Jlg 660AJ Service Manual Bedienungsanleitung

Service and Maintenance ManualModel600A660AJS/N 0300176000to PresentP/N - 3121616January 8, 2014

vi – JLG Lift – 3121616TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3121616Change Oil Filter1. Wipe area around filter to clean any dirt from area.2. Using a suitabl

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-573.13 DEUTZ D2011 ENGINEFigure 3-74. Deutz D2011 Engine Installation - Sheet 1 of 21. Radi

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3121616Figure 3-75. Deutz D2011 Engine Installation - Sheet 2 of 21. Battery2. Battery Hold-Down

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-59NOTE: Refer to engine manufacturer’s manual for detailed oper-ating and maintenance instru

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3121616Changing Oil Filter1. Wipe area around filter to clean any dirt from area.2. Using a suita

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-613.14 SPARK ARRESTER CLEANING INSTRUCTIONS1. Remove cleanout plug in bottom of spark arrest

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3121616Figure 3-78. Deutz Engine Installation - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-63Figure 3-79. Deutz Engine Installation - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 31216163.16 DEUTZ EMR 2The EMR2 consists of sensors, control unit, and actuator.Engine-side contr

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-65Figure 3-81. Deutz EMR 2 Troubleshooting Flow Chart

3121616 – JLG Lift – vii LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 3121616Figure 3-82. Deutz EMR 2 Vehicle Side Connection Diagram

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-67Figure 3-83. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 3121616Figure 3-84. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-69Figure 3-85. EMR 2 Engine Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3121616Figure 3-86. EMR 2 Vehicle Plug Pin Identification

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-71Figure 3-87. EMR2 Fault Codes - Sheet 1 of 5

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3121616Figure 3-88. EMR2 Fault Codes - Sheet 2 of 5

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-73Figure 3-89. EMR2 Fault Codes - Sheet 3 of 5

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3121616Figure 3-90. EMR2 Fault Codes - Sheet 4 of 5

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-75Figure 3-91. EMR2 Fault Codes - Sheet 5 of 5

viii – JLG Lift – 3121616LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 31216163.17 BIO FUEL IN DEUTZ ENGINESGeneralUse of bio fuels is permitted for the compact engines

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-77Biological Contamination In FuelsSYMPTOMSThe following symptoms may indicate a fuel tank i

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 31216163.18 GM ENGINE GENERAL MAINTENANCEDrive Belt MaintenanceThe serpentine drive belt utilizes

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-79Changing Engine OilALWAYS CHANGE OIL FILTER WHEN CHANGING OIL. CHANGE OIL WHENENGINE IS WA

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 3121616WITH ENGINE RUNNING OR WHEN SHUTTING OFF ENGINE, SOME HEATEDCOOLANT MAY SPILL OUT DUE TO A

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-81Figure 3-93. GM 3.0 Dual Fuel System Components1. 1 inch Split Loom2. 90° Fitting3. 90° F

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 3121616Direct Electronic Pressure Regulator (DEPR)THE DEPR IS AN EMISSION CONTROL DEVICE AND SHOU

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-83Electronic Throttle Control (ETC)The Electronic Throttle Control device or "Throttle

SECTION 3 - CHASSIS & TURNTABLE3-84 – JLG Lift – 3121616Heated Exhaust Gas Oxygen SensorThere are two Heated Exhaust Gas Oxygen Sensors (HEGO).The

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-85Fuel FilterAfter fuel is drawn into the fuel pump, the fuel flows throughthe gasoline fuel

3121616 – JLG Lift – ix LIST OF FIGURESFIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-86 – JLG Lift – 3121616Propane Fuel Filter ReplacementREMOVAL1. Relieve propane fuel system pressure. Refer to Pr

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-87Check/Drain Oil Build-Up In 2-Stage Vaporizer NOTE: Refer to Figure 3-93. GM 3.0 Dual Fuel

SECTION 3 - CHASSIS & TURNTABLE3-88 – JLG Lift – 3121616Exhaust System And Catalytic Converter Inspection And MaintenanceEXHAUST SYSTEM ON THIS EM

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-89Electronic Pressure Regulator (EPR) ReplacementREMOVALNOTE: Refer to Figure 3-93. GM 3.0 D

SECTION 3 - CHASSIS & TURNTABLE3-90 – JLG Lift – 3121616Engine Control Module ReplacementREMOVAL1. Disconnect Negative battery cable.2. Remove con

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-913.21 GM ENGINE LPG FUEL SYSTEM DIAGNOSISFuel System DescriptionFigure 3-103. DEPRThe Engi

SECTION 3 - CHASSIS & TURNTABLE3-92 – JLG Lift – 3121616Table 3-10. LP Fuel System DiagnosisSTEP ACTION VALUE(S) YES NO1 Were you referred to this

