Service 3121290

Service and Maintenance Manual
Model
450A Series II
450AJ Series II
S/N 0300160835
to Present
P/N - 3121290
October 4, 2013
NOTE: This manual also applies to machines with the following
Serial Numbers: 0300159794, 0300159795,
0300160088, and 0300160456.
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A GENERAL C MAINTENANCE
This section contains the general safety precautions which
must be observed during maintenance of the aerial platform.
It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
possible injury to themselves or others, or damage to the SAFETY VIOLATION.
equipment. A maintenance program must be followed to
ensure that the machine is safe to operate. • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during maintenance • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
are inserted at the appropriate point in the manual. These pre- FORMING ANY MAINTENANCE.
cautions are, for the most part, those that apply when servic-
ing hydraulic and larger machine component parts. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
Your safety, and that of others, is the first consideration when CAUGHT ON OR ENTANGLED IN EQUIPMENT.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
the aid of a mechanical device. Do not allow heavy objects to MACHINE AND IN SERVICE MANUAL.
rest in an unstable position. When raising a portion of the • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
equipment, ensure that adequate support is provided. SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL-
ANT SYSTEM.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL-
BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
ITY OF THE OWNER/OPERATOR.
BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
HAS BEEN ENGAGED.
B HYDRAULIC SYSTEM SAFETY • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-
FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
It should be noted that the machines hydraulic systems oper-
POWER CONTROLS.
ate at extremely high potentially dangerous pressures. Every
effort should be made to relieve any system pressure prior to • BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING
disconnecting or removing any portion of the system. REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-
VENTS.
3121290 – JLG Lift – A-1

INTRODUCTION
REVISON LOG
Original Issue January 10, 2013

Revision 1 October 4, 2013
A-2 – JLG Lift – 3121290

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 and Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.9 Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.10 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
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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
3121290 – JLG Lift – i

TABLE OF CONTENTS

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires And Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
MAIN DISASSEMBLY for “B” Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Hub-Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Assemble Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Cover Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.3 Re-Align Torque Hub Input Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.4 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Initial Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.5 Adjustment Procedure For Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.6 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Lockout Cylinder Bleeding (Ram Cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Oscillating Axle Lockout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.7 Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Turntable Bearing Mounting Bolt Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Check Frame To Bearing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Check Turntable To Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Wear Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.8 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Preparation Before Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Preparation Before Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
One Piece Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Two Piece Stator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Final Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
ii – JLG Lift – 3121290

TABLE OF CONTENTS

3.9 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
3.10 Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Check Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Change Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Replace Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Clean Fuel Strainer (D2011 L03 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.11 Deutz EMR 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3.12 Bio Fuel in Deutz Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Bio Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Biological Contamination In Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
3.13 GM Engine General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Drive Belt Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Engine Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Coolant Fill Procedure - Dual Fuel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
3.14 GM Engine Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Direct Electronic Pressure Regulator (DEPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Electronic Throttle Control (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Electric Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Heated Exhaust Gas Oxygen Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Gasoline Multi Point Fuel Injection System (MPFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Gasoline Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Gasoline Pressure And Temperature Sensor Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Fuel Injector Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
3.15 GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection . . . . . . . . . . . . . . . . . . . . . . . 3-88
Check/Drain Oil Build-Up In 2-Stage Vaporizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Air Fuel Mixer/Throttle Control Device Maintenance And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Exhaust System And Catalytic Converter Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Temperature Manifold Absolute Pressure (TMAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Throttle Body (ETC) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Mixer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Electronic Pressure Regulator (EPR) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Coolant Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Vapor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Engine Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
3.16 GM Engine LPG Fuel System Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3121290 – JLG Lift – iii

TABLE OF CONTENTS

3.17 DGC Diagnostic Support And Trouble Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
Section Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
Fault Code Broadcast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
CAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
MIL Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
Diagnostic Calibration Configuration and Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
Fault/Diagnostic Trouble Code Interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
DBW Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3.18 Diagnostic Trouble Code Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117
DTC 117- ECT/CHT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120
DTC 122- TPS1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
DTC 123- TPS1 Signal Voltage High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-124
DTC 217- ECT Higher Than Expected 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
DTC 219- RPM Higher Than Max Allowed Governed Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
DTC 337- Loss of Crank Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
DTC 521- Oil Pressure Sender/Switch High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131
DTC 524- Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
DTC 562- Battery Voltage (VBat) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
DTC 601- Microprocessor Failure - FLASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
DTC 604- Microprocessor Failure - RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
DTC 606- Microprocessor Failure - COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148
DTC 643- 5 Volt External High Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-149
DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-150
DTC 1615- Microprocessor Failure - A/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
DTC 1616- Microprocessor Failure - interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
DTC 1625- CAN J1939 Shutdown Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
DTC 1626- CAN J1939 Transmit (Tx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-160
DTC 1627- CAN J1939 Receive (Rx) Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162
DTC 1629- J1939 TSC1 Message Receipt Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-164
DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165
DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
DTC 2112- Unable to Reach Higher TPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168
DTC 9999- Throttle Actuator Failsafe Spring Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-169
DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-170
SECTION 4 - BOOM & PLATFORM
4.1 Boom Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remove Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Main Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Install Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Rotary Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installing Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
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4.3 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Install New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Replace Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Replace Moving End Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
SECTION 5 - HYDRAULICS
5.1 O-Ring Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tower Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Main Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Master Cylinder (450 A/AJ) Without Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Master Cylinder (450 A/AJ) With Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Slave (Platform Level) Cylinder Without Arctic Pkg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Platform Level (Slave) Cylinder With Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Jib Lift Cylinder (AJ Only) Without Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Jib Lift Cylinder (AJ Only) With Arctic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5.3 Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Inspect Parts For Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Reverse Shaft Rotation of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Placing Pump Back Into Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.4 Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Ports and Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
NFPE Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Remove and Install FNR and NFPE Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Remove and Install FNR and NFPE Control Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Charge Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Shaft Seal and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5.5 Hydraulic Component Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5.6 Main Valve Block Pressure Setting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Telescope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Swing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.7 Platform Valve Block Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Platform Level Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Platform Level Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Articulating Jib (AJ Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
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SECTION 6 - JLG CONTROL SYSTEM
6.1 introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Connect JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Using Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Changing Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Adjust Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.8 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Test from Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Test From Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Exclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
vi – JLG Lift – 3121290

LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-3. Deutz Engine Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-4. Torque Chart (SAE Fasteners - Sheet 1 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
3-1. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Bolt Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Drive Hub and Brake Assembly (2WD and 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-4. Drive Hub (4WD Front Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5. Cluster Gear Punch Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-6. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-7. Removing Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-8. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-10. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-11. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-12. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-13. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-14. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-15. Shaft & Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-16. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-17. Cylinder Kit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-18. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-19. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-20. Swash Plate and Journal Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-21. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-22. Cylinder Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-23. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-24. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-25. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-26. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-27. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-29. Chassis Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-30. Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-31. Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-32. Swing Bearing Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-33. Swing Bearing Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3-34. Swing Bearing (Dohi) Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3-35. Swing Bearing (Jing Wei) Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3-36. Swing Bearing Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3-37. Swing Bearing Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-38. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3-39. Swing Motor - Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-40. Swing Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
3-41. Swing Motor - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
3-42. Auxiliary Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3-43. Generator Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
3-44. Deutz Dipstick Markings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-45. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
3-46. EMR 2 Engine Side Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-47. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3121290 – JLG Lift – vii

LIST OF FIGURES

3-48. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3-49. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3-50. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3-51. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3-52. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3-53. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3-58. GM Engine Oil Dip Stick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
3-59. GM 3.0 Dual Fuel System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-60. Direct Electronic Pressure Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
3-61. Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
3-62. ELectronic Throttle Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3-63. Electric Lock Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3-64. ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3-65. ECM Input-Output Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3-66. Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
3-67. Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
3-68. Filter Lock Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3-69. DEPR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3-70. GM 3.0L Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3-71. GM 3.0L Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3-72. Faults Page with Active Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112
3-73. Faults Page with Historic Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
3-74. Custom Fault Variable Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
3-75. Historic Fault Information Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
3-76. Snapshot Data Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3-77. Flight Data Recorder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3-78. Clear Faults Prompt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116
3-79. Exhaust Venturi Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-171
3-80. Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172
4-1. Location of Components - Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2. Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-2. Boom Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-3. Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-4. Rotary Actuator - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-5. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-6. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
5-1. Hydraulic Cylinder Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-4. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-5. Tower Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-6. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-7. Composite Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-8. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-9. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-10. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-11. Head Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-12. Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-13. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-14. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-17. Main Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
viii – JLG Lift – 3121290

LIST OF FIGURES

5-18. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-19. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-20. Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-21. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-22. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-23. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-24. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-25. Master Cylinder (450A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-26. Master Cylinder (450AJ W/O Arctic Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-29. Installation of Head Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-30. Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-31. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-35. Master Cylinder (450AJ W/Arctic Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-36. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-39. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-41. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-45. Telescope Cylinder 450A/AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-48. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-53. Platform Level Slave Cylinder Assembly (450A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-54. Platform Level Slave Cylinder Assembly (450AJ W/O Arctic Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-61. Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-63. Platform Level Slave Cylinder Assembly (450AJ W/Arctic Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-64. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-67. Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-68. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-70. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-71. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
3121290 – JLG Lift – ix

LIST OF FIGURES

5-76. Jib Lift Cylinder (450AJ W/O Arctic Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-79. Cylinder Head Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5-83. Marking Cylinder for Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5-85. Jib Lift Cylinder (450AJ W/Arctic Package) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5-86. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-89. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-90. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-91. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-93. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-96. Removing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-98. Steer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5-99. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-100. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-102. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-103. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-104. Steering Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-105. Cylinder Head Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-106. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5-107. Shim Adjustable Charge Relief Valve Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5-108. Gauge Port Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5-109. Plugs/Fittings Size & Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5-110. Screw Adjustable Charge Relief Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-111. Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-112. Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-113. Shaft Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5-114. Charge Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5-115. Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-116. Platform Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
6-1. Hand-Held Analyzer (WANALYZER Controls and Display Similar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Controller Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3. Analyzer Platform Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4. Analyzer Ground Control Box Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5. Analyzer Software Version 6.8 - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-11. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6-12. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-13. Control Module And Fault Code Light Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
x – JLG Lift – 3121290

LIST OF FIGURES

7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. Applying Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6. Deutsch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7. Dielectric Grease On Female Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-8. Seal Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-9. AMP Mate-N-Lok Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-10. DIN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-11. Brad Harrison/Phoenix Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-12. AMP Junior Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-13. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-14. AMP Contact Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-15. AMP Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-16. AMP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-17. Close Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-18. Seating Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-19. AMP Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-20. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-21. DT/DTP Contact Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-22. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-23. HD/HDP Locking Contacts Into Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-24. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-25. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-26. Electrical Components 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-27. Electrical Components 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-28. Chassis/Platform Electrical Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-29. Chassis/Platform Electrical Schematic -Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7-30. Deutz Engine Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7-31. GM 3.0L Engine/Chassis Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-32. ECM Electrical Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-33. ECM Electrical Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7-34. Main Hydraulic Schematic - 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-35. Main Hydraulic Schematic - 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-36. Two Wheel Drive Hydraulic Schematic - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-37. Two Wheel Drive Hydraulic Schematic - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7-38. Four Wheel Drive Hydraulic Schematic - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-39. Four Wheel Drive Hydraulic Schematic - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
3121290 – JLG Lift – xi

LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Reach Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Deutz D2011L03. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-8 Deutz 2.9 L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-9 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-10 Component Weights - 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-11 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-12 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-13 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-14 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-15 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-16 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-17 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 Drive Hub and Brake Assembly (2WD and 4WD) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-3 Drive Hub (4WD Front Only) Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-4 Excessive Noise and/or Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-5 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-6 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-7 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-8 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-9 Cylinder Block Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-10 Chassis Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-11 Swing Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
3-12 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3-13 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3-14 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
3-15 J1939 Diagnostic Lamp Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
3-16 Diagnostic Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111
3-17 Historic Fault Information Interface Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
5-1 Hydraulic Pump Bolt Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5-2 Recommended Gauge Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-2 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-3 Machine Configuration Programming Information Software Version P6.1 to Present . . . . . . . . . . . . . . . . . . 6-18
6-4 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6-5 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6-6 Help Fault Codes, Displayed Faults, and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
xii – JLG Lift – 3121290

SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS AND 1.2 DIMENSIONAL DATA
PERFORMANCE DATA
Table 1-3. Dimensional Data
Table 1-1. Operating Specifications Overall Width 7 ft. 8.25 in. (2.34 m)
Unrestricted Rated Capacity Tailswing 0
ANSI 500 lb. (227 kg) Stowed Height 7 ft. 6 in. (2.29 m)
CE & Australia 500 lb. (230 kg) Stowed Length-450A SII 21 ft. 11 in. (6.68 m)
Maximum Travel Grade (Grade- Stowed Length-450AJ SII 22 ft. 0.25 in. (6.71 m)
ability)
with Boom retracted and approx- Wheel base 7 ft. 8 in. (2.34 m)
imately horizontal. Tower Boom Ground Clearance 11.5 in. (0.29 m)
fully lowered (if equipped). 30%
2WD 45% 1.3 CHASSIS
4WD
Maximum Travel Grade (Sides- 5° Table 1-4. Chassis Specifications
lope) with Boom retracted and
approximately horizontal. Tower Swing 360° non-continuous
Boom fully lowered (if equipped) Rated Gradeability
- ANSI Markets. 2WD 30%
Maximum Travel Grade (Sides- 4° 4WD 45%
lope) with Boom retracted and Max. Tire Load 7200 lb. (3266 kg)
approximately horizontal. Tower Axle Oscillation 8 in. (0.2 m)
Boom fully lowered (if equipped)
- CE & Australia Markets. System Voltage 12 Volts
Ground Bearing Pressure Max. Hydraulic System Operating 4500 psi

Pressure (310 bar)
Pneumatic 65 psi (4.57 kg/cm2)
Gross Machine Weight - 450A SII
Foam Filled 65 psi (4.57 kg/cm2)
Pneumatic Tires 12,750 lbs. (5783 kg)
Maximum Drive Speed: 4.5 mph (2.0 m/s) Foam-Filled Tires 13,000 lbs. (5897 kg)
Maximum Hyd. Operating Pres- 4500 psi (310 Bar) Gross Machine Weight - 450AJ SII
sure Pneumatic Tires 13,250 lbs. (6010 kg)
Electrical System Voltage 12 volts Foam-Filled Tires 13,550 lbs. (6146 kg)
1.1 REACH SPECIFICATIONS 1.4 CAPACITIES

Table 1-2. Reach Specifications Table 1-5. Capacities
Max. Platform Height 45ft. (13.72 M) Fuel Tank 17 gallons (64.3 liters)
Max. Horizontal Reach-450A SII 24 ft. 7.25 in. (7.50 M) Hydraulic Tank 27 gallons (102 liters)
Max. Horizontal Reach-450AJ SII 24 ft. 6 in. (7.47 M) 23.6 gal. (89 liters) to the mid
point of upper sight window
Up & Over Height-450A SII 25 ft. 9.5 in. (7.56 M) (cold)
Up & Over Height-450AJ SII 25 ft. 10 in. (7.57 M) Drive Hub 23.75 oz. (0.7 liters)
Main Boom Up Angle 75° Drive Brake 2.7 oz. (0.08 liters)
Main Boom Down Angle -24°
3121290 – JLG Lift – 1-1

1.5 TIRES Table 1-9. GM 3.0L
Fuel Gasoline or Gasoline/LP Gas

Table 1-6. Tires
No. of Cylinders 4
Size Type Pressure Weight BHP
12x16.5 Pneumatic 90 psi (6 Bar) 128 lb (58 kg) Gasoline 83 hp @ 3000 rpm
LP 75 hp @ 3000 rpm
12x16.5 Foam-Filled N/A 328 lb (149 kg)
Bore 4.0 in. (101.6 mm)
33/1550x16.5 Pneumatic 90 psi (6 Bar) 135 lb (61 kg)
Stroke 3.6 in. (91.44 mm)
33/1550x16.5 Foam-Filled N/A 395 lb (179 kg)
Displacement 181 cu.in. (3.0 L, 2966 cc)
14x17.5 Pneumatic 90psi (6 Bar) 170 lb (77.2 kg)
Oil Capacity w/filter 4.5 qts. (4.25 L)
14x17.5 Foam-Filled N/A 440 lb (200 kg)
Minimum Oil Pressure
at idle 6 psi (0.4 Bar) @ 1000 rpm
1.6 ENGINE Hot 18 psi (1.2 Bar) @ 2000 rpm
NOTE: RPM Tolerances are ± 100. Compression Ratio 9.2:1
Firing Order 1-3-4-2
Table 1-7. Deutz D2011L03 Max. RPM 2800
Fuel Diesel Table 1-10. Component Weights - 450

No. of Cylinders 3
Component Pounds Kilograms
Bore 3.7 in. (94 mm)
Stroke 4.4 in. (112 mm) Frame (Bare) 1531 695
Displacement 142 cu. in. (2331 cm³) Turntable (Bare) 1355 615
Oil Capacity Boom Link 180 82

crankcase 6.3 Qt (6 L) Boom Timing Link 30 14
cooler 4.75 Qt (4.5 L) Upper Upright 217 98
total capacity 11 Qt (10.5 L)
Lower Upright 115 52
Low RPM 1200
Lower Boom 497 225
Mid RPM
Mid Boom 385 175
Tower Lift, Upper Lift, Tele
Swing, Basket Level, Basket 1800 Upper Boom 1065 484
Rotate, Jib Lift 1500 4 Wheel Drive Axle 266 121
High RPM 2800 2 Wheel Drive Axle 258 117
Counterweight 2297 1042
Table 1-8. Deutz 2.9 L4
Fuel Diesel
No. of Cylinders 4
BHP 48.8 hp (36.4 kW)
Bore 3.6 in. (92 mm)
Stroke 4.3 in. (110 mm)
Displacement 177 cu. in. (2.9L)
Oil Capacity w/filter 9.4 Qt (8.9 L)
Compression Ratio 18.4:1
Firing Order 1-3-4-2
Max. RPM 2600
1-2 – JLG Lift – 3121290

1.8 HYDRAULIC OIL

Table 1-13. Mobil DTE 13M Specs
Table 1-11. Hydraulic Oil ISO Viscosity Grade #32
Hydraulic System Operating S.A.E. Viscosity Specific Gravity 0.877
Temperature Range Grade Pour Point, Max -40°F (-40°C)
+0° to + 180° F 10W Flash Point, Min. 330°F (166°C)
(-18° to +83° C) Viscosity
+0° to + 210° F 10W-20, 10W30
at 40° C 33cSt
(-18° to +99° C)
at 100° C 6.6 cSt
+50° to + 210° F 20W-20
(+10° to +99° C at 100° F 169 SUS
at 210° F 48 SUS
NOTE: Hydraulic oils must have anti-wear qualities at least to API cp at -20° F 6,200
Service Classification GL-3, and sufficient chemical stabil- Viscosity Index 140
ity for mobile hydraulic system service. JLG Industries rec-
ommends Mobilfluid 424 hydraulic oil with an SAE
viscosity index of 152.
Table 1-14. UCon Hydrolube HP-5046
NOTE: When temperatures remain consistently below 20 degrees Type Synthetic Biodegradable
F. (-7 degrees C.), JLG Industries recommends using Mobil Specific Gravity 1.082
DTE13.
Pour Point, Max -58°F (-50°C)
pH 9.1
Viscosity
ASIDE FROM JLG RECOMMENDATIONS, IT IS NOT ADVISABLE TO MIX OILS OF DIF-
at 0° C (32° F) 340 cSt (1600SUS)
FERENT BRANDS OR TYPES. THEY MAY NOT CONTAIN REQUIRED ADDITIVES OR BE
OF COMPARABLE VISCOSITIES. IF USE OF HYDRAULIC OIL OTHER THAN MOBILFLUID at 40° C (104° F) 46 cSt (215SUS)
424 IS DESIRED, CONTACT JLG INDUSTRIES FOR PROPER RECOMMENDATIONS. at 65° C (150° F) 22 cSt (106SUS)
Table 1-12. Mobilfluid 424 Specs Viscosity Index 170
SAE Grade 10W30

Gravity, API 29.0
Table 1-15. Mobil EAL H 46 Specs
Density, Lb/Gal. 60°F 7.35
Type Synthetic Biodegradable
Pour Point, Max -46°F (-43°C)
ISO Viscosity Grade 46
Flash Point, Min. 442°F (228°C)
Specific Gravity .910
Viscosity
Pour Point -44°F (-42°C)
Brookfield, cP at -18°C 2700
Flash Point 500°F (260°C)
at 40° C 55 cSt
Operating Temp. 0 to 180°F (-17 to 162°C)
at 100° C 9.3 cSt
Weight 7.64 lb. per gal.
Viscosity Index 152 (0.9 kg per liter)
Viscosity
at 40° C 45 cSt
at 100° C 8.0 cSt
Viscosity Index 153
3121290 – JLG Lift – 1-3

Table 1-16. Exxon Univis HVI 26 Specs
Specific Gravity 32.1 Table 1-17. Quintolubric 888-46

Pour Point -76°F (-60°C) Density 0.91 @ 15°C (59°F)
Flash Point 217°F (103°C) Pour Point <-20°C (<-4°F)
Viscosity Flash Point 275°C (527°F)
at 40° C 25.8 cSt Fire Point 325°C (617°F)
at 100° C 9.3 cSt Autoignition Temperature 450°C (842°F)
Viscosity Index 376 Viscosity
NOTE: Mobil/Exxon recommends checking oil viscosity at 0° C (32°F) 360 cSt
annually.
at 20° C (68°F) 102 cSt
at 40° C (104°F) 46 cSt
at 100° C (212°F) 10 cSt
Viscosity Index 220
1.9 SERIAL NUMBER LOCATION

A serial number plate is affixed to left rear side of frame. If
serial number plate is damaged or missing, machine serial
number is stamped on left side of frame.
Figure 1-1. Serial Number Locations
1-4 – JLG Lift – 3121290

Figure 1-2. Operator Maintenance and Lubrication Diagram
3121290 – JLG Lift – 1-5

1.10 OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth
NOTE: The following numbers correspond to those in Figure 1-2.,

Operator Maintenance and Lubrication Diagram.
Table 1-18. Lubrication Specifications
KEY SPECIFICATIONS
Multipurpose Grease having a minimum dripping
point of 350° F (177° C). Excellent water resistance
MPG and adhesive qualities, and being of extreme pres-
sure type.
(Timken OK 40 pounds minimum.)
Extreme Pressure Gear Lube (oil) meeting API ser- Lube Point(s) - Grease Fitting
EPGL
vice classification GL-5 or MIL-Spec MIL-L-2105 Capacity - A/R
Hydraulic Oil. API service classification GL-3, e.g. Lube - Lubriplate 930-AAA
HO Interval - A/R
Mobilfluid 424.
Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-
EO L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-
2104C.
OGL Open Gear Lubricant - Mobiltac 375 or equivalent.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-

MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION
FREQUENCIES MUST BE INCREASED ACCORDINGLY.
NOTE: It is recommended as good practice to replace all filters at

the same time.
Lube Point(s) - Grease Fitting (See Note)
Capacity - A/R
1. Swing Bearing - Internal Ball Bearing
Lube - Mobil SHC 007
Lube Point(s) - 2 Grease Fittings Interval - A/R
Capacity - A/R
Lube - Mobil SHC 460
Interval - Every 3 months or 150 hrs of operation
OVERGREASING BEARINGS WILL RESULT IN DAMAGE TO OUTER SEAL IN
HOUSING. DO NOT OVERGREASE BEARINGS.
NOTE: If necessary, install grease fitting into worm gear housing

and grease. Replace fitting with pipe plug when complete.
1-6 – JLG Lift – 3121290

3. Wheel Bearings (2WD Only) 6. Hydraulic Charge Filter
Lube Point(s) - Repack Interval - Change after first 50 hrs. and every 6 months
Capacity - A/R or 300 hrs. thereafter, or as shown by Condition Indi-
Lube - MPG cator.
Interval - Every 2 years or 1200 hours of operation
7. Hydraulic Tank
4. Wheel Drive Hub
Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (0.5 L) - 1/2 Full
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation
5. Hydraulic Return Filter
Lube Point(s) - Fill Cap

Capacity - 27 gallons (102 liters); 23.6 gal. (89 liters) to
mid point of upper sight window (cold) Lube - HO
Interval - Change after first 50 hrs. and every 6 months Interval - Check Level daily; Change every 2 years or
or 300 hrs. thereafter or as indicated by Condition 1200 hours of operation.
Indicator.
3121290 – JLG Lift – 1-7

8. Oil Change w/Filter - Deutz D2011 L03 9. Oil Change w/Filter - Deutz 2.9 L4
Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 10 Qt (9.4 L)
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
10. Oil Change w/Filter - GM
Fill Cap/Spin-on Element (JLG P/N7016641)

Capacity - 11 Qt (10.5 L) Crankcase; 5 Qt (4.7 L)
Cooler
Lube - EO
with engine manual. Refer to Figure 1-3, Deutz Engine
Dipstick Markings.
Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
with engine manual.
11. Fuel Filter - Deutz
Figure 1-3. Deutz Engine Dipstick Markings
Lube Point(s) - Replaceable Element

1-8 – JLG Lift – 3121290

12. Fuel Filter - GM 14. 2-Stage Vaporizer (LP only)

Interval - Every 6 months or 300 hours of operation
13. Air Filter

Comments - Drain oil build up. Refer to Propane Fuel
Filter Replacement in Section 3.
15. Fuel Filter (Propane) - GM Engine
DEUTZ, GM

Comments - Replace filter. Refer to Propane Fuel Filter
Replacement in Section 3.
CAT

Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator
3121290 – JLG Lift – 1-9

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Tensile Torque Torque TM TM
Size TPI Bolt Dia Clamp Load Loctite® 242 or 271 Loctite® 262 TM
Stress Area (Dry) Lubricated
Vibra-TITE
TM
111 or 140 Vibra-TITE TM 131
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 ANAEROBIC THREAD LOCKING COMPOUND
JLG P/N Loctite® P/N ND Industries P/N Description
0100011 242 TM Vibra-TITE TM 121 Medium Strength (Blue)

0100019 271 TM Vibra-TITE TM 140 High Strength (Red)
0100071 262 TM Vibra-TITE TM 131 Medium - High Strength (Red)
Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 7)
1-10 – JLG Lift – 3121290

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
3. * ASSEMBLY USES HARDENED WASHER
3121290 – JLG Lift – 1-11

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
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
*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.
1-12 – JLG Lift – 3121290

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
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
*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.
3121290 – JLG Lift – 1-13

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
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 5 of 7)
1-14 – JLG Lift – 3121290

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
3121290 – JLG Lift – 1-15

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
1-16 – JLG Lift – 3121290

SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND Reference JLG Pre-Delivery and Frequent Inspection Form and
Inspection and Preventative Maintenance Schedule for items
MAINTENANCE requiring inspection during these inspections. Reference
appropriate areas of this manual for service and maintenance
General procedures.
This section provides information needed by personnel Annual Machine Inspection

responsible to place machine in operation readiness and Annual Machine Inspection must be performed on an annual
maintain its safe operating condition. For maximum service basis, no later than thirteen (13) months from date of prior
life and safe operation, ensure all necessary inspections and Annual Machine Inspection. JLG Industries recommends this
maintenance have been completed before placing machine task be performed by a Factory-Trained Service Technician. JLG
into service. Industries, Inc. recognizes a Factory-Trained Service Technician
as a person who has successfully completed the JLG Service
Training School for the subject JLG product model. Reference
Preparation, Inspection, and Maintenance machine Service and Maintenance Manual and appropriate
JLG inspection form for this inspection.
It is important to establish and conform to a comprehensive
inspection and preventive maintenance program. The follow- Reference JLG Annual Machine Inspection Form and Inspec-
ing table outlines periodic machine inspections and mainte- tion and Preventative Maintenance Schedule for items requir-
nance recommended by JLG Industries, Inc. Consult your ing inspection during performance of this inspection.
national, regional, or local regulations for further requirements Reference appropriate areas of this manual for service and
maintenance procedures.
for aerial work platforms. Frequency of inspections and main-
tenance must be increased as environment, severity and fre- For the purpose of receiving safety-related bulletins, it is
quency of usage requires. important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each Annual
Pre-Start Inspection Machine Inspection, notify JLG Industries, Inc. of current
machine ownership.
It is the User’s or Operator’s primary responsibility to perform a
machine Pre-Start Inspection before use daily or at each
Preventative Maintenance
change of operator. Reference the Operator’s and Safety Man- With specified inspections, maintenance shall be performed
ual for completion procedures for Pre-Start Inspection. Opera- by a qualified JLG equipment mechanic. JLG Industries, Inc.
tor and Safety Manual must be read in its entirety and recognizes a qualified JLG equipment mechanic as a person
understood before Pre-Start Inspection. who, by possession of a recognized degree, certificate, exten-
sive knowledge, training, or experience, has successfully dem-
onstrated the ability and proficiency to service, repair, and
Pre-Delivery Inspection and Frequent Inspection maintain the subject JLG product model.
Pre-Delivery Inspection and Frequent Inspection shall be per- Reference Preventative Maintenance Schedule and appropri-
formed by a qualified JLG equipment mechanic. JLG Indus- ate areas of this manual for service and maintenance proce-
tries, Inc. recognizes a qualified JLG equipment mechanic as a dures. Frequency of service and maintenance must be
person who, by possession of a recognized degree, certificate, increased as environment, severity and frequency of usage
extensive knowledge, training, or experience, has successfully requires.
demonstrated the ability and proficiency to service, repair, and
maintain the subject JLG product model.
Pre-Delivery Inspection and Frequent Inspection procedures

are performed in the same manner, but at different times. Pre-
Delivery Inspection shall be performed before each sale, lease,
or rental delivery. Frequent Inspection shall be accomplished
for each machine in service for 3 months or 150 hours (which-
ever comes first); out of service for a period of more than 3
months; or when purchased used. Frequency of this inspec-
tion must be increased as environment, severity and fre-
quency of usage requires.
3121290 – JLG Lift – 2-1

SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operation and Safety Manual
At each Operator change.
Pre-Delivery Inspection Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
rental delivery. and applicable JLG inspection form.
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
comes first; or and applicable JLG inspection form.
Out of service for a period of more than 3 months; or
purchased used.
Annual Machine Inspec- Annually, no later than 13 months from the date of Owner, Dealer, or User Factory-Trained Service Service and Maintenance Manual
tion the prior inspection. Technician and applicable JLG inspection form.
(Recommended)
Preventative At intervals as specified in the Service and Mainte- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.
2.2 SERVICE AND GUIDELINES 2. When air, fuel, or oil lines are disconnected, clean adja-
cent areas as well as openings and fittings themselves.
As soon as a line or component is disconnected, cap or
General cover all openings to prevent entry of foreign matter.
The following information is provided to assist you in use and
3. Clean and inspect all parts during service or mainte-
application of service and maintenance procedures contained
nance. Ensure passages and openings are unobstructed.
in this book.
Cover all parts to keep them clean. Be sure parts are
clean before they are installed. New parts should remain
Safety and Workmanship in their containers until ready for use.
Your safety, and that of others, is the first consideration during
maintenance of equipment. Always be conscious of weight.
Components Removal and Installation
Never attempt to move heavy parts without the aid of a 1. Use adjustable lifting devices if mechanical assistance is
mechanical device. Do not allow heavy objects to rest in an needed. All slings (chains, cables, etc.) should be parallel
unstable position. When raising a portion of the equipment, to each other and as near perpendicular as possible to
always provide adequate support. top of part being lifted.
2. Should it be necessary to remove a component on an
Cleanliness angle, keep in mind the capacity of an eyebolt or similar
1. The most important single item in preserving the long bracket lessens, as the angle between the supporting
service life of a machine is to keep dirt and foreign mate- structure and component becomes less than 90
rials out of vital components. Shields, covers, seals, and degrees.
filters are provided to keep air, fuel, and oil supplies 3. If a part resists removal, check to see whether all nuts,
clean. These items must be maintained on a schedule to bolts, cables, brackets, wiring, etc., have been removed
function properly. and no adjacent parts are interfering.
2-2 – JLG Lift – 3121290

SECTION 2 - GENERAL
Component Disassembly and Reassembly Bolt Usage and Torque Application

When disassembling or reassembling a component, complete
steps in sequence. Do not partially disassemble or assemble
one part, then start on another. Always recheck your work to SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
ensure nothing has been overlooked. Do not make any adjust- LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
ments, other than those recommended, without obtaining
proper approval. 1. Always use new hardware when installing locking fas-
teners. Use bolts of proper length. A bolt which is too
Pressure-Fit Parts long will bottom before head is tight against its related
part. If a bolt is too short, there will not be enough
When assembling pressure-fit parts, use a molybdenum disul- thread area to engage and hold part properly. When
fide base compound or equivalent to lubricate the mating sur- replacing bolts, use only those with the same or equiva-
face. lent specifications of original.
2. If torque requirements are not given within the text, use
Bearings standard torque values on heat-treated bolts, studs, and
1. When a bearing is removed, cover it to keep out dirt and steel nuts, in accordance with recommended shop prac-
abrasives. Clean bearings in nonflammable cleaning sol- tices. (See Torque Chart Section 1.)
vent and allow to drip dry. Compressed air can be used
but do not spin bearing. Hydraulic Lines and Electrical Wiring
2. Discard bearings if races and balls (or rollers) are pitted, Clearly mark or tag hydraulic lines and electrical wiring, and
scored, or burned. their receptacles when disconnecting or removing them to
ensure they are reinstalled correctly.
3. If bearing is found to be serviceable, apply a light coat of
oil and wrap it in clean (waxed) paper. Do not unwrap Hydraulic System
reusable or new bearings until ready to install.
1. Keep system clean. If evidence of metal or rubber parti-
4. Lubricate new or used serviceable bearings before cles are found in hydraulic system, drain and flush entire
installation. When pressing a bearing into a retainer or system.
bore, apply pressure to the outer race. If bearing is
installed on a shaft, apply pressure to the inner race. 2. Disassemble and reassemble parts on clean work sur-
face. Clean all metal parts with non-flammable cleaning
Gaskets solvent. Lubricate components as required to aid assem-
bly.
Check holes in gaskets align with openings in mating parts.
Lubrication
Service applicable components with amount, type, and grade
BLANK GASKETS CAN CAUSE SERIOUS SYSTEM DAMAGE. CUT HOLES IN CORRECT
of lubricant recommended in this manual at specified inter-
LOCATIONS WHEN FABRICATING GASKETS.
vals. When recommended lubricants are not available, consult
your local supplier for an equivalent that meets or exceeds
If it becomes necessary to hand-fabricate a gasket, use gasket
listed specifications.
material or stock of equivalent material and thickness.
NOTE: Components and assemblies requiring lubrication and ser-
Battery vicing are shown in the Lubrication Chart in Section 1.
Clean battery using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After cleaning,
thoroughly dry battery and coat terminals with an anti corro-
sion compound.
3121290 – JLG Lift – 2-3

SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION 2. Always keep hydraulic oil clean. If oil must be poured
from original container into another, clean all possible
contaminants from the service container. Always clean
Hydraulic System the filter mesh element and replace cartridge any time
system oil is changed.
1. The primary enemy of a hydraulic system is contamina-
3. While unit is shut down, make a thorough inspection of
tion. Contaminants can enter the system by using inade-
all hydraulic components, lines, fittings, etc., as well as a
quate hydraulic oil allowing moisture, grease, filings,
functional check of each system, before placing
sealing components, sand, etc., to enter when perform- machine back in service.
ing maintenance, or by permitting pump to cavitate due
to insufficient system warm-up or leaks in pump supply Lubrication Specifications
(suction) lines.
Lubricants specified by component manufacturers are always
2. Design and manufacturing tolerances of component the best choice. However, multi-purpose greases usually have
working parts are very close, even the smallest amount qualities which meet a variety of single purpose grease
requirements. Should any question arise regarding use of
of dirt or foreign matter entering a system can cause
greases in maintenance stock, consult your local supplier for
wear or damage to components and generally results in evaluation. Refer to Section 1 for an explanation of lubricant
faulty operation. Every precaution must be taken to key designations appearing in the Lubrication Chart.
keep hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked, cleaned, 2.4 CYLINDER DRIFT TEST
and/or replaced as necessary, at specified intervals
required in the Lubrication Chart in Section 1. Examine Maximum acceptable cylinder drift is measured using the fol-
lowing methods.
filters for metal particles.
3. Cloudy oils indicate a high moisture content which per- Platform Drift
mits organic growth, resulting in oxidation or corrosion.
Measure drift of platform to the ground. Lower booms (if
If this condition occurs, the system must be drained,
equipped) slightly elevated, main boom fully extended, with
flushed, and refilled with clean oil. rated load in platform and power off. Maximum allowable drift
is 2 inches (5 cm) in 10 minutes. If machine does not pass this
4. It is not advisable to mix oils of different brands or types,
test, proceed with the following.
as they may not contain the same required additives or
be of comparable viscosities. Good grade mineral oils,
Cylinder Drift
with viscosities suited to ambient temperatures in which
Table 2-2. Cylinder Drift
the machine is operating, are recommended for use.
Max. Acceptable Drift
NOTE: Metal particles may appear in oil or filters of new machines Cylinder Bore Diameter
in 10 Minutes
due to wear-in of meshing components. inches mm inches mm
3 76.2 0.026 0.66
Hydraulic Oil 3.5 89 0.019 0.48
4 101.6 0.015 0.38
1. Refer to Section 1 for viscosity ranges. 5 127 0.009 0.22
6 152.4 0.006 0.15
Changing Hydraulic Oil 7 177.8 0.005 0.13
8 203.2 0.0038 0.10
1. Filter elements must be changed after the first 50 hours 9 228.6 0.0030 0.08
of operation and every 300 hours (unless specified oth-
erwise) thereafter. If it is necessary to change the oil, use Measure drift at cylinder rod with a calibrated dial indicator.
only those oils meeting or exceeding specifications Cylinder oil must be stabilized at ambient temperature.
appearing in this manual. If unable to obtain the same Cylinder must have normal platform load applied.
type of oil supplied with machine, consult local supplier
If cylinder passes this test, it is acceptable.
for assistance in selecting the proper equivalent. Avoid
mixing petroleum and synthetic base oils. JLG Industries NOTE: This information is based on 6 drops per minute cylinder
recommends changing hydraulic oil annually. leakage.
2-4 – JLG Lift – 3121290

SECTION 2 - GENERAL
2.5 PINS AND COMPOSITE BEARING REPAIR 2.6 WELDING ON JLG EQUIPMENT
GUIDELINES NOTE: This instruction applies to repairs or modifications to
Filament wound bearings. machine and to welding performed from machine on an
external structure or component,
1. Pinned joints should be disassembled and inspected if
the following occurs:
Do the Following When Welding on JLG Equipment
a. Excessive sloppiness in joints.
• Disconnect the battery.
b. Noise originating from joint during operation.
• Disconnect the moment pin connection (where fitted)
2. Filament wound bearings should be replaced if any of
the following is observed: • Ground only to structure being welded.
a. Frayed or separated fibers on the liner surface. Do NOT Do the Following When Welding on JLG
b. Cracked or damaged liner backing. Equipment
c. Bearings that have moved or spun in their housing.
• Ground on frame and weld on any other area than chassis.
d. Debris embedded in liner surface.
• Ground on turntable and weld on any other area than turn-
3. Pins should be replaced if any of the following is table.
observed (pin should be properly cleaned prior to
inspection): • Ground on platform/support and weld on any other area
than platform/support.
a. Detectable wear in bearing area.
• Ground on a specific boom section and weld on any other
b. Flaking, pealing, scoring, or scratches on pin surface. area than that specific boom section.
c. Rusting of pin in bearing area.
• Allow pins, wear pads, wire ropes, bearings, gearing, seals,
4. Re-assembly of pinned joints using filament wound valves, electrical wiring, or hoses to be between grounding
bearings. position and welded area.
a. Housing should be blown out to remove all dirt and
debris...bearings and bearing housings must be free
of all contamination. FAILURE TO COMPLY WITH ABOVE REQUIREMENTS MAY RESULT IN COMPO-
b. Bearing / pins should be cleaned with a solvent to NENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
remove all grease and oil...filament wound bearing RING, BOOM WIRE ROPES ETC.)
are a dry joint and should not be lubricated unless
otherwise instructed (i.e. sheave pins).
c. Inspect pins for burrs, nicks, and scratches which
can damage bearing during installation and opera-
tion.
3121290 – JLG Lift – 2-5

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

Preventive Preventive or Frequent3 (Yearly) Years
Maintenance Maintenance Inspection Inspection
Boom Assembly
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Boom Assembly 14
Platform Assembly
Platform 1,2
Railing 1 1,2
Gate 5 1 1,5
Floor 1 1,2
Rotator 9,5 15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly
Tires 16,17 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Extendable Axle Systems 5,8 5,8
Steer Components
Spindle Thrust Bearing/Washers 1,2
Drive Hubs 11 11
2-6 – JLG Lift – 3121290

SECTION 2 - GENERAL
INTERVAL

Functions/Controls
Platform Controls 5 6 6
Ground Controls 5 6 6
Function Control Locks, Guards, or Detents 1,5 5 5
Footswitch 5 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Drive Brakes 5
Swing Brakes 5
Auxiliary Power 5 5
Power System
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 9,11 11 11
Air/Fuel Filter 1,7 7 7
Exhaust System 1,9 9 9
Batteries 1,9 19
Battery Fluid 11 11 11
Battery Charger 5 5
Fuel Reservoir, Cap, and Breather 2 1,5 1,5
Hydraulic/Electric System
Hydraulic Pumps 1,9 1,2,9
Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2
Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,9 2 1,5 1,5 24
Hydraulic Filter 1,9 7 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 1 20 20
Instruments, Gauges, Switches, Lights, Horn 1 5,23
General
Operation and Safety Manuals in Storage Box 21 21
ANSI and AEM Manuals/Handbooks Installed (ANSI Mar- 21
kets Only)
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
3121290 – JLG Lift – 2-7

SECTION 2 - GENERAL
INTERVAL

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21
All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or “off” position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
2-8 – JLG Lift – 3121290

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES AND WHEELS Tire Replacement
JLG recommends replacement tire be the same size, ply, and
Tire Inflation brand as originally installed on machine. Refer to the JLG Parts
Pneumatic tire air pressure must be equal to air pressure sten- Manual for part number of approved tires for a particular
ciled on side of JLG product or rim decal for safe and proper machine model. If not using a JLG approved replacement tire,
machine operation. we recommend replacement tires have the following charac-
teristics:
Tire Damage
• Equal or greater ply/load rating and size of original
PNEUMATIC TIRES • Tire tread contact width equal or greater than original
JLG Industries, Inc. recommends when any cut, rip, or tear is
• Wheel diameter, width, and offset dimensions equal to
discovered that exposes sidewall or tread area cords in the tire,
original
measures must be taken to remove the JLG product from ser-
vice immediately. Arrangements must be made for replace- • Approved for the application by the tire manufacturer
ment of the tire or tire assembly. (including inflation pressure and maximum tire load)
Unless specifically approved by JLG Industries Inc. do not
POLYURETHANE FOAM FILLED TIRES
replace a foam filled or ballast filled tire assembly with a pneu-
JLG Industries, Inc. recommends when any of the following are
matic tire. When selecting and installing a replacement tire,
discovered, measures must be taken to remove the JLG prod-
ensure all tires are inflated to pressure recommended by JLG.
uct from service immediately and arrangements made for
Due to size variations between tire brands, both tires on the
replacement of tire or tire assembly:
same axle should be identical.
• Smooth, even cut through cord plies which exceeds
3" (7.5 cm) in total length. Wheel Replacement
• Tears or rips (ragged edges) in cord plies which
exceeds 1" (2.5 cm) in any direction. Rims installed on each product model are designed for stabil-
ity requirements which consist of track width, tire pressure,
• Punctures which exceed 1" in diameter. and load capacity. Size changes such as rim width, center
• Damage to bead area cords. piece location, larger or smaller diameter, etc., without written
factory recommendations, may result in unsafe stability condi-
NOTE: If tire is damaged but within above criteria, tire must be tions.
inspected daily to ensure damage does not exceed allow-
able criteria.
3121290 – JLG Lift – 3-1

Wheel Installation 2. Tighten nuts in the following sequence:
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT PROPER TORQUE TO

PREVENT LOOSE WHEELS, BROKEN STUDS, AND DANGEROUS SEPARATION OF
WHEEL FROM AXLE. USE ONLY NUTS MATCHED TO CONE ANGLE OF WHEEL.
Tighten lug nuts to proper torque to prevent wheels from

coming loose. Use a torque wrench to tighten fasteners. If you
do not have a torque wrench, tighten fasteners with a lug
wrench, then immediately have a service garage or dealer
tighten lug nuts to proper torque.
OVER-TIGHTENING WILL BREAK STUDS OR PERMANENTLY DEFORM MOUNT-

ING STUD HOLES IN WHEELS.
1. Start all nuts by hand to prevent cross threading. DO

NOT use a lubricant on threads or nuts.
Figure 3-1. Wheel Lug Nut Tightening Sequence

3. Torque wheel nuts after first 50 hours of operation and
after each wheel removal. Check torque every 3 months
or 150 hours of operation.
Table 3-1. Wheel Torque Chart
TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
40 ft-lb (55 Nm) 100 ft-lb (130 Nm) 170 ft-lb (255 Nm)
3-2 – JLG Lift – 3121290

3.2 TORQUE HUB Tightening and Torquing Bolts
Oil Information
USE EXTREME CARE WHEN USING AN AIR IMPACT WRENCH. DO NOT TIGHTEN
1. 1. TYPE – EP90
BOLTS BEYOND THEIR TORQUE SPECIFICATION. NEVER USE AN IMPACT
Use EP90 for normal applications. For applications
WRENCH TO TIGHTEN SHOULDER BOLTS. TIGHTEN ALL SHOULDER BOLTS BY
where lubricant must meet special requirements, the
HAND.
O.E.M can recommend a suitable substitute.
2. OIL TEMPERATURE 1. Tighten (but do not torque) bolt ”A” until snug.
Continuous – 160° F (70° C) Intermittent – 200° F (95° C).
2. Go to opposite side of bolt circle and tighten bolt ”B”
3. OIL CHANGE until equally snug.
Initial – After 50 hours or 50,000 revolutions of opera-
3. Continue around bolt circle and tighten remaining bolts.
tion. Subsequent – After 1000 hours or (1) year, which-
ever comes first. 4. Apply specified torque to bolt ”A”.
NOTE: Higher temperatures make it necessary to change oil more 5. Continue around bolt circle and apply equal torque to
frequently. remaining bolts.
4. OIL FILL LEVEL AND VOLUME

Unit mounted horizontal – half full. (See Diagram A.)
Approximate volume - 17 oz. (0.5 1tr).
Roll and Leak Testing

Always roll and leak test Torque-Hubs after assembly to make
sure that the unit’s gears and sealants are working properly.

The following information briefly outlines what to look for
when performing these tests.
ROLL TEST
The roll test determines if the unit’s gears rotate freely and
properly. You should be able to rotate gears by applying a con-
stant force to the roll checker. If you feel more drag in gears
only at certain points, gears are not rolling freely. Examine
them for improper installation or defects.
Some gear packages roll with more difficulty than others. Do
not be concerned if gears seem to roll hard as long as they roll Figure 3-2. Bolt Tightening Sequence
with consistency.
LEAK TEST
The purpose of a leak test is to make sure unit is air tight. You
can tell if your unit has a leak if pressure gauge test reading
starts to fall once you have pressurized the unit.
Leaks usually occur at the main seal or wherever O-rings or
gaskets are located. You can usually detect location of a leak
by brushing a soap and water solution around main seal and
where O-rings or gaskets meet unit exterior, then checking for
air bubbles. Replace part immediately if you detect a leak in a
seal, O-ring, or gasket.
3121290 – JLG Lift – 3-3

Figure 3-3. Drive Hub and Brake Assembly (2WD and 4WD)
3-4 – JLG Lift – 3121290

Table 3-2. Drive Hub and Brake Assembly (2WD and 4WD) Parts List
1 Spindle/Housing Assembly 7D Thrust Spacer

1A Spindle 8 Sun Gear
1B Seal 11 Thrust Washer
1C Bearing Cone 12 Bolt
1D Bearing Cup 13 Dowel Pin
1E Bearing Cup 14 Coupling
1F Bearing Cone 15 Input Spacer
1G Housing/Ring Gear 16 Input Spacer
1H Thrust Washer 17 Brake Assembly
1I Retaining Ring 27 O-Ring
1N Wheel Stud 28 Threaded Rod
2 Internal Gear 29 Nut, 1/2in-13NC
3 Carrier Assembly 30 Gasket
3A Carrier 101 Shaft
3B Retaining Ring 102 Housing
3C Needle Bearing 103 Friction Plate
3D Thrust Washer 104 Pressure Plate
3E Planet Shaft 105 Gasket
3F Planet Gear 106 Outer Plate
3G Roll Pin 107 Gasket
4 Ring Gear 108 Cylinder
5 O-Ring 109 Piston
5A O-Ring 110 Ball Bearing
6 Cover Assembly 111 Retaining Ring
6A Thrust Spacer 112 Shaft Seal
6B Cover Plate 113 Capscrew
6C O-Ring 114 Lockwasher
6D Disconnect Rod 115 O-Ring
6E Disengage Cap 116 Back-up Ring
6F Bolt 117 O-Ring
6G Pipe Plug 118 Back-up Ring
6I Rivet 119 Dowel Pin
6J I.D. Plate 120 Plug
7 Input Shaft Assembly 121 Plug
7A Shaft 122 Spring (Natural)
7B Retaining Ring 123 Spring (Blue)
7C Spring
3121290 – JLG Lift – 3-5

Figure 3-4. Drive Hub (4WD Front Only)
3-6 – JLG Lift – 3121290

Table 3-3. Drive Hub (4WD Front Only) Parts List
1 Spindle/Housing Assembly 6 Cover Assembly

1A Spindle 6A Thrust Spacer
1B Seal 6B Cover Plate
1C Bearing Cone 6C O-Ring
1D Bearing Cup 6D Disconnect Rod
1E Bearing Cup 6E Disengage Cap
1F Bearing Cone 6F Bolt
1G Housing/Ring Gear 6G Plug, Pipe
1H Thrust Washer 6I Rivet
1I Retaining Ring 6J I.D. Plate
1N Wheel Stud 7 Input Shaft Assembly
2 Internal Gear 7A Shaft
3 Carrier Assembly 7B Retaining Ring
3A Carrier 7C Spring
3B Retaining Ring 7D Thrust Spacer
3C Needle Bearing 8 Gear, Sun
3D Thrust Washer 11 Thrust Washer
3E Planet Shaft 12 Bolt
3F Planet Gear 13 Pin, Dowel
3G Roll Pin 14 Coupling
4 Ring Gear 15 Input Spacer
5 O-Ring 16 Input Spacer
5A O-Ring
3121290 – JLG Lift – 3-7

MAIN DISASSEMBLY for “B” Drives Hub-Spindle Disassembly

1. Turn hub (1G) on side, Remove coupling (14) from wide NOTE: Start with large end of hub facing up and large end of spin-
end of spindle (1A). dle facing down.
2. Mark location of shoulder bolt holes on outside of ring
gear and hub for easy realignment when rebuilding.
Remove four shoulder bolts (13) and 12 bolts (12) from
UNCONTROLLED OBJECTS CAN CAUSE EYE DAMAGE OR SERIOUS INJURY.
cover (6).
ALWAYS WEAR EYE PROTECTION.
3. Remove 16 flat washers (16) from cover (6).
1. Remove retaining ring (1I) from around spindle (1A) ia
4. Lift cover sub-assembly (6) off ring gear (4). Set cover on
hub (1G).
table with interior side facing up.
2. Remove spacer (1H) from around spindle (1A) in hub
(1G).
SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP 3. Set hub (1G), with small end/spindle facing down, on
EDGES IN COUNTERBORE WHEN REMOVING O-RING. something that will support the hub’s flange while it lifts
hub up so spindle is not resting on anything. Carefully
5. Remove O-ring (5) from counterbore around edge of press or hammer spindle (1A) down and out of hub (1G).
cover (6A). Discard O-ring.
NOTE: If seal (1B) and bearing cone (1D) come out of hub and rest
NOTE: If O-ring is not in cover counterbore, it is in ring gear coun- on spindle, remove these parts from spindle and set them
terbore. Remove it from hub and discard. aside. Discard seal.
6. Remove thrust washer (11) from counterbore in top of 4. If seal and bearing cone did not come out of small end
carrier (3A). of hub (1G) when you pressed spindle out of hub,
remove seal (1B) and bearing cone (1D) from small end
7. Remove input gear (8) from middle of carrier sub-assem-
of hub (1G). Discard seal.
bly (3).
5. Bearing cone (1F) should be lying loose in wide end of
8. Lift ring gear (4) off hub (1G).
hub (1G). Remove bearing cone (1F) from inside hub
9. Lift carrier sub-assembly (3) out of hub (1G). (1G).
10. Remove thrust spacer (9) from input shaft (7) in middle NOTE: Do not strike counterbore with punch if using a punch and
of spindle (1A). hammer when removing bearing cup.
11. Lift input shaft sub-assembly (7) out of middle of spindle
6. Remove bearing cup (1C) from counterbore in small end
(1A). Stand input shaft (7A) on splined end.
of hub (1G).
NOTE: Do not strike counterbore with punch if using a punch and
hammer when removing bearing cup.
7. Turn hub (1G) over and lift it out of flange-support.
Remove bearing cup (1E) from counterbore in wide end
12. Using retaining ring pliers, remove retaining ring (7B)
of hub (1G).
from groove on input shaft (7A).
8. Turn hub (1G) over onto its small end. Remove two pipe
13. Remove one spacer (7D), one spring (7C), and other
plugs (1J) from side of hub (1G).
spacer (7D) from input shaft (7A).
14. Remove thrust washer (11) from around spindle (1A). NOTE: If your unit does not have studs, skip this step.
15. Lift internal gear (2) out of hub (1G). 9. Press nine studs (1N) out of stud holes in hub (1G).
16. Remove O-ring (5) from counterbore in hub (1G). Dis- 10. Hub-spindle disassembly is complete.
card O-ring.
17. Main disassembly for ”B” drives is complete.
3-8 – JLG Lift – 3121290

Cover Disassembly Assemble Carrier

1. Remove two bolts (6C) holding disconnect cap (6D) to 1. Apply grease to inside of one cluster gear (3F) and line one
cover (6A). half of cluster gear with 16 needle rollers (3C).
2. Remove disconnect cap (6D) from on top of cover cap
(6B) and cover (6A).
3. Remove two bolts (6C) holding cover cap (6B) to cover
(6A).
4. Remove cover cap (6B) from cover (6A).
5. Remove disconnect rod (6K) from cover cap (6B).
6. Pry O-ring (6F) out of groove inside cover cap (6B). Dis-
card O-ring.
7. Remove O-ring (6G) from flange of cover cap (6B). Dis-
card O-ring.
8. Remove pipe plug (6H) from cover (6A). 2. Place spacer (3D) inside cluster gear (3F) so it rests on
top of needle rollers.
9. Cover disassembly is complete.
Carrier Disassembly
NOTE: Discard old needle rollers and use new ones during reas-
sembly.
1. Using a punch and hammer, drive roll pin (3G) into

planet shaft (3E).
DRIVE ROLL PIN ALL THE WAY INTO PLANET SHAFT OR CARRIER WILL BE
DAMAGED WHEN PLANET SHAFT IS REMOVED.
3. Line remaining half of cluster gear (3F) with 16 needle
2. Using a punch and hammer, drive planet shaft (3E) out rollers.
of planet shaft hole in carrier housing (3A).
3. When you remove planet shaft (3E) from carrier housing,
one thrust washer (38), one cluster gear (3F), and one
more thrust washer (3B) will come off planet shaft and
come to rest inside carrier. Remove these parts from
inside carrier.
4. Remove 16 needle rollers (3C) from inside one end of
cluster gear (3F). Discard needle rollers.
5. Remove one spacer (3D) from inside cluster gear (3F).
6. Remove remaining 16 needle rollers (3C) from other side
of cluster gear (3F). Discard needle rollers.
7. Repeat steps 1-6 to remove and disassemble two
remaining cluster gears.
8. At this point carrier disassembly is complete.
3121290 – JLG Lift – 3-9

4. Set carrier housing (3A) on table, sideways. Insert a 7. Following cluster gear, place one more thrust washer
planet shaft (3E), roll pin hole last, into one of the planet (3B) onto planet shaft (3E) through opposite planet shaft
shaft holes from roll-pin-holed side of carrier housing hole in carrier housing (3A).
(3A).
8. Use an alignment punch or similar tool to align roll pin

5. Place thrust washer (3B) on end of planet shaft (3E) holes in carrier housing (3A) and planet shaft (3E).
inside carrier. Fit tang of thrust washer into slot on inside
edge of planet shaft hole.
9. Drive roll pin (3G) into aligned roll pin holes in carrier
housing (3A) and planet shaft (3E).
6. Following thrust washer, place cluster gear (3F), large
end toward roll pin hole in carrier housing, on planet
shaft (3E).
10. Repeat steps 1 thru 9 to assemble and install two

remaining cluster gears.
11. At this point carrier sub-assembly is complete.
3-10 – JLG Lift – 3121290

Cover Sub-Assembly 4. Set cover (6A) on table, exterior side up. Place cover cap
(6B) on cover (6A). Align pipe plug hole in cover cap over
1. Using disconnect rod, push O-ring (6F) into groove pipe plug hole in cover.
inside cover cap (6B).
5. Place two cover cap bolts (6C) in any two bolt holes 180°
2. Place O-ring (6G) onto cover cap (6B) so it rests against apart on cover cap (6B) and tighten bolts.
flange of cover cap.
6. Using a torque wrench, apply 36 to 49 in-lb (4 to 5 Nm) of

3. Insert disconnect rod (6E) into cover cap (6B). torque to both bolts (6C).
3121290 – JLG Lift – 3-11

7. With large end down, place disconnect cap (6D) on 10. Apply a light coat of “Never-Seize” to pipe plug (6H) and
cover cap (6B), aligning pipe plug hole in disconnect cap tighten it in pipe plug hole in cover (6A).
over pipe plug hole in cover cap.
8. Place two remaining bolts (6C) in bolt holes in discon- Hub-Spindle Sub-Assembly
nect cap (6D) and tighten bolts.
NOTE: Make sure cup sits square with counterbore before press-
ing.
1. Set hub (1G) on large end. Press bearing cup (1C) into
counterbore in small end of hub (1G).
9. Using a torque wrench, apply 36 to 49 in-lb (4 to 5 Nm) of

torque to both bolts (6C).
2. Press nine studs (1N) in stud holes in hub (1G).
3-12 – JLG Lift – 3121290

3. Apply a light coat of “Never-Seize” to two pipe plugs (1J) 6. Press seal (1B) in small end of hub (1G).
and tighten them in two pipe plug holes in side of hub
(1G).
7. Oil spindle, then lower hub (1G) small end down, onto
spindle (1A).
NOTE: Make sure cup sits square with counterbore before press-
ing.
4. Turn hub (1G) over to small end. Press bearing cup (1E)
into counterbore in deep end of hub (1G).
8. Press bearing cone (1F) on spindle (1A) in hub (1G).
5. Set hub (1G) on large end. Place bearing cone (1D) into
bearing cup (1C).
3121290 – JLG Lift – 3-13

9. Place spacer (1H) on spindle (1A) in hub (1G). Main Assembly
SHARP EDGES CAN CUT AND CAUSE SERIOUS INJURY. BEWARE OF SHARP
EDGES IN COUNTERBORE WHEN REMOVING O-RING.
1. Grease O-ring (5) and place it into counterbore in hub

(1G).
NOTE: O-ring may be stretched or pinched together to make it fit

into counterbore.
NOTE: Make sure retaining ring is securely seated in groove.
10. Place retaining ring (1I) over spacer onto spindle (1A) in
hub (1G).
2. Oil exposed surfaces inside hub (1G).Place internal gear
11. At this point hub-spindle sub-assembly is complete.
(2) in hub (1G) so its internal splines mesh with external

splines of spindle (1A). Oil internal gear (2).
3-14 – JLG Lift – 3121290

3. Place thrust washer (11) around spindle (1A) so it rests 6. Place other spacer (7D) on smooth end of input shaft
on bottom of internal gear (2). (7A).
4. Stand input shaft (7A) on splined end. Place one spacer

(7D) on smooth end of input shaft (7A).
7. Using retaining ring pliers, insert retaining ring (7B) in

groove on input shaft (7A) by compressing spring and
spacers together.
5. Place spring (7C) on smooth end of input shaft (7A).
8. With large splined end down, place input shaft sub-

assembly (7) into spindle (1A).
3121290 – JLG Lift – 3-15

9. Place thrust spacer (9) onto input shaft (7). 12. Place carrier sub assembly (3) and ring gear (4) together
into mesh with internal gear (2), aligning “X” marked
shoulder bolt hole in ring gear (4) over one of the shoul-
der bolt holes in hub. Mark location of shoulder bolt
holes on outside of ring gear and hub.
NOTE: You may lift ring gear off hub to align shoulder bolt holes.
Ring gear and carrier are installed together only to keep
punch marks on carrier in place.
10. Set carrier sub-assembly (3) on a flat work surface so

large ends of cluster gears (3F) face up. Locate punch
marks on face of each cluster gear (3F) and position
them at 12 o’clock.
13. With internal splines facing up (counterbore end facing

down), place input gear (8) into mesh with carrier sub-
assembly (3).
Figure 3-5. Cluster Gear Punch Marks
11. With “X” marked side facing up, place ring gear (4)
around cluster gears (3F).
NOTE: This will hold punch marks in position while installing car-
rier into hub.
14. Oil all exposed surfaces inside hub (1G). Place thrust
washer (11) into counterbore in top of carrier.
3-16 – JLG Lift – 3121290

18. Place shoulder bolts (13) in four shoulder bolt holes in

cover (6) and hand-tighten.
SHARP EDGES IN COUNTERBORE CAN CUT AND CAUSE INJURY WHEN INSTALL-
ING O-RING.
15. Set cover (6A) on table, interior side up. Grease O-ring (5) and
place in counterbore around edge of cover (6A).
NOTE: O-ring may be stretched or pinched together to make it fit
counterbore.
19. Place remaining 12 flat washers (16) on remaining bolt

holes in cover (6).
16. Place cover sub-assembly (6) on ring gear (4). Align pipe
plug holes before disassembly.
20. Place 12 bolts in remaining bolt holes in cover (6) and

tighten.
17. Place four flat washers (16) on top of bolt holes in cover
sub-assembly.
3121290 – JLG Lift – 3-17

21. Torque shoulder bolts (13) 18 to 25 ft-lb (25 to 34 Nm). 23. Roll test unit in clockwise and counterclockwise direc-
Torque bolts (12) 18 to 25 ft-lb (25 to 34 Nm). tions. Perform same number of turns in each direction as
the ratio of the unit. The ratio is the last two digits of the
model number on the unit’s ID tag.
22. Turn hub (1G) on its side. Insert coupling (14) into end of
spindle (1A).
24. Leak test unit at a pressure of 5 psi (34.47 kPa) for 2 to 3
minutes.
25. At this point main assembly is complete.
3-18 – JLG Lift – 3121290

Tool List 3. T-140433 ASSEMBLY PRESSING TOOL FOR CUP (1E).

