Jlg X23J - X700AJ Service Manual- User Manual

ii – JLG Lift – 3121448 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE 3.1 RUBBER TRACK MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Checking track tension . . . . . . . . . . . . . . . . . . . . ...

3121448 – JLG Lift – iii TABLE OF CONTENTS SECTION NO. TITLE PAGE NO . 6.6 MENU INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 6.7 LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

SECTION 1 - SPECIFICATIONS 3121448 – JLG Lift – 1-1 SECTION 1. SPECIFICATIONS 1.1 CAPACITIES Table 1-1. DRIBE HUB CAPACITIES TYPE DRIBE HUB SPEED MACHINE CAPACITIES BONFIGLIOLI 7C 00 1 G 40 HC0 5.25 065RT01P 3WH LZ 1V X14JH X14J-X390AJ 0,340 kg (0,75 lbs) BONFIGLIOLI 7C 00 1G 40 HC0 5.25 080RT01P 3W...

SECTION 1 - SPECIFICATIONS 1-2 – JLG Lift – 3121448 1.2 TRACKS Table 1-3. Track Specifications M O D E LMACHINE TRACK DIMENSIONS X14JH 180x37x72 X14J-X390AJX17JX19J-X550AJX23J-X700AJ 230x39x96 Table 1-4. Ground bearing pressure PRESSURES AND REACTIONS TO THE GROUND MODEL ON TRACKS ON OUTRIGGER React...

SECTION 1 - SPECIFICATIONS 3121448 – JLG Lift – 1-3 1.3 ENGINE DATA NOTE: RPM Tolerances are ± 50. HONDA ENGINE GX270 - GX390 Table 1-5. SPECIFICATIONS HONDA ENGINE GX270-GX390 Model GX270 GX390UT2 Description code GCALK GCBCT Type 4 stroke, overhead valve, single cylinder, inclined by 25° Displacem...

SECTION 1 - SPECIFICATIONS 1-6 – JLG Lift – 3121448 1.4 SPECIFICATIONS AND PERFORMANCE DATA Reach Specifications Table 1-9. Reach Specifications X14J X14J-H X17J X19J X23J Platform Height w 120 kg capacity 38' 7" (11.80 m) 39' 2" (11.90 m) 48' 5" (14.81 m) 54' 6" (16.67 m) 69' 2"...

SECTION 1 - SPECIFICATIONS 3121448 – JLG Lift – 1-7 Dimensional Data X390AJ X550AJ X700AJ Gasoline Engine Honda GX270 9 hp (6.7 kW) or Honda iGX390 13 hp (9.7 kW) Honda iGX440 15 hp (11.1 kW) Honda iGX440 15 hp (11.1 kW) Diesel Engine Hatz 1B30 7 hp (5.22 kW) Hatz 1B40 10 hp (7.46 kW) Perkins 402.05...

SECTION 1 - SPECIFICATIONS 1-8 – JLG Lift – 3121448 Chassis Table 1-12. Chassis specifications X14J X14J-H X17J X19J X23J Gradeability 36% 33.5% 36% 38% 40% Maximum operating slope 10° 10° 11° 11° 13 Max. Approach / Depart angles Front 20° / Rear 20° Front 24.5° / Rear 18.5° Front 20° / Rear 21° Fro...

SECTION 1 - SPECIFICATIONS 3121448 – JLG Lift – 1-9 1.5 FUNCTION SPEEDS Machine Orientation When Doing Speed Tests Lift: Boom Retracted. Telescope Retracted. Lift Up, Record Time, Lift Down, Record Time. Swing: Machine stabilized, upper Boom at Full Elevation. Telescope Retracted. Swing the Turntabl...

SECTION 1 - SPECIFICATIONS 3121448 – JLG Lift – 1-11 1.7 SERIAL NUMBER LOCATION A serial number plate is affixed on to the frame or the bas-ket A frame. The following illustrations showing the posi-tion on each model. Figure 1-1. Plate Figure 1-2. Plate location on X17J Figure 1-3. Plate location on...

SECTION 2 - GENERAL 3121448 – JLG Lift – 2-1 SECTION 2. GENERAL 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information neededby those personnel that are responsible to place themachine in operation readiness and maintain its safeoperating conditi...

SECTION 2 - GENERAL 2-2 – JLG Lift – 3121448 2.2 SERVICE AND GUIDELINES General The following information is provided to assist you in theuse and application of servicing and maintenance proce-dures contained in this book. Safety and Workmanship Your safety, and that of others, is the first consider...

SECTION 2 - GENERAL 2-4 – JLG Lift – 3121448 fied intervals required in the Lubrication Chart inSection 1. Always examine filters for evidence ofmetal particles. 3. Cloudy oils indicate a high moisture content whichpermits organic growth, resulting in oxidation or cor-rosion. If this condition occur...

SECTION 2 - GENERAL 3121448 – JLG Lift – 2-5 2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings. 1. Pinned joints should be disassembled andinspected if the following occurs: a. Excessive sloppiness in joints. b. Noise originating from the joint during operation. 2. Filament wo...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-1 SECTION 3. CHASSIS & TURNTABLE 3.1 RUBBER TRACK MAINTENANCE Checking track tension Stop the machine on solid, level land. Lift the machine intosafe conditions and place stable supports under the under-carriage frame for total support. ...

SECTION 3 - CHASSIS & TURNTABLE 3-2 – JLG Lift – 3121448 Checking The Rubber Tracks Figure 3-3. Rubber Track Structure The structure of the rubber track is illustrated in Figure 3-3.The steel ropes and the metal core are sunk into the rubber.The carved profiles are used to give stability when mo...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-3 and progressive damage, they allow the trackto continue working. The development of thedamage indicated in point 3 leads to theexposure of the metal cores and if they areexposed for more than half of the track cir-cumference, it means that...

SECTION 3 - CHASSIS & TURNTABLE 3-4 – JLG Lift – 3121448 Figure 3-8. Checking tightness of nuts and bolts Depending on the use of the platform, it is indispensable tocheck the parts and the nuts and bolts in general, which aresubject to loosening. Pay particular attention to the frame components...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-5 Size TPI Bolt Dia Tensile Stress Area Clamp Load Clamp Load In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 4 0 0,1120 0,00604 380 8 0,9 6 0,7 48 0,1120 0,00661 420 9 1,0 7 0,8 6 3 2 0,1...

SECTION 3 - CHASSIS & TURNTABLE 3-6 – JLG Lift – 3121448 Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 Clamp Load See Note 4 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 4 0 0,1120 0,00604 48 0,1120 0,00661 6 3 2 0,1380 0,00909 40 0,1380 ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-7 Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263 TM ) Torque (Lub) Torque (Loctite® 262 TM OR Vibra- TITE TM 131 ) Torque (Loctite® 242 TM or 271 TM OR Vibra- TITE TM 111 or 140 ) Clamp Load Torque (Dry or Loctite® 263...

SECTION 3 - CHASSIS & TURNTABLE 3-8 – JLG Lift – 3121448 3.2 UNDERCARRIGE COMPONENTS a. Stabilize the machine on level ground. b. Fully extend the undercarriage. c. Remove the tracks (see paragraph 3.1). d. Remove the key ignition, and a tag with warningdo not start the machine. Figure 3-12. Rep...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-9 Table 3-1. Final drive torque valves n. Machine model Description Torque valve Loctite type+ 2 X14JH - X14J - X17J - X19J - X390AJ - X550AJ Nut & pin thread M14 125 Nm Loctite 52A43 X23J - X700AJ Nut AB M14 125 Nm X 7 X14JH - X14J - X1...

SECTION 3 - CHASSIS & TURNTABLE 3-10 – JLG Lift – 3121448 3.3 CYLINDERS AND ENLARGEMENT GUIDE Figure 3-15. 12. Stabilize the machine on level surface. 13. Extend the undercarriage. 14. Engine and key off. 15. Remove the key ignition, and a tag with warning donot start the machine. 16. Open the h...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-11 3.4 DRIVE GEAR MOTOR TABLE Table 3-2. SECTION TYPE SPEED MACHINE MOTOR 3.5 BONFIGLIOLI 7C 00 1 G 40 HC0 5.25 065RT01P 3WH LZ 1V X14JH X14J-X390AJ 065 3.5 BONFIGLIOLI 7C 00 1G 40 HC0 5.25 080RT01P 3WI1 LA 1V X17J X19J-X550AJ 080 3.6 BONFIG...

SECTION 3 - CHASSIS & TURNTABLE 3-12 – JLG Lift – 3121448 3.5 TRACK DRIVE - BONFIGLIOLI (MT700C077) Table 3-3. Product Identification The data to identify the product are shown on the identifi-cation plate attached to it. INFORMATION FOR ALL ENQUIRIES REGARDING GENERAL INFOR-M A T I O N O N T H ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-13 TECHNICAL INFORMATIONS PRODUCT DESCRIPTION The TRASMITAL BONFIGLIOLI gear motors of the seriesdescribed in this manual are designed and built for appli-cation as track drive for crawled machines equipped withopen loop hydraulic circuit. T...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-15 Legend: Figure 3-23. 1 M10x1 Filling and draining oil plug 2 M10x1 Level oil plug P1 - P2 3/8“ G 19 TPI (depth 14 mm) Motor port

SECTION 3 - CHASSIS & TURNTABLE 3-16 – JLG Lift – 3121448 INSTALLATION INFORMATIONS INSTALLATION PROCEDURE Before proceeding with installation, follow the instructionsgiven below. 1. Properly clean the product by removing packagingand all remains of protection padding. 2. Prepare the parts to be...

SECTION 3 - CHASSIS & TURNTABLE 3-18 – JLG Lift – 3121448 8. Rotate the gearbox housing, so that the plug (1) ison the top of the cover. 9. Unscrew the two plugs (1-2) and fill from the upperhole until the oil flows out from the hole (2). 10. Tighten the oil plugs (1-2) and let the gearbox run.A...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-19 FIRST START UP AND RUNNING IN In this first stage it is advised to follow the measures givenbelow. 11. Bleed air from every part of the hydraulic circuit andadd oil in the tank if necessary. INFORMATION THE PRESENCE OF RESIDUAL AIR IN THE...

SECTION 3 - CHASSIS & TURNTABLE 3-20 – JLG Lift – 3121448 TROUBLESHOOTING The following table is a guideline to identify the troubles inthe track drive. Table 3-5. Anomalies Causes Remedies External oil leakage: From the lifetime seal a) Lifetime damaged a) Replace lifetime seal From the end cov...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-21 MOTORGEARBOX DISASSEMBLY In the case that it was necessary to undergo a (partial ortotal) revision, it will be necessary to dismount the gear-motor from the machine. As this is known as an out of theordinary maintenance procedure, it is i...

SECTION 3 - CHASSIS & TURNTABLE 3-26 – JLG Lift – 3121448 DISASSEMBLING METHOD Initial inspection can be made without disassembling thesprocket and the track drive from the machine.Beforetrack drive disassembling, make sure that the oil is dis-charge. GEARBOX DISASSEMBLY 1. Unscrew the 4 socket ...

SECTION 3 - CHASSIS & TURNTABLE 3-30 – JLG Lift – 3121448 20. By using pliers remove the circlip (8) from its seat inthe flanged hub (15). Figure 3-53. NOTE: In order to proceed with the gearbox disassembly, it is now necessary to remove it from the ma-chine andbring it to a properly equipped wo...

SECTION 3 - CHASSIS & TURNTABLE 3-32 – JLG Lift – 3121448 HYDRAULIC MOTOR DISASSEMBLY 1. Unscrew the 2 socket head screws M5x40 (55)grade 10.9, which fix the counterbalance valve to thehydraulic motor. Figure 3-61. 2. Remove the counterbalance valve. Figure 3-62. 3. Place the hydraulic motor on ...

SECTION 3 - CHASSIS & TURNTABLE 3-34 – JLG Lift – 3121448 11. Reverse the hydraulic motor body (36a) and ham-mer on the shaft 36b. Figure 3-71. 12. You must present the case. Figure 3-72. 13. Remove distributor shaft bearing (34) the fifth wheelshim (32) and the cover (31) . Figure 3-73. 14. Rem...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-35 COUNTERBALANCE VALVE DISASSEMBLY 1. Remove the O-Ring seals (49-50) from their seat inthe valve housing (56). Figure 3-77. 2. Fix the valve (56) without damaging the motormatching surface and uscrew the valve plugs (48). Figure 3-78. 3. R...

SECTION 3 - CHASSIS & TURNTABLE 3-36 – JLG Lift – 3121448 5. Remove the spool (53) by sliding it and remove thespring seat (47). Figure 3-81. 6. Remove the other spring seat (47). Figure 3-82. 7. View of the loose valve components. INFORMATION THE DISASSEMBLY ENDS WITH THE ABOVE OPERA-T I O N . ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-37 Reassembling method COUNTERBALANCE VALVE REASSEMBLY 1. Slide the spool (53) into the valve housing (56). Figure 3-84. 2. Insert the spring seats (47) into the valve housing(56). Figure 3-85. 3. Insert the springs (46) into the valve housi...

SECTION 3 - CHASSIS & TURNTABLE 3-38 – JLG Lift – 3121448 6. Assemble the O-ring seals (49-50) in their seats inthe valve housing (56). Figure 3-89. HYDRAULIC MOTOR REASSEMBLY 7. Place the motor housing (36a) on the support withthe output side upwards. If removed, apply Loctite542 on the plug (4...

SECTION 3 - CHASSIS & TURNTABLE 3-40 – JLG Lift – 3121448 BECAUSE OF THE VERY TIGHT CLEARANCE, CLEAN THE PARTSV E R Y W E L L A N D G U I D E T H E S H A F T C A R E F U L L Y I N T O T H EMOTOR HOUSING TO PREVENT IT FROM TILTING. Figure 3-97. 15. Insert the 6 socket head screws M6x12 (30), grad...

SECTION 3 - CHASSIS & TURNTABLE 3-44 – JLG Lift – 3121448 31. Connect P1 and P2 ports to an hydraulic power unitwith 10 l/min oil flow and run the motor unloaded. Figure 3-115. INFORMATION WHILE THE MOTOR IS RUNNING UNLOADED, COM-P L E T E T H E T I G H T E N I N G O F T H E H E X A G O N A LHEA...

