Service and Maintenance Manual

Model
E300AJ
E300AJP
S/N 0300138358
to Present

P/N - 3121253

October 24, 2013

 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 per- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
sonnel pay strict attention to these warnings and precau- THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON-
tions to avoid possible injury to themselves or others, or NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.
damage to the 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.
• NO SMOKING IS MANDATORY. NEVER REFUEL DUR-
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM ING ELECTRICAL STORMS. ENSURE THAT FUEL
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE CAP IS CLOSED AND SECURE AT ALL OTHER
MANUFACTURER. TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
The specific precautions to be observed during mainte-
WHEN PERFORMING ANY MAINTENANCE.
nance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply • DO NOT WEAR LONG HAIR UNRESTRAINED, OR
when servicing hydraulic and larger machine component LOOSE-FITTING CLOTHING AND NECKTIES WHICH
parts. ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always • OBSERVE AND OBEY ALL WARNINGS AND CAU-
be conscious of weight. Never attempt to move heavy TIONS ON MACHINE AND IN SERVICE MANUAL.
parts without the aid of a mechanical device. Do not allow • KEEP OIL, GREASE, WATER, ETC. WIPED FROM
heavy objects to rest in an unstable position. When raising STANDING SURFACES AND HAND HOLDS.
a portion of the equipment, ensure that adequate support
is provided. • USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- MOVEMENT BY BLOCKING OR OVERHEAD SLING,
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY OR BOOM SAFETY PROP HAS BEEN ENGAGED.
IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
B HYDRAULIC SYSTEM SAFETY OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTED-
It should be noted that the machines hydraulic systems DURING REPLACEMENT OF ELECTRICAL COMPO-
operate at extremely high potentially dangerous pres- NENTS.
sures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of • KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
the system. MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

3121253 – JLG Lift – A-1

 INTRODUCTION

REVISON LOG

Original Issue - October 27, 2009

Revised - February 3, 2010
Revised - August 23, 2012
Revised - October 24, 2013

A-2 – JLG Lift – 3121253

 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 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.7 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Preventative 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

3121253 – JLG Lift – i

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires and Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Setting Wheel Bearing End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Greasing Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Output Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Output Planet Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Output Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Hub-Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Cover Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.4 Drive Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.5 Speed Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Speed Sensor Installation Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Verification w/ Analyzer Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.6 Positrac/Tilt module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3.7 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Preparation Before Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
One Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Two Piece Stator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Installation Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3.8 Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.9 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Replacement of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Swing Bearing Torque Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3.10 Battery Maintenance And Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
Battery Maintenance, Quarterly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Battery Charging, Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

ii – JLG Lift – 3121253

 TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

3.11 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Battery Charger Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell . . . . . . . 3-59
Checking/Changing the Battery Charger Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.13 Drive Orientation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
3.14 Hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
SECTION 4 - BOOM & PLATFORM
4.1 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Removal of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Disassembly of the Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Assembly of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Installation of the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2 Powertrack Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Removing a Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Installing a New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Replacing Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Replacing Moving End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.3 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
4.4 Tilt Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
4.5 Footswitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
4.6 Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
4.7 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Testing the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Installation and Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
SECTION 5 - HYDRAULICS
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 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Phase Check Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Adjustments made at the Main Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Adjustments made at the Boom Function Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.4 Initial Hydraulic Pump Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

3121253 – JLG Lift – iii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

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
System Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
SECTION 7 - BASIC ELECTRICAL INFORMATION & 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

iv – JLG Lift – 3121253

 LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-3. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
3-1. Steering Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Drive System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-3. Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-4. Main Disassembly Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-5. Main Disassembly Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-6. Output Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-7. Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-8. Input Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-9. Hub Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-10. Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-11. Hub Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-12. Hub Assembly - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-13. Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-14. Cup Pressing Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-15. Drive Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-16. Speed Sensor Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-17. Frame Mounted Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
3-18. Contactor Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3-19. Swing Motor - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
3-20. Swing Motor - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3-21. Swing Drive - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
3-22. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
3-23. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
3-24. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
3-25. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
3-26. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
3-27. Battery Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-57
3-28. Hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
3-29. Drive Orientation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
3-30. Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
4-1. Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2. Boom Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-3. Power Track Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4-4. Clamp Block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-2. Boom Thread Locking Compound Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-3. Boom Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-4. Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4-5. Lower Boom Thread Locking Compound Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

3121253 – JLG Lift – v

 LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

4-6. Lower Boom Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4-7. AJP Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-8. AJP Jib Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
4-9. Boom Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-10. Rotary Actuator - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4-11. Rotary Actuator - Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
4-12. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41
5-1. Gland Seal Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5-2. Tower Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-3. Upper Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-4. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-5. Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-6. Telescope Cylinder - AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-7. Jib Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-8. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-9. Telescope Cylinder - AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5-10. Main Control Valve - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-11. Main Control Valve - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
5-11. Boom Function Valve - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
5-12. Boom Function Valve - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
5-12. Hydraulic Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6-2. Platform Control Module Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-3. Platform Control Module Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6-4. Ground Control Module Location - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6-5. Ground Control Module Location - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
6-6. Power Module Location - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-7. Power Module Location - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
6-8. Tilt Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6-9. Analyzer Flow Chart (Software Version 3.x) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6-10. Analyzer Flow Chart (Software Version 3.x) - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
6-11. Analyzer Flow Chart (Software Version 3.x) - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
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
7-9. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-10. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-11. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7-12. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7-13. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

vi – JLG Lift – 3121253

 LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

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. Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
7-21. Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
7-22. Electrical Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
7-23. Electrical Schematic - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
7-24. Hydraulic Schematic - E300AJ - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
7-25. Hydraulic Schematic - E300AJ - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
7-26. Hydraulic Schematic - E300AJP - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
7-27. Hydraulic Schematic - E300AJP - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

3121253 – JLG Lift – vii

 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Operating specifications - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-2 Operating specifications - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-3 Dimensional Data - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-4 Dimensional Data - E300AJP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-8 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1-9 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1-10 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 Drive Brake Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-3 Swing Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
3-12 Battery Charger Fault Codes (Delta-Q). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
3-4 Battery Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
4-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
5-1 Cylinder Assembly Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5-2 Cylinder Valve Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
5-3 Main Valve Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
5-4 Boom Function Valve Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-3 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
6-4 E300 Diagnostic Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-5 System Test Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28
6-6 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29

viii – JLG Lift – 3121253

 SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA
Table 1-1. Operating specifications - E300AJ Table 1-3. Dimensional Data - E300AJ

Capacity: Unrestricted: 500 lbs. (227 kg) Turning Radius (Inside) 5 ft. (1.52 m)

Maximum Travel Grade, stowed 25% Turning Radius (Outside) 10ft. 2in. (3.1 m)
Position (Gradeability)
Machine Height (stowed) 6ft. 7in. (2.01 m)
Maximum Travel Grade, stowed 5°
Position (Side Slope) Machine Length (stowed) 18ft. 2in. (5.54 m)

Drive Speed (High Drive) - 200 ft. (60.9 M) 45-50 sec Up and Over Platform Height 13ft. 2in. (4.01 m)

Drive Speed (Above Horz.) - 50 ft. (15.24 M) 55-68 sec (0.6 Horizontal Reach Up and Over 20ft. 3in. (6.17 m)
mph[0.9 kph]) Machine Width 4ft. (1.22 m)
Gross Machine Weight - Approximate 15060 lbs. (6831 kg) Wheel Base 5ft. 5in. (1.65 m)
Ground Bearing Pressure - Maximum 170 psi (11.95 kg/ Platform Height 30ft. 2in. (9.19m)
cm2)
Ground Clearance 4in. (10 cm)
Maximum System Voltage 48V DC

Maximum Main Relief Hyd. Pressure 3000 psi (207 bar) Table 1-4. Dimensional Data - E300AJP

Turning Radius (Inside) 5 ft. (1.52 m)

Table 1-2. Operating specifications - E300AJP
Turning Radius (Outside) 10ft. 2in. (3.1 m)
Capacity: Unrestricted: 500 lbs. (227 kg)
Machine Height (stowed) 6ft. 7in. (2.01 m)
Maximum Travel Grade, stowed 25%
Position (Gradeability) Machine Length (stowed) 18ft. 10in. (5.74 m)

Maximum Travel Grade, stowed 5° Up and Over Platform Height 13ft. 2in. (4.01 m)
Position (Side Slope)
Horizontal Reach Up and Over 20ft. 1in. (6.12 m)
Drive Speed (High Drive) - 200ft. (60.9 m) 45-50 sec
(3 mph [4.8 kph]) Machine Width 4ft. (1.22 m)

Drive Speed (Above Horz.) - 50 ft. (15.24 M) 55-68 sec (0.6 Wheel Base 5ft. 5in. (1.65 m)
mph[0.9 kph])
Platform Height 29ft. 5in. (8.97 m)
Gross Machine Weight- Approximate 15400 lbs. (6985 kg)
Ground Clearance 4in. (10 cm)
Ground Bearing Pressure - Maximum 170 psi (11.95 kg/
cm2)

Maximum System Voltage 48V DC

Maximum Main Relief Hyd. Pressure 3000 psi (207 bar)

3121253 – JLG Lift – 1-1

 SECTION 1 - SPECIFICATIONS

1.3 CAPACITIES NOTE: Aside from JLG recommendations, it is not advis-

able to mix oils of different brands or types, as they
Table 1-5. Capacities may not contain the same required additives or be
of comparable viscosities. If use of hydraulic oil
Hydraulic Oil Tank 2.9 Gal. (11 L) other than Mobil DTE 11M is desired, contact JLG
2.1 Gal. ( 8 L) to Full Mark Industries for proper recommendations.
Drive Hub* 25.5 oz. (0.75 L)(1/2 Full)
1.6 MAJOR COMPONENT WEIGHTS
*Drive hubs should be one half full of lubricant.
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS
1.4 TIRES OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BAT-
TERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN
Table 1-6. Tires ANY WAY TO AFFECT STABILITY.

Size 25x7x12 Table 1-8. Critical Stability Weights

Maximum Tire Load 8200 lbs. (3719 kg) Components LBS. KG.
Type Solid Non-Marking Counterweight (AJ) 6188 2807

Counterweight (AJP) 6348 2880

1.5 HYDRAULIC OIL
Tire and Wheel 120 54.4
NOTE: Refer to Figure 1-1., Hydraulic Oil Specifications. Platform (including console) 169 78

Battery (minimum each) - 305AH 87 39.5

Table 1-7. Hydraulic Oil
Battery (minimum each) - 375AH & UL 110 50
Hydraulic System
S.A.E. Viscosity
Operating
Grade
Temperature Range
+0° to + 180° F 10W
(-18° to +83° C)
+0° to + 210° F 10W-20, 10W30
(-18° to +99° C)
+50° to + 210° F 20W-20
(+10° to +99° C

NOTE: Hydraulic oils require anti-wear qualities at least API

Service Classification GL-3, and sufficient chemical
stability for mobile hydraulic system service.

NOTE: Machines may be equipped with Mobil EAL224H

biodegradable and non-toxic hydraulic oil. This is
vegetable oil based and possesses the same anti-
wear and rust protection characteristics as mineral
oils, but will not adversely affect the ground water or
the environment when spilled or leaked in small
amounts.

1-2 – JLG Lift – 3121253

 SECTION 1 - SPECIFICATIONS

AIR TEMPERATURE
°C °F
49 120
43 110

MOBIL EAL ENVIRONSYN H32

38 100

QUINTOLUBRIC 888-46
MOBILFLUID 424
32 90

MOBIL EAL 224 H

27 80

MOBIL DTE 10 EXCEL 15

21 70
MOBIL DTE 11M

UNIVIS HVI 26
16 60
10 50
4 40
1 30
7 20
12 10
18 0
23 10
29 20
34 30 HYDRAULIC FLUID OPERATION CHART
40 40
Fluid Properties Base Classifications
Viscosity at 40° C (cSt, Typical)

Readily Biodegradable*
Synthetic Polyol Esters

Virtually Non-toxic**

Fire Resistant***
Viscosity Index

Vegetable Oils
Mineral Oils
Description

Synthetic

MACHINE OPERATION USING NON-JLG

APPROVED HYDRAULIC FLUIDS OR
OPERATION OUTSIDE OF THE TEMPER-
ATURE BOUNDRIES OUTLINED IN THE Mobilfluid 424 55 145 X
HYDRAULIC FLUID OPERATION CHART Mobil DTE 11M 15 140 X
MAY RESULT IN PREMATURE WEAR OR Mobil DTE 10 Excel 15 15 168 X X
DAMAGE TO COMPONENTS OF THE Univis HVI 26 26 376 X
HYDRAULIC SYSTEM.
Mobil EAH 224 H 36 212 X X X
Mobil EAL Envirosyn H32 32 147 X X X
Quintolubric 888-46 50 185 X X X X
* Readily biodegradable classification indicates one of the following:
CO2 Conversion > 60% per EPA 560/6-82-003
CO2 Conversion > 80% per CEC-L-33-A-93
** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
1001118343 A

Figure 1-1. Hydraulic Oil Specifications

3121253 – JLG Lift – 1-3

 SECTION 1 - SPECIFICATIONS

1.7 FUNCTION SPEEDS Machine Orientation When Doing Speed

Tests
Table 1-9. Function Speeds
NOTE: All tests are to be performed on a smooth, level sur-
Speed face.
Function in seconds (unless
otherwise noted) Lift: Boom Retracted. Telescope Retracted. Lift Up,
Record Time, Lift Down, Record Time.
Main Lift Up 24-27

Main Lift Down 20-23 Swing: Boom at Full Elevation. Telescope Retracted.
Swing the Turntable to the end stop. Swing the Opposite
Swing - Right & Left 75-90 Direction, Record Time.

Telescope Out 8-12 Telescope: Boom at Full Elevation; Telescope Retracted;

Telescope Out, Record Time. Telescope In, Record Time.
Telescope In 8-12
Drive: Test to be done on a smooth level surface. Start
Platform Rotate, Left and Right* 20-24 approximately 25 ft. (7.62 m) from starting point so that
*Max. 15% difference between left and right the unit is at maximum speed when starting the test.
Results should be recorded for a 200 ft. (60.96 m) course.
Jib Up 22 - 25 Drive Forward, record time. Drive Reverse, Record Time.
Jib Down 22 - 25 Drive (Above Horizontal): Test should be done on a
smooth level surface. The Platform Speed Knob should be
Jib Swing (300AJP) 20-35 selected out of the creep speed. This verifies that the
switches are working when the boom is above horizontal.
Lower Lift Up 17 - 20
Results should be recorded for a 50 ft. course. Drive For-
Lower Lift Down 17 - 20 ward, Record Time. Drive Reverse, Record Time.

Travel Speed (Forward & Reverse) Platform Rotate: Platform level and completely rotated
High drive 3 mph (4.8 kmh) one direction. Rotate the opposite direction, Record Time.
(45-50 sec / 200 ft.) Rotate the other direction, Record Time.

Travel Speed (Forward & Reverse) Jib: Platform level and centered with the boom. Start with
Boom Above Horizontal 0.3 mph (0.5 kmh) the Jib down. Jib Up, Record Time. Jib Down, Record
(110-120 sec / 50ft.) Time.

4150273-O Lower Lift: Upper Boom horizontal, Telescoped In. Lower

Lift Up, Record Time. Lower Lift Down, Record Time.

Test Notes Jib Swing: Platform level and centered with the boom.
Start with Jib at Horizontal. Begin with Jib Swing fully to
1. Stop watch should be started with the function, not Left. Swing fully to Right, Record Time. Swing fully to Left,
with the controller or switch. Record Time.

2. Drive test results reflect standard size tires.

3. All speed tests are run from the platform. These

speeds do not reflect the ground control operation.

4. The platform speed knob control must be at full

speed (turned clockwise completely).

5. Function speeds may vary due to cold, thick hydrau-

lic oil. Test should be run with the oil temperature
above 75° F (24° C).

6. Some flow control functions may not work with the

speed knob clicked into the creep position.

1-4 – JLG Lift – 3121253

 SECTION 1 - SPECIFICATIONS

6 6

3,4

5
5

Figure 1-2. Operator Maintenance and Lubrication Diagram

3121253 – JLG Lift – 1-5

 SECTION 1 - SPECIFICATIONS

1.8 OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth

NOTE: The following numbers correspond to those in Fig-

ure 1-2., Operator Maintenance and Lubrication
Diagram.

Table 1-10. Lubrication Specifications

KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of
350 degrees F. Excellent water resistance and adhesive
qualities; and being of extreme pressure type (Timken OK Lube Point(s) - Grease Fittings
40 pounds minimum). Capacity - A/R
Lube - BG
EPGL Extreme Pressure Gear Lube (oil) meeting API Service
Interval - A/R
Classification GL-5 or Mil-Spec Mil-L-2105.
HO Hydraulic Oil. Mobil DTE-11M
BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHC
460.
LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG
Part No. 3020022)
*MPG may be substituted for these lubricants, if necessary, but ser-
vice intervals will be reduced.

Lube Point(s) - Grease Fittings

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION Capacity - A/R
UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI- Lube - Mobile SHC 007
SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRON- Interval - A/R
MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS
1. Swing Bearing WILL RESULT IN DAMAGE TO OUTER SEAL IN HOUSING.

Lube Point(s) - Remote Fitting

Capacity - A/R
Lube - BG
Interval - Every 3 months or 150 hrs of operation
Comments - Apply grease and rotate in 90 degree
intervals until bearing is completely lubricated

1-6 – JLG Lift – 3121253

 SECTION 1 - SPECIFICATIONS

3. Hydraulic Tank 5. Wheel Drive Hub

OIL LEVEL CH
AND FILL

Lube Point(s) - Level/Fill Plug

Lube Point(s) - Fill Cap Capacity - 25.5 oz. (0.75 L)(1/2 Full)
Capacity - 2.9 Gal. (11 L), 2.1 Gal. ( 8 L) to Full Mark Lube - EPGL
Lube - HO Interval - Check level every 3 months or 150 hrs of
Interval - Check Level daily; Change every 2 years or operation; change every 2 years or 1200 hours of
1200 hours of operation. operation
Comments - On new machines, those recently over- 6. Wheel Bearings
hauled, or after changing hydraulic oil, operate all
systems a minimum of two complete cycles and
recheck oil level in reservoir.

4. Hydraulic Return Filter

Lube Point(s) - Repack

Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation

Interval - Change after first 50 hrs. and every 6

months or 300 hrs. thereafter.
Comments - Under certain conditions, it may be
necessary to replace the hydraulic filter on a more
frequent basis.

3121253 – JLG Lift – 1-7

 SECTION 1 - SPECIFICATIONS

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia Clamp Load TM
(Loctite® 262TM or Vibra-
Stress Area (Dry) Lubricated OR Vibra-TITE 111 or
TITETM 131)
140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N Description

0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)

0100019 271TM Vibra-TITE TM 140 High Strength (Red)
0100071 262TM Vibra-TITE TM 131 Medium - High Strength (Red)

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

1-8 – JLG Lift – 3121253

 SECTION 1 - SPECIFICATIONS

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque Torque
Torque
Tensile (Loctite® 242TM or 271TM (Loctite® 262TM or Vibra-
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Stress Area
K= 0.20 OR Vibra-TITE TM 111 or TITETM 131)
140) K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)

3121253 – JLG Lift – 1-9

 SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*
Torque
Torque
(Loctite® 242TM or 271TM (Loctite® 262TM
Tensile Clamp Load Torque
Size TPI Bolt Dia
Stress Area See Note 4 (Dry) K = .17 OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
140 OR Precoat 85® K=0.15
K=0.16
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)

1-10 – JLG Lift – 3121253

 SECTION 1 - SPECIFICATIONS

SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners (Ref 4150707)*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)

3121253 – JLG Lift – 1-11

 SECTION 1 - SPECIFICATIONS

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

Torque
Torque (Loctite®
Tensile Torque
Clamp Torque (Loctite® 262TM 242TM or 271TM
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR Vibra- OR Vibra-
Area 263TM)
TITETM 131) TITETM 111 or
140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

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

1-12 – JLG Lift – 3121253

 SECTION 1 - SPECIFICATIONS

CLASS 10.9 METRIC BOLTS

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

Torque
Torque (Lub OR Loctite® Torque
Tensile
Clamp (Dry or Loctite® 242TM or 271TM OR (Loctite® 262TM OR
Size PITCH Stress
Load 263TM) Vibra-TITE TM 111 or Vibra-TITE TM 131)
Area
K = 0.20 140) K=0.15
K= 0.18

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

3121253 – JLG Lift – 1-13

 SECTION 1 - SPECIFICATIONS

Magni Coating (Ref 4150701)*

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

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

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

1-14 – JLG Lift – 3121253

 SECTION 2 - GENERAL

SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
AND MAINTENANCE Schedule for items requiring inspection during the perfor-
mance of these inspections. Reference the appropriate
General areas of this manual for servicing and maintenance proce-
dures.
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe Annual Machine Inspection
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and The Annual Machine Inspection must be performed by a
maintenance have been completed before placing the Factory-Trained Service Technician on an annual basis, no
machine into service. later than thirteen (13) months from the date of the prior
Annual Machine Inspection. JLG Industries, Inc. recog-
Preparation, Inspection, and Maintenance nizes a Factory-Trained Service Technician as a person
who has successfully completed the JLG Service Training
It is important to establish and conform to a comprehen- School for the subject JLG product model. Reference the
sive inspection and preventive maintenance program. The machine Service and Maintenance Manual and appropri-
following table outlines the periodic machine inspections ate JLG inspection form for performance of this inspec-
and maintenance recommended by JLG Industries, Inc. tion.
Consult your national, regional, or local regulations for fur-
ther requirements for aerial work platforms. The frequency Reference the JLG Annual Machine Inspection Form and
of inspections and maintenance must be increased as the Inspection and Preventative Maintenance Schedule for
environment, severity and frequency of usage requires. items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this man-
Pre-Start Inspection ual for servicing and maintenance procedures.
It is the User’s or Operator’s primary responsibility to per- For the purpose of receiving safety-related bulletins, it is
form a Pre-Start Inspection of the machine prior to use important that JLG Industries, Inc. has updated ownership
daily or at each change of operator. Reference the Opera- information for each machine. When performing each
tor’s and Safety Manual for completion procedures for the Annual Machine Inspection, notify JLG Industries, Inc. of
Pre-Start Inspection. The Operator and Safety Manual the current machine ownership.
must be read in its entirety and understood prior to per-
forming the Pre-Start Inspection.
Preventative Maintenance
Pre-Delivery Inspection and Frequent
In conjunction with the specified inspections, mainte-
Inspection nance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
The Pre-Delivery Inspection and Frequent Inspection shall
equipment mechanic as a person who, by possession of a
be performed by a qualified JLG equipment mechanic.
recognized degree, certificate, extensive knowledge, train-
JLG Industries, Inc. recognizes a qualified JLG equipment
ing, or experience, has successfully demonstrated the
mechanic as a person who, by possession of a recog-
ability and proficiency to service, repair, and maintain the
nized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and subject JLG product model.
proficiency to service, repair, and maintain the subject
Reference the Preventative Maintenance Schedule and
JLG product model.
the appropriate areas of this manual for servicing and
The Pre-Delivery Inspection and Frequent Inspection pro- maintenance procedures. The frequency of service and
cedures are performed in the same manner, but at differ- maintenance must be increased as environment, severity
ent times. The Pre-Delivery Inspection shall be performed and frequency of usage requires.
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser-
vice for 3 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 environment, severity and frequency of
usage requires.

3121253 – 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 Inspec- Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance
tion rental delivery. Mechanic Manual and applicable JLG
inspection form.

Frequent Inspection In service for 3 months or 150 hours, Owner, Dealer, or User Qualified JLG Service and Maintenance
whichever comes first; or Mechanic Manual and applicable JLG
Out of service for a period of more than 3 inspection form.
months; or
purchased used.

Annual Machine Annually, no later than 13 months from Owner, Dealer, or User Factory-Trained Service and Maintenance
Inspection the date of the prior inspection. Service Technician Manual and applicable JLG
inspection form.

Preventative At intervals as specified in the Service Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance and Maintenance Manual. Mechanic Manual

2.2 SERVICE AND GUIDELINES 2. At any time when air, fuel, or oil lines are discon-
nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo-
General nent is disconnected, cap or cover all openings to
The following information is provided to assist you in the prevent entry of foreign matter.
use and application of servicing and maintenance proce- 3. Clean and inspect all parts during servicing or main-
dures contained in this book. tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
Safety and Workmanship clean. Be sure all parts are clean before they are
installed. New parts should remain in their contain-
Your safety, and that of others, is the first consideration ers until they are ready to be used.
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy Components Removal and Installation
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising 1. Use adjustable lifting devices, whenever possible, if
a portion of the equipment, ensure that adequate support mechanical assistance is required. All slings (chains,
is provided. cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
Cleanliness lifted.
2. Should it be necessary to remove a component on
1. The most important single item in preserving the
an angle, keep in mind that the capacity of an eye-
long service life of a machine is to keep dirt and for-
bolt or similar bracket lessens, as the angle between
eign materials out of the vital components. Precau-
the supporting structure and the component
tions have been taken to safeguard against this.
becomes less than 90 degrees.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these 3. If a part resists removal, check to see whether all
items must be maintained on a scheduled basis in nuts, bolts, cables, brackets, wiring, etc., have been
order to function properly. removed and that no adjacent parts are interfering.

2-2 – JLG Lift – 3121253

 SECTION 2 - GENERAL

Component Disassembly and Reassembly 2. Unless specific torque requirements are given within
the text, standard torque values should be used on
When disassembling or reassembling a component, com- heat-treated bolts, studs, and steel nuts, in accor-
plete the procedural steps in sequence. Do not partially dance with recommended shop practices. (See
disassemble or assemble one part, then start on another. Torque Chart Section 1.)
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than Hydraulic Lines and Electrical Wiring
those recommended, without obtaining proper approval.
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
Pressure-Fit Parts them from the unit. This will assure that they are correctly
When assembling pressure-fit parts, use a molybdenum reinstalled.
disulfide base compound or equivalent to lubricate the
mating surface. Hydraulic System
1. Keep the system clean. If evidence of metal or rub-
Bearings ber particles are found in the hydraulic system, drain
and flush the entire system.
1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable 2. Disassemble and reassemble parts on clean work
cleaning solvent and allow to drip dry. Compressed surface. Clean all metal parts with non-flammable
air can be used but do not spin the bearing. cleaning solvent. Lubricate components, as
required, to aid assembly.
2. Discard bearings if the races and balls (or rollers)
are pitted, 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 Service applicable components with the amount, type,
unwrap reusable or new bearings until they are and grade of lubricant recommended in this manual, at
ready to install. the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
4. Lubricate new or used serviceable bearings before that meets or exceeds the specifications listed.
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear- Battery
ing is to be installed on a shaft, apply pressure to the
inner race. Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
Gaskets cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a Lubrication and Servicing
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as Components and assemblies requiring lubrication and
blank gaskets can cause serious system damage. servicing are shown in the Lubrication Chart in Section 1.

Bolt Usage and Torque Application 2.3 LUBRICATION AND INFORMATION

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

3121253 – JLG Lift – 2-3

 SECTION 2 - GENERAL

2. The design and manufacturing tolerances of the Changing Hydraulic Oil

component working parts are very close, therefore,
even the smallest amount of dirt or foreign matter 1. Filter elements must be changed after the first 50
entering a system can cause wear or damage to the hours of operation and every 300 hours (unless
components and generally results in faulty opera- specified otherwise) thereafter. If it is necessary to
tion. Every precaution must be taken to keep change the oil, use only those oils meeting or
hydraulic oil clean, including reserve oil in storage. exceeding the specifications appearing in this man-
Hydraulic system filters should be checked, ual. If unable to obtain the same type of oil supplied
cleaned, and/or replaced as necessary, at the speci- with the machine, consult local supplier for assis-
fied intervals required in the Lubrication Chart in tance in selecting the proper equivalent. Avoid mix-
Section 1. Always examine filters for evidence of ing petroleum and synthetic base oils. JLG
metal particles. Industries recommends changing the hydraulic oil
annually.
3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or cor- 2. Use every precaution to keep the hydraulic oil clean.
rosion. If this condition occurs, the system must be If the oil must be poured from the original container
drained, flushed, and refilled with clean oil. into another, be sure to clean all possible contami-
nants from the service container. Always clean the
4. It is not advisable to mix oils of different brands or mesh element of the filter and replace the cartridge
types, as they may not contain the same required any time the system oil is changed.
additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the 3. While the unit is shut down, a good preventive main-
ambient temperatures in which the machine is oper- tenance measure is to make a thorough inspection
ating, are recommended for use. of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
NOTE: Metal particles may appear in the oil or filters of new placing the machine back in service.
machines due to the wear-in of meshing compo-
nents. Lubrication Specifications
Specified lubricants, as recommended by the component
Hydraulic Oil manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
1. Refer to Section 1 for recommendations for viscosity meet a variety of single purpose grease requirements.
ranges. Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evalua-
tion. Refer to Section 1 for an 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 allowable 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 – 3121253

 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
Max. Acceptable Drift and debris...bearings and bearing housings
Cylinder Bore Diameter
in 10 Minutes must be free of all contamination.
inches mm inches mm b. Bearing / pins should be cleaned with a solvent
3 76.2 0.026 0.66 to remove all grease and oil...filament wound
3.5 89 0.019 0.48 bearing are a dry joint and should not be lubri-
cated unless otherwise instructed (i.e. sheave
4 101.6 0.015 0.38
pins).
5 127 0.009 0.22
c. Pins should be inspected to ensure it is free of
6 152.4 0.006 0.15
burrs, nicks, and scratches which would dam-
7 177.8 0.005 0.13 age the bearing during installation and opera-
8 203.2 0.0038 0.10 tion.
9 228.6 0.0030 0.08
2.6 WELDING ON JLG EQUIPMENT
Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temper- NOTE: This instruction applies to repairs, or modifications to
ature and temperature stabilized. the machine and to welding performed from the
machine on an external structure, or component,
The cylinder must have the normal load, which is the nor-
mal platform load applied.
Do the Following When Welding on JLG
If the cylinder passes this test, it is acceptable. Equipment
NOTE: This information is based on 6 drops per minute cyl-
inder leakage. • Disconnect the battery.

• Disconnect the moment pin connection (where fitted)

2.5 PINS AND COMPOSITE BEARING
REPAIR GUIDELINES • Ground only to structure being welded.

Filament wound bearings. Do NOT Do the Following When Welding on

1. Pinned joints should be disassembled and JLG Equipment
inspected if the following occurs:
a. Excessive sloppiness in joints. • Ground on frame and weld on any other area than the
chassis.
b. Noise originating from the joint during operation.
2. Filament wound bearings should be replaced if any • Ground on turntable and weld on any other area than
of the following is observed: the turntable.

a. Frayed or separated fibers on the liner surface. • Ground on the platform/support and weld on any other
b. Cracked or damaged liner backing. area than the platform/support.

c. Bearings that have moved or spun in their hous- • Ground on a specific boom section and weld on any
ing. other area than that specific boom section.
d. Debris embedded in liner surface.
• Allow pins, wear pads, wire ropes, bearings, gearing,
3. Pins should be replaced if any of the following is seals, valves, electrical wiring, or hoses to be between
observed (pin should be properly cleaned prior to the grounding position and the welded area.
inspection):
a. Detectable wear in the bearing area.
b. Flaking, pealing, scoring, or scratches on the pin FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY
surface. RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES,
c. Rusting of the pin in the bearing area. SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)

3121253 – JLG Lift – 2-5

 SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-
AREA Weekly Monthly
Delivery2 Annual4
Pre-Start1 Preventive Preventive
Every 2
3 (Yearly) Years
Inspection Maintenance Maintenance or Frequent Inspection
Inspection
Boom Assembly 9
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
Platform Assembly 9
Platform 1,2 1,2
Railing 1,2 1 1,2
Gate 5 1 1,5
Floor 1,2 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 2 1,2,10 1,2,10
Turntable Assembly 9
Swing Bearing or Worm Gear 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 9
Tires 1 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 1 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Outrigger or Extendable Axle Systems 5,8 5,8
Steer Components
Spindle Thrust Bearing/Washers 1,2
Drive Motors
Drive Hubs 11 11

2-6 – JLG Lift – 3121253

 SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-
AREA 1 Weekly Monthly
Delivery2 Annual4 Every 2
Pre-Start Preventive Preventive 3 (Yearly) Years
Inspection Maintenance Maintenance or Frequent Inspection
Inspection
Functions/Controls 9
Platform Controls 5 5 6 6
Ground Controls 5 5 6 6
Function Control Locks, Guards, or Detents 1,5 1,5 5 5
Footswitch 1,5 5 5
Emergency Stop Switches (Ground & Platform) 5 5 5
Function Limit or Cutout Switch Systems 5 5 5
Capacity Indicator 5
Drive Brakes 5
Swing Brakes 5
Manual Descent or Auxiliary Power 5 5
Power System 9
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 11 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 5 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5
Hydraulic/Electric System 9
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 11 1,9 2 1,5 1,5 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 11 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 21
ANSI and AEM Manuals/Handbooks Installed 21
Capacity Decals Installed, Secure, Legible 21 21 21

3121253 – JLG Lift – 2-7

 SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-
AREA 1 Weekly Monthly
Delivery2 Annual4 Every 2
Pre-Start Preventive Preventive 3 (Yearly) Years
Inspection Maintenance Maintenance or Frequent Inspection
Inspection
All Decals/Placards Installed, Secure, Legible 21 21 21
Walk-Around Inspection Performed 21
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 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 – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES AND WHEELS Tighten the lug nuts to the proper torque to prevent
wheels from coming loose. Use a torque wrench to tighten
the fasteners. If you do not have a torque wrench, tighten
Tire Wear and Damage the fasteners with a lug wrench, then immediately have a
Inspect tires daily for wear or damage. Tires with worn service garage or dealer tighten the lug nuts to the proper
edges or distorted profiles require replacement. Tires with torque. Over-tightening will result in breaking the studs or
significant damage in the tread area or side wall, require permanently deforming the mounting stud holes in the
immediate evaluation before replacing the machine into wheels. The proper procedure for attaching wheels is as
service. follows:

1. Start all nuts by hand to prevent cross threading.

Wheel and Tire Replacement DO NOT use a lubricant on threads or nuts.
Replacement wheels must have the same diameter and
2. Tighten nuts in the following sequence.
profile as the original. Replacement tires must be the
same size and rating as the tire being replaced.