The following specialized tools are used to assemble this unit.
Tool diagrams in this manual are intended for the customer
who may wish to have a tool made. All tools are one piece and
must be made from mild steel. All dimensions are in inches.
NOTE: Tools may be carburized and hardened to improve tool life.

If this is done, tools must be ground on all surfaces labeled
with a “G” on the tool diagram.
1. T-118126 SEAL PRESSING TOOL FOR SEAL (1B).
4. T-109691 ASSEMBLY PRESSING TOOL FOR CONE (1F).
* These tools are for specific seals, cups or cones. There is a

2. T-138903 ASSEMBLY PRESSING TOOL FOR CUP (1C). specific tool for each cup and cone.
3121290 – JLG Lift – 3-19

3.3 RE-ALIGN TORQUE HUB INPUT COUPLING 3.4 DRIVE MOTOR

This procedure applies to torque hubs with integral brakes: NOTE: This procedure covers:
Equipment Required 2WD motors used on GM powered machines.
1. Hydraulic power supply (hand pump) capable of pro- 2WD motors used on Caterpillar and Deutz powered
ducing 200 psi (13.8 bar). machines.
2. Hydraulic fittings to adapt hydraulic supply to brake
All 4WD motors.
release port on hub.
Procedure Description
Drive motors are low to medium power, two-position axial pis-
1. Using appropriate fittings, connect a line from hydraulic ton motors incorporating an integral servo piston. They are
power supply to brake port. designed for operation in open and closed circuit applications.
The standard control is a direct acting single line hydraulic
2. Pressurize brake release port to 155 - 200 psi (10.6 -
control. The integral servo piston controls motor displace-
13.8 bar) to release brake.
ment.
3. Verify brake is released by rotating input coupling or
Motors are spring biased to maximum displacement and
hub spindle. Once brake is released, input coupling is
hydraulically shifted to minimum displacement. Minimum and
free to re-align with drive motor.
maximum displacement can be set with fixed internal stops.
4. Install drive motor on hub. Release hydraulic pressure at The large diameter servo piston allows smooth acceleration
brake release port. Coupling remains in position. and deceleration with relatively large circuit orificing.
5. Disconnect hydraulic power supply and reconnect line
Bias spring
to brake release port. Servo piston
Minimum
Angle Swashplate
Stop
Output
Cylinder Shaft
Block
Shaft
Seal
Piston
Endcap Slipper Bearing
Valve plate
Figure 3-6. Drive Motor Cross Section
3-20 – JLG Lift – 3121290

Shaft Seal Replacement Loop Flushing Valve

REMOVAL REMOVAL
1. Remove snap ring (1) and support washer (2). 1. Remove plug (1) and (2) with 11/16" internal hex wrench.
1. Snap Ring
2. Support Washer
3. Shaft Seal
Figure 3-7. Removing Shaft Seal
NOTE: To avoid damaging shaft during removal, install a large 1. Plug 5. O-ring 8. Spring 11. Washer
sheet metal screw into chuck of a slide hammer. Drive 2. Plug 6. O-ring 9. Spring 12. Shift Spool
screw into seal surface and use slide hammer to pull seal. 3. Plug 7. Spring 10. Washer 13. Orifice Poppet
4. O-ring
2. Carefully pry out and discard shaft seal (3).
Figure 3-8. Loop Flushing Spool
INSPECT COMPONENTS
2. Use 1/4" in hex wrench to remove plug (3).
Inspect new seal, motor housing seal bore, and sealing area on
shaft for rust, wear, and contamination. Polish shaft and clean 3. Remove O-rings (4, 5, and 6).
housing if necessary. 4. Use pliers to remove centering springs (7, 8, and 9).
INSTALLATION 5. Remove spring retaining washers (10 and 11).
1. Cover shaft splines with an installation sleeve to protect 6. Remove shift spool (12).
shaft seal during installation. 7. Remove orifice poppet (13).
2. Install a new shaft seal (3) with cupped side facing 8. Inspect new O-rings and sealing area for rust, wear, or con-
motor. Press seal into housing until it bottoms out. Press tamination. Check springs and poppet for wear.
evenly to avoid binding and damaging seal.
3. Install seal support washer (2). INSTALLATION
4. Install snap ring (1). 1. Install orifice poppet (13).
5. Remove installation sleeve. 2. Install shift spool (12).

3. Install spring retaining washers on springs (10 and 11).
4. Carefully install centering springs (7, 8, and 9).
5. Install new O-rings (6, 4, and 5).
6. Use 1/4" hex wrench to torque plug (3) to 20 ft-lb (27 Nm).
7. Use 11/16" internal hex and torque plugs (2 and 1) to
27 ft-lb (37 Nm).
3121290 – JLG Lift – 3-21

Troubleshooting
Table 3-4. Excessive Noise and/or Vibration
Item Description Action

Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill reservoir to proper level and ensure oil supply to motor is adequate and
supply to motor. tem noise. lines are unobstructed.
Check for air in system. Air trapped in system lines or motor could result in cavitation that would Ensure system lines and components are purged of air.
cause system noise.
Inspect output shaft couplings. A loose or incorrect shaft coupling will produce vibrations that could result Ensure correct coupling is used and fits properly on shaft.
in system noise.
Inspect output shaft alignment. Misaligned shafts create excessive frictional vibration that could result in Ensure that the shafts are properly aligned.
system noise.
Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation that would lead Replace hydraulic oil with appropriate fluid for operating conditions.
to system noise.
Table 3-5. System Operating Hot

Check oil level in reservoir and oil Insufficient amount of hydraulic fluid will not meet system cooling Fill reservoir to proper level.
supply to pump. demands.
Inspect heat exchanger If heat exchanger fails or becomes obstructed, it may not meet system Ensure heat exchanger is receiving adequate air flow and is in good operat-
(if equipped). cooling demands. ing condition. Repair or replace as necessary.
Check system relief valves. If a system relief valve becomes unseated for an extended period of time or Repair or replace any malfunctioning relief valves and verify loads on
fails for any other reason, the system could become overheated. machine are not excessive.
Table 3-6. Won’t Shift or Slow to Start

Check signal line to servo control Obstructed or restricted flow through the servo control signal lines could Ensure signal lines are not obstructed or restricted and that signal pressure
port. result in slow shift or no shift conditions within the motor. is adequate to shift the motor.
Check correct supply and drain ori- Supply and drain orifices determine motor shift rate. The smaller the ori- Ensure proper control orifices are installed in motor and check they are not
fices are properly installed and not fice, the longer time it takes to shift the motor. Obstruction also increases obstructed. Clean or replace as needed.
obstructed. shift times.
3-22 – JLG Lift – 3121290

Disassembly
17
NOTE: Removal of endcap voids warranty.
19
During assembly, coat all moving parts with a film of

clean hydraulic oil. This ensures parts are lubricated dur-
ing start-up.
15
Replace all O-Rings and gaskets. Lightly lubricate O-rings
with clean petroleum jelly prior to assembly.
14
6
9
5 11
2
7 21
13
3
18
10 12
8
4
1 16
16
20
14. Lock Nut 18. Cavity Plug

15. O-ring Plug 19. Drain Plug
1. Plug 5. O-ring 9. Spring 12. Shift Spool 16. Control Line Plug 20. Drain Plug
2. Plug 6. O-ring 10. Washer 13. Orifice Poppet 17. Control Line Plug 21. Work Port Plug
3. Plug 7. Spring 11. Washer Figure 3-10. Plugs, Fittings, and Speed Sensor
4. O-ring 8. Spring
Figure 3-9. Loop Flushing Spool 8. Remove all fittings from unit. Discard O-rings.
9. Using an 11/16" hex wrench, loosen speed sensor lock
1. Using a 11/16" wrench, remove plug (1) and (2). nut (14) if equipped and remove speed sensor. Units
2. Using a 5/8" hex wrench, remove plug (3). without speed sensor have an O-ring plug (15) installed
in that location; remove it with a 1/4" inch internal hex
3. Remove O-rings (4, 5, and 6). wrench.
4. Using pliers, remove centering springs (7, 8, and 9). 10. Using a 1/4" internal hex wrench, remove control line
5. Remove spring retaining washers (10 and 11). plugs (16, 17). Discard O-rings. Using a 3 mm hex
wrench, remove cavity plug (18) (if equipped with two-
6. Remove shift spool (12). line control), from X2 cavity.
7. Remove orifice poppet (13). 11. Using a 5/16" internal hex wrench, remove drain plugs
(19, 20). Discard O-rings.
12. If equipped with axial ports, use a 9/16" an internal hex
wrench and remove work port plugs (21). Discard O-rings.
3121290 – JLG Lift – 3-23

25
22
27
30
23 29
29
26
24
28
22. Screw
23. End Cap 25. Valve Plate 27. O-ring 29. Angle Stop
24. O-ring 26. End Cap 28. O-ring Servo Spring
Figure 3-11. End Cap Figure 3-12. Valve Plate & Rear Shaft Bearing
13. Using an 8 mm internal hex wrench, remove endcap

screws (22).
DO NOT SCRATCH VALVE PLATE SURFACE.
14. Remove endcap (23). Remove O-ring (24) from housing
or endcap. 15. Remove valve plate (25) and timing pin (26) from endcap.
NOTE: When endcap screws are removed, pressure from servo NOTE: Each displacement has a unique valve plate. The last two
spring will cause endcap to bind on shaft. Press down on digits of the part number are stamped on its surface.
portion of endcap covering servo piston and hold endcap
level while removing. 16. Remove and discard O-rings (27, 28).
17. Remove rear shaft bearing (29) from endcap with a bear-
ing puller.
DO NOT DRIVE BEARING PAST REAR SHAFT JOURNAL. BEARING MAY BECOME
TRAPPED ON SHAFT AND DAMAGED.
NOTE: Bearing may be difficult to remove with a puller. Try this as

an alternative: Pack bearing cavity with heavy grease.
After shaft is removed, insert it into bearing cavity and tap
lightly with a soft mallet on the splined end. Grease will
force out bearing.
18. Remove minimum angle stop (29) and servo spring (30)
from housing.
3-24 – JLG Lift – 3121290

32
33
31
34
30. Cylinder Kit Assembly
Figure 3-13. Cylinder Kit
19. Turn housing on its side and remove cylinder kit assem-
bly (31). Set assembly aside. Do not to scratch running
surface. 31. Snap Ring
32. Support Washer
NOTE: Grooves on surface of cylinder kit identify its displacement: 33. Shaft Seal
Table 3-7. Displacement Identifiers Figure 3-14. Shaft Seal
# of Grooves Frame L Frame K

20. Turn housing over and remove snap ring (32), retaining shaft
1 25 38 seal, and support washer. Remove support washer (33).
2 30 45 Carefully pry out shaft seal (34). Discard seal.
3 35 -- NOTE: To avoid damaging shaft during seal removal. Install a
large sheet metal screw in chuck of a slide hammer. Drive
screw into seal surface. Use slide hammer to pull seal.
36
35
37
38
34. Inner Snap Ring

35. Snap Ring
36. Bearing
37. Shaft
Figure 3-15. Shaft & Front Bearing
21. Remove inner snap ring (35) and shaft/bearing assembly.

22. Remove snap ring (36) retaining shaft front bearing. Pull
bearing (37) off shaft (38).
3121290 – JLG Lift – 3-25

Lift here
44
39
45
47
40
48
43
42
49
41
46
53
52
38. Swashplate 50
39. Servo Piston
40. Piston Seal 51
41. O-ring
42. Journal Bearings
Figure 3-16. Swash Plate & Servo Piston

43. Piston 48. Retaining Ring
23. Turn housing over and remove swashplate (39) by lifting 44. Slipper Retainer 49. Block Spring Washer
on end opposite servo lever. 45. Cylinder Block 50. Spiral Retaining Ring
46. Ball Guide 51. Block Spring
24. Remove servo piston (40). Remove piston seal (41) and 47. Holddown Pins 52. Inner Block Spring Washer
O-ring (42) from servo piston. Discard seal and O-ring.
Figure 3-17. Cylinder Kit Disassembly
25. Remove journal bearings (43) from housing. If bearings
will be reused, note location and orientation of each
bearing for reassembly.
26. Remove pistons (44) and slipper retainer (45) from cylin- RISK OF PERSONAL INJURY: COMPRESSING BLOCK SPRING REQUIRES FORCE
der block (46). OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO MAIN-
TAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS SECURE
NOTE: Pistons are not selectively fitted. Units with high hourly BEFORE ATTEMPTING TO REMOVE SPIRAL RETAINING RING. RELEASE PRES-
usage may develop wear patterns. Number pistons and SURE SLOWLY AFTER RETAINING RING IS REMOVED.
bores for reassembly if they will be reused.
28. Turn block over. Using a press, apply pressure on block
27. Remove ball guide (47), hold-down pins (48), and retain- spring washer (50) to compress block spring enough to
ing ring (49) from cylinder block. safely remove spiral retaining ring (51). Maintain pres-
sure and unwind spiral retaining ring (51). Carefully
NOTE: Most repairs do not require block spring removal. Perform release pressure and remove outer block spring washer
this procedure only if you suspect problems with the block (50), block spring (52), and inner block spring washer
spring. (53) from cylinder block.
3-26 – JLG Lift – 3121290

Inspection Table 3-8. Slipper Foot Thickness & End Play

Wash all parts after disassembly (including end-cap and hous- Measurement L Frame K Frame
ing) thoroughly with clean solvent and allow to air dry. Blow
out oil passages in housing and endcap with compressed air. Slipper Foot Thickness mm 2.71 4.07
Conduct inspection in a clean area and keep all parts free from (in.) (0.11) (0.16)
contamination. Clean and dry parts again after any rework or Piston/Slipper End Play 0.15
resurfacing. (0.006)
PISTON BALL GUIDE AND SLIPPER RETAINER

Inspect pistons for damage and discoloration. Discolored pis- Inspect ball guide and slipper retainer for damage, discolor-
tons may indicate excessive heat. Do not reuse. ation, or excessive wear. A discolored ball guide or slipper
retainer indicates excessive heat. Do not reuse.
Slipper retainer
Ball guide
SLIPPERS CYLINDER BLOCK

Inspect running surface of slippers. Replace piston assemblies Measure cylinder block height. Replace blocks worn beyond
with scored or excessively rounded slipper edges. Measure minimum height specification. Inspect running surface of cyl-
slipper foot thickness. Replace piston assemblies with exces- inder block. Replace or resurface worn or scratched blocks.
sively worn slippers. Check slipper axial end-play. Replace pis- Blocks may be resurfaced if resurfacing will not reduce block
ton assemblies with excessive end-play. height below minimum specification shown in Table 3-9, Cyl-
inder Block Measurements.
Minimum slipper foot thickness and maximum axial end-play
are shown in table 3.6.
Table 3-9. Cylinder Block Measurements
Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)
Cylinder Block Surface Flatness 0.002 0.002 0.002 0.002 0.002
(0.0000079) (0.0000079) (0.0000079) (0.0000079) (0.0000079)
3121290 – JLG Lift – 3-27

VALVE PLATE Inspect journal bearings for damage or excessive wear.

Valve plate condition is critical to motor efficiency. Inspect Replace journal bearings if scratched, warped, or excessively
valve plate surfaces for excessive wear, grooves, or scratches. worn. Polymer wear layer must be smooth and intact.
Replace or resurface grooved or scratched valve plates. Mea- SHAFT BEARINGS

sure valve plate thickness and replace if worn beyond mini- Inspect bearings for excessive wear or contamination. Rotate
mum specification. bearings while feeling for uneven movement. Bearings should
Valve plate can be resurfaced if finished thickness is not below spin smoothly and freely. Replace bearings that appear worn
minimum specification shown in drawing. or do not rotate smoothly.
3.83 mm [0.151 in] min.
0.025 mm
[0.001 in]
0.0076 mm
[0.00030 in]
convex max
SWASHPLATE AND JOURNAL BEARINGS

SHAFT
Inspect running face, servo ball-joint, and swashplate journal
Inspect motor shaft. Look for damage or excessive wear on
surfaces for damage or excessive wear.
output and block splines. Inspect bearing surfaces and sealing
Some material transfer may appear on these surfaces and is surface. Replace shafts with damaged or excessively worn
acceptable providing surface condition meets specifications splines, bearing surfaces, or sealing surfaces.
shown.
SERVO PISTON AND MINIMUM ANGLE STOP
Measure swashplate thickness from journals to running face. Inspect minimum angle stop, servo piston head, and servo pis-
Replace swashplate if damaged or worn beyond minimum ton ball-socket for damage or excessive wear. Replace as needed.
specification.
0.0025 mm
[0.0001 in]
25.8 mm
LV [1.015 in]
KV 24.6 mm
[0.969 in]
Thickness equality
side to side:
0.05 mm [0.002 in] LOOP FLUSHING SPOOL
Inspect loop flushing spool. Check for cracks or damage.
Replace as needed.
3-28 – JLG Lift – 3121290

Assembly
1. Install new O-ring (1) and piston seal (2) to servo piston COMPRESSED SPRING MAY FLY OUT AND CAUSE SERIOUS INJURY. COMPRESS-
(3). Install piston seal over O-ring. ING BLOCK SPRING REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE.
USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASONABLE
NOTE: Installing piston seal stretches it, making it difficult to EFFORT. ENSURE SPRING IS SECURE BEFORE ATTEMPTING TO INSTALL SPIRAL
install servo piston in its bore. Allow 30 minutes for seal to
RETAINING RING. RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS
relax after installation. To speed up seal relaxation, com- INSTALLED.
press seal by installing piston head in servo cavity in end-
cap and let it stand for at least five minutes. 3. Install inner block spring washer (4), block spring (5),
and outer washer (6) in cylinder block. Using a press,
2 compress block spring enough to expose retaining ring
3
groove. Wind spiral retaining ring (7) into cylinder block.
11
12
10
1
9
8
7
1. O-ring
2. Piston Seal
3. Servo Piston
Figure 3-18. Servo Piston 4. Block Spring Washer 9. Holddown Pins

5. Block Spring 10. Ball Guide
6. Outer Washer 11. Piston
2. After piston seal has relaxed, lubricate and install servo 7. Spiral Retaining Ring 12. Slipper Retainer
piston into housing bore. Align piston with ball socket 8. Retaining Ring
facing inside of housing.
Figure 3-19. Cylinder Kit Assembly
4. Turn block over and install retaining ring (8), hold-down

pins (9), and ball guide (10) to cylinder block.
3121290 – JLG Lift – 3-29

8. Press front shaft bearing (15) onto shaft (16). Press bear-
ing onto shaft with lettering facing out. Lubricate bear-
IF REUSING PISTONS, INSTALL THEM IN ORIGINAL BLOCK BORES. ing rollers. Install snap-ring (17) on shaft.
5. Install pistons (11) to slipper retainer (12). Install piston/

retainer assembly in cylinder block. Ensure concave sur-
face of retainer seats on the ball guide. Lubricate pis-
tons, slippers, retainer, and ball guide before assembly.
Set cylinder kit aside on a clean surface until needed.
6. Install journal bearings (13) into housing seats. Use
assembly grease to keep bearings seated during assem-
bly. Ensure locating nubs drop into cavities in seats. If
reusing bearings, install them in original location and
orientation. Lubricate journal bearings.
14
13
13
15. Front Shaft Bearing 17. Snap Ring
16. Shaft 18. Snap Ring
Figure 3-21. Shaft and Front Bearing
9. While holding swashplate in place, turn housing on its

side. Install shaft/bearing assembly into housing from
13. Journal Bearings flange end. Install snap ring (18).
14. Swash Plate
Figure 3-20. Swash Plate and Journal Bearing
7. Install swashplate (14) in housing. Tilt swashplate and

guide servo lever ball into its socket in servo piston rod.
Ensure swashplate seats into journal bearings and
moves freely. Lubricate swashplate running surface.
3-30 – JLG Lift – 3121290

10. Verify swashplate and bearings are properly seated. 12. Press rear shaft bearing (22) into endcap. Install bearing
Install cylinder kit (19) onto shaft. Install with slippers with letters facing out. Press until bearing surface is 0.08
facing swashplate. Rock shaft to align block splines and ±0.01 in (2 ±0.25 mm) above endcap surface.
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate, 22
23
3 mm
[0.12 in]
journal bearings, and servo piston are all secure and 2 mm
[0.08 in]
properly installed.
19
23
22
24
19. Cylinder Kit

23
Figure 3-22. Cylinder Kit Installation
11. Lubricate and install servo spring (20), and minimum

angle stop (21) into housing bore.
22. Rear Shaft Bearing
23. Timing Pin
24. Valve Plate
Figure 3-24. Valve Plate and Rear Bearing

21
13. Install timing pin (23) into bore in endcap. Install pin
20 with groove facing toward or away from shaft. Press pin
until end protrudes 0.12 ±0.01 in (3 ±0.25 mm) above
endcap surface.
14. Install valve plate (24) on endcap. Install valve plate with
yellow surface toward cylinder block. Align slot in valve
plate with timing pin. Apply a liberal coat of assembly
grease to endcap side of valve plate to keep it in place
during installation.
20. Servo Spring

21. Minimum Angle Stop
Figure 3-23. Servo Spring and Minimum Angle Stop
3121290 – JLG Lift – 3-31

15. Install endcap (25) on housing with endcap screws (26). 18. Cover shaft splines with an installation sleeve. Install a
Check endcap properly seats on housing without interfer- new shaft seal (27) with cup side facing motor. Press seal
ence. into housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer
(28) and snap ring (29).
IMPROPER ASSEMBLY OF INTERNAL COMPONENTS MAY PREVENT ENDCAP
FROM SEATING PROPERLY. ENSURE O-RINGS SEAT PROPERLY WHEN INSTALL- 29
ING ENDCAP.
28
26
8 mm
35-45 ft.lbs. 27
(47-61 Nm)
25
27. Shaft Seal

28. Seal Support Washer
29. Snap Ring
Figure 3-26. Shaft Seal
19. Install remaining plugs and fittings to housing. Refer to

drawing below for wrench sizes and torque settings.
25. End Cap

26. Screw
Figure 3-25. End Cap
16. Using an 8 mm internal hex wrench, tighten endcap

screws. Tighten screws in opposite corners slowly and
evenly to compress servo spring and properly seat end-
cap. Torque endcap screws 35 to 45 ft-lb (47-61 Nm).
17. Before installing shaft seal, ensure shaft turns smoothly
with less than 120 in-lb (13.5 Nm) of force. If shaft does
not turn smoothly within specified force, disassemble
and check unit.
Figure 3-27. Plugs and Fittings Installation
3-32 – JLG Lift – 3121290

20. Install orifice poppet (30). Initial Start-Up Procedures

21. Install shift spool (31). Follow this procedure when starting up a new motor or after
reinstalling a motor.
22. Install spring retaining washers on springs (32 and 33).
Prior to installing motor, inspect for damage incurred during
23. Carefully install centering springs (34, 35, and 36). shipping or storage. Make certain all system components (res-
24. Install new O-rings (37, 38, and 39). ervoir, hoses, valves, fittings, heat exchanger, etc.) are clean
before filling with fluid.
25. Using a 5/8" wrench, torque plug (40) to 20 ft-lb (27 Nm).
1. Fill reservoir with recommended hydraulic fluid. Always
26. Using a 11/16" wrench, torque plugs (41 and 42) to 27 ft- filter fluid through a 10 micron filter when pouring into
lb (37 Nm). reservoir. Never reuse hydraulic fluid.
37 2. Fill inlet line leading from pump to reservoir. Check inlet

36 line for properly tightened fittings and be certain it is
39 33 free of restrictions and air leaks.
41
34
30 11/16 in
3. Fill pump and motor housing with clean hydraulic fluid.
40 27 ft.lbs.
(37 Nm) Pour filtered oil directly into upper most case drain port.
5/8 in
20 ft.lbs. 4. Install case drain lines into upper most case drain ports
(27 Nm)
to ensure pump and motor stay filled with oil.
31 5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres-
32
35 sure gauge port of pump to monitor system pressure
38
during start up.
42 6. Watch pressure gauge and run engine at lowest possible
11/16 in
27 ft.lbs.
speed until system pressure builds to normal levels
(37 Nm) (minimum 160 psi [11 bar]). Once system pressure is
established, increase to full operating speed. If system
pressure is not maintained; shut down engine, deter-
mine cause, and take corrective action.
7. Operate hydraulic system at least fifteen minutes under
30. Orifice Poppet 34. Spring 37. O-ring 40. Plug light load conditions.
31. Shift Spool 35. Spring 38. O-ring 41. Plug
32. Spring 36. Spring 39. O-ring 42. Plug 8. Check and adjust control settings as necessary after
33. Spring installation.
Figure 3-28. Loop Flushing Spool 9. Shut down engine and remove pressure gauge. Replace
plug at charge pressure gauge port.
10. Check fluid level in reservoir; add clean filtered fluid if
necessary. Motor is now ready for operation.
3121290 – JLG Lift – 3-33

E D
C
B
Table 3-10. Chassis Torque Values
Ft-Lb Nm
A 120 163
B 240 325
C 170 230
D 85 115
E 165 224
Figure 3-29. Chassis Torque Values
3-34 – JLG Lift – 3121290

3.5 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE 3.6 OSCILLATING AXLE BLEEDING PROCEDURE AND
1. With turntable centered, adjust bracket with washers to LOCKOUT TEST
push plunger in 5/16" ± 1/16" (7.9 ± 1.6 mm).
FULLY LOWER PLATFORM AND CENTER BOOM OVER REAR AXLE BEFORE
STARTING BLEEDING PROCEDURE.
ENSURE MACHINE IS ON A LEVEL SURFACE AND REAR WHEELS ARE BLOCKED,

AND BRAKE WIRE IS DISCONNECTED.
Lockout Cylinder Bleeding (Ram Cylinders)

1. Position turntable to normal stowed position so axle is
free to oscillate. Drive charge pressure will pass through
lockout valve built into swivel and down to pilot section
of holding valves on cylinders. This will automatically
purge air from pilot section of circuit.
2. Attach end of clear tubing to bleeder valve nipple and
place other end in container to catch oil. Using a 3/8"
wrench, slowly turn bleeder valve counter-clockwise to
bleed air from cylinder. Have operator in platform just
crack drive controller in reverse. This will activate brake
valve sending charge pressure to lockout cylinder. Close
valve when an unbroken, steady stream of oil is seen.
3. Repeat procedure for other lockout cylinder.
1. Washer
2. Bracket
3. Lockout Valve
Figure 3-30. Valve Adjustment
2. Ideal adjustment is 3/8" (9.5 mm). Do not push plunger

in more than 3/8" (9.5 mm). The extra adjustment is
needed for turntable bearing play.
3121290 – JLG Lift – 3-35

Oscillating Axle Lockout Test 3.7 SWING BEARING
Description
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- The swing bearing has five major components: housing,
TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS worm, worm gear, output pinion, and gear/pinion cap.
SUSPECTED.
Servicing these units requires a press, a 3/8" 12 point socket, a
1/2" socket, a 3/4" socket, torque wrench (80 ft-lb), steel ham-
NOTE: Ensure boom is fully retracted, lowered, and centered
mer, soft face hammer, bearing puller (external and internal),
between drive wheels before starting lockout cylinder test.
and a large flat blade screw driver. Also needed are a shim and
seal kit (refer to JLG Parts Manual), 3/4" steel rod at least 10"
1. Place a 6" (15 cm) high block with ascension ramp in
long, silicone sealant Mobil SHC 460 grease, Lubriplate No.
front of left front wheel.
930-AAA, JLG Threadlocker PN 0100011 for bolts, and other
2. From platform control station, activate machine hydrau- parts that may be worn out.
lic system.
3. Place FUNCTION SPEED CONTROL and DRIVE SPEED/ Removal
TORQUE SELECT control switches to LOW positions. Refer to Figure 3-31., Swing Bearing Installation.
4. Place DRIVE control lever to FORWARD position and 1. Attach an adequate support sling to boom and draw all
carefully drive machine up ascension ramp until left slack from sling. Prop or block boom if possible.
front wheel is on top of block.
2. Tag and disconnect hydraulic lines running through
5. Carefully activate SWING control lever and position center of turntable (1) and frame (2). Use a suitable con-
boom over right side of machine. tainer catch residual hydraulic fluid. Cap lines and ports.
6. With boom over right side of machine, place DRIVE con- 1. Clean area around swing motor (3) to prevent any dirt
trol lever to REVERSE. Drive machine off block and ramp. from entering system.
7. Have an assistant check to see left front wheel remains 2. Tag and disconnect hydraulic lines running to swing
locked in position off of ground. motor. Cap or plug all openings.
8. Carefully activate SWING control lever and return boom 3. Attach suitable overhead lifting equipment to base of
to stowed position (centered between drive wheels). turntable weldment (1).
When boom reaches center, stowed position, lockout cyl-
4. Scribe a line on inner race of swing bearing (4) and
inders should release and allow wheel to rest on ground.
underside of turntable to help align bearing during
It may be necessary activate DRIVE to release cylinders.
installation. Remove bolts (5) and washers (6) from turn-
9. Place 6" (15 cm) high block with ascension ramp in front table and bearing inner race. Discard bolts.
of right front wheel.
5. Use lifting equipment to lift complete turntable assem-
10. Place DRIVE control lever to FORWARD. Carefully drive bly from bearing. Ensure no damage occurs to turntable,
machine up ramp until right front wheel is on top of bearing, or frame components. Carefully place turntable
block. on a suitably supported trestle.
11. Carefully activate SWING control lever and position 6. Scribe a line on outer race of swing bearing and frame to
boom over left side of machine. help align bearing during installation.
12. With boom over left side of machine, place DRIVE con- 7. Remove bolts (7) and washers (8) from outer race of
trol lever to REVERSE. Drive machine off block and ramp. bearing to frame. Discard bolts.
13. Have an assistant check to see that right front wheel 8. Use suitable lifting equipment to remove bearing and
remains locked in position off ground. rotation box assembly from frame. Move to a clean, suit-
ably supported work area.
14. Carefully activate SWING control lever and return boom
to stowed position (centered between drive wheels).
When boom reaches center, stowed position, lockout
cylinders should release and allow wheel to rest on
ground. It may be necessary activate DRIVE to release
cylinders.
15. If lockout cylinders do not function properly, have qualified
personnel correct malfunction before further operation.
3-36 – JLG Lift – 3121290

3
Inner Race
Outer Race
Figure 3-31. Swing Bearing Installation
3121290 – JLG Lift – 3-37

Disassembly 5. Lift directly up and remove pinion and gear assembly

(10, 16 - 22) from housing (4).
Refer to Figure 3-32., Swing Bearing Drive.
6. Disassemble pinion and gear assembly using a press.
1. Clean area around swing motor (1) to prevent any dirt
Support worm gear (20) on press wIth pinion (10) facing
from entering system.
down. Allow room for pinion to be pressed out of gear.
2. Tag and disconnect hydraulic lines running to swing Press pinon out of bearing (22), spacer (21), and worm
motor. Cap or plug all openings. gear (20).
7. Remove face seal (18) and O-ring (19) from face of worm
gear (20). Note how seal is assembled.
SECURE WORM GEAR SHAFT SO IT DOES NOT PULL OUT ANY WHEN REMOVING
THE SWING MOTOR. FAILURE TO DO SO COULD DAMAGE WORM GEAR SEALS. 8. Remove bearing (17) and Nilos Ring (16) from pinion (18)
with an external bearing puller or press.
3. Remove bolts (2) and washers (3) securing swing motor 9. Remove motor adapter (23) and shim (24).
to swing drive housing (4).
10. Remove two bolts (25) from worm cap (26). Remove and
4. Carefully pull swing motor from housing. discard shims (27) and seal (28).
Refer to Figure 3-40., Swing Motor Removal and Installation. 11. Remove worm (29) from housing (4) by pushing worm
1. Remove two bolts (5) and washers (6) that hold turnta- from motor end using a steel rod and hammer. Use a
ble bearing (7) to housing (4). soft hammer to tap worm on hex end to remove bearing
(30) from opposite end of housing.
2. Remove two machine screws (8) on cover plate (9)
immediately in front of pinion (10). 12. If necessary, remove bearing cup from adapter (23)
using a small pry bar or by welding a small bead of weld
3. Remove eight cap screws (11) from gear pinion cap (12). on internal diameter of the cup.
Pry cap from housing. Cover plate (9) will come off with
cap. Note where sealant is on cover and plate so it can 13. Remove bearing (31) from worm (29) using an external
be applied in same location during assembly. Note num- bearing puller or press.
ber and color of shims (13) between cap and housing.
4. Remove six small screws (14) from cover plate. Pry cover
plate (9) from cap (12). Discard cover plate. Note number
and color of shims (15) between cover plate and cap.
NOTE: If there are five screws or drive screws holding cover plate
to cap, a new cap (12) should be ordered. This is an older
version; new cover plate has six holes.
3-38 – JLG Lift – 3121290

Figure 3-32. Swing Bearing Drive
3121290 – JLG Lift – 3-39

Assembly 16. Place gear cap assembly over pinion assembly and
install shims set aside in Step 6.
Refer to Figure 3-32., Swing Bearing Drive.
17. Install eight 12 point screws (11). Torque to 60 ft-lb (81 Nm).
1. Press bearing (17) in gear cap (12).
18. Install two small screws (8).
2. Place bearing (30) in housing (4).
19. Install seal (28) in worm cap (26).
3. Place face seal (18) and O-ring (19) on hub of worm gear
(20). 20. Install motor (1) to adapter (23) with two bolts (2), washers
(3), and sealant. Torque to 80 ft-lb (108 Nm).
4. Place worm gear (20) on press with face seal up. Press
pinion (10) into worm gear. Place grease ring (16) on pin- 21. Install turntable bearing (7) to housing (4) with two bolts (5)
ion with cup shape up. and washers (6).
5. Turn assembly over. Place spacer (21), with hub facing 22. Fill worm gear with Mobil SHC 460 grease.
up, on pinion against gear hub.
23. Grease pinion gear with Lubriplate No. 930-AAA.
6. Press bearing (22) on pinion and tight to spacer and
gear.
Bearing Bearing
7. Place pinion gear assembly in housing. Place gear cap Lube Point Lube Point
(12) and shims (13) over gear/pinion assembly to
achieve a slight preload on pinion bearings. Remove cap
and shims and set shims aside.
8. Install new cover plate (9) on cap (12) with six screws
(14) and shims (15) equal or close to total thickness of
shims removed. Apply sealant (Permatex #2 or equiva-
lent) to both sides of each shim and tighten screws, tak-
ing care not to twist screws off. Set assembly aside.
Worm Gear
Lube Point
ROLLER BEARINGS MUST BE INSTALLED WITH SMALL ENDS FACING OUT ON Pinion Lube Point
EACH SIDE OF MACHINE OR EXCESSIVE PLAY WILL CAUSE BINDING AND DAM-
AGE TO EQUIPMENT. Figure 3-33. Swing Bearing Lubrication Points
9. Install bearing (30) with small end facing to outside of Installation

machine in motor end of housing (4). Refer to Figure 3-31., Swing Bearing Installation.
10. Install worm (29), hex end facing away from motor side, 1. Install bearing to rotation box with two capscrews, with
into housing (4). fill plug of bearing close to gear as bolt pattern allows.
Do not tighten capscrews.
2. Line up high spot (blue) of bearing with center tooth of
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED worm gear. Set backlash to 0.008 - 0.010 inch (0.20 - 0.25
FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING mm). Tighten capscrews as shown in Figure 3-34., Swing
ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE. Bearing (Dohi) Torque Sequence.
11. Install motor adapter (23) and shim (24) to bore end of 3. Apply Mobiltac 375 Open Gear Compound or equiva-
housing. lent to bearing and worm gear teeth.
12. Install bearing (31) with small end facing to outside of NOTE: Use Multi-Purpose Grease (MPG) If Mobiltac 375 Open Gear
machine on hex end of worm (29). Compound is not available. However, service interval will
be shorter.
13. Install worm cap (26) using shims (27) to achieve 0.000
to 0.001" end play. Install bolts (25) and sealant. Torque 4. Remove plugs at two locations on top of gear and fill
to 80 ft-lb (108.5 Nm). bearing with Mobil SHC 460 grease. Reinstall plugs.
14. Install pinion/gear assembly in housing so gear teeth
mesh with worm gear teeth.
15. Apply silicone sealant to cap assembly contact area on
housing.
3-40 – JLG Lift – 3121290

5. Use suitable lift equipment and install bearing/rotation

box assembly to frame with soft spot (red) 90 degree rel-
ative to load axis. If reusing old bearing, align scribed 6 2
line of outer bearing race with scribed mark on frame. 10 15
6 2 19
14 10 15 11
14
SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN FRAME AND 18 11
TURNTABLE. JLG INDUSTRIES RECOMMENDS ALL REMOVED GRADE 8 BEAR- 18 7
ING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND 22 7
BOLTS. IT IS IMPERATIVE THAT REPLACEMENT HARDWARE MEETS JLG SPECI- 4 4 3 3
FICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.
8 21
6. Apply a light coating of thread locking compound JLG 8 17
12 17
PN 0100019 to new bearing bolts. Loosely install bolts
and washers through frame and outer bearing race. 16 13
12 20 9 13
23 1 5
16 9
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED 1 5
TO TIGHTEN BEARING ATTACHMENT BOLTS, CHECK TORQUE SETTING ACCU-
RACY OF TOOL BEFORE USE.
Figure 3-35. Swing Bearing (Jing Wei) Torque Sequence
7. Tighten bolts to initial torque of 130 ft-lb (176 Nm) follow- 8. Remove lifting equipment from bearing.
ing torque sequence shown in Figure 3-34., Swing Bear-
ing (Dohi) Torque Sequence. Tighten to final torque of 9. Use suitable lift equipment to carefully position turnta-
190 ft-lb (257 Nm) following same sequence. ble assembly above machine frame.
10. Carefully lower turntable onto swing bearing. Align
scribed line of inner race of bearing with scribed mark
6 2 on turntable. If a new swing bearing is used, align 1/8"
10 15 NPT holes with notches in frame.
6 2 23
14 10 19 11
14 15
18 11
18 7
22 7
4 4 3 3
8 21 Install bearing 1/8 in. NPT holes
8 12 17 17 aligned with notches in frame.
16 13
12 20 9 13 Figure 3-36. Swing Bearing Alignment
24 1 5
16 9 11. Apply light coating of JLG Thread Locking Compound PN
1 5 0100019 to new bearing bolts and install through turnta-
ble and inner race of bearing.
12. Tighten bolts to an initial torque of 130 ft-lb (176 Nm)
Figure 3-34. Swing Bearing (Dohi) Torque Sequence
following torque sequence shown in Figure 3-34., Swing
Bearing (Dohi) Torque Sequence. Tighten to a final
torque of 190 ft-lb (257 Nm) following same sequence.
13. Remove lift equipment.
14. Route hydraulic lines through center of turntable and
frame. Connect as tagged prior to removal.
15. Activate hydraulic system following all safety precautions.
Check swing system for proper and safe operation.
3121290 – JLG Lift – 3-41

Turntable Bearing Mounting Bolt Checks Wear Tolerance

NOTE: Check must be performed after first 50 hours of machine
operation and every 600 hours of machine operation
thereafter. Replace missing or loose bolts with new bolts
and torque as specified after lubricating bolt threads with
JLG Thread Locking Compound PN 0100019. Recheck all
bolts for looseness after replacing and torquing individual
bolts.
Check Frame To Bearing Bolts

1. Fully retracted boom and elevate to 70° (full elevation).
2. Try and insert a 0.0015" feeler gauge between bolt head
and hardened washer at positions shown in Figure 3-37.,
Swing Bearing Feeler Gauge Check. Figure 3-38. Swing Bearing Tolerance Measuring Point
1. Position boom over side of machine with upper boom
horizontal, telescope fully extended, and mid/lower
boom stowed. Measure and record distance between
swing bearing and turntable using a magnetic base dial
indicator.
2. At same point, position boom over side of machine with
Upper Boom and Mid/Lower Boom fully elevated. Mea-
sure and record distance between swing bearing and
turntable using a magnetic base dial indicator.
3. If there is a difference greater than 0.057" (1.40 mm),
replace swing bearing.

4. If there is a difference less than 0.057" (1.40 mm) and any
of the following conditions exist, remove and inspect
bearing.
a. Metal particles in grease.
Figure 3-37. Swing Bearing Feeler Gauge Check
b. Increased drive power.
3. Ensure 0.0015" feeler gauge will not fit under bolt head
c. Noise.
to bolt shank.
d. Rough rotation.
4. Swing turntable 90° and check selected bolts at that
position. 5. If bearing inspection shows no defects, reassemble
bearing and return to service.
5. Continue rotating turntable at 90° intervals until sam-
pling of bolts are checked in all quadrants.
Check Turntable To Bearing Bolts

6. Fully retract boom and elevate to 70 degrees (full eleva-
tion).Try and insert a 0.0015" feeler gauge between bolt
head and hardened washer at positions shown in Figure
3-37., Swing Bearing Feeler Gauge Check.
7. Lower boom to horizontal and fully extend boom.
8. Try and insert a 0.0015" feeler gauge between bolt head
and hardened washer at position indicated by arrow in
Figure 3-37., Swing Bearing Feeler Gauge Check.
3-42 – JLG Lift – 3121290

3.8 SWING MOTOR • Before you disassemble motor or any of its components
read this entire section. It provides important information
on parts and procedures to service motor.
• Before disconnecting and removing motor, thoroughly
IF HYDRAULIC SYSTEM FLUID BECOMES OVERHEATED [IN EXCESS OF 200°F
clean off all outside dirt, especially from around fittings
(93.3°C)], SEALS CAN SHRINK, HARDEN, OR CRACK AND LOSE THEIR SEALING
and hose connections. Remove rust or corrosion from cou-
ABILITY.
pling shaft.
Preparation Before Disassembly • Remove coupling shaft connections and hose fittings and
immediately plug port holes and fluid lines.
• Remove motor from system, drain fluid, and move it to a
clean work surface.
PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY CAREFUL
WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE • Clean and dry motor before disassembly.
INJURY OR DEATH. • Keep parts separate to avoid nicks and burrs.
• Discard all seals and seal rings as they are removed from
motor. Replace all seals, seal rings and damaged or worn
WEAR EYE PROTECTION AND COMPLY WITH OSHA OR OTHER MAXIMUM AIR parts with OEM approved service parts.
PRESSURE REQUIREMENTS.
• Clean all parts except seals in clean petroleum-based sol-
vent. Dry with compressed air.
NEVER STEAM OR PRESSURE WASH HYDRAULIC COMPONENTS. DO NOT FORCE OR

ABUSE CLOSELY FITTED PARTS.
Matched Rotor Set Wear Plate

Manifold Housing
Outer Shaft Seal
Coupling Shaft
Bearing
End Cover Drive Link - 12 Tooth Splines

Matched Commutator Set
Figure 3-39. Swing Motor - Cutaway
3121290 – JLG Lift – 3-43

Table 3-11. 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 area deterio- (a) Loosen then tighten single bolt to torque spec-
rated by corrosion. ification.
(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 1. Lack of sufficient oil supply (a) Check for faulty relief valve and adjust or
load replace as required.
(b) Check for and repair worn pump.
(c) Check for and use correct oil for temperature of
operation.
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
disassembling unit.
4. Excessive heat. Locate excessive heat source (usually a restriction)

in the system and correct the condition.
Low mechanical efficiency or 1. Line blockage Locate blockage source and repair or replace.
undue 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 motor unit. Locate source and eliminate cause.
Removal Preparation Before Disassembly

Refer to Figure 3-40., Swing Motor Removal and Installation. • Read this entire section before you disassemble motor or
any of its components for important information on parts
1. Thoroughly clean area around swing motor to prevent
and procedures.
dirt from entering system.
• Thoroughly clean off outside dirt, especially around fittings
2. Tag and disconnect hydraulic lines to swing motor. Cap and hose connections, before disconnecting and removing
or plug all openings. motor. Remove rust or corrosion from coupling shaft.
3. Secure worm gear shaft so it does not pull out any when • Remove coupling shaft connections and hose fittings and
removing swing motor. Failure to do so could damage immediately plug port holes and fluid lines.
worm gear seals.
• Remove motor, drain fluids, and take it to a clean work sur-
4. Remove bolts securing swing motor to swing drive face.
assembly.
• Clean and dry motor before disassembly.
5. Carefully pull the swing motor from the swing drive.
• As you disassemble motor, clean all parts except seals in
clean petroleum-based solvent and blow them dry.
3-44 – JLG Lift – 3121290

PETROLEUM-BASE SOLVENTS ARE FLAMMABLE. BE EXTREMELY CAREFUL NEVER STEAM OR HIGH PRESSURE WASH HYDRAULIC COMPONENTS. DO NOT
WHEN USING ANY SOLVENT. EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE FORCE OR ABUSE CLOSELY FITTED PARTS.
INJURY OR DEATH.
• Keep parts separate to avoid nicks and burrs.
• Discard seals and seal rings as they are removed from
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX- motor. Replace all seals, seal rings and any damaged or
IMUM AIR PRESSURE REQUIREMENTS. worn parts with OEM approved service parts.
SECURE THIS END OF SHAFT

WHEN REMOVING SWING
MOTOR. IF IT STAR TS TO
PULL OUT WITH THE SWING
MOTOR, IT CAN DAMAGE
INTERNAL SEALS.
Torque swing motor

Swing mounting bolts to
Motor 85 ft-lb (115 Nm).
Figure 3-40. Swing Motor Removal and Installation
3121290 – JLG Lift – 3-45

Disassembly and Inspection

Refer to Figure 3-41., Swing Motor - Exploded View.
1. Place motor in a soft jawed vice, with coupling shaft (12)
pointed down and vise jaws clamping firmly on sides of
housing (18) mounting flange, or port bosses. Remove
manifold port O-rings if applicable.
3. Remove special ring head bolts (1) with 1/2" or 9/16"

socket. Inspect bolts for damaged threads or sealing
rings. Replace damaged bolts.
IF MOTOR IS NOT HELD FIRMLY IN VISE, IT COULD DISLODGE DURING SERVICE

PROCEDURES AND CAUSE INJURY.
2. Scribe an alignment mark down and across motor com-

ponents from end cover (2) to housing (18) for proper
reassembly orientation.
4. Remove end cover assembly (2) and seal ring (4). Discard
seal ring.
3-46 – JLG Lift – 3121290

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

blow dry. Be sure end cover valve apertures are free of
contamination. Inspect end cover for cracks and bolt
head recesses for good bolt head sealing surfaces.
Replace end cover as necessary.
NOTE: A polished pattern (not scratches) on the cover from rota-

tion of commutator (5) is normal. Discoloration indicates
excess fluid temperature, thermal shock, or excess speed
and requires system investigation for cause and close
inspection of end cover, commutator, manifold, and rotor
set.
6. Remove commutator ring (6) and inspect for cracks or

burrs.
1. Remove manifold (7). Inspect for cracks, surface scoring, bri-

nelling, or spalling and replace if any of these conditions exist.
A polished pattern on the ground surface from commutator
or rotor rotation is normal. Remove and discard seal rings (4)
on both sides of manifold.
7. Remove commutator (5) and seal ring (3). Remove seal

ring from commutator. Use an air hose to blow air into
ring groove until seal ring lifts out. Discard seal ring.
Inspect commutator for cracks or burrs, wear, scoring,
spalling, or brinelling. Replace commutator and commu-
tator ring as a matched set If any of these conditions
exist.
NOTE: Manifold consists of plates bonded together and cannot be
disassembled. Compare both sides of manifold to ensure
same surface is reassembled against rotor set.
3121290 – JLG Lift – 3-47

2. Remove rotor set (8) and wearplate (9), together to hold NOTE: A polished pattern on wear plate from rotor rotation is nor-
rotor set in its assembled form, keeping same rotor vane mal. Place rotor set (8) and wear plate (9) on a flat surface
to stator contact surfaces. Drive link (10) may come away and center rotor in stator so two rotor lobes (180 degrees
from coupling shaft (12) with rotor set and wearplate. apart) and a roller vane centerline are on the same stator
Shift rotor set on wearplate and remove drive link if centerline. Check rotor lobe to roller vane clearance with a
needed. Inspect assembled rotor set for nicks, scoring, feeler gage at this common centerline. Replace rotor set If
or spalling on any surface, and for broken or worn more than 0.005" (0.13 mm) of clearance.
splines. If a rotor set component requires replacement,
complete rotor set must be replaced as it is a matched
set. Inspect wearplate for cracks, brinelling, or scoring.
3. Discard seal ring (4) between rotor set and wearplate.
NOTE: If rotor set (8) has two stator halves and two sets of seven
vanes as shown, check rotor lobe to roller vane clearance
at both ends of rotor.
4. 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 visible
lash (play) should be seen between mating spline parts.
Remove seal ring (4) from housing (18) and discard.
NOTE: Rotor set (8) components may become disassembled dur-

ing service. Mark surface of rotor and stator facing UP, with
etching ink or grease pencil before removal to ensure cor-
rect reassembly of rotor into stator and rotor set into
motor. Mark all rotor components and mating spline com-
ponents for exact repositioning at assembly for maximum
wear life and performance of rotor set and motor.
3-48 – JLG Lift – 3121290

5. Remove thrust bearing (11) from top of coupling shaft

(12). Inspect for wear, brinelling, corrosion, and missing
rollers.
6. Check exposed portion of coupling shaft (12) for signs of

rust and corrosion which might prevent its withdrawal
through seal and bearing. Use crocus cloth or fine emery
paper as needed.
NOTE: Minor shaft wear in seal area is permissible. If wear exceeds

0.020" (0.51 mm) diametrically, replace coupling shaft. A
slight “polish” is permissible in shaft bearing areas. Any-
thing more requires coupling shaft replacement.
8. Remove and discard seal ring (4) from housing (18).
7. Remove coupling shaft (12), by pushing on output end

of shaft. Inspect coupling shaft bearing and seal sur-
faces for spalling, nicks, grooves, severe wear or corro-
sion and discoloration. Inspect for damaged or worn
internal and external splines or keyway. Replace shaft if
any of these conditions exist.
3121290 – JLG Lift – 3-49

9. Remove thrust bearing (15) and thrust washer (14). 12. Inspect housing (18) assembly for cracks, machined sur-
Inspect for wear, brinelling, corrosion and a full comple- faces for nicks, burrs, brinelling, or corrosion. Remove
ment of retained rollers. burrs that can be removed without changing dimen-
sional characteristics. Inspect tapped holes for thread
damage. If housing is defective in these areas, discard
housing assembly.
10. Remove seal (16) and back up ring (17) from housing
(18) and backup washer (25). Discard both.
13. If housing (18) assembly has passed inspection to this
point, inspect housing bearings/bushings (19) and (13)
if they are captured in housing cavity. Two thrust wash-
ers (14) and thrust bearing (15) bearing rollers must be
firmly retained in bearing cages, but must rotate and
orbit freely.
All rollers and thrust washers must be free of brinelling

and corrosion. Bushing (19)(13) to coupling shaft diame-
ter clearance must not exceed 0.010 inch (0.025 mm).
A bearing, bushing, or thrust washer that does not pass

inspection must be replaced. If housing has passed this
inspection, disassembly of motor is complete.
11. Remove housing (18) from vise. Invert housing and

remove seal (20) with a blind hole bearing or seal puller.
Discard seal.
3-50 – JLG Lift – 3121290

14. Measure and note depth or location of bearing/bushing 15. Use a suitable size bearing puller to remove bearing/
(13) in relation to housing wear plate surface, and depth bushings (19) and (13) from housing (18) If Bearings,
or location of bearing/bushing (19) in relation to begin- bushing or thrust washers must be replaced without
ning of bearing/bushing counter bore before removing damaging housing. Remove thrust washers (14) and
bearings/bushings. This ensures correct reassembly of thrust bearing (15) if previously retained in housing by
new bearings/bushings. bearing (13).
3121290 – JLG Lift – 3-51

1. Bolt 5. Commutator 8A. Rotor 9. Wear Plate 12. Inner Bushing 16. Backup Ring
2. End Cover 6. Commutator Ring 8B. Stator Half 10. Drive Link 13. Thrust Washer 17. Housing
3. Seal Ring 7. Manifold 8C. Stator Vane 11. Coupling Shaft 14. Thrust Bearing 18. Bearing
4. O-Ring 8. Rotor Set 8D. Stator Half 12A. Key 15. Inner Shaft Seal 19. Outer Shaft Seal
Figure 3-41. Swing Motor - Exploded View
3-52 – JLG Lift – 3121290

Assembly NOTE: If A bearing mandrel is not available and alternate meth-

ods are used to press in bearing/bushing (13) and (19).
Refer to Figure 3-41., Swing Motor - Exploded View.
bearing/bushing depths specified must be achieved to
Replace seals and seal rings with new ones each time motor Ensure adequate bearing support and correct relationship
unit is reassembled. Lubricate seals and seal rings with SAE to adjacent components when assembled.
10W40 oil or clean grease before assembly.
NOTE: Do not oil or grease parts before assembly unless other-
wise indicated.
SOLVENTS ARE FLAMMABLE. EVEN A SMALL EXPLOSION OR FIRE CAN CAUSE

INJURY OR DEATH. BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT.
Wash all parts in clean petroleum-based solvents before

assembly. Blow dry with compressed air. Remove any paint
chips from end cover mating surfaces, commutator set, mani-
fold rotor set, wear plate and housing, and from port and seal-
ing areas.
WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAX-
IMUM AIR PRESSURE REQUIREMENTS.
BEARING/BUSHINGS (13) AND (19) HAVE A PRESS FIT INTO HOUSING AND
1. If housing (18) bearing components were removed for MUST BE DISCARDED WHEN REMOVED.
replacement, thoroughly coat and pack a new outer
bearing/bushing (19) with clean corrosion resistant 2. Inner housing bearing/bushing (13) can now be pressed
grease. Press new bearing/bushing into counterbore at into its counter-bore in housing (18) flush to 0.03 inch
mounting flange end of housing, using appropriately (0.76 mm) below housing wear plate contact face. Use
sized bearing mandrel as described to control bearing/ opposite end of bearing mandrel used to press in outer
bushing depth. Housing requires use of bearing man- bearing/bushing (19).
drel to press bearing/ bushing (19) into housing to a
required depth of 0.151/0.161" (3.84/4.09 mm) from end
of bearing counterbore.
NOTE: Bearing mandrel must be pressed against lettered end of

bearing shell. Housing bore must be square with press base
and bearing/bushing not cocked when pressing a bearing/
bushing into housing.
3121290 – JLG Lift – 3-53

3. Press new dirt and water seal (20) into housing (18) 6. Install thrust washer (14) and thrust bearing (15).
outer bearing counterbore. Press in dirt and water seal
(20) until flange is flush against housing.
NOTE: Motor requires one thrust washer (14) with thrust bearing
(15). Coupling shaft seats directly against thrust bearing.
4. Place housing (18) assembly into a soft jawed vise with
coupling shaft bore down, clamping against mounting 7. Apply masking tape around splines or keyway on shaft
flange. (12) to prevent damage to seal.
5. Assemble a new backup ring (17), new backup washer

(25), and new seal (16) with seal lip facing toward inside
of motor, into their counterbores in housing (18).
3-54 – JLG Lift – 3121290

8. Apply a generous amount of clean, corrosion resistant 9. Apply a small amount of clean grease to a new seal ring
grease to lower (outer) housing bearing/bushing (19). (4) and insert it in housing (18) seal ring groove.
Install coupling shaft (12) into housing (18), seating it
against thrust bearing (15).
NOTE: One or two alignment studs screwed finger tight into hous-
ing (18) bolt holes, approximately 180 degrees apart, will
facilitate assembly and alignment of components required
in the following procedures. Studs can be made by cutting
OUTER BEARING (19) IS NOT LUBRICATED BY SYSTEM HYDRAULIC FLUID. BE off heads of 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as
SURE IT IS THOROUGHLY PACKED WITH RECOMMENDED GREASE. required that are over 0.5 inch (12.7 mm) longer than bolts
(1) used in motor.
NOTE: Coupling shaft (12) will be flush or just below housing wear
surface when properly seated with coupling shaft (12). 10. Install drive link (10), long splined end down, in coupling
Coupling shaft must rotate smoothly on thrust bearing shaft (12) and engage drive link splines in mesh with
package. coupling shaft splines.
NOTE: Use alignment marks on coupling shaft and drive link

before disassembly to assemble drive link splines in their
original position in mating coupling shaft splines.
3121290 – JLG Lift – 3-55

