder until it rests on the turntable.

13. Attach an adequate lifting device to support the rear of
the boom.
14. Remove the bolt and keeper pin securing the boom
pivot pin and remove the pivot pin. Remove the boom
from the machine and place it on adequate supports.
4-14 – JLG Lift – 3121262

2. While lifting the boom into position, begin to route the 4. Raise the boom enough to gain access to the lift cylin-
hoses into position so they can be inserted into the der rod pivot fitting.
powertrack.
5. Attach a lifting device to the lift cylinder barrel. Lift the

lift cylinder up to align the lift cylinder rod pivot fittings.
3. Line up the boom pivot fittings and install the boom

pivot pin. Apply JLG Threadlocker P/N 0100019 to the
6. Install the lift cylinder rod pivot pin and secure it in place
bolt threads and secure the pin in place with the keeper
with the keeper pin and bolt.
pin and bolt. Torque the bolt to 285 ft.lbs. (388 Nm).
3121262 – JLG Lift – 4-15

7. Connect the hoses to the main valve and pressure filter 11. Position the hoods in place on the turntable and secure
as tagged during removal. in place with the mounting hardware.
8. Reconnect the negative battery terminal. 12. Cycle test the machine and check for leakage and
proper operation.
9. Using auxiliary power, lower the boom to horizontal.
10. Connect all electrical harnesses as tagged during
removal. Reinstall the wiring into the connector plug in
the ground control box as tagged during removal.
4-16 – JLG Lift – 3121262

4.4 BOOM DISASSEMBLY/ASSEMBLY & CABLE 6. Remove the bolt and keeper pin securing the jib pivot
pin and remove the pin.
REPLACEMENT
It is not necessary to completely remove the entire boom
assembly from the machine to replace the cables. In the fol-
lowing procedure, the base boom section will remain on the
machine.
Disassembly
NEVER HANDLE WIRE ROPE WITH BARE HANDS.

1. Position the boom so that it is horizontal. If the boom is
below horizontal, ensure that the boom is not on the
boom rest.
2. Use an adequate lifting device to support the weight of
the jib and platform assembly. 7. Remove the jib and platform assembly from the boom.
3. Tag and disconnect the hoses and electrical harnesses

that run to the platform. Cap or plug all openings.
4. Pull the hoses and harnesses through the jib and lay
them off to the side of the boom.
5. Remove the bolt and keeper pin securing the platform
level pivot pin and remove the pin.
3121262 – JLG Lift – 4-17

8. Attach a lifting device to the powertrack for support and 9. Unbolt the lower powertrack tube from the outer mid
unbolt the upper powertrack tube from the fly boom. boom section and the mounting bracket from the inner
Pull the disconnected tube back to allow room to dis- mid boom section..
connect the lower tube.
10. Attach a strap or other similar device around the pow-

ertrack and boom to keep the powertrack secure
throughout the cable replacement procedure.
4-18 – JLG Lift – 3121262

3121262
– JLG Lift –
1. Boom Base
2. Boom Inner Mid
3. Boom Outer Mid
4. Boom Fly
Figure 4-2. Boom Assembly - Sheet 1 of 7
4-19
4-20
– JLG Lift –
1. Outer Mid Extend Block 4. Retract Rope Retainer Plate 7. Retract Rope Retainer Plate
2. Outer Mid Retract Sheave 5. Rope Retainer Block 8. Lock Plate
3. Rope Retainer Block 6. Fly Retract Sheave 9. Tele Cylinder Wear Pads
3121262
3121262
– JLG Lift –
1. Upper Rear Wear Pad 6. Shim
2. Shim 7. Tele Cylinder Pulley Assembly
3. Telescope Cylinder 8. Bottom Rear Wear Pad
4. Trunnion Keeper Block 9. Shim
5. Lower Rear Wear Pad
4-21
4-22
– JLG Lift –
1. Sheave Deflector 6. Rope Retainer Block
2. Sheave Deflector 7. Level Cylinder
3. Rope Retainer Block 8. Front Lower Wear Pad
4. Fly Extension Sheave 9. Lock Plate
5. Rope Retainer Block
3121262
3121262
– JLG Lift –
1. Front Upper Wear Pad 4. Shim
2. Shim 5. Lock Plate
3. Front Side Wear Pad
4-23
4-24
– JLG Lift –
1. Outer Mid Extend Rope 4. Outer Mid Retract Rope
2. Fly Extend Rope 5. Proximity Switch Spring
3. Fly Retract Rope 6. Switch Adjustment Block
3121262
3121262 – JLG Lift – 4-25

11. Remove the bolts securing the side wear pads to the 13. Remove the cover over the boom length limit switch at
front of the base boom and remove the pads and shims. the front of the boom base section. Remove the switch.
12. Remove the boom length plate.
14. Remove the rear boom cover.
4-26 – JLG Lift – 3121262

15. Tag and disconnect the wiring harness running to the 18. Remove the keepers for the outer mid retract cable
boom length sensor. Remove all the bolts and washers adjustment nuts at the front of the boom base section.
securing the sensor, including those that secure the
measuring cable to the telescope cylinder, and remove
the length sensor.
19. Loosen and remove the outer mid retract cable adjust-
16. Tag and disconnect the hydraulic hoses from the tele-
ment nuts.
scope cylinder. Cap or plug all openings.
20. Remove the adjustment bolt keepers for the outer mid
extend cable adjustment nuts at the rear of the boom.
17. Remove the front side, top, and lower wear pads from
the boom base section.
3121262 – JLG Lift – 4-27

21. Remove the adjustment nuts for the for the outer mid 23. Remove the cover plate from the bottom of the boom
extend cables along with the Broken Cable proximity and remove the sheave blocks.
switch, spring, and adjustment plate.
22. Remove the cable mounting plate.
24. Remove the trunnion blocks that secure the telescope

cylinder rod to the boom base section.
4-28 – JLG Lift – 3121262

25. Remove the outer mid retract cables from the attach- 27. Pull the inner mid, outer mid, and fly boom sections out
ment fixtures at the front of the boom base section. of the base boom section. Use additional lifting devices
and reposition any lifting straps as necessary as the sec-
tions are withdrawn. It will be helpful during this step to
pull the outer mid retract cable out from the front of the
base section as the other sections are being pulled out.
This will prevent the cables from tangling as the sections
are withdrawn.
26. Attach an auxiliary hydraulic power source to the tele-

scope cylinder and extend the cylinder rod enough to
turn the trunnion in a vertical position.
3121262 – JLG Lift – 4-29

28. Remove the trunnion blocks that secure the telescope 30. Remove the hardware attaching the outer mid extend
cylinder barrel to the inner mid boom section. block and remove the block and outer mid extend
cables.
29. Attach a lifting device to the telescope cylinder and pull

the cylinder, along with the outer mid extend cables out 31. Remove the cable retainer plate, cable retainer block,
of the inner mid boom section. Reposition the lifting bushing, and sheave.
device as necessary to balance the cylinder.
4-30 – JLG Lift – 3121262

32. Remove the rear bottom wear pad. 34. Pull the fly boom extend cables from their mounting
receptacles.
33. Remove the lock plates from the fly boom retract cable
adjustment nuts and remove the adjustment nuts from
the fly boom retract cables and from the fly boom
extend cables at the front of the inner mid boom sec-
tion.
35. Remove the top, side, and bottom wear pads from the
front of the inner mid boom sections.
3121262 – JLG Lift – 4-31

36. Attach a strap to pull the outer mid and fly boom sec- NOTE: When pulling the outer mid and fly boom sections out of
tions out of the inner mid boom section. Secure the rear the inner mid boom section, make sure the outer mid
of the inner mid boom section so it doesn’t move as the retract cables do not catch at the rear of the boom section.
other sections are withdrawn.
38. Pull the sections the rest of the way out of the inner mid
boom section, pulling the fly boom retract cables out at
the same time.
39. Remove the outer mid retract cables from the rear of the
inner mid boom section.
37. Pull the sections out enough to allow easy removal of

the cable retainer blocks and sheave blocks for the fly
boom retract cables at the front of the inner mid boom
section.
4-32 – JLG Lift – 3121262

40. Remove the cable retract retainer plates, cable retainer 42. Remove the upper rear wear pads from the fly boom
blocks, sheaves, and bushings from the rear of the outer section.
mid boom section.
43. Remove the cable retainer blocks and shims.
41. Remove the front wear pads from the outer mid boom
section.
3121262 – JLG Lift – 4-33

44. Pull the fly boom extend cables out enough to have NOTE: When pulling the fly boom section out of the outer mid
clearance to remove the sheave, and remove the retain- boom section, make sure the fly boom retract cables do not
ing bolt, keeper pin, pin, bushings, and sheave from the catch at the rear of the boom section.
front of the outer mid boom section.
45. Attach a lifting device to the fly boom section and pull
the section and fly boom extend cables from the outer
mid boom section. Secure the rear of the outer mid
boom section so it doesn’t move when the fly boom sec-
tion is withdrawn.
4-34 – JLG Lift – 3121262

46. Remove the tape from the fly boom section and remove Assembly
the fly boom retract cables.
NEVER HANDLE WIRE ROPE WITH BARE HANDS.
NOTE: Moderately apply Super Lube JLG Part No. 3020042 to all
four inner surfaces of both ends of each boom section to a
minimum depth of 3 to 4 feet (1 to 1.25 m). The fly boom
section only needs Super Lube applied to the insertion end.
Super Lube is also to be moderately applied to all outer sur-

faces of interior wear pads after they are installed to the
insertion end of boom sections. Care should be taken to
avoid application on exposed painted surfaces of the fully
extended boom. Refer to Section 4.7 - Boom Lubrication
Application.
47. Remove the fly boom extend cables from the bottom of
the fly boom section. WIRE ROPE NUTS ARE CLOSE IN SIZE AND CAN BE SWITCHED. REFER TO THE
JLG PARTS MANUAL. OUTER MID RETRACT NUTS, LOCATED ON BOTTOM OF
BASE BOOM, WILL BE BLACK IN COLOR.
48. Thoroughly clean the boom sections.
3121262 – JLG Lift – 4-35

wire rope and place them into the fly boom, tape the
slots to keep the rope from jumping out.
TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURING THE ASSEMBLY
PROCEDURE.
1. Install the fly extend wire rope button ends into the slots
on the bottom of the fly boom section. Place tape over
the wire ends to keep them in place during assembly.
2. Fabricate a special fixture as shown below to keep four

extend wire ropes from crossing over each other.
3. Install the fly retract wire rope button ends into the slots
in the side of the fly boom, coil the remaining lengths of
4-36 – JLG Lift – 3121262

Ft-Lbs. Nm
A 165 224
B 165 224
C 35 49
D 50 70
Figure 4-7. Boom Assembly Torque Values
3121262 – JLG Lift – 4-37

#0100019
#0100011
#0100011
#0100019
#0100019
#0100011
#0100011
SECTION A-A
Figure 4-8. Locations for Threadlocker Application - Sheet 1 of 4
4-38 – JLG Lift – 3121262

#0100011
#0100011
#0100011
#0100011
#0100011
3121262 – JLG Lift – 4-39

#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
#0100011
4-40 – JLG Lift – 3121262

#0100011
#0100011
#0100011
3121262 – JLG Lift – 4-41

4. Install the fly boom section partially into the outer mid 7. Install the sheave, bushings, pin, keeper pin, and retain-
boom section. ing bolt to the front of the outer mid boom section.
DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND WIRE ROPES
8. Install the cable retainer blocks and shims.
WHILE INSERTING IT INTO THE OUTER MID BOOM.
5. Apply JLG Threadlocker P/N 0100011 to the bolts and

install the front lower wear pads and shims to the outer
mid boom as marked during disassembly. Torque the
bolts to 50 ft.lbs. (68 Nm).

install the front upper, and side wear pads on the outer
mid boom section as marked during disassembly.
Torque the bolts to 50 ft.lbs. (68 Nm).
6. Install the fly boom section most of the way into the
outer mid boom section, leaving enough of the fly out
so there is adequate slack in the fly boom extend cables
to allow for installation of the front sheave.
4-42 – JLG Lift – 3121262

10. Apply JLG Threadlocker P/N 0100011 to the bolts and 12. Apply a thin coat of moly paste lubricant to the inside
install the rear upper and side wear pads on the outer diameter of the sheave composite bearings. Install the
mid boom section as marked during disassembly. fly retract sheaves and bushings while guiding the wire
Torque the bolts to 50 ft.lbs. (68 Nm). ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
P/N 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retract retainer
plates and cable retainer blocks.
11. Uncoil the fly retract wire ropes from the fly boom.
Route the threaded ends of the wire ropes through the
holes in the outer mid boom plates at the retract sheave
locations.

install the lower rear wear pad onto the outer mid boom
section. Torque the bolts to 50 ft.lbs. (68 Nm).

install the side and upper wear pads on the rear of the
inner mid boom section. Torque the bolts to 50 ft.lbs. (68
Nm).
15. Lubricate the wear surfaces on the inside of the inner
mid boom section with Super Lube.
3121262 – JLG Lift – 4-43

16. Feed the fly boom retract cable into the inner mid boom 18. Attach the fly boom retract cables in the inner mid
section from the front. boom section to the receptacles at the rear of the outer
mid boom section.
19. Put tape over the holes to keep the cable ends from
jumping out.
17. Using an adequate lifting device, align the outer mid

boom section with the inner mid boom section.
20. Push the outer mid assembly part way into the inner
mid boom section. Apply JLG Threadlocker P/N 0100011
to the bolts and install the front bottom wear pad into
the inner mid boom section. Torque the bolts to 50
ft.lbs. (68 Nm).
4-44 – JLG Lift – 3121262

21. Push the outer mid assembly into the inner mid while 23. Push the outer mid assembly almost completely into the
pulling the boom cables out the back fo the inner mid inner mid boom section.
section at the same time. Leave 3 to 4 feet of the outer
mid section sticking out of the inner mid section.
24. Install the cable retainer blocks over the fly boom retract
cables and insert the fly boom extend cable into the
22. Push the retract cable ends into the mounting recepta- mounting receptacles.
cles and install the cable sheaves and adjustment nuts.
3121262 – JLG Lift – 4-45

25. Apply JLG Threadlocker P/N 0100011 to the bolts and 27. Apply a thin coat of moly paste lubricant to the inside
install the side and top wear pads into the inner mid diameter of the sheave composite bearings. Install the
boom section. Torque the bolts to 50 ft.lbs. (68 Nm). retract sheaves and bushings while guiding the wire
ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply JLG Threadlocker
P/N 0100019 to the sheave retaining bolts and torque to
165 ft.lbs. (224 Nm). Install the cable retainer blocks and
cable retainer plates.
26. Put moly paste on the sheave mounts at the rear of the
inner mid boom section and install the sheaves.

install the rear bottom wear pad on the rear of the inner
mid boom section. Torque the bolts to 50 ft.lbs. (68 Nm).
4-46 – JLG Lift – 3121262

29. Install a new sheave on the telescope cylinder. 32. Route the cables around the sheave on the cylinder and
install the cable retainer block.
30. Install the outer mid extend cables into the cable pulley
at the rod end of the telescope cylinder. 33. Using an adequate lifting device, insert the cylinder and
cables part way into the inner mid boom.
31. Install the other end of the outer mid extend cables into
the cable guide block.
3121262 – JLG Lift – 4-47

34. Apply JLG Threadlocker P/N 0100019 to the bolts and 37. Using Super Lube®, lubricate all wear surfaces on the
attach the cable guide to the inner mid boom section inside of the boom base section and the outside of the
with the mounting hardware. Torque the bolts to 165 inner mid boom section.
ft.lbs. (224 Nm).
38. Insert the inner mid boom section part way into the
boom base section enough to be able to pull the outer
mid retract cables out through the hole at the bottom
front of the boom base section.
35. Push the cylinder the rest of the way into the inner mid
boom assembly.
36. Install the cylinder trunnion blocks and shims.

install the front lower wear pads into the boom base
4-48 – JLG Lift – 3121262

40. Push the inner mid boom assembly the rest of the way 46. Install the outer mid retract cable adjustment nuts at the
into the boom base section, adjusting the lifting device front of the boom base section.
as necessary to keep the weight balanced.
install the side and upper wear pads into the boom base
42. Install the boom transport length sensor on the side of
the boom base section.
43. Attach the powertrack tubes.
44. If necessary, attach a source of auxiliary hydraulic power
and retract the boom enough to allow installation of the
cable adjustment plate at the rear of the base boom sec-
tion and install the plate.
47. Install the boom length sensors and angle sensors as

tagged during removal.
45. Install the broken cable sensor and the outer mid extend
cable adjustment nuts.
48. Connect the hydraulic hoses to the telescope cylinder as

tagged during removal.
49. Adjust the boom cables. Refer to Section 4.16 - Wire

Rope Tensioning Adjustment.

3121262 – JLG Lift – 4-49

4.5 LOAD SENSING PIN REMOVAL AND size (as shown below). If excessive force is necessary to
move the pin, it may be necessary to carefully activate
INSTALLATION lift using the auxiliary power switch to relieve lift cylin-
der weight from the load sensing pin.
1. Place the machine on a firm, level surface.
NOTE: Replacing the load sensing pin requires the boom sensors
be re-calibrated. Make sure the machine is in an area
where this can be accomplished after installation of the
new pin.
2. Swing the engine tray out to gain access to the sensing

pin and retaining pin.
NOTE: The lift cylinder weighs 787 lbs. (357 kg.)
3. Run a nylon strap capable of supporting the weight of

the lift cylinder around the bottom of the cylinder. Lift
up on the strap to relieve the weight of the lift cylinder
on the load sensing pin. 7. When installing a new pin, make sure all of the holes in
the turntable and lift cylinder are aligned. If the new
load sensing pin does not push 1/2 to 3/4 of the way in
by hand, remove the pin and align the holes better. Also
make sure the pin is installed with the strain relief con-
nector opposing the pin orientation bar as shown. Refer
to Pivot Pin Installation.
4. Loosen and remove the bolt that secures the retaining

pin and remove the retaining pin.
8. Using an oak block, carefully tap the pin until it is fully
installed. Secure the pin in place with the retaining pin
and retaining pin bolt.
DO NOT TAP ON THE CENTER OF THE PIVOT PIN.
9. Connect the wiring harness to the strain relief connector

and re-calibrate the boom sensors.
5. Disconnect the wiring harness from the strain relief con-
nector at the opposite side of the load sensing pin.
6. Use the Load Pin Removal Tool (JLG P/N 4846765) to pre-
vent the pin from being damaged, and use a hammer to
remove the pin. To make the tool refer to Figure 4-12.,
Load Pin Removal Tool, JLG P/N 4846765. If the Load Pin
Removal Tool is not available, use an arbor of the proper
4-50 – JLG Lift – 3121262

Figure 4-12. Load Pin Removal Tool, JLG P/N 4846765
3121262 – JLG Lift – 4-51

4.6 JIB It may be necessary to disconnect additional lines to

gain access to certain fittings. Cap or plug all openings.
Removal
1. Lower the platform to the ground or onto blocking to
support the weight of the jib.
2. Tag and disconnect the electrical harnesses that run to
the jib. If necessary, loosen the guide block to allow the
harnesses and hoses to move more freely.
5. Unbolt the valve from the boom.
3. Remove the jib valve protection plate.
6. Lay the jib control valve aside on the jib. Secure it in

place so it does not fall.

residual hydraulic fluid. Tag and disconnect the hydrau-
lic hoses that run from the boom to the jib control valve.
4-52 – JLG Lift – 3121262

7. Disconnect the jib protractor sensor linkage from the NOTE: The jib and platform assembly weighs approximately 2100
boom. lbs. (953 kg.).
9. Attach an adequate supporting device to the jib to sup-

port its weight. Remove the bolt and keeper pin secur-
ing the jib pivot pin and remove the pin.
8. Remove the bolt and keeper pin securing the jib level
pivot pin and remove the pin. Place blocking under the
cylinder rod or a soft material under the cylinder rod to
protect the rod from being scratched.
10. Remove the jib and platform assembly from the boom.
3121262 – JLG Lift – 4-53

Installation 3. Lift the jib into position on the boom fly section and
install the jib pivot pin. Secure the pin in place with the
1. Attach an adequate lifting device to the jib and position keeper pin and bolt.
it in front of the boom.
2. Place something under the front of the jib that will allow
it to slide or move along the ground easily. Attach a lift-
ing device to the rear of the jib, allowing the front to
pivot on the ground.
4-54 – JLG Lift – 3121262

4. Attach a lifting device to the front of the jib and align 5. Place the mounting bracket on the jib valve and bolt the
the jib level cylinder attachment fittings. Install the pivot jib valve to the fly boom section.
pin. Apply JLG Threadlocker P/N 0100019 to the bolt 6. Install the wiring harnesses and hydraulic hoses on the
threads and secure the pin in place with the keeper pin jib valve as tagged during removal.
and bolt. Torque the bolt to 165 ft.lbs. (224 Nm).
7. Install the jib valve protection plate.

3121262 – JLG Lift – 4-55

JIB
ROTARY
JIB LIFT CYLINDER ACTUATOR
PLATFORM LEVEL CYLINDER
PLATFORM ROTARY ACTUATOR
JIB BASE BOOM
JIB LOCK CYLINDER
JIB POWER TRACK

JIB FLY BOOM
PLATFORM LEVEL CYLINDER
PLATFORM ROTARY ACTUATOR
1001118868-A
Figure 4-13. Jib Assembly - Sheet 1 of 3
4-56 – JLG Lift – 3121262

3121262 – JLG Lift – 4-57

BOLT
LOCKPIN CYLINDER CAP
ALIGN CUTOUT IN CAP
INWARD AS SHOWN
(SEE SECTION A-A BELOW) ALIGN LOCK CYL WITH
PROTRUSIONS CAP
(SEE SECTION A-A BELOW)
JIB LOCK CYLINDER
LOCKNUT
TORQUE 220 FT.LBS. (298 Nm)
LOCK PIN
CYLINDER ALIGN CUTOUT IN CAP
AS SHOWN
CAP
ALIGN HOLES IN LOCK CYL
WITH PROTRUSIONS
IN CAP AS SHOWN
INTERNALS OF ACTUATOR
NOT SHOWN FOR CLARITY
JIB PIVOT
BEARING HOUSING
BEARING
* (PRESS FIT)
FLANGE BEARING
* (PRESS FIT)
JIB ROTATOR
BEARING HOUSING
BEARING
* (PRESS FIT)
JIB PIVOT
BEARING HOUSING
Loctite RC 609 Threadlocker

*
SECTION A-A
1001118868-A
4-58 – JLG Lift – 3121262

4.7 BOOM LUBRICATION APPLICATION 4.8 PLATFORM LEVELING CYLINDER

This procedure applies to booms after assembly or during Removal
annual application using Super Lube® lubricant (JLG p/n
3020042). 1. Ensure the platform is supported by blocking or an ade-
quate lifting device.
1. Position the boom on the boom rest using the 500lb
capacity setting. 2. Remove the bolt and keeper pin securing the retaining
pin that secures the cylinder rod to the platform assem-
2. Telescope main boom section as far as it will extend at bly and remove the pin.
this position, approximately 3 ft. (0.9 m).
3. From the front of the machine (boom pivot end), moder-

ately apply lubricant to the interior surfaces of the base
boom, inner mid boom, and outer mid boom. To pre-
vent misdiagnosis of hydraulic leaks, take care to pre-
vent excessive application of lubrication.
4. At the rear of the machine, apply lubricant to the side,

top and bottom surfaces of the fly boom, outer mid, and
inner mid specifically to wear pad contact paths. To pre-
vent misdiagnosis of hydraulic leaks, take care to pre-
vent excessive application of lubrication.
5. After application of the lubricant is complete, cycle the

boom through its full range of travel 2 times.
3. Tag and disconnect the hydraulic hoses from the plat-

form level cylinder. Cap or plug all openings. Tag and
disconnect the electrical harness running to the cylin-
der.
3121262 – JLG Lift – 4-59

4. Lift the platform to allow enough room for removal of Installation

the cylinder.
1. Attach a lifting or jacking device to the platform and
position the platform to provide adequate room to
install the platform leveling cylinder.
2. Coat the retaining pin holes with an anti-seize com-

NOTE: The platform level cylinder weighs approximately 79 lbs.
pound to lubricate the holes and prevent rust.
(36 kg.).
5. Ensure the cylinder is supported so it will not move

when the rear retaining pin is removed. Remove the bolt
and keeper pin securing the retaining pin at the rear of
the cylinder and remove the pin.
3. Lift the cylinder into place.

4. Line up the rear pivot hole and insert the pivot pin.
6. Carefully lift the cylinder from the machine.
4-60 – JLG Lift – 3121262

5. Secure the pivot pin in place with the keeper pin. 4.9 JIB TELESCOPE CYLINDER
Loosely install the bolt, but do not tighten it at this time.
Removal
1. Remove the guide pad at the rear of the jib to provide
more room for cylinder removal.
6. Thread the length sensor harness around the cylinder

and up to the platform box. Connect the harness to the
connector under the platform box.
7. Route the hydraulic hoses around the cylinder. Connect 2. Extend the jib enough to gain access to the pins that
the hoses to the cylinder as tagged during removal. secure the jib telescope rod to the jib fly boom section.
8. Extend the cylinder to align the front pivot pin hole. It
may be necessary to lower the platform to help align the
components.
9. Install the retaining pin and keeper pin.
install the bolts to secure the keeper pins. Torque the
bolt at the rod end of the cylinder to 40 ft. bs. (55 Nm)
and the bolt at the barrel end cylinder to 95 ft.lbs. (130
Nm).
11. Function check the cylinder to ensure it operates prop-
erly and there is no leakage.
3. Lower the boom so the platform base is on the ground

or supported by blocking.
3121262 – JLG Lift – 4-61

4. Remove the retaining rings securing the retaining pins 8. Tag and disconnect the hoses going to the jib telescope
on the powertrack side of the jib and remove the pins. cylinder.
5. Attach a strap or similar device between the jib base

boom and the jib fly boom to ensure the jib fly boom 9. Place blocking underneath the cylinder to prevent it
will not extend inadvertently when the jib is raised. from falling when the retaining bolts are removed.
Remove the retaining bolts securing the jib telescope
cylinder to the jib base boom.
NOTE: The platform level cylinder weighs approximately 130 lbs.

(59 kg.).
10. Attach an adequate lifting device to the cylinder and lift

the cylinder from the jib. Adjust the device as necessary
as the cylinder is withdrawn to balance the weight of
the cylinder.
6. Raise the jib to horizontal.
7. Retract the jib telescope cylinder.
4-62 – JLG Lift – 3121262

4. Connect the hydraulic hoses to the cylinder as tagged

during removal.
Installation
5. Lower the jib enough to enable easier access to the
1. If installing a new cylinder, test fit the retaining pins that attachment holes in the jib fly boom.
secure the jib telescope rod to the jib fly boom to ensure
they fit properly. Apply an anti-seize compound to the 6. Extend the cylinder enough to align the attachment
attachment holes in the cylinder rod. holes in the jib fly boom with those in the end of the cyl-
inder rod.
2. Lift the cylinder into place, adjusting the lifting device as
necessary to maintain balance. 7. Install the retaining pins and secure them in place with
the retaining rings.
3. Fasten the cylinder barrel to the jib base boom with the
attaching bolts. Do not tighten the bolts at this time.
8. Apply JLG Threadlocker P/N 0100011 to the bolts secur-
ing the cylinder barrel to the jib base boom and torque
the bolts to 95 ft.lbs. (130 Nm).
3121262 – JLG Lift – 4-63

4.10 JIB LIFT CYLINDER 3. Remove the bolt and keeper pin that secure the jib lift
cylinder barrel pivot pin. Remove the jib lift cylinder bar-
rel pin.
Removal
1. Ensure the weight of the jib is fully supported.
4. Lower the cylinder enough to tag and disconnect the

cylinder length sensor harness. Readjust the lifting
2. Place a strap or similar device in place to support the device as necessary to balance the weight of the cylin-
weight of the cylinder. der.
4-64 – JLG Lift – 3121262

5. Remove the bolt and keeper pin that secure the jib lift Installation
cylinder rod pivot pin. Remove the jib lift cylinder rod
pivot pin. 1. If installing a new cylinder, test fit the pivot pins in the
cylinder to ensure they fit properly. Apply an anti-seize
compound to the attachment holes in the cylinder rod
and barrel.
1. Lift the cylinder into position to install the jib lift rod
pivot pin. Install the pivot pin.
2. Secure the pin in place with the keeper pin. Apply JLG
Threadlocker P/N 0100011 to the retaining bolt. Install
the retaining bolt to secure the keeper pin and torque to
165 ft.lbs. (224 Nm).
6. Lower the cylinder from the machine, readjusting the

lifting device as necessary to balance the weight of the
cylinder.
3. Reposition the lifting device as necessary to keep the

cylinder balanced. Raise the cylinder enough to allow
the length sensor harness to be connected and connect
the harness as tagged during disassembly.
3121262 – JLG Lift – 4-65

4. Raise the cylinder into position to allow the jib lift barrel 4.11 JIB STRAIGHT SHIMMING PROCEDURE
pivot pin to be installed and install the pin.
See Figure 4-16., Jib Straight Shimming.
5. Secure the pin in place with the keeper pin. Apply JLG
Threadlocker P/N 0100011 to the retaining bolt. Install 1. Install the jib lock cylinder and fully extend the rod
through the bearing housings in the jib rotator and jib
the retaining bolt to secure the keeper pin and torque to
pivot.
165 ft.lbs. (224 Nm).
2. Align the jib pivot straight with the jib assembly.
3. Insert a 16 gauge shim between the wear pad and pivot
pad mount.
4. Add shims (16 gauge and 20 gauge) as required to fill
the gap between the wear pad and the edge of the bot-
tom plate of the jib rotator.
5. Shim until the thinnest shim can not fit. Do not over
shim and cause jib pivot and jib assembly misalignment.
6. When shimmed properly, the jib pivot and jib assembly
should line up straight as shown below.
ALIGN JIB PIVOT STRAIGHT
WITH JIB ASSEMBLY AS SHOWN
6. Remove the lifting device supporting the cylinder and

the lifting device supporting the jib.

4-66 – JLG Lift – 3121262

PIVOT PAD MOUNT
JIB ROTATOR
BOTTOM PLATE
TORQUE 20 FT.LBS. (27 Nm)
WEAR PAD
SHIMS
(NOMINAL QTY SHOWN)
Figure 4-16. Jib Straight Shimming
3121262 – JLG Lift – 4-67

4.12 BOOM CLEANLINESS GUIDELINES 4. The first attempt to remove debris from inside the boom
must be to utilize pressurized air to blow the debris
The following are guidelines for internal boom cleanliness for toward the nearest exiting point from the boom. Make
machines that are used in excessively dirty environments. sure that all debris is removed before operating the
machine.
1. JLG recommends the use of the JLG Hostile Environment
5. If pressurized air cannot dislodge the debris, then water
Package if available to keep the internal portions of a
with mild solvents applied via a pressure washer can be
boom cleaner and to help prevent dirt and debris from
used. Again the method is to wash the debris toward the
entering the boom. This package reduces the amount of
nearest exiting point from the boom. Make sure that all
contamination which can enter the boom but does not
debris is removed, that no “puddling” of water has
eliminate the need for more frequent inspections and
occurred, and that the boom internal components are
maintenance when used in these types of environ- dry prior to operating the machine. Make sure you com-
ments. ply with all federal and local laws for disposing of the
wash water and debris.
2. JLG recommends that you follow all guidelines for ser-
vicing your equipment in accordance with the instruc- 6. If neither pressurized air nor washing of the boom dis-
tions outlined in the JLG Service & Maintenance Manual lodges and removes the debris, then disassemble the
for your machine. Periodic maintenance and inspection boom in accordance to the instructions outlined in the
is vital to the proper operation of the machine. The fre- JLG Service & Maintenance Manual to remove the
quency of service and maintenance must be increased debris.
as environment, severity and frequency of usage
requires. 4.13 HOSE ROUTING
3. Debris and foreign matter inside of the boom can cause For proper hose routing, refer to Figure 4-17., Figure 4-18., and
premature failure of components and should be Figure 4-19. It is important to periodically inspect hoses, wraps
removed. Methods to remove debris should always be and clamps for proper slack adjustments and clamping integ-
done using all applicable safety precautions outlined in rity (pull check). Any changes as a result of inspection should
the JLG Service & Maintenance Manuals. be verified by performing full strokes of boom functions espe-
cially lift, telescope, jib, and platform rotate.
4-68 – JLG Lift – 3121262

3121262
TELESCOPE RETRACT HOSE
(OUTSIDE OF BEND RADIUS)
TELESCOPE TANK HOSE
(INSIDE OF BEND RADIUS)
HARNESS BUNDLE
TELESCOPE EXTEND HOSE
HOSES AND CABLES SHOULD NOT BE HOSES AND CABLES SHOULD BE AGAINST
PULLED TIGHT AGAINST THE INSIDE THE OUTSIDE RADIUS OF THE POWER TRACK
RADIUS OF THE POWERTRACK
– JLG Lift –
INCORRECT CORRECT
Figure 4-17. Powertrack Hosing - Sheet 1 of 3
4-69
4-70 – JLG Lift – 3121262

3121262 – JLG Lift – 4-71

4.14 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of
the powertrack.
One Piece Bracket Maintenance

1. Place the powertrack on a workbench.
4. Pull up on the loose side of the round bar to allow the

poly roller to slide off.
2. Remove the screws from the bars on one side of the

powertrack on the first link.
4-72 – JLG Lift – 3121262

5. Slide the poly roller off of the round bar. 7. Slide the flat bar out.
6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket.
9. Remove the snap ring from the other side of the bracket.
3121262 – JLG Lift – 4-73

10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance
bracket side up and over the extrusion on the link.
1. Loosen the screw.
11. Repeat the previous step on the other side.
2. Slide the roller off the bar.
12. Slide the bracket off of the powertrack.
3. Hold the bar tightly and remove the other screw.
4-74 – JLG Lift – 3121262

4. Hold the flat bar and remove the screws. 7. Slide the link out.
5. Remove the snap rings and pins. Snap Rings and Screws
WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO

DISCARD AND REPLACE ALL OLD SCREWS.
Make sure screws are tight and installed properly.
6. Remove the screws from the bar. Remove the snap ring
and pin. LOOSE SCREW TIGHT SCREW
3121262 – JLG Lift – 4-75

Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below.
CLOSED
OPEN
10-24 x 0.812 button torx socket head with blue locking patch:
An open snap ring is shown below. • Tighten to 45-50 in.lbs. (5-5.6 Nm).
• Use T-25 torx bit.
• Do not reuse this screw. After removing replace with a new
one.
A snap ring that is not seated is shown below.
4-76 – JLG Lift – 3121262

4.15 WIRE ROPE Three Month Inspection

1. Remove boom covers and visually (with flashlight)
Inspection inspect the ropes for rust, broken wires, frays, abuse, or
any signs of abnormalities.
NOTE: The pictures in this paragraph are just samples to show the 2. Check rope tension by deflecting the ropes by
replacement criteria of the rope. hand...properly tensioned ropes should have little or no
movement.
1. Inspect ropes for broken wires, particularly valley wire
NOTE: Delayed movement of the fly boom indicates loose wire
breaks and breaks at end terminations. ropes.
Eight Year Inspection

1. Mandatory wire rope and sheave replacement.
Additional inspection required if:

Flexing a wire rope can often expose broken wires hid-
den in valleys between strands. a. Machine is exposed to hostile environment or con-
ditions.
b. Erratic boom operation or unusual noise exists.
2. Inspect ropes for corrosion. c. Machine is idle for an extended period.
d. Boom is overloaded or sustained a shock load.
3. Inspect ropes for kinks or abuse.
e. Boom exposed to electrical arc...wires may be fused
internally.
Replacement Criteria
1. Sheaves and wire rope must be replaced as sets.
A kink is caused by pulling down a loop 2. Rusted or corroded wire ropes.
in a slack line during improper handling,
installation, or operation. 3. Kinked, “bird caged”, or crushed ropes.
4. Ropes at end of adjustment range.
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.) 5. Sheaves failing wearout gage inspection.
6. Ropes with 6 total broken wires in one rope lay, 3 in one
5. Inspect sheaves for condition of flanges. (See Dimension
strand in one rope lay, 1 valley break, or 1 break at any
Of Sheaves for proper dimension.) end termination.
6. Inspect sheaves with a groove wearout gauge for exces-
sive wear.
Observe the groove so that it may be clearly seen

whether the contour of the gauge matches the
contour of the bottom of the groove.
7. Ropes passing inspection should be lubricated with wire

rope lubricant before reassembly.
3121262 – JLG Lift – 4-77

4.16 WIRE ROPE TENSIONING ADJUSTMENT INNER MID BOOM SECTION REPOSITIONING
The inner mid section of the boom is positioned by the
hydraulic cylinder. No adjustments can be made to this sec-
tion. The wire ropes within the assembly only control the
ANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED, BOOM CALI- movement of the Outer Mid Boom and Fly Boom sections.
BRATION SHOULD BE PERFORMED IMMEDIATELY AFTERWARD.
OUTER MID BOOM SECTION REPOSITIONING
Before adjusting wire rope tension, the boom sections must If the Outer Mid Boom falls within the dimension and toler-
be in the proper position as shown in Figure 4-21., Wire Rope ance of Figure 4-21., Wire Rope Tensioning, proceed to the Fly
Tensioning. This is so the wire ropes are equalized on both Boom Section Positioning procedure in this section. If the
sides of the sheaves and are seated properly in the sheave Outer Mid Boom section is outside of the tolerance as shown,
grooves. This is necessary for proper tensioning of the wire perform the following procedure.
ropes. 1. Extend the boom assembly so the platform moves 5 to 6
feet (1.5 to 1.8 m) from the fully retracted position.
This section covers the two major operations in tensioning the
wire ropes which are as follows: 2. Remove any covers necessary to access the wire rope
adjustment nuts.
• Positioning the boom sections (so that proper tensioning
can be achieved).
• Tensioning the wire rope.
Boom Section Re-Positioning

NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom section will also affect the position of the Fly Boom
section. Correctly position the Outer Mid Boom before
repositioning the Fly Boom.
NOTE: Use the Telescope function of the machine to position the

boom sections. Do not use the wire rope adjustment nuts
to position the booms. This may cause damage to the wire
rope adjustment threads.
1. Ensure the machine is placed on firm, level ground.
2. Before making any adjustments, position the boom

assembly in the fully retracted position.
3. Take preliminary measurements of the position of each

boom section and compare them to Figure 4-21., Wire
Rope Tensioning. If the measurements fall within the tol-
erances in the figure, proceed to Wire Rope Tensioning
in this section.
PROPER BOOM POSITIONS DO NOT MEAN THAT THE WIRE ROPE TENSIONS
ARE CORRECT.
If the measurements do not fall within the tolerances in Figure

4-21., Wire Rope Tensioning, adjust the booms using the re-
positioning procedures that follow.
4-78 – JLG Lift – 3121262

3. Remove the lock plates and nylon collar locknuts from a. If the Outer Mid Boom still does not fall within the
the wire rope adjustment nuts. dimension and tolerance of Figure 4-21., repeat the
Outer Mid Boom positioning procedure.
b. If the Outer Mid Boom falls within the dimension
and tolerance of Figure 4-21., proceed to the Fly
Boom Section Positioning procedure in this section.
NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom Section will also affect the position of the Fly Boom
section. After repositioning the Outer Mid Boom, always
check the Fly Boom position per Figure 4-21.
FLY BOOM SECTION REPOSITIONING

If the Fly Boom section location and the Outer Mid Boom sec-
tion location are both within the dimensions and tolerances in
Outer Mid Retract Adjusting Figure 4-21., proceed to the Wire Rope Tensioning Procedure
Nuts and Lock Plates in this section.
If the Fly Boom section is outside of the tolerance as shown in

Figure 4-21. while the boom assembly is fully retracted, per-
form the following procedure:
1. Extend the boom assembly such that the platform

moves 4 feet (1.3 m) from the fully retracted position.
2. Remove the lock plates and nylon collar locknuts from

the wire rope adjustment nuts.
3. If the Fly Boom needs to be retracted farther in:
a. Loosen the Fly Boom Extend Adjustment Nuts by an

Outer Mid Extend Adjusting amount equal to twice the distance the boom needs
Nuts and Lock Plates to move to be in tolerance.
4. If the Outer Mid Boom needs to be retracted:

a. Loosen the Outer Mid Boom Extend Adjustment
Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance.
b. Fully retract the boom.
c. To remove the slack caused by the previous step,
tighten the Outer Mid Boom Extend Adjustment
Nuts until they just contact the plate.
5. If the Outer Mid Boom needs to be extended out:
Fly Boom Extend Adjusting
a. Loosen the Outer Mid Boom Retract Adjustment Nuts and Lock Plates
Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance b. Fully retract the boom.
b. Extend the boom 3-4 feet (1-1.5m).
c. To remove the slack caused by the previous step, tighten the Fly Boom Extend Adjustment Nuts until
tighten the Outer Mid Boom Retract Adjustment they just contact the plate.
Nuts until they just contact the plate.
6. Fully retract the boom sections.
7. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-21., Wire
Rope Tensioning.
3121262 – JLG Lift – 4-79

4. If the Fly Boom needs extended: 1. Remove any covers necessary to access the wire rope
adjustment nuts.
a. Loosen the Fly Boom Retract Adjustment Nuts by an
amount equal to twice the distance the boom needs
to move to be in tolerance.
Fly Boom Retract Adjusting

Nuts and Lock Plates
b. Extend the boom 3-4 feet (1-1.5m).

tighten the Fly Boom Retract Adjustment Nuts until
they just contact the plate.
d. Fully retract the boom sections.
5. Verify that the exposed boom section dimensions meet

the dimensions and tolerances of Figure 4-21., Wire
Rope Tensioning.
2. If not already done, remove the lock plates and nylon
a. If the Fly Boom still does not fall within the dimen- collar locknuts from the wire rope adjustment nuts.
sion and tolerance of Figure 4-21., repeat the Fly
Boom Section Repositioning procedure. 3. Position the boom so that it is horizontal within ±5°. If
the boom is below horizontal, ensure that the boom is
b. If the Fly Boom falls within the dimension and toler-
not on the boom rest.
ance of Figure 4-21., proceed to the Wire Rope Ten-
sioning Procedure.
4. Extend the boom so the platform moves 4 feet (1.3 m)
from the fully retracted position. This is done to position
Wire Rope Tensioning Procedure the boom so the ropes to be tensioned are not under
load.
NOTE: Verification of the rope tension should be determined by
5. When extending the boom in the previous step, if the
proper function of the boom assembly and by the dimen-
boom reaches the end of travel and then automatically
sions and tolerances of Figure 4-21., Wire Rope Tensioning.
retracts a small amount, the ropes may still be under
load. If so, perform the following steps:
a. Note where the boom hits the end of stroke.

REPEAT WIRE ROPE TENSIONING PROCEDURE ONLY AS NECESSARY TO
ACHIEVE PROPER TENSION. b. Retract 3-4 feet (1-1.3 m).
c. Extend the boom and stop just before the boom
hits the end of stroke.
IF THE BOOMS HAVE BEEN PROPERLY POSITIONED AND THERE IS NOT

ENOUGH ADJUSTMENT REMAINING ON THE WIRE ROPES TO ACHIEVE TORQUE,
THE SERVICE LIFE OF THE WIRE ROPES HAS BEEN CONSUMED. DO NOT PRO-
CEED WITH THE REMAINDER OF THIS PROCEDURE. REPLACE THE WIRE ROPES
AND SHEAVES.
4-80 – JLG Lift – 3121262

6. Using tool JLG p/n 4120043, torque the Outer Mid Boom 9. Using tool JLG p/n 4120043, torque the Outer Mid Boom
Retract Adjustment Nuts to 80 ft-lb (108 Nm), alternat- Extend Adjustment Nuts to 80 ft-lb (108 Newton
ing between the two ropes until both maintain the meters), alternating between the two ropes until both
required torque. maintain the required torque.
Outer Mid Extend Adjusting

Outer Mid Retract Adjusting
Nuts and Lock Plates 10. Using tool JLG p/n 4120040, torque the Fly Extend
Adjustment Nuts to 10 ft-lb (13.5 Nm), starting with the
7. Using tool JLG p/n 4120043, torque the Fly Boom Retract inside ropes and doing the outside ropes last. Refer to
Adjuster Nuts to 80 ft-lb (108 Nm), alternating between Figure 4-20., Torque Sequence for Fly Extend Rope.
the two ropes until both maintain the required torque. Alternate between the four ropes until all maintain the
required torque.
Fly Boom Retract Adjusting

Nuts and Lock Plates Fly Boom Extend Adjusting
8. Retract the boom 2-3 feet (0.6-1.0 m). Do not fully retract
or bottom out the booms.
3 1 2 4
Figure 4-20. Torque Sequence for Fly Extend Rope
3121262 – JLG Lift – 4-81

11. Repeat the following boom movement steps three 18. Install all covers.
times. This is to ensure that the wire rope tension has
equalized on both sides of the sheaves and the ropes are
seated properly in the sheave grooves.
a. Fully retract the boom.
b. Extend the boom such that the platform moves 4
feet (1.3 m) from fully retracted position.
12. Verify the Fly Boom and Outer Mid Boom Retract wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
13. Retract the boom 2-3 feet (0.5-1 m). Do not fully retract
or bottom out the boom.
14. Verify the Fly Boom and Outer Mid Boom Extend wire
rope torques.
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step.
15. Check for proper function of the boom assembly. When
properly torqued and positioned, all three moving
boom sections will move simultaneously.
16. Install new nylon collar locknuts to the Fly Boom Extend
wire rope fittings. Do not re-use the old nylon collar lock
nuts. Torque the locknuts to 10 ft-lb (13.5 Nm)
17. Reinstall the lock plates to the remaining adjuster nuts.
4-82 – JLG Lift – 3121262

9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
FLY BOOM
BASE BOOM OUTER MID BOOM
INNER MID BOOM
NOTE: Boom shown in fully retracted position.
Figure 4-21. Wire Rope Tensioning
3121262 – JLG Lift – 4-83

Figure 4-22. Outer Mid Boom Extend/Retract Cables
4-84 – JLG Lift – 3121262

Figure 4-23. Fly Boom Extend/Retract Cables
3121262 – JLG Lift – 4-85

1. 2" Socket
2. 3/4” Socket
3. Retaining Bolt
Figure 4-24. Wire Rope Adjustment Tools (Optional)
4-86 – JLG Lift – 3121262

4.17 BROKEN BOOM CABLE PROXIMITY SWITCH To avoid damaging the proximity switch, install and adjust
after assembling the switch block, compression spring, and
This system uses a proximity switch to detect excessive move- torquing the wire ropes.
ment of the cable block. If movement is detected the Cable
Break indicator will illuminate in the platform control panel.
No restrictions are made to the functionality of the control sys-
Adjusting the Proximity Switch
tem. It is the responsibility of the operator to take immediate
1. Thread the switch in until it contacts the adjuster block.
action.
2. Thread the switch out 1/8 to 1/2 turn to achieve proper
sensing range.
3. Tighten the jam nut.
Figure 4-25. Broken Boom Cable Proximity Switch Location
4.18 ELECTRONIC PLATFORM LEVELING PRIMARY AND SECONDARY TILT SENSOR

INTERACTION
NOTE: For more detailed information concerning system adjust- The secondary tilt sensor is used as a backup to the primary tilt
ment and operation, refer to Section 6 - JLG Control Sys- sensor. Any time a tilt set point is reset, a value from each sen-
tem. sor shall be set.
If a fault occurs with the primary sensor, control will revert to

Description the secondary sensor. (This is discussed in more detail in the
Electronic platform leveling replaces the conventional hydrau- Error Response section in Section 6 - JLG Control System.)
lic method of platform leveling.
Because of the mounting orientation of the tilt sensors, the
To control electronic platform leveling the platform is primary tilt sensor will output ascending voltage values with
equipped with a pair of tilt sensors, one primary and one sec- increases in positive platform tilt angle. The backup or second-
ondary, mounted to the non-rotating portion of the platform ary tilt sensor will output descending voltage values with
rotator. The tilt sensors are monitored regularly and the plat- increases in positive platform angle.
form level up and down valves are automatically controlled to
maintain set point as the machine is operated.
3121262 – JLG Lift – 4-87

PLATFORM VALVES In order to obtain acceptable performance while performing

The platform specific valves are located in a manifold at the all hydraulic functions, five sets of parameters are used. These
platform. “zones” allow compensation for differences in how the basket
level changes when doing different functions. These zones are
There are individual proportional control valves that control as follows:
each of the four platform functions; Platform Level, Platform
Rotate, Jib Lift, and Jib Swing. 1. Lift up
There is also a Platform Dump Valve, located in the platform
2. Lift down
valve manifold, which is used to hydraulically isolate the con-
trol valves and to improve hydraulic response. 3. Other boom functions
The Ground Module controls this valve to provide manual
4. Drive
platform leveling in the event that the Platform Module is
inoperable.
5. Auxiliary
In ground mode, the platform dump valve is turned on when-
ever any platform or jib valve output is turned on. Whenever The other boom functions zone includes Swing, Telescope, Jib
all platform and jib valves are turned off, the platform dump swing (It is not necessary to level with jib lift, since the
valve is turned off. mechanical linkage keeps the basket level).
In platform mode, the platform dump valve is turned on These zones are prioritized when multiple functions are active.
whenever the footswitch is depressed. The priorities are as follows.
1. Auxiliary power and any other function, zone = auxiliary

Normal Operation
power
AUTOMATIC LEVELING 2. Drive and any other function, zone = Drive
Two tilt sensors, mounted on either side of the platform sup-
port, are used to measure the incline of the platform with 3. Lift up and any other function, zone = Lift up
respect to gravity and control the automatic leveling function,
one is used as the primary sensor and one as a secondary back 4. Lift down and any other function, zone = Lift down
up sensor.
5. Other boom functions, zone = Other boom functions
The level system shall assume a new fixed set point (fixed
incline of the platform with respect to gravity) each time the During the power-up procedure, function enable, in both Plat-
control system is powered up (cycling of the EMS). form and Ground Mode, is delayed during the 1.5 second
startup lamp test. During this 1.5 second startup period, the
Automatic platform leveling only functions while operating
basket level up valve will be energized at 100% duty cycle for
drive, telescope, lift or swing. It does not operate while operat-
ing any other function (e.g. rotate, jib, or steer). 0.5 second, and then the basket level down valve energized at
100% duty cycle for 0.5 second. This will help to keep the
The proportional control for these valves varies. This is depen- valves from sticking.
dant on the tilt variance from target as well as on the impact
coil temperature is having on the current to the valves. PLATFORM LEVEL MANUAL OVERRIDE
If a command from the Platform Level Up and Down toggle In addition to automatic leveling the operator is able to manu-
switch on either the platform or the ground is received, auto- ally adjust the platform level position by means of the level
matic platform leveling will cease and the appropriate output override switches located at the platform and ground control
will be commanded to turn on. positions (similar to a Master/Slave hydraulic system).
When the toggle switch is released, after ¼ second, the current The level system assumes a new set point after a level over-
filtered value of tilt angle will be taken as the new set point.
ride switch is operated. In other words the operator can chose
a platform level incline other than level with gravity and the
system will maintain this set point during automatic leveling.
4-88 – JLG Lift – 3121262

4.19 ROTARY ACTUATOR As hydraulic pressure is applied, the piston is displaced axially
within the housing - similar to the operation of a hydraulic cyl-
Each actuator is individually serial numbered. The serial num- inder - while, simultaneously, the splines cause the shaft to
ber is a five or six digit number and must be provided before rotate. When the control valve is closed, oil is trapped inside
parts and/ or service issues can be addressed. the housing, preventing piston movement and locking the
shaft firmly in position.
The serial number can be found on the Identification (ID) Tag The shaft is supported radially by the large upper radial bear-
that is affixed to all actuators. The tag is a thin, silver colored, ing and the lower radial bearing (see drawings on pages 8 and
plastic material with a self-adhesive backing. Information is 9). Axially, the shaft is separated from the housing by the
imprinted in black. The tag is located either on the side plate upper and lower thrust washers. The end cap is adjusted for
or on the housing tube of the actuator. axial clearance and locked in position by set screws or pins.
Configurations of parts may be slightly different depending on
Additionally, the serial number of the actuator is stamped model.
onto the side plate or the housing tube. It may be necessary to
remove paint to expose the serial number. Many actuators are equipped with counterbalance valves,
which performs four major functions.
Theory of Operation • Protects the actuator in the event of overload
The rotary actuator is a simple mechanism that uses Helac’s • Enables the actuator to hold position without drifting
sliding spline technology which converts axial piston motion when external loads are applied
into powerful shaft rotation. As seen in the illustration below • Reduces hydraulic backlash by pressuring the hydraulic
left, each actuator is composed of a housing with an integral fluid
ring gear (1) and only two moving parts: the central shaft (2),
• Provides a constant controlled rate of rotation in over-cen-
and the annular piston sleeve (3). Note the actuator shaft fea-
ter load conditions
tures an integral mounting flange and bearing which are not
shown in the illustration. Applying fluid pressure will displace the piston axially while
the helical gearing causes the piston and shaft to rotate simul-
Helical spline teeth machined on the shaft engage matching taneously. The double helix design compounds rotation: shaft
splines on the inside diameter of the piston. The outside diam- rotation is about twice that of the piston. Applying pressure to
eter of the piston carries a second set of splines, of opposite the opposite port will return the piston and shaft to their orig-
hand, which engage the matching splines of the housing’s ring inal starting positions.
gear.
Bars indicate starting positions of piston and shaft. Arrows indicate direction Applying fluid pressure will displace the piston axially while the helical gearing
they will rotate. The housing with integral ring gear remains stationary. For clar- causes the piston and shaft to rotate simultaneously. The double helix design
ity, the shaft flange, bearings, and end cap are not shown. compounds rotation: shaft rotation is about twice that of the piston. Applying
pressure to the opposite port will return the piston and shaft to their original
starting positions.
Figure 4-26. Actuator Theory of Operation
3121262 – JLG Lift – 4-89

Tools Required 9. PLASTIC MANDREL
10. PRY BAR

Removal of end cap and manual rotation of shaft.
11. FELT MARKER

Highlights timing marks and outlines troubled areas.
Permanent ink is recommended.
12. T-HANDLE SCREW EXTRACTOR
13. HEX WRENCH SET

Removal and replacement of port plugs and set screws
(106,110).
14. SEAL TOOLS

Removal and installation of seals and wear guides.
Several basic tools are required for the disassembly and reas-
Directions on making a seal tool are provided at bottom
sembly of the actuator. The tools and their intended functions
are outlined below: 15. PUNCH
1. PIPE VISE 16. DOWEL PINS
Removal and installation of end cap.
2. HEXWRENCH
Removal and replacement of port plugs and set screws. MAKING A SEAL TOOL
3. ASSORTED SCREWS
4. SAFETY GLASSES
5. END CAP REMOVAL TOOLS

(provided with seal kit)
6. DRILL The seal tool is merely a customized standard flat head screw-
driver.
7. FLASHLIGHT
Helps in locating and examining timing marks, compo- 1. Heat the flat end with a torch until it glows.
nent failure and overall condition. 2. Secure the heated end of the screwdriver in a vise and
8. RUBBER MALLET bend the heated end to a slight radius.
Removal and installation of shaft and piston sleeve 3. Round off all sharp edges of the heated screwdriver to a
assembly. polished finish. The tool may be modified slightly to
your own personal preference.
TO AVOID INJURY BE CAREFUL WHEN HANDLING THE SCREWDRIVER WHEN

HOT.
4-90 – JLG Lift – 3121262

Disassembly 4. Remove the lock pins using a screw extracting tool such
as an "Easy Out" (a size #2 is shown).
Inspect the actuator for corrosion prior to disassembly. Severe
corrosion can make it difficult to remove the lock pins (109) If the pin cannot be removed with the screw extractor,
and unthread the end cap (04). If corrosion is evident, soak the use a 5/16" bit to drill out the entire pin. Do not drill
lock pins and end cap with penetrating oil for several hours deeper than 1/2" (12.7 mm).
before disassembling.
Disassembly is easier if the actuator is firmly secured to a work

bench. A pipe vise or mounting fixture works well for this pur-
pose.
5. Install the end cap removal tools provided with the seal
kit. (1/4-20)
1. Remove port plugs (106.1) (106.2) and drain oil. Inspect

oil for signs of contamination, i.e. water, metal shavings.
6. Using a metal bar or similar tool, unthread the end cap

(4) by turning it counterclockwise.
2. Remove the cap screws (113) that cover the end cap lock
pins (109).
3. Using a 1/8" (3 mm) drill bit, drill a hole in the center of

each lock pin to a depth of approximately 3/16" (5 mm).
3121262 – JLG Lift – 4-91

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-27. Rotary Actuator - Assembly Drawing
4-92 – JLG Lift – 3121262

PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 401 Counterbalance Valve
3. Piston Sleeve 106.1. Port Plug 204. O-ring
4. End Cap 106.2. Port Plug 205. Cup Seal
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Exclusion Seal
Figure 4-28. Rotary Actuator - Exploded View
3121262 – JLG Lift – 4-93

7. Remove the end cap (4) and carefully set aside for later marks with a marker before disassembly as outlined in
inspection. the steps below.
8. Remove the stop tube (400) if the actuator is equipped

with one. The stop tube is an available option that limits
the rotation of the actuator.
9. Every actuator has two sets of small punched timing

marks that indicate timing between the gear sets. The
location and appearance of the marks can vary slightly
between models. One set indicates the timing between
the piston sleeve (3) and the housing (1) (upper photo),
the second set between the piston and the shaft (lower
photo). To ensure correct rotation and accurate end
positions, it is essential that the actuator be correctly
timed when it is reassembled. The punched timing
marks can be used, but it is easier to highlight punched 10. Prior to removing the shaft (2), use a felt marker to
clearly indicate the timing between shaft and piston
sleeve (3). This will greatly simplify timing when the
actuator is reassembled.
4-94 – JLG Lift – 3121262

11. Remove the shaft (2) by rotating counterclockwise. As 14. At the point when the piston gear teeth come out of
the shaft is rotated, it will disengage from the piston engagement with the housing gear teeth, mark the pis-
sleeve (3) and can be removed. It may be necessary to ton and housing with a marker as shown.
strike the threaded end of the shaft with a rubber mallet.
12. As in step 9, before removing the piston (3), mark the 15. Remove the O-ring (204) and backup ring (207) from
housing (1) ring gear in relation to the piston outside end cap (4).
diameter gear. There should now be timing marks on
the housing (1) ring gear, the piston (3) and the shaft (2).
13. To remove the piston (3) use a rubber mallet and a plas-
tic mandrel so the piston and housing bore are not dam- TO AVOID DAMAGE TO MACHINED PARTS CAREFULLY REMOVE SEALS USING
aged. REMOVAL TOOLS WITH ROUNDED EDGES.
16. Remove the wear guide (302) from the end cap (4) and
shaft (2).
3121262 – JLG Lift – 4-95

17. Remove the main pressure seal (205). 20. Remove the outside diameter piston seal (202) from the
piston.
18. Remove the thrust washer (304) from the end cap (4)
and shaft (2). 21. Remove the inside diameter piston seal (200).
19. Remove the O-ring (304.1) from its groove in the end
cap (4) and shaft (2). Inspection
PRIOR TO ASSEMBLY OF ACTUATOR, THESE STEPS MUST BE CLOSELY FOL-

LOWED TO ENSURE PROPER OPERATION OF THE ACTUATOR.
1. Clean all parts in a solvent tank and dry with com-

pressed air prior to inspecting.
2. Carefully inspect all critical areas for any surface finish
abnormalities: Seal grooves, bearing grooves, thrust sur-
faces, shaft surface, housing bore and gear teeth.
SMALL OR MINOR SURFACE SCRATCHES CAN BE CAREFULLY POLISHED.
4-96 – JLG Lift – 3121262

Assembly 4. Using a seal tool install the main pressure seal (205) onto
shaft (2) and end cap (4). Use the seal tool in a circular
1. Gather all the components and tools into one location motion.
prior to re-assembly. Use the cut away drawing to refer-
ence the seal orientations.
5. Install the wear guide (302) on the end cap (4) and shaft
(2).
2. Coat the thrust washers (304) with a generous amount
of Lithium grease. Install the thrust washer (304) onto
shaft (2) and end cap (4).
6. Install the O-ring (204) and back-up ring (207) into the
inner seal groove on the end cap (4).
3. Install the exclusion seal (304.1) into the appropriate

grooves on the shaft (2) and end cap (4) around the out-
side edge of the thrust washer (304).
3121262 – JLG Lift – 4-97

7. Install the inner T-seal (200) into the appropriate groove 8. Insert the piston (3) into the housing (1) as shown, until
in the piston (3). Use a circular motion to ensure the seal the outer piston seal (202) contacts the inside housing
is correctly seated in the groove. bore.
Install the outer T-seal (202) by stretching it around the

groove in a circular motion.
9. Looking into the housing bore from the shaft flange

end, rotate the piston (3) until the marks you put on the
piston and the housing (1) during disassembly align as
Each T-seal has 2 back-up rings (see Assembly Drawing shown. Using a rubber mallet, tap the piston into the
for orientation). Beginning with the inner seal (200) housing until the gear teeth contact.
insert one end of backup ring in the lower groove and
feed the rest in using a circular motion. Make sure the
wedged ends overlap correctly.
Insert the other back up ring in upper groove.
Repeat both of these steps for the outer seal (202).
4-98 – JLG Lift – 3121262

10. Looking into the bore from the opposite end of the 12. Looking at the actuator from the end opposite the shaft
housing (1) be sure the timing marks align correctly. flange, use the existing timing marks to align the gear
Rotate the piston as necessary until aligned, then gently teeth on the shaft (2) with the gear teeth on the inside of
tap the piston (3) into the housing until the gear teeth the piston (3). When the marks align, gently tap the
mesh together. Tap the piston into the housing until it flange end of the shaft with a rubber mallet until the
completely bottoms out against the ring gear. gear teeth engage.
13. Install two bolts in the threaded holes in the flange.

