JLG 150HAX Service Manual

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Page 1

Service and Maintenance Manual

Model

150HAX

P/N - 3120679

February 15, 2012

Page 2

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INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

AGENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

CMAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICEMANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

3120679 – JLG Lift – A-1

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INTRODUCTION

REVISON LOG

Original Issue - May 15, 1992 Revised - January 2, 2001 Revised - February 4, 2010 Revised - February 15, 2012

A-2 – JLG Lift – 3120679

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TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Drive/Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.5 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.6 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.7 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.8 Pressure Settings - PSI (Bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.10 Critical Stability weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.12 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SECTION 2 - GENERAL

2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3120679 – JLG Lift – i

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TABLE OF CONTENTS

2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

(Continued)

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION 3 - CHASSIS & TURNTABLE

3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Drive Brake - Mico - Machines Built March 1992 To S/N 33476. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.4 Drive Brake - Mico - Machines Built S/N 33476 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.5 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 3-19

To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.6 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Replacement and Devcon Application Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.7 Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.8 Swing Brake - Ausco - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.9 Swing Brake - Mico - Machines Built To 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

ii – JLG Lift – 3120679

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3.10 Swing Brake - Machines Built 1992 To Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3.11 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3.12 PQ Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

TRIM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

RAMP Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.13 Pump Coupling Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Lovejoy Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Hayes Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.14 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Voltmeter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.15 Throttle Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

SECTION 4 - BOOM & PLATFORM

4.1 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Boom Mounted Limit Switches and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Main Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Tower Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Main Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Tower Boom Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Main Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Tower Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Tower Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Main Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.2 Boom Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Adjusting Procedures - Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.3 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4.4 Platform Rotator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

TABLE OF CONTENTS

SECTION 5 - HYDRAULICS

5.1 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Proportional Control Valves - Vickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

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TABLE OF CONTENTS

5.3 Cylinder Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cylinders w/o Counterbalance Valves - Front and Rear Steer Cylinders, Front and

Rear Frame Lift Cylinders, Upper Master Cylinder, Lower Master Cylinder, Front and

Rear Axle Extension Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cylinders w/Single Counterbalance Valves - Main Lift Cylinder,

Tower Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cylinders w/Dual Counterbalance Valve - Main Telescope Cylinder,

Tower Lift Cylinder, Platform Slave Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Tower Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Tower Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Tower Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Tower Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Main Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Main Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Main Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Main Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Lower Master Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Lower Master Level Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Upper Master Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Upper Master Level Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.5 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

Low Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5 Stack Directional Control Valve (Internal Relief Adjustment) . . . . . . . . . . . . . . . . . . . . . . 5-11

5 Stack Directional Control Valve (External Relief Adjustment Screws) . . . . . . . . . . . . . . . . 5-12

Two Stack Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Three Stack Directional Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Four Stack Directional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.7 Hydraulic Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Wear Guide for Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Recommended Start-up Procedure for New or Rebuilt Pump . . . . . . . . . . . . . . . . . . . . . . . 5-30

Recommended Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

(Continued)

SECTION 6 - SCHEMATICS

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

iv – JLG Lift – 3120679

Page 9

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Operator Maintenance & Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

2-1. Engine Operating Temperature Specifications - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

3-1. Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2. Torque Hub Carrier Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-3. Drive Brake - Mico (March 1992 to S/N 33746) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-4. Drive Brake - Mico (S/N 33476 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-19. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-18. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-19. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

3-20. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-21. Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-22. Swing Brake - Ausco - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-23. Swing Brake - Mico - Machines Built to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-24. Swing Brake - Machines Built 1992 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-25. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37

3-26. Lovejoy Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-27. Hayes Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3-26. Tilt Switch Adjustment - Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3-27. Tilt Switch Adjustment - Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-28. Throttle Checks and Adjustments - Deutz Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

4-1. Boom Mounted Limit Switches and Valves Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2. Main Boom Assembly - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-3. Main Boom Assembly - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-4. Tower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

5-1. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-2. Valve Locations - Turntable Mounted Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-3. Valve Locations - Frame Mounted Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-4. Recommended Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

5-5. Main Gear Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21

6-1. Electrical Schematic - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-2. Electrical Schematic - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

6-3. Electrical Schematic - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

6-4. Electrical Schematic - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

6-5. Electrical Schematic - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

6-6. Hydraulic Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-7. Hydraulic Schematic - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

3120679 – JLG Lift – v

Page 10

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-2 Engine Datas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-3 Drive Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-4 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-5 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-7 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-8 Mobil EAL 224 H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-9 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-10 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-11 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-12 Pressure Settings - 5 Spool Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-13 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-14 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-15 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4-1 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

5-1 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

6-1 Platform Assembly - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Boom Assembly - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-3 Turntable - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4 Chassis - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-5 Hydraulic System - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-6 Electrical System - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

vi – JLG Lift – 3120679

Page 11

SECTION 1. SPECIFICATIONS

Table 1-1. Capacities

Fuel Tank 68 gallons (257 liters)

Hydraulic Oil Tank Approx. 124 gallons (469 liters)

Hydraulic System Approx. 150 gallons (568 liters)

Drive - 90 ounces (2.7 liters) Drive - 90 ounces (2.7 liters)

Swing - 60 ounces (1.8 liters) Swing - 60 ounces (1.8 liters)

Engine Crankcase 10.0 quar ts (9.5 liters) w/o filter

Cooling System S ys t e m Engine R ad i at o r

21.4 quar ts (20.2 liters)

7.4 quar ts (7.0 liters)

14.0 quar ts (13.2 liters)

To rque hubs should be one half full of lubricant.