11. Assemble wear plate (9) over drive link (10) and align- 13. Place assembled rotor set (8) on wear plate (9) with rotor
ment studs onto housing (18). counterbore and seal ring side down and splines into
mesh with drive link splines.
12. Apply a small amount of clean grease to a new seal ring

(4) and assemble it into seal ring groove on wear plate NOTE: It may be necessary to turn one alignment stud out of
side of rotor set stator. housing (18) temporarily to assemble rotor set (8) or mani-
fold (7) over drive link.
NOTE: Rotor set rotor counterbore side must be down against

wear plate for drive link clearance and to maintain original
rotor-drive link spline contact. A rotor set without a coun-
terbore that was not etched before disassembly can be
reinstalled using drive link spline pattern on rotor splines if
apparent, to determine which side was down. Rotor set
seal ring groove faces toward wear plate (9).
14. Apply clean grease to new seal ring (4). Install in seal
ring groove in rotor set contact side of manifold (7).
NOTE: If rotor set is disassembled and cannot be easily reassem-

bled, go to One Piece Stator Assembly, page 3-59 or Two
Piece Stator Assembly, page 3-60.
NOTE: Manifold (7) is made of several permanently bonded

plates. Manifold surface that contacts rotor set has a series
of irregular shaped cavities on largest circumference or cir-
cle around inside diameter. Polished impression left on
manifold by rotor set is another indication of which surface
must contact rotor set.
3-56 – JLG Lift – 3121290

15. Place manifold (7) over alignment studs and drive link 18. Install new seal ring (3) flat side up, into commutator (5).
(10) and onto rotor set. Be sure correct manifold surface Assemble commutator over end of drive link (10) on mani-
is against rotor set. fold (7) with seal ring side up.
16. Apply grease to new seal ring (4) and insert it in mani-
fold seal ring groove.
19. Install new seal ring (4) in end cover (2) and install end
cover over alignment studs and on commutator set. If
17. Install commutator ring (6) over alignment studs on end cover has only 5 bolt holes be sure cover holes are
manifold. aligned with 5 threaded holes in housing (18). Correct 5
bolt end cover bolt hole relationship to housing port
bosses is shown:
3121290 – JLG Lift – 3-57

20. Assemble bolts (1) and screw in finger tight. Remove and
replace two alignment studs with bolts after other bolts
are in place. Alternately and progressively tighten bolts to
pull end cover and other components into place with a
final torque of 25-30 ft-lb (34-41 Nm).
NOTE: If end cover has a valve (24) or five bolt holes, use line
scribed on cover to radially align end cover to its original
position.
3-58 – JLG Lift – 3121290

One Piece Stator Assembly 4. Assemble six vanes, or as many vanes that readily
assemble in stator vane pockets.
A disassembled rotor stator and vanes that cannot be readily
assembled by hand can be assembled using the following pro-
cedures:
1. Place stator on wear plate (9) with seal ring (4) side
down, after following assembly procedures 1 through
13. Be sure seal ring is in place.
EXCESSIVE FORCE USED TO PUSH ROTOR VANES IN PLACE COULD SHEAR OFF
COATING APPLIED TO STATOR VANE POCKETS.
5. Grasp output end of coupling shaft (12) with locking pli-

2. If assembly alignment studs are not used, align stator ers or other appropriate turning device and rotate cou-
bolt holes with wear plate and housing bolt holes. Turn pling shaft, drive link, and rotor to seat rotor and
two bolts (1) finger tight in bolt holes approximately 180 assembled vanes into stator, creating the necessary
degrees apart to retain stator and wear plate stationary. clearance to assemble the seventh or full complement
of seven vanes. Assemble the seven vanes using mini-
3. Assemble rotor, counterbore down if applicable, into mum force.
stator, and onto wear plate (9) with rotor splines into
mesh with drive link (10) splines.
Remove two bolts (1) if used to retain stator and wear plate.
Go to Step 14 on page 3-56 to continue assembly.
3121290 – JLG Lift – 3-59

Two Piece Stator Assembly 8. Assemble six vanes, or as many vanes that readily
assemble into stator vane pockets.
A disassembled rotor set (8) that cannot be easily by hand and
has a two piece stator, can be assembled using the following 9. Grasp output end of coupling shaft (12) with locking pli-
procedures: ers or other appropriate turning device and rotate cou-
pling shaft, drive link, and rotor to seat rotor and
1. Place stator half on wear plate (9) with seal ring (4) side
assembled vanes into stator, creating necessary clear-
down, after following motor assembly procedures 1
ance to assemble seventh or full complement of seven
through 13. Be sure seal ring is in place.
vanes. Assemble seven vanes using minimum force.
2. Align stator bolt holes with wear plate and
Go to Step 14 on page 3-56 to continue assembly.
housing bolts. Turn two alignment studs
finger tight in bolt holes approximately 180° apart to
keep stator half and wear plate stationary. Final Checks
3. Assemble rotor, counterbore down if applicable, into 1. Pressurize motor with 100 psi dry air or nitrogen and
stator half, and onto wear plate (9) with rotor splines submerge in solvent to check for external leaks.
into mesh with drive link (10) splines.
2. Check motor for rotation. Torque required to rotate cou-
NOTE: Use marking applied to rotor set components to reassem- pling shaft should not be more than 50 ft-lb (68 Nm).
ble components in their original relationship to ensure ulti-
3. Pressure port with “A” cast under it on housing (18) is for
mate wear life and performance.
clockwise coupling shaft rotation as viewed from the
output end of coupling shaft. Pressure port with “B” cast
4. Assemble six vanes, or as many vanes that readily
under it is for counter clockwise coupling shaft rotation.
assemble into stator vane pockets.
4. Use test stand and check motor operation.
EXCESSIVE FORCE USED TO PUSH ROTOR VANES IN PLACE COULD SHEAR OFF Installation
COATING APPLIED TO STATOR VANE POCKETS. Refer to Figure 3-40., Swing Motor Removal and Installation.
1. Carefully insert swing motor into swing drive, making
5. Grasp output end of coupling shaft (12) with
sure swing motor shaft key is aligned correctly.
locking pliers or other appropriate turning device and
rotate coupling shaft, drive link and rotor to seat rotor 2. Secure swing motor to swing drive assembly with two
and assembled vanes (8C) into stator half, creating nec- bolts and flat washers. Apply JLG threadlocker P/N
essary clearance to assemble seventh or full comple- 0100019 to threads of retaining bolts. Torque to 85 ft-lb
ment of seven vanes. Assemble the seven vanes using (115 Nm).
minimum force.
6. Place second stator half on a flat surface with seal ring
groove up. Apply a small amount of grease to a new seal TORQUE
ring (4) and install it in stator half ring groove.
7. Assemble second stator half over two alignment studs
and rotor with seal ring side down onto the first stator
half aligning any timing marks applied for this purpose.
3. Connect hydraulic lines running to swing motor as

IF STATOR HALF (8B) IS A DIFFERENT HEIGHT (THICKNESS) THAN STATOR
tagged during removal.
HALF (8D) STATOR VANES (8C) OR (8E)OF THE SAME LENGTH (HEIGHT) AS STA-
TOR HALF MUST BE REASSEMBLED IN THEIR RESPECTIVE STATOR HALF FOR
ROTOR SET TO FUNCTION PROPERLY.
3-60 – JLG Lift – 3121290

Figure 3-42. Auxiliary Pump
3121290 – JLG Lift – 3-61

3.9 GENERATOR Overload Protection
Every 250 hours

Check drive belt tension every 250 hours of operation. STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER.
The circuit breaker protects generator windings from over-

load. If circuit breaker opens, generator output stops. If circuit
breaker continues to open, check for faulty equipment con-
nected to platform receptacles.
1/2 in.
(13 mm)
CIRCUIT
BREAKER
Every 500 hours

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

Refer to Figure 3-43., Generator Brushes and Slip Rings.
INSPECTING BRUSH POSITION

Inspect brush alignment with slip rings. View alignment
through air vents in stator barrel. Brushes must ride com-
Blow out inside of generator with compressed air every 500 pletely on slip rings.
hours of service. Clean monthly If operating in a hostile envi-
ronment. INSPECTING BRUSHES
Remove end panel. Inspect wires. Remove brush holder
assembly. Pull brushes from holders.
Replace brushes if damaged, or at or near minimum length.
CLEANING SLIP RINGS

Visually inspect slip rings. Rings turn dark brown under normal
use. If slip rings are corroded or their surface is uneven,
remove belt to turn shaft by hand for cleaning.
Clean rings with 220 grit emery paper. Remove as little mate-
rial as possible. If rings are deeply pitted and do not clean up,
consult generator factory service.
Reinstall belt, brush holder assembly, and end panel.
3-62 – JLG Lift – 3121290

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

2. Brushes
3. Slip Rings
Figure 3-43. Generator Brushes and Slip Rings
3121290 – JLG Lift – 3-63

3.10 DEUTZ ENGINE 4. Open oil drain valve and drain oil.
5. Close oil drain valve.
NOTE: Refer to engine manufacturer’s manual for detailed oper-
ating and maintenance instructions. 6. Pour in new engine oil. Refer to Section 1 for capacity
and refer to Figure 3-45., Engine Oil Viscosity.
Check Oil Level
1. Make sure machine and engine are level and switch
engine OFF before checking oil level.
2. Remove oil dipstick and wipe with clean cloth.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level to MAX mark or as shown in
figure below with an approved grade and type of oil out-
lined in engine manufacturer’s operator’s manual.
Figure 3-45. Engine Oil Viscosity
Change Oil Filter

NOTE: Tier 3 engine oil filters are mounted vertically. Tier 4 engine
oil filters are mounted horizontally. Removal and installa-
tion is identical.
1. Wipe area around filter to remove any dirt from area.

2. Using a suitable oil filter removal tool, loosen lube oil fil-
ter cartridge and spin off.
Figure 3-44. Deutz Dipstick Markings
5. Replace dipstick until fully seated.
Change Engine Oil

1. Allow engine to warm up. Engine oil should reach
approximately 176° F (80° C).
2. Make sure machine and engine are level and switch off
engine.
3. Place oil tray under engine.
HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN 3. Catch any escaping oil.
DRAINING.
4. Clean any dirt from filter carrier sealing surface.
COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.

DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU-
LATIONS.
3-64 – JLG Lift – 3121290

5. Lightly coat new oil filter rubber gasket with clean oil. Clean Fuel Strainer (D2011 L03 Only)
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1. Unscrew hexagonal nut (1).
6. Screw in new filter by hand until gasket is flush. Hand-

tighten filter another half-turn.
2. Remove fuel strainer cover (2).

3. Clean fuel strainer with diesel fuel and replace as needed.
4. Place seal (3) in position.
7. Check oil level.
5. Install fuel strainer cover (2) in position and tighten hex-
8. Check oil pressure. agonal screw (1).
9. Check oil filter cartridge for leaks. 6. Check for leaks.
Replace Fuel Filter
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.
1. Wipe area around filter to clean any dirt from area.
2. Undo fuel filter cartridge and spin off.
3. Catch any escaping fuel.
4. Clean filter carrier sealing surface.
5. Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
6. Screw in new filter by hand until the gasket is flush.
7. Hand-tighten filter another half-turn.
8. Open fuel shut-off valve.
9. Check for leaks.
3121290 – JLG Lift – 3-65

3.11 DEUTZ EMR 2 The EMR2 is equipped with safety devices and measures in the
hardware and software for emergency running (Limp home)
The EMR2 system consists of sensors, control unit, and an actu- functions.
ator. Engine-side controls and the JLG Control System are con-
To switch engine off, the EMR2 is switched in a de-energized
nected by separate cable harnesses to the EMR control unit.
fashion over the ignition switch. A strong spring in the actua-
Engine sensors provide control unit electronics with informa- tor presses the control rod in the de-energized condition to
tion of the current condition of engine and preconditions the zero position. As a redundancy measure, an additional
(throttle position etc.). The EMR2 controls an actuator that solenoid serves for switching off and this, independently of
operates the injection pump control rod and adjusts fuel the actuator, also moves the control rod in the de-energized
quantity to meet performance requirements. condition into the zero position.
Regulating rod position is reported back and corrected by the After programming over the ISO9141 interface, the EMR2 pos-
control rod travel sensor, situated together with rotation mag- sesses a motor-specific data set matched by engine serial
nets in the actuator housing. number. Modules cannot be swapped between engines.
CONTROL ROD POSITION

SENSOR/ACTUATOR POWER SUPPLY
COOLANT TEMPERATURE CAMSHAFT

SENSOR SPEED
JLG SYSTEM HANDLES ENGINE START/

STOP; EMR2 TAKES CONTROL OF THE
GLOW PLUG ENGINE AT 700RPM
JLG SYSTEM USES JLG ANALYZER TO

REPORT FAULTS
DIAGNOSIS INTERFACE/CAN-BUS;
JLG SYSTEM USES THIS TO CONTROL
OIL PRESSURE
ENGINE & FAULT REPORTING.
SENSOR
Figure 3-46. EMR 2 Engine Side Equipment
3-66 – JLG Lift – 3121290

Figure 3-47. Deutz EMR 2 Troubleshooting Flow Chart
3121290 – JLG Lift – 3-67

3-68
– JLG Lift –
Figure 3-48. Deutz EMR 2 Vehicle Side Connection Diagram
3121290
3121290
– JLG Lift –
Figure 3-49. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
3-69
3-70
– JLG Lift –
Figure 3-50. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
3121290
Figure 3-51. EMR 2 Engine Plug Pin Identification
3121290 – JLG Lift – 3-71

Figure 3-52. EMR 2 Vehicle Plug Pin Identification
3-72 – JLG Lift – 3121290

Figure 3-53. EMR2 Fault Codes - Sheet 1 of 5
3121290 – JLG Lift – 3-73

3-74 – JLG Lift – 3121290

3121290 – JLG Lift – 3-75

3-76 – JLG Lift – 3121290

3121290 – JLG Lift – 3-77

3.12 BIO FUEL IN DEUTZ ENGINES APPROVED ENGINES

912, 913, 914, 1011, 2011, 1012, 2012, 1013, 2013, 413 and 513
series are approved for bio-diesel from year of manufacture
General 1993 under compliance with basic conditions specified below.
Use of bio fuels is permitted for the compact engines made by
DEUTZ. BASIC CONDITIONS TO BE OBSERVED
• A power loss of 5-9% in relation to diesel fuel in accordance
Distillate fuels with residue oil percentages or mixed fuels may
with EN 590 is possible due to the lower heating value.
not be used in DEUTZ compact engines.
Blocking of fuel injector is not allowed.
DEUTZ vehicle engines are designed for diesel fuels in accor-
• Lubricating oil quality must correspond to TR 0199-99-
dance with EN 590 with a cetane number of at least 51. DEUTZ
3002. Lubricating oil change interval must be halved in rela-
engines for mobile machinery are designed for a cetane num-
tion to operation with diesel fuel in accordance with EN 590.
ber of at least 45. When using fuels of a low cetane number, dis-
turbing white smoke and ignition misfires are to be expected • Standstills of longer than 4 to 6 weeks must be avoided
under some circumstances. with bio-diesel. Otherwise, engine must be started and
stopped with diesel fuel.
A cetane number of at least 40 is permissible for the US market,
therefore special engine models have been developed to • Bio-diesels can be mixed with normal diesel fuel but basic
avoid starting difficulties, extreme white smoke or increased conditions described in this subsection apply for mixtures.
hydrocarbon emissions (EPA specification - US EPA REGULA- Mixtures with up to 5% (m/m) bio-diesel (B5) which have
TIONS FOR LARGE NONROAD COMPRESSION-IGNITION recently been on sale at European fuel stations are
ENGINES). excepted. These fuels must be treated like normal diesel
fuels because EN 590 expressly permits adding up to 5%
If white smoke is unacceptable when using a very low cetane (m/m) bio-diesel in accordance with EN 14214.
number, use of ignition improvers is to be recommended as a
later remedial measure. • Approximately 30-50 hours after changing from diesel fuel to
bio-diesel, the fuel filter should be changed as a preventive
Certification measurements for compliance with legal emission measure to avoid a drop in performance due to clogged fuel
limits are carried out with test fuels prescribed by law. These filters. Deposited fuel ageing products are dissolved by bio-
correspond to diesel fuels in accordance with EN 590 and diesel and transported into the fuel filter. They should not
ASTM D 975. No emission values are guaranteed with other be changed immediately, but after 30 to 50 hours because
fuels described. It is the obligation of the owner to check per- that is the time it takes for most dirt to be dissolved.
mission for use of fuels in accordance with regional regula-
tions. PLANT OIL
Bio Fuel
PURE PLANT OILS (E.G. RAPE SEED OIL, SOY OIL, PALM OIL) ARE NOT CLASSIFIED AS
PERMITTED BIO-DIESEL FUELS BIO-DIESEL AND EXHIBIT PROBLEMATICAL PROPERTIES FOR DIESEL ENGINE OPER-
Originally only rape seed oil methylester (RME) was sold as a ATION (STRONG TENDENCY TO COKE, RISK OF PISTON SEIZURE, EXTREMELY HIGH
bio-diesel fuel in Europe but fatty acid methylester (FAME) VISCOSITY, AND POOR EVAPORATION BEHAVIOR).
based on other oils have come onto the market increasingly in
recent years. However, with the latter there is a risk that the limit The conversion of DEUTZ engines to rape seed oil fuel opera-
values of EN 14214 are not kept in the field. Anyone who uses tion with conversion kits and modified tanks systems of vari-
bio-diesel fuel in DEUTZ engines must therefore choose his ous manufacturers is not allowed and leads to loss of warranty
supplier very carefully and have him guarantee compliance rights.
with the EN 14214 limit values. Since experience has shown
that rape seed oil methylester (RME) exceeds the limit values
less often that other esters, it is expressly recommended to use
only rape seed oil methylester. DEUTZ customers in Germany
can additionally ensure the quality by buying bio-diesel fuel
with an AGQM certificate (Arbeitsgemeinschaft Qualitäts-Man-
agement Biodiesel e.V.).
The use of US bio-diesel based on soy oil methylester is only
permissible in mixtures with diesel fuel with a bio-diesel part of
a max. 20 weight-%. The US bio-diesel used for the mixture must
comply with the ASTM D6751-07a (B100) standard.
3-78 – JLG Lift – 3121290

Biological Contamination In Fuels

SYMPTOMS
The following symptoms may indicate a fuel tank is contami-
nated by micro-organisms:
• Internal tank corrosion,
• Filter blockage and associated loss of power due to gel-like
deposits on the fuel filter (especially after long standstills)
CAUSE
Micro-organisms (bacteria, yeasts, funguses) can form bio-
sludge under unfavorable conditions - particularly heat and
water. Penetration by water is usually caused by condensation
of water in the air. Water does not dissolve in fuel, so penetrating
water collects at bottom of the tank. Bacteria and funguses grow
in the watery phase, at phase boundary to the fuel phase, from
which they draw their nutrition. There is an increased risk with
bio-diesel (FAME).
PREVENTIVE MEASURES
• Keep storage tank clean. Perform regular cleaning of the
tank by specialist companies
• Installation of fuel pre-filters with water traps, especially in
countries with frequently fluctuating fuel qualities and high
percentage of water.
If the fuel system and storage tank have already been attacked
by micro-organisms. Biocide must be dosed according to the
manufacturer's specifications.
• Avoid direct exposure of the storage tank to sunlight
• Use smaller storage tanks with corresponding low dwell
times of the stored fuel
FUEL ADDITIVES
The use of fuel additives is not permitted. Flow improvers men-
tioned above are an exception. Use of unsuitable additives will
result in loss of warranty.
3121290 – JLG Lift – 3-79

3.13 GM ENGINE GENERAL MAINTENANCE Checking/Filling Engine Oil Level
Drive Belt Maintenance

The serpentine drive belt utilizes a spring loaded tensioner AN OVERFILLED CRANKCASE (OIL LEVEL OVER THE SPECIFIED FULL MARK)
which keeps the belt properly adjusted. The drive belt is an CAN CAUSE AN OIL LEAK, A FLUCTUATION OR DROP IN THE OIL PRESSURE,
integral part of the cooling and charging systems and should AND ROCKER ARM “CLATTER” IN THE ENGINE.
be inspected frequently.
When inspecting the belts check for:
• Cracks or breaks CARE MUST BE TAKEN WHEN CHECKING THE ENGINE OIL LEVEL. OIL LEVEL
MUST BE MAINTAINED BETWEEN THE “ADD” MARK AND “FULL” MARK ON THE
• Chunking of the belt DIPSTICK.
• Splits
To ensure you are not getting a false reading, make sure the
• Material hanging from the belt
following steps are taken before checking oil level.
• Glazing and hardening
1. Stop engine if running.
• Damaged or improperly aligned pulleys
2. Allow sufficient time (approximately 5 minutes) for the
• Improperly performing tensioner oil to drain back into the oil pan.
Check belt tensioner by pressing down on midway point of 3. Remove the dipstick. Wipe with a clean cloth or paper
the longest stretch between pulleys. The belt should not towel and reinstall. Push the dipstick all the way into the
depress beyond 1/2 inch (13mm). Adjust tension if depression dipstick tube.
is more than allowable,
4. Remove the dipstick and note the oil level.
5. Oil level must be between the “FULL” and “ADD” marks.
ENGINE MANUFACTURER DOES NOT RECOMMEND USE OF “BELT DRESSING”
OR “ANTI SLIPPING AGENTS” ON DRIVE BELT.
Engine Electrical System Maintenance

The engine electrical system uses computers and micropro-
cessors to control engine ignition, fuel control, and emissions.
Periodic inspection of electrical wiring is required due to sensi-
tivity of computers to good electrical connections. When
inspecting electrical system:
• Check and clean battery terminal connections and ensure Figure 3-58. GM Engine Oil Dip Stick
connections are tight.
6. If oil level is below the “ADD” mark, go to Step 7 and 8
• Check battery for any cracks or damage to the case. and reinstall dipstick in dipstick tube.
• Check positive and negative battery cables for corrosion, 7. Remove oil filter cap from valve rocker arm cover.
rubbing, or chafing. Check connection to chassis is tight.
8. Add required amount of oil to bring level up to, but not
• Check entire engine wire harness for rubbing chafing, cuts,
over, “FULL” mark on dipstick.
or damaged connections. Repair as needed.
9. Reinstall oil fill cap to valve rocker cover and wipe off
• Check all wire harness connectors are fully seated and
excess oil.
locked.
• Check ignition coil and spark plug cables for hardening,
cracking, chafing, separation, split boot covers and
proper fit.
• Replace spark plugs at the proper intervals as prescribed in
the engine manufacturer’s manual.
• Make sure all electrical components are fitted securely.
• Check ground and platform control stations to ensure all
warning indicator lights are functioning.
3-80 – JLG Lift – 3121290

Change Engine Oil 1. Loosen worm gear clamp on coolant line to EPR as
shown below and remove hose from EPR. Place a rag
under hose to prevent coolant from running onto
engine/machine.
ALWAYS CHANGE OIL FILTER WHEN CHANGING OIL. CHANGE OIL WHEN
ENGINE IS WARM FROM OPERATION AS OILS WILL FLOW FREELY AND CARRY
AWAY MORE IMPURITIES.
To change oil:
1. Start engine and run until it reaches normal operating
temperature.
2. Stop engine.
3. Remove drain plug and allow oil to drain.
4. Remove and discard oil filter and its sealing ring.
5. Coat sealing ring on filter with clean engine oil and wipe
sealing surface on filter mounting surface to remove
dust, dirt and debris. Tighten filter securely (follow filter
manufacturers instructions). Do not over tighten.
6. Check sealing ring on drain plug for damage, replace if
necessary, wipe plug with a clean rag, and wipe sealing 2. Remove radiator cap. Fill radiator with coolant until
surface on pan and reinstall pan plug. Do not over coolant starts to appear from previously removed hose
tighten. at EPR. Reinstall hose to EPR and continue to fill radiator
7. Fill crankcase with oil. with coolant.
8. Start engine and check for oil leaks.

9. Stop engine and check oil level is at “FULL”.
10. Properly dispose of oil and filter.
Coolant Fill Procedure - Dual Fuel Engine
DAMAGE TO ENGINE COULD OCCUR IF NOT PROPERLY FILLED WITH COOLANT.

LPG FUELED ENGINES ARE MOST PRONE TO CREATING AN AIR LOCK DURING A
COOLANT FILL OPERATION DUE TO THE ELECTRONIC PRESSURE REGULATOR
(EPR) BEING THE HIGHEST POINT IN THE COOLING SYSTEM. AN EPR THAT
APPEARS TO HAVE FROST FORMING ON IT IS A SIGN THE ENGINE COOLING
SYSTEM CONTAINS AIR. APPEARANCE AND TEMPERATURE OF THE EPR
SHOULD BE MONITORED DURING COOLANT FILL OPERATION. A WARM EPR IS
AN INDICATION THAT THE COOLING SYSTEM IS PROPERLY FILLED AND FUNC- 3. With radiator cap still removed, start engine and run
TIONING. until thermostat opens. Thermostat opens at 170° F (77°
C), which can be checked using the JLG handheld ana-
lyzer.
MAKE SURE ENGINE IS COOL BEFORE PERFORMING ANY

MAINTENANCE WORK. WHILE ENGINE IS RUNNING, AIR AND/OR STEAM MAY BE PRESENT COMING
FROM RADIATOR. THIS IS NORMAL.
4. Run engine for 5 minutes after it reaches operating tem-

perature. Shut engine off and continue to step 5.
3121290 – JLG Lift – 3-81

3.14 GM ENGINE DUAL FUEL SYSTEM

HEATED COOLANT MAY SPILL OUT DUE TO AIR “BURPING” The fuel system installed on this engine is designed to meet
OUT OF SYSTEM WITH RADIATOR CAP OFF WITH ENGINE mobile engine emission standards applicable for 2010 and
RUNNING OR WHEN SHUTTING OFF ENGINE. later model years. The Dual Fuel system allows the vehicle to
operate on gasoline or LPG by positioning a selector switch in
5. Verify two coolant hoses on the EPR are warm. If they are the operator's platform. When the operator places the selector
not warm repeat step 3 and 4, otherwise continue to switch in gasoline mode, the gasoline fuel pump is energized.
step 6. In gasoline mode the LPG fuel lock-off is isolated and will not
energize. In addition, the gasoline injector circuit is enabled
and injector pulses are provided to each injector. ECM calibra-
tion for gasoline is also enabled.
A PROPERLY PURGED COOLING SYSTEM WILL YIELD A WARM UPPER RADIA-
TOR HOSE AND A WARM EPR HOSE. IF UPPER RADIATOR HOSE AND/OR EPR When LPG mode is selected the Low Pressure LPG lock-off is
HOSE ARE NOT WARM TO THE TOUCH AFTER ENGINE HAS RUN FOR 5-8 MIN- energized and fuel from the LPG tank flows to the Electronic
UTES AFTER REACHING OPERATING TEMPERATURE, SYSTEM MAY STILL CON- Pressure Regulator (EPR). The EPR receives an electronic signal
TAIN AIR. IT MAY BE NECESSARY TO REPEAT ABOVE STEPS. to position the secondary lever for start or run positions. When
the engine begins to crank, the mixer air valve will rise and fuel
6. Fill radiator with coolant as needed and install radiator begins flowing to engine. During this mode the gasoline fuel
cap. Remove cap off coolant recovery bottle and fill just pump is isolated and is not activated.
below HOT FULL line. Reinstall caps.
Primary components of the gasoline dual fuel system are the
gasoline tank, electric fuel pump and filter, fuel supply line,
injector rail and injectors and the fuel pressure regulator.
Primary components of the LPG dual fuel system are the LPG
fuel tank, in-fuel filter, LPG Low Pressure lock-off, Electronic
Pressure Regulator (EPR) and the fuel mixer module. The LPG
fuel system operates at pressures which range from 14.0
inches (355.60 mm) of water column up to 312 psi (21.5 BAR).
Components shared by both systems include the Electronic
Throttle Control and ECM. The ECM contains a dual calibration;
one controls the gasoline fuel system during gasoline opera-
tion and one controls the LPG fuel system during LPG opera-
tion.
Fuel Filter
Propane fuel, like all other motor fuels, is subject to contami-
nation from outside sources. Refueling and removal of the
tank from the equipment can contaminate the fuel system. It is
necessary to filter fuel before it enters fuel system compo-
nents downstream of the tank.
An in-line fuel filter is installed in the fuel system to remove
fuel contamination. The in-line filter is replaceable as a unit
only. Filter maintenance is critical to proper operation of the
fuel system and should be replaced as listed in Section 1. More
frequent replacement of the filter may be necessary in severe
operating conditions.
3-82 – JLG Lift – 3121290

1. 1 inch Split Loom 7. Hose 16. Regulator 102. Electronic Pressure Regulator 108. Spacer (600A Only) 206. Bolt
2. 90° Fitting 8. Hose 17. 45° Fitting 103. Adapter 201. Throttle Body 207. Washer
3. 90° Fitting 10. Clamp 18. Bolt 104. Mixer 202. Gasket 208. Bolt
4. 90° Fitting 11. Nipple 19. Bolt 105. Bolt 203. O-Ring 402. T-MAP Sensor
5. Clamp 12. Lock-Off Valve 20. Nut 106. Stud 204. Adapter 403. Bolt
6. Adapter Fitting 15. Clamp 101. Plug 107. Nut 205. Spacer 404. Flat Washer
Figure 3-59. GM 3.0 Dual Fuel System Components
3121290 – JLG Lift – 3-83

Direct Electronic Pressure Regulator (DEPR) Air Fuel Mixer
THE DEPR IS AN EMISSION CONTROL DEVICE AND SHOULD ONLY BE SERVICED THE AIR/FUEL MIXER IS AN EMISSION CONTROL DEVICE. COMPONENTS INSIDE
BY QUALIFIED TECHNICIANS. THE MIXER ARE SPECIFICALLY CALIBRATED TO MEET THE ENGINE’S EMIS-
SIONS REQUIREMENTS AND SHOULD NEVER BE DISASSEMBLED OR REBUILT.
The ECI engine management system uses the DEPR to control IF THE MIXER FAILS TO FUNCTION CORRECTLY, REPLACE WITH AN OEM
fuel delivery for precise fuel metering needed for optimum REPLACEMENT PART.
combustion, fuel economy, and transient response.
The air valve mixer is a self-contained air-fuel metering device.
The DEPR is a single-stage microprocessor based electrome-
The mixer is an air valve design, utilizing a relatively constant
chanical fuel pressure regulator that incorporates a high
pressure drop to draw fuel into the mixer from cranking
speed/fast acting actuator. It communicates with the Engine
speeds to full load.
Control Module (ECM) over a Controller Area Network (CAN)
link, receiving fuel pressure commands and broadcasting The mixer is mounted in the air stream ahead of the throttle
DEPR operating parameters back to the ECM. control device. When the engine begins to crank it draws in air
with the air valve covering the inlet, and negative pressure
The DEPR can regulate fuel pressure from -18 to +13 inches of
begins to build. This negative pressure signal is communicated
water column above the Mixer air inlet pressure, providing suf-
to the top of the air valve chamber through vacuum ports in
ficient control authority to stall an engine either rich or lean.
the air valve assembly. A pressure/force imbalance begins to
When the DEPR receives an output pressure command from build across the air valve diaphragm between the air valve
the ECM, the valve is internally driven to attain targeted fuel vacuum chamber and the atmospheric pressure below the
pressure, the DEPR then closes the loop internally using a built diaphragm.
in fuel pressure sensor to maintain target fuel pressure/fuel
The vacuum being created is referred to as Air Valve Vacuum
flow rate, until another external command from the ECM is
(AVV). As the air valve vacuum reaches the imbalance point,
received (intervals < 10 ms).
the air valve begins to lift against the air valve spring. The
The DEPR has an integral fuel temperature sensor that is used amount of AVV generated is a direct result of throttle position.
by the ECM to correct for variations in fuel density. This pro- At low engine speed the air valve vacuum and the air valve
vides an extremely accurate method for open loop fuel con- position is low, creating a small venturi for the fuel to flow. As
trol. Then with the addition of the pre- and post-cat oxygen engine speed increases, AVV increases and the air valve is
sensors, the pressure command transmitted form the ECM can lifted higher creating a much larger venturi. Air valve vacuum
be further adjusted using closed loop feedback. is communicated from the mixer venturi to the IEPR via the
fuel supply hose.
Figure 3-60. Direct Electronic Pressure Regulator
Figure 3-61. Air Fuel Mixer
3-84 – JLG Lift – 3121290

Electronic Throttle Control (ETC) Engine Control Module (ECM)

The Electronic Throttle Control device or "Throttle Body
Assembly" is connected to the intake manifold of the engine. NOTE: The ECM may also be referred to as the Engine Control Unit
The electronic throttle control device utilizes an electric motor (ECU) in some applications.
connected to the throttle shaft.
To obtain maximum effect from the catalyst and accurate con-
When the engine is running, electrical signals are sent from trol of air fuel ratio, the emission certified engine is equipped
equipment controls to the engine ECM. The ECM then sends with an onboard computer or Engine Control Module (ECM).
an electrical signal to the motor on the electronic throttle con- The ECM is a 32 bit controller which receives input data from
trol to increase or decrease the angle of the throttle blade thus sensors fitted to the engine and fuel system and then outputs
increasing or decreasing the air/fuel flow to the engine. various signals to control engine operation.
Two internal Throttle Position Sensors (TPS) provide throttle
shaft and blade position output signals to the ECM. TPS infor-
mation is used by the ECM to correct speed and load control,
as well as emission control.
Figure 3-64. ECM Assembly
One specific function of the controller is to maintain "closed

loop fuel control". Closed loop fuel control is accomplished
when the exhaust gas oxygen sensor (HEGO) mounted in the
exhaust system sends a voltage signal to the controller. The
controller calculates corrections for the air fuel ratio. and out-
Figure 3-62. ELectronic Throttle Control Device puts signals to the DEPR to correct the amount of fuel supplied
to the mixer. At the same time the ECM may correct throttle
Electric Lock Off blade position to correct engine speed and load.
The Electric Lock Off device is an integrated assembly consist-
The controller also performs fuel system diagnostic functions
ing of a 12 volt solenoid and normally closed valve. When
and notifies the operator of malfunctions by turning on a Mal-
energized, the solenoid opens the valve and allows propane
function Indicator Light (MIL) mounted in the Ground Control
fuel to flow through the device. The valve opens during
Station and Platform Control Station. System malfunctions are
engine cranking and run cycles. Lock Off supply voltage is con-
identified by a Diagnostic Code number. In addition to notify-
trolled by the Engine Control Module (ECM).
ing the operator of the system malfunction, the controller also
stores information about the malfunction in its memory.
Figure 3-65. ECM Input-Output Diagram

Figure 3-63. Electric Lock Off Assembly
3121290 – JLG Lift – 3-85

Heated Exhaust Gas Oxygen Sensor Gasoline Fuel Pump

There are two Heated Exhaust Gas Oxygen Sensors (HEGO). Gasoline is stored as a liquid in the fuel tank and in drawn into
The first HEGO is mounted in the exhaust system downstream the fuel system by an electric fuel pump. The fuel pump
of the engine. It is used to measure the amount of oxygen receives a signal from the ECM to prime the fuel system for
present in the exhaust stream and communicate that to the approximately 2 seconds before start. Priming the fuel system
ECM via an electrical signal. The amount of oxygen present in provides for a quicker start when engine begins to crank.
the exhaust stream indicates whether the fuel/air ratio is too
rich or too lean. If the HEGO sensor signal indicates exhaust Gasoline Pressure And Temperature Sensor
stream is too rich, the ECM will decrease or lean the fuel mix-
ture during engine operation. If mixture is too lean the ECM Manifold
will richen the mixture. The ECM continuously monitors the This engine is equipped with a fuel injector rail that does not
HEGO sensor output. If a rich or lean condition is present for an have a pressure regulator or a return circuit to the fuel tank.
extended period of time, and the ECM cannot correct the con- Fuel pressure for this engine is regulated by the engine’s ECM.
dition, the ECM sets a diagnostic code and turns on the MIL The ECM receive fuel pressure and temperature feedback from
light in control box. the gasoline fuel sensor manifold and uses this information to
control the ground side of the fuel pump. Fuel pressure is reg-
The second HEGO is mounted in the exhaust system after the ulated by the ECM pulse width modulating (PWM) the fuel
muffler. It measures the amount of oxygen in the exhaust sys- pump. The fuel pressure and temperature sensor manifold has
tem after the catalyst treatment has been completed in the a return or "bleed" circuit that connects back to the fuel tank.
muffler. If the ECM detects that the catalytic action in the muf- This circuit is used to bleed off any vapor that develops in the
fler is not sufficient and fuel correction cannot correct the mal- line and return a small amount of fuel to the tank.
function the MIL light is illuminated in the control box and a
DTC code will stored in the computer. Fuel comes from the fuel tank and passes through the fuel
pump. Fuel exits the fuel pump, passes through the filter and
then enters the fuel pressure and temperature manifold
assembly. Fuel flows through the feed circuit and is delivered
THE HEATED EXHAUST GAS OXYGEN SENSOR IS AN EMISSION CONTROL
to the fuel injector rail. Fuel that enters the bleed circuits
DEVICE. IF THE HEGO FAILS TO OPERATE, REPLACE IT WITH AN OEM REPLACE-
through the bypass valve in the manifold is returned to the
MENT PART. THE HEGO SENSOR IS SENSITIVE TO SILICONE OR SILICONE
fuel tank.
BASED PRODUCTS AND CAN BECOME CONTAMINATED. AVOID USING SILICONE
SEALERS OR HOSES TREATED WITH SILICONE LUBRICANTS IN THE AIR
STREAM OR FUEL LINES.
Figure 3-66. Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Multi Point Fuel Injection System (MPFI)

The primary components of the Gasoline Multi Point Fuel
Injection (MPFI) fuel system are the fuel tank, electric fuel
pump, fuel pressure and temperature sensor manifold, fuel fil-
ter, and fuel rail.
Figure 3-67. Gasoline Fuel Pressure and Temperature

Manifold Assembly
3-86 – JLG Lift – 3121290

Fuel Filter 3.15 GM ENGINE FUEL SYSTEM REPAIR

After fuel is drawn into the fuel pump, the fuel flows through
the gasoline fuel filter. The fuel filter traps small particles as Propane Fuel System Pressure Relief
fuel passes through the filter to remove debris and prevents
fuel pressure and temperature manifold and fuel injectors
from becoming damaged. Fuel filter maintenance is required
as shown in Section 1. THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5
BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE
Fuel Injector Rail PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING
THE PROPANE FUEL SYSTEM COMPONENTS.
Fuel flows from the fuel pressure and temperature manifold
assembly to the fuel rails where fuel is delivered to the fuel
To relieve propane fuel system pressure:
injectors. The fuel rail also contains a Schrader valve which is
used to test regulated pressure of the fuel system. 1. Close manual shut-off valve on propane fuel tank.
2. Start and run vehicle until engine stalls.
Fuel Injector
The fuel supply is maintained on the top of the injector from 3. Turn ignition switch OFF.
the injector rail. The injector is fed a "pulse" signal through the
wire harness which causes the injector to open. During regular
operating conditions the ECM controls the opening and dura- RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE
tion of opening of the injector. During lower RPM operation WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE.
the injector signals or "pulses" are less frequent then when the
engine is operating at higher RPMs. The engine has been cali-
brated to deliver the precise amount of fuel for optimum per-
Propane Fuel System Leak Test
formance and emission control.
PROPANE IS HIGHLY FLAMMABLE AND CAN EASILY IGNITE AND CAUSE BURNS
AND SERIOUS INJURIES. NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK
FOR PROPANE FUEL SYSTEM LEAKS.
Always inspect propane fuel system for leaks after performing

service. Check for leaks at fittings of the serviced or replaced
component. Use a commercially available liquid leak detector
or an electronic leak detector. When using both methods, use
electronic leak detector first to avoid contamination by liquid
leak detector.
3121290 – JLG Lift – 3-87

Propane Fuel Filter Replacement INSTALLATION
REINSTALL FILTER MAGNET IN HOUSING BEFORE INSTALLING NEW SEAL.
1. Install mounting plate to lock off O-ring seal.

2. Install retaining bolt seal.
3. Install housing seal.
4. Drop magnet in bottom of filter housing.
5. Install filter in housing.
6. Install retaining bolt in filter housing.
7. Install filter up to bottom of electric lock off.
8. Tighten filter retaining bolt to 106 in-lb (12 Nm).
9. Open manual shut-off valve. Start vehicle and leak check
propane fuel system at each serviced fitting. Refer to
1. Electric Lock Off Solenoid 7. Electrical Connector
Propane Fuel System Leak Test.
2. Mounting Plate 8. Fuel Outlet
3. Housing Seal 9. O-ring
4. Filter Magnet 10. Filter Direct Electronic Pressure Regulator (DEPR)
5. Filter Housing 11. Fuel Inlet Maintenance And Inspection
6. Seal 12. Retaining Bolt
Figure 3-68. Filter Lock Assembly NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components.
REMOVAL
1. Relieve propane fuel system pressure. Refer to Propane DEPR COMPONENTS ARE SPECIFICALLY DESIGNED AND CALIBRATED TO MEET
Fuel System Pressure Relief. FUEL SYSTEM REQUIREMENTS OF THE EMISSION CERTIFIED ENGINE. IF THE
2. Disconnect the negative battery cable. DEPR FAILS TO OPERATE OR DEVELOPS A LEAK, IT SHOULD BE REPAIRED OR
REPLACED WITH OEM RECOMMENDED REPLACEMENT PARTS.
3. Slowly loosen the filter housing retaining bolt and
remove it. 1. Check for any fuel leaks at inlet and outlet fittings.
4. Pull filter housing from electric lock off assembly. 2. Check for any fuel leaks in DEPR body.
5. Locate and remove filter magnet. 3. Check inlet and outlet fittings of coolant supply lines for
6. Remove the filter from housing. water leaks if applicable.
7. Remove and discard housing seal. 4. Check DEPR is securely mounted and mounting bolts
are tight.
8. Remove and discard retaining bolt seal.
5. Check DEPR for external damage.
9. Remove and discard mounting plate to lock off O-ring
seal. 6. Check DEPR electrical connections are seated and
locked.
3-88 – JLG Lift – 3121290

Check/Drain Oil Build-Up In 2-Stage Vaporizer 13. Slowly open manual service valve.
NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components.

FUEL CYLINDER MANUAL VALVE CONTAINS AN “EXCESS FLOW CHECK VALVE”.
During normal operation for LPG engines oil or “heavy ends” OPEN MANUAL VALVE SLOWLY TO PREVENT ACTIVATING THE “EXCESS FLOW
may build inside the Vaporizer secondary chamber. These oil CHECK VALVE.”
and heavy ends may be a result of poor fuel quality, fuel con-
tamination, or regional variation of the fuel make up. A signifi- 14. Check for leaks at the inlet and outlet fittings using a
cant build up of oil can affect performance of the secondary soapy solution or an electronic leak detector.
diaphragm response.
15. Check coolant line connections for leaks.
16. 15. Start engine. Recheck regulator for leaks.
FAILURE TO FOLLOW THIS RECOMMENDATION MAY BE USED TO DENY A WAR-
17. 16. Dispose of any drained material in safe and proper
RANTY CLAIM.
manner according to applicable regulations.
Drain oil periodically to maintain emission warranty. More fre-
quent draining of the Vaporizer Regulator is recommended Air Fuel Mixer/Throttle Control Device Maintenance
where substandard fuel may be a problem. Drain Vaporizer And Inspection
Regulator at every engine oil change if contaminated or sub-
standard fuel is suspected or known to be have been used NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components.
with the emission compliant fuel system.
NOTE: Draining regulator when engine is warm will help oils to
flow freely from regulator. AIR FUEL MIXER COMPONENTS HAVE BEEN SPECIFICALLY DESIGNED AND CAL-
IBRATED TO MEET FUEL SYSTEM REQUIREMENTS OF THE EMISSION CERTIFIED
1. Move equipment well ventilated area and ensure no ENGINE. THE MIXER SHOULD NOT BE DISASSEMBLED OR REBUILT. IF MIXER
external ignition sources are present. FAILS TO OPERATE OR DEVELOPS A LEAK, IT SHOULD BE REPLACED WITH OEM
2. Start engine. RECOMMENDED REPLACEMENT PARTS.
3. With engine running, close manual valve. 1. Check for leaks at the inlet fitting.
4. When engine runs out of fuel and stops, turn key OFF. 2. Inspect fuel inlet hose for cracking, splitting, or chaffing.
5. Disconnect negative battery cable. Replace if any of these condition exist.
3. Ensure mixer is securely mounted and not leaking vac-
uum at the mounting gasket or surface.
A SMALL AMOUNT OF FUEL MAY STILL BE PRESENT IN THE FUEL LINE. USE 4. Inspect air inlet hose connection and clamp. Inspect
GLOVES TO PREVENT BURNS AND WEAR PROPER EYE PROTECTION. inlet hose for cracking, splitting, or chafing. Replace if
any of these conditions exist.
NOTE: If fuel continues to flow from connections when loosened,
check manual valve is fully closed. 5. Inspect air cleaner element.
6. Check fuel lines for cracking, splitting, or chafing.
6. Loosen hose clamps at inlet and outlet hoses. Remove Replace if any of these conditions exist.
hoses.
7. Check for leaks at the throttle body and intake manifold.
7. Remove regulator mounting bolts.
8. Place a small receptacle in the engine compartment.
9. Rotate regulator to 90° so outlet fitting is pointing down
into receptacle. Drain regulator.
10. Inspect secondary chamber for any large dried particles
and remove.
11. Remove receptacle and reinstall regulator retaining
bolts. Torque to specifications.
12. Reinstall fuel hoses. Reconnect any other hoses
removed during this procedure.
3121290 – JLG Lift – 3-89

Exhaust System And Catalytic Converter Inspection Throttle Body (ETC) Replacement
And Maintenance NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components.
REMOVAL
EXHAUST SYSTEM ON THIS EMISSION CERTIFIED ENGINE CONTAINS A HEATED 1. Disconnect negative battery cable.
EXHAUST GAS OXYGEN SENSOR (HEGO) WHICH PROVIDES FEEDBACK TO THE
ECM ON AMOUNT OF OXYGEN PRESENT IN THE EXHAUST STREAM AFTER COM- 2. Remove Mixer (See “Mixer Replacement” on page 90).
BUSTION. OXYGEN IN THE EXHAUST STREAM IS MEASURED IN VOLTAGE AND
3. Disconnect TMAP electrical connector.
SENT TO THE ECM. THE ECM THEN MAKES CORRECTIONS TO THE FUEL AIR
RATIO TO ENSURE PROPER FUEL CHARGE AND OPTIMUM CATALYTIC PERFOR- 4. Disconnect electronic throttle control connector.
MANCE. EXHAUST CONNECTIONS MUST REMAIN SECURE AND AIR TIGHT.
5. Remove bolts (208), adapter (204), and throttle body
(201) from manifold.
6. Remove spacer (205).
THE HEGO SENSOR IS SENSITIVE TO SILICONE BASED PRODUCTS. DO NOT USE
SILICONE SPRAYS OR HOSES WHICH ARE ASSEMBLED USING SILICONE LUBRI- 7. Remove and discard gasket (202) and O-ring (203).
CANTS. SILICONE CONTAMINATION CAN CAUSE SEVERE DAMAGE TO THE
HEGO. INSTALLATION
NOTE: Lightly lubricate O-ring.
1. Check exhaust manifold at cylinder head for leaks and
all retaining bolts and shields (if used) are in place. 1. Install O-ring (203) and spacer (205) on throttle body
2. Check manifold to exhaust pipe fasteners are tight and (201).
there are no exhaust leaks. Repair if necessary. 2. Align new gasket (202) and throttle body on manifold.
3. Inspect HEGO electrical connector is seated and locked. 3. Slide adapter (204) on throttle body and secure with
Check wires for cracking, splits, chafing or “burn four bolts (208).
through.” Repair if necessary.
4. Reinstall Mixer (See “Mixer Replacement” on page 90).
4. Check exhaust pipe extension connector for leaks.
Tighten if necessary.
Mixer Replacement
5. Check catalyst muffler is securely mounted. Check for
leaks at inlet and outlet. NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components.
REMOVAL
Temperature Manifold Absolute Pressure (TMAP)
Sensor 1. Remove EPR. (See “Electronic Pressure Regulator (EPR)
Replacement” on page 91)
NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components. 2. Remove Air Intake hose from Mixer.
REMOVAL 3. Remove four bolts (206) and washers (207) securing

mixer (104) to adapter (204). Remove Mixer.
1. Disconnect TMAP (402) electrical connector.
2. Remove retaining bolt (403), washer (404), and TMAP INSTALLATION
(402).
INSTALLATION COVER THROTTLE BODY ADAPTER OPENING TO PREVENT DEBRIS FROM

ENTERING ENGINE.
NOTE: Apply a small amount of O-ring lubricant before installa-
tion.
1. Install Mixer (104) to Adapter (204). Secure with four
washers (207) and bolts (206). Torque to 80 in-lb (9 Nm)
1. Install TMAP (402). Secure with washer (404) and bolt
(403). 2. Install EPR (See “Electronic Pressure Regulator (EPR)
Replacement” on page 91).
2. Torque retaining bolt to 62 in-lb (7 Nm).
3. Reinstall Air Intake Hose.
3. Start vehicle and check for proper operation.
4. Start engine and leak check all fittings and connections.
3-90 – JLG Lift – 3121290

Electronic Pressure Regulator (EPR) Replacement Coolant Hose Replacement

REMOVAL REMOVAL
NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components. 1. Drain coolant.
2. Using hose clamp pliers, disconnect both hose clamps
1. Unplug EPR (102) electrical connector.
on each hose.
2. Remove hoses from EPR.
3. Remove hose from fittings.
3. Remove four flange nuts (107) and EPR from Mixer (104).
INSTALLATION
4. If new EPR is being installed, remove and retain hose
adapter (103) and four bolts (105). NOTE: Use hose material and lengths specified by JLG.
INSTALLATION 1. Install hose clamps to each hose and set clamp back on
each hose to make installation easier.
1. If new EPR is being installed, install adapter (103) and
four bolts (105) to EPR. 2. Fit hose to fittings.
2. Install EPR (102) on Mixer (104). Secure with four flange 3. Secure by positioning each of the clamps.
nuts (107).
3. Reattach all hoses. Vapor Hose Replacement
4. Start engine and leak check all fittings and connections. REMOVAL
1. Disconnect both hose clamps using hose clamp pliers.
Regulator Replacement
2. Remove vapor hose from each fitting.
NOTE: Refer to Figure 3-59. GM 3.0 Dual Fuel System Components.
INSTALLATION
REMOVAL
1. Disconnect and remove Lock-Off Valve (12) from Regula-
tor (16). VAPOR SUPPLY HOSE IS SPECIFICALLY DESIGNED FOR THIS EQUIPMENT. DO
NOT USE HOSE MATERIAL OR LENGTH OTHER THAN JLG SPECIFIED PARTS.
2. Remove hoses from regulator.
3. Remove regulator from engine. 1. Install hose clamps and set back on each hose.
2. Reinstall vapor hose to each fitting.
INSTALLATION
3. Reset clamps.
1. Install Regulator (16) on engine.
4. Start engine and check for leaks.
2. Install hoses on regulator.
3. Install Lock-Off Valve (12) to Regulator. Reconnect Lock-
Off Valve.
4. Start engine and leak check all fittings and connections.
3121290 – JLG Lift – 3-91

Engine Control Module Replacement Heated Exhaust Gas Oxygen Sensor Replacement
REMOVAL
REMOVAL
1. Disconnect negative (-) battery cable.
1. Disconnect Negative battery cable.
2. Disconnect O2 sensor electrical connector.
2. Remove controller from mounting bracket.
3. Using an O2 Sensor socket, remove and discard Sensor.
3. Push connector lock back to unlock connector.
INSTALLATION
4. Unplug and remove controller.
INSTALLATION
LUBRICATE O2 SENSOR THREADS WITH ANTI-SEIZE COMPOUND GM P/N
5613695 OR EQUIVALENT BEFORE INSTALLATION. DO NOT GET COMPOUND
ON SENSOR TIP.
CONTROLLER IS CALIBRATED FOR EACH ENGINE. VERIFY YOU HAVE CORRECT
CONTROLLER. 1. Install O2 sensor. Tighten to 30 lb-ft (41 Nm).
1. Plug connector into controller. 2. Start engine.
2. Push lock into place. 3. Check and clear any DTC codes.
3. Mount controller into mounting bracket. 4. Verify engine is in closed loop and no warning lights are
illuminated.
4. Reconnect the battery cable.
5. Start engine.
6. Check and clear any DTC codes.
7. Verify engine is in closed loop and no warning lights are
illuminated.
3-92 – JLG Lift – 3121290

3.16 GM ENGINE LPG FUEL SYSTEM DIAGNOSIS Diagnostic Aids

This procedure is intended to diagnose a vehicle operating on
Fuel System Description LPG. If vehicle will not continue to run on LPG, refer to Hard
Start for preliminary checks.
NOTE: Before proceeding with this procedure, verify vehicle has
sufficient quantity of fuel and liquid fuel is being delivered
to the LPR. Ensure the LPG tank manual shut off valve is
fully opened and excess flow valve has not been activated.
Tools Required:
• 7/16 Open end wrench (for test port plugs)
• DVOM (GM J 39200, Fluke 88 or equivalent).
• 12 volt test light
Diagnostic Scan Tool
• Diagnostic Display tool.
Pressure Gauges
• IMPCO ITK-2 Test kit
Figure 3-69. DEPR
• Water Column Gauge / Manometer (GM 7333-6 or equiva-
lent).
The Engine Control Module (ECM) receives information from
various engine sensors to control the Direct Electronic Pres- • 0-10 PSI Gauge
sure Regulator (DEPR) and lock-off Valve. Test Description
The lock-off Valve solenoid prevents fuel flow unless the Numbers below refer to step numbers on the diagnostic table.
engine is cranking or running.
5. This step determines if the LPR requires replacement
At Key ON, the DEPR valve receives a two (2) second prime
pulse from the ECM, allowing time for the fuel to flow through 10. This step determines if Mixer requires replacement
the fuel filter and fuel lines to the DEPR. 14. This step determines if Lock Off requires replacement
Fuel travels from the lock-off to the light duty 2- stage regula- 17. This step determines if Fuel Filter requires replacement
tor into the DEPR.
Engine cranking generates vacuum which provided lift for the
mixer air valve and is commonly referred to as air valve vac-
uum. Once in the mixer, fuel is combined with air and drawn
into the engine for combustion.
3121290 – JLG Lift – 3-93

Table 3-12. LPF Fuel System Diagnosis
STEP ACTION VALUE(S) YES NO

1 Were you referred to this procedure by a DTC diagnostic chart? -- Go to Step 3 Go to Step 2
2 Perform On Board Diagnostic (OBD) System Check. -- Go to the Go to Step 3
Are any DTCs present in the ECM? applicable DTC
Table
3 Verify LPG fuel tank has a minimum of 1/4 tank of fuel, manual valve is -- Go to Step 4 --
open and tank quick connect is fully engaged
Does vehicle have fuel?
4 1. Connect a water column gauge or a manometer to Low Pressure -- Go to Step 5 Go to Step 8
Regulator (LPR) secondary test port.
2. Start engine and allow it to reach operating temperature.
Does engine start and run?
5 With engine idling, observe LPR secondary pressure reading. -1.0" to Go to Step 25 Go to Step 6
Does fuel pressure fluctuate rhythmically OUTSIDE specified range? -2.0" w.c
6 1. Disconnect EPR electrical connectors. NOTE: This action will cause a -1.0" to Go to Fuel Control Go to Step 7
DTC to be set by the ECM -2.0" w.c System Diagnosis
2. With engine idling, observe secondary test port pressure reading.
Is fuel pressure WITHIN specified range?
7 1. Inspect air intake stream between mixer assembly and throttle -- Go to Step 26 Go to Step 22
body for leaks.
2. Inspect fuel hose connection between LPR and mixer assembly for
damage or leakage.
3. Inspect vacuum hoses for leaks
Was a problem found and corrected?
8 1. Connect a water column gauge or a manometer to LPR secondary -- Go to Step 12 Go to Step 9
test port.
2. Crank engine and observe pressure reading for LPR secondary pres-
sure.
Does fuel pressure indicate a vacuum is present?
9 1. Remove Air induction hose to mixer -- Go to Step 11 Go to Step 10
2. Observe air valve for movement while engine is cranking. Note:
Movement of air valve will be minimal at cranking speeds.
Does air valve move when engine is cranked?
10 1. Inspect air intake stream to mixer assembly and throttle body for -- Go to Step 26 Go to Step 24
vacuum leaks.
2. Inspect vacuum hoses from mixer for proper connection and condi-
tion.
Was a problem found and repaired?
11 Inspect fuel hose connection between LPR and mixer assembly for -- Go to Step 26 Go to Step 12
damage or leakage.
Was a problem found and repaired?
12 1. Connect a 0-10 psi gauge to primary test port of LPR. 1- 3 PSI Go to Step 22 Go to Step 13
2. Crank engine and observe pressure reading for LPR primary pres-
sure.
Is fuel pressure ABOVE specified value?
13 1. Turn OFF ignition. -- Go to Step 14 Go to Step 16
2. Disconnect LPL connector.
3. Install a test light between pins of LPL connector.
4. Crank engine. Test light should illuminate.
Does test light illuminate?
3-94 – JLG Lift – 3121290

Table 3-12. LPF Fuel System Diagnosis
STEP ACTION VALUE(S) YES NO

14 Using a DVOM, check resistance of Low Pressure Lock-off (LPL). 12W - 16W Go to Step 15 Go to Step 23
Is resistance within specified range?
15 1. Turn ignition OFF. -- Go to Step 23 Go to Step 17
2. Close LPG tank manual shut-off valve.
LIQUID LPG MAY BE PRESENT WHEN DISCONNECTING LPG FUEL LINES. PERFORM
THIS STEP IN A WELL VENTILATED AREA.
3. Loosen fuel inlet hose fitting at LPL inlet.

Was fuel present when fitting was loosened?
16 1. Turn OFF ignition. -- Go to Step 20 Go to Step 21
2. Connect test light to chassis ground and probe pin A of LPL connec-
tor.
3. Crank engine. Test light should illuminate.
Does test light illuminate?
17 1. Remove LPG fuel filter / LPL. -- Go to Step 19 Go to Step 18
2. Remove filter from LPL.
3. Empty contents of inlet side of fuel filter onto a clean surface.
4. Inspect contents of LPG fuel filter for an excessive amount of foreign
material or water. If necessary, locate and repair source of contamina-
tion.
5. Verify LPG fuel filter is not restricted or plugged.
Was a problem found?
18 Fuel supply system or hoses are plugged or restricted. Locate and -- Go to Step 26 --
repair the problem.
Is action complete?
19 Replace fuel filter. Refer to Fuel Filter Replacement. -- Go to Step 26 --
Is action complete?
20 Repair open circuit in lock-off ground circuit. -- Go to Step 26 --
Is action complete?
21 Repair open circuit in lock-off power circuit. -- Go to Step 26 --
Is action complete?
22 Replace LPR. Refer to Low Pressure Regulator Replacement. -- Go to Step 26 --
Is action complete?
23 Replace Lock-Off. Refer to Lock-off Replacement. -- Go to Step 26 --
Is action complete?
24 Replace mixer assembly. Refer to Fuel Mixer Replacement. -- Go to Step 26 --
Is action complete?
25 Fuel supply system is operating normally, if a failure of the control -- System OK --
solenoids is suspected. Refer to Fuel Control System Diagnosis.
1. Install test plug in LPR secondary chamber.