Using a metal bar, rotate the shaft in a clockwise direc-
11. Insert the shaft (2) into the piston (3). Be careful not to tion until the wear guides are seated inside the housing
damage the piston seals. Do not engage the piston gear bore.
teeth yet.
AS THE SHAFT IS ROTATED, BE CAREFUL NOT TO DISENGAGE THE PISTON AND

HOUSING GEARING.
3121262 – JLG Lift – 4-99

14. Install the stop tube (400) onto the shaft end if neces- 17. Tighten the end cap (4) using a metal bar. In most cases
sary. Stop tubes are an available option to limit the rota- the original holes for the lock pins will align.
tion of an actuator.
15. Coat the threads on the end of the shaft with anti-seize 18. Insert the lock pins (109) provided with the Helac seal kit
grease to prevent galling. into the holes with the dimple side up. Then, using a
punch, tap the lock pins to the bottom of the hole.
16. Thread the end cap (4) onto the shaft (2). Make sure the
wear guide remains in place on the end cap as it is 19. Insert the set screws (113) over the lock pins. Tighten to
threaded into the housing (1).
25 in-lbs. (2.8 Nm).
4-100 – JLG Lift – 3121262

Greasing Thrust Washers Installing Counterbalance Valve

Refer to Figure 4-29., Rotator Counterbalance Valve.
1. After the actuator is assembled but before it is put into
service, the thrust washer area must be packed with 1. Make sure the surface of the actuator is clean, free of any
Lithium grease. contamination and foreign debris including old Loctite.
2. Make sure the new valve has the O-rings in the counter-
There are two grease ports located on both the shaft bores of the valve to seal it to the actuator housing.
flange and the end cap. They are plugged with cap
screws (113) or set screws. Remove the grease port 3. The bolts that come with the valve are grade 8 bolts.
screws from the shaft flange and end cap. (See exploded New bolts should be installed with a new valve. Loctite
view) #242 should be applied to the shank of the three bolts at
the time of installation.
4. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4
to 13.5 Nm). Do not torque over 125 inch pounds (14.1
Nm). Torque the 5/16-inch bolts 140 inch pounds (15.8
Nm). Do not torque over 145 inch pounds (16.3 Nm).
Testing the Actuator

If the equipment is available, the actuator should be tested on
a hydraulic test bench. The breakaway pressure — the pres-
sure at which the shaft begins to rotate — should be approxi-
mately 400 psi (28 bar). Cycle the actuator at least 25 times at
3000 psi (210 bar) pressure. After the 25 rotations, increase the
pressure to 4500 psi (315 bar) to check for leaks and cracks.
Perform the test again at the end of the rotation in the oppo-
site direction.
TESTING THE ACTUATOR FOR INTERNAL LEAKAGE

IF A HYDRAULIC TEST BENCH IS NOT AVAILABLE, THE ACTUATOR CAN BE
If the actuator is equipped with a counterbalance valve, plug
ROTATED BY HAND, OPEN THE PRESSURE PORTS AND USE A PRY BAR WITH
the valve ports. Connect the hydraulic lines to the housing
CAP SCREWS INSERTED INTO THE SHAFT FLANGE TO TURN THE SHAFT IN THE
ports. Bleed all air from the actuator (see Installation and
DESIRED DIRECTION.
Bleeding) Rotate the shaft to the end of rotation at 3000 psi
(210 bar) and maintain pressure. Remove the hydraulic line
Insert the tip of a grease gun into one port and apply from the non-pressurized side.
grease to the shaft flange. Continue applying until
grease flows from the opposite port. Cycle the actuator Continuous oil flow from the open housing port indicates
five times and apply grease again. Repeat this process internal leakage across the piston. Replace the line and rotate
on the end cap. Insert the cap screws into the grease the shaft to the end of rotation in the opposite direction.
ports and tighten to 25 in-lbs. (2.8 Nm). Repeat the test procedure outlined above for the other port. If
there is an internal leak, disassemble, inspect and repair.
3121262 – JLG Lift – 4-101

Figure 4-29. Rotator Counterbalance Valve
4-102 – JLG Lift – 3121262

Installation and Bleeding 1. Connect a 3/16" inside diameter x 5/16" outside diame-
ter x 5 foot clear, vinyl drain tube to each of the two
After installation of the actuator on the equipment, it is impor- bleed nipples. Secure them with hose clamps. Place the
tant that all safety devices such as tie rods or safety cables are vinyl tubes in a clean 5-gallon container to collect the
properly re-attached. purged oil. The oil can be returned to the reservoir after
this procedure is completed.
To purge air from the hydraulic lines, connect them together
to create a closed loop and pump hydraulic fluid through
them. Review the hydraulic schematic to determine which
hydraulic lines to connect. The linear feet and inside diameter
of the hydraulic supply lines together with pump capacity will
determine the amount of pumping time required to fully
purge the hydraulic system.
Bleeding may be necessary if excessive backlash is exhibited

after the actuator is connected to the hydraulic system. The
following steps are recommended when a minimum of two
gallons (8 liters) is purged.
TYPICAL CONFIGURATION OF ACTUA-

TOR
2. With an operator in the platform, open both bleed nip-

ples 1/4 turn. Hydraulically rotate the platform to the
end of rotation (either clockwise or counterclockwise),
and maintain hydraulic pressure. Oil with small air bub-
bles will be seen flowing through the tubes. Allow a 1/2
gallon of fluid to be purged from the actuator.
3. Keep the fittings open and rotate the platform in the

opposite direction to the end position. Maintain hydrau-
lic pressure until an additional 1/4 gallon of fluid is
pumped into the container.
4. Repeat steps 2 & 3. After the last 1/2 gallon is purged,

close both bleed nipples before rotating away from the
end position.
3121262 – JLG Lift – 4-103

Troubleshooting
Table 4-1. Troubleshooting
Problem Cause Solution

1. Shaft rotates slowly or not at all 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 the actuator through housing ports
(do not exceed OEM’s operating pressure). The valve must
be replaced if a steady flow of fluid is seen coming from the
valve ports.
d. Piston and/or shaft seal leak d. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test as described in the Testing section on page
24 of this manual.
e. Corrosion build-up on the thrust surfaces e. Re-build the actuator. Remove all rust then polish.
Replacement parts may be needed.
f. Swollen seals and composite bearings caused by incom- f. Re-build the actuator. Use fluid that is compatible with
patible hydraulic fluid seals and bearings.
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 re-
built 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 dur-
ing stroke not reach inside the housing bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal leak a. Disconnect hydraulic lines and bypass valve. Leave valve
ports open and operate the actuator through housing ports
(do not exceed OEM’s operating pressure). The valve must
be replaced if a steady flow of fluid is seen coming from the
valve ports.
b. Piston and/or shaft seal leak b. Remove the plug and the housing’s valve ports. Operate
the actuator through the housing ports. Conduct the inter-
nal leakage test as described in the Testing section on page
24 of this manual.
c. Air in actuator c. Purge air from actuator. See bleeding procedures
4-104 – JLG Lift – 3121262

4.20 JIB ROTATOR TORQUING PROCEDURE 3. Torque the top bolts in a crossing star pattern to 300
ft.lbs. (410 Nm).
See Figure 4-30., JIb Rotator Torque
4. Torque the center bolt to a final torque of 700 ft.lbs. (950
1. Torque the center bolt to 350 ft.lbs. (475 Nm). Nm).
2. Torque the bottom bolts in a crossing star pattern to 170
ft.lbs. (230 Nm).
Figure 4-30. JIb Rotator Torque
3121262 – JLG Lift – 4-105

NOTE: If any rotator bolts are replaced, all bolts on the

rotator should be retorqued.
A Torque to 40 ft.lbs. (55 Nm)

B JLG Threadlocker P/N 0100011
C Torque 85 ft. lbs. (116 Nm)
D Torque 480 ft. lbs. (340-365 Nm)
E Check torque every 150 hours of operation
Figure 4-31. Platform Support Torque Values
4-106 – JLG Lift – 3121262

SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS

5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in the
SYSTEM fitting, making sure the entire o-ring is completely satu-
When assembling connectors in the hydraulic that use o-ring rated.
fittings, it is necessary to lubricate all fittings with hydraulic oil
prior to assembly. To lubricate the fittings, use one of the fol-
lowing procedures.
NOTE: All O-ring fittings must be pre-lubricated with hydraulic oil

prior to assembly.
Cup and Brush

The following is needed to correctly oil the o-ring in this man-
ner:
• A small container for hydraulic oil

• Small paint brush 3. Turn the o-ring on the other side of the fitting and
repeat the previous step, ensuring the entire o-ring is
coated with hydraulic oil.
1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.
3121262 – JLG Lift – 5-1

Dip Method Spray Method

NOTE: This method works best with Face Seal o-rings, but will This method requires a pump or trigger spray bottle.
work for all o-ring fitting types.
1. Fill the spray bottle with hydraulic oil.
The following is needed to correctly oil the o-ring in this man-
2. Hold the fitting over a suitable catch can.
ner:
3. Spray the entire o-ring surface with a medium coat of
• A small leak proof container oil.
• Sponge cut to fit inside the container
• A small amount of hydraulic oil to saturate the sponge.
1. Place the sponge inside the container and add hydraulic
oil to the sponge until it is fully saturated.
2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and drip
from the bottom of the fitting. This should signify an
even coating of oil on the fitting.
Brush-on Method
This method requires a sealed bottle brush.
1. Fill the bottle with hydraulic oil.

2. Using slight pressure to the body of the spray bottle,
invert the bottle so the brush end is in the downward
position.
3. Brush hydraulic oil on the entire o-ring, applying an
3. O-ring Boss type fittings will require more pressure in even coat of oil.
able to immerse more of the fitting into the saturated
sponge. This will also cause more oil to be dispersed
from the sponge.
5-2 – JLG Lift – 3121262

5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512
TORQUE SPECIFICATION
Tapered Thread Types
NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
Figure 5-4. SAE Thread
ORFS = o-ring face seal per SAE J1453
Figure 5-1. NPTF Thread

BSPT = British standard pipe tapered per ISO7-1
Figure 5-5. ORFS Thread

MBTL = metric flareless bite type fitting, pressure rating L
(medium) per ISO 8434, DIN 2353
MBTS = metric flareless bite type fitting, pressure rating S
(high) per ISO 8434, DIN 2353
Figure 5-2. BSPT Thread Figure 5-6. MTBL-MBTS Thread
Straight Thread Types, Tube and Hose Connections BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
JIC = 37° flare per SAE J514
Figure 5-3. JIC Thread

Figure 5-7. Bulkhead Thread
3121262 – JLG Lift – 5-3

Straight Thread Types, Port Connections Flange Connection Types

ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162
6149, DIN 3852
Figure 5-10. ORB-MPP Thread
Tightening Methods
Torque = Application of a twisting force to the applicable con-
Figure 5-8. ORB-MPP Thread nection by use of a precise measurement instrument (i.e.
torque wrench).
MFF = metric flat face port per ISO 9974-1
Finger Tight = The point where the connector will no longer
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- thread onto the mating part when tightened by hand or fin-
2 gers. Finger Tight is relative to user strength and will have
some variance. The average torque applied by this method is 3
ft-lbs [4 N-m] Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by hand (fin-
gers) and applying an additional rotation counted by a
defined number of turns by use of a tool.
FFWR = Flats from Wrench Resistance; Application of a pre-
load to a connection by tightening to the point of initial
wrench resistance and turning the nut a described number of
‘flats’. A ‘flat’ is one side of the hexagonal tube nut and
equates to 1/6 of a turn. Also referred to as the ‘Flats Method.’
Figure 5-9. MFF-BSPP Thread
5-4 – JLG Lift – 3121262

Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the
correct torque values.
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the con- a. Verify the material designation in the table head-
nector being installed. Refer to the Figures and Tables in this ings.
section. b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
GENERAL TUBE TYPE FITTING ASSEMBLY be as follows: Aluminum and Brass- reduce steel val-
INSTRUCTIONS ues by 35%; Stainless Steel- Use the upper limit for
steel.
1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling 5. To achieve the specified torque, the torque wrench is to
or assembly. Nicks and scratches in sealing surfaces can be held perpendicular to the axis of rotation.
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting attach-
ment to ensure that the tube has not been damaged.
3. The assembly process is one of the leading causes for
contamination in air and hydraulic systems. Contamina-
tion can prevent proper tightening of fittings and adapt-
ers from occurring.
a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as nec-
essary before re-installing.
c. Sealing compounds should be applied where speci- Figure 5-11. Torque Wrench Angle
fied; however, care should be taken not to introduce
sealant into the system. 6. Refer to the appropriate section in this manual for more
d. Avoid applying sealant to the area of the threads specific instructions and procedures for each type of fit-
where the sealant will be forced into the system. ting connection
This is generally the first two threads of a fitting.
e. Sealant should only be applied to the male threads.
f. Straight thread fittings do not require sealants. O-
rings or washers are provided for sealing.
g. When replacing or installing an O-ring, care is to be
taken while transferring the O-ring over the threads
as it may become nicked or torn. When replacing an
O-ring on a fitting, the use of a thread protector is
recommended.
h. When installing fittings with O-rings, lubrication
shall be used to prevent scuffing or tearing of the O-
ring. See O-ring Installation (Replacement) in this
section.
3121262 – JLG Lift – 5-5

Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS
TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED
Thread Tapered (NPTF) Connections. TURNS AND USE THE LAST TURN FOR ALIGNMENT.
1. Inspect components to ensure male and female port
threads are free of rust, splits, dirt, foreign matter, or 5. Rotate male fitting the number of turns per Table 5-1,
burrs. NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to
the male pipe threads if not already applied. Ensure the NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
first 1 to 2 threads are uncovered to prevent system con- applicable for the following material configurations:
tamination.
• STEEL fittings with STEEL mating components
3. Assemble connection hand tight.
• STEEL fittings with ALUMINUM or BRASS mating compo-
4. Mark fittings, male and female. nents
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE
PIPE FITTING AND DAMAGE TO THE JOINING FITTING, • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
FLANGE OR COMPONENT MAY OCCUR. mating components.
Table 5-1. NPTF Pipe Thread
TYPE/FITTING IDENTIFICATION
Turns From Finger
Thread Size ØA*
Material Dash Size Tight (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
STEEL, ALUMINUM, OR BRASS MATING C
4 1/4 - 18 0.54 13.61 2 to 3

6 3/8 - 18 0.67 17.05 2 to 3
8 1/2 - 14 0.84 21.22 2 to 3
12 3/4 - 14 1.05 26.56 2 to 3
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
OMPONENTS
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5

32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
* ØA thread dimension for reference only.

** See FFWR and TFFT Methods subsection for TFFT procedure requirements.
5-6 – JLG Lift – 3121262

Assembly Instructions for British Standard Pipe TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED
TURNS AND USE THE LAST TURN FOR ALIGNMENT.
Thread Tapered (BSPT) Connections
1. Inspect components to ensure male and female port 5. Rotate male fitting the number of turns per Table 5-2,
threads are free of rust, splits, dirt, foreign matter, or BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs. procedure requirements.
2. Apply a suitable thread sealant, such as Loctite 567, to NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are
the male pipe threads if not already applied. Ensure the applicable for the following material configurations:
first 1 to 2 threads are uncovered to prevent system con-
tamination. • STEEL fittings with STEEL mating components
3. Assemble connection hand tight. • STEEL fittings with ALUMINUM or BRASS mating compo-
nents
4. Mark fittings, male and female.
nents
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
PIPE FITTING AND DAMAGE TO THE JOINING FITTING, mating components.
FLANGE OR COMPONENT MAY OCCUR.
NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS
Table 5-2. BSPT Pipe Thread
Turns From
Thread Size ØA* Finger Tight
MATERIAL Dash Size (TFFT)**
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
STEEL, ALUMINUM, OR BRASS FITTINGS WITH
4 1/4 - 19 0.52 13.16 2 to 3

6 3/8 - 19 0.66 16.66 2 to 3
STEEL, ALUMINUM, OR BRASS
8 1/2 - 14 0.83 20.96 2 to 3

12 3/4 - 14 1.04 26.44 2 to 3
MATING COMPONENTS
16 1 - 11 1.31 33.25 1.5 to 2.5

20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
* ØA thread dimension for reference only.

** See Appendix B for TFFT procedure requirements.
3121262 – JLG Lift – 5-7

Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37°
Flare (JIC)Thread - Steel or Table 5-4, 37° Flare
1. Inspect the flare for obvious visual squareness and con- (JIC)Thread - Aluminum/Brass while using the Double
centricity issues with the tube OD. Ensure surface is Wrench Method per Double Wrench Method. Refer to
smooth, free of rust, weld and brazing splatter, splits, FFWR and TFFT Methods for procedure requirements if
dirt, foreign matter, or burrs. If necessary replace fitting using the FFWR method.
or adapter.
NOTE: Torque values provided in Table Table 5-3, 37° Flare
(JIC)Thread - Steel and Table 5-4, 37° Flare (JIC)Thread -
Aluminum/Brass are segregated based on the material
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE configuration of the connection.
INTO ALIGNMENT. IT PUTS UNDESIRABLE STRAIN ONTO
THE JOINT EVENTUALLY LEADING TO LEAKAGE. ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
COMPONENTS’ indicate either the following material configu-
2. Align tube to fitting and start threads by hand. rations:
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRI-
CATED OR OILY FITTINGS. NO LUBRICATION OR SEALANT
nents
IS REQUIRED. THE LUBRICATION WOULD CAUSE
INCREASED CLAMPING FORCE AND CAUSE FITTING DAM- • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
AGE. mating components.
5-8 – JLG Lift – 3121262

Table 5-3. 37° Flare (JIC)Thread - Steel
Type/Fitting Identification Torque

Flats from
Thread Wrench
MATERIAL
ØA* ØB* [Ft-Lb] [N-m]

Dash Size Size Resistance
(F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --

4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
UN-LUBRICATED THREADS
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2

8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
* ØA and ØB thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
3121262 – JLG Lift – 5-9

Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass
TYPE/FITTING IDENTIFICATION Torque

Flats from
Thread Wrench
MATERIAL

Dash Size Size Resistance
(F.F.W.R)**
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
MATING COMPONENTS; UN-LUBRICATED THREADS
3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --

4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1
** See FFWR and TFFT Methodsfor FFWR procedure requirements.
5-10 – JLG Lift – 3121262

Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using
1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section. Refer to
centricity issues with the tube OD. Ensure surface is FFWR and TFFT Methods for procedure requirements if using
smooth, free of rust, weld and brazing splatter, splits, the TFFT method.
dirt, foreign matter, or burrs. If necessary replace fitting
or adapter. NOTE: Torque values provided in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass are segre-
gated based on the material configuration of the connec-
tion.
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE
INTO ALIGNMENT. IT PUTS UNDESIRABLE STRAIN ONTO ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
THE JOINT EVENTUALLY LEADING TO LEAKAGE. COMPONENTS’ indicate either the following material configu-
rations:
2. Align tube to fitting.
3. Tighten fitting by hand until hand tight. nents
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRI-
• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
CATED OR OILY FITTINGS. NO LUBRICATION OR SEALANT
IS REQUIRED. THE LUBRICATION WOULD CAUSE mating components.
INCREASED CLAMPING FORCE AND CAUSE FITTING DAM-
AGE.
3121262 – JLG Lift – 5-11

Table 5-5. 45° Flare (SAE) - Steel

Thread
MATERIAL

Dash Size Size
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19
STEEL MATING COMPONENTS;
STEEL FITTINGS WITH
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33

8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125

Table 5-6. 45° Flare (SAE) - Aluminum/Brass

Thread
MATERIAL

Dash Size Size
4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12
MATING COMPONENTS;
OR ALUMINUM/BRASS
ALUMINUM/BRASS
6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20

FITTINGS
8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41

10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83

** See FFWR and TFFT Methods for TFFT procedure requirements.
5-12 – JLG Lift – 3121262

Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal
(ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu-
Fittings minum/Brass while using the Double Wrench Method.
Refer to FFWR and TFFT Methods for procedure require-
1. Ensure proper O-ring is installed. If O-ring is missing ments if using the FFWR method.
install per O-ring Installation (Replacement).
NOTE: Torque values provided in Table 5-7, O-ring Face Seal
2. Ensure surface is smooth, free of rust, weld and brazing (ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
splatter, splits, dirt, foreign matter, or burrs. If necessary minum/Brass are segregated based on the material config-
replace fitting or adapter. uration of the connection.
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING

COMPONENTS’ indicate either the following material configu-
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID rations:
ADDING OIL TO THE THREADED CONNECTION OF THE FIT-
TING. THE LUBRICATION WOULD CAUSE INCREASED • STEEL fittings with ALUMINUM or BRASS mating compo-
CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
• ALUMINUM or BRASS fittings with ALUMINUM or
4. Place the tube assembly against the fitting body so that
the flat face comes in contact with the O-ring. Hand BRASS mating components
thread the nut onto the fitting body.
Table 5-7. O-ring Face Seal (ORFS) - Steel
Flats from Wrench

TYPE/FITTING IDENTIFICATION Torque Resistance
(F.F.W.R)**
MATERIAL
Thread Size ØA* ØB* [Ft-Lb] [N-m] Swivel &

Tube
Dash Size Hose
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Nuts
Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4

STEEL FITTINGS WITH
10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4

12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
3121262 – JLG Lift – 5-13

Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass
Flats from Wrench

TYPE/FITTING IDENTIFICATION Torque Resistance
(F.F.W.R)**
Thread Swivel &
MATERIAL
Dash ØA* ØB* [Ft-Lb] [N-m] Tube

Size Hose
Size Nuts
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS FITTINGS OR
6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4

ALUMINUM/BRASS
10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4

12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
** See FFWR and TFFT Methods for FFWR procedure requirements.
5-14 – JLG Lift – 3121262

Assembly Instructions for DIN 24° Flare Bite Type

Fittings (MBTL and MBTS)
A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY

SEATED FITTINGS AND LEAKAGE.
1. Inspect the components to ensure free of contamina-

tion, external damage, rust, splits, dirt, foreign matter, or
burrs. Ensure tube end is visibly square. If necessary
replace fitting or tube.
2. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
3. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
4. Push the tube end into the coupling body.
5. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed in Table Table 5-9, DIN
24°Cone (MBTL & MBTS) while using the Double Wrench
Method. The tube must not turn with the nut.
3121262 – JLG Lift – 5-15

Table 5-9. DIN 24°Cone (MBTL & MBTS)
DIN 24° CONE FLARELESS BITE FITTING

(With or Without O-Ring)
Tube Thread M Torque Flats from

MATERIAL
ØA* ØB* C* ØD* Wrench

TYPE
O.D. Size [Ft-Lb] [N-m]

Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTL) FITTING
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75

FFWR is the recommended
10 M16 x 1.5 14.50 16.00 7.00 10.20 1.5 to 1.75
method of fitting assembly.
12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
15 M22 x 1.5 20.50 22.00 7.00 15.20 Torque values are application 1.5 to 1.75
18 M26 x 1.5 24.50 26.00 7.50 18.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
22 M30 x 2 27.90 30.00 7.50 22.20 lubrication, and other physical 1.5 to 1.75
STEEL FITTINGS WITH STEEL MATING COMPONENTS
28 M36 x 2 33.90 36.00 7.50 28.20 characteristics of the connection. 1.5 to 1.75
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
Refer to the specific procedure
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
in the
Tube Thread M Torque Flats from
ØA* ØB* C* ØD* Wrench
TYPE
O.D. Size [Ft-Lb] [N-m]

Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTS) FITTING
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75

FFWR is the recommended
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
method of fitting assembly.
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
14 M22 x 1.5 20.50 22.00 8.00 14.20 Torque values are application 1.5 to 1.75
16 M24 x 1.5 22.50 24.00 8.50 16.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
20 M30 x 2 27.90 30.00 10.50 20.20 lubrication, and other physical 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 characteristics of the connection. 1.5 to 1.75
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
Refer to the specific procedure
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
in the
* ØA, ØB, C, & ØD thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
5-16 – JLG Lift – 3121262

Assembly Instructions for Bulkhead (BH) Fittings

1. Ensure threads and surface are free of rust, weld and
brazing splatter, splits, burrs or other foreign material. If
necessary replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting per Table 5-10 and Table 5-11
while using the Double Wrench Method.
3121262 – JLG Lift – 5-17

Table 5-10. Bulkhead Fittings (BH) - INCH
FASTENING JAM NUT

for Bulkhead Connectors
Torque
MATERIAL
Thread Size
TYPE
Dash Size [Ft-Lb] [N-m]

(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
O-RING FACE SEAL (ORFS)
8 13/16-16 55 58 61 75 79 83
BULKHEAD FITTING
10 1-14 85 90 94 115 122 127

12 1 3/16-12 135 142 149 183 193 202
14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Torque
Thread Size
TYPE
Dash Size [Ft-Lb] [N-m]

STEEL FITTINGS
(UNF) Min Nom Max Min Nom Max

3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULKHEAD FITTING
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
5-18 – JLG Lift – 3121262

Table 5-11. Bulkhead Fittings (BH) - METRIC
FASTENING JAM NUT

for Bulkhead Connectors
Connecting Torque
Thread M Size
MATERIAL TYPE Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE
(MBTL) BULKHEAD FITTING
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
STEEL FITTINGS
Connecting Torque
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING
Thread M Size
Tube O.D. [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
3121262 – JLG Lift – 5-19

Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru
Table 5-17 while using the Double Wrench Method.
Fittings
a. The table headings identify the straight thread O-
1. Inspect components to ensure that male and female ring port and the type on the other side of the fit-
port threads are free of rust, splits, dirt, foreign matter, or ting. The torque will be applied to the straight
burrs. thread O-ring port.
2. Ensure proper O-ring is installed. If O-ring is missing b. Torque values provided in Table 5-12 thru Table 5-17
install per O-ring Installation (Replacement). are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID • STEEL fittings with ALUMINUM or BRASS mating compo-
ADDING OIL TO THE THREADED CONNECTION OF THE FIT- nents
TING. THE LUBRICATION WOULD CAUSE INCREASED
CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with STEEL mating compo-
nents
3. Pre-lubricate the O-ring with Hydraulic Oil. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
4. For Non-Adjustable and Plugs, thread the fitting by
hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
washer is seated flat on the counter bore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
Assembly for proper assembly.
5-20 – JLG Lift – 3121262

Table 5-12. O-ring Boss (ORB) - Table 1 of 6
HEX TYPE PLUGS & STUD ENDS

with 37° (JIC) or L series DIN (MBTL) opposite end
Thread Size ØA* Torque
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
COMPONENTS; UN-LUBRICATED THREADS
STEEL FITTINGS WITH STEEL MATING
5 1/2-20 0.50 12.70 23 25 26 32 34 35

6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
HEX TYPE PLUGS & STUD ENDS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22

5 1/2-20 0.50 12.70 15 16 17 20 22 23
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
3121262 – JLG Lift – 5-21

STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end
MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 26 27 28 35 37 38
5 1/2-20 0.50 12.70 30 32 33 40 43 45

6 9/16-18 0.56 14.28 35 37 39 46 50 53
8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
STUD ENDS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 17 18 18 23 24 24

5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-22 – JLG Lift – 3121262

ADJUSTABLE STUD END

MATERIAL Dash Size
2 5/16-24 0.31 7.93 (60) (63) (66) 7 7 7
3 3/8-24 0.37 9.52 (100) (105) (110) 11 12 12
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 21 22 23 28 30 31

6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
10 7/8-14 0.87 22.22 85 90 94 115 122 127
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
ADJUSTABLE STUD END
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (39) (41) (43) 4 5 5
3 3/8-24 0.37 9.52 (65) (69) (72) 7 8 8
4 7/16-20 0.44 11.11 10 11 11 14 15 15

5 1/2-20 0.50 12.70 14 15 15 19 20 20
6 9/16-18 0.56 14.28 19 20 21 26 27 28
8 3/4-16 0.75 19.10 34 36 37 46 49 50
10 7/8-14 0.87 22.22 55 58 61 75 79 83
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121262 – JLG Lift – 5-23

ADJUSTABLE STUD END

MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45

6 9/16-18 0.56 14.28 35 37 39 46 50 53
8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
ADJUSTABLE STUD END
MATERIAL Dash Size
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 10 11 11 14 15 15

5 1/2-20 0.50 12.70 20 21 21 27 28 28
6 9/16-18 0.56 14.28 23 24 24 31 33 33
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-24 – JLG Lift – 3121262

TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

MATERIAL Dash Size
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 14 15 16 19 20 22

6 9/16-18 0.56 14.28 34 36 38 46 49 52
8 3/4-16 0.75 19.10 60 63 66 80 85 89
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
4 7/16-20 0.44 11.11 6 7 7 8 9 9

5 1/2-20 0.50 12.70 9 10 10 12 14 14
6 9/16-18 0.56 14.28 22 24 25 30 33 34
8 3/4-16 0.75 19.10 39 41 43 53 56 58
10 7/8-14 0.87 22.22 65 69 72 88 94 98
12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
3121262 – JLG Lift – 5-25

ZERO LEAK GOLD®

HOLLOW HEX PLUGS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15

6 9/16-18 0.56 14.28 11 12 13 15 16 18
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
ZERO LEAK GOLD®
HOLLOW HEX PLUGS
MATERIAL Dash Size
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12

5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
5-26 – JLG Lift – 3121262

Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18,
Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5-
Metric (MFF) Fittings 23 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the Metric port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the Metric port.
2. If O-ring is not pre-installed, install proper size, taking b. Torque values provided in Table 5-18, Table 5-19,
care not to damage it. See O-ring Installation (Replace- Table 5-20, Table 5-21, Table 5-22, and Table 5-23
ment) for instructions. are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
nents
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
3121262 – JLG Lift – 5-27

Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3
FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end
Thread M Connecting Torque Torque

MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
5-28 – JLG Lift – 3121262



M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
3121262 – JLG Lift – 5-29

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
Thread Connecting Torque Torque Torque

MATERIAL M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
5-30 – JLG Lift – 3121262

Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3

with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end

M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
3121262 – JLG Lift – 5-31

Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3
FORM E (EOLASTIC SEALING RING)

FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS
STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end

M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
5-32 – JLG Lift – 3121262

with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS

M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --
M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
3121262 – JLG Lift – 5-33

Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24
while using the Double Wrench Method.
Port Assembly Stud Ends
a. The table headings identify the Metric port and the
1. Inspect components to ensure that male and female type on the other side of the fitting. The torque will
threads and surfaces are free of rust, splits, dirt, foreign be applied to the Metric port.
matter, or burrs. b. Torque values provided in Table 5-24 are segregated
2. If O-ring is not preinstalled, install proper size, taking based on the material configuration of the connec-
care not to damage it. See O-ring Installation (Replace- tion. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
ment) for instructions. BRASS MATING COMPONENTS’ indicate either the
following material configurations:
nents
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID
ADDING OIL TO THE THREADED CONNECTION OF THE FIT- • ALUMINUM or BRASS fittings with STEEL mating compo-
TING. THE LUBRICATION WOULD CAUSE INCREASED nents
CLAMPING FORCE AND CAUSE FITTING DAMAGE. • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
3. Pre-lubricate the O-ring with Hydraulic Oil.
7. Inspect to ensure the O-ring is not pinched and the
4. For Non-Adjustable Fittings and Plugs, thread the fitting washer is seated flat on the counter bore of the port.
by hand until contact.

5-34 – JLG Lift – 3121262

Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
STUD ENDS STUD ENDS

with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end
Thread Connecting Torque Torque

MATERIAL
M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]

M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
3121262 – JLG Lift – 5-35

Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
STUD ENDS STUD ENDS

with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end
Thread Connecting Torque Torque

MATERIAL
M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]

M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
5-36 – JLG Lift – 3121262

Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25,
Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5-
(BSPP) Fittings 30 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the BSPP port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the BSPP port.
2. If O-ring is not preinstalled, install proper size, taking b. Torque values provided in Table 5-25, Table 5-26,
care not to damage it. See O-ring Installation (Replace- Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
ment) for instructions. segregated based on the material configuration of
the connection. ‘ALUMINUM/BRASS FITTINGS OR
nents
mating components.
4. For Non-Adjustable Fittings and Plugs, thread the fitting
by hand until contact. 7. Inspect to ensure the O-ring is not pinched and the
3121262 – JLG Lift – 5-37

Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

BSPP Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 42 139 146 153 188 198 207 302 318 333 409 431 451
* Typical for JLG Straight Male Stud Fittings

** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
5-38 – JLG Lift – 3121262

FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
Connecting
Thread G
Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 42 259 272 285 351 369 386 259 272 285 351 369 386

3121262 – JLG Lift – 5-39

with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
BSPP Torque Torque Torque
Connecting
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
Connecting
Thread G
Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321

5-40 – JLG Lift – 3121262

Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500

3121262 – JLG Lift – 5-41

FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
Connecting
Thread G
Size
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386

5-42 – JLG Lift – 3121262

BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS

TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end
Connecting
Thread G
Size
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 Service Manual.
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
Connecting
Thread G
Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Fitting type not typically specified on JLG appli-
cations. Refer to the specific procedure in this
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 Service Manual.
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499

3121262 – JLG Lift – 5-43

Assembly Instructions for Flange Connections:

(FL61 and FL62)
1. Make sure sealing surfaces are free of rust, splits,
scratches, dirt, foreign matter, or burrs.
2. See Figure for O-ring installation instructions.
3. Pre-lubricate the O-ring with Hydraulic Oil.
4. Position flange and clamp halves.
5. Place lock washers on bolt and bolt through clamp
halves.
6. Tighten all bolts by hand.
7. Torque bolts in diagonal sequence in two or more incre-
ments to the torque listed on Table Table 5-31and Table
5-32.
5-44 – JLG Lift – 3121262

Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners
STEEL 4-BOLT FLANGE SAE J518

(INCH FASTENERS)
Bolt Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with
Inch
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE Size
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
CODE 61 SPLIT FLANGE (FL61)
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101

24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Inch
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE Size
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66

16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
* A dimension for reference only.
3121262 – JLG Lift – 5-45

Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners
STEEL 4-BOLT FLANGE SAE J518

(INCH FASTENERS)
Inch
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Flange
TYPE Size
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55

24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Inch
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Flange
TYPE Size
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77

16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
* A dimension for reference only.
5-46 – JLG Lift – 3121262

Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper
hose installation. A twisted lay-line usually indicates the hose
To prevent undesired hose or connector rotation, two is twisted. See Figure 5-12. for double wrench method require-
wrenches must be used; one torque wrench and one backup ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,
Figure 5-12. Double Wrench Method
3121262 – JLG Lift – 5-47

FFWR and TFFT Methods Adjustable Stud End Assembly

For Adjustable Stud End Connections; the following assembly
FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed:
1. Tighten the swivel nut to the mating fitting until no lat- 1. Lubricate the o-ring with a light coat of hydraulic oil.
eral movement of the swivel nut can be detected; finger 2. Position #1 – The o-ring should be located in the groove
tight condition. adjacent to the face of the back-up washer. The washer
and o-ring should be positioned at the extreme top end
2. Mark a dot on one of the swivel hex nut flats and of the groove as shown.
another dot in line on the connecting tube adapter. See
Figure B.1. 3. Position #2 – Position the locknut to just touch the back-
up washer as shown. The locknut in this position will
3. Use the double wrench method per Appendix A, turn eliminate potential back up washer damage during the
the swivel nut to tighten as shown in Figure B.1. The nut next step.
is to be rotated clockwise the number of hex flats as
4. Position #3 – Install the connector into the straight
defined by the applicable Table in Section 5.0.
thread box port until the metal back-up washer contacts
the face of the port as shown.
4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering 5. Position #4 – Adjust the connector to the proper posi-
the dots, to indicate the connection has been properly tion by turning out (counterclockwise) up to a maxi-
tightened. See Figure 5-13. mum of one turn as shown to provide proper alignment
with the mating connector, tube assembly, or hose
assembly.
6. Position #5 – Using two wrenches, use the backup
wrench to hold the connector in the desired position
and then use the torque wrench to tighten the locknut
to the appropriate torque.
7. Visually inspect, where possible, the joint to ensure the
o-ring is not pinched or bulging out from under the
washer and that the backup washer is properly seated
flat against the face of the port.
Figure 5-13. FFWR Method
TFFT (TURNS FROM FINGER TIGHT METHOD)
1. Tighten the swivel nut to the mating fitting until no lat-

eral movement of the swivel nut can be detected; finger
tight condition.
2. Mark a dot on one of the swivel hex nut flats and

another dot in line on the connecting tube adapter.
3. Use the double wrench method per Appendix A, turn

the swivel nut to tighten. The nut is to be rotated clock-
wise the number of turns as defined by the applicable
Table in Section 5.0.
4. After the connection has been properly tightened, mark

a straight line across the connecting parts, not covering
the dots, to indicate the connection has been properly
tightened.
5-48 – JLG Lift – 3121262

Figure 5-14. Adjustable Stud End Assembly
O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On

straight threads, ensure O-ring is seated all the way past
Care must be taken when installing O-rings over threads dur- the threads prior to installation.
ing replacement or installation. O-rings could become nicked 5. Inspect O-ring for any visible nicks or tears. Replace if
or torn. A damaged O-ring could lead to leakage problems. found.
1. Inspect O-ring for tears or nicks. If any are found replace

O-ring.
2. Ensure proper O-ring to be installed. Many O-rings look

the same but are of different material, different hard-
ness, or are slightly different diameters or widths.
3. Use a thread protector when replacing O-rings on fit-

tings.
3121262 – JLG Lift – 5-49

5.3 HYDRAULIC CYLINDERS inder head retainer capscrews, and remove capscrews
from cylinder barrel.
Axle Extension Cylinder
DISASSEMBLY
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED

ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source to

the cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES-
Figure 5-16. Cap Screw Removal
SURE.
2. Operate the hydraulic power source and extend the cyl- 6. Attach a suitable pulling device to the cylinder rod end.
inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.
3. Remove the sequence valves from the cylinder port EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
block. Discard o-rings. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
4. Place the cylinder barrel into a suitable holding fixture. PISTON AND CYLINDER BARREL SURFACES.
7. With the barrel clamped securely, carefully withdraw the

complete rod assembly from the cylinder barrel.
Figure 5-15. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch for

easy realignment. Using an allen wrench, loosen the cyl-
Figure 5-17. Cylinder Rod Support
8. Using suitable protection, clamp the cylinder rod in a

vise or holding fixture as close to the piston as possible.
5-50 – JLG Lift – 3121262

7
22
23
4
5
9
14
4
23
22
13
18
19 11
18
15
12
6
17
2,3,16
20
1,2,21
1684102-D
1. Thread Locker 6. Head 11. Wear Ring 16. Rod Wiper 21. Bolt
2. Locking Primer 7. Barrel 12. Backup Ring 17. Seal 22. Holding Valve
3. Loctite RC 609 8. Rod 13. Backup Ring 18. Wear Ring 23. Plug
4. Bolt 9. Piston 14. O-ring 19. T-Seal
5. Tapered Bushing 10. Not Used 15. O-ring 20. Washer Ring
Figure 5-18. Axle Extension Cylinder
3121262 – JLG Lift – 5-51

9. Loosen and remove the capscrew which attach the CLEANING AND INSPECTION
tapered bushing to the piston.
1. Clean all parts thoroughly in an approved cleaning sol-
vent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or

other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if 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. Inspect threaded portion of barrel for damage. Dress

threads as necessary.
6. Inspect piston surface for damage and scoring and for

Figure 5-19. Tapered Bushing Removal distortion. Dress piston surface or replace piston as nec-
essary.
10. Insert the capscrews in the threaded holes in the outer
piece of the tapered bushing. Progressively tighten the 7. Inspect threaded portion of piston for damage. Dress
capscrews until the bushing is loose. threads as necessary.
11. Remove the tapered bushing from the piston. 8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.
12. By hand, screw the piston counterclockwise and remove
it from cylinder rod. 9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace as
13. Remove and discard the piston o-rings, seal rings, and necessary.
backup rings.
10. Inspect threaded portion of head for damage. Dress
14. Remove the rod from the holding fixture. Remove the threads as necessary.
cylinder head gland and washer ring. Discard all seals on
the cylinder head. 11. Inspect seal and o-ring grooves in head for burrs and
5-52 – JLG Lift – 3121262

12. Inspect cylinder head outside diameter for scoring or ASSEMBLY

other damage and ovality and tapering. Replace as nec-
essary. NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary. Apply a light film of hydraulic oil to all components prior to
assembly.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt,
etc. to facilitate bearing installation. 1. A special tool is used to install a new rod seal into the
applicable cylinder head gland groove.
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.
d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
NOTE: Install pin into the composite bearing dry. Lubrication is

not required with nickel plated pins and bearings.
Figure 5-21. Rod Seal Installation
WHEN INSTALLING NEW S EALS, ENSURE SEALS ARE

INSTALLED PROPERLY. IMPROPER SEAL INSTALLATION
COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER
Figure 5-20. Composite Bearing Installation CYLINDER OPERATION.
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.
16. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other

damage. Replace as necessary.
Figure 5-22. Cylinder Head Seal Installation
3121262 – JLG Lift – 5-53

2. Use a soft mallet to tap a new wiper seal into the cylin- NOTE: When installing the tapered bushing, piston and mating
der head gland groove. Install a new wear ring into the end of rod must be free of oil.
cylinder head gland groove.
8. Assemble the tapered bushing loosely into the piston
and insert capscrews through the drilled holes in the
bushing and into the tapped holes in the piston.
Figure 5-23. Wiper Seal Installation
3. Place a new “O-ring and backup ring in the outside

diameter groove of the cylinder head.
Figure 5-25. Tapered Bushing Installation
9. Tighten the capscrews evenly and progressively in rota-

tion to 9 ft.lbs. (12 Nm).
10. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows;
a. Place the shaft against the cylinder rod and in con-

tact with the bushing in the spaces between the
capscrews.
Figure 5-24. Installation of Head Seal Kit b. Tap each space once; this means the tapered bush-
ing is tapped 3 times as there are 3 spaces between
4. Install washer ring onto rod, carefully install the head the capscrews.
gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the
rod to the rod end.
5. Place a new O-ring and backup rings in the inner piston

diameter groove.

vise or similar holding fixture as close to the piston
threads as possible.
7. Carefully thread the piston on the cylinder rod hand

tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.
Figure 5-26. Seating the Tapered Bearing
11. Retorque the capscrews evenly and progressively in

rotation to 9 ft.lbs. (12 Nm).
5-54 – JLG Lift – 3121262

12. Remove the cylinder rod from the holding fixture. 17. Secure the cylinder head gland using the washer ring,
JLG Threadlocker (P/N 0100011) and socket head bolts.
13. Place a new t-seal and wear rings in the outer piston
diameter grooves. (A tube, with I.D. slightly larger than Torque to 35 ft.lbs. (50 Nm)
the O.D.of the piston is recommended to install the seal.)
Figure 5-28. Rod Assembly Installation
18. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
reinstallation of any valves.
Figure 5-27. Piston Seal Kit Installation 19. Install the counterbalance valves in the rod port block.
Torque 50-55 ft.lbs. (68-75 Nm).
14. Position the cylinder barrel in a suitable holding fixture.
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE

CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
PISTON AND CYLINDER BARREL SURFACES.
15. With barrel clamped securely, and while adequately sup-

porting the rod, insert the piston end into the barrel cyl-
inder. Ensure that the piston t-seal is not damaged or
dislodged.
16. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
3121262 – JLG Lift – 5-55

Axle Lockout Cylinder inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
2. Operate the hydraulic power source and extend the cyl- Figure 5-30. Cap Screw Removal
Adequately support the cylinder rod, if applicable. 7. Attach a suitable pulling device to the cylinder rod end.
3. Remove the counterbalance valves from the cylinder
port block. Discard o-rings.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
4. If necessary, remove the bleeder valve. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
5. Place the cylinder barrel into a suitable holding fixture. ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE


5-56 – JLG Lift – 3121262

11
6
24
24
11
1
12
10 4
3
10 19
20
16
5
18
17 15
23
22
17 8,9,21
25
7,8,13
2
11
11
1684081-E
1. Barrel 6. Counterbalance Valve 11. Bearing 16. Backup Ring 21. Wiper
2. Rod 7. Thread locking Compound 12. Plug 17. Lock Ring 22. Seal
3. Piston 8. Locking Primer 13. Bolt 18. Backup Ring 23. Rod Seal
4. Bushing 9. Loctite RC 609 14. Not Used 19. O-ring 24. Bleeder Valve
5. Head 10. Bolt 15. Wear Ring 20. O-ring 25. Washer Ring
Figure 5-32. Axle Lockout Cylinder
3121262 – JLG Lift – 5-57

9. Using suitable protection, clamp the cylinder rod in a CLEANING AND INSPECTION
10. Loosen and remove the capscrews which attach the vent.




distortion. Dress piston surface or replace piston as nec-
essary.
7. Inspect threaded portion of piston for damage. Dress

Figure 5-33. Tapered Bushing Removal
8. Inspect seal and o-ring grooves in piston for burrs and

piece of the tapered bushing. Progressively tighten the
capscrews until the bushing is loose. 9. Inspect cylinder head inside diameter for scoring or
12. Remove the tapered bushing from the piston. necessary.
13. By hand, screw the piston counterclockwise and remove 10. Inspect threaded portion of head for damage. Dress
it from cylinder rod. threads as necessary.
14. Remove and discard the piston o-rings, seal rings, and 11. Inspect seal and o-ring grooves in head for burrs and
backup rings.
15. Remove the rod from the holding fixture. Remove the
the cylinder head.
5-58 – JLG Lift – 3121262


assembly.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
be replaced.





3121262 – JLG Lift – 5-59




capscrews.
rod to the rod end.

diameter groove.



5-60 – JLG Lift – 3121262

12. Remove the cylinder rod from the holding fixture. 14. Position the cylinder barrel in a suitable holding fixture.
WHEN INSTALLING HYDROLOCK PISTON SEALS, ENSURE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTA- ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
TION. IMPROPER SEAL INSTALLATION COULD RESULT IN PISTON AND CYLINDER BARREL SURFACES.
CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERA-
TION.
inder. Ensure that the piston seals are not damaged or
dislodged.
17. Secure the cylinder head gland using the washer ring,
JLG Threadlocker (P/N 0100011), and socket head bolts.
Torque to 85 ft.lbs. (115 Nm)
Figure 5-41. Hydrolock Piston Seal Installation
13. Place new hydrolock seals in the outer piston diameter

grooves. (A tube, with I.D. slightly larger than the O.D.of
the piston is recommended to install the seal.)
19. Install the counterbalance valves in the rod port block.

20. If removed, install the bleeder valve. Torque 12 to 15

ft.lbs. (16 to 20 Nm)
Figure 5-42. Piston Seal Installation
3121262 – JLG Lift – 5-61

Jib Level Cylinder inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
4. Place the cylinder barrel into a suitable holding fixture. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE


5-62 – JLG Lift – 3121262

9**
4
10
108
5
8**
2*
3
107
13
107
108
102
103
102
7
104
109
101
12
105
106 11
14
* Torque 9 ft.lbs. (12 Nm)
1,6***
** Torque 50-55 ft.lbs. (68-75 Nm)
*** Torque 170 ft.lbs. (230 Nm)
1001118142-B
1. Threadlocker 7. Spacer 13. Piston 105. Seal

2. Bolt 8. Holding Valve 14. Washer Ring 106. Rod Wiper
3. Tapered Bushing 9. Counterbalance Valve 101. Wear Ring 107. Seal
4. Plug 10. Barrel 102. Backup Ring 108. Guide Ring
5. Plug 11. Rod 103. O-ring 109. Backup Ring
6. Bolt 12. Head 104. O-ring
Figure 5-47. Jib Level Cylinder
3121262 – JLG Lift – 5-63





essary.
Figure 5-48. Tapered Bushing Removal 7. Inspect threaded portion of piston for damage. Dress
10. Insert the capscrews in the threaded holes in the outer 8. Inspect seal and o-ring grooves in piston for burrs and
piece of the tapered bushing. Progressively tighten the sharp edges. Dress applicable surfaces as necessary.
capscrews until the bushing is loose.
9. Inspect cylinder head inside diameter for scoring or
11. Remove the tapered bushing from the piston. other damage and for ovality and tapering. Replace as
necessary.
it from cylinder rod. 10. Inspect threaded portion of head for damage. Dress
13. Remove and discard the piston o-rings, seal rings, and
backup rings. 11. Inspect seal and o-ring grooves in head for burrs and
14. Remove the piston spacer from the rod.
the cylinder head.
5-64 – JLG Lift – 3121262


assembly.
be replaced.





3121262 – JLG Lift – 5-65




capscrews.
rod to the rod end.
5. Push the spacer onto the rod.
diameter groove.

5-66 – JLG Lift – 3121262

WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
TION. IMPROPER SEAL INSTALLATION COULD RESULT IN
TION.
dislodged.

3121262 – JLG Lift – 5-67

Platform Level Cylinder 7. Using a spanner wrench, unscrew the cylinder head
from the barrel.
DISASSEMBLY 8. Attach a suitable pulling device to the cylinder rod end.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE

SURE.
2. Operate the hydraulic power source and extend the cyl-

3. Remove the cylinder length sensor from the cylinder.

See Section 5.4, Cylinder Length Sensor.

5. Place the cylinder barrel into a suitable holding fixture.
6. Remove the self-tapping screw from cylinder barrel.
5-68 – JLG Lift – 3121262

1,8
17
200
6,16
203
202
201
13 6,9*
4
18**** 4
2**
18****
3
101
108
7
108
101
104 102
106 107
104
105
10
6
14***
103
110
109
* Torque to 4 in.lbs. (0.5 Nm)

** Torque to 9 ft.lbs. (12 Nm)
15 *** Torque to 200 ft.lbs. (271 Nm)
**** 30 to 35 ft.lbs. (41-47.5 Nm)
1001117968-D
1. Threadlocker 8. Bolt 15. Rod 104. Backup Ring 111. Sensor Magnet Assembly
2. Bolt 9. Setscrew 16. Cylinder Length Sensor 105. O-ring 112. Spacer Sleeve
3. Tapered Bushing 10. Spacer 17. Retainer Cap 106. O-ring 113. Sensor Magnet
4. Plug 11. Not Used 18. Counterbalance Valve 107. O-ring 114. Internal Retaining Ring
5. Not Used 12. Not Used 101. Lock Ring 108. Seal
6. Lubricant 13. Barrel 102. Backup Ring 109. Rod Wiper
7. Piston 14. Head 103. Wear Ring 110. Seal
Figure 5-61. Platform Level Cylinder
3121262 – JLG Lift – 5-69





essary.
necessary.
it from cylinder rod.
11. Inspect seal and o-ring grooves in head for burrs and
backup rings.
16. Remove the piston spacer from the rod.
17. If necessary, remove the retaining ring, sensor magnet,

and spacer sleeve from the cylinder rod.
cylinder head gland and discard all seals on the cylinder
head.
5-70 – JLG Lift – 3121262


assembly.
be replaced.





3121262 – JLG Lift – 5-71




capscrews.
rod to the rod end.
diameter groove.

5-72 – JLG Lift – 3121262

13. If removed, install the spacer sleeve, sensor magnet, and 16. Position the cylinder barrel in a suitable holding fixture.
retaining ring.
14. Remove the cylinder rod from the holding fixture.