Table 1-2. Engine Datas

Model Cummins 4B3.9C

Low RPM 1800

High RPM 2500

Alternator 60 Amp, belt driven

Battery 85 Amphour, 550 CCA, 12 volts

Horsepower 76 @ 2500 RPM, no load

Table 1-3. Drive Steer System

Drive Hub Gear Ratio - 93.7:1

Drive Brake Automatic spring applied, hydrau-

lically released. Release pressure 150 psi (10.3 Bar) initial, 170 psi (11.7 Bar) full.

Tires Size - 445/65R22.5, foam-filled

Table 1-4. Performance Data

Maximum Drive Speed 2.7 mph (4.3 kph) @ Max RPM

Maximum Travel Grade (Gradeability)

31%

Turning Radius (Outside) 24 ft. 2 in. (7.4 meters) w/axles

retracted 27 ft. 2 in. (8.3 meters) w/axles extended

Gross Machine Weight 57,000 lbs. (25,855 kg)

Length Stowed 39 ft. 5 in. (12.0 meters) w/main

boom fully retracted and platform in normal position.

41 ft. 7 in. (12.7 meters) w/main boom telescoped out and platform tilted to stow at minimum height.

Machine Width 11 ft. 6 in. (3.5 meters) w/axles

retracted 18 ft. 0 in. (5.5 meters) w/axles extended

Wheelbase 18 ft. 0 in. (5.5 meters)

Platform Capacity 500 lb. (230 kg) unrestricted

1000 lb. (450 kg) restricted

Table 1-5. Function Speeds

Function Speed - In Seconds

Lift Up 115-190

Lift Down 140-160

Tower Lif t Up 89-103

To we r Tel es c op e Ou t 1 25 - 16 0

To we r Tel es c op e In 65 - 90

Tower Lif t Down 61-83

Swing Right & Left 72-84

Te le sc o pe Ou t 4 6- 50

Te le sc o pe In 4 6- 50

Platform Rotate Left & Right 24-26

Jib Up 25-27

Jib Down 21-23

High Drive (200 f t.) 42-46 (3.0 mph)

Drive above Horizontal (50 ft.) 65-71 (0.5 mph)

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

1.2 ENGINE DATA

1.4 PERFORMANCE DATA

1.3 DRIVE/STEER SYSTEM

3120679 – JLG Lift – 1-1

1.5 FUNCTION SPEEDS

Page 12

SECTION 1 - SPECIFICATIONS

Table 1-7. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

Table 1-8. Mobil EAL 224 H Specs

Ty pe Biodegradable Vegetable Oil

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max

-25°F (-32°C)

Flash Point, Min.

428°F (220°C)

Weight

7.64 lb. per gal. (0.9 kg per liter)

Viscosity

at 104° F (40° C) 37 cSt

at 212° F (100° C) 8.4 cSt

Viscosity Index 213

Operating Temp 0-180° F (-17 - -162°C)

Note: Must be stored above 32° F (14° C)

Table 1-9. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Poin t, Ma x

-40°F (-40°C)

Flash Point, Min.

330°F (166°C)

Viscosity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

c p a t - 20 ° F 6 , 20 0

Viscosity Index 140

Table 1-10. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

NOTE: Mobil/Exxon recommends that this oil be

checked on a yearly basis for viscosity.

1.6 LUBRICATION

Table 1-6.Hydraulic Oil

Hydraulic System Operating

Temperature Range

0° to +23° F(-18° to -5° C) 10W

0° to +210° F(-18° to +100° C) 10W-20, 10W-30

+50° to +210° F(+10° to +99° C) 20W-20

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152 .

NOTE: When temperatures remain consistently below 20

degrees F (-7 degrees C.), JLG Industries recommends the use of Mobil DTE11.

NOTE: Aside from JLG recommendations, it is not advisable

to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

SAE Viscosity

Grade

1-2 – JLG Lift – 3120679

Page 13

1.7 TORQUE REQUIREMENTS 1.8 PRESSURE SETTINGS - PSI (BAR)

Table 1-11. Torque Requirements

Description

To rque Va l ue

(Dry)

Interval

Hours

Bearing To Chassis 545 ft. lbs.

(740 Nm)

50/600*

Bearing To Turntable 545 ft. lbs.

(740 Nm)

50/600*

Wheel Lugs 300 ft. lbs.

(407 Nm)

150

Drive To rque Hub to Spindle

260 ft. lbs.