SECTION 3 - CHASSIS & TURNTABLE 3-54 – JLG Lift – 3121448 TECHNICAL INFORMATION PRODUCT DESCRIPTION The BONFIGLIOLI TRASMITAL motor gearboxes of theseries described in this manual are designed and built forapplication as track drive for crawled machines equippedwith open loop hydraulic circuit. ...

SECTION 3 - CHASSIS & TURNTABLE 3-56 – JLG Lift – 3121448 Figure 3-157. 1 G 3/8” Oil filling and draining plug 2 G 3/8” Oil level plug P1 - P2 3/4 - 16 UNF-2B Service port T1 - T2 9/16 - 18 UNF-2B Drain port Ps 9/16 - 18 UNF-2A 37° 2 speed control port a1 - a2 9/16 - 18 UNF Pressure gauge port

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-57 INSTALLATION INFORMATION INSTALLATION PROCEDURE Before proceeding with installation, follow the instructionsgiven below. • Properly clean the product by removing packaging and all remains of protection padding. • Prepare the parts to be c...

SECTION 3 - CHASSIS & TURNTABLE 3-58 – JLG Lift – 3121448 Installation of the track drive on the machine INFORMATION T H E E N T I R E I N S T A L L A T I O N P R O C E S S M U S T B EP L A N N E D A S E A R L Y A S T H E G E N E R A L D E S I G NP H A S E O F T H E M A C H I N E . T H E P E R S...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-59 Hydraulic system connection 12. Make sure that the entire hydraulic system meetsthe cleaning standard as given in level 9 accordingNAS 1638 or 22/18/15 ISO/DIS 4406. INFORMATION C L E AN H O S E S T H O RO UG H L Y P R IO R T O C O N NE C...

SECTION 3 - CHASSIS & TURNTABLE 3-60 – JLG Lift – 3121448 Gearbox lubrication The motor and the gearbox have separate lubrication. Thegearbox is lubricated by oil splashing. The recommended oil type should have EP characteristics according to MIL-L-2105 C & API GL5. – For standard conditions...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-61 Oil filling BEFORE THE STARTING UP, CHECK THE LEVEL OF LUBRICATINGOIL. IF NECESSARY, REFILL WITH LUBRICANT OIL. This procedure is undertaken following the indicationsgiven below. 1. Check that the gearbox axis is horizontal. Rotate thegea...

SECTION 3 - CHASSIS & TURNTABLE 3-62 – JLG Lift – 3121448 First start up and running in In this first stage it is advised to follow the measures givenbelow: 1. Check the correctly lubrication of the unit. 2. Fill the motor housing with hydraulic oil from thedrain port (T1) (see the following pic...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-63 MAINTENANCE INFORMATION PERIODIC MAINTENANCE The gearmotor only requires the scheduled maintenanceprocedures set out by the manufacturer (see table below). Good maintenance will ensure an on going functioning intime as well as maximum rel...

SECTION 3 - CHASSIS & TURNTABLE 3-64 – JLG Lift – 3121448 OIL DRAINING AND REPLACEMENT 11. Check that the gearbox axis is horizontal. Rotate thegearbox housing until the plug (1) is on the bottomof the vertical axis of the end cover. REMOVE THE OIL PLUGS WITH CARE. WHEN THEGEARBOX IS WARM, THE A...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-65 Troubleshooting The following table is a guideline to identify the troubles inthe track drive. Anomalies Causes Remedies External oil leakage : From the lifetime seal a)Lifetime damaged a)Replace lifetime seal From the end cover a)O-ring ...

SECTION 3 - CHASSIS & TURNTABLE 3-66 – JLG Lift – 3121448 DISASSEMBLY In the case that it was necessary to undergo a (partial ortotal) revision, it will be necessary to dismount the gear-motor from the machine. As this is known as an out of theordinary maintenance procedure, it is important that...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-69 Gearbox disassembly Initial inspection of the gears, can be made without disas-sembling the track and the track drive from the machine. INFORMATION T H E C O M P O N E N T S C A N B E V E R Y H E A V Y A N DLARGE DIMENSIONS: PAY ATTENTION...

SECTION 3 - CHASSIS & TURNTABLE 3-72 – JLG Lift – 3121448 16. By using a puller and a metal stopper, remove thebearing (12) from the gearbox housing (10). Figure 3-179. 17. Remove the bearing (12) from the gearbox housing(10). Figure 3-180. Hydraulic motor disassembly ANTICAVITATION VALVE DISASS...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-81 64. By using a puller, take out the bearing (M8) from themotor shaft (M9). 65. By using a screwdriver remove the back-up ring (21)from its seat in the flanged hub (18). INFORMATION D I S A S S E M B L E T H E B A C K - U P R I N G ( 2 1 )...

SECTION 3 - CHASSIS & TURNTABLE 3-82 – JLG Lift – 3121448 Reassembling Method REASSEMBLY OF MOTOR SHAFT AND CYLINDER BLOCK 1. Place the seal ring (M7) into its seat in the flanged hub(M2). 2. Apply a coat of grease on the seal ring (M7). 3. By using the tool (ATZ.06.027) and a rubber hammerpush ...

SECTION 3 - CHASSIS & TURNTABLE 3-92 – JLG Lift – 3121448 Gearbox reassembly 1. Place the bearing (12) inside the gearbox housing (10). 2. By using a press and a metal stopper, push the bearing(12) against the shoulder on the gearbox housing (10)until assembly is complete. 3. By using pliers fit...

SECTION 3 - CHASSIS & TURNTABLE 3-96 – JLG Lift – 3121448 20. By using a rubber hammer push the cover (4) againstthe gearbox housing shoulder (10). 21. Fit the elastic ring (1) into its seat in the gearbox hous-ing (10). 22. Fill the gearbox with the lubricant oil. Insert the plugs (2) into the ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-97 3.7 DRIVE HUB - EATON TR* series Orbit Motor Maintenance Manual INTRODUCTION This manual shows the way of disassembly and reassem-bly of TR* series ORBIT MOTOR . Please see the attachedpapers, Assembly drawing: TRCV49C2204-A (AZ7663B) Too...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-99 Remove the Valve ass’y (17). Remove the bolt (29) and Endcover ass’y (36). Don’t disassembly Endcover ass’y if not necessary. Don’tdisassembly Spindle / wheel ass’y if not necessary. If Bearing (11) and Floating seal (8) are broken, pleas...

SECTION 3 - CHASSIS & TURNTABLE 3-100 – JLG Lift – 3121448 Install the O-ring (31), (32). Install the Endcover ass’y (36), and the bolts (29). Alignfour holes the wheel ass’y with the Endcover. Torque all 4 bolts alternately to 35 N-m. Pour the Gear oil into the Spindle / wheel ass’y (5). Quanti...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-101 Please mark to Valve ass’y(17). Install the Valve ass’y (17) in the wheel ass’y. Align the Pin(23) with the hole. Install the X-ring (26) in the wheel ass’y. Please attend these holes. Install the O-ring (31) in the valve plate (15). Pin...

SECTION 3 - CHASSIS & TURNTABLE 3-102 – JLG Lift – 3121448 Install the Valve plate (15) on the wheel ass’y. Install the Drive (24) into the motor. Align the marked spline with the Valve’s marking. Align themarked spline with the above Valve plate holes. Please attend these holes and top of Star....

SECTION 3 - CHASSIS & TURNTABLE 3-104 – JLG Lift – 3121448 Troubleshooting Condition Cause Correction Motor will not turn No oil Pomp broken Relief valve stuck open or set too low Fill reservoir to proper oil level.Replace pump. Clean and free relief valve spool and Adjust to proper setting. Slo...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-105 3.8 SWING DRIVE (IMO) TECHNICAL DATA – TYPE PLATE Figure 3-181. Type plate The type plate is on the housing and contains the follow-ing information: • Manufacturer• Drawing no./type• Identification code consisting of:• Order number, year...

SECTION 3 - CHASSIS & TURNTABLE 3-106 – JLG Lift – 3121448 TRANSPORTING UNPACKED SLEW DRIVES Figure 3-183. Use suitable lifting gear/never transport product vertically Unpacked slew drives can be transported with lifting gearwhen using eye bolts under the following conditions • The lifting gear ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-107 INSTALLATION AND COMMISSIONING Preparation Cleaning the slew drive and mounting structure Wear the following additional protective equipment forcleaning work: Face protection to protect the eyes and face from solvents. Chemical-resistant...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-109 Figure 3-188. Permissible flatness deviation of the mounting structure δ p = flatness deviation max. δ p = maximum flatness deviation U = circumference • The maximum residual value for flatness deviation δ p in the circumferential direct...

SECTION 3 - CHASSIS & TURNTABLE 3-110 – JLG Lift – 3121448 δ w = perpendicularity deviation B = flange width • The permissible perpendicular deviation dw (tilting) is based on the actual flange width and should only behalf of the values from the tables below. Figure 3-190. Drawing number The siz...

SECTION 3 - CHASSIS & TURNTABLE 3-112 – JLG Lift – 3121448 Permissible deformation of the mounting structure,under maximum load for series WD-H slew drives IMPORTANT AXIAL DEFLECTION, TILTING, RADIAL EXTENSION( O R R A D I A L C O N T R A C T I O N ) O F T H E M O U N T I N GSTRUCTURE UNDER MAX....

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-113 M O U N T I N G S T R U C T U R E S W I T H F R A C T U R ESTRENGTH UNDER 500 N/MM² OR 72520 LBS/IN² AREPROHIBITED. ds = bolt diameter lk = grip length le = insertion depth Permissible interfacial pressure for various materials TIGHTENIN...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-115 POSITIONING THE SLEW DRIVE 1. Determine the main load-carrying zone. The mainload-carrying zone is that area of the slewing ringthat is subject to the highest load, taking all aggres-sive forces and torques, and all occurring loadcases i...

SECTION 3 - CHASSIS & TURNTABLE 3-118 – JLG Lift – 3121448 MAINTENANCE SCHEDULE Maintenance tasks are described in the sections belowthat are required for optimal and trouble-free operation. If increased wear is detected during regular inspections,then reduce the required maintenance intervals a...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-119 If comparable results are not available, the following tablecan be used as a guide value: The specified values are valid for the following conditions: • Operating temperature on the slew drive < 70° C (158° F). • Circumferential speed...

SECTION 3 - CHASSIS & TURNTABLE 3-120 – JLG Lift – 3121448 MAINTENANCE TASKS INSPECTING THE MOUNTING BOLTS IMPORTANT TO COMPENSATE FOR SETTLING, THE BOLTS MUSTBE RET IG H T ENE D WITH THE P RE SC R IBED TIG H T-E N I N G T O R Q U E . R E T I G H T E N I N G M U S T B E E X E -C U T E D W I T H ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-121 LUBRICATING THE SLEW DRIVE IMPORTANT R E G U L A R L Y L U B R I C A T E T H E S L E W D R I V E S T OPROLONG THEIR SERVICE LIFE AND ENSURE SAFEOPERATION. IMPORTANT ALWAYS USE THE LUBRICANTS SPECIFIED IN THEO R D E R D R A W I N G . I F ...

SECTION 3 - CHASSIS & TURNTABLE 3-122 – JLG Lift – 3121448 3.9 HONDA ENGINE GX270 - GX390 SPECIFICATIONS SERIAL NUMBER LOCATION The engine serial number (1), type (2) and model (3) isstamped on thecrankcase.Refer to it when ordering partsor making technical inquiries. (1) (2) (3)

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-123 ENGINE SPECIFICATIONS *1: The power rating of the engine indicated in this docu-ment is the net power output tested on a productionengine for the engine model and measured in accordancewith SAE J1349 at 3,600 rpm (net power) and at 2,500...

SECTION 3 - CHASSIS & TURNTABLE 3-124 – JLG Lift – 3121448 SERVICE INFORMATION TORQUE VALUES ENGINE TORQUE VALUES STANDARD TORQUE VALUES Item Tread Dia. (mm) Torque values N·m kgf·m lbf·ft Crankcase cover bolt M8 x 1.25 24 2.4 17 Cylinder head bolt M10 x 1.25 35 3.5 26 Oil drain plug bolt M12 x ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-125 HARNESS AND TUBE ROUTING Connection of regulator/rectifier, charge/lamp coil, subwire harness, and auto throttle solenoid are depending onthe application of the engine, therefore, it does not indi-cate those parts in this manual. COMBINA...

SECTION 3 - CHASSIS & TURNTABLE 3-126 – JLG Lift – 3121448 ALL TYPE ENGINE WIRE HARNESS IGNITION COIL CYLINDER BARREL RIB FUEL TUBE BREATHER TUBE CARBURETOR INSULATOR CONTROL BASE ASSY. CONTROL BASE ASSY. GOVERNOR ARM TUBE CLIP HIGH-TENSION CORD HIGH-TENSION CORD

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-127 WITH CHARGE COIL / LAMP COIL 12 V-50 W LAMP COIL TYPE: 18A CHARGE COIL TYPE: CORD CLAMPER CORD GROMMET COIL CORD CORD CLAMPER CORD GROMMET COIL CORD CORD CLAMPER CORD GROMMET COIL CORD 12 V - 15 W / 12 V-25 W LAMP COIL TYPE: 1 A / 3 A CH...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-129 ENGINE OIL LEVEL CHECK Place the engine on a level surface. Remove the oil filler cap (1), and wipe the oil level gauge(2) clean. Insert the oil filler cap without screwing it into the oil fillerneck (3). Remove the oil filler cap and ch...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-131 INNER FILTER (PAPER) TYPE: Tap the inner filter (1) lightly several times on a hard sur-face to remove excess dirt, or blow compressed air lightly(207 kPa (2.11 kgf/cm 2 , 30 psi) or less) through the paper filter from the inside out. Ne...

SECTION 3 - CHASSIS & TURNTABLE 3-132 – JLG Lift – 3121448 SPARK PLUG CHECK/ADJUSTMENT IF THE ENGINE HAS BEEN RUNNING, THE ENGINE WILL BE VERYHOT. ALLOW IT TO COOL BEFORE PROCEEDING. Remove the spark plug cap, and then remove the sparkplug (1) using a spark plug wrench (2). Visually check the sp...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-133 A LOOSE SPARK PLUG CAN BECOME VERY HOT AND CAN DAM-A G E T H E E N G I N E . O V E R T I G H T E N I N G C A N D A M A G E T H ETHREADS IN THE CYLINDER BLOCK. INSTALL THE SPARK PLUGCAP SECURELY. SPARK ARRESTER CLEANING THE ENGINE AND THE...

