Jlg 800S Service Manual Manual do Utilizador

Service and Maintenance ManualModels800S860SJP/N - 3121139November 16, 2012

vi – JLG Lift – 3121139TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121139Figure 3-42. Assembly Drawing - With Integral Input Brake - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-551A Spindle2 Input Brake1G Retaining Ring - Ext12 Pressure Plug16 O-ring Pipe Plug1F Thrust

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3121139Figure 3-44. Assembly Tools - Bearing Cone Pressing - “B” Bearing

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-57Figure 3-45. Assembly Tools - Bearing Cone Pressing - “A” Bearing

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121139Figure 3-46. Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-59Figure 3-47. Assembly Tools - Seal Pressing

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3121139Figure 3-48. Assembly Tools - Spacer - Brake Disc Installation

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-61Figure 3-49. Assembly Tools - Brake Retaining Ring Installation

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 31211393.8 DRIVE BRAKE, 2WD - MICO (PRIOR TO S/N 83331)Disassembly1. Remove pressure plate (3) fr

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-631. Capscrew2. Washer3. Pressure Plate4. Case Seal5. O-ring6. Backup Ring7. Piston8. O-ring

3121139 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3121139Bleeding1. Install brake in system and connect pressure lines.2. Bleed pressure release se

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-653.9 RE-ALIGNING TORQUE HUB INPUT COUPLINGThe following procedure applies to torque hubs wi

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121139Oscillating Axle Lockout TestLOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,ANY TIME A SY

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-673.11 SWING DRIVE HUBDisassembly1. Loosen all 12 cover bolts (12)&(13) and drain the oi

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 31211393. Place O-ring (5) into hub counterbore. Use petro-leum jelly to hold O-ring in place. Al

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-698. Input gear (8) is installed, meshing with teeth of thelarge diameter cluster gear (3F).

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 312113914. Pipe plugs (20) are to be installed into cover (6)using a lubricant of some sort.15. T

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-715. The shaft seal (1B) is installed over the output shaft(1A) and into the counterbore of

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 312113910. A soft metal punch should be used to insure that thisretaining ring (1I) is completely

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-734. Place second set of sixteen needle rollers into clus-ter gear.5. Apply grease or petrol

viii – JLG Lift – 3121139LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121139Figure 3-51. Swing Drive Hub (Fairfield)

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-753.12 SWING BRAKE - MICO (PRIOR TO S/N 66417)Disassembly1. Remove pressure plate (3) from c

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 31211391. Capscrew2. Washer3. Pressure Plate4. Case Seal5. O-ring6. Backup Ring7. Piston8. O-ring

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-77Bleeding1. Install brake in system and connect pressure lines.2. Bleed pressure release se

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 31211393.13 SWING MOTOR (PRIOR TO S/N 66417)DisassemblyCleanliness is extremely important when re

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-7913. Reposition motor in vise. Clamp across ports asshown above. Do not clamp side of housi

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 312113917. A metal plug, with seal, plugs a machining hole inthe housing. It is not necessary to

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-81 2. Lubricate output shaft with hydraulic oil, then installshaft in housing.DO NOT PERMIT

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 312113910. Before installing flange and seal assembly overshaft, place protective sleeve or bulle

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-83Reverse rotation align any star valley with marked tooth(see figure below).1. Rotate gerot

3121139 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 31211391. Capscrew2. Exclusion Seal3. Mounting Flange4. Backup Ring (-008, -009 Motors)5. Pressur

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-853.14 SWING MOTOR (S/N 66417 TO PRESENT)Disassembly and inspection1. Place the Torqlink™ in

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 31211395. If the end cover (2) is equipped with shuttle valvecomponents, remove the two previous

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-876. Thoroughly wash end cover (2) in proper solventand blow dry. Be sure the end cover valv

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 3121139NOTE: The manifold is constructed of plates bondedtogether to form an integral component n

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-8912. Remove drive link (10) from coupling shaft (12) if itwas not removed with rotor set an

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 312113917. Remove thrust bearing (15) and thrust washer (14)Inspect for wear, brinelling, corrosi

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-9121. If the housing (18) assembly has passed inspectionto this point, inspect the housing b

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3121139AssemblyReplace all seals and seal rings with new ones each timeyou reassemble the Torqlin

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-93BECAUSE THE BEARING/BUSHINGS (13) AND (19) HAVE APRESS FIT INTO THE HOUSING THEY MUST BE D

x – JLG Lift – 3121139LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 3121139 4. Place housing (18) assembly into a soft jawed visewith the coupling shaft bore down, c

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-957. Apply masking tape around splines or keyway onshaft (12) to prevent damage to seal. 8.