Wheel Installation
It is extremely important to apply and maintain proper
wheel mounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE

PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS,
AND POSSIBLE SEPARATION OF WHEEL FROM THE AXLE. BE
SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE
OF THE WHEEL.

3. The tightening of the nuts should be done in stages.

Following the recommended sequence, tighten nuts
per wheel torque.

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
40 ft lbs (55 Nm) 95 ft lbs (130 Nm) 170 ft lbs (230 Nm)

4. Wheel nuts should be torqued after first 50 hours of

operation and after each wheel removal. Check the
torque as outlined in Section 2.

3121253 – JLG Lift – 3-1

 SECTION 3 - CHASSIS & TURNTABLE

*
**

*
** 6

2 4

RIGHT SIDE VIEW

WITH HUB REMOVED

1. Axle Assembly
2. Spindle Assembly
3. Tie Rod
4. Steer Cylinder
5. Thrust Washer
6. Thrust Bearing

* Torque 35 ft. lbs. (48 Nm)

2
** Threadlocker JLG P/N 0100011

Figure 3-1. Steering Installation

3-2 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

1. Drive Motor
2. Gasket
3. Drive Brake
4. Drive Hub
5. Gasket
6. Speed Sensor
1 7. Tire & Wheel
8. Lug Nut
2
*

Note 1 3

*
4

Note 2
5

* Thread Locking Compound JLG P/N 0100019

Note 1: Torque to 240 ft. lbs. (325 Nm)
Note 2: Before installing brake and motor, apply a light coat of grease to the splined shafts

Figure 3-2. Drive System Components

3121253 – JLG Lift – 3-3

 SECTION 3 - CHASSIS & TURNTABLE

3.2 SPINDLE Specifications

The end play specification is 0.001”/0.010" (0.025 / 0.254
Setting Wheel Bearing End Play mm) for all units.

Checking
BE SURE NOT TO OVER-TIGHTEN THE SPINDLE NUT. The end play is checked by clamping the spindle in a fix-
ture or vise and moving the hub parallel to the spindle
centerline without rocking the hub. If the end play is set
1. Tighten the spindle nut to assure the bearings are
properly the following should apply:
properly seated.
1. Hub should rotate freely when spun by hand.
2. Loosen the spindle nut completely until the nut can
be turned by hand. 2. The hub should not be noticeably loose when
moved parallel with spindle centerline.
3. Tighten the spindle nut by hand using a socket with-
out rotating the hub. Greasing Requirements
4. If the cotter pin can be assembled with the spindle Hub assemblies shall have grease packed in the bearings
nut finger tight, insert cotter pin without backing the via an appropriate greasing spindle or by hand. In either
nut off. If the cotter pin cannot be assembled with method, the bearing must be greased so the grease is
the spindle nut hand tight, tighten the spindle nut to forced thru the entire bearing cavity and thru the rollers of
the nearest available slot and insert cotter pin. If both inner and outer bearings.
more than ½ of the cotter pin hole in the spindle can Dust or grease caps used shall have grease applied to the
be seen in a slot, back nut off to nearest slot and inside of the cap.
insert pin.
The bearing cavity shall be filled 50 - 80% full of grease on
5. Check the unit for end play by moving the hub up & all applications.
down parallel along the centerline of the spindle. If Dust or grease caps shall also be filled 10-20% full of
you can feel excessive end play (over the 0.010" grease on all applications prior to final assembly.
[0.25 mm] specification), recheck the nut to see
what is causing the excessive end play. Keep in Visually verify that grease has flowed thru all rollers of the
mind that there can be some movement and still be inner and outer bearings.
within the 0.010" (0.25 mm) maximum specification.
If there is no way of getting the excessive end play
out by using your fingers, a socket or wrench may
have to be used to set the end play.

6. The units should be checked visually to make sure

the cotter pins are installed and that the correct
components have been used. Each unit must also
be checked for the proper feel to make sure there
isn’t excessive end play and the hubs turn freely.

7. Insert the dust cap and check to make sure the cot-
ter pin is not going to interfere. Cap must be pressed
all the way down. The unit should be checked again
to assure it spins freely after the dust cap is installed.

3-4 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

1. Dust Cap
2. Cotter Pin
3. Spindle Nut
4. Spindle Washer
5. Stud Nut
6. Bearing Cone
7. Hub
8. Bearing Cone
9. Seal
10. Spindle

Figure 3-3. Spindle Assembly

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 SECTION 3 - CHASSIS & TURNTABLE

3.3 DRIVE HUB Main Disassembly

1. Perform Roll Check and Leak Check if applicable
Roll and Leak Testing prior to disassembling the unit.
Torque-Hub units should always be roll and leak tested 2. Drain oil from unit. Note the condition and volume of
before disassembly and after assembly to make sure the oil.
that the unit’s gears, bearings and seals are working
properly. The following information briefly outlines what 3. Remove Coupling (7) from Spindle End first.
to look for when performing these tests. 4. Remove Retaining Ring (6G) by prying the open end
of Retaining Ring out of the groove in the Ring Gear
THE ROLL TEST (1F) with a screwdriver, then grasp the loose end
with pliers and pull the Retaining Ring completely
The purpose of the roll test is to determine if the unit’s
out of the groove.
gears are rotating freely and properly. You should be
able to rotate the gears in your unit by applying con- 5. Remove the Cover Subassembly (6) from the unit.
stant force to the roll checker. If you feel more drag in The unit can be carefully pressurized with air to pop
the gears only at certain points, then the gears are not the cover out of the unit. Washer (2) may have to be
rolling freely and should be examined for improper removed separately because of the loose attach-
installation or defects. Some gear packages roll with ment.
more difficulty than others. Do not be concerned if the
6. Remove the First Stage Sun Gear (10) if applicable.
gears in your unit seem to roll hard as long as they roll
with consistency. NOTE: On units with ratios greater than 36:1 numerically,
there will not be a separate First Stage Sun Gear
THE LEAK TEST (MAIN UNIT) (10), as the gear teeth will be integral to the Input
Shaft (9).
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 7. Remove the Input Carrier Sub-assembly (3). Contin-
gauge reading on your leak checking fitting starts to ued on next page.
fall after the unit has been pressurized and allowed to
8. Remove the Second Stage Sun Gear (11).
equalize. Leaks will most likely occur at the pipe plugs,
the main seal or wherever o-rings or gaskets are 9. Remove the Input Shaft (9).
located. The exact location of a leak can usually be
detected by brushing a soap and water solution
around the main seal and where the o-rings or gaskets
meet on the exterior 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 for 20 minutes.

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 SECTION 3 - CHASSIS & TURNTABLE

NOTE: On units with a ratio 48:1, the Sun Gear (11) and the 12. Lift the Ring Gear (1F) off of the Housing (1G).
Input Shaft (9) will need to be removed together.
13. Remove the O-ring (18) from between the Housing
10. Remove the Output Stage Carrier Sub-assembly (4) (1G) and the Ring Gear (1F).
11. Loosen and remove the three Flat Head Bolts (19)
that retain the Ring Gear (1F) to the Housing (1G).

1F. Ring Gear 7. Coupling

1G. Housing 9. Input Shaft
2. Washer 10. First Stage Sun Gear
3. Input Carrier Subassembly 11. Second Stage Sun Gear
4. Output Carrier Subassembly 15. I.D. Plate
6. Cover Assembly 18. O-ring
6G. Retaining Ring 19. Flat Head Bolts

Figure 3-4. Main Disassembly Drawing 1

3121253 – JLG Lift – 3-7

 SECTION 3 - CHASSIS & TURNTABLE

1F. Ring Gear 9. Input Shaft

1G. Housing 10. First Stage Sun Gear
4. Output Carrier Subassembly 11. Second Stage Sun Gear
5. Retaining Ring 18. O-ring
6. Cover Assembly 19. Flat Head Bolts
6G. Retaining Ring 20. Retaining Ring

Figure 3-5. Main Disassembly Drawing 2

3-8 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

Output Carrier Disassembly 3. Using a 1/8" diameter punch, drive the Roll Pin (4G)
out of the Planet Shaft (4E). NOTE: The Roll Pins
1. Using a 1/8" diameter punch, drive the Roll Pin (4G) (4G) should not be reused when reassembling the
unit.
into the Planet Shaft (4E) until it bottoms against the
Carrier (3A). 4. Slide the Planet Gear Sub-assembly (4) out of the
Output Carrier (4A) being careful to not drop the
2. Using a soft face hammer, tap the Planet Shaft (4E) Needle Bearings (4C) in the process.
out of the Carrier (4A).

4A Output Carrier 4E Planet Shaft

4B Thrust Washer 4F Planet Gear
4C Needle Bearing 4G Roll Pin
4D Thrust Spacer 4H Thrust Washer

Figure 3-6. Output Carrier

3121253 – JLG Lift – 3-9

 SECTION 3 - CHASSIS & TURNTABLE

5. Remove 4 Thrust Washers (4B), 28 Needle Rollers 6. Repeat Steps 1 though 5 for the remaining two
(4C) and the Thrust Spacer (4D) from the Second Planet Gears (4F).
Stage Planet Gear (4F).
7. Remove the Thrust Washer (4H) from the counter-
bore in the Output Carrier (4A).

4B Thrust Washer
4C Needle Bearing
4D Thrust Spacer
4F Planet Gear

Figure 3-7. Planet Gear

3-10 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

Input Carrier Disassembly (4G) should not be reused when reassembling the
unit.
1. Using a 1/8" diameter punch, drive the Roll Pin (4G)
into the Planet Shaft (3E) until it bottoms against the 4. Slide the Planet Gear (3F) and the two Thrust Wash-
Carrier (3A). ers (3B) out of the Carrier (3A).

2. Using a soft face hammer, tap the Planet Shaft (3E) 5. Remove the 14 needle Bearings (3C) from the bore
out of the Carrier (3A). of the Planet Gear (3F).

3. Using a 1/8" diameter punch, drive the Roll Pin (4G) 6. Repeat steps 1 through 5 for each of the two remain-
out of the Planet Shaft (3E). NOTE: The Roll Pins ing planet gears.

3A Carrier
3B Thrust Washer
3C Needle Bearing
3E Planet Shaft
3F Planet Gear
4G Roll Pin

Figure 3-8. Input Carrier

3121253 – JLG Lift – 3-11

 SECTION 3 - CHASSIS & TURNTABLE

Hub-Spindle Disassembly 6. If necessary, press 9 Studs (1H) out of Hub (1G).

Locate Hub (1G) on Seal (1B) end.
1. Place unit on bench with Spindle (1 A) end down.
7. Remove Seal (1B) from Hub (1G).
2. Remove Retaining Ring (1J) with appropriate tool.
NOTE: The Seal (1B) should NOT be reused when reassem-
3. Remove Spacer (1N).
bling the unit.
4. Remove Bearing Cone (1C) from Bearing Cup (1D)
in Hub (1G). 8. Remove Bearing Cone (1E) from Hub (1G).

5. Lift Hub (1G) off of Spindle (1 A). Remove Boot Seal 9. Using a soft steel rod, knock both Bearing Cups
(1Q) from Hub (1G) if applicable. (1D) out of Hub (1G).

1A Spindle 1H Stud
1D Tapered Bearing Cup 1J Retaining Ring Ext.
1E Tapered Bearing Cone 1N Spacer
1G Hub(Housing) 1Q Seal Boot
Figure 3-9. Hub Spindle

3-12 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

Cover Disassembly 4. Pull Disengage Rod (6D) out from Cover (6A).

1. Remove O-Ring (17) from groove in Cover (6A). 5. Use appropriate tool to remove O-ring (6E) from
internal groove in Cover (6A).
2. Remove Thrust Washer (2) from Cover (6A) pockets.
3. Unscrew two Hex Head Bolts (6C) and remove Dis- 6. Remove two O-Ring Pipe Plugs (6F) from Cover
engage Cap (6B) from Cover (6A). (6A).

2 Thrust Spacer
3A Input Carrier
6A Cover
6B Disengage Cap
6C Bolt, Hex
6D Disengage Rod
6E O-ring
6F Pipe Plug
17 O-ring

Figure 3-10. Cover Assembly

3121253 – JLG Lift – 3-13

 SECTION 3 - CHASSIS & TURNTABLE

Input Carrier Assembly Output Planet Gear Assembly

(Refer to Figure 3-8., Input Carrier) (Refer to Figure 3-7., Planet Gear)

1. Apply a liberal coat of grease to the bore of one 1. Apply a liberal coat of grease to the bore of one Out-
Input Planet Gear (3F). put Planet Gear (4F).
2. Line the inside of the Planet Gear (3F) with 14 Nee-
2. Line the inside of the Planet Gear (4F) with 14 Nee-
dle Rollers (3C).
dle Rollers (4C).
NOTE: The last roller installed must be installed end wise.
That is, the end of the last roller must be placed in NOTE: The last roller installed must be installed end wise.
between the ends of the two rollers which form the That is, the end of the last roller must be placed in
space, and then slid, parallel to the other rollers, into between the ends of the two rollers which form the
place. space, and then slid, parallel to the other rollers, into
place.
3. Set Carrier (3A) in an upright position.
3. Place Spacer (4D) into the bore of the Output Planet
4. Insert a Planet Shaft (3E) into the planet shaft hole in (4F).
the end of the Carrier (3A) opposite the splined end.
The end of the planet shaft that does NOT have the 4. Repeat Step 2 to put in second roll of Needle Rollers
roll pin hole should be inserted into the carrier (4C).
FIRST.
5. Apply grease to hold two Thrust Washers (4B)
5. Place one Thrust Washer (3B) onto the end of Planet together and onto Output Planet Gear (4F) counter-
Shaft (3E). Make sure the flat faces towards the bore. Do the same to the other side.
inside of the carrier and make sure the button fits in
the pocket on the inside of the Carrier (3A) towards 6. Repeat Steps 1 -5 to finish the assembly of the two
the OD. remaining Output Planet Gears (4F).
6. Following the thrust washer, place Planet Gear (3F)
with needle rollers, onto Planet Shaft (3E).
7. Following the planet gear, place one more Thrust
Washer (3B) onto Planet Shaft (3E). Align the Thrust
Washer (3B) in the same manner described in Step
5.
8. Now insert Planet Shaft (3E) through the opposite
planet shaft hole on Carrier (3A). Use an alignment
punch or similar tool to align the roll pin holes on
Carrier (3A) and Planet Shaft (3E).

NOTE: Be sure not to hit the Planet Gears (3F) when driving
in the Roll Pins (4G).

9. Drive Roll Pin (4G) down into the aligned roll pin
holes. Pin should be flush with the flat of carrier.
10. Repeat Steps 1-9 for the installation of the two
remaining Planet Gears (3F).

NOTE: Some grease may need to be applied to the Thrust

Washers (3B) to hold them in place while installing
the planet gears.

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 SECTION 3 - CHASSIS & TURNTABLE

Output Carrier Assembly Hub-Spindle Assembly

(Refer to Figure 3-6., Output Carrier) (Refer to Figure 3-9., Hub Spindle)

1. Place Thrust Washer (4H) into counterbore of Carrier NOTE: Spray a light film of oil on all component parts during
(4A). BE SURE the small diameter side of Washer assembly.
(4H) facing planet gear side.
1. Place Hub (1G) into pressing base. Press nine Studs
2. Place Planet Gear Sub-assembly (4) into Carrier (1H) into Hub.
(4A). Visually align the planet gear bore with one of
the planet shaft holes on the Carrier (4A). NOTE: Use enough pressure to press in studs. Don’t use
excessively high pressure to press in studs or hub
3. Insert a Planet Shaft (4E) into the planet shaft hole may crack.
described in Step 2 on Carrier (4A). The end of the
planet shaft that does NOT have the roll pin hole NOTE: Spray a generous amount of oil on bearings during
should be inserted into the Carrier (4A) FIRST. installation.

4. Now insert Planet Shaft (4E) through the first set of 2. Press Bearing Cup (1D) into Hub (1G) using appro-
Thrust Washers (4B), Planet gear, then the second priate pressing tool.
set of Thrust Washers (4B). Use an alignment punch
3. Turn hub over and press Bearing Cup (1D) into hub
or similar tool to align roll pin holes on Carrier (4A)
using appropriate pressing tool.
and Planet Shaft (4E).
4. Place Bearing Cone (1E), into Bearing Cup (1D).
NOTE: Be sure not to hit the Planet Gears (4F) when driving
in Roll Pins (4G). 5. Grease Seal (1B) lip and press seal into Hub (1G)
using appropriate tool until seal is flush with end of
5. Drive Roll Pin (4G) down into the aligned roll pin hub.
holes. Pin should be flush with OD of Carrier (4A).
6. Press Seal Boot (1Q) onto Hub (1G) if required. Turn
6. Repeat Steps 1-5 for the installation of the two Hub (1G) over and lower onto Spindle (1A).
remaining Planet Gears (4F).
7. Install Bearing Cone (1C) into Bearing Cup (1D).

8. Place Bearing Spacer (1N) on top of Bearing Cone

(1C).

9. Using appropriate tool, install Retaining Ring (1J)

into Spindle (1A) groove. Make sure ring is com-
pletely seated in groove.

NOTE: Extra bearing pre-load caused by using tool in Step

#9 must be removed. This should be done by plac-
ing a tool (NOT THE SAME TOOL USED IN STEP #9)
on the end of the spindle, and then striking the tool
with a piece of barstock. This should be adequate to
remove any additional bearing pre-load.

3121253 – JLG Lift – 3-15

 SECTION 3 - CHASSIS & TURNTABLE

Figure 3-11. Hub Assembly - Sheet 1 of 2

3-16 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

1A Spindle 3B Thrust Washer 6C Bolt, Hex (.250-20 Unc, .500 Gr5)

1B Lip Seal 3C Needle Bearing 6D Dowel Pin
1C Tapered Bearing Cone 3E Planet Shaft 6E O-ring
1D Tapered Bearing Cup 3F Planet Gear 6F Pipe Plug
1E Tapered Bearing Cone 4A Output Carrier 6G Retaining Ring - Int 7.086
1F Ring Gear 4B Thrust Washer 7 Coupling
1G Hub(Housing) 4C Needle Bearing 9 Input Shaft
1H Stud 4D Thrust Spacer 10 Input Sun Gear
1J Retaining Ring Ext. 4E Planet Shaft 11 Output Sun Gear
1K Retaining Ring Int. 4F Planet Gear 15 ID Plate
1L Spring (1.460,1.500) 4G Roll Pin 16 Drive Screw
1M Thrust Washer 4H Thrust Washer 17 O-ring
1Q Seal Boot 5 Retaining Ring - Ext 18 O-ring
2 Thrust Spacer 6A Cover 19 Bolt, Flat Head - Hex Skt (.375-16)
3A Input Carrier 6B Disengage Cap 20 Retaining Ring - Ext.
Figure 3-12. Hub Assembly - Sheet 2 of 2

3121253 – JLG Lift – 3-17

 SECTION 3 - CHASSIS & TURNTABLE

Cover Subassembly NOTE: The output carrier sub-assembly does not need
timed with the spindle splines.
(Refer to Figure 3-10., Cover Assembly)
5. Place Output Carrier Sub-Assembly (4) into mesh
1. Grease O-Ring (6E) and insert into internal groove in with Spindle (1A) splines.
Cover (6A). 6. Place External Retaining Ring (5) over 13T spline to
2. Assemble Disengage Cap (6B) onto Cover (6A) the retaining groove on Input Shaft (9).
using two Hex Head Bolts (6C). Torque bolts to 70- NOTE: For ratio 48:1, assemble Output Sun Gear (11) over
80 in-lbs. Input Shaft (9) first, then install External Retaining
3. Insert Disengage Rod (6D) into hole in Cover (6A) Ring (5).
until it touches the inside of the Disengage Cap (6B). 7. Using appropriate tool to install Retaining Ring (20)
NOTE: The Disengage Rod can be inserted either end first. into groove on Output Sun (11)
8. Place Input Shaft (9) spline end into mesh with Inter-
4. Grease Face of Thrust Washer (2) and place in
nal Coupling (7) splines.
Cover (6A) making sure that tangs on washer seat
into pockets in cover. 9. With the modified spline end facing up, place the
Output Sun Gear (11) into mesh with the output
5. Install O-Ring Pipe Plugs (6F) into Cover (6A). The
planet gears.
plugs should be hand tight according to SAE stan-
dard. 10. Place Input Carrier Sub-Assembly (3) onto Output
Sun Gear (11) splines. Drop Input Sun (10) into
Main Assembly mesh with planet gears for specific ratios, if
required. (No timing required)
(Refer to Figure 3-4., Main Disassembly Drawing 1 and
Figure 3-5., Main Disassembly Drawing 2) 11. Grease O-Ring (17) and insert into groove in Cover
Sub-Assembly (6).
NOTE: All components should receive a generous amount
12. Install Cover Sub-Assembly (6) into Ring Gear (1F)
of lubricant oil as they are being assembled.
counterbore and install Retaining Ring (6G) into
1. Place Hub-Spindle Sub-Assembly on the bench. groove in Ring Gear (1F).

2. Grease O-Ring (18) and place it into groove of Hub 13. Attach ID Tag (15) onto unit using Drive Screws (16).
(1G). 14. Check disconnect, roll and air check unit.
3. Place Ring Gear (1F) onto Hub (1G). Align the three 15. Insert Plastic Plug (12) into place if applicable.
shipping Cap Screw Holes on Hub (1G) and Ring
Gear (1F).
4. Install three shipping Cap Screws (19) into ring gear
and hub. Torque them to 15-20 ft-lbs.

3-18 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

Figure 3-13. Cup Pressing Tool

Figure 3-14. Cup Pressing Tool

3121253 – JLG Lift – 3-19

 SECTION 3 - CHASSIS & TURNTABLE

3.4 DRIVE BRAKE - MICO 4. Install shaft assembly and retaining ring (17) in
cover (21).
Disassembly NOTE: Be sure to use the same number of springs and
spring pattern as recorded during disassembly. This
1. Remove pressure plate (3) from cover (21) by should be five red springs evenly spaced.
removing the capscrews (1) and washers (2).

5. Install dowel pins (20), spring retainer (16) and

springs (5) in cover plate (21).
PRESSURE PLATE IS UNDER SPRING TENSION OF APPROXI-
MATELY 1500 LBS (680 KGF). THE FOUR CAP SCREWS SHOULD 6. Position plate (14) on springs (15). NOTE: Disc (13
BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAU- &11) and plate (14) must remain dry during
LIC PRESS IS AVAILABLE, 3000 LBS (1361 KGF) MINIMUM, THE installation. No oil residue must be allowed to
PRESSURE PLATE CAN BE HELD IN POSITION WHILE REMOVING contaminate disc surfaces.
THE CAP SCREWS AND WASHERS
7. Place a new rotor disc (13), including speed sensor
2. Remove case seal (4) from cover (21). ring (12), on the shaft (10) until it contacts the plate
(14). Install stator disc (11).
3. Remove piston (7) from pressure plate (3).
4. Remove o-ring (5), back-up ring (6), o-ring (8) and 8. Install new o-ring (5), new back-up ring (6), new o-
back-up ring (9) from piston (7). ring (8) and new back-up ring (9) on piston (7). Note
order of o-rings and backup rings. Insert piston (7)
into pressure plate (3). Be careful not to shear o-
rings or back-up rings.
IF THE SENSOR RING (12) IS DAMAGED OR NEEDS REPLACED,
THE ENTIRE BRAKE MUST BE REPLACED AS A UNIT. THE SEN- 9. Install new case seal (4) in cover (21).
SOR RING IS NOT AVAILABLE AS A SERVICE PART.
10. Position pressure plate (3) on cover (21) aligning
5. Remove stack assembly, consisting of stator disc dowel pins (20) with holes in pressure plate.
(11), sensor ring (12), rotor disc (13), and plate (14)
from cover (21). NOTE: A hydraulic press will simplify installation of pressure
6. Remove dowel pins (20), springs (15) and spring plate on cover. Clamp pressure plate in position
retainer (16) from cover (21). while tightening the cap screws.

NOTE: Note number and pattern of springs for reassembly 11. Install capscrews (1) and washers (2) and tighten
purposes. evenly to draw pressure plate (3) to cover (21).
Torque capscrews to 55 ft.lbs. (74.6 Nm).
7. Remove retaining ring (17) from cover (21).

8. Remove shaft (10) by pressing or using a soft mallet

on male end of the shaft.
IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
9. Remove retaining ring (19) and bearing (18) from BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED
shaft (10). 2000 PSI (137.9 BAR) UNLESS TWO ADDITIONAL BOLTS ARE
USED FOR SUPPLEMENTAL CLAMPING.
10. Press rotary oil seal (20) from cover (18).

Assembly Bleeding
NOTE: Lubricate all rubber components from the repair kit 1. Install brake in system and connect pressure lines.
with clean type fluid used in the system.
2. Bleed pressure release section of brake by pressur-
1. Clean all parts thoroughly before assembly. izing side inlet port and allowing air to escape from
2. Press new rotary seal (22) into cover (21). Note top port. Pressure should not exceed 100 psi (6.9
direction of seal bar) during bleeding.

3. Install new bearing (18) and retaining ring (19) on 3. Apply sufficient pressure to release brake and check
shaft (10). for proper operation in system.

3-20 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

23
22 NOTE: The speed sensor port in the cover (21)
19 should be 180° from the brake release
port in the pressure plate (3).
21

18
17
16
20
15
14
13
12
11

10

9
8

7
6
5
4

2
1
23

1. Capscrew 7. Piston 13. Rotor Disc 19. Retaining Ring

2. Washer 8. O-ring 14. Plate 20. Dowel Pin
3. Pressure Plate 9. Backup Ring 15. Spring 21. Cover
4. Case Seal 10. Shaft 16. Spring Retainer 22. Rotary Oil Seal
5. O-ring 11. Stator Disc 17. Retaining Ring 23. Gasket
6. Backup Ring 12. Sensor Ring 18. Bearing

Figure 3-15. Drive Brake

3121253 – JLG Lift – 3-21

 SECTION 3 - CHASSIS & TURNTABLE

Table 3-2. Drive Brake Diagnosis

Corrective
Problem Cause Explanation Action

Brake slips Excessive pressure In hydraulic If there is back pressure in the actuation line of the Check filters. hose size, restrictions
system brake, holding torque will be reduced. in other hydraulic components.

Oil In brake if designed for dry Wet linings generate 67% of the dry torque rating. If Replace oil seal in brake. Check
use the brake has oil In it, check the type of oil hydraulic motor seal. Check piston seals.
or gearbox. Note: Internal components will
1. Gearbox oil need to be inspected, cleaned, and
2. Hydraulic oil replaced as required.

Springs broken or have taken a Broken or set springs can cause reduced torque - See spring replacement
permanent set rare occurrence.

Brake drags or runs Low actuation pressure The brake should be pressurized to minimum of Place pressure gauge in bleed port
hot 1.38 bar (20 psi) over the full release pressure under & check pressure with system on.
normal operating conditions. Lower pressures will
cause the brake to drag thus generating heat.

Bearing failure If the bearing should fall. a large amount of drag can Replace bearing.
be generated.

Brake will not release Stuck or clogged valve Brakes are designed to come on when system pres- Place pressure gauge in bleed port
sure drops below stated release pressure. If pres- - check for adequate pressure.
sure cannot get to brake, the brake will not release. Replace defective line or compo-
nent.

Bad o-rings Release piston will not hold pressure, brake will not Replace o-rings.
release.

Discs frozen These brakes are designed for only limited dynamic Replace disc stack.
braking. A severe emergency stop or prolonged
reduced release pressure operation may result in
this type of damage.

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 SECTION 3 - CHASSIS & TURNTABLE

3.5 SPEED SENSOR ADJUSTMENT Speed Sensor Installation Verification

The motor controller averages the readings from the right
and left speed sensors and therefore, it can be difficult to
detect if the speed sensors are adjusted properly. When
the positrac keeps coming in and out while on level sur-
faces, this is a sure indication that one of the speed sen-
sors is not adjusted properly.

The worse case condition of speed sensor misadjustment

occurs when both sensors are installed in a manner that
allows them to indicate the exact opposite direction that
the machine is traveling. This situation causes the control-
ler to believe that the machine is rolling in opposite direc-
tion than that selected by the operator. The controllers
FOR PROPER DRIVE OPERATION, THE SPEED SENSORS (2) reaction to this situation is to put more power into the
MUST BE PROPERLY INSTALLED AND ADJUSTED. THE SENSOR drive motors to attempt to overcome the fact that it
OPERATES ON A LEADING PULSE TO SHOW DIRECTION. IF
believes the machine is rolling backwards. This presents
INSTALLED INCORRECTLY, THE SENSOR WILL NOT BE ABLE TO
itself as uncontrolled movement in the direction selected
SENSE THE PROPER DIRECTION. IF BOTH SENSORS ARE
by the operator until the controller recognizes that it is
INSTALLED INCORRECTLY, THE JLG CONTROL SYSTEM WILL
placing maximum power in the motors and the controller
THINK THE MACHINE IS ON A HILL AND THE MACHINE WILL GO
INTO FULL SPEED MODE IMMEDIATELY. IF ONLY ONE SENSOR IS and the speed sensors are still reporting movement in the
INSTALLED WRONG, THE CONTROLLER SENSES A PROBLEM opposite direction. The controller responds by shutting
AND THE MACHINE WILL ONLY DRIVE AT CREEP SPEED. IF BOTH down drive and reporting flash code 5/5- Vehicle Runaway
SENSORS ARE ADJUSTED TOO FAR OUT, THE CONTROL SYSTEM Check Speed Encoders.
WILL NOT DRIVE THE MACHINE.
If either speed sensor is disconnected or faulty, the con-
troller will recognize this condition and immediately report
Adjustment Procedure flash code 5/5 - Left or Right speed Encoder Faulty.

1. Back off the locking nut and o-ring.

2. Thread the sensor in until it bottoms out. (do not

force).

NOTE: There are two notches on each speed sensor.

3. Back-off 3/4 to 1 turn and align the notches accord-

ing to the inside notch on each speed sensor. If
there are no notches, align the speed sensor wires
as shown in Figure 3-16., Speed Sensor Orientation.

4. Use a 1/2” wrench to hold the sensor and a 11/16”

wrench to snug the lock nut to the brake.

3121253 – JLG Lift – 3-23

 SECTION 3 - CHASSIS & TURNTABLE

Verification w/ Analyzer Procedure 4. Use the right and left cursor keys on the analyzer to
highlight "DIAGNOSTICS" and press enter.
The motor controller averages the readings from the right
and left speed sensors and therefore, it can be difficult to 5. Use the right and left cursor keys on the analyzer to
detect if the speed sensors are adjusted properly. Often highlight "DRIVE" and press enter.
operators report that posi-track keeps coming in and out 6. Use the right and left cursor keys to display "SPEED
while driving on level surfaces. This is a sure sign that one 0%" on the analyzer.
of the two speed sensors is not adjusted properly.
7. While watching the analyzer display select drive for-
The worst case condition of speed sensor maladjustment ward. Be ready to remove your foot from the foot-
occurs when both sensors are installed in a manner that switch if the machine lunges forward.
allows them to indicate the exact opposite direction that
the machine is traveling. This situation causes the control- 8. The analyzer display should ready the following if
ler to believe that the machine is rolling in the opposite the right speed sensor is adjusted properly: "SPEED
direction than that selected by the operator. The control- 20% FWD".
ler's reaction to this situation is to put more power into the 9. If the right speed sensor is adjusted improperly, the
drive motors to attempt to overcome the fact that it analyzer will display "SPEED 20% REV" and the
believes the machine is rolling backwards. This presents machine will lunge forward.
itself as uncontrolled movement in the direction selected
by the operator until the controller recognizes that it is 10. Adjust the right speed sensor using the above illus-
placing maximum power in the motors and the speed sen- tration as a guide until the analyzer displays "SPEED
sors are still reporting movement in the opposite direction. 20% FWD" when forward is selected in the platform.
If either speed sensor is disconnected or faulty, the con- The percentage displayed is not critical, just the
troller will recognize this condition and immediately report direction.
an error message pertaining to a Left or Right Speed
11. After obtaining the display in step 10, operate the
Encoder Faulty message.
machine in both the forward and reverse directions.
The machine should be controllable in both direc-
tions and will only drive at a maximum of creep
THE FOLLOWING PROCEDURE USING THE ANALYZER WILL HELP speed. The display on the analyzer should match
VERIFY THAT THE SPEED SENSORS ARE INSTALLED CORRECTLY. the direction selected.
THIS PROCEDURE REQUIRES A L A R G E S P A C E C L E A R O F
12. After completing adjustment of the right sensor, plug
OBSTRUCTIONS. THE OPERATOR SHOULD BE FAMILIAR WITH
the left sensor into the posi-tilt module.
JLG EQUIPMENT AND BE PREPARED TO USE THE FOOTSWITCH
TO STOP THE MACHINE. READ AND UNDERSTAND THIS ENTIRE 13. Unplug the right sensor from the power module.
PROCEDURE PRIOR TO BEGINNING.
14. Power up the machine in platform mode and plug in
the analyzer in the platform.
1. Before beginning this procedure ensure that there is
at least 10 ft in front and in back of the machine that 15. Use the right and left cursor keys on the analyzer to
is clear of obstruction. Be sure that all other person- highlight diagnostics and press enter.
nel stand clear of the machine during this proce-
dure. 16. Use the right and left cursor keys on the analyzer to
highlight drive and press enter.
2. Unplug the left speed sensor from the posi-track tilt
module. 17. Use the right and left cursor keys to display "SPEED
0%" on the analyzer.
3. Power up the machine in platform mode and plug in
the analyzer in the platform.