SECTION 3 - CHASSIS & TURNTABLE 3-134 – JLG Lift – 3121448 VALVE CLEARANCE CHECK/ADJUSTMENT Remove the head cover bolt (1), the head cover (2),andthe head cover packing (3). Disconnect the spark plug cap from the spark plug. Set the piston near top dead center of the cylinder com-pression stroke...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-135 COMBUSTION CHAMBER CLEANING Remove the cylinder head (page 13-3). Clean any carbon deposits from the combustion chamber(1). (2) (2) To increase valve clearance: screw out. To decrease valve clearance: screw in. (1) VALVE STEM (1)

SECTION 3 - CHASSIS & TURNTABLE 3-136 – JLG Lift – 3121448 FUEL TANK AND FILTER CLEANING GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CANBE BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL. •KEEP HEAT, SPARKS, AND FLAME AWAY. •HANDLE FUEL ONLY OUTDOORS. •WIPE UP SPILLS IMMEDIATELY. Drain the fu...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-137 TROUBLESHOOTING BEFORE TROUBLESHOOTING •Use a known-good battery for troubleshooting. •Check that the connectors are connected securely. •Check for sufficient fresh fuel in the fuel tank. •Read the circuit tester's operation instructions...

SECTION 3 - CHASSIS & TURNTABLE 3-138 – JLG Lift – 3121448 TROUBLESHOOTING STARTING •Check the engine oil level before troubleshooting. Cranks Does not crank Wet Spark No spark Dry Fuel No fuel Normal With starter motor: Turn the combination switch to the START position and check whether the eng...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-141 ENGINE DOES NOT STOP WHEN COMBINATION/ ENGINE STOP SWITCH IS TURNED OFF • Check the engine oil level before troubleshooting. Check the ignition coil air gap. Adjust the ignition coil air gap. Check the ignition coil. Replace the ignition...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-143 COVER COVERFAN COVER REMOVAL/INSTALLATION Remove the recoil starter. Remove the auto throttle (If equipped). Open the harness clip and disconnect the engine stopswitch connector (Without control box type). When installing, refer to the H...

SECTION 3 - CHASSIS & TURNTABLE 3-144 – JLG Lift – 3121448 FUEL SYSTEM FUEL FILLER CAP REMOVAL/INSTALLATION Turn the fuel level gauge (1) to align the fuel filler captether hole (2) with the cutout (3) of the fuel filler neck, andthen remove the fuel filler cap (4). Before installing, check the ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-145 FUEL TANK REMOVAL/INSTALLATION (TYPE B) GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE.YOUCAN BEB U R N E D O R S E R I O U S L Y I N J U R E D W H E N H A N D L I N G F U E L .•KEEP HEAT, SPARKS, AND FLAME AWAY. •HANDLE FUEL ONLYOUTDOORS. •...

SECTION 3 - CHASSIS & TURNTABLE 3-146 – JLG Lift – 3121448 AIR CLEANER REMOVAL/INSTALLATION Dual element type: CHOKE CONTROL STAY SLANT OUT SIDE NOISE SILENCER AIR CLEANERELBOW SEAL COLLAR WASHER BOLT (6 x 22 mm) GROMMET HIGH TENSION CORD 9 N·m (0.9 kgf·m, 6.6 lbf·ft) REMOVAL/INSTALLATION: Remov...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-147 CARBURETOR REMOVAL/INSTALLATION Dual element or cyclone type air cleaner: GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE.YOUCAN BEB U R N E D O R S E R I O U S L Y I N J U R E D W H E N H A N D L I N G F U E L .•KEEP HEAT, SPARKS, AND FLAME ...

SECTION 3 - CHASSIS & TURNTABLE 3-148 – JLG Lift – 3121448 CARBURETOR DISASSEMBLY/ASSEMBLY Dual element or cyclone type air cleaner: GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE.YOUCAN BEB U R N E D O R S E R I O U S L Y I N J U R E D W H E N H A N D L I N G F U E L .•KEEP HEAT, SPARKS, AND FLAME ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-149 CHOKE CONTROL STAY DISASSEMBLY/ASSEMBLY Remove the choke diaphragm. WIRE HOLDER CABLE HOLDER RETURN SPRING CHOKE CONTROL STAY CIRCLIP (5 mm) PAN SCREW (4 x 6 mm) WASHER SCREW (5 x 16 mm)

SECTION 3 - CHASSIS & TURNTABLE 3-150 – JLG Lift – 3121448 CHOKE DIAPHRAGM DISASSEMBLY/ASSEMBLY MANUAL CHOKE ROD RETURN SPRING CHOKE LEVER CHOKE DIAPHRAGM CHOKE ROD STOPPER CHOKE ROD GUIDE CHOKE ROD GROMMET CHOKE LEVER ROD ROD JOINT DIAPHRAGM STAY ARM PIVOT BUSH LEVER COLLAR E RING THRUST WASHER...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-151 CARBURETOR BODY CLEANING TO PREVENT SERIOUS EYE INJUR Y, ALWAYS WEAR SAFETYG O G G L E S O R O T H E R E Y E P R O T E C T I O N W H E N U S I N G C O M -PRESSED AIR. SOME COMMERCIALLY AVAILABLE CHEMICAL CLEANERS AREV E R Y C A U S T I C...

SECTION 3 - CHASSIS & TURNTABLE 3-152 – JLG Lift – 3121448 CARBURETOR INSPECTION FLOAT LEVEL HEIGHT Place the carburetor in the position as shown. Measurethe distance between the float top and carburetor bodywhen the float just contacts the seat without compressingthe valve spring. TOOL: Float l...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-153 CHOKE DIAPHRAGM INSPECTION Check for smooth operation by pressing the rod with a fin-ger. Connect a vacuum pump to the choke diaphragm andapply vacuum. The diaphragm should hold.Replace the choke dia-phragm if necessary. PILOT SCREW REPL...

SECTION 3 - CHASSIS & TURNTABLE 3-154 – JLG Lift – 3121448 GOVERNOR SYSTEM GOVERNOR SYSTEMGOVERNOR ARM/CONTROL BASE ASSY. REMOVAL/INSTALLATION MANUAL OPERATION TYPE Remove the following parts. 1.Air cleaner2.Muffler3.Fuel tank4.Tube clamp Installation is in the reverse of removal.Adjust the maxi...

SECTION 3 - CHASSIS & TURNTABLE 3-156 – JLG Lift – 3121448 CONTROL BASE ASSY. DISASSEMBLY/ASSEMBLY MANUAL OPERATION TYPE Remove the control base assy. CONTROL LEVER SCREW (5 x 32 mm) CONTROL BASE CABLE RETURN SPRING INSTALLATION:Install with the short end of the spring toward the control base. H...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-157 MAXIMUM SPEED ADJUSTMENT Remove the fuel tank. Loosen the 6 mm nut (1) of the governor arm. Turn the governor arm (2) counter clockwise to fully openthe carburetor throttle valve (3). Rotate the governor arm shaft (4) as far as it will g...

SECTION 3 - CHASSIS & TURNTABLE 3-158 – JLG Lift – 3121448 CHARGING SYSTEM SYSTEM DIAGRAM ( W ) Gr Gr ( Gr ) ( Gr ) W W Bl Gr Gr Gr Gr Bl/Y W Bl W/Bu ( Bl ) (W) (W) (W) 3 C10 C9 C8 T2 T3 C11 T1 T4 CONTROL BOX STARTER MOTOR BATTERY CHARGE COIL REGULATOR/ RECTIFIER 4 6 1 2 3 5 ( Gr ) Gr ( W ) W 1 ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-159 BEFORE TROUBLESHOOTING • Use a known-good battery for troubleshooting.• Check that the connectors are connected securely.• Read the circuit tester's operation instructions carefully, and observe the instructions during inspection. • Disc...

SECTION 3 - CHASSIS & TURNTABLE 3-160 – JLG Lift – 3121448 COOLING FAN/FLYWHEEL REMOVAL/INSTALLATIONREMOVAL Remove the following parts: –Fan cover. –Ignition coil. FLYWHEEL SPECIAL NUT (16 mm) COOLING FAN STARTER PULLEY SPECIAL WOODRUFF KEY (25 x 18 mm) REMOVAL: Hold the flywheel with a commerci...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-161 INSTALLATION Clean the tapered parts (1) of dirt, oil, grease, and otherforeign material before installation. Be sure there arenome tal parts or other foreign material on the magnetpart(2) of the flywheel. Set the 25 x 18 mm special wood...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-163 CHARGE COIL INSPECTION 10 A / 18 A CHARGE COIL /12 V-15W /12 V-25 W LAMPCOIL TYPE Disconnect the charge/lamp coil connectors. Measure the resistance between the terminals of thecharge/lamp coil. Resistance: charge coil 10 A:0.16 - 0.24 ....

SECTION 3 - CHASSIS & TURNTABLE 3-164 – JLG Lift – 3121448 IGNITION SYSTEM IGNITION SYSTEMSYSTEM DIAGRAM LED OIL_AL T EXT ( + ) ST EXT ( + ) EXT ( - ) BA T EXT ( - ) R Bl Y ( Y ) ( R ) ( R ) ( Bl ) ( R ) ( Bl ) ( Bl ) C2 C1 1 4 3 1 2 C3 COMBINATION SWITCH IGNITION COIL SPARK PLUG OIL LEVEL SWITC...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-165 IGNITION SYSTEM TROUBLESHOOTING NO SPARK AT SPARK PLUG •Check the engine oil level before troubleshooting. Replace the engine stop switch /combination switch. Check the harness connecting the ignition coil and the combination/the engine ...

SECTION 3 - CHASSIS & TURNTABLE 3-166 – JLG Lift – 3121448 IGNITION COIL REMOVAL/INSTALLATION Remove the following parts: –Air cleaner –Fuel tank –Fan cover ENGINE WIRE HARNESS SPARK PLUG CAP INSTALLATION:Clamp the engine wire harness to the ribs of the cylinder barrel as shown. ENGINE WIRE HARN...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-167 IGNITION COIL INSTALLATION Attach the ignition coil (1) and loosely tighten the two 6x28 mm flange bolts (2). I n s e r t t h e t h i c k n e s s g a u g e ( 3 ) o f p r o p e r t h i c k n e s sbetween the ignition coil and the flywheel...

SECTION 3 - CHASSIS & TURNTABLE 3-168 – JLG Lift – 3121448 IGNITION COIL INSPECTION D i s c o n n e c t t h e s p a r k p l u g c a p f r o m t h e s p a r kplug.Remove the spark plug cap from the high tensioncord(1). Disconnect the engine wire harness connector (2) fromthe ignition coil. Measur...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-169 STARTING SYSTEM SYSTEM DIAGRAM EXT ( - ) BA T EXT ( + ) C4 T1 T2 T3 COMBINATION SWITCH MAINE FUSE (5A BLADE TYPE) STARTER MOTOR BATTERY ST ( Bl/W ) ( W ) ( Bl/W ) ( W ) ( W ) ( W ) (15A BLADE TYPE) (25A BLADE TYPE) CONTROL BOX Bl Black Y...

SECTION 3 - CHASSIS & TURNTABLE 3-170 – JLG Lift – 3121448 STARTING SYSTEM TROUBLESHOOTING STARTER MOTOR DOES NOT OPERATE Replace the blade fuse. Replace the combination switch. Replace with a known-good battery. If the battery runs down again, perform the CHARGING SYSTEM TROUBLESHOOTING. Replac...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-171 RECOIL STARTER REMOVAL/INSTALLATION FLANGE BOLT (6 x 10 mm) RECOIL STARTER LOW PROFILE AIR CLEANER TYPE: DUAL ELEMENT / CYCLONE AIR CLEANER TYPE: TOP TOP INSTALLATION:Install the recoil starter as shown. QDW9 / QHB4 TYPE: TOP

SECTION 3 - CHASSIS & TURNTABLE 3-172 – JLG Lift – 3121448 RECOIL STARTER DISASSEMBLY TO PREVENT SERIOUS EYE INJUR Y, ALWAYS WEAR SAFETYG O G G L E S O R O T H E R E Y E P R O T E C T I O N W H E N U S I N G C O M -PRESSED AIR. Remove the recoil starter. CENTER SCREW SPRING RETAINER FRICTION SPR...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-173 RECOIL STARTER ASSEMBLY TO PREVENT SERIOUS EYE INJUR Y, ALWAYS WEAR SAFETY-G O G G L E S O R O T H E R E Y E P R O T E C T I O N W H E N U S I N G C O M -PRESSED AIR. Pass the recoil starter rope (1) through the hole (2) of therecoil sta...

SECTION 3 - CHASSIS & TURNTABLE 3-174 – JLG Lift – 3121448 Apply grease to the two ratchets (1). Install the two ratchets and the two ratchet springs (2)tothe recoil starter pulley as shown. Apply grease to the inside of the spring retainer (1). Set the friction spring (2) and the spring retaine...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-175 RECOIL STARTER INSPECTION RECOIL STARTER OPERATION Remove the recoil starter (page 10-3).Pull the starter gripseveral times to inspect that the ratchets (1) are operatedproperly (the ratchet ends come out from the springretainer (2). STA...

SECTION 3 - CHASSIS & TURNTABLE 3-176 – JLG Lift – 3121448 STARTER MOTOR REMOVAL/INSTALLATION Disconnect the starter motor wires from the starter motor. Remove the fan cover. STARTER MOTOR FLANGE BOLT (8 x 35 mm) STARTER MOTOR STARTER SOLENOID WIRE

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-177 STARTER MOTOR DISASSEMBLY/ASSEMBLY Remove the starter motor. STARTER SOLENOID WIRE CENTER BRACKET DRIVE SIDE HOUSING SCREW WASHER (5 x 32 mm) (4) HOUSING ARMATURE ASSEMBLY:Make sure there is no obstruction on the magnets. SCREW WASHER(4 ...

SECTION 3 - CHASSIS & TURNTABLE 3-178 – JLG Lift – 3121448 BRUSH HOLDER INSTALLATION Note the installation direction. Install the insulator (1), brush holder (2), negative brushterminals (3), and two 4 x 14 mm screws (4) to the centerbracket as shown. Install the brush springs (5) and brushes, a...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-179 BRUSH CONTINUITY CHECK Check for continuity between the positive (+) brushes(1)and negative (-) brushes (2). There should be continuity between both the positive-brushes.There should be continuity between both thenegativebrushes.There sh...