WHEN INSTALLING HYDROLOC PISTON SEALS, ENSURE PISTON AND CYLINDER BARREL SURFACES.
SEALS ARE INSTALLED PROPERLY. REFER TO HYDROLOCK
PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTA- 17. With barrel clamped securely, and while adequately sup-
TION. IMPROPER SEAL INSTALLATION COULD RESULT IN porting the rod, insert the piston end into the barrel cyl-
CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERA- inder. Ensure that the piston seals are not damaged or
TION. dislodged.
19. Screw the cylinder head gland into the barrel using a
spanner wrench. Torque to 200 ft.lbs. (271 Nm).
Figure 5-70. Hydrolock Piston Seal Installation Torque 30 to 35 ft.lbs. (41-47.5 Nm).
22. Install the cylinder length sensor. See Section 5.4, Cylin-
der Length Sensor.
3121262 – JLG Lift – 5-73

Boom Lift Cylinder inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
3. Remove the check valve, counterbalance valve, and
pressure regulator valve from the cylinder port block.
Discard o-rings. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE
4. Place the cylinder barrel into a suitable holding fixture. ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE


5-74 – JLG Lift – 3121262

30
28***
30
9
29*
27***
4**
5
10
13
12
22
16
12
13
14
15
14
26
15
20
19
21
7
18
2,17
8
23
1,2,25****
30
* Torque 25-27 ft.lbs. (34-36.5 Nm)

*** Torque 30-35 ft.lbs. (40.5-47.5 Nm)
**** Torque 300 ft.lbs. (410 Nm)
30
1001118442-B
1. Threadlocker 7. Head 13. Lock Ring 19. Backup Ring 25. Bolt
2. Locking Primer 8. Rod 14. Backup Ring 20. O-ring 26. Spacer
3. Not Used 9. Barrel 15. O-ring 21. Wear Ring 27. Check Valve
4. Bolt 10. Plug 16. Wear Ring 22. Piston 28. Cartridge Valve
5. Tapered Bushing 11. Not Used 17. Rod Wiper 23. Washer Ring 29. Pressure Regulator Valve
6. Not Used 12. Guide Ring 18. Rod Seal 24. Not Used 30. Bushing
Figure 5-75. Boom Lift Cylinder
3121262 – JLG Lift – 5-75





essary.
11. Remove the tapered bushing from the piston.
12. By hand, screw the piston counterclockwise and remove necessary.
it from cylinder rod.
13. Remove and discard the piston o-rings, seal rings, and threads as necessary.
backup rings.
14. Remove the piston spacer from the rod. Remove and sharp edges. Dress applicable surfaces as necessary.
discard the o-ring inside the piston spacer.
the cylinder head.
5-76 – JLG Lift – 3121262


assembly.
be replaced.





3121262 – JLG Lift – 5-77

3. Place a new O-ring and backup ring in the outside diam-

eter groove of the cylinder head.


capscrews.
rod to the rod end.
5. Place a new O-ring into the spacer and push the spacer
onto the rod.
diameter groove.

5-78 – JLG Lift – 3121262

TION.
dislodged.

20. Install the check valve in the rod port block. Torque 30-
35 ft.lbs. (40.5-47.5 Nm).
21. Install the counterbalance valve in the rod port block.
Torque 30-35 ft.lbs. (40.5-47.5 Nm).
22. Install the pressure regulator valve in the rod port block.
Torque 25-27 ft.lbs. (34-36.5 Nm).
3121262 – JLG Lift – 5-79

Jib Lift Cylinder inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
3. Remove the cylinder length sensor from the cylinder.
See Section 5.4, Cylinder Length Sensor.
4. Remove the counterbalance valve and holding valve CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE
from the cylinder port block. Discard o-rings. ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
5. Place the cylinder barrel into a suitable holding fixture. PISTON AND CYLINDER BARREL SURFACES.


5-80 – JLG Lift – 3121262

* Torque to 4 in.lbs. (0.5 Nm)

**Torque to 9 ft.lbs. (12 Nm)
*** Torque to 120 ft.lbs. (163 Nm)
**** Torque 50-55 ft.lbs. (68-75 Nm)
1001118082-B
1. Threadlocker 8. Plug 15. Setscrew 22. Rod 107. Seal

2. Bolt 9. Plug 16. Spacer 101. Wear Ring 108. Rod Wiper
3. Screw 10. Lubricant 17. Holding Valve 102. Backup Ring 109. Spacer Sleeve
4. Tapered Bushing 11. Piston 18. Counterbalance Valve 103. Lock Ring 110. Sensor Magnet
5. Cable Clamp 12. Washer Ring 19. Cylinder Length Sensor 104. Backup Ring 111. Retaining Ring
6. Cylinder Head 13. Bolt 20. Retainer Cap 105. O-ring
7. Plug 14. Bolt 21. Barrel 106. O-ring
Figure 5-90. Jib Lift Cylinder
3121262 – JLG Lift – 5-81





essary.
necessary.
it from cylinder rod. 10. Inspect threaded portion of head for damage. Dress
backup rings. 11. Inspect seal and o-ring grooves in head for burrs and
15. Remove the piston spacer from the rod. Remove and
discard the o-ring inside the piston spacer.
16. If necessary, remove the retaining ring, sensor magnet,

and spacer sleeve from the cylinder rod.
the cylinder head.
5-82 – JLG Lift – 3121262


assembly.
be replaced.





3121262 – JLG Lift – 5-83




capscrews.
rod to the rod end.
5. Place a new O-ring into the spacer and push the spacer
onto the rod.
diameter groove.

5-84 – JLG Lift – 3121262

TION.
dislodged.

20. Install the holding valve and counterbalance valve in the
rod port block. Torque 50-55 ft.lbs. (68-75 Nm).
21. Install the cylinder length sensor. See Section 5.4, Cylin-
der Length Sensor.
3121262 – JLG Lift – 5-85

Jib Lock Cylinder CLEANING AND INSPECTION

DISASSEMBLY vent.

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED or equivalent. Replace rod if necessary.
1. Connect a suitable auxiliary hydraulic power source to or other damage. Check inside diameter for tapering or
the cylinder port block fitting. ovality. Replace if necessary.

RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES- 5. Inspect piston surface for damage and scoring and for
SURE. distortion. Dress piston surface or replace piston and
rod assembly as necessary.
2. Operate the hydraulic power source and extend the cyl- 6. Inspect seal and o-ring grooves on piston for burrs and
inder. Shut down and disconnect the power source. sharp edges. Dress applicable surfaces as necessary.
3. Place the cylinder barrel into a suitable holding fixture. other damage and for ovality and tapering. Replace as
necessary.
4. Using a spanner wrench, unscrew the cylinder head
from the barrel. 8. Inspect threaded portion of head for damage. Dress
5. Attach a suitable pulling device to the cylinder rod end.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE 10. Inspect cylinder head outside diameter for scoring or
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE other damage and ovality and tapering. Replace as nec-
ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE essary.
7. With the barrel clamped securely, carefully withdraw the or other foreign material. Repair as necessary.
8. Using suitable protection, clamp the cylinder rod in a damage. Replace as necessary.
9. Remove and discard the piston wear ring and t-seal.
cylinder head gland and discard all seals on the cylinder
head.
5-86 – JLG Lift – 3121262

101
108
105
102
104
1,2
103
107
106
1001119313-B
1. Head 4. Rod 103. Wear Ring 106. Rod Wiper

2. Lubricant 101. Wear Ring 104. O-ring 107. Seal
3. Barrel 102. Backup Ring 105. O-ring 108. Seal
Figure 5-102. Jib Lock Cylinder
3121262 – JLG Lift – 5-87

ASSEMBLY 3. Place a new O-rings and backup ring in the outside

diameter groove of the cylinder head and new wear
NOTE: Prior to cylinder assembly, ensure that the proper cylinder rings and polyseal in the inside diameter grooves of the
seal kit is used. See your JLG Parts Manual. cylinder head.
4. Carefully install the head gland on the rod, ensuring that
Apply a light film of hydraulic oil to all components prior to
the wiper and rod seals are not damaged or dislodged.
assembly.
Push the head along the rod to the rod end.
1. A special tool is used to install a new rod seal into the 5. Place a new wear ring and t-seal in the outer piston
applicable cylinder head gland groove. diameter grooves. (A tube, with I.D. slightly larger than
WHEN I NSTALLI NG NEW SEALS, ENSURE SEALS ARE Figure 5-105. Piston Seal Installation
COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER 6. Position the cylinder barrel in a suitable holding fixture.
CYLINDER OPERATION.


dislodged.
9. Apply anti-seize lubricant to the threads and screw the
cylinder head gland into the barrel using a spanner
wrench.
2. Use a soft mallet to tap a new wiper seal into the cylin-
der head gland groove. Install a new wear ring into the
5-88 – JLG Lift – 3121262

Steer Cylinder 4. Mark cylinder cap and barrel with a center punch for
easy realignment. Unscrew the cylinder cap from the
DISASSEMBLY barrel.



SURE.
2. Operate the hydraulic power source and extend the cyl-

inder. Shut down and disconnect the power source. Figure 5-107. Cylinder Cap Removal
5. Attach a suitable pulling device to the cylinder rod end.
3. Place the cylinder barrel into a suitable holding fixture.


3121262 – JLG Lift – 5-89

14
6
9
5* 12
10
8 3
11
7 13
1
* Torque to 400 ft.lbs. (542 Nm) Max

1684314-D
1. Cylinder Cap 6. Piston 11. O-ring

2. Rod 7. Backup Ring 12. Wiper
3. Head 8. Wear Ring 13. Piston Seal
4. Barrel 9. Wear Ring 14. Loctite #222 (not
5. Nut 10. O-ring shown)
Figure 5-109. Steer Cylinder
5-90 – JLG Lift – 3121262

8. Using suitable protection, clamp the cylinder rod in a c. Lubricate inside of the steel bushing with WD40
vise or holding fixture as close to the piston as possible. prior to bearing installation.
9. Loosen and remove the lock nut that secures the piston d. Using an arbor of the correct size, carefully press the
to the cylinder rod. bearing into steel bushing.
10. Remove the piston from the cylinder rod. NOTE: Install pin into the composite bearing dry. Lubrication is
11. Remove and discard the piston o-rings, seal rings, and t-
seal.
cylinder head. Discard all seals on the cylinder head.
CLEANING AND INSPECTION

vent.
or equivalent. Replace rod if necessary. Figure 5-110. Composite Bearing Installation
Dress threads as necessary. 14. Inspect the oil ports for blockage or the presence of dirt
4. Inspect inner surface of cylinder barrel tube for scoring or other foreign material. Repair as necessary.
or other damage. Check inside diameter for tapering or 15. If applicable, inspect piston rings for cracks or other
ovality. Replace if necessary. damage. Replace as necessary.
threads as necessary. ASSEMBLY
6. Inspect piston surface for damage and scoring and for NOTE: Prior to cylinder assembly, ensure that the proper cylinder
distortion. Dress piston surface or replace piston as nec- seal kit is used. See your JLG Parts Manual.
essary.
Apply a light film of hydraulic oil to all components prior to
assembly.
8. Inspect seal and o-ring grooves in piston for burrs and 1. A special tool is used to install a new rod seal into the
sharp edges. Dress applicable surfaces as necessary. applicable cylinder head gland groove.
necessary.
12. Inspect cylinder head outside diameter for scoring or
essary.
correct excessive wear or damage. Replace as necessary.
etc. to facilitate bearing installation.
steel bushing is worn or damaged, rod/barrel must WHEN INSTALLING NEW S EALS, ENSURE SEALS ARE
be replaced. INSTALLED PROPERLY. IMPROPER SEAL INSTALLATION
3121262 – JLG Lift – 5-91

COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER 10. Place a new wear ring and t-seal in the outer piston
CYLINDER OPERATION. diameter grooves. (A tube, with I.D. slightly larger than

2. Use a soft mallet to tap a new wiper seal into the cylin-
der head gland groove. Install new wear rings into the 11. Position the cylinder barrel in a suitable holding fixture.
4. Place the cylinder cap over the rod and carefully install ROD OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE
the head gland on the rod, ensuring that the wiper and PISTON AND CYLINDER BARREL SURFACES.
rod seals are not damaged or dislodged. Push the head
along the rod to the rod end. 12. With barrel clamped securely, and while adequately sup-
diameter groove.
dislodged.
14. Secure the cylinder head using JLG Threadlocker (P/N
7. Install the piston on the cylinder rod hand tight, ensur-
0100035 and the cylinder cap.
ing that the o-ring and back-up rings are not damaged
or dislodged. 15. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted).
8. Carefully thread the lock nut onto the rod to secure the
piston in place. Torque to 400 ft.lbs. (542 Nm).
9. Remove the cylinder rod from the holding fixture.
5-92 – JLG Lift – 3121262

Jib Telescope Cylinder INSPECTION

1. Inspect all seals, backup rings, wipers, and wear rings for
tears, grooves, foreign matter, and excessive wear. Deep
grooves may be an indication of damage to the barrel
USE CARE IN REMOVAL OF ANY, AND ALL, COMPONENTS
bore, rod chrome, or the presence of large particle con-
AS COUNTERBALANCE VALVES MAY RETAIN CONSIDER-
tamination.
ABLE PRESSURE WITHIN THE CYLINDER ASSEMBLY. USE
EXTREME CARE REMOVING PLUGS, VALVES, AND/OR THE 2. Remove the seals, backup rings, wipers, and wear rings
ROD ASSEMBLY TO ENSURE THE INTERNAL CYLINDER using a soft metal tool (brass or aluminum) with
PRESSURE HAS BEEN RELIEVED. rounded edges. Use care not to nick or score the sur-
faces of any component, especially the seal grooves.
NOTE: The jib telescope cylinder weighs approximately 130.5 lbs. 3. Wipe all components clean with a lint-free cloth. Plug
(59.2 kg). the barrel opening with a lint-free cloth. Remove any
adhesive remnants from the head gland, barrel, rod, and
DISASSEMBLY piston threads (where applicable) using a soft wire
brush. Use care not to scratch or otherwise damage the
1. Retract cylinder and support equipment to allow for cyl- critical surfaces of any component including seal
inder removal. Relieve system pressure to the cylinder. grooves, barrel bore, rod chrome, etc.
Clean any debris from around both ports and remove
the hydraulic lines. Plug/cap both ports and remove cyl- 4. Inspect the piston and head gland for excessive wear,
inder from equipment. cracks, scoring, or any other damage. If wear is present
on the O.D. of the piston or the I.D. of the head gland,
2. The cylinder assembly should be secured in such a way check to ensure that the circularity of both dimensions
as to prevent movement of the barrel assembly while are within 0.007”. Beyond this limit the seal performance
removing the rod assembly. (Such as in a vise with pipe is compromised and the components must be replaced.
jaws.) Caution should be used to avoid damaging the
rod surface and to avoid excessive deformation of the 5. The stop tube should be inspected for cracking and
barrel, which could permanently damage the unit. Provi- excessive flaring of the ends.
sions must also be made to support the rod assembly 6. Closely inspect the chrome surface of the rod. Any nicks,
during its removal. gouges, or scratches that penetrate the chrome plating
or result in a sharp edge, which may damage seals, are
3. Remove all dirt, grease, and other contaminants from
cause for rod assembly replacement.
around the ports and the head gland. Drain all oil from
the unit. Extending and retracting the rod manually can 7. Flush the barrel and fluid tube (if equipped), drain, and
help purge the bulk of remaining oil. wipe dry with a lint-free cloth. Closely inspect bore for
nicks, gouges, or scratches. Replace barrel assembly if
4. Mark the orientation of the rod, gland, pad support, and any of these are present.
barrel with a permanent marker or paint pen. Do not
paint the chromed surface of the rod! Remove the cap
screws retaining the head gland from the cylinder
assembly.
NOTE: The threads are “locked” with a non-permanent thread

adhesive during assembly; a quick tug on the wrench may
be necessary to release the thread adhesive.
5. Remove the rod assembly from the barrel using care not
to damage the threads or any other components sur-
face.
6. Clamp the rod mount and support the rod assembly

with the chrome surface protected. Remove the piston
assembly by unthreading the piston itself from the rod
using a spanner wrench.
3121262 – JLG Lift – 5-93

* Torque 25-30 ft.lbs. (34-40.5 Nm) Max

** Torque 20 ft.lbs. (27 Nm) Max
1001118663-C
1. Barrel 7. Pad Support 13. Wear Ring 19. Lockwasher

2. Rod 8. O-ring 14. Plug 20. Nut
3. Gland 9. O-ring 15. Plug 21. Capscrew
4. Piston 10. Rod Seal 16. Wear Ring 22. Shuttle Valve
5. Stop Tube 11. Backup Ring 17. Piston Seal 23. Counterbalance Valve
6. Wear Pad 12. Rod Wiper 18. Capscrew 24. Counterbalance Valve
Figure 5-114. Jib Telescope Cylinder
5-94 – JLG Lift – 3121262

ASSEMBLY ROD, GLAND, PISTON ASSEMBLY
NOTE: Refer to Figure 5-115. and Figure 5-116. provided at the end 1. Lubricate I.D. of head gland assembly with hydraulic
of this procedure for the proper seal locations and orienta- fluid, and slide onto rod (rod wiper end first) using cau-
tions. Improper seal orientation will compromise perfor- tion not to damage rod wiper or seal on rod end.
mance! 2. Slide stop tube (with o-ring) onto rod. Do not scratch
rod chrome.
Inspect all components per above INSPECTION procedure.
3. For pistons with threaded I.D., apply Loctite #7471
Clean all components with a lint-free cloth. The barrel should
(Primer-T) to piston and rod threads. Allow primer to
be flushed out and drained. Compressed air may be used to
evaporate then apply two beads of Loctite #222 Thread
blow out the barrel bore and all ports. Lubricate all seals with
Adhesive axially across the threads of the piston I.D.
hydraulic fluid prior to assembly.
4. Install piston assembly onto threaded end of rod.
HEAD GLAND ASSEMBLY
Tighten piston onto rod end to 100 ft.lbs. An optional
1. Install rod seal; refer to Seal Detail for proper orientation. method for tightening threaded piston is to turn until
piston bottoms out; then set in place by hitting spanner
2. Install wear rings. wrench handle with a hammer; piston should rotate
3. Press in the rod wiper using a soft metal (brass or alumi- slightly while setting.
num) or nylon tool which contacts the wiper 360°. Make FINAL ASSEMBLY
sure the wiper remains perpendicular to the bore at all
times. 1. Make sure all rags, etc. are removed from barrel bore.
Lubricate barrel bore and piston assembly with hydrau-
4. Install the backup ring and o-ring with the backup ring lic fluid. Avoid getting any oil in barrel threads.
nearest the head gland flange.
2. Place pad support on rod assembly before installing into
PISTON ASSEMBLY barrel. Use care to avoid damaging wear rings, seals, and
rod chrome.
1. Install o-ring into groove in I.D. of piston.
3. Align rod with barrel assembly. Insert piston into barrel
2. Install one wear ring onto piston. opening. Use care to avoid damaging wear rings, seals,
3. Install piston seal into central groove on piston O.D. A and piston surface on barrel.
clean, small cross-section o-ring or a thin elastic band 4. Lubricate o-ring and backup on head gland using
may be wrapped around seal to help stretch it over pis- hydraulic fluid.
ton.
5. Align head gland with barrel assembly, position pad
4. Install remaining wear ring. support over head gland (avoid damaging the o-ring
and back-up with the pad support), and press head
gland into barrel assembly.
6. Apply a bead of Loctite #222 Thread Adhesive axially
cap screw threads.
7. Screw cap screws into head gland / barrel assembly and
torque to 20 ft.lbs. (27 Nm).
3121262 – JLG Lift – 5-95

Figure 5-115. Jib Telescope Cylinder Head Gland Detail
Figure 5-116. Jib Telescope Piston Detail
5-96 – JLG Lift – 3121262

Main Boom Telescope Cylinder inder head retainer capscrews, and remove capscrews
DISASSEMBLY



SURE.
3. Remove the check valves, counterbalance valves, and
relief valve from the cylinder port block. Discard o-rings.
4. Place the cylinder barrel into a suitable holding fixture. CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE


3121262 – JLG Lift – 5-97

* Torque to 13 ft.lbs. (17.5 Nm)

1. Loctite #242 8. Barrel 15. O-Ring 22. Piston 29. Flatwasher

2. Locking Primer 9. Rod 16. Backup Ring 23. Capscrew 30. O-Ring Plug
3. Not Used 10. Not Used 17. Rod Wiper 24. Capscrew 31. Head
4. Capscrew 11. Wear Ring 18. T-Seal 25. Capscrew
5. Bolt 12. Backup Ring 19. Rod Seal 26. Spacer
6. Bracket 13. Wear Ring 20. Retaining Ring 27. Valve Assembly
7. Tapered Bushing 14. O-Ring 21. Wear Pad 28. Flatwasher
Figure 5-120. Boom Telescope Cylinder
5-98 – JLG Lift – 3121262





essary.


capscrews until the bushing is loose. 9. Inspect cylinder head inside diameter for scoring or
11. Remove the tapered bushing from the piston. necessary.
12. By hand, screw the piston counterclockwise and remove 10. Inspect threaded portion of head for damage. Dress
it from cylinder rod. threads as necessary.
13. Remove and discard the piston o-rings, seal rings, and 11. Inspect seal and o-ring grooves in head for burrs and
backup rings.
the cylinder head.
3121262 – JLG Lift – 5-99


assembly.
be replaced.

WHEN INSTAL LING NEW S EALS, ENSURE SEALS ARE




5-100 – JLG Lift – 3121262



tion to 30 ft.lbs. (40.5 Nm).

capscrews.
rod to the rod end.

diameter groove.



rotation to 30 ft.lbs. (40.5 Nm).
3121262 – JLG Lift – 5-101

13. Remove the cylinder rod from the holding fixture. 18. Secure the cylinder head gland using the washer ring,
14. Place a new t-seal and wear rings in the outer piston
diameter grooves. (A tube, with I.D. slightly larger than
20. Install the check valves in the rod port block.
15. Position the cylinder barrel in a suitable holding fixture. 22. Install the relief valve in the rod port block.


dislodged.
5-102 – JLG Lift – 3121262

5.4 CYLINDER LENGTH SENSOR 5. Remove the plug that is over the setscrew that secures
the sensor in place.
Both the jib lift cylinder and the platform level cylinder utilize
a cylinder length sensor which communicates with the JLG
control system. These sensors can be removed from without
the cylinder being disassembled.
6. Using an allen wrench, remove the setscrew.
Figure 5-131. Cylinder Length Sensor
Removal
1. Lower the platform to the ground or on suitable block-
ing.
NOTE: The jib lift cylinder weighs approximately 186 lbs.(84 kg)
and the platform level cylinder weighs approximately
76 lbs. (34 kg)
2. Support the weight of the jib cylinder and remove the

bolt and keeper pin that secure the cylinder barrel
retaining pin. Remove the pin.
3. Lower the cylinder to a horizontal position to gain
access to the rear of the cylinder.
4. Place a catch pan under the cylinder to capture any oil
that may drain out of the cylinder. If the cylinder is
removed from the machine, drain the oil out of the cylin-
der.
3121262 – JLG Lift – 5-103

7. Using an allen wrench, remove the bolts securing the 8. Pull sensor out of the cylinder. DO NOT use the wiring
retaining cap and remove the cap. harness to pull the sensor out as this will cause damage
to the wiring.
5-104 – JLG Lift – 3121262

Installation 3. Apply lubricant JLG P/N 3020039 to the setscrew and

install the setscrew. Torque the setscrew to 4 in. lbs. (0.45
1. Carefully insert the sensor into the cylinder. It may be Nm).
necessary to gently tap the end of the sensor to seat the
o-ring into the sensor bore. DO NOT tap on the wiring
harness.
4. Install the plug over the setscrew.
2. Install the cap and secure in place with the retaining

bolts.
5. Raise the cylinder back in place and install the retaining

pin.
6. Install the keeper pin and retaining bolt.
7. Check the cylinder for proper operation.
3121262 – JLG Lift – 5-105

Figure 5-132. Platform Valve Identification
5-106 – JLG Lift – 3121262

Table 5-33. Platform Valve Specifications
Torque
# Item Ohms
ft.lbs. Nm
1 Pressure Check Port 17-18 23-24.5 --
2 Pressure Compensa- 25-30 34-41 --
tor
3 Relief Valve 25-30 34-41 --
4 Relief Valve 25-30 34-41 --
tor
6 Relief Valve 25-30 34-41 --
7 Inlet Valve 2-3 3-4 7.4
8 Platform Level Valve 16-20 22-27 9.8
9 Platform Rotate Valve 16-20 22-27 9.8
Figure 5-133. Platform Valve Torque and Resistance Specifications
3121262 – JLG Lift – 5-107

Table 5-2. Fitting Torque Specifications
Torque
#
ft.lbs. Nm
1 24 32.5
2 24 32.5
3 40 54
4 15 20
Figure 5-134. Platform Valve Fitting Torque Specifications
5-108 – JLG Lift – 3121262

Figure 5-135. Jib Control Valve Identification - Sheet 1 of 2
3121262 – JLG Lift – 5-109

Figure 5-136. Jib Control Valve Identification - Sheet 2 of 2
5-110 – JLG Lift – 3121262

Figure 5-137. Jib Control Valve Torque and Resistance Specifications - Sheet 1 of 2
3121262 – JLG Lift – 5-111

Table 5-33. Platform Valve Specifications
Torque
# Item Ohms
ft.lbs. Nm
tor
tor
3 Jib Lift Valve 16-20 22-27 9.8
4 Jib Tele Valve 16-20 22-27 7.2
5 Jib Level Valve 16-20 22-27 9.8
6 Jib Swing Valve 16-20 22-27 9.8
7 Inlet Valve 29-37 39-50 7.4
8 Relief Valve 25-30 34-41 --
9 Relief Valve 25-30 34-41 --
10 Relief Valve 25-30 34-41 --
11 Relief Valve 25-30 34-41 --
12 Relief Valve 25-30 34-41 --
Figure 5-138. Jib Control Valve Torque and Resistance Specifications - Sheet 2 of 2
5-112 – JLG Lift – 3121262

Table 5-4. Fitting Torque
Torque
#
ft.lbs. Nm
1 24 32.5
2 60 81
3 40 54
4 24 32.5
5 15 20
6 15 20
7 40 54
8 35 47.5
Figure 5-139. Jib Control Valve Fitting Torque Specifications
3121262 – JLG Lift – 5-113

1. Aux Lift Down 5. Dump 9. Lift Up Relief 13. Tele Out Relief
2. Tele Out 6. Swing Relief 10. Lift Down Relief 14. Tele In Relief
3. Lift Up 7. Swing Left 11. Lift Flow 15. Tele Flow
4. Swing Right 8. Lift Down 12. Tele In 16. Lift Down/Aux Select
Figure 5-140. Main Valve Identification
5-114 – JLG Lift – 3121262

Table 5-5. Cartridge Torque Values
Ft-Lbs. Nm Ft-Lbs. Nm
1 25-30 33.9-40.6 9 30-35 40.6-47.4
2 25-30 33.9-40.6 10 30-35 40.6-47.4
3 30-35 40.6-47.4 11 30 40.6
4 30-35 40.6-47.4 12 30-35 40.6-47.4
5 30-35 40.6-47.4 13 30-35 40.6-47.4
6 30-35 40.6-47.4 14 30-35 40.6-47.5
7 30-35 40.6-47.4 15 30-35 40.6-47.5
8 30 40.6
Figure 5-141. Main Valve Cartridge Torque Values
3121262 – JLG Lift – 5-115

5.5 OIL SAMPLING 3. Locate the oil sampling valve on the front of the main
control valve.
See Figure 5-141., Oil Sampling Port. 4. Unscrew the knurled end which is attached to the chain.
5. Place a drip pan under the spout and push in for approx-
This machine is equipped with an oil sampling valve to
imately 10 seconds. This should flush out the valve.
allow for verification of hydraulic oil condition.
6. Open and place the sample bottle under the spout.
Procedure 7. Push in on the end of the valve and fill up the bottle.
1. Function the machine for approximately 15 minutes 8. Cap the bottle immediately.
operating all functions. 9. Thread the knurled cap back onto the valve.
2. Switch the select switch to the ground controls and start 10. The sample is complete.
the engine.
Figure 5-141. Oil Sampling Port
5-116 – JLG Lift – 3121262

5.6 PRESSURE SETTING PROCEDURE

Cold temperatures have a significant impact on pressure read-
ings. JLG Industries Inc. recommends operating the machine
until the hydraulic system has warmed to normal operating
temperatures prior to checking pressures. JLG Industries Inc.
also recommends the use of a calibrated gauge. Pressure read-
ings are acceptable if they are within ± 5% of specified pres-
sures.
To ensure all pressures are set correctly, the following proce-

dures must be followed in order.
1. All applicable steps in Section 5.9, Drive & Function REXROTH PUMP
Pump Start Up Procedures must be followed.
2. Set up of the function pump.
3. Adjustments made at the main valve bank.
4. Adjustments made at the platform valve.
5. Adjustments made at the jib valve.
Set Up of the Function Pump

HIGH PRESSURE RELIEF
1. Install a high pressure gauge at the MP port of the main
valve block.
2. Using a screwdriver, remove the Din connector from the SAUER PUMP
lift down coil.
3. Activate lift down. The gauge should read 3400 psi 5. After adjusting the pressure, tighten the jam nut and the
(234.4 bar). cover nut if applicable. This is the maximum relief pres-
sure for all the functions governed by this pump.
4. To make an adjustment to this pressure on a Rexroth
pump, go to the engine compartment and locate the STAND BY PRESSURE OR LOW PRESSURE RELIEF
function pump which is the back pump. The high pres-
sure relief adjustment is the adjustment closest to the 1. Install a low pressure gauge at port MP of the main valve
pump. Using a 17 mm wrench, remove the cover nut. Be block capable of accurately reading 300 psi (20.6 bar).
careful not to lose the o-ring washer inside the cover
nut. Loosen the jam nut at the setscrew with the 17 mm 2. Start the engine, the gauge should read 300 psi (20.6
wrench. Using a 3 mm allen wrench, adjust clockwise to bar).
increase, or counterclockwise to decrease pressure.
To make an adjustment to this pressure on a Sauer

pump, loosen the 4 mm setscrew towards the engine.
Using a 6 mm allen wrench, turn clockwise to increase
pressure and counterclockwise to decrease pressure.
3121262 – JLG Lift – 5-117

3. To make an adjustment to this pressure, go to the SWING

engine compartment, locate the function pump. The
stand by adjustment is the adjustment outside adjust- NOTE: Left and right are done with one adjustment.
ment, closest to the turntable. Use the same tools that
were used in the High pressure adjustment procedure. 1. Install a high pressure gauge at port MS.
2. Lock the turntable pin.
3. Activate swing, the gauge should read 1500 psi (103.4
Bar). The adjustment cartridge is located below the MS
gauge port.
4. Turn clockwise to increase, counterclockwise to
decrease pressure.
TELESCOPE OUT
1. Install a high pressure gauge at the M8 port of the main
valve bank. Plug the telescope out hose either at the
REXROTH PUMP valve bank (port #8) or at the inlet of the telescope cylin-
der (V1).
2. Activate telescope out. The gauge should read 3200 psi
(220.6 Bar).
3. The adjustment cartridge is located below the M8
gauge port. Turn clockwise to increase, counterclock-
wise to decrease pressure.
TELESCOPE IN
valve block. Plug the telescope in hose either at the
valve bank (port #7) or at the inlet of the telescope cylin-
der (V2).
SAUER PUMP 2. Activate Telescope In. The gauge should read 1800 psi
(124 Bar).
Adjustments made at the Main Valve Bank 3. The adjustment cartridge is located to the left of the M7
LIFT UP wise to decrease pressure.
1. Install a high pressure gauge at the M5 port of the main Adjustments Made at the Frame Valve Bank
valve block. Plug and cap the hose on port 5.
AXLE EXTEND AND RETRACT, FRONT AND REAR
2. Activate lift up. The gauge should read 2750 psi (189.6
Bar). 1. To extend the axles, drive the machine back and forth
until fully extended. A machine that cannot be driven
3. The adjustment cartridge is located below the M5 must be jacked up.
wise to decrease pressure. 2. On both the front and rear frame valve banks, install a
high pressure gauge on ports MA1 for extend and MA2
LIFT DOWN for retract. The gauge should read 2500 psi (172.3 Bar) in
both directions.
valve block. 3. The axle extend/retract cylinders are connected hydrau-
lically in parallel. In order to get the correct pressure of
2. Activate lift down to the end of the stroke. The gauge the circuit being adjusted, unscrew the solenoid coil
should read 2000 psi (137.9 Bar). from the circuit not being adjusted and pull it away from
the valve.
3. The adjustment cartridge is located to the left of the M4
gauge port. Turn clockwise to increase, counterclock- 4. Turn clockwise to increase, counterclockwise to
wise to decrease pressure. decrease pressure.
5-118 – JLG Lift – 3121262

STEERING, FRONT AND REAR 2. Install the Analyzer in the platform control box and scroll
menu’s to Access Level 2 and insert password (33271) to
NOTE: The following procedure requires 2 people to perform. One get into Access Level 1.
is needed for verifying / adjusting pressure readings and
wheel spindle alignment the other for operating the steer
functions and using the Analyzer from the platform.
The Analyzer is required to perform the pressure check proce-

dure through access of the calibration menu. The calibration
menu will allow for extending and retracting the steer cylin-
ders individually, verifying pressures, and proper steer sensor
calibration. Verification of the steer sensor calibration will
require one of two types of measuring methods; using a
square and ruler or using string as explained in Section 6 - JLG
Control System. The purpose of these measuring tools is to
assure that the wheel spindle is aligned “straight” with the
extended axle weldment.
1. Position the machine with both front and rear axles fully
extended.
3. Scroll to the calibration mode. Once in the calibration

mode, press “ENTER” and scroll to steer. Once in the
steer calibration mode, the Analyzer is going to ask to
calibrate the steer sensors, this is going to allow extend-
ing and retracting each steer cylinder individually dur-
ing this process. The JLG control system will ask to
calibrate the left front sensor, the left rear sensor, the
right front sensor and finally the right rear sensor in that
order. During this calibration mode each individual steer
cylinder will be extended and retracted to verify correct
pressures with the marked MS (Measure Steer) ports on
the steer / axle valve that pertains to that steer cylinder.
Refer to the Hydraulic Schematic in Section 7 - Schemat-
ics.
3121262 – JLG Lift – 5-119

Figure 5-142. Steer Pressure Adjustments
5-120 – JLG Lift – 3121262

4. Remove the front circular steer/axle access covers at the mounted next to the MS2 port, clockwise to increase or
front of the chassis, and the rear square cover at the top counterclockwise to decrease pressure.
rear of the chassis to gain access to the axle/steer valves.
6. Remove the pressure gauge from MS2 port and install

on the MS1 port, which is on the right side of the front
axle/steer valve, closest to the right front wheel spindle.
Position the steer switch to activate the left front steer
cylinder until the rod is in the fully retracted position
and hold the switch for a few seconds after the rod has
stopped. The MS1 port should read 2600 psi (179 Bar). If
the pressure is not correct, adjust relief valve next to
MS1 port, clockwise to increase or counterclockwise to
decrease pressure.
5. Install a pressure gauge at the front axle/steer valve at
MS2 port. This should be located on the left side of the
valve closest to the left front wheel spindle. Position the
steer switch to activate the left front steer cylinder until
the rod is in the fully extended position and hold the
switch for a few seconds after the rod has been fully
extended. The MS2 port should read 2000 psi (138 Bar).
If the pressure is not 2000 psi (138 Bar) adjust relief valve
7. This step involves aligning the left front wheel spindle

with the axle weldment. Position the left front wheel
spindle “straight” using a square and rule or string for
proper alignment (Refer to Section 6 - JLG Control Sys-
tem). Once the left front wheel spindle has been prop-
erly measured, press “ENTER” on the Analyzer. This is
calibrating data to the JLG Control System that the left
front steer sensor is centered.
3121262 – JLG Lift – 5-121

8. Checking the left rear steer cylinder is identical to the mounted next to MS2 port clockwise to increase or
procedure for left front steer cylinder, except now we are counterclockwise to decrease pressure.
checking pressures at the rear axle/steer valve location.
Install pressure gauge at MS1 port. This should be
located on the left side of the valve closest to the left
rear wheel spindle. MS1 port should read 2600 psi (179
Bar) when the left rear steer cylinder is activated with
the rod in the fully retracted position. If the pressure is
not 2600 psi (179 Bar) adjust relief valve mounted next
to MS1 port clockwise to increase or counterclockwise
to decrease pressure.
10. The next step is identical to the left front step men-
tioned above. Make sure the left rear wheel spindle is
straight and press “ENTER” to accept the new calibration
settings, now press “ESC” (escape) and scroll to the right
front steer calibration step.
11. Checking the right front steer cylinder is identical to the

procedure laid out for the left front steer cylinder, except
the pressures are now checked at MS3 port of the front
9. Remove the gauge from MS1 port and install on MS2
axle/steer valve. This should be at the right side of the
port, which is on the right side of the rear axle/steer
valve closest to the right front wheel spindle. Install the
valve, closest to the right rear wheel spindle. Position
gauge at MS3 port. Position the steer switch to activate
the steer switch to activate the left rear steer cylinder
the right front steer cylinder until the rod is in the fully
until the rod is in the fully extended position and hold
retracted position and hold the steer switch for a few
the steer switch for a few seconds after the rod has been
seconds after the rod has been fully retracted. If the
fully extended. The MS2 port should read 2000 psi (179
pressure is not 2600 psi (179 Bar), adjust the relief valve
Bar). If the pressure is not correct, adjust the relief valve
mounted next to the MS3 port clockwise to increase or
counterclockwise to decrease pressure.
5-122 – JLG Lift – 3121262

12. Remove the gauge from MS3 port and install on MS4 16. The next step is identical to the left front step men-
port, which is on the left side of the front axle/steer tioned above, make sure the right rear wheel spindle is
valve, closest to the left front wheel spindle. Position the straight and press “ENTER” to accept the new calibration
steer switch to activate the right front steer cylinder settings, now escape out of the calibration menu and
until the rod is in the fully extended position and hold remove the Analyzer and pressure gauge.
the steer switch for a few seconds after the rod has
stopped extending. The MS4 port should read 2000 psi Adjustments Made at the Platform Valve Bank
(138 Bar). If the pressure is not correct, adjust relief valve
mounted next to the MS4 port clockwise to increase or
PLATFORM LEVEL UP
counterclockwise to decrease pressure.
1. Install a high pressure gauge at the gauge port M2.
13. The next step is identical to the left front step men-
tioned above. Make sure the right front wheel spindle is 2. Activate level up to the end of stroke, it should read
straight and press “ENTER” to accept the new calibration 2500 psi (172.3 Bar).
settings. Scroll over to right rear steer calibration step.
3. All the relief valves are located on the same face. The
14. Checking the right rear steer cylinder is identical to the level up relief valve is located closest to the M2 gauge
procedure laid out for the left rear steer cylinder. Install port. Turn clockwise to increase, counterclockwise to
gauge at MS4 port of the rear axle/steer valve. This decrease pressure.
should be at the right side of the valve closest to the
right rear wheel spindle. Position the steer switch to acti- PLATFORM LEVEL DOWN
vate the right rear steer cylinder until the rod is in the
fully extended position and hold the steer switch for a 1. Install a high pressure gauge at gauge port M1.
few seconds after the rod has stopped extending. The
MS4 port should read 2000 psi (138 Bar). If the pressure 2. Activate level down to the end of stroke, it should read
is not correct, adjust relief valve next to the MS4 port 2000 psi (138 Bar).
clockwise to increase or counterclockwise to decrease
3. The level down relief valve is located to the left of the
pressure.
level up relief valve. Turn clockwise to increase, counter-
clockwise to decrease pressure.
15. Remove gauge from MS4 port and install on MS3 port,
which is on the left side of the rear axle/steer valve, clos-
est to the left rear wheel spindle. Position the steer JIB PIN EXTEND
switch to activate the right rear steer cylinder until the
1. Install a high pressure gauge on gauge port MS1.
rod is in the fully retracted position and hold the steer
switch for a few seconds after the rod stops retracting. If 2. Using the analyzer and set pressures menu, select jib
the pressure is not 2600 psi (179 Bar), adjust the relief lock pin extend. Pressure can be checked as the jib is
valve mounted next to the MS3 port clockwise to moved from the stowed to the work position and should
increase or counterclockwise to decrease pressure. read 2500 psi (172 Bar). If adjustment is required, turn
clockwise to increase, counterclockwise to decrease
pressure.
3121262 – JLG Lift – 5-123

Adjustments Made at the Jib Valve 6. Using the arrow keys scroll until MENU: SERVICE MODE is
JIB LEVEL UP reached. Press ENTER .

NOTE: To check or adjust the jib level up pressure setting the JLG
Analyzer must be used to override the automatic jib level
function.
1. Install a high pressure gauge at MLB.
2. Connect the analyzer to the ground control connector.

3. Position the main boom on the boom rest and the jib to
horizontal.
7. The analyzer should read JIB & SWING. Press ENTER
4. Using the analyzer, press the RIGHT or LEFT .

arrow key until ACCESS LEVEL 2 is reached. Press ENTER
.
5. Using the arrow keys, enter access code 33271 and press
ENTER .
5-124 – JLG Lift – 3121262

11. When the function bottoms out, pressure should read

2600 psi.(180bar).
8. Enter code 58237 and Press ENTER . The screen
should read SERVICE MODE: JIB & SWING AND JIB LEVEL. 12. If necessary to adjust pressure, CW increases and CCW
decreases setting. Jib level up adjustment is adjacent to
MLB.
JIB LEVEL DOWN

1. Install high pressure gauge at MLA.
9. Press ENTER again. The screen will read JIB LEVEL
OVERRIDE: OFF. Use the UP or DOWN arrow

keys to toggle the override from Off to On.
2. Connect the analyzer to the ground control connector.

3. Position the main boom on the boom rest and the jib
fully elevated.
4. Using the analyzer, press the RIGHT or LEFT

arrow key until ACCESS LEVEL 2 is reached. Press ENTER
.
5. Using the arrow keys, enter access code 33271 and press
ENTER .
10. Once turned on, operate the Jib Lift Up function. This
will activate the jib level up function.
3121262 – JLG Lift – 5-125

6. Using the arrow keys scroll until MENU: SERVICE MODE is

8. Enter code 58237 and Press ENTER . The screen
reached. Press ENTER . should read SERVICE MODE: JIB & SWING AND JIB LEVEL.
7. The analyzer should read JIB & SWING. Press ENTER
9. Press ENTER again. The screen will read JIB LEVEL

.
OVERRIDE: OFF. Use the UP or DOWN arrow

keys to toggle the override from Off to On.
NOTE: Using this override may set the Jib Leveling System Fault,
depending upon how far out of level the jib is moved.
5-126 – JLG Lift – 3121262

10. Once turned on, operate the Jib Lift Down function. This 14. Adjust the jib level using
will activate the Jib Level Down function. the Jib Lift function
switch until the jib level
11. When the cylinder is completely retracted, the pressure
control angle reads zero
should be 1500 psi. (104bar). CW increases and CCW
(0).
decreases setting. Jib level down adjustment is adjacent
to MLA.
15. After the control angle is set, use the UP or DOWN
arrow keys to toggle the override from On to Off.

16. Cycle power and operate the main boom to verify jib
level is working properly.
12. To adjust the jib back to level, go into override mode for
jib leveling. Turne the override mode to "On" and press
the ESCAPE key until out of the Service Modes

menu.
13. Go to the Diagnostics/Boom Sensors menu. Use the
Right arrow key until reaching the "Jib Level CNTL: Angle
0.0" screen.
3121262 – JLG Lift – 5-127

JIB TELESCOPE OUT JIB TELESCOPE IN
1. Install a high pressure gauge at the MTB port. 1. Install a high pressure gauge at the MTA port.
2. Fully extend the jib boom. 2. Fully retract the jib boom.
3. Set the Jib Telescope pressure to 2850 psi (196.5 Bar). 3. Set the Jib Telescope In pressure to 2850 psi (196.5 Bar).
Turning the adjustment clockwise increases pressure,
Turning the adjustment clockwise increases pressure,
turning the adjustment counterclockwise decreases
turning the adjustment counterclockwise decreases pressure.
pressure.
5-128 – JLG Lift – 3121262

JIB LIFT UP JIB LIFT DOWN

1. Install a high pressure gauge at the MJA port.
1. Install a high pressure gauge at the MJB port.
2. Fully extend the jib lift cylinder or cap port JB. 2. Fully retract the jib lift cylinder or cap port JB.
3. Set the Jib Lift Up pressure to 2800 psi (193 Bar). Turning 3. Set the Jib Lift Down pressure to 1200 psi (82.7 Bar).
the adjustment clockwise increases pressure, turning Turning the adjustment clockwise increases pressure,
the adjustment counterclockwise decreases pressure. turning the adjustment counterclockwise decreases
pressure.
3121262 – JLG Lift – 5-129

5.7 DRIVE PUMPS 2. Transmission does not propel the machine, diesel
engine running properly - Charge Pump/Relief Valve
Troubleshooting Procedure a. Is there any charge pressure at port G or indicated
by measuring pressure at Ma and Mb?
To aid in troubleshooting, refer also to the pressure measuring No - Proceed to step 2.d
port connections for test gauge installation information as Yes - Proceed to step 2.b
shown on the hydraulic circuit diagram. Procedure assumes
b. Is the charge pressure at least 500 psi while running
proper gauges are installed. (Minimum gauges required: (2) 0-
at high engine speed?
6000 psi, (1) 0-3000 psi & (1) 0-1000 psi [{2} 0-415 bar, {1} 0-210
No - Proceed to step 2.c
bar & {1} 0-70 bar]). This procedure was written to aid the trou-
Yes - Proceed to step 3.a
bleshooter in following a logical approach to a hydraulic sys-
tem fault. c. Can the charge pressure be raised by removing dirt/
debris from charge relief poppet or by adding or
1. Transmission does not propel the machine, diesel
removing shims from the charge pressure relief
engine running properly
valve mounted in the second pump of the triple?
a. Is there oil in the reservoir? No - Proceed to step 2.d
No - Fill reservoir Yes - Adjust pressure to 500 psi +50 psi, -0 psi (34.4
Yes - If yes, proceed to step 1.b bar +3.4 bar, -0 bar)
b. Is the pump input shaft connected to the engine NOTE: The propulsion circuit uses a hot oil flushing valve to
flex plate or rear of forward pump? obtain brake release pressure. The hot oil flushing valve
No - Connect pump input shaft cartridge (#120) is mounted in the Traction Control Mani-
Yes - If yes, proceed to step 1.c fold. The flushing valve receives its oil from the "left side"
c. Are the hydraulic hoses and tubing connected in wheel drive pump; the middle pump of the triple. With the
accordance with the hydraulic circuit diagram? engine running and propelling the machine forward or
reverse, the "hot oil flushing valve" and the brake release
No - Correct the hoses/tubing pressure must be adjusted to 475 psi, +25 psi, -0 psi (32.7
Yes - If yes, proceed to step 1.d bar, +1.7 bar, -0 bar), as set by adjusting pressure relief car-
tridge (#130). The brake release pressure must be 25 psi less
d. Is the pump direction of rotation correct? (clockwise
than the charge pump pressure. Measure pressure at port
as looking at the shaft)
"MP" using a 0-1000 psi (0 - 70 bar) pressure gauge.
No - Fit pump having the correct direction of rota- d. Is the transmission pumps suction hose pinched
tion shut?
Yes - If yes, proceed to step 1.e No - Proceed to step 2e
e. Are there O-rings missing from fittings (as example - Yes - Repair damaged hose
suction leak), pinched hoses, broken tubing, etc? e. Is the charge pump suction pressure/vacuum within
recommended limits? (0.8 bar absolute or 6.3 inches
No - Proceed to step 1.f of mercury)
Yes - Repair damage or fault No - Proceed to step 2.f
f. Are the electrical connectors/wiring intact and Yes - Proceed to step 2.g
secure to the pump control solenoids? f. Is the suction strainer inside the reservoir blocked,
No - Repair damage or fault clogged, restricted?
Yes - If yes, proceed to step 1.g No - Proceed to step 2.g
g. Does the engine "labor" when attempting drive, are Yes - Repair/replace with a clean suction strainer
the brakes released? g. Is the reservoir air breather blocked or restricted?
No - Proceed to step 1.h No - Proceed to step 2.h
Yes - Check brake release circuit, measure pressure Yes - Clean or replace air breather
at port "MP" on Traction Control manifold
h. Are all four wheel drive planetary reduction gear-
boxes engaged?
No - Engage wheel drive(s)
Yes - If yes, proceed to step 2.a
5-130 – JLG Lift – 3121262

h. Remove charge pressure relief valve from the mid- f. Stroke pump in both directions, while measuring
dle pump and inspect. Is it damaged? pressure at Ma & Mb ports of the pump. Does any
No - Refit cartridge and proceed to step 2.i pressure greater than charge pressure alternate
Yes - Clean & inspect cartridge, poppet, springs, between ports Ma & Mb?
seals to determine cause of damage. Repair or fit a No - Verify that loading the pump will cause system
new cartridge and return to step 2.a pressure to increase above charge pressure. Proceed
to step 3.a
i. Remove and inspect charge pump assemblies. Are
Yes - Proceed to step 3.g
they damaged?
No - Proceed to step 2.j g. Is it possible to adjust high pressure relief valves
Yes - Repair and/or replace damaged components using 0-6000 psi (0 - 415 bar) gauges to monitor
and return to step 2.a pressure at Ma & Mb? (Refer to relief valve adjust-
ment)
j. Is the charge pump installed for the clockwise rota-
No - Replace high pressure relief valve and return to
tion?
step 3.c
No - Refit charge pump. Return to step 2.a
Yes - Adjust high pressure relief valves to 5000 psi
Yes - With proper charge pressure and transmission
+50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
still does not operate, proceed to step 3.a
h. Actuate control in both directions. Does transmis-
3. Transmission does not propel the machine, diesel sion operate?
engine running properly - Pump Control: (Insure Gener- No - Check that minimum displacement stops on
ator Drive option is not turned "on") the wheel drive motors are adjusted properly, check
a. Are the electrical connectors & wiring connected that the motors stroke between maximum to mini-
properly to the pump control solenoids? mum.
No - Connect a ammeter in series with solenoid wir- Yes - Operate the transmission
ing. Is a current of 400 mA to 1060 mA being 4. Transmission Drive is Sluggish or Erratic
applied. (Current signal varies with joystick position)
Yes - Proceed to step 3.b a. Does the "EP" proportional pump control current
vary with joystick movement?
b. Are all four of the two-speed motors, mounted in No - Rectify the problem - broken wires, electrical
the wheel drive planetary reduction gearboxes, connector, open solenoid coil, etc.
shifted to maximum displacement (high torque - Yes - Proceed to step 4.b
low speed)?
No - Select maximum displacement b. Are all four (4) brakes fully released?
Yes - Proceed to step 3.c No - Check brake release pressure and insure each
wheel receives correct release pressure.
c. Actuate the pump control in both directions. Do the Yes - Proceed to step 4.c
pumps stroke? Do they go to full stroke?
c. Are the pumps stroking time orifices installed tight
No - Refer to the pump service manual and then
and clean?
proceed to step 3.d
No - Remove the Plugs in ports X1 and X2. Remove
Yes - Operate the transmission
orifices with a 3mm allen wrench. Check that orifices
d. Remove stroking orifices in X1 and X2. Install pres- are clean & re-install.
sure gauges in X 1 and X 2 (0-500 psi [0 - 35 bar]). Yes - Proceed to step 4.d
Stroke the pump in both directions. Do the pres- d. Is an motor displacement stroking time orifice
sures at X1 and X2 alternate between 30 & 250 psi (2 plugged or is the two-speed shift hose pinched?
& 17 bar)? Yes - Inspect and clean stroking orifice, check two-
No - Remove the EP control module & replace it with speed hose routing
a new unit. Repeat step 3.c
e. Is a flow divider/combiner cartridge stuck in the
Yes - Proceed to step 3.e.
Traction Control Manifold? Flow divider/combiner
e. Is the pressure at port "R", case pressure, less than 15 cartridge # 111 controls the right side wheels, # 112
psi (1 bar) gauge pressure? controls the left side wheels. Also check to insure
No - Correct problem restricting case drain oil flow bypass orifices #151 (right side) and # 152 (left side
(oil cooler blockage, pinched hoses, etc.) are not plugged.
Yes - Proceed to step 3.f
3121262 – JLG Lift – 5-131

5. Transmission Drives in one direction only 7. Transmission Does Not Find or Hold Neutral
a. Are electrical connections to pump control propor- a. Does pump remain in neutral with electrical con-
tional solenoids correct, intact and without defects? nectors removed?
Yes - Proceed to step 5.b No - proceed to step 7.b
No - Rectify the problem Yes - Check electrical system for signal problem
b. Check hot oil flushing valve cartridge #120 located b. With electrical connectors removed and machines
in the Traction Control Manifold. wheels jacked off the ground and engine running,
Remove and inspect flushing valve cartridge for momentarily apply 12 volt DC signal (battery volt-
stuck spool or damaged cartridge O-ring seals & age) to a pump control solenoid. Does the pump
backup rings. return to neutral after the 12 volt signal is removed?
No - Apply 12 volts to opposite solenoid & recheck.
c. Inspect "Make-Up" check valve cartridges, #190.1- No - Replace pump control module, repeat step 7.a
190.4, installed in the Traction Control Manifold. Is a Yes - Possibly dirt was dislodged from control mod-
cartridge "stuck" open with debris or is an O-ring ule, re-check thoroughly to determine problem has
failed? definitely been resolved.
No - Proceed to step 5.d
Yes - Clean/repair or replace Make-Up check car- c. Check mechanical centering of the pumps
tridge. 8. Transmission Drives at a High Noise Level
d. Swap high pressure relief valves in the transmission. a. Are the wheel drive planetary reduction gearboxes
Does the transmission drive in the other direction? filled to the correct level and do they have the
No - Proceed to step 5.e proper lubricant?
Yes - Repair/clean/adjust or replace high pressure No - Fill gearbox with correct grade of oil to the pre-
relief valve on the non-driving side scribed level.
e. Replace "EP" control module. Does pump operate Yes - Proceed to step 8.b
properly? b. Is the engine flex plate and drive coupling correctly
No - Replace or repair pump installed and aligned with the transmission pump?
Yes - Operate the transmission No - Install flex plate and bell housing per manufac-
turer's instructions
6. Transmission Drives in Wrong Direction Yes - proceed to step 8.c
a. Check to see if electrical connectors or wiring have c. Is a rigid item or object contacting the resilient
been swapped on the pump. mounted engine/pump assembly?
b. Check to determine want end of the machine the No - Proceed to step 8.d
boom is swung over. Yes - Insure no item is contacting the unit, transmit-
ting air borne noise.
d. Is the suction pressure/vacuum at the charge
pumps inlets within recommended limits?
No - Return to step 1.h
Yes - Proceed to step 8.e
e. Is there air in the hydraulic fluid? This may be indi-
cated by foaming or milky colored oil.
No - Proceed to step 8.f
Yes - De-aerate the oil and inspect system for cause
of air induction. Check for loose or missing O-rings
on face seal connections.
5-132 – JLG Lift – 3121262

f. Is a wheel drive hydraulic motor operating at exces- 11. Transmission Pump(s) Do Not Develop Maximum Horse-
sive speed? power (Flow & Pressure)
Yes - Check minimum displacement stop screw
adjustments on the motors. Should be 0.433" or a. Does the charge pump pressure meet specification?
11mm above the stop screw lock nut. Is one or more No - Return to step 2.a
motors "stuck" at minimum displacement, check for Yes - Proceed to step 11.b
plugged/blocked two-speed stroking orifice(s).
b. Does the pump case pressure exceed 15 psi gauge
9. Transmission Operates at a Higher than Normal Temper- pressure?
ature
No - Proceed to step 11.c
a. Is the reservoir temperature above 195oF (90.5° C)? Yes - Check case drain hoses, oil cooler, etc. for
No - 195oF (90.5° C) is the upper limit. If temperature pinched or restricted oil flow
is over 195oF (90.5° C), the oil cooler may need to be c. Are the pump(s) high pressure cross port relief
cleaned. valves adjusted to the required pressure (5000 psi)
Yes - Proceed to step 9.c so they do not bypass prematurely?
b. Are the hydraulic motor(s) stalling (wheels not turn- No - Inspect/clean/adjust and or replace valve car-
ing) intermittently? tridge
No - Proceed to step 9.c Yes - Replace the pump, after blocking the "A" & "B"
Yes - Hydraulic fluid is being heated through system ports, running the pump and measuring pressure
pressure relief valves. Shut down system and rectify developed at "A" & "B". This must be done to insure
the cause of motor stall. that flow & pressure loss in not elsewhere in the sys-
tem. (motors, swivel coupling, etc.)
c. Does oil temperature remain above 195oF (90.5° C),
after cleaning the oil cooler? d. Is the diesel engine capable of developing horse-
No - Operate transmission. Check oil cooler more power at design rpm?
often. Follow recommended troubleshooting procedures
Yes - Proceed to step 8.a to insure the engine is developing full power at
10. Transmission Operates at a Higher than Normal Temper- specified rpms.
ature
a. Check for differential temperature across the oil Charge Pressure Relief Valve Adjustment
cooler. Is there a temperature difference?
No - Check to determine if the bypass check valve
(10 psi [0.7 bar] crack pressure) is stuck open. Check
to determine if the oil cooler is restricted internally,
causing oil flow to pass across the bypass check
valve.
Yes - Proceed to step 8.b
NOTE: Oil cooler flow is received from the transmission pumps

cases, max. continuous pump case pressure is 15 psi gauge
pressure. Higher pressure will prematurely damage pump
shaft seals
b. Disconnect pump case drain from oil cooler & check CHARGE RELIEF
flow rate from charge pumps. Is the flow rate 3.8
GPM (14.4 LPM) with diesel idle speed of 1200 rpm?
With a low pressure (0 – 1000 psi [0 - 70 bar]) pressure gauge
No - Refer to charge pump removal & inspection
tee’d into the ”G” port or two (2) low pressure gauges installed
procedure
into ”Ma” and ”Mb”, run pump at engine idle speed. Do not
place the pump on stroke – low pressure gauges installed in
”Ma” & ”Mb” will be damaged! Prior to adjusting pressure,
insure charge pressure relief valve is clean of any dirt or debris.
The charge pressure relief valve does not wear appreciably
over time. If charge pressure was normal and then has
decayed, check for other causes of low charge pressure. If pres-
sure is low, remove relief valve and add shim(s). If pressure is
high, remove relief valve and take out shim(s).
3121262 – JLG Lift – 5-133

NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules
able in 0.3, 0.5, and 1.0 mm thickness.
PREPARATION FOR ADJUSTMENT

When control modules are exchanged or replaced, it is gener-
ally necessary to center the new module. This is done by run-
ning the pump with gauges installed at ports X1, X2, MA, and
MB Release the jam nut and turn the adjustment screw on top
of the control module valve body.
Mechanical Centering of Pump
PREPARATION FOR ADJUSTMENT

The control piston has strong centering springs to ensure that
once the pump is adjusted for the neutral position it will
always return to neutral. If an adjustment is necessary follow
the steps listed below.
To ensure there is equal pressure on both sides of the control
module during the centering operation, it is necessary to con-
nect the X1 and X2 ports together by means of hose or tubing.
(No less than a 1/4 inch ID) The port sizes are:
Pump Size Allen Wrench Wrench
28 5 mm 17 mm
With pressure gages installed at MA, and MB, and with A and B
ports blocked (or motor stalled), and with the pump running, The adjustment screw is an eccentric, therefore, turning more
loosen the jam nut. Turn the mechanical centering adjusting
than 90’ in either direction will have no further centering
screw until 1000 psi is read on MA, or MB then turn screw
opposite direction until 1000 psi is read on other pressure effect, and could cause damage to the eccentric pin.
port. Turn the screw back, splitting the distance between the Pump Size Tool Required Wrench
previous two positions. This should be the neutral position.
28 Screwdriver 10 mm
Pressure on MA, and MB should be equal.
CENTERING THE EP CONTROL MODULE

With no electrical signal to solenoids A and B, (remove both
plug-in connectors), the EP control module is correctly
adjusted when any or all of the following conditions exist:
1. Approximately, when equal control pressures are

obtained at control pressure ports X1 and X2.
2. The hydraulic motor does not turn when the brake is

released.
3. Charge pressure is registered equally at ports MA and

MB, when the flow output of the pump is deadheaded
against a locked motor or a valve.
Tighten jam nut, stop the pump drive, remove the hose con- If difficulties are encountered in obtaining neutral position of
necting ports X1 and X2. the HD or EP control modules, check that the ends of the con-
5-134 – JLG Lift – 3121262

trol spring are correctly located in the grooves near the end of Removal and inspection of charge pump
the feedback lever arms.
Before removing cap screws, mark the position of the charge
pump housing and separator plate in relation to the port
block.
High Pressure Relief Valve Adjustments

1. Remove relief valve cover from pump (ref. item 1).
Loosen screws with metric allen wrench.

Pump Size Allen Wrench
28 8 mm
2. Loosen jam screw (ref. item 2).