3-24 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

18. While watching the analyzer display select drive for- 3.6 POSITRAC/TILT MODULE
ward. Be ready to remove your foot from the foot-
switch if the machine lunges forward. When installing a new positrac/tilt module, Refer to
JLG Control System Analyzer Kit instructions. Use a
19. The analyzer display should ready the following if standard bubble level in two different directions to
the left speed sensor is adjusted properly: "SPEED ensure that the machine’s frame is level prior to install-
20% FWD". ing the new positrac/tilt module.
1. Place the machine on a flat, level surface. Check for
20. If the left speed sensor is adjusted improperly, the level by placing a bubble level on the frame in both
analyzer will display "SPEED 20% REV" and the directions.
machine will lunge forward.
2. Plug in the analyzer (Analyzer - p/n 1600244, Cable -
21. Adjust the left speed sensor using the above illustra- p/n 1600633) into port J9 on the power module or
tion until the analyzer displays "SPEED 20% FWD" port J1 on the platform module.
when forward is selected in the platform. The per- 3. Use the right arrow key to curse over to “ACCESS
centage displayed is not critical, just the direction. LEVEL 2". Depress Enter.

22. After obtaining the display in step 10, operate the 4. Use Up/Down arrow keys to enter the following
machine in both the forward and reverse directions. password “33271”. Depress Enter.
The machine should be controllable in both direc- 5. Use the right arrow key to curse over to “LEVEL
tions and will only drive at a maximum of creep VEHICLE”. Hit Enter. Depress Enter again.
speed. The display on the analyzer should match
6. Verify that the tilt reading is now “0.0; 0.0".
the direction selected.

23. Plug in the right sensor to the power module.

TO ASSURE PROPER OPERATION, THE MACHINE MUST BE LEVEL
24. Test the machine. The machine should now have WHEN ADJUSTING OR INSTALLING AND CALIBRATING A NEW
maximum drive speed available in both directions POSITRAC/TILT MODULE
and should be controllable in both directions. The
analyzer display should match the direction
selected.

3121253 – JLG Lift – 3-25

 SECTION 3 - CHASSIS & TURNTABLE

BLACK
WIRE WHITE GREEN
RED WIRE WIRE
WIRE
NOTCH
NOTCH

BLACK RED
GREEN WHITE WIRE WIRE
WIRE WIRE

SENSOR IN SENSOR IN
LEFT MOTOR BRAKE RIGHT MOTOR BRAKE

RED
WIRE WHITE
WIRE
GREEN
WIRE BLACK BLACK
WIRE WIRE GREEN
NOTCH
NOTCH WIRE
WHITE
WIRE RED
WIRE

SENSOR IN SENSOR IN
LEFT MOTOR BRAKE RIGHT MOTOR BRAKE
(MOTOR A) (MOTOR B)

Figure 3-16. Speed Sensor Orientation

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 SECTION 3 - CHASSIS & TURNTABLE

MAIN CONTACTOR
FWD/REV
CONTACTOR POSI-TRAC CONTACTOR

POSI-TRAC/TILT
MODULE
DRIVE
MOTOR B

POWER
DIODE

DRIVE
MOTOR A

Figure 3-17. Frame Mounted Electrical Components

3121253 – JLG Lift – 3-27

3-28
NOTE: CONNECTS TO
PUMP MOTOR NEGATIVE.
(-) ON POWER MODULE.

NOTE: DRIVE
FORWARD/REVERSE
CONTACTOR
SECTION 3 - CHASSIS & TURNTABLE

NOTE: POSI TRAC

CONTACTOR

– JLG Lift –
NOTE: CURRENT SHUNT

4933100-E

Figure 3-18. Contactor Wiring Diagram

3121253
 SECTION 3 - CHASSIS & TURNTABLE

3.7 SWING MOTOR

Figure 3-19. Swing Motor - Cutaway

IF THE HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN

EXCESS OF 200°F (93.3°C)], SEALS IN THE SYSTEM CAN
SHRINK, HARDEN OR CRACK, THUS LOSING THEIR SEALING
ABILITY.

3121253 – JLG Lift – 3-29

 SECTION 3 - CHASSIS & TURNTABLE

Table 3-3. Swing Motor Troubleshooting

Trouble Cause Remedy

Oil Leakage 1. Hose fittings loose, worn or damaged. Check & replace damaged fittings or "O" Rings. Torque to
manufacturers specifications.

2. Oil seal rings (4) deteriorated by excess heat. Replace oil seal rings by disassembling unit.

3. Special bolt (1, 1 A, 1B or 1C) loose or its sealing (a) Loosen then tighten single bolt to torque specification.
area deteriorated by corrosion. (b) Replace bolt.

4. Internal shaft seal (16) worn or damaged. Replace seal. Disassembly of motor unit necessary.

5. Worn coupling shaft (12) and internal seal (16). Replace coupling shaft and seal by disassembling unit.
Significant loss of speed under load 1. Lack of sufficient oil supply (a) Check for faulty relief valve and adjust or replace as
required.
(b) Check for and repair worn pump.
(c) Check for and use correct oil for temperature of opera-
tion.

2. High internal motor leakage Replace worn rotor set by disassembling unit.

3. Severely worn or damaged internal splines. Replace rotor set, drive link and coupling shaft by disas-
sembling unit.

4. Excessive heat. Locate excessive heat source (usually a restriction) in the

system and correct the condition.
Low mechanical efficiency or undue 1. Line blockage Locate blockage source and repair or replace.
high pressure required to operate unit
2. Internal interference Disassemble unit, identify and remedy cause and repair,
replacing parts as necessary.

3. Lack of pumping pressure Check for and repair worn pump.

4. Excessive binding or loading in system external to Locate source and eliminate cause.
motor unit.

3-30 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

20

18
8

25
8C 17
16
8E 14
15 19
14
8B
13
4 12
8A
4
8D
10
9
4
8

4
7
5
4
6
3

4
2

1. Bolt 6. Commutator Ring 8C. Stator Vane 12. Coupling Shaft 17. Backup Ring 22. Not Used
2. End Cover 7. Manifold 8D. Stator Half 13. Inner Bushing 18. Housing 23. Not Used
3. Seal Ring 8. Rotor Set 9. Wear Plate 14. Thrust Washer 19. Outer Bushing 24. Not Used
4. Seal Ring 8A. Rotor 10. Drive Link 15. Thrust Bearing 20. Dirt & Water Seal 25. Backup Washer
5. Commutator 8B. Stator Half 11. Thrust Bearing 16. Seal 21. Not Used

Figure 3-20. Swing Motor - Exploded View

3121253 – JLG Lift – 3-31

 SECTION 3 - CHASSIS & TURNTABLE

Preparation Before Disassembly flange or port bosses. Remove manifold port O-

Rings if applicable.
• Before you disassemble the motor unit or any of its
components read this entire section. It provides impor-
tant information on parts and procedures you will need
to know to service the motor.
• Thoroughly clean off all outside dirt, especially from
around fittings and hose connections, before discon-
necting and removing the motor. Remove rust or corro-
sion from coupling shaft.
• Remove coupling shaft connections and hose fittings
and immediately plug port holes and fluid lines.
• Remove the motor from system, drain it of fluid and
take it to a clean work surface.
• Clean and dry the motor before you start to disassem-
ble the unit.
• As you disassemble the motor clean all parts, except
seals, in clean petroleum-based solvent, and blow
them dry. IF THE MOTOR IS NOT FIRMLY HELD IN THE VISE, IT COULD BE
DISLODGED DURING THE SERVICE PROCEDURES, CAUSING
INJURY.
PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY 2. Scribe an alignment mark down and across the
CAREFUL WHEN USING ANY SOLVENT. EVEN A SMALL EXPLO- motor components from end cover (2) to housing
SION OR FIRE COULD CAUSE INJURY OR DEATH. (18) to facilitate reassembly orientation where
required.

WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA

OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.

NEVER STEAM OR HIGH PRESSURE WASH HYDRAULIC COMPO-

NENTS. DO NOT FORCE OR ABUSE CLOSELY FITTED PARTS.

• Keep parts separate to avoid nicks and burrs.

• Discard all seals and seal rings as they are removed
from the motor. Replace all seals, seal rings and any
damaged or worn parts with OEM approved service
parts.

Disassembly and Inspection

1. Place the motor 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

3-32 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

5. Thoroughly wash end cover (2) in proper solvent

and blow dry. Be sure the end cover valve apertures
are free of contamination. Inspect end cover for
cracks and the bolt head recesses for good bolt
head sealing surfaces. Replace end cover as neces-
sary.

3. Remove the 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.
NOTE: A polished pattern (not scratches) on the cover from
rotation of the commutator (5) is normal. Discolor-
ation would indicate excess fluid temperature, ther-
mal shock, or excess speed and require system
investigation for cause and close inspection of end
cover, commutator, manifold, and rotor set.

6. Remove commutator ring (6). Inspect commutator

ring for cracks, or burrs.

4. Remove end cover assembly (2) and seal ring (4).

Discard seal ring.

7. Remove commutator (5) and seal ring (3) Remove

seal ring from commutator, using an air hose to blow
air into ring groove until seal ring is lifted out and dis-
card seal ring. Inspect commutator for cracks or
burrs, wear, scoring, spalling or brinelling. If any of

3121253 – JLG Lift – 3-33

 SECTION 3 - CHASSIS & TURNTABLE

these conditions exist, replace commutator and tion of both sides of the manifold to ensure that same
commutator ring as a matched set. surface is reassembled against the rotor set.

9. Remove rotor set (8) and wearplate (9), together to

retain the rotor set in its assembled form, maintain-
ing the same rotor vane to stator contact surfaces.
The drive link (10) may come away from the cou-
pling shaft (12) with the rotor set, and wearplate. You
may have to shift the rotor set on the wearplate to
work the drive link out of the rotor and wearplate.
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 set component requires
replacement, the complete rotor set must be
replaced as it is a matched set. Inspect the wear-
plate for cracks, brinelling, or scoring. Discard seal
ring (4) that is between the rotor set and wearplate.

8. Remove manifold (7) and inspect for cracks surface

scoring, brinelling or spalling. Replace manifold if
any of these conditions exist. A polished pattern on
the ground surface from commutator or rotor rota-
tion is normal. Remove and discard the seal rings (4)
that are on both sides of the manifold.

NOTE: The rotor set (8) components may become disas-

sembled during service procedures. Marking the sur-
face of the rotor and stator that is facing UP, with
etching ink or grease pencil before removal will
ensure correct reassembly of rotor into stator and
rotor set into motor. Marking all rotor components
NOTE: The manifold is constructed of plates bonded and mating spline components for exact reposition-
together to form an integral component not subject to ing at assembly will ensure maximum wear life and
further disassembly for service. Compare configura- performance of rotor set and motor.

3-34 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

NOTE: A polished pattern on the wear plate from rotor rota- 12. Remove thrust bearing (11) from top of coupling
tion is normal. shaft (12). Inspect for wear, brinelling, corrosion and
a full complement of retained rollers.
10. Place rotor set (8) and wear plate (9) on a flat sur-
face and center rotor in stator such that two rotor
lobes (180 degrees apart) and a roller vane center-
line 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.

13. Check exposed portion of coupling shaft (12) to be

sure you have removed all signs of rust and corro-
sion which might prevent its withdrawal through the
seal and bearing. Crocus cloth or fine emery paper
may be used.

NOTE: If rotor set (8) has two stator halves and two sets of
seven vanes as shown, check the rotor lobe to roller
vane clearance at both ends of rotor.

11. Remove drive link (10) from coupling shaft (12) if it

was not removed with rotor set and wear plate.
Inspect drive link for cracks and worn or damaged
splines. No perceptible lash (play) should be noted
between mating spline parts. Remove and discard
seal ring (4) from housing (18).

14. Remove coupling shaft (12), by pushing on the out-

put end of shaft. Inspect coupling shaft bearing and
seal surfaces for spalling, nicks, grooves, severe
wear or corrosion and discoloration. Inspect for
damaged or worn internal and external splines or

3121253 – JLG Lift – 3-35

 SECTION 3 - CHASSIS & TURNTABLE

keyway. Replace coupling shaft if any of these con- 16. Remove thrust bearing (15) and thrust washer (14).
ditions exist. Inspect for wear, brinelling, corrosion and a full com-
plement of retained rollers.

17. Remove seal (16) and back up ring (17) from hous-
ing (18) and backup washer (25). Discard both.

NOTE: Minor shaft wear in seal area is permissible. If wear

exceeds 0.020 inches (0.51 mm) diametrically,
replace coupling shaft.
18. Remove housing (18) from vise, invert it and remove
NOTE: A slight "polish" is permissible in the shaft bearing and discard seal (20). A blind hole bearing or seal
areas. Anything more would require coupling shaft puller is required.
replacement.

15. Remove and discard seal ring (4) from housing (18).

19. Inspect housing (18) assembly for cracks, the

machined surfaces for nicks, burrs, brinelling or cor-

3-36 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

rosion. Remove burrs that can be removed without replaced. If the housing has passed this inspection
changing dimensional characteristics. Inspect the disassembly of the motor is completed.
tapped holes for thread damage. If the housing is
defective in these areas, discard the housing assem-
bly.

20. 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 brinel-
ling and corrosion. The bushing (19) or (13) to cou-
pling 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

NOTE: The depth or location of bearing/bushing (13) in rela-

tion to 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.

3121253 – JLG Lift – 3-37

 SECTION 3 - CHASSIS & TURNTABLE

21. If the bearings, bushing or thrust washers must be

replaced use a suitable size bearing puller to
remove bearing/bushings (19) and (13) from hous- SINCE THEY ARE FLAMMABLE, BE EXTREMELY CAREFUL WHEN
ing (18) without damaging the housing. Remove USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE
thrust washers (14) and thrust bearing (15) if they COULD CAUSE INJURY OR DEATH.
were previously retained in the housing by bearing
(13).
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA
OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS.
1. If the housing (18) bearing components were
removed for replacement, thoroughly coat and pack
a new outer bearing/bushing (19) with clean corro-
sion resistant grease recommended in the material
section. Press the new bearing/bushing into the
counterbore at the mounting flange end of the hous-
ing, using the appropriate sized bearing mandrel as
described which will control the bearing/ bushing
depth.

The housing requires 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.

Assembly
NOTE: Bearing mandrel must be pressed against the let-
Replace all seals and seal rings with new ones each time tered end of bearing shell. Take care that the hous-
you reassemble the motor unit. Lubricate all seals and ing bore is square with the press base and the
seal rings with SAE 10W40 oil or clean grease before bearing/ bushing is not cocked when pressing a
assembly. bearing/bushing into the housing.
NOTE: Unless otherwise indicated, do not oil or grease
parts before assembly.
IF A BEARING MANDREL IS NOT AVAILABLE AND ALTERNATE
Wash all parts in clean petroleum-based solvents before
METHODS ARE USED TO PRESS IN BEARING/BUSHING (13) AND
assembly. Blow them dry with compressed air. Remove
(19) THE BEARING/BUSHING DEPTHS SPECIFIED MUST BE
any paint chips from mating surfaces of the end cover,
ACHIEVED TO INSURE ADEQUATE BEARING SUPPORT AND COR-
commutator set, manifold rotor set, wear plate and hous-
ing and from port and sealing areas.

3-38 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

RECT RELATIONSHIP TO ADJACENT COMPONENTS WHEN seal (20) must be pressed in until its’ flange is flush
ASSEMBLED. against the housing.

4. Place housing (18) assembly into a soft jawed vise

with the coupling shaft bore down, clamping against
the mounting flange.
BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE A
PRESS FIT INTO THE HOUSING THEY MUST BE DISCARDED
WHEN REMOVED. THEY MUST NOT BE REUSED.

2. The inner housing bearing/bushing (13) can now be

pressed into its counter-bore in housing (18) flush to
0.03 inch (0.76 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).

5. Assemble a new backup ring (17), new backup

washer (25) and new seal (16) with the seal lip fac-
ing toward the inside of the motor, into their respec-
tive counterbores in housing (18).

3. Press a new dirt and water seal (20) into the housing
(18) outer bearing counterbore. The dirt and water

3121253 – JLG Lift – 3-39

 SECTION 3 - CHASSIS & TURNTABLE

6. Assemble thrust washer (14) then thrust bearing (15) coupling shaft (12) into housing (18), seating it
that was removed from the motor. against the thrust bearing (15).

NOTE: The motor requires one thrust washer (14) with

thrust bearing (15). The coupling shaft will be seated
directly against the thrust bearing. THE OUTER BEARING (19) IS NOT LUBRICATED BY THE SYS-
TEM’S HYDRAULIC FLUID. BE SURE IT IS THOROUGHLY PACKED
7. Apply masking tape around splines or keyway on WITH THE RECOMMENDED GREASE.
shaft (12) to prevent damage to seal.
NOTE: The coupling shaft (12) will be flush or just below the
housing wear surface when properly seated while
the coupling shaft (12). The coupling shaft must
rotate smoothly on the thrust bearing package.

8. Be sure that a generous amount of clean corrosion

resistant grease has been applied to the lower
(outer) housing bearing/bushing (19). Install the

3-40 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

9. Apply a small amount of clean grease to a new seal 11. Assemble wear plate (9) over the drive link (10) and
ring (4) and insert it into the housing (18) seal ring alignment studs onto the housing (18).
groove.

12. Apply a small amount of clean grease to a new seal

NOTE: One or two alignment studs screwed finger tight into ring (4) and assemble it into the seal ring groove on
housing (18) bolt holes, approximately 180 degrees the wear plate side of the rotor set stator.
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 motor.

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.

13. Install the assembled rotor set (8) onto wear plate
(9) with rotor counterbore and seal ring side down
and the splines into mesh with the drive link 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 mat-
ing coupling shaft splines.

3121253 – JLG Lift – 3-41

 SECTION 3 - CHASSIS & TURNTABLE

NOTE: It may be necessary to turn one alignment stud out 15. Assemble the manifold (7) over the alignment studs
of the housing (18) temporarily to assemble rotor set and drive link (10) and onto the rotor set. Be sure the
(8) or manifold (7) over the drive link. correct manifold surface is against the rotor set.

NOTE: If necessary, go to the appropriate, "Rotor Set Com-

ponent Assembly Procedure."

NOTE: The rotor set rotor counterbore side must be down

against wear plate for drive link clearance and to
maintain the original rotor-drive link spline contact. A
rotor set without 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). 16. Apply grease to a new seal ring (4) and insert it in
the seal ring groove exposed on the manifold.

NOTE: The manifold (7) is made up of several plates

bonded together permanently to form an integral
17. Assemble the commutator ring (6) over alignment
component. The manifold surface that must contact
studs onto the manifold.
the rotor set has it’s series of irregular shaped cavi-
ties on the largest circumference 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.

18. Assemble a new seal ring (3) flat side up, into com-
mutator (5) and assemble commutator over the end

3-42 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

of drive link (10) onto manifold (7) with seal ring side
up.

19. 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 is shown below.

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.

20. Assemble the 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

3121253 – JLG Lift – 3-43

 SECTION 3 - CHASSIS & TURNTABLE

cover and other components into place with a final 1. Place stator onto wear plate (9) with seal ring (4)
torque of 25-30 ft. lbs. (34-41 N m). side down, after following assembly procedures 1
through 13. Be sure the seal ring is in place.

2. If assembly alignment studs are not being utilized,

align stator bolt holes with wear plate and housing
bolt holes and turn two bolts (1) finger tight into bolt
holes approximately 180 degrees apart to retain sta-
tor and wear plate stationary.
3. Assemble the rotor, counterbore down if applicable,
into stator, and onto wear plate (9) with rotor splines
into mesh with drive link (10) splines.

One Piece Stator Construction

A disassembled rotor stator and vanes that cannot be
readily assembled by hand can be assembled by the fol-
lowing procedures.

3-44 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

4. Assemble six vanes, or as many vanes that will read- Two Piece Stator Construction
ily assemble into the stator vane pockets.
A disassembled rotor set (8) that cannot be readily assem-
bled by hand and has a two piece stator can be assem-
bled by the following procedures.
1. Place stator half onto wear plate (9) with
seal ring (4) side down, after following motor assem-
bly procedures 1 through 13. Be sure the seal ring is
in place.
2. Align stator bolt holes with wear plate and
housing bolts and turn two alignment studs
finger tight into bolt holes approximately 180
degrees apart to retain stator half and wear plate
stationary.
3. Assemble rotor, counterbore down if applicable, into
stator half, and onto wear plate (9) with rotor splines
into mesh with drive link (10) splines.

NOTE: Use any marking you applied to rotor set compo-

EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO nents to reassemble the components in their original
PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STA- relationship to ensure ultimate wear life and perfor-
TOR VANE POCKETS. mance.

5. Grasp the output end of coupling shaft (12) with 4. Assemble six vanes, or as many vanes that will read-
locking pliers or other appropriate turning device ily assemble into the stator vane pockets.
and rotate coupling shaft, drive link and rotor to seat
the rotor and the assembled vanes into stator, creat-
ing the necessary clearance to assemble the sev-
enth or full complement of seven vanes. Assemble EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO
the seven vanes using minimum force. PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STA-
TOR VANE POCKETS.

5. Grasp the output end of coupling shaft (12)

with locking pliers or other appropriate turning
device and rotate coupling shaft, drive link and rotor
to seat the rotor and the assembled vanes (8C) into
stator half, creating the necessary clearance to
assemble the seventh or full complement of seven
vanes. Assemble the seven vanes using minimum
force.
6. Place second stator half on a fl at surface with seal
ring groove up. Apply a small amount of grease to a
new seal ring (4) and assemble it into stator half ring
groove.
7. Assemble the second stator half over the two align-
ment studs and rotor with seal ring side down onto
the first stator half aligning any timing marks applied
for this purpose.

6. Remove the two assembled bolts (1) if used to retain IF THE STATOR HALF (8B) IS A DIFFERENT HEIGHT (THICKNESS)
stator and wear plate. THAN STATOR HALF (8D) THE STATOR VANES (8C) OR (8E)OF
THE SAME LENGTH (HEIGHT) AS THE STATOR HALF MUST BE
Go to assembly procedure #15, to continue assem- REASSEMBLED IN THEIR RESPECTIVE STATOR HALF FOR THE
bly. ROTOR SET TO FUNCTION PROPERLY.

3121253 – JLG Lift – 3-45

 SECTION 3 - CHASSIS & TURNTABLE

8. Assemble six vanes, or as many vanes that will read- 3.8 SWING DRIVE
ily assemble into the stator vane pockets.

9. Grasp the output end of coupling shaft (12) NOTE: The swing drive must be removed from the machine
with locking pliers or other appropriate turning to be serviced.
device and rotate coupling shaft, drive link and rotor
to seat the rotor and the assembled vanes into sta- The swing drive has five major components; the housing,
tor, creating the necessary clearance to assemble worm, worm gear, output pinion, and gear/pinion cap.
the seventh or full complement of seven vanes.
Assemble the seven vanes using minimum force. Tools required:

Go to assembly procedure #15, to continue assem- • hydraulic press

bly.
• 5/16" 12 point socket
Final Checks • 7/16" socket

1. Pressurize the motor with 100 p.s.i. dry air or nitro- • 3/4" socket
gen and submerge in solvent to check for external
leaks. • torque wrench (80 lb-ft)

2. Check motor for rotation. Torque required to rotate • steel hammer

coupling shaft should not be more than 50 ft. lbs.
• soft face hammer
(68 N m)
• bearing puller (external and internal)
3. Pressure port with "A" cast under it on housing (18)
is for clockwise coupling shaft rotation as viewed • large flat blade screw driver
from the output end of coupling shaft. Pressure port
with "B" cast under it is for counter clockwise cou- NOTE: Also needed are a shim and seal kit, 3/4" steel rod at
pling shaft rotation. least 10" long, LocTite #515, Mobil SHC 007 grease
(available as SW007GK), Mobil SHC 460 grease,
4. Use test stand if available, to check operation of the
LocTite 242/243 for bolts and any other parts that
motor.
may be worn out.

Installation Torque
Disassembly
When installing the swing motor onto the swing drive,
torque apply threadlocker JLG P/N 0100019 to the 1. Remove the slew ring (14) by removing the two 1/4"
threads of the retaining bolts and torque to 85 ft.lbs. (115 bolts (12) and washers (13) that hold the slew ring to
Nm). the housing.

2. Remove four #6 machine screws (29) that are

located on cover plate (20) immediately in front of
TORQUE Pinion (22).

3. Remove eight 5/16" 12 point capscrews (3) from

gear/pinion cap (19). Pry the cap from the housing.
The cover plate (20) will come off with cap. Note
where sealant is on Cover and plate so when assem-
bling sealant can be applied in the same place. Note
number and color of shims (26) between the cap
and housing. Remove six small screws (29) from
cover plate. Pry the cover plate (20) from cap (19)
and discard the cover plate. Note the number and
color of shims between cover plate and cap.

4. Remove the Pinion and Gear assembly (15, 16,

17,22,24,25,30) from the housing. The assembly lifts
directly upward from the housing.

3-46 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

1. Bearing 8. Seal 14. Slew Ring 20. Cover Plate 26. Shim
2. Oil Seal 9. Grease Fitting 15. Bearing 21. Worm Cap 27. Shim
3. Capscrew 10. Grease Fitting 16. Ring 22. Pinion 28. Shim
4. Bolt 11. Grease Fitting 17. Bearing 23. Motor Adapter 29. Machine Screw
5. Bolt 12. Bolt 18. Housing 24. Face Seal 30. Worm Gear
6. Plug 13. Washer 19. Gear/Pinion Cap 25. Spacer 31. Worm
7. Pressure Vent

Figure 3-21. Swing Drive - Exploded View

3121253 – JLG Lift – 3-47

 SECTION 3 - CHASSIS & TURNTABLE

5. Using a press, disassemble the pinion and gear 5. Turn the assembly over and place the spacer (25) on
assembly. Support the worm gear (30) on the press the pinion against the gear hub so the large chamfer
with the pinion (22) down allowing room for pinion to on the I.D. of spacer is against the bronze gear.
be pressed out of gear. Press pinion out of bearing Press the bearing (17) onto the pinion tight to the
(17) spacer (25) and worm gear (30) Pressing on spacer and gear.
end of pinion. Remove face seal (24) from face of
worm gear (30). Note how the seal is assembled. 6. Place the pinion/gear assembly into the housing.
Place the gear cap (19) and shims (26) over the
6. Remove the bearing (15) and Nilos Ring (16) from gear/pinion assembly to achieve a slight preload on
the pinion (22) using an external bearing puller or the pinion bearings. Remove the cap and shims and
press. set the shims aside. Install a new cover plate (20)
onto the cap using 6 screws (29) and shims (27)
7. Remove the motor and motor adapter (23) and equal to or close to equal to the total thickness of
shims (28). shims set aside during Disassembly. Apply sealant
(LocTite #515) to both sides of each of these shims
8. Remove 1/2" bolts (5) from the Worm Cap (21) using
and tighten the screws taking care not to twist these
3/4" socket. Remove the shim (28) and seal (8) and
screws off. Clean extra sealant from the surfaces of
discard.
the cover plate. Apply a small amount of grease to
9. Remove the worm (31) from the housing (18) by this flap. Set this assembly to the side.
pushing it from the motor end using steel rod and a
7. Install the bearing (1) on the bore end of the worm
hammer. The bearing cup (1) on the hex end of the
(31) only. This is almost a slip fit, may have to be
worm will be forced out of the housing. Once the
lightly tapped with soft hammer.
bearing cup (1) has come out of housing, use a soft
hammer to tap the worm on the hex end to remove 8. Install the worm (31) into the housing (18), hex end
the other bearing cup (1) out the other end of hous- first.
ing.
9. On the bore end of the worm, install the bearing cup
10. Remove both bearings (1) from the worm (31) worm (1) into the worm bore of the housing. Also on the
using external bearing puller or press. bore end of worm (31), install the motor adapter (23)
and 1 shim (28 yellow) to the housing using 1/2-13 x
11. The bearing cup (17) can be removed from the 1" bolts (4) and sealant. Torque to 75 ft.lbs. (101.5
housing (18) by lifting it out (this is not a press fit just Nm). These bolts will be replaced with motor bolts
a close slip fit). when the motor is mounted.
12. The bearing cup (15) can be removed from the cap 10. Install the bearing cone (1) on the hex end of the
(19) using a small pry bar, or by welding a small worm (31). Place a bearing cup (1) over the bearing
bead of weld on the internal diameter of cup, this is and lightly tap the cup into the bore using a soft
a press fit. hammer.

Assembly
1. Press the bearing cup (15) into the cap (19).

2. Place the bearing cup (17) into the housing (18).

3. Put the face seal (24) onto the hub of the worm gear
(30) with the flap of the seal pointing away from gear.

4. Place the worm gear (30) onto the press with the
face seal up and press the pinion (22) into the worm
gear. Place the Nilos Ring (16) onto the pinion so the
cup shape is up and press the bearing (15) onto the
pinion tight to the Nilos Ring.

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 SECTION 3 - CHASSIS & TURNTABLE

11. Install the worm cap (21) using proper shims (28) to 3.9 SWING BEARING
achieve 0.000 to 0.001" (0.000 to 0.025 mm) end
play. Apply LocTite 242 to end of 1/2-13 x 1.25" Turntable Bearing Mounting Bolt Condition
grade 5 bolts (5) and LocTite #515 sealant to shims.
Torque the bolts to 75 lbs-ft (101.5 Nm).
Check
12. Place the pinion/gear assembly into the housing so NOTE: This check is designed to replace the existing bear-
ing bolt torque checks on JLG Lifts in service. This
the gear teeth mesh with the worm gear teeth. The
check must be performed after the first 50 hours of
worm or gear set may have to be turned by hand to
machine operation and every 600 hours of machine
achieve this. operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
13. Apply LocTite #515 to surfaces of the housing loose bolts with new bolts and torque to the value
where the cap assembly will touch. This includes the specified in the torque chart, after lubricating the bolt
vertical surfaces. threads with threadlocker JLG P/N 0100019. After
replacing and retorquing bolt or bolts recheck all
14. Place the gear cap assembly and shims set aside in existing bolts for looseness.
step 6, over the pinion assembly.

15. Apply LocTite 242 to the end of eight 5/16" 12 point 1. Check the frame to bearing bolts as follows:
screws (3) and torque to 20 ft.lbs. (27 Nm). a. On a firm level surface, elevate the fully retracted
boom to full elevation.
16. Install 4 small screws (29) through the cover plate
(20) and into the housing (18). Tighten the screws b. At the position indicated on Figure 3-24., Swing
Bearing Tolerance Boom Placement try and
taking care not the twist the screws off.
insert the 0.0015” feeler gauge between the bolt
head and hardened washer at the arrow indi-
17. Install the seal (8) in the worm cap at the hex end of
cated position.
the worm.
c. Assure that the 0.0015” feeler gauge will not
18. Install the slew ring (14) using two 1/4" bolts (12) penetrate under the bolt head to the bolt shank.
and washers (13). Adjust backlash with the pinion to d. Swing the turntable 90 degrees, and check
0.008/0.012" (0.203/0.304 mm) and torque bolts to some selected bolts at the new position.
10 ft.lbs. (13.5 Nm). e. Continue rotating the turntable at 90 degrees
intervals until a sampling of bolts have been
19. Fill the unit with SHC 007 grease (available as
checked in all quadrants.
SW007GK) and grease the pinion bearing (15) thru
the fitting (9) with Mobil SHC 460 grease. 2. Check the turntable to bearing bolts as follows:

a. On a firm level surface, elevate the fully retracted

boom to full elevation.
b. At the positions indicated on Figure 3-24., Swing
Bearing Tolerance Boom Placement try and
insert the 0.0015” feeler gauge between the bolt
head and hardened washer at the arrow indi-
cated position.

3121253 – JLG Lift – 3-49

 SECTION 3 - CHASSIS & TURNTABLE

c. Lower the main boom to horizontal and fully

extend the boom.
d. At the position indicated on Figure 3-24., Swing
Bearing Tolerance Boom Placement try and
insert the.0015” feeler gauge between the bolt
head and hardened washer at the arrow indi-
cated position.

Figure 3-23. Swing Bearing Tolerance Measuring Point

3. If a difference greater than 0.057 in. (1.40 mm) is

determined, the swing bearing should be replaced.
4. If a difference less than 0.057 in. (1.40 mm) is deter-
mined, and any of the following conditions exist, the
bearing should be removed.
a. Metal particles in the grease.
Figure 3-22. Swing Bearing Feeler Gauge Check
b. Increased drive power.
c. Noise.
Wear Tolerance d. Rough rotation.
1. With the boom positioned over the side of the 5. If bearing inspection shows no defects, reassemble
machine, the Upper Boom horizontal with telescope bearing and return to service.
fully extended and Tower Boom raised half way
(approx 37°)See Figure 3-25., Swing Bearing Toler-
ance Boom Placement, using a magnetic base dial
indicator, measure and record the distance between
the swing bearing and turntable. (See Figure 3-23.,
Swing Bearing Tolerance Measuring Point)
2. At the same point, with the boom positioned over
the side of the machine, the Upper Boom fully
extended and fully retracted, the platform rotated
max. to the side, and the Tower Boom fully elevated,
(See Figure 3-24., Swing Bearing Tolerance Boom
Placement) using a magnetic base dial indicator,
measure and record the distance between the swing
bearing and turntable (Figure 3-23., Swing Bearing
Tolerance Measuring Point).