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3121139bolts as required that are over 0.5 inch (12.7 mm)longer than the bolts (1) used in the To

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-97manifold by the rotor set is another indication ofwhich surface must contact the rotor set

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3121139NOTE: If the end cover has a valve (24) or has five boltholes, use the line you previousl

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-9922. Torque the two shuttle valve plug assemblies (21) inend cover assembly to 9-12 ft. lbs

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 31211395. Grasp the output end of coupling shaft (12) withlocking pliers or other appropriate tu

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1015. Apply Loctite #271 to the capscrews (shown below)and pre-torque to 30 foot-pounds (42

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3121139Figure 3-55. Swing Bearing Torque SequenceNOTE: Swing Bearing Torque Sequence is typical

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1031. Swing Motor2. Swing Brake3. Swing Drive4. Swing Bearing5. Remote Lube Fitting6. Backla

3121139 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 31211393.16 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is desi

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-105Figure 3-57. Swing Bearing Tolerance Boom Placement. (Sheet 1 of 2)

SECTION 3 - CHASSIS & TURNTABLE3-106 – JLG Lift – 3121139Figure 3-58. Swing Bearing Tolerance Boom Placement.(Sheet 2 of 2)

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-107Wear Tolerance1. From the underside of the machine, at rear center,with the main boom ful

SECTION 3 - CHASSIS & TURNTABLE3-108 – JLG Lift – 3121139Figure 3-61. Swing Bearing Removal - 800S

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-109Figure 3-62. Swing Bearing Removal - 860SJ

SECTION 3 - CHASSIS & TURNTABLE3-110 – JLG Lift – 31211398. Carefully place the turntable on a suitably supportedtrestle.9. Use a suitable tool to

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1113.17 ROTARY COUPLINGUse the following procedure to install the seal kit.1. If not already

SECTION 3 - CHASSIS & TURNTABLE3-112 – JLG Lift – 31211391. Center Body2. Seal3. Housing4. O-ring5. Seal6. Thrust Ring7. Snap Ring8. Valve Block (

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-113Figure 3-65. Rotary Coupling Port Location

xii – JLG Lift – 3121139LIST OF TABLES TABLE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-114 – JLG Lift – 31211393.18 GENERATOREvery 250 hoursEvery 250 hours of operation, check the drive belt forproper

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-115Overload ProtectionSTOP THE ENGINE WHENEVER CHECKING OR INSPECTING THECIRCUIT BREAKER.The

SECTION 3 - CHASSIS & TURNTABLE3-116 – JLG Lift – 312113911/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must rideco

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1173.19 FORD EFI ENGINEPerforming Diagnostics1. Verify the complaint and determine if it is

SECTION 3 - CHASSIS & TURNTABLE3-118 – JLG Lift – 3121139ECM and SensorsCRANKSHAFT POSITION (CKP) SENSORThe crankshaft position (CKP) sensor provi

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-119Table 3-11. ECM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription11All Systems OK1

SECTION 3 - CHASSIS & TURNTABLE3-120 – JLG Lift – 3121139ENGINE COOLANT TEMPERATURE (ECT) SENSORThe engine coolant temperature (ECT) sensor is a g

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-121Figure 3-67. EFI Component Location

SECTION 3 - CHASSIS & TURNTABLE3-122 – JLG Lift – 3121139INTAKE AIR TEMPERATURE (IAT) SENSORThe intake air temperature (IAT) sensor is a thermisto

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-123The ECM is designed to maintain exhaust emission levelsto government mandated standards w

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS 1.2 SPECIFICATIONS AND PERFORMANCE DATATable

SECTION 3 - CHASSIS & TURNTABLE3-124 – JLG Lift – 3121139ELECTROSTATIC DISCHARGE DAMAGEElectronic components used in the ECM are oftendesigned to

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-125FUEL METERING SYSTEM PURPOSEThe basic function of the air/fuel metering system is tocontr

SECTION 3 - CHASSIS & TURNTABLE3-126 – JLG Lift – 3121139FUEL PRESSURE REGULATORThe fuel pressure regulator is a relief valve mounted in thefuel f

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-127OPEN LOOP AND CLOSED LOOP OPERATIONThe ECM will operate in the following two modes:• Open

SECTION 3 - CHASSIS & TURNTABLE3-128 – JLG Lift – 3121139IGNITION COILThe electronic ignition system uses a coil pack with oneignition coil for ea

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1293.20 DEUTZ EMR 2 (S/N 85332 TO PRESENT)The EMR2 consists of the sensors, the control unit

SECTION 3 - CHASSIS & TURNTABLE3-130 – JLG Lift – 3121139Figure 3-69. EMR 2 Engine Side EquipmentGLOW PLUGPOWER SUPPLYCOOLANT TEMPERATURESENSORCO

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-131Figure 3-70. Deutz EMR 2 Troubleshooting Flow Chart

SECTION 3 - CHASSIS & TURNTABLE3-132 – JLG Lift – 3121139Figure 3-71. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-133Figure 3-72. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31211391.3 CAPACITIES1.4 COMPONENT DATA Engine Data Table 1-3. CapacitiesFuel Tank Approx. 31 gallons (117

