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1. sete 400psi Lift Relief Steer Relief Right Main Relief Steer Relief Left Figure 2 19 Valve Components JLG Lift 9 Steer Solenoid Right 10 Lift Solenoid 11 Steer Solenoid Left 12 MP 3121108 SECTION 2 PROCEDURES Leveling Jacks Directional Valve os faz N Zaa 2 A4 PA4 Figure 2 20 Leveling Jacks Directional Valve Leveling Jacks Pressure Relief Valve Location 02580952 B vendor info Table 2 3 Leveling Jacks Directional Valve Torque Specs Item Torque 40 Ib ft 54 Nm 23 lb ft pon 31 Nm 7 40 Ib ft 54 Nm 3121108 JLG Lift 2 21 SECTION 2 PROCEDURES 2 14 DRIVE PUMP START UP PROCEDURE NOTICE THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER
2. Figure 1 1 Serial Number Location 1 4 JLG Lift 3121108 SECTION 1 SPECIFICATIONS Figure 1 2 Lubrication Diagram Table 1 15 Lubrication Chart INDEX NO COMPONENT NUMBER TYPE LUBE P0INTS LUBE METHOD slate Check HO Level 1 Hydraulic Oil Reservoir Fill Cap Drain Plug HO Change HO 10 500 2 Hydraulic Filter Element N A Initial Change 50 Hours 250 Engine Crankcase Fill Cap Drain Plug Check Engine Oil Level 10 100 3 Engine Oil Filter Filter Element Initial Change 50 Hours 200 Engine Fuel Filter Filter Element Check amp Clean every 100 hrs 400 Engine Fuel Filter Kubota DF752 Filter Element Check amp Clean every 100 hrs Yearly 4 Rail Slides N A MPG Brush 100 KEY TO LUBRICANTS exposed to hostile environments or conditions lubrication frequencies must be increased accord MPG Multi purpose Grease ingly EPGL Extreme Pressure Gear Lube UN NOTE Operate hydraulic functions through one complete HO Hydraulic Oil Mobil 424 cycle before checking hydraulic oil level in tank Oil sho
3. MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key position the cursor to the right one space to enter the second digit of the pass word Use the UP or DOWN arrow key to enter the second digit of the password which is 3 Repeat this process until you have entered all five digits of the password which is 33271 Once the correct password is displayed press ENTER 2 32 JLG Lift 3121108 SECTION 2 PROCEDURES Adjusting Parameters Using the Hand Held Analyzer Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example f N aL ET PERSONALI TI ES DHIVE ACCEL 4 0s c PERSONALITIES DRIVE ACCEL 4 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 when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular per sonality If the value does not change when pressing the up and down arrows check the access level to ensure you are at access level 1 Machine Setup When a machine digit item is selected press the UP or
4. 3 10 3 5 Ry d IECIT 3 12 3 6 Troubleshooting wo PER eee Det ee quia da deer val udis ose 3 13 3121108 JLG Lift TABLE OF CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 SerialiNumber Location ss t a y aan tw S oe A UE e a Ka AA RE eas 1 4 1 2 Lubrication Diagrami u ERE Ure ususi ee Ste T ME 1 5 1 3 Operating Temperature Specifications Kubota 1 6 1 4 Torque Chart SAE Fasteners Sheet 1 7 1 7 1 5 Torque Chart SAE Fasteners Sheet 2 7 1 8 1 6 Torque Chart SAE Fasteners Sheet 3 7 1 9 1 7 Torque Chart SAE Fasteners Sheet 4 7 1 10 1 8 Torque Chart METRIC Fasteners Sheet 5 7 1 11 1 9 Torque Chart METRIC Fasteners Sheet 6 7 1 12 1 10 Torque Chart METRIC Fasteners Sheet 7 of7 esee 1 13 2 1 Arms and Platform Positioning and Support Cylinder 2 6 2 2 Kugel prc 2 7 2 3 Cylinder Barrel Support lissssseeeeseseeee 2 8 2 4 Gapscrew Removal ura ii uyu uae GR Dei ie Sue ee 2 8 2 5 Cylinder Rod SUDport sl ee i e Pet Re ea
5. ELEVATION 7 SWITCH LEVELING JACK SWITCHES Figure 3 25 Electrical Components Installation Prior to S N 141689 Sheet 2 3121108 JLG Lift 3 31 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS COMPONENTS PLATFORM WORK LIGHTS CIRCUIT BREAKER Vj CE SPEC ONLY Figure 3 26 Electrical Components Installation S N 141689 to Present Sheet 1 3 32 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS GROUND SENDER BEACON LIGHT HORN ALARM ELEVATION SWITCH TO ROXIMITY SWITCH C CONTROLLER MODULE DIRECTIONAL GROUND WA SPLICE Y 6 cR 7 A NGA SED N lt VALVE a U o pz WP 2 JA LEVELING JACK SWITCHES Figure 3 27 Electrical Components Installation S N 141689 to Present Sheet 2 3 33 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS 2792402 T x 1 E Os Ao 0 REAR DRIVE MOTORS f l 9f FRONT DRIVE MOTORS x8 a A 0 AAA RIGHT 10 2 4 l GED D S MA MB 4 CV FITTI FITT
6. Terminal Color Function 1 Yellow Steer Right 2 Green Steer Left 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 4 7 Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot JLG Lift 2 25 SECTION 2 PROCEDURES 2 17 TILT SENSOR Tilt Sensor JLG P N 4000006 VAS 1 Ground Control Box 2 Tilt Sensor JLG P N 4000006 Figure 2 24 Tilt Sensor Location Tilt Sensor Removal NOTE Refer to Figure 2 24 Tilt Sensor Removal for num bers in parenthesis 1 Disconnect the batteries 2 Open the Ground Control Box to gain access to the Tilt Sensor Assembly 3 Remove the four Screws 2 and Lockwashers 3 to remove the Tilt Sensor 1 from the Ground Control Box NOTE Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 2 18 Calibrations 2 26 JLG Lift lt rh om EA 1 Tilt Sensor JLG P N 4000006 2 Screw 6 32 x 3 4 3 Lockwasher Figure 2 24 Tilt Sensor Removal Table 2 8 Tilt Sensor Harness Chart Wire Color Function Connector Pin Red VCC 1 Black Ground 4 Blue PWMX 2 Yellow PWMY 3 3121108 SECTION 2 PROCEDURES Tilt Sensor JLG P N
7. PISTON REF Figure 2 13 Poly Pak Piston Seal Installation 10 Position the cylinder barrel in a suitable holding fix ture NOTICE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 11 With barrel clamped securely and while adequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged 12 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder 13 Secure the cylinder head gland using the washer ring and socket head bolts SPACER CYLINDER BARREL PISTON ASY WASHER RING Figure 2 14 Rod Assembly Installation 14 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves 15 If applicable install the cartridge type holding valve and fittings in the rod port block using new o rings 2 12 JLG Lift as applicable See Table 2 1 Cylinder Component Torque Specifications A CAUTION IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE EKTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED USE EITHER A TRAVELING OVERHEAD HOIST FORK
8. HT OIL TANK EX HY TE 8 OR ABOVE NDED DRIVING WITH ERATURES OF 180 F HYD 180 F 82 C OIL TANK TEMP AMBIENT AIR TEMPERATURE NS 120 F 49 C ER OR BOTH ITH T J ADDITION OF A HYDRAULI COOLER CONSULT CONDITIONS LG HIGHLY RECOMMENDS JLG SERVICE 110 43 AMBIENT TEMPERATURE NO OPERATION ABOVE THIS PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE 100 F 38 C 90 F 32 C 80 F 27 C TOF 21 C 60 F 16 C 50 F 10 C 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C o FC I8 C 10 F 23 C MOBIL 424 10W 30 MOBIL DTE 13 EXXON UNIVIS HVI 26 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE 20 29 30 34 40 F 40 C 4150548_E DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE NO OPERATION BELOW THIS AMBIENT TEMPERATURE NOTE 1 RECOMMENDATIONS A CONSISTANTLY WITH RE FOR AMBIENT TEMPERATURES IN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 3 WITH COLD WEATHER POSSIBLE 5 F PKG GASOLINE COLD START ALA Figure 1 3 Operating Temperature Specifications
9. 3 31 Electrical Components Installation S N 141689 to Present Sheet 1 3 32 Electrical Components Installation S N 141689 to Present Sheet 2 3 33 Hydraulic Schematic Prior to S N 141689 3 34 Hydraulic Schematic S N 141689 to 3 35 Hydraulic Diagram Generator 3 36 Hydraulic Diagram Leveling 3 37 LIST OF TABLES TITLE PAGE NO Operating Specifications ii es ee ee ys Cu Ta E NG E ELS BN ee LE ERE 1 1 Capaciltl S 2 c Bee ead vate tr E re ee ee lt E dre het 1 1 WG750 B Kubota Gasoline LP a aa IH n 1 1 DF752 E2 Kubota Gasoline LP 3 1 1 01005 Kubota Diesel a ls i eee OY ee eae RUE EE RES 1 2 Tite Specifications odora Vee PT Gada kbd pe he eb deste 1 2 PUMP Specifications a tes eaten og eb et eae pode LER MERE Ente RARO Edd 1 2 D905 B Kubota Diesels ere ee a a bee ps bea erre pese pu eu bee EE 1 2 Hydraulic Gil besten eee mee Een d e 1 2 Lubrication Specifications u u UU uu Sas su Guss ee 1 2 Cylinder Specifications 1 3 Pressure Settings ed eser veg bet Pu rue Ge a NS 1 3 Major Component Weight
10. YEL RED 2 8 THIS SYMBOL IS A WIRE CABLE CONTINUATION TO C6 ELRED 2 5 SEL RED 2 6 Tenaga HEL IRED 2 10 D ANOTHER LOCATION ease ON THF DRAWING A BLU ORN 52 4B gd LETTER NUMBER A GENERATOR 5 sl sls BLU ORN 52 4 A A A A A AAA A ES OTHER 5 VALVE AQ fa A lt s e m SHE s R S5 5 3 S S ai Lum Em ez e228 88 9878 8 878 8 Sum 80227818 3 S222 s s CHOKE gt amp 55555 5 5 DUAL AXIS RELAY ANALOG TILT SENSOR A 20 iur ENGINE mE WHT YEL 48 11 YEL RED 2 58 WHITE TAN 3 ORANGE 8 1 ORANGE 1 1 ORANGE 55 1 YELLOW 10 2 ow 9 RFD WHI 50 1 g FUEL DUMP STEER STEER BRAKE DRIVE DRIVE LIFT LIFT z VALVE LEFT RIGHT FOR REV UP DOWN gt La ew m GND 2 5 5 2222 5 8 2 ZZ 5 2 2 GND ig 6 o oa 9 9 SS gt Z 5 2 e 205 If fe 9 8 amp al Fj fea S o N 5 EJ mE E SEMEN a ACTUATOR BLACK 4 VV V V V VV
11. S3 0N YING SHA 2911501 3 3 0N WAIN SIN 31 IH3A 13411 011501 SNOLLWY SITY p LDN D LDN TW 100102 0V01 HLONAT 145 34 INNIN Y9 t LW YOSNAS 111 5 11 SNOLLVY NAW 114 10010 0V01 SHA 1 Sov 9NI13M1 140403 ISNY 1 LWW 7135310 144090 I 700 ON 0 Sov INTIAN ISNY 0 LDN dVSV9 14409 0 1300W 91135 3NIH VH 133HS WOWd 2 39 JLG Lift 3121108 SECTION 2 PROCEDURES 2 21 MACHINE MODEL ADJUSTMENT Table 2 11 Machine Model Adjustment 2 40 Adjustment Adjustment range Default Values Gas Default Values Diesel DRIVE ACCEL 1 010 5 0 sec 4 4 1 010 5 0 sec 2 2 FWD MIN Oto 100 21 21 FWD MAX Oto 100 52 52 FWD ELEV Oto 35 32 32 REV MIN Oto 100 21 21 REV MAX Oto 100 52 52 REV ELEV 0to 35 30 30 LO MAX 35 to 65 50 50 ENGINE SPD 2800 to 3600 RPM 3600 3000 GAIN 0t0 999 180 50 DROOP 010 999 200 250 STABILITY Oto 999 170 80 LIFT ACCEL 0 2T05 0 3 3 DECEL 0 2T05 0 0 5 0 5 UP MIN ENG 1400 TO 2200 RPM 2000 1800 UP MAX ENG 2600 to 3600 RPM 3600 3000 LO MAX 35 to 55 50 50 GAIN 0t0 999 150 5 DROOP 010999 220 200 STABILITY 010999 125 90 IDLE ENGINE SPE
12. 1 2 CAPACITIES Table 1 2 Capacities Fuel Tank 72gal 27 2L Hydraulic Oil Tank 15 gal 56 8 L Hydraulic System including tank 18 gal 68 1 L 3121108 Table 1 2 Capacities Engine Crankcase Gasoline Engine Diesel Engine Engine Coolant Gasoline Engine Diesel Engine 1 3 COMPONENT DATA 3 4 qts 3 251 4 2 qts 4 L 1 25 gal 4 7L 1 5 gal 5 7 L Engine Table 1 3 WG750 B Kubota Gasoline LP Type 3 cylinder liquid cooled Power 24 5 horsepower 3600 rpm Idle 1500 rpm High Engine 3600 rpm Alternator 40 Amp Fuel Consumption Low RPM 1 3 gph 4 9 L ph High RPM 2 4 gph 9 Lph Table 1 4 DF752 E2 Kubota Gasoline LP Tier 3 Type 3 cylinder liquid cooled Power 24 8 horsepower 3600 rpm Idle 1500 rpm High Engine 3600 rpm Alternator 40 Amp Fuel Consumption Low RPM 1 3 gph 4 9 L ph High RPM 2 4 gph 9 Lph The Altitude Compensation Kit on this TIER 3 engine is set up from the factory to EPA emission standards for altitudes below 2800 ft 700m Kits for operating at higher altitudes are available from Kubota If operating at higher altitudes without the proper kit installed this engine will run with a rich fuel mixture and may therefore exhibit the following issues Excessive exhaust temperature This may rapidly or immediately damage the catalyst if equipped Engine overheating
13. ino 135 11 7135 1313 Nad0 135 1303 3501 NIW 01728 1132 NO 55391510 SAS 14 03345 340 135 03345 3501 10 134 QN11X3 fri vu 1 MEE 114 W01V01DV M019 d1 dNnd 1313 dh 111 OLIYA TIN NO NIL NYOH N340 NYOH 1501 NMOG 1317 N340 NMOG 1311 3501 33315 1 0 NIK 01 0W411N NO 3909 1301 1 1 390 1415 3501 dh L417 390 dh 1411 3507 333151131 XWW 01 TINI NO 135 1311 13 1311 N3d0 73 1311 3507 914 M014 90 9114 M079 3501 ASWIATY 331832 01 1100 NO 135 JANG 13 JANN N340 14 3M00 3501 LYVLS 340 1915 3501 3131480 51531 QUII 40 4 1531 5031 1531 MS WHALW 1531 MS ANNOYD 1531 ONT 9 1531 3399141 340 3399141 3501 STON W31N3 S31 1531 WILSAS NOY 133HS NO 0 1807 S1S31 31VALDV NIN 133H N01 2 37 JLG Lift 3121108 SECTION 2 PROCEDURES padugy pamal fj ag op wan nuapjanal nua doy N01 93A4 39VMI10S NV NOLLVYNSIINOD INTHIVW NOdA 9NI0N3431Q0 JTGVIUVAV 38 LON 83392 3H05 310N t JO JOYS WeYD Jez jeuy 0 eunbi4 045 9NI N39 310 MT gVLS 3M yd d00 3M
14. Yd NI 3M v5 ya d ANID 3M Ni yd 3M 01 yd Dv 102 310 A113 AJN 3M yd DV XVW AJY 3A yd NIW A3V yd 310 A313 041 3A yd XYK AJY 10011950 1141 12101 XVYN d ld XVN G 3A yd NIN AJY 10011950 9000 ad 9NJ NIN d ld NIW Md 3M yd NIN 10011950 NIV 12101 1323 JA 13230 yd XYK OM4 10011950 045 3NIDN3 ad 3A 00V yd WOILSAO f 3ILETVNO SU d 1101 SHILITVNOSY 3d 11H SHILITVNO 9 3d 83ILETVNO 5434 00000 300 713431 322V 133H NO 0 1302 SiL LETVNOSY 3d 3N 134315 320V NNAW 133H NOVI 3121108 JLG Lift 2 38 SECTION 2 PROCEDURES pasuey 10 t JO t 199uS WeYD JezAjeuy 18 Z eunbi4 Pama A 98 0 nua qn nua doy N01 133A4 33YM110 ONY NOLLVYNSIINOI 3NIH VH NOdA 318 V VAY 38 LON SN3389 5 INOS 310N 11111 TV 1L840 11314802 12 3001840 YILNI 9 ISYIAIY 11011 50 13A3110N 31 IH3A 1341 YILNI 9 YILNI 25DUSAO 3un1Iv1 HOSNAS 1341 YIING 9 CYYMYOd WIILSAOL XXX XXX LL 31 1H3A 13431
15. 3 14 Chassis Troubleshooting arcaei ee melas uqapas asa AURA 3 16 Hydraulic System Troubleshooting 3 19 Electrical System Troubleshooting aa a nn 3 20 JL G Lift iii TABLE OF CONTENTS This page left blank intentionally JLG Lift 3121108 SECTION 1 SPECIFICATIONS 1 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS Table 1 1 Operating Specifications Machine Weight 7330 Ibs 3324 8 kg Machine Height Fully Elevated 26 ft 8m Stowed 7 9 ft 2 3 Machine Width 5 9 ft 1 8 Machine Length 8 9 ft 2 7 m Platform Railing Height 43 5 1 1m Platform Dimensions 8 5x5 4ft 2 59x 1 65 m Platform Capacity 1250 Ibs 570 kg Platform Extension Capacity 300 Ibs 140 kg Max Travel Speed 2 8 mph 4 5 kmh Max Travel Grade 35 Slope Sideto Side 3 Fore amp Aft 5 Turning Radius Inside 6 9ft 2 1 m Outside 14 4 ft 4 4m Lift Speed no load Dual Fuel Up 25 29 sec Down 21 27 sec Diesel Up 32 34 sec Down 21 27 sec MaxTire Load 2600 Ibs 1180 kg Max Ground Bearing Pressure 33 psi 2 3 kg cm Max Hydraulic system Pressure 3000 psi 20 68 Mpa Electrical System Voltage 12 Volt Wheelbase 78in 2m Ground Clearance 8in 20 3 cm Max Windspeed 28 mph 12 5 m s Max Horizontal Manual Side Force 90 bf 400 N Number of Persons 2
16. Hydraulic pump not functioning properly Repair or replace pump Platform will not raise Joystick not activated within three sec onds after lift switch is activated Activate lift switch then activate joystick within three seconds Enable circuit not functioning properly Replace enable circuit card Load capacity exceeded Personnel and or equipment on platform Reduce load Refer to capacity placard Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve Lift cylinder not functioning properly Repair or replace lift cylinder Engine does notrespond when lift control Switch is moved to up position Referto Electrical System Troubleshoot ing Noresponseto control switch Noelectrical signal being sentto lift up control valve cartridge Referto Electrical System Troubleshooting No response to control switch Platform will not lower Joystick not activated within three sec after lift switch is activated Depress lift switch then activate control ler within three seconds Enable circuit not functioning properly Replace enable circuit card No electrical signal sent to lift down con trol valve cartridge Refer to Electrical System Troubleshoot ing No response to control
17. 2 a z 2 e a 2 E 0 e e P 4 I 184 2 CD gt Ma gt JO e 2Vd m 5 t TT Rh z gt Se m a S lt z lt sdh wp 5 CH P 5 E E 5 B a Figure 3 31 Hydraulic Diagram Leveling Jacks JLG Lift 3 37 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS JES NOTES 3 38 JLG Lift 3121108 Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 B JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia F 612 65 811111 612 65 810122 JLG Latino Americana Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 EL 55 19 3295 1025 USA 717 485 5161 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 3121108 JLG France SAS 2 1 Baulieu 47400 Fauillet France 33 0 5 53 88 3