(353 Nm)

200

Main Boom Chains 50 ft. lbs.

(68 Nm)

200

Swing Motor to Swing Brake

110 ft. lbs.

(149 Nm)

500

To rq u e H u b to Tu r nt a bl e Mounting Plate

340 ft. lbs.

(461 Nm)

500

Platform Rotator Brake Bolt

140 ft. lbs.

(190 Nm)

500

*Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereaf ter. (See Swing Bearing in Section 2)

NOTE: When maintenance becomes necessary or a

fastener has loosened, refer to the Torque Chart to determine proper torque value.

Table 1-12. Pressure Settings - 5 Spool Proportional

Valve

PSI BAR

5 Spool Proportional Valve

Main Relief 3800 262

Main Tele Out Relief 2000 138

Main Tele In Relief 3300 228

Main Lift Up Relief 3000 207

Main Lift Down Relief 1850 128

To we r Tel e O u t R el i ef 3 00 0 2 0 7

To we r Tel e I n Re li e f 2 60 0 1 79

Tower Lif t Up Relief 3700 255

Tower Lif t Down Relief 3000 207

Swing Relief 1700 117

2 Spool Solenoid Valve

Main Relief 2750 190

Rotate Relief 2500 172

Level Reliefs 2500 172

3 Spool Solenoid Valve

Steer Reliefs 2000 138

4 Spool Solenoid Valve

Extension Cylinder Reliefs 2000 138

Low Drive System

Sequence Valve 450 31

M ai n Re l ie f o n E x te r n al R el i ef Va l v e 3 20 0 2 2 1

Proportional Drive Valve Section Relief Fact ory se t, does not normally need to be adjusted

3200 221

SECTION 1 - SPECIFICATIONS

3120679 – JLG Lift – 1-3

Page 14

SECTION 1 - SPECIFICATIONS

1.9 MAJOR COMPONENT WEIGHTS 1.10 CRITICAL STABILITY WEIGHTS

Table 1-13. Major Component Weights

LB. KG.

36 x 96 Platform 420 191

Platform Level Cylinder 80 36

Main Boom 6350 2880

Main Lift Cylinder 830 377

Master Level Cylinder (each) 60 27

Tow er Boom 14700 66 68

Tow er Lift Cylinder 1100 499

Turntable Complete (includes swing bearing)

Frame Complete 19200 8709

Complete Machine 57000 25855

14200 6441

Table 1-14. Critical Stability Weights

LB. KG.

Counterweight 3285 1490

Tire & Wheel Assembly 1020 494

Engine 680 308

8 ft. Platform 295 134

1.11 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the machine. The plate is located on the left side of the turntable, just behind the fuel tank. If the serial number plate is missing, the machine serial number is stamped on the left side of the frame, below the turntable bearing. In addition, the last five digits of the serial number are stamped on the top of the fly end of each of the tower boom and main boom sections.

1-4 – JLG Lift – 3120679

Page 15

SECTION 1 - SPECIFICATIONS

Figure 1-1. Operator Maintenance & Lubrication Diagram

1.12 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Fig-

ure 1-1., Operator Maintenance & Lubrication Diagram.

NOTE: The lubrication intervals in Figure 1-1., Operator

Maintenance & Lubrication Diagram are equivalent to the following: 150 hours = 3 months 300 hours = 6 months 600 hours = 1 year 1200 hours = 2 years

Table 1-15. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350°

F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oil) meeting API ser vice classifi-

c at io n G L-5 o r M IL- Sp e c M IL- L-2 10 5

HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid

424.

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-

2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTISHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY.

NOTE: It is recommended as a good practice to replace all

filters at the same time.

3120679 – JLG Lift – 1-5

Page 16

SECTION 1 - SPECIFICATIONS

1. To r q u e H u b s

Lube Point(s) - 1 Fill Plug per hub Capacity Lube - EPGL Interval - Check oil level at side plug on hub weekly.

Change after first 3 months or 150 hours then every 2 years or 1200 hours of operation.

Comments - Place Fill port at 12 o’clock position

and pour lubricant into fill port until it just starts to flow out of check port when it’s at the 3 o’clock position.

2. Steer Spindles

3. Tie Rod Center Pivot Links

Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

4. Steer Cylinder Barrel Ends

Lube Point(s) - 4 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

5. Steer Cylinder Rod Ends

Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

1-6 – JLG Lift – 3120679

Page 17

SECTION 1 - SPECIFICATIONS

6. Extending Axles

Lube Point(s) - N/A Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Apply by brush

7. Swing Bearing Gear

Interval - Every 3 months or 150 hrs of operation Comments - Remote Fitting on Left Rear of Turnta-

ble

9. Tower Boom Lift Cylinder Barrel End

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Remote Fitting on Left Rear of Turnta-

ble

10. Swing Bearing

Lube Point(s) - N/A Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Apply by brush