SECTION 3 - CHASSIS & TURNTABLE3-134 – JLG Lift – 3121139Figure 3-73. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-135Figure 3-74. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-136 – JLG Lift – 3121139Figure 3-75. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-137Figure 3-76. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3-138 – JLG Lift – 3121139Figure 3-77. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-139Figure 3-78. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3-140 – JLG Lift – 3121139Figure 3-79. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-141Figure 3-80. EMR2 Fault Codes - Sheet 5 of 5

SECTION 3 - CHASSIS & TURNTABLE3-142 – JLG Lift – 31211393.21 GM ENGINE GENERAL MAINTENANCEMaintenance of the Drive BeltThe serpentine drive belt

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1436. If the oil level is below the "ADD" mark, proceed toStep 7 and 8 and reinsta

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-3Battery1.5 TIRES1.6 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsLift: Telescope Retract

SECTION 3 - CHASSIS & TURNTABLE3-144 – JLG Lift – 31211392. Remove the radiator cap. Fill the radiator with cool-ant until coolant starts to appea

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-145Fuel FilterPropane fuel like all other motor fuels is subject to con-tamination from outs

SECTION 3 - CHASSIS & TURNTABLE3-146 – JLG Lift – 3121139Low Pressure Regulator (LPR)The LPR is a combination vaporizer, pressure regulatingdevice

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-147Electronic Throttle Control (ETC)Engine speed and load control is maintained by an ETCdev

SECTION 3 - CHASSIS & TURNTABLE3-148 – JLG Lift – 3121139Heated Exhaust Gas Oxygen SensorThere are two Heated Exhaust Gas Oxygen Sensors(HEGO). Th

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-149Fuel FilterAfter the fuel is drawn into the fuel pump, the fuel flowsthrough the gasoline

SECTION 3 - CHASSIS & TURNTABLE3-150 – JLG Lift – 3121139Propane Fuel Filter ReplacementREMOVAL1. Relieve the propane fuel system pressure. Refer

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1515. Remove the Electric Lock Off from the regulator. 6. Remove the lock pin from the vapor

SECTION 3 - CHASSIS & TURNTABLE3-152 – JLG Lift – 3121139Temperature Manifold Absolute Pressure (TMAP) SensorREMOVAL1. Disconnect the TMAP electri

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1532. Install the two quad seals. Install one seal at a timeto insure the seal does not roll

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3121139Drive (Elevated): Test should be done on a smooth levelsurface. Drive Select Switch should be set to

SECTION 3 - CHASSIS & TURNTABLE3-154 – JLG Lift – 3121139Coolant Hose ReplacementREMOVAL1. Drain the coolant. 2. Using hose clamp pliers, disconne

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1553.24 GM ENGINE LPG FUEL SYSTEM DIAGNOSISFuel System DescriptionTo maintain fuel and emiss

SECTION 3 - CHASSIS & TURNTABLE3-156 – JLG Lift – 3121139Table 3-12. LPF Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to th

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-15713 1. Turn OFF the ignition.2. Disconnect the LPL connector.3. Install a test light betwe

SECTION 3 - CHASSIS & TURNTABLE3-158 – JLG Lift – 312113925 The fuel supply system is operating normally, if a failure of the control solenoids is

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-159Table 3-13. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using This S

SECTION 3 - CHASSIS & TURNTABLE3-160 – JLG Lift – 3121139Intermittent Malfunction Indicator Lamp (MIL)The following components can cause intermitt

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-161Exhaust System Checks  Check the exhaust system for a possible restriction:

SECTION 3 - CHASSIS & TURNTABLE3-162 – JLG Lift – 3121139Exhaust System Checks  Check the exhaust system for a possible restriction: - Inspec

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-163Hesitation, Sag, StumbleDEFINITION: The vehicle has a momentary lack of response when dep

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-51.9 PRESSURE SETTINGS1.10 MAJOR COMPONENT WEIGHTSTable 1-15. Mobil DTE 13M SpecsISO Viscosity Grade

SECTION 3 - CHASSIS & TURNTABLE3-164 – JLG Lift – 3121139Lack of Power, Sluggishness, or SponginessDEFINITION: The engine delivers less than exp

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-165Ignition System Checks  Verify that the spark plugs are correct for use with LPG (R42LT

SECTION 3 - CHASSIS & TURNTABLE3-166 – JLG Lift – 3121139Engine Mechan ical Check  Check the engine for th e f ol lowin g:

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-167Table 3-14. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 Crank

SECTION 3 - CHASSIS & TURNTABLE3-168 – JLG Lift – 3121139562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid 628

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-169ABDCA. Exhaust VenturiB. 1/4" (6.35 mm) minimum clearance all around.C. 3

SECTION 3 - CHASSIS & TURNTABLE3-170 – JLG Lift – 3121139NOTES:

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM MAINTENANCERemoval1. Remove the platform/support as fol

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121139h. With powertrack support and using all applica-ble safety precautions, remove bolts #3 and #4

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-35. Using a 3/8 drive extension approximately 4 feet (1.2m) long, remove the bolts and washers s

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31211391.11 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Fig-ure 1-1., Operator M

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121139Figure 4-4. Boom Assembly Cutaway - Sheet 1 of 2