2. If you were sent to this routine by another diagnostic chart, return to
previous diagnostic procedure.
Is action complete?
26 1. Disconnect all test equipment -- System OK --
2. Install primary and secondary test port plugs.
3. Start engine.
4. Using SNOOP or equivalent, leak check test port plugs.
Is action complete?
3121290 – JLG Lift – 3-95

Table 3-13. Symptom Diagnosis
Checks Action
Important Preliminary Checks
Before Using This Section Before using this section, you should have performed On Board Diagnostic Check and determined that:
1. The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but without a MIL.
Several of the following symptom procedures call for a careful visual and physical check. Visual and phys-
ical checks are very important. These checks can lead to correcting a problem without further checks that
may save valuable time.
LPG Fuel System Check 1. Verify customer complaint.
2. Locate correct symptom table.
3. Check items indicated under that symptom.
4. Operate vehicle under conditions the symptom occurs. Verify HEGO switching between lean and rich.
IMPORTANT! Normal HEGO switching indicates the LPG fuel system is in closed loop and operat-
ing correctly at that time.
Visual and Physical Checks 1. Check all ECM system fuses and circuit breakers.
2. Check the ECM ground for being clean, tight and in its proper location.
3. Check the vacuum hoses for splits, kinks and proper connections.
4. Check thoroughly for any type of leak or restriction.
5. Check for air leaks at all mounting areas of intake manifold sealing surfaces.
6. Check for proper installation of the mixer module assembly.
7. Check for air leaks at mixer assembly.
8. Check ignition wires for the following conditions:
- Cracking
- Hardness
- Proper routing
- Carbon tracking
9. Check wiring for the following items:
- Proper connections, pinches or cuts.
The following symptom tables contain groups of possible causes for each symptom. The order of these
procedures is not important. If scan tool readings do not indicate problems, proceed in a logical order,
easiest to check or most likely to cause first.
Intermittent
DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL) or store a Diagnostic Trouble Code (DTC).
Preliminary Checks Refer to Important Preliminary Checks. Do not use DTC tables. If a fault is intermittent, use of DTC tables
may result in replacement of good parts.
Faulty Electrical Connections Faulty electrical connections or wiring can cause most intermittent problems.
or Wiring 1. Check suspected circuit for the following conditions:
- Faulty fuse or circuit breaker
- Connectors poorly mated
- Terminals not fully seated in the connector (backed out)
- Terminals not properly formed or damaged
- Terminal to wires poorly connected
- Terminal tension insufficient.
2. Carefully remove all connector terminals in the problem circuit to ensure proper contact tension. If nec-
essary, replace all connector terminals in the problem circuit to ensure proper contact tension. Checking
for poor terminal to wire connections requires removing terminal from connector body.
Operational Test If a visual and physical check does not locate cause of the problem, drive vehicle with a scan tool. When
problem occurs, an abnormal voltage or scan reading indicates the problem may be in that circuit.
3-96 – JLG Lift – 3121290

Checks Action
Intermittent Malfunction Indi- The following components can cause intermittent MIL and no DTC(s):
cator Lamp (MIL) 1. A defective relay, Control Module driven solenoid, or a switch that can cause electrical system interfer-
ence. Normally, the problem will occur when the faulty component is operating.
2. Improper installation of electrical devices, such as lights, 2-way radios, electric motors, etc.
3. Ignition secondary voltage shorted to a ground.
4. Malfunction Indicator Lamp (MIL) circuit or the Diagnostic Test Terminal intermittently shorted to
ground.
5. Control Module grounds.
Loss of DTC Memory To check for the loss of DTC Memory:
1. Disconnect TMAP sensor.
2. Idle engine until Malfunction Indicator Lamp illuminates.
The ECM should store a TMAP DTC. The TMAP DTC should remain in memory when ignition is turned OFF.
If the TMAP DTC does not store and remain, the ECM is faulty
Additional Checks
No Start
DEFINITION: Engine cranks OK, but does not start.
Preliminary Checks Refer to Important Preliminary Checks.
Control Module Checks If a scan tool is available:
1. Check for proper communication with both the ECM
2. Check the fuse in the ECM battery power circuit. Refer to Engine Controls Schematics.
3. Check battery power, ignition power and ground circuits to the ECM. Refer to Engine Control Schemat-
ics. Verify voltage and/or continuity for each circuit.
Sensor Checks 1. Check TMAP sensor.
2. Check magnetic pickup sensor (RPM).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create a no start condition.
1. Check for air intake system leakage between mixer and throttle body.
2. Verify proper operation of low pressure lock-off solenoids.
3. Check fuel system pressures. Refer to LPG Fuel System Diagnosis.
4. Check for proper mixer air valve operation.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for the equivalent
gasoline operating conditions.
1. Check proper ignition voltage output with J 26792 or equivalent.
2. Verify spark plugs are correct for use with LPG (R42LTS)
3. Check spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
4. Check for bare or shorted ignition wires.
5. Check for loose ignition coil connections at the coil.
3121290 – JLG Lift – 3-97

Checks Action
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensi-
tive to intake manifold leakage than a gasoline fuel supply system.
Check for the following:
- Vacuum leaks
- Improper valve timing
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes.
Exhaust System Checks 1. Check exhaust system for a possible restriction:
- Inspect exhaust system for damaged or collapsed pipes
- Inspect muffler for signs of heat distress or internal failure.
2. Check for plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis
Hard Start
DEFINITION: Engine cranks OK, but does not start for a long time. Engine does eventually run or may start, but immediately dies.
Preliminary Checks 1. Refer to Important Preliminary Checks.
2. Make sure operator is using correct starting procedure.
Sensor Checks 1. Check Engine Coolant Temperature (ECT) sensor with scan tool. Compare engine coolant temperature
with ambient air temperature on a cold engine. IF coolant temperature reading is more than 5 degrees
greater or less than ambient air temperature on a cold engine, check for high resistance in coolant sensor
circuit. Refer to DTC 111
2. Check Crankshaft Position (CKP) sensor.
3. Check the Throttle Position Sensor (TPS).
Fuel System Checks Important: A closed LPG manual fuel shut off valve will create an extended crank OR no start condition.
1. Verify excess flow valve in LPG manual shut-off valve is not tripped.
2. Check mixer module assembly for proper installation and leakage.
3. Verify proper operation of low pressure lock-off solenoids.
4. Verify proper EPR operation.
5. Check for air intake system leakage between mixer and throttle body.
6. Check the fuel system pressures. Refer to Fuel System Diagnosis.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages for equivalent gaso-
line operating conditions.
1. Check proper ignition voltage output with J 26792 or the equivalent.
3. Check spark plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
4. Check for bare or shorted ignition wires.
5. Check for moisture in distributor cap if applicable.
6. Check for loose ignition coil connections.
NOTICE:
1. If engine starts but then immediately stalls, Check Crankshaft Position (CKP).
2. Check for improper gap, debris, or faulty connections.
3-98 – JLG Lift – 3121290

Checks Action
Engine Mechanical Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensi-
1. Check for the following:
- Vacuum leaks
- Low compression
- Bent pushrods
- Worn rocker arms
- Broken or weak valve springs
- Worn camshaft lobes
2. Check intake and exhaust manifolds for casting flash.
Exhaust System Checks 1. Check exhaust system for a restriction:
- Inspect exhaust system for damaged or collapsed pipes.
- Inspect muffler for signs of heat distress or internal failure.
2. Check for plugged catalytic converter. Refer to Restricted Exhaust System Diagnosis or Exhaust System
in GM Base Engine Service Manual.
Additional Checks
Cuts Out, Misses
DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as engine load increases which is not normally felt
above 1500 RPM. Exhaust has a steady spitting sound at idle, low speed, or hard acceleration for fuel starvation that can cause the engine to
cut-out.
Ignition System Checks 1.Start engine.
2. Wet down secondary ignition system with water from a spray bottle and look/listen for arcing or misfir-
ing as you apply water.
3. Check for proper ignition output voltage with spark tester J 26792.
4. Check for a cylinder misfire.
6. Remove spark plugs in these cylinders and check for the following conditions:
- Insulation cracks.
- Wear.
- Improper gap.
- Burned electrodes.
- Heavy deposits.
7. Visually/Physically inspect secondary ignition for the following:
- Ignition wires for arcing, cross-firing and proper routing.
- Ignition coils for cracks or carbon tracking.
Engine Mechanical Checks 1. Perform a cylinder compression check.
2. Check engine for the following:
- Bent pushrods.
- Worn rocker arms.
- Broken or weak valve springs.
3. Check intake and exhaust manifold passages for casting flash.
Fuel System Checks 1. Check the fuel system - plugged fuel filter, low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.
2. Check the condition of the wiring to the low pressure lock-off solenoid.
Additional Check Check for Electromagnetic Interference (EMI).
- EMI on reference circuit can cause a missing condition.
- Monitoring engine RPM with a scan tool can detect an EMI.
- A sudden increase in RPM with little change in actual engine RPM indicates EMI is present.
- If problem exists, check routing of secondary wires and ground circuit.
3121290 – JLG Lift – 3-99

Checks Action
Hesitation, Sag, Stumble
DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed.
The condition may cause the engine to stall if it's severe enough.
Fuel System Checks 1. Check fuel pressure. Refer to LPG Fuel System Diagnosis.
2. Check for low fuel pressure during a moderate or full throttle acceleration. If fuel pressure drops below
specification, there is possibly a faulty low pressure regulator or a restriction in the fuel system.
3. Check Manifold Absolute Pressure (MAP) sensor response and accuracy.
4. Check LPL electrical connection
5. Check mixer air valve for sticking or binding.
6. Check mixer module assembly for proper installation and leakage.
7. Check EPR electrical connections.
Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition system voltages than equivalent gas-
oline operating conditions. If a problem is reported on LPG and not gasoline, do not discount the possi-
bility of an LPG only ignition system failure and test system accordingly.
1. Check for proper ignition voltage output with J 26792 or the equivalent.
3. Check for faulty spark plug wires
4. Check for fouled spark plugs.
Additional Check 1. Check for manifold vacuum or air induction system leaks
2. Check generator output voltage.
Backfire
DEFINITION: Fuel ignites in the intake manifold or exhaust system, making a loud popping noise.
Preliminary Check Refer to Important Preliminary Checks.
Ignition System Checks NOTE: LPG, being a gaseous fuel, requires higher secondary ignition system voltages for than equivalent
gasoline operating conditions. The ignition system must be maintained in peak condition to prevent
backfire.
1. Check for proper ignition coil output voltage using spark tester J26792 or equivalent.
2. Check spark plug wires by connecting an ohmmeter to ends of each wire in question. If meter reads
over 30,000 ohms, replace wires.
3. Check connection at each ignition coil.
4. Check for deteriorated spark plug wire insulation.
5. Check spark plugs. Correct spark plugs for LPG are (R42LTS)
6. Remove and inspect plugs for the following conditions:
- Wet plugs.
- Cracks.
- Wear.
- Improper gap.
- Heavy deposits.
Engine Mechanical Check NOTE: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensitive to
intake manifold leakage than a gasoline fuel supply system.
1. Check engine for the following:
- Improper valve timing.
- Engine compression.
- Manifold vacuum leaks.
- Intake manifold gaskets.
- Sticking or leaking valves.
- Exhaust system leakage.
2. Check intake and exhaust system for casting flash or other restrictions.
Fuel System Checks Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.
3-100 – JLG Lift – 3121290

Checks Action
Lack of Power, Sluggishness, or Sponginess
DEFINITION: Engine delivers less than expected power. There is little or no increase in speed when partially applying accelerator pedal.
2. Refer to LPG Fuel system OBD System Check
3. Compare customer's vehicle with a similar unit. Make sure customer has an actual problem. Do not
compare power output of vehicle operating on LPG to a vehicle operating on gasoline as fuels have dif-
ferent drive feel characteristics.
4. Remove air filter and check for dirt or restriction.
5. Check vehicle transmission Refer to OEM transmission diagnostics.
Fuel System Checks 1. Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure. Refer to LPG Fuel System
Diagnosis.
2. Check for the proper ignition output voltage with the spark tester J 26792 or the equivalent.
3. Check for proper installation of the mixer module assembly.
4. Check all air inlet ducts for condition and proper installation.
5. Check for fuel leaks between the LPR and the mixer.
6. Verify that the LPG tank manual shut-off valve is fully open.
7. Verify that liquid fuel (not vapor) is being delivered to the LPR.
Sensor Checks 1. Check Heated Exhaust Gas Oxygen Sensor (HEGO) for contamination and performance.
2. Check proper operation of MAP sensor.
3. Check proper operation of TPS sensor.
Exhaust System Checks Check exhaust system for a possible restriction:
- Inspect exhaust system for damaged or collapsed pipes.
- Inspect muffler for signs of heat distress or for possible internal failure.
- Check for possible plugged catalytic converter.
Engine Mechanical Check Check the engine for the following:
- Engine compression
- Valve timing
- Improper or worn camshaft. Refer to Engine Mechanical in the Service Manual.
Additional Check 1. Check ECM grounds for being clean, tight, and in their proper locations.
3. If all procedures have been completed and no malfunction has been found, review and inspect the fol-
lowing items:
- Visually and physically inspect all electrical connections within suspected circuit and/or systems.
- Check scan tool data.
Poor Fuel Economy
DEFINITION: Economy is noticeably lower as shown by refueling records.
2. Check air cleaner element (filter) for dirt or restriction.
3. Visually (Physically) check vacuum hoses for splits, kinks, and proper connections.
4. Check operator driving habits for the following items:
- Is there excessive idling or stop and go driving?
- Are tires at correct air pressure?
- Are excessively heavy loads being carried?
- Is there often rapid acceleration?
5. Suggest to owner to fill fuel tank and recheck fuel economy.
6. Suggest a different operator use equipment and record results.
Fuel System Checks 1. Check LPR fuel pressure. Refer to LPG Fuel System Diagnosis.
2. Check fuel system for leakage.
Sensor Checks Check Temperature Manifold Absolute Pressure (TMAP) sensor.
3121290 – JLG Lift – 3-101

Checks Action
Ignition System Checks 1. Verify that the spark plugs are correct for use with LPG (R42LTS)
2. Check spark plugs. Remove and inspect plugs for the following conditions:
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Heavy deposits
3. Check ignition wires for the following items:
- Cracking
- Hardness
- Proper connections
Cooling System Checks Check engine thermostat for always being open or for the wrong heat range
Additional Check 1. Check transmission shift pattern. Refer to OEM Transmission Controls section Service Manual.
2. Check for dragging brakes.
Rough, Unstable, or Incorrect Idle, Stalling
DEFINITION: Engine runs unevenly at idle. If severe enough, engine or vehicle may shake. Engine idle speed may vary in RPM. Either condi-
tion may be severe enough to stall the engine.
Preliminary Check Refer to Important Preliminary Checks.
Sensor Checks 1. Check for silicon contamination from fuel or improperly used sealant. The sensor will have a white pow-
dery coating. The sensor will result in a high but false signal voltage (rich exhaust indication). ECM will
reduce the amount of fuel delivered to the engine causing a severe driveability problem.
2. Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance:
3. Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and accuracy.
Fuel System Checks 1. Check for rich or lean symptom that causes the condition. Drive the vehicle at the speed of the com-
plaint. Monitoring the oxygen sensors will help identify the problem.
2. Check for a sticking mixer air valve.
3. Verify proper operation of the EPR.
4. Perform a cylinder compression test. Refer to Engine Mechanical in the Service Manual.
5. Check the LPR fuel pressure. Refer to the LPG Fuel System Diagnosis.
6. Check mixer module assembly for proper installation and connection.
Ignition System Checks 1. Check for proper ignition output voltage using spark tester J26792 or equivalent.
- Wet plugs
- Cracks
- Wear
- Improper gap
- Burned electrodes
- Blistered insulators
- Heavy deposits
4. Check spark plug wires by connecting an ohmmeter to ends of each wire in question. If meter reads
over 30,000 ohms, replace wires.
Additional Checks Important: The LPG Fuel system works on a fumigation principle of fuel introduction and is more sensi-
1. Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and low throttle angle con-
trol command.
2.Check ECM grounds for being clean, tight, and in their proper locations.
3. Check battery cables and ground straps. They should be clean and secure. Erratic voltage may cause
faulty sensor readings resulting in poor idle quality.
3-102 – JLG Lift – 3121290

Checks Action
Engine Mechanical Check Check engine for the following:
- Broken motor mounts.
- Improper valve timing.
- Low compression.
- Bent pushrods.
- Worn rocker arms.
- Broken or weak valve springs.
Surges/Chuggles
DEFINITION: Engine has a power variation under a steady throttle or cruise. Vehicle feels as if it speeds up and slows down with no change
in accelerator pedal.
Sensor Checks Check Heated Exhaust Gas Oxygen Sensor (HEGO) performance.
Fuel System Checks 1. Check Rich or Lean symptom that causes condition. Drive vehicle at speed of complaint. Monitoring
oxygen sensors will help identify problem.
2. Check fuel pressure while condition exists. Refer to LPG Fuel System Diagnosis.
3. Verify proper fuel control solenoid operation.
4. Verify LPG manual shut-off valve is fully open.
5. Check in-line fuel filter for restrictions.
Ignition System Checks 1. Check proper ignition output voltage using spark tester J26792 or equivalent.
2. Verify spark plugs are correct for use with LPG (R42LTS).
- Wet plugs.
- Cracks.
- Wear.
- Improper gap.
- Heavy deposits.
4. Check Crankshaft Position (CKP) sensor.
Additional Check 1. Check ECM grounds clean, tight, and in proper locations.
3. Check vacuum hoses for kinks or leaks.
4. Check transmission.
3121290 – JLG Lift – 3-103

Table 3-14. DTC to SPN/FMI Cross Reference Chart
DTC Description SPN Code FMI Code

16 Crank Never Synced at Start 636 8
91 Fuel Pump Low Voltage 94 4
92 Fuel Pump High Voltage 94 3
107 MAP Low Voltage 106 4
108 MAP High Pressure 106 16
111 IAT Higher Than Expected 1 105 15
112 IAT Low Voltage 105 4
113 IAT High Voltage 105 3
116 ECT Higher Than Expected 1 110 15
117 ECT Low Voltage 110 4
118 ECT High Voltage 110 3
121 TPS 1 Lower Than TPS 2 51 1
122 TPS 1 Signal Voltage Low 51 4
123 TPS 1 Signal Voltage High 51 3
127 IAT Higher Than Expected 2 105 0
129 BP Low Pressure 108 1
134 EGO 1 Open/Inactive 724 10
154 EGO 2 Open/Inactive 520208 10
171 Adaptive Learn High Gasoline 520200 0
172 Adaptive Learn Low Gasoline 520200 1
182 Fuel Temp Gasoline Low Voltage 174 4
183 Fuel Temp Gasoline High Voltage 174 3
187 Fuel Temp LPG Low Voltage 520240 4
188 Fuel Temp LPG High Voltage 520240 3
217 ECT Higher Than Expected 2 110 0
219 Max Govern Speed Override 515 15
221 TPS 2 Signal Voltage Low 51 0
222 TPS 2 Signal Low Voltage 520251 4
223 TPS 2 Signal High Voltage 520251 3
261 Injector Driver 1 Open 651 5
262 Injector Driver 1 Shorted 651 6
336 Crank Sync Noise 636 2
337 Crank Loss 636 4
341 Cam Sync Noise 723 2
342 Cam Sensor Loss 723 4
420 Gasoline Cat Monitor 520211 10
524 Oil Pressure Low 100 1
3-104 – JLG Lift – 3121290

Table 3-14. DTC to SPN/FMI Cross Reference Chart
DTC Description SPN Code FMI Code

562 System Voltage Low 168 17
563 System Voltage High 168 15
601 Flash Checksum Invalid 628 13
604 RAM Failure 630 12
606 COP Failure 629 31
642 External 5V Reference Low 1079 4
643 External 5V Reference High 1079 3
685 Power Relay Open 1485 5
686 Power Relay Shorted 1485 4
687 Power Relay Short to Power 1485 3
1111 Fuel Rev Limit 515 16
1112 Spark Rev Limit 515 0
1151 Closed Loop Multiplier High LPG 520206 0
1152 Closed Loop Multiplier Low LPG 520206 1
1155 Closed Loop Multiplier High Gasoline 520204 0
1156 Closed Loop Multiplier Low Gasoline 520204 1
1161 Adaptive Learn High LPG 520202 0
1162 Adaptive Learn Low LPG 520202 1
1165 LPG Cat Monitor 520213 10
1171 LPG Pressure Higher Than Expected 520260 0
1172 LPG Pressure Lower Than Expected 520260 1
1173 EPR Comm Lost 520260 31
1174 EPR Voltage Supply High 520260 3
1175 EPR Voltage Supply Low 520260 4
1176 EPR Internal Actuator Fault 520260 12
1177 EPR Internal Circuitry Fault 520260 12
1178 EPR Internal Comm Fault 520260 12
1612 RTI 1 loss 629 31
1613 RTI 2 Loss 629 31
1614 RTI 3 Loss 629 31
1615 A/D Loss 629 31
1616 Invalid Interrupt 629 31
1625 Shutdown Request 1384 31
1626 CAN Tx Failure 639 12
1627 CAN Rx Failure 639 12
1628 CAN Address Conflict Failure 639 13
1629 Loss of TSC 1 639 31
2111 Unable to Reach Lower TPS 51 7
2112 Unable to Reach Higher TPS 51
2135 TPS 1/2 Simultaneous Voltages 51 31
2229 BP Pressure High 108 0
3121290 – JLG Lift – 3-105

1. Battery 6. O2 Sensor 11. Motor Mount

2. Coolant Overflow 7. Crankshaft Position Sensor 12. Start/Aux Power Relays
3. Air Cleaner 8. Muffler 13. Engine Tray Pivot
4. Radiator 9. Piston Pump 14. Auxiliary Pump
5. Alternator 10. Gear Pump
Figure 3-70. GM 3.0L Engine - Sheet 1 of 2
3-106 – JLG Lift – 3121290

15. O2 Sensor 20. Oil Filter 25. Mixer

16. Dipstick 21. Water Pump 26. PCV Valve
17. Control Module 22. Coolant Sensor 27. Oil Pressure Switch
18. Starter 23. Pressure Regulator 28. Coil
19. Distributor 24. MAP Sensor 29. Fuel Filter
Figure 3-71. GM 3.0L Engine - Sheet 2 of 2
3121290 – JLG Lift – 3-107

3.17 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE Section Layout

DEFINITIONS This section is organized in the following manner:
This section defines diagnostics and recommended trouble-

shooting procedures associated with EControls, Diesel Gover-
nor Control (DGC), and Engine Control Module (ECM) used on
industrial engines.
DTC XXXX- Diagnostic Condition
Block Diagram of Circuit
External Hardware Input/Output- This identifies the hardware that either sends an input
to the ECM or is driven by and ECM output.
Check Condition- This defines what condition to troubleshoot the fault condition.
Fault Condition(s)- This identifies the condition(s) that set the fault.
Corrective Action(s)- This identifies the RECOMMENED corrective action(s) that the
ECM is generally programmed to perform. In some instances, the calibration
engineer(s) may choose to perform a different action.
Emissions or Non-emissions related fault
Text to identify the circuit of interest and its use for control.
Text to describe t he conditions that cause the fault to set.
DTC XXXX- Diagnostic Condition
Note: Helpful tips used to aid troubleshooting
Yes
Troubleshooting flow
chart
No
3-108 – JLG Lift – 3121290

List of Abbreviations in this Section

AL Adaptive Learn LED Light Emitting Diode
BP Barometric Pressure LPG Liquefied Propane Gas
CAN Controller Area Network MAP Manifold Absolute Pressure
CCP CAN Calibration Protocol MGCP Marine Global Control Platform
CHT Cylinder Head Temperature μP Microprocessor
CL Closed Loop Mfg Manufacture
CNG Compressed Natural Gas MIL Malfunction Indicator Lamp
DBW Drive-By-Wire NG Natural Gas
DGC Diesel Governor Control OBD On-Board Diagnostics
DM Diagnostic Message OEM Original Equipment Manufacture
DMM Digital Multi-Meter (high impedance) PC Personal Computer
DST Diagnostic Scan Tool PCU Powertrain Control Unit
DTC Diagnostic Trouble Code PFI Port Fuel Injection
DVOM Digital Voltage and Ohm Meter (high impedance) PGN Parameter Group Number
ECI EControls Inc. PWM Pulse Width Modulated
ECIPP EControls Inc. Proprietary Protocol RAM Random Access Memory
ECM Engine Control Module RPM Revolutions Per Minute
ECT Engine Coolant Temperature Rx Receive
ECU Engine Control Unit SAE Society of Automotive Engineering
EDIS EControls Display and Interface Software SA Source Address
EGO Exhaust Gas Oxygen Sensor, typically heated SPFI Sequential Port Fuel Injection
EMWT Exhaust Manifold Water Temperature SPN Suspect Parameter Number
EPR Electronic Pressure Regulator Tach Tachometer
ERWT Exhaust Manifold Riser Temperature TBI Throttle Body Injection
ETB Electronic Throttle Body TDC Top Dead Center
ETC Electronic Throttle Control TIP Throttle Inlet Pressure
FDR Flight Data Recorder TPS Throttle Position Sensor
FMI Failure Mode Indicator TSC Torque/Speed Control
FO Firing Order Tx Transmit
FP Fuel Pressure UEGO Universal Exhaust Gas Oxygen Sensor (Wide-Range EGO)
FPP Foot Pedal Position VDC Voltage, Direct Current
FRP Fuel Rail Pressure VR Variable Reluctance
FRT Fuel Rail Temperature Vsw Switched, Ignition Voltage
FSS Fault Snapshot WGP Waste-Gate Pressure
FT Fuel Temperature
GCP Global Control Platform
HDGCP Heavy-Duty Global Control Platform
(On-Road Heavy-Duty)
HEGO Heated Exhaust Gas Oxygen Sensor (same as HO2S)
HO2S Heated Oxygen Sensor (same as HEGO)
IAC Idle Air Control
IAT Intake Air Temperature
ICAV Instant Crank Angle Velocity
IVS Idle Validation Switch
LDGCP Light-Duty Global Control Platform
(Industrial, Smart/Logic Coil)
3121290 – JLG Lift – 3-109

Fault Code Broadcast Data capture at occurrence of a fault, known in the ECM as
fault snapshot (FSS), is available upon DM4 request. The fol-
All diagnostic trouble codes are broadcast through EDIS for
lowing bytes are supported for DM4 if configured in ECM soft-
display on a PC. EDIS can acquire the data from the ECU via
ware:
CAN using the EControls Inc. Proprietary Protocol (ECIPP).
Faults may also be acquired over the CAN network through • Byte 1: Freeze Frame Length
CAN J1939-based scan tools or multi-function display units.
• Byte 2-6: SPN, FMI, SPN Conversion Method, and Occur-
rence
Diagnostic Trouble Codes
• Byte 7: Manifold Absolute Pressure
Numeric diagnostic trouble codes assigned to faults in this
manual are cross-referenced to SAE.s “Recommended Practice • Byte 8-9: Engine Speed
for Diagnostic Trouble Code Definitions” (SAE J2012). While
• Byte 10: Engine Load (MAP based estimate)
these codes are recommended, customers may define their
own codes by assigning a new number to the flash code in the • Byte 11: Engine Coolant Temperature
diagnostic calibration. This assigns the DTC as displayed in • Byte 14: # of starts since fault was last active
EDIS and flash code output on the MIL output pin. EDIS may
be used to connect to the DGC ECM via CAN. • Byte 15: Index into FSS_storage table for Fault Snap Shot
retrieval
CAN Resetting active and previously active DTCs is handled
The DGC supports SAE J1939 CAN based diagnostic support. through DM11 and DM3, respectively DM1 and DM2 lamp
This includes: indicators are assigned to each fault based on the faults diag-
nostic action as defined in the calibration. Lamps are assigned
• DM1: Active Diagnostic Trouble Codes based on configuration outlined in Table 3-15.
• DM2: Previously Active Diagnostic Trouble Codes
Table 3-15. J1939 Diagnostic Lamp Configuration
• DM3: Diagnostic Data Clear/Reset of Previously Active
DTCs ECI DIAGNOSTIC ACTION J1939 LAMP
• DM4: Freeze Frame Parameters
MIL MIL
• DM5: Diagnostic Readiness (bytes 1, 2, and 3 are sup-
ported) Soft Warning Amber
• DM11: Diagnostic Data Clear/Reset For Active DTCs Hard Warning, Low Rev Limit, Shutdown Red Stop
• DM12: Emissions-Related Active Diagnostic Trouble Codes Power Derate 1 & 2 Protect
• DM19: Calibration Information Forced Idle None (use in combination with other
All diagnostic trouble codes broadcast over CAN are SAE J1939 action)
DM1 and DM2 formatted messages. DGC ECMs are compliant
with J1939 OBD-M, supporting the Diagnostic Messages
above as well as user indicators and CAN data defined in the
MIL Output
OBD-M protocol. Faults available for broadcast and their Malfunction Indicator Lamp (MIL) output displays fault infor-
respective SPN/FMI numbers are dependent on the applica- mation to the equipment operator. The MIL is always on
tion and engine calibration. There are 4 CAN SPN/FMI lists (grounded) when the system is in a key-on (Vsw), engine-off
available in the DGC software set, contact EControls Inc. for a state. This shows the output is functional. If a DTC is logged as
list of CAN SPN/FMIs. previously-active (historic), the MIL sends a single flash for the
“Blink on-time” every “Blink off-time.”
Diagnostic Calibration Configuration and

Corrective Actions
Each fault within the DGC is capable of being uniquely config-
ured in the engines diagnostic calibration to cause one or
more corrective actions while a given fault is active.
Table 2 identifies configuration options and corrective actions
available for configuration of each fault.
3-110 – JLG Lift – 3121290

The desired action is set by OEM calibration engineers.
Table 3-16. Diagnostic Corrective Actions
CORRECTIVE ACTION DESCRIPTION
Enable Enables the fault for fault detection
Shutdown Cause an engine shutdown when fault becomes active
Never Forget Retain fault as historic/previously active until cleared by a technician and does not allow historic fault to be “auto-cleared”
Turn on MIL Turn on MIL output when fault becomes active
CL Disable Disable closed-loop while the fault is active
CL Disable Key- Cyc Disable closed-loop while the fault is active and for the remainder of the key cycle
AL Disable Disable adaptive learn while the fault is active
AL Disable Key-Cyc Disable adaptive learn while the fault is active and for the remainder of the key cycle
Power Derate 1 Limit TPS to the Power Derate 1 percent set in the diagnostic calibration while the fault is active. The Power Derate 1 TPS percent should be set higher
than Power Derate 2 as Power Derate 2 adds a higher level of protection.
Power Derate 2 Limit TPS to the Power Derate 2 percent set in the diagnostic calibration while the fault is active. If the calibration is set to “Latched for Key-Cycle”
Power Derate 2 remains active until engine speed and FPP conditions are satisfied. The Power Derate 2 TPS percent should be set lower than Power
Derate 1 as Power Derate 2 adds a higher level of protection.
Low Rev Limit Limit RPM to the Low Rev Limit speed set in the diagnostic calibration while the fault is active. If the calibration is set to “Latched for Key-Cycle” Low
Rev Limit remains active until engine speed and FPP conditions are satisfied.
Forced Idle Limit RPM to the Forced Idle speed set in the diagnostic calibration while the fault is active and for the remainder of the key cycle
Soft Warning Turn on the soft warning output when the fault becomes active
Hard Warning Turn on the hard warning output when the fault becomes active
Stopped Check Run fault detection/checking while the engine is in a key-on, engine-off condition. NOTE: It is recommended that this feature only be used for general
sensor faults (high/low voltage) and some output drivers
Fault/Diagnostic Trouble Code Interaction

All fault and diagnostic information is managed through the
Faults page. Interaction includes viewing fault messages,
downloading fault data (fault snapshot and flight data
recorder), erasing faults from memory, and defining variables
for fault data logging.
Faults are separated into two categories, Active and Historic.
Active faults are active in real-time and historic faults have
been generated at some instance in time that may or may not
be active in real-time. Once a fault has become active, it is
immediately logged as historic and a snapshot and flight data
log is saved. Figure 3-72. shows an example of the fault page
when an active fault has been generated. Notice fault is pres-
ent in active and historic lists and the Malfunction Indicator
Lamp (MIL) has been illuminated. Figure 3-73. shows an exam-
ple of the fault page with a historic fault stored in memory.
3121290 – JLG Lift – 3-111

Base Fault snapshot

variable definitions
(CAN NOT be altered)
Custom Fault Snapshot

variable definitions (User
Defined)
Base Flight Data

Recorder variable
definitions (CAN
NOT be altered)
Custom Flight Data
Recorder variable
definitions (User Defined)
Figure 3-72. Faults Page with Active Fault Message
3-112 – JLG Lift – 3121290

Figure 3-73. Faults Page with Historic Fault Message
Once an active fault has occurred, two sets of data are FDR information is stored in RAM, therefore this data is only
recorded; fault snapshot and flight data recorder. The fault available if the ECM has not lost battery power. In addition, if
snapshot (FSS) is a sample of data taken when the fault trig- there is a “Dirty Flash Page” in the ECM, FDR data will not be
gered. Variables included in the FSS are defined in the Snap- available. FSS data is stored in EEPROM and is retained when
shot Base and Snapshot Custom Definition fields found on the the ECM loses battery power.
Faults Page. An FSS is saved with each of the first eight (8)
Both sets of data are accessed from the Historic Fault Informa-
faults the first time the fault becomes active.
tion interface and can be saved to a PC upon retrieval. Base
Conversely, the flight data recorder (FDR) is a ten-second variables for FSS and FDR are generally defined by the OEM to
stream of data that includes eight-seconds prior and two-sec- include variables most often referenced during fault diagnosis.
onds after triggering the fault. An FDR is saved for each of the Base definitions are not fault dependent. Additional variables
first two (2) faults for the first time the fault becomes active. may be selected for capture during a fault occurrence through
Variables included in the FDR are defined in the Flight Data a single, left-click of the custom table and selecting desired
Base and Flight Data Custom Definition fields found on the variables from a list. An example of custom fault variable defi-
Faults Page. nitions is shown in Figure 3-74.
3121290 – JLG Lift – 3-113

Figure 3-74. Custom Fault Variable Interface
Accessing fault information is accomplished through a double From this interface, FDR data may be saved to the PC in text,
left-click of the fault LED in the historic fault list. This produces tab-delimited format with an .fdr file extension. Once saved to
the Historic Fault Information interface shown in Figure 3-75. PC, FDR data may be reviewed with any graphical post-pro-
From this interface a user can interpret a diagnostic trouble cessing software capable of handling tab-delimited format-
code (DTC) message, identify whether or not the fault ting.
occurred during the current key cycle, identify if the fault
Fault information may be manually erased using the “Clear”
caused engine shutdown, determine how many key cycles
button functions. Once a “Clear” function has been selected,
have occurred since fault was last active, clear selected or all
the dialog prompt shown in Figure 3-78. will be displayed.
historic faults, and view snapshot and flight data.
Choosing YES deletes all fault information from the ECM.
Table 3-17 outlines options displayed in the Historic Fault
Information screen. Historic faults are not overwritten if the DBW Diagnostic Test
same fault becomes active, storing data from the original
The DGC engine control module uses a diagnostic test to ver-
active fault.
ify proper drive-by-wire throttle actuator operation. This diag-
Figure 3-76. is an example of a fault snapshot after View Fault nostic test is software selectable through the EDIS using the
Snapshot is selected. Data is presented in two columns; base ECIPP protocol. The test permits full-authority operation of an
and custom variables. FSS data may be saved to a PC in text electronic throttle via the throttle command input while
format with an .fss extension when retrieved. An FSS saved to engine is in “Stopped” state only. The ECM reverts to normal
a PC may be reviewed in any ASCII based software program. operation if “Off” state is selected, ignition voltage is lost, or
engine speed is sensed.
Figure 3-77. shows the Flight Data Recorder interface after
View Flight Data Recorder is selected. The FDR captures a ten To enable test, go to DBW page of the EDIS. Set “DBW test
second (eight seconds prior and two seconds after generating mode” to “Enabled”. Double-click “TPS Command” setting and
the fault) strip of data for base and custom variables. FDR data enter desired DBW throttle actuator position. The throttle
is presented in an interface similar to the Plot interface for a actuator should move to position entered. To disable test, set
quick graphical presentation. “DBW test mode” to “Off.”
3-114 – JLG Lift – 3121290

Figure 3-75. Historic Fault Information Interface
Table 3-17. Historic Fault Information Interface Functions
Fault Description Message Box Customized text that references the DTC flash code and describes the fault.
Fault During Key Cycle Checkbox Informs that the fault occurred during the current key-on event.
Fault Caused Engine Shutdown Checkbox Informs that the fault caused the engine to shutdown.
Key Cycles Since Fault Active Indicator Displays the amount of key-on events since the fault was last active.
Clear This Fault Button* Erases the selected historic fault from the ECM.
Clear All Faults Button* Erases all historic faults from the ECM.
View Snap Shot Data Button Retrieves a data “snap shot” from the ECM for variables defined in the base and custom snapshot variable defini-
tion lists. An example of a fault snap shot is shown in Figure 5.
View Flight Data Recorder Data Button Retrieves a 10-second data strip chart (8 seconds prior, 2seconds after fault trigger) from the ECM for variables
defined in the base and custom flight data recorder definition lists. An example of a fault snap shot is shown in Fig-
ure 6.
Close Button Exits the Historic Fault Information interface. DOES NOT cancel or clear any faults.
* Snapshot and flight data recorder data for historic faults is erased after the prompt shown in Figure 3-78. is satisfied
3121290 – JLG Lift – 3-115

Figure 3-76. Snapshot Data Interface
Figure 3-77. Flight Data Recorder Interface
Figure 3-78. Clear Faults Prompt
3-116 – JLG Lift – 3121290

3.18 DIAGNOSTIC TROUBLE CODE FAULT DTC 116- ECT Higher Than Expected Stage 1
DESCRIPTIONS
• Engine Coolant Temperature Sensor. Diagnostic Aids

• Check Condition-Engine Running. If “ECT High Voltage” fault is also present, follow troubleshoot-
• Fault Condition-Engine Coolant Temperature reading or ing procedures for that fault as it may have caused “ECT
estimate greater than stage 1 limit when operating at a Higher Than Expected 1.”
speed greater than defined in diagnostic calibration. Cooling system with air-to-water heat exchanger (radiator)
• Corrective Action(s): Sound audible warning or illuminate and fan:
secondary warning lamp, disable adaptive learn fueling
• Check radiator has a proper amount of ethylene glycol/
correction during active fault. Recommend a power derate
water and is not leaking.
1/2 and/or a low rev limit to protect engine from possible
damage. • Ensure there is no trapped air in cooling path.
• Non-emissions related fault. • Inspect cooling system (radiator and hoses) for cracks and
connections are leak free.
The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in engine coolant. Some • Check fan is operating properly.
engines use a CHT sensor located in cylinder head coolant. • Check thermostat is not stuck closed.
Some engines use an ECT (Engine Coolant Temperature) sen-
sor located in coolant near the thermostat. If engine is Cooling system with water-to-water heat exchanger:
equipped with a CHT sensor, the ECT value is estimated. If • Check heat exchanger has proper amount of ethylene gly-
equipped with an ECT sensor, the CHT value is estimated. They col/water and that the heat exchanger is not leaking.
are used for engine airflow calculation, ignition timing control,
to enable certain features, and for engine protection. The ECM • Ensure there is no trapped air in the cooling path.
provides a voltage divider circuit. The sensor reads higher volt- • Inspect cooling system (radiator and hoses) for cracks and
age when cold and lower when warm. connections are leak free.
This fault helps protect engine in the event of over tempera- • Check raw water pickup is not blocked/restricted by debris
ture. When coolant exceeds x deg. F and engine RPM exceeds and hose is tightly connected.
y RPM for the latch time this fault will set.
• Check thermostat is not stuck closed.
• Check raw water pump/impeller is intact and not
restricted.
3121290 – JLG Lift – 3-117

DTC 117- ECT/CHT Low Voltage
• Engine Coolant Temperature Sensor The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in the engine coolant.
• Check Condition-Engine Running
Some engines use an ECT sensor that is located in the coolant
• Fault Condition-CHT/ECT sensor voltage less than the limit near the thermostat. Some engines use a CHT (Cylinder Head
defined in the diagnostic calibration Temperature) sensor that is located in the coolant in the cylin-
• Corrective Action(s)- Sound audible warning or illuminate der head. If the engine is equipped with an ECT sensor then
secondary warning lamp, disable adaptive learn fueling the CHT value is estimated. If equipped with a CHT sensor then
correction during active fault, or any combination thereof the ECT value is estimated. The ECM provides a voltage divider
as defined in calibration. Recommend a power derate 1/2 circuit so that when the coolant is cool, the signal reads higher
to reduce the possibility of engine damage due to the voltage, and lower when warm.
inability to sense temperature. This fault will set if the signal voltage is less than the limit
• Non-emissions related fault defined in the diagnostic calibration anytime the engine is
running. The limit is generally set to 0.10 VDC. The ECM will
use a default value for the CHT/ECT sensor in the event of this
fault.
3-118 – JLG Lift – 3121290

3121290 – JLG Lift – 3-119

DTC 118- ECT/CHT High Voltage
• Engine Coolant Temperature Sensor The Engine Coolant Temperature sensor is a thermistor (tem-
perature sensitive resistor) located in the engine coolant.
• Check Condition-Engine Running
Some engines use an ECT sensor that is located in the coolant
• Fault Condition-CHT/ECT sensor voltage higher than the near the thermostat. Some engines use a CHT (Cylinder Head
limit defined in the diagnostic calibration Temperature) sensor that is located in the coolant in the cylin-
• Corrective Action(s)- Sound audible warning or illuminate der head. If the engine is equipped with an ECT sensor then
secondary warning lamp, disable adaptive learn fueling the CHT value is estimated. If equipped with a CHT sensor then
correction during active fault, or any combination thereof the ECT value is estimated. The ECM provides a voltage divider
as defined in calibration. Recommend a power derate 1/2 circuit so that when the coolant is cool, the signal reads higher
to reduce the possibility of engine damage due to the voltage, and lower when warm.
inability to sense temperature. This fault sets if signal voltage is higher than high voltage limit
• Non-emissions related fault as defined in diagnostic calibration anytime engine is running.
The limit is generally set to 4.90 VDC. In many cases, this condi-
tion is caused by the CHT/ECT sensor being disconnected from
the engine harness, an open-circuit or short-to-power of the
CHT/ECT circuit in the wire harness, or a failure of the sensor.
The ECM will use a default value for the CHT/ECT sensor in the
event of this fault.
3-120 – JLG Lift – 3121290

3121290 – JLG Lift – 3-121

DTC 122- TPS1 Signal Voltage Low
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
+ 1
W
B
D +
TPS1 5V_ext
16
tr
o
-M 2
W
B
D d
ri
-B
H
e
g
1
S
P
T _
V
5
6
1 te
x
E
S
P
T D
5
+
s=
V
R C
a
ri
e
lS 2
1
te
i
rxm 3
1
E
S
P
T M
C
E
R
-
rtn
_
V
5
9
1
h
iT
n
le
E
/S
rw
o
a
tu
c
A lte
ria
o
d
e
F
itn
s
o
P b
k
c
a
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor 1. There are two types of throttle actuators;
• Check Condition-Key On, Engine Off. 1) actuator with analog position feedback
• Fault Condition-TPS1 sensor voltage lower than the limit and

defined in the diagnostic calibration. 2) actuator with digital position feedback.
• Corrective Action(s): Sound audible warning or illuminate
The first type, with analog position feedback, provides an ana-
secondary warning lamp, shutdown engine.
log return signal between 0 and 5 volts that is proportional to
• Non-emissions related fault. the throttle actuator position. The second type, with digital
position feedback, provides a serial data signal to the ECM
In the case of a diesel engine, an actuator controls a fuel injec-
with the throttle actuator position voltage level encoded in
tion pump, directly affecting the fueling level into the cylin-
the data stream.
ders. This may be by direct manipulation of the fuel injection
pump rack or by manipulation of the mechanical governor This fault sets if TPS1 voltage is lower than the low voltage
control level or “throttle arm.” limit as defined in the diagnostic calibration at any operating
condition while the engine is cranking or running. The limit is
In the DGC ECM and EDIS, references to the throttle and throt-
generally set to 4.90 VDC. In many cases, this condition is
tle position sensor refer to these fuel injection pump control
caused by the TPS sensor being disconnected from the engine
actuators and their position feedback sensors. When the fuel
harness, an open-circuit or short-to-ground of the TPS circuit
injection pump is electronically controlled it can be used to
in the wire harness, or a failure of the sensor. This fault should
control the idle stability and limit engine speed based on
be configured to trigger an engine shutdown and the engine
will not start with this fault active.
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit
or
2) a non-contact hall-effect sensor to determine throttle actu-
ator position, and is located within the throttle actuator.
3-122 – JLG Lift – 3121290

3121290 – JLG Lift – 3-123

DTC 123- TPS1 Signal Voltage High
+ 1
+
W
B
D
tr
o
-M -2
W
B
D d
ri
-B
H
e
g
1
S
P
T t
x
e
_
V
5
6
1
+
R
E
S
P
T C
D
5
+
=
s
V
ria
e
lS 2
1
i
m
rx
te 3
-1
R
E
S
P
T M
C
E
rtn
_
V
5
9
1
le
E
tu
c
A h
T
c
ln
ia
e
/S
rw
to
it
s
o
P k
c
a
b
d
e
F
n
io
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor 1. There are two types of throttle actuators, 1) actuator with ana-
log position feedback and 2) actuator with digital position
• Check Condition-Key On, Engine Off.
feedback. The first type, with analog position feedback, pro-
• Fault Condition-TPS1 sensor voltage higher than the limit vides an analog return signal between 0 and 5 volts that is pro-
defined in the diagnostic calibration. portional to the throttle actuator position. The second type,
• Corrective Action(s): Sound audible warning or illuminate with digital position feedback, provides a serial data signal to
secondary warning lamp, shutdown engine. the ECM with the throttle actuator position voltage level
encoded in the data stream.
• Non-emissions related fault.
This fault will set if TPS1 voltage is higher than the limit set in
In the case of a diesel engine, an actuator controls a fuel injec- the diagnostic calibration at any operating condition while the
tion pump, directly affecting fueling level into the cylinders. engine is cranking or running. The limit is generally set to 4.90
This may be by direct manipulation of the fuel injection pump VDC. In many cases, this condition is caused by a short-to-
rack or by manipulation of the mechanical governor control power of the TPS circuit in the wire harness or a failure of the
level or “throttle arm.” In the DGC ECM and EDIS, references to sensor. This fault should be configured to trigger an engine
throttle and throttle position sensor refer to these fuel injec- shutdown and the engine will not start with this fault active.
tion pump control actuators and their position feedback sen-
sors. When the fuel injection pump is electronically controlled
it can be used to control the idle stability and limit engine
speed based on operating conditions.
The Throttle Position Sensor uses either;
1) a variable resistor and voltage divider circuit
or
2) a non-contact hall-effect sensor to determine throttle actu-
ator position, and is located within the throttle actuator.
3-124 – JLG Lift – 3121290

3121290 – JLG Lift – 3-125

DTC 217- ECT Higher Than Expected 2
• Engine Coolant Temperature Sensor. Diagnostic Aids

• Check Condition-Engine Running.
If “ECT High Voltage” fault is present, follow troubleshooting
• Fault Condition-Engine Coolant Temperature reading or procedures for that fault as it may have caused “ECT Higher
estimate greater than the stage 2 limit when operating at a Than Expected 2.”
speed greater than defined in the diagnostic calibration.
If cooling system uses an air-to-water heat exchanger (radia-
• Corrective Action(s)- Sound audible warning or illuminate
tor) and fan:
secondary warning lamp, disable adaptive learn fueling
correction during active fault. Recommend a power derate • Check radiator has a proper amount of ethylene glycol/
2 and/or a forced idle or engine shutdown to protect water and is not leaking.
engine from possible damage. • Make sure there is no trapped air in the cooling path.
• Non-emissions related fault • Inspect cooling system (radiator and hoses) for cracks and
The Engine Coolant Temperature sensor is a thermistor (tem- ensure connections are leak free.
perature sensitive resistor) located in the engine coolant. • Check fan is operating properly.
Some engines use a CHT sensor that is located in the coolant
in the cylinder head. Some engines use an ECT (Engine Cool-
ant Temperature) sensor that is located in the coolant near the If cooling system uses a water-to-water heat exchanger:
thermostat. If the engine is equipped with a CHT sensor then • Check heat exchanger has proper amount of ethylene gly-
the ECT value is estimated. If equipped with an ECT sensor col/water and heat exchanger is not leaking.
then the CHT value is estimated. The ECM provides a voltage
divider circuit so when the sensor reading is cool the sensor • Make sure there is no trapped air in the cooling path.
reads higher voltage, and lower when warm. • Inspect cooling system (radiator and hoses) for cracks and
connections are leak free.
This fault helps protect the engine in the event of over tem-
perature. When coolant exceeds x deg. F and engine RPM • Check raw water pickup is not blocked/restricted by debris
exceeds y RPM for the latch time this fault will set. and hose is tightly connected.
• Check raw water pump/impeller is intact and not
restricted.
3-126 – JLG Lift – 3121290

DTC 219- RPM Higher Than Max Allowed Governed

Speed
+ 1
W
B
D +
tr
o
-M 2
W
B
D rid
-B
H
e
g
1
S
P
T _
V
5
6
1 e
t
x
2
1
E
S
P
T D
5
+
s=
V
R C
ta
iS
rlxm
e 3
1
E
S
P
T -
R
rtn
_
V
5
9
1 M
C
E
h
iT
n
le
E
/S
rw
o
a
tu
c
A o
lt
ria
e
d
e
F
itn
s
o
P k
c
a
b
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Max Govern Speed Override- Crankshaft Position Sensor Diagnostic Aids

• Check Condition-Engine Running. NOTE: If any other DTCs are present, diagnose those first.
• Fault Condition-Engine speed greater than the max gover-
• Ensure no programmed governor speeds exceed limit set
nor override speed as defined in the diagnostic calibration.
in diagnostic calibration for Max Gov Override Speed
• Corrective Action(s): Sound audible warning or illuminate
• Check mechanical operation of the throttle actuator
secondary warning lamp, reduce throttle to limit speed.
Recommend closed loop and adaptive learn fueling correc-
tion remains active during fault.
• Non-emissions related fault
This fault sets anytime engine RPM exceeds limit set in diag-
nostic calibration for latch time or more. This speed overrides
any higher max governor speeds programmed by the user.
This fault is designed to help prevent engine or equipment
damage.
Throttle lowers to govern engine to speed set in diagnostic
calibration.
DTC 219- RPM Higher Than Max Allowed Governed Speed
(continued).
3121290 – JLG Lift – 3-127

DTC 336- Crank Signal Input Noise
• Crankshaft Position sensor. The crankshaft position sensor is a magnetic sensor (variable
reluctant/magnetic pick-up or Hall effect) installed in the
• Check Condition- Key On, Engine On.
engine block adjacent to a “coded” trigger wheel located on
• Fault Condition- Electrical noise or irregular crank pattern the crankshaft. The sensor-trigger wheel combination deter-
detected causing x number of crank resynchronization mines crankshaft position (with respect to TDC cylinder #1
events as defined in diagnostic calibration. compression) and the rotational engine speed.
• Corrective Action(s)- Illuminate MIL and/or sound audible Determination of crankshaft position and speed is necessary
warning or illuminate secondary warning lamp and disable to properly activate ignition, fuel injection, and throttle gov-
adaptive fueling correction for remainder of key-cycle. erning systems for precise engine control.
• Emissions related fault The ECM must see a valid crankshaft position signal while run-
ning. If no signal is present, signal amplitude is too high (due
to improper air gap with respect to trigger wheel), or an irreg-
ular crank pattern is detected causing the ECM to resynchro-
nize x times for y ms or longer as defined in the diagnostic
calibration, this fault will set. Irregular crank patterns can be
detected by the ECM due to electrical noise, poor machining
of trigger wheel, or trigger wheel runout and/or gear lash.
Ensure crank circuit used with VR/magnetic pick-up sensors
are properly twisted.
3-128 – JLG Lift – 3121290

• Key On, Engine Running

• System Mode= “Running”
Operate engine at condition

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

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

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

• Bad crankshaft position sensor
• Bad ECM
3121290 – JLG Lift – 3-129

DTC 337- Loss of Crank Input Signal
• Crankshaft Position sensor. Diagnostic Aids

• Check Condition- Key On, Engine On. • Check crankshaft position sensor is securely connected to
• Fault Condition- Loss of crankshaft position signal while harness.
valid camshaft position signals continue for x number of • Check crankshaft position sensor is securely installed in
cam pulses as defined in the diagnostic calibration. engine block.
• Corrective Action(s)- Illuminate MIL and/or sound audible • Check crankshaft position sensor circuit wiring for open cir-
warning or illuminate secondary warning lamp. cuit.
• Emissions related fault.
The crankshaft position sensor is a magnetic sensor (variable
reluctant/magnetic pick-up or Hall effect) installed in the
engine block adjacent to a ¡§coded¡¨ trigger wheel located on
the crankshaft. The sensor-trigger wheel combination is used
to determine crankshaft position (with respect to TDC cylinder
#1 compression) and rotational engine speed. Determination
of the crankshaft position and speed is necessary to properly
activate the ignition, fuel injection, and throttle governing sys-
tems for precise engine control.
The ECM must see a valid crankshaft position signal while run-
ning. If no signal is present while x cam pulses continue, the
fault will set. The engine typically stalls or dies as a result of
this fault condition due to lack of crankshaft speed input,
resulting in loss of ignition timing control.
3-130 – JLG Lift – 3121290

DTC 521- Oil Pressure Sender/Switch High Pressure
• Engine Oil Pressure The ECM can be configured to monitor oil pressure through a
proportional transducer or through a switch. Oil pressure
• Check Condition- Key on, Engine on (or Engine off )
monitoring is important to prevent engine damage due to low
• Fault Condition- For sender types, oil pressure higher than oil pressure resulting in higher friction and lack of lubrication.
x psia while engine speed is greater that y RPM. For switch In addition, high oil pressure can be undesirable because it
types, oil pressure is indicating high when the engine has can cause oil to leak past seals and rings, can be a result of a
been stopped for more than n seconds. restriction in the oil flow path, or can be a sign of a malfunc-
• Corrective Action(s)- Illuminate MIL and/or sound audible tioning oiling system.
warning or illuminate secondary warning lamp, possibly For normally-open type oil pressure switches, a high pressure
configure for power derate 1 or low rev limit indication while engine is off is a symptom of a failed oil pres-
• Non-emissions related fault sure switch. The ECM can monitor oil pressure indication when
engine is stopped for this failure mode.
For sender types, this fault sets if engine oil pressure is higher
than x psia and engine speed greater than y RPM as defined in
diagnostic calibration.
For switch types, this fault sets if engine oil pressure is indicat-
ing high when engine is stopped for more than n seconds.
Recommend a power derate and/or low rev limit to help pre-
vent possible engine damage and reduce oil pressure.
3121290 – JLG Lift – 3-131

Normally Open Switch
• Key-On, Engine Off

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

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

• Faulty engine oiling system (verify with
mechanical gauge)
Normally Closed Switch
• Key-On, Engine Off

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

Is switch open?
• Faulty ECM
Yes

mechanical gauge)
3-132 – JLG Lift – 3121290

Sensor/Transducer Type
3121290 – JLG Lift – 3-133

DTC 524- Oil Pressure Low
• Engine Oil Pressure. The ECM can be configured to monitor oil pressure through a
proportional transducer or through a switch. Oil pressure
• Check Condition- Key on, Engine on.
monitoring is important to prevent engine damage due to low
• Fault Condition- Engine oil pressure lower than expected oil pressure resulting in higher friction and lack of lubrication.
while engine has been running for a minimum amount of In addition, high oil pressure can be undesirable because it
time while engine speed is above some limit as defined in can cause oil to leak past seals and rings, can be a result of a
the diagnostic calibration. restriction in the oil flow path, or can be a sign of a malfunc-
• Corrective Action(s)- Illuminate MIL and/or sound audible tioning oiling system.
warning or illuminate secondary warning lamp, generally For systems that use a transducer, this fault sets if engine oil
configured to derate the engine and trigger an engine pressure is less than x psia and engine speed is greater than y
shutdown. RPM after engine has been running for z seconds as defined in
• Non-emissions related fault. diagnostic calibration. For systems that use a switch, this fault
can be configured two different ways. It may use a normally
closed switch or a normally open switch.
If switch is normally open, fault sets if circuit becomes
grounded.
If switch is normally closed, fault sets if circuit becomes open.
Go to Faults page in EDIS to determine how the input is con-
figured. (“Open=OK” is normally open and “Ground=OK” is
normally closed). The engine should be configured to derate
or force idle and/or shut down in the event of this fault to pre-
vent possible damage.
3-134 – JLG Lift – 3121290

Normally Open Switch
• Key-On, Engine On
• Key Off
• Disconnect harness from Oil Pressure switch
• Warm engine at idle to normal • Clear DTC 524
operating temperature • Key On, Engine On
• Increase RPM above limit set • System Mode= “Running”
in diagnostic calibration • Operate engine et idle for at least one minute
• Increase RPM above limit set in diagnostic calibration
Yes
Does DTC 524
reset ?
Yes • Oil Pressure circuit shorted-to-ground in harness
Does DTC 524
reset? • Faulty ECM
No
No
mechanical gauge)
3121290 – JLG Lift – 3-135

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

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

• Faulty ECM resistance < 5.0 ohms?
No
• Faulty harness
(open circuit)
3-136 – JLG Lift – 3121290

Sensor/Transducer Type
3121290 – JLG Lift – 3-137

DTC 562- Battery Voltage (VBat) Low
• System voltage to ECM. Battery voltage powers the ECM and must be within limits to
correctly operate throttle actuator, power supplies, and other
• Check Condition- Key on, Engine on.
powered devices the ECM controls.
• Fault Condition- Battery voltage to ECM less than x volts
while the engine is operating at y RPM or greater as This fault sets if the ECM detects system voltage less than x
defined in the diagnostic calibration. volts while the engine is operating at y RPM as defined in diag-
nostic calibration as the alternator should be charging the sys-
• Corrective Action(s)- Illuminate MIL and/or sound audible tem.
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle.
3-138 – JLG Lift – 3121290

3121290 – JLG Lift – 3-139

DTC 563- Battery Voltage (VBat) High
• System voltage to ECM. Battery voltage powers the ECM and must be within limits to
correctly operate throttle actuator, power supplies, and other
• Check Condition-Key on, Engine Cranking or Running.
powered devices the ECM controls.
• Fault Condition- Battery voltage to ECM greater than x
volts while the engine is running as defined in the diagnos- This fault sets if the ECM detects system voltage greater than x
tic calibration. volts while engine is running or cranking as defined in diag-
nostic calibration.
• Corrective Action(s)- Illuminate MIL and/or sound audible
warning or illuminate secondary warning lamp, disable
adaptive fueling correction for remainder of key cycle.
3-140 – JLG Lift – 3121290