8. Lower Master Cylinder Barrel End

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG

Lube Point(s) - 2 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Remote Fitting on Left Rear of Turnta-

ble

11. Lower Master Cylinder Rod End

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments -

3120679 – JLG Lift – 1-7

Page 18

SECTION 1 - SPECIFICATIONS

12. Platform Hinges

Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

13. Platform Door Latch

Lube Point(s) - N/A Capacity - A/R Lube - EO Interval - Every 3 months or 150 hrs of operation

14. Platform Rotate Pivot/Rotator Worm Gear

15. Platform Level Links

Lube Point(s) - 3 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

16. Level Cylinder Rod End

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

17. Level Cylinder Barrel End

Lube Point(s) - 2 Grease Fittings on pivot; 1 Grease

Fitting on worm gear Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

18. Engine Crankcase

Lube Point(s) - Fill Cap/Drain Plug Capacity - 10 quarts (9.5 L) w/o filter Lube - EO Comments - Check daily. Refer to Engine Manual for

Change interval.

1-8 – JLG Lift – 3120679

Page 19

SECTION 1 - SPECIFICATIONS

19. Engine Oil Filter

Lube Point(s) - N/A Lube - EO Comments - Refer to Engine Manual for Change

interval.

20. Main Boom Chains

Lube Point(s) - N/A Capacity - N/A Lube - Chain Lube Interval - Every 2 years or 1200 hours of operation.

21. Main Boom Extend Chain Sheave

24. Main Boom Pivot Pin

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

25. Tower Boom Pivot Pin

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Align access holes in mid and fly boom

22. Main Boom Lift Cylinder

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

23. Main Boom Retract Chain Sheave

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Align with access hole in base boom.

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

26. Level Links

Lube Point(s) - 3 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments -

3120679 – JLG Lift – 1-9

Page 20

SECTION 1 - SPECIFICATIONS

27. Upper Master Cylinder Rod End

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments -

28. Upper Master Cylinder Barrel End

31. Hydraulic Filter

Interval - Replace filter after first 50 hours of opera-

tion, then every 6 months or 300 hours thereafter.

32. Air Filter

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments -

29. Tower Boom Lift Cylinder Rod End

Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments -

30. Hydraulic Oil

Lube Point(s) - Fill Cap/Drain Plug Capacity - A/R Lube - HO Interval - Check daily. Change every 2 years or 1200

hours Comments - On new machines, those recently over-

hauled, or after changing hydraulic oil, operate

all systems a minimum of two complete cycles

and recheck oil level in reservoir.

Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation

or as indicated by the condition indicator

1-10 – JLG Lift – 3120679

Page 21

SECTION 1 - SPECIFICATIONS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N

Description

0100011

242

Vibra-TITE

121

Medium Strength (Blue)

0100019

271

Vibra-TITE

140

High Strength (Red)

0100071

262

Vibra-TITE

131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

or Vibra-

TITE

131)

Torque

Lubricated

Torque

(Loctite® 242

or 271

OR Vibra-TIT E

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

Figure 1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7)

3120679 – JLG Lift – 1-11

Page 22

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5

1580 60 7

1800 68 8 2860 143 16 129 15 3280 164 19 148 17

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000456040 553550 7900 50 70 45 60 35 50

9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110

14400 120 165 110 150 90 120

16400 155 210 140 190 115 155

18250 170 230 155 210 130 175

20350 210 285 190 260 160 220

23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875

59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475 87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140) K=.18

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry or Loctite® 263)

K= 0.20

1-12 – JLG Lift – 3120679

Figure 1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7)

Page 23

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K = .17

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

SECTION 1 - SPECIFICATIONS

3120679 – JLG Lift – 1-13

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7)

Page 24

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242TM or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW AL UMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

1-14 – JLG Lift – 3120679

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7)

Page 25

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

Torque

(Lub)

Torque

(Loctite® 262

OR Vibra-

TITE

131)

Torque

(Loctite®

242

or 271

OR Vibra-

TITE

111 or

140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7)

3120679 – JLG Lift – 1-15

Page 26

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

K = 0.20

Torque

(Lub OR Loctite®

242

or 271TM OR

Vibra-TITE

111 or

140)

K= 0.18

Torque

(Loctite® 262

Vibra-TITE

131)

K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.25 36.60 22.8 36.5 32.8 27.4

10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150

16 2 157 97.8

315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT

REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

1-16 – JLG Lift – 3120679

Page 27

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

Torque

(Dry or Loctite®

263

)

K = .17

Torque

(Lub OR Loctite®

242

or 271

OR Vibra-TITE

111 or 140)

K = .16

Torque

(Loctite® 262

OR Vibra-TITE

131)

K = .15

Sq mm kN [N.m] [N.m] [N.m]

30.55.03

3.5 0.6 6.78

40.78.78

50.814.20

6120.1012.5 13 12 11

7128.9018.0 21 20 19

8 1.25 36.60 22.8 31 29 27 10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT

REPRESENT FULL STRENG TH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

3120679 – JLG Lift – 1-17

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

Page 28

SECTION 1 - SPECIFICATIONS

NOTES:

1-18 – JLG Lift – 3120679

Page 29

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the Pre-Start Inspection. The Operator and Safety Manual must be read in its entirety and understood prior to performing the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a Factory-Trained Service Technician on an annual basis, no later than thirteen (13) months from the date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory-Trained Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this inspection.

Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.

3120679 – JLG Lift – 2-1

Page 30

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start Inspection Prior to use each day; or

At each Operator change.

Pre-Delivery

Inspection

Frequent Inspection In service for 3 months or 150 hours, which-

Annual Machine

Inspection

Preventative

Maintenance

Prior to each sale, lease, or

rental delivery.

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as specified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.

Safety and Workmanship

Cleanliness

Primary

Responsibility

User or Operator User or Operat or Operator and Safety Manu al

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Trained

Owner, Dealer, or User Qualified JLG

2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Service

Qualification

Mechanic

Service Technician

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if mechanical assistance is required. All slings (chains, cables, etc.) should be parallel to each other and as near perpendicular as possible to top of part being lifted.

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

2. Should it be necessary to remove a component on an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90 degrees.

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

2-2 – JLG Lift – 3120679

Page 31

SECTION 2 - GENERAL

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.

Bearings

1. When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

3. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1.

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

1. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent.

2. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)

2.3 LUBRICATION AND INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient system warm-up or leaks in the pump supply (suction) lines.

2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the speci-

3120679 – JLG Lift – 2-3

Page 32

SECTION 2 - GENERAL

fied intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles.

3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.

Hydraulic Oil

1. Refer to Section 1 for recommendations for viscosity ranges.

2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -15 degrees F (-26 degrees C) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, 100VAC heater to a minimum temperature of -15 degrees F (-26 degrees C).

3. The only exception to the above is to drain and fill the system with Mobil DTE 13 oil or its equivalent. This will allow start up at temperatures down to -20 degrees F (-29 degrees C). However, use of this oil will give poor performance at temperatures above 120 degrees F (49 degrees C). Systems using DTE 13 oil should not be operated at temperatures above 200 degrees F (94 degrees C) under any condition.

Changing Hydraulic Oil

1. Filter elements must be changed after the first 50 hours of operation and every 300 hours (unless specified otherwise) thereafter. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed.

3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured using the following methods.

Platform Drift

Measure the drift of the platform to the ground. Lower booms (if equipped) slightly elevated, main boom fully extended with the rated load in the platform and power off. Maximum allowable drift is 2 inches (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following.

2-4 – JLG Lift – 3120679

Page 33

SECTION 2 - GENERAL

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

8 203.2 0.0038 0.10

9 228.6 0.0030 0.08

Drift is to be measured at the cylinder rod with a calibrated dial indicator. The cylinder oil must be at ambient temperature and temperature stabilized.

The cylinder must have the normal load, which is the normal platform load applied.

If the cylinder passes this test, it is acceptable.

NOTE: This information is based on 6 drops per minute cyl-

inder leakage.

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

b. Flaking, pealing, scoring, or scratches on the pin

surface.

c. Rusting of the pin in the bearing area.

4. Re-assembly of pinned joints using filament wound

bearings.

a. Housing should be blown out to remove all dirt

and debris...bearings and bearing housings must be free of all contamination.

b. Bearing / pins should be cleaned with a solvent

to remove all grease and oil...filament wound bearing are a dry joint and should not be lubricated unless otherwise instructed (i.e. sheave pins).

c. Pins should be inspected to ensure it is free of

burrs, nicks, and scratches which would damage the bearing during installation and operation.

2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to

the machine and to welding performed from the machine on an external structure, or component,

Do the Following When Welding on JLG Equipment

• Disconnect the battery.

• Disconnect the moment pin connection (where fitted)

• Ground only to structure being welded.

Filament wound bearings.

1. Pinned joints should be disassembled and inspected if the following occurs:

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

2. Filament wound bearings should be replaced if any

of the following is observed:

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their hous-

ing.

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is

observed (pin should be properly cleaned prior to inspection):

a. Detectable wear in the bearing area.

Do NOT Do the Following When Welding on JLG Equipment

• Ground on frame and weld on any other area than the chassis.

• Ground on turntable and weld on any other area than the turntable.

• Ground on the platform/support and weld on any other area than the platform/support.

• Ground on a specific boom section and weld on any other area than that specific boom section.

• Allow pins, wear pads, wire ropes, bearings, gearing, seals, valves, electrical wiring, or hoses to be between the grounding position and the welded area.

FAILURE TO COMPLY WITH THE ABOVE REQUIREMENTS MAY RESULT IN COMPONENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR RING, BOOM WIRE ROPES ETC.)