SECTION 3 - CHASSIS & TURNTABLE 3-180 – JLG Lift – 3121448 OVERRUNNING CLUTCH Check the pinion gear shaft (1) for smooth axial move-ment. Apply oil or replace the overrunning clutch if necessary. Check the pinion gear (2) operation by holding the piniongear shaft and turning the pinion gear. The...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-181 OTHER ELECTRICAL COMPONENT LOCATION CONTROL BOX OIL LEVEL SWITCH ENGINE STOP SWITCH (If equipped)

SECTION 3 - CHASSIS & TURNTABLE 3-182 – JLG Lift – 3121448 CONTROL BOX REMOVAL/INSTALLATION Disconnect the control box wires. When installing, refer to the HARNESS AND TUBE ROUT-ING (with circuit protector). CONTROL BOX (Without Circuit Protector) IGNITION COIL WIRES STARTER SOLENOID WIRE FLANGE...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-183 CONTROL BOX DISASSEMBLY/ASSEMBLY Remove the control box. PROTECTOR LENS(If equipped) CASE MOUNTING BRACKET 18A REGULATOR/RECTIFIER(If equipped) 10A REGULATOR/RECTIFIER(If equipped) SILICON RECTIFIER(If equipped) SHORT LONG CIRCUIT PROTEC...

SECTION 3 - CHASSIS & TURNTABLE 3-184 – JLG Lift – 3121448 OIL LEVEL SWITCH INSPECTION Disconnect the engine wire harness from the oil levelswitch. Check continuity between the switch terminal and engineground.There should be no continuity when the engine isfull of oil. Drain the engine oil comp...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-185 Without Circuit Protector Check continuity between the terminals at each switchposition. If the correct continuity is not obtained, replace the combi-nation switch. SILICON RECTIFIER INSPECTION Remove the silicon rectifier. Check continu...

SECTION 3 - CHASSIS & TURNTABLE 3-186 – JLG Lift – 3121448 REGULATOR/RECTIFIER INSPECTION Measure the resistance between the terminals and besure that the measurements conform to the ranges shownin the table. 10A TYPE 18A TYPE Use a tester that is equivalent to or higher than the perfor-mance sp...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-187 MUFFLER REMOVAL/INSTALLATION T H E M U F F L E R B E C O M E S V E R Y H O T D U R I N G O P E R A T I O NANDREMAINS HOT FOR A WHILE AFTER STOPPING THE ENGINE.BE CAREFUL NOT TO TOUCH THE MUFFLER WHILE IT IS HOT.AL-LOW IT TO COOL BEFORE P...

SECTION 3 - CHASSIS & TURNTABLE 3-188 – JLG Lift – 3121448 CYLINDER HEAD/VALVES CYLINDER HEAD/VALVES INSPECTION CYLINDER COMPRESSION CHECK Start the engine and warm up to normal operatingtemper-ature.Turn the fuel valve lever to the OFF position, andthen remove the drain screw to drain the carbu...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-189 CRANKCASE COVER REMOVAL/INSTALLATION E TYPE Drain the engine oil. BOTTOM RUBBER (SMALL) BOTTOM RUBBER (LARGE) (2) DUCT COVER BOLT (5 x 10 mm) (3) (If equipped) DOWEL PIN (8 x 12 mm) (2) CASE COVER PACKING CRANKCASE COVER OIL FILLER CAP O...

SECTION 3 - CHASSIS & TURNTABLE 3-190 – JLG Lift – 3121448 WIRING DIAGRAMS

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-191 WIRING DIAGRAMSHOW TO READ A WIRING DIAGRAM & RELATED INFORMATION The wiring diagram, connector general layout drawing,connector drawings, and the symbols used in trouble-shooting are explained in this section. HOW TO READ CONNECTOR ...

SECTION 3 - CHASSIS & TURNTABLE 3-192 – JLG Lift – 3121448 HOW TO READ WIRING DIAGRAM 1 2 C1 4 5 GND2 T1 T2 1 2 13 10 11 3 C8 C7 1 2 5 34 6 7 10 9 1 2 5 4 6 7 10 123 121 234 91 25 3 4 87 10 12 9 25 47 10 123 4 1 6 12 C10 C9 T8 T6 T7 T5 T3 T4 G G/W G/R G/Bl R/W Br Br Y G G R R R R W W W R B l / R...

SECTION 3 - CHASSIS & TURNTABLE 3-194 – JLG Lift – 3121448 QUICK TROUBLESHOOTING HONDA GX270 - GX390 • HOW TO START ON THE THERMIC ENGINE WITH- OUT THE BOARD CONNEXION 1 2 3 4 5 6 7 7

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-195 3.10 HONDA ENGINE IGX440 SERIAL NUMBER LOCATION The engine serial number is stamped on the cylinder bar-rel. Refer to this when ordering parts or making technicalinquiries. ENGINE SERIEL NUMBER

SECTION 3 - CHASSIS & TURNTABLE 3-196 – JLG Lift – 3121448 SPECIFICATIONS DIMENSIONS AND WEIGHT ENGINE Model iGX440U PTO types S Q V Overall length 407 mm (16.0 in) 433 mm (17.0 in) 450 mm (17.7 in) Overall width 505 mm (19.9 in) Overall height 454 mm (17.9 in) Maximum angle of inclination 20° D...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-197 WIRING DIAGRAMS With starter motor and charge coil (20A) type

SECTION 3 - CHASSIS & TURNTABLE 3-198 – JLG Lift – 3121448 TROUBLESHOOTING SELF-DIAGNOSIS AS INDICATED BY THE LED When the battery is disconnected, self-diagnosis with theLED is not possible. The LED for a failure flashes periodically, as shown in thefollowing figure. Example: in the case of ...

SECTION 3 - CHASSIS & TURNTABLE 3-210 – JLG Lift – 3121448 COILS AND IGNITION SWITCHES CHECK P. 2-19

SECTION 3 - CHASSIS & TURNTABLE 3-212 – JLG Lift – 3121448 SPARK TEST GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CANBE BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL.KEEP HEAT, SPARKS AND FLAME AWAY. HANDLE FUEL ONLYOUTDOORS. WIPE UP SPILLS IMMEDIATELY. DO NOT OPERATE THE STAR TER MOTOR FOR...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-213 CYLINDER COMPRESSION CHECK 7. Remove the spark plug and spark plug. 8. Turn the throttle control to the HIGH position. 9. With recoil starter type: Pull the recoil starter forcefully several times, andmeasure the cylinder compression. Wi...

SECTION 3 - CHASSIS & TURNTABLE 3-214 – JLG Lift – 3121448 HARNESS ROUTING

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-217 TUBE ROUTING

SECTION 3 - CHASSIS & TURNTABLE 3-218 – JLG Lift – 3121448 MAINTENANCE MAINTENANCE SCHEDULE • Emission related items. (1) For commercial use, log hours of operation to deter-mine proper maintenance intervals. (2) Service more frequently when used in dusty areas. (3) Check the belt for cracks or ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-219 ENGINE OIL Oil level check: 1. Place the engine on a level surface. 2. Turn the oil filler cap counterclockwise 90 degrees tounlock the cap and remove the oil level gauge fromthe oil filler neck. Wipe the oil level gauge clean. 3. Insert...

SECTION 3 - CHASSIS & TURNTABLE 3-220 – JLG Lift – 3121448 Oil change: 5. Check the engine on a level surface and remove theoil filler cap. 6. Remove the oil drain bolt and sealing washer. anddrain the oil into a suitable container. Please dispose of used motor oil in a manner that iscompatible ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-221 air flow through the form element and may causethe engine to smoke at startup. 4. Paper element: Tap the element lightly several timeson a hard surface to remove excess dirt or blowcompressed air lightly 207 kPa (2.1 kgf/cm2, 30 psi)or l...

SECTION 3 - CHASSIS & TURNTABLE 3-222 – JLG Lift – 3121448 5. Install the spark plug fingerings to beat the washer,and then tighten with a plug wrench. If reinstallingthe used spark plug, tighten 1/8-1/4 turf after thespark plug seats. If installing a new spark plug,tighten 1/2 turn after the sp...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-223 VALVE CLEARANCE Inspection/adjustment: Valve clearance inspection and adjustment must be performed with the engine cold. 1. Remove the cylinder head cover. 2. With recoil starter type : Set the piston at top dead center of the compressio...

SECTION 3 - CHASSIS & TURNTABLE 3-224 – JLG Lift – 3121448 4. If adjustment is necessary proceed is follows: a. Hold the tappet adjusting screw using the spe-cial too and loosen the tappet adjusted screwlock nut. b. Turn the tappet adjusting screw to obtain thespecifier clearance. c. Heighten th...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-225 FUEL TUBE Inspection: GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CANBE BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL.KEEP HEATH QUIRK: AND FLAME AWAY. HANDLE FULL ONLYOUTDOORS. WIPE UP SPILLS IMMEDIATELY. • After connecting the fue...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-227 MUFFLER REMOVAL/INSTALLATION THE ENGINE AND MUFFLER BECOME VERY HOT DURING OPERA-TION AND THEY REMAIN HOT FOR A WHILE AFTER OPERATION.BE SURE THE ENGINE IS COOL BEFORE MUFFLER REMOVAL/INSTALLATION. 4. Remove the air cleaner.

SECTION 3 - CHASSIS & TURNTABLE 3-228 – JLG Lift – 3121448 EXHAUST PIPE/MUFFLER PROTECTOR INSTALLATION: 1. Attach a new muffler basket and exhaust pipe to thecylinder head. 2. Move the exhaust pipe all the way to the fuel tankside and tighten the 8 mm flange nuts. 3. Attach a new muffler gasket ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-229 CARBURETOR REMOVAL/INSTALLATION GASOLINE IS HIGH FLAMMABLE AND EXPLOSIVE. YOU CAN BETURNED USURIOUSLY INJURED WHEN HANDLING FUEL. KEEPHEAT, SPARKS IND FLAME AWAY. HANDLE FUEL ONLY OUT-DOORS. WIPE UP SPILLS IMMEDIATELY. • Before removal, ...

SECTION 3 - CHASSIS & TURNTABLE 3-232 – JLG Lift – 3121448 FUEL CUT SOLENOID Measure the resistance between the terminals. When 12V battery voltage is applied, check that the fuelcut solenoid operates normally. Check the extended length of the needle at ON (batteryconnected) position and OFF (ba...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-233 FUEL TANK REMOVAL/INSTALLATION GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE. YOU CANBE BURNED OR SERIOUSLY INJURED WHEN HANDLING FUEL.KEEP HEAT, SPARKS AND FLAME AWAY. HANDLE FUEL ONLYOUTDOORS. WIPE UP SPILLS IMMEDIATELY. Before removal, d...

SECTION 3 - CHASSIS & TURNTABLE 3-234 – JLG Lift – 3121448 DISASSEMBLY/REASSEMBLY Auto fuel valve type only.

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-235 TUBE CLIP INSTALLATION: Install the tube clips as shown. Make sure that the clip anddoes not touch the auto fuel valve or fuel tank. After installing the tank stay, check that the tube clip anddoes not touch the tank stay. INSPECTION AUT...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-237 REASSEMBLY 11. Insert the starter rope end into the. starter reel andtie the rope as shown. 12. Wind the rope onto the reel counterclockwise andhook the starter rope into the cutout of the starterreel. 13. Wind the starter spring and ins...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-239 CONTROL PANEL REMOVAL/INSTALLATION Remove the electric parts cover.

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-241 INSPECTION COMBINATION SWITCH Check continuity between the terminals at each switchposition. Perform this inspection with fuses installed in the switchharness. ENGINE STOP SWITCH Check continuity between the terminals at each switchposit...

SECTION 3 - CHASSIS & TURNTABLE 3-242 – JLG Lift – 3121448 RECTIFIER/REGULATOR RECTIFIER Measure the resistance between the terminals. • Use a tester that is equivalent to or higher than the per- formance specified: Internal resistance: 20 Ω /VDC, 9 Ω /VAC • Be careful not to touch the metallic ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-243 FAN COVER / FLYWHEEL REMOVAL/INSTALLATION 3. Remove the air cleaner and electric parts cover. 4. Remove the recoil starter or fan cover protector. 5. Remove the control panel. 6. Remove the pulser coil.

SECTION 3 - CHASSIS & TURNTABLE 3-244 – JLG Lift – 3121448 FLYWHEEL REMOVAL 7. Hold the flywheel with a commercially availablestrap wrench, and remove the 16 mm special nut. BEFORE ATTACHING THE STRAP WRENCH, REMOVE THE FANCOVER STUD BOLTS AND CRANKSHAFT COWGIRL (CKP) SEN-SOR. DO NOT POSITION TH...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-245 ELECTRIC EQUIPMENT COILS REMOVAL/INSTALLATION 16. Remove the air cleaner and electric party cover. 17. Remove the carburetor. 18. Remove the recoil sterner or fan cover protector. 19. Remove the control panel. 20. Remove the fan coverand...

SECTION 3 - CHASSIS & TURNTABLE 3-246 – JLG Lift – 3121448 COINS

SECTION 3 - CHASSIS & TURNTABLE 3-248 – JLG Lift – 3121448 STARTER MOTOR REMOVAL/INSTALLATION 3. Disconnect the starter motor terminal of the combi-nation switch harness and starter motor battery ter-minal. 4. Remove the harness bracket A. 5. Remove the oil filler extension.

SECTION 3 - CHASSIS & TURNTABLE 3-250 – JLG Lift – 3121448 FRONT BRACKET/REAR BRACKET ASSEMBLY 6. Install the rear bracket lo the armature/yoke by align-ing the brush terminal grommet with the cutout ofthe rear bracket. 7. Attach the pinion drive lever to the starter solenoid.Set the pinion driv...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-251 ARMATURE Mica depth: When the mica is fillers or its depth is smaller than the ser-vice limit value, recut the grooves using: a hacksaw bladeor t small file. Service limit 0.2 mm (0,01 in) Continuity check-commutator segments: Check for ...