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-5Figure 4-5. Boom Assembly Cutaway - Sheet 2 of 21. Base Boom2. Mid Boom3. Fly Boom4. Telescope

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 31211391. Pivot Pin2. Power Link3. Tower4. Level Link5. Boom Pivot Pin6. Pin Cover7. Lift Cylinder Piv

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-71. Pivot Pin2. Level Link Pivot Pin3. Lift Cylinder Pivot Pin4. Boom Rest5. Level Cylinder Atta

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31211398. Carefully remove the telescope cylinder and sheaveassembly. Place telescope cylinder on a su

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-9InspectionNOTE: When inspecting pins and bearings Refer to theguidelines established in Section

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121139Figure 4-9. Proximity Switch AdjustmentNOTE: To avoid damaging the proximity switch, install

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-114. Install retract wire ropes into rear end of fly section,route wire ropes thru holes in side

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 312113919. Using adequate lifting equipment, carefully push thetelescope cylinder assembly and cables

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-13Figure 4-11. Boom Powertrack Installation

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-72. Wheel BearingsLube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 years or 1200 hour

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3121139Installation1. Using a suitable lifting device, position boomassembly on upright so that the p

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-157. Remove the four bolts, shims, and mounting blocksthat secure the telescope cylinder rod to

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 312113912. Twist the ends of the retraction cables to remove theends of the cables from the slots in

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-17WHEN PUSHING THE TELESCOPE CYLINDER INTO THE BOOM, ITMAY BE NECESSARY AT SOME POINT TO TURN TH

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3121139Lift Cylinder Removal1. Elevate the boom enough to gain access to the liftcylinder lower pivot

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-194.2 WIRE ROPEEach day before using the machine:1. Raise the main boom to approximately horizon

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 31211394.3 BOOM ROPE TORQUING PROCEDURESTorque Procedures1. Position boom in fully down and fully ret

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-214.4 ELEVATION & CAPACITY SWITCHES - 800S123456(ANSI Only)(ANSI Only)Figure 4-13. Elevatio

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3121139BOOM CAPACITYLENGTH SWITCHBOOM CAPACITYANGLE SWITCHBOOM ELEVATIONSWITCHBOOM TRANSPORTLENGTH SW

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-234.5 ELEVATION, DUAL CAPACITY, & TRANSPORT SWITCH - 860SJ123465(ANSI Only)(ANSI Only)Figure

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31211397. Platform FilterInterval - Change as necessary8. Suction StrainersLube Point(s) - 2Interval - Ever

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3121139BOOM CAPACITYLENGTH SWITCHBOOM TRANSPORTLENGTH SWITCHBOOM CAPACITYANGLE SWITCHBOOM ELEVATIONSW

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-254.6 ELECTRONIC PLATFORM LEVELINGDescriptionElectronic platform leveling replaces the conventio

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121139Figure 4-17. Level Switches - 800S

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-27Figure 4-18. Level Switches - 860SJ

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 3121139PLATFORM VALVESThe platform specific valves are located in a manifold atthe platform. There ar

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-293. Lift up and any other function, zone = Lift up4. Lift down and any other function, zone = L

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3121139VALVE DRIVER ERRORSThere are three possible level valve driver errors, short tobattery, short

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-31When both sensors appear to be working but have mea-surements that disagree by ±5.5º The follo

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 3121139STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS (FOR PLATFORM SOFTWARE PRIOR TOVERSION P3.4)1.

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-334.7 POWERTRACK MAINTENANCEOne Piece Bracket Maintenance1. Place the powertrack on a workbench.

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-912. Oil Change w/Filter - GMLube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965)Capacity

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 31211395. Slide the poly roller off of the round bar.6. Hold the round bar to remove the other screw.

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-3510. Push down with slight pressure on the link and slidethe bracket side up and over the extru

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 31211394. Hold the flat bar and remove the screws.5. Remove the snap rings and pins.6. Remove the scr

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-37Snap Rings and ScrewsWHEN PERFORMING MAINTENANCE ON THE POWERTRACK,MAKE SURE TO DISCARD AND RE

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 31211394.8 HELAC ROTARY ACTUATORTheory of OperationThe rotary actuator is a simple mechanism that use

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-391. Housing2. Shaft3. Piston Sleeve4. End Cap109. Lock Pin113. Cap Screw200.

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 31211391. Housing2. Shaft3. Piston Sleeve4. End Cap103.1 Screw (Optional)103.