18. AAAAAARARAARAAAA 16 63 START S B 502065 Bom BS z LIFT H DOWN Ta eee E 5 ouuu 3 CHOKE 25 Sg 83a 338332585585 gd gEzusz Bir ad 888888 8f22228 a B X Ps 2 2 Dn 7 gt TAN 3 1 AT GROUND CONTROL YEL RED 2 1 y 15 3 RED 1 2 63 RED 1 1 U WHT YEL 48 8 A NOTE WHT YEL 48 7 GLOW qe Gor EL 48 8 lt PGYS lt 2 2 lt LPV GLWS 5 4 E PLUG SLOSED WHEN 9 ETEVATIOW CHR ELEV 8 J RELAYS ai FULLY LOWERED SWITCH IGN az IGN ELEVATION 86 30 EROX SW L J OPTION or zi LOCATED _ 0 ON a ORN RFD 49 8 Ds E ENGINE 2 5 lt ene E Mar WEL RED 2 5A 5 Z E Z 5 8 cs E FE e Z o V 1 Nd A o22 5 532222246 5 z Z lt GLOW OPTIONAL PLUGS STROBE Q Q A 3 S A Q mg 5 IGN CONNECTOR x e e e e zV 5 0 7 ON CHASSIS B B RED 1 1 PIELIRED 2 5 C X HARNESS 10 V V V V i 5 1 0 MODULE gt o BLU ORN 52 3 im RED 1 1 DI BRN WHT 41 6 A F BLORA 32 2 PE z i 7 M 4 28 BUM BLACK 2 a 9 8 5 3 z 2 P g c ENGINE LOW OIL PRESSURE 289g START E 7 E SWITCH 8PS1 3 V amp 8 z m RELAY a EE z mE worn e5 dg Seca gt e NVI s A lt lt 58 Pet En 00000 O
19. Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 3 If a part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scor
20. CSA 0 CE AUSTRALIA LEVELING JACKS YES SPECIAL LENGTH NO YES 0 TILT CONFIG 3 DEGREES F R 5 DEGREES F R 1 1 O 1 1 6 DEGREES F R SPECIAL LOAD N o O N O CUTOUT PLATFORM 0 1 O 1 1 NO CUTOUTALL 1001113688_C JLG Lift 3121108 SECTION 2 PROCEDURES 2 23 PREVENTIVE MAINTENANCE AND The inspection and maintenance code numbers are as fol INSPECTION SCHEDULE lows 1 The preventive maintenance and inspection checks are listed and defined in the following table This table is and the INTERVA at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that 2 divided into two basic parts the AREA to be inspected 3 4 system are listed The INTERVAL portion of the table is 5 divided into five columns representing the various inspec tion time periods The numbers listed within the interval 6 column represent the applicable inspection code for which that component is to be checked 7 The checks and services listed in this schedule are not intended to replace any local or regional regulations that 8 may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times 9 may occur due to climate and or conditions and depend 10 ing on the location and use of the machine JLG Industries
21. Troubleshooting Information The troubleshooting procedures applicable to the aerial platform are listed and defined in following troubleshooting tables Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determi nation of the applicable remedial action The probable causes and the remedial action should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electri cal systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir cuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechani cally or electrically so that oil is available to the function valve then overriding the function valve mecha
22. lt I PUE Em UU mi a UC T SNL MEN NL e nece Nr a d 2 8 ere d S c EE 4 CN nn me 0o 7 c de qo BOW U l a a a e oo eo inj Bes O O OL Z Z Z LE om 0 on v m ra i X le es I isle _ wi oO __ l a a ki d l ee WE em pa 1 Lefa 1 eum b gt lt L l c 1 I lt L A m ii 2 FAN 1 1 l l j Em 1 1 u i I I N 2792448 Figure 3 30 Hydraulic Diagram Generator 3 36 JLG Lift TANK 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS 2792686 o o 2 E a P lt k a E E lt a 2 9 lt gt Q ER o _
23. ul u aW ia kaida m b AA gk 2 13 2 12 Limit Switch Adjustment 2 19 2 13 Pressure Setting Procedures 2 19 2 14 Drive Pump Start up Procedure 2 22 2 15 Automatic Choke Field Adjustment 750 2 23 2 16 Joystick Controller cas vou sa Mee NG We Sb es ea ei we a ee u 2 24 2 17 Tilt SONSOM sree a ire aren p en a hoe a RR pace Dd we ee es A pe ete eh mas 2 26 2 18 Calibrations 2 Yate ae re aC REV uha wd bes dol ee pooch ett p 2 28 2 19 Electronic Control System 2 30 2 20 Flash Codes and Descriptions cece eee 2 34 2 21 Machine Model Adjustment aee a aa aa aa aa aaa aa aa aa aa aaa aaa 2 40 2 22 Machine Configuration Programming Information 2 41 2 23 Preventive Maintenance and Inspection 2 43 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 1 General sss ectetur x to a DE titi x App a So 3 1 3 2 Multimeter Basics pulu eta eee ee Mee Nan GA s a ae ee wu eer RA 3 1 3 3 Applying Silicone Dielectric Compound To Amp Connectors 3 5 3 4 Working With Deutsch
24. 2 40 gt se RECEPTACLE H 42 1 To ON PFDTH JI 1 EE gen FL LJ CHASSIS HARNESS PEDTHI 31 2 IGN 05 9 m VALVE FR LJ SOURCE J2 5 ON SFDTH 3 E GND 32 3 BLAK ex 118 VALVE RL LJ GROUND BOARD Xeon GND 21 4 55 0000 122 11 ORN WHT 55 20 VALVE RR LJ gt IGN 01 5 poor J2 12 QRUIT 55 21 Y20 VALVE LJ EXTEND 1 CANH 001 6 0002 15 1 22 77 po 021 VALVE LJ EXTEND 2 BECK CANL II 10003 15 2 a lt Y22 VALVE LJ RETRACT CAN SHIELD J1 8 20004 J5 3 Q 22 71 a x Yit 50005 15 4 lt Y23 0006 15 5 D100 SFDTH J2 4 IGN 4 1 0105 42 9 GND 04 2 ANLG4 2 10 CAN H J4 3 DIOL 32 5 CAN L J4 4 0102 72 6 CAN SHIELD J4 5 0103 02 1 SPARE J4 6 0007 J5 6 0008 15 1 0009 15 8 YEL RED 2 20 m 0104 22 8 RECEPTACLE RX 15 10 525 TX 75 11 LET STOWED GND 105 12 BLACK SWITCH WHITE J3 RECEPTACLE Ne a 333 26 255285255758 ENT STONED BLACK WHITE 599255255655 ne mane ee Ss 521 REAR LFT STOWED BLACK SWITCH WHITE On 9 s28 REAR RHT STOWED BLACK SWITCH WHITE NG UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE IN INCHES 1 85 J ddd eel MEC 22 FOR CODE UPGRADE ONLY THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES INC 4 dq 5 8 3 305 73 H8 4 8 AND CONTAINS PROPRIETARY AND CONFIDENTIAL ds 3383 as a 5 INFORMATION JLG MAY NOT BE COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT JLG S WRITTE
25. 2010 874 n 79 12 19 a 125 3660 15 9 28 55 12 175 8430 367 ss 66 97 154 241 331 469 22 303 639 24 353 811 27 459 1130 30 1530 33 36 42 5 4 817 355 5 2560 1920 2690 5 4 1120 487 0 4090 3070 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED 3121108 Figure 1 8 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M3 M5 Torque m Torque Lub OR Loctite amp Torque Dry or Loctite 24277 or 271 OR Loctite 262 OR Size PITCH Stress TM N TM TM Area 263 Vibra TITE 111 Vibra TITE 131 K 0 20 140 K 0 15 K 0 18 3 os sos 313 ECCE Tan ni a oz ez sa 0 8 25 2 22 7 18 9 1 25 36 5 32 8 a DET NI NN ERE de ee e E c Tia 2 wm ze 200 1 150 16 2 17
26. 5 5 8 ow Cp 51 90 ETR BULK BULK gt GROUND HEAD ENGINE GROUND HEAD ENGINE F a3 HARNESS DUAL HARNESS HARNESS DUAL HARNESS ECET PM DISPEM LTP 32272 11108 4 1 4 PLUG PLUG PLUG SOCKET PLUG NE 2582255358 arp 33 HELLOM 10 1 PGW PEW4 PGYI NC gt NC PEY4 es See Wa Kadi A PGW2 PEW3 P6Y2 PGW3 84 PEN P6Y3 E PEY2 i j 3 T e ALAR NC Ie PGY4 3 PEYI gd 83 CoU oe ee KL g V V YFL RED 2 12 4 PGWS PEW8 P6Y5 k PEY8 a gH bo WHT RED 57 2 25 PEW PGY6 PEYT TRIGGER ag YEL RED 2 13 NITIRED ST 3 P6WI NC NC PEWS PGYT PEY6 SWITCH K gt PGW PEWS 8 PEY5 HEIDE WHT RED 57 4 GROUND ENGINE HARNESS GROUND ENGINE HARNESS xxm go WHITE CONNECTORS YELLOW CONNECTORS 3 a4 a 4 A A Se ee H NOTE 1 ALL PGWX AND PGYX TERMINALS SHOWN ON THIS DRAWING ARE REFERENCED FROM THE A A A GROUND HARNESS PLUG AND ACTUALLY REPRESENT THE CONNECTION BETWEEN THE GROUND lt HARNESS PLUG AND THE ASSOCIATED ENGINE HARNESS PLUG VIA A FEMALE TO FEMALE BULKHEAD SOCKET THIS CONFIGURATION DOES NOT ALLOW A ONE TO ONE TERMINAL CONNECTION BETWEEN THE TWO PLUGS ACTUAL TERMINAL INTERFACE CONNECTIONS ARE SHOWN ABOVE NO CONNECTION FOR PGW4 PGW7 AND PGYI s s Sp ee a a a a E eye ol s s sl al ES Els 5 YEL RED 2 2 A AA PS AAA AAAAA
27. Kubota JLG Lift 3121108 SECTION 1 SPECIFICATIONS 1 12 TORQUE CHARTS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS 4 Torque 1 Tensile Torgue Loctite 242 271 i a Ara Bolt Dia Clamp Load Loctite 262 or Vibra D Lubricated OR Vibra TITE 111 or Stress Area TITETM 131 140 0 00604 6 oz J Torque 1 01380 0 01015 60 18 20 13 25 001400 900 30 34 2 25 01640 0 01474 940 35 26 I 8 09 6 4 0 1120 0 00661 420 9 1 0 7 0 8 0 1380 0 00909 580 16 1 8 12 14 1 6 3 2 0 1900 0 02000 1285 49 5 5 36 4 A NE anes KA s ef E 02500 00364 2320 120 135 86 10 135 m ie rr mm rms Wm Fr wm rms ww 03125 0 0580 3700 139 26 4 19 21 2 17 2 01900 001750 1120 a 48 32 35 8 7 16 40 8 20 14 0 3750 0 0878 5600 35 47 25 34 40 54 32 43 0 4375 0 1063 6800 50 68 35 47 55 75 45 61 6 04375 01187 7550 5 75 40 54 6 8 50 4 2 1 0 5000 0 1419 9050 75 102 55 75 85 116 68 92 2 0 5000 0 1599 10700 90 122 65 88 100 136 80 108 1 110 9 0 5625 80 108 3 es 0 5625 0 2030 12950 120 163 90 122 135 184 109 148 0 6250 0 2260 14400
28. amp amp B cu SL UP E BULK BULK GROUND HEAD ENGINE GROUND HEAD ENGINE PLATFORM DISPLAY HARNESS DUAL HARNESS HARNESS DUAL HARNESS 5 pM DEC ER PLUG SOCKET PLUG PLUG SOCKET PLUG RTP DaN PGWI k PEW4 PC fe s woe Hos PGW2 PEW3 PGY2 PEY3 q lt gt 4 44 Q fe TT al 3 fol e PGW3 PEW P6Y3 PEY2 EMI Ns E B MESE ALARM gs BLACK 2R pojac 2_ S co Pew P6Y4 k PEYI i V V V V 5 PEW8 P6Y5 PEY8 ES gt lt gt PGW6 le SJ PEWT PGY6 y PEYT YEL RED 2 3 WAT RED 51 2 YEL RED 2 13 PGWT NC NC PEWG PGYT PEY6 TR166ERAG gt SWITCH PGW8 PEWS PGY8 PEY5 A Pre 141745 35 WHT RED 51 4 A A el N N el e GROUND ENGINE HARNESS GROUND ENGINE HARNESS 38 83 58 383 WHITE CONNECTORS YELLOW CONNECTORS lt 395959 Gaga a NOTE ALL PGWX AND PGYX TERMINALS SHOWN ON THIS DRAWING ARE REFERENCED FROM THE 7 GROUND HARNESS PLUG AND ACTUALLY REPRESENT THE CONNECTION BETWEEN THE GROUND A A A A HARNESS PLUG AND THE ASSOCIATED ENGINE HARNESS PLUG VIA A FEMALE TO FEMALE BULKHEAD SOCKET THIS CONFIGURATION DOES NOT ALLOW A ONE TO ONE TERMINAL CONNECTION BETWEEN THE TWO PLUGS ACTUAL TERMINAL INTERFACE CONNECTIONS ARE SHOWN ABOVE NO CONNECTION FOR PGWA PGW7 AND PGYI oi bee tes Gas JE JORE HEIEIPIES YEL RED 2 2 AAA SA ASA A A AAA n YEL RED 2 4 a E RSS 63 5 y 885 H Tum 2 plstarr uP DOWN ae E Bog sc
29. 150 203 110 149 165 224 135 183 0 6250 0 2560 16300 1 1 1 0 4 8 2 8 4 8 1 5 7 0 7500 0 3340 21300 260 353 200 271 285 388 240 325 0 7500 0 3730 23800 300 407 220 298 330 449 268 363 0 8750 1 1 1 1 1 0 8750 0 5090 32400 470 637 350 475 520 707 425 576 1 0000 0 6060 38600 640 868 480 651 675 918 579 785 1 0000 0 6630 530 719 1 1250 0 7630 42300 800 1085 600 813 840 1142 714 968 1 1250 0 8560 47500 880 1193 660 895 925 1258 802 1087 0 9690 53800 840 1139 Az oo 1 2500 1 0730 59600 1240 1681 920 1247 1300 1768 1118 1516 1 3750 1 1550 64100 1460 1979 1100 1491 1525 2074 1322 1792 73000 1260 1708 NOTES 3121108 1 5000 1 4050 78000 1940 2630 1460 1979 2025 2754 1755 2379 1 5000 1 5800 87700 2200 2983 1640 2224 2300 3128 1974 2676 NO 5000059 REV J 1 THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND 0100011 242 Vibra TITE 121 Medium Strength Blue Vira TITE 140 High Strength Red Vibra TITE 131 Medium High Strength Red Figure 1 4 Torque Chart SAE Fasteners Sheet 1 of 7 24 0100019 0100071 JLG Lift 1 7 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Re
30. 2 Reconnect harness if it was disconnected for step a and turn on machine 3 Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer See vehicle or control system documentation on how to do this 4 Place sensing face of switch on the object to be sensed by the switch If that is not available use a piece of ferrous metal physically similar to it The switch state in the control system diagnostics should change 5 When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the switch and object sensed Automatic Switches 3 12 If the switch is actuated automatically by temperature or pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pressure for example to the switch These switches may need to be ener gized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe switch state in control system with the Analyzer See vehicle or control system documentation on how to do this 3 Operate system such that the switch actuates This could be going over a certain pressure or temperature for exam ple The state indicated in the control system should change JLG Lift 3121108 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Switch Wiring Low Side High Side When controlling a load a switch
31. 3 Component Bala NA E eA A eae e ga 1 1 1 4 Lubrication 2 ua yu ESA BE TANGEN redet peces a bua WA ah a Kap a aged 1 2 1 5 Lubrication Specifications 1 2 1 6 Cylinder Specifications s uuu uuu Id Reng pa da BN UE ed td ee eae N ah 1 3 1 7 Pressure Settings u u aa acd whe i uqu aaa 1 3 1 8 Eimit SWitehes s 53b s o ERR mte o m EM SE EP MN PC S ent uq aulas 1 3 1 9 Major Component Weights aa aa hm rr 1 3 1 10 Critical Stability Weights Rs RR I HI a Lesa 1 3 1 11 Serial NumberEecations e ehh ga Yen nga 1 4 1 12 TOrgUe Charts n 1 7 SECTION 2 PROCEDURES 2 1 General oraria pp papa Ca a deg oie a ieee dui 2 1 2 2 Servicing and Maintenance Guidelines 2 1 2 3 Lubrication Information eese mm em mee ded wae cae eich 2 2 2 4 Cylinders Theory of 2 3 2 5 Valves Theory of 2 3 2 6 Component Functional Description 4 2 4 2 7 Wear Pads pe EE 2 4 2 8 Cylinder Checking 2 4 2 9 Lift Cylinder Removal and Installation lieee eee 2 5 2 10 Cylinder Repais un ERE ere a NA e eae Ba gan Wen AEA 2 8 2 11 Steer Cylinder Repair
32. 4000021 4 Ground Control Box 5 Tilt Sensor Assembly JLG P N 1810140 Figure 2 25 Tilt Sensor Location Tilt Sensor Removal NOTE NOTE 3121108 Refer to Figure 2 26 Tilt Sensor Removal for num bers in parenthesis Disconnect the batteries Open the Ground Control Box to gain access to the Tilt Sensor Assembly Remove the four Screws 3 Lockwashers 4 Standoff Insulators 5 and Washers 6 to remove the Tilt Sensor 1 and Sensor Mount 2 from the Ground Control Box The Tilt Sensor 1 can be removed from the Sensor Mount 2 by removing the three Screws 7 Follow the above procedures in reverse order when installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 2 18 Calibrations 1 6 9 am x 00 93 M gt CD 05 99 1 Tilt Sensor JLG P N 4000021 Mount Screw 6 32 1 Lockwasher Standoff Insulator Washer 0 313 x 0 250 Nylon Screw M3 5 x 0 6 x 10 DLO gg P co Figure 2 26 Tilt Sensor Removal Table 2 9 Tilt Sensor Harness JLG Lift Wire Color Function Connector Pin Red VCC 1 Green PWMX 2 White PWMY 3 Black Ground 4 2 27 SECTION 2 PROCEDURES 2 18 CALIBRATIONS Tilt Sensor Calibration 1 2 28 Drive t
33. 978 ss PETA BA ET NETTO WARE F CNN DRE RN 20 25 245 155 io sso 460 24 3 220 1065 960 800 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s n ewo ses sx 4395 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED A NJO Figure 1 9 Torque Chart METRIC Fasteners Sheet 6 of 7 1 12 JLG Lift 3121108 SECTION 1 SPECIFICATIONS Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS 6 AND ABOVE A i H TM Tensile Dry or Loctite 242 or 271 Loctite 262 Size PITCH Stress Vibra TITEM Aten OR Vibra TITE i um or 140 M K 15 678 78 8 78 36 60 115 12 5 18 0 22 8 36 1 52 5 e as mm sen em m 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 8 ASSEMBLY USES
34. ALARA ORN RFD 49 3 V YFL RFD 2 12 WHT RED 57 2 WHT RED 51 3 13 333333 i WHT RED 51 4 6944444 3 4 gH 39 5 A T AA A L A x scm alala THIS SYMBOL 15 a a 2 2 2 A WIRE CABLE JE EDA HEE SALE i 2 S 85 LOCATION A ANAN ANA SASA A A AAAAAAAA JA THE DRAWING ABBE f S S s S f e FE A s E es e LETTER_NUMBER 2 Q SFR MOON O OX X OX X X oX INDICATES OTHER LOCATION 3 4 DL SSS eff 2228 OCT UN Mns Se BO Fe hes os Sones DUAL AXIS CHOKE WHT YEL 20 AMP TILT SENSOR TOGA PARLAY 7 GAS ENGINE a 86 E CHOKE 2 x ons WHITE UPS IAN 3 2 RVS ORANGE 8 1 FWS ORANGE BRS ORANGE 55 RTS YFLLOW 10 2 LTS YELLOW 9 2 DPS 2 107 RFD WHT 50 1 2 FUEL Q2 22 a DUMP STEER STEER BRAKE DRIVE DRIVE LIFT LIFT i VALVE LEFT RIGHT FOR REV UP DOWN 6ND E ETE a ka Yi ig z s E s EE 2 E e 9 ow S 2 20 J 8 23 13 t3 13 13 E 2 2 28 amp amp 9 z zs E gm E A RR R el m N xx Rae EJ Sj ACTUATOR BLACK 4 V V V V V V V 52 7 d 4 BLACK 11 i BLACK 2 q d dg ej ENGINE LOW OIL PRESSURE 3 He SWITCH 8 1 3 NOTE in q PGY5 e TF NOTE 1 SPEED 3 E A 3 PICK UP J VALVE Q i ENGINE d 3 HIGH TEMP ge 25233158 SWITCH GAS ALL DIMENSIO
35. Connector Disassembly a aaa a aaa mrs 3 8 3 14 Connector Installation 2 0 a aa GR ren 3 9 JLG Lift 3121108 TABLE OF CONTENTS 3 12 3 13 3 14 3 15 3 16 3 17 3 18 3 19 3 20 3 21 3 22 3 23 3 24 3 25 3 26 3 27 3 28 3 29 3 30 3 31 TABLE NO OQ N O 3121108 DT DTP Contact Installation 3 10 DT DTP Contact Removal 0 aaa a aN wasispa m mre 3 10 HD HDP Contact Installation aaa 3 10 HD HDP Locking Contacts Into Position 3 11 HD HDP Contact Removal aas au hukaq PAP qua LA ee a 3 11 HD HDP Unlocking Contacts 5 3 11 Electrical Schematic Sheet 1 of 3 _ 3 22 Electrical Schematic Sheet 2 of 3 3 23 Electrical Schematic Sheet 3 of3 9 3 24 Electrical Schematic Generator Sheet 1of 3 3 26 Electrical Schematic Generator Sheet 2 3 27 Electrical Schematic Generator Sheet 3 3 28 Electrical Components Installation Prior to S N 141689 Sheet 1 3 30 Electrical Components Installation Prior to S N 141689 2