3121290 – JLG Lift – 3-141

DTC 601- Microprocessor Failure - FLASH
• Engine Control Module- Flash Memory. The ECM has checks that must be satisfied each time an
instruction is executed. Several different things can happen
• Check Condition- Key on.
within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error.
If this fault sets, the ECM will reset itself and log the code. The
• Corrective Action(s)- Illuminate MIL and/or sound audible fault should be configured to never forget and will not self-
warning or illuminate secondary warning lamp, disable erase and will not clear until a technician performs diagnostics
adaptive fueling correction for remainder of key cycle, rec- and manually clears the code. This fault should be configured
ommend power derate 2 and low rev limit to reduce possi- to set a power derate 2 and low rev limit to reduce possible
ble engine damage and/or overspeed condition. engine damage and reduce possibility of an overspeed condi-
• Non-emissions related fault. tion. A fault of flash memory can occur for any calibration vari-
able set and thus could cause undesirable operation.
3-142 – JLG Lift – 3121290

3121290 – JLG Lift – 3-143

DTC 604- Microprocessor Failure - RAM
• Engine Control Module- Random Access Memory. Random Access Memory is located in the microprocessor and
can be read or written at any time. Data stored in RAM include
DTCs (when fault configuration is set to “Battery Power
• Fault Condition- Internal ECM microprocessor memory Retained"), adaptive fuel learn tables, octane adaptation table,
access failure. misfire adaptation tables, and closed loop fuel multipliers. The
• Corrective Action(s)- Illuminate MIL and/or sound audible ECM has checks that must be satisfied each time an instruction
warning or illuminate secondary warning lamp, disable is executed.
adaptive fueling correction for remainder of key cycle, rec- This fault sets if the ECM detects a problem accessing or writ-
ommend power derate 2 and low rev limit to reduce possi- ing information to RAM and should be configured to set a
ble engine damage and/or overspeed condition. power derate 2 and low rev limit to reduce possible engine
• Non-emissions related fault damage and reduce possibility of an overspeed condition. If
this fault sets, the ECM will reset itself and log the code. This
fault should be erased by a technician after diagnostics are
performed. The fault should be configured to never forget and
will not self-erase.
3-144 – JLG Lift – 3121290

3121290 – JLG Lift – 3-145

DTC 606- Microprocessor Failure - COP
• Engine Control Module. The ECM has checks that must be satisfied each time an
within the microprocessor that will cause this fault.
• Fault Condition- Internal microprocessor error.
If this fault sets, the ECM will reset itself and log the code. The
• Corrective Action(s) - Illuminate MIL and/or sound audible fault should be configured to never forget and will not self-
warning or illuminate secondary warning lamp, disable erase and will not clear until a technician performs diagnostics
adaptive fueling correction for remainder of key cycle, rec- and manually clears the code. This fault should be configured
ommend power derate 2 and low rev limit to reduce possi- to set a power derate 2 and low rev limit to reduce possible
ble engine damage and/or overspeed condition. engine damage and reduce possibility of an overspeed condi-
• Non-emissions related fault. tion.
3-146 – JLG Lift – 3121290

3121290 – JLG Lift – 3-147

DTC 642- 5 Volt External Low Voltage

+ 1
+
W
B
D
tr
o
-M -2
W
B
D d
ri
-B
H
e
g
1
S
P
T 6
xt1
e
_
V
5
+
R
E
S
P
T C
D
5
+
s=
V
ria
e
lS 2
1
i
rxm
te 3
-1
R
E
S
P
T M
C
E
rtn
_
V
5
9
1
le
E
tu
c
A h
T
c
ln
ia
e
/S
rw
to
it
s
o
P k
c
a
b
d
e
F
n
io
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Engine Control Module. Diagnostic Aids

• Check Condition- Key on. • Measure ECM 5-volt output while cycling key on with
• Fault Condition- ECM 5-volt output is below the acceptable engine stopped. Verify output is lower than fault thresh-
limit. olds configured in diagnostic calibration.
• Corrective Action(s)- Illuminate MIL and/or sound audible • Inspect 5-Volt output circuit in wire harness and look for
warning or illuminate secondary warning lamp. shorts to ground or other harness circuits.
• Non-emissions related fault. • Disconnect each device powered by the ECM 5-volt output
one-at-a-time. Powered devices may include throttle actu-
The ECM supplies 5-volt power to sensors, switches, and actuator, smart sensors, smart actuators, etc. After disconnect-
ators external to the ECM. By supplying the power to these ing device, observe system fault and determine if fault has
devices, the ECM can accurately measure their output relative cleared. If fault clears, troubleshoot disconnected device
to its own ground reference. The ECM can also control when for failures.
the devices are active and put the devices in a low or no power
state based on the current operating condition of the engine • With all 5-volt powered devices disconnected, look for a
or vehicle. change in fault state and measure ECM 5-volt output. Verify
it is within acceptable limits.
If this fault sets, something other than the ECM is drawing ECM
5-volt power output below an acceptable threshold. This may
be due to a short in wire harness, malfunctioning device, or
ECM power output circuitry failure.
3-148 – JLG Lift – 3121290

DTC 643- 5 Volt External High Voltage

+ 1
W
B
D +
tr
o
-M 2
W
B
D rid
-B
H
e
g
1
S
P
T 6
1
_
V
5 xte
E
S
P
T R
D
5
+
s=
V C
a
ri
e
lS 2
1
te
i
rxm 3
1
E
S
P
T M
C
E
-
R
rtn
_
V
5
9
1
h
iT
n
le
E
/S
rw
o
a
tu
c
A lto
ria
e
d
e
F
itn
s
o
P b
k
c
a
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Engine Control Module. Diagnostic Aids

• Check Condition- Key on. • Measure 5-volt ECM output while cycling key on and
• Fault Condition- ECM 5-volt output is above the acceptable engine stopped. Verify output is lower than fault thresh-
limit. olds configured in diagnostic calibration.
• Corrective Action(s)- Illuminate MIL and/or sound audible • Inspect 5-Volt output circuit in wire harness and look for
warning or illuminate secondary warning lamp. shorts to ground or other harness circuits.
• Non-emissions related fault. • Disconnect each device powered by the ECM 5-volt output
one-at-a-time. Powered devices may include the throttle
The ECM supplies 5-volt power to sensors, switches, and actu- actuator, smart sensors, smart actuators, etc. After discon-
ators external to the ECM. By supplying the power to these necting device, observe system fault and determine if fault
devices, the ECM can accurately measure their output relative has cleared. If fault clears, troubleshoot disconnected
to its own ground reference. The ECM can also control when device for failures.
devices are active and put devices in a low or no power state
based on current operating condition of engine or vehicle. • With all 5-volt powered devices disconnected, look for a
change in fault state, measure the ECM 5-volt output and
If this fault sets, something other than the ECM is drawing the verify it is within acceptable limits.
5-volt power output of the ECM above an acceptable thresh-
old. This may be due to a wire harness short, device malfunc-
tion, or ECM power output circuitry failure.
3121290 – JLG Lift – 3-149

DTC 1612- Microprocessor Failure - RTI 1
within the microprocessor that will cause this fault. The ECM
• Fault Condition- Internal microprocessor error. will reset itself in the event this fault is set, and the MIL will be
• MIL- On until code is cleared by technician. on until the code is cleared. This fault should be erased after
diagnosis by removing battery power. It will not self-erase.
• Adaptive- Disabled for the remainder of the key-on cycle.
• During this active fault, Power Derate (level 2) is enforced
• Closed Loop- Enabled. and maximum throttle position is 20%. This is enforced
• Power Derate (level 2 until fault is cleared manually). until fault is manually cleared.
3-150 – JLG Lift – 3121290

• Engine Control Module The ECM has checks that must be satisfied each time an
• Check Condition- Key on
• Fault Condition- Internal microprocessor error will reset itself in the event this fault is set, and the MIL will be
• MIL- On until code is cleared by technician on until the code is cleared. This fault should be erased after
• Adaptive- Disabled for the remainder of the key-on cycle
During this active fault, Power Derate (level 2) will be enforced.
• Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%.
• Power Derate (level 2 until fault is cleared manually) This is enforced until the fault is manually cleared.
3121290 – JLG Lift – 3-151

SFC 555- RTI 2 Loss
Key On - Engine Running

System Data Mode
Check all power and

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

with engine idling?
Yes Replace ECM with known
Are all circuits ok?
good part and retest
No
No
Fault is intermittent
Repair wiring to
ECM and retest
3-152 – JLG Lift – 3121290

instruction is executed. Several different things happen within
the microprocessor that causes this fault. The ECM will reset
• Fault Condition- Internal microprocessor error itself in the event this fault is set, and MIL will be on until the
• MIL- On until code is cleared by technician code is cleared. This fault should be erased after diagnosis by
removing battery power. It will not self-erase.
During this active fault, Power Derate (level 2) is enforced and
• Closed Loop- Enabled maximum throttle position is 20%. This is enforced until the
• Power Derate (level 2 until fault is cleared manually) fault is manually cleared.
3121290 – JLG Lift – 3-153

SFC 556- RTI 3 Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 556 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3-154 – JLG Lift – 3121290

DTC 1615- Microprocessor Failure - A/D
• Fault Condition- Internal microprocessor error. will reset itself in the event this fault is set, and the MIL will be
• MIL- On until code is cleared by technician. on until the code is cleared. This fault should be erased after
• Adaptive- Disabled for the remainder of the key-on cycle.
• Closed Loop- Enabled. When this is enforced, maximum throttle position will be 20%.
• Power Derate (level 2 until fault is cleared manually). This is enforced until the fault is manually cleared.
3121290 – JLG Lift – 3-155

SFC 513- A/D Loss

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 513 reset

with engine idling?
Yes
Replace ECM with known
No
No
Repair wiring to
ECM and retest
3-156 – JLG Lift – 3121290

DTC 1616- Microprocessor Failure - interrupt
• Fault Condition- Internal microprocessor error will reset itself in the event this fault is set, and the MIL will be
• MIL- On until code is cleared by technician on until the code is cleared. This fault should be erased after
• Closed Loop- Enabled When this is enforced, maximum throttle position will be 20%.
• Power Derate (level 2 until fault is cleared manually) This is enforced until fault is manually cleared.
3121290 – JLG Lift – 3-157

SFC 512- Invalid Interrupt

System Data Mode
Check all power and

Clear System Fault
Yes
Does SFC 512 reset

with engine idling?
No
No
Repair wiring to
ECM and retest
3-158 – JLG Lift – 3121290

DTC 1625- CAN J1939 Shutdown Request
• Controller Area Network Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running • ECM has shutdown engine upon command by an external
• Fault Condition- ECM has received shutdown message controller. This is requested and expected behavior.
from another CAN device and is shutdown on request.
• Corrective Action(s)- Illuminate MIL, sound audible warn-
ing or illuminate secondary warning lamp
In some situations, external controllers may send a request to
the ECM to shutdown engine operation and stop the engine.
This request may be sent in response to a safety related condi-
tion in the vehicle.
This fault sets if the ECM receives a J1939 shutdown request via
the CAN interface. This is the expected behavior.
3121290 – JLG Lift – 3-159

DTC 1626- CAN J1939 Transmit (Tx) Fault
• Controller Area Network. Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running. • Verify all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver transmit error grounded
counts greater than the limit defined in the diagnostic cali- • Verify the CAN network is properly terminated
bration (must be < 125 failures).
• Check CAN wire routing with respect to noise sources (igni-
• Corrective Action(s)- Illuminate MIL, sound audible warn- tion coils, spark plug coil wires, etc.) and shield if necessary
ing or illuminate secondary warning lamp.
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital data.
This fault will set if CAN communication is enabled and the
ECM transceiver broadcasts a number of packets (as defined in
the diagnostic calibration, must be set to less than 125 fail-
ures) to the network that are not received.
3-160 – JLG Lift – 3121290

DTC 1627- CAN J1939 Receive (Rx) Fault
• Controller Area Network. Diagnostic Aids

• Check Condition- Key On, Engine Off and/or Running. • Verify all CAN devices are powered and are properly
• Fault Condition- ECM CAN transceiver receive error counts grounded
greater than the limit defined in the diagnostic calibration • Verify CAN network is properly terminated
(must be < 125 failures).
• Corrective Action(s)- Illuminate MIL, sound audible warn- tion coils, spark plug coil wires, etc.) and shield if necessary
ing or illuminate secondary warning lamp.
• Check CAN (+) and (-) wires for short circuits
The Controller Area Network (CAN) is a serial communication
network used to transmit and receive data between intelligent
devices. Systems that utilize CAN communication include
smart actuators, smart sensors, dash panels and gauges, and
other microcomputers. Each smart sensor, actuator, or control-
ler incorporates a CAN transceiver that interprets logic level
signals on the network and translates the information into dig-
ital data.
This fault will set if CAN communication is enabled and the
ECM transceiver is expecting to see network traffic and either
does not see traffic (as defined in the diagnostic calibration,
must be set to less than 125 failures).
3121290 – JLG Lift – 3-161

DTC 1628- CAN Address Conflict Failure
• CAN device(s). The Controller Area Network serves as a communication portal

between intelligent devices. These devices may be, but are not
• Check Condition- Key On, Engine on.
limited to other engine ECMs (slave), diagnostic tools, “smart”
• Fault Condition- two or more devices on the network that gauges, “smart” sensors, powertrain control units, vehicle con-
contain the same SA. trollers, actuators, etc. The network permits several devices to
• Corrective Action(s)- Sound audible warning or illuminate communicate with each other receiving and broadcasting
secondary warning lamp. commands as programmed. This type of network allows
devices to be added to an entire system through only two con-
• Non-emissions related fault. ductors and permits all other devices to broadcast and receive
commands to and from the device when properly com-
manded.
This fault indicates there are two (2) or more devices on the
network that use the same source address.
3-162 – JLG Lift – 3121290

3121290 – JLG Lift – 3-163

DTC 1629- J1939 TSC1 Message Receipt Loss
• Controller Area Network. DIAGNOSTIC AIDS

• Check Condition- Key On, Engine Running.
• Verify CAN device generating the TSC1 message is pow-
• Fault Condition- ECM is expecting to receive J1939 TSC1 ered and properly grounded.
messages and has not received a message for more than n
• Verify CAN network is properly terminated.
seconds (as defined in the diagnostic calibration).
tion coils, spark plug coil wires, etc.) and shield if necessary.
ing or illuminate secondary warning lamp. Govern engine
speed at a forced idle.
• Non-emissions related fault. • Check CAN (+) and (-) wires for short circuits.
J1939 TSC1 may be used to send a commanded (or desired)
engine speed to the ECM. If configured, the ECM governs
engine speed to commanded speed if possible. When operat-
ing in this mode, the ECM expects to receive TSC1 messages
on a regular interval. When this message is not received, the
ECM must operate the engine at a default idle speed until
commanded to do otherwise.
This fault sets if CAN communication is enabled, the engine is
running, and no TSC1 messages are received over the CAN bus
for more than n seconds (as determined by diagnostic calibra-
tion).
3-164 – JLG Lift – 3121290

DTC 1652- TPS1 Loss of Communications

+ 1
W
B
D +
tr
o
-M 2
W
B
D rid
-B
H
e
g
1
S
P
T _
V
5
6
1 xte
E
S
P
T R
D
5
+
s=
V C
a
ri
e
lS 2
1
te
i
rxm 3
1
E
S
P
T M
C
E
-
R
rtn
_
V
5
9
1
h
iT
n
le
E
/S
rw
o
a
tu
c
A lto
ria
e
d
e
F
itn
s
o
P b
k
c
a
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Actuator (with serial/digital position feedback). Diagnostic Aids

• Check Condition- Key On, Engine Running and/or Stopped. • Verify throttle actuator 5V supply voltage is present at the
actuator.
• Fault Condition- ECM is expecting to receive throttle posi-
tion information from the throttle actuator and is not. • Check for a all four TPS feedback wires for short circuits.
• Corrective Action(s)- Illuminate MIL, sound audible warn- • Check TPS SER+ and TPS SER- wire routing with respect to
ing or illuminate secondary warning lamp. Shutdown noise sources (ignition coils, spark plug coil wires, etc.) and
engine. shield if necessary.
For a throttle actuator with serial/digital position feedback,
the ECM receives a constant data stream from the throttle
actuator. If communication is absent or interrupted, the ECM
can no longer control the throttle position.
This fault will set if the key is on, the throttle actuator is receiv-
ing power, and the ECM is not receiving digital information
from the actuator.
3121290 – JLG Lift – 3-165

DTC 2111- Unable to Reach Lower TPS

+ 1
+
W
B
D
tr
o
-M -2
W
B
D d
ri
-B
H
e
g
1
S
P
T 6
xt1
e
_
V
5
+
R
E
S
P
T C
D
5
+
s=
V
ria
e
lS 2
1
i
rxm
te 3
-1
R
E
S
P
T M
C
E
rtn
_
V
5
9
1
le
E
tu
c
A h
T
c
ln
ia
e
/S
rw
to
it
s
o
P k
c
a
b
d
e
F
n
io
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor The Throttle Position Sensor uses either 1) a variable resistor
and voltage divider circuit or 2) a non-contact hall-effect sen-
• Check Condition-Cranking or Running
sor to determine throttle actuator position, and is located
• Fault Condition-Throttle command is 20% less than throttle within the throttle actuator.
position for 200ms or longer
There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault log position feedback and 2) actuator with digital position
• Engine Shut Down feedback. The first type, with analog position feedback, pro-
vides an analog return signal between 0 and 5 volts that is pro-
On a diesel engine, an actuator controls a fuel injection pump, portional to the throttle actuator position. The second type,
directly affecting the fueling level into the cylinders. This may with digital position feedback, provides a serial data signal to
be by direct manipulation of the fuel injection pump rack or the ECM with the throttle actuator position voltage level
by manipulation of the mechanical governor control level or encoded in the data stream.
“throttle arm.” In the DGC ECM and EDIS, references to the
throttle and throttle position sensor refer to these fuel injec- Fault sets if throttle command is 20% less than actual throttle
tion pump control actuators and their position feedback sen- position. During active fault, MIL light is on and engine shuts
sors. When the fuel injection pump is electronically controlled down.
it can control idle stability and limit engine speed based on
3-166 – JLG Lift – 3121290

3121290 – JLG Lift – 3-167

DTC 2112- Unable to Reach Higher TPS

DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Position Sensor. The Throttle Position Sensor uses either 1) a variable resistor
and voltage divider circuit or 2) a non-contact hall-effect sen-
• Check Condition-Cranking or Running.
sor to determine throttle actuator position, and is located
• Fault Condition-Throttle command is 20% more than within the throttle actuator.
actual throttle position.
There are two types of throttle actuators, 1) actuator with ana-
• MIL-On during active fault. log position feedback and 2) actuator with digital position
• Engine Shut Down. feedback. The first type, with analog position feedback, pro-
vides an analog return signal between 0 and 5 volts that is pro-
On a diesel engine, an actuator controls a fuel injection pump, portional to the throttle actuator position. The second type,
directly affecting the fueling level into the cylinders. This may with digital position feedback, provides a serial data signal to
be by direct manipulation of the fuel injection pump rack or the ECM with the throttle actuator position voltage level
by manipulation of the mechanical governor control level or encoded in the data stream.
“throttle arm.” In the DGC ECM and EDIS, references to throttle
and throttle position sensor refer to these fuel injection pump This fault sets if throttle command is 20% or more than actual
control actuators and their position feedback sensors. When throttle position. During this active fault the MIL light is on and
the fuel injection pump is electronically controlled it can con- engine will shut down.
trol idle stability and limit engine speed based on operating
conditions.
3-168 – JLG Lift – 3121290

DTC 9999- Throttle Actuator Failsafe Spring Failure

+ 1
W
B
D +
tr
o
-M 2
W
B
D rid
-B
H
e
g
1
S
P
T _
V
5
6
1 xte
E
S
P
T R
D
5
+
s=
V C
a
ri
e
lS 2
1
te
i
rxm 3
1
E
S
P
T M
C
E
-
R
rtn
_
V
5
9
1
h
iT
n
le
E
/S
rw
o
a
tu
c
A lto
ria
e
d
e
F
itn
s
o
P b
k
c
a
DBW+
+ 1
Motor H-Bridge
DBW-
- 2
TPS1 5V_ext
16
Vs=+5 VDC
TPS SER +
12
Serial
xmitter TPS SER -
13
ECM
5V_rtn
19
Electronic Throttle
Actuator w/Serial
Position Feedback
• Throttle Actuator Diagnostic Aids

• Check Condition- Key Off, Engine Stopped • Disconnect throttle actuator from wire harness. Remove
• Fault Condition- When key is off (or actuator is unpow- throttle actuator from engine and manually move it. Verify
ered), the ECM is expecting failsafe spring in actuator to internal spring forces throttle back to near 0% position.
return throttle position to near 0%. If throttle does not • Inspect throttle arm or fuel rack on fuel pump. Verify it is
reach this position when actuator is powered, a fault is not stuck.
generated.
ing or illuminate secondary warning lamp. Govern engine
speed to a forced idle speed.
Throttle actuator has a return spring that causes throttle to
move to a near 0% position when powered off. This causes
engine shutdown following a key off. If ECM detects throttle
position to be above x volts when key is off (as determined by
diagnostic calibration), it will power up the actuator and
attempt to drive it to a zero position. This should ensure
engine is stopped.
Fault sets if throttle does not return to a near 0% position with
key OFF.
3121290 – JLG Lift – 3-169

DTC to SPN/FMI Table
FAULT DTC SET

DESCRIPTION
INDEX SPN FMI
2 DTC 118: ECT voltage high 110 3
3 DTC 117: ECT voltage low 110 4
4 DTC 116: ECT higher than expected stage 1 110 15
9 DTC 563: Vbat voltage high 168 15
10 DTC 562: Vbat voltage low 168 17
11 DTC 643: Sensor supply voltage 1 high 1079 3
12 DTC 642: Sensor supply voltage 1 low 1079 4
13 DTC 123: TPS1 voltage high 51 3
14 DTC 122: TPS1 voltage low 51 4
29 DTC 524: Oil pressure low 100 1
86 DTC 217: ECT higher than expected stage 2 110 0
89 DTC 2112: Unable to reach higher TPS 51 7
90 DTC 2111: Unable to reach lower TPS 51 7
96 DTC 336: CRANK input signal noise 636 2
98 DTC 606: Microprocessor failure - COP 629 31
99 DTC 1612: Microprocessor failure - RTI 1 629 31
102 DTC 1615: Microprocessor failure - A/D 629 31
103 DTC 1616: Microprocessor failure - Interrupt 629 31
104 DTC 601: Microprocessor failure - FLASH 628 13
105 DTC 604: Microprocessor failure - RAM 630 12
106 DTC 219: RPM higher than max allowed govern speed 515 15
144 DTC 337: Crank signal loss 636 4
145 DTC 1625: J1939 shutdown request 1384 31
146 DTC 1626: CAN-J1939 Tx fault 639 12
147 DTC 1627: CAN-J1939 Rx fault 639 12
175 DTC 1628: J1939 CAN address / engine-number conflict 639 13
188 DTC 521: Oil pressure high 100 0
189 DTC 1652: TPS1 loss of communications 51 9
190 DTC 1629: CAN-J1939 TSC1 Parameter Rx Fault 695 9
191 DTC 1113: Unable to achieve lower RPM 515 31
192 DTC 9999: TPS1 failsafe spring failure 51 7
3-170 – JLG Lift – 3121290

OUTLET PIPE MUST BE CENTERED WITHIN 1/4" (6.35 MM) MINIMUM CLEARANCE TO A
EXHAUST VENTURI AROUND VENTURI’S PERIMETER. IF EXHAUST PIPE TOUCHES VEN-
TURI, IT WILL MELT THE HOOD. IF EXHAUST PIPE IS NOT CENTERED, ADJUST MUFFLER
OR OUTLET AS NEEDED FOR NECESSARY CLEARANCE.
D C
A. Exhaust Venturi
B. 1/4" (6.35 mm) minimum clearance all around.
C. 3/4" (19.05 mm) minimum engagement
D. Exhaust Pipe Outlet
Figure 3-79. Exhaust Venturi Adjustment
3121290 – JLG Lift – 3-171

A
Counterweight installed on turntable.
Counterweight
A
B,C
Counterweight mounting bolts (underside of turntable shown).
A. Part Number\Actual Weight Stamping
B. Apply Loctite #271 to Bolt Threads and to Threads in Counterweight.
C. Torque to 285 ft-lb (386 Nm).
Figure 3-80. Counterweight Installation
3-172 – JLG Lift – 3121290

SECTION 4. BOOM & PLATFORM

4.1 BOOM MAINTENANCE
CAP HYDRAULIC LINES AND PORTS IMMEDIATELY AFTER DISCONNECTING
LINES TO PREVENT ENTRY OF CONTAMINANTS INTO SYSTEM.
DO NOT USE A LIFTING DEVICE TO LIFT BOOMS UNLESS
HOLDING VALVES HAVE BEEN REMOVED FIRST. FAILURE b. Tag and disconnect boom to control valve hydraulic
TO DO SO WILL RESULT IN SEVERE DAMAGE TO BOOM. lines. Use a suitable container to retain residual
hydraulic fluid. Cap all hydraulic lines and ports.
Remove Boom Assembly c. Support boom weight along entire length with
appropriately rated lifting equipment.
1. Remove platform and platform support as follows:
d. Remove bolts and keeper pins from lift cylinder
a. Disconnect control console electrical cable. pivot pin. Using a suitable brass drift and hammer,
b. Tag and disconnect rotate cylinder hydraulic lines. remove pivot pin from lower boom.
Use a suitable container to retain residual hydraulic NOTE: To gain access for removal of pivot pins, it may be neces-
fluid. Cap hydraulic lines and ports. sary to remove ground control box, hydraulic and fuel
c. Use an appropriately rated overhead crane or suit- tanks, and counterweight.
able lifting device and nylon support straps to sup-
port the platform/support. e. Remove retaining hardware from level link pivot
pin. Using a suitable brass drift and hammer,
NOTE: Properly support cylinder when removing retaining pin
remove pin from level link and turntable.
from rod end of level cylinder.
f. Remove hardware securing lower boom pivot pin.
d. Remove bolts and keeper pins from retaining pins. Using a suitable brass drift and hammer, remove pin
Remove retaining pins from platform support using from the turntable.
suitable brass drift and hammer. g. Using all applicable safety precautions, carefully lift
boom assembly clear of turntable and lower to
2. Remove boom from turntable as follows:
ground or suitable supported work surface.
a. Disconnect wiring harness from ground control har-
ness connector.
Figure 4-1. Location of Components - Boom Removal
3121290 – JLG Lift – 4-1

Main Boom Disassembly Inspection

1. Loosen jam nuts on aft end of fly boom wear pad adjust- 1. Inspect all boom pivot pins for wear, scoring or other
ment and loosen adjustments. damage, and tapering or ovality. Replace pins as
needed.
2. Using a portable power source, attach hose to telescope
cylinder port block. Using all applicable safety precau- 2. Inspect lift cylinder pins for wear, scoring or other dam-
tions, activate hydraulic system and extend cylinder to age, and for tapering or ovality. Ensure pin surfaces are
gain access to cylinder rod retaining pin. Shut down protected prior to installation. Replace pins as needed.
hydraulic system.
3. Inspect telescope cylinder rod attach pin for wear, scor-
3. Carefully disconnect hydraulic hose from retract port of ing or other damage. Replace pin as needed.
cylinder. There will be initial weeping of hydraulic fluid
4. Inspect inner diameter of boom pivot bushings for scor-
which can be caught in a suitable container. After initial
ing, distortion, wear or other damage. Replace bushings
discharge, there should be no further leakage from the
as needed.
retract port.
5. Inspect wear pads for wear.
4. Remove hardware securing telescope cylinder to the fly
boom section, then remove pin from fly. 6. Inspect all threaded components for damage such as
stretching, thread deformation, or twisting. Replace as
5. Remove hardware securing telescope cylinder to the
needed.
base boom section.
7. Inspect structural units of boom assembly for bending,
cracking, separation of welds, or other damage. Replace
WHEN REMOVING TELESCOPE C YLINDER FROM BOOM SECTIONS. CARE boom sections as needed.
SHOULD BE TAKEN NOT TO LEAVE CYLINDER REST ON POWERTRACK WHICH
COULD CAUSE DAMAGE TO POWERTRACK.
6. Using a suitable lifting device, remove telescope cylin-

der from boom sections.
7. Using a piece of tape, mark length of hoses and wires
from front of fly boom and bottom of base boom for
reassembly.
8. Remove hardware securing front wear pads on base
boom section. Remove wear pads.
9. Remove hardware securing powertrack to aft end of fly
boom section.
10. Using a suitable lifting device, remove fly boom from
boom section.
11. Remove hydraulic lines and electrical cables from pow-
ertrack.
12. Remove hardware securing powertrack to base boom
section. Remove powertrack.
4-2 – JLG Lift – 3121290

Main Boom Assembly Install Boom Assembly

1. Install power track to the attach point on the base boom 1. Using suitable lifting equipment, position boom assem-
section. Secure power track with the attaching hard- bly on turntable so boom pivot holes in boom and turn-
ware. table are aligned.
2. Install hydraulic lines and electrical cables in power 2. Install boom pivot pin, ensuring location of hole in pivot
track. pin aligns with attach point on upright.
3. Install wear pads to the aft end of the fly section. 3. Using all applicable safety precautions, operate lifting
equipment to position boom lift cylinder and level link
4. Using suitable lifting equipment, slide fly section into
so holes in cylinder rod end and level link are aligned
the base section until power track attach point aligns
with one in turntable. Insert cylinder pins.
with holes in side of base section.
4. If necessary, gently tap pins into position with a soft
5. Attach power track to aft end of fly boom section.
headed mallet. Ensure attach holes in pins are aligned
Secure power track with attaching hardware.
with attach holes in boom structure. Secure with hard-
6. Using suitable lifting equipment, slide fly boom section ware.
out to gain access to telescope cylinder attach pin hole.
5. Connect all hoses and wiring.
7. Measure distance between telescope cylinder port
6. Install platform to boom assembly.
block attach point on base boom section and attach
point on fly boom section. 7. Connect hoses and wiring at platform control station.
8. Connect a suitable auxiliary hydraulic power source to 8. Using all safety precautions, operate machine systems
telescope cylinder port block. and extend and retract boom for four or five cycles.
9. Extend telescope cylinder the distance of the two attach 9. Shut down machine systems and check for leaks.
points.
10. Secure sling and lifting device at telescope cylinder’s
approximate center of gravity. Lift cylinder to aft end of
boom assembly.
WHEN INSERTING TELESCOPE CYLINDER INTO BOOM, CARE MUST BE TAKEN

NOT TO DAMAGE POWER TRACK ASSEMBLY.
11. Slowly slide telescope cylinder into boom assembly

Align rod end with attach point in fly section. Insert pin
and secure with retaining ring.
12. Align bolt holes at aft end of base boom section with
telescope cylinder port block. Secure telescope cylinder
with hardware.
13. Install wear pads at end of base boom section. Using
shims, adjust adjustable wear pads to zero clearance.
Adjust pads alternately side to side, so fly boom section
is centered in base boom section.
14. Retract boom section fully. Using shims, adjust wear
pads at aft end of boom section to zero clearance.
Adjust pads alternately side to side, so fly boom section
is centered in base boom section.
15. Disconnect auxiliary power source from telescope cylin-
der.
3121290 – JLG Lift – 4-3


1. Upper Boom
2. Tower Link
3. Upper Upright
4A. Upper Lift Cylinder Master
4B. Upper Lift Cylinder Slave
5. Upper Tower Boom
6. Tower Link
7. Boom
8. Lower Lift Cylinder
9. Lower Upright
Figure 4-2. Boom Assembly
4-4 – JLG Lift – 3121290


!

!

Figure 4-2. Boom Limit Switches
3121290 – JLG Lift – 4-5

Wear Pads Wear Pads
Telescope Cylinder Rod End
Wear Pads
Figure 4-3. Main Boom
4-6 – JLG Lift – 3121290

4.2 ROTARY ACTUATOR Required Tools

Basic tools required for assembly and disassembly of the actu-
Theory of Operation ator and their intended functions are as follows:
The L20 Series rotary actuator converts linear piston motion to
shaft rotation. Each actuator is composed of a housing with
integrated gear teeth (01) and only two moving parts: the cen-
tral 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 inside
diameter of piston. Outside diameter of piston carries a sec-
ond set of splines, of opposite hand, which engage with
matching splines in the housing.
As hydraulic pressure is applied, piston is displaced axially in
the housing - similar to a hydraulic cylinder - while splines
cause shaft to rotate. When control valve is closed, oil is
trapped inside actuator, preventing piston movement and
locking shaft in position.
1. Flashlight - helps examine timing marks, component

failure, and overall condition.
2. Felt Marker - match mark timing marks and outline trou-
bled 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 - end cap removal 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 a customized flat-head screwdriver. To make this
Bars indicate starting positions As fluid pressure is applied, pis- tool, heat flat end with a torch and bend to a slight radius in a
of piston and shaft. Arrows indi- ton is displaced axially while vice. Round off sharp edges with a grinder.
cate rotation direction. Housing helical gearing causes piston
with integral ring gear remains and shaft to rotate simultane-
stationary. ously.
Shaft glands, bearings, and end Double helix design com-
cap are not shown for clarity. pounds rotation: shaft rotation is
about twice of piston.
Shaft is supported radially by large upper radial bearing and

lower radial bearing. Axially, shaft is separated from housing
by upper and lower thrust washers. End cap is adjusted for
axial clearance and locked in position by set screws or pins.
3121290 – JLG Lift – 4-7


1. Housing 4. End Cap 9. Cap Seal 12. Piston Seal 16. Thrust Washer
2. Shaft 5. Exclusion Seal 10. Cap Ring 13. Bearing Packing 17. Counterbalance Valve
3. Piston Sleeve 8. Bolt 11. Rod Seal 14. Cap Bearing 53. Lock Pin
15. Shaft Bearing 54. Countersunk Screw
Figure 4-4. Rotary Actuator - Exploded View
4-8 – JLG Lift – 3121290

Disassembly 4. Install end cap (4) removal tools provided with Helac
seal kit.
1. Remove capscrews (54) over end cap lock pins (53).
2. Using a 1/8" (3.18mm) drill bit, drill hole in center of each 5. Using a metal bar or similar, unscrew end cap (4) by
lock pin to a depth of approximately 3/16" (4.76mm). turning it counter clockwise.
3. Remove lock pins using an ”Easy Out” (#2 shown).

6. Remove end cap (4) and set aside.
If pin will not come out with ”Easy Out”, use 5/16" drill bit
to a depth of 1/2" (12.7mm) and drill out entire pin.
3121290 – JLG Lift – 4-9

7. Actuator has timing marks for proper engagement. 9. Remove shaft (2). It may be necessary to strike threaded
end of shaft with a rubber mallet.
10. Mark housing (1) ring gear in relation to piston O.D. gear
before removing piston sleeve (3). There should be tim-
ing marks on housing ring gear (1), piston (3) and shaft
(2).
8. Use a felt marker to clearly indicate timing marks

between shaft and piston before removing shaft, (2).
This simplifies timing during assembly.
11. Use a rubber mallet and plastic mandrel to prevent dam-

age when removing piston sleeve (3).
4-10 – JLG Lift – 3121290

12. Mark piston and housing with a marker where piston 15. To remove main pressure seals (13), it is easiest to cut
gear teeth come out of engagement with housing gear them using a sharp razor blade being careful not to
teeth as shown. damage the seal groove.
13. Remove O-ring (9) and backup ring (10) from end cap (4)
16. Remove thrust washers (16), from end cap (4) and shaft
and set aside.
(2).
14. Remove wear guides (14) from end cap (4) and shaft (2). 17. Remove exclusion seal (5) from groove in end cap (4)
and shaft (2).
3121290 – JLG Lift – 4-11

18. Remove piston O.D. seal (12). Inspection

1. Clean parts in a solvent tank and dry with compressed air
before inspecting. Inspect seal grooves, bearing grooves,
thrust surfaces, rod surface, housing bore, and gear teeth
for surface finish abnormalities.
19. Remove piston I.D. seal (11).
2. Inspect thrust washers (16) for rough or worn edges and

surfaces. Measure thickness to make sure it is not less
than 0.092" (2.34 mm).
4-12 – JLG Lift – 3121290

3. Inspect wear guide condition. Measure thickness not Assembly

less than 0.123" (3.12 mm).
1. Gather all components and tools to one location.
2. Install thrust washer (16) on shaft (2) and end cap (4).
3. Install exclusion seal (5) in groove on shaft (2) and end cap
(4) around outside edge of thrust washer (16).
3121290 – JLG Lift – 4-13

4. Use seal tool in a circular motion to install main pressure 7. Install outer T-seal (12) by stretching it around groove in
seal (13) on shaft (2) and end cap (4). a circular motion. Each T-seal has 2 back-up rings (see
drawing for orientation).
5. Install wear guide (14) on end cap (4) and shaft (2).
8. Beginning with inner seal (11), insert one end of backup
ring in lower groove and feed the rest in using a circular
motion. Make sure wedged ends overlap correctly.
9. Repeat for outer seal (12).
6. Install inner T-seal (11) in piston (3) using a circular

motion.
4-14 – JLG Lift – 3121290

10. Insert piston (3) in housing (1) until outer piston seal (12) 13. Look from opposite end of housing (1) to see if timing
is touching inside housing bore. marks line up. When they do, tap piston (3) in until gear
teeth mesh together. Tap piston into housing until it
bottoms out.
11. Looking from angle shown, rotate piston (3) until marks
on piston and housing (1) line up as shown.
14. Install shaft (2) into piston (3). Do not damage seals. Do
12. Using a rubber mallet, tap piston into housing to point not engage piston gear teeth yet.
where gear teeth meet.
3121290 – JLG Lift – 4-15

15. Looking from view shown, use existing timing marks to 17. Coat threads on end of shaft with anti-seize grease to
line up gear teeth on shaft (2) with gear teeth on inside prevent galling.
of piston (3). Now tap flange end of shaft with a rubber
mallet until gear teeth engage.
18. Install 0-ring (9) and back-up ring (10) in inner seal
groove on end cap (4).
16. Install 2 bolts in threaded holes in flange. Using a bar,
rotate shaft clockwise until wear guides are seated
inside housing bore.
4-16 – JLG Lift – 3121290

19. Thread end cap (4) on shaft (2) end. Make sure wear 21. Place lock pins (53) provided in Helac seal kit in holes
guide stays in place on end cap as it is threaded in hous- with dimple side up. Using a punch, tap lock pins to bot-
ing (1). tom of hole.
20. Tighten end cap (4) and align holes for lock pins. 22. Insert set screws (54) over lock pins. Tighten to 25 in-lb
(2.825 Nm).
3121290 – JLG Lift – 4-17

Installing Counterbalance Valve 3. Bolts that come with valve are grade 8 bolts. Install new
bolts with a new valve. Apply Loctite #242 to shank of
Refer to Figure 4-5., Rotator Counterbalance Valve.
three bolts during installation.
1. Clean actuator surface of contamination and foreign
4. Torque 1/4" bolts 110 to 120 in-lb (12.4 to 13.5 Nm).
debris including old Loctite.
Torque 5/16" bolts 140 in-lb (15.8 Nm).
2. Make sure new valve has O-rings in counterbores of
valve to seal it to actuator housing.
Figure 4-5. Rotator Counterbalance Valve
4-18 – JLG Lift – 3121290

NOTE: Retorque all bolts on rotator if any

rotator bolts are replaced.

A Torque to 50 ft-lb (68 Nm)

B Loctite #242
C Torque to 480 ft-lb (650 Nm)
D Check torque every 150 hours of operation
E Torque to 85 ft-lb (115 Nm)
Figure 4-6. Platform Support Torque Values
3121290 – JLG Lift – 4-19

4.3 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove screw from other side of
track. Remove bar/poly roller from powertrack.
Remove Link
NOTE: Hoses shown in powertrack are for example only. Actual
hose and cable arrangements are different.
1. Clamp bar and poly roller tightly so they do not spin

when removing screw. With a small ¼” ratchet and a T-
20 torx bit, remove 8-32 x 0.500 screw from one side.
4-20 – JLG Lift – 3121290

5. After grinding it may be necessary to use a center punch

with a hammer to remove rivet.
REPOSITION CABLES/HOSES AND KEEP COVERED DURING GRINDING TO PRE-
VENT DAMAGE. NOTE: It may be necessary to loosen fixed end brackets from
machine to move track section enough to disconnect links.
3. To remove a link, rivets holding links together must be
removed. Use a right-angle pneumatic die grinder with
a ¼” ball double cut bur attachment.
4. insert tool into rolled over end of rivet. Grind out middle
of rivet until rolled over part of rivet falls off. Repeat for
all rivets to be removed.
3121290 – JLG Lift – 4-21

6. Insert flat head screwdriver between links. Twist and pull 7. Remove link from other section of powertrack using
links apart. screwdriver.
4-22 – JLG Lift – 3121290

Install New Link 2. Spread half-shear (female) end of new link and slide cut-
out end of track section into it. Use a screwdriver if nec-
1. Squeeze cut-out end of new link into half-shear (female) essary.
end of track section.
3. After new link is installed round half-shears do not fit

properly in cut-outs.
3121290 – JLG Lift – 4-23

4. Pull moving end over track so new connection is posi- 6. Push pin through center hole then slide washer on pin.
tioned in curve of powertrack. Round half-shears will
rotate into cut-outs.
7. Install snap ring in groove on pin. Repeat pin installation

steps for all center holes with rivets removed.
5. Parts shown below connect new link to powertrack.
4-24 – JLG Lift – 3121290

NOTE: Make sure snap rings are seated in pin groove and closed 2. Pull up on other end of round bar and slide new poly
properly. roller on bar.
Correct Incorrect
1. Install new 8-32 x 0.500 self-threading torx head screw

in end of new aluminum round bar. Torque to 18-20 in-
lb (2-2.25 Nm).
3121290 – JLG Lift – 4-25

3. Install new 8-32 x 0.500 self threading screw on other Replace Fixed End Brackets
side. Torque to 18-20 in-lb (2-2.25 Nm).

VENT DAMAGE.
1. Remove rivets as shown in link removal instructions on

page 4-20.
NOTE: When tightening screws make sure screw head is seated

against link with no space in between link and underside of
screw head.
4-26 – JLG Lift – 3121290

2. Parts used: Bracket Center Pin and Center Pin Snap Ring. Replace Moving End Brackets
3. Take new bracket and install bracket center pin and

snap ring. Repeat on other bracket if replacing it.
VENT DAMAGE.
1. Remove existing pins and center rivet. Remove rivet as

shown in link removal instructions on page 4-20. Repeat
on other bracket if replacing it.
NOTE: When installing snap rings make sure they are seated in
pin groove and closed properly.
Correct Incorrect
3121290 – JLG Lift – 4-27

2. Install center pin with snap ring in new bracket. NOTE: When installing snap rings make sure they are seated in
pin groove and closed properly.
Correct Incorrect
4. Make sure both brackets rotate correctly.

3. Install radius pins and snap rings in original locations.
Repeat with other moving end if replacing it.
4-28 – JLG Lift – 3121290

SECTION 5. HYDRAULICS
5.1 O-RING LUBRICATION 2. Hold fitting over hydraulic oil container and brush an
even film of oil around entire O-ring in fitting. Make sure
All fittings with O-rings must be lubricated with hydraulic oil O-ring is completely saturated.
before assembly using one of the following four methods:
• Cup and Brush
• Dip
• Spray
• Brush-On
Cup and Brush

Tools needed:
• Small container for hydraulic oil

• Small paint brush
3. Turn over fitting repeat previous step to O-ring on other
side of fitting. Make sure entire O-ring is coated with
hydraulic oil.
1. Hold fitting in one hand and dip brush into container

with other hand. Remove excess hydraulic oil from
brush so an even film of oil is applied to O-ring.
3121290 – JLG Lift – 5-1

Dip Spray
NOTE: This method works best with Face Seal O-rings, but will This method requires a pump or trigger spray bottle.
work for all O-ring fitting types.
1. Fill spray bottle with hydraulic oil.
Tools needed: 2. Hold fitting over suitable catch can.
• Small leak proof container 3. Spray entire O-ring surface with medium coat of oil.
• Sponge cut to fit inside container
• Small amount of hydraulic oil to saturate sponge.
1. Place sponge inside container and add hydraulic oil to
sponge until fully saturated.
2. Dip fitting into sponge using firm pressure.
Brush-On
This method requires a sealed bottle brush.
1. Fill bottle with hydraulic oil.

2. Using slight pressure to body of spray bottle, invert bot-
3. After lifting fitting, a small droplet should form and drip tle so brush end faces down.
from bottom of fitting. This indicates an even coating of
oil. 3. Brush an even coat of hydraulic oil on entire O-ring.
NOTE: O-ring boss-type fittings require more pressure to immerse

more of fitting into saturated sponge. This also causes
more oil to be dispersed from sponge.
5-2 – JLG Lift – 3121290

5.2 HYDRAULIC CYLINDERS
1. Tower Lift 5. Slave (Platform Level)

2. Main Lift 6. Jib Lift
3. Master 7. Axle Lockout
4. Telescope 8. Steer
Figure 5-1. Hydraulic Cylinder Locations
3121290 – JLG Lift – 5-3

Tower Lift Cylinder 5. Mark cylinder head and barrel with a center punch for
realignment. Remove eight cylinder head cap screws.
DISASSEMBLY
Refer to Figure 5-5.
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

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

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

SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate hydraulic power source and extend cylinder.

Shut down and disconnect power source. Adequately Figure 5-3. Cylinder Head Removal
support cylinder rod, if applicable.
3. Remove cartridge-type counterbalance valve and fittings
from cylinder port block. Discard O-rings. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
4. Place cylinder barrel in a suitable holding fixture. Tap USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound. 6. Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.
7. Protect cylinder rod from damage and clamp in a vise or
holding fixture as close to piston as possible.
Figure 5-2. Cylinder Barrel Support
Figure 5-4. Cylinder Rod Support
5-4 – JLG Lift – 3121290

1. Locking Compound 6. Bushing 11. Ring Washer 16. Wear Ring 21. Seal
2. Locking Primer 7. Head 12. Socket Head Bolt 17. Backup Ring 22. Wiper
3. Not Used 8. Barrel 13. Tube Spacer 18. Backup Ring 23. T-Seal
4. Capscrew 9. Rod 14. Not Used 19. O-Ring 24. Cartridge Valve
5. Tapered Bushing 10. Piston 15. Wear Ring 20. O-Ring 25. O-Ring Plug
Figure 5-5. Tower Lift Cylinder
3121290 – JLG Lift – 5-5

8. Remove cap screws from tapered bushing. 7. Inspect threaded portion of piston for damage. Dress
threads as necessary.
9. Insert cap screw in threaded holes in outer piece of
tapered bushing. Progressively tighten cap screw(s) until 8. Inspect seal and O-ring grooves in piston for burrs and
bushing is loose on piston. sharp edges. Dress surfaces as necessary.
10. Remove bushing from piston. 9. Inspect cylinder head inside diameter for scoring or
other damage. Replace as necessary.
10. Inspect threaded portion of head for damage. Dress
11. Inspect seal and O-ring grooves in head for burrs and
sharp edges. Dress surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring or
other damage, ovality, and tapering. Replace as needed.
13. Inspect rod and barrel bearings for signs of excessive
wear or damage. Replace as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.
Figure 5-6. Tapered Bushing Removal c. Lubricate inside of the steel bushing with WD40
prior to bearing installation.
11. Screw piston counter-clockwise and remove from rod.
d. Using a correct size arbor, press bearing into steel
12. Remove and discard piston O-rings, seal rings, and bushing.
backup rings.
NOTE: Lubrication is not required with nickel plated pins and
13. Remove piston spacer and two wear rings from rod. bearings. Install pin in composite bushing dry.
14. Remove rod from holding fixture. Remove cylinder head
and ring washer. Discard O-rings, back-up rings, rod
seals, and wiper seals.
CLEANING AND INSPECTION
1. Clean all parts in approved cleaning solvent.
2. Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.
Figure 5-7. Composite Bushing Installation
4. Inspect inner surface of cylinder barrel for scoring or
14. Inspect travel limiting collar or spacer for burrs and
other damage. Check inside diameter for tapering or
sharp edges. Dress inside diameter as needed. Inspect
ovality. Replace if necessary.
port block fittings and holding valves. Replace as
5. Inspect threaded portion of barrel for damage. Dress needed. Torque holding valves to 50-55 ft-lb (68-75 Nm).
15. Inspect oil ports for blockage or presence of dirt or other
6. Inspect piston surface for damage and scoring and for foreign material. Repair as necessary.
distortion. Dress piston surface or replace piston as nec-
16. Inspect piston rings for cracks or other damage. Replace
essary.
as necessary.
5-6 – JLG Lift – 3121290

ASSEMBLY
NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.
Apply a light film of hydraulic oil to all components before

assembly.
1. Use seal tool to install new rod seal in cylinder head

gland groove.
Figure 5-10. Wiper Seal Installation

3. Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-8. Rod Seal Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER

CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION. Figure 5-11. Head Seal Installation
NOTE: Install wiper seal with flat part towards head. 4. Install washer ring on rod. Carefully install head on rod.
Ensure wiper and rod seals are not damaged or dis-
2. Use a soft mallet to tap new wiper seal into applicable lodged. Push head to rod end.
cylinder head gland groove. Install new wear ring into
5. Install two wear rings and piston spacer on rod.
applicable cylinder head gland groove.
6. Place two new O-rings and back-up rings in inner piston
diameter grooves.
Figure 5-9. Poly-Pak Piston Seal Installation
Figure 5-12. Piston Seal Installation
3121290 – JLG Lift – 5-7

7. Using suitable protection, clamp cylinder rod in a vise or 11. Remove cylinder rod from holding fixture.
similar holding fixture as close to piston as possible.
12. Place new guide locks and seals in applicable outside
8. Carefully thread piston on cylinder rod hand tight. diameter grooves of cylinder piston.
Ensure O-ring and back-up rings are not damaged or
13. Position cylinder barrel in a suitable holding fixture.
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON.
9. Thread piston onto rod until it aligns with spacer end.
Install tapered bushing. 14. Clamp barrel securely and support rod. Insert piston end
into barrel cylinder. Do not damage or dislodge piston
loading O-ring and seal ring.
APPLY JLG THREAD LOCKING COMPOUND P/N 0100011 TO TAPERED BUSHING 15. Continue pushing rod into barrel until cylinder head can
BOLTS WHEN REBUILDING MASTER, SLAVE, LIFT, OR TELESCOPE CYLINDERS, be inserted into barrel cylinder.
TIGHTEN TO SPECIFIED TORQUE.
16. Apply locking primer and locking compound to eight
10. Install bolts in tapered bushing using JLG Thread Lock- socket head bolts. Secure cylinder head and washer ring
ing Compound P/N 0100011. Torque to 9 ft-lb (12 Nm). with socket head bolts. Torque to 95 ft-lb (130 Nm).
Figure 5-14. Rod Assembly Installation
Figure 5-13. Tapered Bushing Installation
5-8 – JLG Lift – 3121290

Main Lift Cylinder

DISASSEMBLY PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
6. Clamp barrel securely. Pull rod assembly from barrel.


DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER


Shut down and disconnect power source. Adequately
3. If applicable, remove cartridge-type holding valve and fit-
tings from cylinder port block. Discard O-rings.
4. Place cylinder barrel in a suitable holding fixture. Tap
around outside of cylinder head end cap with hammer Figure 5-16. Cylinder Rod Support
to break thread-locking compound.
7. Using suitable protection, clamp cylinder rod in a vise or
8. Loosen setscrew and remove nut from rod. Remove pis-
ton.
9. Remove and discard piston O-ring, seal ring, and backup
rings.
10. Mark spacer location. Loosen setscrew and remove
spacer.
and end cap. Discard O-ring, wear ring, rod seal, and
wiper.
5. Use a strap wrench to remove cylinder end cap.
3121290 – JLG Lift – 5-9

1. Barrel 6. Hex Nut 11. Setscrew 16. Wear Ring 21. Locking Primer
2. Rod 7. Tube Spacer 12. Setscrew 17. O-Ring 22. Locking Compound
3. End Cap 8. Not Used 13. Wear Ring 18. Seal 23. Bushing
4. Piston 9. Cartridge Valve 14. Seal 19. Wiper
5. Head 10. O-Ring Plug 15. O-Ring 20. Locking Compound
Figure 5-17. Main Lift Cylinder
5-10 – JLG Lift – 3121290

CLEANING AND INSPECTION 11. Inspect rod and barrel bushings for excessive wear or
damage. Replace rod or barrel as necessary.
1. Clean all parts in approved cleaning solvent.
a. Thoroughly clean rod and barrel steel bushing of
2. Inspect cylinder rod for scoring, tapering, ovality, or burrs and contamination.
or equivalent. Replace rod if necessary. b. Lubricate inside of bushing housing with WD40
before installing composite bushings.
3. Inspect threaded portion of rod for excessive damage. c. Using correct size arbor, press composite bushing
Dress threads as necessary. into barrel or rod steel bushing.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
bearings. Install pin in composite bushings dry.
5. Inspect threaded portion of barrel for damage. Dress
6. Inspect piston surface for damage, scoring, and distor-
tion. Dress piston surface or replace piston as needed.
7. Inspect seal and O-ring grooves in piston for burrs and
8. Inspect cylinder head inside diameter for scoring or
other damage, ovality, and tapering. Replace as needed. 12. Inspect travel limiting spacer for burrs and sharp edges.
If necessary, dress inside diameter surface with Scotch
Brite or equivalent.
13. Inspect port block fittings and holding valve. Replace as
necessary. Torque valve to 30-35 ft-lb (41-48 Nm).
contamination. Clean and repair as necessary.
3121290 – JLG Lift – 5-11

ASSEMBLY 3. Carefully install assembled head (5) on rod. Make sure

wiper and rod seals are not damaged or dislodged. Push
NOTE: Use proper cylinder seal kit for cylinder assembly. See your head along rod to rod end.
JLG Parts Manual.
4. Carefully slide spacer on rod to marked position. Apply
Apply a light film of hydraulic oil to all components before locking compound to setscrew. Tighten setscrew.
assembly. 5. Insert new O-ring (15) in piston (4) groove. Install seal
(14) on center of piston. Install wear rings (13) on each
1. Use seal tool to install new rod seal (18) in cylinder head end of piston.
gland groove.
Figure 5-19. Rod Seal Installation Figure 5-21. Piston Seal Kit Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER 7. Carefully slide assembled piston on cylinder rod. Make
CYLINDER OPERATION.INSTALL SEAL (18) AND WIPER (19) IN CYLINDER sure O-ring is not damaged or dislodged.
HEAD GROOVE. INSTALL NEW WEAR RING (16) IN CYLINDER HEAD GROOVE.
INSTALL NEW O-RING (17) IN OUTSIDE DIAMETER GROOVE OF CYLINDER 8. Apply locking primer and locking compound to rod
HEAD. threads. Install nut and torque to 200 ft-lb (270 Nm).
Tighten setscrew to 100 in-lb (11 Nm).
9. Remove cylinder rod from holding fixture.
INSTALLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
11. Clamp barrel clamped securely and support rod. Insert

piston end into barrel cylinder. Do not damage or dis-
lodge piston loading O-ring and seal ring.
12. Continue pushing rod and cylinder head into barrel.
13. Apply locking compound to barrel threads and tighten
end cap using strap wrench.
Figure 5-20. Head Seals

2. Slide End Cap on rod with threads facing open end of
rod.
5-12 – JLG Lift – 3121290

Master Cylinder (450 A/AJ) Without Arctic Package 4. Mark cylinder head and barrel with a center punch for
realignment. Unscrew cylinder head with pin-face span-
450A Refer to Figure 5-25. 450AJ refer to Figure 5-26. ner wrench.
DISASSEMBLY
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN

WORK SURFACE IN A DIRT FREE WORK AREA.



Shut down and disconnect power source. Support cylin-
der rod as needed.
around outside of cylinder head retainer with suitable
hammer to break thread-locking compound.
Figure 5-23. Cylinder Head Removal
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
3121290 – JLG Lift – 5-13

1. Barrel 5. Head 9. Seal 13. Backup Ring 17. Retaining Ring

2. Rod 6. Not Used 10. Wear Ring 14. Seal 18. O-Ring
3. Not Used 7. Not Used 11. O-Ring 15. O-Ring 19. Retainer
4. Piston 8. Bushing 12. O-Ring 16. Wiper 20. Spacer
Figure 5-25. Master Cylinder (450A)
5-14 – JLG Lift – 3121290

1. Barrel 6. Not Used 11. O-Ring 16. Wear Ring 21. Not Used
2. Rod 7. Not Used 12. Seal 17. Seal 22. Not Used
3. Not Used 8. O-Ring 13. Backup Ring 18. Retainer 23. Head
4. Piston 9. Retaining Ring 14. O-Ring 19. Not Used
5. Bushing 10. Wiper 15. O-Ring 20. Not Used
Figure 5-26. Master Cylinder (450AJ W/O Arctic Package)
3121290 – JLG Lift – 5-15

6. Using suitable protection, clamp cylinder rod in a vise or NOTE: Lubrication is not required with nickel plated pins and
similar holding fixture as close to piston as possible. bearings. Install pin in composite bushing dry.
7. Remove retainer from end of rod.
8. Unscrew and remove piston assembly.
9. 450A only. Remove spacer.
10. Remove head assembly from rod.
1. Clean all parts thoroughly in an approved cleaning sol-
vent.
or equivalent. Replace rod if necessary. 14. Inspect spacer (450A only) for burrs and sharp edges.
Dress inside diameter surface with Scotch Brite or equiv-
alent as needed.
foreign material. Repair as necessary.
ovality. Replace if necessary. 16. Inspect piston rings for cracks or other damage. Replace
as needed.
threads as necessary. ASSEMBLY
6. Inspect piston surface for damage, scoring, and distor- NOTE: Use proper cylinder seal kit for cylinder assembly. See your
tion. Dress piston surface or replace piston as necessary. JLG Parts Manual.
7. Inspect threaded portion of piston for damage. Dress
threads as necessary. Apply a light film of hydraulic oil to all components before
assembly.
sharp edges. Dress surfaces as necessary. 1. Use seal tool to install new rod seal in cylinder head
gland groove.
a. Thoroughly clean hole (steel bushing) of burrs, dirt,
or other contamination.
steel bushing is worn or damaged, rod/barrel must Figure 5-28. Rod Seal Installation
be replaced.
c. Lubricate inside of steel bushing with WD40 before
installing composite bushings.
bushing.
5-16 – JLG Lift – 3121290


TATION.
2. Place new wiper in cylinder head with flat side facing in.
Use a soft mallet to seat wiper in cylinder head groove.
3. Install retainer in cylinder head groove.
4. Install O-ring in cylinder head groove.
5. Place new O-rings and back-up ring in outside diameter
cylinder head grooves.

14. Position cylinder barrel in suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
15. Clamp barrel securely and support rod. Insert piston end
O-rings and backup ring.
16. Continue pushing rod into barrel. Screw in cylinder
head. Torque to 442 ft-lb (600 Nm).
Figure 5-29. Installation of Head Seal Kit
6. Carefully install head on rod, ensuring wiper and rod
seals are not damaged or dislodged. Push head along
rod to rod end, as applicable.
7. 450A only. Carefully slide piston spacer on rod.
NOTE: Upper telescope cylinder piston has an O-ring installed

inside spacer.
8. Place new O-ring and in inner piston diameter groove.

10. Carefully thread piston on cylinder rod. Do not damage
or dislodge O-ring. Torque to 295 ft-lb (400 Nm).
11. Install retaining ring on end of rod.
12. Install seal and wear rings in outside piston grooves.
Figure 5-31. Cylinder Head Installation
NOTE: Marks made during disassembly should line up.
3121290 – JLG Lift – 5-17

Master Cylinder (450 A/AJ) With Arctic Package 4. Mark cylinder head and barrel with a center punch for
easy reassembly. Remove eight cylinder head retainer
450A Refer to Figure 5-25. 450AJ refer to Figure 5-26. cap screws.
DISASSEMBLY
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN

WORK SURFACE IN A DIRT FREE WORK AREA.