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-41Tools Required for Assembly/DisassemblyUpon assembly and disassembly of the actuator there are

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 31211394. Install the end cap (4) removal tools provided withthe Helac seal kit.5. Using a metal bar,

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-439. Prior to removing the shaft, (2), use a felt marker toclearly indicate the timing marks bet

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 312113918. Electronic Pressure Regulator (LP only)Interval - 3 Months or 150 hours of operationComments -

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 312113915. Remove the wear guides (302) from the end cap (4)and shaft (2).16. To remove the main pres

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-45Inspection1. Clean all parts in a solvent tank and dry with com-pressed air prior to inspectin

SECTION 4 - BOOM & PLATFORM4-46 – JLG Lift – 31211394. Using a seal tool install the main pressure seal (205)onto shaft (2) and end cap (4). Use t

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-479. Looking from the opposite end of the housing (1)you can see if your timing marks are lining

SECTION 4 - BOOM & PLATFORM4-48 – JLG Lift – 312113915. Install the O-ring (204) and back-up ring (207) intothe inner seal groove on the end cap (

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-49Installing Counterbalance ValveRefer to Figure 4-21., Rotator Counterbalance Valve.1. Make sur

SECTION 4 - BOOM & PLATFORM4-50 – JLG Lift – 3121139Testing the ActuatorIf the equipment is available, the actuator should be testedon a hydraulic

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-51TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 4 - BOOM & PLATFORM4-52 – JLG Lift – 31211394.9 LOAD SENSING DEVICECalibrating the Load SensorNOTE: Refer to Section 6 - JLG Control Syste

SECTION 4 - BOOM & PLATFORM3121139 – JLG Lift – 4-5317. Adjust P1 until the Load = 100%18. Remove the weight from the basket.19. Seal the potentio

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-115. Disconnect the electrical connection to the LPG fueltemperature sensor in the auxiliary fuel por

SECTION 4 - BOOM & PLATFORM4-54 – JLG Lift – 3121139NOTES:

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 LUBRICATING O-RINGS IN THE HYDRAULIC SYSTEMWhen assembling connectors in the h

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121139Dip MethodNOTE: This method works best with Face Seal o-rings, butwill work for all o-ring fitting types

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-35.2 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31211399. With the barrel clamped securely, apply pressure tothe rod pulling device and carefully withdraw thec

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-59. Inspect cylinder head inside diameter for scoring orother damage and for ovality and tapering. Replac

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 3121139wear ring into the applicable cylinder head glandgroove.3. Place a new “O-ring and back-up seal in the a

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-711. Remove the cylinder rod from the holding fixture.12. Place new guide locks and seals in the applicab

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 3121139Steer Cylinder Seal Repair Instructions1. The cylinder should be disassembled in a cleanenvironment to p

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-91. 1. 30 ft. lbs. (40.6 Nm)2. 5 ft. lbs. (6.7 Nm)3. 10-12 ft. lbs. (13.5-16.2 Nm)4. 35 f

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121139INSTALLATIONBE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS-ING BEFORE INSTALLING NEW SEAL1. I

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31211391. Main Valve2. Platform Valve Filter3. Dual Flow Divider (4WD)4. Auxiliary Pump5. Jib Valve6. Platform

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-115.3 PRESSURE SETTING PROCEDURECold temperatures have a significant impact on pressurereadings. JLG Indu

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3121139HIGH PRESSURE RELIEF1. Install a high pressure gauge at the “M1” port of themain valve block. 2. Activa

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-13Adjustments Made at the Platform Valve AssemblyNOTE: When replacing the level up or level down cartridg

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 31211391. Check Valve2. Pilot Valve - Lift3. Check Valve (100 psi - 6.9 Bar)4. Tele Out Relief5. Lift Up Dump6

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-151. Level Down Relief2. Level Up Relief3. Flow Regulator (0.5 gpm - 1.9 lpm)4. Check Valve (25 psi - 1.7

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3121139Table 5-3. Cartridge Torque ValuesFt-Lbs. Nm1 20 27.12 25 33.93 20 274 35 47.45 20 27.16 30 40.67 25 33

SECTION 5 - HYDRAULICS3121139 – JLG Lift – 5-17Table 5-5. Cartridge Torque ValuesFt-Lbs. Nm1 20 272 20 273 20 274 20 275 20 276 25 347 20 278 20 279 2

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31211395.4 START UP PROCEDURESStart Up After Overhaul or Replacement of ComponentsPRE-FILL OF BOTH THE DRIVE A

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING A NEW GROUND MODULE CONTROLLER ONT

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-13Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121139Figure 6-2. EPBCS Block Diagram

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-3To Connect the JLG Control System Analyzer1. Connect the four pin end of the cable supplied with

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121139Figure 6-3. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-5When a top level menu is selected, a new set of menuitems may be offered: for example: DRIVEBOOM

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121139Figure 6-4. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-7Once the correct password is displayed, press ENTER.The access level should display the followin

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121139Machine SetupWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust its

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-9ACCESS LEVEL:CODE 33271MENU:ACCESS LEVEL 1MENU:PERSONALITIESTOMENU:MACHINE SETUPPERSONALITIES:DR

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121139FROMPERSONALITIES:SWINGPERSONALITIES:TOWER LIFTPERSONALITIES:UPPER TELESCOPEPERSONALITIES:BASKE

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-11FROMMENU:PERSONALITIESMENU:MACHINE SETUPTOMENU:CALIBRATIONSMODEL NUMBER:1=400ENGINE:1=FORD EFI