SECTION 3 - CHASSIS & TURNTABLE 3-252 – JLG Lift – 3121448 OVERRUNNING CLUTCH 1. Hold the pinion.gear.as shown and check that thegear turns clockwise and slides smoothly. If neces-sary, apply oil or replace the overrunning clutch. 2. Check the pinion gear for wear or damage andreplace if necessa...

SECTION 3 - CHASSIS & TURNTABLE 3-254 – JLG Lift – 3121448 INSPECTION FUEL CUT SOLENOID RECTIFIER Check continuity between the terminals. Use a tester that is equivalent to or higher than the perfor-mance specified: Internal resistance: 20 DNDC, 9 Ω /v AC Be careful not to touch the metallic par...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-255 IGNITION COIL Primary side Measure the resistance between the GND and IGN termi-nals. Secondary side Measure the resistance between the GND terminal andthe sprig in the spark plug cap. Specified resistance 0.16-0.21 Ω Specified resistanc...

SECTION 3 - CHASSIS & TURNTABLE 3-256 – JLG Lift – 3121448 BREATHER VALVE/CRANKSHAFT/BALANCER/PISTON BREATHER VALVE DISASSEMBLY/REASSEMBLY Remove only if necessary for breather valve and breathercover repair. 3. Remove the air cleaner and electric parts cover. 4. Remove the carburetor. 5. Remove...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-257 BREATHER COVER INSTALLATION 8. Clean the old liquid gasket, oil and contaminationfrom the breather cover/crankcase mating surface. 9. Apply a bead (Ø1.0 - 1.5 mm (Ø 0.04-0.06 in)) of theliquid gasket (ThreeBond® 1207B) to the matingsurfa...

SECTION 3 - CHASSIS & TURNTABLE 3-258 – JLG Lift – 3121448 OPERATION STR (SELF TUNING REGULATOR) GOVERNOR T hi s e n gi n e us e s a n e l e c t r on i c c o n tr o l go ve r n or a sopposed to the conventional mechanical governor.TheECM controls various functions to attain high power out-put an...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-259 AUTO CHOKE The ECM automatically controls the choke so that the userdoes not have to perform this task. Since the ECM detectsthe engine temperature, the choke valve position in auto-matically adjusted to its most appropriate opening from...

SECTION 3 - CHASSIS & TURNTABLE 3-260 – JLG Lift – 3121448 AUTO FUEL VALVE The auto fuel valve and crankcase are connected. Vac-u u m p r o d u c e d b y t h e m o v e m e n t o f t h e p i s t o n a n dbreather function while the engine operates opens the dia-phragm inside the fuel valve, letti...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-263 FIRST OPERATION Check fueling from fuel tank to carburetor. Lose drain screw. Let fuel drain. Pull recoil 3 or 4 times. Check fuel coming from fuel tank. If fuel is not coming from fuel tank proceed to replace fuelfilter in fuel tank. Fu...

SECTION 3 - CHASSIS & TURNTABLE 3-264 – JLG Lift – 3121448 SECOND OPERATION IF PROBLEM IS ON ENGINE Spark checking

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-267 DESCRIPTION OF THE ENGINE 1. Type plate 2. Cylinder head cover 3. Exhaust silencer 4. Exhaust mesh insert 5. Oil pressure switch 6. Starter motor 7. Voltage regulator 8. Crankshaft - power take-off 9. Oil drain plug 10. Speed adjustment ...

SECTION 3 - CHASSIS & TURNTABLE 3-268 – JLG Lift – 3121448 GENERAL NOTES Technical data 1) These values are intended as an approximate guide. Themax.marking on the dipstick is the deter-mining factor. 2) Depending on model (see maintenance charts). 3) Exceeding these limits causes engine breakdo...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-269 TYPE PLATE The type plate is placed on the noise insulating hood andincludes the following engine information: 1. engine type 2. code (only for special equipment) 3. engine number (also stamped on crankcase) 4. max. engine speed For any ...

SECTION 3 - CHASSIS & TURNTABLE 3-270 – JLG Lift – 3121448 OPERATION ENGINE OIL Oil quality Qualified are all trademark oils which fulfil at least one ofthe following specifications: ACEA – B2 / E2 or more significant API – CD / CE / CF / CF-4 / CG-4or more significant. If engine oil of a poorer...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-271 Fuel STOP THE ENGINE BEFORE REFILLING THE FUEL TANK. NEVERR E F U E L N E A R A N A K E D F L A M E OR S P AR K S W H I C H C O U L DS T A R T A F I R E . D O N ’ T S M O K E . U S E O N L Y P U R E F U E L A N DCLEAN FILLING EQUIPMENT. ...

SECTION 3 - CHASSIS & TURNTABLE 3-272 – JLG Lift – 3121448 Set speed adjustment lever „1“either to 1/2START or max.START position, as desired or necessary. Starting at a lower speed will help to prevent exhaustsmoke. Recoil starter (down to –6 °C) For starting preparations. Starting procedure – ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-275 Stopping the engine Speed adjuster, standard version – Move the speed adjustment lever „1“back to the STOPposition. The engine cuts out. NOTE: Engines with a fixed lower idling speed cannot be switched off using the speed adjustment leve...

SECTION 3 - CHASSIS & TURNTABLE 3-276 – JLG Lift – 3121448 Maintenance O N L Y CA R R Y O U T M A I N T EN A N CE W O R K W IT H T H E E NG I N ESWITCHED OFF.OBSERVE ALL RELEVANT LAWS AND REGULA-TIONS GOVERNING THE HANDLING AND DISPOSAL OF USED OIL,FILTERS AND CLEANING AGENTS. PROTECT THE STARTI...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-277 On new or reconditioned engines, after the first 25operating hours, always: – Change engine oil. – Check valve clearances and adjust if necessary. – Examine screw connections. Do not tighten the cylin- der head fastening. If the engine i...

SECTION 3 - CHASSIS & TURNTABLE 3-278 – JLG Lift – 3121448 CHECKING THE WATER TRAP The intervals at which you should check the water trapdepend entirely on the amount of water in the fuel and thecare taken when re-fuelling. The normal interval is once aweek. - Loosen hexagon screw „1“with approx...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-279 CHANGING ENGINE OIL The engine must be standing level and be switched off.Only change the oil when the engine is warm. DANGER OF SCALDING FROM HOT OIL! TRAP THE OLD OIL ANDDISPOSE OF IT IN ACCORDANCE WITH LOCAL LEGISLATION. – Take out oi...

SECTION 3 - CHASSIS & TURNTABLE 3-280 – JLG Lift – 3121448 – On version with oilbath air cleaner, remove screw „2“and take off cover plate with noise-insulating hood. – Remove any contamination adhering to the cover for thecylinder head. – Remove screws „1“and take off the cylinder head coverwit...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-281 CLEANING COOLING AIR AREA T H E E N G I N E M U S T B E S W I T C H E D O F F A N D C O O L E D D O W NBEFORE CLEANING! – If severely contaminated, clean the cooling fins on thecylinder and cylinder head, and also the fan blades in thefl...

SECTION 3 - CHASSIS & TURNTABLE 3-282 – JLG Lift – 3121448 – Insert exhaust screen with hook „1“ into hole, them pulloutwards again so that the hook is retained. – Tighten the hexagon nut fully. MAINTENANCE EVERY 500 OPERATING HOURS Renewing fuel filter The maintenance intervals for the fuel fil...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-283 Model with fuel filter in fuel tank – Open the tank cover and pull the fuel filter out of the tankby its cord. – Pull fuel supply line „1“off fuel filter „2“and insert a newfilter. – Fit the fuel filter again and close the tank cap. Blee...

SECTION 3 - CHASSIS & TURNTABLE 3-284 – JLG Lift – 3121448 – Always renew the fuel filter. Note the arrows indicatingthe correct direction of flow. – Secure the filter to its mount. – Fill the fuel tank with diesel oil. Air is vented from the fuelsystem automatically. – Check the fuel filter and...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-285 CLEANING THE FILTER CARTRIDGE Dry contamination Use compressed air to blow through the filter cartridgefrom the inside outwards, until no further dirt emerges. IMPORTANT! THE PRESSURE MUST NOT EXCEED 5BAR. PERSONS HANDLING COMPRESSED AIR...

SECTION 3 - CHASSIS & TURNTABLE 3-286 – JLG Lift – 3121448 – Use an air line to blow out oil filter dirt from the insideoutwards. PERSONS HANDLING COMPRESSED AIR MUST WEAR PROTEC-TIVE GOGGLES. – Check joint washer „1“whether it is damage; replace-ment if necessary. – Check joint washer „2“whethe...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-287 MALFUNCTIONS – CAUSES AND REMEDIES y d e m e R s e s u a c e l b i s s o P s n o i t c n u f l a M 1. Engine does notstart, or not imme-diately, but can beturned over easilyas usual. At lowtemperatures. Speed control lever in stop oridle...

SECTION 3 - CHASSIS & TURNTABLE 3-288 – JLG Lift – 3121448 y d e m e R s e s u a c e l b i s s o P s n o i t c n u f l a M At low temperatures: If equipped with astop solenoid orautomatic electri-cal shutdown sys-tem (additionalequipment) 2.Engine fires butdoes not run. Automatic electrical shut...

SECTION 3 - CHASSIS & TURNTABLE 3-290 – JLG Lift – 3121448 y d e m e R s e s u a c e l b i s s o P s n o i t c n u f l a M 7.Engine becomesvery hot. Indicatorlamp for cylindertemperature (optional extra)comes on. 8.Moisture conden-sate emergingfrom exhaust. Too much lubricating oil in engine. In...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-291 Technical data ** These values are to be understood as approximate.Always refer to the max. mark on the dipstick. Type 1 B 30 1 B 40 Description air-cooled four-stroke diesel Fuel supply/combustion system direct injection Number of cylin...

SECTION 3 - CHASSIS & TURNTABLE 3-292 – JLG Lift – 3121448 Engine oil circuit 1. Oil pressure switch 2. Camshaft bearing, timing end 3. Oil pump 4. Camshaft bearing, flywheel end 5. Main and big-end bearings (crankshhaft) 6. Intake screen 7. Oil mesh filter 8. Gap between crankcase and cylinder ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-293 Additional equipment FUEL TANK 1B 30, 1B 40 General information: On 1B 30 / 40 engines from the start of series production,an injector with oil leak-off return line to the tank was intro-duced. Retrofitting : – Remove the edge at the ang...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-297 STARTER Preliminary work: – Disconnect the battery: negative pole first, positive polesecond. – Disconnect cables as far as necessary. Dismantling: – Take out screw 1 with washer 2 and nut 3. – Unscrew nut 4 with spring washer 5 and wash...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-299 GENERATOR General information: Before dismantling, check operation of the generator(measure off-load voltage). Preliminary work: – Disconnect the battery: negative pole first, positive polesecond. – Take off the fuel tank with the air gu...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-301 FITTINGS Preliminary work: – Disconnect the battery: first the nega tive pole, then thepositive pole. Dismantling: – Take out machine screws 1 with washer 2. – Detach cables and take off the electrical fitting. Testing / repair: – Examin...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-303 GEAR RING Preliminary work: – Take off the flywheel. Testing / repair: – Inspect the gear ring for broken teeth or other damage. – If necessary, file the gear ring to shape or renew it. Dismantling: – Heat the gear ring carefully until i...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-305 Basic engine equipment ADJUSTING LOWER IDLE SPEED General information: The lower idle speed must only be adjusted when theengine is warm and with power take-off componentsattached. Initial adjustment with engine stopped: – Turn adjusting...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-307 GENERATOR GOVERNOR, SPEED CONTROL Dismantling: – Remove parts in the order 1...10. – Mark the position of retaining plate 13 in relation to thetiming case cover with a scriber. – Remove parts in the order 11...18. Testing / repair: – Che...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-309 GOVERNOR, ENGINE SPEED ADJUSTMENT WITH INTERNAL STOP General: In connection with EPA certification, the engine speedadjustment screws together with stop were located insidethe timing case cover. The rest of the governor is the sameas the...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-311 RECOIL STARTER Preliminary work: Dismantling: – Take out retaining screws 1 and pull housing 2 off hori-zontally by hand. – Pull starting cable 3 out of handgrip 4 and unfasten theknot. – Turn cable pulley 5 back slowly until return spri...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-313 AIR GUIDE Preliminary work: – Take off the fuel tank and air guide housing. – Take off the flywheel. Dismantling: – Unscrew support bracket 2 from dividing plate 3. – Take out cylinder screw 4, noting the pres ence ofwasher 5. – Take off...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-315 BREATHER Preliminary work: – Take off the air cleaner cover, the noise insulating hoodand the air cleaner housing. Dismantling: – Pull oil trap 1 out of suction pipe 2 in the timing casecover, and take out of the crankcase complete with ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-317 Troubleshooting chart - electrical system TROUBLESHOOTING AT THE BATTERY Battery is not being charged sufficiently or at all, or is being dis-charged too rapidly. Battery is overcharged. Malfunction Indication Possible cause Remedial act...

SECTION 3 - CHASSIS & TURNTABLE 3-318 – JLG Lift – 3121448 Post terminals corroded. Acid level too low. Malfunction Indication Possible cause Remedial action Acid level less than 10 mm (0. 4 in) above top of cell plates. Overloading, natural water loss caused by evaporation (esp. in summer). Add...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-319 Malfunction Indication Possible cause Remedial action Battery out-put is too low. Long-term charging rate is insufficient. Voltage drops severely when a load is applied. Terminal voltage drops to 7 V nom- inal voltage (12 V circuit) even...

SECTION 3 - CHASSIS & TURNTABLE 3-324 – JLG Lift – 3121448 HATZ wiring designations X 4 Socket on emergency stop switch X 5 Terminal block on control box / terminal box Y 1 Speed control actuating solenoid Y 2 Engine shutdown actuating solenoid Y 3 Servo solenoid (= valve solenoid) for engine sh...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-325 Circuit diagram for current and voltage measurements Measuring charge current: 0 I II III P 30 15 50a 24 22 M 50 30 1 G G L C W 2 + _ G Display-panel A _ Measuring off-load voltage: 0 I II III P 30 15 50 a 2 4 22 M 50 30 1 G G L C W 2 + ...

SECTION 3 - CHASSIS & TURNTABLE 3-326 – JLG Lift – 3121448 Charge current: B a tt e r y vo l t a g e 12.5 V, n orm al o pe r a t in g t e m pe r a tur e I [A] 1000 1500 2000 2500 3000 3500 n [min -1 ] 2 4 6 8 10 12 14 16 Off-load AC voltage: measured between a yellow and a red wire at the coil (...