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 SECTION 3 - CHASSIS & TURNTABLE

JIB ELEVATED
90 DEGREES
PLATFORM ROTATED
90 DEGREES

MAIN BOOM FULLY ELEVATED

AND FULLY RETRACTED AJP Models

LOWER BOOM
FULLY ELEVATED

NOTE:
MEASURING POINT

Figure 3-24. Swing Bearing Tolerance Boom Placement

3121253 – JLG Lift – 3-51

 SECTION 3 - CHASSIS & TURNTABLE

MAIN BOOM
MAIN BOOM
FULLY EXTENDED
HORIZONTAL

LOWER BOOM
FULLY ELEVATED

NOTE:
MEASURING POINT

Figure 3-25. Swing Bearing Tolerance Boom Placement

3-52 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

Replacement of Swing Bearing 2. Installation.

a. Install bearing to rotation box with two cap

1. Removal. screws, so that fill plug of bearing is as close to
gear as bolt pattern will allow. Do not tighten cap
a. Attach an adequate support sling to the boom
screws.
and draw all slack from sling. Prop or block the
boom if feasible. b. Line up high spot (blue) of bearing as shown
below. Set backlash to 0.008 - 0.010 inch (0.20 -
b. Tag and disconnect hydraulic lines running
0.25 mm). Tighten cap screws as shown in Fig-
through center of turntable and frame. Use a
ure 3-26., Swing Bearing Torque Sequence.
suitable container to retain any residual hydrau-
lic fluid. Cap lines and ports.
c. Attach suitable overhead lifting equipment to the
base of turntable weldment.
d. Use a suitable tool to scribe a line on the inner
race of the swing bearing and on the underside
of the turntable. This will aid in aligning the bear-
ing upon installation. Remove bolts, nuts and
washers which attach the turntable to the bear-
ing inner race. Discard nuts and bolts.
e. Use the lifting equipment to carefully lift the com-
plete turntable assembly from the bearing.
Ensure that no damage occurs to the turntable,
bearing or frame mounted components.
POSITION POINT OF
f. Carefully place the turntable on a suitably sup- MINIMAL BACKLASH
ported trestle. IN THIS AREA
g. Use a suitable tool to scribe a line on the outer c. Grease bearing with Mobilith SHC Bearing
race of the swing bearing and the frame. This Grease. Grease fitting is remotely mounted.
line will aid in aligning the bearing upon installa-
tion. Remove the bolts and washers which d. Using suitable lifting equipment, install bearing/
attach the outer race of the bearing to the frame. rotation box assembly to frame with soft spot
Discard the bolts. Use suitable lifting equipment (red) 90 degree relative to load axis. If reusing
to remove the bearing and rotation box assem- old bearing, ensure that scribed line of outer
bly from the frame; move to a clean, suitably race of the bearing aligns with the scribed mark
supported work area. on the frame.

h. Remove the two cap screws securing the bear-

ing to the rotation box to separate the two for
inspection. JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8
BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED
WITH NEW NUTS AND BOLTS. SINCE THE SWING BEARING IS
THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURN-
TABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT HARD-
WARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG
HARDWARE IS HIGHLY RECOMMENDED.

e. Apply a light coating of threadlocker JLG P/N

0100019 to the new bearing bolts and loosely
install the bolts and washers through the frame
and outer race of bearing.

IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT

WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT
BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD
BE CHECKED PRIOR TO USE.

3121253 – JLG Lift – 3-53

 SECTION 3 - CHASSIS & TURNTABLE

f. Following the torque sequence diagram shown k. Following the torque sequence shown in Figure
i n F i g u r e 3 - 2 6 . , S w i n g B e a r i n g To r q u e 3-26., Swing Bearing Torque Sequence, tighten
Sequence, tighten the bolts to an initial torque of the bolts to an initial torque of 150 ft. lbs. (200
140 ft. lbs. (190 Nm). Then following the same Nm). Then following the same sequence, tighten
sequence, tighten to a final torque of 190 ft. lbs. the bolts to 210 ft. lbs (285 Nm).
(260 Nm).
l. Remove the lifting equipment.
g. Remove lifting equipment from bearing.
m. Route hydraulic lines through center of turntable
h. Use suitable lifting equipment to carefully posi-
and frame and connect as tagged prior to
tion the turntable assembly above the machine
removal.
frame.
i. Carefully lower the turntable onto the swing n. Using all applicable safety precautions, activate
bearing. Ensure that the scribed line of the inner the hydraulic system and functionally check
race of the bearing aligns with the scribed mark swing system for proper and safe operation.
on the turntable. If a new swing bearing is used,
ensure that the filler plug fitting is at 90 degrees Swing Bearing Torque Value
from the fore and aft centerline of the turntable.
j. Apply a light coating of threadlocker JLG P/N Install bolts with threadlocker JLG P/N 0100019 - 190
0100019 to the new bearing bolts and install ft. lbs. (260 Nm).
through the turntable and inner race of bearing.

3
7 13
11 9

7 3
13
15 11 9 5
14 5
2 2 1 1
6 15
6 10 12 16
8
4
10 12

14 8
4

Figure 3-26. Swing Bearing Torque Sequence

3-54 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

3.10 BATTERY MAINTENANCE AND Battery Charging, Daily

CHARGING
NOTE: To avoid excessive battery charging time, do not
allow batteries to become completely discharged.

TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR NOTE: To avoid electrolyte overflow, add distilled water to
ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC- batteries after charging.
ING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SER-
VICING BATTERIES. NOTE: When adding water to the battery, fill only to level
indicated or 3/8" above separators.
Battery Maintenance, Quarterly
1. Charge batteries at the end of each work day, or
1. Open battery compartment cover to allow access to when machine performance is significantly reduced
battery terminals and vent caps. due to batteries becoming discharged.

2. Charge batteries in accordance with the following

procedure:
WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELEC-
TROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS a. Open battery compartment, and battery charger
ELECTROLYTE COVERS THE PLATES. compartment covers.

NOTE: When adding distilled water to batteries, non-metal-

lic containers and/or funnels must be used.
WHEN BATTERY CHARGER IS TO BE USED, CHARGING HARNESS
MUST BE PLUGGED INTO A GROUNDED RECEPTACLE. IF RECEP-
To avoid electrolyte overflow, add distilled water to
TACLE IS NOT GROUNDED AND A MALFUNCTION SHOULD
batteries after charging.
OCCUR, THE MACHINE COULD CAUSE SERIOUS ELECTRICAL
SHOCK.
When adding water to the battery, fill only to level
indicated or 3/8" above separators. b. Remove charging harness cable and connect to
a receptacle or the correct voltage.
2. Remove all vent caps and inspect electrolyte level of c. Allow batteries to charge until 100% LED is illu-
each cell. Electrolyte level should be to the ring minated.
approximately one inch from top of battery. Fill bat-
teries with distilled water only. Replace and secure NOTE: When batteries are completely charged, disconnect
all vent caps. charging harness cable from receptacle. Store
charging harness cable.
3. Remove battery cables from each battery post one
at a time, negative first. Clean cables with acid neu- d. Ensure battery cables are positioned and are not
tralizing solution (e.g. baking soda and water or pinched. Close and secure all compartment
ammonia) and wire brush. Replace cables and/or doors.
cable clamp bolts as required.

4. Clean battery post with wire brush then re-connect

cable to post. Coat non-contact surfaces with min-
eral grease or petroleum jelly.

5. When all cables and terminal posts have been

cleaned, ensure all cables are properly positioned
and do not get pinched. Close battery compartment
cover.

6. Start hydraulic system and ensure that it functions

properly.

3121253 – JLG Lift – 3-55

 SECTION 3 - CHASSIS & TURNTABLE

3.11 BATTERY CHARGER Maintenance Instructions

1. For flooded lead-acid batteries, regularly check
water levels of each battery cell after charging and
LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN add distilled water as required to level specified by
GAS DURING NORMAL OPERATION. KEEP SPARKS, FLAMES, battery manufacturer. Follow the safety instructions
AND SMOKING MATERIALS AWAY FROM BATTERIES. PROVIDE recommended by the battery manufacturer.
ADEQUATE VENTILATION DURING CHARGING. NEVER CHARGE A
2. Make sure charger connections to battery terminals
FROZEN BATTERY. STUDY ALL BATTERY MANUFACTURERS'
are tight and clean.
SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF
CHARGE AND REMOVING OR NOT REMOVING CELL CAPS WHILE 3. Do not expose charger to oil or to direct heavy water
CHARGING. spraying when cleaning vehicle.

Battery Charger Fault Codes

If a fault occurred during charging, the red "Fault" LED will
RISK OF ELECTRIC SHOCK. CONNECT CHARGER POWER CORD
flash with a code corresponding to the error. Refer to the
TO AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND
table following for the flash codes and their removal.
GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND
ORDINANCES. A GROUNDED OUTLET IS REQUIRED TO REDUCE Table 3-12. Battery Charger Fault Codes (Delta-Q)
RISK OF ELECTRIC SHOCK - DO NOT USE GROUND ADAPTERS
OR MODIFY PLUG. DO NOT TOUCH UNINSULATED PORTION OF Flash(s) Fault Fault Removal
OUTPUT CONNECTOR OR UNINSULATED BATTERY TERMINAL. Battery voltage Auto-recover - Indicates a high battery pack
DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING 1
high voltage
THE CONNECTIONS TO THE BATTERY WHILE CHARGING. DO NOT Auto-recover - Indicates either a battery pack
OPEN OR DISASSEMBLE CHARGER. DO NOT OPERATE CHARGER Battery voltage failure, battery pack not connected to charger or
IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS 2
low battery volts per cell is less than 0.5 VDC.
RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE Check the battery pack and connections
DAMAGED IN ANY WAY - REFER ALL REPAIR WORK TO QUALI-
FIED PERSONNEL. NOT FOR USE BY CHILDREN. Indicates the batteries did not charge in the
allowed time. This could occur if the batteries
Charge
3 are a larger capacity than the algorithm is
Operating Instructions time-out
intended for or if the batteries are damaged old
or in poor condition.
Indicates the batteries could not be trickle
ALWAYS USE A GROUNDED OUTLET. WHEN USING AN EXTEN- 4 Check battery charged up to the minimum voltage per cell
SION CORD, AVOID EXCESSIVE VOLTAGE DROPS BY USING A level required for the charge to be started.
GROUNDED 3-WIRE 12 AWG CORD. Over- Auto-recover - Indicates charger has shut
5
temperature down due to high internal temperature
1. The charger will automatically turn on and go Indicates that the battery will not accept
through a short self-test. All LED’s will flash in an up- charge current, or an internal fault has been
down sequence for two seconds. The yellow "Charg- detected in the charger. This fault will nearly
ing" LED will turn on and a trickle current will be always be set within the first 30 seconds of
applied until a minimum voltage is reached. operation. Once it has been determined that
6 QuiQ fault
2. Once a minimum battery voltage of 2 volts per cell is the batteries and connections are not faulty
detected, the charger will enter the constant-current and fault 6 is again displayed after interrupt-
charging stage and the yellow LED will remain on. ing AC power for at least 10 seconds, the
The length of charge time will vary by input voltage charger must be brought to a qualified service
and ambient temperature. depot.

3. When the green "Charged" LED turns on, the batter-

ies are completely charged. The charger may now
be unplugged from AC power. If left plugged in, the
charger will automatically restart a complete charge
cycle if battery voltage drops below a minimum volt-
age or 30 days have elapsed.

4. If a fault occurred during charging, the red "Fault"

LED will flash with a code corresponding to the error.

3-56 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

1*
2

3**

6 7 8

9 1. Battery Terminal Grease

11 2. Left Battery Box
3. Dielectric Grease
4. Battery Connector
5. Draw Latch
6. Battery
7. Battery Hold Down
8. Right Battery Box
9. Left Cover
10. Right Cover
11. Latch

* Apply to Battery Terminal Connections Only

** Apply to Contacts of Connectors Only

10

1001108560-B

Figure 3-27. Battery Boxes

3121253 – JLG Lift – 3-57

 SECTION 3 - CHASSIS & TURNTABLE

NO LIGHTS AT ALL [3 Flashes] - Charge Timeout

No Lights at all indicate that AC power to the charger is
not connected or that the AC voltage is too low. It could Indicates the battery failed to charge within the allowed
also indicate an internal failure in the charger. time. This could occur if the battery is of larger capacity
than the algorithm is intended for. In unusual cases it
1. Check the connections to AC power. Check for AC
voltage between 90 and 260 VAC at the charger. could mean charger output is reduced due to high ambi-
ent temperature. It can also occur if the battery is dam-
2. If the AC voltage is verified to be correct at the con- aged, old, or in poor condition.
nection to the charger, and the charger still displays
no lights at all, return the charger for service. 1. Check the battery for damage such as shorted cells
and insufficient water. Try the charger on a good bat-
FAULT LED FLASHING
The Fault LED flashes to indicate the microcontroller tery.
inside the battery charger has detected a fault. The fault
2. If the same fault occurs on a good battery, check the
detected is indicated by the number of flashes. Count the
number of flashes to determine the fault. connections on the battery and connection to AC,
and the AC voltage itself.
With any battery system, the most common problem will
be a faulty battery connection. Because of the high likeli- 3. Confirm that the nominal battery pack voltage is the
hood of a battery connection problem, it is always worth-
same as the battery charger voltage.
while to confirm that all connections are good before
checking for any other problems. 4. This fault must be cleared manually by unplugging
[1 Flash] - High Battery Voltage the AC, waiting 30 seconds and reconnecting the
AC power.
1. Indicates a high battery voltage. Check that the bat-
tery charger voltage is consistent with the battery 5. If a charger displays this fault on a battery pack, and
pack voltage. The first two digits of the four digit
the pack is of questionable status, reset the charger
model name indicate the battery voltage the charger
supports. by disconnecting AC for 30 seconds, and then
reconnect the AC to start a new charge cycle. After a
2. Check for wiring errors.
few charge cycles, this problem could stop occur-
3. This fault will automatically clear and the charger will ring as the pack "recovers."
restart charging when this problem is removed.
[4 Flashes] - Check Battery
4. High battery voltage could also occur if there is
another source charging the battery. Disconnect any This fault indicates the battery pack could not be trickle
other sources during charging. charged up to the minimum level required for the normal
5. If this problem does not clear after the battery volt- charge cycle to be started.
age is confirmed to be less than 2.4V per cell, return
the charger for service. 1. Check that none of the battery pack connections
between modules are reversed or incorrectly con-
[2 Flashes] - Low Battery Voltage
nected.
1. Indicates either a battery failure, no battery con-
nected, or a lower than expected battery voltage. 2. Check that one or more cells in the battery are no
Check the battery and battery connections. shorted.
2. Check the nominal battery voltage. The first two dig- 3. Confirm that the nominal battery pack voltage is the
its of the four digit model name indicate the battery
same as the battery charger voltage.
voltage the charger supports. Confirm that a nomi-
nal battery voltage is the same as the charger volt-
4. Try the charger on a good battery.
age.
3. This fault will clear automatically when the low bat- 5. If this fault occurs, the battery is likely in poor condi-
tery voltage problem is rectified. tion. Try to recover the pack with a charger that can
charge the individual cells - such as an automotive
4. If this problem does not clear after the battery volt-
age is confirmed to be higher than 1.0V per cell and charger. Be sure to set this charger to the appropri-
all connections are good, return the charger for ser- ate voltage - 6V per 6V battery, 12V per 12V string/
vice. battery.

3-58 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

[5 Flashes] - Over Temperature Excessive Battery Watering Requirements or

This fault indicates the charger has become too hot during Strong Sulphur (Rotten Egg) Smell
operation. Though not damanging to the charger, charge
time will be extended significantly. These symptoms indicate over-charging or high battery
temperature. These symptoms are unlikely to be caused
1. This fault indication will not clear automatically, but by too high a charge current since the maximum charge
the charger will restart charging automatically when current of the charger will be small compared to even a
the temperature drops. The fault indicaiton must be moderately sized battery pack. The most likely cause for
cleared manually by unplugging the AC, waiting 30 this problem is incorrect charge algorithm setting and/or
seconds and reconnecting the AC power. high ambient temperatures.
2. If possible, move the machine to a cooler location. 1. Confirm that the battery pack is not too small - usu-
3. Confirm that dirt or mud is not blocking the cooling ally > 50Ah.
fins of the charger. Clean the charger. Rinse the
2. Confirm that the nominal battery voltage matches
charger with a low pressure hose if required. Do no
the charger output voltage.
use high pressure. Do not us a pressure washer.

[6 Flashes] - Over Load/Over Temperature 3. Confirm the correct battery charge algorithm. If the
battery pack is new, the algorithm will need to be
This fault indicates that the batteries will not accept charge changed if the pack is not the same as the old one.
current, or an internal fault has been detected in the char- for instructions on how to determine and change the
ger. This fault will nearly always be set within the first 30 battery charge algorithm see the following sub-sec-
seconds of operation. If it occurs after the charger has tion.
started charging normally, be sure to make a note of it.
4. If the output voltage of the charger seems excessive,
1. Remove excessive AC loads from inverter if return the charger for service. Contact JLG to get the
installed. expected battery voltage settings for the charger in
question. Be sure to have the charger’s serial num-
2. Try to clear the fault by unplugging the AC, waiting
ber and charge algorithm setting available when
30 seconds and reconnecting the ac power.
calling.
3. Check all battery connections. Look for a high resis-
tance connection.The most likely reason for this fault
is a fault in the battery such as a bad battery con-
nection, an open cell, or insufficient water.

4. This fault will occur if an internal fuse inside the char-

ger blows. If the green wire is shorted to ground
even momentarily, this fuse will blow. To check the
fuse, measure with an ohmmeter between the green
and red wires with the AC disconnected. If a short
circuit is not measured, the fuse has blown. Return
unit to a service depot to have this fuse replaced.

5. If this fault occurs after battery charging has started,

confirm that AC power was not interrupted and that
all battery connections are good.

6. If all battery connections are good, an internal fault

has been detected and the charger must be brought
to a qualified service depot.

3121253 – JLG Lift – 3-59

 SECTION 3 - CHASSIS & TURNTABLE

Checking/Changing the Battery Charger 3. Remove the AC power from the charger and recon-
nect the charger’s positive connector to the battery.
Algorithm It is recommended to check a newly changed algo-
The charger is pre-loaded with programming algorithms rithm by repeating the above steps 1 and 3.
for the specific batteries detailed in Table 3-4, Battery
Algorithms. Table 3-4. Battery Algorithms

NOTE: Contact JLG if your specific battery model is not Proper

listed. Algorithm # JLG P/N Battery Type Algorithm
Setting
Each time AC power is applied with the battery pack not
173 1001114782 DISCOVER EV 305A-A 43
connected, the charger enters an algorithm select/display
mode for approximately 11 seconds. During this time, the
current Algorithm # is indicated on the Yellow Charging
LED. A single digit Algorithm # is indicated by the number
of blinks separated by a pause. A two digit Algorithm # is
indicated by the number of blinks for the first digit followed
by a short pause, then the number of blinks for the second
digit followed by a longer pause.
To check / change the charging algorithm:
1. Disconnect the charger positive connector from the
battery pack. Apply AC power and after the LED test,
the Algorithm # will display for 11 seconds.
2. To change the algorithm, touch the connector to the
battery’s positive terminal for 3 seconds during the
11 second display period and then remove. The
Algorithm # will advance after 3 seconds. Repeat
this procedure until the desired Algorithm # is dis-
played. A 30 second timeout is extended for every
increment. Incrementing beyond the last Algorithm
will recycle back to the first Algorithm. When the
desired Algorithm is displayed, touch the charger
connector to the battery positive terminal until the
output relay makes a clicking noise (approx. 10 sec-
onds). The algorithm is now in the permanent mem-
ory.

3-60 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

3.13 DRIVE ORIENTATION SYSTEM turntable is swung past the switch point, the system is
ignored until drive/steer is released. When drive is initiated
The Drive Orientation System (DOS) is intended to indi- with the boom swung past the switch point, the DOS indi-
cate to the operator conditions that could make the direc- cator will flash and the drive/steer functions will be dis-
tion of movement of the chassis different than the
abled. The operator must engage the DOS override switch
direction of movement of the drive/steer control handle.
to enable Drive/steer (high drive will remain disabled).
The system indicates to the operator the need to match
When the DOS is enabled, the DOS indicator will be illumi-
the black and white directional arrows on the platform
nated continuously and a 3-second enable timer will be
control panel to the arrows on the chassis. The system
uses a proximity switch mounted under the turntable, a started and will continue for 3 seconds after the end the
"target" mounted to the frame, an indicator light and an last drive/steer command. If the timer expires, the DOS
override switch on the platform display panel. The proxim- override switch must be re-engaged to enable drive/steer.
ity switch trips when the turntable is swung +/- 28
degrees off center of the normal driving position. This
occurs roughly when the boom is swung past a rear tire. 3.14 HOODS
When the turntable is in the normal drive position with the
boom between the rear tires, no indications or interlocks The right hood weighs 15 lbs. (6.8 kg) and the left hood
are made. When the machine is actively driving when the weighs 10.3 lbs. (4.7 kg). See Figure 3-28., Hoods

THREADLOCKER JLG P/N 0100011

TORQUE 16-20 FT.LBS. (22-27 Nm)

Figure 3-28. Hoods

3121253 – JLG Lift – 3-61

 SECTION 3 - CHASSIS & TURNTABLE

56.0°
WHEN BOOM IS OUTSIDE
THIS 56° WINDOW OVER
REAR TIRES, DRIVE
ORIENTATION OVERRIDE
MUST BE ACTIVATED TO
ALLOW DRIVE TO BE
ENABLED.

+.00
.25
-.13
CLEARANCE FOR
SWITCH TO TARGET
WITH HORIZONTAL
SLOTS IN ITEM #14

SWITCH MOUNTING
UNLESS OTHERWISE SPECIFIED, ALL
BRACKET
DIMENSIONS ARE IN INCHES.

PROXIMITY SWITCH
DRIVE TARGET CAM

Figure 3-29. Drive Orientation Switch

3-62 – JLG Lift – 3121253

 SECTION 3 - CHASSIS & TURNTABLE

* AJ = 6188 ± 130 lbs. (2807 ± 59 kg)

* AJP = 6406 ± 130 lbs. (2906 ± 59 kg)

COUNTER-
WEIGHT*

RETAINING
HOOK
TURNTABLE

RETAINING BOLT,
NOTE A,
NOTE B
A - Torque 285 ft.lbs. (388 Nm)
B - Apply JLG P/N 0100019Thread Locking Compound

Figure 3-30. Counterweight

3121253 – JLG Lift – 3-63

 SECTION 3 - CHASSIS & TURNTABLE

NOTES:

3-64 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

4.1 BOOM MAINTENANCE 14. Unbolt the power track from the boom and remove
the power track and hoses/lines from the boom.
Removal of the Main Boom 15. Remove the cover at the rear of the boom.

16. Tag and disconnect the hydraulic lines running to

the telescope cylinder. Cap or plug all openings.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CON- NOTE: When removing the retaining pin from the rod end of
TAMINANTS INTO SYSTEM. the upper lift cylinder, make sure the cylinder is prop-
erly supported.
1. Raise the boom to a horizontal position.
17. Remove the retaining bolt, keeper, and pin that
2. Place blocking in the tower boom for support and secures the upper lift cylinder rod end to the main
prevent it from lowering. boom.
NOTE: The jib/platform assembly weighs approximately 500 NOTE: When removing the retaining pin from the rod end of
lbs. (230 kg). the master cylinder, make sure the cylinder is prop-
erly supported.
3. Support the weight of the jib/platform assembly
using adequate lifting or blocking equipment. 18. Remove the retaining bolt, keeper, and pin that
secures the master cylinder rod end to the main
NOTE: The main boom assembly weighs approximately 475 boom.
lbs. (216 kg).
19. Remove the retaining bolt, keeper, and pin that
4. Support the weight of the main boom with an ade- secures the main boom to the upper upright.
quate lifting device.
20. Remove the boom from the machine and place it on
5. Tag and disconnect all electrical lines running to the suitable blocking.
platform.
6. Tag and disconnect all hydraulic lines running to the
Disassembly of the Main Boom
plaform rotator, jib rotator (if equipped), and jib cylin- 1. Loosen the wear pad retaining bolts at the rear of fly
der. Cap or plug all openings. boom section and remove the shims and wear pads
7. Remove the hose cover from the top of the jib and noting the location and amount of shims to aid in
remove the hydraulic hoses from the jib. reassembly.

NOTE: When removing the retaining pin from the rod end of 2. Using a portable power source, attach hose to tele-
the level cylinder, make sure the cylinder is properly scope cylinder port block. Using all applicable
supported. safety precautions, activate hydraulic system and
extend cylinder to gain access to cylinder rod retain-
8. Remove the retaining bolt, keeper, and pin that ing pin. Shut down the portable power source.
secures the level cylinder to the jib.
3. Carefully disconnect hydraulic hose from retract port
9. Remove the retaining bolt, keeper, and pin that of cylinder. There will be initial weeping of hydraulic
secures the main boom to the jib. fluid which can be caught in a suitable container.
After initial discharge, there should be no further
10. Remove the jib and platform assembly from the
leakage from the retract port. Cap or plug all open-
boom.
ings.
11. Tag and disconnect the hydraulic lines running to
the level cylinder. Cap or plug all openings. NOTE: When removing the retaining pin from the rod end of
the telescope cylinder, make sure the cylinder is
12. Remove the cable cover from the side of the main properly supported.
boom.
4. Remove the retaining ring and pin securing the tele-
13. Tag and disconnect all the hose/line couplings scope cylinder rod end to the fly boom section.
found behind the cable cover. Cap or plug all open-
ings. Remove the clamp blocks securing the hoses/ 5. Remove the bolts and washers securing telescope
lines. cylinder to the rear of the base boom section.

3121253 – JLG Lift – 4-1

 SECTION 4 - BOOM & PLATFORM

2 1. Tower Lift Cylinder

2. Tower Upright
3. Upper Upright
3 4. Upper Lift Cylinder
5. Master Cylinder
6. Level Cylinder
1 7. Boom Assembly
8. Jib Rotator
9. Jib

8
9

Figure 4-1. Boom Assembly

4-2 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

NOTE: The telescope cylinder weighs approximately 53 lbs. Assembly of the Main Boom
(24 kg).
1. Lubricate the boom sections as shown in Figure 4-
6. Using a suitable lifting device, remove telescope cyl- 2., Boom Lubrication Instructions.
inder from the rear of the boom sections. 2. Using JLG P/N 0100011 thread locking compound
7. Remove hardware securing the front wear pads on or equivalent, install the bottom wear pads and
base boom section, remove wear pads and shims, shims as noted during disassembly on the rear of
noting the location and amount of shims to aid in the fly section. Torque the retaining bolts to 40 ft.lbs.
reassembly. (55 Nm). Install the rest of the wear pads on the rear
of the fly section but do not install the shims or
NOTE: The fly boom section weighs approximately 188 lbs. torque them at this time.
(85 kg).
3. Using an adequate lifting device, slide the fly boom
section into the base boom section. Install the
8. Using a suitable lifting device, remove fly boom from remaining shims on the rear of the fly section as
boom section. noted during disassembly and torque the retaining
bolts to 40 ft.lbs. (55 Nm). Pull the fly section out of
Inspection the base section enough to install the pin that
secures the telescope cylinder rod to the fly boom
1. Inspect all boom pivot pins for wear, scoring or other section.
damage, and for tapering or ovality. Replace pins as
necessary. 4. Using JLG P/N 0100011 thread locking compound
or equivalent, install the front wear pads and shims
2. Inspect lift cylinder pins for wear, scoring or other as noted during disassembly on the base boom sec-
damage, and for tapering or ovality. Ensure pin sur- tion. Torque the retaining bolts to 40 ft.lbs. (55 Nm).
faces are protected prior to installation. Replace pins
as necessary. 5. Using an adequate lifting device, install the tele-
scope cylinder into the boom assembly. It will aid
3. Inspect telescope cylinder rod attach pin for wear, assembly if the cylinder is extended to enable con-
scoring or other damage. Replace pin as necessary. nection to the fly boom section.
4. Inspect inner diameter of boom pivot bushings for 6. Align the telescope cylinder rod end with the corre-
scoring, distortion, wear or other damage. Replace sponding hole in the fly boom section. If necessary,
bushings as necessary. attach a portable power supply to the cylinder to
extend or retract the cylinder for alignment. Install
5. Inspect wear pads for wear. the retaining pin and secure it in place with the
6. Inspect all threaded components for damage such retaining ring.
as stretching, thread deformation, or twisting. 7. Using JLG P/N 0100011 thread locking compound
Replace as necessary. or equivalent, secure the rear of the telescope cylin-
der to the base boom section with the attaching
7. Inspect structural units of boom assembly for bend-
bolts and washers. Torque the bolts 95 ft.lbs. (129
ing, cracking, separation of welds, or other damage.
Nm).
Replace boom sections as necessary.

3121253 – JLG Lift – 4-3

 SECTION 4 - BOOM & PLATFORM

MODERATELY APPLY BOOM GREASE TO

ALL FOUR OUTER SURFACES OF FLY
MODERATELY APPLY BOOM GREASE TO OUTER BOOM TUBE IN SPECIFIED LOCATION
SURFACE OF WEAR PADS ON FLY BOOM (8X) JLG P/N 3020022
JLG P/N 3020022

12” ± 1”
46” ± 1” (30.5 cm ± 2.5 cm)
(116.8 cm ± 2.5 cm)

MODERATELY APPLY BOOM GREASE TO

ALL FOUR INNER SURFACES OF BASE
BOOM TUBE IN SPECIFIED LOCATION
JLG P/N 3020022 12” ± 1” 39” ± 1”
(30.5 cm ± 2.5 cm) (99 cm ± 2.5 cm)

Figure 4-2. Boom Lubrication Instructions

Installation of the Main Boom 4. Using JLG P/N 0100011 thread locking compound
or equivalent, install the retaining bolt, keeper, and
NOTE: The main boom assembly weighs approximately 475 pin that secures the upper lift cylinder rod end to the
lbs. (216 kg). main boom. Torque the retaining bolts to 85 ft.lbs.
(116 Nm).

1. Using suitable lifting equipment, position boom 5. Connect the hydraulic lines running to the telescope
assembly into the upper upright so the boom pivot cylinder as tagged during removal.
holes in both the boom and upright are aligned.
6. Install the cover at the rear of the boom.
2. Using JLG P/N 0100011 thread locking compound 7. Install the power track and hoses/lines onto the
or equivalent, install the retaining bolt, keeper, and boom support brackets and secure in place with the
pin that secures the main boom to the upper retaining hardware. Refer to Figure 4-3., Power Track
upright. Torque the retaining bolt to 85 ft.lbs. (116 Hoses.
Nm).

3. Using JLG P/N 0100011 thread locking compound

or equivalent, install the retaining bolt, keeper, and
pin that secures the master cylinder rod end to the
main boom. Torque the retaining bolt to 35 ft.lbs. (48
Nm).

4-4 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

POSITION BOTH LEVEL CYL

HOSES TO THE OUTSIDE OF
PUSH TUBE AS SHOWN

PLATFORM SUPPLY HOSE

PLATFORM RETURN HOSE
LOWER BOOM CONTROL HARNESS
WELD LEAD OR AIR LINE
A/C CABLE ROUTED ON TOP OF JIB CYL HOSES
JIB CYL EXTEND HOSE
JIB CYL RETRACT HOSE
LEVEL (MASTER) RETRACT HOSE
LEVEL (MASTER) EXTEND HOSE

Figure 4-3. Power Track Hoses

8. Connect all the hose/line couplings on the side of 11. Align the jib and platform assembly with the attach
the boom as tagged during removal. Install the points on the boom.
clamp blocks securing the hoses/lines. Refer to Fig-
12. Using JLG P/N 0100011 thread locking compound
ure 4-4., Clamp Block Installation.
or equivalent, install the retaining bolt, keeper, and
9. Install the cable cover onto the side of the main pin that secures the main boom to the jib. Torque the
boom. retaining bolt to 85 ft.lbs. (116 Nm).
10. Connect the hydraulic lines running to the level cyl-
inder as tagged during removal.

3121253 – JLG Lift – 4-5

 SECTION 4 - BOOM & PLATFORM

ORIENT CLAMP BLOCK SECTIONS

USING ALIGNMENT HOLES AS SHOWN

PUSH NUT

CLAMP BLOCK INSTALLATION INSTRUCTIONS

1. TO PROVIDE ORIENTATION OF THREADED STUDS,
LOOSELY INSTALL THREADED STUD INTO
CLIP NUT UNTIL FIRST SECTION OF CLAMP
BLOCK IS INSTALLED

2. TORQUE THREADED STUD TO 10 FT.LB. (13.5 Nm)

3. CONTINUE INSTALLING HOSES, CABLES, AND CLAMP

BLOCK SECTIONS
CLAMP BLOCK
4. INSTALL PUSH NUTS ONTO THREADED STUDS
TO HOLD CLAMP BLOCKS IN POSITION WHILE
COVER IS INSTALLED.

Figure 4-4. Clamp Block Installation

13. Using JLG P/N 0100011 thread locking compound 15. Connect all hydraulic lines running to the plaform
or equivalent, install the retaining bolt, keeper, and rotator, jib rotator (if equipped), and jib cylinder as
pin that secures the level cylinder to the jib. Torque tagged during removal.
the retaining bolt to 35 ft.lbs. (48 Nm).
16. Connect all electrical lines running to the platform as
14. Route the hydraulic hoses on top of the jib and tagged during removal.
install the hose cover.
17. Using all safety precautions, operate machine sys-
ROUTE HOSES AND CABLES tems and extend and retract boom for four or five
THROUGH CHANNELS ON JIB cycles, checking for proper operation.
AS SHOWN
18. Shut down the machine and check for leakage.

4-6 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

*
*

Use JLG P/N 0100011 Thread Locking Compound or equivalent

*
Figure 4-2. Boom Thread Locking Compound Location

3121253 – JLG Lift – 4-7

 SECTION 4 - BOOM & PLATFORM

A
B

A - Torque35 ft.lbs. (48 Nm)

B - Torque 85 ft.lbs. (116 Nm)

Figure 4-3. Boom Torque Values

4-8 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

10

8
7 2

10

1. Link 6. Upper Upright

2. Level Link 7. Tower Upright
3. Lower Boom 8. Tower Lift Cylinder
4. Mid Boom 9. Bumper
5. Timing Link 10. Hose Channel

Figure 4-4. Lower Boom

3121253 – JLG Lift – 4-9

 SECTION 4 - BOOM & PLATFORM

*
*

*
*

* Use JLG P/N 0100011 Thread Locking Compound or equivalent

Figure 4-5. Lower Boom Thread Locking Compound Location

4-10 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

A
B

A - Torque35 ft.lbs. (48 Nm)

B - Torque 85 ft.lbs. (116 Nm)

Figure 4-6. Lower Boom Torque Values

3121253 – JLG Lift – 4-11

 SECTION 4 - BOOM & PLATFORM

1 3
2

8
5
4 7

1
5

4
1. Platform Rotator
2. Jib Rotator
3. Upper Jib Link
4. Jib Link
5. Jib Cylinder
6. Platform Support
7. Jib Rotator Center Bolt
8. Platform Rotator Center Bolt
6

Figure 4-7. AJP Jib

4-12 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

A,E,F
A B,E,F
A

C,F
A A D,F

NOTE: If any rotator bolts are replaced, all bolts

on the rotator should be retorqued.