3. Holding spring loading nut (ref. item 4) rotate valve
spindle (ref. item 3). For high range relief valve, one turn
equals approximately 630 psi (44 bar). For low range
relief valve, one turn equals approximately 377 psi (26
bar).
4. After adjustment is completed torque jam screw (ref.
item 4) to 5 ft.lb. (7 Nm). Remove charge pump housing and inspect for wear or dam-
5.Install relief valve assembly into pump, reinstall cover age to gear set and 0-ring seals. Grease 0-rings prior to reas-
(ref. item 1) to proper torque.
Table 5-6. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque

28 32 mm 66 ft.lb. (90 Nm)
3121262 – JLG Lift – 5-135

sembly. Make sure 0-rings are completely seated in their Routine Maintenance
grooves.
The Variable Displacement Hydrostatic Transmission Pumps
are relatively maintenance free. Maintenance work is confined
to the system, by way of maintaining hydraulic fluid condition,
the "life blood" of the machine. Oil monitoring, changes and
filter renewal promote system cleanliness. This will prevent
premature breakdown and repairs. Under normal application
conditions, the following maintenance intervals are sug-
gested:
1. Renewal of Filter Elements
a. After commissioning or re-build.
b. At every 500 operating hours or when filter indica-
tor shows a dirty element.
c. With the suction strainer, the strainer should be
renewed as soon as charge pump inlet pressure is
less than -3.2 psi, 6.3"Hg or 0.8 bar absolute.
d. Only JLG recommended filter elements are to be
used. Paper elements cannot be cleaned; use throw-
Withdraw pinion shaft and inspect gear teeth and bearing sur- away cartridges.
faces for abnormal wear. 2. Hydraulic Fluid Change
When reassembling, make sure chamfer (on outer edge of
a. After 2000 operating hours (1st oil change)
driven gear and drive gear) is installed into housing per illus-
tration. b. Thereafter, every 2000 operating hours or annually,
irrespective of operating hours achieved.
c. Oil change should be performed with the system in
warm running condition. Before re-filling, the reser-
voir interior should be inspected and cleaned to
remove any sludge.
d. Rags or threaded material must not be used.
e. This machine has been designed & manufactured to
operate on an Exxon-Mobil Oil Co. hydraulic fluid,
Mobilfluid #424, Product #52233-4. Consult JLG
Industries prior to introducing any other type of
fluid to prevent interaction or possible contamina-
tion.
f. The recommended interval between oil changes is
based on various factors and should be carried out
Torque value for bolts when replacing charge pump. according to the degree of aging, contamination
Pump Size Torque and water content.
28 18 ft.lb. (24 Nm)
NOTE: If serious wear or damage has occurred to one component,

the complete charge pump assembly must be replaced
because they are matched components.
5-136 – JLG Lift – 3121262

g. Under application conditions with a heavy occur- b. The air/oil cooler surfaces and engine radiator
rence of dust or severe temperature fluctuations, should be cleaned at the same time.
the intervals between fluid maintenance should be
shortened accordingly. c. If hose connections are disassembled, it is impera-
tive that the utmost care be taken that no foreign
bodies infiltrate the oil circuit. Catastrophic compo-
nent failure may occur.
PRACTICAL EXPERIENCE SHOWS THAT MOST FLUID MAIN-
TENANCE ERRORS OCCUR DURING AN OIL CHANGE DUE 5. Oil Level Inspection
TO:
a. Inspect oil level in the reservoir daily.
• USE OF AN UNSUITABLE HYDRAULIC FLUID b. If "topping off" is required, use only the same Mobil-
fluid #424, Product #52233-4.
• USE OF OIL CONTAMINATED DUE TO POOR STORAGE PRACTICES
• FAILURE TO CLEAN THE RESERVOIR c. Do Not Mix Fluids.
• INADEQUATE CLEANLINESS WHEN FILLING THE RESERVOIR (DIRTY 6. Hydraulic Fluid - The "Life Blood" of the Machine
DRUMS, CONTAINERS, WATER, ETC)
a. The type of hydraulic fluid supplied in the machine
3. Leakage Inspection from the factory was selected after extensive testing
and development. The fluid was selected to perform
a. After commissioning
under "most" applications and conditions. Should
b. The complete transmission drive system (pumps, this machine be in service for extended time peri-
motors, hosing, filters, valves, etc.) should be ods at the extremes (hot or cold), JLG should be con-
checked for leakage at regular intervals. sulted for assistance in selection of the most
c. Leaking joints & connections must only be tight- suitable fluid type and grade for your application.
ened when pressureless.
b. When operating at temperatures below 0oF, allow a
4. Cleanliness Inspection warm-up period, if at all possible, to a temperature
a. The oil tank breather should be regularly cleaned of of 40oF.
dirt and dust to prevent clogging. With each cylin-
c. When beginning motion of a "cold" machine, oper-
der movement, gallons of oil pumped, an equal
ate all functions at reduced speeds until the "cold"
amount of air exchange occurs across the reservoir
oil has circulated out of the drive loop.
breather. A dirty or clogged breather will affect all
machine functions!
3121262 – JLG Lift – 5-137

Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap
ring.
Remove the retaining ring with snap ring pliers.
Screw in sheet metal screw into the holes fitted with rubber.
Pull out shaft seal with pliers.
5-138 – JLG Lift – 3121262

5.8 FUNCTION PUMP
Figure 5-143. Function Pump - Sectional View
Spare Parts 2. Drive Shaft
1. Sealing kit, existing spare parts: shaft sealing ring, o-

rings, and a circlip.
3. Bearing set, miscellaneous parts.
3121262 – JLG Lift – 5-139

4. Rotary Group complete: 9 pistons, cylinder subassem- Sealing the Drive Shaft
bly, valve plate, retaining plate, and retaining ball.
BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED

DURING THE REMOVAL OF THE SHAFT SEALING RING.
1. Remove the snap ring.
5. Swash Plate.
2. Change the shaft seal and check its sliding surface (drive
shaft) and housing. Grease the sealing ring.
6. Parts of the control valve: control piston, piston rod,

plug, spring stopper max flow, hex nut, and hex head
nut.
3. Be careful while you seal the drive shaft. Use an adhesive

tape to prevent the shaft splines from damaging the
seal.
7. DFR pilot valve.
5-140 – JLG Lift – 3121262

4. Assemble the sealing ring, fitting tool holds the correct 2. Mark the position of the port plate and remove the
position of the sealing ring in the pump housing. socket screw of the port plate.
5. Assemble the snap ring. 3. Remove the port plate together with the valve plate
(hold the valve plate so the plate can’t fall down).
6. Assemble the snap ring in the correct position.

4. Remove the o-ring.
Disassembly and Assembly of the Complete Unit

5. Disassemble the taper roller bearing (nearby port plate).
1. Disassemble the pilot valve.
3121262 – JLG Lift – 5-141

6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position.
7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow.
8. Loosen the fixing nut of the stopper max flow and disas- 12. Remove the threaded pin.
semble it.
13. Disassemble the plug.

9. Turn in the stopper max flow to get swivel angle zero.
5-142 – JLG Lift – 3121262

14. Disassemble the control piston while moving the swash 18. Remove both bearing shells.
plate.
19. Remove the drive shaft.

15. The swash plate must be lifted a little bit to disassemble
the piston rod.
20. Disassemble the snap ring.
16. Remove the swash plate.
21. Disassemble the sealing ring.
17. Remove the spring.
3121262 – JLG Lift – 5-143

22. The external front bearing ring is pulled out of the pump 25. The spring has additional pretension while you disas-
housing. semble the three pressure pins inside the cylinder.
23. Remove the o-ring. Lifting of the valve plate isn’t shown.
Assembly
1. Measurement of the taper roller bearing pretention.
24. A bearing puller is used to disassemble the external

bearing ring of the taper roller bearing inside the port
plate. Take care of the surface of the port plate.
2. Ensure there is a correct connection of the piston rod
and the swash plate.
5-144 – JLG Lift – 3121262

3. Pumps clockwise driven must have a position of the Adjustments

valve plate 4 degrees out of center in the same direction
de-centered like drive direction. TAPER ROLLER BEARING INITIAL TENSION
Cast Iron pump housing must have initial tension of the bear-
ings: 0 to 0.05 mm.
4. Pumps counterclockwise driven must have a position of

the valve plate 4 degrees de-centered in the counter-
clockwise position.
MECHANICAL FLOW LIMITER

Differential volume if you are rotating the threaded pin - each
rotation is approximately 3.1 cm3.
5. Note the correct position of the drilling that connects Tightening Torques
high pressure to the control valve. Check control valve
drilling position at the pump housing and fit together. For break-off plugs, use Loctite #601.
For all other parts, use Loctite #242.
Table 5-7. Tightening Torques
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8.8 2.3 5.0 8.5 21 41 72 115 176 240 350 600 1220
10.9 3.2 7.2 12 29 58 100 165 250 350 490 840 1670
12.9 4.1 8.5 14.5 35 70 121 195 300 410 590 990 2000
3121262 – JLG Lift – 5-145

Figure 5-144. Function Pump, Pressure and Flow Control - Sheet 1
5-146 – JLG Lift – 3121262

Pump Control Disassembly For Cleaning 3. Hydraulic fluid may drip from the pump. Wiping the sur-
face clean and installing some adhesive tape should pre-
NOTE: If the Function Pump does not perform correctly after vent oil from seeping from the pump control.
following the pre-start start-up procedures, it is possible that a 4. Work on a clean, lint free area.
contaminate particle has lodged in the pump control prevent-
ing proper operation. The pump control’s internal parts are NOTE: The pump control can be equipped with either O-rings or a
not provided as spare parts due to the close tolerances sealing plate. These components are NOT interchangeable.
required between the mating parts. However, the control can
5. Remove the three (3) ”0”-rings (Parker # 2-011, Viton 90
be disassembled, cleaned and placed back in service should
shore)
the only problem prove to be contamination. Disassembly,
inspection, cleaning and reassembly MUST BE done in a clean 6. Remove both the adjustment hex caps and bonded seal
well-illuminated area. rings. (17 mm wrench)
Pump Control removal: 7. Remove both the adjustment lock nuts and bonded seal
rings. (17 mm wrench)
1. Disconnect plug the hose attached to the pump control 8. Remove both the adjusting screws. (3-mm Allen
Port ”X”. wrench)
2. Remove the four (4) socket head cap screws that attach 9. Remove the spring cover hex cap for the ”outer” flow
the control to the pump. Insure that the three (3) ”0”- regulation adjustment this requires a 19-mm wrench.
rings are also removed with the control.
3121262 – JLG Lift – 5-147

10. Remove the spring disc. 21. Inspect the housing for contamination or plugged ori-
fices. Clean orifices carefully with a dead soft steel wire
11. Remove the adjusting springs (two springs, one to insure they are open. Inspect all parts for burrs, scor-
”nested” inside the other) and spring follower. ing, debris, etc.
12. The flow regulation spool should slide from the control NOTE: On the mounting surface of the control housing, between
housing, (a magnet should aid in removal). If it does not, the oil ports is what appears to be a slotted head screw. IT
remove the hollow hex head plug at the rear of the flow IS NOT A SCREW. This is a bleed orifice, which must be ori-
regulation spool and carefully push the spool from the entated to allow proper control operation. The slot in the
housing - do not scratch/mar the spool’s bore. head should be oriented to fall in-line with the oil ports,
13. Remove the spring cover hex cap for the ”inner” pres- NOT PERPENDICULAR to the oil ports. If the slot is oriented
sure compensation adjustment – this requires a 30-mm perpendicular to the three ports, the pump pressure will
wrench. not return from load pressure to stand-by pressure at the
end of operating a function! The pump pressure will
14. Remove the spring disc. remain at the last highest pressure generated.)
15. Remove the adjusting springs (two springs, one
22. After all parts are clean and dry, lightly oil a control
”nested” inside the other).
spool and install in its bore. The spool must slide
16. Remove the spring follower. smoothly and easily within the housing. If it does not,
check for contamination. If contamination cannot be
17. The pressure compensation spool should slide from the found check for ”scoring” or ”burring” of the control
control housing, (a magnet should aid in removal). If it housing. If the spool does not slide smoothly & freely,
does not, remove the hollow hex head plug at the rear the control must be replaced with a new unit.
of the flow regulation spool and carefully push the spool
from the housing - do not scratch/mar the spool’s bore. 23. Lightly oil and check operation of the second spool. The
spools are installed correctly when there ”pointed” end
18. The spools are identical. faces the spring followers
19. Wash the housing and all parts in a clean JLG approved 24. Re-assemble in reverse order.
solvent such as non-chlorinated brake cleaner, Stoddard
solvent, etc. 25. Bench set the pressure adjustments as described in ”C.
4” of the Operating Instructions.
20. Blow off all the parts with clean, dry compressed air.
NOTE: The pump control can be equipped with either O-rings or a
sealing plate. These components are NOT interchangeable.
26. Re-install on the Function Pump, insure the ”0”-rings are

installed properly and tighten the four (4) M6 socket
head cap screws to 105 inch pounds.
5-148 – JLG Lift – 3121262

5.9 DRIVE & FUNCTION PUMP START UP The middle transmission pump also supplies oil to a hot oil
flushing valve cartridge, #120, in the Traction Control Mani-
PROCEDURES fold. This cartridge provides a means to obtain brake release
oil pressure. The brake release pressure is controlled by a pres-
Start-Up Procedure sure relief valve cartridge # 130 and a solenoid operated brake
release directional control cartridge, #170, also located in the
The Boom Lift utilizes a Triple Combination Pump coupled to Traction Control Manifold. This is important to note as the
the Deutz diesel engine. The pumps are connected in-line to brake release oil pressure must be set 25 psi (1.7 bar) below
each other as follows: the boost oil pressure relief valve. If the brake release pressure
1. The front hydrostatic transmission pump, or drive pump, is set too low, brake drag and pump control will be affected. If
is coupled directly to the diesel engine and provides oil set too high, damage to the wheel drive parking brakes could
flow to operate the machine's right side wheels. result. Prior to start, connect appropriate pressure gauges to
the unit.
2. The middle hydrostatic transmission pump, or drive
pump, is coupled to the back of the front pump and pro- FOR THE START-UP OF NEW OR OVERHAULED INSTALLA-
vides oil flow to operate the machine's left side wheels. TIONS:
3. The third or rear pump is the function pump. It is cou- 1. Insure all electrical checks have been performed & the
pled to the back of the middle pump and provides oil machine is set up correctly with the JLG Analyzer.
flow to operate the boom, axle, steer and platform func-
2. Insure the machine has all four wheels jacked & blocked
tions.
off the ground per JLG procedures.
The transmission pumps share some common connections.
3. Insure the triple pump assembly is installed and con-
Each pumps charge oil suction ports are connected by steel
nected correctly per the hydraulic circuit diagram.
tubing, the charge pumps discharge oil flows are connected
and flow to a common charge pump inline oil filter, cleaned & 4. Disconnect the electrical connector from the diesel's
filtered oil flows back to the transmission pumps "G" ports. The throttle actuator, to prevent engine start.
pumps case drain ports are connected (T1 & T2), oil flow from
5. Crank the engine until charge pressure reaches 50 psi or
the middle pumps T1 port also provides flows to the oil cooler.
more.
The charge pumps oil pressure is regulated by a single boost
oil pressure relief valve installed in the middle pump. The front 6. Re-connect throttle actuator electrical connector and
pump has an orifice cartridge (0.047" diameter) installed in start engine. Allow engine to run at idle speed only for at
place of a charge oil pressure relief cartridge. This insures that least 5 minutes. This will allow the hydrostatic system to
only one valve controls charge pressure & provides an amount filled.
of charge oil flow to the front pump's case to insure flushing &
removal of hot oil. 7. Listen for any abnormal noises.
Each pump has its own separate electrical proportional direc- 8. Check for oil leaks.
tional control valve to control oil flow and direction. The sig- 9. Check charge pressure (500 psi +50psi, - 0 psi [34.4 bar
nals or command values to each pump are similar except +3.4 bar, - 0 bar]). Pressure can be measured a pump
when steering. During steering and propel of the machine the ports Ma & Mb or by "teeing" into the inlet for the
pump supplying oil to the "inside turning radius" has a com- charge oil filter. Charge pressure is checked with the joy-
mand less than the pump supplying oil flow to the "outside stick in neutral. A 0-1000 psi (0-70 bar) pressure gauge
turning radius" pump. must be used. (If pressure gauges were installed in Ma &
"Posi-Traction" control, front to rear on a given side of the Mb to check charge pressure, disconnect the gauges
machine, is accomplished by a flow divider/combiner car- installed in Ma & Mb, as they will be damaged if loop
tridge installed in the Traction Control Manifold. There is a flow pressure rises above 1000 psi [34.4 bar].)
divider/combiner for each side. Each flow divider/combiner
also has a "bleed orifice" to limit the amount of flow splitting
or combining.
3121262 – JLG Lift – 5-149

10. Operate the drive system in the "turtle mode", forward 17. Check oil level & temperature.
and reverse. 18. Remove and inspect charge pressure oil filter, replace
11. De-aerate the system by bleeding fluid from the Ma & with new element.
Mb ports. 19. Operate the transmission under no load conditions for
12. Switch the drive mode speed control from "turtle" to about 15 minutes to stabilize the temperature and
"rabbit". Gradually increase drive speed forward & remove any residual air from the fluid.
reverse, still with no load - wheels off the ground. 20. Set the machine back on the ground. Operate the trans-
13. With the joystick in neutral, check for creep in neutral. If missions under full and normal conditions.
evident, most likely dirt is present in the proportional 21. Erratic operation may indicate there is still air trapped in
pump control, an incorrect electrical signal is present on the system. By working the pump controls forward and
the pump's electrical control(s) or the control was not reverse the remaining air can be eliminated. The system
centered properly when overhauled. See service manual is free of air when all functions can be operated
for centering instructions. smoothly and when the oil in the reservoir is no longer
14. Check that the controls are connected so that the trans- aerated. (Usually less than one hour of operation)
missions operate in the correct direction related to con-
trol input. NOTE: If the transmissions do not perform correctly after follow-
ing the pre-start & start-up procedures, refer to the relevant
15. Continue to monitor all pressure gauges & correct any sections of the trouble-shooting procedures.
irregularities.
16. Remove the brake coil (leaving the electrical connection
intact) from the brake release solenoid cartridge located
on the Traction Manifold. This disables the machine's
ability to release the brakes! Stroke the transmission
pumps slightly (less than 20%) and check the setting of
the high pressure cross port relief valves. Setting should
be 5000 psi +50 psi, - 0 psi (344.7 bar +3.4 bar, -0 bar).
Install 0-6000 psi (0 - 415 bar) gauges on Pump ports Ma
& Mb.
5-150 – JLG Lift – 3121262

3121262 – JLG Lift – 5-151

Figure 5-147. Hydraulic Schematic - Sheet 1 of 10
5-152 – JLG Lift – 3121262

1001120628-F
3121262 – JLG Lift – 5-153

5-154 – JLG Lift – 3121262

1001120628-F
3121262 – JLG Lift – 5-155

M14 M14
Front Rear
C2 C1
Drive C1 C2 Drive
Pump Pump
M3 MB MC E
F00B F00A F00B F00A
L3
L1
CW CW
M5 M4 L2 MA A B C D MD M5 M4
To port B, Main control

valve, page 1.
To port T2, main control

valve, Page 1
PORT PORT PORT PORT PORT PORT PORT

#7 #6 #5 #2 #1 SWIVEL PORTS #4 #3
REAR AXLE
LEFT A2
D MP B2
MOTOR
A3 A4
B
G1 G
500 PSI
B3 B4
LOP
TRACTION
MANIFOLD
MLOP
A5 A6
B G1 G P2
P1
B1 STEER
BRAKE 2-SPEED
B5 B6
P4 P3 MBR BR TS A1
See Sheet #2
"P" Port
Steer Valve
See Sheet #2
"P" Port FRONT DRIVE
REAR DRIVE Steer Valve
BRAKES BRAKES
5-156 – JLG Lift – 3121262

Front Pump
Fire coil C1; flow to port A, measure at port M4 CHARGE PUMP FILTER
Fire coil C2; flow to port B; measure at port M5 B5 >= 200
Rear Pump BYPASS 50 PSI
Fire coil C1; flow to port C; measure at port M4
Fire coil C2; flow to port D; measure at port M5
CHARGE PUMP
1.025 in3
30 Mesh
3 PSI Bypass
Oil Cooler Option

Port L3 of the pump
to the inlet of the
cooler. Cooler outlet
back to tank.
PORT
#7
FRONT AXLE
LEFT
MOTOR
B V V
G
G1
P P
L
L1
A
OSCILLATING
AXLE CIRCUIT
B
DRIVE SYSTEM
G
G1 SAUER/DANFOSS
L
PUMPS
L1
A
1001120628-F
3121262 – JLG Lift – 5-157

FRONT DRIVE MIDDLE DRIVE CHARGE PUMP FILTER

PUMP PUMP B10 >= 1000
2.75 in3 2.75 in3 BYPASS 43 PSI
T P T P
PS B A G Fe PS B A G Fe
MB MB B
5000psi 5000psi
550
psi
MA MA A
R,T1,T2 R,T1,T2
A B S S
X1 X2 X1 X2
Suction
Strainer
60 Mesh
Oil (238 Micron)
Cooler 3 PSI Bypass
PORT PORT PORT PORT PORT PORT PORT

#7 #6 #5 #2 #1 SWIVEL PORTS #4 #3
REAR AXLE
LEFT A2
D MP B2
MOTOR
A3 A4
B
G1 G
500 PSI
B3 B4
TRACTION LOP
MANIFOLD
MLOP
A5 A6
B G1 G P2
P1
B1 STEER
BRAKE 2-SPEED
B5 B6
P4 P3 MBR BR TS A1
See Sheet #2
"P" Port
REAR DRIVE Steer Valve
BRAKES See Sheet #2
"P" Port
Steer Valve
5-158 – JLG Lift – 3121262

PORT
#7
FRONT AXLE
LEFT
MOTOR
B V V
G
G1
P P
L
L1
A
OSCILLATING
AXLE CIRCUIT
FRONT DRIVE
B BRAKES
G
G1
L
L1
A DRIVE SYSTEM
REXROTH PUMPS
1001120628-F
3121262 – JLG Lift – 5-159

C1 C2
JIB STOW ROTATOR

66 CU IN
10:1 PILOT RATIO
SPRING 3300 PSI
V1 T V2
JIB TELESCOPE CYLINDER

BORE 2.5" 4.91 sq in
ROD 1.5" 1.78 sq in JIB LIFT CYLINDER
JIB LEVEL CYLINDER ANNULAR 3.14 sq in BORE 5" 19.63 sq in
BORE 5.5" 23.76 sq in STROKE 118" ROD 2.5" 4.91 sq in
ROD 2.5" 4.91 sq in RATIO 1.56:1 ANNULAR 14.73 sq in
ANNULAR 18.85 sq in STROKE 25.15"
STROKE 16.59" RATIO 1.33:1
RATIO 1.26:1
V2 V1
V2 V1
V1 V2
MTB
MLA MLB MTA MJA
LA LB TA TB SA SB JB MJB
JA
+0 +0
2600 - 50 3000
PSI - 50 +50
PSI +50
1200 2800 -0
-0
+50 PSI PSI
1500 +50 3000 - 0
PSI - 0 PSI
T3 0.3 2.0
GPM GPM
T2
T1
TO GR
PORT ON
MAIN
CONTROL
VALVE
MP
TO PORT ON
HIGH PRESSURE
FILTER
P1
JIB CONTROL VALVE

P2
5-160 – JLG Lift – 3121262

PLATFORM ROTATOR
14.1 cu in
3:1 PILOT RATIO
SPRING 3000 PSI
PLATFORM LEVEL CYLINDER C1 C2

BORE 3.5" 9.62 sq in JIB LOCK CYLINDER
ROD 1.5" 1.76 sq in BORE 2.5" 4.91 sq in
ROD 1.75" 2.41 sq in
ANNULAR 7.85 sq in
ANNULAR 2.50 sq in
STROKE 14.79" STROKE 13.375"
RATIO 1.23:1 RATIO 1.96:1
V2
V1 T V2
V1
L1 L2 ML2
ML1 R1 R2 S2
S1
2000 + 0
PSI - 50
2500 +50 2000 +50

PSI - 0 PSI - 0
0.2
GPM
T2
T1
MP 2.0
GPM
P PLATFORM CONTROL VALVE
JIB BOOM FUNCTIONS
1001120628-F
3121262 – JLG Lift – 5-161

NOTES:
5-162 – JLG Lift – 3121262

SECTION 6. JLG CONTROL SYSTEM
6.1 JLG CONTROL SYSTEM ANALYZER KIT viewing and adjusting the various personality settings for
smooth control of: acceleration, deceleration, creep, min
INSTRUCTIONS speed, and max.-speed for all boom, drive, and steering func-
tions.
Introduction
The main lift, swing, and drive are controlled by individual joy-
sticks, with steering being controlled by a rocker switch built
into the top the drive joystick. To activate Drive, Lift, and Swing
WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON THE MACHINE, IT simply pull up on the slide lock location on the joystick and
WILL BE NECESSARY TO PROGRAM THE CONTROLLER FOR THE PROPER move the handle into the direction desired.
MACHINE CONFIGURATION, INCLUDING OPTIONS.
The control system will control the voltage output to the
valves and pump, as programmed for smooth operation and
maximum cycle time. Ground control speeds for all boom
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- functions can also be programmed into the control system.
TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUS- The JLG Control System controller has a built in LED to indicate
TRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A any faults. The system stores recent faults which may be
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO- accessed for troubleshooting. Optional equipment includes a
NENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING soft touch system, head and tail lights, and ground alarm.
MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SAT- These options may be added later but must be programmed
URATION. into the control system when installed.
The Control System may be accessed utilizing a custom

The JLG designed Control System is a 12 volt based control designed, hand held analyzer (Analyzer Kit, JLG part no.
unit installed on the boom lift. 2901443) which will display two lines of information at a time,
The JLG Control System has reduced the need for exposed ter- by scrolling through the program.
minal strips, diodes and trimpots and provides simplicity in
Analyzer Display
Enter Key
Escape Key
Stores and selects Top Level, Sub
To return home or access pre-
Level, and item menus
vious menu
Left & Right Arrow Keys

Up & Down Arrow Keys
Used to move between Top Level, Sub
Value Selector
Level, and item menus
Figure 6-1. Hand Held Analyzer
3121262 – JLG Lift – 6-1

To Connect the JLG Control System Analyzer Using the Analyzer

1. Connect the four pin end of the cable supplied with the With the machine power on and the analyzer connected prop-
analyzer, to the motor controller module located in the erly, the analyzer will display the following:
platform box or at the power module and connect the
remaining end of the cable to the analyzer.
NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards.
2. Power up the Control System by turning the lower key to

the platform or ground position and pulling both emer-
gency stop buttons on.
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow

keys, you can move between the top level menu items. To
select a displayed menu item, press ENTER . To cancel a
selected menu item, press Escape ; then you will be able

to scroll using the right and left arrow keys to select a different
menu item.
6-2 – JLG Lift – 3121262

The top level menus are as follows: When a top level menu is selected, a new set of menu items
may be offered: for example:
HELP
DIAGNOSTICS DRIVE
ACTIVATE TEST BOOM
ACCESS LEVEL SYSTEM
PERSONALITIES DATALOG
MACHINE SETUP VERSIONS
LEVEL VEHICLE (level 1 only)
CALIBRATIONS (view only)
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected menu. In
If you press ENTER , at the HELP: PRESS ENTER display, some cases, such as DRIVE, the next level is the parameter or
and a fault is present, the analyzer display will scroll the fault information to be changed. Refer to the flow chart for what
across the screen. If there was no fault detected, the display menus are available within the top level menus. You may only
will read: HELP: EVERYTHING OK. If powered up at the view the personality settings for selected menus while in
ground station, the display will read: GROUND OK. access level 2. Remember, you may always cancel a selected
If ENTER is pressed again, the display moves to the fol- menu item by pressing the ESCAPE key.
lowing display:
Changing the Access Level of the Hand Held
Analyzer
When the 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 the access level, the correct password must
be entered. To enter the password, scroll to the ACCESS LEVEL
menu. For example:
LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the system
has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the
beginning, press ESCAPE two times. STARTUP (2/1)

indicates a power up.
ACCESS LEVEL:
CODE 00000
3121262 – JLG Lift – 6-3

Adjusting Parameters Using the Hand Held

Press ENTER to select the ACCESS LEVEL menu. Analyzer
Once you have gained access to level 1, and a personality item
Using the UP or DOWN arrow keys, enter the first
digit of the password, 3.
is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the sec-

ond digit of the password which is 33271.
Once the correct password is displayed, press ENTER .

The access level should display the following, if the password
was entered correctly:
DRIVE:
ACCEL 1.5s
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 when at the maximum value nor will
the value decrease if the DOWN arrow is pressed and

the value is at the minimum value for any particular personal-
ity. If the value does not change when pressing the up and
MENU:
down arrows, check the access level to ensure you are at
ACCESS LEVEL 1
access level 1.
Repeat the above steps if the correct access level is not dis-
played or you can not adjust the personality settings.
6-4 – JLG Lift – 3121262

Machine Setup There is a setting that JLG strongly recommends that you do
not change. This setting is so noted below:
ELEVATION CUTBACK
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF
YOUR MACHINE.
ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-

TRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH
AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES
INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI-
MUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM THESE COMPONENTS. IF
ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT
BE DIRECT AND BE 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 will give you access to level 1, which will
permit you to change all machine personality settings.
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2 ENTER confirms that

vehicle is currently level, and zeroes the tilt sensor measure-
ments
3121262 – JLG Lift – 6-5

Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations
ABBREVIATION MEANING ABBREVIATION MEANING

ACCEL ACCELERATE GND GROUND
ACT ACTIVE GRN GREEN
A/D ANALOG DIGITAL CONVERTER COUNT GM GROUND MODULE
AMB. AMBIENT H HOURS
ANG ANGLE HW HARDWARE
AUX AUXILIARY HWFS HARDWARE FAILSAFE
BCS BOOM CONTROL SYSTEM I IN or CURRENT
BM BOOM LENGTH ANGLE MODULE JOY JOYSTICK
BLAM BOOM LENGTH ANGLE MODULE L LEFT
BR BROKEN LB POUND
BSK BASKET LEN LENGTH
CAL CALIBRATION LIM LIMIT
CL CLOSED LT LEFT
CM CHASSIS MODULE LVL LEVEL
CNTL CONTROL M MINUTES
CNTRL CONTROL MIN MINIMUM
C/O CUT OUT MAX MAXIMUM
CONT(S) CONTRACTOR(S) M MAIN
COOR COORDINATED MN MAIN
CRK PT CRACK POINT NO NORMALLY OPEN or NO
CRP CREEP NC NORMALLY CLOSED
CUT CUTOUT O OUT
CYL CYLINDER O/C OPEN CIRCUIT
DECEL DECELERATE OP OPEN
D DOWN O/R OVERRIDE or OUTRIGGER
DN DOWN O//R OVERRIDE
DWN DOWN OSC OSCILLATING
DEG. DEGREE OVRD OVERRIDE
DOS DRIVE ORIENTATION SYSTEM P PLATFORM
DRV DRIVE P PRESSURE
E ERROR PCV PROPORTIONAL CONTROL VALVE
E&T ELEVATED & TILTED PLAT PLATFORM
ELEV ELEVATION PLT PLATFORM
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
G GROUND RT RIGHT
6-6 – JLG Lift – 3121262

Table 6-1. Analyzer Abbreviations

ABBREVIATION MEANING
S/C SHORT CIRCUIT
SEL SELECTOR
SN SERIAL NUMBER
SPD SPEED
STOW STOWED
STOWD STOWED
SW SWITCH or SOFTWARE
TELE TELESCOPE
TEMP TEMPERATURE
TORQ. TORQUE
TRN TRANSPORT
T/T TURNTABLE
T TOWER
TURNTBL TURNTABLE
TWR TOWER
U UPPER or UP
V VOLT
VER VERSION
VLV VALVE
WIT WITNESS
YEL YELLOW
3121262 – JLG Lift – 6-7

Table 6-2. Machine Configuration Programming Information
Default
Configuration Digit Number Description
Number
NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personal-
ity settings first and then changing the model number of the machine configuration will cause the personality settings
to return to default
MODEL NUMBER: 0 No Model 0

1 1
1 1500SJ
ENVELOPE HEIGHT: 0 1500SJ: 150' MAX 0

2
Note: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial default setting.
MARKET: 0 ANSI USA 0

3
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
ENGINE: 1 DEUTZ F4 TIER1: Deutz BF4M1011 Diesel (Tier 1) 3

4
2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
3 DEUTZ ECM: Engine Control Module
4 CAT Engine
GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start 0
6 can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permit-
ted until pre-glow is finished.
6-8 – JLG Lift – 3121262

Default
Number
ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil
pressure is less than 8 PSI.
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more 1
8 than 5 degrees and above elevation; also reduces drive speed to creep.
4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees
2 and above elevation; also reduces drive speed to creep.
3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees
3 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
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
5 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: 0 NO: No Jib installed. 2

9
1 YES: Jib installed.
2 SIDESWING: Jib with Sideswing installed.
4WS: 0 NO: 2WS mode enabled. 1

10
1 YES: 4WS mode enabled.
DRIVE: 0 2WD drive mode enabled. 1

11
1 4WD drive mode enabled.
SOFT TOUCH: 0 NO: No soft touch system installed. 0

12
1 YES: Soft touch system installed.
3121262 – JLG Lift – 6-9

Default
Number
GEN SET/WELDER: 0 NO: No generator installed. 1

13
1 BELT DRIVE: Belt driven setup.
2 HYDRAULIC DRIVE: Hydraulic driven setup.
GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
14*
1 MOTION CUTOUT: Motion cutout in platform mode only.
* Only visible if Gen Set / Welder Menu selection is not 0.
H & T LIGHTS: 0 NO: No head and tail lights installed. 0

15
1 YES: Head and tail lights installed.
LOAD SYSTEM: 0 0
NO: No load sensor installed.
16*
1
WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
2
CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
3
SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform
alarm beeps (5 sec ON, 2 sec OFF).
4
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
6-10 – JLG Lift – 3121262

Default
Number
FUNCTION CUTOUT: 0 NO: No drive cutout. 0

17*
1 BOOM CUTOUT: Boom function cutout while driving above elevation.
2 DRIVE CUTOUT: Drive cutout above elevation.
3 DRIVE CUT E&T: Drive cutout above elevation and tilted.
* Only visible under certain market selections.
* Certain market selections will limit function cutout options or alter default setting.
GROUND ALARM: 0 NO: No ground alarm installed. 0

18*
1 DRIVE: Travel alarm sounds when the drive function is active (Option).
2 DESCENT: Descent alarm sounds when lift down is active (Option).
3 MOTION: Motion alarm sounds when any function is active (Option).
* Certain market selections will alter default setting.
OSCILLATING AXLE: 0 NO: No oscillating axle system installed. 1

19
1 YES: Oscillating axle system installed.
TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1

20*
1 FAHRENHEIT: Fahrenheit unit selection.
* Certain market selections will alter default setting.
LEVELING MODE: 0 LIFT: Platform leveling during lift only. 1

21
1 ALL: Platform leveling during all functions.
CLEARSKY: 0 NO: ClearSky Telematics system not installed. 0

22
1 YES: ClearSky Telematics system installed.
1001128802-1
3121262 – JLG Lift – 6-11

Table 6-3. Machine Configuration Programming Settings
ANSI Export
Table 6-3. Machine Configuration Programming Settings
Australia
ANSI USA
Japan
CSA
1500SJ
CE
ANSI Export
Australia
ANSI USA
Japan
CSA
1500SJ
CE
Function Cutout 0 0 0 0 0 0
X 1 1 1 1 1
Model Number 3 3 3 3 3 3
X 2 X X 2 2
Envelope Height 1 1 1 1 1 1
X 3 3 X 3 3
Market 0 1 2 3 4 5
Ground Alarm 0 0 0 0 0 0
Engine 3 3 3 3 3 3
1 1 1 1 1 1
Glow Plug 0 0 0 0 0 0
2 2 2 2 2 2
1 1 1 1 1 1
3 3 3 3 3 3
2 2 2 2 2 2
Oscillating Axle 0 0 0 0 0 0
Starter Lockout 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Temperature 0 0 0 0 0 0
Engine Shutdown 0 0 0 0 0 0
1 1 1 1 1 1
1 1 1 1 1 1
Leveling Mode 0 0 0 0 0 0
Tilt 1 1 1 1 1 1
1 1 1 1 1 1
2 2 2 2 2 2
Clearsky 0 0 0 0 0 0
3 3 3 3 3 3
1 1 1 1 1 1
4 4 4 4 4 4
BOLD TEXT indicates the default setting. Plain text indicates another available selec-
5 5 5 5 5 5 tion. ITALIC TEXT indicates the default when option is factory installed. SHADED CELLS
Jib 0 0 0 0 0 0 indicate hidden menu or selection.
1 1 1 1 1 1
2 2 2 2 2 2
4 Wheel Steer 0 0 0 0 0 0
1 1 1 1 1 1
Drive Type 0 0 0 0 0 0
1 1 1 1 1 1
Soft Touch 0 0 0 0 0 0
1 1 1 1 1 1
Gen Set / Welder 0 0 0 0 0 0
1 1 1 1 1 1
2 2 2 2 2 2
Gen Set Cutout 0 0 0 0 0 0
1 1 1 1 1 1
Head & Taillights 0 0 0 0 0 0
1 1 1 1 1 1
Load System 0 0 0 0 0 0
X 1 X X 1 1
X 2 X 2 2 2
X 3 X 3 3 3
X 4 X X 4 4
6-12 – JLG Lift – 3121262

6.2 MACHINE PERSONALITY SETTINGS AND NOTE: Personality settings can be adjusted within the adjustment
range in order to achieve optimum machine performance.
FUNCTION SPEEDS
Table 6-4. Machine Personality Settings and Function Speeds
SUBMENU PARAMETER
DEFAULT TIME RANGE
(DISPLAYED ON (DISPLAYED ON ANALYZER 2ND DESCRIPTION RANGE
VALUES (SEC)
ANALYZER 1ST LINE) LINE)
DRIVE: ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2
DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3
MIN forward XX% Displays/adjusts minimum forward drive speed 0 to 35% 1
MAX forward XXX% Displays/adjusts maximum forward drive speed 0 to 100% 100 44-48 (see orientation)
MIN reverse XX% Displays/adjusts minimum reverse drive speed 0 to 35% 1
MAX reverse XXX% Displays/adjusts maximum reverse drive speed 0 to 100% 100 44-48 (see orientation)
ELEV. MAX XX% Displays/adjusts maximum drive speed 0 to 50% 25 93-104 (see orientation)
NOTE: used when elevation cutout switches are
limiting maximum speed
CREEP MAX XX% Displays/adjusts maximum drive speed 0 to 50% 35 79-87 (see orientation)
NOTE: used when creep switch on pump pot is
active
STEER: MAX SPEED XXX% Displays/adjusts maximum steer speed. 0 to 100% 100
3121262 – JLG Lift – 6-13

SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
MAIN LIFT: ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1
DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1
MIN UP XX% Displays/adjusts minimum main lift up speed 0 to 60% 20
MAX UP XX% Displays/adjusts maximum main lift up speed 0 to 100% 60 75-100 (see orientation)
CREEP UP XX% Displays/adjusts maximum main lift up speed 0 to 65% 50
active
MIN DOWN XX% Displays/adjusts minimum main lift down 0 to 60% 10
speed
MAX DOWN XXX% Displays/adjusts maximum main lift down 0 to 100% 60 85-110 (see orientation)
speed
CREEP DOWN XX% Displays/adjusts maximum main lift down 0 to 75% 45
speed
active
SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2

DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5
MIN LEFT XX% Displays/adjusts minimum swing left speed 0 to 50% 40
MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 100% 65 115-125 (see orientation)
CREEP LEFT XX% Displays/adjusts maximum swing left speed 0 to 65% 52
active
MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 40
MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 100% 60 115-125 (see orientation)
CREEP RIGHT XX% Displays/adjusts maximum swing right speed 0 to 65% 47
active
MAIN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts main telescope deceleration 0.1 to 3.0 sec 1
MIN IN XX% Displays/adjusts minimum main telescope in 0 to 65% 15
speed. Same as Creep speed
MAX IN XXX% Displays/adjusts maximum main telescope in 0 to 100% 65 30-40 (see orientation)
speed
MIN OUT XX% Displays/adjusts minimum main telescope out 0 to 65% 10
MAX OUT XXX% Displays/adjusts maximum main telescope out 0 to 100% 60 25-35 (see orientation)
speed
6-14 – JLG Lift – 3121262

SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
PLATFORM LEVEL: ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5
MIN UP XX% Displays/adjusts minimum basket level up 0 to 65% 55
MAX UP XXX% Displays/adjusts maximum basket level up 0 to 100% 70
speed
MIN DOWN XX% Displays/adjusts minimum basket level down 0 to 65% 50
MAX DOWN XXX% Displays/adjusts maximum basket level down 0 to 100% 70
speed
PLATFORM ROTATE: ACCEL X.Xs Displays/adjusts basket rotate acceleration 0.1 to 5.0 sec 1
DECEL X.Xs Displays/adjusts basket rotate deceleration 0.1 to 3.0 sec 0.5
MIN LEFT XX% Displays/adjusts minimum basket rotate left 0 to 100% 60
MAX LEFT XXX% Displays/adjusts maximum basket rotate left 0 to 100% 60 24-30 (180°)
speed
MIN RIGHT XX% Displays/adjusts minimum basket rotate right 0 to 100% 60
MAX RIGHT XXX% Displays/adjusts maximum basket rotate right 0 to 100% 60 24-30 (180°)
speed
3121262 – JLG Lift – 6-15

SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
JIB LIFT: ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1
MIN UP XX% Displays/adjusts minimum jib up speed. Same 0 to 65% 55

as Creep speed
MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 80 70-90
MIN DOWN XX% Displays/adjusts minimum jib down speed. 0 to 65% 60
Same as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 85 70-90
JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5
MIN LEFT XX% Displays/adjusts minimum jib left speed. Same 0 to 65% 48
as Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 60-68 (180°)
MIN RIGHT XX% Displays/adjusts minimum jib right speed. 0 to 65% 55
Same as Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 60-68 (180°)
JIB TELESCOPE: ACCEL X.Xs Displays/adjusts jib tele acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib tele deceleration 0.1 to 3.0 sec 1
MIN IN XX% Displays/adjusts minimum jib tele in speed. 0 to 65% 45
Same as Creep speed
MAX IN XXX% Displays/adjusts maximum jib tele in speed 0 to 100% 70 15-25 (see orientation)
MIN OUT XX% Displays/adjusts minimum jib right speed. 0 to 65% 40
Same as Creep speed
MAX OUT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 15-25 (see orientation)
6-16 – JLG Lift – 3121262

SUBMENU PARAMETER
DEFAULT TIME RANGE
VALUES (SEC)
JIB LEVEL: ACCEL X.Xs Displays/adjusts jib level acceleration 0.1 to 5.0 sec 1.5
DECEL X.Xs Displays/adjusts jib level deceleration 0.1 to 3.0 sec 0.5
MIN UP XX% Displays/adjusts minimum jib level up speed. 0 to 65% 60
Same as Creep speed
MAX UP XXX% Displays/adjusts maximum jib level up speed 0 to 100% 100
MIN DOWN XX% Displays/adjusts minimum jib level down 0 to 65% 60
MAX DOWN XXX% Displays/adjusts maximum jib level down 0 to 100% 100
speed
GROUND M. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 100% 60

MODE: M. lift DN XXX% Displays/adjusts main lift down speed 0 to 100% 60
SWING XXX% Displays/adjusts fixed swing speed 0 to 100% 60
PLATFORM LVL XXX% Displays/adjusts fixed basket level speed 0 to 100% 75
PLATFORM ROT XXX% Displays/adjusts fixed basket rotate speed 0 to 100% 75
MAIN TELE XXX% Displays/adjusts fixed main telescope speed 0 to 100% 60
JIB (U/D) XXX% Displays/adjusts jib lift speed 0 to 100% 80
Not displayed if JIB = 0
JIB (L/R) XXX% Displays/adjusts jib swing speed 0 to 100% 80
Displayed if JIB = 2
JIB TELE XXX% Displays/adjusts jib tele speed 0 to 100% 80
JIB LEVEL XXX% Displays/adjusts jib level speed 0 to 100% 100
GEN SET/WELDER: Engine XXXX RPM Control generator/welder RPM. Not displayed if 1200-2800 1800
GEN
SET/WELDER = 0
1001128803-C
3121262 – JLG Lift – 6-17

6.3 MACHINE ORIENTATION WHEN SETTING Test Notes

FUNCTION SPEEDS 1. Personality settings can be adjusted anywhere within
the adjustment range in order to achieve optimum
LIFT UP, from platform control, lowest elevation up to maxi-
machine performance.
mum elevation, boom retracted, jib retracted.
2. Stop watch should start when the function is acti-
LIFT DOWN, from platform control, maximum elevation down vated.Not with the controller or switch.
to minimum elevation, boom retracted, jib retracted.
3. Unless noted, function speeds should be measured from
JIB LIFT UP, from platform control, lowest jib elevation up to platform.
maximum jib elevation, boom retracted, jib retracted. 4. Platform speed knob must be at full speed (fully clock-
wise).
JIB LIFT DOWN, from platform control, maximum jib elevation
down to minimum jib elevation, boom retracted, jib retracted. 5. All test should be done with the oil temp above 100° F
(38° C).
SWING RIGHT(Max),360 Degrees, from platform control,
boom approximately 45° elevation, boom retracted, jib
retracted.
SWING LEFT(Max), 360 Degrees, from platform control, boom

approximately 45° elevation, boom retracted, jib retracted.
TELESCOPE OUT, from platform control, boom @ 20 degrees,

500 lb. capacity selected.
TELESCOPE IN, from platform control, boom @20 degrees,

500 lb. capacity selected.
JIB TELESCOPE IN, from platform control, boom horizontal, jib

horizontal, 500 lb. capacity selected.
JIB TELESCOPE OUT, from platform control, boom horizontal,

jib horizontal, 500 lb. capacity selected.
DRIVE FORWARD (Max), high speed - low torque setting,

drive 200 ft. front wheels to front wheels. Timed after machine
has obtained maximum speed.
DRIVE REVERSE (Max), high speed - low torque setting, drive

200 ft. front wheels to front wheels Timed after machine has
obtained maximum speed.
DRIVE FORWARD (Creep Max), high torque - low speed set-

ting, platform speed knob at full creep
DRIVE REVERSE (Creep Max), high torque - low speed set-

ting, platform speed knob at full creep
DRIVE FORWARD (Elevated Max - Boom Beyond Trans-

port), high speed - low torque setting, platform speed knob
out of creep, Lift boom above transport, drive forward 50 ft.
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.
6-18 – JLG Lift – 3121262

6.4 CANBUS COMMUNICATIONS The GROUND MODULE (UGM) is the master system controller.
Most functions are dispatched and coordinated from this
CANbus: CAN (Control Area Network) is a two wire differential module, all other system modules (PLATFORM, JIB, BLAM,
serial link between the Platform Module, Jib Module, Ground CHASSIS) handle sub-tasks. All characterized information (val-
Module, Boom Length Angle Module and the Chassis Module ues) are stored into the ground module (i.e., Personalities or
providing bi-directional communications. Calibrations).
Interlocks: Any device that sends an electrical input. (For an
Two-wire: One wire (red) is driven high (5v) and the other low
example a limit switch, proximity switch, etc;)
(black) (0v) to send a signal; both wires ”float” (2.5v) when no
signal is being sent. Platform Level: The GROUND MODULE stores the default val-
ues and handles interlocks. The PLATFORM MODULE reads the
Differential: Any electrical line noise can affect the high or the sensors mounted on the platform assembly and controls the
low wires but never both, so communications is not corrupted. Level Up / Down valves to maintain setpoint sent from the
GROUND MODULE.
Serial Link: Messages are being sent bit by bit along the wires;
Steer: The GROUND MODULE stores crack points, sends
the high bus speed allow all modules to be constantly
desired drive direction, sends steering mode and sends axle
updated around 20 times per second. Typical traffic is 300 -
extend / retract commands. The PLATFORM MODULE reports
500 messages per second.
the steering switch position to the GROUND MODULE. The
CHASSIS MODULE modulates each steer left / right valve to
A complete CANbus circuit is approximately 60 ohms, which
maintain commanded wheel position.
can be verified at the ”T” fitting inside the ground station or
below the BLAM. Each individual circuit from the modules is Drive: The GROUND MODULE stores crack points, sends com-
approximately 120 ohms. mands for each drive pump to the BLAM. (Command is com-
puted from drive joystick input, interlocks, wheel angle, etc).
BLAM maintains proper current for the drive pumps by modu-
lating PWM outputs.
Lift, Tele, & Swing: The GROUND MODULE stores default val-
ues, handles interlocks and calibration information. Lift, Tele-
scope and Swing commands are dependent upon interlocks
through out the machine. Boom angle, length and swing are
controlled by the GROUND MODULE. The BLAM monitors and
communicates (CANbus) to the GROUND MODULE boom
angle and boom length via two angle sensors, a length sensor
and a load moment pin.
3121262 – JLG Lift – 6-19

Figure 6-2. Control System Block Diagram
6-20 – JLG Lift – 3121262

6.5 CALIBRATION INSTRUCTIONS Table 6-5. Calibration Instructions
This machine incorporates a variety of sensors and a high Telescope Crack Point Cali- Ground module replacement
degree of function interaction. For safety and proper machine bration Telescope proportional valve replacement
functionality, the calibration procedures must be repeated for Erratic controlled arc operation
any control module replacement, system calibration related Erratic controlled boom angle operation
fault, or removal or replacement of any sensors, valves, coils,
motors, or pumps. The chart below lists the calibrations Chassis Tilt Ground module removal or replacement
required and potential reasons for re-calibration. All calibra- Calibration Main terminal box removal or replacement
tion procedures are menu driven through the use of the stan- Tilt indication inaccuracy
dard analyzer. With the exception of steering calibration, no
Boom Sensors Ground module removal or replacement
external tools are required to complete the calibration proce-
Calibration BLAM module removal or replacement
dures. The user is prompted to exercise the machine in a spe-
Boom angle sensor removal or replacement
cific order to use the machines physical properties to
Boom length sensor removal or replacement
consistently establish sensor response and the interaction of
Moment pin removal or replacement
valves, pumps, and motors. Steering calibration also uses the
Boom angle sensor calibration fault
analyzer and is performed on one side of the machine at a
Boom length sensor calibration fault
time requiring the use of a string or other means to determine
Moment pin fault
when the tires are in line with each other. With the exception
Failed BCS functional check
of the load control calibration, all calibrations are accessed by
Boom control system inaccuracies
connecting the analyzer into the control system inside the
Installing or removing approved accessories
main terminal box or on the bottom of the platform control
Changing Platform Size
box.
Table 6-5. Calibration Instructions
Calibration Reasons for Re-calibration

Procedure
Steering Calibration Ground module replacement
Chassis module replacement
Steer sensor removal or replacement
Persistent wheel misalignment
Drive Calibration Ground module replacement

BLAM module replacement
Drive pump/coil replacement
Drive pulls to one side
Drive lugs engine
Poor slow speed control
Platform Leveling Ground module replacement

Calibration Platform module replacement
Platform level sensor removal or replacement
Platform level sensor calibration fault
Platform Level Crack Point Platform module replacement

Calibration Ground module replacement
Platform level valve/coil replacement
Erratic platform leveling
Lift Crack Point Ground module replacement

Calibration Lift proportional valve/coil replacement
Erratic controlled arc operation
Erratic controlled boom angle operation
3121262 – JLG Lift – 6-21

6-22
ACCESS LEVEL: MENU: MENU: MENU: MENU: MENU: MENU: MENU: MENU:
CODE 33271 ACCESS LEVEL 1 PERSONALITIES MACHINE SETUP CALIBRATIONS SERVICE MODE HELP:PRESS ENTER DIAGNOSTICS SYSTEM TEST
ACCESS LEVEL: SERVICE MODE: HELP: SYSTEM TEST:

(See Figure 6-4.) (See Figure 6-5.) (See Figure 6-6.) (See Figure 6-7.)
CODE 00000 JIB & SWING? GROUND MODE OK ACTIVATE?

or
JIB & SWING: (See Figure 6-8.)
JIB LEVEL? or
(See Figure 6-9.)
JIB & SWING:
JIB LOCK PIN?
JIB & SWING:

SWING ENVELOPE?
JIB & SWING:

BOOM RECOVERY?
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine con-
figuration.
Figure 6-3. Analyzer Flow Chart
3121262
3121262
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some
screens may not be available depending upon machine configuration.
Figure 6-4. Analyzer Flow Chart - Personalities (Software Version 7.X)
6-23
6-24
– JLG Lift –
NOTE: The layout shown includes all possible ana-
lyzer screens. Please note that some screens
may not be available depending upon
machine configuration.
Figure 6-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X)
3121262
3121262
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending upon machine configuration.
Figure 6-6. Analyzer Flow Chart - Calibrations (Software Version 7.X)
6-25
6-26
– JLG Lift –
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens
may not be available depending upon machine configuration.
Figure 6-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3
3121262
3121262
– JLG Lift –
6-27
6-28
– JLG Lift –
3121262
Figure 6-10. Control Module Location
3121262 – JLG Lift – 6-29