Shut down and disconnect power source. Support cylin-
der rod as needed. Figure 5-33. Cylinder Head Removal

around outside of cylinder head retainer with suitable
hammer to break thread-locking compound. PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
5-18 – JLG Lift – 3121290

1. Locking Compound 5. Composite Bushing 9. Barrel 102. Wear Ring 106. Wiper
2. Locking Primer 6. Piston 10. Rod 103. Backup Ring 107. Seal
3. Bolt 7. Ring Washer 11. Bolt 104. O-Ring 108. Backup Ring
4. Tapered Bushing 8. Head 101. Lock Ring 105. O-Ring 109. Seal
Figure 5-35. Master Cylinder (450AJ W/Arctic Package)
3121290 – JLG Lift – 5-19

6. Using suitable protection, clamp cylinder rod in a vise or 6. Inspect piston surface for damage, scoring, and distor-
similar holding fixture as close to piston as possible. tion. Dress piston surface or replace piston as needed.
7. Loosen and remove cap screws attaching tapered bush- 7. Inspect threaded portion of piston for damage. Dress
ing to piston. threads as necessary.
8. Insert cap screws in threaded holes in outer piece of 8. Inspect seal and O-ring grooves in piston for burrs and
tapered bushing. Progressively tighten cap screws until sharp edges. Dress surfaces as necessary.
bushing is loose on piston.
9. Remove bushing from piston. other damage, and for ovality and tapering. Replace as
necessary.
13. Inspect rod and barrel bearings for excessive wear or
damage. Replace as necessary.
be replaced.
Figure 5-36. Tapered Bushing Removal c. Lubricate inside of steel bushing with WD40 before
10. Screw piston counter-clockwise by hand and remove
piston from cylinder rod. d. Using a correct size arbor, press bearing into steel
bushing.
11. Remove and discard piston seals and lock rings.
12. Remove rod from holding fixture. Remove cylinder head bearings. Install pin in composite bushing dry.
and ring washer. Discard O-rings, back-up rings, rod
seals, and wiper seals.
vent.
other damage. Dress rod with Scotch Brite or equivalent
as needed. Replace rod if necessary.
Dress threads as necessary. Figure 5-37. Composite Bushing Installation
4. Inspect inner surface of cylinder barrel tube for scoring 14. Inspect oil ports for blockage or presence of dirt or other
or other damage. Check inside diameter for tapering or foreign material. Repair as needed.
5. Inspect threaded portion of barrel for damage. Dress as needed.
5-20 – JLG Lift – 3121290

ASSEMBLY 5. Install washer ring on rod. Carefully install cylinder head

assembly head on rod. Do not damaged or dislodge
NOTE: Use proper cylinder seal kit for cylinder assembly. See your wiper and rod seals. Push head to rod end.
JLG Parts Manual.
6. Place a new O-ring and back-up rings in inner piston
Apply a light film of hydraulic oil to all components before diameter groove.
assembly.
1. Use seal tool to install new seal in cylinder head groove.

IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER similar holding fixture as close to piston as possible.
8. Carefully thread piston on cylinder rod hand tight. Do
not damage or dislodge O-ring and back-up rings.
TATION.
NOTE: Tapered bushing, piston, and mating end of rod must be
2. Use a soft mallet to tap new wiper seal into applicable free of oil.
cylinder head gland groove. Install new wear ring into
applicable cylinder head gland groove. 9. Thread piston onto rod until it aligns with spacer end
and install tapered bushing.
3. Install wear ring in cylinder head.
4. Place new O-ring and back-up seal in outside diameter
grooves of cylinder head.
Figure 5-39. Cylinder Head Seal Installation
3121290 – JLG Lift – 5-21

APPLY JLG THREAD LOCKING COMPOUND P/N 0100011 TO TAPERED BUSHING

BOLTS WHEN REBUILDING MASTER, SLAVE, LIFT, OR TELESCOPE CYLINDERS. INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
TIGHTEN TO SPECIFIED TORQUE.
10. Install bolts in tapered bushing using JLG Thread Lock- 14. Clamp barrel clamped securely and support rod. Insert
ing Compound P/N 0100011. Torque to 5 ft-lb (6.7 Nm).
15. Continue pushing rod into barrel until cylinder head
gland can be inserted into barrel cylinder.
socket head bolts. Secure cylinder head and washer ring
with socket head bolts. Torque to 30 ft-lb (40.6 Nm).

diameter grooves of cylinder piston.
5-22 – JLG Lift – 3121290

Telescope Cylinder 5. Use a strap wrench to remove cylinder end cap.

DISASSEMBLY PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.




3. Remove cartridge-type holding valve and fittings from
cylinder port block. Discard O-rings.
8. Remove nut securing piston to rod and remove piston.
9. Remove and discard piston seals and lock rings.
10. Remove piston O-ring from rod (450 AJ only).
11. Loosen setscrew (450A only) on spacer. Remove spacer
from rod.
and end cap. Discard O-rings, back-up rings, rod seals,
and wiper seals.
3121290 – JLG Lift – 5-23

1. Thread Locking Compound 5. Piston 10. O-Ring 15. Counter-Balance Valve Block 104. Wear Ring
2. Thread Locking Primer 6. Spacer 11. Counter-Balance Valve 16. Setscrew (450A Only) 105. O-Ring
3. Barrel 7. Lock Nut 12. 90° Adapter 101. Wear Ring 106. Seal
3A. End Cap 8. Cylinder Head 13. O-Ring (450AJ Only) 102. Seal 107. Wiper Seal
4. Rod 9. O-Ring Plug 14. Bolt 103. O-Ring 108. Backup Ring
Figure 5-45. Telescope Cylinder 450A/AJ
5-24 – JLG Lift – 3121290

CLEANING AND INSPECTION 13. Inspect rod bearings for excessive wear or damage.
Replace as needed.
1. Clean all parts thoroughly with approved cleaning sol-
vent. a. Thoroughly clean hole, (steel bushing) of burrs, dirt
other damage. If necessary, dress rod with Scotch Brite b. Inspect steel bushing for wear or other damage. If
or equivalent. Replace rod if necessary. steel bushing is worn or damaged, rod/barrel must
be replaced.
3. Inspect threaded portion of rod for excessive damage. c. Lubricate inside of steel bushing with WD40 prior to
Dress threads as necessary. bearing installation.
4. Inspect inner surface of cylinder barrel tube for scoring d. Press bearing in bushing using correct size arbor.
ovality. Replace if necessary. NOTE: Lubrication is not required with nickel plated pins and
bearings. Install pin in composite bushing dry.
6. Inspect piston for damage, scoring, and distortion. Dress
piston surface or replace piston as necessary.
7. Inspect threaded portion of piston for damage. Dress
other damage, ovality, and tapering. Replace as needed. Figure 5-46. Composite Bushing Installation
10. Inspect threaded portion of head and end cap for dam- 14. Inspect travel limiting collar or spacer for burrs and
age. Dress threads as necessary. sharp edges. If necessary, dress inside diameter surface
11. Inspect seal and O-ring grooves in head for burrs and with Scotch Brite or equivalent.
sharp edges. Dress applicable surfaces as necessary. 15. Inspect port block fittings and holding valves. Replace
12. Inspect cylinder head outside diameter for scoring or as needed. Torque valves 30-35 ft-lb (41-48 Nm).
other damage, ovality, and tapering. Replace as needed. 16. Inspect oil ports for blockage or presence of dirt or other
foreign material. Repair as necessary.
as needed.
3121290 – JLG Lift – 5-25

ASSEMBLY 3. Slide End Cap on rod with threads facing open end of
rod.
JLG Parts Manual. 4. Carefully install assembled head on rod. Make sure
wiper and rod seals are not damaged or dislodged. Push
Apply a light film of hydraulic oil to all components before head along rod to rod end.
assembly. 5. Install O-ring inside spacer (450AJ only). Carefully slide
spacer on rod to marked position. Apply locking com-
1. Use seal tool to install new rod seal in cylinder head pound to setscrew (450A only). Tighten setscrew.
gland groove.
6. Insert new O-ring in rod groove. Install seal on center of
piston. Install wear rings on each end of piston.

CYLINDER OPERATION. 7. Using suitable protection, clamp cylinder rod in a vise or
2. Install wear ring in cylinder head. Install seal and wiper
in cylinder head groove. Install new wear ring in cylinder 8. Carefully slide assembled piston on cylinder rod. Make
head groove. Install new backup ring and O-ring in out- sure O-ring is not damaged or dislodged.
side diameter groove of cylinder head.
9. Apply locking primer and locking compound to rod
threads. Install nut and torque to 200 ft-lb (270 Nm).
Tighten setscrew to 100 in-lb (11 Nm).
INSTALLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
12. Clamp barrel clamped securely and support rod. Insert

13. Continue pushing rod and cylinder head into barrel.
14. Apply locking compound to barrel threads and tighten
Figure 5-48. Cylinder Head Seal Installation end cap using strap wrench.
5-26 – JLG Lift – 3121290

Slave (Platform Level) Cylinder Without Arctic Pkg 5. Mark cylinder head and barrel with a center punch for
realignment. Unscrew cylinder head with pin-face span-
Refer to Figure 5-53. (450A) or Figure 5-54. (450 AJ). ner wrench.
DISASSEMBLY




around outside of cylinder head retainer with a suitable Figure 5-51. Cylinder Head Removal
3121290 – JLG Lift – 5-27

1. Barrel 6. Not Used 11. Wear Ring 16. Retaining Ring 21. Retainer 26. Plug
2. Rod 7. Not Used 12. O-Ring 17. O-Ring 22. Not Used 27. Not Used
3. Not Used 8. Bushing 13. Backup Ring 18. Not Used 23. Cartridge Valve 28. O-Ring
4. Head 9. Seal 14. Seal 19. Not Used 24. Cartridge Valve
5. Piston 10. O-Ring 15. Wiper 20. Not Used 25. Plug
Figure 5-53. Platform Level Slave Cylinder Assembly (450A)
5-28 – JLG Lift – 3121290

1. Barrel 6. Not Used 11. Wear Ring 16. Retaining Ring 21. Retainer 26. Plug
2. Rod 7. Not Used 12. O-Ring 17. O-Ring 22. Not Used 27. Not Used
3. Not Used 8. Bushing 13. Backup Ring 18. Not Used 23. Cartridge Valve 28. O-Ring
4. Piston 9. Seal 14. Seal 19. Not Used 24. Cartridge Valve
5. Head 10. O-Ring 15. Wiper 20. Not Used 25. Plug
Figure 5-54. Platform Level Slave Cylinder Assembly (450AJ W/O Arctic Package)
3121290 – JLG Lift – 5-29

7. Using suitable protection, clamp cylinder rod in a vise or NOTE: Lubrication is not required with nickel plated pins and
similar holding fixture as close to piston as possible. bearings. Install pin in composite bushing dry.
8. Remove retainer from end of rod.
9. Unscrew and remove piston assembly.
10. Remove head assembly from rod.
vent.
Dress threads as necessary. 14. Inspect port block fittings and holding valves. Replace
as needed. Torque valves to 51 ft-lb (70 Nm).
or other damage. Check inside diameter for tapering or 15. Inspect oil ports for blockage or presence of dirt or other
ovality. Replace if necessary. foreign material. Repair as necessary.
5. Inspect threaded portion of barrel for damage. Dress 16. Inspect piston rings for cracks or other damage. Replace
threads as necessary. as needed.
6. Inspect piston surface for damage, scoring, and distor- ASSEMBLY

tion. Dress piston surface or replace piston as necessary. NOTE: Use proper cylinder seal kit for cylinder assembly. See your
7. Inspect threaded portion of piston for damage. Dress JLG Parts Manual.
8. Inspect seal and O-ring grooves in piston for burrs and assembly.
9. Inspect cylinder head inside diameter for scoring or 1. Use seal tool to install new rod seal in cylinder head
other damage, ovality, and tapering. Replace as needed. gland groove.

a. Thoroughly clean hole (steel bushing) of burrs, dirt,
or other contamination.
be replaced. Figure 5-56. Rod Seal Installation
bushing.
5-30 – JLG Lift – 3121290


TATION.
2. Place new wiper in cylinder head with flat side facing

inside. Use a soft mallet to seat wiper in cylinder head
groove.
5. Place new O-rings and back-up ring in outside diameter


seals are not damaged or dislodged. Push head along
rod to rod end, as applicable.
NOTE: Upper telescope cylinder piston has an O-ring installed
inside spacer.

10. Install retaining ring on end of rod.
11. Install seal and wear rings in outside piston grooves.
3121290 – JLG Lift – 5-31

Platform Level (Slave) Cylinder With Arctic Package 5. Mark cylinder head and barrel with a center punch for
reassembly. Remove eight cylinder head retainer cap
Refer to Figure 5-63. screws from cylinder barrel.
DISASSEMBLY




support cylinder rod, if applicable. Figure 5-61. Marking Cylinder for Alignment
5-32 – JLG Lift – 3121290

1. Locking Compound 6. Head 11. Vented Counterbalance Valve 103. Backup Ring 107. Seal
2. Locking Primer 7. Rod 12. Non-Vented Counterbalance Valve 104. O-Ring 108. Backup Ring
3. Socket Head Bolt 8. Barrel 13. Socket Head Bolt 105. O-Ring 109. Seal
4. Tapered Bushing 9. Ring Washer 101. Lock Ring 106. Wiper
5. Composite Bushing 10. Piston 102. Wear Ring
Figure 5-63. Platform Level Slave Cylinder Assembly (450AJ W/Arctic Package)
3121290 – JLG Lift – 5-33

1. Using suitable protection, clamp cylinder rod in a vise or 7. Inspect threaded portion of piston for damage. Dress
similar holding fixture as close to piston as possible. threads as necessary.
2. Loosen and remove cap screws attaching tapered bush- 8. Inspect seal and O-ring grooves in piston for burrs and
ing to piston. sharp edges. Dress surfaces as necessary.
3. Insert cap screws in threaded holes in outer piece of 9. Inspect cylinder head inside diameter for scoring or
tapered bushing. Progressively tighten cap screws until other damage, ovality, and tapering. Replace as needed.
4. Remove bushing from piston. threads as necessary.
5. Screw piston counter-clockwise. Remove from cylinder 11. Inspect seal and O-ring grooves in head for burrs and
rod. sharp edges. Dress applicable surfaces as necessary.
other damage and ovality and tapering. Replace as
needed.
damage. Replace as needed.
be replaced.
c. Lubricate inside of steel bushing with WD40 prior to
bearing installation.
d. Press bearing in bushing using correct size arbor.

Figure 5-64. Tapered Bushing Removal bearings. Install pin in composite bushing dry.
6. Remove and discard piston O-rings, seal rings, and
backup rings.
7. Remove piston spacer from rod.
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.
vent.
2. Inspect cylinder rod for scoring, tapering, ovality, or Figure 5-65. Composite Bushing Installation
other damage. If necessary, dress rod with Scotch Brite 14. Inspect travel limiting collar or spacer for burrs and
or equivalent. Replace rod if necessary. sharp edges. If necessary, dress inside diameter surface
3. Inspect threaded portion of rod for excessive damage. with Scotch Brite or equivalent.
4. Inspect inner surface of cylinder barrel tube for scoring as needed. Torque valves 50-55 ft-lb (68-75 Nm).
threads as necessary. as needed.
6. Inspect piston for damage, scoring, and distortion. Dress
piston surface or replace piston as necessary.
5-34 – JLG Lift – 3121290

ASSEMBLY
JLG Parts Manual.

assembly.
1. Use seal tool to install new rod seal into applicable cylin-
der head gland groove.


TATION.
2. Use a soft mallet to tap new wiper seal into applicable 4. Install washer ring on rod. Carefully install head gland
cylinder head gland groove. Install new wear ring into on rod. Do not damage or dislodge wiper and rod seals.
applicable cylinder head gland groove. Push head along rod to rod end, as applicable.
5. Carefully slide piston spacer on rod.
6. Place new O-ring and back-up rings in inner piston
diameter groove.
Figure 5-70. Piston Seal Kit Installation
3121290 – JLG Lift – 5-35

7. Using suitable protection, clamp cylinder rod in a vise or 11. Remove cylinder rod from holding fixture.
8. Carefully thread piston on cylinder rod hand tight. diameter grooves of cylinder piston. (See Figure 2-28.
Ensure O-ring and back-up rings are not damaged or Piston Seal Kit Installation.)
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
9. Thread piston onto rod until it aligns with spacer end SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
and install tapered bushing. AND PISTON.
NOTE: Apply JLG Thread Locking Compound P/N 010011 to
tapered bushing bolts when rebuilding master, slave, lift, 14. Clamp barrel securely. Support rod and insert piston
and telescope cylinders. end in barrel. Do not damage or dislodge O-rings and
seals.
10. Install bolts in tapered bushing using JLG Thread Lock- 15. Continue pushing rod into barrel until cylinder head
ing Compound P/N 0100011. Torque to 5 ft-lb (6 Nm). gland is inserted into barrel cylinder. Align marks made
during disassembly.
socket head bolts. Secure cylinder head and washer ring
with socket head bolts. Torque to 30 ft-lb (40 Nm).
5-36 – JLG Lift – 3121290

Jib Lift Cylinder (AJ Only) Without Arctic Package 5. Mark cylinder head and barrel with a center punch for
reassembly. Unscrew cylinder head with spanner
Refer to Figure 5-76. wrench.
DISASSEMBLY




3. If applicable, remove cartridge-type holding valve and fit-
tings from cylinder port block. Discard O-rings.
Figure 5-74. Cylinder Head Removal
3121290 – JLG Lift – 5-37

1. Barrel 7. Piston 13. Not Used 19. Seal 25. Plug 30. Not Used
2. Rod 8. Bushing 14. Bushing 20. O-Ring 26. Not Used 31. Retaining Ring
3. Not Used 9. Bushing 15. Sleeve 21. Backup Ring 27. Not Used 32. Wear Ring
4. Not Used 10. Not Used 16. Nut 22. O-Ring 28. O-Ring
5. Not Used 11. Cartridge Valve 17. Retainer 23. O-Ring 29. Seal
6. Head 12. Not Used 18. Wiper 24. O-Ring
Figure 5-76. Jib Lift Cylinder (450AJ W/O Arctic Package)
5-38 – JLG Lift – 3121290

7. Using suitable protection, clamp cylinder rod in a vise or 11. Inspect seal and O-ring grooves in head for burrs and
similar holding fixture as close to piston as possible. sharp edges. Dress applicable surfaces as necessary.
8. Remove retainer from end of rod. 12. Inspect cylinder head outside diameter for scoring or
9. Remove nut, sleeve, and bushing.
13. Inspect rod and barrel composite bushings for wear or
10. Remove piston from rod.
11. Screw piston counter-clockwise by hand and remove
from cylinder rod.
12. Remove and discard piston O-rings, seal rings, and b. Inspect steel bushing for wear or other damage. If
backup rings. steel bushing is worn or damaged, rod/barrel must
13. Remove piston bushing from rod. be replaced.
c. Lubricate inside of the steel bushing with WD40
14. Remove rod from holding fixture. prior to bearing installation.
15. Remove cylinder head. Discard O-rings, back-up rings, d. Using a correct size arbor, press bearing into steel
rod seals, and wiper seals. bushing.
CLEANING AND INSPECTION NOTE: Lubrication is not required with nickel plated pins and
vent.
threads as necessary. Figure 5-77. Composite Bushing Installation
6. Inspect piston surface for damage and scoring and for 14. Inspect travel limiting collar or spacer for burrs and
distortion. Dress piston surface or replace piston as nec- sharp edges. If necessary, dress inside diameter surface
essary. with Scotch Brite or equivalent.
7. Inspect threaded portion of piston for damage. Dress 15. Inspect port block fittings and holding valves. Replace
threads as necessary. as necessary. Torque valves to 51 ft-lb (70 Nm).
8. Inspect seal and O-ring grooves in piston for burrs and 16. Inspect oil ports for blockage or presence of dirt or other
sharp edges. Dress surfaces as necessary. foreign material. Repair as necessary.
9. Inspect cylinder head inside diameter for scoring or 17. Inspect piston rings for cracks or other damage. Replace
other damage, and for ovality and tapering. Replace as as necessary.
necessary.
3121290 – JLG Lift – 5-39

ASSEMBLY 5. Place new O-rings and back-up ring in outside diameter

JLG Parts Manual.

assembly.
1. Use seal tool to install new rod seal in cylinder head

gland groove.
Figure 5-79. Cylinder Head Seals

seals are not damaged or dislodged. Push head to rod
end.
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER 9. Install bushing on rod.
TATION.
11. Install bushing and sleeve on rod.
2. Place new wiper in cylinder head with flat side facing
12. Install nut and retaining ring on end of rod.
inside. Use a soft mallet to seat wiper in cylinder head
groove. 13. Install seal and wear rings in outside piston grooves.
5-40 – JLG Lift – 3121290



3121290 – JLG Lift – 5-41

Jib Lift Cylinder (AJ Only) With Arctic Package 5. Mark cylinder head and barrel with a center punch for
easy realignment. Remove eight cylinder head retainer
Refer to Figure 5-85. cap screws from cylinder barrel.
DISASSEMBLY




support cylinder rod, if applicable. Figure 5-83. Marking Cylinder for Alignment
4. Place cylinder barrel in a suitable holding fixture. Tap PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
around outside of cylinder head retainer with a suitable USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
5-42 – JLG Lift – 3121290

1. Locking Compound 6. Bushing 11. O-Ring Plug 101. Backup Ring 106. O-Ring
2. Locking Primer 7. Head 12. Piston 102. Ring, Metallic Seal 107. Seal
3. Bolt 8. Barrel 13. Socket Head Bolt 103. Ring, Wear 108. Wiper
4. Tapered Bushing 9. Rod 14. Cartridge Valve 104. Ring, Wear 109. T-Seal
5. Bushing 10. Ring Washer 15. Backup Ring 105. O-Ring
Figure 5-85. Jib Lift Cylinder (450AJ W/Arctic Package)
3121290 – JLG Lift – 5-43

7. Using suitable protection, clamp cylinder rod in a vise or 7. Inspect threaded portion of piston for damage. Dress
similar holding fixture as close to piston as possible. threads as necessary.
8. Loosen and remove cap screws attaching tapered bush- 8. Inspect seal and O-ring grooves in piston for burrs and
ing to piston. sharp edges. Dress surfaces as necessary.
9. Insert cap screws in threaded holes in outer piece of 9. Inspect cylinder head inside diameter for scoring or
tapered bushing. Progressively tighten cap screws until other damage, ovality, and tapering. Replace as needed.
10. Remove bushing from piston. threads as necessary.
11. Screw piston counter-clockwise by hand and remove 11. Inspect seal and O-ring grooves in head for burrs and
from cylinder rod. sharp edges. Dress applicable surfaces as necessary.
a. Clean hole, (steel bushing) of burrs, dirt, etc.
b. Inspect steel bushing for wear or damage. If steel
bushing is worn or damaged, rod/barrel must be
replaced.
bearing installation.
bushing.
Figure 5-86. Tapered Bushing Removal
12. Remove and discard piston O-rings, seal rings, and
backup rings.
13. Remove piston spacer from rod.
gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.
1. Clean parts thoroughly with approved cleaning solvent.
other damage. If necessary, dress rod with Scotch Brite 14. Inspect travel limiting collar or spacer for burrs and
or equivalent. Replace rod if necessary. sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.
as necessary. Torque valves to 30 ft-lb (40Nm).
threads as necessary. as necessary.
6. Inspect piston surface for damage, scoring, and distor-
tion. Dress piston surface or replace piston as necessary.
5-44 – JLG Lift – 3121290

ASSEMBLY
JLG Parts Manual.

assembly.
1. Use seal tool to install new rod seal in applicable cylin-

der head gland groove.


TATION.
2. Use a soft mallet to tap new wiper seal into applicable Figure 5-91. Installation of Head Seal Kit
cylinder head gland groove. Install new wear ring in
applicable cylinder head gland groove. 2. Install washer ring on rod. Carefully install cylinder head
on rod. Ensure wiper and rod seals are not damaged or
dislodged. Push head to rod end.
3. Place new O-ring and back-up rings in inner piston
diameter groove.
3121290 – JLG Lift – 5-45

4. Using suitable protection, clamp cylinder rod in a vise or 10. Position cylinder barrel in a suitable holding fixture.
5. Carefully thread piston on cylinder rod hand tight.
Ensure O-ring and back-up rings are not damaged or INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
dislodged. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON.
NOTE: Piston and mating end of rod must be free of oil when 11. Clamp barrel clamped securely and support rod. Insert
installing tapered bushing. piston end into barrel cylinder. Do not damage or dis-
6. Thread piston on rod until tight. Install tapered bushing.
12. Continue pushing rod into barrel until cylinder head can
be inserted into barrel cylinder.
APPLY JLG THREAD LOCKING COMPOUND P/N 0100011 TO TAPERED BUSHING 13. Screw in cylinder head until tight and mark is aligned on
BOLTS WHEN REBUILDING MASTER, SLAVE, LIFT, AND TELESCOPE CYLINDERS. barrel.
TORQUE TO SPECIFICATIONS. 14. Apply locking primer and locking compound to eight
socket head bolts. Install in cylinder head and barrel.
7. Install bolts in tapered bushing using JLG Thread Lock- Torque to 50-55 ft-lb (68-75 Nm).
ing Compound P/N 0100011. Torque to 5 ft-lb (6 Nm).

diameter grooves of cylinder piston.
5-46 – JLG Lift – 3121290

Steer Cylinder 5. Unscrew cylinder head with hook spanner on rod end to
be pulled.
DISASSEMBLY




Figure 5-96. Removing Cylinder Head
support cylinder rod.
around outside of cylinder head retainer with a suitable PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
hammer to break thread-locking compound. SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD AND PIS-
TON.
6. Clamp securely. Apply pressure to rod pulling device

and carefully withdraw complete rod assembly from cyl-
inder barrel.

4. Remove burrs and contamination from cylinder before
disassembly.

7. Remove cylinder head from opposite end.
3121290 – JLG Lift – 5-47

1. Barrel 4. Wiper 7. O-Ring 10. Piston Seal

2. Rod 5. Rod Seal 8. Backup Ring 11. Wear Ring
3. Cylinder Head 6. Bearing 9. O-Ring 12. Composite Bushing
Figure 5-98. Steer Cylinder Assembly
5-48 – JLG Lift – 3121290

8. Remove wear ring (11) from piston. CLEANING AND INSPECTION

9. Remove seal (10) from piston. Do not damage piston 1. Clean all parts in an approved cleaning solvent.
groove.
NOTE: Piston seal is a combination-type seal. If seal separates it other damage. If necessary, dress rod with Scotch Brite™
cannot be reused. or equivalent. Replace rod if necessary.
3. Inspect inner surface of cylinder barrel tube for scoring,
tapering, ovality, or other damage. Replace if necessary.
5. Inspect piston surface for damage and scoring and for
distortion. Inspect seal and O-ring grooves in piston for
burrs and sharp edges. Dress piston surfaces or replace
rod assembly as necessary.
6. Inspect rod bushings for excessive wear or damage.
Replace as necessary.
a. Thoroughly clean rod bushing of burrs, dirt, etc.
b. Inspect rod bushing for wear or other damage. If rod
bushing is worn or damaged, rod must be replaced.
Figure 5-99. Piston Seal and Wear Ring
c. Lubricate inside of rod bushing with WD40 before
10. Remove O-Ring (7), O-Ring (9), and Backup Ring (8) from installing composite bushing.
two Cylinder Heads (3). d. Press composite bushing in rod bushing using cor-
11. Remove Rod Seal (5). Do not damage cylinder head rect size arbor.
groove. NOTE: Pin is installed in composite bushing dry. Lubrication is not
12. Remove Wiper (4). required with nickel plated pins and bearings.
13. Remove pressed-in Bearing (6).

7. Inspect cylinder head inside diameter for scoring, taper-
ing, ovality, or other damage. Replace as necessary.
8. Inspect threads, and seal and O-Ring grooves in head for
burrs, sharp edges, and other damage. Dress surfaces as
necessary.
Figure 5-100. Cylinder Head Disassembly 9. Inspect oil ports for blockage or contamination. Repair
as necessary.
3121290 – JLG Lift – 5-49

ASSEMBLY
NOTE: Apply a light film of hydraulic oil to all components before INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
assembly. SURFACES. USE EXTREME CARE INSTALLING CYLINDER ROD AND PISTON.
1. Position cylinder barrel in a suitable holding fixture. 9. Install Cylinder Head (3) on one end of Barrel (1).
10. Insert Rod Assembly (2) in Barrel (1) until end of Rod is
through Cylinder Head (3).
CYLINDER OPERATION. 11. Install remaining Cylinder Head (3) to Barrel (1).
2. Install Rod Seal (5) in Cylinder Head (3).

3. Press-in Bearing (6).
4. Install Wiper (4).
5. Install O-Ring (7), Backup Ring (8), and O-Ring (9).
6. Repeat for other Cylinder Head.
Figure 5-104. Steering Cylinder Assembly

12. Tighten two Cylinder Heads (3) with Hook Spanner to
397 ft-lb (538 Nm).
Figure 5-102. Cylinder Head Assembly

7. Install wear ring (11) in piston groove.
8. Install seal (10) in piston groove.
Figure 5-105. Cylinder Head Torque
Figure 5-103. Piston Seal and Wear Ring
5-50 – JLG Lift – 3121290

Axle Lockout Cylinder ASSEMBLY
Refer to Figure 5-106., Axle Lockout Cylinder. Refer to Figure 5-106., Axle Lockout Cylinder.
DISASSEMBLY 1. Install two new wear rings (5) and rod seal (7) in piston
bore grooves. Make sure they are not twisted.
2. Install new wiper (6) in housing.
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A 3. Lubricate piston bore with clean hydraulic fluid.
INSERTING PISTON OFF-CENTER CAN DAMAGE PISTON AND PISTON BORE

PISTON CAN FALL OUT OF HOUSING AND CAUSE INJURY SURFACES. USE EXTREME CARE WHEN INSTALLING PISTON.
OR DAMAGE TO EQUIPMENT. BE CAREFUL WHEN REMOV-
ING AXLE CYLINDER. OPENING BLEED VALVE CAN CAUSE 4. Install piston (2) in bore and push to top of bore.
PISTON TO FALL OUT OF HOUSING. 5. Install check valve (9). Torque to 25 - 27 ft-lb (33 - 36 Nm).
1. Open bleed valve (8). Rotate piston (2) and remove from 6. Bleed system. Refer to 3.6, Oscillating Axle Bleeding Pro-
housing (1). cedure and Lockout Test.
2. Remove wiper (6). Do not scratch housing bore.

3. Remove two wear rings (5) and rod seal (7) from grooves
in piston bore. Do not scratch housing bore.
4. Remove check valve (9), if required.
1. Inspect bore and piston for scoring, pitting, or excessive
wear.
2. Remove minor surface blemishes with wet 2000-grit
sandpaper. Pitting requires replacement of housing or
piston.
3. Clean all parts with approved solvent and dry with com-
pressed air.
3121290 – JLG Lift – 5-51

FALLING PARTS CAN CAUSE INJURY AND EQUIPMENT DAMAGE. CYLINDER

ROD CAN FALL OUT WHEN BLEEDER VALVE IS OPENED.
1. Barrel 6. Wiper
2. Rod 7. Rod Seal
3. Plug 8. Bleeder
4. Pilot Piston 9. Cartridge Valve
5. Wear Ring
Figure 5-106. Axle Lockout Cylinder
5-52 – JLG Lift – 3121290

5.3 HYDRAULIC PUMP (GEAR) 7. Remove pump from vise and place on clean work bench.
Remove four hex head bolts and spacers if applicable.
Disassembly
NOTE: The following general instructions also apply to multiple
section gear pumps. The only extra parts are the coupling
between drive shafts and center distance plate which
divides the two pump sections. This repair procedure also
applies to ”W” series Gear Motors.
1. Always work in a clean work area when repairing

hydraulic products. Plug ports and wash exterior of
pump with approved cleaning solvent.
2. Remove port plugs and drain oil from pump.
8. Lift and remove end cover.
3. Use a permanent marker pen to mark a line across

mounting flange, gear housing and end cover. This will
assure proper reassembly and rotation of pump.
4. Remove key from drive shaft if applicable. 9. Carefully remove gear housing and place on work
bench. Make sure rear bearing block remains on drive
and idler shafts.
5. Clamp mounting flange in a protected jaw vise with

pump shaft facing down.
6. Loosen four metric hex head bolts.
3121290 – JLG Lift – 5-53

10. Remove rear bearing block from drive and idler shafts. 13. Remove front bearing block.
11. Remove idler shaft from bearing block. 14. Turn mounting flange over, with shaft seal up. Remove
retaining ring with snap ring pliers.
12. Remove drive shaft from mounting flange.

15. Remove oil seal from mounting flange. Do not mar or
NOTE: Shaft seal will be replaced.
scratch seal bore.
16. Remove dowel pins from gear housing. Do not lose pins.
17. Remove and discard seals from both bearing blocks.
5-54 – JLG Lift – 3121290

Inspect Parts For Wear 4. Inspect gear face for scoring or excessive wear. If face
edge of gear teeth are sharp, they will mill into the bear-
1. Clean and dry all parts thoroughly before inspection. It ing blocks. If wear has occurred, parts are unusable.
is not necessary to inspect seals. They will be replaced.
5. Inspect bearing blocks for excessive wear or scoring on

2. Check drive shaft spine for twisted or broken teeth, surfaces in contact with gears. Inspect bearings for
check keyed drive shaft for broken or chipped keyway. excessive wear or scoring.
No marks or grooves on shaft in seal area, some discolor- 6. Inspect area inside gear housing. A clean ”wipe” on
ation of shaft is allowable. inside surface of intake side is normal. There should not
3. Inspect drive gear shaft and idler gear shafts at bearing be excessive wear, deep scratches, or gouges.
points and seal area for rough surfaces and excessive wear.
3121290 – JLG Lift – 5-55

General Information 2. Install retaining ring in groove in seal bore of mounting

flange.
FAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT WITH LITTLE OR

NO FLOW AT RATED PRESSURE. RELATIONSHIP OF MOUNTING FLANGE, BEAR-
ING BLOCKS, AND GEAR HOUSING MUST BE CORRECT.
Reverse Shaft Rotation of Pump

NOTE: Pump is not bi-rotational. Use the following procedure if
shaft rotation direction is changed.
Reverse shaft rotation of ”W” series gear pump by rotating, as

a group, two bearing blocks and gear housing 180° in relation-
ship to remaining parts of pump. This places pressure port
opposite from original position.
3. Place front and back bearing blocks on a clean surface
Assembly with E-seal grooves facing up. Apply a light coating of
petroleum jelly in the grooves. Coat E-seal and backup
NOTE: Install new seals when reassembling pump or motor. Go to with petroleum jelly. This helps keep seals in place dur-
page 8 for kit part numbers for W-600, W-900, and W-1500 ing reassembly
pumps and motors.
4. Place E-seals, flat side out, into grooves in both bearing

blocks. Carefully place backup ring, flat side out, in
1. Install new shaft seal in mounting flange with part num- groove made by E-seal and groove in bearing block.
ber side facing out. Press seal into seal bore until seal (Note: W900 series pump - In center of backup ring and E-
reaches bottom of bore. Use uniform pressure to pre- seal there is a notch. Make sure notches line up so backup
vent seal misalignment or damage. ring is flush with E-seal). Backup ring in W1500 pump is
symmetrical.
5-56 – JLG Lift – 3121290

5. Place mounting flange, with shaft seal side down, on a 10. Place rear bearing block over drive and idler gear shafts
clean flat surface. with seal side up and open end of E-seal
facing intake side of pump.
6. Apply a light coating of petroleum jelly to exposed face
of front bearing block. 11. Install two dowel pins in mounting flange holes or two
long dowel pins through gear housing if pump is a mul-
tiple section pump.
7. Insert drive end of drive shaft through bearing block

with seal side down and open side of E-seal pointing to
intake side of pump. 12. Apply a light coating of petroleum jelly in grooves on
both sides of gear housing. Coat new O-rings and install
8. Install seal sleeve over drive shaft. Carefully slide drive in grooves.
shaft through shaft seal. Remove seal sleeve from shaft.
9. Install idler gear shaft in remaining position in bearing

block. Apply a light coat of clean oil to face of drive and
idler gears.
3121290 – JLG Lift – 5-57

13. Gently slide gear housing over rear bearing block 15. Install four spacers (if applicable) and hex head bolts
assembly. Slide housing down until it engages dowel through bolt holes in end cover. Hand tighten.
pins. Press firmly in place with hands, do not force or use
any tool. Check intake port in housing is on same side as
open end of E-seal, and marked lines on mounting
flange and gear housing are aligned.
NOTE: Rear bearing block surface should be slightly below gear
housing face. If bearing block is higher than rear face of
gear housing, E-seal or O-ring have shifted out of groove.
Remove gear housing and check seal installation.
16. Place mounting flange of pump in protected jawed vise.

Torque bolts alternately to torque chart specifications.
All torque figures are for ”dry torque” bolts.
Table 5-1.Hydraulic Pump Bolt Torque Chart
Torque Torque
Pump Values, Values, Zinc
Thread Size
Series Black Oxide Plated End
14. Install two remaining dowel pins in rear of gear housing, End Cover Cover
if applicable. Place end cover over back of pump.
W-600 M 8 x 1.25 18-21 ft-lb 16-18 ft-lb
24-30 Nm 21.7-24.4 Nm
W-900 M 10 x 1.5 50-55 ft-lb 38-43 ft-lb

68-75 Nm 51.5-58.3 Nm
W-1500 M 12 x 1.75 80-85 ft-lb 68-73 ft-lb

108-115 Nm 92.2-99 Nm
17. Remove pump from vise.

18. Place a small amount of clean oil in pump inlet and
rotate drive shaft away from inlet one revolution. If drive
shaft binds, disassemble pump and check for assembly
problems. Reassemble pump.
5-58 – JLG Lift – 3121290

Placing Pump Back Into Service 5.4 VARIABLE PUMP

1. If shop test stand is available, use the following proce- Ports and Pressure Gauges
dure for testing rebuilt pumps:
Proper servicing of pumps and motors requires pressure mea-
a. Mount pump on test stand. Make sure proper level sured and monitored at various hydraulic circuit points. The
of clean oil is available in reservoir. Check suction Series 42 pump has several locations at which to take these
line for leaks and obstructions. measurements. The following outlines show gauge port loca-
b. Start pump and run for three minutes at zero pres- tions, and gauge and fitting size for each port.
sure.
Table 5-2. Recommended Gauge Size
c. Intermittently load pump to 500 P.S.I. for three min-
utes.
Recommended
d. Intermittently load pump to 1000 P.S.I. for three Gauge
Pressure Gauge Size
minutes. Port Fitting
Measured
Name
e. Intermittently load pump to 2000 P.S.I. for three PSI Bar
minutes.
M1 & System 10000 600 9/16-18 ORF
f. Remove pump from test stand and check for free- M2 Pressure
ness of drive shaft. Check pump for signs of external Ports A & B
leakage.
M3 Charge 1000 60 3/4-16 ORF
2. If shop test stand is not available, use the following proce-
dure for testing rebuilt pumps: M4 & Servo 1000 60 9/16-18 ORF
M5
a. For engine driven pumps, mount pump on equip-
ment and run pump at 1/2 engine speed at zero L1 & L2 Case 500 35 1-1/16-12
pressure for three minutes. ORF
b. Operate control valve and build pressure intermit-
S Charge Pump 30 in. Hg 1 1-1/16-12
tently for three minutes. Inlet Vacuum Vac. ORF
c. Increase engine speed to full throttle and build
pressure intermittently for three minutes.
d. Stop engine and check pump for external leaks. NFPE Control
The 3-position FNR control, and electric and hydraulic non-
feedback proportional (NFPE and NFPH) controls are non-
feedback type controls. FNR and NFPE controls consist of
pump housing mounted modules. Hydraulic input for NFPH is
received through ports on top of pump [9/16–18 SAE O-ring
fitting].
Non-feedback controls are factory set. Control modules can be
removed to clean ports and change O-rings.
FNR and NFPE orifice plugs are located inside the servo piston
covers. NFPH orifice plugs are located in the NFPH ports. Ori-
fice plugs may be cleaned or replaced.
3121290 – JLG Lift – 5-59

Remove and Install FNR and NFPE Modules SHIM ADJUSTABLE STYLE
1. Clean pump and module housings.

2. Remove four screws retaining module to pump housing (4
mm Int. Hex). Remove module from housing.
3. Remove O-rings from the control ports. Examine ports
for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws. Torque to 3.5 - 4.5 ft-lb (4.7-6.1 Nm).
Remove and Install FNR and NFPE Control Orifices

NOTE: Future models may contain an orifice plate between mod-
ule and pump housing. This will take the place of the orifice
plugs beneath the servo piston cover.
1. Remove servo piston cover. 1. Plug 4. Spring T-Seal

2. O-Ring 5. Poppet
2. Remove orifice plug (1/8" Int. Hex).
3. Shims
3. Examine orifice and port for cleanliness.
Figure 5-107. Shim Adjustable Charge Relief Valve
4. Install orifice plug. Torque to 1.5 - 2.5 ft-lb (2.0-3.4 Nm). Components
Charge Relief Valve

1. Remove shim adjustable charge relief valve plug (1" Hex)
Charge relief valve may be removed for cleaning and installa-
tion of new O-rings. Pressure setting may be changed for dif- from pump housing. Remove O-ring from plug.
ferent charge flows depending on charge pump size and 2. Remove spring and poppet from housing.
pump speed.
3. Do not alter shims which may be installed between
Factory setting is set relative to case pressure at 1800 rpm. spring and valve plug, or interchange parts with another
Actual charge pressure varies at different speeds. valve. Inspect poppet and mating seat in housing for
damage or foreign material.
4. If desired, change charge relief valve setting. An approx-
imate rule of thumb is 4 bar / 1.25 mm (58 psi / 0.050 in).
Effective setting will vary.
To confirm charge relief valve setting, measure charge

pressure (port M3) with pump in stroke. Charge pressure
should level off when relief setting is reached.
5-60 – JLG Lift – 3121290

1. System Pressure Gauge Port M2 7. Case Drain Port L2
2. System Pressure Port B 8. Servo Pressure Gauge Port L4
3. System Pressure Port A 9. Case Drain Port L1
4. System Pressure Gauge Port M1 10. Case Drain Port L1 (non-feedback)
5. Servo Pressure Gauge Port M5 11. Charge Pressure Gauge
6. Case Drain Port L2 (non-feedback) 12. Charge Pump Inlet Port S
Figure 5-108. Gauge Port Locations
3121290 – JLG Lift – 5-61

Plug/ Torque
#
Fitting lb. ft. Nm
1 Servo Gauge Port M4 N/A N/A
2 11/16 20-35 27-47
3 9/16 70-100 95-135
4 Case Drain Port L1 N/A N/A
5 Charge Pressure Gauge M3 N/A N/A
6 Charge Pump Inlet Port S 85 115
7 Case Drain Port L2 N/A N/A
8 Port N N/A N/A
9 System Gauge M1 & M2 N/A N/A
10 System Ports A&B 85 115
11 11/16 20-35 27-47
12 9/16 70-100 95-135
13 11/16 20-35 27-47
14 Servo Gauge M5 N/A N/A
15 11/16 20-35 27-47
Figure 5-109. Plugs/Fittings Size & Torque
5-62 – JLG Lift – 3121290

5. Install new O-ring on valve plug. Reinstall poppet, Shaft Seal and Shaft Replacement
spring, and plug (with shims and O-ring) into pump
housing. Torque to 40-100 ft-lb (55-135 Nm).
SCREW ADJUSTABLE STYLE
1. Retaining Ring 2. Seal Carrier Assembly

1. Lock Nut 4. Spring T-Seal
2. O-Ring 5. Poppet Figure 5-111. Shaft Seal Removal
3. Plug
A lip type shaft seal is used in Series 42 pumps. Seal and shaft
Figure 5-110. Screw Adjustable Charge Relief Valve can be replaced without major unit disassembly. Replacement
Components generally requires removing pump from machine.
1. Mark plug, lock nut, and housing to maintain original

adjustment before removing screw adjustable relief valve
plug. Loosen lock nut (1-1/16" Hex) and remove plug (8
mm Int. Hex). Remove O-ring from plug.
2. Remove spring and poppet from housing.
3. Inspect poppet and mating seat in housing for damage
or foreign material.
4. Install new O-ring on valve plug. Reinstall poppet and
spring. Reinstall plug and lock nut. Torque to 34 - 42 ft-lb
(47-57 Nm), aligning marks made at disassembly.
5. Check and adjust charge pressure if necessary. For screw
adjustable “anti-stall” charge relief valves, an approxi-
mate rule of thumb is 2.8 bar/quarter turn (40 psi/quar-
ter turn).
6. Measure charge pressure (port M3) with pump in stroke.
Charge pressure should level off when relief setting is
reached. 1. O-Ring 4. Use sealant on outside diameter
2. Seal 5. Inside Lip (face down)
3. Seal Carrier 6. Press Seal to Bottom of Seal Carrier
Figure 5-112. Installation of Shaft Seal
3121290 – JLG Lift – 5-63

1. Position pump with shaft facing up.
NOTE: If unit is positioned horizontally when shaft is removed, cyl-

inder block could move out of place, making shaft installa-
tion difficult.
2. Remove retaining ring from housing.

3. Pull out seal carrier assembly.
4. Remove O-ring from seal carrier. To install a new shaft
only, go to step 8.
5. Place seal carrier in an arbor press with shaft bearing
side down and press out old seal. An appropriately sized
pipe spacer or socket wrench can be used as a press
tool. Seal is not reusable.
6. Inspect seal carrier and new seal for damage. Inspect
sealing area on shaft for rust, wear, or contamination.
Polish sealing area on shaft if necessary.
7. Press new seal in shaft bearing side of seal carrier. Seal
lip must face outside of pump. Do not damage seal. Out-
side diameter of seal may be coated with a sealant (e.g.
Loctite High Performance Sealant #59231) before instal-
lation. This helps prevent leaks caused by damage to
seal bore in seal carrier. If shaft is not being replaced go
to step 11.
8. Remove shaft and roller bearing assembly from pump or
motor.
9. Remove retaining ring from roller bearing assembly with
snap ring pliers. Remove roller bearing assembly.
1. Key 4. Roller Bearing

2. Shaft Assembly 5. Shaft
3. Retaining Ring
Figure 5-113. Shaft Components

1. Place roller bearing assembly on new shaft and secure
with retaining ring.
2. Wrap spline or key end of shaft with thin plastic to pre-
vent damage to seal lip during installation. Lubricate
inside diameter of shaft seal with petroleum jelly.
3. Place O-ring on shaft bearing and lubricate with petro-
leum jelly.
4. Slide seal carrier assembly over shaft and into housing
bore. Press against O-ring. Hold inward pressure against
shaft to compress cylinder block spring while pressing seal
carrier into place.
5. Install retaining ring.
5-64 – JLG Lift – 3121290

Charge Pump
NOTE: Disassemble charge pump to inspect and clean, or change
auxiliary shaft drive coupling.
1. Remove auxiliary pump if necessary.

2. Remove screws retaining charge pump cover to pump
housing (Torx T). Seven screws are used with “no pad” or
SAE “A” auxiliary mounting pad charge pump cover, and
six screws are used with SAE “B” auxiliary mounting pad
charge pump cover. Remove charge pump cover, gas-
ket, and cover locating pins.
3. Remove gerotor cover assembly from charge pump
cover or back of pump housing. Remove gerotor cover
O-rings. Two O-rings are used on gerotor cover of all
pumps.
4. Remove gerotor assembly from gerotor cover or pump
housing.
5. Remove gerotor drive pin and drive coupling. Remove
gerotor cover locating pin from pump housing.
6. Inspect each part if they are to be reused. If either gerotor
assembly parts needs to be replaced, they must both be
replaced. Always replace O-rings and charge pump cover
gasket. Inspect journal bearing in gerotor cover for exces-
sive wear.
7. Lubricate gerotor assembly with clean hydraulic oil
before assembly.
8. Install gerotor drive pin into hole in drive coupling.
Apply grease or petroleum jelly to keep in place.
9. Install drive coupling on pump shaft with smaller out-
side diameter facing away from shaft.
10. Install gerotor assembly onto coupling.
11. Install gerotor cover locating pin into pump housing.
Install gerotor cover assembly over gerotor. Locating pin
must engage slot in gerotor cover.
NOTE: Charge pump rotation is determined by location of gerotor
recess and pressure balance hole in gerotor cover. Different
gerotor covers are used for clockwise and counterclockwise
rotation pumps.
1. Cover Retaining Screw 6. Geroter Cover Locating Pin
12. Install new pressure balance O-rings to gerotor cover
2. O-Ring 7. Charge Pump Cover
and retain with petroleum jelly or grease.
3. Geroter Cover Locating Pin
13. Install charge pump cover locating pins and new charge
pump cover gasket. 4. Geroter Assembly 8. Geroter Drive Pin
5. Drive Coupling 9. Gasket
14. Install charge pump cover. Cover must engage gerotor
cover and locating pins. Install charge pump cover
Figure 5-114. Charge Pump Components
screws. Torque evenly to 26 - 32 ft-lb (36-43 Nm).
15. Reinstall auxiliary pump if necessary.
3121290 – JLG Lift – 5-65

5.5 HYDRAULIC COMPONENT START-UP NOTE: Oil used to fill component housing must be clean. Store fill
container properly to prevent contamination.
The goal at hydrostatic system start up is to preserve the
designed life span of the system. Use the following start-up Install 1000 psi (60 bar) pressure gauge in charge pressure
procedure when a new pump or motor is installed or a system gauge port to monitor charge pressure during start-up.
is restarted after a pump or motor has been removed and rein-
It is recommended external control input signal, (electrical
stalled.
connections for EDC), be disconnected at pump control until
after initial start-up. This ensures pump remains in its neutral
position.
THE FOLLOWING PROCEDURE MAY REQUIRE MACHINE TO BE DISABLED
(WHEELS RAISED OFF THE GROUND, WORK FUNCTIONS DISCONNECTED, ETC.)
WHILE PERFORMING PROCEDURE. TO PREVENT INJURY. TAKE NECESSARY
DO NOT START ENGINE UNLESS PUMP IS IN NEUTRAL POSITION (0° SWASH-
SAFETY PRECAUTIONS BEFORE MOVING VEHICLE/MACHINE.
PLATE ANGLE). TAKE PRECAUTIONS TO PREVENT MACHINE MOVEMENT IN
CASE PUMP IS ACTUATED DURING INITIAL START-UP.
Inspect pumps or motors for damage that may have been
incurred during shipping and handling before installation.
”Jog” or slowly rotate engine until charge pressure starts to
Make sure all system components (reservoir, hoses, valves, fit-
rise. Start engine and run at lowest possible RPM until charge
tings, heat exchanger, etc.) are clean before filling with fluid.
pressure is established. Excess air should be bled from system
Fill reservoir with recommended hydraulic fluid. This fluid lines as close to motors as possible.
should be passed through a 10 micron (nominal, no bypass)
filter before entering reservoir. Using contaminated fluid can NOTE: With engine on low idle loosen, do not remove, system lines
damage components and may cause unexpected vehicle/ at motor(s). Continue to run engine at low idle and tighten
machine movement. system lines as soon as oil is observed to leak from them.
When oil is observed to ”leak” at motor, line is full and air is
purged. Tighten system hoses to specified torque.
INSPECT ALL PUMPS OR MOTORS FOR DAMAGE AND CONTAMINATION IF ANY Once charge pressure is established, increase speed to normal
PUMP OR MOTOR IS REPLACED DUE TO INTERNAL DAMAGE. FLUSH AND operating RPM. Charge pressure should be as indicated in the
REPLACE ALL HYDRAULIC SYSTEM FLUID OR DAMAGE TO ENTIRE SYSTEM MAY pump model code. If charge pressure is inadequate, shut
RESULT. down and determine cause.
Inlet line from reservoir to pump must be filled prior to start-

up. Check inlet line for properly tightened fittings, restrictions,
and air leaks. INADEQUATE CHARGE PRESSURE WILL AFFECT OPERATOR'S ABILITY TO CON-
TROL MACHINE.
NOTE: Reservoir is usually above pump inlet. Pressure head cre-
ated by higher oil level helps keep inlet pressures within Shut down engine and connect external control input signal.
acceptable range and prevent high vacuum levels. How- Reconnect machine function(s), if disconnected earlier. Start
ever, air may be trapped due to hose routing or low reser- engine, checking pump remains in neutral. With engine at nor-
voir locations. Bleed air by loosening hose at fitting closest mal operating RPM, slowly check forward and reverse machine
to pump. When oil begins to flow, line is full and air has operation.
been purged. Tighten fitting to specified torque. If tank
needs to be pressurized to start oil flow, take a vacuum Charge pressure may slightly decrease during forward or
reading at pump inlet during operation to verify pump is reverse operation. Continue to cycle slowly between forward
not trying to draw an inlet vacuum higher than its capabil- and reverse for at least five minutes.
ity. Shut down engine, remove gauges, and plug ports. Check res-
ervoir level and add filtered fluid if needed.
Fill pump and motor housing with clean hydraulic fluid before
start up. Fill housing by pouring filtered oil in upper case drain Machine is ready for operation.
port.
NOTE: Use highest possible case drain port. This ensures housing con-
tains as much oil as possible and offers the greatest amount of
lubrication to internal components.
NOTE: It may be easier to fill housing before installing the case drain
line. Component (especially motor) location may prevent case
drain port access after installation.
5-66 – JLG Lift – 3121290

5.6 MAIN VALVE BLOCK PRESSURE SETTING 5.7 PLATFORM VALVE BLOCK PRESSURE SETTING
PROCEDURES PROCEDURES
NOTE: Refer to Figure 5-115., Main Control Valve. NOTE: Refer to Figure 5-116., Platform Control Valves.
Cold temperatures have a significant impact on pressure read- Cold temperatures have a significant impact on pressure read-
ings. JLG Industries Inc. recommends operating machine until ings. JLG Industries Inc. recommends operating machine until
hydraulic system has warmed to normal operating tempera- hydraulic system has warmed to normal operating tempera-
tures. tures.
Check pressures with a calibrated gauge. Pressure readings Check pressures with a calibrated gauge. Pressure readings
must be ± 5% of specified pressures. must be ± 5% of specified pressures.
Turn relief valves clockwise to increase or counter-clockwise to Turn relief valves clockwise to increase or counter-clockwise to
decrease pressure. decrease pressure.
Telescope Platform Level Extend

1. Install high pressure gauge in port M1 (11). 1. Install high pressure gauge in port M2 (9).
2. Activate telescope in. 2. Activate level up to end of stroke. Set relief valve (10) to
2800 psi (190 bar).
3. Set Telescope relief valve (12) to 3300 psi (230 bar).
Main Relief Platform Level Retract

1. Install high pressure gauge in port M1 (7).
2. Activate level down to end of stroke. Set relief valve (8)
2. Raise boom up to end of stroke, or remove hose from
to 1800 psi (125 bar).
port #10 and plug and cap. Activate lift up.
3. Set Main relief valve (13) to 3200 psi (220 Bar). Articulating Jib (AJ Only)
Steer 1. Install high pressure gauge in port M3 (5).
2. Activate Jib up or down. Set relief valve (6) to 1500 psi
(105 bar).
2. Set Steer relief valve (14) to 2500 psi (170 bar).
Lift Down
2. Activate lift down.
3. Set Lift Down relief valve (15) to 1200 psi (80 bar).
Swing
NOTE: Left and right is a single adjustment.

2. Remove one swing hose, and plug and cap, or swing
turntable around until it hits stop. Activate swing.
3. Set Swing relief valve (2) to 1700 psi (120 bar).
3121290 – JLG Lift – 5-67

1. M2 - Proportional Main Pressure Test Port 7. Flow Control Solenoid 13. Proportional Main Relief Valve
2. Swing Relief Valve 8. Lower Lift Solenoid: Bottom - Down, Top - Up 14. Steer Relief Valve
3. Swing Solenoid: Bottom - Left, Top - Right 9. Telescope Solenoid: Bottom - In, Top - Out 15. Lift Down Relief Valve
4. Main Dump Solenoid 10. Flow Control 16. Check Valve
5. Lift Solenoid: Bottom - Down, Top - Up 11. M1 - Telescope Pressure Test Port 17. Check valve
6. Steer Solenoid: Bottom - Right, Top - Left 12. Telescope Relief Valve 18. M4 - Swing Pressure Test Port
19. M3 - Steer Pressure Test Port
Figure 5-115. Main Control Valve
5-68 – JLG Lift – 3121290

1. Rotate Solenoid Valve Assy. 3. Jib Solenoid Valve Assy. 7. Level Retract Pilot Check Valve
Bottom Solenoid - Right Bottom Solenoid - Down 8. Level Retract Relief Valve**
Top Solenoid - Left Top Solenoid - Up 9. M1 - Level Retract Pressure Test Port
2. Level Solenoid Valve Assy. 4. Flow Control Valve 10. Level Extend Relief Valve***
Bottom Solenoid - Down 5. M3 - Jib Pressure Test Port 11. M2- Level Extend Pressure Test Port
Top Solenoid - Up 6. Jib Relief Valve* 12. Flow Control Valve
13. Pilot Check Valve
Figure 5-116. Platform Control Valves
3121290 – JLG Lift – 5-69

NOTES:
5-70 – JLG Lift – 3121290

SECTION 6. JLG CONTROL SYSTEM

6.1 INTRODUCTION speed, and max.-speed for all boom, drive, and steering func-
tions.
Upper lift, swing, and drive are controlled by individual joy-
sticks. Steering is controlled by a rocker switch built in the top
WHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT IS NECESSARY
of the drive joystick. To activate Drive, Lift, and Swing; pull up
TO PROGRAM THE CONTROLLER FOR PROPER MACHINE CONFIGURATION,
the slide lock on the joystick and move the handle in the
INCLUDING OPTIONS.
desired direction.
The control system provides voltage output to the valves and
pump, as programmed, for smooth operation and maximum
AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF cycle time. Ground control speeds for all boom functions can
PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/ also be programmed in the control system.
ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM
The JLG Control System controller has a built in LED to indicate
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5
any faults. The system stores recent faults which may be
CM) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS
accessed for troubleshooting. Optional equipment includes a
ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND FOR BRIEF TIME PERI-
soft touch system, head and tail lights, and ground alarm.
ODS TO AVOID HEAVY SATURATION.
These options may be added later but must be programmed
into the control system when installed.
The JLG designed Control System is a 12 volt based motor con-
trol unit installed on the boom lift. The Control System may be accessed with a custom designed,
direct connect hand held analyzer or wireless adapter using an
The JLG Control System has reduced the need for exposed ter-
app on your Android or iPhone/iPad device. The analyzer or
minal strips, diodes and trimpots and provides simplicity in
wireless output displays two lines of information at a time, by
viewing and adjusting the various personality settings for
scrolling through the program.
smooth control of: acceleration, deceleration, creep, min
Each module has a label with JLG part number and a serial number
containing a date code.

!

"
#

$

%

#
!

!

"
#
Figure 6-1. Hand-Held Analyzer (WANALYZER Controls and Display Similar)
3121290 – JLG Lift – 6-1


&"(
#
!"
)*

#

!"