SECTION 3 - CHASSIS & TURNTABLE 3-334 – JLG Lift – 3121448 Specifications (1) Naturally Aspirated ENGINE IDENTIFICATION Perkins engines are identified by a serial number. Thisnumber is shown on a serial number plate that is mountedabove the fuel injection pump on the right hand side of theengine...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-335 DISASSEMBLY AND ASSEMBLY INSTALLATION PROCEDURE KEE P A L L P A R TS C L E A N F R O M C O N T A M I N A N T S. C O N T A M I -NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. NOTE: If the engine is equipped with a hand priming pu...

SECTION 3 - CHASSIS & TURNTABLE 3-336 – JLG Lift – 3121448 1. Turn the fuel supply to the OFF position. 2. Loosen hose clamps (3) and disconnect hoses (4). 3. If necessary, remove fuel filter element (5). Refer toOperations and Maintenance Manual, “Fuel SystemFilter - Replace”. 4. Remove bolt (1...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-337 FUEL TRANSFER PUMP - REMOVE AND INSTALL (MECHANICAL FUEL TRANSFER PUMP) REMOVAL PROCEDURE D O N O T A L L O W D I R T T O E N T E R T H E F U E L S Y S T E M . T H O R-OUGHLY CLEAN THE AREA AROUND A FUEL SYSTEM COMPO-NENT THAT WILL BE DI...

SECTION 3 - CHASSIS & TURNTABLE 3-338 – JLG Lift – 3121448 in two positions. Ensure that the fuel transfer pumpis oriented in the correct position. 2. Install a new O-ring seal (3) to fuel transfer pump (1). 3. Lubricate the operating plunger of fuel transferpump (1) with clean engine oil. 4. Po...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-339 INSTALLATION PROCEDURE 1. Ensure that the electric transfer pump is clean andfree from damage. If necessary, replace the electrictransfer pump. 2. Position electric transfer pump (3) on the mountingand install bolts (2). 3. Tighten bolts...

SECTION 3 - CHASSIS & TURNTABLE 3-340 – JLG Lift – 3121448 11. Disconnect nuts (1) for fuel injection lines (2) fromthe fuel injection pump. 12. Remove fuel injection lines (2) from the engine as aunit. 13. Use suitable caps in order to plug the open ports ofthe fuel injection pump immediately. ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-341 17. Remove the caps from fuel injectors (7). Install newwashers (6) and fuel return line (3) to fuel injectors(7). NOTE: The washers (6) have two small holes. 18. Install nuts (5) to fuel injectors (7). For engines with a rigid fuel retu...

SECTION 3 - CHASSIS & TURNTABLE 3-342 – JLG Lift – 3121448 1. Turn the battery disconnect switch to the OFF posi-tion. 2. Disconnect electrical connection (3) from the har-ness assembly (not shown). Mark all connections forinstallation. 3. Remove fuel shutoff solenoid (1) from the fuel injec-tio...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-343 INSTALLATION PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS. CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. 1. Clean the bore for the fuel injector in the cylinderhead. Ensure that no debris enters the cylinder.Cle...

SECTION 3 - CHASSIS & TURNTABLE 3-344 – JLG Lift – 3121448 INSTALLATION PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS . CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. NOTE: The two cylinder, the three cylinder and the four cyl- inder engines have different exhaust manifol...

SECTION 3 - CHASSIS & TURNTABLE 3-346 – JLG Lift – 3121448 7. Position banjo bolt (5) and new washers (6) onto oilline (1). Install the banjo bolt and the oil line to thecylinder head finger tight. 8. Tighten nut (2) that attaches the clip on oil line (1) tothe fuel injection pump. NOTE: For 402...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-347 INSTALLATION PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS. CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. 7. Ensure that the oil cooler is clean and free fromdamage. Clean the mating surfaces of the cylinderblock...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-349 3. Remove bolt (3) and remove adjusting link (2) for thealternator from water pump (1). NOTE: On some engines, the adjusting link for the alterna- tor is secured by two bolts. 4. Remove fasteners (7) and remove water pump (1). NOTE: If n...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-351 INSTALLATION PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS. CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. 18. Inspect the water temperature regulator for wear,damage and correct operation. Refer to SystemsOperati...

SECTION 3 - CHASSIS & TURNTABLE 3-352 – JLG Lift – 3121448 27. Remove pulley (2) from crankshaft (4). 28. Remove woodruff key (1) from crankshaft (4). INSTALLATION PROCEDURE 29. Ensure that the following components are clean andfree from damage: the taper of the crankshaft, thewoodruff key, and ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-353 2. Use Tooling (A) to carefully remove crankshaft frontseal (2). Alternate the position of Tooling (A) fromone hole to another hole. This will allow you toevenly remove the crankshaft front seal from fronthousing (1). ALTERNATIVE REMOVAL...

SECTION 3 - CHASSIS & TURNTABLE 3-354 – JLG Lift – 3121448 HOUSING (FRONT) - REMOVE REMOVAL PROCEDUREStart By: a. Remove the fuel injection pump. Refer to Disas-sembly and Assembly, “Fuel Injection Pump -Remove”. b. Remove the crankshaft pulley. Refer to Disas-sembly and Assembly, “C rankshaft P...

SECTION 3 - CHASSIS & TURNTABLE 3-356 – JLG Lift – 3121448 INSTALLATION PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS . CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. M A K E S U R E T H A T T H E C O M P O N E N T S O F T H E B R E A T H E RASSEMBLY ARE INSTALLED CORRECT...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-357 VALVE MECHANISM COVER - REMOVE AND INSTALL REMOVAL PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS. CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. CAR E M US T B E T AK EN T O EN SU R E TH AT FLU ID S AR E CO N-T A ...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-359 COOLANT TEMPERATURE SWITCH - REMOVE AND INSTALL REMOVAL PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS. CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. CAR E M US T B E T AK EN T O EN SU R E TH AT FLU ID S AR E CO N...

SECTION 3 - CHASSIS & TURNTABLE 3-360 – JLG Lift – 3121448 ENGINE OIL PRESSURE SWITCH - REMOVE AND INSTALL REMOVAL PROCEDURE KE E P A L L P A R T S C L E A N F R O M C O N T A M I N A N T S . C O N T A M I -NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. CAR E M US T B E T AK EN T O EN S...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-361 NOTE: If a used engine oil pressure switch is installed, apply a thin layer of Tooling (A) to the threads of theengine oil pressure switch. 1. If engine oil pressure switch (1) is located in thevalve mechanism cover, install the engine o...

SECTION 3 - CHASSIS & TURNTABLE 3-362 – JLG Lift – 3121448 INSTALLATION PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS . CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. 5. Ensure that the threads of the glow plugs are cleanand free from damage. Replace any damaged glowplugs...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-363 INSTALLATION PROCEDURE KEE P ALL PAR TS CL EAN FROM CO NTAMINANTS. CONTAMI-NANTS MAY CAUSE RAPID WEAR AND SHORTENED COMPONENTLIFE. 4. Check the condition of the V-belt. If the V-belt is wornor damaged, use a new V-belt for replacement. 5...

SECTION 3 - CHASSIS & TURNTABLE 3-364 – JLG Lift – 3121448 INSTALLATION PROCEDURE 3. Ensure that all components are clean and free fromdamage. Replace any components that are worn ordamaged. 4. Position pulley (4) and spacer (3) on water pump(5). Ensure that the bolt holes are aligned. 5. Instal...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-365 INSTALLATION PROCEDURE 7. If necessary, install adjusting link (2) and install bolts(5) finger tight. NOTE: The adjusting link on some engines is secured by one bolt. 8. For engines that have an adjusting link that issecured by one bolt,...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-367 PERKINS RPM CONTROL SYSTEM Mount the proximity cod.26514900 sure that inside seethe hole on the reduction of the tooth crown, screw untilyou come into abutment with the sensor, make a markand unscrew for a ride, then pull the nut to secu...

SECTION 3 - CHASSIS & TURNTABLE 3-370 – JLG Lift – 3121448 3.13 ENGINE REMOVAL 1. Stabilize and turn the machine on level surface at90° (image 1). 2. Remove the key ignition, and a tag with warning donot start the machine. 3. Remove the cover 1. 4. Disconnect, tag and isolate the wires from thee...

SECTION 3 - CHASSIS & TURNTABLE 3121448 – JLG Lift – 3-371 3.14 CHANGING THE ELECTRIC MOTOR 1. Stabilize and turn the machine on level ground at90° (image 1). 2. Before beginning the maintenance check that themachine is disconnected from the mains and unplugthe ignition key. 3. Remove casing (1)...

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-1 SECTION 4. BOOM & PLATFORM 4.1 BOOM MAINTENANCE IF PERFORMING MAINTENANCE ON THE BOOM, DO NOT USE ALIF TING DEVICE TO LIF T THE BOOMS UNLESS THE HOLDINGVALVES HAVE BEEN REMOVED FIRST. FAILURE TO DO SO WILLRESULT IN SEVERE DAMAGE TO THE BOO...

SECTION 4 - BOOM & PLATFORM 4-2 – JLG Lift – 3121448 a. e. Remove hardware securing the level link pivot pin. Using a suitable brass drift and hammer,remove the pin from the level link and turntable. b. f. Remove hardware securing the lower boom pivot pin. Using a suitable brass drift and ham-me...

SECTION 4 - BOOM & PLATFORM 4-4 – JLG Lift – 3121448 Installation of the Boom Assembly 1. Using suitable lifting equipment, position boomassembly on turntable so that boom pivot holes inboth boom and turntable are aligned. 2. Install boom pivot pin, ensuring that location of thehole in pivot pin...

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-5 1 3 2 5 6 4 1. Upper Boom 2. Upper Upright 3. Upper Lift Cylinder 4. Tower Link 5. Boom 6. Lower Lift Cylinder Figure 4-5.

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-7 4.2 BOOM DISASSEMBLY X23J - X700AJ NOTE: The following procedure assumes the boom is removed from the machine. 1. Extend the boom approximately 2 feet (0.6 m). Thiswill enable access to the bolts that secure the cablemount block to the boom fl...

SECTION 4 - BOOM & PLATFORM 4-8 – JLG Lift – 3121448 SLOWLY FROM THE BOOM. DAMAGE TO COMPONENTS MAYRESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES. NOTE: The telescope cylinder weighs approximately 600 lbs. (275 kg). 7. Using overhead cranes or other suitable lifting/sup-porting devices, caref...

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-11 4.3 INSPECTION Checking wear and deformation of ropes and pulleys If only one of the following situations is detected the ropesor pulleys must be replaced. 1. Check that there are no broken threads on the sur-face of the rope, in the internal...

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-13 vent it from coming out of the socket before itengages the mounting threads. Figure 4-21. 22. Connect all the hydraulic lines to the cylinder astagged during the removal procedure. 23. Adjust the boom cables as outlined under Section4.4, ROPE...

SECTION 4 - BOOM & PLATFORM 4-14 – JLG Lift – 3121448 Three month inspection 1. Remove all protection sumps from the third arm andthe two extensions. Use an electric torch to visuallycheck the state of the ropes and the extension pul-leys. 2. Check the correct rope tension, trying to bend themma...

SECTION 4 - BOOM & PLATFORM 4-16 – JLG Lift – 3121448 4.5 ROTARY ACTUATOR ARP SERIES

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-17 Installation and maintenance manual TECHNICAL DATA Figure 4-27. a. Rotary actuator model. b. Construction year. c. Serial number. Please refer to this number inorder to obtain every further details from ourtechnical department. d. Max working...

SECTION 4 - BOOM & PLATFORM 4-20 – JLG Lift – 3121448 DISASSEMBLY THE SEALS MUST BE REMOVED USING APPOSITE TOOLS, SEAL-ING SURFACES MUST NOT BE DAMAGED. • After disassembly all parts must be cleaned and degreased. • Clean all parts with compressed air.• Lubricate all sealing surfaces.• Make sure...

SECTION 4 - BOOM & PLATFORM 4-22 – JLG Lift – 3121448 Assembly • Fix the actuator in a proper way to the bench• Reinstall all sealing elements on their particulars pay- ing attention to mounting direction (see drawing). Ifyou have difficulty use appropriate bushings cone. NOTE: For easy mounting...

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-23 Installing Counterbalance Valve Refer to Figure 4-24, Rotator Counterbalance Valve. 1. Make sure the surface of the actuator is clean, freeof any contamination and foreign debris includingold Loctite. 2. Make sure the new valve has the O-ring...

SECTION 4 - BOOM & PLATFORM 4-24 – JLG Lift – 3121448 4.6 PLATFORM REMOVAL/INSTALLATION NOTE: If the platform is removed only track movement is allowed. 1. Remove the platform/remote control box from themounting support. 2. Loosen and remove the aluminium caps that securethe platform to the jib ...

SECTION 4 - BOOM & PLATFORM 3121448 – JLG Lift – 4-25 4.7 LOAD CELL AND FOOTSWITCH REMOVAL/INSTALLATION Removal load cell 1. Turn the machine off and unplugged from the power supply. 2. Remove the basket of the machine (see dismantling basket). 3. Remove screws (2) and remove cover (3). 4. Remov...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-1 SECTION 5. HYDRAULICS 5.1 CYLINDER REPAIR SPECIFICATION Cylinders overview Figure 5-1. PISTON THREAD

SECTION 5 - HYDRAULICS 5-2 – JLG Lift – 3121448 Figure 5-2. PISTON   WITH   NUT   THREAD

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-3 Figure 5-3. TELESCOPE CYLINDER TELESCOPE   CYLINDER

SECTION 5 - HYDRAULICS 5-4 – JLG Lift – 3121448 Figure 5-4. CYLINDER   WITH   SENSOR

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-5 HYDRAULIC CYLINDERS TORQUE SPECIFICATIONS Piston nut thread torque specification Table 5-1. PISTON WITH NUT THREAD NUT TORQUE VALUE X14J-X390AJ OUTRIGGER NUT M27X2 300N/m X14J-X390AJ JIB CYLINDER NUT M20X1.5 160N/m X14J-X390AJ LEVELING CYLINDER BASKET ...