INTRODUCTION3121139 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121139Figure 1-5. Torque Chart (SAE Fasteners - Sheet 2 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121139Figure 6-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-13Figure 6-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4NOTE: Some screens may not

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121139Figure 6-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-15FROM:MENU:PERSONALITIESMENU:MACHINE SETUPTO:MENU:CALIBRATIONSMODEL NUMBER:400SENGINE:FORD EFI G

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121139MENU:HELP:PRESS ENTERHELP:GROUND MODE OKFROM:MENU:MACHINE SETUPMENU:CALIBRATIONSMENU:DIAGNOSTIC

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-17Machine Personality Settings NOTE: Personality settings can be adjusted within theadjustment ra

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121139TELEscope ACCELeration 0.1 to 5.0 3.5 3.5DECELeration 0.1 to 3.0 1.0 1.0MINimum IN speed 0 to 6

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-19GROUND MODE LIFT speed (Up & Down) 0 to 100 60 60SWING speed 0 to 100 60 60TELEscope speed

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121139Table 6-2. Analyzer Fault Code ListingDTC Analyzer Text001 EVERYTHING OK002 GROUND MODE OK0010

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-21331 BRAKE - SHORT TO BATTERY332 BRAKE - OPEN CIRCUIT3311 GROUND ALARM - SHORT TO BATTERY3316 RI

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-15Figure 1-6. Torque Chart (SAE Fasteners - Sheet 3 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 31211393370 TWO SPEED VALVE - SHORT TO BATTERY3371 GROUND ALARM - SHORT TO GROUND3372 GROUND ALARM - O

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-2333115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND33116 TOWER TELESCOPE OUT VALVE - OPEN CIRCUIT

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 312113933315 FLOW CONTROL VALVE - SHORT TO BATTERY33316 FLOW CONTROL VALVE - SHORT TO GROUND33317 DRIV

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-25431 FUEL SENSOR - SHORT TO BATTERY432 FUEL SENSOR - SHORT TO GROUND433 OIL PRESSURE - SHORT TO

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 31211398311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY8312 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-279920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTO

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121139Table 6-3. Machine Configuration Programming Information Prior to Software Version P5.3Configur

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-29GLOW PLUG:5012NO GLOW PLUGS: No glow plugs installed.W/O STARTER LOCK: Automatic pre-glow time

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121139GEN SET CUTOUT:12* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-31GROUND ALARM:18* * Certain market selections will alter default setting.0123NO: No ground alarm

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121139Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 1 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121139Table 6-4. Machine Configuration Programming Information Software Version P5.3 to P6.1Configura

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-33ENGINE:3* * Engine selections vary depending on model selec-tion.12345678910111213FORD EFI GAS

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121139ENGINE SHUTDOWN:701DISABLED: No engine shutdown.ENABLED: Shutdown engine when coolant temperatu

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-35GEN SET CUTOUT:13* * Only visible if Gen Set / Welder Menu selection is not 0.01MOTION ENABLED

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121139FUNCTION CUTOUT:18* * Only visible under certain market selections. * Certain market selectio

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-37Table 6-5. Machine Configuration Programming Information Software Version P6.1 to PresentConfig

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121139ENGINE:3* * Engine selections vary depending on model selec-tion.123456789101112131415FORD EFI

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-39STARTER LOCKOUT:601DISABLED: Automatic pre-glow time determined by ambient air temperature; eng

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3121139GEN SET/WELDER:1201NO: No generator installed.BELT DRIVE: Belt driven setup.0GEN SET CUTOUT:13*

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-41LOAD SENSOR:17* * Only visible if Load Sen-sor Menu selection is not 0 and under certain marke

SECTION 1 - SPECIFICATIONS3121139 – JLG Lift – 1-17Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 2 of 3))

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 3121139LEVELING MODE:22* * Only visible on 800S models.01ALL FUNCTIONS: Platform level with all funct

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-43800SMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUTENGINE SHUTDOWNTILTJIB4 WHEE

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 3121139860SJMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSSTARTER LOCKOUTENGINE SHUTDOWNTILTJIB4 WHE

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-45Table 6-6. Machine Configuration ParametersConfiguration DigitParameter (Displayed on Analyzer

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 31211396Tilt: 1=5Deg2=4Deg3=3DegDisplays/adjusts tilt sensor function1235 degree – reduces the maxi-mu

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-4713 Head & Tail LIGHTS0=NO1=YESDisplays presence of head and tail lights01No Head and Tail L

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 312113920 PLATFORM ALARM0=NO1=FAULT CODEDisplays/adjusts platform alarm presence/functions0 1Sounds Co

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-49Analyzer Diagnostics Menu Structure In the following structure descriptions, an intended item i

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121139SWINGACCEL … Displays/adjusts swing accelerationDECEL … Displays/adjusts swing decelerationMIN

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-51ACCEL … Displays/adjusts jib accelerationDECEL … Displays/adjusts jib decelerationMIN UP … Disp

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3121139Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 3 of 3)