A Torque to 35 ft.lbs. (48 Nm)

B Torque to 85 ft.lbs. (115 Nm)
C Torque to 250 ft. lbs. (339 Nm)
D Torque to 480 ft. lbs. (650 Nm)
E JLG P/N 0100011Thread Locking Compound
F Check torque every 150 hours of operation

Figure 4-8. AJP Jib Torque Values

3121253 – JLG Lift – 4-13

 SECTION 4 - BOOM & PLATFORM

NOTE: UPPER BOOM ANGLE TO BE 1° BELOW

HORIZONTAL TO 3° ABOVE HORIZONTAL
TO ACTIVATE SWITCH. UPPER BOOM
ANGLE TO BE 1° TO 4° BELOW HORIZONTAL
TO RESET SWITCH.

NOTE: LOWER BOOM ANGLE TO BE 1°

TO 5° ABOVE HORIZONTAL TO ACTIVATE
SWITCH. LOWER BOOM ANGLE TO
BE 0° TO 5° BELOW HORIZONTAL TO
RESET SWITCH.
Figure 4-9. Boom Limit Switches

4-14 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

4.2 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove the screw from the other
side of track. Remove the bar/poly roller from the
powertrack. .
Removing a Link
NOTE: Hoses shown in the powertrack are for example only.
Actual hose and cable arrangements will be differ-
ent.

1. Clamp the bar and poly roller tightly so they do not

spin when removing the screw. With a small ¼”
ratchet and a t-20 torx bit, remove the 8-32 x 0.500
screw from one side.

3121253 – JLG Lift – 4-15

 SECTION 4 - BOOM & PLATFORM

3. To remove a link, the rivets holding the links together 4. insert the tool into the rolled over end of the rivet as
must be removed. Use a right-angle pneumatic die shown. Grind out the middle of the rivet until the
grinder with a ¼” ball double cut bur attachment. rolled over part of the rivet falls off. Repeat this step
for all the rivets that must be removed.

MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE

GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND
CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON
THEM.

4-16 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

5. After grinding it may be neccesary to help the rivet 6. Using a flat head screwdriver between the links,
out by using a center punch with a hammer. twist the screwdriver and pull the links apart.

NOTE: It may be necessary to loosen the fixed end brackets

from the machine in order to twist and pull the track
section enough to disconnect the links.

3121253 – JLG Lift – 4-17

 SECTION 4 - BOOM & PLATFORM

7. Remove the link from the other section of the pow- Installing a New Link
ertrack using a screwdriver.
1. Squeeze the peanut cut out end of the new link into
the half-shear (female) end of the track section.

4-18 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

2. Spread apart the half-shear (female) end of the new 3. After the new link is installed in the powertrack the
link and slide the peanut end of the track section round half-shears will not fit properly in the peanut
into it. a screwdriver may be necessary to do this. cut-outs yet.

3121253 – JLG Lift – 4-19

 SECTION 4 - BOOM & PLATFORM

4. Pull the moving end out over the track so that the 6. Push pin thru center hole then slide washer on pin.
new connection is positioned in the curve of the
powertrack. In this position the round half-shears will
rotate into the peanut cut outs.

7. Install the snap ring in the groove on the pin. Repeat

the pin installation steps for all center holes that
have the rivets removed.

5. The parts shown below will be used to connect the

new link to the powertrack.

4-20 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

NOTE: When installing snap rings make sure they are 8. Hold new aluminum round bar tightly, then install
seated in pin groove and closed properly. new 8-32 x 0.500 self-threading torx head screw into
one end.

NOTE: Maximum tightening torque is 18-20 in-lbs.

CLOSED SNAP RING

SNAP RING NOT

CLOSED PROPERLY

3121253 – JLG Lift – 4-21

 SECTION 4 - BOOM & PLATFORM

9. Pull up on the other end of the round bar and slide 10. Install a new 8-32 x 0.500 self threading screw on
the new poly roller onto the bar. the other side.

NOTE: When tightening screws make sure screw head is

seated against link with no space in between the link
and underside of screw head. Maximum tightening
torque is 18-20 in-lbs.

4-22 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

Replacing Fixed End Brackets CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON
THEM.

1. Remove the rivets the same way as shown under the

link removal instructions.

MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE

GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND

2. Parts used: Bracket Center Pin and Center Pin Snap

Ring.

3121253 – JLG Lift – 4-23

 SECTION 4 - BOOM & PLATFORM

3. Take the new bracket and install bracket center pin Replacing Moving End Brackets
and snap ring. Repeat on the other bracket if replac-
ing it as well.

1. Remove existing pins and center rivet. Remove the

NOTE: When installing snap rings make sure they are
rivet the same way as shown in the link removal
seated in pin groove and closed properly.
instructions. Repeat on other bracket if replacing it
as well.

CLOSED SNAP RING

SNAP RING NOT

CLOSED PROPERLY

4-24 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

2. Take new bracket and install center pin with snap

ring.
MOVE THE CABLES/HOSES OUT OF THE WAY DURING THE
GRINDING PROCESS TO PROTECT THEM. KEEP THE HOSES AND
CABLES COVERED TO PREVENT ANY DEBRIS FROM GETTING ON
THEM.

3121253 – JLG Lift – 4-25

 SECTION 4 - BOOM & PLATFORM

3. Install radius pins into their original locations and NOTE: When installing snap rings make sure they are
install snap rings. Repeat with other moving end if seated in pin groove and closed properly.
replacing as well.

CLOSED SNAP RING

SNAP RING NOT

CLOSED PROPERLY

4. When complete make sure that both brackets rotate

correctly.

4-26 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

4.3 BOOM CLEANLINESS GUIDELINES 4.4 TILT SENSOR CHECK

The following are guidelines for internal boom cleanliness
for machines that are used in excessively dirty environ-
ments.
PERFORM TILT SENSOR CHECK PROCEDURE A MINIMUM OF
1. JLG recommends the use of the JLG Hostile Envi- EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND
ronment Package if available to keep the internal ADJUSTMENT OF SWITCH.
portions of a boom cleaner and to help prevent dirt
and debris from entering the boom. This package 1. Check chassis out of level indicator light located on
reduces the amount of contamination which can the platform control console by driving, with the
enter the boom but does not eliminate the need for machine in level position, up a suitable ramp of at
more frequent inspections and maintenance when
least 6° slope. Check the out of level alarm, with the
used in these types of environments.
machine on the ramp, raise the upper boom until it
2. JLG recommends that you follow all guidelines for is parallel with the chassis. DO NOT RAISE ABOVE
servicing your equipment in accordance with the THE PARALLEL POSITION. If the light does not illu-
instructions outlined in the JLG Service & Mainte- minate, return the machine to a level surface, shut
nance Manual for your machine. Periodic mainte- down the machine, and contact a qualified techni-
nance and inspection is vital to the proper operation cian before resuming operation.
of the machine. The frequency of service and main-
tenance must be increased as environment, severity 2. If necessary, verify the tilt sensor with the analyzer.
and frequency of usage requires. Refer to Section 3.

3. Debris and foreign matter inside of the boom can

cause premature failure of components and should 4.5 FOOTSWITCH ADJUSTMENT
be removed. Methods to remove debris should
always be done using all applicable safety precau- Adjust switch so that functions will operate when pedal is
tions outlined in the JLG Operation & Safety Manual at center of travel. If switch operates within last 1/4 inch
and the JLG Service & Maintenance Manuals. (6.35 mm) of travel, top or bottom, it should be adjusted.

4. The first attempt to remove debris from inside the

boom must be to utilize pressurized air to blow the
4.6 BOOM LIMIT SWITCHES
debris toward the nearest exiting point from the
boom. Make sure that all debris is removed before Refer to Figure 4-9., Boom Limit Switches for adjustments
operating the machine. to be made of the two Limit Switches which bolt in place
on the main boom upright and turntable.
5. If pressurized air cannot dislodge the debris, then
water with mild solvents applied via a pressure
washer can be used. Again the method is to wash
the debris toward the nearest exiting point from the
boom. Make sure that all debris is removed, that no
“puddling” of water has occurred, and that the
boom internal components are dry prior to operating
the machine. Make sure you comply with all federal
and local laws for disposing of the wash water and
debris.
6. If neither pressurized air nor washing of the boom
dislodges and removes the debris, then disassem-
ble the boom in accordance to the instructions out-
lined in the JLG Service & Maintenance Manual to
remove the debris.

3121253 – JLG Lift – 4-27

 SECTION 4 - BOOM & PLATFORM

4.7 ROTARY ACTUATOR Required Tools

Upon assembly and disassembly of the actuator there are
Theory of Operation basic tools required. The tools and their intended func-
tions are as follows:
The rotary actuator is a simple mechanism that uses the
sliding spline operating concept to convert linear piston
motion into powerful shaft rotation. Each actuator is com-
posed of a housing with integrated gear teeth (01) and
only two moving parts: the central shaft with integrated
bearing tube and mounting flange (02), and the annular
piston sleeve (03). Helical spline teeth machined on the
shaft engage matching splines on the in- side diameter of
the piston. The outside diameter of the piston carries a
second set of splines, of opposite hand, which engage
with matching splines in the housing. As hydraulic pres-
sure is applied, the piston is displaced axially within the
housing - similar to the operation of a hydraulic cylinder -
while the splines cause the shaft to rotate. When the con-
trol valve is closed, oil is trapped inside the actuator, pre-
venting piston movement and locking the shaft in position.

1. Flashlight - helps examine timing marks, component

failure and overall condition.
2. Felt Marker - match mark the timing marks and out-
line troubled areas.
3. Allen wrench - removal of port plugs and set screws.
4. Box knife - removal of seals.
5. Seal tool - assembly and disassembly of seals and
wear guides.
6. Pry bar - removal of end cap and manual rotation of
shaft.
7. Rubber mallet- removal and installation of shaft and
piston sleeve assembly.
8. Nylon drift - installation of piston sleeve
9. End cap dowel pins - removal and installation of end
cap (sold with Helac seal kit).
The seal tool is merely a customized standard flat head
Bars indicate starting posi- As fluid pressure is applied, screwdriver. To make this tool you will need to heat the flat
tio ns of pisto n and shaft. the piston is displaced axially end with a torch. Secure the heated end of the screwdriver
Arrows indicate direction they while the helical gearing in a vice and physically bend the heated end to a slight
will rotate. The housing with causes the piston and shaft to radius. Once the radius is achieved round off all sharp
integral ring gear remains sta- rotate simultaneously. The edges of the heated end by using a grinder. There may be
tionary. double helix design com-
some slight modifications for your own personal prefer-
pounds rotation: shaft rota-
tion is about twice that of the
ence.
piston.

The shaft is supported radially by the large upper radial

bearing and the lower radial bearing. Axially, the shaft is
separated from the housing by the upper and lower thrust
washers. The end cap is adjusted for axial clearance and
locked in position by set screws or pins.

4-28 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

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 4-10. Rotary Actuator - Exploded View

3121253 – JLG Lift – 4-29

 SECTION 4 - BOOM & PLATFORM

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 4-11. Rotary Actuator - Assembly Drawing

4-30 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

Disassembly 5/1 6” drill bit to a depth of 1/2” (12.7mm) to drill out

the entire pin.
1. Remove the capscrews (113) over end cap lock pins 4. Install the end cap (4) removal tools provided with
(109). the Helac seal kit.

2. Using a 1/8” (3.18mm) drill bit, drill a hole in the cen-

5. Using a metal bar, or something similar, unscrew the
ter of each lock pin to a depth of approximately 3/ end cap (4) by turning it counter clockwise.
16” (4.76mm).

3. Remove the lock pins using an ”Easy Out” (a size

#2 is shown).

If the pin will not come out with the ”Easy Out”, use

3121253 – JLG Lift – 4-31

 SECTION 4 - BOOM & PLATFORM

6. Remove the end cap (4) and set aside for later 8. Every actuator has timing marks for proper engage-
inspection. ment.

7. Remove the stop tube if included. The stop tube is

an available option to limit the rotation of the actua-
tor.

9. Prior to removing the shaft, (2), use a felt marker to

clearly indicate the timing marks between shaft and
piston. This will greatly simplify timing during assem-
bly.

4-32 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

10. Remove the shaft (2). It may be necessary to strike 13. At the point when the piston gear teeth come out of
the threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the
piston and housing with a marker as shown.

11. Before removing the piston (3), mark the housing (1)
ring gear in relation to the piston O.D. gear. There 14. Remove the o-ring (204) and backup ring (207) from
should now be timing marks on the housing (1) ring end cap (4) and set aside for inspection.
gear, the piston (3) and the shaft (2).

15. Remove the wear guides (302) from the end cap (4)
12. To remove the piston (3) use a rubber mallet and a and shaft (2).
plastic mandrel so the piston is not damaged.

3121253 – JLG Lift – 4-33

 SECTION 4 - BOOM & PLATFORM

16. To remove the main pressure seals (205), it is easi- 19. Remove the piston O.D. seal (202).
est to cut them using a sharp razor blade being
careful not to damage the seal groove.

20. Remove the piston I.D. seal (200). You may now pro-
ceed to the inspection process.

17. Remove the thrust washers (304), from the end cap
(4) and shaft (2).

18. Remove the wiper seal (304.1) from its groove in the
end cap (4) and shaft (2).

4-34 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

Inspection 3. Inspect the wear guide condition and measure thick-

ness (not less than 0.123” or 3.12 mm).
1. Clean all parts in a solvent tank and dry with com-
pressed air prior to inspecting. Carefully inspect all
critical areas for any surface finish abnormalities:
Seal grooves, bearing grooves, thrust surfaces, rod
surface, housing bore and gear teeth.

Assembly
1. Gather all the components and tools into one loca-
tion prior to re-assembly. Use the cut away drawing
to reference the seal orientations.
2. Inspect the thrust washers (304) for rough or worn
edges and surfaces. Measure it’s thickness to make
sure it is within specifications (Not less than 0.092”
or 2.34 mm).

3121253 – JLG Lift – 4-35

 SECTION 4 - BOOM & PLATFORM

2. Install the thrust washer (304) onto shaft (2) and end 4. Using a seal tool install the main pressure seal (205)
cap (4). onto shaft (2) and end cap (4). Use the seal tool in a
circular motion.

3. Install the wiper seal (304.1/green 0-ring) into it’s 5. Install the wear guide (302) on the end cap (4) and
groove on the shaft (2) and end cap (4) around the shaft (2).
outside edge of the thrust washer (304).

6. Install the inner T-seal (200) into the piston (3) using
a circular motion.

Install the outer T-seal (202) by stretching it around

the groove in a circular motion.

4-36 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

Each T-seal has 2 back-up rings (see drawing for ori- 7. Insert the piston (3) into the housing (1) as shown,
entation). until the outer piston seal (202) is touching inside
the housing bore.

Beginning with the inner seal (200) insert one end of

b/u ring in the lower groove and feed the rest in
using a circular motion. Make sure the wedged ends 8. Looking from the angle shown, rotate the piston (3)
overlap correctly. until the marks you put on the piston and the hous-
ing (1) during disassembly line up as shown. Using
Repeat this step for the outer seal (202). a rubber mallet, tap the piston into the housing up to
the point where the gear teeth meet.

3121253 – JLG Lift – 4-37

 SECTION 4 - BOOM & PLATFORM

9. Looking from the opposite end of the housing (1) 11. Looking from the view shown, use the existing tim-
you can see if your timing marks are lining up. When ing marks to line up the gear teeth on the shaft (2)
they do, tap the piston (3) in until the gear teeth with the gear teeth on the inside of the piston (3).
mesh together. Tap the piston into the housing the Now tap the flange end of the shaft with a rubber
rest of the way until it bottoms out. mallet until the gear teeth engage.

12. Install 2 bolts in the threaded holes in the flange.

10. Install the shaft (2) into the piston (3). Be careful not Using a bar, rotate the shaft in a clockwise direction
to damage the seals. Do not engage the piston gear until the wear guides are seated inside the housing
teeth yet. bore.

13. Install the stop tube onto the shaft end. Stop tube is
an available option to limit the rotation of an actua-
tor.

4-38 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

14. Coat the threads on the end of the shaft with anti- 17. Tighten the end cap (4). In most cases the original
seize grease to prevent galling. holes for the lock pins will line up.

18. Place the lock pins (109) provided in the Helac seal
15. Install the 0-ring (204) and back-up ring (207) into
kit in the holes with the dimple side up. Then, using
the inner seal groove on the end cap (4).
a punch, tap the lock pins to the bottom of the hole.

16. Thread the end cap (4) onto the shaft (2) end. Make
sure the wear guide stays in place on the end cap as 19. Insert the set screws (113) over the lock pins.
it is threaded into the housing (1). Tighten them to 25 in. lbs. (2.825 Nm).

3121253 – JLG Lift – 4-39

 SECTION 4 - BOOM & PLATFORM

Installing Counterbalance Valve Testing the Actuator

Refer to Figure 4-12., Rotator Counterbalance Valve. If the equipment is available, the actuator should be tested
on a hydraulic test bench. The breakaway pressure — the
1. Make sure the surface of the actuator is clean, free pressure at which the shaft begins to rotate — should be
of any contamination and foreign debris including approximately 400 psi (28 bar). Cycle the actuator at least
old Loctite. 25 times at 3000 psi (210 bar) pressure. After the 25 rota-
tions, increase the pressure to 4500 psi (315 bar) to check
2. Make sure the new valve has the O-rings in the for leaks and cracks. Perform the test again at the end of
counterbores of the valve to seal it to the actuator the rotation in the opposite direction.
housing.
TESTING THE ACTUATOR FOR INTERNAL
3. The bolts that come with the valve are grade 8 bolts. LEAKAGE
New bolts should be installed with a new valve. Loc- If the actuator is equipped with a counterbalance valve,
tite #242 should be applied to the shank of the three plug the valve ports. Connect the hydraulic lines to the
housing ports. Bleed all air from the actuator (see Installa-
bolts at the time of installation.
tion and Bleeding) Rotate the shaft to the end of rotation
4. Torque the 1/4-inch bolts 110 to 120 inch pounds at 3000 psi (210 bar) and maintain pressure. Remove the
hydraulic line from the non-pressurized side.
(12.4 to 13.5 Nm). Do not torque over 125 inch
pounds (14.1 Nm). Torque the 5/16-inch bolts 140 Continuous oil flow from the open housing port indicates
inch pounds (15.8 Nm). Do not torque over 145 inch internal leakage across the piston. Replace the line and
pounds (16.3 Nm). rotate the shaft to the end of rotation in the opposite direc-
tion. Repeat the test procedure outlined above for the
other port. If there is an internal leak, disassemble, inspect
and repair.

4-40 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

Figure 4-12. Rotator Counterbalance Valve

3121253 – JLG Lift – 4-41

 SECTION 4 - BOOM & PLATFORM

Installation and Bleeding 1. Connect a 3/16" inside diameter x 5/16" outside

diameter x 5 foot clear, vinyl drain tube to each of the
After installation of the actuator on the equipment, it is two bleed nipples. Secure them with hose clamps.
important that all safety devices such as tie rods or safety Place the vinyl tubes in a clean 5-gallon container to
cables are properly reattached. collect the 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 deter-
mine 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 exhib-

ited after the actuator is connected to the hydraulic sys-
tem. The following steps are recommended when a
minimum of two gallons (8 liters) is purged.

TYPICAL CONFIGURATION
OF ACTUATOR

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

nipples 1/4 turn. Hydraulically rotate the platform to
the end of rotation (either clockwise or counterclock-
wise), and maintain hydraulic pressure. Oil with
small air bubbles 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
hydraulic 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.

4-42 – JLG Lift – 3121253

 SECTION 4 - BOOM & PLATFORM

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 c. Disconnect hydraulic lines and bypass valve.
leak 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 internal 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 pol-
ish. Replacement parts may be needed.

f. Swollen seals and composite bearings caused f. Re-build the actuator. Use fluid that is compati-
by incompatible hydraulic fluid ble with seals and bearings.
2. Operation is erratic or not responsive a. Air in actuator a. Purge air from actuator. See bleeding proce-
dures.
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 during stroke not reach inside the housing
bore.
4. Selected position cannot be maintained a. Control or counterbalance valve has internal a. Disconnect hydraulic lines and bypass valve.
leak 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 internal 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 proce-

dures

3121253 – JLG Lift – 4-43

 SECTION 4 - BOOM & PLATFORM

NOTES:

4-44 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

SECTION 5. HYDRAULICS
5.1 LUBRICATING O-RINGS IN THE 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in
HYDRAULIC SYSTEM the fitting, making sure the entire o-ring is com-
When assembling connectors in the hydraulic that use o- pletely saturated.
ring fittings, it is necessary to lubricate all fittings with
hydraulic oil prior to assembly. To lubricate the fittings, use
one of the following procedures.

NOTE: All O-ring fittings must be pre-lubricated with hydrau-

lic oil prior to assembly.

Cup and Brush

The following is needed to correctly oil the o-ring in this
manner:

• 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.

3121253 – JLG Lift – 5-1

 SECTION 5 - HYDRAULICS

Dip Method Spray Method

NOTE: This method works best with Face Seal o-rings, but This method requires a pump or trigger spray bottle.
will 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
2. Hold the fitting over a suitable catch can.
manner:
3. Spray the entire o-ring surface with a medium coat
• A small leak proof container of 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 even coat of oil.
in able to immerse more of the fitting into the satu-
rated sponge. This will also cause more oil to be dis-
persed from the sponge.

5-2 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

5.2 HYDRAULIC CYLINDERS GLAND SEAL DISASSEMBLY

Disassembly 3 4 5

NOTE: Disassembly of the cylinder should be performed on 2

a clean work surface in a dirt free work area. 1

1. Drain the oil from the cylinder.

2. Place the cylinder in a suitable holding fixture.
3. Position the cylinder vertically or horizontally.
4. Use the bottom and pin hole to prevent the cylinder
from turning and secure the axis.

NOTE: If there is a valve block that interferes with securing

the cylinder, remove the block.)
8 7 6
5. Unscrew the cylinder head.
6. Unscrew the gland 1 or 2 times with a spanner tool. 1. Dust Ring 5. Bushing
2. Retaining Ring 6. O-ring
ROD DISASSEMBLY 3. Backup Ring 7. Backup Ring
4. Rod Seal 8. O-ring

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL- Figure 5-1. Gland Seal Disassembly
INDER ROD, GLAND AND PISTON. AVOID PULLING THE ROD OFF-
CENTER, WHICH CAN CAUSE DAMAGE TO THE PISTON AND CYL-
INDER BARREL SURFACE. 1. Withdraw the rod seal carefully with a tool which is
not sharp so as to not damage the seals.
7. With the tube clamped securely, apply the pressure 2. Remove the retaining ring with a screwdriver prior to
to the devise and withdraw the Rod assembly from removing the dust wiper.
the cylinder barrel.
3. Since the dust wiper is pressurized, tap it and then
8. Withdraw the piston nut piston gland as below. withdraw the dust wiper by using a tool such as a
ROD ASSEMBLY GLAND PISTON NUT screwdriver.

3121253 – JLG Lift – 5-3

 SECTION 5 - HYDRAULICS

21

21
5
4
7
6
3
8 10
9
11
14
12 16*
13
15 22
19
20
19

18**

23

** 23

17 ***

* Torque 25-30 ft.lbs. (34-40.5 Nm) Max

1
** Torque 20 ft.lbs. (27 Nm) Max
*** Torque 4-5 ft.lbs. (5.4-6.8 Nm) Max
1001107886-D

1. Tube Assembly 7. Backup Ring 13. Piston Seal 19. Plug

2. Rod Assembly 8. Bushing 14. O-ring 20. Orifice
3. Gland 9. O-ring 15. Hex Nut 21. Bearing
4. Dust Wiper 10. Backup Ring 16. Counterbalance Valve 22. Plug
5. Retaining Ring 11. O-ring 17. Poppet Valve 23. Bearing
6. Rod Seal 12. Piston 18. Check Valve

Figure 5-2. Tower Lift Cylinder

5-4 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

23

23

5
4
7
6
8
3
11
10
9

16 18*
17 22
14 24 21
12 21
13 20**
15

23
1

**
19 ***
* Torque 25-30 ft.lbs. (34-40.5 Nm) Max
** Torque 20 ft.lbs. (27 Nm) Max
23
*** Torque 4-5 ft.lbs. (5.4-6.8 Nm) Max
1001106880-D

1. Tube Assembly 6. Rod Seal 11. O-ring 16. Spacer 21. Plug
2. Rod Assembly 7. Backup Ring 12. Piston 17. O-ring 22. Orifice
3. Gland 8. Bushing 13. Piston Seal 18. Counterbalance Valve 23. Bearing
4. Dust Wiper 9. O-ring 14. O-ring 19. Poppet Valve 24. Plug
5. Retaining Ring 10. Backup Ring 15. Hex Nut 20. Check Valve

Figure 5-3. Upper Lift Cylinder

3121253 – JLG Lift – 5-5

 SECTION 5 - HYDRAULICS

16

16 5
4
7
6
3
8
11
10
9

13
14
12
15 16

17 1

16

17

1001105989-B

1. Tube Assembly 6. Rod Seal 11. O-ring 16. Bearing

2. Rod Assembly 7. Backup Ring 12. Piston 17. Plug
3. Gland 8. Bushing 13. Piston Seal
4. Dust Wiper 9. O-ring 14. O-ring
5. Retaining Ring 10. Backup Ring 15. Hex Nut

Figure 5-4. Master Cylinder

5-6 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

16

16
5
4
7
6
3
8
11
10
9

21

13 19 19 18*
14 20
12

20
15

17*
16

1
16

* Torque 25-30 ft.lbs. (34-40.5 Nm) Max 1001105153-C

1. Tube Assembly 6. Rod Seal 11. O-ring 16. Bearing 21. Phase Valve
2. Rod Assembly 7. Backup Ring 12. Piston 17. Counterbalance Valve
3. Gland 8. Bushing 13. Piston Seal 18. Counterbalance Valve
4. Dust Wiper 9. O-ring 14. O-ring 19. Plug
5. Retaining Ring 10. Backup Ring 15. Hex Nut 20. Plug

Figure 5-5. Level Cylinder

3121253 – JLG Lift – 5-7

 SECTION 5 - HYDRAULICS

24

24

17
5
4
7
6
16 3
8
10
13 9
14 11
12
15

1 18**
20*
21

21
23
22
21 21
* Torque 18-20 ft. lbs. (24.5-27 Nm) Max
** Torque 25-30 ft.lbs. (34-40.5 Nm) Max
19**
1001106878-C

1. Tube Assembly 6. Rod Seal 11. O-ring 16. Spacer 21. Plug
2. Rod Assembly 7. Backup Ring 12. Piston 17. O-ring 22. Dust Plug
3. Gland 8. Bushing 13. Piston Seal 18. Counterbalance Valve 23. Dust Plug
4. Dust Wiper 9. O-ring 14. O-ring 19. Counterbalance Valve 24. Bearing
5. Retaining Ring 10. Backup Ring 15. Hex Nut 20. Load Shuttle Valve

Figure 5-6. Telescope Cylinder - AJ

5-8 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

18

18
2

5
4
7
6
3
8
11
9
10

20
14 19*
13
12
15
14
16

21

19*
1

17

* Torque 25-30 ft.lbs. (34-40.5 Nm) Max 17

1. Tube Assembly 6. Rod Seal 11. O-ring 16. Hex Nut 21. Plug
2. Rod Assembly 7. Backup Ring 12. Piston 17. Bearing
3. Gland 8. Bushing 13. Piston Seal 18. Bearing
4. Dust Wiper 9. O-ring 14. Piston Ring 19. Counterbalance Valve
5. Retaining Ring 10. Backup Ring 15. O-ring 20. Plug

Figure 5-7. Jib Cylinder

3121253 – JLG Lift – 5-9

 SECTION 5 - HYDRAULICS

17
2

17 5
4
3
10
9
11
8
7
6

18

18
13
14
12
15

16

16
1001108310-B

1. Tube Assembly 6. Rod Seal 11. O-ring 16. Bearing

2. Rod Assembly 7. Backup Ring 12. Piston 17. Bearing
3. Gland 8. Bushing 13. Piston Seal 18. Plug
4. Dust Wiper 9. O-ring 14. O-ring
5. Retaining Ring 10. Backup Ring 15. Hex Nut

Figure 5-8. Steer Cylinder

5-10 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

24

24

2
16

17
5
4
7
6
13 3
8
14 10
12 9
15 11

1 18**
20*
21

21
23
22
21 21
* Torque 18-20 ft. lbs. (24.5-27 Nm) Max
19**
** Torque 25-30 ft.lbs. (34-40.5 Nm) Max
1001106879-D

1. Tube Assembly 6. Rod Seal 11. O-ring 16. Spacer 21. Plug
2. Rod Assembly 7. Backup Ring 12. Piston 17. O-ring 22. Dust Plug
3. Gland 8. Bushing 13. Piston Seal 18. Counterbalance Valve 23. Dust Plug
4. Dust Wiper 9. O-ring 14. O-ring 19. Counterbalance Valve 24. Bearing
5. Retaining Ring 10. Backup Ring 15. Hex Nut 20. Load Shuttle Valve

Figure 5-9. Telescope Cylinder - AJP

3121253 – JLG Lift – 5-11

 SECTION 5 - HYDRAULICS

4. Withdraw the O-ring and back up ring carefully as 11. Inspect the cylinder head outside diameter for dam-
not to damage the seals. age, ovality and tapering. If necessary, replace it.

5. It is impossible to disassemble the bushing because 12. Inspect rod and tube bearings for signs of excessive
it is pressed on. Remove it by using a press. wear or damage.

PISTON SEAL DISASSEMBLY Assembly

PISTON SEAL NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. Refer to the JLG parts man-
ual.
O-RING
GLAND, PISTON SEAL ASSEMBLY
1. Install the new rod seal into the applicable cylinder
gland grooves by hand.

2. Use a soft mallet to tap a new wiper seal into the

applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head gland
1. The piston seal is used in pairs and the ring at the groove.
outer diameter is easily removed by hand. Remove 3. Place the o-ring and back up seal in the outside
the inner rubber ring carefully with the disassembly grooves of the cylinder gland.
tool so as not to cause damage to a processed
good. 4. Install a washer ring onto the rod and carefully install
the gland on the rod ensuring that the wiper and rod
2. Carefully remove the o-ring and back up ring with seals are not damaged or dislodged. Push the head
the disassembly tool as not to cause damage to the gland along the rod to the rod end, as applicable.
seals.
5. Carefully slide the piston spacer on the rod.
Cleaning and Inspection
NOTE: The main boom telescope cylinder piston has an o-
1. Clean all parts thoroughly in an approved cleaning ring installed inside the spacer.
solvent.
6. If applicable, correctly place the o-ring in the inner
2. Inspect the rod threads for the additional damage. If piston diameter groove. The back up ring side fac-
necessary, dress rod threads. ing the o-ring is grooved.
3. Inspect the inside of the cylinder barrel for any dam-
age. Inspect the inside diameter for tapering or oval- GLAND, PISTON, PISTON NUT ASSEMBLY
ity.
1. Clamp the rod assembly
4. Inspect the barrel threads for the damage and dress
2. Use a guide jig so as not to cause damage to the
threads as necessary.
inner seal of the gland and assemble it.
5. Inspect the piston surface for the damage. Replace
the piston if necessary. ROD ASSEMBLY
GUIDE JIG
6. Inspect the piston threads for damage.

7. Inspect the seal and o-ring grooves for burrs and

sharp edges. Dress the surface as necessary.
GLAND
8. Inspect the cylinder head inside diameter for dam-
age, ovality and tapering. Replace as necessary. 3. Assemble the piston onto the rod assembly
9. Inspect the head threads for damage. Dress the
threads as necessary. ROD ASSEMBLY GLAND PISTON NUT

10. Inspect the gland seal and o-ring grooves for the
burr and sharp edge. Dress the surface as neces-
sary.

5-12 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

4. Push the piston to the rod assembly to the end of Phase Check Cartridge
the thread and then install the piston nut. When
installing the piston nut, gland and valve, refer to The phase valve is a back-to-back pair of check valves,
Table 5-1, Cylinder Assembly Torques. one of which is mechanically actuated. This valve is
installed in the piston of the level cylinder and is used to
Table 5-1. Cylinder Assembly Torques keep the master and level cylinders in phase.

Torque Value * NOTE: Activating the Level Override Up circuit for 30 sec-
Cylinder onds can bleed the level circuit.
Cylinder Head Piston Nut
Tower Lift 463 lb. ft. (628 Nm) 267 lb. ft. (362 Nm) TEST PROCEDURE
Upper Lift 550 lb. ft. (746 Nm) 528 lb. ft. (716 Nm) 1. Place the machine in the following position:
Master 463 lb. ft. (628 Nm) 267 lb. ft. (362 Nm)
• Firm and level surface
Level 463 lb. ft. (628 Nm) 267 lb. ft. (362 Nm)
• Upper boom horizontal (level)
Telescope (AJ) 318 lb. ft. (431 Nm) 267 lb. ft. (362 Nm)
• Upper boom fully retracted
Jib 405 lb. ft. (549 Nm) 267 lb. ft. (362 Nm)
Steer 463 lb. ft. (628 Nm) 267 lb. ft. (362 Nm) • Jib down
Telescope (AJP) 318 lb. ft. (431 Nm) 267 lb. ft. (362 Nm) • Platform empty
* All torque values ± 10% 2. With no load in the platform, activate Level Up for
approximately 20 seconds. If the Upper Boom rises,
the phase valve is not functioning correctly and must
Table 5-2. Cylinder Valve Torques
be replaced.
Cylinder Valve Ft. Lbs. Nm
Tower Lift Counterbalance 25-30 34-40.5
Poppet 19-21 25-28
Check Valve 20 27
Coil Nut 4-5 5-6
Upper Lift Counterbalance 25-30 34-40.5
Poppet 19-21 25-28
Check Valve 20 27
Coil Nut 4-5 5-6
Level Counterbalance 25-30 34-40.5
Telescope-AJ Counterbalance 25-30 34-40.5
Load Shuttle 18-20 24.5-27
Jib Counterbalance 25-30 34-40.5
Telescope-AJP Counterbalance 25-30 34-40.5
Load Shuttle 18-20 24.5-27

5. Assemble the rod assembly equipped with gland,

piston and piston nut to the barrel assembly hori-
zontally (avoid pushing it off-center, which could
cause damage to the piston seal or the outside of
the piston).