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-9315 1. Turn the ignition OFF. 2. Close the manual shut-off valve on the LPG tank.CAUTION:

SECTION 3 - CHASSIS & TURNTABLE3-94 – JLG Lift – 3121616Table 3-11. Symptom DiagnosisChecks ActionImportant Preliminary ChecksBefore Using This Se

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-95Intermittent Malfunction Indicator Lamp (MIL)The following components can cause intermitte

x – JLG Lift – 3121616LIST OF FIGURES FIGURE NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-96 – JLG Lift – 3121616Exha us t Sy st em Ch ec ks ² Che ck t he e xh au st s ys te m fo r a pos si ble re st

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-97Additional Checks ²Cuts Out, MissesDEFINITION: A surging or jerking that follows engine sp

SECTION 3 - CHASSIS & TURNTABLE3-98 – JLG Lift – 3121616Ignition System Checks Note: LPG being a gaseous fuel requires higher secondary ignition s

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-99Fuel System Checks ² Check for a restricted fuel filter, contaminated fuel, or improper fu

SECTION 3 - CHASSIS & TURNTABLE3-100 – JLG Lift – 3121616Additional Check ² Check the transmission shift pattern. Refer to the OEM Transmission Co

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-101Fuel System Checks ² Check for Rich or Lean symptom that causes the condition. Drive the

SECTION 3 - CHASSIS & TURNTABLE3-102 – JLG Lift – 3121616Table 3-12. DTC to SPN/FMI Cross Reference ChartDTC Description SPN Code FMI Code16 Crank

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-103562 System Voltage Low 168 17563 System Voltage High 168 15601 Flash Checksum Invalid 628

SECTION 3 - CHASSIS & TURNTABLE3-104 – JLG Lift – 3121616NOTES:

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 MAIN BOOM MAINTENANCEUNSECURED COMPONENTS CAN MOVE OR FALL A

3121616 – JLG Lift – xi LIST OF FIGURESFIGURE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 3121616Figure 4-1. Rotator, Platform Level Cylinder, and Jib Lift Cylinder InstallationRemove Main Bo

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-3Remove Main Boom1. Support boom assembly weight along entire lengthusing suitable lifting equip

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3121616INSTALLATION1. Use a suitable lifting device to position boom assemblyon turntable. Align pivot

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-5Remove Tower Boom1. Tag and disconnect all hydraulic lines from tower boomassembly to turntable

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3121616INSPECTIONNOTE: Replace worn or damage components as needed.1. Inspect tower boom pivot pin for

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-74.3 BOOM CLEANLINESS GUIDELINESFollowing are guidelines for machines used in excessively dirtye

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31216164.4 ROTARY ACTUATORTheory of OperationThe L20 Series rotary actuator is a simple mechanism that

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-9Figure 4-6. Rotary Actuator - Exploded View876600A5214141112391078513411516600AJ1. Housing2. S

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3121616Disassembly1. Remove capscrews (113) over end cap lock pins (109). 2. Using a 1/8” (3.18mm) dr

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-117. Remove stop tube if installed. 8. Actuator has timing marks for proper engagement. 9. Befor

xii – JLG Lift – 3121616LIST OF TABLES TABLE NO. TITLE

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 312161611. Before removing piston (3), mark housing (1) ring gear inrelation to piston O.D. gear. The

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-1315. Remove wear guides (302) from end cap (4) and shaft(2). 16. To remove main pressure seals

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 312161620. Remove piston I.D. seal (200). Inspection1. Clean all parts in a solvent tank and dry with

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-15Assembly1. Gather all components and tools to one location. Usecut away drawing to reference s

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 31216166. Install inner T-seal (200) in piston (3) using a circularmotion. Install outer T-seal (202)

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-1710. Looking from opposite end of housing (1) when timingmarks line up, tap piston (3) in until

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 312161616. Install 0-ring (204) and back-up ring (207) in inner sealgroove on end cap (4). 17. Threa

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-19Installing Counterbalance ValveRefer to Figure 4-7., Rotator Counterbalance Valve.1. Make sure

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3121616Testing ActuatorIf equipment is available, test actuator on a hydraulic testbench. Breakaway p

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-21TroubleshootingTable 4-1. TroubleshootingProblem Cause Solution1. Shaft rotates slowly or not

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATATable 1-1. Operating Spec

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 31216164.5 FOOT SWITCH ADJUSTMENTAdjust foot switch to operate functions when pedal is at centerof tr

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-234.7 POWERTRACK MAINTENANCERemove LinkNOTE: Hoses shown in powertrack are for example only. Act

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3121616REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENTDAMAGE.3. To remove a link, ri

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-256. Insert flat head screwdriver between links. Twist and pulllinks apart. 7. Remove link from