SECTION 5 - HYDRAULICS 5-6 – JLG Lift – 3121448 Screws torque specifications Hose connections torque specifications Table 5-2. CYLINDER SCREWS TORQUE VALUE DRILLED SCREW 3/8" 70N/m SCREW M8 25N/m SCREW M6 11N/m SCREW M4 3N/m CAP 1/4" 30N/m PURGE SCREW 8N/m GREASE NIPPLE 2N/m SENSOR SETSCREW ...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-7 Cylinders head torque specification Table 5-4. Tightening torque head Head diameter (mm) Torque [Nm] Min Max 30 50 100 35 50 100 40 100 150 45 100 150 50 150 200 55 150 200 60 200 250 65 200 250 70 250 300 75 250 300 80 300 350 90 350 400 100 400 450 1...

SECTION 5 - HYDRAULICS 5-8 – JLG Lift – 3121448 EQUIPMENT AND PRODUCT LIST • Spanner wrancher Figure 5-5. NOTE: The following are general procedures that apply to all of the cylinders with sensor. Procedures that apply to a spe-cific cylinder will be so noted. CYLINDER WITH SENSOR Disassembly Genera...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-9 Push the connector inside the hole and fix the plateagain. Figure 5-10. Screw off the setscrew and remove the pin.Use a magnet to pull out the pin. Figure 5-11. Fix the setscrew in order to keep the air pressure. Figure 5-12. Blow pressurized air with ...

SECTION 5 - HYDRAULICS 5-10 – JLG Lift – 3121448 CLEANNESS AND INSPECTION Cylinder Cleaning Instructions 1. Discard all seals, back-up rings and o-rings. Replacewith new items from complete seal kits to helpensure proper cylinder function. Figure 5-16. 2. Clean all metal parts with an approved clean...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-11 MAGNETIC SENSOR REMOVING 1. Pull out retain clip with pliers. Figure 5-20. 2. Pull out the spacer. Figure 5-21. 3. Pull out the magnet. Figure 5-22. 4. Pull out the other spacer. Figure 5-23. THREADED PISTON DISASSEMBLING PROTECT THE FINISH ON THE ROD...

SECTION 5 - HYDRAULICS 5-12 – JLG Lift – 3121448 General Cylinder Assembly 1. Use the proper tools for specific installation tasks.Clean tools are required for assembly. 2. Install new seals, back-up rings and o-rings on thepiston and the head. 3. Fasten the rod eye in a soft-jawed vise, and place a...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-13 Replace the seals on the piston. DO NOT attempt to sal- vage cylinder seals, sealing rings or o-rings. ALWAYS usea new, complete seal kit when rebuilding hydraulic com-ponents. Consult the parts manual for ordering informa-tion. Figure 5-29. Mount the...

SECTION 5 - HYDRAULICS 5-14 – JLG Lift – 3121448 SENSOR ASSEMBLING Spacer has chamfer. Figure 5-33. Mount spacer with chamfer face outside. Figure 5-34. Lubricate the o-ring Figure 5-35. Joint the sensor pin with a guidance cable. Figure 5-36. Insert sensor with a cable pass Figure 5-37. Use plastic...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-15 Figure 5-40. Remove the set screw, insert the pin and than fix the setscrew. Pay attention do not tight too much set screw because thesensor could be damaged. Tightening torque 05N/m seal with AREXON 35A77. Figure 5-41. Figure 5-42. CYLINDER ASSEMBLIN...

SECTION 5 - HYDRAULICS 5-16 – JLG Lift – 3121448 NOTE: The following are general procedures that apply to all of the cylinders without sensor. Procedures thatapply to a specific cylinder will be so noted CYLINDER REPAIR WITHOUT SENSOR Rod Removing General Cylinder Disassembly 1. Clean the cylinder w...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-17 PISTON WITH NUT DISASSEMBLING PROTECT THE FINISH ON THE ROD AT ALL TIMES. DAMAGE TOTHE SURFACE OF THE ROD CAN CAUSE SEAL FAILURE. Fix the rod into the vice. NOTE: Before attempting to disassemble the piston remove any accessible seals. Figure 5-48. NO...

SECTION 5 - HYDRAULICS 5-18 – JLG Lift – 3121448 CYLINDER ASSEMBLING General Cylinder Assembly 1. Use the proper tools for specific installation tasks.Clean tools are required for assembly. 2. Install new seals, back-up rings and o-rings on thepiston and the head. 3. Fasten the rod eye in a soft-jaw...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-19 Figure 5-54. PROTECT THE FINISH ON THE ROD AT ALL TIMES. DAMAGE TOTHE SURFACE OF THE ROD CAN CAUSE SEAL FAILURE. Replace the seals on the piston. DO NOT attempt to sal- vage cylinder seals, sealing rings or o-rings. ALWAYS usea new, complete seal kit ...

SECTION 5 - HYDRAULICS 5-20 – JLG Lift – 3121448 EMPTYING OF THE CYLIDER Vent Valve Air inside the circuit has to be removed in order to avoidvibration and irregular motion of the cylinder, vent valvesare apply to make this kind of operation. Failure to remove air from the circuit can cause dieselef...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-21 5.2 REPLACEMENT HYDRAULIC PUMP Pump removal 1. Open the top cap of the hydraulic oil tank. 2. Tag & disconnect the hoses from the pump 15. 3. Loose screws 16. 4. Remove from the pump 15 from the adapter 12. 5. Loosen nut 10 and remove the coupling...

SECTION 5 - HYDRAULICS 5-22 – JLG Lift – 3121448 5.3 FUNCTION PUMP HYDRAULIC PUMP REPAIR SEAL KIT REPLACEMENT INSTRUCTION 65602813 POMPA PLP10.4-86E1/10.4 D/FS-EL VZN 65602807 POMPA PLP10.3,15-86E1/10.3,15 D/FS-EL-D VZN CASAPPA Figure 5-63. Main operations: GENERAL SUGGESTION 1. Check the parts have...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-23 External components disassembly Figure 5-64. USE SOME ALUMINIUM PROTECTION ON THE VICE TO NOT DAM-AGE THE MACHINED SURFACES. PUT THE PUMP IN ORIZONTALPOSITION AND BLOCK THE COVER IN THE VICE'S JAWS. LOOSENTHE BOLTS. Figure 5-65. Unscrew the nut and re...

SECTION 5 - HYDRAULICS 5-24 – JLG Lift – 3121448 Components disassembly Remove the first section from the second section. Figure 5-68. Remove the connecting hub and the dowel pins. Figure 5-69. Remove the rear cover. Figure 5-70.

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-25 Second section components disassembly Using a marker draw a reference mark on the plate andthe body. It will be used later during reassembly. Figure 5-71. Remove the gears and the pressure plates. Figure 5-72. Second section seals disassembly Remove t...

SECTION 5 - HYDRAULICS 5-26 – JLG Lift – 3121448 Second section seals replacement Place on the body the new seals. Use clean grease tokeep the seal in place. Figure 5-75. Fit the new seal (1) and back-up ring (2) on the plate. Figure 5-76. First section seals disassembly Remove the front cover. Figu...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-27 First section seals disassembly Remove the seals from the body. Figure 5-80. Remove from the plate the back-up ring (1) and the seal(2). Figure 5-81. Remove from the plate the back-up ring (1) and the seal(2). Figure 5-82. 1 2 2 1

SECTION 5 - HYDRAULICS 5-28 – JLG Lift – 3121448 First section seals replacement Use clean grease on the pressure plate to help the sealsstay in place before fitting them. Figure 5-83. Fit the new seal (1) and back-up ring (2) on the plate. Figure 5-84. Fit the new seal (1) and back-up ring (2) on t...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-29 Cover seals replacement Section Figure 5-87. Put the cover on the working bench. Remove the snap ring (1). Paying attention not to damage the seat remove with ascrew driver (flat head) the shaft seals.(2 - 3) Put some clean grease into the seat seal. ...

SECTION 5 - HYDRAULICS 5-30 – JLG Lift – 3121448 Cover seals replacement INSER T THE SECOND SHAFT SEAL. PAY ATTENTION TO THEASSEMBLING DIRECTION OF THE SHAFT SEAL (SEE SECTION).USING A MALLET PUSH ALL THE WAY DOWN THE CASAPPATOOL PN.06100091 Figure 5-90. Insert the back-up ring. Using a mallet push ...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-31 First section components reassembly Reassemble the gears and the plates. Use as refer- ence the mark made previously. Figure 5-94. Components reassembly Put back the flange and the pins. Put the connecting hubinto the second section shaft. Figure 5-95...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-33 Final bolting and check Put the pump in the vice and tighten the bolts with atorque wrench. Tightening torque 30 Nm. Figure 5-101. WITH A CLAMP VERIFY THAT THE SHAFT OF THE PUMP CANRO TATE AF TE R THE OPERATI ON IN BOT H DI RE CTI ONS. THESHAFT MUST E...

SECTION 5 - HYDRAULICS 5-34 – JLG Lift – 3121448 5.4 HYDRAULIC COMPONENT START-UP PROCEDURES AND RECOMMENDATIONS From a hydrostatic component standpoint, the goal atsystem start up is to put into functional operation, thehydrostatic system in such a way as to preserve thedesigned life span of the sy...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-35 Install a 60 bar (or 1000 psi) pressure gauge in the chargepressure gauge port in order to monitor the charge pres-sure during start-up. It is recommended that the external control input signal,(electrical connections for EDC), be disconnected at thep...

SECTION 5 - HYDRAULICS 5-36 – JLG Lift – 3121448 5.5 PRESSURE SETTING PROCEDURE Cold temperatures have a significant impact on pressurereadings. JLG Industries Inc. recommends operating themachine until the hydraulic system has warmed to normaloperating temperatures prior to checking pressures. JLGI...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-37 Automatic reductions drive speed (X23J-X700AJ only) Adjust pressure reducing valve (only X23J-X700AJ) 1. Adjust the pressure when the machine iscompletely closed. Figure 5-105. 2. Install the pressure gauge at the port 5. 3. Activate the function outr...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-41 5.6 HYDRAULIC SCHEMATIC Figure 5-110. X23J-X700AJ

SECTION 5 - HYDRAULICS 5-42 – JLG Lift – 3121448 5.7 HYDRAULIC SCHEMATIC B A R M M A B R SFILO CESTO CILINDRO ANTERIORE DX STABILIZZATORE POSTERIORE DX STABILIZZATORE ANTERIORE SX POSTERIORE SX STABILIZZATORE STABILIZZATORE CINGOLO SINISTRO DESTRO CINGOLO BRACCI ROTAZIONE CINGOLI ALLARGAMENTO CILIND...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-43 LEGENDA HYDRAULIC SYSTEM X14JH 1. Hand pump 2. 2 2.2 W, 4 IP55 poles, electric engine 3. GX270 QME2 petrol engine 1B30 Diesel engine 4. Double geared pump 5. Pump inlet manifold block 6. 6 way switch 7. Exhaust filter 8. Solenoid valve 9. Distributor ...

SECTION 5 - HYDRAULICS 5-44 – JLG Lift – 3121448 B A M M A B SFILO CEST O CILINDRO ANTERIORE DX ST ABILIZZA TORE POSTERIORE DX ST ABILIZZA TORE ANTERIORE SX POSTERIORE SX ST ABILIZZA TORE ST ABILIZZA TORE CINGOLO SINISTRO DESTRO CINGOLO BRACCI ROT AZIONE CINGOLI ALLARGAMENT O CILINDRO 3° BRACCIO 2° ...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-45 LEGENDA HYDRAULIC SYSTEM WITH 2 ND SPEED X14JH 1. Hand pump 2. 2.2 W, 4 IP55 poles, electric engine 3. GX270 QME2 petrol engine 1B30 Diesel engine 4. Double geared pump 5. Pump inlet manifold block 6. 6 way switch 7. Exhaust filter 8. Solenoid valve 9...

SECTION 5 - HYDRAULICS 3121448 – JLG Lift – 5-47 LEGENDA HYDRAULIC SYSTEM X17J 1. Hand pump 2. 2 kW 4 pole electric motor, IP55 3. Honda iGX440 petrol engine / Hatz 1B40 dieselengine 4. Double gear pump 5. Pump outlet manifold block 6. Discharge filter 7. Discharge manifold 8. Electroproportional di...

SECTION 5 - HYDRAULICS 5-50 – JLG Lift – 3121448 LEGENDA HYDRAULIC SYSTEM X14J-X390AJ 1. Hand pump 2. 2 kW 4 pole electric motor, IP55 3. GX270 QME2 petrol engine 1B30 diesel engine 4. Double gear pump 5. Pump outlet manifold block 6. Discharge filter 7. Distributor 8. Stabilizer stop valve 9. Stabi...

SECTION 5 - HYDRAULICS 5-62 – JLG Lift – 3121448 L E G E N D A H Y D R A U L I C S Y S T E M X 2 3 J - X700AJ 1. Hand pump 2. 2.2 kW 4 pole IP55 electric engine 3. Honda IGX440 petrol engine/Perkins 402-05 dieselengine 4. Double gear-type pump 4+4 5. Double gear-type pump 3.15+3.15 6. Delivery pump ...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-1 SECTION 6. JLG CONTROL SYSTEM 6.1 INTRODUCTION WHEN INSTALLING ANY NEW MODULE CONTROLLER ON THEMACHINE, IT WILL BE NECESSARY TO PROGRAM THE CONTROL-LER FOR THE PROPER MACHINE CONFIGURATION, INCLUDINGOPTIONS AND PROPERLY CALIBRATE THE TILT SENSO...

SECTION 6 - JLG CONTROL SYSTEM 6-2 – JLG Lift – 3121448 6.2 PLATFORM/REMOTE CONTROL STATION LCD DISPLAY At machine start-up and during machine operation themain LCD display screen (Figure 6.1) is activated. There are eight (8) display positions which indicate machine sta-tus during various stages of...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-3 Position 1 Reduced operating area if all outriggers are not fullydeployed. Position 2 Displays the capacity based on jib position. Position 3 Displays the selected engine (gas/diesel or electric) andwhether it is on or off. The X on the icon in...

SECTION 6 - JLG CONTROL SYSTEM 6-4 – JLG Lift – 3121448 Position 7 Can indicate any of the following situations: • An emergency stop is pushed in (off).• A low battery. The batteries need charged by running the gas/diesel engine or connecting to a power source. • Tower boom sensor is faulty.• Main b...