6. Push the gland thread until it meets the barrel

threads, and then assemble the gland to the barrel.

3121253 – JLG Lift – 5-13

 SECTION 5 - HYDRAULICS

5.3 PRESSURE SETTING PROCEDURE SWING RIGHT / LEFT – 750 PSI (52 BAR)

Adjustments made at the Main Valve Bank

MAIN PRESSURE RELIEF VALVE – 3000 PSI (207
BAR)

SWING RELIEF
VALVE

1. Install pressure gauge at port MP of Main Valve

Bank.

MAIN RELIEF
VALVE
1. Install pressure gauge at port MP of Main Valve
Bank.

2. Activate Swing Right or Left and hold to the turntable

stop. Take pressure reading.
3. After loosening the relief valve jam nut, adjust valve
clockwise to increase pressure or counterclockwise
to reduce pressure accordingly.

USE CAUTION NOT TO EXCEED A RELIEF VALVE SETTING OF 750

2. Actuate and hold Telescope In to “end of stroke” &
PSI (51 BAR) AS COMPONENTS OF THE SWING CIRCUIT CAN BE
take pressure reading.
DAMAGED.
3. After loosening relief valve jam nut, adjust valve
clockwise to increase setting or counter-clockwise to 4. Tighten relief valve jam nut and repeat step 2 to ver-
reduce the setting accordingly. ify setting.
4. Tighten relief valve jam nut and repeat step 2 to ver-
ify setting.

5-14 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

STEER RIGHT – 1400 PSI (97 BAR)) STEER LEFT – 2000 PSI (138 BAR)

STEER LEFT
STEER RIGHT
RELIEF VALVE
RELIEF VALVE
1. Install pressure gauge at port MP of Main Valve
1. Install pressure gauge at port MP of Main Valve Bank.
Bank.

2. Activate Steer Left and hold to end of stroke. Take

2. Activate Steer Right and hold to end of stroke. Take pressure reading.
pressure reading.
3. After loosening relief valve jam nut, adjust valve
3. After loosening relief valve jam nut, adjust valve clockwise to increase pressure or counterclockwise
clockwise to increase pressure or counterclockwise to reduce pressure accordingly.
to reduce pressure accordingly.
4. Tighten relief valve jam nut and repeat step 2 to ver-
4. Tighten relief valve jam nut and repeat step 2 to ver- ify setting.
ify setting.

3121253 – JLG Lift – 5-15

 SECTION 5 - HYDRAULICS

Adjustments made at the Boom Function JIB LIFT DOWN – 1200 PSI (83 BAR)
Valve Bank
JIB LIFT UP – 2000 PSI (138 BAR)

JIB DOWN
RELIEF VALVE
1. Install pressure gauge at port MP of Main Valve
JIB UP Bank.
RELIEF VALVE
1. Install pressure gauge at port MP of Main Valve
Bank.

2. Activate Jib Lift Down and hold to end of stroke.

Take pressure reading.
3. After loosening relief valve jam nut, adjust valve
2. Activate Jib Lift Up and hold to end of stroke. Take clockwise to increase pressure or counterclockwise
pressure reading. to reduce pressure accordingly.

3. After loosening relief valve jam nut, adjust valve 4. Tighten relief valve jam nut and repeat step 2 to ver-
clockwise to increase pressure or counterclockwise ify setting.
to reduce pressure accordingly.
4. Tighten relief valve jam nut and repeat step 2 to ver-
ify setting.

5-16 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

PLATFORM LEVEL UP – 3000 PSI (207 BAR) • at port M15 of Boom Function Valve

PLATFORM
LEVEL UP
RELIEF VALVE
1. Refer to the Main Pressure Relief Valve procedure
and temporarily set Main Pressure Relief Valve to
• at port 15 of Boom Function Valve
3300 psi (227.5 Bar).
2. Disconnect, cap, & plug the platform level up hose &
adapter either at the platform level master cylinder
or at port 15 of the Boom Function Valve.

USE CAUTION WHEN DISCONNECTING / RECONNECTING HOSES

ON THE PLATFORM LEVEL CIRCUIT AS THIS CIRCUIT MAINTAINS
PRESSURE.

PLATFORM LEVEL
UP HOSE

3. Install a pressure gauge in one of the following loca-

tions:

3121253 – JLG Lift – 5-17

 SECTION 5 - HYDRAULICS

• at end of platform level up hose (do not use this loca- PLATFORM LEVEL DOWN – 1200 PSI (83 BAR)
tion if port 15 was chosen in step 2.)

PLATFORM LEVEL
UP HOSE
4. Activate Platform Level Up and hold. Take pressure
reading.
5. After loosening relief valve jam nut, adjust valve
clockwise to increase pressure or counterclockwise
to reduce pressure accordingly.
PLATFORM
6. Tighten relief valve jam nut. Repeat step 4 and verify
LEVEL DOWN
the pressure setting.
RELIEF VALVE
7. Reconnect the platform level up hose that was dis-
There are two different methods that can be used to set
connected in Step 2.
the Platform Level Down pressure, Option 1 and Option 2.
They are outlined as follows.

USE CAUTION WHEN DISCONNECTING / RECONNECTING HOSES Option 1:

ON THE PLATFORM LEVEL CIRCUIT AS THIS CIRCUIT MAINTAINS
PRESSURE 1. Install pressure gauge at port “M16” of Boom Func-
tion Valve Bank.
8. Refer to the Main Pressure Relief Valve procedure
and return Main Pressure Relief Valve to 3000 psi
(207 Bar).

2. Activate Upper Lift Up and hold to end of stroke.

3. Activate Platform Level Down to end of stroke. Take

pressure reading.

5-18 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

4. After loosening relief valve jam nut, adjust valve

clockwise to increase pressure or counterclockwise
to reduce pressure accordingly.
5. Tighten relief valve jam nut. Repeat step 3 and verify
the pressure setting.
Option 2:
1. Disconnect, cap, and plug the platform level down
hose and adapter either at the platform level master
cylinder, at the platform level slave cylinder, or at
port “16” of the Boom Function Valve Bank.

MASTER CYLINDER

PLATFORM LEVEL
DOWN HOSE

USE CAUTION WHEN DISCONNECTING / RECONNECTING HOSES

SLAVE CYLINDER ON THE PLATFORM LEVEL CIRCUIT AS THIS CIRCUIT MAINTAINS
PRESSURE
2. Install pressure gauge in one of the following loca-
tions:
• at port “16” of Boom Function Valve Bank
• at end of platform level down hose which was discon-
PLATFORM LEVEL nected in step 1 (do not use this location if port “16”
DOWN HOSE was chosen in step 1).
3. Activate Platform Level Down and hold. Take pres-
sure reading.
4. After loosening relief valve jam nut, adjust valve
clockwise to increase pressure or counterclockwise
to reduce pressure accordingly.
5. Tighten relief valve jam nut. Repeat step 3 and verify
the pressure setting.
6. Reconnect the platform level down hose that was
disconnected in step 1.

USE CAUTION WHEN DISCONNECTING / RECONNECTING HOSES

ON THE PLATFORM LEVEL CIRCUIT AS THIS CIRCUIT MAINTAINS
PRESSURE.

3121253 – JLG Lift – 5-19

 SECTION 5 - HYDRAULICS

NOTE: Coil Resistance (@ 68° F [20° C]) is 7.2 Ohms for Tower
Lift Up, Main Lift Up, and Flow Control. All other coils
have 9.8 Ohms resistance. These values are all ± 15%.

TT-SWG-RT
(OUTSIDE COIL)
BRK-PRES-SW

TWR-LFT-UP TT-SWG-LT
(INSIDE COIL)

BRAKE

STEER-RT
(OUTSIDE COIL)

MAIN-LFT-UP
STEER-LT
FLOW-CNTL (INSIDE COIL)

Figure 5-10. Main Control Valve - Sheet 1 of 2

5-20 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

13

14

14

14

12 9
5 11 11
10 4

10 4
3 11
2 11 11

4 10

14 7
8
6

Table 5-3. Main Valve Torques

# Description Ft. Lbs. Nm # Description Ft. Lbs. Nm

1 Pressure Switch 15 20 8 Relief Valve 20 27
2 Solenoid Valve 20 27 9 Relief Valve 20 27
3 Solenoid Valve 20 27 10 Coil 5 7
4 Solenoid Valve 25 34 11 Coil 5 7
5 Solenoid Valve 20 27 12 Valve 20 27
6 Relief Valve 20 27 13 Load Sense Valve 20 27
7 Relief Valve 20 27 14 Port Plug 15 20

Figure 5-11. Main Control Valve - Sheet 2 of 2

3121253 – JLG Lift – 5-21

 SECTION 5 - HYDRAULICS

NOTE: Coil Resistance (@ 68° F [20° C]) is

9.8 Ohms ± 15%.

TELE-OUT TELE-IN
(INSIDE COIL)
(OUTSIDE COIL)
PLTF-ROT-LT
(INSIDE COIL) JIB-LEFT
(INSIDE COIL)

PLTF-ROT-RT JIB-RIGHT
(OUTSIDE COIL) (OUTSIDE COIL)
JIB-UP
(OUTSIDE COIL)
JIB-DN
(INSIDE COIL)

PLATF-LVL-UP
(OUTSIDE COIL)
PLATF-LVL-DN
(INSIDE COIL)

Figure 5-11. Boom Function Valve - Sheet 1 of 2

5-22 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

16

13
13
5
3

13 3

4 12 13
8

10 15

7 13 13
2 11 11
16 E300AJ

11 11 3 13
E300AJP
9
2 11 11
11 11 1

13
AJP
6 ONLY

13 12 6 2 11 11

Table 5-4. Boom Function Valve Torques

# Description Ft. Lbs. Nm # Description Ft. Lbs. Nm # Description Ft. Lbs. Nm

1 Solenoid Valve 20 27 7 Manual Valve 25 34 13 Port Plug 15 20
2 Solenoid Valve 20 27 8 Hand Pump 30 40.5 14 Port Plug 25 34
3 Relief Valve 20 27 9 Check Valve 20 27 15 Valve 20 27
4 Relief Valve 25 34 10 Check Valve 20 27 16 Screw 5 7
5 Relief Valve 20 27 11 Coil 5 7
6 Valve 20 27 12 Orifice Plug 4 5

Figure 5-12. Boom Function Valve - Sheet 2 of 2

3121253 – JLG Lift – 5-23

 SECTION 5 - HYDRAULICS

A
HYDRAULIC
TANK

ELECTRIC
MOTOR &
PUMP

MAIN
CONTROL
VALVE

BOOM
FUNCTION
VALVE

c
BOOM
FUNCTION PUMP
VALVE HANDLE

ELECTRIC
MOTOR &
PUMP

Torque Ft-Lbs. Nm
A 14-18 19-24.5
B B 17-23 23-31
C 6-9 8-12
D 16-20 22-27

Figure 5-12. Hydraulic Components Location

5-24 – JLG Lift – 3121253

 SECTION 5 - HYDRAULICS

5.4 INITIAL HYDRAULIC PUMP START-UP 4. Insert the other end of the pressure test hose into
the hydraulic reservoir’s breather/filler port.
PROCEDURE
This procedure must be used when the hydraulic pump or
pump/motor assembly is removed or replaced to ensure
there is no air trapped in the hydraulic system. Having air
in the system can cause damage to the pump.

Procedure
1. Fill the hydraulic reservoir approximately 3/4 full of
hydraulic fluid.

NOTE: Steps 5 and 6 require an assistant.

5. From the Ground Control Console, momentarily (1

second maximum) activate the platform rotate
switch and release.

2. Unscrew the breather/filler cap from the reservoir.

3. Connect a pressure test hose to the MP port on the
Main Control Valve.

3121253 – JLG Lift – 5-25

 SECTION 5 - HYDRAULICS

6. Continue activating the platform rotate switch NOTE: An audible change in the tone of the gear pump
momentarily until the assistant sees a clear, uniform should be heard when the air is purged from the
stream of hydraulic fluid flowing from the test hose gear pump.
into the hydraulic reservoir.
7. Disconnect the pressure test hose from the MP port
on the Main Control Valve.
8. Remove the hose end from the hydraulic reservoir’s
breather/filler port.
9. Install the breather/filler cap.

5-26 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

SECTION 6. JLG CONTROL SYSTEM

6.1 JLG CONTROL SYSTEM ANALYZER KIT The JLG designed Control System is a 48 volt based
motor control unit installed on the boom lift.
INSTRUCTIONS The JLG Control System has reduced the need for
exposed terminal strips, diodes and trimpots and provides
Introduction simplicity in viewing and adjusting the various personality
settings for smooth control of: acceleration, deceleration,
creep and max.-speed for all boom, drive, and steering
functions.
WHEN INSTALLING A NEW POWER MODULE CONTROLLER ON
THE MACHINE, IT WILL BE NECESSARY TO PROGRAM THE CON- The upper lift, swing, and drive are controlled by individual
TROLLER FOR THE PROPER MACHINE CONFIGURATION, INCLUD- joysticks, with steering being controlled by a rocker switch
ING OPTIONS. built into the top the drive joystick. To activate Drive, Lift,
and Swing simply pull up on the slide lock location on the
joystick and move the handle into the direction desired.
The motor controller will control current output, as pro-
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- grammed for smooth operation and maximum cycle time.
TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- Ground control speeds for all boom functions can also be
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- programmed into the motor controller. The motor control-
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. REC- ler also features an adjustable time limit for positive trac-
OMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A tion.
MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE
FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

Analyzer Display

Enter Key
Escape Key
Stores and selects Top Level,
To return home or
Sub Level, and item menus
access previous menu

Left & Right Arrow Keys

Up & Down Arrow Keys
Used to move between Top Level,
Value Selector
Sub Level, and item menus

Figure 6-1. Hand Held Analyzer

3121253 – JLG Lift – 6-1

 SECTION 6 - JLG CONTROL SYSTEM

The JLG Control System controller has a built in LED to Using the Analyzer
indicate any faults. The system stores recent faults which
may be accessed for troubleshooting. Optional equip- With the machine power on and the analyzer connected
ment includes an hour meter, beacon light, function cut- properly, the analyzer will display the following:
out, and ground alarm. These options may be added later
but must be programmed into the motor controller when
installed.
The Control System may be accessed by using a custom
HELP:
designed, hand held analyzer (Analyzer Kit, JLG P/N PRESS ENTER
2901443 or separately, Analyzer, JLG P/N 1600244 &
Cable, JLG P/N 1600633) which will display two lines of
information at a time, by scrolling through the program.

NOTE: Each module has a label with the JLG part number
and a serial number which contains a date code.

The following instructions are for using the hand held ana-
lyzer.

To Connect the JLG Control System Analyzer

1. Connect the four pin end of the cable supplied with
the analyzer, to the motor controller module located
in the platform box or at the power module and con-
nect 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 back-
wards. HELP:
PRESS ENTER
2. Power up the Control System by turning the lower
key to the platform or ground position and pulling At this point, using the RIGHT and LEFT arrow keys, you
both emergency stop buttons on. can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.

6-2 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

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) Pressing ENTER with any of the above displayed menus,
CALIBRATIONS (view only) will display additional sub-menus within the selected
If you press ENTER, at the HELP: PRESS ENTER display, menu. In some cases, such as DRIVE, the next level is the
and a fault is present, the analyzer display will scroll the parameter or information to be changed. Refer to the flow
fault across the screen. If there was no fault detected, the chart for what menus are available within the top level
display will read: HELP: EVERYTHING OK. If powered up menus. You may only view the personality settings for
at the ground station, the display will read: GROUND OK. selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the
If ENTER is pressed again, the display moves to the fol- ESC. key.
lowing display:
Changing the Access Level of the Hand Held
Analyzer
LOG: (XXX) When the analyzer is first connected, you will be in access
XX: XXXXXXXXXXXX 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 can-
not be accidentally altered. To change the access level,
the correct password must be entered. To enter the pass-
word, scroll to the ACCESS LEVEL menu. For example:

access l evel :
code 00000

LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the sys-
tem 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 ESC. two times. STARTUP
(2/1) indicates a power up.

ACCESS LEVEL:
CODE 00000

3121253 – JLG Lift – 6-3

 SECTION 6 - JLG CONTROL SYSTEM

Press ENTER to select the ACCESS LEVEL menu. Adjusting Parameters Using the Hand Held
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Analyzer
Then using the RIGHT arrow key, position the cursor to Once you have gained access to level 1, and a personality
the right one space to enter the second digit of the pass- item is selected, press the UP or DOWN arrow keys to
word. adjust its value, for example:
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
Once the correct password is displayed, press ENTER.
The access level should display the following, if the pass- Dr ive:
word was entered correctly: ACCEL 1.5s

MENU:
ACCESS LEVEL 1

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
MENU: the value is at the minimum value for any particular per-
ACCESS LEVEL 1 sonality. If the value does not change when pressing the
Repeat the above steps if the correct access level is not up and down arrows, check the access level to ensure
displayed or you can not adjust the personality settings. you are at access level 1.

6-4 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Machine Setup There is a setting that JLG strongly recommends that you
do not change. This setting is so noted below:
When a machine digit item is selected, press the UP or
ELEVATION CUTBACK
DOWN arrow keys to adjust its value, for example:

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER-

GROUND ALARM: FORMANCE OF YOUR MACHINE.
2=DRIVE

ITS IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC-

TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-
WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI-
CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOM-
MENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A
MINIMUM DISTANCE OF 12 INCHES (30.5CM) AWAY FROM
THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
NENTS 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
LEVEL VEHICLE
machine was equipped with a ground alarm and you YES:ENTER, NO:ESC
wanted it to sound when driving. There are certain set-
tings 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 Table 6-3, 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 person-
ality 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 mea-
surements

3121253 – JLG Lift – 6-5

 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-2. Platform Control Module Location - Sheet 1 of 2

6-6 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

MATING MATING MATING MATING

POSITION PIN TYPE POSITION PIN TYPE
CONNECTOR TERMINAL FUNCTION CONNECTOR TERMINAL FUNCTION
4460226 1 ANALYZER PWR (12V) POWER OUTPUT 4460226 1 FSWIN DIGITAL INPUT
4460226 2 RS-232 RECEIVE SERIAL INPUT 4460226 2 SOFT TOUCH O/R INPUT DIGITAL INPUT
J1 4460321
4460226 3 RS-232 TRANSMIT SERIAL OUTPUT 4460226 3 PLATF LEVEL DOWN INPUT DIGITAL INPUT
4460226 4 ANALYZER GROUND POWER OUTPUT 4460226 4 PLATF LEVEL UP INPUT DIGITAL INPUT
4460226 1 N/C N/C N/C 4460226 5 BASKET ROT RIGHT INPUT DIGITAL INPUT
J2 4460326 4460226 2 N/C N/C N/C 4460226 6 BASKET ROT LEFT INPUT DIGITAL INPUT
4460226 3 LSS GROUND N/C N/C 4460226 7 TELESCOPE OUT INPUT DIGITAL INPUT
4460226 1 ANALOG POWER SUPPLY AN-PWR OUTPUT J7 4460434 4460226 8 TELESCOPE IN INPUT DIGITAL INPUT
4460226 2 ANALOG MAIN LIFT INPUT ANALOG INPUT 4460226 9 TOWER LIFT DOWN INPUT DIGITAL INPUT
4460226 3 ANALOG GROUND RETURN AN-PWR INPUT 4460226 10 N/C N/C N/C
4460226 4 ANALOG PWR SUPPLY AN-PWR OUTPUT 4460226 11 TOWER LIFT UP INPUT DIGITAL INPUT
J3 4460265 4460226 5 ANALOG T/T SWING INPUT ANALOG INPUT 4460226 12 TRACTION CONTROL INPUT DIGITAL INPUT
4460226 6 ANALOG GROUND RETURN AN-PWR INPUT 4460226 13 PLATF MOD GND RETURN POWER OUTPUT
4460226 7 ANA MAIN LIFT CENTER TAP ANALOG INPUT 4460226 14 POWER OUTPUT (12V) POWER OUTPUT
4460226 8 ANA SWING CENTER TAP ANALOG INPUT 4460226 15 PLATF MOD PWR SUP (12V) POWER INPUT
4460226 9 N/C N/C N/C 4460227 1 JIB UP INPUT DIGITAL INPUT
4460226 1 POWER OUTPUT (12V) POWER OUTPUT 4460227 2 JIB DOWN INPUT DIGITAL INPUT
4460226 2 N/C N/C N/C 4460227 3 JIB SIDESWING LEFT INPUT DIGITAL INPUT
4460226 3 CREEP SWITCH INPUT DIGITAL INPUT
J8 4460225
4460227 4 JIB SIDESWING RT INPUT DIGITAL INPUT
J4 4460225
4460226 4 ANALOG PUMP SPEED INPUT ANALOG INPUT 4460227 5 POWER OUTPUT (12V) POWER OUTPUT
4460226 5 N/C N/C N/C 4460227 6 LSS DIGITAL INPUT
4460226 6 ANALOG GROUND RETURN AN-PWR INPUT 4460227 1 DRIVE ORIENTATION INPUT DIGITAL INPUT
4460226 1 ANALOG PWR SUPPLY AN-PWR OUPUT 4460227 2 HORN INPUT DIGITAL INPUT
4460226 2 ANALOG DRIVE INPUT ANALOG INPUT 4460227 3 N/C DIGITAL INPUT
4460226 3 ANALOG GROUND RETURN AN-PWR INPUT
J9 4460225
4460227 4 N/C DIGITAL INPUT
4460226 4 STEER LEFT INPUT DIGITAL INPUT 4460227 5 POWER OUTPUT (12V) POWER OUTPUT
J5 4460265 4460226 5 STEER RIGHT INPUT DIGITAL INPUT 4460227 6 N/C DIGITAL INPUT
4460226 6 POWER OUTPUT (12V) POWER OUPUT 4460227 1 N/C N/C N/C
4460226 7 ANALOG CENTER TAP ANALOG INPUT 4460227 2 CAN HIGH SERIAL I/O
4460226 8 N/C N/C N/C
J11 4460321
4460227 3 CAN LOW SERIAL I/O
4460226 9 N/C N/C N/C 4460227 4 CAN SHIELD POWER DRAIN
4460227 1 CREEP INDICATOR DIGITAL OUPUT
4460227 2 LSS INDICATOR DIGITAL OUPUT
4460227 3 PLATFORM ALARM DIGITAL OUPUT
4460227 4 TRACTION CNTL INDICATOR DIGITAL OUPUT
J6 4460265 4460227 5 ENABLE INDICATOR DIGITAL OUPUT
4460227 6 FAULT INDICATOR DIGITAL OUPUT
4460227 7 DRIVE ORIENT INDICATOR DIGITAL OUPUT
4460227 8 GROUND RETURN POWER INPUT
4460227 9 TILT INDICATOR DIGITAL OUPUT

Figure 6-3. Platform Control Module Location - Sheet 2 of 2

3121253 – JLG Lift – 6-7

 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-4. Ground Control Module Location - Sheet 1 of 2

6-8 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

MATING MATING
POSITION TERMINAL PIN TYPE POSITION TERMINAL PIN TYPE
CONNECTOR FUNCTION CONNECTOR FUNCTION
4460226 1 N/C N/C N/C 4460227 1 TOWER LIFT UP INPUT DIGITAL INPUT
4460226 2 CAN HIGH (1) SERIAL I/O 4460227 2 TOWER LIFT DOWN INPUT DIGITAL INPUT
J1 4460321
4460226 3 CAN LOW (1) SERIAL I/O 4460227 3 MAIN LIFT UP INPUT DIGITAL INPUT
4460226 4 CAN SHIELD (1) POWER DRAIN 4460227 4 MAIN LIFT DOWN INPUT DIGITAL INPUT
4460226 1 N/C N/C N/C 4460227 5 T/T SWING LEFT INPUT DIGITAL INPUT
4460226 2 CAN HIGH (1) SERIAL I/O 4460227 6 T/T SWING RIGHT INPUT DIGITAL INPUT
J2 4460321
4460226 3 CAN LOW (1) SERIAL I/O 4460227 7 PLATF LEVEL UP INPUT DIGITAL INPUT
4460226 4 CAN SHIELD (1) POWER DRAIN J7 4460434 4460227 8 PLATF LEVEL DOWN INPUT DIGITAL INPUT
4460226 1 TOWER LIFT UP COIL DIGITAL OUTPUT PWM2 4460227 9 TELESCOPE IN INPUT DIGITAL INPUT
4460226 2 STEER LEFT COIL DIGITAL OUTPUT 4460227 10 TELESCOPE OUT INPUT DIGITAL INPUT
4460226 3 STEER RIGHT COIL DIGITAL OUTPUT 4460227 11 BASKET ROT LEFT INPUT DIGITAL INPUT
4460226 4 MAIN LIFT UP COIL DIGITAL OUTPUT PWM4 4460227 12 BASKET ROT RIGHT INPUT DIGITAL INPUT
4460226 5 MAIN LIFT DOWN COIL DIGITAL OUTPUT PWM6 4460227 13 JIB UP INPUT DIGITAL INPUT
4460226 6 TOWER LIFT DOWN COIL DIGITAL OUTPUT PWM1 4460227 14 POWER OUTPUT (12V) POWER OUTPUT
4460226 7 T/T SWING LEFT COIL DIGITAL OUTPUT PWM6 4460227 15 JIB DOWN INPUT DIGITAL INPUT
J4 4460434 4460226 8 T/T SWING RIGHT COIL DIGITAL OUTPUT PWM8
J8 4460320
4460226 1 CHGR INTERLOCK INPUT DIGITAL INPUT
4460226 9 PLATF LEVEL UP COIL DIGITAL OUTPUT PWM9 4460226 2 POWER OUTPUT (12V) POWER OUTPUT
4460226 10 PLATF LEVEL DOWN COIL DIGITAL OUTPUT 4460227 1 ELEVATION LIMIT INPUT DIGITAL INPUT
4460226 11 TELESCOPE IN COIL DIGITAL OUTPUT
J9 4460320
4460227 2 POWER OUTPUT (12V) POWER OUTPUT
4460226 12 N/C (SPARE PWM) DIGITAL OUTPUT PWM7 4460226 1 DRIVE ORIENT SW INPUT DIGITAL INPUT
4460226 13 TELESCOPE OUT COIL DIGITAL OUTPUT
J10 4460320
4460226 2 POWER OUTPUT (12V) POWER OUTPUT
4460226 14 GROUND RETURN POWER INPUT 4460227 1 LSS INDICATOR DIGITAL OUTPUT
4460226 15 FLOW CONTROL COIL DIGITAL OUTPUT PWM4 4460227 2 N/C DIGITAL OUTPUT
4460227 1 PLATF ROTATE LEFT COIL DIGITAL OUTPUT 4460227 3 NOT POPULATED DIGITAL OUTPUT
4460227 2 JIB SWING LEFT COIL DIGITAL OUTPUT 4460227 4 GROUND ALARM POWER DIGITAL OUTPUT
4460227 3 BRAKE RELEASE COIL DIGITAL OUTPUT J11 4460265 4460227 5 NOT POPULATED DIGITAL OUTPUT
4460227 4 JIB UP COIL DIGITAL OUTPUT 4460227 6 N/C DIGITAL OUTPUT
J5 4460265 4460227 5 PLATF ROTATE RIGHT COIL DIGITAL OUTPUT 4460227 7 N/C DIGITAL OUTPUT
4460227 6 MOTION ALARM (PWM) DIGITAL OUTPUT PWM3 4460227 8 GROUND RETURN POWER INPUT
4460227 7 JIB SWING RIGHT COIL DIGITAL OUTPUT 4460227 9 N/C DIGITAL OUTPUT
4460227 8 GROUND RETURN POWER INPUT 4460227 1 12V POWER INPUT POWER INPUT
4460227 9 JIB DOWN COIL DIGITAL OUTPUT 4460227 2 PLATF PWR PASS THRU POWER OUTPUT
4460226 1 N/C DIGITAL INPUT 4460227 3 12 POWER INPUT POWER INPUT
4460226 2 N/C DIGITAL INPUT
J12 4460225
4460227 4 PCB GROUND CONCTN POWER INPUT
4460226 3 N/C DIGITAL INPUT 4460227 5 PCB GROUND CONCTN POWER OUTPUT
4460226 4 N/C DIGITAL INPUT 4460227 6 PCB GROUND CONCTN POWER OUTPUT
J6 4460265 4460226 5 JIB SWING LEFT INPUT DIGITAL INPUT 4460227 1 CAN HIGH (2) SERIAL I/O
4460226 6 JIB SWING RIGHT INPUT DIGITAL INPUT J14 4460326 4460227 2 CAN LOW (2) SERIAL I/O
4460226 7 BRAKE SWITCH INPUT DIGITAL INPUT 4460227 3 CAN SHIELD (2) POWER DRAIN
4460226 8 POWER OUTPUT (12V) POWER OUTPUT 4460227 1 ANALYZER POWER POWER OUTPUT
4460226 9 N/C DIGITAL INPUT 4460227 2 ANALYZER RS-232 Rx SERIAL INPUT
J15 4460321
4460227 3 ANALYZER RS-232 Tx SERIAL INPUT
4460227 4 ANALYZER GROUND POWER INPUT

Figure 6-5. Ground Control Module Location - Sheet 2 of 2

3121253 – JLG Lift – 6-9

 SECTION 6 - JLG CONTROL SYSTEM

Figure 6-6. Power Module Location - Sheet 1 of 2

6-10 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

CONNECTOR PIN TAGNAME FUNCTION TYPE

1 PLTEMS PLATFORM EMS VBAT INPUT
2 GNDEMS GROUND EMS VBAT INPUT
3 FSW IN FOOTSWITCH DIGITAL INPUT
4 IGN GROUND MODULE POWER +12V OUTPUT
5 FSW OUT FOOTSWITCH SIGNAL PASSTHROUGH DIGITAL OUTPUT
6 IGN GROUND MODULE POWER +12V OUTPUT
J1
7 IGN TILT MODULE POWER +12V OUTPUT
8 GND GROUND MODULE GROUND GROUND INPUT
9 N/C NOT CONNECTED +12V OUTPUT
10 GND TILT MODULE GROUND GROUND INPUT
11 GND GROUND MODULE GROUND GROUND INPUT
12 N/C NOT CONNECTED GROUND INPUT
1 CONT MAIN CONTACTOR DIGITAL OUTPUT
2 FWD DRIVE FORWARD DIGITAL OUTPUT
3 REV DRIVE REVERSE DIGITAL OUTPUT
J2
4 N/C NOT CONNECTED GROUND INPUT
5 GND GROUND GROUND INPUT
6 N/C NOT CONNECTED GROUND INPUT
1 IGN SPEED ENCODER POWER +12V OUTPUT
2 SPD SPEED ENCODER SIGNAL DIGITAL INPUT
3 GND SPEED ENCODER GROUND GROUND INPUT
J3
4 DIR SPEED ENCODER DIRECTION DIGITAL INPUT
5 N/C NOT CONNECTED N/C N/C
6 N/C NOT CONNECTED N/C N/C
1 N/C NOT CONNECTED DIGITAL INPUT
J4
2 N/C NOT CONNECTED +12V OUTPUT
1 N/C NOT CONNECTED DIGITAL INPUT
J5
2 N/C NOT CONNECTED +12V OUTPUT
1 N/C NOT CONNECTED DIGITAL OUTPUT
2 N/C NOT CONNECTED DIGITAL OUTPUT
3 N/C NOT CONNECTED DIGITAL OUTPUT
4 N/C NOT CONNECTED DIGITAL OUTPUT
5 N/C NOT CONNECTED DIGITAL OUTPUT
6 N/C NOT CONNECTED DIGITAL OUTPUT
7 N/C NOT CONNECTED DIGITAL OUTPUT
J7 8 N/C NOT CONNECTED DIGITAL OUTPUT
9 N/C NOT CONNECTED DIGITAL INPUT
10 N/C NOT CONNECTED DIGITAL OUTPUT
11 N/C NOT CONNECTED N/C N/C
12 N/C NOT CONNECTED DIGITAL INPUT
13 N/C NOT CONNECTED DIGITAL OUTPUT
14 N/C NOT CONNECTED GROUND INPUT
15 N/C NOT CONNECTED +12V OUTPUT
1 N/C NOT CONNECTED N/C N/C
2 CANH CAN HIGH SERIAL I/O
J8
3 CANL CAN LOW SERIAL I/O
4 CANSHD CAN SHIELD GROUND INPUT
1 ANLPWR ANALYZER POWER +12V OUTPUT
2 ANLRX ANALYZER RS-232 Rx SERIAL INPUT
J9
3 ANLTX ANALYZER RS-232 Tx SERIAL OUTPUT
4 ANLGND ANALYZER GROUND GROUND INPUT
1 SHNTREF SHUNT REFERENCE ANALOG INPUT
P2 2 TRATCUR TRACTION CURRENT SHUNT ANALOG INPUT
3 PUMPCUR PUMP CURRENT SHUNT ANALOG INPUT

Figure 6-7. Power Module Location - Sheet 2 of 2

3121253 – JLG Lift – 6-11

 SECTION 6 - JLG CONTROL SYSTEM

CONNECTOR PIN TAG NAME FUNCTION TYPE

1 ENCPWR POWER OUTPUT (12V) POWER OUTPUT
2 SPD SPEED DIGITAL INPUT
3 GND GROUND RETURN POWER INPUT
J1 4 DIR DIRECTION DIGITAL INPUT
5 N/C N/C N/C N/C
6 N/C N/C N/C N/C