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3121616Install New Link1. Squeeze cut-out end of new link into half-shear (female)end of track sectio

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-274. Pull moving end over track so new connection is posi-tioned in curve of powertrack. Round h

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 3121616NOTE: Make sure snap rings are seated in pin groove and closedproperly.1. Install new 8-32 x 0

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-293. Install new 8-32 x 0.500 self threading screw on otherside. Torque to 18-20 in-lb (2-2.25 N

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 31216162. Parts used: Bracket Center Pin and Center Pin Snap Ring. 3. Take new bracket and install br

SECTION 4 - BOOM & PLATFORM3121616 – JLG Lift – 4-312. Install center pin with snap ring in new bracket.3. Install radius pins and snap rings in o

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31216161.3 CAPACITIES1.4 TIRES1.5 ENGINE DATA Table 1-3. CapacitiesFuel Tank 30 gal (113.6 L)Hydraulic Oil

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 3121616NOTES:

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 O-RING LUBRICATIONWhen assembling connectors, all fittings with O-rings must b

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 3121616DipNOTE: This method works best with Face Seal O-rings, but willwork for all O-ring fitting types.Tools

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-35.2 CYLINDERS - THEORY OF OPERATIONSystems With Double Acting CylindersSystems with double acting cylind

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 3121616Cylinders With Single Counterbalance Valve(Upper Lift Cylinder)OPERATE ALL FUNCTIONS FROM GROUND CONTROL

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-55.4 CYLINDER REMOVAL AND INSTALLATIONCylinder LocationsFigure 5-2. Hydraulic Cylinder LocationsItem Cyl

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 3121616Main Boom Telescope Cylinder Removal1. Place machine on flat and level surface with main boomhorizontal.

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-7Main Boom Lift Cylinder Removal1. Place machine on flat and level surface. Start engine andplace main bo

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 3121616Upright Level Cylinder Removal1. With aid of an assistant, manually override Plunger Valvewith a pry bar

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-9Tower Boom Lift Cylinder RemovalRefer to Figure 5-6., Boom Positioning and Support, CylinderRepair.1. Pl

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-31.6 FUNCTION SPEEDSMachine Orientation When Doing Speed TestsLift: Boom retracted. Telescope retract

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 3121616Tower Lift Cylinder Installation1. With main boom and tower boom positioned and sup-ported as in Figure

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-115.5 HYDRAULIC CYLINDER REPAIRTower Boom Lift CylinderDISASSEMBLYRefer to Figure 5-11.CONTAMINATION MAY

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3121616Figure 5-11. Tower Boom Lift Cylinder1. Barrel1a. Composite Bushing2. Rod2a. Composite Bushing3. Pisto

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-138. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3121616AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-156. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-18. Pisto

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 3121616Upright Level CylinderDISASSEMBLYRefer to Figure 5-24.CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE C

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-17Figure 5-24. Upright Level Cylinder1. Barrel1a. Composite Bushing2. Rod2a. Composite Bushing3. Head4.

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31216168. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-19AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 31216161.8 HYDRAULIC OILNOTE: Hydraulic oils require anti-wear qualities at least API Ser-vice Classificati

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31216166. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-31. Pisto

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-21Master CylinderDISASSEMBLYRefer to Figure 5-37. Master Cylinder.CONTAMINATION MAY DAMAGE EQUIPMENT. DIS

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 3121616Figure 5-37. Master Cylinder Assembly1683266 (A)1683263 (AJ)*9 ft-lb (12 Nm)1A1A1241918415161761413121

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-238. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 3121616AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-256. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-44. Pisto

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 3121616Main Boom Lift CylinderDISASSEMBLYRefer to Figure 5-50.CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-27Figure 5-50. Main Boom Lift Cylinder Assembly1. Barrel1a. Composite Bushing2. Rod2a. Composite Bushing

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 31216168. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-29AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-51.9 MAJOR COMPONENT WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENTWEIGHT

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 31216166. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-57. Pisto

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-31Main Boom Telescope CylinderRefer to Figure 5-63.DISASSEMBLYCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSE

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 3121616Figure 5-63. Main Boom Telescope Cylinder Assembly1. Barrel 2. Rod3. Piston4. Head5. Spacer6. Taper Bu

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-338. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 3121616AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-356. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-70. Pisto

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 3121616Tower Boom Telescope CylinderRefer to Figure 5-76.DISASSEMBLYCONTAMINATION MAY DAMAGE EQUIPMENT. DISASS

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-37Figure 5-76. Tower Boom Telescope Cylinder Assembly1. Barrel 2. Rod3. Piston4. Head5. Ring Washer6. Ta

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 31216168. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-39AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3121616Figure 1-1. Operator Maintenance and Lubrication1.10 OPERATOR MAINTENANCENOTE: The following number