$

-./0

$
#
+,
%&
#'
Figure 6-2. Controller Block Diagram
6-2 – JLG Lift – 3121290

Connect JLG Control System Analyzer Using Analyzer

1. Connect four pin end of cable supplied with hand-held 1. Power up Control System by turning lower key to plat-
or wireless analyzer to controller module on platform form or ground position and pulling both emergency
box or at controller module inside ground control box. stop buttons out.
Connect other end of cable to analyzer. Analyzer displays the following with machine power on and
NOTE: Cable has a keyed four pin connector at each end. It cannot analyzer connected properly:
be connected backwards.
Figure 6-3. Analyzer Platform Connector
MENU:
HELP:PRESS ENTER
Move between top level menu items using
RIGHT and LEFT arrow keys. To select a dis-
played menu item, press ENTER . To cancel a selected
menu item press ESC . Scroll using right and left arrow
Figure 6-4. Analyzer Ground Control Box Connector keys to select a different menu item.
NOTE: Follow instructions provided with Wireless Analyzer (WAN- Top level menus:
ALYZER) kit. JLG Analyzer application must be downloaded
HELP
and installed to your smartphone or tablet device.
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)
3121290 – JLG Lift – 6-3

If ENTER is selected at the HELP: PRESS ENTER display, Pressing ENTER with any of the above displayed menus,
and a fault is present, the analyzer display scrolls the fault displays additional sub-menus within the selected menu. In
across the screen. If no fault is detected, the display shows: some cases, such as DRIVE, the next level is the parameter or
HELP: EVERYTHING OK. If powered up at the ground station, information to be changed. Refer to the flow chart for what
the display shows: GROUND OK. menus are available within the top level menus. You may only
view the personality settings for selected menus while in
access level 2. Remember, you may always cancel a selected
If ENTER is pressed again, display shows the following:
menu item by pressing the ESCAPE key.
Changing Access Level

When analyzer is first connected, you will be in access level 2
which enables you to only view most settings which cannot be
changed until you enter a password to advance to a lower
level. This ensures a setting cannot be accidentally altered. To
change access level, the correct password must be entered. To
enter password, scroll to ACCESS LEVEL menu. For example:
LOGGED HELP
1: POWER CYCLE (0/0)
Analyzer displays last system fault if any are present. Use right
and left arrow keys to scroll through fault logs and view last 25
faults. Press ESC two times to return to MENU screen.

POWER CYCLE (0/0) indicates a power up.
When a top level menu is selected, a new set of menu items
may be offered: for example: ACCESS LEVEL:
CODE 00000
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
6-4 – JLG Lift – 3121290

Adjust Parameters
Press ENTER to select the ACCESS LEVEL menu. Once you have gained access to level 1, and a personality item
Using UP or DOWN arrow keys, enter first digit of is selected, press UP or DOWN arrow keys to
the password, 3. adjust its value, for example:
Using RIGHT arrow key, position cursor right one space

to enter the second digit of the password.
Use UP or DOWN arrow key to enter second digit

of the password which is 33271.
When correct password is displayed, press ENTER . The

access level displays the following if password was entered
correctly:
DRIVE:
ACCEL 1.0S
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if the UP
arrow is pressed at maximum value or decrease if the
DOWN arrow is pressed at minimum value for any per-

sonality. If value does not change when pressing up and down
arrows, check access level is at access level 1.
MENU:
ACCESS LEVEL 1
Repeat above steps if correct access level is not displayed or
you can not adjust personality settings.
3121290 – JLG Lift – 6-5

Machine Setup There is a setting that JLG strongly recommends you do not
change. This setting is so noted below:
ELEVATION CUTBACK
When a machine digit item is selected, press UP or
DOWN arrow keys to adjust its value, for example: CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFOR-
MANCE OF YOUR MACHINE.
AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF

PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/
ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOMMENDS A MAXIMUM
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES
(30.5CM) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND FOR BRIEF TIME
PERIODS TO AVOID HEAVY SATURATION.
Level Vehicle Description
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
GROUND ALARM:
2 = DRIVE
The effect of the machine digit value is displayed along with
its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when driving. There are certain settings allowed to
install optional features or select the machine model.
When selection the machine model to match the size of the
machine, the personality settings will all default to the factory
recommended setting.
NOTE: Refer to Personality Ranges/Defaults for the recommended
factory settings.
NOTE: Password 33271 allows access to level 1 to change

machine personality settings.
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2. ENTER confirms vehi-

cle is current.
6-6 – JLG Lift – 3121290

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
3121290 – JLG Lift – 6-7

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
6-8 – JLG Lift – 3121290

MENU: HELP: (001)

HELP:PRESS ENTER EVERYTHING OK
LOG:(xxx)
x:xxxxxxxxxxx
TO
MENU: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS:
DIAGNOSTICS DRIVE/STEER BOOM FUNCTIONS
ENGINE
JOYSTICK DRIVE: JOYSTICK LIFT:

FORWARD XXX% MAIN UP XXX%
JOYSTICK STEER: LIFT OUTPUT:

LEFT XXX% MAIN UP XXX%
DRIVE OUTPUT: LIFT UP

FORWARD XXX% COMMANDED:XXXXMA
DRIVE FORWARD: BRAKES STATUS: LIFT DOWN

COMMANDED:XXXXMA LOCKED COMMANDED:XXXXMA
DRIVE REVERSE: CREEP: LIFT OUTPUT

COMMANDED:XXXXMA SWITCH: CLOSED ACTUAL:XXXXMA
DRIVE OUTPUT: CREEP MODE: JOYSTICK SWING:

ACTUAL: XXXXMA OFF LEFT XXX%
STEER OUTPUT: 2-SPEED: SWING OUTPUT:

LEFT XXX% SWITCH: OPEN LEFT XXX%
LEFT TRACK 2-SPEED VALVE SWING LEFT

OUTPUT: FWD XXX% OUTPUT: OFF COMMANDED:XXXXMA
STEER TYPE: HIGH ENGINE SWING RIGHT

NORMAL SWITCH: OPEN COMMANDED:XXXXMA
RIGHT TRACK DRIVE MODE: SWING OUTPUT

ACTUAL: XXXXMA MID ENGINE ACTUAL:XXXXMA
LEFT TRACK FWD DRV. ORIENTATION PLATFORM LEVEL: FLOW VALVE

COMMANDED:XXXXMA FEATURE:DISABLED UP XXX% COMMANDED:XXXXMA
LEFT TRACK REV DRV. ORIENTATION PLATFORM ROTATE: FLOW VALVE

COMMANDED:XXXXMA SWITCH: OPEN LEFT XXX% ACTUAL:XXXXMA
LEFT TRACK DRV. ORIENTATION MAIN TELESCOPE: PLATFORM CONTROL

ACTUAL: XXXXMA OVERRIDE: OPEN IN XXX% VALVE: OFF
RIGHT TRACK DRV. ORIENTATION TOWER TELESCOPE: FUNCTION SPEED:

OUTPUT: FWD XXX% STATUS:CONFIRMED IN XXX% PUMP POT XXX%
RIGHT TRACK FWD DRIVE CONTROL: TOWER LIFT: CREEP

COMMANDED:XXXXMA NORMAL UP XXX% SWITCH: CLOSED
TO
MENU: CRIBBING MODE: JIB LIFT: CREEP MODE:
RIGHT TRACK REV
SYSTEM TEST DISABLED UP XXX% OFF
COMMANDED:XXXXMA
Figure 6-5. Analyzer Software Version 6.8 - Sheet 1 of 6
3121290 – JLG Lift – 6-9

From TO
DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS: DIAGNOSTICS:
ENGINE SYSTEM UMS
BOOM FUNCTIONS LOAD
START SEQUENCE: GROUND MODULE: CHASSIS TILT

NOT ACTIVE BATTERY: XX.XV ANGLE: XX.X
BATTERY VOLTAGE: PLATFORM MODULE: UMS TO TURNTABLE

XX.XV BATTERY: XX.XV ANGLE: XX.X
COOLANT AMBIENT UMS INCLINATION

TEMPERATURE:XXXF TEMPERATURE:XXXF ANGLE: XX.X
ELECTRIC FAN PLATFORM SELECT CHASSIS TILT UMS STATUS:

OUTPUT: OFF KEYSWITCH: OPEN X-AXIS: XX.X NORMAL
ELECTRIC FUEL GROUND SELECT CHASSIS TILT

PUMP OUTPUT: OFF KEYSWITCH: OPEN Y-AXIS: XX.X
ENGINE OIL STATION CONTROL: AUXILIARY POWER

PRESSURE:XXX PSI GROUND SWITCH: OPEN
FUEL SELECTION FOOTSWITCH INPUT HORN

SWITCH: GAS GROUND: OPEN SWITCH: OPEN
FUEL SELECTION FOOTSWITCH INPUT RETURN HYDRAULIC

STATUS: GAS PLATFORM: OPEN FILTER: OPEN
AMBIENT TRANSPORT CHARGE PUMP

TEMPERATURE:XXXF SWITCHES: OPEN FILTER: OPEN
FUEL LEVEL TRANSPORT MODE: SOFT TOUCH LIMIT

SENSOR: OK OUT OF TRANSPORT SWITCH: OPEN
STARTER END OF STROKE STOUCH OR SKYGRD

CRANK TIME: XX S PROXIMITY:CLOSED RELAYS: OPEN
ENGINE SPEED TOWER LIFT ST/SG OVERRIDE

ACTUAL: XXXX RPM PROXIMITY:CLOSED OVERRIDE: OPEN
ENGINE SPEED TOWER TELESCOPE GENSET.WELDER

TARGET: XXXX RPM PROXIMITY:CLOSED SWITCH: OPEN
TOWER POSITION: LIGHTS

RETRACTED SWITCH: OPEN
CABLE BREAK PLATFORM TILT1

SWITCH: CLOSED ANGLE: XX.X
CREEP PLATFORM TILT2

SWITCH: CLOSED ANGLE: XX.X
CREEP MODE: PLATFORM TILT1

OFF VOLTAGE: XX MV
CHASSIS TILT: PLATFORM TILT2

XX.X DEGREES VOLTAGE: XX MV
6-10 – JLG Lift – 3121290

FROM
DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: 1 DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS:
LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
UMS
CAPACITY LENGTH CAN STATISTICS CALIBRATION DATA 1 DATALOG: GROUND MODULE

SWITCH: CLOSED RX/SEC: X LOAD ZERO: ON: XXXh XXm SOFTWARE: XX.XX
CAPACITY ANGLE CAN STATISTICS CALIBRATION DATA 1 DATALOG: GROUND MODULE

SWITCH: CLOSED TX/SEC: X LOAD 500LB: ENGINE: XXXh XXm COST. DATA:XX.XX
PERCENT OF MAX CAN STATISTICS CALIBRATION DATA 1 DATALOG: GROUND MODULE

LOAD: XXX% BUS OFF: X PLATFORM UP: DRIVE: XXXh XXm HARDWARE: REV XX
PLATFORM LOAD CAN STATISTICS CALIBRATION DATA 1

1 DATALOG: GROUND MODULE
STATE: OK PASSIVE: X PLATFORM DN: LIFT: XXXh XXm S/N: XXXXXX
CAN STATISTICS DATALOG: PLATFORM MODULE

MSG ERROR: XXXX SWING: XXXh XXm SOFTWARE: XX.XX
DATALOG: PLATFORM MODULE

TELE: XXXh XXm HARDWARE: REV XX
DATALOG: PLATFORM MODULE

MAX TEMP: XXXF S/N: XXXXXX
DATALOG: PROPULSION MOD

MIN TEMP: XXXF SOFTWARE: XX.XX
DATALOG: TCU MODULE

MAX VOLTS: XX.XV SOFTWARE: XX.XX
DATALOG: TCU MODULE

RENTAL: XXXh XXm HARDWARE: REV XX
CLEAR RENTAL: 1 DATALOG: 1 TCU MODULE

YES:ENTER,NO:ESC ERASE RENTAL? S/N: XXXXXX
GATEWAY MODULE
SOFTWARE: XX.XX
GATEWAY MODULE
HARDWARE: REV XX
ANALYZER:
ANALYZER XX.XX
3121290 – JLG Lift – 6-11

FROM
MENU:
DIAGNOSTICS
MENU: SYSTEM TEST:

SYSTEM TEST ACTIVATE?
MENU: ACCESS LEVEL:

ACCESS LEVEL CODE XXXXXX
TO
MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES:
PERSONALITIES DRIVE STEER LEFT TRACK RIGHT TRACK
MAIN LIFT
DRIVE: STEER: LEFT TRACK: RIGHT TRACK:

ACCEL X.XS MAX SPEED XXX% ACCEL X.XS ACCEL X.XS
DRIVE: LEFT TRACK: RIGHT TRACK:

DECEL X.XS DECEL X.XS DECEL X.XS

MIN FORWARD XXX% MIN FORWARD XXX% MIN FORWARD XXX%

MAX FORWARD XXX% MAX FORWARD XXX% MAX FORWARD XXX%

MIN REVERSE XXX% MIN REVERSE XXX% MIN REVERSE XXX%

MAX REVERSE XXX% MAX REVERSE XXX% MAX REVERSE XXX%

ELEV. MAX XXX% ELEV F MAX XXX% ELEV F MAX XXX%

CREEP MAX XXX% ELEV R MAX XXX% ELEV R MAX XXX%
LEFT TRACK: RIGHT TRACK:

CREEP F MAX XXX% CREEP F MAX XXX%
LEFT TRACK: RIGHT TRACK:

CREEP R MAX XXX% CREEP R MAX XXX%
TO
MENU: TRACK COUNTER
MACHINE SETUP ROTATE MAX XXX%
6-12 – JLG Lift – 3121290

FROM
PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES:
MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE
RIGHT TRACK
MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE:

ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS

DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS

MIN UP XXX% MIN LEFT XXX% MIN UP XXX% MIN IN XXX% MIN IN XXX%

MAX UP XXX% MAX LEFT XXX% MAX UP XXX% MAX IN XXX% MAX IN XXX%

CREEP UP XXX% CREEP LEFT XXX% MIN DOWN XXX% MIN OUT XXX% MIN OUT XXX%

MIN DOWN XXX% MIN RIGHT XXX% MAX DOWN XXX% MAX OUT XXX% MAX OUT XXX%
MAIN LIFT: SWING:

MAX DOWN XXX% MAX RIGHT XXX%
MAIN LIFT: SWING:

CREEP DOWN XXX% CREEP RIGHT XXX%
PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:

PLATFORM LEVEL PLATFORM ROTATE JIB LIFT GROUND MODE GEN SET/WELDER
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: GROUND MODE: GEN SET/WELDER:
ACCEL X.XS ACCEL X.XS ACCEL X.XS MAIN UP: XXX% ENGINE XXXX RPM
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: GROUND MODE:

DECEL X.XS DECEL X.XS DECEL X.XS MAIN DOWN: XXX%

MIN IN XXX% MIN LEFT XXX% MIN UP XXX% SWING: XXX%

MAX IN XXX% MAX LEFT XXX% MAX UP XXX% PLT LEVEL: XXX%

MIN OUT XXX% MIN RIGHT XXX% MIN DOWN XXX% PLT ROTATE: XXX%

MAX OUT XXX% MAX RIGHT XXX% MAX DOWN XXX% MAIN TELE: XXX%
GROUND MODE:
TOWER TELE: XXX%
GROUND MODE:
TOWER UP: XXX%
GROUND MODE:
TOWER DOWN: XXX%
GROUND MODE:
JIB LIFT: XXX%
GROUND MODE:
JIB SWING: XXX%
3121290 – JLG Lift – 6-13

FROM
MENU:
PERSONALITIES
MENU: MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG:

MACHINE SETUP 600S CE PERKINS ECM 133 TEETH IN-CYLINDER
STARTER LOCKOUT: ENGINE SHUTDOWN: TILT: JIB: 4 WHEEL STEER:

DISABLED ENABLED 5 DEGREES NO NO
STOUCH/SKYGUARD: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: CABLE SWITCH:
NO NO MOTION ENABLED NO NO
LOAD SYSTEM: LOAD SENSOR: FUNCTION CUTOUT: GROUND ALARM: DRIVE:

NO 4 UNDER PLATFORM NO MOTION 4WD
TEMPERATURE: LEVELING MODE: DRIVE CONTROL: BOOM CONTROL: CLEARSKY:

FAHRENHEIT ALL FUNCTIONS ENHANCED NORMAL NO
CRIBBING OPTION: FUEL TANK SIZE: ALARM / HORN:

NO 31 GALLON SEPARATE
MENU: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1

CALIBRATIONS TILT SENSOR UMS SENSOR FORD ENGINE LOAD SENSOR DEUTZ SETUP
TILT SENSOR: 1 UMS SENSOR: 1 FORD ENGINE: 1 LOAD SENSOR: 1 DEUTZ SETUP 1
CALIBRATE? CALIBRATE? DISABLE RS-485? CALIBRATE? SETUP X
UMS SENSOR: 1
RAW: XX.X
CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1 CALIBRATIONS: 1

PLAT. LEVELING LEVEL UP CRKPT LEVEL DOWN CRKPT PROP MODULE
PROP MODULE: 1
J1-7 MIN: XXX
PROP MODULE: 1 PROP MODULE: 1

J1-7 MAX: XXX DEADBAND: XXXXX

J1-8 MIN: XXX FF NUM: XXXXX

J1-8 MAX: XXX FF DEN: XXXXX

J1-9 MIN: XXX I NUM: XXXXX

J1-9 MAX: XXX I DEN: XXXXX

J1-10 MIN: XXX NEG ERR: XXXXX

J1-10 MAX: XXX GAIN FLAG: XXXXX
6-14 – JLG Lift – 3121290

NOTE: Adjust personality settings within range for optimum

machine performance.
Table 6-2. Personality Ranges/Defaults
FUNCTION PERSONALITY RANGE DEFAULTS
DRIVE ACCELeration 0.0s to 5.0s 1.0
DECELeration 0.0s to 3.0s 0.5
MINimum speed 1 to 35% 30
MAXimum speed 1 to 100% 60
REVerse MINimum speed 1 to 35% 30
REVerse MAXimum speed 1 to 100% 60
ELEVATED MAXimum speed 1 to 100% 38
CREEP MAXimum speed 1 to 90% 38
Engine RPM 800 to 2900 1800
TOWER LIFT ACCELeration 0.0 to 5.0 1.0
DECELeration 0.0 to 3.0 1.0
MlNimum UP speed 1 to 60% 31
MAXimum UP speed 1 to 100% 47
MINimum DOWN speed 1 to 60% 28
MAXimum DOWN speed 1 to 100% 44
MAIN LIFT ACCELeration 0.0 to 5.0 2.0
MlNimum UP speed 1 to 60% 36
CREEP Maximum UP speed 1 to 65% 45
CREEP maximum DOWN speed 1 to 75% 49
3121290 – JLG Lift – 6-15

SWING ACCELeration 0.0 to 5.0s 2.0
DECELeration 0.0 to 3.0s 1.5
MINimum LEFT speed 1 to 50% 32
MAXimum LEFT speed 1 to 100% 66
CREEP maximum LEFT speed 1 to 65% 51
MINimum RIGHT speed 1 to 50% 38
MAXimum RIGHT speed 1 to 100% 61
CREEP maximum RIGHT speed 1 to 65% 51
TELESCOPE MAIN ACCELeration 0.0 to 5.0 2.0
MINimum IN speed 1 to 65% 27
MAXimum IN speed 1 to 100% 40
MINimum OUT speed 1 to 65% 27
MAXimum OUT speed 1 to 100% 37
PLATFORM LEVEL ACCELeration 0.0 to 5.0 2.5
MINimum UP speed 1 to 65% 15
MlNimum DOWN speed 1to 65% 15
PLATFORM ROTATE ACCELeration 0.1 to 5.0 2.0
MlNimum LEFT speed 1 to 65% 15
MAXimum LEFT speed 1 to 100% 30
MINimum RIGHT speed 1 to 65% 15
MAXimum RIGHT speed 1 to 100% 30
6-16 – JLG Lift – 3121290

JIB LIFT ACCELeration 0.0 to 5.0 3.0
MINimum UP speed 1 to 65% 19
STEER MAXimum speed 1 to 100% 100
GROUND MODE Tower LIFT UP speed 1 to 100% 42
Tower LIFT DOWN speed 1 to 100% 37
Upper LIFT UP 1 to 100% 50
Upper LIFT DOWN 1 to 100% 60
SWING speed 1 to 100% 60
Upper TELEscope speed 1 to 100% 43
BASKET ROTATE speed 1 to 100% 50
BASKET LEVEL speed 1 to 100% 50
JIB LIFT speed 1 to 100% 25

4150365-3
3121290 – JLG Lift – 6-17

Table 6-3. Machine Configuration Programming Information Software Version P6.1 to Present
Configuration Label/ Numb Default

Description
Digit er Number
MODEL NUMBER: 1 400S 1

1
2 450A
3 510A
4 600S
5 600A
6 600SC
7 601S
8 740A
9 800A
10 800S
MARKET: 0 ANSI USA 0

2
1 ANSI EXPORT
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
6-18 – JLG Lift – 3121290


Description
Digit er Number
ENGINE: 1 FORD EFI GAS: Ford LRG425 EFI Gas (Tier 1) 14

3*
* Engine selections 2 FORD EFI D/F: Ford LRG425 EFI dual fuel (Tier 1)
vary depending on
model selection. 3 DEUTZ F4 TIER1: Deutz F4M1011F Diesel (Tier 1)
4 DEUTZ F3 TIER1: Deutz F3M1011F Diesel (Tier 1)
5 CAT. 3024C: CAT 3024C Diesel (Tier 2)
6 CAT. 3044C: CAT 3044C Diesel (Tier 2)
7 PERKINS 404C (Tier 2)
8 DEUTZ F4 TIER2: Deutz F4M2011 Diesel (Tier 2)
9 DEUTZ F3 TIER2: Deutz F3M2011 Diesel (Tier 2)
10 FORD GAS TIER2: Ford LRG425 EFI Gas (Tier 2)
11 FORD D/F TIER2: Ford LRG425 EFI Dual Fuel (Tier 2)
12 DEUTZ ECM: Engine Control Module - ECM (Tier 2 and Tier 3)
13 DUAL FUEL ECM: GM/PSI 3.0L Dual Fuel (Tier 2)
14 PERKINS ECM
15 CAT ECM
FLYWHEEL TEETH: 0 133 TEETH: 133 flywheel teeth. 1

4*
* This menu item is only 1 110 TEETH: 110 flywheel teeth.
visible if Deutz engine
selections 3 or 4 are
selected.
GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2

5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2 IN-CYLINDER: Glow plugs installed in each cylinder.
3121290 – JLG Lift – 6-19


Description
Digit er Number
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air tempera- 0
6 ture; engine start can be attempted at any time during pre-glow.
1 ENABLED: Automatic pre-glow time determined by ambient air tempera-

ture; engine start is NOT permitted until pre-glow is finished.
ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1

7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110
deg. C or the oil pressure is less than 8 PSI.
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep 1
8* when tilted more than 5 degrees and above elevation; also reduces drive
* Certain market selec- speed to creep.
tions will limit tilt 2
options and alter 4 DEGREES: Reduces the maximum speed of all boom functions to creep
default setting. when tilted more than 4 degrees and above elevation; also reduces drive
3 speed to creep.
Note: Any of the selec-
tions above will light the 3 DEGREES: Reduces the maximum speed of all boom functions to creep
tilt lamp when a tilted 4 when tilted more than 3 degrees and above elevation; also reduces drive
condition occurs and will speed to creep.
sound the platform
alarm when the machine 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to
is also above elevation. 5 creep when tilted more than 4 degrees and above elevation; also disallows
tower lift up, tower telescope out, drive, main telescope out and main lift up.
3 DEGREES + CUT: Reduces the maximum speed of all boom functions to

creep when tilted more than 3 degrees and above elevation; also disallows
tower lift up, tower telescope out, drive, main telescope out and main lift up.
JIB: 0 NO: No jib installed. 0

9*
* Only visible under cer- 1 YES: Jib installed which has up and down movements only.
tain model selections.
4 WHEEL STEER: 0 NO: No four-wheel steer installed. 0

10*
* Only visible under cer- 1 YES: Four-wheel steer installed.
6-20 – JLG Lift – 3121290


Description
Digit er Number
STOUCH/SKYGUARD: 0 None: No soft touch or SkyGuard system installed. 0

11
1 SOFT TOUCH - Soft touch only installed.
2 SKYGUARD - Skyguard only installed.
3 BOTH(CUTOUT) - Soft Touch and Skyguard installed.
GEN SET/WELDER: 0 NO: No generator installed. 0

12
1 BELT DRIVE: Belt driven setup.
GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
13*
* Only visible if Gen Set 1 MOTION CUTOUT: Motion cutout in platform mode only.
/ Welder Menu selec-
tion is not 0.
H & T LIGHTS: 0 NO: No head and tail lights installed. 0

14
1 YES: Head and tail lights installed.
CABLE SWITCH: 0 NO: No broken cable switch installed. 0

15*
* Only visible under cer- 1 YES: Broken cable switch installed.
* Certain market and
model selections will
alter the default setting.
LOAD SYSTEM: 0 NO: No load sensor installed. 0

16*
* Only visible under cer- 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5
tain market selections. sec ON, 2 sec OFF).
* Certain market selec-
tions will limit load sys- 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm
tem options or alter beeps (5 sec ON, 2 sec OFF).
default setting.
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS
off ), platform alarm beeps (5 sec ON, 2 sec OFF).
4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out
& main lift up, platform alarm beeps (5 sec ON, 2 sec OFF).
3121290 – JLG Lift – 6-21


Description
Digit er Number
LOAD SENSOR: 0 1 ON ROTATOR: Use the on-board load sensor for all models except those 1
17* which use the Leveling Platform Module.
* Only visible if Load
Sensor Menu selection 1 4 UNDER PLATFORM: Use the EIM for load sensing.
is not 0 and under cer-
tain market selections.
* Certain market selec-
tions will limit load sen-
sor options.
FUNCTION CUTOUT: 0 NO: No drive cutout. 0

18*
* Only visible under cer- 1 BOOM CUTOUT: Boom function cutout while driving above elevation.
tain market selections.
* Certain market selec- 2 DRIVE CUTOUT: Drive & steer cutout above elevation.
tions will limit function
cutout options or alter 3 DRIVE CUT E&T: Drive & steer cutout above elevation and tilted.
default setting.
GROUND ALARM: 0 NO: No ground alarm installed. 3

19*
* Certain market selec- 1 DRIVE: Travel alarm sounds when the drive function is active (Option).
tions will alter default
setting. 2 DESCENT: Descent alarm sounds when lift down is active (Option).
3 MOTION: Motion alarm sounds when any function is active (Option).
DRIVE: 0 4WD: Four wheel drive. 0

20*
* Only visible under cer- 1 2WD: Two wheel drive.
2 2WD W/2-SPEED: Two wheel drive with 2-speed valve.
DISPLAY UNITS: 0 IMPERIAL: Deg F, PSI, LBS. 0

21*
* Certain market selec- 1 METRIC: DEG C, KPA, KGS.
tions will alter default
setting.
6-22 – JLG Lift – 3121290


Description
Digit er Number
LEVELING MODE: 0 ALL FUNCTIONS: Platform level with all functions. 0

22*
* Only visible on 800S 1 LEVEL LIFT/TELESCOPE: Platform level on lift and telescope only.
models.
DRIVE CONTROL: 0 NORMAL: Drive coils are energized from Ground Module. 2
23
1 PROPULSION: Drive coils are energized from Propulsion Module.
2 ENHANCED: Drive coils are energized from Ground Module. Ground side of
drive coils are brought back to current feedback returns.
BOOM CONTROL: 0 NORMAL: Boom function coils are energized from Ground Module. 0
24
1 ENHANCED: Boom function coils are energized from Ground Module.
Ground side of drive coils are brought back to current feedback returns.
CLEARSKY: 0 NO: Clearsky (telematics) option is disabled. 0

25
1 YES: Clearsky (telematics) option is enabled.
CRIBBING OPTION: 0 NO: Cribbing Option is disabled. 0

26
1 YES: Cribbing Option is enabled.
FUEL TANK SIZE: 0 31 Gallon Tank 0

27
1 52 Gallon Tank
ALARM/HORN: 0 SEPERATE: Separate alarm and horn. 0

28
1 COMBINED: Combination alarm and horn.
4150364E
3121290 – JLG Lift – 6-23

NOTE: Bold Italic Numbers indicate default setting. Plain text indicates available selection. Bold, Italic underlined
numbers indicate default when option is factory installed. Shaded cells indicate hidden menu or selection.
450A Series II
ENGINE SHUTDOWN
STOUCH\SKYGUARD
HEAD & TAIL LIGHTS

STARTER LOCKOUT
GEN SET / WELDER

FLYWHEEL TEETH
GEN SET CUTOUT

MODEL NUMBER
4 WHEEL STEER
GLOW PLUGS
MARKET
ENGINE
TILT
JIB
ANSI USA 2 0 14 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 2 3 0 1 0 1 0 1
ANSI EXPORT 2 1 14 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 2 3 0 1 0 1 0 1
CSA 2 2 14 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 2 3 0 1 0 1 0 1
CE 2 3 14 0 1 0 1 2 0 1 0 1 X 2 3 4 5 0 0 0 1 2 3 0 1 0 1 0 1
AUSTRALIA 2 4 14 0 1 0 1 2 0 1 0 1 X 2 3 4 5 0 0 0 1 2 3 0 1 0 1 0 1
JAPAN 2 5 14 0 1 0 1 2 0 1 0 1 1 2 3 4 5 0 0 0 1 2 3 0 1 0 1 0 1
450A Series II
CABLE BREAK SWITCH
FUNCTION CUTOUT
GROUND ALARM
BOOM CONTROL
LEVELING MODE
DRIVE CONTROL
DISPLAY UNITS
LOAD SENSOR
LOAD SYSTEM
DRIVE TYPE
ANSI USA 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0 1 2 0 1 0 1
ANSI EXPORT 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CSA 0 1 0 X X X X 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CE 0 1 0 X 2 3 X 0 1 0 1 X X 0 1 2 3 0 1 2 0 1 0 1
AUSTRALIA 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
JAPAN 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
6-24 – JLG Lift – 3121290

NOTE: Bold Italic Numbers indicate default setting. Plain text indicates available selection. Bold, Italic underlined
numbers indicate default when option is factory installed. Shaded cells indicate hidden menu or selection.
450AJ Series II
ENGINE SHUTDOWN
STARTER LOCKOUT
GEN SET / WELDER

FLYWHEEL TEETH
GEN SET CUTOUT

MODEL NUMBER
4 WHEEL STEER
GLOW PLUGS
SOFT TOUCH
MARKET
ENGINE
TILT
JIB
ANSI USA 2 0 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
ANSI EXPORT 2 1 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
CSA 2 2 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
CE 2 3 11 0 1 0 1 2 0 1 0 1 X 2 3 4 5 1 0 0 1 0 1 0 1
AUSTRALIA 2 4 11 0 1 0 1 2 0 1 0 1 X 2 3 4 5 1 0 0 1 0 1 0 1
JAPAN 2 5 11 0 1 0 1 2 0 1 0 1 1 2 3 4 5 1 0 0 1 0 1 0 1
450AJ Series II
CABLE BREAK SWITCH
HEAD & TAIL LIGHTS
FUNCTION CUTOUT
GROUND ALARM
LEVELING MODE
TEMPERATURE
LOAD SENSOR
LOAD SYSTEM
DRIVE TYPE
ANSI USA 0 1 0 1 0 X X X X 0 1 0 X X X 0 1 2 3 0 1 2 0 1 0 1
ANSI EXPORT 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CSA 0 1 0 1 0 X X X X 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
CE 0 1 0 1 0 X 2 3 X 0 1 0 1 X X 0 1 2 3 0 1 2 0 1 0 1
AUSTRALIA 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
JAPAN 0 1 0 1 0 1 2 3 4 0 1 0 1 2 3 0 1 2 3 0 1 2 0 1 0 1
3121290 – JLG Lift – 6-25

6.8 SYSTEM TEST 3. Pull out Emergency Stop switch and start engine.
The Control System uses a built-in system test to check system

components and functions.
Test from Platform

1. Position Platform/Ground select switch to Platform.
4. Analyzer screen should read:
2. Plug analyzer into connector at base of platform control

box.
5. Use arrow button to reach SYSTEM TEST and press Enter.

Analyzer prompts to activate system test. Press Enter to
activate.
6. Follow flow path in Figure 6-11., System Test Flow Chart
- Platform Tests and go through component tests. Press
ESC key during any part of test to return to main menu
without completing all tests or wait until all tests are
complete. During TEST ALL INPUTS sequence, analyzer
allows control switches to be operated and shows if they
are closed (CL) or open (OP).
6-26 – JLG Lift – 3121290

Figure 6-11. System Test Flow Chart - Platform Tests
3121290 – JLG Lift – 6-27

Test From Ground Station 4. The analyzer screen should read:
1. Set Platform/Ground select switch to Ground.
2. Plug analyzer into connector inside Ground control box.
5. Use arrow button to reach SYSTEM TEST. Press Enter.

Analyzer will prompt you asking if you want to activate
system test. Press Enter again to activate.
6. Follow flow path in Figure 6-12., System Test Flow Chart
- Ground Station Tests and go through component tests.
Press ESC key during any part of test to return to main
menu without completing all tests or wait until all tests
are complete. During TEST ALL INPUTS sequence, the
analyzer allows control switches to be operated and
shows if they are closed (CL) or open (OP).
3. Pull out Emergency Stop switch and start engine.
6-28 – JLG Lift – 3121290

3121290
– JLG Lift –
Figure 6-12. System Test Flow Chart - Ground Station Tests
6-29
Table 6-4. System Test Messages
Message Displayed on Message Displayed on

Description
Analyzer Analyzer
RUNNING Initial display when system test is run; certain “critical” checks are made.
Problems that can be reported include below messages.
ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16
V).
CHECK CAN WIRING The system test cannot run in platform mode unless data is being
received from the platform and ground modules. The system test can-
not run in ground mode unless data is being received from the platform
module.
CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check
speed encoder.
BAD GROUND MODULE An internal problem was detected in the ground module.
HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged.
Check tilt sensor.
HOT ENGINE The engine temperature exceeds 100°C. This is only a warning.
BAD I/O PORTS The controller detected a problem with its internal circuits at switch on.
If other problems are also detected, the controller may need replacing.
SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality
settings at switch on. Check and, if necessary correct, all personality
settings.
OPEN FSW In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW In platform mode, the footswitch must be closed when this message is
displayed; the footswitch MUST BE KEPT CLOSED during the valve &
contactor tests.
BAD FSW The two footswitch signals are not changing together, probably
because one is open-circuit. One footswitch signal (“FSW1”) is routed to
the power module, the other (“FSW2”) is routed to the platform mod-
ule. Check footswitch and wiring.
6-30 – JLG Lift – 3121290


Description
Analyzer Analyzer
TESTING VALVES Indicates valve test is beginning. Each valve is alternately energized
and de-energized; checks are made for open- and short- circuit valve
coils.
NOTE: In platform mode, the footswitch must be closed.
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower tele-
scope valves are not tested if TOWER TELE=NO. Jib valves are not tested
if JIB = NO. Extendable axle valves are not tested if EXT AXLES=NO. Four
wheel steer valves are not tested if 4WS=NO.
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.
CANT TEST VALVES There is a wiring problem, which prevents the valve test from function-
ing correctly. Check valve wiring. Check ground alarm & hour meter
wiring.
XXXXXXX S/C Named valve is drawing too much current so is presumed to be short-
circuited. Check valve wiring.
XXXXXXX O/C Named valve is drawing too little current so is presumed to be open-cir-
cuit. Check valve wiring.
CHECKING INPUTS Indicates 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 any non-neutral platform switch or joystick is
reported; any active cutouts are reported.
In ground mode any non-neutral ground switches is reported; any
active cutouts are reported.
NOTE: Switches not in use (due to the settings of machine digits), are
not checked.
NOTE: Pump pot is checked only for a wire-off condition; it can be at any
demand from creep to maximum.
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.
TESTING LAMPS Indicates lamps test is beginning. Each lamp is energized in turn; a
prompt asks for confirmation the lamp is lit.
ENTER must be pressed or clicked to continue the test.
NOTE: Lamps, which are not in use (due to the settings of machine dig-
its), are not checked.
NOTE: Platform Lamps are only tested in platform mode.
NOTE: The GM overload lamp and 500# capacity lamp are not tested.
NOTE: Head and tail lamps are tested in both platform and ground
mode if enabled by a machine digit.
TESTING ALARMS Indicates alarms test is beginning. Each alarm is energized in turn; a
prompt asks for confirmation the alarm is sounding.
ENTER must be pressed or clicked to continue test.
NOTE: Platform alarm and horn are only tested in platform mode.
NOTE: Ground alarm is not tested if GROUND ALARM = NO.
3121290 – JLG Lift – 6-31


Description
Analyzer Analyzer
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or
clicked, system test ends. If ENTER is pressed or clicked, each operator
input is prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower tele-
scope switches are not tested if TOWER TELE=NO. Jib switches are not
tested if JIB = NO. Extendable axle switches are not tested if EXT
AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX Named switch should be closed.
OPEN XXXXXXX Named switch should be opened.
XXXXXXX XXXXXXX TO MAX Named joystick should be pushed to its full extent in the named direc-
tion.
XXXXXXX XXXXXXX TO MIN Named joystick should be returned to neutral from the named direc-
tion.
PUMP POT TO MAX Pump pot should be turned to maximum.
PUMP POT TO MIN 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 system test is complete. Problems reported should have been
noted and now be rectified. Press ESC/CANCEL to return to
RUN SYSTEM TEST
Analyzer menu.
6-32 – JLG Lift – 3121290

Table 6-5. Fault Codes
DTC Analyzer Text

001 EVERYTHING OK
002 GROUND MODE OK
0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION
0011 FSW OPEN
0012 RUNNING AT CREEP - CREEP SWITCH OPEN
0013 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION
0014 CHASSIS TILT SENSOR OUT OF RANGE
0015 LOAD SENSOR READING UNDER WEIGHT
0035 APU ACTIVE
211 POWER CYCLE
212 KEYSWITCH FAULTY
213 FSW FAULTY
227 STEER SWITCHES FAULTY
2211 FSW INTERLOCK TRIPPED
2212 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
2213 STEER LOCKED - SELECTED BEFORE FOOTSWITCH
2214 DRIVE/STEER LOCKED - JOYSTICK MOVED BEFORE ENABLE
2216 D/S JOY. OUT OF RANGE HIGH
2217 D/S JOY. CENTER TAP BAD
2218 L/S JOY. OUT OF RANGE LOW
2219 L/S JOY. OUT OF RANGE HIGH
2220 L/S JOY. CENTER TAP BAD
2221 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
2222 WAITING FOR FSW TO BE OPEN
2223 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE
2224 FOOTSWITCH SELECTED BEFORE START
234 FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM
235 FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER
236 FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH
237 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH
259 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS
2513 GENERATOR MOTION CUTOUT ACTIVE
2514 BOOM PREVENTED - DRIVE SELECTED
2516 DRIVE PREVENTED - ABOVE ELEVATION
2517 DRIVE PREVENTED - TILTED & ABOVE ELEVATION
2518 DRIVE PREVENTED - BOOM SELECTED
2519 DRIVE PREVENTED - TILTED & EXTENDED OR HIGH ANGLE
2520 FUNCTIONS LOCKED OUT - CONSTANT DATA VERSION IMPROPER
2530 UMS SENSOR FORWARD LIMIT REACHED
2531 UMS SENSOR OUT OF USABLE RANGE
2532 UMS SENSOR BACKWARD LIMIT REACHED
331 BRAKE - SHORT TO BATTERY
332 BRAKE - OPEN CIRCUIT
3311 GROUND ALARM - SHORT TO BATTERY
3316 RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND
3121290 – JLG Lift – 6-33

DTC Analyzer Text

3319 RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY OR OPEN CIRCUIT
3320 RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND
3323 RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY OR OPEN CIRCUIT
3324 LEFT FORWARD DRIVE PUMP - SHORT TO GROUND
3327 LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY OR OPEN CIRCUIT
3328 LEFT REVERSE DRIVE PUMP - SHORT TO GROUND
3331 LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY OR OPEN CIRCUIT
3332 FORWARD DRIVE PUMP - SHORT TO GROUND
3333 FORWARD DRIVE PUMP - SHORT TO BATTERY OR OPEN CIRCUIT
3334 REVERSE DRIVE PUMP - SHORT TO GROUND
3335 REVERSE DRIVE PUMP - SHORT TO BATTERY OR OPEN CIRCUIT
3336 ALTERNATOR POWER - SHORT TO GROUND
3340 AUX POWER - SHORT TO GROUND
3341 AUX POWER - OPEN CIRCUIT
3342 AUX POWER - SHORT TO BATTERY
3346 ELECTRIC FAN - SHORT TO GROUND
3347 ELECTRIC FAN - OPEN CIRCUIT
3348 ELECTRIC FAN - SHORT TO BATTERY
3349 ELECTRIC PUMP - SHORT TO GROUND
3350 ELECTRIC PUMP - OPEN CIRCUIT
3351 ELECTRIC PUMP - SHORT TO BATTERY
3352 LP LOCK - SHORT TO GROUND
3353 LP LOCK - OPEN CIRCUIT
3354 LP LOCK - SHORT TO BATTERY
3355 LP START ASSIST - SHORT TO GROUND
3356 LP START ASSIST - OPEN CIRCUIT
3357 LP START ASSIST - SHORT TO BATTERY
3358 MAIN DUMP VALVE - SHORT TO GROUND
3359 MAIN DUMP VALVE - OPEN CIRCUIT
3360 MAIN DUMP VALVE - SHORT TO BATTERY
3361 BRAKE - SHORT TO GROUND
3362 START SOLENOID - SHORT TO GROUND
3363 START SOLENOID - OPEN CIRCUIT
3364 START SOLENOID - SHORT TO BATTERY
3365 STEER DUMP VALVE - SHORT TO GROUND
3366 STEER DUMP VALVE - OPEN CIRCUIT
3367 STEER DUMP VALVE - SHORT TO BATTERY
3368 TWO SPEED VALVE - SHORT TO GROUND
3369 TWO SPEED VALVE - OPEN CIRCUIT
3370 TWO SPEED VALVE - SHORT TO BATTERY
3371 GROUND ALARM - SHORT TO GROUND
3372 GROUND ALARM - OPEN CIRCUIT
3373 GEN SET/WELDER - SHORT TO GROUND
3374 GEN SET/WELDER - OPEN CIRCUIT
3375 GEN SET/WELDER - SHORT TO BATTERY
3376 HEAD TAIL LIGHT - SHORT TO GROUND
6-34 – JLG Lift – 3121290

DTC Analyzer Text

3377 HEAD TAIL LIGHT - OPEN CIRCUIT
3378 HEAD TAIL LIGHT - SHORT TO BATTERY
3379 HOUR METER - SHORT TO GROUND
3382 PLATFORM LEVEL UP VALVE - SHORT TO GROUND
3383 PLATFORM LEVEL UP VALVE - OPEN CIRCUIT
3384 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY
3385 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND
3386 PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT
3387 PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY
3388 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND
3389 PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT
3390 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY
3391 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND
3392 PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT
3393 PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY
3394 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND
3395 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT
3396 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY
3397 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND
3398 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT
3399 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY
33100 JIB LIFT UP VALVE - SHORT TO GROUND
33101 JIB LIFT UP VALVE - OPEN CIRCUIT
33102 JIB LIFT UP VALVE - SHORT TO BATTERY
33103 JIB LIFT DOWN VALVE - SHORT TO GROUND
33104 JIB LIFT DOWN VALVE - OPEN CIRCUIT
33105 JIB LIFT DOWN VALVE - SHORT TO BATTERY
33106 TOWER LIFT UP VALVE - SHORT TO GROUND
33107 TOWER LIFT UP VALVE - OPEN CIRCUIT
33108 TOWER LIFT UP VALVE - SHORT TO BATTERY
33109 TOWER LIFT DOWN VALVE - SHORT TO GROUND
33110 TOWER LIFT DOWN VALVE - OPEN CIRCUIT
33111 TOWER LIFT DOWN VALVE - SHORT TO BATTERY
33112 TOWER TELESCOPE IN VALVE - SHORT TO GROUND
33113 TOWER TELESCOPE IN VALVE - OPEN CIRCUIT
33114 TOWER TELESCOPE IN VALVE - SHORT TO BATTERY
33115 TOWER TELESCOPE OUT VALVE - SHORT TO GROUND
33116 TOWER TELESCOPE OUT VALVE - OPEN CIRCUIT
33117 TOWER TELESCOPE OUT VALVE - SHORT TO BATTERY
33118 SWING RIGHT VALVE - SHORT TO GROUND
33119 SWING RIGHT VALVE - OPEN CIRCUIT
33120 TELESCOPE IN VALVE - SHORT TO BATTERY
33121 SWING RIGHT VALVE - SHORT TO BATTERY
33122 SWING LEFT VALVE - SHORT TO GROUND
33123 TELESCOPE OUT VALVE - SHORT TO BATTERY
33124 LIFT UP DUMP VALVE - SHORT TO GROUND
3121290 – JLG Lift – 6-35

DTC Analyzer Text

33125 LIFT UP DUMP VALVE - OPEN CIRCUIT
33126 LIFT UP DUMP VALVE - SHORT TO BATTERY
33127 LIFT DOWN HOLDING VALVE - SHORT TO GROUND
33128 LIFT DOWN HOLDING VALVE - OPEN CIRCUIT
33129 LIFT DOWN HOLDING VALVE - SHORT TO BATTERY
33130 THROTTLE ACTUATOR - SHORT TO GROUND
33131 THROTTLE ACTUATOR - OPEN CIRCUIT
33132 THROTTLE ACTUATOR - SHORT TO BATTERY
33133 PLATFORM CONTROL VALVE - SHORT TO GROUND
33134 PLATFORM CONTROL VALVE - OPEN CIRCUIT
33135 PLATFORM CONTROL VALVE - SHORT TO BATTERY
33170 LIFT DOWN VALVE - OPEN CIRCUIT
33171 LIFT DOWN VALVE - SHORT TO BATTERY
33172 LIFT DOWN VALVE - SHORT TO GROUND
33175 JIB ROTATE LEFT VALVE - OPEN CIRCUIT
33176 JIB ROTATE LEFT VALVE - SHORT TO BATTERY
33177 JIB ROTATE LEFT VALVE - SHORT TO GROUND
33178 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT
33179 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY
33180 JIB ROTATE RIGHT VALVE - SHORT TO GROUND
33186 TELESCOPE OUT VALVE - OPEN CIRCUIT
33188 TELESCOPE OUT VALVE - SHORT TO GROUND
33189 TELESCOPE IN VALVE - OPEN CIRCUIT
33190 TELESCOPE IN VALVE - SHORT TO GROUND
33207 HORN - OPEN CIRCUIT
33208 HORN - SHORT TO BATTERY
33209 HORN - SHORT TO GROUND
33279 GLOWPLUG - OPEN CIRCUIT
33280 GLOWPLUG - SHORT TO BATTERY
33281 GLOWPLUG - SHORT TO GROUND
33295 SWING LEFT VALVE - OPEN CIRCUIT
33306 SWING LEFT VALVE - SHORT TO BATTERY
33314 FLOW CONTROL VALVE - OPEN CIRCUIT
33315 FLOW CONTROL VALVE - SHORT TO BATTERY
33316 FLOW CONTROL VALVE - SHORT TO GROUND
33317 DRIVE FORWARD VALVE - OPEN CIRCUIT
33318 DRIVE FORWARD VALVE - SHORT TO BATTERY
33319 DRIVE FORWARD VALVE - SHORT TO GROUND
33320 DRIVE REVERSE VALVE - OPEN CIRCUIT
33321 DRIVE REVERSE VALVE - SHORT TO BATTERY
33322 DRIVE REVERSE VALVE - SHORT TO GROUND
33323 LIFT UP VALVE - OPEN CIRCUIT
33324 LIFT UP VALVE - SHORT TO BATTERY
33325 LIFT UP VALVE - SHORT TO GROUND
33331 DRIVE - CURRENT FEEDBACK READING TOO LOW
33332 LEFT TRACK - CURRENT FEEDBACK READING TOO LOW
6-36 – JLG Lift – 3121290

DTC Analyzer Text

33333 RIGHT TRACK - CURRENT FEEDBACK READING TOO LOW
33408 LEFT TRACK - CURRENT FEEDBACK READING LOST
33409 RIGHT TRACK - CURRENT FEEDBACK READING LOST
33410 DRIVE - CURRENT FEEDBACK READING LOST
341 PLATFORM LEVEL UP VALVE - OPEN CIRCUIT
342 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY
343 PLATFORM LEVEL UP VALVE - SHORT TO GROUND
344 PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
345 PLATFORM LEVEL DOWN VALVE - OPEN CIRCUIT
346 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY
347 PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND
348 PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
349 PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT
3410 PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY
3411 PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND
3412 PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT
3413 PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY
3414 PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND
3415 JIB LIFT UP VALVE - OPEN CIRCUIT
3416 JIB LIFT UP VALVE - SHORT TO BATTERY
3417 JIB LIFT UP VALVE - SHORT TO GROUND
3418 JIB LIFT DOWN VALVE - OPEN CIRCUIT
3419 JIB LIFT DOWN VALVE - SHORT TO BATTERY
3420 JIB LIFT DOWN VALVE - SHORT TO GROUND
3421 JIB ROTATE LEFT VALVE - OPEN CIRCUIT
3422 JIB ROTATE LEFT VALVE - SHORT TO BATTERY
3423 JIB ROTATE LEFT VALVE - SHORT TO GROUND
3424 JIB ROTATE RIGHT VALVE - OPEN CIRCUIT
3425 JIB ROTATE RIGHT VALVE - SHORT TO BATTERY
3426 JIB ROTATE RIGHT VALVE - SHORT TO GROUND
431 FUEL SENSOR - SHORT TO BATTERY
432 FUEL SENSOR - SHORT TO GROUND
433 OIL PRESSURE - SHORT TO BATTERY
434 OIL PRESSURE - SHORT TO GROUND
435 COOLANT TEMPERATURE - SHORT TO GROUND
436 FORD FAULT CODE ##
437 ENGINE TROUBLE CODE
438 HIGH ENGINE TEMP
439 AIR FILTER BYPASSED
4310 NO ALTERNATOR OUTPUT
4311 LOW OIL PRESSURE
4312 485 COMMUNICATIONS LOST
4313 THROTTLE ACTUATOR FAILURE
4314 WRONG ENGINE SELECTED - ECM DETECTED
4322 LOSS OF ENGINE SPEED SENSOR
4323 SPEED SENSOR READING INVALID SPEED
3121290 – JLG Lift – 6-37

DTC Analyzer Text

441 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN
442 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN
445 BATTERY VOLTAGE LOW
662 CANBUS FAILURE - PLATFORM MODULE
664 CANBUS FAILURE - ACCESSORY MODULE
665 CANBUS FAILURE - PROPULSION MODULE
666 CANBUS FAILURE - ENGINE CONTROLLER
6620 CANBUS FAILURE - UMS SENSOR
671 ACCESSORY FAULT
813 CHASSIS TILT SENSOR NOT CALIBRATED
815 CHASSIS TILT SENSOR DISAGREEMENT
816 UMS SENSOR NOT CALIBRATED
817 UMS SENSOR FAULT
825 LSS HAS NOT BEEN CALIBRATED
826 RUNNING AT CREEP - PLATFORM OVERLOADED
827 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED
828 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED
831 PLATFORM LEVELING OVERRIDE ON
832 PLATFORM LEVELING OVERRIDE OFF
833 PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED
834 PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED
835 PLATFORM LEVEL SENSOR #1 - NOT ZERO CALIBRATED
836 PLATFORM LEVEL SENSOR #1 - ZERO OUT OF RANGE
837 PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY
838 PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT
839 PLATFORM LEVEL SENSOR #2 - NOT ZERO CALIBRATED
8310 PLATFORM LEVEL SENSOR #2 - ZERO OUT OF RANGE
8311 PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY
8312 PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT
8313 PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE
8314 PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE
8315 PLATFORM LEVELING SENSOR - DISAGREEMENT
8316 PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST
8317 PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST
8318 PLATFORM LEVELING SYSTEM TIMEOUT
8639 FRONT LEFT STEER VALVE - OPEN CIRCUIT
8640 FRONT LEFT STEER VALVE - SHORT TO BATTERY
8641 FRONT LEFT STEER VALVE - SHORT TO GROUND
8642 FRONT RIGHT STEER VALVE - OPEN CIRCUIT
8643 FRONT RIGHT STEER VALVE - SHORT TO BATTERY
8644 FRONT RIGHT STEER VALVE - SHORT TO GROUND
8645 REAR LEFT STEER VALVE - OPEN CIRCUIT
8646 REAR LEFT STEER VALVE - SHORT TO BATTERY
8647 REAR LEFT STEER VALVE - SHORT TO GROUND
8648 REAR RIGHT STEER VALVE - OPEN CIRCUIT
8649 REAR RIGHT STEER VALVE - SHORT TO BATTERY
6-38 – JLG Lift – 3121290

DTC Analyzer Text

8650 REAR RIGHT STEER VALVE - SHORT TO GROUND
8652 RIGHT TRACK FORWARD VALVE - OPEN CIRCUIT
8653 RIGHT TRACK FORWARD VALVE - SHORT TO BATTERY
8654 RIGHT TRACK FORWARD VALVE - SHORT TO GROUND
8655 RIGHT TRACK REVERSE VALVE - OPEN CIRCUIT
8656 RIGHT TRACK REVERSE VALVE - SHORT TO BATTERY
8657 RIGHT TRACK REVERSE VALVE - SHORT TO GROUND
8658 LEFT TRACK FORWARD VALVE - OPEN CIRCUIT
8659 LEFT TRACK FORWARD VALVE - SHORT TO BATTERY
8660 LEFT TRACK FORWARD VALVE - SHORT TO GROUND
8661 LEFT TRACK REVERSE VALVE - OPEN CIRCUIT
8662 LEFT TRACK REVERSE VALVE - SHORT TO BATTERY
8663 LEFT TRACK REVERSE VALVE - SHORT TO GROUND
871 RETURN FILTER BYPASSED
872 CHARGE PUMP FILTER BYPASSED
998 EEPROM FAILURE - CHECK ALL SETTINGS
9910 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER
9913 FUNCTIONS LOCKED OUT - PROPULSION MODULE SOFTWARE VERSION IMPROPER
9914 PLATFORM MODULE SOFTWARE UPDATE REQUIRED
9915 CHASSIS TILT SENSOR NOT GAIN CALIBRATED
9916 CHASSIS TILT SENSOR GAIN OUT OF RANGE
9917 HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST
9918 HIGH RESOLUTION A2D FAILURE - REINIT LIMIT
9919 GROUND SENSOR REF VOLTAGE OUT OF RANGE
9920 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE
9921 GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY
9922 PLATFORM MODULE FAILURE - HWFS CODE 1
9923 GROUND MODULE FAILURE - HWFS CODE 1
9924 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED
9944 CURRENT FEEDBACK GAINS OUT OF RANGE
9945 CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT
3121290 – JLG Lift – 6-39

Figure 6-13. Control Module And Fault Code Light Locations
6-40 – JLG Lift – 3121290

Table 6-6. Help Fault Codes, Displayed Faults, and Descriptions
Flash Code Fault Displayed on Analyzer Description Priority

None No flash code indicated for the following help messages. They indi-
1
cate a possible problem if vehicle is not operating as expected.
EVERYTHING OK “Normal” help message in platform mode
GROUND MODE OK “Normal” help message in ground mode
FSW OPEN A drive or boom function has been selected but footswitch is open.
RUNNING AT CREEP – CREEP All function speeds limited to creep because creep switch is open.
SWITCH OPEN
RUNNING AT CREEP – TILTED AND All boom function speeds limited to creep because vehicle is tilted
ABOVE ELEVATION and above elevation.
RUNNING AT CUTBACK – OUT OF Drive speed is limited to “ELEVATED MAX” because vehicle is out of
TRANSPORT POSITION transport position.
CHASSIS TILT SENSOR OUT OF Chassis tilt sensor has indicated a tilt angle greater than 19 degrees
RANGE for more than 4 seconds. Not reported during 2 second power-up.
LOAD SENSOR READING UNDER Load sensor is reading 20% or more under calibrated zero point. This
WEIGHT fault may occur if basket is resting on ground. Not reported during 2
second power-up.
ENVELOPE ENCROACHED – Machines with envelope control ONLY. System has detected an
HYDRAULICS SUSPENDED envelope violation
OVER MOMENT – HYDRAULICS Only occurs on machines with moment control. System has
SUSPENDED detected an over moment violation.
UNDER MOMENT – HYDRAULICS Machines with moment control ONLY. System has detected an
SUSPENDED under moment violation.
1/1 Flash code 1/1 indicates a “sleep” mode.
NOT REQUIRED
2/1 Flash code 2/1 indicates problems with footswitch. 2
FSW FAULTY Two footswitch inputs have read the same state for more than one
second. An EMS cycle is required.
KEYSWITCH FAULTY Platform and ground modes selected simultaneously
2/2 Flash code 2/2 indicates problems with drive & steer selection. 3
Except where noted, these faults are not reported during 2 sec-
ond power-up sequence.
DRIVE LOCKED – JOYSTICK MOVED Drive selected before and during footswitch closure. Can be
BEFORE FOOTSWITCH reported during power-up sequence.
FSW INTERLOCK TRIPPED Footswitch closed for seven seconds with no function selected. Can
be reported during power-up sequence.
STEER LOCKED – SELECTED Steer was selected before and during footswitch closure.
BEFORE FOOTSWITCH
STEER SWITCHES FAULTY Both steer switches are active at same time.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if Vref voltage is below
8.1 volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or
a short to battery has occurred.
3121290 – JLG Lift – 6-41


2/2 D/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when center tap voltage is not
(Continued) between 3.08 volts and 3.83 volts. Due to resistor tolerances there is
a +/-.1 volt range around these values where fault may be indicated.
WAITING FOR FSW TO BE OPEN Footswitch closed when platform mode was selected. Can be
reported during power-up sequence.
FOOTSWITCH SELECTED BEFORE User attempted to start machine with footswitch engaged.
START
2/3 Flash code 2/3 indicates problems with boom function selec- 3
tion.
LIFT/SWING LOCKED – JOYSTICK Platform upper lift or swing was selected before and during foot-
MOVED BEFORE FOOTSWITCH switch closure.
PUMP SWITCHES FAULTY – CHECK A boom function (lower lift, telescope, basket level, basket rotate,
DIAGNOSTICS/BOOM jib) has both directions selected together.
PUMP SWITCHES LOCKED – A platform boom function (lower lift, telescope, basket level, basket
SELECTED BEFORE FOOTSWITCH rotate, jib) was selected before key switch or footswitch closure.
PUMP SWITCHES LOCKED – A ground boom function (lower lift, telescope, basket level, basket
SELECTED BEFORE AUX POWER rotate, jib) was selected before aux power.
l/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
l/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if Vref voltage is below
8.1 volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or
a short to battery has occurred.
l/S JOY. CENTERTAP BAD Resistive joysticks: These faults occur when center tap voltage is not
between 3.08 volts and 3.83 volts. Due to resistor tolerances there is
a +/-.1 volt range around these values where fault may be indicated.
PUMP SWITCHES LOCKED – Hydraulic function switch closed before start switch closed.
SELECTED BEFORE START SWITCH
FOOTSWITCH SELECTED BEFORE User attempted to start machine with footswitch engaged.
START
2/4 Flash code 2/4 indicates steering digital inputs are faulty.
NOT REQUIRED
2/5 Flash code 2/5 indicates a function is prevented due to a cutout. 4
BOOM PREVENTED – DRIVE A boom function is selected while a drive function is selected and
SELECTED drive cutout is configured to prevent simultaneous drive & boom
operation.
DRIVE PREVENTED – ABOVE ELEVA- Drive is selected while above elevation and drive cutout is config-
TION ured to prevent drive.
DRIVE PREVENTED – BOOM Drive is selected while a boom function is selected and drive cutout
SELECTED is configured to prevent simultaneous drive & boom operation.
DRIVE PREVENTED – TILTED & Drive is selected while tilted and above elevation and tilt is config-
ABOVE ELEVATION ured to cutout drive.
JIB SWING PREVENTED – IN 1000# User is trying to jib swing in 1000# mode, which is not allowed.
MODE
CAN DONGLE ATTACHED – System allows user to operate all hydraulics with very limited restric-
HYDRAULICS NOT RESTRICTED tions.
MODEL CHANGED – HYDRAULICS User changed model number using analyzer. User must cycle power 11
SUSPENDED – CYCLE EMS before hydraulics system will be active again.
BACKUP BLAM COMMUNICATIONS Serial backup communications link to BLAM module is active
ACTIVE
6-42 – JLG Lift – 3121290