Connector Pin Function Type

1 THROTTLE ACTUATOR (DIESEL ONLY) DIGITAL OUTPUT
2 SPARE (LP NOT USED) DIGITAL OUTPUT
3 TOWER BOOM LIFT POWER DIGITAL OUTPUT
4 GROUND GROUND INPUT
6 TOWER TELESCOPE ENABLE DIGITAL OUTPUT
7 SPARE (LP NOT USED) DIGITAL OUTPUT
10 IGNITION ON RELAY DIGITAL OUTPUT
11 START SOLENOID (DIESEL ONLY) DIGITAL OUTPUT
12 GLOW PLUG (DIESEL ONLY OPTION) DIGITAL OUTPUT
13 AUXILIARY POWER DIGITAL OUTPUT
14 COOLANT TEMP (DIESEL ONLY) ANALOG INPUT
15 OIL PRESSURE (DIESEL ONLY) ANALOG INPUT
16 FLYWHEEL SPEED PICKUP (DIESEL ONLY) FREQUENCY INPUT
J1
18 SPARE GROUND GROUND INPUT
(Natural)
19 SPARE GROUND GROUND INPUT
20 TWO SPEED DIGITAL OUTPUT
21 MAIN LIFT PILOT PRESSURE SWITCH DIGITAL INPUT
22 GENERATOR/WELDER (OPTION) DIGITAL OUTPUT
23 PARKING BRAKE DIGITAL OUTPUT
24 CONSTANT BATTERY N/C N/C
25 RS-485 HI SERIAL I/O
26 RS-485 LO SERIAL I/O
28 ANALYZER POWER VOLTAGE OUTPUT
29 ANALYZER RS-232 Rx SERIAL INPUT
30 ANALYZER RS-232 Tx SERIAL OUTPUT
31 ANALYZER GROUND GROUND INPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT
33 GROUND SHIELD GROUND INPUT
34 SPARE DIGITAL INPUT
35 HYDRAULIC OIL TEMPERATURE SWITCH DIGITAL INPUT

1 MAIN LIFT PILOT DIGITAL OUTPUT
2 HORN DIGITAL OUTPUT
3 PLATFORM CONTROL VALVE DIGITAL OUTPUT
4 UPPER TELESCOPE IN DIGITAL OUTPUT
5 BASKET LEVEL UP OVERRIDE DIGITAL OUTPUT
7 BASKET LEVEL DOWN OVERRIDE DIGITAL OUTPUT
8 TOWER TELESCOPE POWER DIGITAL OUTPUT
9 TELESCOPE FLOW CONTROL DIGITAL OUTPUT
10 LIFT PILOT DIGITAL OUTPUT
11 UPPER LIFT UP DIGITAL OUTPUT
12 LIFT DOWN AUXILIARY DIGITAL OUTPUT
13 MAIN DUMP DIGITAL OUTPUT
15 NOT CONNECTEDRS232 BACKUP COMM. ENABLE DIGITAL OUTPUT
16 UPPER TELESCOPE OUT DIGITAL OUTPUT
J2
18 SPARE PIN GROUND INPUT
(Gray)
19 LIFT FLOW CONTROL DIGITAL OUTPUT
20 SPARE OUTPUT DIGITAL OUTPUT
21 MAIN BOOM ANGLE SENSOR #2 POWER DIGITAL OUTPUT
22 UPPER LIFT DOWN DIGITAL OUTPUT
23 MAIN BOOM LIFT ENABLE DIGITAL OUTPUT
24 TOWER CYLINDER TYPE DIGITAL INPUT
25 FUEL SENSOR ANALOG INPUT
26 HEAD/TAIL LIGHT DIGITAL OUTPUT
27 ALARM DIGITAL OUTPUT
31 PVG ENABLE DIGITAL OUTPUT
32 TOWER BOOM TELESCOPE PILOT DIGITAL OUTPUT
33 TOWER BOOM LIFT ENABLE DIGITAL OUTPUT
34 SWING LEFT DIGITAL OUTPUT
35 SWING RIGHT DIGITAL OUTPUT

1 SPARE VAVLE RETURN 1 GROUND INPUT
J3 7 VBAT VBAT OUTPUT
(Black) 8 SPARE HS DIGITAL IN (FREQ. CAPABLE) DIGITAL INPUT
9 ALTERNATOR EXCITATION INPUT DIGITAL INPUT
10 SPARE HS SWITCH INPUT (MODEL INPUT FOR 1100S) DIGITAL INPUT
11 SPARE LS DIGITAL INPUT DIGITAL INPUT
12 ANALOG REF. VOLTAGE VOLTAGE OUTPUT
13 SPARE ANALOG INPUT 8 ANALOG INPUT
14 SPARE VALVE RETURN 3 GROUND INPUT
1001119509A
Figure 6-11. Ground Control Module - Sheet 1 of 3
6-30 – JLG Lift – 3121262


1 PLATFORM EMS DIGITAL INPUT
2 PLATFORM MODE DIGITAL INPUT
3 GROUND MODE DIGITAL INPUT
4 TOWER CYLINDER PRESSURE ANALOG INPUT
5 REFERENCE VOLTAGE VOLTAGE OUTPUT
6 CAN TERMINATION TERM I/O
7 SPARE ANALOG INPUT
11 BOOM RETRACTED CLOSED DIGITAL INPUT
12 BROKEN CABLE SWITCH INPUT
13 CAN HI SERIAL I/O
14 GROUND MODE OUT TO PLATFORM DIGITAL INPUT
15 FOOTSWITCH ENGAGE DIGITAL INPUT
17 CAN TERMINATION TERM I/O
J7
18 CAN SHEILD GROUND INPUT
(Black)
21 PUSH TO TEST DIGITAL INPUT
22 TOWER BOOM TRANSPORT ANGLE DIGITAL INPUT
23 GROUND CONTROL ENABLE DIGITAL INPUT
24 CAN LO SERIAL I/O
29 VBAT VBAT OUTPUT
30 VBAT VBAT OUTPUT
31 VBAT VBAT OUTPUT
32 VBAT VBAT OUTPUT
33 VBAT VBAT OUTPUT
34 CLEARSKY POWER (VBAT) VBAT OUTPUT
35 BOOM RETRACT OPEN DIGITAL INPUT

1 FREQUENCY INPUT 2 FREQUENCY INPUT
2 FREQUENCY INPUT 2 RETURN FREQUENCY INPUT
3 CAN 2 H SERIAL I/O
J12 4 CAN 2 L SERIAL I/O
(Black) 5 CAN 2 SHIELD GROUND INPUT
6 CAN 2 TERMINATOR TERM I/O
7 CAN 2 TERMINATOR TERM I/O
8 SPARE LS DIGITAL INPUT DIGITAL INPUT
1001119509A
3121262 – JLG Lift – 6-31


1 GROUND FROM BATTERY GROUND INPUT
J8 2 GROUND EMS GROUND INPUT
(Black) 3 GROUND TO PLATFORM GROUND OUTPUT
4 GROUND EMS OUT TO PLATFORM GROUND OUTPUT

1 AXLES SET LAMP DIGITAL OUTPUT
2 500# CAPACITY LAMP DIGITAL OUTPUT
3 BOOM CONTROL SYSTEM LAMP DIGITAL OUTPUT
4 START SWITCH DIGITAL INPUT
5 BASKET LEVEL DOWN DIGITAL INPUT
6 BASKET LEVEL DOWN DIGITAL INPUT
7 UPPER TELESCOPE IN DIGITAL INPUT
8 JIB DOWN DIGITAL INPUT
9 JIB LEFT DIGITAL INPUT
10 TOWER UP DIGITAL INPUT
11 MAIN TOWER TRANSPORT ANGLE OPEN DIGITAL INPUT
12 HOUR METER DIGITAL OUTPUT
13 BCS CALIBRATED LAMP DIGITAL OUTPUT
14 OVERLOAD LAMP DIGITAL OUTPUT
15 SPARE DIGITAL OUTPUT
16 AUXILIARY POWER DIGITAL INPUT
17 BASKET LEVEL UP DIGITAL INPUT
J4
18 BASKET ROTATE RIGHT DIGITAL INPUT
(Blue)
19 JIB UP DIGITAL INPUT
20 JIB RIGHT DIGITAL INPUT
21 TOWER DOWN DIGITAL INPUT
22 MAIN BOOM TRANSPORT ANGLE CLOSED DIGITAL INPUT
23 UPPER LIFT UP DIGITAL INPUT
24 VBAT VBAT OUTPUT
25 VBAT VBAT OUTPUT
26 NO CHARGE LAMP DIGITAL OUTPUT
27 1000# CAPACITY LAMP DIGITAL OUTPUT
28 ENGINE HIGH TEMPERATURE LENGTH DIGITAL OUTPUT
29 ENGINE LOW OIL PRESSURE LAMP DIGITAL OUTPUT
30 UPPER TELESCOPE OUT DIGITAL INPUT
33 UPPER LIFT DOWN DIGITAL INPUT
34 SWING LEFT DIGITAL INPUT
35 SWING RIGHT DIGITAL INPUT
1001119509A
6-32 – JLG Lift – 3121262

Connector Pin FUNCTION Type

1 Power Feed Thru to J1-1 Power I/O
1 Power Feed Thru to J2-1 Power I/O 2 Power Feed Thru to J1-2 Power I/O
2 Power Feed Thru to J2-2 Power I/O 3 Ground Power Output
3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output
4 Front Axles Limit Switch Digital Input
4 Master Ground Connect Power Input 2 Ground Power Output
5 Rear Axles Limit Switch Digital Input
5 Master Ignition Connect Power Input 3 CANbus High Serial I/O
6 Drive Orientation Switch Digital Input
6 CANbus High Serial I/O 4 CANbus Low Serial I/O J2 (Black)
J1 (Grey) J4 (Grey) 7 Oscillating Axle Pres Sw Digital Input
7 CANbus Low Serial I/O 5 CANbus Shield Power Input
6 Bootstrap Mode Digital Input 8 Turntable Angle Sensor #1 Digital Input
8 CANbus Shield Serial I/O
7 Ignition Power Output 9 Turntable Angle Sensor #2 Digital Input
9 CANbus Terminator Serial I/O
10 CANbus Terminator Serial I/O 8 Ground Power Output 10 Spare Analog Analog Input
11 Ignition Power Output 11 Front/Rear Axle Extend Digital Output
12 Ground Power Output 12 Front/Rear Axle Retract Digital Output
Connector Pin FUNCTION Type Connector Pin FUNCTION Type

1 +5V Analog Reference Power Output 1 Right Front Steer Right Digital Output
2 Front Right Steer Angle Analog Input 2 Right Front Steer Left Digital Output
3 Ground Power Output 3 Left Front Steer Right Digital Output
4 +5V Analog Reference Power Output 4 Left Front Steer Left Digital Output
5 Front Left Steer Angle Analog Input 5 Right Rear Steer Right Digital Output
6 Ground Power Output 6 Right Rear Steer Left Digital Output
J3 (Green) J5 (Brown)
7 +5V Analog Reference Power Output 7 Left Rear Steer Right Digital Output
8 Rear Right Steer Angle Analog Input 8 Left Rear Steer Left Digital Output
9 Ground Power Output 9 Ignition Power Output
10 +5V Analog Reference Power Output 10 RS232 Receive Serial Input
11 Rear Left Steer Angle Analog Input 11 RS232 Transmit Serial Output
12 Ground Power Output 12 Ground Power Output
1001112758-C
Figure 6-14. Chassis Control Module
3121262 – JLG Lift – 6-33


1 Power Feed Thru to J1-1 Power I/O
2 Power Feed Thru to J2-2 Power I/O 3 Ground Power Output
3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output
4 Spare Input Digital Input
4 Master Ground Connect Power Input 2 Ground Power Output
5 Master Ignition Connect Power Input 3 CANbus High Serial I/O
6 CANbus High Serial I/O 4 CANbus Low Serial I/O J2 (Black)
J1 (Grey) J4 (Grey) 7 Spare Input Digital Input
7 CANbus Low Serial I/O 5 CANbus Shield Power Input
6 Bootstrap Mode Digital Input 8 Main Boom Ang 1 (Gravity) Digital Input
8 CANbus Shield Serial I/O
9 CANbus Terminator Serial I/O 7 Ignition Power Output 9 Main Boom Ang 2 (Gravity) Digital Input
10 CANbus Terminator Serial I/O 8 Ground Power Output 10 Spare Analog Analog Input
11 Ignition Power Output 11 Right Drive Pump Forward Digital Output
12 Ground Power Output 12 Right Drive Pump Reverse Digital Output

1 +5V Analog Reference Power Output 1 Left Drive Pump Forward Digital Output
2 Ref Voltage from J3-1 Analog Input 2 Left Drive Pump Forward Digital Output
3 Ground Power Output 3 Oscillating Axles Digital Output
4 +5V Analog Reference Power Output 4 Spare Output - D005 Digital Output
5 Main Cyl Angle #1(Absolute) Analog Input 5 Spare Output - D006 Digital Output
6 Ground Power Output 6 Spare Output - D007 Digital Output
7 +5V Analog Reference Power Output 7 Spare Output - D008 Digital Output
8 Boom Length Sensor Analog Input 8 Spare Output - D009 Digital Output
11 Main Cyl Angle #2(Absolute) Analog Input 11 RS232 Transmit Serial Output
1001112757-C
Figure 6-15. BLAM Control Module
6-34 – JLG Lift – 3121262

2 Power Feed Thru to J2-2 Power I/O Connector Pin FUNCTION Type 2 Power Feed Thru to J1-2 Power I/O
3 Signal Feed Thru to J2-4 Digital Input 1 Ignition Power Output 3 Ground Power Output
4 Master Ground Connect Power Input 2 Ground Power Output 4 Lock Pin NO Contact Digital Input
5 Master Ignition Connect Power Input 3 CANbus High Serial I/O 5 Lock Pin NC Contact Digital Input
6 CANbus High Serial I/O 4 CANbus Low Serial I/O 6 Jib Transport #1 NO Contact Digital Input
J1 (Grey) J4 (Grey) J2 (Black)
7 CANbus Low Serial I/O 5 CANbus Shield Power Input 7 Jib Transport #1 NC Contact Digital Input
8 CANbus Shield Serial I/O 6 Bootstrap Mode Digital Input 8 Spare Input Digital Input
9 CANbus Terminator Serial I/O 7 Ignition Power Output 9 Spare Input Digital Input
10 CANbus Terminator Serial I/O 8 Ground Power Output 10 Spare Analog Input Analog Input
11 Ignition Power Output 11 Jib Level Up Digital Output
12 Ground Power Output 12 Jib Level Down Digital Output
1 +5V Analog Reference Power Output 1 Jib Lift Up Digital Output

2 Jib Level Angle #1 Analog Input 2 Jib Lift Down Digital Output
3 Ground Power Output 3 Jib Swing Right Digital Output
4 +5V Analog Reference Power Output 4 Jib Swing Left Digital Output
5 Jib level Angle #2 Analog Input 5 Jib Telescope In Digital Output
6 Ground Power Output 6 Jib Telescope Out Digital Output
7 +5V Analog Reference Power Output 7 Spare Output Digital Output
8 Jib Swing Angle #1 Analog Input 8 Spare Output Digital Output
11 Jib Swing Angle #2 Analog Input 11 RS232 Transmit Serial Output
1001119262-A
Figure 6-16. Jib Control Module
3121262 – JLG Lift – 6-35

PLATFORM CONNECTION
GROUND CONTROL CONNECTION
Figure 6-17. Analyzer Connecting Points
6-36 – JLG Lift – 3121262

6.6 CONTROL SYSTEM BOOM SENSORS Sensor #2 - Main Boom Angle Sensors
NOTE: Note: The machine is defined as being in transport mode if:
Axles are retracted.

Main boom lift is below elevation angle.
Main boom telescope is fully retracted.
Jib boom telescope is fully retracted.
Jib boom locked inline with the main boom via the jib lock
pin.
Turntable swung so that the main boom is between the
rear wheels.
The Boom Control System (BCS) uses a number of sensors to

measure the position of the boom. The sensors used to deter-
mine main boom and jib boom position are shown in Figure 6-
18., Control System Boom Sensors.
Sensor #1 - Moment Pin
MOMENT
PIN
These sensors measure Main Boom angle in reference to grav-

ity. They are located in the rear of the Base Boom and mounted
such that they generate opposing signals with respect to
boom movement.
The Main Lift Cylinder is attached to the Turntable with a sin-

gle axis load cell pin which measures load on the boom.
3121262 – JLG Lift – 6-37

MAIN BOOM LIMIT SWITCH
MAIN BOOM STRING POT
MAIN BOOM
PROTRACTOR JIB TELESCOPE
MAIN BOOM SENSOR PROXIMITY SENSORS
ANGLE SENSORS
PLATFORM
WIRE ROPE PROXIMITY SENSOR LEVEL SENSORS
JIB ROTATE
SENSORS
JIB LEVEL PROTRACTOR SENSOR
JIB LOCK PIN PROXIMITY SENSORS
Figure 6-18. Control System Boom Sensors
6-38 – JLG Lift – 3121262

Sensor #3 - Main Boom Length Sensor Sensor #4 - Main Boom Cylinder Angle Sensor
This sensor's function is to measure Main Boom angle in rela-

tionship to the turntable. A rotary type sensor is mounted to
the Turntable and attached to the Main lift cylinder. This sen-
sor is used for velocity control only.
Sensor #5 - Main Boom Transport Length Switch
This sensor measures total stroke of the Main Boom. It is

located in the rear of the Base Boom and consists of a small
wire rope and a rotating drum.
This switch is used to indicate the Main Boom is in the

retracted position for transport. This sensor is a mechanical
limit switch.
3121262 – JLG Lift – 6-39

Sensor #6 - Jib Level Angle Sensor Sensor #7 - Jib Lock Pin Switch
This sensor is used to indicate the Jib Lock Pin is fully engaged.
It is an inductive proximity switch mounted to the Jib Pivot
weldment with both Normally Open and Normally Closed con-
tacts wired into the control system.
Sensor #8 - Jib Stow Angle Sensor
This sensor is used to measure Jib Level angle in relationship This sensor is used to measure Jib swing angle. It is a rotary
to the Main Boom. It is a rotary type sensor mounted between sensor mounted to the underside of the Jib Pivot weldment.
the Main Boom Fly nose and the Jib Pivot weldment. This sen- This sensor is used for velocity control only.
sor is used for velocity control and for jib leveling closed loop
control. Sensor #9 - Jib Lift Cylinder Angle Sensor
This sensor's function is to measure the Jib angle in relation-
ship to the Main Boom Pivot weldment. The sensor does this
by measuring cylinder stroke. It is a linear position type sensor
located inside the Jib lift cylinder. This sensor is used for veloc-
ity control only.
6-40 – JLG Lift – 3121262

Sensor #10 - Dual Capacity / Jib Transport Length Sensor #11 - Platform Level Cylinder Angle Sensor
Switches This sensor is used to measure Platform angle in relationship
to the Jib. A linear position sensor is located inside the Plat-
form Level cylinder to measure cylinder stroke and be trans-
lated into Platform angle. This sensor is used for velocity
control only.
Sensor #12 - Platform Level Sensors
These sensors are located on the Platform Support and are

used to measure platform angle in relationship to gravity. They
are mounted in a manner to generate opposing signals.
Sensor #13 - Rotary Turntable Angle Sensor
These switches are located on the Jib Base Boom and are used
to measure transport position and 1000# length limit. These
are proximity switches mounted in a manner to generate
opposing signals. Both Normally Open and Normally Closed
contacts from both sensors are wired into the control system.
This sensor will be mounted to the commutator and is used to

measure the turntable angle.
3121262 – JLG Lift – 6-41

6.7 JIB CONTROL MODULE 6.8 CAN GATEWAY

See Figure 6-16., Jib Control Module.
The Jib Control Module is mounted at the end of the main

boom to aid in control of Jib Lift, Jib Level, Jib Telescope, and The CAN gateway is located in the ground control box. To
Jib Swing functions and also to process the information trans- decrease overall bus loading, the CAN gateway module
mitted by the Jib Level angle sensor, the Jib Rotate angle sen- divides the CANbus so that the platform module, the jib con-
sor, and the Jib lock pin sensing proximity switch. trol module, the LSS (if equipped), and the in cylinder length
sensors are on gateway CAN bus 2 and the ground module,
the BLAM, the moment pin, and the chassis module are on
gateway CANbus 1. The CAN gateway is transparent to the
control system and passes all messages from one CANbus to
the other.
6-42 – JLG Lift – 3121262

6.9 SYSTEM TEST 3. Before proceeding, ensure that the switches on the plat-
form console are in the following positions:
The Control System Incorporates a built-in system test to a. Drive speed switch is in the Middle position. (Turtle
check the system components and functions. To use this func- Icon)
tion, use the following procedures.
b. 4WS switch is in the Middle position. (2WS mode)
Test from the Platform c. Capacity select switch in the 1000 lb. (450 kg) mode.
d. Function speed potentiometer out of creep mode
1. Position the Platform/Ground select switch to the Plat- switch.
form position. e. Generator (if equipped) switched to the off position.
f. Head and Tail lights (if equipped) switched to the off
position.
2. Plug the analyzer into the connector at the base of the

platform control box.
3121262 – JLG Lift – 6-43

4. Pull out the Emergency Stop switch and Start the 6. Use the arrow button to reach SYSTEM TEST. Hit Enter.
engine. The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
7. Follow the flow path in Figure 6-19., System Test Flow
Chart - Platform Tests and go through the component
tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
5. The analyzer screen should read:
6-44 – JLG Lift – 3121262

Figure 6-19. System Test Flow Chart - Platform Tests
3121262 – JLG Lift – 6-45

Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the
engine.
1. Position the Platform/Ground select switch to the
Ground position.

2. Plug the analyzer into the connector inside the Ground
control box.
5. Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
6. Follow the flow path in Figure 6-20., System Test Flow

Chart - Ground Station Tests and go through the compo-
nent tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
6-46 – JLG Lift – 3121262

3121262
– JLG Lift –
Figure 6-20. System Test Flow Chart - Ground Station Tests
6-47
Table 6-6. System Test Messages
Message Displayed on Message Displayed on

Description
Analyzer Analyzer
RUNNING Initial display when system test is run; certain “critical” checks are made. Problems that can be
reported include below messages.
ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V).
CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from the platform and
ground modules. The system test cannot run in ground mode unless data is being received from
the platform module.
CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed encoder.
BAD GROUND MODULE An internal problem was detected in the ground module.
HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt sensor.
HOT ENGINE The engine temperature exceeds 100°C. This is only a warning.
BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other problems are also
detected, the controller may need replacing.
SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at switch on.
Check and, if necessary correct, all personality settings.
OPEN FSW In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW In platform mode, the footswitch must be closed when this message is displayed; the footswitch
MUST BE KEPT CLOSED during the valve & contactor tests.
BAD FSW The two footswitch signals are not changing together, probably because one is open-circuit. One
footswitch signal (“FSW1”) is routed to the power module, the other (“FSW2”) is routed to the
platform module. Check footswitch and wiring.
TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized;
checks are made for open- and short- circuit valve coils.
NOTE: In platform mode, the footswitch must be closed.
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if
TOWER TELE=NO. Jib valves are not tested if JIB = NO. Extendable axle valves are not tested if EXT
AXLES=NO. Four wheel steer valves are not tested if 4WS=NO.
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.
Problems that can be reported include below messages.
CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning correctly. Check valve
wiring. Check ground alarm & hour meter wiring.
XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-circuited. Check valve
wiring.
XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit. Check valve wir-
ing.
6-48 – JLG Lift – 3121262


Description
Analyzer Analyzer
CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “nor-
mal” position; function switches should be open, cutout switches should be closed, joysticks
should be in neutral.
In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are
reported.
In ground mode any non-neutral ground switches is reported; any active cutouts are reported.
NOTE: Switches, which are not in use (due to the settings of machine digits), are not checked.
NOTE: The pump pot is checked only for a wire-off condition; it can be at any demand from creep
to maximum.
Problems that can be reported include below messages.
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.
TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a prompt asks for con-
firmation that the lamp is lit.
ENTER must be pressed or clicked to continue the test.
NOTE: Lamps, which are not in use (due to the settings of machine digits), are not checked.
NOTE: Platform Lamps are only tested in platform mode.
NOTE: The GM overload lamp and 500# capacity lamp are not tested.
NOTE: Head and tail lamps are tested in both platform and ground mode if enabled by a machine
digit.
TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a prompt asks for con-
firmation that the alarm is sounding.
ENTER must be pressed or clicked to continue the test.
NOTE: The platform alarm and the horn are only tested in platform mode.
NOTE: The ground alarm is not tested if GROUND ALARM = NO.
3121262 – JLG Lift – 6-49


Description
Analyzer Analyzer
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends.
If ENTER is pressed or clicked, each operator input is prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not
tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are
not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX The named switch should be closed.
OPEN XXXXXXX The named switch should be opened.
XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction.
XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX The pump pot should be turned to maximum.
PUMP POT TO MIN The pump pot should be turned to minimum.
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short
between two inputs.
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and
should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu.
6-50 – JLG Lift – 3121262

Table 6-7. Machine Diagnostics Parameters
Diagnostics Submenu
Parameter (Displayed on Parameter Value
(Displayed on Analyzer Description
Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
1st Line)
DRIVE:
DRIVE FOR/REV XXX% Displays drive joystick direction & demand
STEER RIGHT/LEFT XXX% Displays steer switch direction & demand
4WS NORMAL/COOR/CRAB Displays status of four wheel steer input (Displayed if 4WS = 1)
BRAKES LOCKED/RELEASED Displays brake control system status
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
CRP MODE ACTIVE/NOT ACT Displays creep mode status
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in drive joystick (Displayed if JOYSTICK TYPE =
1)
TWO SPEED OP/CL Displays status of two speed switch input if selected model has two speed.
2 speed mode ON/OFF Displays status of two speed valve if selected model has two speed
high engine OP/CL Displays status of high engine switch
LT F ANG XX.X Displays status of left front steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT F ANG XX.X Displays status of right front steer angle (Displayed if MODEL NUMBER = 7 or
8)
LT R ANG XX.X Displays status of left rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
RT R ANG XX.X Displays status of right rear steer angle (Displayed if MODEL NUMBER = 7 or 8)
DOS LIM sw OP/CL Displays status of Drive Orientation System limit switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R sw OP/CL Displays status of Drive Orientation Limit System override switch. (Displayed if
MODEL NUMBER = 7 or 8)
3121262 – JLG Lift – 6-51

Diagnostics Submenu
1st Line)
BOOM:
U LIFT UP/DOWN XXX% Displays main lift joystick direction & demand
SWING RIGHT/LEFT XXX% Displays swing joystick direction & demand
QPRX1 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
QPRX2 ACTIVE/NOT ACTIVE Displays status of Q-Prox sensor in lift/swing joystick (Displayed if JOYSTICK
TYPE = 1)
LEVEL UP/DOWN XXX% Displays basket level switch direction & demand. NOTE: demand is controlled
by the pump pot
ROT. RIGHT/LEFT XXX% Displays basket rotate switch direction & demand. NOTE: demand is con-
trolled by the pump pot
U TELE IN/OUT XXX% Displays main telescope switch direction & demand. NOTE: demand is con-
T TELE IN/OUT XXX% Displays tower telescope switch direction & demand. NOTE: demand is con-
Not displayed if TOWER TELE=NO (machine digit = 0)
T LIFT UP/DOWN XXX% Displays tower lift switch direction & demand. NOTE: demand is controlled by
the pump pot
Not displayed if TOWER LIFT=NO (machine digit = 0)
JIB UP/DOWN XXX% Displays jib lift switch direction & demand. NOTE: demand is controlled by the
pump pot
Not displayed if JIB = NO (machine digit = 0)
JIB RIGHT/LEFT XXX% Displays jib swing switch direction & demand. NOTE: demand is controlled by
the pump pot
Displayed if JIB = SIDESWING (machine digit = 2)
JIB INLINE OP/CL Displays status of jib inline limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIMIT OP/CL Displays status of jib right limit switch. Displayed on models equipped with
the Jib Stow System
JIB LIM OVRD OP/CL Displays status of jib limit override switch. Displayed on models equipped
with the Jib Stow System
PCV ON/OFF Displays status of Platform Control Valve. Displayed on models equipped with
Electronic Platform Leveling.
PUMP POT XXX% Displays pump pot demand. Not displayed if MODEL = 601 (machine digit =
4)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status
6-52 – JLG Lift – 3121262

Diagnostics Submenu
1st Line)
ENGINE:
START ACTIVE/NOT ACTIVE Displays status of the engine start circuit
AIR FILTER OP/CL Displays measured status of air filter by-pass switch. (Not displayed if MODEL
NUMBER = 7 or 8)
BATTERY XX.XV Displays measured battery voltage
COOLANT XXXC Displays measured coolant temperature
OIL PRS LOW / OK or XXPSI Displays measured oil pressure
FUEL SELECT GAS/LP Displays status of fuel select switch. (Displayed if MODEL NUMBER = 2)
AMB. TEMP XXXC Displays measured ambient air temperature
FUEL LEVEL ¼ / ½ / ¾ / FULL or LOW / OK Displays measured fuel level
XXXX rpm Engine RPM
3121262 – JLG Lift – 6-53

Diagnostics Submenu
1st Line)
SYSTEM:
GM BATTERY XX.XV Ground module battery voltage
PM BATTERY XX.XV Platform module battery voltage
AMB. TEMP XXXC Ambient temperature
FSW1 OP/CL Displays footswitch status. NOTE: FSW1 is wired to the ground module.
FSW2 OP/CL Displays footswitch status. NOTE: FSW2 is wired to the platform module.
ABOVE ELEV. OP/CL/YES/NO Displays above elevation cutout switch status or above angle status
LEN SW 1 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
LEN SW 2 OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 7 or 8)
RETRACTED YES/NO Displays status of boom length retracted (Displayed if MODEL NUMBER = 7 or
8)
TRANSPORT YES/NO Displays status of transport position
U LIFT CUTOUT OP/CL Displays status of boom length retracted limit switch (Displayed if MODEL
NUMBER = 6)
T LIFT PROX OP/CL Displays status of tower lift proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
T TELE PROX OP/CL Displays status of tower telescope proximity switch (Displayed if TOWER PROX
SWITCHES = 1)
BR CABLE CUT. OP/CL Displays status of broken cable switch (Displayed if BROKEN CABLE SWITCH =
1)
CREEP ACTIVE/NOT ACTIVE Displays pump pot creep switch status. Not displayed if MODEL = 601
(machine digit = 4)
SUPER CREEP ON/OFF Displays super creep mode status (Displayed if MODEL NUMBER = 7 or 8)
TILT XX.X DEG Displays measured vehicle tilt. (Displayed if internal tilt sensor is configured)
LO TILTED - NO/YES Displays status of lo tilt input. (Displayed if external tilt sensor is configured)
6-54 – JLG Lift – 3121262

Diagnostics Submenu
1st Line)
HI TILTED - NO/YES Displays status of hi tilt input. (Displayed if external tilt sensor is configured)
AUX POWER OP/CL Displays the status of the auxiliary power switch input
HORN OP/CL Displays the status of the horn input
R FILTER OP/CL Displays the status of the return hydraulic filter by-pass switch. Displayed
ONLY if MODEL = 600 (Configuration digit = 3)
C FILTER OP/CL Displays measured status of charge pump filter bypass switch. Displayed ONLY
if MODEL = 600 (Configuration digit = 3)
JIB BLOCK OP/CL Displays jib block limit switch status. Not displayed if associated configuration
digit = 0
BASKET STOWD YES/NO Displays status of basket stowed mode. (Displayed if MODEL NUMBER = 7 or 8)
SOFT LIMIT OP/CL Displays status of soft touch limit switch. Not displayed if associated configu-
ration digit = 0
SOFT O/R OP/CL Displays status of soft touch override switch. Not displayed if associated con-
figuration digit = 0
GEN SET/WELDER OP/CL Displays generator/welder switch input status. Not displayed if associated
configuration digit = 0
LIGHTS OP/CL Displays head and tail light switch input status. Not displayed if associated
configuration digit = 0
BSK TILT1 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
BSK TILT2 XX.X Displays indicated platform tilt angle. Displayed on models equipped with
AXLE RET SW OP/CL Displays status of axle extension user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE EXT SW OP/CL Displays status of axle retraction user switches. (Displayed if MODEL NUMBER
= 7 or 8)
AXLE LIM SW RET/EXT Displays status of axle extension limit switches. (Displayed if MODEL NUMBER
= 7 or 8)
DOS LIM SW OP/CL Displays status of Drive Orientation System Limit Switch. (Displayed if MODEL
NUMBER = 7 or 8)
DOS O/R SW OP/CL Displays status of Drive Orientation System Override switch. (Displayed if
MODEL NUMBER = 7 or 8)
CAPACITY SW 500/1000 Displays status of capacity selection switch. (Displayed if MODEL NUMBER = 7
or 8)
3121262 – JLG Lift – 6-55

Diagnostics Submenu
1st Line)
OSC AXLE P SW OP/CL Displays status of oscillating axle pressure switch. (Displayed if OSCILLATING
AXLE = 1)
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
(Displayed if MODEL NUMBER = 7 or 8)
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
LOAD: Not displayed if LOAD=NO, LENGTH=NO, and ANGLE=NO (machine digits =

0)
LENGTH OP /CL Displays measured length, NOTE: Not displayed if MODEL NUMBER = 7 or 8
ANGLE OP / CL Displays measured angle, NOTE: Not displayed if MODEL NUMBER = 7 or 8
WEIGHT XXXX% Percentage of maximum calibrated weight on the platform. An uncalibrated

load cell will read 1000% Displayed if LOAD is not 0 and LOAD TYPE is 0.
OK/OVERLOADED Displayed if LOAD is not 0 and LOAD TYPE is 1.
6-56 – JLG Lift – 3121262

Diagnostics Submenu
1st Line)
MOMENT: Displayed if MODEL NUMBER = 7 or 8
(LB-IN) ACTUAL XXXXXXXX Displays current moment value
(LB-IN) XXXXXXXX Displays current over moment setpoint.

OVER
(LB-IN) XXXXXXXX Displays current under moment setpoint.

UNDER
CAL PT XXXXXXXX Displays the under moment value recorded during boom sensor calibration.
UNDER
CAL PT XXXXXXXX Displays the yellow witness mark moment value recorded during boom sen-
WIT YEL sor calibration.
CAL PT XXXXXXXX Displays the green witness mark moment value recorded during boom sensor
WIT GRN calibration.
CYL PIN X.XXX Displays the current cylinder moment pin ratio of X and Y forces.
RATIO
PIN 0xXXXX Displays the current error flag status of the cylinder moment pin.
E FLAGS
SKY WELDER YES/NO Displays the status of Sky Welder selected during boom sensor calibration.
SKY CUTTER YES/NO Displays the status of Sky Cutter selected during boom sensor calibration.
SKY GLAZIER YES/NO Displays the status of Sky Glazier selected during boom sensor calibration.
SKY BRIGHT YES/NO Displays the status of Sky Bright selected during boom sensor calibration.
PIPE RACKS YES/NO Displays the status of Pipe Racks selected during boom sensor calibration.
CAMERA MOUNT YES/NO Displays the status of Camera Mount selected during boom sensor calibration.
3121262 – JLG Lift – 6-57

Diagnostics Submenu
1st Line)
ENVELOPE: Displayed if MODEL NUMBER = 7 or 8
LENGTH XXXX.X Displays the current indicated boom length in inches.
ANGLE 1 XX.X Displays the current indicated boom angle 1 in degrees.
ANGLE 2 XX.X Displays the current indicated boom angle 2 in degrees.
A/D LNGTH XXXXX Displays the current indicated boom length in A/D counts.
A/D ANG1 XXXXX Displays the current indicated boom angle 1 in A/D counts or raw angle if cali-
brated.
A/D ANG2 XXXXX Displays the current indicated boom angle 2 in A/D counts or raw angel if cali-
brated.
CAN STATISTICS: CAN Statistics as detected by the Ground Module
RX/SEC XXX Displays the number of received messages per second
TX/SEC XXX Displays the number of transmitted messages per second
BUS OFF XX Displays the number of bus off occurrences
PASSIVE XX Displays the number of bus passive occurrences
6-58 – JLG Lift – 3121262

Diagnostics Submenu
1st Line)
CALIBRATION DATA
BASKET UP XXX Displays the basket up calibration point
BASKET DOWN XXX Displays the basket down calibration point
L FWD DRIVE XXX Displays the left forward drive calibration point
R FWD DRIVE XXX Displays the right forward drive calibration point
L REV DRIVE XXX Displays the left reverse drive calibration point
R REV DRIVE XXX Displays the right reverse drive calibration point
F LT STEER XXX Displays the forward left steer calibration point
F RT STEER XXX Displays the forward right steer calibration point
R LT STEER XXX Displays the reverse left steer calibration point
R RT STEER XXX Displays the reverse right steer calibration point
U LIFT UP XXX Displays the main lift up calibration point
U LIFT DOWN XXX Displays the main lift down calibration point
U TELE IN XXX Displays the main telescope in calibration point
U TELE OUT XXX Displays the main telescope out calibration point
BM ANG 1 LO XXX Displays the boom angle 1 low calibration point
BM ANG 1 HI XXX Displays the boom angle 1 high calibration point
BM ANG 2 LO XXX Displays the boom angle 2 low calibration point
BM ANG 2 HI XXX Displays the boom angle 2 high calibration point
LEN RETRACT XXX Displays the length sensor retracted calibration point
LEN EXTEND XXXXX Displays the length sensor extended calibration point
LEN WIT XXXXX Displays the witness mark calibration point
LEN SWITCH XXXX Displays the length switch calibration point
3121262 – JLG Lift – 6-59

Diagnostics Submenu
1st Line)
DATALOG:
ON XXXXhXXm Displays total controller on (EMS) time
ENGINE XXXXhXXm Display engine run time
DRIVE XXXXhXXm Displays total controller drive operation time
LIFT XXXXhXXm Displays total controller lift operation time
SWING XXXXhXXm Displays total controller swing operation time
TELE XXXXhXXm Displays total controller telescope operation time
MAX TEMP XXC Displays maximum measured ambient temp.
MIN TEMP XXC Displays minimum measured ambient temp.
MAX VOLTS XX.XV Displays maximum measured battery voltage
RENTAL XXXXhXXm Displays total controller operation time. NOTE: can be reset
ERASE RENTAL? Not available at Access Level 2.

ENTER resets rental data log time to zero.
VERSIONS:
GM SW PX.X Displays ground module software version
GM HW REV XXXX Displays ground module hardware revision
GM SN XXXXXX Displays ground module serial number
PM SW PX.X Displays platform module software version
PM HW REV XXXX Displays platform module hardware revision
PM SN XXXXXX Displays platform module serial number
CM SW PX.X Displays chassis module software version
BM SW PX.X Displays BLAM module software version
C PIN SW Displayed if cylinder moment load pin transmits software version.
C PIN SN Displayed if cylinder moment load pin transmits serial number.
ANALYZER VX.XXXX Displays Analyzer software version
6-60 – JLG Lift – 3121262

6.10 CALIBRATING STEER 1. Position the Platform/Ground select switch to the Plat-
form position.
When calibrating steering, each individual wheel must be cali-
brated in order to make the tire and wheel parallel with the
frame. Two methods to help ensure proper calibration are the
use of a carpenter’s square to square the spindle to the axle or
aligning the two wheels on one side using a stretched string.

3121262 – JLG Lift – 6-61

3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Steer. The screen will read:
engine.
9. Hit Enter. The screen will read:
5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.

6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
6-62 – JLG Lift – 3121262

10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer.
15. Left Rear Steer Calibration will be followed by Right For-
ward Steer Calibration which will be followed by Right
Rear Steer Calibration.
16. After completing all the Steer Calibrations, hit ESC twice
to go back to CALIBRATIONS.
12. Activate the steer control until the tire and wheel are
straight in relationship with the chassis, then leave off
the control. The display will read FRT LEFT = and show
the numeric calibration value for that wheel.
3121262 – JLG Lift – 6-63

6.11 CALIBRATING DRIVE 3. Pull out the Emergency Stop switch and Start the
engine.
1. Position the Platform/Ground select switch to the Plat-
form position.


Enter.
6-64 – JLG Lift – 3121262

8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read:
9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read:
12. Activate the Drive Joystick forward full stroke until the
machine just begins to move, then leave off the joystick
immediately. The display will read CRK PT = and show
the numeric crack point value.
3121262 – JLG Lift – 6-65

13. Hit Enter. The number displayed will be the value that 14. Hit Enter. The screen will read:
the crack point is set to. The screen will show:
15. Repeat steps 10 thru 12 for left reverse drive.

16. Left Reverse Drive Calibration will be followed by Right
Forward Drive Calibration which will be followed by
Right Reverse Calibration.
17. After completing all the Drive Calibrations, hit ESC twice
6-66 – JLG Lift – 3121262

6.12 ELECTRONIC PLATFORM LEVELING VALVE DRIVER ERRORS

There are three possible level valve driver errors, short to bat-
Platform Leveling Fault Warning tery, short to ground, and open circuit.
The JLG Control System takes a snapshot of the two sensor val- 1. In the case of a short to ground or an open circuit, the
ues and records the difference once on each power up. The platform valve cannot be turned on and the following
will occur:
Control system allows a ±5 degree difference from those val-
ues. For example, if Sensor 1 is at 5 degrees and Sensor 2 is at a. All interactions with platform leveling shall cease
11 degrees, the difference is 6 degrees and the DTC is trig-
b. The Electronic Leveling System Fault Lamp shall
gered when the sensors are 1 degree (or less) apart or 11
flash (to indicate that the leveling function has been
degrees (or more) apart.
lost).
If a fault occurs in the platform leveling system the following c. The platform alarm will sound.
will occur:
d. A system fault will be logged.
1. Automatic platform leveling will stop (except when e. All function speeds (lift, swing, telescope and drive)
there is a fault in only one sensor automatic leveling will will be placed in creep mode (except when the plat-
remain active as the control system will use the other form is in the transport position).
sensor to control leveling)
2. In the case of a short to battery on one of the platform
2. The level fault lamp will flash
leveling valves, the valve cannot be turned off and the
3. The audible alarm will sound following will occur:
4. All functions will default to creep speed if the platform is a. The platform dump valve will be turned off to pre-
out of the transport position. vent unintended tilting of the platform.
To reset the fault the emergency stop switch should be recy- b. All interactions with platform leveling shall cease.
cled. c. The Electronic Leveling System Fault Lamp shall
lost).
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE GROUND POSITION, d. The platform alarm will sound.
SWITCH THE MACHINE OFF AND CONTACT A QUALIFIED SERVICE REPRESEN- e. A system fault will be logged.
TATIVE TO INVESTIGATE THE FAULT.
f. All function speeds (lift, swing, telescope and drive)
will be placed in creep mode (except when the plat-
Fault Response form is in the transport position)
ERROR RESPONSE 3. In the case of a short to battery on the platform dump

If basket level varies from the current setpoint by ± 5.5º for valve, the valve cannot be turned off. The controllability
more than 1.5 seconds when the platform is not in the trans- of the platform leveling function will be impaired and
port position, the following events will occur: the following will occur:
1. The platform dump valve will be disabled (level, rotate a. All interactions with platform leveling shall cease.
and jib functions disabled). b. The Electronic Leveling System Fault Lamp shall
2. The level system fault lamp will flash (to indicate that lost).
the leveling function has been lost).
c. The platform alarm will sound.
3. The platform alarm will sound.
d. A system fault will be logged.
4. A system fault will be logged. e. All function speeds (lift, swing, telescope and drive)
5. All function speeds (lift, swing, telescope and drive) will will be placed in creep mode (except when the plat-
be placed in creep mode (except when the platform is in form is in the transport position).
the transport position see below). Lift, swing, drive and telescope will continue to operate
When the unit is in the transport position and driving and the In each of the cases above it shall be necessary to re-cycle the
current setpoint varies by ± 5.5º for more than 8 seconds the EMS to clear the fault. Operable functions shall be in the creep
events 1,2,3 & 4 above will occur. (note function speeds will mode except while below elevation.
operate normally). Cycling the EMS will clear the fault and
allow the operator to operate the machine as a new level set-
point is taken.
3121262 – JLG Lift – 6-67

TILT SENSOR ERRORS 6.13 CALIBRATING PLATFORM LEVEL

If the secondary tilt sensor is faulty, the control system will
continue to utilize information from the primary sensor. STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
If the primary sensor is faulty, the control system will switch to 1. Position the Platform/Ground select switch to the
the backup sensor for control. Ground position.
In both cases above the following will occur:
1. The Electronic Leveling System Fault Lamp will flash (to

indicate that there is a leveling fault).
3. A system fault will be logged.
4. All function speeds (lift, swing, telescope, jib and drive)

will be placed in creep mode (except when the platform
is in the transport position).
5. Automatic leveling remains active.
Lift, swing, drive and telescope will continue to operate.
In each of the cases above it will be necessary to re-cycle the

EMS to clear the fault. Operable functions shall be in the creep 2. Plug the analyzer into the connector inside the Ground
mode except while below elevation. control box.
When both sensors appear to be working but have measure-
ments that disagree by ±5.5º The following will occur:
1. All interactions with platform leveling shall cease.
2. The Electronic Leveling System Fault Lamp shall flash (to

indicate that the leveling function has been lost).
4. A system fault will be logged.
5. All function speeds (lift, swing, telescope and drive) will

be placed in creep mode (except when the platform is in
the transport position)
At this point, the operator must use the level up and down
toggle switch to manually level during descent. It shall be nec-
essary to re-cycle the EMS to clear the fault.
3. Pull out the Emergency Stop switch and start the
engine.
6-68 – JLG Lift – 3121262

4. The analyzer screen should read: STEP 2: BLEEDING THE PLATFORM VALVES
Ground position.

control box.

7. Use the arrow button to reach PERSONALITIES adjust
the following personalities. Refer to the Personality
Ranges/Defaults table for proper setting values.
Basket Level Up Min

Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
8. Recycle EMS.

engine.
3121262 – JLG Lift – 6-69

4. The analyzer screen should read: STEP 3: CALIBRATING THE PLATFORM LEVEL UP AND
DOWN VALVE CRACKPOINTS
Ground position.

control box.

7. Go to the PERSONALITIES menu.
8. Using the left arrow button, go to the GROUND MODE
menu.
9. Hit ENTER.
10. Using the UP/DOWN arrows, adjust the following per-
sonalities to 100%.
Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform

function (from the ground) eight (8) to ten (10) times for 3. Pull out the Emergency Stop switch and start the
5 seconds in each direction. engine.
11. Return the personality settings back to the values as

shown in the Personality Ranges/Defaults table in Sec-
tion 6 - JLG Control System.
12. Recycle EMS.
6-70 – JLG Lift – 3121262

4. The analyzer screen should read: 11. Using UP ARROW, increase the value until you see the
basket up movement.
12. Hit ENTER again. CAL. COMPLETE message should
appear
13. Engine should again return to idle.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”
screen. Hit ENTER.
16. CALIBRATE? prompt should appear. Hit ENTER again.
17. You will hear engine go to 1800 rpm.
Using UP ARROW, increase the value until you see the basket
down movement.
Hit ENTER again. CAL. COMPLETE message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
6.14 CALIBRATING LIFT CRACK POINT

5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. form position.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the BASKET U CRKPT Screen. Hit ENTER.
3121262 – JLG Lift – 6-71

2. Plug the analyzer into the connector at the base of the 4. The analyzer screen should read:
3. Pull out the Emergency Stop switch and Start the

engine.

Enter.
6-72 – JLG Lift – 3121262

8. Use the arrow keys to reach Upper Lift Crack Point 10. Hit Enter. The screen will read:
(UPPER LIFT CRKPT). The screen will read:
11. Hit Enter again. The screen will read:

9. Hit enter. The screen will read:
12. Activate the Lift Up function by fully stroking the joy-

stick until the boom starts to move, then leave off imme-
diately. The display will read CRK PT = and show the
numeric crack point value.
3121262 – JLG Lift – 6-73

13. Hit enter. The number displayed will be the value that 6.15 CALIBRATING TELESCOPE CRACK POINT
form position.

15. Repeat steps 10 thru 12 for the Lift Down function.

16. After completing all the Tele Calibrations, hit ESC twice
6-74 – JLG Lift – 3121262

3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Upper Telescope Crack Point
engine. (UPPER TELE CRKPT). The screen will read:

Enter.
3121262 – JLG Lift – 6-75

10. Hit Enter. The screen will read: NOTE: In the following step, a minimum value of 10 must be indi-
cated on the analyzer before the crack point can be set. The
JLG Control System will not accept a value less than 10 and
the analyzer will not advance to "CAL COMPLETE" if the
crack point is set at a lesser value.
12. While reading the crack point setting on the analyzer,

activate the Tele Out function until the boom starts to
move or until the crack point setting reaches a value of
10 if the boom begins to move at a value lesser than 10,
then leave off the control switch immediately. The dis-
play will read CRK PT = and show the numeric crack
point value.
13. Hit enter. The number displayed will be the value that
11. Hit enter again. The screen will read:
6-76 – JLG Lift – 3121262

14. Hit Enter. The screen will read: 15. Hit Enter. The screen will read:
16. Repeat steps 10 thru 12 for the Tele In function.
17. After completing all the Tele Calibrations, hit ESC twice
3121262 – JLG Lift – 6-77

6.16 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the Ground
control box.
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE
FOLLOWING PROCEDURE IS PERFORMED.
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE.
1. Use the following procedure to calibrate the tilt sensor.
Before the tilt sensor can be calibrated, the following

conditions must be met:
a. Steering previously calibrated.
b. Axles extended.
c. Wheels straight.
d. Turntable centered. 4. Pull out the Emergency Stop switch and start the
e. Boom fully retracted. engine.
f. Boom angle is less than 45°. 5. The analyzer screen should read:
g. Machine on firm, level ground.
Ground position.

Enter.
6-78 – JLG Lift – 3121262

9. Use the arrow keys to reach the TILT SENSOR. The screen 11. When prompted, swing turntable 180° to opposite end
should read: of chassis.
12. Press ENTER. The screen should read:
10. Press ENTER.
13. Upon completing swing calibration, swing turntable

180° back to the stowed position.
14. Hit ESC twice to go back to CALIBRATIONS.
3121262 – JLG Lift – 6-79

6.17 JIB SENSOR CALIBRATIONS 4. The analyzer screen should read:
To calibrate the jib sensors, the analyzer must be in access

level 1. All jib sensors can be calibrated at one time or each cal-
ibration can be performed on an individual basis.
Ground position.

control box. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.
Enter.

engine.
6-80 – JLG Lift – 3121262

8. Use the arrow keys to reach the JIB SENSORS. The screen 10. Press ENTER. The screen should read as shown below.
should read: When it does, activate boom lift until the control system
stops it at 20 degrees boom angle.
9. Press ENTER. The screen should read:
3121262 – JLG Lift – 6-81

11. Press ENTER. The screen should read as shown below. 12. If the operator presses enter at the jib lift sensor calibra-
When it does, the operator can either press enter to tion prompt, the screen shown below will be displayed.
begin the jib lift sensor calibration, or use the right or At this point, lift the jib up to the mechanical stop.
left arrow key to locate the desired jib sensor calibration.
The available sensor calibrations are:
JIB LIFT
JIB LEVEL
JIB SWING
PLATFORM LEVEL
13. When the jib is at the mechanical stop, press ENTER. The
screen shown below will be displayed. At that point, jib
lift down until the control system stops the jib.
6-82 – JLG Lift – 3121262

14. Once the jib is stopped the screen shown below will be 16. Hitting the ENTER key at this point will take the operator
displayed. to the next jib sensor calibration. The screen will show:
15. Hitting the escape key (ESC) will take the system back to 17. Press Enter. The screen will show:
the initial jib lift calibration display.
NOTE: At this point the left or right arrow key may be used to skip
to any of the other jib sensor calibrations.
3121262 – JLG Lift – 6-83

18. Operate jib lift down until the jib stops. When the jib is 20. Press ENTER. The screen should read:
at the mechanical stop the operator must hit ENTER
again. The screen will show:
21. Operate jib lift up until the jib stops. When the jib is at
the mechanical stop, Hit ENTER again. The screen will
show:
19. When the system completes this step, the next screen
will show:
6-84 – JLG Lift – 3121262

22. When the system completes this step, the next screen 24. When the system completes the previous step, the
will show: screen will read:
23. Press ENTER. The screen should read as shown below. 25. Hitting the escape key (ESC) will take the system back to
The control system will jib level down and stop the jib the initial jib lift calibration display.
leveling command.
NOTE: At this point the left or right arrow key may be used to skip
to any of the other jib sensor calibrations.
3121262 – JLG Lift – 6-85

26. Hitting the ENTER key at this point will take the operator 28. When the jib reaches the mechanical stop, press ENTER.
to the next jib sensor calibration. The screen will show: The screen will show:
27. Press Enter. The screen shown below will be displayed. 29. When the system is complete with this step, the screen
At this point, use the platform rotate right function below will be displayed.
switch to swing the jib right.
6-86 – JLG Lift – 3121262

30. Press Enter. The screen shown below will be displayed. 32. At the finish of the jib swing lift calibration the jib lock
At this point, use the platform rotate left function switch pin will be locked by the control system. The screen will
to swing the jib left. read:
31. When the jib is at the mechanical stop, press ENTER. The 33. Press ENTER. The screen will show:
screen will show:
34. Hitting the escape key (ESC) will take the system back to
the initial jib lift calibration display.
3121262 – JLG Lift – 6-87

NOTE: At this point the left or right arrow key may be used to skip 37. When the platform level up is at mechanical stop, Press
to any of the other jib sensor calibrations. ENTER. The screen will show:
35. Hitting the ENTER key at this point will continue the cali-
bration sequence. The screen will show:
38. When the system is complete with this step, the screen
below will be displayed.
36. Press Enter. The screen shown below will be displayed.

At this point, use the platform level up function switch
to level up.
6-88 – JLG Lift – 3121262

39. Press ENTER. The display will then show: 40. The control system will stop the platform level and the
screen will show:
41. Pressing ENTER will take you back to the beginning and
escape (ESC) will take you to the initial screen.
Calibrating the Jib Level Up and Down Valve

Crackpoints
Ground position.
3121262 – JLG Lift – 6-89

2. Plug the analyzer into the connector inside the Ground 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.
control box.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the JIB LVL UP CRKPT Screen. Hit ENTER.
11. Using UP ARROW, increase the value until you see the jib
level movement.
12. Hit ENTER again. CAL. COMPLETE message should
appear
13. Engine should again return to idle.
14. Hit ESC should return to JIB LVL UP CRKPT screen.
15. Hit RIGHT ARROW to get to the JIB LVL DN CRKPT screen.
Hit ENTER.
3. Pull out the Emergency Stop switch and start the 16. CALIBRATE? prompt should appear. Hit ENTER again.
engine.
4. The analyzer screen should read: Using UP ARROW, increase the value until you see the jib level
down movement.
Hit ENTER again. CAL. COMPLETE message should appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
6-90 – JLG Lift – 3121262

6.18 CALIBRATING THE BOOM SENSORS 2. Position the Platform/Ground select switch to the
Ground position.
DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS NORMAL FOR

THE REAR WHEEL TO LIFT FROM THE GROUND APPROXIMATELY 1 INCH (2.5
CM). IF THE WHEEL RAISES APPRECIABLY MORE THAN THIS (I.E. 4 INCHES [10
CM] OR MORE), CHECK THE AXLE OSCILLATION SYSTEM FOR PROPER OPERA-
TION OR THE NEED FOR BLEEDING, THEN PROCEED WITH THE BOOM SENSOR
CALIBRATION PROCEDURE.
Use the following step-by-step procedure to calibrate the

boom sensors.
1. Before the boom sensors can be calibrated, the follow-

ing conditions must be met:
a. Steering, telescope crack points, and tilt previously
calibrated
b. Axles Extended
c. Wheels Straight control box.
d. Platform Unloaded
e. Jib Horizontal
f. Jib Swing Centered
g. Platform Level
h. Platform Centered
i. Turntable Centered
j. Boom Fully Retracted
k. Level Ground (within 1.5°)
Figure 6-21. Boom Sensor Calibration Position 1

engine.
3121262 – JLG Lift – 6-91

5. The analyzer screen should read: 9. Use the arrow keys to reach BOOM SENSORS. The screen
should read:

Enter.
6-92 – JLG Lift – 3121262

11. After verifying all the conditions listed in step 1 are met, 13. After visually verifying that the jib is horizontal, hit Enter.
hit Enter. The screen will read: The screen will read:
12. After verifying all load (personnel or material) is 14. After visually verifying the platform is level, hit Enter. The
removed from the platform, hit Enter. The screen will screen will read:
read:
3121262 – JLG Lift – 6-93

15. After visually verifying the platform is centered, hit 17. Use the up/down arrows to select YES if the accessory is
Enter. The screen will read: installed, NO if it is not installed and hit enter. The screen
will read:
16. After operating telescope in to verify the boom is fully

retracted, hit Enter. The screen will read: 18. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen
will read:
6-94 – JLG Lift – 3121262

19. Use the up/down arrows to select YES if the accessory is 21. Use the up/down arrows to select YES if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, NO if it is not installed and hit enter. The screen
will read: will read:
20. Use the up/down arrows to select YES if the accessory is 22. Use the up/down arrows to select yes if the accessory is
installed, NO if it is not installed and hit enter. The screen installed, no if it is not installed and hit Enter. The screen
will read: will read:
3121262 – JLG Lift – 6-95

23. After making sure the machine is in Calibration Position The screen will read:
1, hit Enter. The screen will read:
24. Lift up to stop (full stroke of cylinder) for Calibration

Position 2. When the machine is in that position, hit
Enter.
6-96 – JLG Lift – 3121262

25. Swing 180 degrees (centered over opposite end of chas- When Position 3 calibrating is complete the screen will
sis) for Calibration Position 3. read:
When the machine is in the proper position, hit Enter.