CONNECTOR PIN TAG NAME FUNCTION TYPE

1 N/C N/C N/C N/C
2 CANH CAN HIGH SERIAL I/O
J2 3 CANL CAN LOW SERIAL I/O
4 SHD CAN SHIELD POWER DRAIN

CONNECTOR PIN TAG NAME FUNCTION TYPE

1 N/C N/C N/C N/C
2 CANH CAN HIGH SERIAL I/O
J3 3 CANL CAN LOW SERIAL I/O
4 SHD CAN SHIELD POWER DRAIN

CONNECTOR PIN TAG NAME FUNCTION TYPE

1 FSWIN FOOR SWITCH INPUT DIGITAL INPUT

J4 2 ING 12V POWER INPUT POWER INPUT

3 GND PCB GROUND COONECTION POWER OUTPUT

CONNECTOR PIN TAG NAME FUNCTION TYPE

1 GND GROUND RETURN POWER INPUT
J5 2 ARMB ARMATURE B POWER OUTPUT
3 ARMA ARMATURE A POWER OUTPUT

Figure 6-8. Tilt Module Location

6-12 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

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

3121253 – JLG Lift – 6-13

 SECTION 6 - JLG CONTROL SYSTEM

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

6-14 – JLG Lift – 3121253

 MENU: HELP: (001)
HELP:PRESS ENTER SYSTEM OK

3121253
LOG: (XXX)
XX:XXXXXXXXXXXXX

MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:

DIAGNOSTICS DRIVE BOOM SYSTEM DATALOG VERSIONS

DRIVE: BOOM: SYSTEM: DATALOG: VERSIONS:

DRIVE 0% TOWER 0% TRACTION 0A MAX.TEMP 53c POWER vX.X

DRIVE: BOOM: SYSTEM: DATALOG: VERSIONS:

To Sheet 2 SPEED STOPPED 0% MAIN 0% PUMP 0A MIN.TEMP -6c PLATFORM vX.X

DRIVE: BOOM: SYSTEM: DATALOG: VERSIONS:

POSITRAC OFF SWING 0% VALVE 0.0A MAX.BATTERY 63V GROUND vX.X

DRIVE: BOOM: SYSTEM: DATALOG: VERSIONS:

STEER 0% LEVEL 0% BATTERY 50.4V ON XXXhXXm POSITILT vX.X

DRIVE: BOOM: SYSTEM: DATALOG: VERSIONS:

BRAKES LOCKED TELE 0% TEMPERATURE 27c DRIVE XXXhXXm ANALYZER vX.X

DRIVE: BOOM: SYSTEM: DATALOG:

CREEP ACTIVE ROTATE 0% FSW1 OPEN PUMP XXXhXXm

– JLG Lift –
DRIVE: BOOM: SYSTEM: DATALOG:
DOS LIM SW OP JIB (U/D) 0% FSW2 OPEN LIFT XXXhXXm

DRIVE: BOOM: SYSTEM: DATALOG:

DOS O//R SW OP JIB (L/R) 0% DRIVE CUTOUT OP SWING XXXhXXm

BOOM: SYSTEM: DATALOG:

PUMP POT 0% ELEV. CUTOUT OP TELE XXXhXXm

BOOM: SYSTEM: DATALOG:

CREEP ACTIVE DOS OFF RENTAL XXXhXXm

SYSTEM: DATALOG: 1
BRAKES LOW PRES. ERASE RENTAL
NOTE: The layout shown includes all possible analyzer screens.
Please note that some screens may not be available depending
SYSTEM:
upon machine configuration. MAN. RELEASE OP 1 - Only Available in Access Level 1

SYSTEM:
TILT 99.9',99.9'

Figure 6-9. Analyzer Flow Chart (Software Version 3.x) - Sheet 1 of 3

6-15
SECTION 6 - JLG CONTROL SYSTEM
6-16
From Sheet 1

MENU: ACTIVATE TESTS :

ACTIVATE TESTS YES: ENTER,NO:ESC

MENU: ACCESS LEVEL:

ACCESS LEVEL 1 CODE 00000

MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES DRIVE LIFT SWING TELE PLATFORM LEVEL PLATFORM ROTATE JIB STEER GROUND MODE

DRIVE: 2 LIFT : LIFT : 2 SWING: 2 TELE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE

: 2 JIB : 2 STEER: 2 GROUND MODE: 2

To Sheet 3 ACCEL 1. 5s TOWER LIFT MAIN LIFT ACCEL 2. 0s ACCEL 1. 0s ACCEL 1. 0s ACCEL 0. 5s ACCEL 1. 0s MIN SPEED 75% TWR LIFT UP 75%

DRIVE: 2 TOWER LIFT: MAIN LIFT : 2 SWING: 2 TELE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE
: 2 JIB : 2 STEER: 2 GROUND MODE: 2
DECEL 0. 5s ACCEL 1. 0s ACCEL 1. 0s DECEL 1. 5s DECEL 0. 5s DECEL 1. 0s DECEL 0. 5s DECEL 0. 5s MAX SPEED 100 % TWR LIFT DWN 55%

DRIVE: 2 TOWER LIFT: SWING: 2 TELE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE

: 2 JIB : 2 GROUND MODE: 2
MAIN LIFT :
MIN 3% DECEL 0. 5s DECEL 0. 3s MIN LEFT 5% MIN IN 22% MIN UP 15% MIN LEFT 13% MIN UP 13% MAIN LIFT 65%
SECTION 6 - JLG CONTROL SYSTEM

DRIVE: 2 TOWER LIFT: SWING: 2 TELE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE

: 2 JIB : 2 GROUND MODE
: 2
MAIN LIFT :
MAX 95% MIN UP 18% MIN UP 18% MAX LEFT 30% MAX IN 50% MAX UP 30% MAX LEFT 22% MAX UP 40% SWING 30%

DRIVE: 2 TOWER LIFT: SWING: 2 TELE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE

: 2 JIB : 2 GROUND MODE
: 2
MAIN LIFT :
ELEVATED MAX 10% MAX UP 83% MAX UP 80% CREEP LEFT 20% MIN OUT 16% MIN DOWN 10% MIN RIGHT 13% MIN DOWN 10% TELE 35%

DRIVE: 2 TOWER LIFT: SWING: 2 TELE: 2 PLATFORM LEVEL: 2 PLATFORM ROTATE

: 2 JIB : 2 GROUND MODE: 2
MAIN LIFT :
CREEP MAX 20% MIN DOWN 36% MIN RIGHT 5% MAX OUT 40% MAX DOWN22% MAX RIGHT 22% MAX DOWN26% PLT LEVEL 22%
CREEP UP 30%

DRIVE: 2 TOWER LIFT: SWING: 2 JIB : 2 GROUND MODE: 2

MAIN LIFT :
POSITRAC 10s MAX DOWN58% MIN DOWN 30% MAX RIGHT 30% MIN LEFT 13% PLT ROTATE 20%

– JLG Lift –
DRIVE: 2 SWING: JIB : 2 GROUND MODE : 2
MAIN LIFT :
POSITRAC 170 A MAX DOWN 63% CREEP RIGHT 20% MAX LEFT 23% JIB ( U/ D) 30%

JIB : 2 GROUND MODE : 2

MAIN LIFT :
CREEP DOWN 55% MIN RIGHT 13% JIB ( L/ R) 23%

JIB : 2
MAX RIGHT 23%

2 - Only Available in Access Level 2

NOTE: The layout shown includes all possible analyzer screens. Please note
that some screens may not be available depending upon machine
configuration.

Figure 6-10. Analyzer Flow Chart (Software Version 3.x) - Sheet 2 of 3

3121253
 From Sheet 2

3121253
MENU: MODEL NUMBER: 2 TILT: 2 DRIVE CUTOUT: 2 SOFTTOUCH CUTOUT 2 JIB: 2 GROUND ALARM: 2 PLATFORM ALARM: 2 LOAD: 2 LEVELinhibit: 2 MACHINE SETUP: 2
MACHINE SETUP 1=300 1=5Deg 0=CHARGER 0=NO 1=YES 0=NO 0=NO 0=NO 0=NO ALARM (dB) 90

MENU: 1 LEVEL VECHICLE? 1

LEVEL VEHICLE YES:ENTER,NO:ESC

MENU: 1 CALIBRATIONS: 1 CALIBRATIONS: 1

CALIBRATIONS CONTROLLER CALS MACHINE CALS

CONTROLLER CALS: 1 MACHINE CALS: 1

TEMPERATURE 49 BRAKE 60%

CONTROLLER CALS: 1 MACHINE CALS: 1

TRACTION I 1.28 FLOW@0% 30%

CONTROLLER CALS: 1 MACHINE CALS: 1

PUMP I 1.26 FLOW@100% 50%

CONTROLLER CALS: 1 MACHINE CALS: 1

TILTdelayIN 62! TLIFT@0% 30%

CONTROLLER CALS: 1 MACHINE CALS: 1

TILTdelayOUT 6! TLIFT@100% 50%

MACHINE CALS: 1
MLIFT@0% 30%
1 - Only Available in Access Level 1
MACHINE CALS: 1
MLIFT@100% 50% 2 - Only Available in Access Level 2
MACHINE CALS: 1
SWINGcalSw OFF

– JLG Lift –
MACHINE CALS: 1
SWINGL@0% 43%

MACHINE CALS: 1
SWINGL@100% 87%

MACHINE CALS: 1
SWINGR@0% 43%

MACHINE CALS: 1
SWINGR@100% 87%

MACHINE CALS: 1 NOTE: The layout shown includes all possible analyzer screens. Please note
SPEEDprop1 4
that some screens may not be available depending upon machine
MACHINE CALS: 1
SPEEDprop2 16
configuration.

MACHINE CALS: 1
SPEEDint 0.3

MACHINE CALS: 1
PLUGmax 60%

Figure 6-11. Analyzer Flow Chart (Software Version 3.x) - Sheet 3 of 3

6-17
SECTION 6 - JLG CONTROL SYSTEM
 SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number
NOTE: When configuring the E300 machine, the machine configuration must be completed before any personality set-
tings can be changed. Changing the personality settings first and then changing the model number of the machine
configuration will cause the personality settings to return to default values.
1 1 300 1
(Model #)
2 400

3 450

2 1 5Deg - reduces the maximum speed of all boom functions to creep when tilted and above 1
(Tilt Switch) elevation. Reduces drive speed to creep when tilted. Domestic and Japan

2 3Deg - reduces the maximum speed of all boom functions to creep when tilted and above
elevation. Reduces drive speed to creep when tilted. European and Australian

3 3Deg CUTOUT - drive and reduce boom functions to creep speed when tilted and above
elevation. Reduces drive speed to creep when tilted only. Option

4 3Deg CUTOUT BOOM - cuts out drive, telescope out, Main boom, lift up and reduces all
other boom functions to creep speed when tilted and above elevation. Option
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 tilted and above elevation.

3 0 CHARGER - Battery Charger Cutout-cuts out drive when the battery charger is plugged in. 0
(Drive Cutout)
1 CHARGER & BOOM - Battery Charger Cutout and Simultaneous Drive and Boom Func-
tions disabled above elevation. Europe and Australia

2 CHARGER & ELEV - Battery Charger Cutout and Drive Cutout above elevation. Option

4 0 NO - No Function Cutout 0
(Soft Touch)
1 BOOM & DRIVE - Cuts out all functions when switch opens. Option

5 0 NO - JIB Not installed. 0

(JIB)
1 YES - JIB installed which has up and down movements only. Option

2 SIDESWING - JIB installed which has up and down movements and side to side move-
ments. Option

6 0 NO - No ground alarm installed. 0

(Ground
Alarm) 1 DRIVE - Travel alarm- Sounds when the drive function is active. Option

2 LIFT DOWN - Descent Alarm- Sounds when either lift down is active. Option

3 BOOM & DRIVE - Motion alarm- Sounds when any function is active. Option

6-18 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-2. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

7 0 No - Sounds continuously when above elevation and tilted only. 0

(Platform Alarm)
1 Fault Code - Sounds continuously when above elevation and tilted, and in conjunction
with fault code flashes. Option

8 0 NO - No Load Cell Installed 0

(Load)
1 WARN ONLY - Warn if overload is detected

2 CUTOUT PLT - Cuts out Platform functions if overload is detected

3 CUTOUT ALL - Cuts out ALL functions if overload is detected

9 0 NO 0
(Level inhibit)
1 ELEV - Platform level can not operated when boom is raised above transport position
10 Adjusts output of alarm 90
(ALARM dB) Range 90 - 107 dB
1001115577-2

3121253 – JLG Lift – 6-19

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Personality Ranges/Defaults

Adjustment Default
Adjustment
Range Value
DRIVE
ACCEL 0.5 to 5 sec 1.5s
DECEL 0.1 to 2 sec 0.5s
MIN 0 to 25% 3%
MAX 0 to 100% 95%
ELEVATED MAX 0 to 25% 20%
CREEP MAX 0 to 45% 30%
POSITRAC 0 to 60 sec 10s
POSITRAC 50 to 250 amps 170A
LIFT
LOWER LIFT
ACCEL 0.5 to 5 sec 1.0s
DECEL 0.1 to 3.0 sec 0.5s
MIN UP 0 to 50% 18%
MAX UP 0 to 100% 83%
MIN DOWN 0 to 50% 36%
MAX DOWN 0 to 100% 58%
LIFT
UPPER LIFT
ACCEL 0.5 to 5 sec 1.0s
DECEL 0.1 to 3 sec 0.3s
MIN UP 0 to 50% 18%
MAX UP 0 to 100% 80%
CREEP UP 0 to 50% 30%
MIN DOWN 0 to 50% 20%
MAX DOWN 0 to 100% 63%
CREEP DOWN 0 to 80% 55%
SWING
ACCEL 0.5 to 5 sec 2.0s
DECEL 0.1 to 3 sec 1.5s
MIN LEFT 0 to 50% 5%
MAX LEFT 0 to 100% 30%
CREEP LEFT 0 to 100% 20%
MIN RIGHT 0 to 50% 5%
MAX RIGHT 0 to 100% 30%
CREEP RIGHT 0 to 100% 20%
TELE
ACCEL 0.5 to 5 sec 1.0s
DECEL 0.1 to 3 sec 0.5s
MIN IN 0 to 50% 22%
MAX IN 0 to 100% 45%

6-20 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-3. Personality Ranges/Defaults

Adjustment Default
Adjustment
Range Value
MIN OUT 0 to 50% 16%
MAX OUT 0 to 100% 35%
PLATFORM LEVEL
ACCEL 0.5 to 5 sec 1.0s
DECEL 0.1 to 3 sec 1.0s
MIN UP 0 to 50% 15%
MAX UP 0 to 80% 30%
MIN DOWN 0 to 50% 10%
MAX DOWN 0 to 80% 22%
PLATFORM ROTATE
ACCEL 0.1 to 5 sec 0.5s
DECEL 0.1 to 3 sec 0.5s
MIN LEFT 0 to 50% 13%
MAX LEFT 0 to 100% 22%
MIN RIGHT 0 to 50% 13%
MAX RIGHT 0 to 100% 22%
JIB
ACCEL 0.5 to 5.0 sec 1.0s
DECEL 0.1 to 3 sec 0.5s
MIN UP 0 to 50% 13%
MAX UP 0 to 100% 40%
MIN DOWN 0 to 50% 10%
MAX DOWN 0 to 100% 26%
MIN LEFT 0 to 50% 13%
MAX LEFT 0 to 100% 23%
MIN RIGHT 0 to 50% 13%
MAX RIGHT 0 to 100% 23%
STEER
MIN SPEED 0 to 100% 75%
MAX SPEED 0 to 100% 100%
GROUND MODE
L.LIFT UP 0 to 100% 75%
L.LIFT DOWN 0 to 100% 55%
UPPER LIFT 0 to 100% 65%
SWING 0 to 100% 30%
TELE 0 to 100% 35%
PLT.LEVEL 0 to 100% 22%
PLT.ROTATE 0 to 100% 20%
JIB (U/D) 0 to 100% 30%
JIB (L/R) 0 to 100% 23%
NOTE: Personality settings can be adjusted anywhere within the adjust-
ment range in order to achieve optimum machine performance.
1001115579-2

3121253 – JLG Lift – 6-21

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. E300 Diagnostic Fault Codes

Flash
DTC Fault Message Description
Code
001 00 EVERYTHING OK The "normal" help message in platform mode
002 00 GROUND MODE OK The "normal" help message in ground mode
0010 00 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Drive speed is limited to "ELEVATED MAX" while the vehicle is
out of transport position.
0011 00 FSW OPEN A drive or boom function has been selected but footswitch is
open.
0012 00 RUNNING AT CREEP - CREEP SWITCH OPEN All function speeds are limited to creep because the creep
switch is open.
0013 00 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION All function speeds are limited to creep because the vehicle is
tilted and above elevation.
0032 00 PUMP MOTOR AT CURRENT LIMIT Pump current has reached controller current limit or safe operat-
ing area limit.
0033 00 TRACTION MOTOR AT CURRENT LIMIT Traction current has reached controller current limit or safe
operating area limit.
0034 00 DRIVING AT CREEP - TILTED Drive speed is limited to creep because the vehicle is tilted.
211 21 POWER CYCLE The normal help message is issued at each power cycle.
212 21 KEYSWITCH FAULTY Both Platform and Ground modes are selected simultaneously.
213 21 FSW FAULTY Both Footswitch Inputs are closed for more then one second.
221 22 FUNCTION PROBLEM - HORN PERMANENTL Y SELECTED Input was CLOSED during startup
224 22 FUNCTION PROBLEM - STEER LEFT PERMANENTLY The Steer Left Switch was closed during power-up.
SELECTED
225 22 FUNCTION PROBLEM - STEER RIGHT PERMANENTLY The Steer Right Switch was closed during power-up.
SELECTED
227 22 STEER SWITCHES FAULTY Both Steer Left and Steer Right inputs are closed simultane-
ously.
2211 22 FSW INTERLOCK TRIPPED The Footswitch was closed for more then seven seconds.
2212 22 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH A drive function was selected with Footswitch open.
2213 22 STEER LOCKED - SELECTED BEFORE FOOTSWITCH A steer function was selected with Footswitch open.
2221 22 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOT- A lift / swing function was selected with Footswitch open.
SWITCH
2222 22 WAITING FOR FSW TO BE OPEN The Footswitch was closed during Platform selection.
2245 22 FUNCTION PROBLEM - JIB SWING LEFT PERMANENTLY Input was CLOSED during startup
SELECTED
2246 22 FUNCTION PROBLEM - JIB SWING RIGHT PERMANENTLY Input was CLOSED during startup
SELECTED
2247 22 FUNCTION PROBLEM - PLATFORM ROTATE LEFT PERMA- Input was CLOSED during startup
NENTLY SELECTED
2248 22 FUNCTION PROBLEM - PLATFORM ROTATE RIGHT PERMA- Input was CLOSED during startup
NENTLY SELECTED
2249 22 FUNCTION PROBLEM - JIB LIFT UP PERMANENTLY SELECTED Input was CLOSED during startup
2250 22 FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY Input was CLOSED during startup
SELECTED
2251 22 FUNCTION PROBLEM - TELESCOPE IN PERMANENTLY Input was CLOSED during startup
SELECTED

6-22 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. E300 Diagnostic Fault Codes

Flash
DTC Fault Message Description
Code
2252 22 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY Input was CLOSED during startup
SELECTED
2253 22 FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED Input was CLOSED during startup
2254 22 FUNCTION PROBLEM - SWING RIGHT PERMANENTLY Input was CLOSED during startup
SELECTED
2255 22 FUNCTION PROBLEM - MAIN LIFT UP PERMANENTLY Input was CLOSED during startup
SELECTED
2256 22 FUNCTION PROBLEM - MAIN LIFT DOWN PERMANENTLY Input was CLOSED during startup
SELECTED
2257 22 FUNCTION PROBLEM - TOWER LIFT UP PERMANENTL Y Input was CLOSED during startup
SELECTED
2258 22 FUNCTION PROBLEM - TOWER LIFT DOWN PERMANENTLY Input was CLOSED during startup
SELECTED
2259 22 FUNCTION PROBLEM - DRIVE FORWARD PERMANENTLY Input was CLOSED during startup
SELECTED
2260 22 FUNCTION PROBLEM - DRIVE REVERSE PERMANENTL Y Input was CLOSED during startup
SELECTED
2261 22 FUNCTION PROBLEM - MULTIPLE SWITCHES PERMANENTL Y Input was CLOSED during startup
SELECTED
2262 22 FUNCTION PROBLEM - PLATFORM LEVEL UP PERMANENTLY Input was CLOSED during startup
SELECTED
2263 22 FUNCTION PROBLEM - PLATFORM LEVEL DOWN PERMA- Input was CLOSED during startup
NENTL Y SELECTED
2264 22 FUNCTION PROBLEM - DOS DOWN PERMANENTL Y SELECTED Input was CLOSED during startup
2265 22 FUNCTION PROBLEM - POSI DOWN PERMANENTL Y SELECTED Input was CLOSED during startup
2266 22 LIFT/SWING JOYSTICK FAULTY Joystick was out of the Neutral position during startup
2267 22 DRIVE/STEER JOYSTICK FAULTY Joystick was out of the Neutral position during startup
2268 22 JOYSTICKS FAULTY Both Joysticks are faulty, or one joystick is faulting the 5 volt sup-
ply to both joysticks.
2376 23 SWING SWITCH FAULTY Both states actively HIGH in Ground Mode
2387 23 JIB LIFT SWITCH FAULTY Both states actively HIGH
2388 23 JIB SWING SWITCH FAULTY Both states actively HIGH
2389 23 PLATFORM ROTATE SWITCH FAULTY Both states actively HIGH
2390 23 TELESCOPE SWITCH FAULTY Both states actively HIGH
2391 23 MAIN LIFT SWITCH FAULTY Both states actively HIGH
2392 23 TOWER LIFT SWITCH FAULTY Both states actively HIGH
2393 23 PLATFORM LEVEL SWITCH FAULTY Both states actively HIGH
2394 23 PUMP POT FAULTY Creep pot is OPEN circuit
2395 23 FUNCTION SWITCHES FAULTY Function switch has both direction selected at the same time
253 25 DRIVE PREVENTED - CHARGER CONNECTED Driving is not possible while the vehicle is charging
254 25 DRIVE & LIFT UP PREVENTED - CHARGER CONNECTED Drive or Lift is not possible while the vehicle is charging AND is
configured to prevent all motion.
2510 25 DRIVE PREVENTED - BRAKES NOT RELEASING No Brake pressure was detected when running the pump motor
and energizing the brake valve

3121253 – JLG Lift – 6-23

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. E300 Diagnostic Fault Codes

Flash
DTC Fault Message Description
Code
2514 25 BOOM PREVENTED - DRIVE SELECTED Boom functions are not possible while the vehicle is being driven
AND is configured to not allow simultaneous drive & boom opera-
tion.
2516 25 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 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Driving is not possible while the vehicle is tilted and above eleva-
tion AND is configured to prevent drive while tilted and above ele-
vation.
2518 25 DRIVE PREVENTED - BOOM SELECTED Driving is not possible while the vehicle boom functions are
selected AND is configured to not allow simultaneous drive &
boom operation.
2536 25 ALL FUNCTIONS PREVENTED - FUNCTION CUTOUT Machine Setup’s set for "1 =CHARGER & BOOM" and machine is
above elevation
2542 25 FUNCTION PREVENTED - BRAKES ELECTRONICALL Y Indicates Manual Brake release active in Ground mode
RELEASED FOR TOWING
2548 25 SYSTEM TEST MODE ACTIVE System test mode active
2549 25 DRIVE & BOOM PREVENTED - SOFT TOUCH ACTIVE Machine Setup’s SOFT TOUCH is set for "2=BOOM & DRIVE" and
Soft touch switch is OPEN
2550 25 BOOM PREVENTED - FUNCTION CUTOUT ACTIVE Machine Setup’s DRIVE CUTOUT is set for "1 =CHARGER &
BOOM" and machine is above elevation
2551 25 TELESCOPE OUT PREVENTED - TIL TED & ABOVE ELEVATION Telescope OUT is not possible while the vehicle is tilted and above
elevation AND is configured to prevent drive while tilted and
above elevation.
2552 25 LIFT UP PREVENTED - TILTED & ABOVE ELEVATION Lift UP is not possible while the vehicle is tilted and above eleva-
tion AND is configured to prevent drive while tilted and above ele-
vation.
2553 25 LEVELING PREVENTED - ABOVE ELEVATION Machine Setup’s LEVEL inhibit is set for "1 =ELEV" and machine
is above elevation
2554 25 DRIVE PREVENTED - SPEED SENSORS FAULTY Both Speed sensor input voltages are out of range
2555 25 FUNCTION PREVENTED - SELECTED BEFORE FSW Function switch was selected before and during foot switch clo-
sure
2556 25 FUNCTION PREVENTED - SELECTED BEFORE EMS Function was CLOSED at power up
321 32 LINE CONTACTOR WELDED OR MISWIRED The capacitor bank charge did not decrease from battery supply
when line contactor was de-energized (this could be caused due
to a power wiring error)
325 32 LINE & DIRECTION CONTACTORS MISWIRED When the line contactor was closed, traction point A went HIGH
(and the capacitor bank charge did not increase to battery supply)
- this occurs if the line contactor coil wiring is swapped with that
for a direction contactor coil
33300 33 LINE CONTACTOR COIL - OPEN CIRCUIT The capacitor bank did not increase to battery supply when the
line contactor was CLOSED
33301 33 LINE CONT ACTOR COIL - SHORT TO GROUND Line contactor was not energized when required, due to over cur-
rent protection
33361 33 DIRECTION CONTACTOR COIL - OPEN CIRCUIT Traction point A is collapsing when the traction MOSFETs are
pulsed. This maybe due to an open circuit traction motor or power
wiring error

6-24 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. E300 Diagnostic Fault Codes

Flash
DTC Fault Message Description
Code
33364 33 FORWARD CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when forward contactor was
energized. This maybe due to an open circuit traction motor or
power wiring error
33369 33 REVERSE CONTACTOR COIL - OPEN CIRCUIT Traction point A did not go HIGH when reverse contactor was
energized. This maybe due to an open circuit traction motor or
power wiring error
33370 33 FORWARD CONTACTOR COIL - SHORT CIRCUIT The forward contactor was not energized when required, due to
over current protection
33371 33 REVERSE CONTACTOR COIL - SHORT CIRCUIT The reverse contactor was not energized when required, due to
over current protection
33411 33 VALVE SUPPLY OVERLOADED There is a high current draw from the valve supply when no valve
is energized; this maybe due to a wiring error at the ground mod-
ule
421 42 POWER MODULE TOO HOT - PLEASE WAIT Controller heat sink temperature reached 75*C, the controller is
shut down until it cools to below 70*C
441 44 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN Battery voltage is below 33 volts EMS recycle is required
442 44 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN Battery voltage is above 62 volts, EMS recycle is required
445 44 BATTERY VOLTAGE LOW Battery voltage is below 40 volts, this is only a warning, the con-
troller does not shut down
469 46 VEHICLE OVERSPEED Speed in the wrong direction was measured with the traction
motor full ON. This maybe due to a faulty speed sensor being
installed incorrectly; it could also be due to a speed sensor fault or
faults for NO VEHICLE MOVEMENT DETECTED with the vehicle
on a grade
4610 46 RIGHT SPEED SENSOR - NOT RESPONDING PROPERL Y The right speed sensor is indicating an impossible number of
pulses, this maybe due to a faulty speed sensor
4611 46 LEFT SPEED SENSOR - NOT RESPONDING PROPERL Y The left speed sensor is indicating an impossible number of
pulses, this maybe due to a faulty speed sensor
4615 46 SPEED SENSOR - INVALID READING Both speed sensors are indicating impossible number of pulses,
this maybe due to a faulty speed sensor
4616 46 BRAKES DID NOT LOCK Brake pressure did not clear when the brake valve was de- ener-
gized
4617 46 NO VEHICLE MOVEMENT DETECTED AT MAXIMUM POWER No speed was measured with the traction motor full ON. This
could be due to a traction motor fault, a power wiring error, a
speed sensor fault, the brakes not releasing (though brake pres-
sure is OK) or the vehicle being overloaded so that the motor can-
not turn the wheels
661 66 CANBUS FAILURE - POWER MODULE Power Module CAN communication lost.
662 66 CAN BUS FAILURE - PLATFORM MODULE Platform Module CAN communication lost.
6631 66 CAN BUS FAILURE - GROUND MODULE Ground Module CAN communication lost.
6636 66 CANBUS FAILURE - TILT MODULE Tilt Module CAN communication lost.
772 77 STALLED TRACTION MOTOR OR POWER WIRING ERROR The power module traction MOSFET protection circuit is active,
This is due to a massive current drain and could be a stalled trac-
tion motor or a power wiring error
773 77 CAPACITOR BANK FAULT - CHECK POWER CIRCUITS The capacitor bank is not charging, this maybe due to a power
wiring error causing illegal current drain or a very low battery volt-
age

3121253 – JLG Lift – 6-25

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. E300 Diagnostic Fault Codes

Flash
DTC Fault Message Description
Code
776 77 STALLED PUMP MOTOR OR POWER WIRING ERROR The power module pump MOSFET protection circuit is active,
This is due to a massive current drain and could be a stalled pump
motor or a power wiring error
777 77 OPEN CIRCUIT PUMP MOTOR WIRING Pump point A is collapsing when the pump MOSFETs are pulsed,
this maybe due to an OPEN circuit pump motor or a power wiring
error
7734 77 TRACTION A HIGH - CHECK POWER CIRCUITS Traction point A is near battery supply when neither direction con-
tactor is energized and the traction MOSFETs are OFF, this maybe
due to a welded direction contactor or a power wiring error
7735 77 TRACTION A LOW - CHECK POWER CIRCUITS Traction point A is near ZERO volts when neither direction contac-
tor is energized and the traction MOSFETs are OFF, this maybe due
to a power wiring error
7736 77 TRACTION MOTOR OVERLOADED The traction motor has been operating in current limit at a low per-
centage on for a long time greater than 10 seconds
7737 77 PUMP MOTOR OVERLOADED The pump motor has been operating in current limit at a low per-
centage on for a long time greater than 10 seconds
7738 77 PUMP A LOW - CHECK POWER CIRCUITS Pump point A is near ZERO volts when the pump MOSFETs are
OFF, this maybe due to a power wiring error
7739 77 B+ AND A CROSSED - CHECK POWER CIRCUITS startup test detected B+ is connected to point A and point A is
connected to B+
7740 77 TRACTION CURRENT AT ZERO - CHECK SHUNT WIRING Traction current is at ZERO, this maybe due to an open circuit
between the current measurement shunt and the power module
826 82 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.
827 82 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Driving and boom functions are not possible while the Load Sens-
ing System indicates the Platform is overloaded AND is config-
ured to prevent drive and boom functions while the Platform is
overloaded.
99125 99 POWER MODULE FAILURE - HWFS CODE 2 Hardware failsafe tests did not com plete because traction point A
is not safe, or the hardware failsafe is permanently tripped
99126 99 POWER MODULE FAILURE - HWFS CODE 3 Hardware failsafe tests did not complete because a contactor
was energized when all should be turned off
99127 99 POWER MODULE FAILURE - HWFS CODE 4 Hardware failsafe tests did not complete because the hardware
failsafe tripped immediately when the traction MOSFETs were
turned ON
99128 99 POWER MODULE FAILURE - HWFS CODE 10 Hardware failsafe tests failed because the hardware failsafe did
not trip within the allowed test time
99129 99 POWER MODULE FAILURE - HWFS CODE 11 Hardware failsafe tests failed because the hardware failsafe
tripped too slowly
99130 99 POWER MODULE FAILURE - HWFS CODE 12 Hardware failsafe tests failed because the hardware failsafe
tripped too Quickly
99131 99 POWER MODULE FAILURE - HWFS CODE 13 Hardware failsafe tests failed because the hardware failsafe
remained tripped when the traction MOSFETs were turned OFF
99132 99 POWER MODULE FAILURE - HWFS CODE 14 Hardware failsafe tests failed because the hardware failsafe the
line contactor could not be energized when the hardware failsafe
was tripped

6-26 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-4. E300 Diagnostic Fault Codes

Flash
DTC Fault Message Description
Code
99133 99 POWER MODULE FAILURE - HWFS CODE 15 Hardware failsafe tests failed because the hardware failsafe the
contactor drive failsafe did not trip within the allowed test time
99134 99 POWER MODULE FAILURE - HWFS CODE 16 Hardware failsafe tests failed because the hardware failsafe the
contactor drive failsafe tripped tooslowly
99135 99 POWER MODULE FAILURE - HWFS CODE 17 Hardware failsafe tests failed because the hardware failsafe the
drive contactor failsafe tripped too quickly
99136 99 POWER MODULE FAILURE - HWFS TEST STALLED Hardware failsafe tests did not complete, but no reason can be
determined
99137 99 POWER MODULE FAILURE - LINE CONTACTOR DRIVER The line contactor energized when the footswitch was CLOSED
before it was ON, this maybe due to a failed driver within the
power module, or a power wiring error
99138 99 POWER MODULE FAILURE - TEMPERATURE SENSOR The temperature sensor measurement is invalid, this maybe due
to a disconnected wire within the power module.
99139 99 POWER MODULE FAILURE - CONTACTOR CODE 1 A contactor remained energized when turned OFF
99140 99 TILT MODULE FAILURE - INTERNAL ERROR Startup test detected faulty tilt sensors, or voltages on the tilt sen-
sor are bad (could be caused if positilt is mounted upside down or
vertical
99141 99 GROUND MODULE - OBSOLETE ON THIS VEHICLE The power module determined the hardware version of the
Ground module was incompatible with the current software
99142 99 48V PROTECTION TRIPPED The power module is not receiving acknowledgements from the
platform module or ground module to transmitted data, and the
protection circuit which supplies the platform and ground mod-
ules has tripped. This maybe due to wiring problems at the plat-
form or groundmodule.