36. DOWN arrow keys to adjust its value for example A WARNING FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU LAR MACHINE CAN RESULT IN IMPROPER OPERATION CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF THE MACHINE 3121108 N x Me leveling j acks 1 yes ESC ENTER LEVELING JACKS 1 YES 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 set tings allowed to install optional features or select the machine model When selecting the machine model to match the size of the machine the personality settings will return to default settings NOTE Refer to the appropriate Machine Personality Set tings Table and the Machine Setup Table in the JLG Service Manual for the recommended factory set tings Password 33271 will give you access to level 1 which will permit you to change all machine person ality settings NOTICE IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS A
37. Drive Motor Rexroth JLG Lift Hydraulic Filter Inline Full flow paper filter Cartridge type Torque Requirement All wheel lug nuts should be torqued to 105 ft Ib 142 Nm every 150 hours NOTE When maintenance becomes necessary or a fas tener has loosened refer to the Torque Chart in this section to determine proper torque value 1 4 LUBRICATION Hydraulic Oil NOTE Hyaraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 Table 1 9 Hydraulic Oil HYDRAULIC SYSTEM OPERATING SAE VISCOSITY TEMPERATURE RANGE GRADE 18 5 tow 10W 20 10W 30 1000 20w 20 NOTE Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Indus tries for proper recommendations 1 5 LUBRICATION SPECIFICATIONS Table 1 10 Lubrication Specifications KEY SPECIFICATIONS Multipurpose Grease having aminimum dripping point of 350 F Excellent water resistance and adhesive qual ities and being of extreme pressure type Timken OK 40 pounds minimum MPG Extreme
38. LIFT OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD 16 Ifapplicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable SeeTable 2 2 Holding Valve Torque Specifications Table 2 1 Cylinder Component Torque Specifications Torque Value Component w Loctite X 80 ftlbs Tapered Bushing Retaining Screws Lift Cylinder 108 Nm I 9ftlbs Head Retaining Screws Lift Cylinder 12 Nm Table 2 2 Holding Valve Torque Specifications Description Torque Value 30 35 10 Sun 7 8 hex M20 x 1 5 thds 41 48 Nm 45 50ftlbs Sun 1 1 8 hex 1 14 UNS thds 61 68 Nm 150 153 ftlbs Sun 1 1 4 hex M36 x 2 thds 204 207 Nm 50 55 105 Racine 1 1 8 hex 1 1 16 12 thds 68 75 Nm 75 80ftlbs Racine 1 3 8 hex 1 3 16 12 thds 102 109 Nm 100 110ftlbs Racine 1 7 8 hex 1 5 8 12 thds 136 149 Nm 3121108 SECTION 2 PROCEDURES 2 11 STEER CYLINDER REPAIR Removal Before beginning this procedure ensure that the parking brake is engaged and the rear wheels are chocked 1 Tag and disconnect the hydraulic lines to the steer cylinder then cap the steer cylinder hydraulic lines and ports 2 At each steer spindle remove the bolt and lock nut securing the steer cylinder to the spindle 3 When the steer cylinder is disconnected from the steer spindles turn each wheel by hand to
39. Manual for the proper procedure JLG Lift 2 23 SECTION 2 PROCEDURES 2 16 JOYSTIGK GONTROLLER 150 ohm 2W 150 ohm 2W TER TAP SUPPLY TRIGGER SWITCHES RIGGER SWITCH STEER LEFT SUPPLY STEER ROCKER SWITCHES STEER RIGHT Figure 2 22 Joystick Controller JLG P N 1600308 Table 2 4 Joystick Specifications Table 2 5 Joystick Plug Loading Chart Input Voltage 4 3V 0 1V Terminal Color Function Centered Output Voltage 2 2V 0 1V 1 Yellow Steer Right Full Positive Rev Deflection Output Voltage 4 0V 0 1V 2 Green Steer Left Full Negative Fwd Output Voltage 0 4V 0 1V 3 Brown Pot Wiper 4 Red Handle Common 5 N A Not Connected 6 White Red Pot 7 Violet Trigger Switch 8 Blue Trigger Supply 9 White Black Pot 2 24 Lift 3121108 SECTION 2 PROCEDURES 49 9 ohm POT WIPER POT TRIGGER SUPPLY TRIGGER SWITCH TRIGGER SWITCHES STEER LEFT SUPPLY STEER ROCKER STEER RIGHT SWITCHES Figure 2 23 Joystick Controller JLG P N 1600403 Table 2 6 Joystick Specifications Table 2 7 Joystick Plug Loading Chart Input Voltage 5V Centered Output Voltage 4 25V to 2 60V Reverse Voltage 4 60V to 4 80V Forward Voltage 0 40V to 0 60V 3121108
40. Software 1 5 and Higher and Higher Using the Analyzer in Access Level 1 go to MENU CALIBRATION JOYSTICK and press ENTER 1 Following the analyzer screen prompts a Move the Joystick FORWARD and press ENTER b Allow Joystick to be in CENTER position and press ENTER c Move the Joytstick REVERSE and press ENTER 2 CAL COMPLETE or CAL FAILED will display on the analyzer 3 Possible reasons if calibration failed a The forward position must be a lower voltage than reverse position b The difference between center and forward amp center and reverse must be atleast 1V 3121108 JLG Lift 2 29 SECTION 2 PROCEDURES 2 19 ELECTRONIC CONTROL SYSTEM Hand Held Analyzer menu Analyzer Display HELP PRESS ENTER Escape Key Enter Key Toreturnhomeoraccess gt Esc Stores and selects Top Level Sub previous menu Level anditem menus Left amp Right Arrow Keys Used to move between Top Level Sub Level and item menus Up amp Down Arrow Keys Value Selector Figure 2 27 Hand Held Analyzer To Connect the Hand Held Analyzer 1 Connect the four pin end of the cable supplied with the analyzer to the top connection of the motor con troller and connect the remaining end of the cable to the analyzer NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the Control System by turning the lower key to the platform pos
41. THE PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM THE FOLLOWING PROCEDURE SHOULD ALWAYS BE PER FORMED WHEN STARTING A NEW PUMP OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAVE BEEN REMOVED FROM THE SYSTEM THE FOLLOWING PROCEDURE MAY REQUIRE THE MACHINE TO BE DISABLED WHEELS RAISED OFF THE GROUND DRIVE FUNCTION DISCONNECTED ETC WHILE PERFORMING THE PROCEDURE IN ORDER TO PREVENT INJURY TO TECHNICIAN AND OTHER PERSONNEL TAKE NECESSARY SAFETY PRECAU TIONS BEFORE MOVING THE MACHINE Prior to installing pump and or motor inspect unit s for damage incurred during shipping and handling Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with hydraulic fluid Fill reservoir with recommended hydraulic fluid which should be passed through a 10 micron nominal no bypass filter prior to entering the reservoir The use of contaminated fluid will cause damage to components which may result in unexpected machine movement The inlet line leading from the reservoir to the pump should be filled prior to start up Check inlet line for prop erly tightened fittings and make sure it is free of restric tions and air leaks Be certain to fill pump and or motor housing with clean hydraulic fluid prior to start up Fill housing by pouring fil tered oil into upper case drain port Install a 0 to 500 psi 0 to 35 bar pressure gauge in the charge
42. VY V V SENDER yi 5 lt BLACK 11 a x 5 Ri BLACK 2 J 920 s S des T c ENGINE LOW OIL PRESSURE B9E 2 E SWITCH 8PSI y wore c 7 Z NOE D Para 2615 E s hi d INE NOTE 1 SPEED UNLESS OTHERWISE SPECIFIED ALL P eM AL e gt PICK UP DIMENSIONS ARE IN INCHES E HIGH ag NOTE 1 4 SWITCH z gt A uote vo Wi THIS PRINT 15 THE PROPERTY OF JLG INDUSTRIES INC E ex CP6Y6 gt e i AND CONTAINS PROPRIETARY AND CONFIDENTIAL J INFORMATION OF JLG IT MAY NOT BE COPIED OR FUEL TGN DISCLOSED TO ANY THIRD PARTY WITHOUT JLG S zc 8 PUMP SYSTEM WRITTEN CONSENT AND IS PROVIDED FOR THE gra 9 T a LIMITED PURPOSE OF REVIEW AND EVALUATION Ye pe 2 YEL RED 2 5 Z N o 70 amp j TEMPERATURE BLACK SWITCH i mi 1001109561_B Sheet 1 Figure 3 22 Electrical Schematic Generator Sheet 2 of 3 3121108 JLG Lift 3 27 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS SERIAL DATA IN YEL BLK Q2 30 gt SERIAL DATA CLOCK WHT RED ROI R02 300 300 IW R03 300 SERIAL DATA OUT
43. all three wires the wire under test wire 1 and wire 2 These should be open If not repair the shorted wires or replace the harness 3 Onone side jumper from contact of wire 1 and wire 2 4 Measure continuity between wire 1 and wire 2 If there is continuity both wires are good and can be used for this test If there is not continuity either wire could be bad Check connections and measurement setup Redo measure ment If still no continuity repair wires or consult schematic for other wires to use for test 5 Jumper from wire under test to wire 1 6 Measure continuity If there is continuity the wire under test is good Resistance of a wire increases as the length increases and as the diameter decreases One can find the continuity of two wires here 1 and 2 at once by following steps 1 through 4 If there is a problem the third wire is used to troubleshoot the other wires To find the problem start at step 1 and use the entire procedure 3 4 JLG Lift 3121108 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the
44. and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual integral reliefs are provided for each side of the circuit 2 6 COMPONENT FUNCTIONAL DESCRIPTION Hydraulic Pump The machine is equipped with two hydraulic pumps a function pump and a drive pump The function pump is a single section gear pump that controls the lift and steer functions and provides a maximum output of 4 75 gom 18 lpm The drive pump is a single section piston pump that controls the drive function and provides an output of 22 gpm 83 3 Ipm Lift Cylinder Counterbalance Manual Descent Valve The lift cylinder counterbalance manual descent valve is located on top of the lift cylinder The counterbalance valve is used to hold the platform in place when raised A cable is connected to the valve which when pulled manu ally opens the lift down port and allows the platform to be lowered in the event hydraulic power is l
45. can be wired between the positive side of the power source and the load This switch is called a high side switch The switch supplies the power to the load When a switch is wired between the negative side of the power source and the load it is a low side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle What is actually being measured is the voltage drop across the switch This could mislead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load measure voltage across the load s power terminals Also the technician can mea sure the voltage at both power terminals with respect to battery ground The difference between those two measure ments is the voltage applied to the load 3 6 TROUBLESHOOTING General This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any mainte nance
46. cylinder ports 4 Extend the cylinder rod until the attach pin hole aligns with those in the upper arm assembly Using a suitable drift drive the cylinder rod attach pin through the aligned holes taking care to align the pin retaining hole with the hole in arm assembly Secure the pin in place with the bolt and locknut 5 Lower platform to stowed position and shut down motor Check hydraulic fluid level and adjust accord ingly JLG Lift 2 5 SECTION 2 PROCEDURES NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS BLOCKING OR OVERHEAD SLING o STRAP SAFETY PROP Figure 2 1 Arms and Platform Positioning and Support Cylinder Repair 2 6 JLG Lift 3121108 SECTION 2 PROCEDURES 1 Barrel 6 Restrictor Check Valve 11 O Ring 16 Seal 2 Rod 7 Locknut 12 Spacer 17 O Ring 3 Solenoid Valve 8 Wear Ring 13 O Ring 18 Head 4 Cotter Pin 9 Seal 14 Back Up Ring 19 Wiper 5 Cable Adaptor 10 Piston 15 Wear Ring 20 Bushing Figure 2 2 Lift Cylinder 3121108 JLG Lift 2 7 SECTION 2 PROCEDURES 2 10 CYLINDER REPAIR Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Connect a suitable auxiliary hydraulic power source to the cy
47. 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 connection It is possible to inspect a connection within a closed con nector by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent conditions while alone For example you can read the voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the location of the signal and that the leads are connected to the device under test cor rectly Also check that the lead on the COM port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal Scale M Mega 1 000 000 Displayed Number kilo 1 000 Displayed Number m milli Displayed Number 1 000 micro Displayed Number 1 000 000 Example 1 2 kO 1200 Q Example 50 mA 0 05 A 3121108 JLG Lift 3 1 SECTION GENERAL ELECTRICA
48. electrical connectors 1 To prevent oxidation and low level conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole plug into this and or any unused wire seal that has silicone dielectric compound escaping from it PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY RETENTION LEG WEDGE LOCK HOUSING Figure 3 5 AMP Connector 3121108 JLG Lift 3 5 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS Assembly Check to be sure the wedge lock is in the open or as shipped position See Figure 3 6 Connector Assembly 1 of 4 Pro ceed as follows CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Figure 3 6 Connector Assembly 1 of 4 1 To insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 3
49. give clearance to remove the steer cylinder from the front axle 4 Carefully lift the steer cylinder until the cylinder mounting block clears the mounting slot in the bot tom of the axle then slowly remove the cylinder from the axle and place it in a suitable work area Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Place the cylinder barrel into a suitable holding fix ture 2 Using a suitable chain wrench carefully remove the cylinder head retainer from one end of the cylinder barrel 3 Attach a suitable pulling device to one end of the cylinder rod NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD SPACER AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 4 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 5 Using a suitable chain wrench carefully remove the remaining cylinder head retainer from the opposite end of the cylinder barrel Remove the head and remove and discard the wiper rod seal O ring and wear ring 6 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture 3121108 7 Carefully remove the head from the cylinder rod and remove and discard the wiper rod seal o ring and wear ring 8 Carefully rem
50. have selected If meter is not auto ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire longer than the reach of standard instrument leads is possible to perform the check without excessively long leads Using the other wires in the harness one can determine the condition of a particular wire in the harness Requirements Harness with at least three separate wires including the wire under test These wires must be able to be isolated from other wires etc Jumper or method to connect contacts on one side of harness Meter that can measure resistance or continuity Procedure Test multimeter leads resistance Subtract this value from the measured resistance of the wires to get a more accurate mea surement Consult the circuit schematic to determine which wires to use in addition to wire under test here called wire 1 and wire 2 and how to isolate these wires These wires should appear in the same connectors as the wire under test or are within reach of the jumper 1 Disconnect all connections associated with the wire under test and the two additional wires If harness is not com pletely isolated disconnect battery terminals also as a precaution 2 Measure continuity between
51. matching that required by the load A small line connected to a load sensing port feeds load pressure back to a sequence valve The sequence valve senses the differ ence between the load and pump outlet pressure and varies the pump displacement to keep the difference con stant This differential pressure is applied across the valve s meter in spool with the effect that pump flow is determined by the degree of spool opening independent of load pressure Return lines are connected together simplifying routing of return flow and to help reduce cavi tation Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence JLG Lift 2 3 SECTION 2 PROCEDURES valve Integral actuator port relief valves anti cavitation check valves and load check valves are standard Relief Valves Main relief valves are installed at various points within the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing rupture of the cylinder hydraulic line or fitting Complete failure of the system pump is also avoided by relieving cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line