The screen will read:
3121262 – JLG Lift – 6-97

26. Press Enter. The screen will read: When the machine is in the proper position, hit Enter.
Swing the machine back 180 degrees (centered over When Position 4 calibrating is complete, the screen will
original end of chassis) for Calibration Position 4. read:
6-98 – JLG Lift – 3121262

27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter.
Telescope out to stop (boom must be fully extended) for

Calibration Position 5.
3121262 – JLG Lift – 6-99

28. Retract to stop (boom must be fully retracted) for Cali- 29. Lift down to stop (boom must be on boom rest) for Cali-
bration Position 6. bration Position 7.

The screen will read as follows:

6-100 – JLG Lift – 3121262

When Position 7 Calibrating is complete, the screen will 30. Lift until the function stops (controller will stop at 5
read: degrees above horizontal) for Calibration Position 8.

Press Enter. The screen will read:
3121262 – JLG Lift – 6-101

Press Enter. The screen will read: When the boom is in the proper position, hit Enter. The
screen will read:
31. Telescope to the yellow witness mark (controller will be

close - operator must position the pointer to center line When Position 9 calibrating is complete, the screen will
on decal within 0.25" [6 mm]) for Calibration Position 9. read:
6-102 – JLG Lift – 3121262

Press Enter. The screen will read: When the boom is in the proper position, the screen will
read:
32. Telescope in to green witness mark (controller will find

the position - operator must visually verify the position). Pressing enter will bring up:
3121262 – JLG Lift – 6-103

33. Operate the Lift Up function switch. The control system 35. Operate the Jib Telescope Out function to the mechani-
will stop the boom at the desired angle. The display will cal stop. Press ENTER. The display will read:
read:
36. When the control system completes the calibration step

34. Operate the Telescope Out function switch. The control the display will read:
system will stop the boom at the desired length. The dis-
play will read:
6-104 – JLG Lift – 3121262

37. Operate the Jib Telescope In function switch until the jib 39. When the calibration step is done, the display will read:
is telescoped in to the mechanical stop. Press ENTER.
The display will read:
40. Press ENTER. The display will read:
38. Operate the Boom Telescope In function switch. The

control system will stop the boom at the desired length.
The display will read:
3121262 – JLG Lift – 6-105

41. Operate the Main Boom Telescope function until the 43. Press ENTER. The display will read:
main boom is telescoped in to the stop. The display will
read:
44. After completing all the Boom Sensors Calibrations, hit

ESC twice to go back to Calibrations.
42. Operate the Boom Lift Down function until the main
45. Cycle the emergency stop switch.
boom is lifted down to the rest. The display will read:
6-106 – JLG Lift – 3121262

Boom Control System Check Procedure 5. Push and hold the gray Boom Control System Test But-
ton on the ground control panel. The lighting of the
Perform the following check with no load (personnel or mate-
green Boom Control System Calibrated indicator indi-
rial) in the platform from the ground control station.
cates the system is functioning properly. No indicator
1. With the boom fully retracted, raise the boom off the light or the lighting of the red Boom Control System
boom rest to horizontal. Warning indicator indicates the system must be repaired
by JLG authorized Service Personnel before the machine
2. Position the jib horizontal, jib straight, and platform can be used.
level.
3. Extend the boom until it stops.
4. Boom must stop on colored stripe matching the capac-

ity indicator. If the boom does not stop on the correct
stripe, the system must be repaired by JLG authorized
Service Personnel before the machine can be used.
3121262 – JLG Lift – 6-107

FAULT
CODE
LIGHT
1706741A
1705744 A
1702566 B 1702565 B
1001125195 B
1702938 1705170 A
1001125194 A
PLATFORM
CONTROL
MODULE
GROUND
FAULT
CONTROL CODE
MODULE
LIGHT
Figure 6-31. Fault Code Light Location
6-108 – JLG Lift – 3121262

Table 6-8. Diagnostic Trouble Code Chart
Flash
DTC Sequence Fault Message Fault Description Check
Code
001 00 1 EVERYTHING OK The normal help message in
Platform Mode.
002 00 2 GROUND MODE OK The normal help message in
Ground Mode.
0010 00 10 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELE-
VATED MAX" while the vehicle is
out of transport position.
000 00 0 <<< HELP COMMENT >>>
0011 00 11 FSW OPEN A drive / boom function was
selected with the Footswitch
open.
0012 00 12 RUNNING AT CREEP - CREEP SWITCH OPEN All functions at creep while the
Creep Switch is open.
0013 00 13 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All functions at creep while the
Platform is elevated and the
Chassis is tilted.
0014 00 14 CHASSIS TILT SENSOR OUT OF RANGE The Chassis is tilted > 19 - Not reported during power-up.
degrees for more then 4 sec-
onds.
0016 00 16 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED There is an envelope violation. - Envelope control system
equipped vehicle only.
0017 00 17 OVER MOMENT - HYDRAULICS SUSPENDED There is an over moment viola- - Envelope control system
tion. equipped vehicle only.
0018 00 18 UNDER MOMENT - HYDRAULICS SUSPENDED There is an under moment viola- - Envelope control system
tion. equipped vehicle only.
0021 00 21 ADS 1213 REINITIALIZED
0030 00 30 RUNNING AT CREEP - PLATFORM STOWED
0031 00 31 FUEL LEVEL LOW - ENGINE SHUTDOWN
0035 00 35 APU ACTIVE
0037 00 37 JIB UNLOCKED OUT OF TRANSPORT - HYDRAULICS SUSPENDED
0038 00 38 SWING ENVELOPE ENCROACHED - HYDRAULICS
SUSPENDED
210 21 0 <<< POWER-UP >>>
211 21 1 POWER CYCLE The normal help message is
issued at each power cycle.
212 21 2 KEYSWITCH FAULTY Both Platform and Ground
modes are selected simultane-
ously.
213 21 3 FSW FAULTY Both Footswitches are closed for
more then one second.
3121262 – JLG Lift – 6-109

Flash
Code
220 22 0 <<< PLATFORM CONTROLS >>>
227 22 7 STEER SWITCHES FAULTY Both Steer Left and Steer Right
inputs are closed simultane-
ously.
2211 22 11 FSW INTERLOCK TRIPPED The Footswitch was closed for - Can be reported during power-
more then seven seconds. up.
2212 22 12 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected - Can be reported during power-
with Footswitch open. up.
2213 22 13 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected
with Footswitch open.
2215 22 15 D/S JOY. OUT OF RANGE LOW The D/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2216 22 16 D/S JOY. OUT OF RANGE HIGH The D/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2217 22 17 D/S JOY. CENTER TAP BAD The D/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2218 22 18 L/S JOY. OUT OF RANGE LOW The L/S Joystick reference volt- - Resistive joysticks, these faults
age is low. do not occur.
2219 22 19 L/S JOY. OUT OF RANGE HIGH The L/S Joystick reference volt- - Resistive joysticks.
age is > 8.1V. - If the reference voltage is > 7.7V
then the reference voltage is out
of tolerance of a short to battery
has occurred.
2220 22 20 L/S JOY. CENTER TAP BAD The L/S Joystick center tap volt- - Resistive joysticks.
age is < 3.08V or > 3.83V. - There is a +/- .1V range. around
these values due to resistor toler-
ances
2221 22 21 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A lift / swing function was
selected with Footswitch open.
2222 22 22 WAITING FOR FSW TO BE OPEN The Footswitch was closed dur- - Can be reported during power-
ing Platform selection. up.
2223 22 23 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE A boom function was selected
with Footswitch open.
2224 22 24 FOOTSWITCH SELECTED BEFORE START The Footswitch was closed dur-
ing engine start.
6-110 – JLG Lift – 3121262

Flash
Code
240 24 0 <<< OTHER CONTROLS >>>
250 25 0 <<< FUNCTION PREVENTED >>>
259 25 9 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS The model selection has been
changed.
2513 25 13 GENERATOR MOTION CUTOUT ACTIVE Driving is not possible while the
vehicle generator is running
AND is configured to prevent
drive.
2514 25 14 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible
while the vehicle is being driven
AND is configured to not allow
simultaneous drive & boom
operation.
2515 25 15 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the
vehicle above elevation AND is
configured to prevent drive
while above elevation.
2516 25 16 DRIVE PREVENTED - ABOVE ELEVATION Driving is not possible while
Boom functions are selected
AND is configured to not allow
simultaneous drive & boom
operation.
2517 25 17 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the
vehicle is tilted and above eleva-
tion AND is configured to pre-
vent drive while tilted and
above elevation.
2521 25 21 JIB SWING PREVENTED - IN 1000# MODE JIB Swing is not possible while
the vehicle is in 1000 LB Mode.
2522 25 22 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED CAN Dongle attached. Very lim-
ited restrictions for all hydrau-
lics systems.
2546 25 46 MACHINE SETUP FAULT - JIB SWING
2547 25 47 MACHINE SETUP FAULT - MODEL
330 33 0 <<< GROUND OUTPUT DRIVER >>>
331 33 1 BRAKE - SHORT TO BATTERY There is a Short to Battery to the
Brake Valve.
332 33 2 BRAKE - OPEN CIRCUIT There is an Open Circuit to the
Brake Valve.
3311 33 11 GROUND ALARM - SHORT TO BATTERY There is a Short to Battery to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3316 33 16 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Forward Drive Valve. cles only.
3121262 – JLG Lift – 6-111

Flash
Code
3317 33 17 RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3318 33 18 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3320 33 20 RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Right Reverse Drive Valve. cles only.
3321 33 21 RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3322 33 22 RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3324 33 24 LEFT FORWARD DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Forward Drive Valve. cles only.
3325 33 25 LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3326 33 26 LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3328 33 28 LEFT REVERSE DRIVE PUMP - SHORT TO GROUND There is a Short to Ground to the - Chassis Module equipped vehi-
Left Reverse Drive Valve. cles only.
3329 33 29 LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT There is an Open Circuit to the - Chassis Module equipped vehi-
3330 33 30 LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY There is a Short to Battery to the - Chassis Module equipped vehi-
3336 33 36 ALTERNATOR/ECM POWER - SHORT TO GROUND There is a Short to Ground to the
Alternator/ECM.
3338 33 38 ALTERNATOR POWER - OPEN CIRCUIT There is an Open Circuit to the
Alternator.
3339 33 39 ALTERNATOR POWER - SHORT TO BATTERY There is a Short to Battery to the
Alternator
3340 33 40 AUX POWER - SHORT TO GROUND There is a Short to Ground to the
Auxiliary Power Pump Relay.
3341 33 41 AUX POWER - OPEN CIRCUIT There is an Open Circuit to the
3342 33 42 AUX POWER - SHORT TO BATTERY There is a Short to Battery to the
6-112 – JLG Lift – 3121262

Flash
Code
3343 33 43 COLD START ADVANCE SOLENOID - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Cold Start Advance Solenoid.
3344 33 44 COLD START ADVANCE SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
3345 33 45 COLD START ADVANCE SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
3349 33 49 ELECTRIC PUMP - SHORT TO GROUND There is a Short to Ground to the - CAT engines only.
Pump Relay.
3350 33 50 ELECTRIC PUMP - OPEN CIRCUIT There is an Open Circuit to the - CAT engines only.
Pump Relay.
3351 33 51 ELECTRIC PUMP - SHORT TO BATTERY There is a Short to Battery to the - CAT engines only.
Pump Relay.
3358 33 58 MAIN DUMP VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Dump Valve.
3359 33 59 MAIN DUMP VALVE - OPEN CIRCUIT There is an Open Circuit to the
Main Dump Valve.
3360 33 60 MAIN DUMP VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Dump Valve.
3361 33 61 BRAKE - SHORT TO GROUND There is a Short to Ground to the
Brake Valve.
3362 33 62 START SOLENOID - SHORT TO GROUND There is a Short to Ground to the - Diesel engines only.
Start Relay.
3363 33 63 START SOLENOID - OPEN CIRCUIT There is an Open Circuit to the - Diesel engines only.
Start Relay.
3364 33 64 START SOLENOID - SHORT TO BATTERY There is a Short to Battery to the - Diesel engines only.
Start Relay.
3368 33 68 TWO SPEED VALVE - SHORT TO GROUND There is a Short to Ground to the
Two Speed Valve.
3369 33 69 TWO SPEED VALVE - OPEN CIRCUIT There is an Open Circuit to the
Two Speed Valve.
3370 33 70 TWO SPEED VALVE - SHORT TO BATTERY There is a Short to Battery to the
Two Speed Valve.
3371 33 71 GROUND ALARM - SHORT TO GROUND There is a Short to Ground to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3372 33 72 GROUND ALARM - OPEN CIRCUIT There is an Open Circuit to the - Ground Alarm equipped vehicles
Ground Alarm. only.
3373 33 73 GEN SET/WELDER - SHORT TO GROUND There is a Short to Ground to the - Generator / Welder equipped
Generator Relay. vehicles only.
3374 33 74 GEN SET/WELDER - OPEN CIRCUIT There is an Open Circuit to the - Generator / Welder equipped
3375 33 75 GEN SET/WELDER - SHORT TO BATTERY There is a Short to Battery to the - Generator / Welder equipped
3376 33 76 HEAD TAIL LIGHT - SHORT TO GROUND There is a Short to Ground to the - Head Light equipped vehicles
Head Light Relay. only.
3121262 – JLG Lift – 6-113

Flash
Code
3377 33 77 HEAD TAIL LIGHT - OPEN CIRCUIT There is an Open Circuit to the - Head Light equipped vehicles
3378 33 78 HEAD TAIL LIGHT - SHORT TO BATTERY There is a Short to Battery to the - Head Light equipped vehicles
3379 33 79 HOUR METER - SHORT TO GROUND There is a Short to Ground to the
Hour Meter.
3380 33 80 HOUR METER - OPEN CIRCUIT There is an Open Circuit to the - Can be reported during power-
Hour Meter. up.
3381 33 81 HOUR METER - SHORT TO BATTERY There is a Short to Battery to the
Hour Meter.
3385 33 85 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Up Override equipped vehicles only.
Valve.
3386 33 86 PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3387 33 87 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3391 33 91 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Level Down Override equipped vehicles only.
Valve.
3392 33 92 PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
Valve.
3393 33 93 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Valve.
3394 33 94 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Left Valve.
3395 33 95 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3396 33 96 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY There is a Short to Battery to the
3397 33 97 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Rotate Right Valve.
3398 33 98 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT There is an Open Circuit to the
3399 33 99 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY There is a Short to Battery to the
33120 33 120 MAIN TELESCOPE IN VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope In Valve.
6-114 – JLG Lift – 3121262

Flash
Code
33123 33 123 MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY There is a Short to Battery to the
Main Telescope Out Valve.
33130 33 130 THROTTLE ACTUATOR - SHORT TO GROUND There is a Short to Ground to the
Throttle Actuator.
33131 33 131 THROTTLE ACTUATOR - OPEN CIRCUIT There is an Open Circuit to the
Throttle Actuator.
33132 33 132 THROTTLE ACTUATOR - SHORT TO BATTERY There is a Short to Battery to the
Throttle Actuator.
33133 33 133 PLATFORM CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the - Electronic leveling system
Platform Control Valve. equipped vehicles only.
33134 33 134 PLATFORM CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the - Electronic leveling system
33135 33 135 PLATFORM CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
33150 33 150 LIFT PILOT VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Pilot Valve. cles only.
33151 33 151 LIFT PILOT VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33152 33 152 LIFT PILOT VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33153 33 153 LIFT DOWN AUX VALVE - SHORT TO GROUND There is a Short to Ground to the - Gravity Lift Down equipped vehi-
Lift Down Auxiliary Valve. cles only.
33154 33 154 LIFT DOWN AUX VALVE - OPEN CIRCUIT There is an Open Circuit to the - Gravity Lift Down equipped vehi-
33155 33 155 LIFT DOWN AUX VALVE - SHORT TO BATTERY There is a Short to Battery to the - Gravity Lift Down equipped vehi-
33173 33 173 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY There is a Short to Battery or an
OR OPEN CIRCUIT Open Circuit to the Axle Lockout
Valve.
33174 33 174 RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIR- There is a Short to Battery or an
CUIT Open Circuit to the Brake.
33182 33 182 LIFT VALVES - SHORT TO BATTERY
33186 33 186 MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT There is an Open Circuit to the
33188 33 188 MAIN TELESCOPE OUT VALVE - SHORT TO GROUND There is a Short to Ground to the
33189 33 189 MAIN TELESCOPE IN VALVE - OPEN CIRCUIT There is an Open Circuit to the
3121262 – JLG Lift – 6-115

Flash
Code
33190 33 190 MAIN TELESCOPE IN VALVE - SHORT TO GROUND There is a Short to Ground to the
33207 33 207 HORN - OPEN CIRCUIT There is an Open Circuit to the
Horn.
33208 33 208 HORN - SHORT TO BATTERY There is a Short to Battery to the
Horn.
33209 33 209 HORN - SHORT TO GROUND There is a Short to Ground to the
Horn.
33279 33 279 GLOWPLUG - OPEN CIRCUIT There is an Open Circuit to the - Glowplugs equipped vehicles
Glow Plugs. only.
33280 33 280 GLOWPLUG - SHORT TO BATTERY There is a Short to Battery to the - Glowplugs equipped vehicles
Glow Plugs. only.
33281 33 281 GLOWPLUG - SHORT TO GROUND There is a Short to Ground to the - Glowplugs equipped vehicles
Glow Plugs. only.
33285 33 285 ALTERNATOR EXCITATION LINE - SHORT TO BATTERY
33307 33 307 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Telescope Flow Control
Valve.
33308 33 308 MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
Valve.
33309 33 309 MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
Valve.
33311 33 311 MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND There is a Short to Ground to the
Main Lift Flow Control Valve.
33312 33 312 MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT There is an Open Circuit to the
33313 33 313 MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY There is a Short to Battery to the
33429 33 429 JIB LIFT UP OVERRIDE VALVE - SHORT TO GROUND
33430 33 430 JIB LIFT UP OVERRIDE VALVE - OPEN CIRCUIT
33431 33 431 JIB LIFT UP OVERRIDE VALVE - SHORT TO BATTERY
33432 33 432 JIB LIFT DOWN OVERRIDE VALVE - SHORT TO GROUND
33433 33 433 JIB LIFT DOWN OVERRRIDE VALVE - OPEN CIRCUIT
33434 33 434 JIB LIFT DOWN OVERRIDE VALVE - SHORT TO BATTERY
33435 33 435 JIB CONTROL VALVE - SHORT TO GROUND
33436 33 436 JIB CONTROL VALVE - OPEN CIRCUIT
33437 33 437 JIB CONTROL VALVE - SHORT TO BATTERY
340 34 0 <<< PLATFORM OUTPUT DRIVER >>>
343 34 3 PLATFORM LEVEL UP VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Up Valve.
6-116 – JLG Lift – 3121262

Flash
Code
344 34 4 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Open Circuit to the Platform equipped vehicles only.
Level Up Valve.
347 34 7 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND There is a Short to Ground to the
Platform Level Down Valve.
348 34 8 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an - Electronic leveling system
Level Down Valve.
3427 34 37 JIB LOCK VALVE - OPEN CIRCUIT
3428 34 38 JIB LOCK VALVE - SHORT TO BATTERY
3429 34 29 JIB LOCK VALVE - SHORT TO GROUND
3430 34 30 JIB UNLOCK VALVE - OPEN CIRCUIT
3431 34 31 JIB UNLOCK VALVE - SHORT TO BATTERY
3432 34 32 JIB UNLOCK VALVE - SHORT TO GROUND
350 35 0 <<< OTHER OUTPUT DRIVERS >>>
351 35 1 JIB LEVEL UP VALVE - SHORT TO GROUND
352 35 2 JIB LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
353 35 3 JIB LEVEL DOWN VALVE - SHORT TO GROUND
354 35 4 JIB LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
355 35 5 JIB LIFT UP VALVE - SHORT TO GROUND
356 35 6 JIB LIFT UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
357 35 7 JIB LIFT DOWN VALVE - SHORT TO GROUND
358 35 8 JIB LIFT DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
359 35 9 JIB ROTATE LEFT VALVE - SHORT TO GROUND
3510 35 10 JIB ROTATE LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
3511 35 11 JIB ROTATE RIGHT VALVE - SHORT TO GROUND
3512 35 12 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
3513 35 13 JIB TELESCOPE IN VALVE - SHORT TO GROUND
3514 35 14 JIB TELESCOPE IN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
3515 35 15 JIB TELESCOPE OUT VALVE - SHORT TO GROUND
3516 35 16 JIB TELESCOPE OUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
430 43 0 <<< ENGINE >>>
431 43 1 FUEL SENSOR SHORT TO BATTERY The Fuel Sensor reading is >
4.3V.
432 43 2 FUEL SENSOR SHORT TO GROUND The Fuel Sensor reading is <
0.2V.
3121262 – JLG Lift – 6-117

Flash
Code
433 43 3 OIL PRESSURE SHORT TO BATTERY The Oil Pressure Sensor reading - Deutz engine only.
is > 6.6V.
434 43 4 OIL PRESSURE SHORT TO GROUND The Oil Pressure Sensor reading - Deutz engine only.
is < 0.1V for more then 5 sec- - Not reported during engine
onds. start.
435 43 5 COOLANT TEMPERATURE SHORT TO GROUND The Coolant Temperature Sen- - Deutz engine only.
sor reading is < 0.1V.
437 43 7 ENGINE TROUBLE CODE Displays engine SPN FMI code.
438 43 8 HIGH ENGINE TEMP (Ford engine only) The engine - Ford / Deutz engine only.
temperature is > 117 C.
(Deutz engine only) The engine
temperature is > 130 C.
439 43 9 AIR FILTER BYPASSED The Air Filter is clogged.
4310 43 10 NO ALTERNATOR OUTPUT Battery voltage is < 11.5 volts
for more then 15 seconds after
engine start.
4311 43 11 LOW OIL PRESSURE (Ford engine only) The ECM has - Ford / Deutz engine only.
reported a low oil pressure fault.
(Deutz engine only) Oil pressure
is < 8 PSI for more then 10 sec-
onds after engine start.
4313 43 13 THROTTLE ACTUATOR FAILURE The engine RPM is > XXX for
more then XX seconds.
4314 43 14 WRONG ENGINE SELECTED - ECM DETECTED A ECM was detected with a non-
ECM type engine selected.
4322 43 22 LOSS OF ENGINE SPEED SENSOR The engine RPM sensor indi- - Diesel engine only.
cates 0 RPM AND the Oil Pressure
Sensor indicates > 8 PSI for
three seconds.
4323 43 23 SPEED SENSOR READING INVALID SPEED The engine RPM sensor indi- - Diesel engine only.
cates > 4000 RPM.
440 44 0 <<< BATTERY SUPPLY >>>
441 44 1 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Battery voltage is < 9V.
442 44 2 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Battery voltage is > 16V.
443 44 3 LSS BATTERY VOLTAGE TOO HIGH
444 44 4 LSS BATTERY VOLTAGE TOO LOW
445 44 5 BATTERY VOLTAGE LOW Battery voltage is < 11V for
more then 5 seconds.
660 66 0 <<< COMMUNICATION >>>
662 66 2 CANBUS FAILURE - PLATFORM MODULE Platform Module CAN commu-
nication lost.
6-118 – JLG Lift – 3121262

Flash
Code
663 66 3 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE
666 66 6 CANBUS FAILURE - ENGINE CONTROLLER Engine Control Module CAN - ECM equipped engine only.
communication lost.
6610 66 10 CANBUS FAILURE - BLAM BLAM CAN communication lost. - BLAM equipped vehicles only.
6611 66 11 CANBUS FAILURE - CHASSIS MODULE Engine Control Module CAN - ECM equipped engine only.
communication lost.
6612 66 12 CANBUS FAILURE - CYLINDER LOAD PIN Cylinder Load Pin CAN commu- - Cylinder Load Pin equipped
nication lost. engine only.
6613 66 13 CANBUS FAILURE - EXCESSIVE CANBUS ERRORS There has been > 500 Bus Off
errors or >500 Bus Passive
Errors.
6622 66 22 CANBUS FAILURE - TCU MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6623 66 23 CANBUS FAILURE - GATEWAY MODULE Machine Setup/ Telemat-
ics=YES, No device heartbeat
for 30 sec
6629 66 29 CANBUS FAILURE - TELEMATICS CANBUS LOADING X -Telematics only
TOO HIGH
6639 66 39 CANBUS FAILURE - JIB CONTROL MODULE
6640 66 40 CANBUS FAILURE - JIB LIFT ANGLE SENSOR
6641 66 41 CANBUS FAILURE - PLATFORM LEVEL ANGLE SENSOR
680 68 0 <<< TELEMATICS >>>
681 68 1 REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP X -Telematics only
810 81 0 <<< TILT SENSOR >>>
813 81 3 CHASSIS TILT SENSOR NOT CALIBRATED The Chassis Tilt Sensor has not
been calibrated.
815 81 5 CHASSIS TILT SENSOR DISAGREEMENT X
820 82 0 <<< PLATFORM LOAD SENSE >>>
821 82 1 LSS CELL #1 ERROR
822 82 2 LSS CELL #2 ERROR822822
823 82 3 LSS CELL #3 ERROR823823
824 82 4 LSS CELL #4 ERROR824824
825 82 5 LSS HAS NOT BEEN CALIBRATED The Load Sensing System Mod-
ule has not been calibrated.
826 82 6 RUNNING AT CREEP - PLATFORM OVERLOADED All functions at creep, the Load
Sensing System indicates the
Platform is overloaded AND is
configured to warn only while
the Platform is overloaded.
3121262 – JLG Lift – 6-119

Flash
Code
827 82 7 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are
not possible while the Load
Sensing System indicates the
Platform is overloaded AND is
configured to prevent drive and
boom functions while the Plat-
form is overloaded.
828 82 8 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED Lift up and telescope out are not
possible while the Load Sensing
System indicates the Platform is
overloaded AND is configured to
prevent Lift up and telescope
out while the Platform is over-
loaded.
830 83 0 <<< PLATFORM LEVELING >>>
831 83 1 PLATFORM LEVELING OVERRIDE ON Platform Leveling forced on
with Access Level 0 selection.
832 83 2 PLATFORM LEVELING OVERRIDE OFF Platform Leveling forced off
with Access Level 0 selection.
833 83 3 PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED The Platform Level Up Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
834 83 4 PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED The Platform Level Down Valve - Electronic leveling system
Crackpoint has not been cali- equipped vehicles only.
brated.
837 83 7 PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #1. equipped vehicles only.
838 83 8 PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #1.
8311 83 11 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY There is a Short to Battery to the - Electronic leveling system
Platform Level Sensor #2. equipped vehicles only.
8312 83 12 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an - Electronic leveling system
Level Sensor #2.
8313 83 13 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #1 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
8314 83 14 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE Platform Level Sensor #2 rever- - Electronic leveling system
ence voltage is outside accept- equipped vehicles only.
able range (4.9 to 5.1 volts).
6-120 – JLG Lift – 3121262

Flash
Code
8315 83 15 PLATFORM LEVELING SENSOR - DISAGREEMENT The Control System reads the - Electronic leveling system
sensor values at power-up. The equipped vehicles only.
fault is triggered when there is a
± 5 degree difference from the
initial reading.
8316 83 16 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST Platform Level Sensor #1 serial
communication lost.
8317 83 17 PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST Platform Level Sensor #2 serial
communication lost.
8318 83 18 PLATFORM LEVELING SYSTEM TIMEOUT The Platform was unable to
maintain desired level within
range for the allotted time.
8319 83 19 JIB LEVEL SENSOR #1 - OUT OF RANGE LOW
8320 83 20 JIB LEVEL SENSOR #1 - OUT OF RANGE HIGH
8321 83 21 JIB LEVEL SENSOR #2 - OUT OF RANGE LOW
8322 83 22 JIB LEVEL SENSOR #2 - OUT OF RANGE HIGH
8323 83 23 JIB LEVEL SENSORS - NOT CALIBRATED
8324 83 24 JIB LEVEL SENSORS - DISAGREEMENT
8325 83 25 JIB SWING SENSOR #1 - OUT OF RANGE LOW
8326 83 26 JIB SWING SENSOR #1 - OUT OF RANGE HIGH
8327 83 27 JIB SWING SENSOR #2 - OUT OF RANGE LOW
8328 83 28 JIB SWING SENSOR #2 - OUT OF RANGE HIGH
8329 83 29 JIB SWING SENSORS - NOT CALIBRATED
8330 83 30 JIB SWING SENSORS - DISAGREEMENT
8331 83 31 JIB LOCK PIN SENSOR - DISAGREEMENT
8332 83 32 JIB TRANSPORT SENSOR #1 - DISAGREEMENT
8333 83 33 JIB TRANSPORT SENSOR #2 - DISAGREEMENT
8334 83 34 JIB LIFT ANGLE SENSOR - NOT CALIBRATED
8335 83 35 JIB LEVEL UP CRACKPOINT - NOT CALIBRATED
8336 83 36 JIB LEVEL DOWN CRACKPOINT - NOT CALIBRATED
8337 83 37 JIB LEVELING SYSTEM TIMEOUT
8338 83 38 WRONG JIB LOCK PIN RESPONSE
8339 83 39 PLATFORM LEVEL ANGLE SENSOR - NOT CALIBRATED
840 84 0 <<< ENVELOPE >>>
841 84 1 BOOM ANGLE SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Boom Angle Sen- cles only.
sors.
842 84 2 BOOM LENGTH SWITCH FAILED The Boom Length Switches are - Envelope Control equipped vehi-
reporting the same state. cles only.
843 84 3 BOOM LENGTH SWITCH/SENSOR DISAGREEMENT There is a disagreement - Envelope Control equipped vehi-
between the Boom Length cles only.
Switch and the Boom Length
Sensor.
3121262 – JLG Lift – 6-121

Flash
Code
844 84 4 BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE The Boom Length Sensor is not - Envelope Control equipped vehi-
changing during a boom tele- cles only.
scope command.
845 84 5 BOOM LENGTH SENSOR - OUT OF RANGE HIGH Boom Length Sensor out of - Envelope Control equipped vehi-
range high. cles only.
846 84 6 BOOM LENGTH SENSOR - OUT OF RANGE LOW Boom Length Sensor out of - Envelope Control equipped vehi-
range low. cles only.
847 84 7 BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH Boom Length out of range high. - Envelope Control equipped vehi-
cles only.
848 84 8 BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW Boom Length out of range low. - Envelope Control equipped vehi-
cles only.
849 84 9 BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT Boom Angle Sensor #1 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8410 84 10 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT Boom Angle Sensor #2 commu- - Envelope Control equipped vehi-
nications lost. cles only.
8411 84 11 BOOM ANGLE SENSOR #1 - INVALID ANGLE Boom Angle Sensor #1 out of - Envelope Control equipped vehi-
range. cles only.
8412 84 12 BOOM ANGLE SENSOR #2 - INVALID ANGLE Boom Angle Sensor #2 out of - Envelope Control equipped vehi-
range. cles only.
8413 84 13 WRONG TELESCOPE RESPONSE Boom telescope is moving in the - Envelope Control equipped vehi-
opposite direction of the com- cles only.
mand.
8414 84 14 WRONG LIFT RESPONSE Boom lift is moving in the oppo- - Envelope Control equipped vehi-
site direction of the command. cles only.
8479 84 79 MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE LOW
8480 84 80 MAIN CYLINDER ANGLE SENSOR #1 - OUT OF RANGE HIGH
8492 84 92 MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE LOW
8493 84 93 MAIN CYLINDER ANGLE SENSOR #2 - OUT OF RANGE HIGH
8494 84 94 MAIN CYLINDER ANGLE SENSORS - DISAGREEMENT
8495 84 95 TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE LOW
8496 84 96 TURN TABLE SENSOR #1 - FREQUENCY OUT OF RANGE HIGH
8497 84 97 TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE LOW
8498 84 98 TURN TABLE SENSOR #2 - FREQUENCY OUT OF RANGE HIGH
8499 84 99 CHASSIS TURN TABLE SENSORS - DISAGREEMENT
84100 84 100 CHASSIS TURN TABLE SENSORS AND DRIVE ORIENTATION SWITCH - DIS-
AGREEMENT
84101 84 101 CHASSIS TURN TABLE SENSORS - NOT CALIBRATED
6-122 – JLG Lift – 3121262

Flash
Code
84102 84 102 MAIN CYLINDER ANGLE SENSOR - NOT DETECTING CHANGE
84103 84 103 JIB LEVEL ANGLE SENSOR - NOT DETECTING CHANGE
84104 84 104 JIB LIFT ANGLE SENSOR - NOT DETECTING CHANGE
84105 84 105 PLATFORM LEVEL ANGLE SENSOR - NOT DETECTING CHANGE
84106 84 106 JIB LEVEL MOVEMENT WITHOUT COMMAND
84107 84 107 JIB LIFT MOVEMENT WITHOUT COMMAND
84108 84 108 PLATFORM LEVEL MOVEMENT WITHOUT COMMAND
850 85 0 <<< MOMENT / LOAD PINS >>>
851 85 1 MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE The Moment Pin horizontal
force is out of range.
852 85 2 MOMENT PIN - VERTICAL FORCE OUT OF RANGE The Moment Pin vertical force is
out of range.
855 85 5 MOMENT PIN - SENSOR FAULT The Moment Pin has reported a
fault.
857 85 7 NEW MOMENT PIN DETECTED A new Moment Pin has been
detected.
860 86 0 <<< STEERING / AXLE >>>
861 86 1 RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH DIS- The Oscillating Axle Pressure - Electrically released Oscillated
AGREEMENT Switch indicates pressure while Axles equipped vehicles only.
not driving or does not indicate
pressure while driving and
restricted to transport.
862 86 2 AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Extend
Valve.
863 86 3 AXLE EXTEND VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Extend Valve.
864 86 4 AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Axle Retract
Valve.
865 86 5 AXLE RETRACT VALVE - SHORT TO GROUND There is a Short to Ground to the
Axle Retract Valve.
866 86 6 RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Right Valve.
867 86 7 RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Right Valve.
868 86 8 RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Front
Steer Left Valve.
3121262 – JLG Lift – 6-123

Flash
Code
869 86 9 RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Front Steer Left Valve.
8610 86 10 LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Right Valve.
8611 86 11 LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Right Valve.
8612 86 12 LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Front
Steer Left Valve.
8613 86 13 LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Front Steer Left Valve.
8614 86 14 RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Right Valve.
8615 86 15 RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Right Valve.
8616 86 16 RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Right Rear
Steer Left Valve.
8617 86 17 RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Right Rear Steer Left Valve.
8618 86 18 LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Right Valve.
8619 86 19 LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Right Valve.
8620 86 20 LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT There is a Short to Battery or an
Open Circuit to the Left Rear
Steer Left Valve.
8621 86 21 LEFT REAR STEER LEFT VALVE - SHORT TO GROUND There is a Short to Ground to the
Left Rear Steer Left Valve.
8622 86 22 FRONT RIGHT STEER SENSOR - DECOUPLED The Front Right Steer Sensor has
become decoupled.
8623 86 23 FRONT LEFT STEER SENSOR - DECOUPLED The Front Left Steer Sensor has
become decoupled.
6-124 – JLG Lift – 3121262

Flash
Code
8624 86 24 REAR RIGHT STEER SENSOR - DECOUPLED The Rear Right Steer Sensor has
become decoupled.
8625 86 25 REAR LEFT STEER SENSOR - DECOUPLED The Rear Left Steer Sensor has
become decoupled.
8626 86 26 FRONT LEFT STEER SENSOR - NOT RESPONDING The Front Right Steer Sensor is
not responding to steer com-
mands.
8627 86 27 FRONT RIGHT STEER SENSOR - NOT RESPONDING The Front Left Steer Sensor is not
responding to steer commands.
8628 86 28 REAR LEFT STEER SENSOR - NOT RESPONDING The Rear Right Steer Sensor is
not responding to steer com-
mands.
8629 86 29 REAR RIGHT STEER SENSOR - NOT RESPONDING The Rear Left Steer Sensor is not
responding to steer commands.
8630 86 30 FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Right
Steer Sensor.
8631 86 31 FRONT RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Right Steer Sensor.
8632 86 32 FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Front Left
Steer Sensor.
8633 86 33 FRONT LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Front Left Steer Sensor.
8634 86 34 REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Right
Steer Sensor.
8635 86 35 REAR RIGHT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Right Steer Sensor.
8636 86 36 REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT There is a Short to Ground or an
Open Circuit to the Rear Left
Steer Sensor.
8637 86 37 REAR LEFT STEER SENSOR - SHORT TO BATTERY There is a Short to Battery to the
Rear Left Steer Sensor.
8651 86 51 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT Engine Start is prevented while
there is an Oscillating Axle fault
and vehicle is out of transport
position
990 99 0 <<< HARDWARE >>>
991 99 1 LSS WATCHDOG RESET
992 99 2 LSS EEPROM ERROR
3121262 – JLG Lift – 6-125

Flash
Code
993 99 3 LSS INTERNAL ERROR - PIN EXCITATION
994 99 4 LSS INTERNAL ERROR - DRDY MISSING FROM A/D
998 99 8 EEPROM FAILURE - CHECK ALL SETTINGS The Ground Module has
reported an EEPROM failure.
9910 99 10 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION The Platform Module software
IMPROPER version is not compatible with
the rest of the system.
9911 99 11 FUNCTIONS LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER
9914 99 14 PLATFORM MODULE SOFTWARE UPDATE REQUIRED The Platform Module software
requires an updated.
9915 99 15 CHASSIS TILT SENSOR NOT GAIN CALIBRATED The Chassis Tilt Sensor gain cali-
bration has been lost.
9916 99 16 CHASSIS TILT SENSOR GAIN OUT OF RANGE The Chassis Tilt Sensor gain cali-
bration has become corrupted.
9917 99 17 HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST The Platform Module has
reported that its ADS1213 chip
has stopped asserting its inter-
rupt.
9918 99 18 HIGH RESOLUTION A2D FAILURE - REINIT LIMIT The Platform Module has
reported that its ADS1213 chip
had to be reset 3 or more times.
9919 99 19 GROUND SENSOR REF VOLTAGE OUT OF RANGE The Ground Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
9920 99 20 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE The Platform Module has - Not reported during power-up.
reported that its sensor refer-
ence voltage is outside accept-
able range.
9921 99 21 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY The Ground Module has
reported that its high side driver
cutout failed.
9922 99 22 PLATFORM MODULE FAILURE - HWFS CODE 1 The Platform Module has
reported that the V(Low) FET
has failed.
9923 99 23 GROUND MODULE FAILURE - HWFS CODE 1 The Ground Module has
reported that the V(Low) FET
has failed.
9924 99 24 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED
6-126 – JLG Lift – 3121262

Flash
Code
9925 99 25 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION The Chassis Module software
IMPROPER version is not compatible with
the rest of the system.
9926 99 26 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER The BLAM software version is
not compatible with the rest of
the system.
9927 99 27 GROUND MODULE CONSTANT DATA UPDATE REQUIRED The Ground Module constant
data requires an updated.
9928 99 28 ENVELOPE CONTROL DISABLED Envelope Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
9929 99 29 MOMENT CONTROL DISABLED Moment Control has been dis- - Envelope Control equipped vehi-
abled by the user from Access cles only.
Level 0.
9930 99 30 STEER SENSORS NOT CALIBRATED The Steer Sensors have not been
calibrated.
9931 99 31 BOOM SENSORS NOT CALIBRATED The Boom Sensors have not - BLAM equipped vehicles only.
been calibrated.
9932 99 32 LIFT CRACKPOINTS NOT CALIBRATED The Lift Crackpoints have not
been calibrated.
9933 99 33 TELESCOPE CRACKPOINTS NOT CALIBRATED The Telescope Crackpoints have
not been calibrated.
9934 99 34 DRIVE CRACKPOINTS NOT CALIBRATED The Drive Crackpoints have not
been calibrated.
9935 99 35 BLAM SENSOR SUPPLY OUT OF RANGE HIGH The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is high.
9936 99 36 BLAM SENSOR SUPPLY OUT OF RANGE LOW The Boom Angle Sensors supply - BLAM equipped vehicles only.
voltage is low.
9937 99 37 LENGTH SENSOR REF VOLTAGE HIGH The Boom Length Sensors sup-
ply voltage is high.
9938 99 38 LENGTH SENSOR REF VOLTAGE LOW The Boom Length Sensors sup-
ply voltage is low.
9939 99 39 BLAM HIGH RES A/D FAILURE The BLAM high resolution ana- - BLAM equipped vehicles only.
log to digital converter has
failed.
9940 99 40 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH The Chassis Sensors supply volt-
age is high.
9941 99 41 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW The Chassis Sensors supply volt-
age is low.
9944 99 44 CURRENT FEEDBACK GAINS OUT OF RANGE The factory set current feedback
gains are out of range.
9945 99 45 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT The factory set current feedback
checksum is not correct.
99155 99 155 JIB CONTROL MODULE - HIGH RESOLUTION A2D FAILURE
99156 99 156 JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE LOW
99157 99 157 JIB CONTROL MODULE - HIGH RESOLUTION A2D REFERENCE HIGH
99158 99 158 PLATFORM LEVEL ANGLE SENSOR - INTERNAL ERROR
3121262 – JLG Lift – 6-127

Flash
Code
99159 99 159 JIB LIFT ANGLE SENSOR - INTERNAL ERROR
99160 99 160 FUNCTIONS LOCKED OUT - JIB CONTROL MODULE SOFTWARE VERSION
IMPROPER
6-128 – JLG Lift – 3121262

SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 GENERAL that the leads are connected to the device under test correctly.
Also check that the lead on the "COM" port goes to the Ground
This section contains basic electrical information and sche- or negative side of the signal and the lead on the other port
matics to be used for locating and correcting most of the oper- goes to the positive side of the signal.
ating problems which may develop. If a problem should
develop which is not presented in this section or which is not Scale
corrected by listed corrective actions, technically qualified
guidance should be obtained before proceeding with any M = Mega = 1,000,000 * (Displayed Number)
maintenance. k = kilo = 1,000 * (Displayed Number)
NOTE: Some of the procedures/connectors shown in this section m = milli = (Displayed Number) / 1,000
may not be applicable to all models.
μ = micro = (Displayed Number) / 1,000,000
7.2 MULTIMETER BASICS Example: 1.2 kW = 1200 W
Example: 50 mA = 0.05 A
A wide variety of multimeters or Volt Ohm Meters (VOM) can
be used for troubleshooting your equipment. This section Voltage Measurement
shows diagrams of a common, digital VOM configured for sev-
eral different circuit measurements. Instructions for your VOM
may vary. Please consult the meter operator’s manual for more
information.
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 cir-
cuit 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 connec-
tor such that the test also checks both terminals of the con-
nection. 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 gen- Figure 7-1. Voltage Measurement (DC)
tle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector. • If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
Min/Max • Use firm contact with meter leads
Use of the "Min/Max" recording feature of some meters can
help when taking measurements of intermittent conditions
while alone. For example, you can read the Voltage applied to
a solenoid when it is only operational while a switch, far from
the solenoid and meter, is held down.
Polarity
Getting a negative Voltage or current reading when expecting
a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and
3121262 – JLG Lift – 7-1

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 conti-
Figure 7-2. Resistance Measurement nuity
• First test meter and leads by touching leads together. • Disconnect component from circuit before testing
Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads
tance)
• First test meter and leads by touching leads together.
• Circuit power must be turned OFF before testing resis-
Meter should produce an audible alarm, indicating
tance
continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
7-2 – JLG Lift – 3121262

Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND

TO ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-
RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
NOTE: Do NOT apply dielectric grease to the following connec-

tions:
• 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 follow-
ing reasons:
• To prevent oxidation at the mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level con-

Figure 7-4. Current Measurement (DC) ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-

• Set up the meter for the expected current range
pound to the electrical connectors. This procedure applies to
• Be sure to connect the meter leads to the correct jacks all plug connections not enclosed in a box. Silicone grease
should not be applied to connectors with external seals.
for the current range you have selected
1. To prevent oxidation, silicone grease must be packed
• If meter is not auto ranging, set it to the correct range
completely around male and female pins on the inside
(See multi meter’s operation manual) of the connector prior to assembly. This is most easily
achieved by using a syringe.
NOTE: Over a period of time, oxidation increases electrical resis-
tance 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 connec-
tors 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.
3121262 – JLG Lift – 7-3

3. Anderson connectors for the battery boxes and battery Deutsch HD, DT, DTM, DRC Series
chargers should have silicone grease applied to the con-
tacts only. The Deutsch connector system is commonly used for harsh
environment interconnect. Follow the installation instructions.
NOTE: Curing-type sealants might also be used to prevent short-
ing and would be less messy, but would make future pin
removal more difficult.
When applied to electrical connections, dielectric grease helps

to prevent corrosion of electrical contacts and improper con-
ductivity between contacts from moisture intrusion. Open and
sealed connectors benefit from the application of dielectric
grease.
Dielectric grease shall be applied to all electrical connectors at
the time of connection (except those noted under Exclusions).
Installation of Dielectric Grease

Before following these instructions, refer to excluded connec-
tor types (See Exclusions below).
1. Use dielectric grease in a tube for larger connection AMP Seal
points or apply with a syringe for small connectors.
The AMP Seal connector system is used on the Control ADE
2. Apply dielectric grease to the female contact (fill it Platform and Ground Modules.
approximately ½ full; see example below)
Apply dielectric grease to the female contact. If trapped air
3. Leave a thin layer of dielectric grease on the face of the prevents the connector from latching, pierce one of the
connector unused wire seals. After assembly, install a seal plug (JLG
4. Assemble the connector system immediately to prevent #4460905) in that location to prevent moisture ingress.
moisture ingress or dust contamination Note that seal plugs may be installed by the wire harness man-
5. Pierce one of the unused wire seals prior to assembly if ufacturer if an unused wire seal becomes compromised (wire
the connector system tends to trap air (i.e. AMP Seal) inserted in the wrong cavity during assembly and then cor-
and then install a seal plug. rected).
Figure 7-5. Application to Female Contacts
7-4 – JLG Lift – 3121262

DIN Connectors
This connector is typically used on hydraulic valves. Follow the
installation instructions.
Figure 7-6. Use of Seal Plugs

Exclusions
AMP Mate-N-Lok A limited number of connectors do not benefit from dielectric
grease, or may be permanently damaged by application.
Follow the installation instructions. Dielectric grease may not be required in properly sealed
enclosures.
3121262 – JLG Lift – 7-5

BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER

The connector uses gold contact material to resist corrosion This type of connector uses back-seals for moisture integrity.
and an o-ring seal for moisture integrity. If dielectric grease is However, the low-force contacts cannot displace dielectric
mistakenly applied to this connector system, the low-force
grease and create electrical contact. It is possible to use sol-
contacts cannot displace the grease to achieve electrical con-
vents (i.e. contact cleaner or mineral spirits) for the removal of
tact. Once contaminated, there is no practical way to remove
improperly applied dielectric grease. The EMR2 engine control
the dielectric grease (replacement of female contacts
module from Deutz employs this connector system (for exam-
required). The JLG Load Sensing System and 1250AJP Rotary
ple).
Angle Sensors are examples of components with the M12 con-
nector system.
7-6 – JLG Lift – 3121262

7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to
be sure the retention fingers are holding the contact
Assembly (See Figure 7-9.).
Check to be sure the wedge lock is in the open, or as-shipped,

position (See Figure 7-7.). Proceed as follows:
Figure 7-7. Connector Assembly Figure 1
1. To insert a contact, push it straight into the appropriate

circuit cavity as far as it will go (See Figure 7-9.).
Figure 7-8. AMP Connector
3121262 – JLG Lift – 7-7

3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-11.).
Release the locking latches by squeezing them inward
(See Figure 7-10.).
7-8 – JLG Lift – 3121262

Figure 7-12. Connector Disassembly
Disassembly Service - Voltage Reading

5. Insert a 4.8 mm (3/16") wide screwdriver blade between
the mating seal and one of the red wedge lock tabs.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
6. Pry open the wedge lock to the open position.
It has been common practice in electrical troubleshooting to
7. While rotating the wire back and forth over a half turn probe wires by piercing the insulation with a sharp point. This
(1/4 turn in each direction), gently pull the wire until the practice should be discouraged when dealing with the
contact is removed. AMPSEAL plug assembly, or any other sealed connector sys-
tem. The resulting pinholes in the insulation will allow mois-
NOTE: The wedge lock should never be removed from the housing
ture to invade the system by traveling along the wire strands.
for insertion or removal of the contacts.
This nullifies the effectiveness of the connector seals and
could result in system failure.
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.
3121262 – JLG Lift – 7-9

Figure 7-13. Connector Installation
7-10 – JLG Lift – 3121262

7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly

DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-14. DT/DTP Contact Installation Figure 7-15. DT/DTP Contact Removal
5. Remove wedgelock using needlenose pliers or a hook

1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.
barrel.
6. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you. while at the same time releasing the locking finger by
3. Push contact straight into connector grommet until a moving it away from the contact with a screwdriver.
click is felt. A slight tug will confirm that it is properly 7. Hold the rear seal in place, as removing the contact may
locked in place. displace the seal.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
3121262 – JLG Lift – 7-11

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C C
Figure 7-16. HD/HDP Contact Installation Figure 7-18. HD/HDP Contact Removal
8. Grasp contact about 25mm behind the contact crimp

11. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
9. Hold connector with rear grommet facing you.
12. Slide tool along into the insert cavity until it engages
10. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
13. Pull contact-wire assembly out of connector.
properly locked in place.
Figure 7-19. HD/HDP Unlocking Contacts

Figure 7-17. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing
7-12 – JLG Lift – 3121262

Figure 7-20. Jib Electrical Components
3121262 – JLG Lift – 7-13

Figure 7-21. Chassis Electrical Components - Sheet 1 of 2
7-14 – JLG Lift – 3121262

Figure 7-22. Chassis Electrical Components - Sheet 2 of 2
3121262 – JLG Lift – 7-15

Figure 7-23. Turntable Electrical Components - Sheet 1 of 2
7-16 – JLG Lift – 3121262

Figure 7-24. Turntable Electrical Components - Sheet 2 of 2
3121262 – JLG Lift – 7-17

Figure 7-25. Console Box Harness - Sheet 1 of 2
7-18 – JLG Lift – 3121262

Figure 7-26. Console Box Harness - Sheet 2 of 2
3121262 – JLG Lift – 7-19

Figure 7-27. Platform Valve Harness - Sheet 1 of 2
7-20 – JLG Lift – 3121262

Figure 7-28. Platform Valve Harness - Sheet 2 of 2
3121262 – JLG Lift – 7-21

Figure 7-29. Jib Valve Harness - Sheet 1 of 3
7-22 – JLG Lift – 3121262

3121262 – JLG Lift – 7-23

7-24 – JLG Lift – 3121262

Figure 7-32. Boom Length and Angle Harness - Sheet 1 of 2
3121262 – JLG Lift – 7-25

Figure 7-33. Boom Length and Angle Harness - Sheet 2 of 2
7-26 – JLG Lift – 3121262

Figure 7-34. Main Terminal Box Harness - Sheet 1 of 4
3121262 – JLG Lift – 7-27

7-28 – JLG Lift – 3121262

3121262 – JLG Lift – 7-29

7-30 – JLG Lift – 3121262

Figure 7-38. Turntable Harness - Sheet 1 of 3
3121262 – JLG Lift – 7-31

7-32 – JLG Lift – 3121262

3121262 – JLG Lift – 7-33

Figure 7-41. Pump Harness
7-34 – JLG Lift – 3121262

Figure 7-42. Chassis Harness - Sheet 1 of 3
3121262 – JLG Lift – 7-35

7-36 – JLG Lift – 3121262

3121262 – JLG Lift – 7-37

T/T SWING MAIN LIFT MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL
KEY SWITCH DIAGNOSITC DISPLAY
EMERGENCY MOUNTED IN GROUND BOX TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH
HOURMETER MOMENT CONTROL TEST
EMS IGNITION RELAY
PUSH BUTTON
SEE ZONE-[6,C]
87a
87
30
85
86
SW206-1B
SW206-1A
SW206-2A
SW206-2B
SW228-1
SW228-2
SW219
SW220
SW221
SW223
SW222
SW225
SW226
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
SW139-B1
1B
1A
2A
2B
SW139-B
SW139-1
SW139-3
SW139-2
SW139-4
RL80
1
4
1
3
2
5
ORN/RED 49-102
YEL/RED 2-40-02
YEL/RED 2-40-03
YEL/RED 2-40-10
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-08
YEL/RED 2-40-05
BLU 28-2
YEL/RED 2-40-02
YEL/RED 2-40-03
YEL/RED 2-40-10
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-08
YEL/RED 2-40-09
YEL/RED 2-40-05
BLU 27-2
GRY 23-2
GRY 24-2
PNK 25-2
PNK 26-2
RED 1-1-2 (10)
BRN 29-2
YEL/RED 2-1-2
YEL/RED 2-1-2
BRN 14-2
YEL/RED 2-1-1 (12)
YEL/RED 2-1-1 (12)
BRN 13-2
TAN 3-3
YEL/RED 2-2
TAN 3-2
WHT 22-2
YEL/RED 2-8
YEL/RED 2-40-01
WHT 21-2
GD275
3
4
5
6
1
2
BRN 30-2
IP213
IP212
30A
YEL/RED 2-30-1
IP284
YEL/RED 2-40-07
BLK 000-31-11
YEL/RED 2-8
BLK 000-03
YEL/RED 2-3
YEL CAN1-H_MDI
GRN CAN1-L_MDI
YEL/RED 2-8-1 (12)
RED 1-1 (10)
TURNTABLE HARNESS
YEL/RED 2-2
SEE ZONE-[7,A]
RED 1-3
YEL/RED 2-3
SEE ZONE-[7,A]
BRN 30-2
ORN/RED 49-103
BRN/ORN 53-2
ORN/RED 49-101
WHT/YEL 48-1
YEL/RED 2-40-01
ORN/RED 49-100
CAN-1 SPLICE (GROUND) CAN-2 SPLICE
RED/YEL 54-4
WHT/YEL 39-1
BRN/WHT 47-6
WHT/YEL 48-6
BRN/WHT 47-5
BRN/WHT 47-8
BLU 28-2
BLK 000-31-01
MNTD BESIDE GROUND MODULE MNTD BESIDE GROUND MODULE
GRY 23-2
BLU 27-2
RED/YEL 54-5
GRY 24-2
PNK 25-2
PNK 26-2
BRN 29-2
BRN 14-2
BRN 13-2
WHT 22-2
YEL/RED 2-8-5
WHT 21-2
TAN 3-3
TAN 3-2
12
10
12
10
11
11
MS287
MS134
1
2
3
4
9
5
6
7
8
1
2
3
4
9
5
6
7
8
CO239-J4
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
21
10
24
14
13
5A
YEL CAN1-H_MDI
GRN CAN1-L_MDI
IP140
RED
SHIELD
BLK
YEL CAN2-HIGH
GRN CAN2-LOW
BLK CAN2-SHIELD
SHIELD TP-CBL12
ROTL
500#
BCSCAL
1000#
GLOW
SWGLT
SWGRT
TELEOT
JIBOUT
IGN
LIFTUP
LIFTDN
TELEIN
JIBIN
JIBDN
JIBUP
LVLUP
STRT
AXLE
TEMP
OILP
ALT
BCS
ROTR
LVLDN
AUX
OVRLD
GND
IGN
RED TP-CBL12
BLK CAN1-SHIELD
BLK TP-CBL12
GRN CAN1-LOW
YEL CAN1-HIGH
J4 (BLUE)
GRN CAN1-L_GTWY
YEL CAN1-H_GTWY
SEE ZONE-[7,C]
SEE ZONE-[7,C]
SEE ZONE-[7,C]
SHIELD
BLK CAN2-SHIELD
RED
BLK
GRN CAN2-LOW
YEL CAN2-HIGH
TURNTABLE HARNESS
TURNTABLE HARNESS
TURNTABLE HARNESS
J2 (GRAY)
B
J
5A YEL/RED 2-6
H
ADVANCED G IP102
DIAGNOSTIC F
YEL CAN2-HIGH
C CO239-J12
CONNECTOR GRN CAN2-LOW
D
BLK CAN2-SHIELD
1 J12 (BLACK)
E 2
BLK 000-9
A 5 CAN2S
X272 4 CAN2L
3 CAN2H
ORN/RED 49-16
6 CAN2T
7 CAN2T
8
12 120
11 CO239-J7
BLK 000-25 (16) SEE ZONE-[1,D] BLK CAN1-SHIELD
8 18 CAN1S
RED/WHT 50-3 (16) SEE ZONE-[1,D] GRN CAN1-LOW
7 24 CAN1L
BLK 000-24-1 (16) SEE ZONE-[1,D] YEL CAN1-HIGH
10 13 CAN1H
RED/WHT 50-2-1 (16) SEE ZONE-[1,D] YEL/RED 2-30-1
9 3 GNDMODE
ORN/RED 49-88 ORN/RED 49-88
4 12 BRKNCBL
YEL/RED 2-61 YEL/RED 2-61
5 32 IGN
BLK 000-26 BLK 000-26
3 19 GND
1 29 IGN 120
2 11 BMRTCL
6 35 BMRTOP
X146 6 CANT
ORN/RED 49-17
17 CANT
BLK 000-9
12 5
BLK 000-03 YEL/RED 2-6
11 34 IGN
MOUNTED IN GROUND BOX
10 16
BLK 000-01 (12)
9
BLK 000-06
TURNTABLE HARNESS
YEL/RED 2-31
4 J7 (BLACK) J1 (WHITE)
GROUND BUSS
8 TURNTABLE HARNESS 23 GNDE