3121253 – JLG Lift – 6-27

 SECTION 6 - JLG CONTROL SYSTEM

System Self Test up switch. When the controller sees that the tower lift
up switch has been closed, it will move on to the
The system self test is utilized to locate typical problems. next input. If the switch is faulty or the wiring is faulty,
See Table 6-5, System Test Descriptions for information the controller will not move on to the next input. The
concerning the tests performed and available messages controller will continue to wait for the closure of the
in this mode. input. If the operator knows the switch is faulty and
1. When the key switch is in the platform position and wants to continue the tests he must simply press the
the self test enabled, the self test function will test all enter key on the analyzer to continue.
valves, contactors, platform inputs, indicator lamps,
3. After the controller has conducted the tests from the
and system alarms for various fault conditions.
chosen operator station, it will display “TESTS COM-
PLETE”. This indicates that the controller has
When the key switch is in the ground position, the
checked all inputs and outputs for that station.
self test function will test all valves, the line contac-
tor, ground control inputs, and the ground alarm out-
put for various fault conditions.
2. In order to test the inputs on the machine, the con- IN ORDER FOR THE MACHINE TO FUNCTION AFTER THE SELF
troller will ask the service technician to perform vari- TEST IS COMPLETE, POWER MUST BE RECYCLED USING THE
ous tasks at the appropriate operator control station. EMS OR THE KEY SWITCH.
An example of this is “Close TWR U Switch”. The
controller expects the operator to close the tower lift

Table 6-5. System Test Descriptions

ACTIVATE TESTS Not available once tests are activated
YES:ENTER, NO:ESC ENTER activates system tests
NOTE: cannot be done while controller is in use (footswitch closed) and for a short time after-
wards
RUN SYSTEM TEST ENTER starts system test
Not available until tests are activated Displays messages while system test
runs Some messages are prompts, requiring user intervention.
ENTER can be pressed if a fault is found, to confirm that the fault has been
noted and to continue the system test.
NOTE: a flashing message is critical, and prevents the system test running

6-28 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. System Test Messages

RUNNING Initial display when system test is run; certain “critical” checks are made. Problems which can be reported include:
ONLY 1 ANALYZER!
Do not connect two Analyzers while running the system test.
BAD POWER WIRING
The capacitor bank is not charged or pump point A is low or traction point A is high or low.
Check all power wiring.
LINE CONT WELDED
The capacitor bank is at battery voltage.
Check line contactor.
Check all power wiring.
BATTERY TOO LOW
The system test cannot run with battery voltage below minimum.
BATTERY TOO HIGH
The system test cannot run with battery voltage above maximum.
CHECK CAN WIRING
The system test cannot run in platform mode unless data is being received from the
platform, ground and positrac/tilt modules. The system test cannot run in ground mode
unless data is being received from the ground and positrac/tilt modules.
CHECK LEFT SPD.
There is an open- or short- circuit in the left speed encoder wiring. Check left speed
encoder.
CHECK RIGHT SPD.
There is an open- or short- circuit in the right speed encoder wiring. Check right speed
encoder.
CHECK SHUNT
The traction current measurement is open-circuit.
Check wiring between power module contactor panel.
BAD PUMP WIRING
Pump point A is not high, probably caused by an open-circuit pump motor or wiring.
Check all power wiring. Check pump motor.
BAD POWER WIRING
Traction point A is high, probably caused by incorrect faction motor wiring. Check all
power wiring. Check traction motor.
BAD POWER MODULE
An internal problem was detected in the power module.
HIGH TILT ANGLE
The vehicle is very tilted, or the tilt sensor has been damaged. Check tilt sensor.
HOT POWER MODULE
The heat sink temperature exceeds 75°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.
WAIT:CAPBANK HI
This message can be displayed if the system test is run shortly after the vehicle was used;
after a short wait, it should clear.
OPEN FWS
In platform mode, the footswitch must be open at the start of the test.
CLOSE FWS
In platform mode, the footswitch must be closed when this message is displayed; the foot
switch MUST BE KEPT CLOSED during the valve & contactor tests.
BAD FWS
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.

3121253 – JLG Lift – 6-29

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. System Test Messages

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.
The valves are tested in the order: STEER L, STEER R, BRAKE, FLOW, TWR U, MAIN U, SWING L, SWING R,
LEVEL U, LEVEL D, ROTATE L, ROTATE R, JIB U, JIB D, JIB L, JIB R, TELE I, TELE O
NOTE: in platform mode, the footswitch must be closed.
NOTE: jib valves are not tested if JIB = NO
NOTE: left/right jib are not tested unless jib = side swing.
NOTE: Tower Down and Main Down valves are not be tested by system test.
Problems which can be reported include:
CANT TEST VALVES
There is a wiring problem which prevents the valve test from functioning correctly.
Check valve wiring.
Check ground alarm wiring.
valve name S/C
The named valve is drawing too much current so is presumed to be short-circuit.
Check valve wiring.
valve name O/C
The named valve is drawing too little current so is presumed to be open-circuit.
Check valve wiring.
VALVE TEST DONE Indicates that the valve test is complete (with or without faults).
TESTING CONTS Indicates that the contactor test is beginning.
In platform mode, the forward & reverse direction contactors are energized and de-energized; checks are made that
they
close & open correctly and for short-circuit coils.
In platform and ground mode, the line contactor is energized and de-energized; checks are made that it closed &
opened
correctly and for a short-circuit coil.
In platform mode, the positrac contactors are energized and de-energized; checks are made for short-circuit and
open-
circuit coils.
Problems which can be reported include:
CANT TEST CONTS
There is a wiring problem which prevents the contactor test from functioning correctly.
Check power wiring.
Check contactor wiring.
BAD CONT WIRING
There is a wiring problem which caused the capacitor bank to be charged when a direction contactor was
energized; probably the wiring to the contactor coils is incorrect.
Check contactor wiring.
Check power wiring.
contname WELDED
The named contactor appears to have not opened.
Check named contactor.
Check power wiring.
contname COIL S/C
The named contactor coil overloaded its driver circuit so is presumed to be short-circuit.
Check contactor wiring.
contname DIDN’T CLOSE
The named contactor appears to have not closed.
Check contactor wiring.
Check power wiring.
CONT TEST DONE Indicates that the contactor test is complete (with or without faults).

6-30 – JLG Lift – 3121253

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. System Test Messages

CHECKING INPUTS Indicates that the inputs test is beginning.

Every input is checked to ensure that it is in its “normal” position; function switches should be open,
cutout switches should be closed, joysticks should be in neutral.
In platform mode, inputs are tested in the order: MAIN U, MAIN D, SWING L, SWING R, SWING JOY,
LEVEL U, LEVEL D, PUMP POT, ROTATE L, ROTATE R, TWR U, TWR D, JIB U, JIB D, JIB L, JIB R,
TELE I, TELE O, DRIVE FWD, DRIVE REV, DRIVE JOY, STEER L, STEER R,
POSITRAC, DRIVE C/O, ELEV C/O, FUNC. C/O, SOFT TOUCH, LOAD CELL, BRAKE PRES
In ground mode, inputs are tested in the order: ROTATE L, ROTATE R, LEVEL U, LEVEL D, JIB U, JIB D,
JIB L, JIB R, TELE I, TELE O, MAIN U, MAIN D, TWR U, TWR D, SWING L, SWING R, ELEV. C/O,
FUNC. C/O, LOAD CELL, BRAKE PRES, MAN. BRAKE
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 which can be reported include:
CHECK switch name
The named switch is not in its “normal” position.
Check switch & wiring.
CHECK switch name JOY.
The named joystick appears to be faulty.
Check joystick.
INPUTS DONE Indicates that the inputs test is complete (with or without faults).
TESTING LAMPS Indicates that the lamps test is beginning.
Each lamp is energized in turn; a prompt asks for confirmation that the lamp is lit - ENTER must be
pressed to continue the test.
Lamps are tested in the order: ENABLE, FAULT, TILT, CREEP, POSlTRAC, LOAD CELL
NOTE: lamps which are not in use (due to the settings of machine digits) are not checked.
NOTE: lamps are only tested in platform mode.
Problems which can be reported include:
lamp name S/C
A short-circuit condition appeared while the named lamp was being tested, presumably
because it is short-circuit.
LAMP TEST DONE Indicates that the lamps test is complete.
TESTING ALARMS Indicates that the alarms test is beginning.
Each alarm is energized in turn; a prompt asks for confirmation that the alarm is sounding - ENTER
must be pressed to continue the test.
Alarms are tested in the order: P.ALARM, G.ALARM.
NOTE: the platform alarm is only tested in platform mode.
NOTE: the ground alarm is not tested if GROUND ALARM = NO.
Problems which can be reported include:
alarm name S/C
A short-circuit condition appeared while the named alarm was being tested, presumably
because it is short-circuit.
ALARM TEST DONE Indicates that the alarms test is complete.

3121253 – JLG Lift – 6-31

 SECTION 6 - JLG CONTROL SYSTEM

Table 6-6. System Test Messages

TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed, the system test ends.
If ENTER is pressed, each operator input is prompted for in turn.
In platform mode, operator inputs are tested in the order: POSITRAC, MAIN U, MAIN D, SWING L, SWING R,
LEVEL U, LEVEL D, PUMP POT, CREEP, ROTATE L, ROTATE R, TWR U, TWR D, JIB U, JIB D, JIB L, JIB R,
TELE I, TELE O, DRIVE FWD, DRIVE REV, STEER L, STEER R
In ground mode, operator inputs are tested in the order: ROTATE L, ROTATE R, LEVEL U, LEVEL D,
JIB U, JIB D, JIB L, JIB R, TELE I, TELE O, MAIN U, MAIN D, TWR U, TWR D, SWING L, SWING R
NOTE: the jib switches are not tested if JIB = NO.
Prompts displayed during the operator input test include:
CLOSE switch name
The named switch should be closed.
OPEN switch name
The named switch should be opened.
joystick name direction TO MAX
The named joystick should be pushed to its full extent in the named direction.
joystickname direction 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 recti-
fied.
Press ESC to return to the RUN SYSTEM TEST Analyzer menu.

6-32 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL Polarity
This section contains basic electrical information and Getting a negative Voltage or current reading when
schematics to be used for locating and correcting most of expecting a positive reading frequently means the leads
the operating problems which may develop. If a problem are reversed. Check what reading is expected, the loca-
should develop which is not presented in this section or tion of the signal and that the leads are connected to the
which is not corrected by listed corrective actions, techni- device under test correctly. Also check that the lead on the
cally qualified guidance should be obtained before pro- "COM" port goes to the Ground or negative side of the sig-
ceeding with any maintenance. nal and the lead on the other port goes to the positive side
of the signal.
NOTE: Some of the procedures/connectors shown in this
section may not be applicable to all models. Scale
M = Mega = 1,000,000 * (Displayed Number)
7.2 MULTIMETER BASICS k = kilo = 1,000 * (Displayed Number)

A wide variety of multimeters or Volt Ohm Meters (VOM) m = milli = (Displayed Number) / 1,000
can be used for troubleshooting your equipment. This μ = micro = (Displayed Number) / 1,000,000
section shows diagrams of a common, digital VOM con-
figured for several different circuit measurements. Instruc- Example: 1.2 k = 1200 
tions for your VOM may vary. Please consult the meter Example: 50 mA = 0.05 A
operator’s manual for more information.
Voltage Measurement
Grounding
"Grounding the meter" means to take the black lead
(which is connected to the COM (common) or negative
port) and touch it to a good path to the negative side of
the Voltage source.

Backprobing
To "backprobe" means to take the measurement by
accessing a connector’s contact on the same side as the
wires, the back of the connector. Readings can be done
while maintaining circuit continuity this way. If the connec-
tor 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 tech-
nique, especially on sealed connectors. Whenever possi-
ble insert probes into the side of the connector such that
the test also checks both terminals of the connection. It is
possible to inspect a connection within a closed connec-
tor by backprobing both sides of a connector terminal and
measuring resistance. Do this after giving each wire a
gentle pull to ensure the wires are still attached to the con- Figure 7-1. Voltage Measurement (DC)
tact 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 condi-
tions 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.

3121253 – JLG Lift – 7-1

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Resistance Measurement Continuity Measurement

Figure 7-3. Continuity Measurement

• Some meters require a separate button press to

enable audible continuity testing
• Circuit power must be turned OFF before testing
Figure 7-2. Resistance Measurement continuity
• First test meter and leads by touching leads • Disconnect component from circuit before testing
together. Resistance should read a short circuit
• Use firm contact with meter leads
(very low resistance)
• First test meter and leads by touching leads
• Circuit power must be turned OFF before testing
together. Meter should produce an audible alarm,
resistance
indicating continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct
range (See multimeter’s operation manual)
• Use firm contact with meter leads

7-2 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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 MATERIAL APPROVED FOR USE AS A DIELECTRIC
GREASE.

NOTE: Do NOT apply dielectric grease to the following con-

nections:

• Main Boom Rotary sensor connections (on Celesco

Sensor),

• LSS Modules connections,

• Deutz EMR 2 ECM connection.

Silicone Dielectric Compound must be used on all electri-

cal connections except for those mentioned above for the
following reasons:

Figure 7-4. Current Measurement (DC) • To prevent oxidation at the mechanical joint between
male and female pins.
• Set up the meter for the expected current range
• To prevent electrical malfunction caused by low level
• Be sure to connect the meter leads to the correct conductivity between pins when wet.
jacks for the current range you have selected Use the following procedure to apply Silicone Dielectric
Compound to the electrical connectors. This procedure
• If meter is not auto ranging, set it to the correct
applies to all plug connections not enclosed in a box. Sili-
range (See multi meter’s operation manual)
cone grease should not be applied to connectors with
• Use firm contact with meter leads external seals.

1. To prevent oxidation, silicone grease must be

packed completely around male and female pins on
the inside of the connector prior to assembly. This is
most easily achieved by using a syringe.

NOTE: Over a period of time, oxidation increases electrical

resistance at the connection, eventually causing cir-
cuit 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 con-
nectors come together. Any other joints (around
strain reliefs, etc.) where water could enter the con-
nector 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.

3121253 – JLG Lift – 7-3

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

3. Anderson connectors for the battery boxes and bat- Deutsch HD, DT, DTM, DRC Series
tery chargers should have silicone grease applied to
the contacts only. The Deutsch connector system is commonly used for
harsh environment interconnect. Follow the installation
NOTE: Curing-type sealants might also be used to prevent instructions.
shorting 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 conductivity between contacts from moisture
intrusion. Open and sealed connectors benefit from the
application of dielectric grease.
Dielectric grease shall be applied to all electrical connec-
tors at the time of connection (except those noted under
Exclusions).

Installation of Dielectric Grease

Before following these instructions, refer to excluded con-
nector 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
2. Apply dielectric grease to the female contact (fill it ADE 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 prevents the connector from latching, pierce one of the
the connector unused wire seals. After assembly, install a seal plug (JLG
4. Assemble the connector system immediately to pre- #4460905) in that location to prevent moisture ingress.
vent moisture ingress or dust contamination Note that seal plugs may be installed by the wire harness
5. Pierce one of the unused wire seals prior to assem- manufacturer if an unused wire seal becomes compro-
bly if the connector system tends to trap air (i.e. mised (wire inserted in the wrong cavity during assembly
AMP Seal) and then install a seal plug. and then corrected).

Figure 7-5. Application to Female Contacts

7-4 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

DIN Connectors
This connector is typically used on hydraulic valves. Fol-
low the installation instructions.

Figure 7-6. Use of Seal Plugs

Exclusions
AMP Mate-N-Lok A limited number of connectors do not benefit from dielec-
tric grease, or may be permanently damaged by applica-
Follow the installation instructions. tion. Dielectric grease may not be required in properly
sealed enclosures.

3121253 – JLG Lift – 7-5

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

BRAD HARRISON / PHOENIX CONTACT M12 AMP JUNIOR TIMER

The connector uses gold contact material to resist corro- This type of connector uses back-seals for moisture integ-
sion and an o-ring seal for moisture integrity. If dielectric rity. However, the low-force contacts cannot displace
grease is mistakenly applied to this connector system, the
dielectric grease and create electrical contact. It is possi-
low-force contacts cannot displace the grease to achieve
ble to use solvents (i.e. contact cleaner or mineral spirits)
electrical contact. Once contaminated, there is no practi-
for the removal of improperly applied dielectric grease.
cal way to remove the dielectric grease (replacement of
The EMR2 engine control module from Deutz employs
female contacts required). The JLG Load Sensing System
this connector system (for example).
and 1250AJP Rotary Angle Sensors are examples of com-
ponents with the M12 connector system.

7-6 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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
Assembly contact (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 appropri-

ate circuit cavity as far as it will go (See Figure 7-9.).

Figure 7-8. AMP Connector

3121253 – JLG Lift – 7-7

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-9. Connector Assembly Figure 2

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.).

Figure 7-11. Connector Assembly Figure 4

Figure 7-10. Connector Assembly Figure 3

7-8 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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 READ-
INGS.
6. Pry open the wedge lock to the open position.
7. While rotating the wire back and forth over a half It has been common practice in electrical troubleshooting
turn (1/4 turn in each direction), gently pull the wire to probe wires by piercing the insulation with a sharp
until the contact is removed. point. This practice should be discouraged when dealing
with the AMPSEAL plug assembly, or any other sealed
NOTE: The wedge lock should never be removed from the connector system. The resulting pinholes in the insulation
housing for insertion or removal of the contacts. will allow moisture to invade the system by traveling along
the wire strands. This nullifies the effectiveness of the con-
Wedge Lock nector seals and could result in system failure.

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.

3121253 – JLG Lift – 7-9

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-13. Connector Installation

7-10 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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

1. Grasp crimped contact about 25mm behind the con- hook shaped wire to pull wedge straight out.
tact 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
3. Push contact straight into connector grommet until a by moving it away from the contact with a screw-
click is felt. A slight tug will confirm that it is properly driver.
locked in place. 7. Hold the rear seal in place, as removing the contact
4. Once all contacts are in place, insert wedgelock with may displace the seal.
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.

3121253 – JLG Lift – 7-11

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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

11. With rear insert toward you, snap appropriate size
crimp barrel.
extractor tool over the wire of contact to be
9. Hold connector with rear grommet facing you. removed.
10. Push contact straight into connector grommet until a 12. Slide tool along into the insert cavity until it engages
positive stop is felt. A slight tug will confirm that it is contact and resistance is felt.
properly locked in place.
13. Pull contact-wire assembly out of connector.

Figure 7-17. HD/HDP Locking Contacts Into Position Figure 7-19. HD/HDP Unlocking Contacts

NOTE: For unused wire cavities, insert sealing plugs for full NOTE: Do Not twist or insert tool at an angle.
environmental sealing

7-12 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

This page left blank intentionally.

3121253 – JLG Lift – 7-13

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

FOOTSWITCH

PLATFORM
FLOODLIGHTS

POS

NEG

INVERTER

J11

J9
J8
J7 STROBE
J6
LIGHT

J5
J4
J2
J3 J1

PLATFORM
CONTROL
BOX
BATTERY
CHARGER
DRIVE
ORIENTATION
SWITCH

GRD
MOD
J11 A
J10 B+
J9 PWR
J8 MOD P2
J7
J6
J5 J2
J4 J3
J3 J4 J1
J5
DIAGNOSTIC
J2 ANALYZER
J14 J1 J7
J8
J12
J9
GROUND
CONTROL P B–
BOX

ACCY

Figure 7-20. Electrical Components - Sheet 1 of 2

7-14 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

AC POWER AT
PLATFORM
BATTERIES

POSI-TRACK/
TILT MODULE
S2 A2 A1 S1
J2 J3 J4 J5
J1
S1 A1 A2 S2

RH DRIVE
LH DRIVE BRAKE/MOTOR
BRAKE/MOTOR

PUMP

MAIN BOOM
LIFT CYLINDER

300AMP FUSE MAIN BOOM

LIMIT SWITCH
(UL Only)

BOOM
FUNCTION
VALVE TOWER BOOM
MAIN LIMIT SWITCH
VALVE

TOWER BOOM
LIFT CYLINDER

ALARM
Figure 7-21. Electrical Components - Sheet 2 of 2

3121253 – JLG Lift – 7-15

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

INDICATOR
LAMP PANEL

TRACTION
CONTROL
BRN/WHT 47-4 4

WHT/BLK
BRN/WHT 47-5 1
PLATFORM CONTROL MODULE

58-6
BRN/WHT 47-1 9 J6
CREEP
BRN/WHT 47-2 6 9 SOCKET
BRN/WHT 47-3 5

WHT/BLK
BRN/WHT 47-6 7 J5 J4 J11
BRN/WHT 47-7 2 J7

58-6
9 PIN 6 PIN 4 SOCKET 15 PIN
TILT
3
8

WHT/BLK
5 4 6 3 2 1 7 4 6 1 3

N/C
N/C
N/C
N/C
2 3 4 1 14 12 8 7 6 5 15 13 10 11 9 4 3 1 2

58-6

N/C

BROWN 13-3
FAULT

BROWN 14-3
WHT/RED 57-6

WHT/RED 57-5
BROWN

GRAY 24-2

N/C
ORN/RED 49-11

GRAY 23-2

WHT/BLK 58-5
BLUE
BLACK

RED

TAN 5-3
TAN 6-3
PINK 25-3
PINK 26-3
WHT/RED

GREEN
RED/ORN

BLACK
WHITE
WHT/BLK

BLU/YEL

SHIELD
RED
58-6
WHT/YEL
ENABLE
WHT/GRN
WHT/BLK
LEFT
DRIVE
58-6

ORIENT
STEER CREEP
WHT/BLK

ORN/RED 49-5

WHT/BLK 58-6
RIGHT SWITCH
(LSS)
58-6

OVERLOAD 5K

DOWN

DOWN
PLATFORM

OUT

LEFT

RIGHT

UP

UP
IN
ALARM
5K DRIVE
DRIVE/STEER
JOYSTICK ASSEMBLY PUMP SPEED AND
REV FWD CREEP-MODE SWITCH TRACTION TELE. PLATFROM TOWER PLATFORM
ASSEMBLY CONTROL ROTATE LIFT LEVEL

BARE
RED
BLACK
WHT/RED 57-5

SEE
ZONE
H-2
J K A C B P N

PLATFORM MODULE
PLATFORM MODULE

PCB GROUND FOR

CAN BUSS SHILED
(TWISTED PAIR)

(TWISTED PAIR)

12V SUPPLY FOR

BRAIDED SHIELD
(TWISTED PAIR)
CAN BUSS LO
CAN BUSS HI
18/11 1STP

N/C

N/C

ORN/BLK

BLU/BLK
BLACK
BOOM CABLE

RED
BOOM FUNCTION J K A C B P N
VALVE BLOCK

JIB PLATF PLATF

BLACK
TELE SIDESWING LEVEL ROTATE

BARE
UP

RED
OUT LEFT LEFT JIB UP

PLATF PLATF
JIB
TELE LEVEL ROTATE
SIDESWING
IN DOWN RIGHT JIB DOWN
RIGHT
GROUND
ALARM

ORN/RED
49-4

6 POSITION DEUTSCH WHT/BLK 58-4

BLUE 28-1
CONNECTOR ON TURNTABLE;

BRAIDED
BLUE 27-1
BOOM SWITCHES ARE ALSO

BRAIDED
SHIELD
ORN/RED 49-3
WHT/BLK 58-4

SHIELD
GRAY 24-1
WIRED THROUGH THIS
CONNECTOR ON PIN 5 & 6; GRAY 23-1
WHITE 60-1
WHITE 59-1

BLACK
BARE
RED

BLACK
ORANGE 55-1

BARE
RED

WHT/RED 57-5

WHT/BLK 58-5
N/C

N/C
3 2 7 1 5 4 9 8 6 2 3 4 2 3 4

PINK 26-1 10
J5 J1 J2-4 SOCKET
PINK 25-1 9
BROWN 13-1 11
9 PIN 4 SOCKET
TOWER 2
BROWN 14-1 13 4
CYLINDER 12 J12 1 WHT/RED 57-1
WHITE 21-1 7 6 PIN 3 WHT/RED 57-2
3
TAN 6-1 6 5 WHT/BLK 58-1
TOWER 1 TAN 4-1 5 J4
LIFT DWN MAIN 15 SOCKET 6 WHT/BLK 58-2
WHITE 22-1 8
LIFT DWN
TAN 5-1 1
2
YELLOW 9-1 2
4 WHT/BLK 58-3 RED/WHT 50-1 15

LIFT
YELLOW 10-1 3 GROUND CONTROL MODULE
TAN 3-1 4
CYLINDER 14

BRAKE PRESSURE
SWITCH; (CLOSES ON 4 WHT/RED 57-1
RISING PRESSURE)
TOWER MAIN 9 N/C
N.O. T/T SWING FLOW
LEFT LIFT UP CONTROL LIFT 7 N/C
C UP
6 N/C
N.C. 5 N/C
J11 3 N/C
9 PIN 2 N/C
CNCTD CNCTD BRAKE T/T SWING STEER STEER 8 WHT/BLK 58-8 1
TO J6-8 TO J6-7 RELEASE RIGHT LEFT RIGHT
OUTPUT 1 BRN/WHT 47-7 2
OPTIONAL:
WHT/BLK 58-3 LSS OVERLOAD
MNTD IN MTB
MAIN VALVE BLOCK 6
5 J10 1
4 J3 2 SOCKET 2
DRIVE ORIENT.
3 6 SOCKET PROX. SWITCH
2
1 J8 2 ORN/RED 49-7
2 SOCKET 1 ORN/RED 49-6

SHIELD 3
J14
RED 2 J9 2 YEL/RED 2-12
1 3 PIN
2 RED 1-3-2 SEE BLACK
2 PIN 1 P
ZONE C-4 UPPER BOOM ELEVATION
8 YEL/RED 2-2-2
J6 J7 SWITCH NORMALLY OPEN
CLEARSKY CONNECTOR 3 HELD CLOSED
9 SOCKET
ORN/RED 49-8

SEE SHEET 2 FOR 4 15 PIN

ORN/RED

CLEARSKY SCHEMATIC
49-9

5
1
P
LOWER BOOM ELEVATION
1 2 3 4 5 6 7 8 10 9 12 11 13 15 14
BLACK

8
5

SWITCH NORMALLY OPEN

N/C
N/C
N/C

N/C

N/C

HELD CLOSED
BROWN 14-2
BROWN 13-2
GRAY 24-2
GRAY 23-2
WHITE 21-2
WHITE 22-2
TAN 5-2
TAN 6-2
TAN 3-2
TAN 4-2

PINK 25-2
PINK 26-2
WHITE 59-2

WHT/RED 57-11
ORN/RED 49-2

SEE ZONE D-5

BLUE 28-2 ENABLE
WHITE 60-2
ORN/RED 49-1-1

BLUE 27-2
HOURMETER,
BLACK

BATTERY DISCHARGE
INDICATOR,
ON-BOARD
DIAGNOSTICS
WHT/RED 57-11

2
RIGHT

DOWN
RIGHT
N.C.

N.O.

LEFT

3
LEFT

UP
DOWN

DOWN

DOWN
RIGHT

WHT/RED 57-12

4 BRAKE PRESSURE
LEFT

OUT

SWITCH LOCATED IN
UP

UP

UP

1
IN

MAIN VALVE BLOCK

5 (CLOSES ON RISING
C

PRESSURE)
6 WHT/RED 57-4

JIB TOWER MAIN T/T LEVEL TELESCOPE PLATF JIB

SWING LIFT LIFT SWING ROT

Figure 7-22. Electrical Schematic - Sheet 1 of 2

7-16 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

SEE ZONE G-5

WHT/RED 57-5 1
WHT/BLK 58-8 2
1 2 3 4 3
1 2 3 4
ANALYZER BRN/WHT 47-9 5
CONNECTION 6
J1 OPTIONAL:

4 3 5 2 1 6
J2 7

6 SOCKET
4 PIN 3 PIN J1 CNCTR
8
9 ON LSS MOD
10

J8
J9 J3
6 PIN 11
9 PIN
12

UP JIB
5 1 4 3 6 2 3 7 1 2 4 5 6 8

N/C
BLUE 27-3

N/C
N/C
N/C
ORANGE 55-50

ORN/RED 49-4
WHT/RED 57-7
BLUE 28-3
BLACK 16/3 CABLE DOWN

FOOTSWITCH WHT/RED 57-9

LEFT
WHITE 59-3
WHITE (16/3 CABLE)

HORN
WHITE 60-3 SIDE-SWING
RIGHT JIB
WORKLIGHT B+ SUPPLY
COLOR DICTATED BY
WORKLIGHT VENDOR

WHITE
BLU/YEL
P SWING
5K
OPTIONAL
PLATFORM
PLATFORM WORKLIGHTS DRIVE
STATION ORIENTATION
GREEN (16/3 CABLE)

EMS OVERRIDE
YEL/RED 2-7

ORN/YEL
48V ACCESSORY B+
48V CONTROL B+

YEL/RED 2-6

BLUE
WORKLIGHT B- SUPPLY BROWN
YEL/RED 2-4

COLOR DICTATED BY SWING/ LIFT

YEL/RED 2-5

WORKLIGHT VENDOR RED JOYSTICK

ASSEMBLY
LIFT
5K

GREEN
BLACK
G F D E H M L
FOOTSWITCH SIGNAL
TO POWER MODULE
48V RETURN FROM
48V ACCESSORY B+
48V CONTROL B+

WORKLIGHTS
RETURN FOR

CONDUCTOR
PLATFORM EMS

RED/BLK

YEL/BLK
SPARE
BRN/BLK

18/11 1STP
BOOM CABLE
BROWN

ORANGE
YELLOW

BLUE

N/C
N/C

GREEN
BLACK
4 2 3 1

WHITE
RED
G F D E H M L 1 J3 POSI TRAC
RED 2 4 SOCKET
BLACK 3 TILT MODULE JI
LEFT SPEED SENSOR
6 PIN
BLACK

BARE 4 J4 J5
J2
YEL/RED 2-4-2
YEL/RED 2-6

YEL/RED 2-3

CONNECTIONS
YEL/RED 2-4

YEL/RED 2-5

3 SOCKET 4 SOCKET 3 PIN SUPPLY - RED

GROUND - BLACK
SPEED - WHITE
1 2 3 2 3 4 1 2 3 1 DIRECTION - GREEN

BLACK

GREEN
BARE

BLACK
WHITE
RED
WHT/RED 57-7
WHT/BLK 58-8

YEL/RED 2-8
YEL/RED
PLATFORM

2-4-1

RIGHT SPEED SENSOR

GROUND

BLACK SEE ZONE A-8

2
1
3

4
MODE

MODE

CONNECTIONS
STROBE SUPPLY - RED
CONTROL
GROUND - BLACK
ACC'Y
B B1 GROUND BLACK SPEED - WHITE
BLACK
BARE
RED

DIRECTION - GREEN
STATION
KEYSWITCH
YEL/RED 2-1

YEL/RED 2-2

N/C
N/C
YEL/RED 2-4-2

N/C
N/C
N/C
N/C
N/C

N/C
N/C

RED
GREEN
WHITE
BLACK
(12 AWG)

(12 AWG)

2 3 4
WHT/RED 57-7
WHT/BLK 58-8

YEL/RED 2-8

YEL/RED N/C
2-2-2 J9 J5 J4 J8 N/C
P
4 PIN 2 SOCKET 2 PIN 4 SOCKET 4 ORN/RED 49-19
5 ANALZER 2 ORN/RED 49-18

GROUND
7 CONNECTION J3 3 ORN/RED 49-17

STATION 10 6 PIN 1 ORN/RED 49-16

EMS
N/C
GREEN
BLACK
WHITE

N/C 5
YEL/RED 2-3 3 J1 3
YEL/RED 2-6 1 12 PIN J2 2
6 SOCKET 1 ARMATURE
YEL/RED 2-4-2 2
WHT/RED 57-1 4 N/C A2 A A1
ORN/RED 49-15
ORN/RED 49-14
ORN/RED 49-13
ORN/RED 49-12

WHT/RED 57-2 6 N/C

WHT/BLK 58-1 8
WHT/BLK 58-2 11 POWER MODULE
ARMATURE

B
RED 1-3 (12)

A2 A1
5
1

3
2

N/C
N/C BLACK
N/C WHITE S2
REV

RED 1-3 N/C GREEN FIELD

N/C
A S1
CB 15A

RED
CB 15A

N/C
SEE J7 DRIVE
N/C
ZONE 15 PIN MOTOR
N/C PT A
B-7 N/C
N/C
FWD
PUMP MTR

B
NEGITIVE

S2
N/C
PLUGGING
POSITIVE
BATTERY

FIELD
N/C S1
RED 1-1-1 (12)

RED 1-1-2 (12)

DIODE

N/C
P2
N/C 3 PIN
N/C - +
- BATTERY
NEGATIVE
1 2 3 MAIN
PUMP +

CONTACTOR
RED 1-1 (10)

BLUE BLUE
300 AMP RED RED
EE ONLY WHITE WHITE
PUMP -
M
RED 1-1-3 (10)
#1 RED LED

#3 GRN LED
#2 YEL LED

1 BLACK #4 GROUND
BLACK

2 WHITE #2 YEL LED

3 GREEN #1 GRN LED B+
4 RED #3 RED LED
PUMP
1 4 2 3 MOTOR
POS
BATTERY
CHARGER NEG BLACK (10)

P2

P1 LOCK B-
OUT

GENERATOR + -
AC PROVIDED DC
IN PLATFORM
& TURNTABLE
AC

1001108541-B

Figure 7-23. Electrical Schematic - Sheet 2 of 2

3121253 – JLG Lift – 7-17

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-24. Hydraulic Schematic - E300AJ - Sheet 1 of 2

7-18 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001112910-A

Figure 7-25. Hydraulic Schematic - E300AJ - Sheet 2 of 2

3121253 – JLG Lift – 7-19

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

Figure 7-26. Hydraulic Schematic - E300AJP - Sheet 1 of 2

7-20 – JLG Lift – 3121253

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

1001112910-A

Figure 7-27. Hydraulic Schematic - E300AJP - Sheet 2 of 2

3121253 – JLG Lift – 7-21

 SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

NOTES:

7-22 – JLG Lift – 3121253

 3121253

Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417

JLG Worldwide Locations

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+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65 810122 +44 (0)161 654 1001

JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte
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+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 Singapore, 639379
(852) 2639 5797 +65-6591 9030

Plataformas Elevadoras JLG Sverige AB

JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 176 27 Jarfalla
08755 Castellbisbal, Barcelona Sweden
Spain +46 (0)850 659 500
+34 93 772 4700 +46 (0)850 659 534
+34 93 771 1762

www.jlg.com