52. may also occur Excessive soot This will rapidly deteriorate the engine oil the valves and the exhaust ports with carbon deposits If enough soot is built up the cata lyst if equipped may not function properly Emissions Kubota cannot guarantee emissions without the proper Altitude Compensation kit installed JLG Lift 1 1 SECTION 1 SPECIFICATIONS Table 1 5 D905 B Kubota Diesel Type 3 cylinder liquid cooled Power 26 horsepower 3000 rpm Low Idle 800 rpm High Engine 3800 rpm Alternator 40 Amp Fuel Consumption Low RPM 0 68 gph 2 6 Lph High RPM 1 48 gph 5 5 Lph Table 1 6 D1005 Kubota Diesel Type 3 cylinder liquid cooled Power 23 5 horsepower 3000 rpm Bore x Stroke 76 0 mmx73 6 mm Low Idle 800 rpm High Idle 3800 rpm Alternator 12V 30 Amp Starter 12V 1 0Amp Tires Table 1 7 Tire Specifications Description Standard Non Marking Size 26x12 15 Load Range 8Ply Pressure 55 psi Pumps Table 1 8 Pump Specifications Description Drive Pump Lift Steer Pump Type Piston Gear 22 gpm 83 3 lpm 4 75 gpm 18 lpm Max Output 3000rpm 3000rpm 1 7 inS rev 0 36 in 3 rev Displacement 28 cm rev 1 4 cm rev Steer Drive System Tire Pneumatic or foam filled 26 x 12 15 lug NOTE Inflate pneumatic tire to 55 psi 3 8 bar Toe In Adjust to 1 4 inch 6 4 mm overall
53. pressure gauge port to monitor charge pressure during start up It is recommended that the external control input signal electrical connections be disconnected at the pump con trol until after initial start up This will allow the pump to remain in its neutral position Jog or slowly rotate prime mover until charge pressure starts to rise Start prime mover and run at the lowest pos sible RPM until charge pressure has been established Excess air may be bled from high pressure lines through high pressure gauge ports 2 22 JLG Lift A WARNING DO NOT START PRIME MOVER UNLESS PUMP IS IN NEUTRAL POSITION 0 DEGREES SWASHPLATE ANGLE TAKE PRECAU TIONS TO PREVENT MACHINE MOVEMENT IN CASE PUMP IS ACTUATED DURING INITIAL START UP Once charge pressure has been established increase speed to normal operating RPM Charge pressure should be approximately 300 psi 20 7 bar minimum If charge pressure is incorrect shut down and determine cause for improper pressure A WARNING INADEGUATE CHARGE PRESSURE WILL AFFECT THE OPERA TOR S ABILITY TO CONTROL THE MACHINE Shut down prime mover and connect external control input signal start prime mover checking to be certain pump remains in neutral with prime mover at normal operating speed slowly check for forward and reverse machine operation Charge pressure should remain at 300 psi to 320 psi 20 7 bar to 22 1 bar minimum during forward or reverse opera tion Continue t
54. requires that a complete annual inspection T be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each 12 new machine and are also available from JLG Customer Service Form must be completed and returned to JLG i Industries 14 NOTICE JLG INDUSTRIES REGUIRES THAT A CONPLETE ANNUAL 15 INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM 16 NOTE This machine requires periodic safety and mainte nance inspections be a JLG Dealer A decal located on the frame affords a place to record stamp inspection dates Notify dealer if inspection is over due 3121108 JLG Lift Check for proper and secure installation Check for visible damage and legibility Check for proper fluid level Check for any structural damage cracked or broken welds bent or warped surfaces Check for leakage Check for presence of excessive dirt or foreign material Check for proper operation and freedom of move ment Check for excessive wear or damage Check for proper tightness and adjustment Drain clean and refill Check for proper operation while pump motor is running Check for proper lubrication Check for evidence of scratches nicks or rust and for straightness of rod Check for condition of element replace as neces sary Check for proper inflation Check Inspection Decal for current inspection stamp 2 43 SECTION 2 PROCED
55. switch has more than two terminals consult the schematic or switch diagram to determine what terminals will be connected The test is similar to testing a switch with two terminals a Place one meter lead on the common contact and the other on a different contact in the same circuit b Cycle through all positions of the switch The meter should read short only when the switch connects the two terminals and open otherwise c Ifthe switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit switches are just like manually oper ated switches except that the moving object operates the switch These switches can be tested the same way as a stan dard switch by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Inductive proximity switches are actuated only by ferrous metal metal that contains Iron such as steel near the switch They do not require contact and must be energized to actuate These types of switches can be used to detect boom or platform position for example These switches have a sensing face where the switch can detect ferrous metal close to it To find the sensing face take note how the switch is mounted and how the mechanisms meet the switch Test this type of switch as follows Remove prox switch from its mount
56. test meter perform continuity test on wire Repair or replace wire as necessary Defective electric motor start relay Replace electric motor start relay No voltage supplied to motor from start Check battery cable from relay to motor relay for proper connection or damage Repair or replace wire as necessary Defective motor pump assembly Replace motor pump assembly 3121108 JLG Lift 3 21 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS ORN WHT 55 3 WHT YEL 48 10 1001106560_B Sheet 1 PETTA E BIU ORN 52 1 WHT YF 48 1 WHT YFI 48 2 YEL RED 2 38 TAN 55 2 ORANGE 55 1 AAAAAAA AAAA fo Q fe fe fo feo fo 2 Fsssssssess ee POE S S 5 S Bats amp enaa e 2 5388 5
57. the machine is sitting on is off level by a few degrees flat doesn t imply level park ing lots are often not level The tilt sensor has failed one or both of the channels X axis and Y axis Tilt sensor has moisture intrusion that has shifted its output Water and or corrosion in the box has corrupted electrical connections or caused a tilt sensor or ground control board failure observe any cracks in the box 3121108 SECTION 2 PROCEDURES e The Ground Control Box as mounted on the machine does not allow the tilt sensor to be level For the following troubleshooting steps a bubble level smaller is better willbe needed and the machine must be on a level surface 1 the Analyzer go to Diagnostics System and read the tilt angle If either angle reports 20 0 there is an electrical electronic failure tilt sensor control board electrical connections a Open the Ground Control Box b Disconnect the sensor and clean any corrosion off of the tilt sensor and control board connections c Reassemble and test If fault persists replace tilt sensor 2 Ifthe Analyzer displays angles other than 20 0 attempt to calibrate If machine will not calibrate note the reason dis played on Analyzer a SENSOR FAILURE tilt sensor internal frequency is out of range replace sensor b NOT LEVEL tilt sensor has either developed an offset or it is to unlevel as mounted on the machine Joystick Calibration
58. wiper wire shorted to battery negative could cause this JOYSTICK FAULTY STEER SWITCHES ACTIVE TOGETHER Both the steer left and steer right inputs are closed at the same time A shortin the steer switch wiring or a failed steer switch can cause this FUNCTIONLOCKED OUT JOYSTICK NOT CENTERED Selected function is not allowed because the joystick is not centered Return joystick to center and reselect function FUNCTION PROBLEM JOYSTICK CALIBRATION FAULTY The Personalities for theJoystick are improperly adjusted or a joystick calibration attempt failed Re adjust or recalibrate 2 34 Lift 3121108 SECTION 2 PROCEDURES Table 2 10 Help Messages and Flash Codes Software P1 X FLASH CODE HELP MESSAGES AND FLASH CODES 2 2 FUNCTION PROBLEM TRIGGER PERMANENTLY CLOSED Trigger switch in the platform control box closed at start up Release switch to clear fault TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL Trigger switch in the platform control box closed for more than ten seconds while the joystick is in the neutral position Release switch to clear fault 2 3 FUNCTION PROBLEM LIFT PERMANENTLY SELECTED Lift switch up or down in the ground control box closed at start up Release switch to clear fault FUNCTION PROBLEM START PERMANENTLY SELECTED Start switch in the ground control box closed at start up Release switch to clear fault FUNCTION P
59. 1 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany FE 49 0 421 69 350 20 EL 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore T E P Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 65 6591 9030 65 6591 9031 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 EL 34 93 771 1762 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 Ca www jlg com
60. 12 LIMIT SWITGH ADJUSTMENT Platform Limit Switch The platform limit switch is located on the left side of the frame of the machine When activated the switch cuts out the High Drive function Adjust the switch to activate when the platform is raised above the stowed position 2 13 PRESSURE SETTING PROCEDURES NOTE Make all pressure adjustments with the engine oper ating and the hydraulic oil at normal operating tem perature In addition all functions must be operated from the platform control station in order to achieve full pump speed It may be necessary to use an assistant to adjust the pressure settings while oper ating the functions from the platform control station Pressure Adjustment Install a pressure gauge at gauge port MP located on the front upper right side of the valve body The port is identified by a stamping on the valve body Disconnect lift up solenoid connector From the Ground control panel activate the lift up function Bottom out the Lift Up function and adjust the main pressure to 3300 psi 228 bar Reconnect lift up solenoid connector Lift Relief Adjustments 1 4 3121108 Install a pressure gauge at gauge port MP located on the front upper right side of the valve body The port is identified by a stamping on the valve body From the platform control station activate the Lift Up function by selecting the lift control switch and posi tioning the joystick to the up position Bot
61. 3 2 25 2 24 Tilt Sensor Location ARANG eee TENG mero agr ui MR arr Cade t 2 26 2 24 Til Sensor Removal ay um ies Shes LR aa MG aa a s Cia 2 26 2 25 Sensor isa e SS aa ga e Na Jen aa Tay Ga KN mmn 2 27 2 26 Till Sensor Removal asa ld Ra KANA eben ds BR ku Becta dents 2 27 2 27 Held Analyzer uuu ee a v ana ag a qu AREE ER Reg 2 30 2 28 Analyzer Flow Chart Sheet 1of4 2 36 2 29 Analyzer Flow Chart Sheet 2of4 2 37 2 30 Analyzer Flow Chart Sheet3 of4 ren 2 38 2 31 Analyzer Flow Chart Sheet 4 of4 res 2 39 3 1 Voltage Measurement DC 3 2 3 2 Resistance Measurement 5 3 2 3 3 Continuity 3 3 3 4 Current Measurement DC aaa aa aa eaaa hh 3 3 3 5 AMP Connectl zi cid teri eg ei ng Sa a aaa NA ga apk a ee ea na E 3 5 3 6 Connector Assembly 1 of4 3 6 3 7 Connector Assembly 2 of4 3 6 3 8 Connector Assembly 3 0f 4 us y pus ER m EAER Suku aa uya Md 3 7 3 9 Connector Assembly 4 of4 0 3 7 3 10
62. 50 170 230 155 210 130 1 5 5 8 1 0 6250 0 2260 20350 210 285 190 260 160 220 18 0 6250 0 2560 215 290 180 245 3 4 10 0 7500 0 3340 340 460 380 16 0 7500 0 3730 380 515 430 14 0 8750 0 5090 45800 670 910 600 815 500 680 12 100 06630 59700 995 1355 895 1215 745 1015 LT 12 11250 08560 77000 1445 1965 1300 1770 1085 1475 12 12500 1 0730 X 96600 2015 2740 1810 2460 1510 2055 12 1375 13150 118100 2705 3680 2435 3310 2030 2760 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 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 7 Torque Chart SAE Fasteners Sheet 4 of 7 JLG Lift 3121108 SECTION 1 SPECIFICATIONS Tensile Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite Loctite 262 242 or 271 OR Vibra OR Vibra TITE 131 TITE 111 or 140 561 3 694 302 0 1990 1490 2090 14 23 0 7 8 78 3 82 34 6 8 6 1
63. 7 Connector Assembly 2 of 4 2 Pull back on the contact wire with a force of 1 or 2 Ibs to be sure the retention fingers are holding the contact See Fig ure 3 7 Connector Assembly 2 of 4 3 After all required contacts have been inserted the wedge lock must be closed to its locked position Release the lock ing latches by squeezing them inward See Figure 3 8 Connector Assembly 3 of 4 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 3 9 Connector Assembly 4 of 4 e ses PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT Figure 3 7 Connector Assembly 2 of 4 3 6 Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 3 8 Connector Assembly 3 of 4 WEDGE LOCK FLUSH WITH SS MENT E wawww D Figure 3 9 Connector Assembly 4 of 4 3121108 JLG Lift 3 7 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS Disassembly 5 Insert a 4 8 mm 3 167 wide screwdriver blade between the mating seal and one of the red wedge lock tabs 6 Pry open the wedge lock to the open position 7 While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed messe Figure 3 10 Connector Disassembly NOTE The wedge lock should never b
64. 83 09 3 3NI9N3 dW SHAT 0 VA MS 313 31848 1uv1 5N3 ANNOYS N 20903 YdH 9 LV UNISNG 1H9 33 15 VA NYOH WILSAS 131 0 10 9 20903 YAZATWNY 801593A 104100 DV 3NIDN3 1131133 15 VA 35nv5 1313 WILSAS N0015 135033 WYOJIY 0 1 SNOISUJA 39 yl NIDN3 35034 SHA WIL SAOL WALSAS dNn049 0 10 9 13 HI WYO dNn0y9 SNOISUJA 045 T0 DV 3NIDN3 ANI AMALIE WALSAS 114 015 135 FAY WYO SNOISV3A SDILSONDVIG 501V1vd 8911 0ND VI Q ANISNG SIILSONSVIG SIN VA 8911 0ND VIG WALSAS 2521150 9 10 GNNOYDS SIILSONDVIG I1S0N5VI0 411H 03550 41 L133H NO Q 1N02 SJILSONSVIG NIN 331N3 S5394 413H MNAW 3121108 Lift 2 36 SECTION 2 PROCEDURES t JO Z JOYS Heyo MoOld JezAleuV 6Z Z enDi4 pagueu Juo pamapag oj W nua nu Wl A 1 doy NOISUIATYVMIIOS ANY NOILVYNSIINOD 3NIHDVH NOd h SNIN3d3Q 318V1 38 LON N33925 INOS 11410 115 1N340 195 1 3501 ONTGNNOS VIS 18018 N340 VIS LHOIY 3507 iNO 034015 1 33315 13318340 33315 1331 3501 ino 123135 914 M019 390 9114 M079 3501
65. ARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPON SIBILITY OF THE OWNER OPERATOR B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system 3121108 Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss C MAINTENANCE A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND ISA SAFETY VIOLATION NO SMOKING IS MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND CAU TIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UN
66. C two times When a top level menu is selected a new set of menu items may be offered for example PLATFORM DRIVE LIFT SEL SPEED SEL HORN ENGINE START FUEL GLOW STEER LEFT STEER RIGHT JOYSTICK Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the personality settings for selected menus JLG Lift 2 31 SECTION 2 PROCEDURES while in access level 2 Remember you may always can cel a selected menu item by pressing the ESC key The access level should display the following if the pass word was entered correctly Changing the Access Level of the Hand Held f N Analyzer When the analyzer is first connected you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a pass word to advance to a lower level This ensures that a set ting cannot be accidentally altered To change the access level the correct password must be entered To enter the ESC ENTER password scroll to the ACCESS LEVEL menu For exam ple 7 S S fF MEG TORS LEVEL 2 Sy f MENU ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings
67. DER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue March 27 2000 Revised January 23 2002 Revised April 15 2004 Revised October 21 2004 Revised July 3 2006 Revised August 30 2006 Revised October 11 2007 Revised April 28 2008 Revised December 19 2008 Revised October 20 2011 Revised June 8 2012 Revised April 19 2013 b JLG Lift 3121108 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A Generals bara iat la Pe aa a RENE RR UL d REC 1 A B Hydraulic System Safety anas wia tet a a Na aa aana 1 Maintenance tres CENE ect er eee Se Ped ve qas eo b Sah eae En 1 A SECTION 1 SPECIFICATIONS 1 1 SPEGINGANONS su te ha wasqa E tdi Ka Er dU ad 1 1 1 2 Capacities suce ER E Su DEAE sb qu E a ee 1 1 1
68. E O YEL RED 2 5 I PRESSURE JAN N 0 70 TEMPERATURE BLACK 8 SWITCH SF START START 16N ALTERNATOR O y Z S T NOTE 1 lt PGWZ NOTE LAMP Figure 3 18 Electrical Schematic Sheet 1 of 3 3 22 Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS ORN WHT 55 3 WHT YEL 48 10 48 4 BLU ORN 52 1 WHT YF 48 1 WHT YFI 48 2 TAN 55 2 ORANGF 55 1 A A AAAAAAA fa fos foo Ret foo for fe Fel ie fel fe fel Fe 9 ie IK OHM 8 s E ES SLE J S iss W 150 OHM CURRENT LIMITING RESISTORS E E E b S88 255228 RP eee 5 a 5 sas T VY V T23V CENTER PLATFORM DISPLAY Le iis H YELLOW 9 1 rums ET tedy DRIVE LIFT P ENGINE 610 CHOKE UJ 3835 RTP YELLOW 10 1 SELECT SELECT SPEED START PLUGS Lp GAS SELECT SELECT L J OPTION SELECT