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 31216166. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-83. Pisto

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-41Platform Level (Slave) CylinderRefer to Figure 5-89., Platform Level (Slave) Cylinder Assembly.DISASSEM

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 3121616Figure 5-89. Platform Level (Slave) Cylinder Assembly1. Barrel1a. Composite Bushing2. Rod2a. Composite

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-438. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 3121616AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-456. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-96. Pisto

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 3121616Jib Lift Cylinder (AJ Only)Refer to DISASSEMBLYCCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDE

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-47Figure 5-102. Jib Lift Cylinder Assembly (600AJ)1683609 G *50-55 ft-lb (68-75 Nm)**5 ft-lb (9 Nm)26**1

SECTION 5 - HYDRAULICS5-48 – JLG Lift – 31216168. Using suitable protection, clamp cylinder rod in a vise orsimilar holding fixture as close to piston

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-49AssemblyNOTE: Use proper cylinder seal kit for cylinder assembly. See yourJLG Parts Manual.Apply a lig

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-72. Wheel Bearings (If equipped)Lube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 year

SECTION 5 - HYDRAULICS5-50 – JLG Lift – 31216166. If applicable, place new O-ring and back-up rings ininner piston diameter groove.Figure 5-109. Pist

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-51Steer CylinderDISASSEMBLYRefer to Figure 5-115.CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER

SECTION 5 - HYDRAULICS5-52 – JLG Lift – 3121616 Figure 5-115. Steer Cylinder Assembly1. Piston2. Seal3. O-Ring4. Setscrew5. Barrel6. Rod7. Head8. O-R

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-537. Remove two Seals (2) and O-Ring (3) from Piston (1).8. Loosen two Setscrews (4) in Piston (1). Unscr

SECTION 5 - HYDRAULICS5-54 – JLG Lift – 3121616Assembly NOTE: Apply a light film of hydraulic oil to all components beforeassembly.1. Position cylind

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-55Axle Lockout CylinderNOTE: Refer to Figure 5-122., Axle Lockout Cylinder.DISASSEMBLYCONTAMINATION MAY D

SECTION 5 - HYDRAULICS5-56 – JLG Lift – 3121616Figure 5-122. Axle Lockout Cylinder 1349*856572 632557491684465 F*Torque to 25 - 27 ft-lb (33 - 36 Nm)

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-575.6 HYDRAULIC PUMP (GEAR)DisassemblyNOTE: The following general instructions also apply to multiplesect

SECTION 5 - HYDRAULICS5-58 – JLG Lift – 312161610. Remove rear bearing block from drive and idler shafts.11. Remove idler shaft from bearing block.12.

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-59Inspect Parts For Wear1. Clean and dry all parts thoroughly before inspection. Itis not necessary to in

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31216167. Hydraulic Charge FilterInterval - Change after first 50 hrs. and every 6 monthsor 300 hrs. therea

SECTION 5 - HYDRAULICS5-60 – JLG Lift – 3121616General InformationFAILURE TO PROPERLY ASSEMBLE THIS PUMP WILL RESULT WITH LITTLE ORNO FLOW AT RATED PR

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-615. Place mounting flange, with shaft seal side down, on aclean flat surface.6. Apply a light coating of

SECTION 5 - HYDRAULICS5-62 – JLG Lift – 312161613. Gently slide gear housing over rear bearing blockassembly. Slide housing down until it engages dowe

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-63Placing Pump Back Into Service1. If shop test stand is available, use the following proce-dure for tes

SECTION 5 - HYDRAULICS5-64 – JLG Lift – 3121616Remove and Install FNR and NFPE Modules1. Clean pump and module housings.2. Remove four screws retainin

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-65Figure 5-124. Gauge Port Locations1. System Pressure Gauge Port M2 7. Case Drain Port L22. System Pres

SECTION 5 - HYDRAULICS5-66 – JLG Lift – 3121616Figure 5-125. Plugs/Fittings Size & Torque#Plug/FittingTorquelb. ft. Nm1 Servo Gauge Port M4N/A N/

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-675. Install new O-ring on valve plug. Reinstall poppet,spring, and plug (with shims and O-ring) into pum

SECTION 5 - HYDRAULICS5-68 – JLG Lift – 31216161. Position pump with shaft facing up.NOTE: If unit is positioned horizontally when shaft is removed, c

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-69Charge PumpNOTE: Disassemble charge pump to inspect and clean, or changeauxiliary shaft drive coupling.