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121139Table 6-8. Diagnostic Menu DescriptionsDRIVEDRIVE FOR … Displays drive joystick direction &

SECTION 6 - JLG CONTROL SYSTEM3121139 – JLG Lift – 6-53PM BATTERY … Displays battery voltage at platform moduleTEMP... Displays ground module tempera

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121139NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121139Resistance Measurement• First test meter and leads by touching leadst

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-3Current Measurement• Set up the meter for the expected current range•

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 31211397.4 AMP CONNECTORApplying Silicone Dielectric Compound to AMP Connect

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-53. After all required contacts have been inserted, thewedge lock must

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 3121139Disassembly5. Insert a 4.8 mm (3/16") wide screwdriver bladebetw

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-7Figure 7-11. Connector Installation

SECTION 2 - GENERAL3121139 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31211397.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-9HD30/HDP20 Series Assembly8. Grasp contact about 25mm behind the cont

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121139Figure 7-18. Electrical Components Installation (Prior to S/N 03000

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-11J7HEADLIGHTSANDTAILLIGHTSSPEEDPICKUP(DEUTZENGINE)RECEPTACLEAT PLATFO

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121139J5J6J7J2J2J1J8J3J1J8DIAGNOSTICANALYZERPLATFORMCONTROLBOXGROUNDCONTRO

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-13GENERATORCONTROL BOXCATERPILLAR/DEUTZ ENGINESANSI SPECS ONLY BOSCH

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121139Figure 7-22. Electrical Schematic - Deutz EMR2, GM & Cat - Shee

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-15Figure 7-23. Electrical Schematic - Deutz EMR2, GM & Cat - Shee

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121139Figure 7-24. Electrical Schematic - Deutz EMR2, GM & Cat - Shee

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-17J1-11J1-12DEUTZ ENGINETIER II AND III8685873087aLINKRED 1-3 (12)RED

SECTION 2 - GENERAL2-2 – JLG Lift – 31211392.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121139Figure 7-26. Electrical Schematic - Deutz EMR2, GM & Cat - Shee

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-19Figure 7-27. Electrical Schematic - Deutz EMR2, GM & Cat - Shee

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121139Figure 7-28. Hydraulic Schematic - Sheet 1 of 8

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-21Figure 7-29. Hydraulic Schematic - Sheet 2 of 82792678 C

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121139Figure 7-30. Hydraulic Schematic - Sheet 3 of 8

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-23Figure 7-31. Hydraulic Schematic - Sheet 4 of 82792678 C

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121139Figure 7-32. Hydraulic Schematic - Sheet 5 of 8

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-252792678 CFigure 7-33. Hydraulic Schematic - Sheet 6 of 8

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-26 – JLG Lift – 3121139Figure 7-34. Hydraulic Schematic - Sheet 7 of 8

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121139 – JLG Lift – 7-272792678 CFigure 7-35. Hydraulic Schematic - Sheet 8 of 8

SECTION 2 - GENERAL3121139 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-28 – JLG Lift – 3121139NOTES:

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

SECTION 2 - GENERAL2-4 – JLG Lift – 31211392.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3121139 – JLG Lift – 2-5Cylinder DriftDrift is to be measured at the cylinder rod with a calibrateddial indicator. The cylinder oil

INTRODUCTIONA-2 – JLG Lift – 3121139REVISON LOGOriginal Issue - October 31, 2001Revised - January 16, 2002Revised - February 4, 2002Revised - May 10,

SECTION 2 - GENERAL2-6 – JLG Lift – 3121139Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3121139 – JLG Lift – 2-7Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Stop

SECTION 2 - GENERAL2-8 – JLG Lift – 3121139Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additio

SECTION 2 - GENERAL3121139 – JLG Lift – 2-9Figure 2-1. Engine Operating Temperature Specifications - Deutz4150548 D

SECTION 2 - GENERAL2-10 – JLG Lift – 3121139Figure 2-2. Engine Operating Temperature Specifications - Ford4150548 D

SECTION 2 - GENERAL3121139 – JLG Lift – 2-11Figure 2-3. Engine Operating Temperature Specifications - Caterpillar4150548 D

SECTION 2 - GENERAL2-12 – JLG Lift – 3121139Figure 2-4. Engine Operating Temperature Specifications - GM4150548 D

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES & WHEELSTire InflationThe air pressure for

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 3121139Wheel InstallationIt is extremely important to apply and maintain properwheel mounting torq

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-3Assembly and Installation1. If re-installing the old studs or installing new ones,coat the

3121139 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 31211393.3 DRIVE MOTOR - 2WD (PRIOR TO S/N 83331)Replacing the Drive Shaft Seal1. Remove snap ring

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-5Disassembly1. Disassemble the pilot valve.2. Mark the position of the port plate and remove

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 31211397. Unscrew the cap nut and remove it.8. Loosen the fixing nut of the stopper max flow anddi

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-714. Disassemble the control plate while moving theswash plate.15. The swash plate must be l

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 312113921. Disassemble the sealing ring.22. The external front bearing ring is pulled out of thepu