69. ED 1200 TO 1500 rpm 1500 1500 GAIN 010 999 150 10 DROOP 0t0 999 250 90 STABILITY 010999 100 130 MIN 070 100 19 18 MAXACTL D 0 0 100 60 100 MAXACTIDLE 0 0 100 55 55 CUTACT 200 T0 2800 RPM 500 500 GEN ENG SPD 2000 T0 3600RPM 3000 3000 4150335 JLG Lift 3121108 SECTION 2 PROCEDURES 2 22 MACHINE CONFIGURATION NOTE kaa kn d machine configuration must be completed before PROGRAMMING INFORMATION any personality settings can be changed Changing the personality settings first and then changing the NOTICE model number of the machine configuration will TABLE 2 12 APPLIES TO MACHINES WITH 4170010 SOFTWARE cause the personalitysettings To return to q lault vals ues Table 2 12 Machine Configuration Programming Information 4170010 Software CONFIGURATION DEFAULT DIGIT NUMBER DESCRIPTION NUMBER 0 260 MRT 0 Model 2 0 750 Dual Fuel 0 Engine Selection 1 905 Diesel 0 CE W O Cutout Default setting for CE machines Tilt angle is 3 side to side and 5 front to back 3 1 DOM CSA W CUT Cutout lift up and drive if tilted and elevated Required for CSA market Tilt angle is 3 side side and front to back 1 Tilt Config 2 LIFTup and DRIVE Cutout lift up and drive if tilted and elevated Required for AUS and BRZ markets Optional for DOM and CE markets angle is 3 side to side and 5 frontto back 4 0 No drive cutout switch i
70. GAINST 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 SECTION 1 SPECIFICATIONS SOCKET HEAD SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Loctite 242 or 271 Torque gees Semp eee Loctite 262 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 85 K 0 15 12 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 PI K 0 18 o ose ie mm oe mm os 4 40 0120 000604 X39 J pg j 01 jJ 6 32 01380 0009009 j j j j 40 0130 000015 j j j j 9 8 32 0140 00400 T T j O 36 01640 00474 TO 10 24 0190 001750 OT 32 01900 j j j j O U 1 4 20 0250 0 0318 280 143 16 129 15 C 28 0250 00364 3280 1 164 19 148 J 12 sm 24 0 3125 0 0580 5220 25 3 25 3 2 2 24 0350 00878 790 5 70 45 3 5 716 14 04375 0 1063 950 70 95 j 6 9 50 7 20 0437 0 1187 1070 80 no J 70 95 j 60 80 20 0 5000 01599 amp 14400 120 165 150 90 120 18 0 5625 02030 182
71. 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 10 Torque Chart METRIC Fasteners Sheet 7 of 7 3121108 JLG Lift 1 13 SECTION 1 SPECIFICATIONS JES NOTES JLG Lift 3121108 SECTION 2 PROCEDURES SECTION 2 PROCEDURES 2 1 GENERAL This section provides information necessary to perform maintenance on the scissor lift Descriptions techniques and specific procedures are designed to provide the saf est and most efficient maintenance for use by personnel responsible for ensuring the correct installation and oper ation of machine components and systems A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED The maintenance procedures included consist of servic ing and component removal and installation disassembly and assembly inspection lubrication and cleaning Infor mation on any special tools or test equipment is also pro vided where applicable 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information
72. I 4 To x H Zao Q n t 0 g s Mo J Sao Er o lt d s O co o S weas o oJ lt MAE mos a Id bar lt Oc lt mO k C a To ps BEX di 8i 25 PETIT A ZVV 0 4 t 7m z aa v lt a ovwon 5 ER gt x z a E m a4 m A OF X 9 ih 8 amp g h A B In Wo J m ak CE ON CV PORT ADAPTER B EL RA oia A Lu SUCTION STEER 16 17 66 AND 67 z s is 14 ma J in Ly e z zs gt Oan a 2 o a E 2 G es lt o wee lt lt 5 lt 4 2oo gt dh oo ou ulmo tA m Figure 3 28 Hydraulic Schematic Prior to S N 141689 3 34 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMAT
73. IL ENGINE VALVE I TER PRESSURE N z HIGH TEMP x 5e N LOCATED ON z S gt 7 ENGINE NA z VALVE ENGINE TEMP gu S FUEL TGN zard 8 PUMP SYSTEM 7 CHARGE I YEL RED 2 5 PRESSURE N Z 10 Sj TEMPERATURE BLACK 8 7 SWITCH START m IGN ALTERNATOR NOTE 1 LAMP 3 26 Figure 3 21 Electrical Schematic Generator Sheet 1 of 3 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ORN WHT 55 3 WHT YEL 48 4 BLU ORN 52 1 WAT YEL 48 1 WHT YEL 48 10 WHT YEL 48 2 B TAN 55 2 ORANGE 55 1 AAAAAAA A A i e fo 3 f ER f ERE IK OHM 5 W 150 OHM CURRENT LIMITING RESISTORS 622888 Ts gt gt 8 2 Z z Z 52 5 4 5V OUTPUT 2 Gs D gt T VYYN TZ e CENTER PLATFORM DISPLAY LE GENERATOR YELLOW 9 1 HI tei v DRIVE P LIFT 51 ENGINE EM 522888865 5 RTP SELECT SELECT SPEED START HORN PLu6s LP GAS CHOKE FUEL SELECT SELECT L J OPTION ALAA EEE 5 5 5 ORN RFD 49 3 BLACK 28 V V V V V V YFL RED 2 12 e e T WHT RED 57 2 iR WHT RFD 51 3 BLU ORN 52 4 3 WHT RED 57 4
74. ION 86 SCHEMATICS 2792717 D NOIIORS Nu nl3q ANVIL 1404 NO 031883SSv SYOLOW 42018 SATIVA MOT 1H91U 199007 6195 o 0 SYOLOW 3AlNQ 1 0 udJ40008 09 ud40098 033dS 3NI9N3 LEETE 1311 3 35 Figure 3 29 Hydraulic Schematic S N 141689 to Present JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS due E 7 e o H o m Fad vu ea pow kaosan ene naa A DU mun 1 Nw 9 Lo ep bas BENE LU lt 1 H lt lt e W E a
75. L INFORMATION 6 SCHEMATICS Voltage Measurement Resistance Measurement Figure 3 1 Voltage Measurement DC Figure 3 2 Resistance Measurement If meter is not auto ranging set it to the correct range First test meter and leads by touching leads together See multimeter s operation manual Resistance should read a short circuit very low resis Use firm contact with meter leads tance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing f meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads 3 2 JLG Lift 3121108 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Current Measurement 7 7 a E eee Figure 3 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity Figure 3 4 Current Measurement DC Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you
76. N CONSENT AND IS PROVIDED FOR THE LIMITED PURPOSE OF REVIEW AND EVALUATION REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT PRESSURE PRESSURE PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER TRANSDUCER NOTE ALL COMPONENTS SHOWN ON THIS PAGE ARE FITTED FOR THE LEVELING JACK OPTION ONLY ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR SHIELDED CABLE THE SHIELD FOR EACH CABLE SHOULD BE TERMI HATED WITH THE RESPECTIVE BLACK IRE AT J3 1001109561 B Sheet 2 Figure 3 23 Electrical Schematic Generator Sheet 3 of 3 3 28 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS BS NOTES 3121108 JLG Lift 3 29 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS HIGH PRESSURE FILTER TO OVERLOAD TO ENGINE 2 COMPONENTS Jj PLATFORM WORK LIGHTS RECEPTACLE AT PLATFORM ka i A SSS LIFT I t CYLINDER 6 lt B B NN GENERATOR Figure 3 24 Electrical Components Installation Prior to S N 141689 Sheet 1 3 30 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS 24 SENDER BEACON LIGHT
77. NS IN ARE IN mm 3 a F ve VALVE J lud ex P616 DS 4 THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES INC AND CONTAINS 3 PROPRIETARY AND CONFIDENTIAL INFORMATION OF JLG IT MAY NOT BE gz FUEL TGN COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT JLG S WRITTEN 238358 a PUMP SYSTEM CONSENT AND 1S PROVIDED FOR THE LIMITED PURPOSE OF REVIEW AND E EVALUATION YEL RED 2 5 N O 70 TEMPERATURE SLACK A SEQUENCE NO SWITCH AN I NA QUANTITY 3121108 Figure 3 19 Electrical Schematic Sheet 2 of 3 JLG Lift 1001106560 B Sheet 1 3 23 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS SERIAL DATA IN 202 30 0 CLOCK R 02 300 Q lt 300 Q 1 lw R03 300 Q SERIAL DATA OUT 1 w Q2 40 gt JI RECEPTACLE PFDTH 2 1 PFOTH 41 1 E PFOTHI 2 2 FL LJ BLK YEL PFDTH JI 2 510 35 9 VALVE FRLJ FROM IGN SFDTH 41 3 GND 12 3 BLACK x 118 VALVE LJ CONNECTOR ON GND JI 4 40000 042 11 ORAL 55 2 vig VALVE RR LJ CHASSIS HARNESS NZ 16N JI 5 DOO 42 12 ORAM 55 21 Y20 VALVE LJ EXTEND SOURCE J2 5 ON CANH JI 6 10002 45 1 ORN WHT 55 22 f
78. Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 3121108 SECTION 1 SPECIFICATIONS Table 1 10 Lubrication Specifications KEY SPECIFICATIONS Engine crankcase Oil Gas API SF SG class MIL L EO 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C HO Hydraulic Oil API service classification GL 3 e g Mobil 424 1 6 CYLINDER SPEGIFIGATIONS Table 1 11 Cylinder Specifications Description Bore Stroke Rod Dia pas 4 00in 47 in 2 50in 10 2 119 4 6 4 cm 2 00in 7 841 1 12 in SIS Cylinder G am 20cm 2 8 cm 1 9 MAJOR COMPONENT WEIGHTS Table 1 13 Major Component Weights Component Weight Platform p Platform and Extension dis Manual Platform Extension eau Arm Assembly Includes Lift Cylinder Chassis w Standard Tires Bs 1 10 CRITICAL STABILITY WEIGHTS 1 7 PRESSURE SETTINGS A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS ENGINES AXLES OR TIRES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY Table 1 12 Pressure Settings 3300 psi 50 psi 234 bar x 3 4 bar 2300 psi 159 bar 1700 psi 117 bar 2300 psi 159 bar 2500 psi 207 bar Main Relief Steer Relief Left Steer Relief Right Lift Up Relief Leveling Jack Relief 1 8 LIMIT SWI
79. RAL ELECTRICAL INFORMATION 86 SCHEMATICS SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop Ifa problem should develop which is not presented in this section or which is not corrected by listed corrective actions tech nically qualified guidance should be obtained before proceeding with any maintenance 3 2 MULTIMETER BASICS A wide variety of multimeters or Volt Ohm Meters VOM can be used for troubleshooting your equipment A digital meter with reasonable accuracy within 796 is recommended for the measurements in these procedures This section shows dia grams of a common digital VOM configured for several different circuit measurements Instructions for your VOM may vary Please consult the meter operator s manual for more information Grounding Grounding the meter means to take the black lead which is connected to the COM common or negative port and touch it to a good path to the negative side of the voltage source Backprobing To backprobe means to take the measurement by accessing a connector s contact on the same side as the wires the back of the connector Readings can be done while maintaining circuit continuity this way If the connector is the sealed type great care must be taken to avoid damaging the seal around the wire It is best to use probes or probe tips specifically
80. RE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION JLG Lift 2 33 SECTION 2 PROCEDURES 2 20 FLASH CODES AND DESCRIPTIONS Table 2 10 Help Messages and Flash Codes Software P1 X FLASH CODE HELP MESSAGES AND FLASH CODES No Flash Code EVERYTHING OK GROUND MODE OK ALARM SOUNDING TILTED amp ABOVE ELEVATION Platform is elevated and the chassis is not level DIFFERENT FUNCTION SELECTED amp IGNORED A function i e Drive Lift etc is active and the operator has selected another function The system has ignored the new selection DRIVING AT CUTBACK ABOVE ELEVATION Platformis elevated and the machine is in the drive mode of operation FUNCTION SELECTED BUT TRIGGER SWITCH OPEN Afunction i e Drive Lift etc has been selected by the operator butthe trigger switch is not active closed JOYSTICK MOVED BUT NO FUNCTION SELECTED The joystick was moved out ofthe center position before a function was selected DRIVE PREVENTED ABOVE DRIVE CUTOUT HEIGHT Machinis elevated above the drive cutout height 2 1 STARTUP Anew system power up has occurred since the last help message 2 2 FUNCTIONS LOCKED OUT SHORT TO PLATFORM ROW INPUT DETECTED Battery power has been detected on a row input pins J1 8 J1 9 or J1 13 FUNCTION PROBLEM DRIVE PERMANENTLY SELECTED Drive select switch in the platform control box closed at start up or for more t
81. ROBLEM GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the ground control box closed at start up Release switch to clear fault NO DATA FROM TILT SENSOR NOT CONNECTED OR FAULTY No signal from the tilt switch Check wiring and plug connections at the level sensor and at the ground control board 2 5 DRIVE amp LIFTUP PREVENTED OSC AXLE NOT SET DRIVE amp LIFTUP PREVENTED FUNCTION CUTOUT ACTIVE ALL FUNCTIONS PREVENTED FUNCTION CUTOUT ACTIVE PLATFORM OVERLOAD ELEV PROX PERMANENTLY CLOSED CHECK PROX amp CAM SWITCH ADJUSTMENT LEVEL PREVENTED CHASSIS TILTED EXCESSIVELY 2 6 FRONT LEFT LEVELING JACK SHORT TO GROUND FRONT RIGHT LEVELING JACK SHORT TO GROUND REARLEFT LEVELING JACK SHORT TO GROUND REAR RIGHT LEVELING JACK SHORT TO GROUND FRONT LEFT LEVELING JACK SHORT TO BATTERY FRONT RIGHT LEVELING JACK SHORT TO BATTERY REARLEFT LEVELING JACK SHORT TO BATTERY REAR RIGHT LEVELING JACK SHORT TO BATTERY 3 3 OUTPUT ENERGIZED EXTERNALLY CHECK WIRING OUTPUT SHORTED CHECK WIRING 4 4 BATTERY VOLTAGE TOO LOW Battery voltage below 8 0V Check battery and alternator BATTERY VOLTAGE TOO HIGH Battery voltage above 16V Check battery and alternator 5 5 ENGINE SHUTDOWN OVERSPEED The engine speed exceeded 4500 RPM for more than 2 seconds Check throttle actuator for debris or interference which prevents free movement of actuator Rec
82. TABLE Figure 2 5 Cylinder Rod Support 9 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 10 Loosen and remove the cap screw s if applicable which attach the tapered bushing to the piston 3121108 SECTION 2 PROCEDURES 11 12 13 14 15 16 Insert the cap screw s in the threaded holes in the outer piece of the tapered bushing Progressively tighten the cap screw s until the bushing is loose on the piston Remove the bushing from the piston PISTON Figure 2 6 Tapered Bushing Removal Screw the piston CCW by hand and remove the piston from cylinder rod Remove and discard the piston o rings seal rings and backup rings Remove piston spacer if applicable from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer plate if applica ble Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 3121108 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality R
83. TCHES The machine is equipped with the following limit switches Tilt Alarm Illuminates a light on the platform and sounds an alarm when the machine is 3 side to side or 5 fore and aft High Drive Cut Out High drive speed is cut out when the platform is raised above the stowed position Max Drive Height The drive function is cut out when the platform is raised by 7 5 8 ft 2 3 2 4 m 3121108 TO AFFECT STABILITY Table 1 14 Critical Stability Weights Component Weight 50105 Tire and Wheel Assembly Std each 23 152 Ibs Tire and Wheel Assembly FF each 69 kp Kubota Gas DF Engine 136105 Dry with flywheel and housing 61 7 kg Kubota Diesel Engine 256 Ibs Dry with flywheel and housing 116 kg JLG Lift SECTION 1 SPECIFICATIONS 1 11 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The plate is located on the rear center of the machine frame just below the middle step of the lad der In addition if the serial number plate is damaged or missing the machine serial number is stamped on the right front frame rail adjacent to the sizzor arms SERIAL NUMBER PLATE
84. TION Figure 3 15 HD HDP Locking Contacts Into Position NOTE For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly T Figure 3 16 HD HDP Contact Removal 11 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 12 Slide tool along into the insert cavity until it engages contact and resistance is felt 13 Pull contact wire assembly out of connector TOOL INSERTED TO TOOL AND CONTACT UNLOCK CONTACT REMOVED Figure 3 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121108 Lift SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS 3 5 SWITCHES Basic check The following check determines if the switch is functioning properly not the circuit in which the switch is placed A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected De energize the circuit Isolate the switch from the rest of the circuit if possible If not possible keep in mind it may affect readings Access the terminals to the switch Boo INO If the switch has two terminals a Measure resistance across the terminals b Change the switch position c Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it should read short 5 If the
85. TIONS SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 3121108 CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 6 Torque Chart SAE Fasteners Sheet 3 of 7 JLG Lift Torgue Si TPI Bolt Di Tensile Clamp Load Torque Vk A 245 Loctite 262 Os otma Stress Area See Note 4 Dry K 17 ORVibra TITE 7111 or or Vibra TITE 131 140 OR Precoat 85 4 4 0120 00600 j T 48 000661 J T e 32 01380 00001 T T T T 8 32 0 1640 0 01400 L L LECCE 10 24 0 1900 0 01750 32 01900 oo00 T T j 14 20 02500 00318 2860 12 14 n 33 J 28 0250 0 0364 3280 139 16 131 315 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 3 8 16 0 3750 0 0775 7000 50 35 50 35 50 7716 12 9 16 5 8 3 4 78 08750 04620 4160 55 700 45 660 455 620 1 8 1000 06060 5150 730 95 65 930 6 875 118 12 114 7 12 13 8 6 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED A