SECTION 6 - JLG CONTROL SYSTEM 6-6 – JLG Lift – 3121448 6.3 CANBUS COMMUNICATIONS The electrical system works with a CAN BUS system,where: CAN = Control Area Network BUS = Channels for peripherals CANbus: CAN (Control Area Network) is a two wire differ-ential serial link between the, Ground Module E...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-7 Additional components on X700AJ - X23J Only Photocell A-B Outrigger Pressure sensors Safety Key switch Outrigger Switches Ropes switch Accessory Options Engine Throttle Actuator Main Valve OUTPUTS Ground Control ECM 1 & 2 Module INPUTS X17J...

SECTION 6 - JLG CONTROL SYSTEM 6-8 – JLG Lift – 3121448 Ground Control ECM 1 & 2 Module Modem RAHM Module Cylinders Position Sensor X700AJ –X23J Only (All Models) Remote Control (All Models) Envelop ECM 4 Module (X700AJ - X23J Only) LSS ECM 3 Module (All Models) FWD Radio Receiver Module (X17J O...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-9 MODULE FLASHING CODE MODULE ECM 1 With Led’s permanently ON: DL1-GREEN Power +5V to CPU DL2- Yellow Power for aerial functions available DL3-Yellow: Power for drive functions available Figure 6-5. Module ECM 1 MODULE ECM 2 With Led’s permanentl...

SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3121448 MODULE LOAD SENSING SYSTEM ECM3 With Led’s DL1 –DL3 & DL2 –DL4 Blinking (green/red)Module LSS not calibrate. With Led’s DL1 DL2 green permanently ON, means LSSModule calibrate (even if out of range). Figure 6-7. Modu l e Load Sens i ng Sys...

SECTION 6 - JLG CONTROL SYSTEM 6-12 – JLG Lift – 3121448 Remote Control Operation On models with Remote Control connected by cable, ifshown the message PREOPERATIN, that means an issuewith CanBus link: On models with Radio Remote Control shown the mes- sage of PREOPERATN, can be one of the following...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-13 6.4 CALIBRATION INSTRUCTIONS This machine incorporates a variety of sensors and a highdegree of function interaction. For safety and propermachine functionality, the calibration procedures must berepeated for any control module replacement, sy...

SECTION 6 - JLG CONTROL SYSTEM 6-14 – JLG Lift – 3121448 6.5 PLATFORM REMOTE CONTROL SERVICE SERVICE BUTTON A SERVICE button is present on the remote control whichallows to view the status of the machine parameters and isan aid in the safety checks of the machine. With machine power on, by pressing ...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-15 USING THE SERVICE PROGRAM To select a displayed menu item, press button 6 SERVICE . To cancel a selected menu item, press button 9 ESC , to escape. From the SERVICE menu use the buttons 1-2-3-7-8 to nav-igate through the menu. SAVE Button 3 Us...

SECTION 6 - JLG CONTROL SYSTEM 6-16 – JLG Lift – 3121448 From the SERVICE menu, use button “7 Setup”, the but-ton “5 Password” than enter a proper password (by usingbuttons 1 to 9) to advance to a lower level. Once OK is displayed, press button “9 ESC ”, MENUshould display and than press the button ...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-17 1 MENU INPUT ANSI-SPEC X390AJ - X550AJ - X700AJ CE-SPEC X14J - X19J - X23J Figure 6-13. MENU INPUT 1-2

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-19 3 MENU ERRORS Figure 6-15. MENU ERRORS

SECTION 6 - JLG CONTROL SYSTEM 6-20 – JLG Lift – 3121448 4 MENU RAMPS Figure 6-16. MENU RAMPS

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-21 5 MENU CURRENTS Figure 6-17. MENU CURRENTS

SECTION 6 - JLG CONTROL SYSTEM 6-22 – JLG Lift – 3121448 6 MENU WORKING HOURS Figure 6-18. MENU WORKING HOURS

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-23 7 MENU SETUP Figure 6-19. MENU SETUP 1-2

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-25 6.6 MENU INPUT From the SERVICE menu, pressing button 1”INPUT” toaccesses menu INPUT. The menu INPUT visualize the status (or changes of sta-tus) of all the devices connected to the main control mod-ule. Machine diagnostic devices status or va...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-27 ST4A OPEN X23J - X700AJ Only ON Outrigger N° 4 completely opened – the switch is released and A line is closed OFF Outrigger N° 4 closed or partially opened – the switch is pressed and A line isopened ST4B OPEN X23J - X700AJ Only ON Outrigger ...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-35 6.7 LANGUAGE From the SERVICE menu, pressing button 2”LANGUAGE”to accesses menu language. Using the buttons 1 to 4 to select the language desired. Press button 9”ESC” to save the change. The languages available are: Button 1-Italian Button 2-G...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-37 SCREEN ERRORS 1 SCREEN ERRORS 2 SCREEN ERRORS 3 ST1 GND Control switch if outrigger no. 1is on the ground. ST1 OPEN 700AJ – X23J only Control switch if outrigger no. 1is open. ST2 GND Control switch if outrigger no. 2is on the ground. ST2 OPEN...

SECTION 6 - JLG CONTROL SYSTEM 6-38 – JLG Lift – 3121448 SCREEN CAN MESSAGE SCREEN FOR MODELS LITHIUM POWERED The screen LITH ERR, present on all unities, provide indi-cation for models powered with Lithium batteries only On unities powered with Gasoline or Diesel engine, thevalue BATT; INVER and CA...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-39 Table 6-5. BMS Diagnostic trouble code chart CODE ERROR TYPE A99E01 System Configuration Error A99E02 Unexpected voltage A99E03 Unexpected temperature A99E04 Over current Discharge A99E05 Over current Charge A99E06 Pre-Charge Error A99E07 No 1...

SECTION 6 - JLG CONTROL SYSTEM 6-40 – JLG Lift – 3121448 Table 6-6. INVERTER Diagnostic trouble code chart CODE MEANING 1 Wrong Config Cause: Eeprom memory not configured Solution: Contact JLG after sales dept. 8 Watch Dog Cause: The inverter is unable to activate or turn off the electric motor Solu...

SECTION 6 - JLG CONTROL SYSTEM 6-44 – JLG Lift – 3121448 240 the digital input is open and is managed as start-stop hardware. The battery charger stops the charge until the digital input is not reclosed. Close the digital input. 253 Network voltage higher than the max value of the functioning window...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-45 6.9 RAMPS From the SERVICE menu, pressing button 4”RAMP ”accesses the menu RAMP to adjust the parameter set-tings in order to achieved optimum machine performance. 1. Press button 7 “SETUP”. 2. Press button 5 “PASSWORD”. Using the remote contr...

SECTION 6 - JLG CONTROL SYSTEM 6-50 – JLG Lift – 3121448 6.12 MACHINE SETUP From the SERVICE menu, pressing button 7 ”SETUP ”accesses the menu SETUP to adjust the parameter set-tings in order to achieved proper machine performance. When selection the machine model to match the size ofthe machine, th...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-51 SETUP 1 - ACCELER (CALIBRATING TILT SENSOR) This menu allows the calibration of the tilt sensor. A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THETIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. CALIBRATE THE LEVEL SENSOR EXCEPT WITH TH...

SECTION 6 - JLG CONTROL SYSTEM 6-52 – JLG Lift – 3121448 SETUP 2 - VERSION MODEL NUMBER ENGINE TYPE This menu allows the setting of the machine model andthe engine type. 1. Press button 6 "SERVICE" 2. Press button 7 "SETUP “. 3. Press button 5 “PASSWORD”. Using the remote control buttons...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-53 SETUP 3 - OPTIONAL This menu allows the setting of those options: 1. Foot Pedal 2. Motion Alarm 3. Drive Speed 4. Power electrical Motor 5. Lamps on Outrigger 1 - FOOT PEDAL 1. Press button 7 "SETUP“. 2. Press button 5 “PASSWORD”. Using th...

SECTION 6 - JLG CONTROL SYSTEM 6-54 – JLG Lift – 3121448 2 - MOTION ALARM This menu allows the set ON or OFF of the motion alarmwith upper fame and undercarriage movements, or forboom down only. 1. Press button 7 "SETUP“. 2. Press button 5 “PASSWORD”. Using the remote control buttons to enter th...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-55 4 - ELECTRICAL MOTOR 1. Press button 7 "SETUP“. 2. Press button 5 “PASSWORD”. Using the remote control buttons to enter the pass-word 3522. NOTE: password above allow to choose the options shown on the screen. Once the correct password is ...

SECTION 6 - JLG CONTROL SYSTEM 6-56 – JLG Lift – 3121448 SETUP 4 - CALIBRATING SWING SENSOR (X23J –X700AJ Only) A N E W S W I N G S E N S O R W I L L A C T A S I F I T I S W I T H O U TRESTRICTED AREA UNTIL THE FOLLOWING PROCEDURE IS PER-FORMED. THE UPPER FRAME COULD INTERFER WITH THE OUT-RIGGERS. T...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-57 1. Press button 6 "SERVICE" 2. Press button 7 "SET-UP“. 3. Press button 5 “PASSWORD”. Using the remote control buttons to enter the pass-word 2857. NOTE: password above allow to choose machine number and engine type. Once the corre...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-59 Add weight of 200 kg (CE) / 440 Lb (ANSI) in the basket. Wait for about 5 seconds. Press button 2 to SET 200KG. Press 3 times button 9 to Esc to escape. LSS VALIDATION 1. Stabilize the machine. 2. Press button 6 "SERVICE“. 3. Press button ...

SECTION 6 - JLG CONTROL SYSTEM 6-60 – JLG Lift – 3121448 SETUP 7 - TIME SETUP This menu allows the setting of the clock. 1. Press button 6 "SERVICE" 2. Press button 7 "SETUP“. 3. Press button 5 “PASSWORD”. Using the remote control buttons to enter the pass-word 1468. NOTE: password above...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-61 6.13 JOYSTICK From the SERVICE menu, pressing button 8 ”JOYSTICK”accesses the menu JOYSTICK to visualize the numericvalues. Engine Key Switch ON. USE Buttons 1 or 2 to choose the JOYSTICK. Joystick Neutral position Value = 0 Joystick Fully str...

SECTION 6 - JLG CONTROL SYSTEM 6-62 – JLG Lift – 3121448 6.14 CALIBRATING JOYSTICK This menu allows the calibration on Joystick replacement. A NEW JOYSTIC WILL ACT AS IF IT IS AWATING FOLLOWINGPROCEDURE IS PERFORMED. 1. Engine and Electrical Motor OFF. 2. Press at the same time the 3 buttons below f...

SECTION 6 - JLG CONTROL SYSTEM 3121448 – JLG Lift – 6-63 6.15 CONFIGURATION SERIAL NUMBER RADIO REMOTE CONTROL (X17J ONLY) This menu allows the configuration of the Radio RemoteControl with the Radio Receiver Module. 1. Press Stop Button. 2. Keeping pressed buttons 9 & 10, while release the Stop...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-1 SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS 7.1 DESCRIPTION FOR MODELS X14J/X390AJ-X19J/X550AJ-X23J/X700AJ Table 7-1. X14J/X390AJ-X19J/X550AJ-X23J/X700AJ How to read the electric wiring diagrams A Photoce...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-2 – JLG Lift – 3121448 7.2 A - HOW TO READ THE WIRING DIAGRAMS The wiring diagram is shown divided by individual applica-tion, in order to an easier and faster reading. Some considerations are valid for all machines, unlessotherwise specifi...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-7 7.5 D - AERIAL PART SAFETY CHAIN: OUTRIGGERS SWITCHES NAME DESCRIPTION CONNECTOR CONNECTOR CONNECTOR STAB 1 FRONT LEFT OUTIGGER CONNECTOR CONNECTOR STAB 2 REAR LEFT OURIGGER CONNECTOR CONNECTOR STAB 3 FRONT RIGHT OUTR...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-21 7.12 M - GROUND PART: OUTRIGGERS - ELECTRIC DIVERTER NAME DESCRIPTION ECM2 ELECTRONIC CONTROL MODULE 2 EV - DEV ELECTRIC DIVERTER EV - STAB 1 (F) LEFT FRONT OUTRIGGER ON-OFF ELECTRO VALVE (OPENING) EV - STAB 1 ( R) L...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-23 7.13 N - AERIAL PART: BASKET LEVELLING - BASKET ROTATION - JIB - PROPORTIONAL ELECTRO VALVE NAME DESCRIPTION AE - PROP EV AERIAL PART PROPORTIONAL ELECTRO VALVE ECM2 ELECTRONIC CONTROL MODULE 2 EV - B LEV (F) BASKET ...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-35 7.19 Q - 110-220 VOLT ELECTRIC POWER SUPPLY - ELECTRIC ENGINE NAME DESCRIPTION ARM SCH SECOND ARM SCHEDULE CAPACITOR CAPACITOR CONNECTOR CONNETTOR ECM1 ELECTRONIC CONTROL MODULE 1 ELECTRIC ENGINE ELECTRIC ENGINE ELEC...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-41 7.21 DESCRIPTION FOR MODELS X14JH - X17J Table 7-2. X14JH - X17J How to read the electric wiring diagrams A Photocells – Safety Exclusion – Slew proximity – Stabilizerspressure sensors – 1° Arm switch B Aerial part s...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-49 7.26 E - HANDLE SWITCHES - LOAD CELL - PEDAL NAME DESCRIPTION BASKET LEVELLING HSW BASKET LEVELLING HANDLE SWITCH BASKET ROTATION HSW BASKET ROTATION HANDLE SWITCH ECM3 ELECTRONIC CONTROL MODULE 3 EXT HSW EXTENSION H...

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-67 7.35 ELECTRIC SCHEDULES LAYOUT Figure 7-33.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 7-68 – JLG Lift – 3121448 7.36 COMPONENTS LOCATION Figure 7-34.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS 3121448 – JLG Lift – 7-73 7.39 Z3 - CAN BUS LINE - MAIN SWITCH - IGNITION KEY NAME DESCRIPTION BC BATTERY CHARGER MMEB MACHINE MASTER ELECTRIC BOX MAIN KEY ENGINE KEY MR MASTER RELE' F5 FUSE F6 FUSE FP MAIN FUSE INV INVERTER INV A CONNECTOR A...

Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia +61 2 65 811111 +61 2 65813058 JLG Latino Americana Ltda.Rua Eng. Carlos...