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-910. Oil Change w/Filter - Deutz D2.9Lube Point(s) - Fill Cap/Spin-on ElementCapacity - 8.45 Qt (8 L)

SECTION 5 - HYDRAULICS5-70 – JLG Lift – 31216165.8 HYDRAULIC COMPONENT START-UPThe goal at hydrostatic system start up is to preserve thedesigned life

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-715.9 PRESSURE SETTING PROCEDURESCOLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS.JLG IND

SECTION 5 - HYDRAULICS5-72 – JLG Lift – 3121616Figure 5-132. Main Control Valve - Sheet 1 of 2

SECTION 5 - HYDRAULICS3121616 – JLG Lift – 5-73Figure 5-133. Main Control Valve - Sheet 1 of 2

SECTION 5 - HYDRAULICS5-74 – JLG Lift – 3121616Figure 5-134. Location of Components - Main Control Valve

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3121616Figure 6-2. Controller Block Diagram

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-3Connect JLG Control System Analyzer1. Connect four pin end of cable supplied with hand-heldor wi

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3121616If ENTER is selected at the HELP: PRESS ENTER display,and a fault is present, the analyzer dis

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-5Press ENTER to select the ACCESS LEVEL menu.Using the UP or DOWN arrow keys, enter firstdig

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 31216161. Oil Change w/Filter - GM2. Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965)Capaci

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3121616Machine SetupWhen a machine digit item is selected, press UP orDOWN arrow keys to adjust its

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-7Table 6-1. Analyzer AbbreviationsABBREVIATION MEANINGACCEL ACCELERATEACT ACTIVEA/D ANALOG DIGITA

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 3121616S/C SHORT CIRCUITSEL SELECTORSN SERIAL NUMBERSPD SPEEDSTOW STOWEDSTOWD STOWEDSW SWITCH or SOFTWA

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-9Figure 6-5. Analyzer Software Version 6.8 - Sheet 1 of 6 MENU: HELP:PRESS ENTER HELP: (001

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3121616Figure 6-6. Analyzer Software Version 6.8 - Sheet 2 of 6FromDIAGNOSTICS:BOOM FUNCTIONSTODIAGNO

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-11Figure 6-7. Analyzer Software Version 6.8 - Sheet 3 of 6 CALIBRATION DATA LOAD 500LB: CALIBRAT

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3121616Figure 6-8. Analyzer Software Version 6.8 - Sheet 4 of 6FROM MENU:DIAGNOSTICSTO PERSONALITIES:

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-13Figure 6-9. Analyzer Software Version 6.8 - Sheet 5 of 6FROM PERSONALITIES:RIGHT TRACK PERSONA

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3121616Figure 6-10. Analyzer Software Version 6.8 - Sheet 6 of 6FROMMENU:PERSONALITIES MENU: MACHINE

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-156.2 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within the adjustme

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-11Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)REFERENCE JLG ANAEROBIC THREAD LOCKING COMP

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3121616SWING ACCELeration 0.1 to 5.0s 2.0DECELeration 0.1 to 3.0s 1.8MINimum LEFT speed 0 to 50% 30MAX

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-17BASKET ROTATE ACCELeration 0.1 to 5.0 1.8DECELeration 0.1 to 3.0 0.7MlNimum LEFT speed 0 to 65

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 3121616Table 6-3. Help Fault Codes, Displayed Faults, and DescriptionsFault FlashCodeCommunicated (Dis

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-19D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if the Vref voltage i

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3121616l/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when center tap voltage is not

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-21HORN SHORT TO BATTERYAUX POWER SHORT TO GROUNDAUX POWER OPEN CIRCUITAUX POWER SHORT TO BATTERYG

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3121616GROUND ALARM OPEN CIRCUITGROUND ALARM SHORT TO BATTERYGENERATOR SHORT TO GROUNDGENERATOR OPEN C

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-23BASKET RIGHT OPEN CIRCUITBASKET RIGHT SHORT TO BATTERYJIB UP SHORT TO GROUNDJIB UP OPEN CIRCUIT

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3121616LIFT UP DUMP SHORT TO BATTERYLIFT DOWN HOLDING SHORT TO GROUNDLIFT DOWN HOLDING OPEN CIR-CUITLI

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-25JIB DOWN SHORT TO BATTERYJIB DOWN SHORT TO GROUNDJIB DOWN OPEN CIRCUITJIB LEFT SHORT TO BATTERY

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3121616Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3121616FUEL SENSOR SHORT TO GROUNDIndicates fuel sensor is reading below 0.2 volts.4/4 Flash code 4/4

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-27Table 6-4. Help Message/Fault ListingHELP MESSAGE FAULT FAULT REMOVALOK 0 0 CLEARS WHEN FAULT I

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3121616FORD ECM POWER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTHORN SHORT TO GROU

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-29ALARM SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTGENERATOR SHORT TO GROUND

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3121616TOWER UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTTOWER UP OPEN CIRCUIT 3

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-31FORD FAULT CODE 31 4 3 CLEARS WHEN FAULT IS REMOVEDFORD FAULT CODE 32 4 3 CLEARS WHEN FAULT IS

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 3121616NO ALTERNATOR OUTPUT 4 3 CLEARS WHEN FAULT IS REMOVEDOIL PRESSURE LOW 4 3 CLEARS WHEN FAULT IS

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-33Table 6-5. Machine Configuration Programming InformationConfiguration Digit Number DescriptionD

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 3121616TILT:8123455 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-35H & T LIGHTS:1401NO: No head and tail lights installed.YES: Head and tail lights installed.