86. TP Contact Installation 1 Grasp crimped contact about 25mm behind the contact barrel 2 Hold connector with rear grommet facing you 3 Push contact straight into connector grommet until a click is felt A slight tug will confirm that it is properly locked in place 4 Once all contacts are in place insert wedgelock with arrow pointing toward exterior locking mechanism The wed gelock will snap into place Rectangular wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly Figure 3 13 DT DTP Contact Removal 5 Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out 6 To remove the contacts gently pull wire backwards while at the same time releasing the locking finger by moving it away from the contact with a screwdriver 7 Hold the rear seal in place as removing the contact may displace the seal HD30 HDP20 Series Assembly Figure 3 14 HD HDP Contact Installation 8 Grasp contact about 25mm behind the contact crimp barrel 9 Hold connector with rear grommet facing you 3 10 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS 10 Push contact straight into connector grommet until a positive stop is felt A slight tug will confirm that it is properly locked in place LOCKING FINGERS CONTACT cm CONTACT INSERTION UNLOCKED POSITION CONTACT LOCKED IN POSI
87. URES Table 2 14 Preventive Maintenance and Safety Inspection AREA INTERVAL 10Hours Daily 50 Hours Weekly 200 Hours Monthly 500 Hours 3 Month 1000 Hours 6 Month PLATFORM 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 1 2 4 Control Tags 12 5 Hoses and Cables 48 6 Wear Pads 7 Handrails and Chains CHASSIS 1 Engine Oil 2 Battery 3 Air Cleaner 4 Exhaust System c 1 5 5 Engine Mounts 6 Hydraulic Pump 7 Valves 8 Hydraulic Filter See Lubrication Chart 9 Hydraulic Hoses and Tubing 10 Hydraulic Oil Tank 4 1 Hydraulic Tank Breather 12 Fuel Tank 3 5 13 Lift Cylinder 1 12 14 Limit Switch 17 15 Tilt Alarm Switch 4 6 Placards and Decals 12 4 7 Wheel and Tire Assemblies 8 9 4 8 Drive Motors 1 5 6 4 9 Drive Brakes 1 6 20 Drive Torgue Hubs 1 3 5 6 21 Steer Cylinder 5 6 13 22 Steer Components 46 23 Wheel Bearings 2 Wheel Drive 24 Sizzor Arms 25 Safety Props 26 Sliding Wear Pads 27 Pivot Pins Bolts 7 8 28 Switches Ground Control 29 Control Tags Inspection and Maintenance code 10 to be performed annually 2 44 JLG Lift 3121108 SECTION GENE
88. ag Yel VALVE LJ EXTEND 2 GROUND BOARD CANL OD S D003 J5 2 55 23 Y22 Ld RETRACT G2 CAN SHIELD 01 8 0004 15 3 0005 45 4 ORMAWUT 55 25 Y23 0006 J5 5 44 DI00 SFDTH J2 4 IGN 4 1 0105 2 9 GND 4 2 ANLG4 12 10 J4 3 DIOL 2 5 CAN L J4 4 0102 J2 6 CAN SHIELD 34 5 0103 J2 7 SPARE J4 6 D007 J5 6 0008 J5 7 0009 J5 8 YEL RED 2 20 m 0104 32 8 RECEPTACLE RX 05 10 525 TX 75 11 LFT STOWED GND 25 12 BLACK SWITCH WHITE 526 ENT STOWED BLACK SWITCH WHITE nS S21 REAR LFT STOWED BLACK SWITCH WHITE exse S28 REAR RHT STOWED BLACK SWITCH WHITE nS caren EB WHITE FOR CODE UPGRADE ONLY g Ss 8 REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT PRESSURE PRESSURE PRESSURE PRESSURE TRANSDUCER TRANSDUCER TRANSDUCER TRANSDUCER NOTE ALL COMPONENTS SHOWN ON THIS PAGE ARE FITTED FOR THE LEVELING JACK OPTION ONLY ALL TRANSDUCERS ARE WIRED USING A 3 CONDUCTOR SHIELDED CABLE THE SHIELD FOR EACH CABLE SHOULD BE TERMINATED WITH THE RESPECTIVE BLACK WIRE AT J3 ALL DIMENSIONS IN ARE IN mm THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES INC AND CONTAINS 1001109660 B Sheet 2 PROPRIETARY AND CONFIDENTIAL INFORMATION OF JLG IT MAY NOT BE eet COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT JLG S WRITTEN CONSENT AND IS PROVIDED FOR THE LIMITED PURPOSE OF REVIEW AND EVALUATION Figure 3 20 Electrical Schematic Shee
89. ar Ring Guide 10 Wiper 11 O Ring O oN o D p DY 12 Retaining Ring Figure 2 15 Steer Cylinder Assembly 3121108 JLG Lift 2 15 SECTION 2 PROCEDURES 1 Barrel 7 Flatwasher 1 1 4 Narrow 13 O Ring 19 Rod 2 Counter Balance Valve 8 Guidelock 14 Wear Ring 20 Plate 3 Check Valve 9 Polyseal 15 Head 21 Trailer Ball 4 Plug 10 Piston 16 Hydrolock 22 Jack Pad 5 Nut 11 O Ring 17 Wiper Seal 23 Retainer Ring 6 Locking Screw 12 Spacer Tube 18 Cap 24 Bolt Figure 2 16 Leveling Jack Assembly Prior to S N 105371 2 16 JLG Lift 3121108 SECTION 2 PROCEDURES oak OD 3121108 Barrel 7 Flatwasher 1 1 4 Narrow 13 Wear Ring 19 Plate Check Valve 8 Guidelock 14 Head 20 Screw 1 2 Counter Balance Valve 9 Polyseal 15 Hydrolock 21 Jack Pad Plug 10 Piston 16 Wiper Seal Rod 11 O Ring 17 Cap Nut 12 O Ring 18 Retaining Ring Figure 2 17 Leveling Jack Assembly S N 105371to S N 141689 Lift 2 17 SECTION 2 PROCEDURES 2 18 1 Barrel 5 Wear Ring 9 2 Rod 6 O Ring 10 3 Wear Ring 7 Back Up Ring 11 4 Seal 8 Head 12 Figure 2 18 Leveling Jack Assembly AUS Spec JLG Lift Polyseal 13 Wiper Seal 14 Washer Ring 15 Screw 5 16 16 Retaining Ring Plate Screw 1 2 Jack Pad S N 128985 to Present amp CE Spec S N 141689 to Present 3121108 SECTION 2 PROCEDURES 2
90. aulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hydraulic System General Hydraulic Pump Noisy Air bubbles in oil Reservoir too low Replenish oil as necessary Oil filter dirty Clean and or replace filter as necessary Pump cavitating Vacuum in pump due to oil starvation Oil in reservoir low Replenish oil as necessary Restricted reservoir air vent Clean vent Oil viscosity too high Drain system and replace with recom mended oil Refer to Hydraulic Oil System overheating Oil viscosity too high Drain system and replace with recom mended oil Refer to Hydraulic Oil Main relief valve set too high Adjust relief valve to proper pressure Hydraulic system oil low Replenish oil as necessary Pump not delivering oil Defective pump Repair or replace pump System pressure too low Main relief valve set too low Reset valve as required Hydraulic pump not functioning properly Repair or replace pump Leak in component line or fitting Repair or replace component line or fit ting Scored valve spool scored cylinder Replace valve replace cylinder System s operate erratically Sticking or binding valve cartridge piston rod etc Clean repair or replace components as necessary Hydraulic oil not at operating tempera ture Allow oil sufficien
91. be An Oshkosh Corporation Company Service amp Maintenance Manual Model 260MRT P N 3121108 April 19 2013 MG An Oshkosh Corporation Company INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that main tenance personnel pay strict attention to these warn ings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consider ation when engaging in the maintenance of equip ment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is pro vided A W
92. ding problem 2 To adjust the choke at 70 F ambient remove the air horn and reinstall the nut that holds the choke and support bracket securely making sure the choke moves freely 3 Loosen the 3 top cover screws and rotate the top cover till the choke butterfly is closed with 1 32 in space between the plate and the wall of the carbure tor 4 lf the ambient temperature is less then 70 F the top cover counter should be rotated CCW 1 mark for every 5 F less then 70 F Vacuum Connection Vacuum Pull off Positive Connection Side View Bs Horizontal Adjusting yt Screws NE Bronze Coupling Air mies Auto choke Assembly Li Figure 2 21 Automatic Choke Adjustment DF 750 Reassembly Reassemble the air horn making sure the choke is not binding test to insure that none of the settings have moved and the choke is not binding The vacuum pull off should be set such that when vacuum is applied to the choke system the choke butterfly is full open NOTE If the machine starts and stalls immediately or if it is extremely cold limiting the choke pull off to 75 to 90 may improve the performance of the machine No adjustment is normally required Diesel Engine NOTE Never run the fuel tank dry Diesel engines cannot be restarted after running out of fuel until the fuel sys tem has been air vented or bled of air See the Kubota Instruction
93. e 2 S ewe CHOKE ud E ELE 2k 2 2 2 RB 8 GLOW GNDS s 35575 PLUGS BLACK GND TAN 4 1 ONG TAN 3 1 UPG am un NTROL a 1 U N GNDE RED 1 2 lt RED 1 1 4B B B NOTE SIRS WHT YEL 48 8 A WHT YEL 48 1 GLOW ZD LPV 6LWS GLOW x CLOSED WHEN ELEV LOCATED PLATFORM S ELEVATION GAM E ON FULLY LOWERED IGN DIESEL ENGINE ELEVATION iu o oPROE SW L J OPTION io LOW QRILRED 49 8 ss 2 E PLUGS RED 2 5 lt I IGN ee Si Re ct tS a _ amp E E gt e22255 2222845 8 z z fM 5 225 5 5 2 STROBE EE 8 amagsmegeaeaage o si connector m m Rl le n 5 d ON CHASSIS gt O 6 S m ae a p RED 5C lips V V Y VY M 1 0 MODULE RED 1 1 2 BRUM 41 6 A b d 8 aa i BLACK 2 7 3 3 5 q a ggl J Hj ENGINE LOW OIL PRESSURE Hd 928 a js SWITCH 8PS1 gay 2 81 lt A zi 4 SCHED NOTE 1 d e HOUR y LP E Bos 60000 G d J vave EEDE c go 730 PMSSU AA 3 ENGINE ES LOCATED ON 449 SWITCH GAS ENGINE Ne ad Jg 3 3 F ye 4 VALVE IGN ENGINE 8 dg PGs De 4 i TEMP ATN gigs E FUEL NA 5 5 J d bo BATT LAMP YeeTe 4 CHARG
94. e es 2 8 2 6 Tapered Bushing Removal aa aaa dr a mn ate aaa aa a Sake aa aa aaa ae n 2 9 2 7 Rod SeatlIristallation E TA qe Ae ne ee ee eee 2 10 2 8 Wiper Seal Installations uu uu Rp ek ee Ca Cus hee Ae ee 2 10 2 9 Installation of Head Seal Kit 2 10 2 10 Piston Seal Kit Installation 0 2 11 2 11 Tapered Bushing Installation RII 2 11 2 12 Seating the Tapered Bearing 2 11 2 13 Poly Pak Piston Seal Installation 0 2 12 2 14 Rod Assembly Installation 0 0 0 ett 2 12 2 15 Steer 2 15 2 16 Leveling Jack Assembly Prior to S N 105371 2 16 2 17 Leveling Jack Assembly S N 105371to S N 141689 lesse 2 17 2 18 Leveling Jack Assembly AUS Spec S N 128985 to Present amp CE Spec S N 141689 to Present he a Pe nes 2 18 2 19 Valve Components osse cos erede per pue EP Re RM Diesen ee pgs 2 20 2 20 Leveling Jacks Directional Valve sisse IH 2 21 2 21 Automatic Choke Adjustment 750 2 23 2 22 Joystick Controller JLG P N 1600308 2 24 2 23 Joystick Controller JLG P N 160040
95. e joy stick within three seconds Enable circuit not functioning properly Replace enable circuit card Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve Drive motor notfunctioning properly Repair or replace motor Brake notfunctioning properly Repair or replace brake Engine will not respond when enable Switch is activated and drive controller is activated Referto Electrical System Troubleshoot ing No response to control switch No electrical signal being sentto the drive valve cartridge Referto Electrical System Troubleshoot ing No response to control switch Machine will not travel in reverse See Machine will nottravel forward 3 16 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY High Speed Drive function does not operate Loose or damaged wiring between drive controller and High Speed switch Ensure proper connection of wires Using suitabletestmeter perform continuitytest on wiring between switches Repair or replace wires as necessary Defective high speed control switch Replace high speed control switch Loose or damaged wiring in co
96. e removed from the housing for insertion or removal of the contacts 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 3 8 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Service Voltage Reading A CAUTION DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands This nullifies the effectiveness of the connector seals and could result in system failure WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA CUTOFF TAB MUST BE VISIBLE SCREWDRIVER SLOT LOCKING LATCH MUST BE TO LIFT LATCH FOR SECURELY FASTENED UNMATING FOR MATING PLUG AND HEADER MUST BE OF IDENTICAL COLOR IN ORDER FOR THEM TO MATE Figure 3 11 Connector Installation 3121108 JLG Lift 3 9 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS 3 4 WORKING WITH DEUTSCH CONNECTORS DT DTP Series Assembly Figure 3 12 DT D
97. eal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD O RING BACKUP RING Figure 2 9 Installation of Head Seal Kit NOTE JLG Lift Install washer ring onto rod carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable Carefully slide the piston spacer on the rod If applicable correctly place new o ring in the inner piston diameter groove The backup ring side fac ing the O ring is grooved If applicable correctly place new seals and guide lock rings in the outer piston diameter groove A tube with I D slightly larger than the O D of the pis ton is recommended to install the solid seal The backup rings for the solid seal have a radius on one side This side faces the solid seal See magni fied insert in Figure 2 10 The split of seals and backup rings are to be positioned so as not to be in alignment with each other 3121108 SECTION 2 PROCEDURES NOTE 3121108 PISTON BACKUP SPLIT SEAL RINGS T RING SPLITBACKUP RING SPLIT SEAL Figure 2 10 Piston Seal Kit Installation Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are no
98. ed or burned 3 Ifa bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install JLG Lift 2 1 SECTION 2 PROCEDURES 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacle
99. eplace as necessary 10 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 11 Inspect the cam follower for wear or damage Replace as necessary JLG Lift 2 13 SECTION 2 PROCEDURES Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used Apply a light film of hydraulic oil to all components prior to assembly Using suitable protection clamp the cylinder rod in a vise or similar holding fixture Place a new o ring into the cylinder rod piston groove Place a new T seal on the piston then carefully install the piston the cylinder rod ensuring that the o ring in the rod groove is not damaged or dis lodged Secure the piston in place with two new retaining rings Carefully slide the spacers onto the cylinder rod Place a new wiper rod seal o ring and wear ring on each of the two cylinder heads Set the heads aside for later installation on the cylinder rod Remove the cylinder rod assembly from the holding fixture Position the cylinder barrel in a suitable holding fix ture NOTICE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD PISTON AND HEADS AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 8 2 14 With the barrel clamped securely and while ade quately supporting the cylinder rod assembly insert the cylinder rod assembl
100. eplace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary Inspect threaded portion of piston for damage Dress threads as necessary 10 11 12 13 14 15 16 17 JLG Lift Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect rod and barrel bearings for signs of correct 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 c Lubricate inside of the steel bushing with WD40 prior to bearing installation d Using an arbor of the correct size carefully press the bearing into steel bushing Inspect travel limiting collar or spacer for burr
101. eto a function control switch cont No voltage present at applicable control Check applicable wire for proper con valve coil nection at terminal strip valve harness plug pin valve harness receptacle pin and engine start relay Using suitable test meter perform continuity test on wire Repair or replace wire or harness as nec essary No voltage supplied from terminal strip to Check applicable wire for proper con engine start relay nection at terminal strip valve harness plug pin valve harness receptacle pin and engine start relay Using suitable test meter perform continuity test on wire Repair or replace wire or harness as nec essary Defective engine start relay Replace engine start relay No voltage supplied to engine from start Check battery cable from relay to engine relay for proper connection or damage Repair or replace cable as necessary No voltage present at applicable control Check applicable wire for proper con valve coil nection at terminal strip valve harness plug pin valve harness receptacle pin and valve coil Using suitable test meter perform continuity check on wires Repair or replace harness as necessary NO TERMINAL STRIPS No voltage Check applicable wire for proper con supplied from terminal strip to electric nection at terminal strip valve harness motor start relay plug pin valve harness receptacle pin and electric motor start relay Using suit able
102. f 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS T Torque Torque orque TM TM i TM rad se ma cam Semaia eda or e Cie ai Ma Stress Area OR Vibra TITE 111 or TITE 131 140 K 18 K 0 15 In Sq In Dd LB N m IN LB N m IN LB N m 4 40 0 1120 0 00604 0 1120 0 00661 1 0 1380 0 00909 0 1380 0 01015 m 03640 001400 __ L T nr 0 1640 001474 13 0 43 5 _ __ 24 0190 00170 1580 0 7 0 1900 0 02000 1800 68 oco x1 14 20 02500 00318 2860 0 2500 0 0364 3280 eus m rus Ne FS i 25 25 3 8 16 0370 0 0775 700 45 60 40 55 35 50 50 70 20 0437 0 1187 10700 80 10 70 95 60 80 12 13 110 120 155 ie a 8999 1280 iro ae ps 288 EE 175 210 285 190 220 240 325 215 245 375 510 340 380 420 570 380 430 i 0 5090 45800 670 910 600 815 500 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER Figure 1 5 Torque Chart SAE Fasteners Sheet 2 of 7 Lift 3121108 SECTION 1 SPECIFICA