3120679 – JLG Lift – 2-5

Page 34

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Boom Assembly

Boom Weldments 1,2,4 1,2,4

Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12

Pivot Pins and Pin Retainers 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pads 1,2 1,2

Covers or Shields 1,2 1,2

Extend/Retract Chain or Cable Systems 1,2,3 1,2,3

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 511,5

Floor 1,2 1 1,2

Rotator 9,5 15

Lanyard Anchorage Point 2 1,2,10 1,2,10

Turntable Assembly

Swing Bearing or Worm Gear 1,2,14 1,2,3,13,14

Oil Coupling 9

Swing Drive System 11 11

Turntable Lock 1,2,5 1,2,5

Hood, Hood Props, Hood L atches 51,2,5

Chassis Assembly

Tires 1 16,17 16,17,18 16,17,18

Wheel Nuts/Bolts 115 1515

Wheel Bearings 14,24

Oscillating Axle/Lockout Cylinder Systems 5,8

Outrigger or Extendable Axle Systems 5,8 5,8

Steer Components

Drive Motors

Drive Hubs 11 11 24

Functions/Controls

Platform Controls 55 66

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery or Frequent

Inspection

Annual

(Yearly)

Inspection

Every 2

Years

2-6 – JLG Lift – 3120679

Page 35

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

Preventive

Maintenance

Weekly

Monthly

Preventive

Maintenance

Pre-Delivery or Frequent

Inspection

Ground Controls 55 66

Function Control Locks, Guards, or Detent s 1,5 1,5 5 5

Footswitch 1,5 5 5

Emergency Stop Switches (Ground & Platform) 555

Function Limit or Cutout Switch Systems 555

Capacity Indicator 5

Drive Brakes 5

Swing Brakes 5

Boom Synchronization/Sequencing Systems 5

Manual Descent or Auxiliary Power 55

Power System

Engine Idle, Throttle, and RPM 33

Engine Fluids (Oil, Coolant, Fuel) 11 9,11 11 11

Air/Fuel Filter 1,7 7 7

Exhaust System 1,9 9 9

Batteries 51,9 19

Battery Fluid 11 11 11

Battery Charger 55

Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5

Hydraulic/Electric System

Hydraulic Pumps 1,9 1,2,9

Hydraulic Cylinders 1,9,7 2 1,2,9 1,2,9

Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2

Hydraulic Hoses, Lines, and Fittings 1,9 12 1,2,9,12 1,2,9,12

Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 12020

Instruments, Gauges, Switches, Lights, Horn 15,23

General

Operators and Safety Manuals in Storage Box 21 21 21

ANSI and AEM Manuals/Handbooks Installed 21

Capacity Decals Installed, Secure, Legible 21 21 21

All Decals/Placards Installed, Secure, L egible 21 21 21

Annual

(Yearly)

Inspection

Every 2

Years

3120679 – JLG Lift – 2-7

Page 36

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery or Frequent

Inspection

Walk-Around Inspection Performed 21

Annual Machine Inspection Due 21

No Unauthorized Modifications or Ad ditions 21 21

All Relevant Safety Publications Incorporated 21 21

General Structural Condition and Welds 2,4 2,4

All Fasteners, Pins, Shields, and Covers 1,2 1,2

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 21 21 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footnotes:

Prior to use each day; or at each Operator change

Prior to each sale, lease, or delivery

In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purch ased used

Annually, no later than 13 months from the date of the prior inspection

Performance Codes: 1 - Check for proper and secure installation 2 - Visual inspection for damage, cracks, distortion or exc essive wear 3 - Check for proper adjustment 4 - Check for cracked or broken welds 5 - Operates Properly 6 - Returns to neutral or "off" position when released 7 - Clean and free of debris 8 - Interlocks function properly 9 - Check for signs of leakage 10 - Decals installed and legible 11 - Check for proper fluid level 12 - Check for chafing and proper routing 13 - Check for proper tolerances 14 - Properly lubricated 15 - Torqued to proper specification 16 - No gouges, excessive wear, or cords showing 17 - Properly inflated and seated around rim 18 - Proper and authorized components 19 - Fully charged 20 - No loose connections, corrosion, or abrasions 21 - Verify 22 - Perform 23 - Sealed Properly 24 - Drain, Clean, Refill

Annual

(Yearly)

Inspection

Every 2

Years

2-8 – JLG Lift – 3120679

Page 37

SECTION 2 - GENERAL

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE

180° F (82° C)

PROLONGED OPERATION IN AMBIENT AIR TEMPERA TURES OF 100° F (38° C) OR ABOVE.

EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180° F (82° C) OR ABOVE.

NO OPERATION BELOW THIS AMBIENT TEMPERA T URE

HYDRAULIC SPECIFICATIONS

NO OPERATION ABOVE THIS AMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

-40°F(-40

°C)

-30°

F(-34

°C)

-20°

F(-29

°C)

-10°

F(-23

°C)

0°

F(-18

°C)

10°

F(-12

°C)

20° F(-7°C)

30° F(-1°C)

40° F(4°C)

50° F(10°C)

60° F(16°C)

70° F(21°C)

80° F(27°C)

90° F(32°C)

100°

F(38°C)

110°

F(43°

120°

F(49°

ENGINE SPECIFICATIONS

ENGINE WILL START AND OPERATE UNAIDED AT THIS

TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A

FULLY CHARGED BATTERY.