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-13Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3121616FUNCTION CUT-OUT:18*0123NO: No drive cutout.BOOM CUTOUT: Boom function cutout while driving abo

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-376.3 MACHINE ORIENTATION WHEN SETTING FUNCTION SPEEDSLIFT UP: from platform control, lowest elev

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3121616Test Notes1. Personality settings can be adjusted anywhere withinthe adjustment range for optim

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-39.Table 6-6. Fault Code ListDTC Text001 EVERYTHING OK0010 RUNNING AT CUTBACK - OUT OF TRANSPORT

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 31216162371 FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED2372 FUNCTION PROBLEM - SWING LEFT PE

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-413374 GEN SET/WELDER - OPEN CIRCUIT3375 GEN SET/WELDER - SHORT TO BATTERY3376 HEAD TAIL LIGHT -

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 312161633281 GLOWPLUG - SHORT TO GROUND33287 LIFT - CURRENT FEEDBACK READING TOO LOW33295 SWING LEFT V

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-433419 JIB LIFT DOWN VALVE - SHORT TO BATTERY3420 JIB LIFT DOWN VALVE - SHORT TO GROUND431 FUEL S

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 31216168211 LSS READING UNDER WEIGHT8639 FRONT LEFT STEER VALVE - OPEN CIRCUIT8640 FRONT LEFT STEER VA

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-45600AMODEL NUMBERMARKETENGINEFLYWHEEL TEETHGLOW PLUGSTARTER LOCKOUTENGINE SHUTDOWNTILTJIB4 WHEEL

INTRODUCTION3121616 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains general safety precautions

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3121616Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)Size TPI Bolt DiaTensile Stress AreaClamp L

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3121616600ADRIVE TYPEDISPLAY UNITSLEVELING MODEDRIVE CONTROLBOOM CONTROLCLEARSKYCRIBBING OPFUEL TANK S

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-47600AJGEN SET / WELDERGEN SET CUTOUTHEAD & TAIL LIGHTSCABLE BREAK SWITCHLOAD SYSTEMLOAD SENS

SECTION 6 - JLG CONTROL SYSTEM6-48 – JLG Lift – 3121616Figure 6-11. Control Module Locations 

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-49Figure 6-12. Ground Control Module Pin Connections 1 of 3   

SECTION 6 - JLG CONTROL SYSTEM6-50 – JLG Lift – 3121616Figure 6-13. Ground Control Module Pin Connections 2 of 3   

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-51Figure 6-14. Ground Control Module Pin Connections 3 of 3   

SECTION 6 - JLG CONTROL SYSTEM6-52 – JLG Lift – 3121616Figure 6-15. Platform Control Module Pin Connections 1 of 2  

SECTION 6 - JLG CONTROL SYSTEM3121616 – JLG Lift – 6-53Figure 6-16. Platform Control Module Pin Connections 2 of 2  

SECTION 6 - JLG CONTROL SYSTEM6-54 – JLG Lift – 3121616NOTES:

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-1SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS7.1 GENERALT

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-15Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-2 – JLG Lift – 3121616Resistance Measurement• First test meter and leads by touching leads

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-3Current Measurement• Set up meter for expected current range• Be sure

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-4 – JLG Lift – 3121616Dielectric Grease ApplicationBefore following these instructions, ref

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-5AMP Mate-N-LokFollow manufacturer installation instructions.Figure 7-

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-6 – JLG Lift – 31216167.4 AMP CONNECTORPlug and header assembly colors are mechanically key

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-74. After all contacts are inserted, close wedge lock to itslocked pos

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-8 – JLG Lift – 31216167.5 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-9HD30/HDP20 Series Assembly1. Grasp contact (1) about 25mm behind cont

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-10 – JLG Lift – 3121616Figure 7-26. Electrical Components 1 of 2J2J3J4J7J12J1J8DIAGNOSTICA

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-11Figure 7-27. Electrical Components 2 of 2ORENGINEHARNESS(DEUTZ D201

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3121616Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)Size PITCHTensile Stress AreaClamp LoadT

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-12 – JLG Lift – 3121616Figure 7-28. Platform and Ground Control Electrical Schematic - 1 o

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-13Figure 7-29. Platform and Ground Control Electrical Schematic - 2 o

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-14 – JLG Lift – 3121616Note: Zones refer to Figure 7-28 and 7-29.Figure 7-30. Generator Wi