103. han ten seconds Release switch to clear fault FUNCTION PROBLEM LIFT PERMANENTLY SELECTED Liftselect switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM O R or L J PERMANENTLY SELECTED Anoutrigger select switch in the platform control box closed at start up or for more than ten seconds Release switch to clear fault FUNCTION PROBLEM START PERMANENTLY SELECTED Start switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM GLOW PLUG PERMANENTLY SELECTED Glow plug switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM STEER LEFT PERMANENTLY SELECTED Steer left switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED Steer right switch in the platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM HORN PERMANENTLY SELECTED Horn switch in platform control box closed at start up Release switch to clear fault FUNCTION PROBLEM JOYSTICK CALIBRATIONFAULTY The Personalities for theJoystick are improperly adjusted or a joystick calibration attempt failed Re adjust or recalibrate JOYSTICK FAULTY WIPER OUT OF RANGE The joystick wiper signal inputis outside the acceptable voltage range The wiper wire being off the wiper wire shorted to battery power or the
104. he machine onto a measured level surface 0 5 for both x and y axis Using the Analyzer go to MENU CALIBRATION TILT SENSOR Press Enter LEVEL VEHICLE will dis play Press Enter again to calibrate Both axis raw angles need to be within 5 0 other wise the machine is to unlevel and the software will prohibit calibration Should this occur attempt to dissect the three areas of error to find the primary contributor a Machine mounting and or grade With a digital level measure the top of the Ground Control box for levelness If unable to get a good reading check the box s mounting surface for levelness 1 Ground Control Box 2 Digital Level Tilt sensor mounting on machine or wedged crooked in control box If the machine mounting grade appears accept able open the Ground Control box carefully Observe whether the tilt sensor is properly seated 1 Ground Control Box 2 Tilt Sensor Tilt sensor has developed an offset shift Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and Ground Control box electrically connected Level one axis of the tilt sensor and observe the raw read ing should be within 2 0 Do the same for the other axis If either axis is greater than 2 0 replace the tilt sensor Some possible reasons that the tilt sensor will not cali brate are a JLG Lift The surface
105. igh Drive does not operate below horizontal Damaged wiring on limit switch Repair or replace wiring Damaged limit switch Replace limit switch 3121108 JLG Lift 3 15 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Drive System Noresponseto drive controller Joystick not activated within three sec onds after drive select switch is activated Activate drive select switch then activate joystick withinthree seconds Enable circuit not functioning properly Replace enable circuit card Hydraulic system oil low Replenish oil as necessary Hydraulic pump not functioning properly Repair or replace pump Restricted or broken pump supply line Clean repair or replace line Drive motor not functioning properly Repair or replace motor Damaged wiring on drive controller Repair or replace wiring Drive controller not functioning properly Repair or replace controller Drive brake not releasing Determine cause and repair or replace brake Machine drives erratically Microcircuit on controller improperly adjusted Adjust microswitch on controller for proper operation Machine will not travel forward Joystick not activated within three sec onds after drive switch is activated Activate drive switch then activat
106. is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Cleanliness 1 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this Shields covers seals and filters are provided to keep air fuel and oil supplies clean however these items must be maintained on a scheduled basis in order to function properly 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo 3121108 nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used
107. ition and pulling both emer gency stop buttons on 2 30 JLG Lift 3121108 SECTION 2 PROCEDURES Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following 4 5 ED IVENU HELP PRESS ENTER e HELP PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS ACTIVATE TESTS ACCESS LEVEL PERSONALITIES MACHINE SETUP LEVEL VEHICLE If you press ENTER at the HELP PRESS ENTER display and a fault is present during power up the analyzer dis play will scroll the fault across the screen If there was no fault detected during power up the display will read HELP EVERYTHING OK 3121108 If ENTER is pressed again the display moves to the fol lowing display U V P LOGGED HELP 1 STARTUP 2 1 At this point the analyzer will display the current fault if any are present You may scroll through the fault logs to view what the last 15 faults were Use the right and left arrow keys to scroll through the fault logs To return to the beginning press ES
108. lector switch to platform or ground as required Circuit breaker open Determine and correct cause Reset cir cuit breaker No voltage present at emergency stop switch Check battery cable from battery to emergency stop switch for proper con nection or damage Repair or replace cable as necessary EMERGENCY STOP switch not function ing properly Replace switch No voltage supplied to engine start relay from emergency stop switch Check battery cable from emergency stop switch to start relay for proper con nection or damage Repair or replace cable as necessary No voltage input at terminal strip Check wire from battery to terminal strip for proper connection or damage Repair or replace wire as necessary No voltage present at circuit breaker Check wire from terminal strip to circuit breaker for proper connection or dam age Repair or replace wire as necessary Defective circuit breaker Replace circuit breaker No voltage present at function control Switch Check wiring from emergency stop Switch to function control switch for proper connection or damage Repair or replace wiring as necessary Defective function control switch Replace function control switch 3 20 JLG Lift 3121108 SECTION 3 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 3 4 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Norespons
109. linder port block fitting NOTICE DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if nec essary 3 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture BARREL CLAMP SUPPORT TABLE Figure 2 3 Cylinder Barrel Support 5 Mark cylinder head and barrel with a center punch for easy realignment Using an allen wrench loosen 2 8 JLG Lift the cylinder head retainer cap screws and remove cap screws from cylinder barrel CAPSCREWS WASHER Figure 2 4 Capscrew Removal 6 Using a spanner wrench loosen the end cap or head retainer and remove from cylinder barrel 7 Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable NOTICE EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 8 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel ROD SUPPORT SUPPORT
110. low Adjust pressure Loose or damaged wiring on control switch or solenoid valve Ensure proper connection of wires at con trol switch or solenoid valve Using suit able test meter perform continuity test on wires Repair or replace wires as neces sary Solenoid valve not functioning properly Repair or replace valve Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair or replace line Relief valve improperly set or not function ing properly Reset repair or replace valve as neces sary Steer cylinder not functioning properly Repair or replace cylinder Machine will not steer left or right Steer switch on controller not functioning properly Replace controller Wiring on steer control switch is dam aged Repair or replace wiring Wiring on solenoid valve damaged Repair or replace wiring Coilin solenoid damaged Replace coil Bent cylinder rod Repair or replace cylinder Damaged steer linkage Repair or replace steer linkage Machine wanders steering not firm Crossover relief valve settoo low or not functioning properly Reset repair or replace valve as neces sary Steer linkage loose Tighten linkage Spindle bushings badly worn Replace bushings 3 18 JLG Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS Table 3 3 Hydr
111. n made carefully reconnect hydraulic hoses to the appropriate ports 6 Remove lifting device from platform activate hydrau lic system and run cylinder through one complete cycle to check for leaks 3121108 2 9 LIFT CYLINDER REMOVAL AND INSTALLATION Removal 1 Place the machine on a flat and level surface Start the motor and raise the platform Shut down the engine and attach a suitable lifting device to the plat form 2 Remove the bolt and locknut securing the cylinder rod attach pin to the upper inner arm assembly Using a suitable brass drift drive out the rod end attach pin from the arm assembly 3 Retract the lift cylinder rod completely 4 disconnect the hydraulic lines then cap the lift cylinder hydraulic lines and ports 5 Remove the bolt and locknut securing the barrel end attach pin to the lower arm assembly Using a suit able brass drift drive out the barrel end attach pin from the arm assembly 6 Carefully remove the cylinder from the scissor lift and place in a suitable work area Installation 1 Install lift cylinder in place using suitable slings aligning barrel end attach pin mounting holes on lower arm assembly 2 Using a suitable drift drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly Secure in place with the bolt and locknut 3 Remove oylinder port plugs and hydraulic line caps and correctly attach lines to
112. nically If the function performs satisfactorily the problem exists with the control circuit Hydraulic Circuit Checks The first reference for improper function of a hydraulic system where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a systematic check of the circuit components beginning with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagrams of the various circuits 3121108 JLG Lift 3 13 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS Table 3 1 Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform Elevation System No Response to LIft Control Lift not performed within three seconds after lift function switch is selected Reselect lift function switch then activate joystick within three seconds Enable circuit not functioning properly Replace enable circuit card Lift control switch inoperative Repair or replace control switch Hydraulic system oil low Replenish oil as necessary Restricted or broken supply line on valve bank or pump Clean repair or replace line Control valve not functioning properly Repair or replace valve Lift cylinder not functioning properly Repair or replace cylinder
113. nstalled Drive Cutout 1 Cuts out drive when deck is elevated above a predetermined elevation 0 Not available on 260MRT 5 0 FWD amp LIFT up 0 Control Direction 1 FWD amp LIFT down for future use 6 0 No 0 Leveling Jacks 1 Yes 7 0 DOM and CE FIXED Axle Type 1 DOMESTIC OSCILLATING 0 Sune 2 CE OSCILLATING 8 0 NONE Function Cutout 1 DRIVE and LIFT UP 0 2 ALL FUNCTIONS 9 0 NOT INSTALLED Load 1 CUTOUT PLATFORM 0 2 CUTOUT ALL 4150336 F 3121108 JLG Lift 2 41 SECTION 2 PROCEDURES TABLE 2 13 APPLIES TO MACHINES WITH 4170044 SOFTWARE 1 2 42 The Model and Market configuration must be com pleted before any Personality settings can be changed The Leveling Jacks configuration must be set to YES for standard 260MRT equipped with leveling jacks gt 325PSI set lt 200 PSI unset This configuration must be set to YES SPL LENGTH for 260MRT with optional special length jacks gt 200PSI set lt 50 PSI unset 3 The Tilt Configuration setting is assigned a default based on Market selection This configuration must be set to 6 DEG F R SPL for special option vehicles for Australia that are capable of 6 chassis tilt front to rear Table 2 13 Machine Configuration Programming Information 4170044 Software Configuration Digit Number Market Default Description F3 4 MODEL 260 Gas LP 260MRT Diesel MARKET ANSIEXPORT ANSI
114. ntrol box wire harness Ensure proper connection of wires atthe control switch Using suitable test meter perform continuity test on wires Repair or replace harness as necessary Loose or damaged wiring between plat form and high speed solenoid Ensure proper connection of wires at the platform and at the high speed solenoid Using suitable test meter perform conti nuity test on wires Repair or replace Wires as necessary High speed solenoid not functioning properly Replace solenoid Loose or damaged wiring between high speedrelay and high speed limit switch Ensure proper connection of wires between high speed relay and high speed limit switch Using suitable test meter per form continuity test on wires Repair or replace wires as necessary High speed limit switch not functioning properly Repair or replace limit switch Loose or damaged wiring in valve wiring harness Ensure proper connection of wires at ter minal strip Using suitable test meter per form continuity test on wires Repair or replace wires as necessary Steering System No response to steer control switch on controller Steer switch on controller not functioning properly Repair or replace switch Hydraulic system oil low Replenish oil as necessary Hydraulic system pressure too low Adjust pressure Loose or damaged wiring on control switch or solenoid valve Ensure prope
115. o cycle slowly between forward and reverse for at least five minutes Shut down prime mover remove gauges and plug ports Check reservoir level and add fluid if necessary 3121108 SECTION 2 PROCEDURES 2 15 AUTOMATIC CHOKE FIELD 5 Ifthe ambient is ak m is ps cover counter should be rotate mark for ADJUSTMENT DF 750 every 5 F less then 70 F Inspection EUM NOTE All automatic choke assemblies have been pre set to Top Cover Screw 3121108 operate between 20 F and 100 F with little or no adjustment If the machine will be operated for pro long use outside these temperature ranges adjust ments could be made to improve performance of the engine The machine will take time to warm up and you may experience low power or rough running for the first few minutes of operation or until the engine warms up LET THE ENGINE WARM UP Make sure that the choke shaft operates freely and does not bind this can be done without removing the air horn by rotating the bronze coupling with an eraser on a pencil or by removing the vacuum pull off line at the manifold and supply a small amount of vacuum to the hose the choke rod should move freely using either method Adjustments NOTE If the choke rod is binding make sure the support bracket is straight 1 There are two adjustments Vertical loosening the air horn nuts and Horizontal loosening the bracket to adaptor screws These two adjustments should resolve any bin
116. oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive main tenance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion 2 4 CYLINDERS THEORY OF OPERATION Oylinders are of the double acting type The Lift and Steer systems incorporate double acting cylinders A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite di
117. ort for leakage 7 If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If extend port leakage is less than 6 8 drops per min ute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks 3121108 SECTION 2 PROCEDURES Cylinders w Single Counterbalance Valves Lift Cylinder OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE PLAT FORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Raise platform completely then retract cylinder slightly to avoid trapping pressure Place a suitable overhead lifting device approximately 1 inch 2 5 cm below the platform 3 Shut down hydraulic system and allow machine to sit for 10 15 minutes Carefully remove hydraulic hoses from cylinder port block 4 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the counterbalance valve is defective and must be replaced 5 f no repairs are necessary or when repairs have bee