BLK 000-38 SEE ZONE [2,B]
7 30 IGN
BLK 000-08
6 7
BLK 000-05-1 (12) TURNTABLE HARNESS ORN/RED 49-102
5 SEE ZONE-[5,H] 21 PTST
BLK 000-04 (12) TURNTABLE HARNESS
4 10
BLK 000-45-1 (12)
3 20
BLK 000-39-1 (12)
2 25
BLK 000-2 (12)
1 8
MS96 28
26
YEL/RED 2-8-1 (12)
12 9
11 31
YEL/RED 2-8-7
10 33
YEL/RED 2-8-5 SEE ZONE [3,F]
9 27
YEL/RED 2-8-8
IGNITION BUSS
8 SEE ZONE [2,B] 22

YEL/RED 2-8-6 SEE ZONE [2,C] YEL/RED 2-3-2
7 1 PLTS
YEL/RED 2-8-9 TURNTABLE HARNESS YEL/RED 2-2-1
6 2 PLTE
YEL/RED 2-8-3 (12) TURNTABLE HARNESS
5 14 GNDMODE
YEL/RED 2-8-4 (18) TURNTABLE HARNESS
4 15 FTSWCL
YEL/RED 2-8-11 (12)
3
YEL/RED 2-8-10 (12)
2
CO239-J8
YEL/RED 2-8-2 (12)

1
2
3
4
1
MS95
YEL/RED 2-8-2 (12)
1
YEL/RED 2-30
2
BLK 000-2 (12)
YEL/RED 2-20
3
S218
4
5
6
CAN-1 REPEATER MODULE TO PLATFORM
CAN-2 LOW 7
MOUNTED WITH GROUND MODULE
CAN-2 HIGH 8
GRN CAN1-L_GTWY
CAN-1 LOW 9
YEL CAN1-H_GTWY
CAN-1 HIGH 10
BLK 000-08
GROUND 11
YEL/RED 2-8-7
IGNITION 12
YEL/RED 2-3-4
CO75-J1
YEL/RED 2-3
BLK 000-45-1 (12)
BLK 000-39-1 (12)
1
YEL/RED 2-8-11 (12)
YEL/RED 2-8-10 (12)
2
BLK CAN2-SHIELD
CAN-2 - SHIELD 3
4
5
YEL/RED 2-3
BLU 27-3-4
BLU 28-3-4
6 SEE ZONE-[8,G]
PNK 25-3
PNK 26-3
YEL/RED 2-2
7 SEE ZONE-[8,G]
8
GRN CAN1(A)-LOW
CAN-3 LOW 9
YEL CAN1(A)-HIGH
CAN-3 HIGH 10
11
12
X46
CO75-J2
3
2
5
1
10
12
16
18
8
14
17
19
4
11
6
13
9
7
15
***120 RESISTOR ACROSS J2-9 & J2-10

BOOM CABLE CONNECTOR
SEE SHEET 3, ZONE C-8
Figure 7-45. Ground Control Box Wiring Diagram - Sheet 1 of 2
7-38 – JLG Lift – 3121262

MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER
TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH
MOMENT CONTROL TEST
PUSH BUTTON
SEE ZONE-[6,C]
SW228-1
SW228-2
SW221
SW223
SW222
SW225
SW226
SW227
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
(CE ONLY)
500# CAP AXLE SET GLOW PLUG HIGH COOLANT LOW OIL NO ALTERNATOR MOMENT CNTL BOOM CONTROL PLATFORM 1000# CAP
ORN/RED 49-102
LIGHT LIGHT LIGHT TEMP LIGHT PRES LIGHT OUTPUT LIGHT TEST LIGHT SYSTEM LIGHT OVERLOAD LIGHT
YEL/RED 2-40-03
YEL/RED 2-40-10
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-08
YEL/RED 2-40-09
YEL/RED 2-40-05
BLU 28-2
YEL/RED 2-40-10
YEL/RED 2-40-04
YEL/RED 2-40-06
YEL/RED 2-40-08
YEL/RED 2-40-09
YEL/RED 2-40-05
YEL/RED 2-40-07
BLU 27-2
GRY 23-2
GRY 24-2
PNK 25-2
PNK 26-2
WHT/YEL 48-1
BRN/ORN 53-2
BRN 29-2
BRN 14-2
BRN 13-2
BRN 30-2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
LB229
LB230
LB231
LB232
LB233
LB234
LB235
LB236
LB237
LB238
BLK 000-31-10
BLK 000-31-09
BLK 000-31-08
BLK 000-31-07
BLK 000-31-06
BLK 000-31-05
BLK 000-31-04
BLK 000-31-03
BLK 000-31-02
BLK 000-31-10
BLK 000-31-09
BLK 000-31-08
BLK 000-31-07
BLK 000-31-06
BLK 000-31-05
BLK 000-31-04
BLK 000-31-03
BLK 000-31-02
RED/YEL 54-4
WHT/YEL 39-1
BLK 000-31-11
WHT/YEL 48-6
BRN/WHT 47-6
BRN/WHT 47-5
BRN/WHT 47-8
ORN/RED 49-103
ORN/RED 49-101
ORN/RED 49-100
RED/YEL 54-5
BLK 000-31-01
BRN 30-2
ORN/RED 49-103
BRN/ORN 53-2
ORN/RED 49-101
WHT/YEL 48-1
YEL/RED 2-40-01
ORN/RED 49-100
CAN-2 SPLICE
WHT/YEL 39-1
RED/YEL 54-4
BRN/WHT 47-6
WHT/YEL 48-6
BRN/WHT 47-5
BRN/WHT 47-8
YEL/RED 2-8-5
BLU 28-2
BLK 000-31-01
MNTD BESIDE GROUND MODULE [2,B]

GRY 23-2
BLU 27-2
RED/YEL 54-5
GRY 24-2
PNK 25-2
PNK 26-2
BRN/WHT 47-9
BRN 29-2
BRN 14-2
BRN 13-2
WHT 22-2
YEL/RED 2-8-5
WHT 21-2
TAN 3-3
TAN 3-2
10
4
9
5
6
7
8
CO239-J4
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
21
10
24
14
13
12
11
10
9
8
7
6
5
4
3
2
1
BLK CAN2-SHIELD
SHIELD TP-CBL12
SWGLT
IGN
SWGRT
LIFTUP
TELEOT
JIBOUT
LIFTDN
TELEIN
JIBIN
JIBDN
JIBUP
ROTR
LVLUP
STRT
LVLDN
AUX
AXLE
TEMP
OILP
ALT
BCS
OVRLD
GND
IGN
ALTE
GLOW
ROTL
500#
BCSCAL
1000#
J3 (BLACK)
BLK TP-CBL12
WHT 22-3
SWGRT 35 VALVE HARNESS
WHT 21-3
J4 (BLUE) SWGLT 34 VALVE HARNESS
33
32
BLK 000-35-1
GND 30 VALVE HARNESS
28
BLU/ORN 52-10
GNDALRM 27 VALVE HARNESS
BLU/ORN 52-12
HEAD/TAIL 26 VALVE HARNESS
SEE ZONE-[7,C]
SEE ZONE-[7,C]
BRN/WHT 47-12
BLK CAN2-SHIELD
FUEL 25 VALVE HARNESS

24
23
GRN CAN2-LOW
TAN 4-3
LIFTDN 22 VALVE HARNESS
21
20
TAN 55-20
LIFTFLOW 19 VALVE HARNESS
BLK 000-34
BRN 14-3
MNTELEOUT 16 VALVE HARNESS
J2 (GRAY) 15
BLK 000-36-1
RED/WHT 50-1
MAINDMP 13 VALVE HARNESS
TAN 55-22
LIFTDNAUX 12 VALVE HARNESS
TAN 3-3
LIFTUP 11 VALVE HARNESS
TAN 55-21
LIFTPILOT 10 VALVE HARNESS
BRN 55-10
TELEFLOW 9 VALVE HARNESS
8
BLK 000-33
GND 6 VALVE HARNESS
BRN 13-3
CO239-J12 MNTELEIN 4 VALVE HARNESS
BLU/ORN 52-2
1 J12 (BLACK) HORN 2
BLK 000-25
VALVE HARNESS
2 GND 18 SEE ZONE-[7,D]
RED/WHT 50-3
5 CAN2S JIB DMP 1 SEE ZONE-[7,D]
BLK 000-24-1
4 CAN2L GND 29 SEE ZONE-[7,D]
RED/WHT 50-2-1
3 CAN2H PLTDMP 3 SEE ZONE-[7,D]
ORN/RED 49-16 BLU 28-3-4
6 CAN2T JIBDNO/R 31
PNK 26-3
7 CAN2T PLVLDNO/R 7
PNK 25-3
8 PLVLUPO/R 5
120 CO239-J2
CO239-J7 X245
BLK CAN1-SHIELD YEL/RED 2-5
18 CAN1S ANALP 28 1
GRN CAN1-LOW
24 CAN1L ANALR 29
ORN/RED 49-5
2 ANALYZER
YEL CAN1-HIGH ORN/RED 49-6
13 CAN1H ANALT 30 3
YEL/RED 2-30-1 BLK 000-37
3 GNDMODE ANALG 31 4
ORN/RED 49-88
12 BRKNCBL 35
YEL/RED 2-61
32 IGN 34
BLK 000-26
19 GND 33
YEL/RED 2-60
29 IGN 120 27
ORN/RED 49-64
11 BMRTCL 26
ORN/RED 49-65
35 BMRTOP 25
6 CANT 24
ORN/RED 49-17 BRN/WHT 47-9
17 CANT 21 X274
BRN/WHT 47-8-1 BRN/WHT 47-8-2
5 ALTE 32 5
YEL/RED 2-6 WHT/YEL 48-3 S86
34 IGN START 11
RED TP-CBL12
2 ENGINE
16 19 [3,E] 3
BLK TP-CBL12 CONNECTOR #1
YEL/RED 2-31
4 J7 (BLACK) J1 (WHITE) 18 [3,E]
SHIELD TP-CBL12 S276
4
23 GNDE 17 [4,E] 6
YEL/RED 2-8-6
30 IGN 16 [2,B] 1
7 15
ORN/RED 49-102
21 PTST 14
10 1
ORN 55-45
20 BRK 23 T/T HARNESS
ORN 55-47
25 2SPD 20 T/T HARNESS
BRN/ORN 53-3
8 AUXP 13 T/T HARNESS
28 4
26 6
9 5
31 2
YEL/RED 2-1-88
33 10 X266
BLK 000-42 (16)
27 GND 8 2
WHT/YEL 48-8
22 SP 7 7
YEL/RED 2-3-2 BLU/ORN 52-5
1 PLTS GEN 22 3 ENGINE
YEL/RED 2-2-1 WHT/YEL 48-9
2 PLTE GLOW 12 4
CONNECTOR #2
BLK 000-22
14 GNDMODE GND 9 6
BLU 27-3-4
15 FTSWCL JIBUPO/R 3 1
YEL/RED 2-8-8
CO239-J1 [2,B] 5
WHT/YEL 48-7 (16)
8
CO239-J8
1
2
3
4
YEL/RED 2-8-2 (12)
(CAT ENGINE ONLY)

BLK 000-2 (12)
X93 ELECTRIC FUEL

WHT/YEL 48-7 (16)
1
2 PUMP CONNECTOR
BLK 000-38
[2,C]
LOCATED NEAR
FUEL TANK
BLU 28-3-4
PNK 25-3
PNK 26-3

9
7
15
1001120332 D
Figure 7-46. Ground Control Box Wiring Diagram - Sheet 2 of 2
3121262 – JLG Lift – 7-39

7-40 – JLG Lift – 3121262

Figure 7-47. Electrical Schematic - Sheet 1 of 18
3121262 – JLG Lift – 7-41

F
A
B
E
7-42
C
D
H
G
R
R
BCS
FAILURE
PLTF LEVEL
GD47-J1
BRN/WHT 47-1 FUEL 1/4
1
8
8
G
G
2
3
BLK 000-51-3 FUEL GND
4
AXLE SET
BLK 000-51-2 SPARE14
GENERATOR
[5,G] 5
BRN/WHT 47-4 FUEL FULL
6
Y
R
DRIVE
OVERLOAD
ORIENTATION
GD47-J2
ORN/RED 49-15 CREEP
1
1
2
3
4
YEL/RED 2-21 ENABLE
2
BRN/WHT 47-13 LOW FUEL Y
G
3
N/C
4
N/C
X54-ANALYZER
5 500# MODE
BLK 000-52 GROUND
1000# MODE
6
BOTTOM OF CONSOLE BOX

R
R
TILT
LED BOARD
CABLE
BROKEN
GD47-J3
ORN/RED 49-1000 BCS
1
PLATFORM DISPLAY
WHT/YEL 39-1 AXLE SET

2
ORN 55-51 DRIVE ORIENTATION
3
RED/YEL 54-3 1000# MODE
Y
Y
4
ORN/RED 49-101 BROKEN CABLE
5
BRN/WHT 47-12 SYSTEM FAULT
FAULT
ENGINE
6
SYSTEM
PREHEAT
7
7
G
G
GD47-J4
BRN/WHT 47-10 PLATF LEVEL FAILURE
CREEP
ENABLE
1
BLU/ORN 52-4-1 GENERATOR
2
ORN/RED 49-100 OVERLOAD
ORN/RED 49-92
ORN/RED 49-91
ORN/RED 49-90
ORN/RED 49-89
3
RED/YEL 54-2 500# MODE
4
ORN/RED 49-3 TILT
G
5
WHT/YEL 48-6 ENGINE PREHEAT
DRIVE & STEER 6
ELECTRONIC JOYSTICK
SPARE14
LOW FUEL
PIEZO
DRIVE LIFT & SWING
ALARM
STEER ELECTRONIC JOYSTICK
Y
G
G
G
5K
SWING LIFT
5K 5K
FUEL GAUGE
BRN/WHT 47-1
BRN/WHT 47-2
BRN/WHT 47-3
BLK 000-51-3
1
1
BRN/WHT 47-4
ORN/RED 49-15
YEL/RED 2-21
BRN/WHT 47-13
WHT/YEL 48-5
BLK 000-52
1
ORN/RED 49-1000
AH142-
AH142+
WHT/YEL 39-1
ORN 55-51
RED/YEL 54-3
YEL/RED 2-10-1
ORN/RED 49-101
BRN/WHT 47-12
2
YEL/RED 2-11-1
YEL/RED 2-16-1
BRN/WHT 47-10
BLU/ORN 52-3
BLU/ORN 52-4-1
ORN/RED 49-100
ORN 55-46
RED/YEL 54-2
ORN/RED 49-3
WHT/YEL 48-6
3
WHT 59-60
ORN/RED 49-42
WHT 59-1
WHT 60-4
ORN 55-50
4
5
HIGH DRIVE
6
TOGGLE SWITCH
SW63
CO01-J2
3
9
7
6
1
2
4
5
8
12
14
17
13
10
16
29
19
30
11
33
34
28
23
21
18
15
32
22
24
25
35
20
31
26
27
YEL 55-16
BRN
GRN
BLU
RED
BLK
1
BLK 000-54
WHT
YEL/RED 2-10-1
BLU
BLK
2
BRN
RED
ORN/RED 49-4
BLU/YEL
YEL 55-17
ORN/YEL
3
CO01-J5 YEL/RED 2-10-2
1/4
1/2
3/4
4
WHT/YEL
WHT/GRN
WHT/RED
IGN
IGN
IGN
TILT
ENV
DOS
DOS
GEN
GND
GND
500#
GRN
ALVL
FULL
[G,3]
JIBLT
AXLE
[G,3]
2 5
JIBRT
1000#
CTAP
GLOW
LFUEL
ANALT
STEER MODE
ANALP
ENBLE
ANALR
JIBLCK
ANALG
BRN
OVRLD
CREEP
SYSDIS
3 6
TOGGLE SWITCH
SFTTCH
6
6
BKNCBL
LFT
SHEET 8
SHEET 8
RED SW64
1 VREF
BLU
SEE SHEET 3
ZONE C-8, C-6
6
BLK PNK 25-1
– JLG Lift –
8 1
BLU/YEL YEL/RED 2-10-2
7 GND 2
ORN/YEL PNK 26-1
15 POS MATE-N-LOCK
4 SWG 3
J5 (WHITE)
WHT YEL/RED 2-10-3
5 CTAP 4
J2 (GRAY)
YEL/RED P2
YEL/RED P9
5
CONNECTOR IN CONSOLE BOX

6
TOGGLE SWITCH
CO01-J6 SW65
PLATF LEVEL OVERRIDE
15 15 8
BLU YEL/RED 2-10-3
14 14 2 CTAP SW76-1
BLK YEL/RED 2-10-4
13 13 7 GND 1
BRN
12 12 3 DRV SW76-2
RED BLU/ORN 52-1
HORN
11 11 4 1
WHT/GRN
10 10 5
PUSH BUTTON
STRLT
YEL/RED 2-16-2 WHT/RED
6 6 1 VREF
J6 (BLACK)
WHT/YEL
5 5 6 STRRT
ORN/RED 49-67 YEL/WHT 43-1
4 4 1
9 9 2
YEL/RED 2-16-1 ORN/RED 49-4 WHT/YEL 48-5 YEL/WHT 44-1
8 8 19 ALRM ENGSPD 28 3
BLU/ORN 52-3 BLK 000-54 ORN 55-46 YEL/RED 2-10-5
2 2 20 GND 2SPD 27 4
ORN/RED 49-70 S366 ORN/RED 49-70 YEL 55-16
7 7 8 FTSWOP CRBSTR 16 5
BLU/ORN 52-4-2 BLU/ORN 52-4-2 YEL 55-17
1 1 9 17 6
TOGGLE SWITCH
GEN CRDSTR
ORN/RED 49-69 ORN/RED 49-69 PNK 25-1 SW66
3 3 18 SFTTCH PLVLUP 9 SW118
AXLE EXTEND/RETRACT
BLK P6 PNK 26-1

X154 X155 17 PLVLDN 10 1
ORN/RED 49-81 BLU/ORN 52-1 ORN/RED 49-11

33 GND HORN 31 2
BLK 000-46-1 YEL/WHT 43-1 YEL/RED 2-10-5
29 GND AXLEXT 23 3
WHT 55-2 YEL/WHT 44-1 RED/WHT 55-30

26 JBLKOUT AXLRET 24 4
WHT 55-1 ORN/RED 49-11 RED/WHT 55-31
25 JBLKIN CREEP 32 5
GENERIC
PUMP POT
GRY 24-3 RED/WHT 55-30 BLK 000-53
5
5
6 PROTRT POTREF 34 6
SHEET 8 [G,2]
GRY 23-3 RED/WHT 55-31 YEL/RED 2-10-6
5 PROTLT PUMPPOT 35
ORN/RED 49-68 BLK 000-53
21 GND POTGND 13
PNK 26-3-2 GRY 23-1
16 PLVLDN PROTRT 7
PNK 25-3-2 GRY 24-1
15 PLVLUP PROTLT 8
YEL/RED 2-30-1 BRN 29-1
1 GNDMODE JIBTELEIN 3
YEL/RED 2-3-3 BRN 30-1
3 PLTFEMS JIBTELEOUT 4
YEL/RED 2-3-5 ORN/RED 49-40
2 PLTFEMS SFTTCH 29
BROWN X05-PWR BLU 27-1
7 IGN JIBUP 11
BLU 28-1
22 GND JIBDN 12
J1 (WHITE)
J7 (BLACK)
BROWN X04-PWR BLU/ORN 52-12
4 IGN HEAD/TAIL 30
GOLD PIN
BRN 13-1
34 GND MNTELEIN 5
BLK CANS BRN 14-1 LB132+
32 CAN1S MNTELEOUT 6
GRN CANL ORN/RED 49-120 WHT 59-60
30 CAN1L ENVLP 22 1
120
YEL CANH WHT/YEL 48-1
31 CAN1H START 14
BRN/ORN 53-1
LIGHT
10 AUX 15 1
RED/YEL 54-1
JIB LOCK PIN
11 500/1000 21 LB132-
YEL/RED 2-10-16
12 IGN 18
13 2 YEL/RED P3 SHEET 8 [H,3]
WHITE X05-GND GRY 23-1
14 20 1
WHITE X04-GND YEL/RED 2-10-6
23 19 2
ORN/RED 49-80 GRY 24-1
24 PLVL2 26 3
ORN/RED 49-63 YEL/RED 2-10-8
27 PLVL1 25 4
SILVER PIN
ORN/RED 49-12-1
28 PROX2NO 33 5
ORN/RED 49-13-1
35 1 6
TOGGLE SWITCH
PROX2NC
PLATFORM ROTATE
CO01-J1 SW67
BLK 000-51-1
1
2
BRN 29-1
1
YEL/RED 2-10-8
CAN1-SPLICE (PLATFORM) 2
BRN 30-1
3 x 4 Buss Bar 3
CO01-J8
4
4
YEL/RED 2-10-9
4
5
JIB TELESCOPE
6
TOGGLE SWITCH
SW68
1
2
12
3
4
9
10
5
6
7
8
11
LB128
BLK 000-51-2
[1,F] 1
MS156
BLK 000-49 (12)

BLK 000-24-3 (12)
ORN/RED 49-42
LIGHT
1
YEL/RED 2-1-2 (12)
YEL/RED 2-8-13 (12)
SOFT TOUCH
LB128
WHT 59-1
YEL CANH
BLK CANS
GRN CANL
YEL CANH
1
BLK CANS
GRN CANL
Platform Box
YEL/RED 2-10-9
2
WHT 60-4
3
BLUE X05-CANH
YEL/RED 2-10-19
GRAY X05-CANS
SHEET: 2
BLACK X05-CANL
BLUE X04-CANH
4
GRAY X04-CANS
JIB SWING
5
BLACK X04-CANL
3121262
TOGGLE SWITCH
6
10 10
YEL/RED 2-16-2 WHT/RED
6 6 1 VREF
WHT/YEL
5 5 6 STRRT
ORN/RED 49-67 YEL/WHT 43-1
4 4 1
9 9 2
YEL/RED 2-16-1 ORN/RED 49-4 WHT/YEL 48-5 YEL/WHT 44-1
8 8 19 ALRM ENGSPD 28 3
BLU/ORN 52-3 BLK 000-54 ORN 55-46 YEL/RED 2-10-5
J6 (BLACK)
2 2 20 GND 2SPD 27 4
ORN/RED 49-70 S366 ORN/RED 49-70 YEL 55-16
7 7 8 FTSWOP CRBSTR 16 5
BLU/ORN 52-4-2 BLU/ORN 52-4-2 YEL 55-17
1 1 9 17 6
TOGGLE SWITCH
GEN CRDSTR
ORN/RED 49-69 ORN/RED 49-69 PNK 25-1 SW66
3121262
3 3 18 SFTTCH PLVLUP 9 SW118
AXLE EXTEND/RETRACT
BLK P6 PNK 26-1
SHEET: 2
X154 X155 17 PLVLDN 10 1
ORN/RED 49-81 BLU/ORN 52-1 ORN/RED 49-11
33 GND HORN 31 2
BLK 000-46-1 YEL/WHT 43-1 YEL/RED 2-10-5
29 GND AXLEXT 23 3
WHT 55-2 YEL/WHT 44-1 RED/WHT 55-30
26 JBLKOUT AXLRET 24 4
WHT 55-1 ORN/RED 49-11 RED/WHT 55-31
25 JBLKIN CREEP 32 5
GENERIC
PUMP POT
GRY 24-3 RED/WHT 55-30 BLK 000-53
5
5
6 PROTRT POTREF 34 6
SHEET 8 [G,2]
GRY 23-3 RED/WHT 55-31 YEL/RED 2-10-6
5 PROTLT PUMPPOT 35
ORN/RED 49-68 BLK 000-53
21 GND POTGND 13
PNK 26-3-2 GRY 23-1
16 PLVLDN PROTRT 7
PNK 25-3-2 GRY 24-1
15 PLVLUP PROTLT 8
YEL/RED 2-30-1 BRN 29-1
1 GNDMODE JIBTELEIN 3
YEL/RED 2-3-3 BRN 30-1
3 PLTFEMS JIBTELEOUT 4
YEL/RED 2-3-5 ORN/RED 49-40
2 PLTFEMS SFTTCH 29
BROWN X05-PWR BLU 27-1
7 IGN JIBUP 11
BLU 28-1
22 GND JIBDN 12
J1 (WHITE)
J7 (BLACK)
BROWN X04-PWR BLU/ORN 52-12
4 IGN HEAD/TAIL 30
GOLD PIN
BRN 13-1
34 GND MNTELEIN 5
BLK CANS BRN 14-1 LB132+
32 CAN1S MNTELEOUT 6
GRN CANL ORN/RED 49-120 WHT 59-60
30 CAN1L ENVLP 22 1
120
YEL CANH WHT/YEL 48-1
31 CAN1H START 14
BRN/ORN 53-1
LIGHT
10 AUX 15 1
RED/YEL 54-1
JIB LOCK PIN
11 500/1000 21 LB132-
YEL/RED 2-10-16
12 IGN 18
13 2 YEL/RED P3 SHEET 8 [H,3]
WHITE X05-GND GRY 23-1
14 20 1
WHITE X04-GND YEL/RED 2-10-6
23 19 2
ORN/RED 49-80 GRY 24-1
24 PLVL2 26 3
ORN/RED 49-63 YEL/RED 2-10-8
27 PLVL1 25 4
ORN/RED 49-12-1
SILVER PIN
28 PROX2NO 33 5
ORN/RED 49-13-1
35 1 6
TOGGLE SWITCH
PROX2NC
PLATFORM ROTATE
CO01-J1 SW67
BLK 000-51-1
1
2
BRN 29-1
1
YEL/RED 2-10-8
CAN1-SPLICE (PLATFORM) 2
BRN 30-1
3 x 4 Buss Bar 3
CO01-J8
4
4
YEL/RED 2-10-9
4
5
JIB TELESCOPE
6
TOGGLE SWITCH
SW68
1
2
12
3
4
9
10
5
6
7
8
11
LB128
BLK 000-51-2
[1,F] 1
MS156
BLK 000-49 (12)

BLK 000-24-3 (12)
ORN/RED 49-42
LIGHT
YEL/RED 2-1-2 (12)

YEL/RED 2-8-13 (12)
SOFT TOUCH
LB128
WHT 59-1
1
YEL/RED 2-10-9
2
WHT 60-4
3
YEL CANH
BLK CANS
GRN CANL
YEL CANH
YEL/RED 2-10-19
BLK CANS
GRN CANL
4
JIB SWING
BLUE X05-CANH
6
TOGGLE SWITCH
GRAY X05-CANS
BLACK X05-CANL
BLUE X04-CANH
GRAY X04-CANS
SW69
BLACK X04-CANL
YEL/RED 2-10-19
SW129-1
YEL/RED 2-10-10
1
SW129-2
ORN/RED 49-40
1
OVERRIDE
Platform Box
SOFT TOUCH
BLU 27-1
1
YEL/RED 2-10-10
2
BLU 28-1
3
YEL/RED 2-10-18
4
JIB LIFT
5
6
TOGGLE SWITCH
SW70
YEL/RED 2-10-18
3
3
SW125-1
YEL/RED 2-10-11
1
SW125-2
BLU/ORN 52-12
LIGHT
1
HEAD/TAIL
BRN 13-1
1
YEL/RED 2-10-11
2
– JLG Lift –
BRN 14-1
3
YEL/RED 2-10-12
4
5
6
TOGGLE SWITCH
SW71
MAIN BOOM TELESCOPE
YEL/RED 2-11-1
YEL/RED 2-10-12
X1001
2
ORN/RED 49-120
3
YEL/RED 2-10-13
A
B
C
4
5
6
TOGGLE SWITCH
SW135
BOOM CONTROL SELECT
PNK 25-3-2
PNK 26-3-2 S104
X1002
Sheet_3 (Platf_and_Jib)-[8,C]
Sheet_3 (Platf_and_Jib)-[6,C]
S145
S108
2
2

WHT/YEL 48-1
1
YEL/RED 2-10-13
2
BRN/ORN 53-1
3
YEL/RED 2-10-14
BLK 000-24-3 (12)
ORN/RED 49-81
BLK 000-49 (12)
BLK 000-46-1
YEL/RED 2-1-2 (12)
WHT 55-2
4
WHT 55-1
YEL/RED 2-8-13 (12)
GRY 24-3
GRY 23-3
ORN/RED 49-68
YEL CANH
GRN CANL
5
BLK CANS
BLUE X05-CANH
BLACK X05-CANL
GRAY X05-CANS
BLUE X04-CANH
WHITE X04-GND
GRAY X04-CANS
TOGGLE SWITCH
6
BROWN X04-PWR
GRN (FOOT SWITCH)

WHITE X05-GND
BLACK X04-CANL
START/AUX POWER
BROWN X05-PWR
SW72
YEL/RED 2-3-3
YEL/RED 2-30-1
YEL/RED 2-3-5
PNK 25-3-1
PNK 26-3-1
YEL/RED 2-11-2
YEL/RED 2-11-3
YEL/RED 2-2
ORN/RED 49-12-1
ORN/RED 49-13-1
YEL/RED 2-2
1
YEL/RED 2-10-14
2
RED/YEL 54-1
3
YEL/RED 2-10-15
X51
X05
X04
ORN/RED 49-63
7
9
4
8
6
3
2
1
5
1
2
3
4
5
1
2
3
4
5
ORN/RED 49-80
11
15
13
19
17
14
18
16
12
10
5
DISPLAY
PNK 25-3-3
1
2
3
4
5
1
2
3
4
5
SW48-2B
SW48-2A
SW48-1A
SW48-1B
PNK 26-3-3
GRAPHIC
2B
2A
1A
1B
SENSOR
6
TOGGLE SWITCH
CAPACITY SELECT
15
13
19
17
7
9
14
11
4
8
6
18
16
12
10
3
2
1
5
X117
X286
SW73
PLATF LEVEL
X60
X141
1
9
8
3
4
7
6
5
2
11
15
20
17
12
10
13
21
18
14
19
16
ORN 55-50
1
YEL/RED 2-10-15
SEE
SEE
15
1
20
17
12
10
9
8
3
13
21
18
4
14
7
6
5
19
2
16
11
2
EMS YEL/RED 2-10-16
SEE
SHEET 3
SHEET 3
3
ZONE E-8
X138
SWITCH
ZONE E-8
SHEET 3
4
ZONE D-8
5
6
TOGGLE SWITCH
DRIVE ORIENTATION
SW74
SEE
SHEET 3
ZONE G-8
1
1
1001119266 Q
F
A
B
E
C
D
H
7-43
8 7 6 5 4
SENSOR #2 (LH) SENSOR #1 (RH) JIB LIFT

PLATF LEVEL PLATF LEVEL PLATF ROT PLATF ROT JIB LOCK JIB LOCK PLATFORM
PLATFORM LEVEL SENSOR PLATFORM LEVEL SENSOR LENGTH SENSOR
UP DOWN LEFT RIGHT PIN - IN PIN - OUT DUMP JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN
PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR
CANH
CANS
CANL
PWR
GND
H
1
2
1
2
1
2
1
2
1
2
1
2
1
2
V28
V29
V30
V31
V32
V33
V27
SN115
5
4
3
2
1
SN136
SN137
SN114
1
2
3
1
2
3
3
4
2
1
3
4
2
1
1
2
4
3
SN17
SN18
BRN SN115-PWR
WHT SN115-GND
PNK 25-3-5
PNK 26-3-5
GRY 23-3
GRY 24-3
WHT 55-5
WHT 55-6
BLK 000-46-4
BLK 000-46-7
BLK 000-46-3
BLK 000-46-8
RED (12)
BLK (12)
GRY SN115-CANS
BLK SN115-CANL
BLU SN115-CANH
ORN
YEL
BLK
RED
BLU
BLK
ORN/RED 49-1
ORN/RED 49-14
ORN
ORN/RED 49-21
15 15
ORN/RED 49-2
BLK 000-41
YEL/RED 2-16
YEL
YEL/RED 2-16-3
BLK 000-40
16 16
BLK
17 17
BLK 000-46-5
BLK 000-46-6
RED
1 1
BLU
2 2
YEL/RED 2-16-2
BLK
3 3
BLK 000-39-2
5 5
19 19
ORN/RED 49-12-2
ORN/RED 49-13-2
PNK 25-3-5
7 7
PNK 26-3-5
6 6
GRY 23-3
SEE SHEET 2 8 8
GRY 24-3
9 9
ZONE C-1 10 10
WHT 55-5
WHT 55-6
11 11
G BLK 000-46-4 BLK 000-46-7
BLK 000-46-3 S78 BLK 000-46-8
BLK 000-46-2 BLK 000-46-2
12 12
21 21
4 4
13 13
BLK 000-41
14 14
YEL/RED 2-16
18 18 LSS MODULE
20 20 MOUNTED UNDER
X141 X138 YEL/RED 2-16-3
CONSOLE BOX
BLK 000-40
BLK CAN1-SHIELD
GRN CAN1-LOW
YEL CAN1-HIGH
J1 (GRAY) J2 (BLACK)
CO148-J1
CO148-J2
10
12
10
12
11
11
1
2
3
4
5
6
7
8
9
4
9
5
1
2
3
6
7
8
BRN SN115-PWR
F WHT SN115-GND
YEL/RED 2-15-1 (14)
BLK 000-39-5 (14)
BLU 28-3-4
BROWN LSS-PWR BLU 27-3-4
WHITE LSS-GND YEL CAN1-HIGH
BLUE LSS-CANH BLK CAN1-SHIELD GRN CAN1-LOW
8
MOUNTED IN JCM BOX
BLACK LSS-CANL BLK CAN1-SHIELD

7
CAN-1 SPLICE (JIB)
GRAY LSS-CANS GRY SN115-CANS

6
BLK CAN1-SHIELD
3 x 4 Buss Bar
5
GRN CAN1-LOW
10
1 9
GRAPHIC DISPLAY BLK SN115-CANL
2 4
MOUNTED ON PLATFORM GRN CAN1-LOW
3 3
YEL CAN1-HIGH
X149
4 12
SEE SHEET 2 5 11
1
2
3
4
5
BLU SN115-CANH
6 2
ZONE E-1 BRN LCD-PWR
7 1
YEL CAN1-HIGH
GRAY LCD-CANS MS109
5 5 8
BLACK LCD-CANL
4 M12 TEE OPT 4
BLUE LCD-CANH
9
3 3 10
2 W/LSS ADDED 2
WHITE LCD-GND
11
BROWN LCD-PWR BRN LCD-PWR
1 1 12
E X05 X286 S292 CO217-J1
YEL/RED 2-16-2
MOUNTED IN JCM BOX
9
YEL/RED 2-15-1 (14)
IGNITION/GROUND
8
YEL/RED 2-8-11 (12)
7
2 x 6 Buss Bar
LENGTH SENSOR
BROWN YEL/RED 2-8-10 (12)

PLATF LEVEL
1 1 1 PWR 6
WHITE YEL/RED 2-8-12 (12)
SEE SHEET 2 2 2
BLUE
2 GND 5
YEL/RED 2-15-2 (12)
3 3 3 CANH 4
ZONE E-1 4 4
BLACK
4 CANL 12
BLK 000-39-2
GRAY BLK 000-39-5 (14)
5 5 5 CANS 11
X04 X117 SN116 BLK 000-39-3 (12)
10
BLK 000-45-2 (12)
3
BLK 000-45-3 (12)
2
BLK 000-39-4 (12)
1
MS112
BLK (12)
RED (12)
X59
BLK 12 AWG BLK 000-39-4 (12)
16 16 16 16
BLK/WHT 12 AWG BLK 000-45-3 (12)
D 18
12
18
12
RED 12 AWG
18
12
18
12
YEL/RED 2-15-2 (12)
ORN 12 AWG YEL/RED 2-8-12 (12)
10 10 10 10
RED 18 AWG YEL CAN1-HIGH
3 3 3 3
BLK 18 AWG GRN CAN1-LOW
2 2 2 2
SHIELD 18 AWG BLK CAN1-SHIELD
BOOM CABLE 1 1
ORN/BLK 18 AWG
1 1
ORN/RED 49-12-2
13 13 13 13
YEL/BLK 18 AWG ORN/RED 49-13-2
CONNECTOR 15 15
ORN 18 AWG
15 15
YEL/RED 2-3-1
4 4 4 4
BLU 18 AWG YEL/RED 2-2-2
SEE SHEET 2 5 5
YEL 18 AWG
5 5
YEL/RED 2-21-1
6 6 6 6
BRN 18 AWG PNK 25-3-4
ZONE D-2 7 7 7 7
8 8 8 8
RED/BLK 18 AWG PNK 26-3-4
9 9 9 9
BLU/BLK 18 AWG YEL/RED 2-30-1
11 11 11 11
14 14 14 14
17 17 17 17
19 19 19 19
X51 X60 X58
GRN
Sheet_2 (Platform-Box)-[2,D]
GRN
Sheet_2 (Platform-Box)-[2,D]
C 15 15
15 15 14 14
14 14 13 13
YEL/RED P8 12 12
13 13
12 12 11 11
11 11 15 POSITION 10 10
9 9
15 POSITION 10 10 WHT
9 9 MATE-N-LOCK 8 8
BLK
WHT 7 7
MATE-N-LOCK 8 8 BLK
7 7
BLK SEE SHEET 2 6 6
WHT
YEL/RED P8 5 5
SEE SHEET 2 6 6
ZONE A-4 4 4
BLK
5 5 WHT
ZONE A-5 4 4 3 3
BRN/ORN 52-3
WHT 2 2
3 3 BRN/ORN 52-4
BRN/ORN 52-3 1 1
2 2
BRN/ORN 52-4 X155 X154
1 1
X155 X154
SHEET 8
[G,3]
GRN
SHEET 8
WHT
[G,3]
WHT
GRN
BLK
BLK
WHT
BLK
WHT
BLK
B
SW150
SW144
SN151
SN152
SW150
SW144
1
2
3
4
5
6
1
2
1
2
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
LIMIT SWITCH LIMIT SWITCH

FOOT SWITCH
TOGGLE SWITCH LH SOFT TOUCH RH SOFT TOUCH
FOOT SWITCH MNTD ON PLTF FLOOR
TOGGLE SWITCH GENERATOR (OPT)
MNTD ON PLTF FLOOR
GENERATOR (OPT)
OPTION 2: SKYGUARD ONLY

OPTION 1: SKYGUARD ONLY AND SOFT TOUCH
SHEET: 3
8 7 6 5 4
7-44 – JLG Lift – 3121262

5 4 3 2 1
MOUNTED IN JCM BOX

JIB LIFT JIB LEVEL JIB LEVEL JIB LIFT JIB LIFT JIB TELE JIB TELE JIB SWING JIB SWING JIB
LENGTH SENSOR 3 x 4 Buss Bar
JIB TRANSPORT-2 JIB TRANSPORT-1 JIB LOCK PIN UP DOWN UP DOWN IN OUT RIGHT LEFT ENABLE
PROXIMITY SENSOR PROXIMITY SENSOR PROXIMITY SENSOR
CANH
CANS
CANL
12
10
11
PWR
GND
MS349
1
2
3
4
9
5
6
7
8
H
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
V41
V42
V39
V40
V43
V44
V88
V87
V34
BLU 28-3-1
BLU 27-3-1
BLK 000-43-1
BLU 27-3-2
BLU 28-3-3
BLU 27-3-3
BLU 28-3-2
BLK 000-43-2
BLK 000-43-3
SN115
5
4
3
2
1
BLK 000-43-2
BLU 55-3
BLU 55-4
BRN 29-3
RED (12)
BLK 000-43-3
BLU 27-3-3
BRN 30-3
BLK (12)
BLU 28-3-3
WHT 60-3
BLK 000-44-5
WHT 59-3
BLK 000-44-4
BLK 000-44-3
BLK 000-44-2
BLK 000-44-6
BLK 000-44-7
SN136
SN137
SN114
3
4
2
1
3
4
2
1
1
2
4
3
BRN SN115-PWR
WHT SN115-GND
GRY SN115-CANS
BLK SN115-CANL
BLU SN115-CANH
ORN/RED 49-1
ORN/RED 49-14
ORN/RED 49-21
ORN/RED 49-2
BLK 000-41
YEL/RED 2-16
YEL/RED 2-16-3
BLK 000-40
CO49-J2
YEL/RED 2-16-2
BLU 27-3-2 BLU 27-3-1

2 JIBUPO/R JIBUP 1
BLK 000-39-2
BLU 28-3-2 BLU 28-3-1

1 JIBDNO/R JIBDN 2
J2 (BLACK)
BLU 55-4 BRN 29-3
12 JLVLDN JIBTELEIN 5
ORN/RED 49-12-2
ORN/RED 49-13-2
BLK 000-43-1 BRN 30-3

3 GND JIBTELEOUT 6
BLU 55-3 WHT 60-3
11 JLVLUP JIBSWGRT 3
ORN/RED 49-2 WHT 59-3
4 LOCKNO JIBSWGLT 4
ORN/RED 49-1
5 LOCKNC 7
ORN/RED 49-14
J5 (RUST)
7 PROX1NC 8
ORN/RED 49-21
6 PROX1NO 9
8 10 G
9 11
BLK 000-44-1
10 GND 12
CO49-J5
MOUNTED IN JCM BOX

8
BLK 000-44-7
CO49-J4 7
1 x 8 Buss Bar
BLK 000-41 BLK 000-44-6
2 GND 6
YEL/RED 2-16 BLK 000-44-5
J4 (GRAY)
1
6
IGN JIB BLK 000-44-4
5
4
YEL/RED 2-16-3 BLK 000-44-3
BLK 000-40
7
8
IGN
GND
CONTROL BLK 000-44-2
3
2
BLK CAN1-SHIELD BLK 000-44-1
GRN CAN1-LOW
5
4
CAN1S
CAN1L
MODULE 1
MS350
YEL CAN1-HIGH
3 CAN1H
JIB SWING ANGLE SENSOR

SN84
DUAL OUTPUT ROTARY

RED
B
WHT
CO49-J1 D
RED BLK
10 5VREF 10 A
WHT ORN
J1 (GRAY)
9 ROT2 11 F
BLK BLU
3 GND 12 C
J3 (GREEN)
BRN SN115-PWR ORN GRN
11 IGN 5VREF 7 E
WHT SN115-GND
12 GND ROT1 8
BLU F
YEL/RED 2-15-1 (14) GRN
5 IGN GND 9
BLK 000-39-5 (14) RED
4 GND 5VREF 4
BLU 28-3-4 WHT
1 JUMP TO J2-1 LVL2 5
JIB LEVEL ANGLE SENSOR

BLU 27-3-4 BLK SN82
DUAL OUTPUT ROTARY

2 JUMP TO J2-2 GND 6
YEL CAN1-HIGH ORN RED
6 CAN1H 5VREF 1 B
GRN CAN1-LOW BLU WHT
7 CAN1L LVL1 2 D
BLK CAN1-SHIELD GRN BLK
8 CAN1S GND 3 A
CO49-J3 ORN
F
BLU
C
GRN
E
CONNECTION LOCATED NEAR BLK (12)

Sheet_4 (T/T & Boom)-[4,H]
JIB ENABLE VALVE RED (12)
Sheet_4 (T/T & Boom)-[4,H]
BLK (12) BLU (12) BLU (12)
2 2 Sheet_4 (T/T & Boom)-[4,H]
RED (12) ORN (12) ORN (12)
1 1 Sheet_4 (T/T & Boom)-[4,H]
X300 X299
X57 X61 X46
BLK CAN1-SHIELD SHIELD 18 AWG
1 1 1 1
GRN CAN1-LOW BLK 18 AWG
YEL CAN1-HIGH
2
3
2
3
RED 18 AWG
2
3
2
3
D
BLU 27-3-4 ORN/BLK 18 AWG
13 13 13 13
BLU 28-3-4 YEL/BLK 18 AWG
YEL/RED 2-8-11 (12)
15 15
RED 12 AWG
15 15 MAIN TERMINAL
12 12 12 12
BLK 000-39-3 (12) BLK 12 AWG
BLK 000-45-2 (12)
16 16
BLK/WHT 12 AWG
16 16 BOX CONNECTION
18 18 18 18
YEL/RED 2-8-10 (12) ORN 12 AWG
YEL/RED 2-3-1
10 10
ORN 18 AWG
10 10 SEE SHEET 5
4 4 4 4
YEL/RED 2-2-2 BLU 18 AWG
YEL/RED 2-21-1
5 5
YEL 18 AWG
5 5 ZONE A-6
6 6 6 6
PNK 25-3-4 BRN 18 AWG
7 7 7 7
8 8 8 8
PNK 26-3-4 RED/BLK 18 AWG
9 9 9 9
YEL/RED 2-30-1 BLU/BLK 18 AWG
11 11 11 11
14 14 14 14
17 17 17 17
19 19 19 19
X55
GRN
WHT
BLK
BLK
WHT
BLK
WHT
BRN/ORN 52-3
BRN/ORN 52-4
SHEET 8
[G,3]
GRN
WHT
WHT
BLK
BLK
WHT
BLK
B
SW150
SW144
SN151
SN152
1
2
3
4
5
6
1
2
1
2
1
2
3
4
5
6
LIMIT SWITCH LIMIT SWITCH

FOOT SWITCH
TOGGLE SWITCH LH SOFT TOUCH RH SOFT TOUCH
MNTD ON PLTF FLOOR
GENERATOR (OPT)
OPTION 2: SKYGUARD ONLY

AND SOFT TOUCH
SHEET: 3 1001119266 Q
5 4 3 2 1
3121262 – JLG Lift – 7-45

7-46
F
A
B
E
C
D
H
G
Boom Length Sensor
X20
6 6 X56 X62
ORN 8-2-1
5 5 1 1
BRN/BLK - BLK 000-27-3 ORN 8-3-1
SN09 4 4 S94 2 2
8
8
BLK BLK BLK 000-27-2 BLK 000-10
COMMON B 2 2 6 6
BLU BLU ORN/RED 49-110 ORN 7-2-1
OUTPUT C 3 3 3 3
RED RED YEL/RED 2-80 ORN 7-3-1
PUMP
POWER A 1 1 4 4
String Pot
ZONE B-8
X19 5 5
CONNECTOR
SEE SHEET 7
Boom Length Sensor

BRN/BLK
GRN BLK 000-30
E 6 6
BLU ORN/RED 49-9
C 5 5
ORN RED/WHT 50-7
F 4 4
BLK BLK 000-29
A 3 3
WHT ORN/RED 49-19
D 2 2
RED RED/WHT 50-6
ANGLE SENSOR
B 1 1
ORN 60-1-1
X290 X291
ORN 8-2-1
MAIN BOOM CYLINDER

ORN 8-3-1
BLK 000-10
ORN/RED 49-110
YEL/RED 2-80
SN08
YEL/RED 2-81
ORN/RED 49-18
BLK 000-27-1
4
6
5
7
8
9
2
1
3
3
4
5
6
7
8
2
1
9
CO11-J3
CO11-J5
11
11
10
12
10
12
IGN
GND
GND
GND
GND
AXLE
REFV
5VREF
5VREF
5VREF
5VREF
BMLEN
MNCYL2
MNCYL1
LTDRVFD
LTDRVRV
J3 (GREEN)
J5 (RUST)
J1 (GRAY) J4 (GRAY) J2 (BLACK)
7
7
(BLAM)
IGN
IGN
IGN
IGN
GND
CAN1H
GND
CAN1H
GND
GND
GND
RTDRVFD
CAN1S
CAN1L
JUMP TO J2-1
JUMP TO J2-2
CAN1S
CAN1L
MNANG2
MNANG1
RTDRVRV
11
11
5
4
8
7
6
9
10
3
1
2
12
5
4
3
2
1
6
8
7
4
5
6
7
2
9
1
3
8
10
12
CO11-J1
CO11-J4
CO11-J2
BLK
BOOM LENGTH & ANGLE MODULE

BLK
BLK
RED
GRN
WHT
RED
YEL/RED 2-8-3 (12)
ORN 7-2-1
ORN 7-3-1
Sheet_5 (Ground Box)-[7,C]
BLK 000-28
BLK 000-28
SHIELD
BLK 000-05-1 (12)
YEL/RED 2-9
YEL/RED 2-9
BLK 000-04 (12)
BLK 000-56-1
YEL/RED 2-82
BLK 000-05-2 (14)

ORN/RED 49-111
YEL/RED 2-1-4 (14)

BLK 000-55-1
ORN/RED 49-112
SN10
E
B
A
NEAR BLAM
CONNECTIONS
GND
PWR
YEL/RED 2-8-3 (12)
CANL
CANH
1 1
BLK 000-04 (12) BLK 000-05-1 (12)
5 2 2
9 3 3
ORN 60-1-2 ORN 60-1-1 YEL/RED 2-81 RED
8 4 4 1 1 1
X288 X289 LIFT CYLINDER ORN/RED 49-111 BLU
10 2 2 2
LOAD PIN BLK 000-55-2 BLK
12 3 3 3
YEL/RED 2-13 (14) BLK 000-55-3 BLK
#1 Right Side
4 S83 4 4 SN06
Boom Angle Sensor
11 MS97-3 X35 X37
6
6
RED RED
1 A
BLK BLK
2 B
SHIELD SHIELD SHIELD
– JLG Lift –
3 C C
CONNECT TO
ORN 55-47 BLK
6 MS97-2 B
ORN 55-45 RED RED YEL/RED 2-82 ORN
7 A A 1 1 1
SWIVEL CONNECTOR
X26 BLK MS97-1 ORN/RED 49-112 YEL
B 2 2 2
SHIELD BLK 000-56-2 BLK
C 3 3 3
#2 Left Side
S85 BLK 000-56-3 BLK SN07

4 4
Boom Angle Sensor
X36 X38

5
5
YEL/RED 2-8-9
Sheet_5 (Ground Box)-[7,C] 1
BLK 000-06
LIGHT
Sheet_5 (Ground Box)-[7,C] 2

STROBE
LB264
AH260 V246
BLK 000-35-2 BLK 000-35-3
2 2
MAIN
BLU/ORN 52-10 RED/WHT 50-1

DUMP
1 1
ALARM
MOTION
BLU (12)
Sheet_3 (Platf_and_Jib)-[1,D]
ORN (12)
AH259-G Sheet_3 (Platf_and_Jib)-[1,D]
BLK 000-34 BLK 000-35-4
1 V255
BLK 000-35-5
AH259 2
BLU/ORN 52-2 WHT 22-3 BLK (12)
HORN
RIGHT
SWING
1 1 Sheet_3 (Platf_and_Jib)-[1,D]
RED (12)
4
4
Turntable & Boom

Empty: 270 SN258 V254 SN241
Full: 30 BLK 000-33 BLK 000-35-5 BRN
2 2 1
LEFT
BRN/WHT 47-12 WHT 21-3 BLK

SWING
1 1 4
BLU
3
FUEL SENSOR
BROKEN CABLE
PROXIMITY SENSOR
BLK 000-35-6
V252
BLK 000-35-7
2
UP
TAN 3-3
1
BLK 000-35-2
BLK 000-35-3
MAIN LIFT
BLK 000-35-4
SHEET: 4
3121262
5 4 3 2 1
BROKEN CABLE BOOM LENGTH

PROXIMITY SENSOR LIMIT SWITCH
H
SN242
13
21
22
14
SN241
1
4
3
WHT
BLK
WHT
RED
BLU
BLK
BRN
X244 X146
WHT
1 1
RED (12)
BLK (12)
ORN (12)
BLU (12)
BLK
2 2
RED
6 6
BLU
3 3
BLK
BRN
4 4 SEE SHEET 5
5 5
RED (12)
BLK (12)
7 7 ZONE D-8
8 8
ORN (12)
9 9
BLU (12)
10 10
11 11
STROBE 12 12
MAIN SWING SWING MAIN LIFT MAIN LIFT LIFT MAIN TELE MAIN TELE TELESCOPE LIFT DOWN LIFT
LIGHT DUMP RIGHT LEFT UP DOWN FLOW CONTROL OUT IN FLOW CONTROL AUXILARY PILOT
G
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
V246
V255
V254
V252
V253
V256
V249
V248
V247
V251
V250
BLK 000-36-6
BLK 000-36-5
1
2
LB264
BLK 000-36-4
BLK 000-35-6
TAN 55-21
TAN 55-22
BRN 55-10
BLK 000-35-5
BLK 000-35-5
BLK 000-35-7
BLK 000-35-8
BLK 000-35-8
BLK 000-36-3
BLK 000-36-3
BRN 13-3
BRN 14-3
BLK 000-35-7
TAN 55-20
TAN 4-3
TAN 3-3
WHT 21-3
WHT 22-3
RED/WHT 50-1
BLK 000-36-2
BLK 000-35-3
BLK 000-35-4
CO239-J2
TAN 55-21
10
TAN 55-22
12
BRN 55-10
9
YEL/RED 2-8-9
BRN 13-3
BLK 000-06
4
BRN 14-3
16
TAN 55-20
19
TAN 4-3
22
TAN 3-3
11
WHT 21-3
34
WHT 22-3
35
RED/WHT 50-1
13
F
BLK 000-36-2 BLK 000-36-1
14
BLK 000-35-4 S262
J2 CONNECTOR
BLK 000-35-3 BLK 000-35-1 BLK 000-35-1

30
BLK 000-35-2 S263
BLU/ORN 52-10
ON GROUND BOARD
27
BLK 000-34
BLU/ORN 52-2
17 (GRAY)
2
BLK 000-33
BRN/WHT 47-12
6 SEE SHEET 5
25
15 ZONE E-3
18
20
21
23
24
BLU/ORN 52-12 BLU/ORN 52-12
1 26
BLU/ORN 52-10
BRN/WHT 47-12
X147
BLU/ORN 52-2
28
BLK 000-35-2
HEAD & TAILLIGHT

BLK 000-34
32
BLK 000-33
SIGNAL 33
8
1
165AH/1150CCA
29
12V BATTERY
31
E
CHASSIS POWER 7
AH259-G
AH260
AH259
SN258
RELAY 5
3
2
1
2
1
BT200+
BT200-
1
1
87a
87
30
85
86
Empty: 270
Full: 30
RED (1/0)
BLK (1/0)
MOTION HORN
4
1
3
2
5
RL52
RED (1/0)
ALARM
BLK (1/0)
FUEL SENSOR
RED (1/0)
YEL/RED 2-13 (14)
YEL/RED 2-12 (12)
Sheet_7 (Deutz Engine)-[8,F]

BLK (1/0)
BLK 000-3
Sheet_7 (Deutz Engine)-[8,F]

BRN/ORN 53-3
YEL/RED 2-8-4

RED 1-1 (10)
Sheet_5 (Ground Box)-[8,G]
S240
RL267-87
D
RED (1/0) 87
1
1-FSLNK (14)
RL267-30
RED (1/0) 30
AUX PUMP
1
RELAY
YEL/RED 2-12 (12) 2-FSLNK (14)
RL267-86
S301 BRN/ORN 53-3 86
1
RL267-85
BLK 000-07 85
1
MS214+
AUX PUMP
RED (1/0)
MOTOR
1
BLK 000-07
BLK (1/0)
MS214- M
1
BLK 000-3
BLK 000-01 (12)
BLK 000-01 (12)

Sheet_5 (Ground Box)-[7,B]
C
YEL/RED 2-8-4
Sheet_5 (Ground Box)-[7,B]
SHIELD
Sheet_5 (Ground Box)-[5,F]
BLK
RED
ORN 55-47
ORN 55-45
Turntable & Boom