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-15Note: Zones refer to Figure 7-28 and 7-29.Figure 7-31. Generator Wi

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-16 – JLG Lift – 3121616Note: Zones refer to Figure 7-28 and 7-29.Figure 7-32. Deutz Engine

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-17Note: Zones refer to Figure 7-28 and 7-29.Figure 7-33. GM/PSI Engin

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-18 – JLG Lift – 3121616Figure 7-34. Hydraulic Schematic 1 of 21001110345D - Sheet 6

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-19Figure 7-35. Hydraulic Schematic 2 of 21001110345D - Sheet 6

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-20 – JLG Lift – 3121616Figure 7-36. 2-Wheel Drive Hydraulic Schematic 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-21Figure 7-37. 2-Wheel Drive Hydraulic Schematic 2 of 2

SECTION 1 - SPECIFICATIONS3121616 – JLG Lift – 1-17Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)Size PITCHTensile Stress AreaClamp Load

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-22 – JLG Lift – 3121616Figure 7-38. 4-Wheel Drive Hydraulic Schematic 1 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS3121616 – JLG Lift – 7-23Figure 7-39. 4-Wheel Drive Hydraulic Schematic 4 of 2

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS7-24 – JLG Lift – 3121616NOTES:

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

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3121616NOTES:

SECTION 2 - GENERAL3121616 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides informa

SECTION 2 - GENERAL2-2 – JLG Lift – 31216162.2 SERVICE AND GUIDELINESGeneralFollowing information is provided to assist you in using servic-ing and ma

SECTION 2 - GENERAL3121616 – JLG Lift – 2-3Component Disassembly and ReassemblyComplete procedural steps in sequence when disassemblingor reassembling

SECTION 2 - GENERAL2-4 – JLG Lift – 31216162.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contamina-tion

SECTION 2 - GENERAL3121616 – JLG Lift – 2-52.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINESFilament wound bearings.1. Pinned joints should be disassem

INTRODUCTIONA-2 – JLG Lift – 3121616REVISON LOGOriginal Issue - January 8, 2014

SECTION 2 - GENERAL2-6 – JLG Lift – 3121616Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALWeeklyPreventiveMaintenanceMonthlyPrev

SECTION 2 - GENERAL3121616 – JLG Lift – 2-7Functions/ControlsPlatform Controls 5 6 6Ground Controls 5 6 6Function Control Locks, Guards, or Detents 1,

SECTION 2 - GENERAL2-8 – JLG Lift – 3121616Annual Machine Inspection Due 21No Unauthorized Modifications or Additions 21 21All Relevant Safety Publica

SECTION 2 - GENERAL3121616 – JLG Lift – 2-9Figure 2-1. Deutz Engine and Hydraulic Operating Temperature Specifications

SECTION 2 - GENERAL2-10 – JLG Lift – 3121616Figure 2-2. GM Engine and Hydraulic Operating Temperature Specifications

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 TIRES AND WHEELSTire InflationPneumatic tire air pre

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 31216163. Torque to specifications shown in Table 3-1 below.4. Torque wheel nuts after first 50 ho

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-3Figure 3-3. Torque Hub

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3121616Main Disassembly1. Perform Roll Check, Leak Check, and Brake Check ifapplicable before disa

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-5Output Carrier Disassembly11. Use a 1/8” diameter punch to drive Roll Pin (4G) in PlanetSha

3121616 – JLG Lift – i TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 3121616Hub-Spindle Disassembly1. Place unit on bench with Spindle (1A) end down.2. Remove 2 Set S

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-7Spindle-Brake DisassemblyNOTE: Units with integral Input Brake (8) only.COMPRESSED SPRINGS

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 3121616Cover Disassembly1. Remove O-Ring (17) from groove in Cover (6A).2. Remove Thrust Washer (2

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-9Input Carrier Sub-Assembly1. Apply a liberal coat of grease to bore of one Input PlanetGear

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 3121616 Hub-Spindle Sub-AssemblyNOTE: Spray a light film of oil on all component parts duringasse

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-119. Place Input Carrier Sub-Assembly (3A) on Output SunGear (11) splines. Drop Input Sun (1

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 3121616Figure 3-10. Hub Assembly1A. Spindle1B. Lip Seal1C. Tapered Bearing1D. Housing1E. Ri

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-13Figure 3-11. Bearing Cup Pressing ToolFigure 3-12. Seal Pressing Tool

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 3121616Figure 3-13. Bearing Cup Pressing ToolFigure 3-14. Drift Pin for Lining Up Thrust Washer

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-153.3 FREE WHEELING OPTIONDisengage Drive Motors and Brakes for Towing, etc. (Free Wheel)1.