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-9Assembly1. Assemble the variable displacement pump inreverse order.2. Measurement of the ta

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121139Figure 3-2. Bearing Tension

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-113.4 DRIVE MOTOR (S/N 83331 TO PRESENT)DescriptionThe drive motors are low to medium power,

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121139Loop Flushing ValveREMOVAL1. Using a 11/16 in internal hex wrench remove plug(1) and (2).2

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-13TroubleshootingTable 3-2. Excessive Noise and/or VibrationItem Description ActionCheck oil

ii – JLG Lift – 3121139TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121139DisassemblyNOTE: Removal of the endcap voids warranty.During assembly, coat all moving par

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1513. Using an 8 mm internal hex wrench, remove theendcap screws (22).14. Remove the endcap

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 312113918. Remove minimum angle stop (29) and servo spring(30) from the housing.19. Turn the hous

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-1723. Turn housing over and remove the swashplate (39)by lifting on the end opposite the ser

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 312113928. Turn the block over. Using a press, apply pressureon the block spring washer (50) to c

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-19BALL GUIDE AND SLIPPER RETAINERInspect the ball guide and slipper retainer for damage,disc

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3121139SERVO PISTON AND MINIMUM ANGLE STOPInspect the minimum angle stop, servo piston head, ands

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-21RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRINGREQUIRES ABOUT 80 TO 90 LBF (350 TO 4

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31211398. Press front shaft bearing (15) onto shaft (16). Pressbearing onto shaft with lettering

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-2312. Press the rear shaft bearing (22) into the endcap.Install the bearing with letters fac

3121139 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 312113918. Cover shaft splines with an installation sleeve. Installa new shaft seal (27) with the

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-2520. Install orifice poppet (30).21. Install shift spool (31).22. Install spring retaining

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 31211393.5 TORQUE HUBDisassembly1. Position hub over suitable container and removedrain plugs (10

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-27Repair1. Cover Assembly.a. Remove two bolts (25) securing disconnect cap(26) to cover (23)

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3121139m. While keeping thrust washers in place, slidecluster gear into carrier with larger gear

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-29Assembly.1. Using a suitable press, press new bearing cups (3,5), with large inside diamet

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121139EYE PROTECTION SHOULD BE WORN DURING RETAINING RINGINSTALLATION.7. Install new retaining r

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-3114. Place o-ring (22) into hub counter bore. Use petro-leum or grease to hold o-ring in pl

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 312113921. Place o-ring (22) into cover assembly counter bore.Use petroleum jelly or grease to ho

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-33Figure 3-26. Torque Hub Drive (Fairfield)1. Spindle2. Seal3. Bearing Cup4. Bearing Cone5.

iv – JLG Lift – 3121139TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 31211393.6 WHEEL DRIVE ASSEMBLY, 4WDRemoval and DisassemblyNOTE: The drive motor can be removed t

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-353.7 TORQUE HUB (4WD MACHINES W/ INTEGRAL BRAKE)Roll, Leak and Brake TestingTorque-Hub unit

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121139Main Disassembly1. Perform Roll Check, Leak Check and Brake Check ifapplicable prior to di

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-37Figure 3-29. Main Disassembly Drawing 27. Input Shaft8. Output Sun Gear17. Inpu

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121139Input Carrier Disassembly1. Place the Carrier (3A) on a press with the spline endup and dr

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-39Output Carrier Disassembly1. Using a small diameter punch, Drive the Roll Pin(4G) which ho

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121139Housing-Spindle Disassembly1. Place unit on bench with Spindle (1A) end down.EYE PROTECTIO

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-41Spindle-Brake DisassemblyNOTE: This procedure applies only to units with integralinput bra

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 31211391. Compress the Compression Springs (2-13) byinstalling a minimum of three M4 x 16mm Socke

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-43Figure 3-34. Input Carrier Sub-Assembly3A. Carrier3B. Thrust Washers3C. Needl

3121139 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121139Output Carrier Sub-Assembly1. Place Spring (4I) into the deep counterbore of theOutput Car

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-454A. Output Carrier4B. Thrust Washer4C. Needle Rollers4E. Planet Shaft4F.

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3121139Spindle-Brake Sub-AssemblyNOTE: This procedure applies only to units with integralinput br

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-47Figure 3-36. Spindle Brake Sub-Assembly1-A. Spindle12. Pressure Plug2-1. Inte

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3121139Housing-Spindle Sub-AssemblyNOTE: Spray a light film of oil on all component parts duringa

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-49Figure 3-37. Housing-Spindle Disassembly1B. Seal1C. Bearing Cups1D. Bearing C

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 3121139Main AssemblyNOTE: All components should receive a generous amountof lubricant oil as they

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-51Figure 3-39. Main Assembly Drawing 26. Cover9. Input Coupling10. Thrust Spacer1

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 3121139Figure 3-40. Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121139 – JLG Lift – 3-531A Spindle1G Retaining Ring - Ext12 Pressure Plug16 O-ring Pipe Plug1F Thrust Washer1E Hou