118. osity index of 152 2 2 JLG Lift 3121108 SECTION 2 PROCEDURES 3121108 NOTE Start up of hydraulic system with oil temperatures below 15 F 26 C is not recommended If it is necessary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of 15 F 26 C 3 The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent This will allow start up at temperatures down to 20 F 29 C However use of this oil will give poor perfor mance at temperatures above 120 F 49 C Sys tems using DTE 11 oil should not be operated at temperatures above 200 F 94 C under any condi tion Changing Hydraulic Oil 1 Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis However filter elements must be changed after the first 50 hours of operation and every 300 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifications appearing in this man ual If unable to obtain the same type of oil supplied with the machine consult local supplier for assis tance in selecting the proper equivalent Avoid mix ing petroleum and synthetic base oils JLG Industries recommends changing the hydraulic oil every two years 2 Use every precaution to keep the hydraulic oil clean If the
119. ost 2 4 JLG Lift 2 1 WEAR PADS Sliding Pads The original thickness of the sliding pads is 2 inches 51 mm Replace sliding pads when worn to 1 875 inches 48 mm 2 8 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylinder w o Counterbalance Valves Steer Cylinder NOTICE OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 1 Using all applicable safety precautions activate motor and fully extend cylinder to be checked Shut down motor 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port 3 Activate motor and activate cylinder extend function Check retract port for leakage 4 If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder 5 With cylinder fully retracted shut down motor and carefully disconnect hydraulic hose from cylinder extend port 6 Activate motor and activate cylinder retract function Check extend p
120. ove the spacers from the cylinder rod then remove the retaining rings securing the piston in place on the cylinder rod Discard the retaining rings 9 Carefully remove the piston from the cylinder rod Remove and discard the T seal and o ring 10 Remove the cylinder rod from the holding fixture Cleaning and Inspection 1 Clean all parts thoroughly in an approved cleaning solvent 2 Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress the rod with Scotch Brite or equivalent Replace the rod if neces sary 3 Inspect the threaded portion of the rod for excessive damage Dress the threads as necessary 4 Inspect the inner surface of the cylinder barrel tube for scoring or other damage Check the inside diam eter for tapering or ovality Replace the barrel if nec essary 5 Inspect the piston surface for damage scoring and distortion Dress the piston surface or replace the piston as necessary 6 Inspect the seal and o ring grooves in the piston for burrs and sharp edges Dress applicable surfaces as necessary 7 Inspect the inside diameter of the spacers and heads for scoring or other damage and for ovality and tapering Replace as necessary 8 Inspect the seal and o ring grooves in the heads for burrs and sharp edges Dress applicable surfaces as necessary 9 Inspect the outside diameter of the spacers and heads for scoring or other damage and ovality and tapering R
121. r connection of wires at con trol switch or solenoid valve Using suit abletest meter perform continuity test on wires Repair or replace wires as neces sary Restricted or broken hydraulic line on valve bank or hydraulic pump Clean repair or replace line Control valve not functioning properly Repair or replace valve Steer cylinder not functioning properly Repair or replace cylinder Machine hard to steer or steering is erratic Hydraulic system oil low Replenish oil as necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line or fitting 3121108 JLG Lift SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS Table 3 2 Chassis Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Machine hard to steer or steering is erratic cont Lack oflubrication on steer components Lubricate steercomponents in accor dance with Lubrication Chart Restricted crossover relief valve Clean orreplace valve Steer system pressure low Adjust pressure Bent steering linkage Repair or replace linkage as required Hydraulic pump not functioning properly Repair or replace valve Steer cylinder not functioning properly Repair or replace cylinder Steering inoperative Steer switch on controller not functioning properly Repair or replace switch Hydraulic system pressure too
122. rection and the cyl inder rod will retract A holding valve is used in the Lift circuit to prevent retrac tion of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve 2 5 VALVES THEORY OF OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three position solenoid valves of the sliding spool design When a circuit is acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Proportional Control Valves The proportional control valves provide a power output
123. s 1 1 3 Critical Stability Weights BAR En RR m Ea ah 1 3 Lubrication Chart 2 1 5 Cylinder Component Torque 2 12 Holding Valve Torque Specifications _ 2 12 Leveling Jacks Directional Valve Torque 2 21 Joystick Specifications cere ae ye IRR Pe eee E RUE pes rada ae re ae 2 24 Joystick Plug Loading Chart uu ua GR TAN SURA ue ys men 2 24 Joystick Specifications aus GAN a UR D RERO IO 2 25 Joystick Plug Loading Chart a aa aa a aaa aaa aa aa aaa aaa aaa aaa 2 25 Tilt Sensor Harness Chart iu asin u a e A Aa Nad 2 26 Tilt Sensor Harness ERU xe ne mum a ga Gak ag aa 2 27 Help Messages and Flash Codes Software 1 2 34 Machine Model Adjustment eaaa a aaa aa aa aa aa aa aaa aaa ae 2 40 Machine Configuration Programming Information 4170010 Software 2 41 Machine Configuration Programming Information 4170044 Software 2 42 Preventive Maintenance and Safety Inspection 2 44 Elevation System Troubleshooting
124. s when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles is found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Section 1 2 3 LUBRICATION INFORMATION Hydraulic System 1 The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply
125. s and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary 2 9 SECTION 2 PROCEDURES Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual Apply a light film of hydraulic oil to all components prior to assembly 1 A special tool is used to install a new rod seal into the applicable cylinder head gland groove ROD SEAL SEAL TOOL SMOOTH SIDE CYLINDER HEAD Figure 2 7 Rod Seal Installation WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLA TION FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 2 Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable cylinder head gland groove CYLINDER HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head MALLET Figure 2 8 Wiper Seal Installation 2 10 3 Place a new o ring and back up s
126. suc tion lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary at the speci fied intervals required in the Lubrication Chart in Section 1 and the Preventive Maintenance and Inspection Chart in this section Always examine fil ters for evidence of metal particles 3 Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types except as recommended as they may not contain the same required additives or be of compa rable viscosities Good grade mineral oils with vis cosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil 1 Refer to Section1 for recommendations for viscosity ranges 2 JLG recommends Mobilfluid 424 which has an SAE viscosity of 10W 30 and a visc
127. switch Lift down control valve cartridge not functioning properly Repair or replace lift down control valve cartridge Lift cylinder not functioning properly Repair or replace lift cylinder Engine does not respond when lift switch is moved to down position Referto Electrical System Troubleshoot ing No response to control switch No electrical signal being sentto lift down control valve Referto Electrical System Troubleshoot ing No response to control switch 3 14 Lift 3121108 SECTION 3 GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS Table 3 1 Elevation System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Platform raises and lowers erratically Hydraulic system oillow Replenish oilas necessary Restricted or broken hydraulic line or fit ting Clean repair or replace line Counterbalance valve on lift cyl improp rely adjusted or not functioning properly Replace valve Control valve not functioning properly Repair or replace valve Worn seals in lift cylinder Replace seals Lift cylinder not functioning properly Repair or replace lift cylinder Platform drifts down Manual lowering valve not functioning properly Repair or replace valve Worn seals in lift cylinder Replace seals Holding valve on lift cylinder not function ing properly Repair or replace valve H
128. t 3 of 3 3 24 Lift 3121108 SECTION GENERAL ELECTRICAL INFORMATION 86 SCHEMATICS BS NOTES 3121108 JLG Lift 3 25 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS ORN WHT 55 3 1001109561 B Sheet 1 WHT YEL 48 4 BLU ORN 52 1 WHT YEL 48 1 WHT YEL 48 10 WHT YEL 48 2 YEI RED 2 38 TAN 55 2 ORANGE 55 1 AAAAA A A A fol fel e lel e feo S s kS S s fea kS a Ka 5 3 9 S S S S S ss sae Wd a BLACK 2 S S S Sisse amp 8 amp suena 5 Z 22
129. t damaged or dislodged Thread piston onto rod until it abuts the spacer end and install the tapered bushing When installing the tapered bushing piston and mat ing end of rod must be free of oil Assemble the tapered bushing loosely into the pis ton and insert JLG capscrews not vendor cap screws through the drilled holes in the bushing and into the tapped holes in the piston JLG Lift PISTON TAPERED BUSHING CAP SCREWS Figure 2 11 Tapered Bushing Installation Tighten the capscrews evenly and progressively in rotation to the specified torque value See Table 2 1 Cylinder Component Torque Specifications After the screws have been torqued tap the tapered bushing with a hammer 16 to 24 oz and brass shaft approximately 3 4 in diameter as follows a Place the shaft against the cylinder rod and in contact with the bushing in the spaces between the capscrews b Tap each space once this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews PISTON TAPERED BUSHING BRASS SHAFT Figure 2 12 Seating the Tapered Bearing Re torque the capscrews evenly and progressively in rotation to the specified torque value spec Remove the cylinder rod from the holding fixture 2 11 SECTION 2 PROCEDURES 9 Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston See Figure 2 10 Piston Seal Kit Installation
130. t time to warm up 3121108 JLG Lift 3 19 SECTION GENERAL ELECTRICAL INFORMATION 6 SCHEMATICS Table 3 4 Electrical System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hand Controller Valve will notfunction when handle ism ovedin either direction Enable switch not activated Activate enable switch Controller not activated within three sec onds after enable switch is activated Activate enable switch then activate con troller withinthree seconds Enable circuit not functioning properly Replace enable circuit card No electrical power to handle Check electrical input to hand controller 12 Volts No electrical power to valve Check electrical output of printed circuit board and electrical signal at the valve Improper ground Check for proper grounding of handle Control Switches No response to a function control switch Enable switch not activated Activate enable switch Control switch not activated within three seconds after enable switch is activated Activate enable switch then activate con trol switch within three seconds Enable circuit not functioning properly Replace enable circuit card Applicable emergency stop switch not positioned properly Place applicable emergency stop switch toon Power selector switch on ground control box not positioned properly Place power se
131. tom out the Lift Up function and adjust the Lift Up relief to 2300 psi 159 bar Remove the pressure gauge from gauge port MP Steer Relief Adjustment 1 4 Install a pressure gauge at gauge port MP located on the lower right side of the valve body The port is identified by a stamping on the valve body Activate the Steer Right function and check Steer pressure If necessary adjust Steer pressure to 1700 psi 117 bar Activate the Steer Left function and check Steer pressure If necessary adjust Steer pressure to 2300 psi 159 bar Remove the pressure gauge from gauge port MP Leveling Jack Relief Adjustment 1 2 JLG Lift Refer to Figure 2 19 Main Valve Block Install a pressure gauge 5000 psi 345 bar or higher at port MP on the main valve block Start the engine and activate jack retract When all jacks are retracted the gauge should read 2500 psi 172 bar Adjust the relief valve located on the leveling jack directional valve refer to Figure 2 20 clockwise to increase counter clockwise to decrease The relief valve is on the same face as the solenoid valves Remove the pressure gauge from gauge port MP 2 19 SECTION 2 PROCEDURES Main Valve Components 2 20 m Tow Brake Release Acuator Valve Knob Brake Solenoid Dump Valve MAIN MANIFOLD Z Omm
132. uld be visible in ADD sight window on hydraulic tank If oil is not visible add oil until oil is visible in TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL both ADD and FULL sight windows on tank Do not MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED overfill tank NOTE Be sure to lubricate like items on each side Any time the pump coupling is removed coat splines of coupling with Texaco Code 1912 grease Recommended lubricating intervals are based on prior to assembly machine operations under normal conditions For machines used in multi shift operations and or 3121108 JLG Lift 1 5 SECTION 1 SPECIFICATIONS OPERATING TEMPERATURE SPECIFICATION KUBOTA GAS NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIF ICATIONS ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 120 110 100 90 H SAE 30 SAE 10W 30 gt 60 50 30 20 SAE 10 SAE 20 n 1 lt lt SAE 5W 30 NO OPERATION BELOW THIS 1 TEMPERATURE 49 43 38 PF 32 C 80 F 27 C ae TO F 21 C PFC 16 C PFC 10 C 40 F 4 C PF C 1 C F T C 10 F 12 C 0 18 10 23 20 29 30 F 34 C 40 F 40 C amp DIESELI AMBIENT AIR TEMPERATURE
133. y into the cylinder barrel Ensure that the piston T seal and o ring are not dam aged or dislodged 10 11 12 13 Continue pushing the rod assembly into the cylinder barrel until the cylinder rod is approximately cen tered in the barrel Carefully install one of the cylinder heads on one end of the cylinder rod and push the head onto the rod until it is snug against the end of the cylinder barrel Install one of the cylinder head retainers on the end of the cylinder barrel and tighten with a suitable chain wrench Carefully install the remaining cylinder head on the opposite end of the cylinder rod and push the head onto the rod until it is snug against the end of the cylinder barrel Install the remaining cylinder head retainer on the end of the cylinder barrel and tighten with a suitable chain wrench Installation 1 JLG Lift Carefully install the steer cylinder assembly into the front axle Align the cylinder mounting block on the barrel with the mounting slot in the bottom of the axle and lower the steer cylinder until the mounting block rests in the slot Turn the steer wheels to line up the mounting holes in the steer spindles and the steer cylinder ends Secure each end of the steer cylinder with a bolt and lock nut Reconnect the hydraulic hoses to the applicable cyl inder ports 3121108 SECTION 2 PROCEDURES Barrel Rod Locknut Seal Piston O Ring Back Up Ring We
134. ycle power to clear the fault and restart ENGINE SHUTDOWN OIL PRES COOLANT TEMP The engine oil pressure was too low or the engine coolant temperature was too high for more than 10 seconds Check engine fluid levels Recycle power to clear fault and restart 6 6 COMMUNICATION FAILURE MO MODULE 3121108 JLG Lift 2 35 SECTION 2 PROCEDURES paduey pamapag oj qns nua jada NOISYIA TYVMLIOS ONY N0IIVVA2IJNOO INIHIVW NOAR 9N0N343G0 318V1lVAV 38 LON AVW 83392 3N0 310N v Jo 1 199uS eyo Jez Ajeuy gz z e1nDi4 MS 1 Wd 831545 MS ruv W3154 MS r4 31545 Ms fr 2 315245 M I VA Sd 1 WY WILSAS M VA 1ru 3184 y 4 31 SAS Ti SAS SISSVH WILSAS 1 83 XXX XX NIL WALSAS M019 41 3NIDN3 Nal SHA 5NISN3 0101 WALSAS dNnd 1301 191 411 S 1V1S 301104134 WILSAS 12135 A NdOHIY1d GELALI WYO 31V 1d 339919 8911 SOND VIG 3211840 WYO 11V 1H9IV Wu01 1131 Wu01 0 19 Wu01 ISKON V31NY 534 W3svui Viluis 3NI9N3 IN YA 313 WILSAS 9114 M019 N0015 luwis Wu01 ISTON 131N3 534 IVANJU 35793 WINGY 00 19

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