ii – JLG Lift – 3121616TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 3121616Shaft Seal ReplacementREMOVAL1. Remove snap ring (1) retaining shaft seal, and supportwash

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-17Loop Flushing ValveREMOVAL1. Remove plug (1) and (2) using an 11/16 in internal hexwrench

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3121616TroubleshootingTable 3-2. Excessive Noise and/or VibrationItem Description ActionCheck o

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-19DisassemblyNOTE: Removal of endcap voids warranty.Coat all moving parts with a film of cle

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 312161613. Using an 8 mm internal hex wrench, remove endcapscrews (22).14. Remove endcap (23). Re

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-2119. Turn housing on its side and remove cylinder kit assem-bly (31). Set assembly aside. D

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 312161626. Remove pistons (44) and slipper retainer (45) from cylin-der block (46). Pistons are n

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-23CYLINDER BLOCKMeasure cylinder block height. Replace blocks worn beyond minimum height spe

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 3121616SHAFT BEARINGSInspect bearings for excessive wear or contamination. Rotatebearings while f

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-253. Install inner block spring washer (4), block spring (5),and outer washer (6) in cylinde

3121616 – JLG Lift – iii TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 31216168. Press front shaft bearing (15) on shaft (16). Press bearingon shaft with lettering faci

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-2712. Press rear shaft bearing (22) in endcap. Install bearingwith letters facing out. Press

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 312161618. Cover shaft splines with an installation sleeve. Install anew shaft seal (27) with cup

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-294. To ensure pump and motor stay filled with oil, installcase drain lines in upper most ca

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3121616Oscillating Axle Lockout TestLOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A S

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-313.7 SWING DRIVEFigure 3-41. Swing Drive Assembly21I1H1E1G1J131C1A122065A45113114481A. Out

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 3121616Figure 3-42. Swing Motor and Brake Assembly1011021041051031061071041091081101121041041041

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-33Gear BacklashSet backlash to .010 - .015 in (0.254 to 0.381mm).1. Insert shim (JLG P/N 407

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 3121616Motor Control Valve Disassembly1. Place unit on bench with motor end up.2. Remove Drain Pl

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-35Main Disassembly1. Remove Sun Gear (8) with Retaining Ring (44) inside.2. With unit restin

iv – JLG Lift – 3121616TABLE OF CONTENTS SECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3121616Carrier Disassembly1. Using a 3/16" punch drive Roll Pin (3G) holding PlanetShaft (3E

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-37Hub-Shaft Subassembly1. Press Bearing Cup (1C) in Housing (1G). Make sure cupstarts square

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 3121616Carrier Subassembly1. Apply a liberal coat of grease to bore of Cluster Gear (3F).This hol

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-39Main Assembly1. With Hub Shaft Subassembly resting on Shaft (1A) installInternal Gear (2).

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 3121616Motor and Brake Assembly1. Insert Stator (8K) (O.D. lobes) in bore of Brake Housing(6). Al

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-413.8 SWING BEARINGTurntable Bearing Mounting Bolt Condition CheckNOTE: This check is design

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 3121616Measuring PointMeasuring Pointa. Tower boom fully elevated and main boom level.b. Main bo

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-43Swing Bearing ReplacementREMOVAL1. Operate boom from Ground Control station to provideacce

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3121616a. Carefully lower turntable onto swing bearing.Ensure scribed line of inner bearing race

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-453.9 SWING BRAKE - MICODisassembly1. With shaft protrusion downward, remove end cover (13)b

3121616 – JLG Lift – v TABLE OF CONTENTSSECTION NO. TITLE

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 31216163.10 ROTARY COUPLINGUse the following procedure to install the seal kit.NOTE: Step 1 appli

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-4723456789DETAIL A11312141516171817181615131210111. O-ri ng2. Plu g3. Ch eck Va

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 31216163412234677312345771,57523742,7656172Figure 3-63. Rotary Coupling Port Location - 2WS

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-491,5,9752,83742,7656172341223467789983123457788Figure 3-64. Rotary Coupling Port Location

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 31216163.11 GENERATOREvery 250 hours Check drive belt tension every 250 hours of operation,.Every

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-51Overload ProtectionSTOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER.The circuit

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 312161611/4 in (6 mm)Or Less - Replace27/16 in - 1/2 in(11 - 12 mm) New323Brushes must ridecom

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-533.12 DEUTZ D2.9 L4 ENGINEFigure 3-70. Deutz D2.9 L4 Engine Installation - Sheet 1 of 21.

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 3121616Figure 3-71. Deutz D2.9 L4 Engine Installation - Sheet 2 of 21. Coolant Recovery Tank2. R

SECTION 3 - CHASSIS & TURNTABLE3121616 – JLG Lift – 3-55NOTE: Refer to engine manufacturer’s manual for detailed oper-ating and maintenance instru