2/5 DISCONNECT ANALYZER AND Ground module needs to use RS232 backup communications link to
(Continued) CYCLE EMS TO PERFORM BOOM BLAM module but an analyzer is connected. Remove analyzer and
RETRIEVAL cycle power
FUNCTIONS LOCKED OUT - PLAT- Major version of platform module does not match major version of
FORM MODULE SOFTWARE VER- ground module
SION IMPROPER
FUNCTIONS LOCKED OUT - CHAS- Major version of chassis module does not match major version of
SIS MODULE SOFTWARE VERSION ground module
IMPROPER
FUNCTIONS LOCKED OUT - BLAM Major version of BLAM module does not match major version of
MODULE SOFTWARE VERSION ground module
IMPROPER
2/7 Flash code 2/7 indicates that accelerator input is faulty.
NOT REQUIRED
2/8 Flash code 2/8 indicates a problem with a hydraulic filter. Not 5
reported during 2 second power-up.
RETURN FILTER BYPASSED Hydraulic return filter clogged
charge pump filter bypassed Charge pump filter clogged
3/1 Flash code 3/1 indicates a contactor did not close when ener-
gized.
NOT REQUIRED
3/2 Flash code 3/2 indicates a contactor did not open when ener-
gized.
NOT REQUIRED
3/3 Flash code 3/3 indicates a driver problem. All driver faults are 6
detected in a similar manner. Open circuit faults are detected
when analog feedback reads too high and output is com-
manded off. Short to ground is detected when analog feedback
reads low and output is commanded on. Short to battery is
detected when analog feedback reads Vbat and output is
commanded off. Not reported during 2 second power-up. An
EMS cycle is required.
RIGHT FORWARD DRIVE PUMP Machines with chassis module ONLY.
SHORT TO GROUND
SHORT TO BATTERY
OPEN CIRCUIT
RIGHT REVERSE DRIVE PUMP Machines with chassis module ONLY.
SHORT TO GROUND
RIGHT REVERSE DRIVE PUMP Machines with chassis module ONLY.
SHORT TO BATTERY
RIGHT REVERSE DRIVE PUMP OPEN Machines with chassis module ONLY.
CIRCUIT
LEFT FORWARD DRIVE PUMP Machines with chassis module ONLY.
SHORT TO GROUND
LEFT FORWARD DRIVE PUMP Machines with chassis module ONLY.
SHORT TO BATTERY
3121290 – JLG Lift – 6-43


3/3 LEFT FORWARD DRIVE PUMP OPEN Machines with chassis module ONLY.
(Continued) CIRCUIT
LEFT REVERSE DRIVE PUMP SHORT Machines with chassis module ONLY.
TO GROUND
LEFT REVERSE DRIVE PUMP SHORT Machines with chassis module ONLY.
TO BATTERY
LEFT REVERSE DRIVE PUMP OPEN Machines with chassis module ONLY.
CIRCUIT
ALTERNATOR/ECM POWER SHORT
TO GROUND
HOUR METER SHORT TO GROUND
HOUR METER SHORT TO BATTERY
HORN SHORT TO GROUND
HORN OPEN CIRCUIT
HORN SHORT TO BATTERY
AUX POWER SHORT TO GROUND
AUX POWER OPEN CIRCUIT
AUX POWER SHORT TO BATTERY
GLOW PLUG SHORT TO GROUND Machines with glowplugs configured ONLY.
GLOW PLUG OPEN CIRCUIT Machines with glowplugs configured ONLY
GLOW PLUG SHORT TO BATTERY Machines with glowplugs configured ONLY
LP LOCK SHORT TO GROUND Machines with dual-fuel engines ONLY.
LP LOCK OPEN CIRCUIT Machines with dual-fuel engines ONLY.
LP LOCK SHORT TO BATTERY Machines with dual-fuel engines ONLY.
LP START ASSIST SHORT TO Machines with dual-fuel engines ONLY.
GROUND
LP START ASSIST OPEN CIRCUIT Machines with dual-fuel engines ONLY.
LP START ASSIST SHORT TO BAT- Machines with dual-fuel engines ONLY.
TERY
MAIN DUMP SHORT TO GROUND
MAIN DUMP OPEN CIRCUIT
MAIN DUMP SHORT TO BATTERY
PARKING BRAKE SHORT TO
GROUND
PARKING BRAKE OPEN CIRCUIT
PARKING BRAKE SHORT TO BAT-
TERY
START SOLENOID SHORT TO Machines with diesel engines ONLY.
GROUND
START SOLENOID OPEN CIRCUIT Machines with diesel engines ONLY.
START SOLENOID SHORT TO BAT- Machines with diesel engines ONLY.
TERY
MAIN LIFT APU SHORT TO GROUND 1250AJP ONLY.
MAIN LIFT APU OPEN CIRCUIT 1250AJP ONLY.
MAIN LIFT APU SHORT TO BATTERY 1250AJP ONLY.
6-44 – JLG Lift – 3121290


3/3 MAIN LIFT PILOT PRESSURE FAIL- 1250AJP ONLY.
(Continued) URE
NO MAIN LIFT PILOT PRESSURE 1250AJP ONLY.
MAIN LIFT PILOT PRESSURE 1250AJP ONLY.
SWITCH FAILURE
STEER DUMP SHORT TO GROUND
STEER DUMP OPEN CIRCUIT
STEER DUMP SHORT TO BATTERY
TWO SPEED SHORT TO GROUND
TWO SPEED OPEN CIRCUIT
TWO SPEED SHORT TO BATTERY
GROUND ALARM SHORT TO Machines with ground alarm configured ONLY.
GROUND
GROUND ALARM OPEN CIRCUIT Machines with ground alarm configured ONLY
GROUND ALARM SHORT TO BAT- Machines with ground alarm configured ONLY
TERY
GEN SET/WELDER SHORT TO Machines with a generator configured ONLY.
GROUND
GEN SET/WELDER OPEN CIRCUIT Machines with a generator configured ONLY.
GEN SET/WELDER SHORT TO BAT- Machines with a generator configured ONLY
TERY
HEAD TAIL LIGHT SHORT TO Machines with headlights option configured ONLY.
GROUND
HEAD TAIL LIGHT OPEN CIRCUIT Machines with headlights option configured ONLY
HEAD TAIL LIGHT SHORT TO BAT- Machines with headlights option configured ONLY
TERY
BASKET UP OVERRIDE SHORT TO Machines with electronic leveling systems ONLY.
GROUND
BASKET UP OVERRIDE OPEN CIR- Machines with electronic leveling systems ONLY.
CUIT
BASKET UP OVERRIDE SHORT TO Machines with electronic leveling systems ONLY.
BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO BATTERY
BASKET DOWN SHORT TO
GROUND
BASKET DOWN OPEN CIRCUIT
BASKET DOWN SHORT TO BATTERY
BASKET DOWN OVERRIDE SHORT Machines with electronic leveling systems ONLY.
TO GROUND
BASKET DOWN OVERRIDE OPEN Machines with electronic leveling systems ONLY.
CIRCUIT
BASKET DOWN OVERRIDE SHORT Machines with electronic leveling systems ONLY.
TO BATTERY
3121290 – JLG Lift – 6-45


3/3 TOWER LIFT APU VALVE STUCK 1250AJP ONLY.
(Continued) OPEN
TOWER LIFT ENABLE STUCK OPEN 250AJP ONLY.
TOWER LIFT ENABLE SHORT TO 250AJP ONLY.
GROUND
TOWER LIFT ENABLE OPEN CIRCUIT 250AJP ONLY.
TOWER LIFT ENABLE SHORT TO 250AJP ONLY.
BATTERY
TOWER TELESCOPE APU SHORT TO 250AJP ONLY.
GROUND
TOWER TELESCOPE APU OPEN CIR- 250AJP ONLY.
CUIT
TOWER TELESCOPE APU SHORT TO 250AJP ONLY.
BATTERY
BASKET LEFT OPEN CIRCUIT
BASKET LEFT SHORT TO BATTERY
BASKET LEFT SHORT TO GROUND
BASKET RIGHT SHORT TO GROUND
BASKET RIGHT OPEN CIRCUIT
BASKET RIGHT SHORT TO BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB DOWN SHORT TO GROUND
JIB DOWN OPEN CIRCUIT
JIB DOWN SHORT TO BATTERY
JIB LEFT SHORT TO GROUND
JIB LEFT OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
JIB RIGHT SHORT TO GROUND
JIB RIGHT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
TOWER UP SHORT TO GROUND
TOWER UP OPEN CIRCUIT
TOWER UP SHORT TO BATTERY
TOWER DOWN SHORT TO GROUND
TOWER DOWN OPEN CIRCUIT
TOWER DOWN SHORT TO BATTERY
TOWER IN SHORT TO GROUND
TOWER IN OPEN CIRCUIT
TOWER IN SHORT TO BATTERY
TOWER OUT SHORT TO GROUND
TOWER OUT OPEN CIRCUIT
TOWER OUT SHORT TO BATTERY
6-46 – JLG Lift – 3121290


3/3 MAIN IN SHORT TO GROUND
(Continued) MAIN IN OPEN CIRCUIT
MAIN IN SHORT TO BATTERY
MAIN OUT SHORT TO GROUND
MAIN OUT OPEN CIRCUIT
MAIN OUT SHORT TO BATTERY
LIFT UP DUMP SHORT TO GROUND
LIFT UP DUMP OPEN CIRCUIT
LIFT UP DUMP SHORT TO BATTERY
LIFT DOWN HOLDING SHORT TO
GROUND
LIFT DOWN HOLDING OPEN CIR-
CUIT
LIFT DOWN HOLDING SHORT TO
BATTERY
LIFT PILOT VALVE SHORT TO Machines with gravity lift down ONLY.
GROUND
LIFT PILOT VALVE SHORT TO BAT- Machines with gravity lift down ONLY.
TERY
LIFT PILOT VALVE OPEN CIRCUIT Machines with gravity lift down ONLY.
LIFT DOWN AUX VALVE SHORT TO Machines with gravity lift down ONLY.
GROUND
LIFT DOWN AUX VALVE SHORT TO Machines with gravity lift down ONLY.
BATTERY
LIFT DOWN AUX VALVE OPEN CIR- Machines with gravity lift down ONLY.
CUIT
TOWER LIFT APU SHORT TO 1250AJP ONLY.
GROUND
TOWER LIFT APU OPEN CIRCUIT 1250AJP ONLY.
TOWER LIFT APU SHORT TO BAT- 1250AJP ONLY.
TERY
MAIN LIFT ENABLE SHORT TO 1250AJP ONLY.
GROUND
MAIN LIFT ENABLE OPEN CIRCUIT 1250AJP ONLY.
MAIN LIFT ENABLE SHORT TO BAT- 1250AJP ONLY.
TERY
TOWER TELE APU VALVE STUCK 1250AJP ONLY.
OPEN
TOWER TELE ENABLE STUCK OPEN 1250AJP ONLY.
TOWER TELE APU SHORT TO 1250AJP ONLY.
GROUND
TOWER TELE APU OPEN CIRCUIT 1250AJP ONLY.
TOWER TELE APU SHORT TO BAT- 1250AJP ONLY.
TERY
PVG VALVE SHORT TO GROUND 1250AJP ONLY.
3121290 – JLG Lift – 6-47


3/3 PVG VALVE OPEN CIRCUIT 1250AJP ONLY.
(Continued) PVG VALVE SHORT TO BATTERY 1250AJP ONLY.
FOX SPARE OUTPUT SHORT TO Fox machines ONLY.
GROUND
FOX SPARE OUTPUT SHORT TO Fox machines ONLY.
BATTERY
FOX SPARE OUTPUT OPEN CIRCUIT Fox machines ONLY.
HOUR METER OPEN CIRCUIT This fault cannot be detected during normal operation. It may be
reported during self test.
RESTRICTED TO TRANSPORT – Machines with electrically released oscillating axles configured
AXLE LOCKOUT VALVE STB OR OC ONLY. A short to battery or open circuit has been detected on axle
lockout valve and machine is restricted to transport position.
RESTRICTED TO TRANSPORT – Machines with electrically released oscillating axles configured
PARKING BRAKE STB ONLY. A short to battery has been detected on parking brake valve
and machine is restricted to transport position.
3/4 Flash code 3/4 indicates a driver problem on a platform valve 6
block valve driver. All driver faults are detected in a similar man-
ner. Open circuit faults are detected when analog feedback
reads too high and output is commanded off. Short to ground is
detected when analog feedback reads low and output is com-
manded on. Short to battery is detected when analog feedback
reads Vbat and output is commanded off. Not reported during 2
second power-up. An EMS cycle is required.
BASKET UP SHORT TO BATTERY
BASKET UP SHORT TO GROUND
BASKET UP OPEN CIRCUIT
BASKET UP SHORT TO BATTERY OR Machines with electronic basket leveling ONLY.
OPEN CIRCUIT
BASKET DOWN SHORT TO BATTERY
BASKET DOWN SHORT TO
GROUND
bASKET DOWN OPEN CIRCUIT
BASKET DOWN SHORT TO BATTERY Machines with electronic basket leveling ONLY.
OR OPEN CIRCUIT
BASKET LEFT SHORT TO BATTERY
BASKER LEFT SHORT TO GROUND
BASKET LEFT OPEN CIRCUIT
BASKET RIGHT SHORT TO BATTERY
BASKET RIGHT SHORT TO GROUND
BASKET RIGHT OPEN CIRCUIT
JIB UP SHORT TO BATTERY
JIB UP SHORT TO GROUND
JIB UP OPEN CIRCUIT
JIB DOWN SHORT TO BATTERY
JIB DOWN SHORT TO GROUND
JIB DOWN OPEN CIRCUIT
JIB LEFT SHORT TO BATTERY
6-48 – JLG Lift – 3121290


3/4 JIB LEFT SHORT TO GROUND
(Continued) JIB LEFT OPEN CIRCUIT
JIB RIGHT SHORT TO BATTERY
JIB RIGHT SHORT TO GROUND
JIB RIGHT OPEN CIRCUIT
PLATFORM CONTROL VALVE Machines with electronic basket leveling ONLY.
SHORT TO BATTERY
PLATFORM CONTROL VALVE Machines with electronic basket leveling ONLY.
SHORT TO GROUND
PLATFORM CONTROL VALVE OPEN Machines with electronic basket leveling ONLY.
CIRCUIT
3/5 Flash code 3/5 indicates a brake pressure problem.
NOT REQUIRED
4/2 Flash code 4/2 indicates that the engine is over temperature.
NOT REQUIRED
4/3 Flash code 4/3 indicates engine problems. These faults are not 9
reported during 2 second power-up sequence except where
noted.
HIGH ENGINE TEMP Occurs when engine temperature is above 117 degrees Celsius for
Ford and 130 degrees Celsius for Deutz engines.
AIR FILTER BYPASSED Air filter clogged
NO ALTERNATOR OUTPUT Engine running for 15 seconds or more and battery voltage still
below 11.5 volts.
LOW OIL PRESSURE If a Deutz engine is configured, oil pressure is below 8 PSI and engine
has been running for at least 10 seconds. If a Ford engine is config-
ured, Ford ECM has reported a low oil pressure fault.
OIL PRESSURE SHORT TO BATTERY If a Deutz engine is configured, this indicates oil pressure sensor is
reading above 6.6 volts.
OIL PRESSURE SHORT TO GROUND If a Deutz engine is configured, this indicates oil pressure sensor is
reading below 0.1 volts for more than 5 seconds. This fault is not
detected during crank.
COOLANT TEMPERATURE SHORT If a Deutz engine is configured, this indicates coolant temperature is
TO GROUND reading below 0.1 volts.
FORD FAULT CODE ## All Ford fault codes except 63 are simply passed through from the
FORD ECM. They only occur if a Ford engine is selected in machine
configuration digits. Can be reported during power-up sequence.
ENGINE FAULT CODE : All J1939 CANBUS ECMs report fault messaging in this format. SPN
###(SPN) :###(FMI) number represents what is broken and FMI number represents how
component is broken.
FORD FAULT CODE UNKNOWN An unrecognized Ford ECM fault code has been received. Can be
reported during power-up sequence.
485 COMMUNICATIONS LOST Ford engine ONLY. No responses received from ECM for 2.5 seconds.
Can be reported during power-up sequence.
FUEL SENSOR SHORT TO BATTERY Fuel sensor reading above 4.3 volts.
FUEL SENSOR SHORT TO GROUND Fuel sensor is reading below 0.2 volts.
WRONG ENGINE SELECTED – ECM Engine Control Module (ECM) detected on the CANBUS. Only
PRESENT applies when non-CANBUS engine setups are configured.
3121290 – JLG Lift – 6-49


4/3 ECM CAN COMMUNICATION LOST Engine is configured to have a CANBUS controlled engine and JLG
(Continued) system does not detect an ECM. This fault can be the result of power
lost to ECM or a break in CANBUS communications connection from
ECM to JLG system.
4/4 Flash code 4/4 indicates problems with battery supply. Not 7
reported
during 2 second power-up.
BATTERY LOW Battery voltage is below 11V for more than 5 seconds. Fault is not
detected
during crank. This is a warning – controller does not shut down.
BATTERY TOO HIGH – SYSTEM Battery voltage is above 16V. EMS recycle required.
SHUT DOWN
BATTERY TOO LOW – SYSTEM SHUT Battery voltage is below 9V.
DOWN
4/5 Flash code 4/5 indicates problems with the S-D CAN based PVG
valves currently used on the 1250AJP only. 7
MAIN LIFT PVG COMMUNICATIONS CAN communications lost with Main Lift PVG valve.
tower lift pvg communications CAN communications lost with Tower Lift PVG valve.
tOWER TELESCOPE PVG COMUNI- CAN communications lost with Tower Telescope PVG valve.
CATIONS
MAIN LIFT PVG internal fault Main boom lift pvg valve internal fault.
tower lift pvg internal fault Tower boom lift pvg valve has an internal fault.
tOWER TELESCOPE PVG internal Tower boom telescope pvg valve internal fault.
fault
MAIN LIFT PVG VALVE HIGH VOLT- Main boom lift pvg valve high excitation voltage.
AGE
TOWER LIFT PVG VALVE HIGH VOLT- Tower boom lift pvg valve high excitation voltage.
AGE
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve high excitation voltage.
HIGH VOLTAGE
MAIN LIFT PVG VALVE LOW VOLT- Main boom lift pvg valve low excitation voltage.
AGE
TOWER LIFT PVG VALVE LOW VOLT- Tower boom lift pvg valve low excitation voltage.
AGE
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve low excitation voltage.
LOW VOLTAGE
MAIN LIFT PVG VALVE STUCK NEU- Main boom lift pvg valve spool stuck in neutral position.
TRAL
TOWER LIFT PVG VALVE STUCK Tower boom lift pvg valve spool stuck in neutral position.
NEUTRAL
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool stuck in neutral position.
STUCK NEUTRAL
MAIN LIFT PVG VALVE STUCK Main boom lift pvg valve spool stuck in extended position.
EXTENDED
TOWER LIFT PVG VALVE STUCK Tower boom lift pvg valve spool stuck in extended position.
EXTENDED
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool stuck in extended position.
STUCK EXTENDED
6-50 – JLG Lift – 3121290


4/5 MAIN LIFT PVG VALVE STUCK Main boom lift pvg valve spool stuck in retracted position.
(Continued) RETRACTED
TOWER LIFT PVG VALVE STUCK Tower boom lift pvg valve spool stuck in retracted position.
RETRACTED
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool stuck in retracted position.
STUCK RETRACTED
MAIN LIFT PVG VALVE Main boom lift pvg valve spool could not achieve command.
OBSTRUCTED
TOWER LIFT PVG VALVE Tower boom lift pvg valve spool could not achieve command.
OBSTRUCTED
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve spool could not achieve com-
OBSTRUCTED mand.
MAIN LIFT PVG VALVE COMMAND Main boom lift pvg valve received invalid control system command.
IMPROPER
TOWER LIFT PVG VALVE COMMAND Tower boom lift pvg valve received invalid control system com-
IMPROPER mand.
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve received invalid control system
COMMAND IMPROPER command.
MAIN LIFT PVG VALVE TIMEOUT Main boom lift pvg valve has not received a position command in
250mS.
TOWER TELESCOPE PVG VALVE Tower boom lift pvg valve has not received a position command in
TIMEOUT 250mS.
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg has not received a position command in
TIMEOUT 250mS.
MAIN LIFT PVG VALVE SETUP FAULT Main boom lift pvg valve setup data is incorrect. Requires valve cali-
bration.
TOWER LIFT PVG VALVE SETUP Incorrect tower boom lift pvg valve setup data. Requires valve cali-
FAULT bration.
TOWER TELESCOPE PVG VALVE Incorrect tower boom telescope pvg valve setup data. Requires
SETUP FAULT valve calibration.
MAIN LIFT PVG VALVE SENT UNREC- Main boom lift pvg valve sent unrecognized fault.
OGNIZED FAULT
TOWER LIFT PVG VALVE SENT Tower boom lift pvg valve sent an unrecognized fault.
UNRECOGNIZED FAULT
TOWER TELESCOPE PVG VALVE Tower boom telescope pvg valve sent an unrecognized fault.
SENT UNRECOGNIZED FAULT
MAIN LIFT PVG VALVE PARAME- Main lift pvg valves spool data is incorrect. Requires valve calibra-
TERS INCORRECT tion.
TOWER LIFT PVG VALVE PARAME- The tower lift pvg valves spool data is incorrect. Requires valve cali-
TERS INCORRECT bration.
TOWER TELESCOPE PVG VALVE The tower telescope pvg valves spool data is incorrect. Requires
PARAMETERS INCORRECT valve calibration.
MAIN LIFT PVG VALVE LOCATION Main lift pvg valve was hosed wrong or wiring incorrect during cali-
IMPROPER bration.
TOWER LIFT PVG VALVE LOCATION Tower lift pvg valve was hosed wrong or wiring incorrect during cali-
IMPROPER bration.
TOWER TELESCOPE PVG VALVE Tower telescope pvg valve was hosed wrong or wiring incorrect dur-
LOCATION IMPROPER ing calibration.
3121290 – JLG Lift – 6-51


4/5 MAIN LIFT PVG VALVE WIRING Power wire for main lift pvg valve not wired to that valve.
(Continued) INCORRECT
TOWER LIFT PVG VALVE WIRING Power wire for tower lift pvg valve not wired to that valve.
INCORRECT
TOWER TELESCOPE PVG VALVE Power wire for tower telescope pvg valve not wired to that valve.
WIRING INCORRECT
5/5 Flash code 5/5 indicates problems with vehicle engine RPM or 8
the encoder. Not reported during 2 second power-up.
SPEED SENSOR READING INVALID Diesel engines only. RPM pickup indicating a speed greater than
SPEED 4000 RPM or approximately 8875 Hz.
SPEED INPUT LOST Diesel engines only. No RPM detected and oil pressure input reading
above 8 PSI for more than three seconds. This is probably due to wir-
ing problems at ground module or a faulty speed sensor.
6/6 Flash code 6/6 indicates problems with the CAN bus. 10
PLATFORM CAN COMMUNICA- Ground module or platform module not receiving CAN messages.
TIONS LOST This is
probably due to wiring problems between platform and ground
modules.
BLAM CAN COMMUNICATIONS Machines with a BLAM ONLY. Ground module or BLAM module not
LOST receiving CAN messages. This is probably due to wiring problems
between BLAM and ground modules.
CHASSIS CAN COMMUNICATIONS Machines with a chassis module ONLY. Ground module or chassis
LOST module is not receiving CAN messages. This is probably due to wir-
ing problems between chassis and ground modules.
CYLINDER LOAD PIN CAN COMMU- Machines with a cylinder load pin ONLY. Ground module or cylinder
NICATIONS LOST load pin not receiving CAN messages. This is probably due to wiring
problems between cylinder load pin and ground module.
EXCESSIVE CAN BUS COMMUNICA- More than 500 Bus Off or more than 500 Bus Passive conditions
TION ERRORS detected by Ground Module in current power cycle.
MAIN ANGL1 CAN COMMUNICA- Control system lost CAN communications with main boom angle
TIONS LOST sensor #1 (1250AJP only)
MAIN ANGL2 CAN COMMUNICA- Control system lost CAN communications with main boom angle
TIONS LOST sensor #2 (1250AJP only)
7/7 Flash code 7/7 indicates problems with a motor.
NOT REQUIRED
8/1 Flash code 8/1 indicates problems with the Chassis tilt detection 10
system.
CHASSIS TILT SENSOR NOT CALI- Leveling (zeroing) calibration not performed for chassis tilt sensor.
BRATED
8/2 Flash code 8/2 indicates problems with the platform load sens- 10
ing system.
LOAD SENSOR NOT CALIBRATED Calibration procedure not been performed for load sensor.
6-52 – JLG Lift – 3121290


8/3 Flash code 8/3 indicates problems with the Basket Leveling sys- 10
tem.
BASKET LEVELING CRACKPOINT UP Only occurs on machines with electronic leveling systems. Indicates
NOT CALIBRATED that the basket up valve crackpoint has not been calibrated
BASKET LEVELING CRACKPOINT Only occurs on machines with electronic leveling systems. Indicates
DOWN NOT CALIBRATED that the basket down valve crackpoint has not been calibrated
BASKET LEVELING SENSOR 1 NOT Only occurs on machines with electronic leveling systems. Indicates
ZERO CALIBRATED that the primary basket leveling tilt sensor has not been calibrated.
BASKET LEVELING SENSOR 1 ZERO Only occurs on machines with electronic leveling systems. Indicates
OUT OF RANGE that the primary basket leveling tilt sensor zero is outside of the
allowable range
BASKET LEVELING SENSOR 1 Only occurs on machines with electronic leveling systems. Indicates
SHORT TO BATTERY that the primary basket leveling tilt sensor is shorted to battery. An
EMS cycle is required.
SHORT TO GROUND OR OPEN CIR- that the primary basket leveling tilt sensor is either shorted to
CUIT ground or is not connected. An EMS cycle is required.
BASKET LEVELING SENSOR 2 NOT Only occurs on machines with electronic leveling systems. Indicates
ZERO CALIBRATED that the secondary basket leveling tilt sensor is not zero calibrated.
BASKET LEVELING SENSOR 2 ZERO Only occurs on machines with electronic leveling systems. Indicates
OUT OF RANGE that the secondary basket leveling system tilt sensor zero is outside
the allowable range.
SHORT TO BATTERY that the secondary basket leveling tilt sensor is shorted to battery.
An EMS cycle is required.
SHORT TO GROUND OR OPEN CIR- that the secondary basket leveling tilt sensor is either shorted to
CUIT ground or not connected. An EMS cycle is required.
BASKET LEVELING TILT REFERENCE Only occurs on machines with electronic leveling systems. Indicates
1 OUT OF RANGE that the reference voltage for the primary basket leveling tilt sensor
is outside the expected range (4.9 to 5.1 volts). An EMS cycle is
required.
BASKET LEVELING TILT REFERENCE Only occurs on machines with electronic leveling systems. Indicates
2 OUT OF RANGE that the reference voltage for the secondary basket leveling tilt sen-
sor is outside the expected range. (4.9 to 5.1 volts). An EMS cycle is
required.
BASKET LEVELING TILT SENSOR Only occurs on machines with electronic leveling systems. Indicates
DIFFERENCE TOO GREAT that the basket leveling tilt readings both appear to be good but
their measurements do not agree within a specified adjustable toler-
ance. An EMS cycle is required.
BASKET LEVELING SYSTEM TIME- Only occurs on machines with electronic leveling systems. Indicates
OUT that the basket was not able to maintain the desired level within an
adjustable range for and adjustable time
BASKET LEVELING OVERRIDE ON User has forced basket leveling on through Access Level 0.
BASKET LEVELING OVERRIDE OFF User has forced basket leveling off through Access Level 0.
BASKET LEVELING TILT SENSOR 1 Communications have been lost with a serial leveling sensor. Only
COMMUNICATIONS LOST on 1200S and 1350S models. An EMS cycle is required.
BASKET LEVELING TILT SENSOR 2 Communications have been lost with a serial leveling sensor. Only
COMMUNICATIONS LOST on 1200S and 1350S models. An EMS cycle is required.
3121290 – JLG Lift – 6-53


8/4 Flash code 8/4 indicates problems with the envelope system. 10
Only occur on machines with envelope control.
BOOM ANGLE SENSOR DISAGREE- The boom angle sensors are reporting angles that differ too greatly.
MENT An EMS cycle is required.
BOOM LENGTH SWITCH FAILED The boom length switch inputs are reporting the same state. An EMS
cycle is required.
BOOM LENGTH SWITCH/SENSOR The boom length switch and sensor differ in their reports of
DISAGREEMENT extended or retracted. An EMS cycle is required.
BOOM LENGTH SENSOR NOT The boom length sensor has not detected a change in length while
DETECTING LENGTH CHANGE the user is commanding telescope. An EMS cycle is required.
BOOM LENGTH SENSOR OUT OF Indicates that the voltage for the boom length sensor is above the
RANGE HIGH expected range.
BOOM LENGTH SENSOR OUT OF Indicates that the voltage for the boom length sensor is below the
RANGE LOW expected range.
BOOM LENGTH SENSOR VALUE Indicates the length reported for the boom length sensor is above
OUT OF RANGE HIGH the expected range. An EMS cycle is required.
BOOM LENGTH SENSOR VALUE Indicates the length reported for the boom length sensor is below
OUT OF RANGE LOW the expected range. An EMS cycle is required.
BOOM ANGLE SENSOR #1 COMMU- Boom angle sensor #1 lost communications with the BLAM. An EMS
NICATIONS FAULT cycle is required.
BOOM ANGLE SENSOR #2 COMMU- Boom angle sensor #2 lost communications with the BLAM. An EMS
NICATIONS FAULT cycle is required.
ANGLE SENSOR #1 INVALID ANGLE An EMS cycle is required.
ANGLE SENSOR #2 INVALID ANGLE An EMS cycle is required.
WRONG TELE RESPONSE The boom telescope is contrary to the user command
WRONG LIFT RESPONSE The boom lift is contrary to the user command
TOWER ANGLE SENSOR DISAGREE- The tower angle sensors are reporting angles that differ too greatly.
MENT An EMS cycle is required.
TOWER LENGTH SENSOR DIS- The tower length sensors are reporting angles that differ too greatly.
AGREEMENT An EMS cycle is required.
MAIN ANGLE SENSOR DISAGREE- The main boom angle sensors are reporting angles that differ too
MENT greatly. An EMS cycle is required.
BOOM LENGTH SENSOR #1 OUT OF Reported from the BLAM, indicates tower length sensor one value is
RANGE HIGH out of range high.
BOOM LENGTH SENSOR #1 OUT OF Reported from the BLAM, indicates tower length sensor one value is
RANGE LOW out of range low.
BOOM LENGTH SENSOR #2 OUT OF Reported from the BLAM, indicates tower length sensor two value is
RANGE HIGH out of range high.
BOOM LENGTH SENSOR #2 OUT OF Reported from the BLAM, indicates tower length sensor two value is
RANGE LOW out of range low.
TWR LENGTH SENSOR NOT Tower tele is being commanded and the length sensors are not
DETECTING LENGTH CHANGE changing value.
TWR LENGTH MOVEMENT WITH- Tower length is changing without a tower tele command
OUT CMD
TWR LENGTH SENSOR ONE VALUE This fault is reported by the Ground module when the length sensor
OUT OF RANGE HIGH value is outside the constant data limit
TWR LENGTH SENSOR ONE VALUE This fault is reported by the Ground module when the length sensor
OUT OF RANGE LOW value is outside the constant data limit
6-54 – JLG Lift – 3121290


8/4 TWR LENGTH SENSOR TWO VALUE This fault is reported by the Ground module when the length sensor
(Continued) OUT OF RANGE HIGH value is outside the constant data limit
TWR LENGTH SENSOR TWO VALUE This fault is reported by the Ground module when the length sensor
OUT OF RANGE LOW value is outside the constant data limit
TWR ANGL1 INVALID ANGLE Tower boom angle sensor #1 out of range
TWR ANGL2 INVALID ANGLE Tower boom angle sensor #2 out of range
INVALID ANGLE SENSOR #1 MODEL Wrong tower angle sensor Mfgr. Installed on a 1250AJP (Must be a
Rieker, not Spectron)
INVALID ANGLE SENSOR #2 MODEL Wrong tower angle sensor Mfgr. Installed on a 1250AJP (Must be a
Rieker, not Spectron)
MAIN ANGL1 INVALID ANGLE Main boom angle sensor #1 out of range
MAIN ANGL2 INVALID ANGLE Main boom angle sensor #2 out of range
MAIN ANGLE SENSOR NOT The main boom is being commanded to move and the main angle
DETECTING ANGLE CHANGE sensors are not detecting any movement
MAIN ANGLE MOVEMENT WITH- The main boom angle is changing without a main lift command
OUT CMD
WRONG TWR TELE RESPONSE The tower telescope is moving in the opposite direction the user is
commanding.
WRONG TWR LIFT RESPONSE The tower lift is moving in the opposite direction the user is com-
manding
TWR CYL ANGLE SENSOR OUT OF The tower cylinder angle sensor is below 4721 A/D counts
RANGE LOW
TWR CYL ANGLE SENSOR OUT OF The tower cylinder angle sensor is above 29535 A/D counts.
RANGE HIGH
TWR CYL ANGLE NOT DETECTING The cylinder angle is not changing during a tower lift up/down user
ANGLE CHANGE command.
TWR CYL ANGLE MOVEMENT The cylinder angle is changing without a tower lift command
WITHOUT CMD
MAIN TRN ANGLE SW FAILED The system detected a disagreement of the N.O. vs N.C. contacts on
the main boom angle switch.
TWR TRN SW DISAGREEMENT The system detected a disagreement between the tower boom
length switch and the tower length sensors.
TRN DUAL CAP SWITCHES BAD The system detected both the Dual capacity and the transport
switches are bad.
TRN DUAL CAP BAD TRANSITION The system detected that the Dual capacity or the transport
switches changed state out of order.
MAIN TRN LEN SW DISAGREEMENT The system detected a disagreement between the main boom
transport length switches.
DCAP LEN SW DISAGREEMENT The system detected a disagreement between the main boom dual
capacity length switches.
MAIN BOOM TRN ANGLE SW/SEN- The system detected a disagreement between the main boom
SOR DISAGREEMENT transport angle switch and the main boom angle sensors.
CYL ANGLE SENSOR/SW DIS- The system detected a disagreement of the tower angle input from
AGREEMENT the BLAM and the tower cylinder angle sensor.
3121290 – JLG Lift – 6-55


8/5 Flash code 8/5 indicates problems with the moment or load pin 10
system. Only occur on machines with moment or load pin con-
trol. An EMS cycle is required.
MOMENT PIN HORIZONTAL FORCE The horizontal force is out of the allowed range.
OUT OF RANGE
MOMENT PIN VERTICAL FORCE The vertical force is out of the allowed range.
OUT OF RANGE
LOAD PIN HORIZONTAL FORCE The horizontal force is out of the allowed range.
OUT OF RANGE
LOAD PIN VERTICAL FORCE OUT OF The vertical force is out of the allowed range.
RANGE
MOMENT PIN SENSOR FAULT The moment pin has reported a fault flag.
LOAD PIN SENSOR FAULT The load pin has reported a fault flag.
NEW MOMENT PIN DETECTED A moment pin was detected on the system different from the one
FAULT used to calibrate the machine.
NEW LOAD PIN DETECTED FAULT A load pin was detected on the system different from the one used to
calibrate the machine.
8/6 Flash code 8/6 indicates steering system problem. An EMS cycle 10
is required except as noted.
RESTRICTED TO TRANSPORT – OSC Only occurs on machines with electrically released oscillating axles
AXLE PRESS SW DISAGREEMENT configured. The oscillating axle pressure switch indicates pressure
when machine is not driving or does not indicate pressure when
machine is driving and machine is restricted to transport position.
AXLE EXT STB OR OC A short to battery or open circuit was detected on the axles exten-
sion valve.
AXLE EXT STG A short to ground was detected on the axles extension valve.
AXLE RET STB OR OC A short to battery or open circuit was detected on the axles retract
valve.
AXLE RET STG A short to ground was detected on the axles retract valve.
RT FNT STEER RT STB OR OC A short to battery or open circuit has been detected on the right
front steer right valve.
RT FNT STEER RT STG A short to ground has been detected on the right front steer right
valve.
RT FNT STEER LT STB OR OC A short to battery or open circuit has been detected on the right
front steer left valve.
RT FNT STEER LT STG A short to ground has been detected on right front steer left valve.
LT FNT STEER RT STB OR OC A short to battery or open circuit has been detected on the left front
steer right valve.
LT FNT STEER RT STG A short to ground has been detected on left front steer right valve.
LT FNT STEER LT STB OR OC A short to battery or open circuit has been detected on the left front
steer left valve.
LT FNT STEER LT STG A short to ground has been detected on the left front steer left valve.
RT REAR STEER RT STB OR OC A short to battery or open circuit has been detected on the right rear
steer right valve.
RT REAR STEER RT STG A short to ground has been detected on right rear steer right valve.
6-56 – JLG Lift – 3121290


8/6 RT REAR STEER LT STB OR OC A short to battery or open circuit has been detected on right rear
(Continued) steer left valve.
RT REAR STEER LT STG A short to ground has been detected on right rear steer left valve.
LT REAR STEER RT STB OR OC Left rear steer right valve short to battery or open circuit.
LT REAR STEER RT STG Left rear steer left valve short to ground.
LT REAR STEER LT STB OR OC Left rear steer left valve short to battery or open circuit.
LT REAR STEER LT STG Left rear steer left valve short to ground.
FRONT LEFT WHEEL FAULT – CHECK Steering angle sensor decoupled.
MOUNTING
FRONT RIGHT WHEEL FAULT – Steering angle sensor decoupled.
CHECK MOUNTING
REAR LEFT WHEEL FAULT – CHECK Steering angle sensor decoupled.
MOUNTING
REAR RIGHT WHEEL FAULT – CHECK Steering angle sensor decoupled.
MOUNTING
FRONT LEFT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condi-
tion clears.
FRONT RIGHT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condi-
tion clears.
REAR LEFT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condi-
tion clears.
REAR RIGHT WHEEL BLOCKED Wheel not responding to steer commands. Fault clears when condi-
tion clears.
FRONT LEFT WHEEL SENSOR OUT Steering angle sensor short to ground or open circuit detected.
OF RANGE LOW
FRONT LEFT WHEEL SENSOR OUT Steering angle sensor short to battery detected.
OF RANGE HIGH
FRONT RIGHT WHEEL SENSOR OUT Steering angle sensor short to ground or open circuit detected.
OF RANGE LOW
FRONT RIGHT WHEEL SENSOR OUT Steering angle sensor short to battery detected.
OF RANGE HIGH
REAR LEFT WHEEL SENSOR OUT OF Steering angle sensor short to ground or open circuit detected.
RANGE LOW
REAR LEFT WHEEL SENSOR OUT OF Steering angle sensor short to battery detected.
RANGE HIGH
REAR RIGHT WHEEL SENSOR OUT Steering angle sensor short to ground or open circuit detected.
OF RANGE LOW
REAR RIGHT WHEEL SENSOR OUT Steering angle sensor short to battery detected.
OF RANGE HIGH
8/7 Flash code 8/7 indicates new main angle sensors 10
NEW MAIN ANGL1 SENSOR System detected a different main angle #1 sensor than it was cali-
DETECTED brated with. (1250AJP only.)
NEW MAIN ANGL2 SENSOR System detected a different main angle #2 sensor than it was cali-
DETECTED brated with. (1250AJP only.)
3121290 – JLG Lift – 6-57


9/9 Flash code 9/9 indicates problems with the controller or the user 11
disabling safety systems from Access Level 0.
PLATFORM MODULE SOFTWARE Platform module code is too old to support the EIM or BPE load sen-
UPDATE REQUIRED sor and machine is configured to use one of these two sensors. PM
code must be updated to a newer version.
GROUND MODULE CONSTANT Ground module has old constant data that is not compatible with
DATA UPDATE REQUIRED current ground module software. GM constant data must be
updated to a newer
version. An EMS cycle is required.
HIGH RESOLUTION A2D FAILURE – ADS1213 chip in the platform module has stopped asserting its
INTERRUPT LOST interrupt (DRDY) line for some reason. An EMS cycle is required.
HIGH RESOLUTION A2D FAILURE- ADS1213 has needed to be reset 3 or more times. An EMS cycle is
REINIT LIMIT required.
PLATFORM MODULE FAILURE: hwfs Platform module V(Low) FET has failed. An EMS cycle is required.
CODE 1
GROUND MODULE FAILURE: hwfs Ground module V(Low) FET has failed. An EMS cycle is required.
CODE 1
GROUND SENSOR REF VOLTAGE Seven volt reference voltage for joysticks, sensors, etc. is out of
OUT OF RANGE range. Not reported during 2 second power-up. An EMS cycle is
required.
GROUND MODULE FAILURE: hIGH Hardware based high side driver cutout circuit fault. An EMS cycle is
SIDE DRIVER CUTOUT FAULTY required.
PLATFORM SENSOR REF VOLTAGE These faults occur when the seven volt reference voltage used for
OUT OF RANGE the joysticks, sensors, etc goes out of range. Not reported during 2
second power-up. An EMS cycle is required.
EEPROM FAILURE – CHECK ALL SET- EEPROM critical failure. Personalities, machine configuration digits,
TINGS etc may be reset to default values and should be checked. An EMS
cycle is required.
CHASSIS TILT SENSOR NOT GAIN Chassis tilt sensor calibration information has been lost. Machine
CALIBRATED indicates it is tilted at all times. This calibration data is programmed
into unit at the factory.
CHASSIS TILT SENSOR GAIN OUT OF Chassis tilt sensor calibration has become corrupted. This calibra-
RANGE tion data is programmed into unit at the factory.
ENVELOPE CONTROL DISABLED Machines with envelope control ONLY. User has forced envelope
control off with analyzer from Access Level 0.
MOMENT CONTROL DISABLED Only occurs on machines with envelope control ONLY. The user has
forced moment control off with the analyzer from Access Level 0.
STEER SENSORS NOT CALIBRATED Machines with a chassis module ONLY. Steer sensors require calibra-
tion.
BOOM SENSORS NOT CALIBRATED Machines with a BLAM module ONLY. Boom sensors require calibra-
tion.
LIFT CRACKPOINTS NOT CALI- 1200S and 1350S machines ONLY. Lift valves require a calibration.
BRATED
TELESCOPE CRACKPOINTS NOT 1200S and 1350S machines ONLY. Telescope valves require a calibra-
CALIBRATED tion.
DRIVE CRACKPOINTS NOT CALI- 1200S and 1350S machines ONLY. Drive valves require a calibration.
BRATED
6-58 – JLG Lift – 3121290


9/9 BLAM SENSOR SUPPLY OUT OF Supply voltage for boom angle sensors is above expected range. An
(Continued) RANGE HIGH EMS cycle is required.
BLAM SENSOR SUPPLY OUT OF Supply voltage for boom angle sensors is below expected range. An
RANGE LOW EMS cycle is required.
LENGTH SENSOR REF VOLTAGE Supply voltage for boom length sensors is above expected range. An
HIGH EMS cycle is required.
LENGTH SENSOR REF VOLTAGE Supply voltage for boom length sensors is below expected range.
LOW An EMS cycle is required.
BLAM HIGH RES A/D FAILURE High resolution analog to digital converter in the BLAM module has
failed. An EMS cycle is required.
CHASSIS SENSOR SUPPLY OUT OF Supply voltage for chassis sensors is below expected range. An EMS
RANGE LOW cycle is required.
CHASSIS SENSOR SUPPLY OUT OF Supply voltage for chassis sensors is above expected range. An EMS
RANGE HIGH cycle is required.
BLAM BACKUP COMMUNICATIONS Backup communications link to the BLAM failed test at startup.
LINK FAULTY
BLAM BACKUP COMMUNICATIONS Backup communications link to the BLAM module was activated but
LOST - HYDRAULICS SUSPENDED could not establish/maintain communications with the BLAM.
4150461-E
3121290 – JLG Lift – 6-59

NOTES:
6-60 – JLG Lift – 3121290

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERAL Polarity
This section contains basic electrical information and sche- Getting a negative Voltage or current reading when expecting
a positive reading frequently means the leads are reversed.
matics for locating and correcting most electrical problems. If
Check what reading is expected, location of the signal and
a problem develops which is not presented in this section or
leads are correctly connected to the device under test. Also
corrected by listed corrective actions, obtain technically quali- check the lead on the "COM" port goes to the ground or nega-
fied guidance before proceeding with any additional mainte- tive side of the signal and lead on the other port goes to the
nance. positive side of the signal.
NOTE: Some procedures/connectors shown in this section may Scale

not apply to all models.
M = Mega = 1,000,000 * (Displayed Number)
7.2 MULTIMETER BASICS k = kilo = 1,000 * (Displayed Number)

m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM) can
μ = micro = (Displayed Number) / 1,000,000
be used for troubleshooting your equipment. This section
shows diagrams of a common, digital VOM configured for sev- Example: 1.2 kΩ = 1200 Ω
eral different circuit measurements. Instructions for your VOM Example: 50 mA = 0.05 A
may vary. Please consult the meter 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 cir-
cuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen- Figure 7-1. Voltage Measurement (DC)
tle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector. • If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
Min/Max • Use firm contact with meter leads
"Min/Max" recording feature of some meters can help when

taking measurements of intermittent conditions while alone.
For example, you can read voltage applied to a solenoid when
it is only operational while a switch, far from the solenoid and
meter, is held down.
3121290 – JLG Lift – 7-1

Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement
• Some meters require a separate button press to enable

audible continuity testing
• Circuit power must be turned OFF before testing conti-
Figure 7-2. Resistance Measurement nuity
• First test meter and leads by touching leads together. • Disconnect component from circuit before testing
Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads
tance)
• First test meter and leads by touching leads together.
• Circuit power must be turned OFF before testing resis-
Meter should produce an audible alarm, indicating
tance
continuity
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
7-2 – JLG Lift – 3121290

Current Measurement • To prevent oxidation at mechanical joint between male

and female pins.
• To prevent electrical malfunction caused by low level con-
ductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Com-
pound to the electrical connectors. This procedure applies to
all plug connections not enclosed in a box. Silicone grease
should not be applied to connectors with external seals.
1. To prevent oxidation, silicone grease must be packed
completely around male and female pins on the inside
of the connector prior to assembly. This is most easily
achieved by using a syringe.
NOTE: Over a period of time, oxidation increases electrical resis-
tance at the connection, eventually causing circuit failure.
2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.
NOTE: This condition is especially common when machines are

pressure washed since the washing solution is much more
Figure 7-4. Current Measurement (DC) conductive than water.
• Set up meter for expected current range 3. Anderson connectors for battery boxes and battery
• Be sure to connect meter leads to correct jacks for chargers should have silicone grease applied to contacts
selected current range only.
• If meter is not auto ranging, set it to correct range (See NOTE: Curing-type sealants can also be used to prevent shorting
multi meter’s operation manual) and would be less messy, but make future pin removal diffi-
cult.
When applied to electrical connections, dielectric grease helps
7.3 APPLYING SILICONE DIELECTRIC COMPOUND prevent corrosion of electrical contacts and improper conduc-
TO ELECTRICAL CONNECTIONS tivity between contacts from moisture intrusion. Open and
sealed connectors benefit from application of dielectric
NOTE: This section is not applicable for battery terminals. grease.
Dielectric grease shall be applied to all electrical connectors at
the time of connection (except those noted under Exclusions).
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-
RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
NOTE: Do NOT apply dielectric grease to the following connec-

tions:
• Main Boom Rotary sensor connections (on Celesco Sensor),

• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical
connections except for those mentioned above for the follow-
ing reasons:
3121290 – JLG Lift – 7-3

Dielectric Grease Application AMP Seal

Before following these instructions, refer to excluded connec- The AMP Seal connector system is used on Control ADE Plat-
tor types (See Exclusions below). form and Ground Modules.
1. Use dielectric grease in a tube for larger connection Apply dielectric grease to the female contact. If trapped air
points or apply with a syringe for small connectors. prevents connector from latching, pierce one of the unused
wire seals.
2. Apply dielectric grease to the female contact (fill it
approximately ½ full; see example below)
3. Leave a thin layer of dielectric grease on connector face.
4. Assemble connector system immediately to prevent

moisture or dust contamination
5. Pierce one of the unused wire seals before assembly if

the connector system tends to trap air (i.e. AMP Seal)
and then install a seal plug.
Figure 7-7. Dielectric Grease On Female Contacts

After assembly, install a seal plug (JLG #4460905) to keep out

moisture. Seal plugs may also be installed by the wire harness

manufacturer if an unused wire seal was damaged during

assembly.
Figure 7-5. Applying Dielectric Grease
Deutsch HD, DT, DTM, DRC Series

The Deutsch connector system is commonly used for harsh
environments. Follow installation instructions.
Figure 7-8. Seal Plugs
Figure 7-6. Deutsch Connector
7-4 – JLG Lift – 3121290

AMP Mate-N-Lok BRAD HARRISON/PHOENIX CONTACT M12
Follow manufacturer installation instructions. This connector uses gold contact material to resist corrosion
and an O-ring seal for moisture integrity. Low-force contacts
cannot displace dielectric grease to achieve electrical contact.
Once contaminated, replacement of female contacts is
required. The JLG Load Sensing System and 1250AJP Rotary
Angle Sensors are examples of components with the M12 con-
nector system.
Figure 7-9. AMP Mate-N-Lok Connector
DIN Connectors
Figure 7-11. Brad Harrison/Phoenix Connectors
This connector is typically used on hydraulic valves. Follow
manufacturer installation instructions. AMP JUNIOR TIMER
This type of connector uses back-seals to keep out moisture.
Low-force contacts cannot displace dielectric grease and cre-
ate electrical contact. Use solvents (i.e. contact cleaner or min-
eral spirits) to remove dielectric grease. The Deutz EMR2
engine control module uses this connector.
Figure 7-10. DIN Connector
Exclusions
Some connectors do not require or may be permanently dam-
aged by application of dielectric grease. Dielectric grease may
not be required in properly sealed enclosures.
DO NOT USE DIELECTRIC GREASE ON BRAD HARRISON/PHOENIX CONTACT Figure 7-12. AMP Junior Timer
M12 OR AMP JUNIOR TIMER CONNECTORS. LOW-FORCE CONTACTS CANNOT
DISPLACE DIELECTRIC GREASE AND CREATE ELECTRICAL CONTACT.
3121290 – JLG Lift – 7-5

7.4 AMP CONNECTOR Connector Assembly

Plug and header assembly colors are mechanically keyed to 1. Check wedge lock is in the open, or as-shipped, position.
mate only with identical colors.

Figure 7-13. AMP Connector

Figure 7-15. AMP Connector Assembly
Contact Assembly
2. Push contact straight into circuit cavity as far as it will go.
1. Strip wire and install in crimp end of connector as
3. Pull on contact wire with a force of 1 - 2 lb to be sure
shown in Figure 7-14.
retention fingers are holding contact.
2. Crimp connector. Do not damage cutoff tab.

Figure 7-16. AMP Contact Installation

Figure 7-14. AMP Contact Assembly
7-6 – JLG Lift – 3121290

4. After all contacts are inserted, close wedge lock to its NOTE: Wedge lock should never be removed from housing for
locked position. Release locking latches by squeezing insertion or removal of contacts.
them inward.

Figure 7-17. Close Wedge Lock

5. Slide wedge lock in housing until flush with housing.

Figure 7-19. AMP Connector Disassembly
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.
Service - Voltage Reading
Figure 7-18. Seating Wedge Lock

HOLES IN WIRE INSULATION CAN LET IN MOISTURE AND CAUSE SYSTEM FAIL-
Disassembly URE. DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
1. Insert a 4.8 mm (3/16") wide screwdriver blade between It has been common practice in electrical troubleshooting to
mating seal and one of red wedge lock tabs. probe wires by piercing insulation with a sharp point. This
2. Pry wedge lock open. practice should be discouraged when dealing with an
AMPSEAL plug assembly or any other sealed connector sys-
3. While rotating wire back and forth over a half turn (1/4 tem. Resulting pinholes in the insulation allows moisture to
turn in each direction), gently pull wire until contact is enter by traveling along wire strands and could result in sys-
removed. tem failure.
3121290 – JLG Lift – 7-7

7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly

1. Remove wedgelock (1) using needle-nose pliers or a
DT/DTP Series Assembly hook shaped wire to pull wedge straight out.
1. Grasp crimped contact (1) about 25mm behind contact 2. To remove contacts, gently pull wire backwards at the
barrel. same time releasing the locking finger (2) by moving it
2. Hold connector with rear grommet (2) facing you. away from contact with a screwdriver.
3. Push contact straight into connector grommet (3) until a 3. Hold rear seal (3) in place. Removing contact may dis-
click is felt. A slight tug confirms it is locked in place. place seal.
4. Once all contacts are in place, insert wedgelock (4) with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. They may go in either way.
NOTE: Receptacle shown - use same procedure for plug.
1 2
1 2
Figure 7-21. DT/DTP Contact Removal
3 4
Figure 7-20. DT/DTP Contact Installation
7-8 – JLG Lift – 3121290

HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly

1. Grasp contact (1) about 25mm behind contact crimp 1. With rear insert toward you, snap appropriate size
barrel. extractor tool (1) over wire of contact to be removed.
2. Hold connector with rear grommet (2) facing you. 2. Push tool in the insert cavity (2) until it engages contact
and resistance is felt.
1 2
1 2
Figure 7-22. HD/HDP Contact Installation
3. Push contact straight into connector grommet until a Figure 7-24. HD/HDP Contact Removal
positive stop is felt. A slight tug will confirm it is locked 3. Pull contact-wire assembly out of connector
in place.
NOTE: Do Not twist or insert tool at an angle.
Figure 7-23. HD/HDP Locking Contacts Into Position

Figure 7-25. HD/HDP Unlocking Contacts
NOTE: Insert sealing plugs in unused wire cavities for full environ-
mental sealing.
3121290 – JLG Lift – 7-9

Figure 7-26. Electrical Components 1 of 2
7-10 – JLG Lift – 3121290

Figure 7-27. Electrical Components 2 of 2
3121290 – JLG Lift – 7-11

Figure 7-28. Chassis/Platform Electrical Schematic - Sheet 1 of 2
7-12 – JLG Lift – 3121290

1001141989E - 1/5
Figure 7-29. Chassis/Platform Electrical Schematic -Sheet 2 of 2
3121290 – JLG Lift – 7-13

1001141989E 3/5
Figure 7-30. Deutz Engine Electrical Schematic
7-14 – JLG Lift – 3121290

1001141989E - 4 of 5
Figure 7-31. GM 3.0L Engine/Chassis Electrical Schematic
3121290 – JLG Lift – 7-15

Figure 7-32. ECM Electrical Schematic - Sheet 1 of 2
7-16 – JLG Lift – 3121290

1001141989E 5/5
Figure 7-33. ECM Electrical Schematic - Sheet 2 of 2
3121290 – JLG Lift – 7-17

Figure 7-34. Main Hydraulic Schematic - 1 of 2
7-18 – JLG Lift – 3121290

2792780F 1/3
Figure 7-35. Main Hydraulic Schematic - 2 of 2
3121290 – JLG Lift – 7-19

Figure 7-36. Two Wheel Drive Hydraulic Schematic - 1 of 2
7-20 – JLG Lift – 3121290

2792780F 2/3
Figure 7-37. Two Wheel Drive Hydraulic Schematic - 2 of 2
3121290 – JLG Lift – 7-21

Figure 7-38. Four Wheel Drive Hydraulic Schematic - 1 of 2
7-22 – JLG Lift – 3121290

2792780F 3/3
Figure 7-39. Four Wheel Drive Hydraulic Schematic - 2 of 2
3121290 – JLG Lift – 7-23

NOTES:
7-24 – JLG Lift – 3121290

3121290
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65813058 +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 Ltd
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4,
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Singapore, 639379
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591 9030
(852) 2639 5797 +65-6591 9031
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

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Service and Maintenance Manual

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

3121290 – JLG Lift – A-1

Original Issue January 10, 2013

A-2 – JLG Lift – 3121290

SECTION NO. TITLE PAGE NO.

3121290 – JLG Lift – i

SECTION NO. TITLE PAGE NO.

ii – JLG Lift – 3121290

SECTION NO. TITLE PAGE NO.

3121290 – JLG Lift – iii

SECTION NO. TITLE PAGE NO.

iv – JLG Lift – 3121290

SECTION NO. TITLE PAGE NO.

3121290 – JLG Lift – v

SECTION NO. TITLE PAGE NO.

vi – JLG Lift – 3121290

FIGURE NO. TITLE PAGE NO.

3121290 – JLG Lift – vii

FIGURE NO. TITLE PAGE NO.

viii – JLG Lift – 3121290

FIGURE NO. TITLE PAGE NO.

3121290 – JLG Lift – ix

FIGURE NO. TITLE PAGE NO.

x – JLG Lift – 3121290

FIGURE NO. TITLE PAGE NO.

3121290 – JLG Lift – xi

TABLE NO. TITLE PAGE NO.

xii – JLG Lift – 3121290

Ground Bearing Pressure Max. Hydraulic System Operating 4500 psi

1.1 REACH SPECIFICATIONS 1.4 CAPACITIES

3121290 – JLG Lift – 1-1

1.5 TIRES Table 1-9. GM 3.0L

Fuel Gasoline or Gasoline/LP Gas

Fuel Diesel Table 1-10. Component Weights - 450

Oil Capacity Boom Link 180 82

1-2 – JLG Lift – 3121290

1.8 HYDRAULIC OIL

SAE Grade 10W30

3121290 – JLG Lift – 1-3

Table 1-16. Exxon Univis HVI 26 Specs

Specific Gravity 32.1 Table 1-17. Quintolubric 888-46

1.9 SERIAL NUMBER LOCATION

Figure 1-1. Serial Number Locations

1-4 – JLG Lift – 3121290

Figure 1-2. Operator Maintenance and Lubrication Diagram

3121290 – JLG Lift – 1-5

1.10 OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth

NOTE: The following numbers correspond to those in Figure 1-2.,

Table 1-18. Lubrication Specifications

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR-

NOTE: It is recommended as good practice to replace all filters at

NOTE: If necessary, install grease fitting into worm gear housing

1-6 – JLG Lift – 3121290

3. Wheel Bearings (2WD Only) 6. Hydraulic Charge Filter

Lube Point(s) - Fill Cap

3121290 – JLG Lift – 1-7

Fill Cap/Spin-on Element (JLG P/N7016641)

Figure 1-3. Deutz Engine Dipstick Markings