A
SHEET: 4 1001119266 Q
5 4 3 2 1
3121262 – JLG Lift – 7-47

8 7 6 5 4
T/T SWING MAIN LIFT MAIN TELESCOPE JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER
KEY SWITCH DIAGNOSITC DISPLAY
EMERGENCY MOUNTED IN GROUND BOX TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITC
HOURMETER MOMENT CONTROL TEST
EMS IGNITION RELAY
PUSH BUTTON

87a
87
30
85
86
SW206-1B
SW206-1A
SW206-2A
SW206-2B
SW228-1
SW228-2
SW219
SW220
SW221
SW223
SW222
SW225
SW226
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
SW139-B1
SW139-B
1B
1A
2A
2B
SW139-1
SW139-3
SW139-2
SW139-4
RL80
1
4
1
3
2
5
H
WHT 21-2
YEL/RED 2-40-01
WHT 22-2
YEL/RED 2-40-02
TAN 3-2
YEL/RED 2-40-02
TAN 3-3
YEL/RED 2-40-03
BRN 13-2
YEL/RED 2-40-03
BRN 14-2
YEL/RED 2-40-10
YEL/RED 2-40-10
YEL/RED 2-40-05
ORN/RED 49-102
BRN 29-2
YEL/RED 2-40-05
BRN 30-2
YEL/RED 2-40-04
BLU 28-2
YEL/RED 2-40-04
BLU 27-2
YEL/RED 2-40-06
GRY 23-2
YEL/RED 2-40-06
GRY 24-2
YEL/RED 2-40-08
PNK 25-2
YEL/RED 2-40-08
PNK 26-2
YEL/RED 2-40-09
WHT/YEL 48-1
YEL/RED 2-40-09
BRN/ORN 53-2
YEL/RED 2-40-07
RED 1-1-2 (10)
YEL/RED 2-1-1 (12)
YEL/RED 2-1-1 (12)

YEL/RED 2-1-2
YEL/RED 2-2
YEL/RED 2-1-2
YEL/RED 2-30-1
YEL/RED 2-8
YEL/RED 2-8-1
GD275
3
4
5
6
1
2
IP213
IP212
30A
GRN CAN1-L_MDI
YEL CAN1-H_MDI
YEL/RED 2-40-07
BLK 000-31-11
IP284
BLK 000-03
YEL/RED 2-8
YEL/RED 2-3
RED 1-1 (10)
Sheet_4 (T/T & Boom)-[8,D]
S362
YEL/RED 2-2B
Sheet_5 (Ground Box)-[8,A]
YEL/RED 2-3
Sheet_5 (Ground Box)-[8,A]
G
RED 1-3
CAN-1 SPLICE (GROUND) CAN-2 SPLICE

MNTD BESIDE GROUND MODULE MNTD BESIDE GROUND MODULE
YEL/RED 2-40-01
ORN/RED 49-103
ORN/RED 49-101
ORN/RED 49-100
BRN/WHT 47-6
BRN/WHT 47-5
BRN/WHT 47-8
BRN/ORN 53-2
YEL/RED 2-8-5
BLK 000-31-01
WHT/YEL 48-1
WHT/YEL 39-1
WHT/YEL 48-6
RED/YEL 54-4
RED/YEL 54-5
WHT 21-2
WHT 22-2
GRY 23-2
GRY 24-2
BRN 13-2
BRN 14-2
BRN 29-2
BRN 30-2
PNK 25-2
PNK 26-2
BLU 28-2
BLU 27-2
TAN 3-2
TAN 3-3
12
10
12
10
11
11
MS287
MS134
1
2
3
4
9
5
6
7
8
1
2
3
4
9
5
6
7
8
CO239-J4
SHIELD TP-CBL12
YEL CAN1-HIGH
RED
YEL CAN1-H_GTWY
BLK CAN1-SHIELD
SHIELD
YEL CAN2-HIGH
BLK CAN2-SHIELD
BLK CAN2-SHIELD
YEL CAN1-H_MDI
GRN CAN1-L_GTWY
BLK
GRN CAN1-L_MDI
GRN CAN1-LOW
GRN CAN2-LOW
GRN CAN2-LOW
YEL CAN2-HIGH
RED TP-CBL12
BLK TP-CBL12
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
21
10
24
14
13
12
11
10
9
8
7
6
5A
IP140
SWGLT
SWGRT
STRT
ALT
LIFTUP
TELEOT
JIBOUT
JIBUP
LVLUP
AUX
AXLE
TEMP
OILP
BCS
ALTE
IGN
LIFTDN
TELEIN
JIBIN
JIBDN
ROTR
ROTL
LVLDN
OVRLD
GND
IGN
500#
GLOW
BCSCAL
1000#
S365
S363
J4 (BLUE)
S364
RED 1-3A
1
BLK 000-03A
2
YEL/RED 2-8-1A
TELEMATICS 3

YEL/RED 2-2A
4
X361
Sheet_4 (T/T & Boom)-[8,B]
WHT 71-1 MSSO SW

E
RED 1-3B
B
J
5A YEL/RED 2-6
H
ADVANCED G IP102
DIAGNOSTIC F
YEL CAN2-HIGH
C CO239-J12
CONNECTOR GRN CAN2-LOW
D
BLK CAN2-SHIELD
1 J12 (BLACK)
E 2
BLK 000-9
A 5 CAN2S
X272 4 CAN2L
3 CAN2H
ORN/RED 49-16
6 CAN2T
7 CAN2T
WHT 71-1 MSSO SW
8
12 12 120
11 11 CO239-J7
BLK 000-25 (16) BLK CAN1-SHIELD
8 8 Sheet_5 (Ground Box)-[8,D] 18 CAN1S
RED/WHT 50-3 (16) GRN CAN1-LOW
7 7 Sheet_5 (Ground Box)-[8,D] 24 CAN1L
BLK 000-24-1 (16) YEL CAN1-HIGH
10 10 Sheet_5 (Ground Box)-[8,D] 13 CAN1H
RED/WHT 50-2-1 (16) YEL/RED 2-30-1
D SEE SHEET 3 9 9
ORN/RED 49-88
Sheet_5 (Ground Box)-[8,D]
ORN/RED 49-88
3 GNDMODE
4 4 12 BRKNCBL
ZONE H-8 5 5
32 IGN
BLK 000-26 BLK 000-26
3 3 19 GND
1 1 29 IGN 120
2 2 11 BMRTCL
6 6 35 BMRTOP
X244 X146 6 CANT
ORN/RED 49-17
17 CANT
BLK 000-9
12 5
BLK 000-03B YEL/RED 2-6
11 34 IGN
10 16
BLK 000-01 (12)
9
BLK 000-06
Sheet_4 (T/T & Boom)-[8,C]
YEL/RED 2-31
4 J7 (BLACK)
GROUND BUSS
8 Sheet_4 (T/T & Boom)-[5,F] 23 GNDE

BLK 000-38
7 [7,B] 30 IGN
BLK 000-08
6 7
BLK 000-05-1 (12) ORN/RED 49-102
5 Sheet_4 (T/T & Boom)-[3,A] Sheet_5 (Ground Box)-[4,H] 21 PTST
BLK 000-04 (12)
4 Sheet_4 (T/T & Boom)-[3,A] 10
BLK 000-45-1 (12)
3 20
BLK 000-39-1 (12)
2 25
BLK 000-2 (12)
1 8
MS96 28
C 26
YEL/RED 2-8-1B (12)
12 9
11 31
YEL/RED 2-8-7
10 33
YEL/RED 2-8-5
9 [6,F] 27
YEL/RED 2-8-8
IGNITION BUSS
8 [7,B] 22
YEL/RED 2-8-6 YEL/RED 2-3-2
7 [7,C] 1 PLTS
6 Sheet_4 (T/T & Boom)-[5,F] 2 PLTE
YEL/RED 2-8-3 (12)
5 Sheet_4 (T/T & Boom)-[3,A] 14 GNDMODE
YEL/RED 2-8-4 (18)
4 Sheet_4 (T/T & Boom)-[8,C] 15 FTSWCL
YEL/RED 2-8-11 (12)
3
YEL/RED 2-8-10 (12)
2
YEL/RED 2-8-2 (12)
CO239-J8
1
2
3
4
1
MS95
1
YEL/RED 2-8-2 (12)
YEL/RED 2-30
YEL/RED 2-20
2
3
S218
BLK 000-2 (12)
4
5
6
CAN-1 REPEATER MODULE TO PLATFORM
CAN-2 LOW 7
B
MOUNTED WITH GROUND MODULE
CAN-2 HIGH 8
GRN CAN1-L_GTWY
CAN-1 LOW 9
YEL CAN1-H_GTWY
CAN-1 HIGH 10
BLK 000-08
GROUND 11
YEL/RED 2-8-7
IGNITION 12
YEL/RED 2-3
YEL/RED 2-3-4
CO75-J1
1
2
BLK CAN2-SHIELD
CAN-2 - SHIELD 3
4
YEL/RED 2-8-10 (12)
YEL/RED 2-8-11 (12)
Ground Box
BLK 000-39-1 (12)
BLK 000-45-1 (12)
YEL/RED 2-3
6 Sheet_5 (Ground Box)-[8,G]
YEL/RED 2-2B
7 Sheet_5 (Ground Box)-[8,G]
BLU 27-3-4
BLU 28-3-4
8
PNK 25-3
PNK 26-3
GRN CAN1(A)-LOW
CAN-3 LOW 9
YEL CAN1(A)-HIGH
CAN-3 HIGH 10
11
12
X46
CO75-J2
3
2
5
1
10
12
16
18
8
14
17
19
4
11
6
13
9
7
15
10
12
16
18
14
17
19
13
15
11
***120 RESISTOR ACROSS J2-9 & J2-10 SEE SHEET 3, ZONE C-8
3
2
5
1
9
7
X61
SHEET: 5
8 7 6 5 4
7-48 – JLG Lift – 3121262

5 4 3 2 1
JIB TELESCOPE JIB LIFT PLATFORM ROTATE PLATFORM LEVEL START/AUX POWER
(CE ONLY)
TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH TOGGLE SWITCH
MOMENT CONTROL TEST 500# CAP AXLE SET GLOW PLUG HIGH COOLANT LOW OIL NO ALTERNATOR MOMENT CNTL BOOM CONTROL PLATFORM 1000# CAP GENERIC
PUSH BUTTON GENERIC
LIGHT LIGHT LIGHT TEMP LIGHT PRES LIGHT OUTPUT LIGHT TEST LIGHT SYSTEM LIGHT OVERLOAD LIGHT
SW228-1
SW228-2
SW358-1
SW358-2
SW221
SW223
SW222
SW225
SW226
SW227
LB229
LB230
LB231
LB232
LB233
LB234
LB235
LB236
LB237
LB238
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
H
YEL/RED 2-40-10
YEL/RED 2-40-05
ORN/RED 49-102
BRN 29-2
YEL/RED 2-40-05
BRN 30-2
YEL/RED 2-40-04
BLU 28-2
YEL/RED 2-40-04
BLU 27-2
YEL/RED 2-40-06
GRY 23-2
YEL/RED 2-40-06
GRY 24-2
YEL/RED 2-40-08
PNK 25-2
YEL/RED 2-40-08
PNK 26-2
YEL/RED 2-40-09
WHT/YEL 48-1
YEL/RED 2-40-09
BRN/ORN 53-2
YEL/RED 2-40-07
RED/YEL 54-4
BLK 000-31-11
BLK 000-31-10
WHT/YEL 39-1
BLK 000-31-10
BLK 000-31-09
WHT/YEL 48-6
BLK 000-31-09
BLK 000-31-08
BRN/WHT 47-6
BLK 000-31-08
BLK 000-31-07
BRN/WHT 47-5
BLK 000-31-07
BLK 000-31-06
BRN/WHT 47-8
BLK 000-31-06
BLK 000-31-05
ORN/RED 49-103
BLK 000-31-05
BLK 000-31-04
ORN/RED 49-101
BLK 000-31-04
BLK 000-31-03
ORN/RED 49-100
BLK 000-31-03
BLK 000-31-02
RED/YEL 54-5
WHT 71-1 MSSO SW

BLK 000-31-02
BLK 000-31-01
BLK 72-1 MSSO CONFIG

BLK 72-2 MSSO GND
G
YEL/RED 2-8-5
[2,B]
Sheet_5 (Ground Box)-[1,E]

BRN/WHT 47-9
YEL/RED 2-40-01
ORN/RED 49-103
ORN/RED 49-101
ORN/RED 49-100
BRN/WHT 47-6
BRN/WHT 47-5
BRN/WHT 47-8
BRN/ORN 53-2
YEL/RED 2-8-5
BLK 000-31-01
WHT/YEL 48-1
WHT/YEL 39-1
WHT/YEL 48-6
BLK 72-1 MSSO CONFIG

RED/YEL 54-4
RED/YEL 54-5
WHT 21-2
WHT 22-2
GRY 23-2
GRY 24-2
BRN 13-2
BRN 14-2
BRN 29-2
BRN 30-2
PNK 25-2
PNK 26-2
BLU 28-2
BLU 27-2
TAN 3-2
TAN 3-3
CO239-J4
CO239-J3
12
34
25
35
23
33
7
30
11
22
8
19
20
9
18
6
17
5
4
16
2
1
15
28
29
26
13
3
14
27
31
32
21
10
24
14
13
12
11
10
9
8
7
6
5
4
3
2
1
SWGLT
SWGRT
STRT
ALT
LIFTUP
TELEOT
JIBOUT
JIBUP
LVLUP
AUX
AXLE
TEMP
OILP
BCS
ALTE
F
IGN
LIFTDN
TELEIN
JIBIN
JIBDN
ROTR
ROTL
LVLDN
GLOW
IGN
500#
BCSCAL
OVRLD
GND
1000#
J3 (BLACK)
SWGRT 35
J4 (BLUE) SWGLT 34
33
32
GND 30
28
GNDALRM 27
HEAD/TAIL 26
FUEL 25
24
23
LIFTDN 22
21 SEE SHEET 3 FOR
20
LIFTFLOW 19 OTHER CONNECTIONS
GND 17
MNTELEOUT 16
J2 (GRAY) 15
GND 14
E
MAINDMP 13
LIFTDNAUX 12
LIFTUP 11
LIFTPILOT 10
TELEFLOW 9
8
GND 6
CO239-J12 MNTELEIN 4
1 J12 (BLACK) HORN 2
BLK 000-25
2 GND 18 Sheet_5 (Ground Box)-[2,D]
RED/WHT 50-3
5 CAN2S JIB DMP 1 Sheet_5 (Ground Box)-[2,D]
BLK 000-24-1
4 CAN2L GND 29 Sheet_5 (Ground Box)-[2,D]
RED/WHT 50-2-1
3 CAN2H PLTDMP 3 Sheet_5 (Ground Box)-[2,D]
BLU 28-3-4
6 CAN2T JIBDNO/R 31
PNK 26-3
7 CAN2T PLVLDNO/R 7
PNK 25-3
8 PLVLUPO/R 5
120 CO239-J2
CO239-J7 X245
YEL/RED 2-5
18 CAN1S ANALP 28 1
24 CAN1L ANALR 29
ORN/RED 49-5
2 ANALYZER
ORN/RED 49-6
13 CAN1H ANALT 30 3
BLK 000-37
3 GNDMODE ANALG 31 4 D
12 BRKNCBL 35
32 IGN 34
BLK 72-2 MSSO GND
19 GND 33
29 IGN 120 27
11 BMRTCL 26
35 BMRTOP 25
6 CANT 24
BRN/WHT 47-9
17 CANT 21 X274 X271
BRN/WHT 47-8-1 BRN/WHT 47-8-2
5 ALTE 32
WHT/YEL 48-3 S86
5 5 ENGINE
34 IGN START 11 2 2
16 19 [3,E]
RED TP-CBL12
3 3
CONNECTOR #1
BLK TP-CBL12
4 J7 (BLACK) J1 (WHITE) 18 [3,E]
SHIELD TP-CBL12 S276
4 4
SEE SHEET 7
23 GNDE 17 [4,E] 6 6
YEL/RED 2-8-6
30 IGN 16 [2,B] 1 1 ZONE E-1
7 15
21 PTST 14
10 1
ORN 55-45
20 BRK 23 Sheet_4 (T/T & Boom)-[8,B]
ORN 55-47
25 2SPD 20 Sheet_4 (T/T & Boom)-[8,B]
BRN/ORN 53-3
8 AUXP 13 Sheet_4 (T/T & Boom)-[8,D]
28 4
26 6 C
9 5
31 2
YEL/RED 2-1-88
33 10 X266 X201
BLK 000-42 (16)
27 GND 8 2 2
WHT/YEL 48-8
22 SP 7 7 7
1 PLTS GEN 22
BLU/ORN 52-5
3 3 ENGINE
WHT/YEL 48-9
2 PLTE GLOW 12
BLK 000-22
4 4 CONNECTOR #2
14 GNDMODE GND 9 6 6
BLU 27-3-4
15 FTSWCL JIBUPO/R 3 1 1
CO239-J1 [2,B]
YEL/RED 2-8-8
5 5
SEE SHEET 7
WHT/YEL 48-7 (16)
8 8 ZONE F-1
CO239-J8
1
2
3
4
YEL/RED 2-8-2 (12)
WHT/YEL 48-7 (16)

X93 (CAT ENGINE ONLY)
1
ELECTRIC FUEL
BLK 000-2 (12)
BLK 000-38
[2,C] 2
PUMP CONNECTOR
LOCATED NEAR
FUEL TANK
B
Ground Box
SHEET: 5 1001119266 Q
5 4 3 2 1
3121262 – JLG Lift – 7-49

7-50
F
A
B
E
C
D
H
G
SN193
RED/WHT 50-4-2
B
ORN/RED 49-8
D
BLK 000-17-2
A
RED/WHT 50-5-2
F
ORN/RED 49-7
C
TURNTABLE
BLK 000-18-2
ANGLE SENSOR
E
8
8
LEFT FRONT RIGHT FRONT

STEER SENSOR STEER SENSOR
3
2
1
3
2
1
SN92
SN81
BLU
RED
BLK
BLU
RED
BLK
7
7
BLK 000-17-2
RED/WHT 50-4-2
X100 X107
RED RED S171 RED/WHT 50-4-1
1 1
BLU WHT
2 2
BLK BLK BLK 000-17-1
3 3
BRN/BLK BRN/BLK S119
4 4
X101 X110 CO21-J3

RED RED BLK 000-16
SWIVEL
1 1 1 VREF GND 12 X22

COUPLING
BLU WHT WHT ORN/RED 49-10

2 2 2 FTRTSTR CANT 10 9 9 9 9
BLK BLK BLK 000-20 BLK 000-17-1 ORN/RED 49-10
3 3 3 GND CANT 9 10 10 10 10
BRN/BLK BRN/BLK S120 RED RED RED GRN
4 4 4 VREF CAN1H 6 1 1 1 1
WHT BLK BLK YEL
5 FTLTSTR CAN1L 7 2 2 2 2
120
BLK 000-20 SHIELD SHIELD BLK
6 GND CAN1S 8 3 3 3 3
BLK 000-19 YEL/RED 2-1 YEL/RED 2-1 RED (14)
9 GND IGN 5 4 4 4 4
WHT BLK 000-15 (14) BLK 000-15 (14) BLK (14)
8 RERTSTR GND 4 5 5 5 5
BRN/BLK BRN/BLK RED YEL/RED 2-4
J3 (GREEN)
4 4 7 VREF 3 11 11 11 11
BLK BLK BLK 000-19 BLK 000-18-1 ORN/RED 49-106
3 3 12 GND 2 12 12 12 12
BLU WHT S121 WHT ORN 55-47-2 YEL
2 2 11 RELTSTR 1 6 6 6 6
RED RED YEL/RED 2-4 ORN 55-45 ORG
1 1 10 VREF IGN 11 7 7 7 7
J1 (GRAY)
X105 X111 CO21-J1 ORN 60-2 VIO
8 8 8 8
BLK 000-18-2
SEE SHEET 4 ZONE B-6
X26
BRN/BLK BRN/BLK
4 4
BLK BLK BLK 000-18-1
3 3
BLU WHT S122 BLK 000-17
2 2 GND 8
RED RED RED/WHT 50-5-1 BLK 000-14
1 1 GND 2
X106 X113 RED/WHT 50-5-2 S199 ORN 60-2
6 1
BLK 000-16
5 2
BLK
VALVE
4 V196
BLK
6
6
J4 (GRAY)
YEL/RED 2-1-3
IGN 7
OSC. AXLE LOCK-OUT
YEL/RED 2-1-2
1
BLK
IGN
BLU
RED
– JLG Lift –
ORN 55-45
BLK
BLU
RED
CO21-J4 1
BLK 000-17
2
VALVE
BRAKE
V195
CHASSIS MODULE
CO21-J5
YEL 9-1
SN99
SN98
4 LTFTSTRRT 10
3
2
1
3
2
1
YEL 9-2 ORN/RED 49-8
2 RTFTSTRLT TTANG2 9
YEL 10-2 ORN/RED 49-7 ORN 55-47-2
1 RTFTSTRRT TTANG1 8 1
YEL 10-1 ORN/RED 49-106 BLK 000-14
3 LTFTSTRRT DOS 6 2
YEL 11-1
VALVE
8 LTRESTRLT 2 V194
YEL 11-2
TWO SPEED
6 RTRESTRLT 1
YEL 12-2 ORN/RED 49-104
5 RTRESTRRT FAXLS 4
YEL 12-1 ORN/RED 49-105
7 LTRESTRRT RAXLS 5
J5 (RUST)
J2 (BLACK)
BLK 000-12-01 YEL/WHT 40-2-44-1
12 GND AXLRT 12
BLK 000-13-1
RIGHT REAR LEFT REAR 10 GND 3
YEL/WHT 39-2-43-1
STEER SENSOR STEER SENSOR 11 AXLET 11
2
1
SN176
STEER LEFT STEER LEFT YEL/RED 2-1-4 ORN/RED 49-107

9 IGN AXLPR 7
RIGHT FRONT LEFT FRONT CO21-J2
FRONT AXLES
RETRACT
BLK 000-12-01
PROXIMITY SENSOR
2
1
2
1
DRIVE ORIENTATION
V165
V164
S170
1
2

V166
YEL 9-1
YEL 9-2
5
5
BLK 000-12-03
BLK 000-13-4
YEL/WHT 40-2
BLK 000-12-05
BLK 000-12-02
BLK 000-12-02
BLK 000-12-04
S168
YEL/RED 2-1-3
YEL/RED 2-1-2
ORN/RED 49-104
ORN/RED 49-105
BLK 000-12-06
YEL 10-2
YEL 10-1
BLK 000-13-5
YEL/WHT 39-2
BLK 000-12-07
S192
S190
S189
S187
V167
2
1
V163
V162
2
1
2
1
S191
S188
WHT
BLK
FRONT AXLES
BLK
WHT
EXTEND RIGHT FRONT LEFT FRONT

WHT
BLK 000-13-4
BLK 000-13-5
BLK
STEER RIGHT STEER RIGHT

BLK
WHT
S174
STEER LEFT STEER LEFT
REAR AXLES RIGHT REAR LEFT REAR
4
4
RETRACT
WHT
2
1
2
1
1
2
BLK
V159
V153
BLK 000-13-3
V161
LEFT FRONT AXLE
YEL/RED 2-1-4
ORN/RED 49-107
EXTEND LIMIT SWITCH
YEL 11-2
YEL 11-1
BLK 000-12-09
BLK 000-12-08
BLK 000-13-6
YEL/WHT 44-1
SHEET: 6
3121262
5 4 3 2 1
H
LEFT FRONT AXLE RIGHT FRONT AXLE LEFT REAR AXLE RIGHT REAR AXLE
EXTEND LIMIT SWITCH EXTEND LIMIT SWITCH RETRACT LIMIT SWITCH RETRACT LIMIT SWITCH
WHT
BLK
WHT
BLK
WHT
BLK
WHT
BLK
G
YEL/RED 2-1-3 WHT

S187 BLK
S188 WHT
ORN/RED 49-104 BLK
S189
YEL/RED 2-1-2 WHT
S190 BLK
S191 WHT
ORN/RED 49-105 BLK
S192
YEL/WHT 39-2-43-1
ORN/RED 49-107
F
BLK 000-13-1
CO21-J2
3
11
7
GND
AXLET
AXLPR
PRESSURE SWITCH
AXLE LOCK OUT
ORN/RED 49-107
3
YEL/RED 2-1-4
1
SN178
GND
IGN
E
12
10
11
9
YEL/RED 2-1-4
BLK 000-12-04
YEL/WHT 39-2-43-1
BLK 000-12-01 BLK 000-12-02

S170
BLK 000-12-02
BLK 000-12-04
YEL/WHT 40-2-44-1
D
S168
S169
S172
STEER RIGHT
STEER RIGHT
LEFT FRONT
LEFT FRONT
STEER LEFT
STEER LEFT
LEFT REAR
LEFT REAR
YEL 9-1 YEL 10-1 YEL 11-1 YEL 12-1

1 1 1 1
BLK 000-12-03 BLK 000-12-07 BLK 000-12-08 BLK 000-12-10
YEL/WHT 39-2
YEL/WHT 43-1
2 2 2 2
V164 V162 V153 V123
S173
RIGHT FRONT
RIGHT FRONT
STEER RIGHT
STEER RIGHT
RIGHT REAR
RIGHT REAR
STEER LEFT
STEER LEFT
YEL 9-2 YEL 10-2 YEL 11-2 YEL 12-2

1 1 1 1
BLK 000-12-05 BLK 000-12-06 BLK 000-12-09 BLK 000-12-11
2 2 2 2
V165 V163 V159 V124
YEL/WHT 40-2
YEL/WHT 44-1
C
FRONT AXLES
FRONT AXLES
REAR AXLES
REAR AXLES
BLK 000-13-4 YEL/WHT 39-2 BLK 000-13-6 YEL/WHT 43-1

RETRACT
RETRACT
EXTEND
EXTEND
2 1 2 1
YEL/WHT 40-2 BLK 000-13-5 YEL/WHT 44-1
1 2 1 2
V166 V167 V161 V160
BLK 000-13-5 BLK 000-13-2

BLK 000-13-4 BLK 000-13-3 BLK 000-13-3 BLK 000-13-1
S174 BLK 000-13-6 S175
Chassis B
SHEET: 6 1001119266 Q
5 4 3 2 1
3121262 – JLG Lift – 7-51

8 7 6 5 4
GLOW PLUGS
IN HEAD
WHT/YEL 48-13 (8)
1
EC91
GLOWPLUG START
RELAY RELAY
ENGINE TRAY ENGINE

PIVOT PIN BLOCK
1
X268
X269
X270
85
86
30
87
85
86
30
87
RL198-85
RL197-85
RL198-86
RL198-30
RL198-87
RL197-86
RL197-30
RL197-87
1
1
G
BLK (1/0)
BLK (1/0)
BLK (14)
BLK (1/0)
WHT/YEL 48-13 (8)

BLK (14)
BLK (14)
WHT/YEL 48-12 (12)

BLK (14)
RED (1/0)
RED (1/0)
RED (1/0)
RED (1/0)
WHT/YEL 48-9
WHT/YEL 48-3
1
STARTER
EC204-B-
WHT/YEL 48-12 (12)
12V
1
BLK (1/0) EC204
RED (1/0) RED (1/0)
RED (8)
1 M
EC204-B+
X266 X201
WHT/YEL 48-9
ENGINE 4 4
5 5
CONNECTOR #2 1 1
F 3 3
SEE SHEET 5 6 6
BLK 000-21
2 2
ZONE C-1 7 7
8 8
S261
EC203-B+
#12_FUSE-LINK (12)
ALTERNATOR
1 B+
14V, 95A
EC203-D+
BRN/WHT 47-8
1 D+
EC203-W
1 W
CO133-J1
BLK 000-21
1 25
4 24
5 23
6 22
7 21
8 DEUTZ 20
ENGINE 6 6
WHT/YEL 48-3
9 19
CONNECTOR #1
2 2
BRN/WHT 47-8
15 EMR2 18
5 5 16 17
BLK BLK
SEE SHEET 5
4 4
RED RED
13 MODULE 16
3 3 12 15
YEL/RED 2-1-99 YEL/RED 2-1-99 BLK 2-1-99
ZONE D-1 1 1
S265
14 14
X274 X271 18 13
19 12
DEUTZ A
BLK 000-1 BLK 000-1
20 11
B 2 10
DIAGNOSTIC K
11 9
PORT L 10 8
D X273 21 7
22 6
23 5
24 4
25 3
3 2
17 1
CO133-J2
RIGHT SIDE RIGHT SIDE

DRIVE FORWARD DRIVE REVERSE
C Deutz Engine - EMR2

1
2
1
2
V277
V278
ORN 7-3-2
ORN 7-2-2
BLK 000-22-5
BLK 000-22-4
5 5
ORN 7-3-2
4 4
ORN 7-2-2
PUMP 3 3
BLK 000-22-5
CONNECTOR 6 6
BLK 000-22-1 BLK 000-22-4
S103 BLK 000-22-3
SEE SHEET 4 BLK 000-22-2
ORN 8-2-2
CONNECT TO X56 1 1
ORN 8-3-2
2 2
X56 X62
BLK 000-22-3
BLK 000-22-2
ORN 8-2-2
ORN 8-3-2
B
V279
V280
1
2
1
2
DRIVE FORWARD DRIVE REVERSE

LEFT SIDE LEFT SIDE
1001119266 Q
SHEET: 7
8 7 6 5 4
7-52 – JLG Lift – 3121262

This Page Left Blank Intentionally.
3121262 – JLG Lift – 7-53

8 7 6 5 4
H
LEFT FRONT RIGHT FRONT
LIGHT LIGHT
HEAD & TAIL LIGHT
RELAY
(OPTION)
1
87a
7500W GENERATOR
86
85
30
87
CONTROL BOX
5
2
3
1
4
C
A
B
BLACK
BLACK
WHITE
WHITE
WHITE
BLACK
YEL/RED 2-8-8
WHITE
WHITE
RED 1-1 (12)
BLU/ORN 52-5
BLK 000-22
CONNECT TO X147 BLU/ORN 52-12
1
IN TURNTABLE
X201
CONNECT TO B- BLACK 4
G 1
ENGINE 5
YEL/RED 2-8-8 5A
ON ENGINE TRAY 1 IP328
CONNECTOR #2 3
BLU/ORN 52-5
BLK 000-22
CONNECT TO B+ #14 FUSIBLE LINK 6
1
REFERENCE ONLY 2
ON AUX POWER RELAY 7 WIRES INSERTED ON ASSY LINE
8
BLACK
CONNECTED TO B- 1
BLACK (12) BLACK
7500W GENERATOR
ON AUX POWER RELAY
WHITE
BLACK
BLACK
WHITE
WHITE
BLACK
LOW TEMPERATURE CUTOUT OPTION

1
F
LEFT REAR RIGHT REAR 110V GENERATOR
LIGHT LIGHT RELAY
PARKER SENSOR
87a
86
85
30
87
HEAD & TAIL LIGHTS & (OPTION)
1500W POWERMITE X1
CHASSIS ILLUMINATION
5
2
3
1
4
CONNECTOR 1
BLK GND
1
2
3
4
2
BLK CAN L
3
RED CAN H
4
BLU/ORN 52-6
NC
BLACK
BLACK
BLU/ORN 52-6
WHITE
RED 1-3 (12)
GREEN
E 2
YEL/RED 12AWG YEL/RED 12AWG
2
X2
BLK 12AWG BLK 12AWG
BLU/ORN 52-5
1
BLK 16AWG BLK 16AWG
1 CONNECT TO J8 2
BLK GND
J8 J8_1 1
SHT 2 ZONE C-4
P-J8
MOLEX
X201 042816-0212
4
#14GA FUSIBLE LINK CONNECT TO B+ SIDE OF
ENGINE 5 1
3A
1
START OR AUX POWER RELAY
CONNECTOR #2
IP312
3
3A
6
REFERENCE ONLY 2
BLACK
1
CONNECT TO B-
ON ENGINE TRAY
IP313
7
8
BLK 16AWG
BLK 16AWG
2500W GENERATOR
D
LIGHTS
1
2
3
4
LIGHTS_1
1
2
3
4
INSIDE CONSOLE BOX

2 2
BLK 12AWG BLK 12AWG
YEL/RED 16AWG
1 1
J8 BLK 16AWG BLK 16AWG J8_1
BLK 16AWG
3A
IP324
3A
C
IP325
PLATFORM FLOOD LIGHTS
BLK 16AWG
BLK 16AWG
ON/OFF SWITCH
1
YEL/RED 16AWG
2
YEL/RED 16AWG
3
4
5
6
SWITCH
LIGHTS
S402
1 1
2 2
3 3
4 4
BLK 16AWG
LIGHTS_1
YEL/RED 16AWG
FLOOD_1 INSIDE CONSOLE BOX
1 1
BLK 16AWG
2 2
BLK OR BRN
BLK OR BRN
LED FLOODLIGHT
TRAPEZOID BEAM PATTERN
B MOUNTED ON RAIL CORNER MOUNTED ON RAIL CORNER
RED
RED
S401
FLOOD_2
YEL/RED 16AWG BLK OR BRN RED
1 1
BLK 16AWG RED BLK OR BRN
2 2
LED FLOODLIGHT LED WORKLIGHT

SPOT BEAM PATTERN
TRAPEZOID BEAM PATTERN SPOT BEAM PATTER
LED WORKLIGHT
PLATFORM FLOOD LIGHTS PLATFORM WORK LIGHTS

(OPTION) (OPTION)
8 7 6 5 4
7-54 – JLG Lift – 3121262

5 4 3 2 1
H
PLATFORM SENSOR
(FOR PASSIVE SYSTEM, REMOVE

(OPTION) PLATFORM SENSOR AND 2 RELAYS)
7500W GENERATOR
RL502-87
CONTROL BOX SHEET 2 YEL/RED P3 YEL/RED P3
1
87
[F,4]
C
A
B
RL502-30
YEL/RED P9-1 30
1
RL502-87A
87a
1
RL502-85
YEL/RED 2-8-8
BLU/ORN 52-5
BLK 000-22
ORN/RED P5 85
1
ORN/RED P5-1
RL502-86
ORN/RED P4 86
1
PLATFORM SENSOR ORN/RED P4-1
ORN/RED P4
4
3 ORN/RED P5
YEL/RED 2-8-8
IP328
5A
2
BLK P6 SHEET 2
[B,5]
G
YEL/RED P10 YEL/RED P2 SHEET 2
BLU/ORN 52-5 1
R501 [A,3]
BLK 000-22
WIRES INSERTED ON ASSY LINE RL503-87

SHEET 3 YEL/RED P1 YEL/RED P1 87
[B,7] 1
YEL/RED P9 YEL/RED P9
[B,5] RL503-30
YEL/RED P9-1 30
1
RL503-87A
7500W GENERATOR SHEET 2
1
87a
[B,6]
RL503-85
ORN/RED P5-1 85
1
RL503-86
ORN/RED P4-1 86
1
LOW TEMPERATURE CUTOUT OPTION P-J8A

X3 F
YEL/RED EMS GND 2-1-3 CONNECT TO P8
110V GENERATOR 2
BLK GND
RELAY (MATING CONNECTOR OF J8)
1
MOLEX SHT 2 ZONE C-4

042818-0212
PARKER SENSOR
87a
30
87
(OPTION)
1500W POWERMITE X1 YEL/RED EMS GND 2-1-3
3
1
4
CONNECTOR 1
YEL/RED EMS GND 2-1-5 YEL/RED EMS GND 2-1-4
BLK GND S531
1
2
3
4
2
3
BLK CAN L
RED CAN H BLK GND
BLK GND
BLK GND
X4
4 B
CONNECT TO X1002
BLU/ORN 52-6
NC S532 A
BLACK C SHT 2 ZONE D-2
BLK CAN L
BLU/ORN 52-6
BLK CAN L
WHITE
RED 1-3 (12)
BLK CAN L DEUTSCH

GREEN
S533 RED CAN H

RED CAN H RED CAN H JLG PN 4460536
S534
SHIELD CANSHD X5
SHIELD CANSHD SHIELD CANSHD B
CONNECT TO X1001
X2 A
SHT 2 ZONE D-2
E
S535 C
YEL/RED EMS GND 2-1-4
CONNECT TO J8 2
BLK GND
SHT 2 ZONE C-4 1 DEUTSCH
P-J8 JLG PN 4460539
MOLEX LTC OPTION BOOM HARNESS
042816-0212
#14GA FUSIBLE LINK CONNECT TO B+ SIDE OF
1
START OR AUX POWER RELAY
BLACK
1
CONNECT TO B-
ON ENGINE TRAY
2500W GENERATOR

2 2
BLK 12AWG BLK 12AWG
1 1
J8 BLK 16AWG BLK 16AWG J8_1
4000W GENERATOR GENERATOR
CONTROL
BOX
B A C
3A
IP324
3A
C
BLU/ORN 52-5
BLACK
IP325
BLK 16AWG
BLK 16AWG
SEE SHEET5, ZONE B3

SEE SHEET6, ZONE B6
SEE SHEET5, ZONE B3

BLU/ORN 52-5
SEE SHEET6, ZONE B6
LIGHTS
1 1
2 2
3 3
4 4
LIGHTS_1
INSIDE CONSOLE BOX

BLK OR BRN
BLK OR BRN
MOUNTED ON RAIL CORNER B

RED
RED
RED
BLK OR BRN Accessories
LED WORKLIGHT
SPOT BEAM PATTERN
PLATFORM WORK LIGHTS

(OPTION)
1001119266 Q
5 4 3 2 1
3121262 – JLG Lift – 7-55

8 7 6 5 4
ECM-J2 X999 X1003 EIC BUSSMANN DIODE PACK

BLK 248-33 INJECTOR 1 BLK 248-33 INJECTOR 1 1.5mm² FUEL PUMP 20A (SW), ECM 30A (CONT)
33 1 1 62 (BLUE)
BLK 248-16 INJECTOR 1 BLK 248-16 INJECTOR 1 1.5mm² YELLOW CONNECTOR GLOWPLUG SOLENOID
16 2 2 35
BLK 248-48 INJECTOR 4 BLK 248-48 INJECTOR 4 1.5mm² GENERIC 150 AMP
48 3 3 42
BLK 248-18 INJECTOR 4 BLK 248-18 INJECTOR 4 1.5mm² RELAY, POWER MODULE
18 4 4 37
H 32
BLK 248-32 INJECTOR 3
BLK 248-2 INJECTOR 3
5 5
BLK 248-32 INJECTOR 3 1.5mm²
BLK 248-2 INJECTOR 3 1.5mm²
38
5A 10A
2 6 6 61
BLK 248-46 INJECTOR 2 BLK 248-46 INJECTOR 2 1.5mm²
46 7 7 40
BLK 248-3 INJECTOR 2 BLK 248-3 INJECTOR 2 1.5mm²
3 8 8 41
87
30
BLK 248-5 MPROP ACTUATOR
6 9 9 2
BLK 248-4 MPROP ACTUATOR BLK 248-5 MPROP ACTUATOR 1.5mm²
5 10 10 20
RL930-B+
MS932
RL931-87
RL931-87
RL931-87
RL931-30
RL930-1
RL930-2
BLK 248-19 EXH GAS RECIRC BLK 248-4 MPROP ACTUATOR 1.5mm²
G
C
D
H
B
A
E
F
RL930
1
1
2
1
4 11 11 19
BLK 248-20 EXH GAS RECIRC BLK 248-37 ENGINE SPEED CAMSHAFT 0.75mm²
37 12 12 14
BUSBAR
BLK 248-52 ENGINE SPEED CAMSHAFT 0.75mm²
BLK 248-23 GLOW SENSE 0.75mm²

52 13
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

YEL 2-1-99 IGNITION 18AWG
ORG 248-23-1 GLOW SENSE 18AWG
SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²
53 9
WHT 48-96 FUEL PUMP 14AWG
RED 1-148-135 ECM PWR 8AWG
150A
BLK 248-39 ENGINE SPEED CRANKSHAFT 0.75mm²
39 15
RED 48-13 GLOW 8AWG

BLK 248-54 ENGINE SPEED CRANKSHAFT 0.75mm²
RED 48-14 GLOW 8AWG

54 X1000 X1004 21
BLK 248-37 ENG CAM SHLD 248-38 ENGINE SPEED CRANKSHAFT 0.75mm²
38 1 1 1
BLK 148-7 RAIL PRESSURE FUEL BLK 248-52 ENG CAM BLK 248-7 RAIL PRESSURE FUEL 0.75mm²
7 2 2 32
BUSBAR
SHLD 248-53 ENG CAM
8 3 3 57
BLK 248-39 ENG CRANK
9 4 4 3
BLK 248-54 ENG CRANK
10 5 5 4
SHLD 248-38 ENG CRANK
11 6 6 5
12 7 7 6
EIC (ENGINE INTERFACE CONNECTION)

13 8 8 7
14 9 9 8
A [J2] 15 10 10 10
17 11 11 11
G ECM CONNECTOR 19 12 12
BLK 248-19 EHXAUST GAS RECIRCULATION 1.5mm²
47
20 48
21 12
22 59
S946
BLK 248-23 GLOW SENSE
23 X1001 X1005 16
BLK 248-24 BOOST PRESSURE / TEMP 0.75mm² BLK 248-24 BOOST PRESSURE / TEMP 0.75mm²
24 1 1 22
BLK 248-25 RAIL PRESSURE FUEL 0.75mm² BLK 248-25 RAIL PRESSURE FUEL 0.75mm²
25 2 2 31
BLK 248-26 RAIL PRESSURE FUEL 0.75mm² BLK 248-26 RAIL PRESSURE FUEL 0.75mm²
26 3 3 25
BLK 248-27 BOOST PRESSURE / TEMP 0.75mm² BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²
27 4 4 29
BLK 248-28 COOLING TEMPERATURE 0.75mm² BLK 248-28 COOLING TEMPERATURE 0.75mm²
28 5 5 24
BLK 248-29 OIL PRESSURE 0.75mm² BLK 248-29 OIL PRESSURE 0.75mm²
29 6 6 27
30 7 7 33
31 8 8 60
BLK 148-61 FUEL LOW PRESSURE 0.75mm²
34 9 9 17
BLK 248-35 GLOW RELAY CONTROL GND
35 10 10 18
36 11 11 58
1 12 12 30
BLK 248-40 AIR INLET TEMP BLK 248-40 AIR INLET TEMP 0.75mm²
40 28
BLK 148-56 AIR INLET TEMP 0.75mm²
41 34
42 36
BLK 248-43 OIL PRESSURE BLK 248-43 OIL PRESSURE 0.75mm²
43 23
BLK 248-44 OIL PRESSURE BLK 248-44 OIL PRESSURE 0.75mm²
44 26
45 39
F 47 43
49 44
50 45
51 46
BLK 148-72 THROTTLE FLAP 3 0.75mm²
55 49
56 50
BLK 148-38 THROTTLE FLAP 4 0.75mm²
57 52
58 51
59 53
60 54
55
56
ECM-J1
1.5MM (7,29,51,73) 7
8
9
10
11
12
BLK 148-13 COOLANT LEVEL SIG
13
S951
14
E 15
BLK 148-15-68 CLUTCH SWITCH
16
17
S952
18
19
20
21
22
23
24
25
BLK 148-26 FUEL PUMP RELAY CONTROL GND
26
27
28
1.5MM (7,29,51,73) BLK 148-29 COOLANT LEVEL PWR
29
30
31
32
33
34
35
36
37 X1002 X1006
D 38
BLK 148-38 THROTTLE FLAP 4
1 1
39 2 2
40 3 3
41 4 4
42 5 5
43 6 6
BLK 148-44 EXH GAS RECIRC
44 7 7
45 8 8
46 9 9
47 10 10
48 11 11
49 12 12
50
1.5MM (7,29,51,73) 51
52
GRN CAN 2 LO DIAG CAN LOW S968
53
Y EL CAN 1 HI CUSTOMER CAN HIGH
54
55 S953
BLK 148-56 AIR INLET TEMP
56
BLK 148-57 WATER IN FUEL SW RTN
57
K [J1] 58 X965
YEL CAN 2 HI 120 OHM
59 A A
ECM CONNECTOR 60
GRN CAN 2 LO
B B
C 61
BLK 148-61 FUEL LOW PRESSURE
C C
62 X966
63
BLK 148-64 WATER IN FUEL SW
64
65
66
67 X955
BLK 148-15-68 CLUTCH SWITCH YEL CAN 1 HI 120 OHM
68 A A
GRN CAN 1 LO
69 B B
70 C C
71 X956
BLK 148-72 THROTTLE FLAP 3
72
1.5MM (7,29,51,73) 73
74 S969
YEL CAN 2 HI DIAG CAN HIGH
75
GRN CAN 1 LO CUSTOMER CAN LOW
76
77 S954
X1008 X1010
YEL CAN 2 HI
78 1 1
GRN CAN 2 LO
79 2 2
80 3 3
YEL CAN 1 HI
81 4 4
BLK 148-82 EXH GAS RECIRC GRN CAN 1 LO
82 5 5
SHLD CAN 1 SHLD
83 6 6
B 84 7 7
BLK 148-85 EXH GAS RECIRC
85 8 8
86
BLK 148-87 COOLANT LEVEL GND
87
BLK148-88 IGNITION
88
89
90
91
92
93
94
RED 148-5 ECM PWR 2.5mm²
5 S944 X1007
RED 148-3 ECM PWR 2.5mm²
3 1 1
RED 148-1 ECM PWR 2.5mm² X1009
1
2.5MM (1-6) BLK 148-2 ECM GND 2.5mm²
2 S945
BLK 148-4 ECM GND 2.5mm²
4
BLK 148-6 ECM GND 2.5mm²
6
SHLD CAN 1 SHLD
NC
SHEET: 9
8 7 6 5 4
7-56 – JLG Lift – 3121262

5 4 3 2 1
BUSSMANN DIODE PACK

FUEL PUMP 20A (SW), ECM 30A (CONT)
Deutz Engine
(BLUE)
YELLOW CONNECTOR GLOWPLUG SOLENOID GLOWPLUGS
GENERIC 150 AMP
RELAY, POWER MODULE
H
5A 10A
GENERIC
Tier 4 Final
87
30
86
85
GENERIC
ALTERNATOR
RL930-B+
RL931-85
MS932
RL931-87
RL931-87
RL931-87
RL931-30
RL931-86
B+
RL930-1
RL930-2
W
G
C
D
H
B
A
E
F
RL930
1
1
2
1
2
L
EC18
BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²
EC241-B+
EC241-W
BUSBAR
EC241-L
1
1
BLK 248-23 GLOW SENSE 0.75mm²
BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

RED 1-148-135 ECM PWR 8AWG

BATTERY
150A
RED 48-13 GLOW 8AWG
RED 48-13 GLOW 8AWG

RED 48-14 GLOW 8AWG
RED 48-14 GLOW 8AWG

RED - - 4AWG
RED 47-8 ALT EXCITE 16AWG

POSITIVE
BUSBAR
BUSBAR
RED - - 2/0AWG
RED - - 2/0AWG
X923
1
150A
G
BUSBAR
EC971-B+
1 M
S946
GENERIC
GENERIC
EC971
1
EC971-B-
1
RL974
WHT 48-3 START 18AWG
1 DEUTZ PROVIDED
BLK 000-48-4 ENG GND
2
START RELAY
X901
1 VSW
WHT 48-3 START 18AWG START
2
YEL CAN 1 HI CUSTOMER CAN HIGH CAN + (HI)
3
GRN CAN 1 LO CUSTOMER CAN LO
4 CAN - (LOW) ENGINE CONNECTOR #1
RED 47-8 ALT EXCITE 16AWG
5 ALT EXCITE TO SHEET 5, D1
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD CAN SHIELD
6
F
X902
YEL 2-1-99 IGNITION 18AWG EMR4 IGNITION
1
2 GROUND
3 GENERATOR ENABLE
4 GLOW
5 GENERATOR POWER ENGINE CONNECTOR #2

6 GENERATOR GROUND TO SHEET 5, C1
7 PLUGGED
8 PLUGGED
S951
E
S952
X950
YEL 2-48-2 IGNITION
A
B
C
D
E
GRN CAN 1 LO CUSTOMER CAN LO
F
GRN CAN 2 LO DIAG CAN LOW
S963 S964 YEL CAN 2 HI DIAG CAN HIGH
G DEUTZ DIAGNOSTIC
H
J
K
L
YEL CAN 1 HI CUSTOMER CAN HIGH
M D
X960
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
A A
GRN CAN 2 LO DIAG CAN LOW
B B
C C
X961
NORMALLY CLOSED
SN939 PWR
COOLANT LEVEL
BLK 148-29 COOLANT LEVEL PWR 0.75mm²

1
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
3 SIG
BLK 148-87 COOLANT LEVEL GND 0.75mm²
2
4
GND
C
WIF SWITCH
X941 X942
BLK 148-64 WATER IN FUEL SW 0.75mm² BLK 148-64 WATER IN FUEL SW 16AWG
1 1 1
BLK 148-57 WATER IN FUEL SW RTN 0.75mm² BLK 148-57 WATER IN FUEL SW RTN 16AWG
2 2
2
SN959
WATER IN FUEL
3 3
BLK 000-48-1 ENG GND 14AWG BLK 000-48-1 ENG GND 14AWG
4 4
FUEL PUMP
1
M
2
EC958
FUEL PUMP
X958A EC958+
FUEL PUMP
WHT 48-96 FUEL PUMP

1 1
2
EC958- M
1
X1008 X1010
BLK 000-48-2 ENG GND T920 2 x 5mm 14 AWG RING
YEL CAN 2 HI
1 1
BLK 000-48-1 ENG GND 14AWG
1 GND
GRN CAN 2 LO
2 2
3 3 3/8" 10-12 AWG RING
YEL CAN 1 HI
4 4 X1011
GRN CAN 1 LO BLK 000-148-246 ECM GND 8AWG
5 5 1
SHLD CAN 1 SHLD
6 6
7 7 3/8" 8 AWG RING B
8 8
SHEET: 9 1001119266 Q
5 4 3 2 1
3121262 – JLG Lift – 7-57

F
A
B
E
C
D
H
7-58
BEACON MODULE
12
WHT - CAN SHIELD
11
BLK - CAN LOW
10
RED - CAN HIGH
9
8
8
8
7
6
5
4
3
2
1
X2
X5
RED - CAN HIGH
1
BLK - CAN LOW
3
WHT - CAN SHIELD
5
2
1
RED - CAN HIGH
2
X3
BLK - CAN LOW
4
WHT - CAN SHIELD
6
RED - CAN HIGH
11
BLK - CAN LOW
9
WHT - CAN SHIELD
7
RED - CAN HIGH
12
7
7
BLK - CAN LOW

ALERT BEACON OPTION
10
WHT - CAN SHIELD
8
HARNESS P/N 1001142736
BLK - GROUND
RED - BEACON PWR
TO ENG DIAG CONN (ORIGINAL)

J
WHT - IGNITION
H
G
F
WHT - CAN SHIELD
E
BLK - CAN LOW
D
RED - CAN HIGH
C
RED - BATTERY
B
S1
BLK - GROUND
A
X9
CAN TERMINATOR
WHT - CAN SHIELD
C
BLK - CAN LOW
B
RED - CAN HIGH
A
6
6
X7
BLK - GROUND
TO ENG DIAG CONN (NEW)
– JLG Lift –
J
WHT - IGNITION S3
H
G
F
WHT - CAN SHIELD
E
BLK - CAN LOW
D
RED - CAN HIGH
C
RED - BATTERY
B
BLK - GROUND
WHT - IGNITION
BLK - GROUND S2
A
RED - BEACON PWR
X4
X1
1
2
3
4
5
6
7
8
9
11
10
12

5
5
BEACON MODULE
4
4
SHEET: 10
3121262
5 4 3 2 1
CRIBBING HARNESS OPTION

TO CRIBBING MODULE- J1 TO CRIBBING MODULE - J2 H
10
12
11
10
12
1
2
3
4
5
6
7
8
9
11
1
2
3
4
5
6
7
8
9
X378
X383
CRIBBING ENABLE LAMP
GRN CANL
YEL CANH
RED/ORN
BLK/ORN
LB373
RED
BLK
1
2
BLK/ORN
BLK
G
CRIBBING ENABLE SW
SW374
RED
BLK BLK J7 28 CONNECT TO
S369
RED RED GROUND CONTROLLER (SHEET 5)
J7 33
S370
MS377-3
GRN CANL
1
YEL CANH
2
2 YEL CANH YEL CANH J7 13 CONNECT TO
GRN CAN1-LOW
MS377-2 1 GRN CANL GRN CANL
J7 24 GROUND CONTROLLER (SHEET 5)
1
YEL CAN1-HIGH
2 MS377-1 F
EXTRACT WIRES FROM
GROUND CONTROLLER J7-13 & J7-24
AND CONNECT AS SHOWN
(SEE SHEET 5)
(EXISTING HARNESS)
1001210632 CRIBBING HARNESS

1001210633 CRIBBING HARNESS
SHEET: 10 1001119266 Q
5 4 3 2 1
3121262 – JLG Lift – 7-59

NOTES:
7-60 – JLG Lift – 3121262

3121262
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161(Corporate)
(800) 554-5438(Service)
(717) 485-6417
JLG Worldwide Locations

JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin)
358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Equipment Technology LTD
Regents Park Breitwaterstraat 12A Distrito Industrial Joao Narezzi Shanghai Branch
NSW 2143 3630 Maasmechelen Indiaatuba-SP 13347-404 No 465 Xiao Nan Road
Sydney 2143 Belgium Brasil Feng Xian District
Australia +32 (0) 89 84 82 26 +55 (19) 3936 7664 (Parts) Shanghai 201204
+6 (12) 87186300 Email: emeaservice@jlg.com +55(19)3936 9049 (Service) China
+6 (12) 65813058 Email: comercialpecas@jlg.com +86 (21) 800 819 0050
Email: techservicesauc@jlg.com Email: servicos@jlg.com
JLG Industries Dubai JLG France SAS JLG Deutschland GmbH JLG Equipment Services Ltd.
Jafza View Z.I. Guillaume Mon Amy Max Planck Str. 21 Rm 1107 Landmark North
PO Box 262728, LB 19 30204 Fauillet 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue
20th Floor, Office 05 47400 Tonniens Germany Sheung Shui N. T.
Jebel Ali, Dubai France +49 (0) 421 69350-0 Hong Kong
+971 (0) 4 884 1131 +33 (0) 553 84 85 86 +49 (0) 421 69350-45 +(852) 2639 5783
+971 (0) 4 884 7683 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797
Email: emeaservice@jlg.com Email: pieces@jlg.com
JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries
Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b.
20010 Pregnana Milanese (MI) 2132 JH Hoofdorf 2B Fisher Cresent Khimki
Italy The Netherlands Mt Wellington 1060 Moscow Region 141400
+39 (0) 2 9359 5210 +31 (0) 23 565 5665 Auckland, New Zealand Russia Federation
+39 (0) 2 9359 5211 Email: emeaservice@jlg.com +6 (12) 87186300 +7 (499) 922 06 99
Email: ricambi@jlg.com +6 (12) 65813058 +7 (499) 922 06 99
Email:techservicesaus@jlg.com
Oshkosh-JLG Singapore JLG Iberica S.L. JLG Sverige AB JLG Industries (UK) Ltd.
Technology Equipment Pte Ltd. Trapadella, 2 Enkopingsvagen 150 Bentley House
35 Tuas Avenue 2 Pol. Ind. Castellbisbal Sur 176 27 Jarfalla Bentley Avenue
Jurong Industrial Estate 08755 Castellbisbal Sweden Middleton, Greater Manchester
Singapore 639454 Barcelona +46 (0) 8 506 595 00 M24 2GP
+65 6591 9030 Spain +46 (0) 8 506 595 27 United Kingdom
+65 6591 9045 +34 (0) 93 772 47 00 Email: nordicsupport@jlg.com +44 (0) 161 654 1000
Email: SEA@jlg.com +34 (0) 93 771 1762 +44 (0) 161 654 1003
Email:parts_iberica@jlg.com Email: ukparts@jlg.com
www.jlg.com

JLG 1500SJ Service Maintenance Manual

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JLG 1500SJ Service Maintenance Manual

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Service and Maintenance Manual

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-

3121262 – JLG Lift – A-1

Original Issue - September 12, 2011

A-2 – JLG Lift – 3121262

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FIGURE NO. TITLE PAGE NO.

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xx – JLG Lift – 3121262

Capacity - ANSI Turning Radius (Axles Retracted)

Capacity - CE & Australia Turning Radius (Axles Extended)

Wheelbase 12ft. 6in. (3.81 m)

Tailswing 5ft. 5-7/8 in. (1.6 m)

Ground Clearance (Axle) 12 in. (30.4 cm)

Ground Clearance (Chassis) 25.5 in. (64.7 cm)

3121262 – JLG Lift – 1-1

1.3 CAPACITIES 1.5 ENGINE DATA

1-2 – JLG Lift – 3121262

1.6 HYDRAULIC OIL

Table 1-7. Hydraulic Oil ISO Viscosity Grade #32

3121262 – JLG Lift – 1-3

1.7 MAJOR COMPONENT WEIGHTS