AMBIENT AIR

TEMPERATURE

SUMMER

GRADE

FUEL

WINTER

GRADE

FUEL

NO OPERATION BELOW THIS AMBIENT TEMPERATURE

NO OPERATION ABOVE THIS AMBIENT TEMPERATURE

Figure 2-1. Engine Operating Temperature Specifications - Cummins

4150548 D

3120679 – JLG Lift – 2-9

Page 38

SECTION 2 - GENERAL

NOTES:

2-10 – JLG Lift – 3120679

Page 39

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Tire Inflation

The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics.

Tire Damage

For pneumatic tires, JLG Industries, Inc. recommends that when any cut, rip, or tear is discovered that exposes sidewall or tread area cords in the tire, measures must be taken to remove the JLG product from service immediately. Arrangements must be made for replacement of the tire or tire assembly.

For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly.

• a smooth, even cut through the cord plies which exceeds 3 inches (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plies which exceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

• any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria.

Tire Replacement

JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics:

ment tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

Wheel Replacement

The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability.

Wheel Installation

It is extremely important to apply and maintain proper wheel mounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.

Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. If you do not have a torque wrench, tighten the fasteners with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper torque. Over-tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels. The proper procedure for attaching wheels is as follows:

1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

2. Tighten nuts in the following sequence:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to the original

• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load)

Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replace-

3120679 – JLG Lift – 3-1

Page 40

SECTION 3 - CHASSIS & TURNTABLE

3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart.

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

70 ft. lbs.

(95 Nm)

4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation.

170 ft. lbs.

(225 Nm)

300 ft. lbs.

(405 Nm)

3.2 DRIVE TORQUE HUB

Disassembly

1. Position hub over suitable container and remove drain plug (37) from unit. Allow oil to completely drain.

2. Remove sixteen bolts (1), four shoulder bolts (2), and twenty lockwashers (3) from cover (4) and lift cover from unit. Remove o-ring (14) from counterbore of cover.

3. Disassemble cover (4) as follows:

a. Remove two bolts (12) securing disconnect cap

(11) to cover and remove disconnect cover.

b. Remove two bolts (12) securing cover cap (7) to

cover and remove cap.

c. Remove disconnect rod (9) from cover cap and

remove o-rings (8 and 10) from cover cap. Discard o-rings.

d. If necessary, remove pipe plugs (5 and 6) from

cover.

4. Remove two thrust washers (15) and thrust bearing (16) from carrier counterbore. One thrust washer may stick to cover. Inspect thrust washers and bearing for wear and replace if necessary.

5. Lift carrier assembly (22) from hub and spindle assembly (30).

6. Disassemble carrier as follows:

b. Remove spacer (26) from planet shaft, then,

using a suitable drift, drive planet shaft from carrier, shearing off roll pin. Tap remaining roll pin from carrier using a suitable punch.

c. Remove cluster gear (27) from carrier and

remove bearing cones (29) from cluster gear.

d. If necessary, press bearing cups (28) from clus-

ter gear.

7. Lift ring gear (13) from housing (36). Remove o-ring (14) from counterbore of ring gear and discard.

8. Remove input (sun) gear (17), input spacer (18), and input shaft (20) from spindle (30).

9. Remove two thrust washers (15) and thrust bearing (16) from end of spindle. One thrust washer may stick in carrier counterbore. Inspect thrust washers and thrust bearing for wear and replace if necessary.

10. Lift internal gear (21) out of hub.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

11. Remove keeper ring (40), retaining ring (35), and bearing shim (34) from end of spindle. Remove hub from spindle.

12. Remove bearing cone (32) and seal (31) from spindle (30). Seal will possibly hold bearing cone into hub. If so, remove both from hub. If bearing cups (33) require replacing they can be driven out of hub counterbores. Discard seal and replace with new seal.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

13. To remove cluster gear (27) from carrier, remove retaining ring (25) from planet shaft (23) and drive planet shaft out of carrier.

14. Cluster gear and bearings (27, 29) can now be slid out of carrier and spacer (18) removed from carrier bore. If bearing cups (28) require replacing they can be driven out of cluster gear counterbores.

15. Repeat steps (12) and (13) for remaining cluster gears.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

a. Remove retaining ring (25) from planet shaft

(23).

WHEN REBUILDING THE UNIT, O-RINGS AND RETAINING RINGS SHOULD ALWAYS BE REPLACED.

3-2 – JLG Lift – 3120679

Page 41

SECTION 3 - CHASSIS & TURNTABLE

1. Bolt

2. Bolt

3. Lockwasher

4. Cover

5. Pipe Plug

6. Pipe Plug

7. Cover Cap

8. O-ring

9. Disconnect Rod

10. O-ring

11. Disconnect Cap

12. Bolt

13. Ring Gear

14. O-ring

15. Thrustwasher

16. Thrust Bearing

17. Input Gear

18. Thrust Spacer

19. Retaining Ring

20. Input Shaft

21. Internal Gear

22. Carrier

23. Planet Shaft

24. Roll Pin

25. Retaining Ring

26. Spacer

27. Cluster Gear

28. Bearing Cup

29. Bearing Cone

30. Spindle

31. Seal

32. Bearing Cup

33. Bearing Cone

34. Bearing Shim

35. Retaining Ring

36. Hub

37. Pipe Plug

38. Magnetic Plug

39. Stud

40. Keeper Ring

41. Retaining Ring

42. Washer

43. Spring

44. Not Used

45. Input Coupling

Figure 3-1. Drive Torque Hub

3120679 – JLG Lift – 3-3

Page 42

SECTION 3 - CHASSIS & TURNTABLE

Cleaning and Inspection

1. Thoroughly clean all parts in an approved cleaning solvent.

2. Inspect geared or splined components in primary and secondary planet carriers, input and output sun gears, ring gear, coupling and input shaft for chipped or broken teeth, and excessive or uneven wear patterns. Replace components as necessary.

3. Inspect all thrust washers for scoring, pitting, erosion, discoloration or excessive wear. Replace thrust washers as necessary.

4. Inspect all bearing cones and cups for scoring, pitting or excessive wear. If necessary, using a suitable press, remove bearing cups from hub and replace bearings as a set.

5. Inspect all needle rollers for scoring, pitting or excessive wear. Replace all rollers as necessary.

6. Inspect planet gear pins for grooves, scoring or excessive wear. Replace pins as necessary.

7. Inspect all threaded components for damage including stretching, thread deformation, or twisting. Replace as necessary.

b. Turn hub over, small diameter up. Install two

pipe plugs (37) into hub.

c. Press bearing cup (33) into small diameter end

of hub. If no press is available, bearing cup may be frozen and tapped into place with a nonmetallic faced hammer.

d. Install bearing cone (32) into bearing cup.

8. Inspect oil seal surfaces in hub and spindle for burrs

or sharp edges. Dress applicable surfaces or replace components as necessary.

9. Inspect mating surfaces of hub, ring gear and cover for burrs and sharp edges. Dress applicable surfaces or replace components as necessary.

Assembly

1. If necessary, assemble the hub/spindle assembly (36 and 30) as follows:

a. With large open end of hub (36) up, press bear-

ing cup (33) into hub. If no press is available, bearing cup may be frozen and tapped into place with a non-metallic faced hammer.

e. Press seal (31) into hub counterbore with flat

metal side facing out. Use a flat object to ensure that seal is pressed evenly and is flush with hub face.

3-4 – JLG Lift – 3120679

Page 43

SECTION 3 - CHASSIS & TURNTABLE

f. Lower hub onto spindle (30) with large open end

up.

g. Place bearing cone (32) over end of spindle and

into bearing cup.

i. Secure retaining ring (35) completely into spin-

dle groove and against bearing shim. Ensure retaining ring is entirely in groove.

j. Install retaining ring keeper ring (40) in location

around retaining ring and on bearing shim.

h. Place bearing shim (34) over end of spindle and

against bearing cone.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

k. With large open end of hub/spindle assembly

facing up, place one spacer washer (42) into spindle counterbore.

3120679 – JLG Lift – 3-5

Page 44

SECTION 3 - CHASSIS & TURNTABLE

l. Place spring (43) into spindle counterbore.

m. Set second spacer washer (42) on top of spring.

2. Position hub/spindle assembly (36 and 30) with

large open end up.

3. Lower internal gear (21) onto spindle.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

n. Compress spacer washer and spring into spin-

dle counterbore and install retaining ring (41) into spindle groove.

4. Place one thrust bearing (16) between two thrust washers (15) and place them onto spindle pilot.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

3-6 – JLG Lift – 3120679

Page 45

SECTION 3 - CHASSIS & TURNTABLE

5. Install retaining ring (19) in groove of input shaft (20).

6. Place input shaft into spindle counterbore of hub/ spindle assembly. The action of the disengaged spring should be checked at this time.

8. Place o-ring (14) into counterbore of hub/spindle assembly. Use grease or petroleum jelly to hold oring in place.

9. Assemble carrier assembly (22) as follows:

a. Press bearing cups (28) into both ends of cluster

gear (27) with large inside diameter facing out. Use an arbor type press with an adapter tool.

7. Slide thrust spacer (18) onto input shaft.

BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING THIS O-RING.

b. Place planet shaft (23) on a flat surface with

large diameter down. Place one bearing cone (29) over shaft and against shoulder. This should be a slip fit.

3120679 – JLG Lift – 3-7

Page 46

SECTION 3 - CHASSIS & TURNTABLE

c. Place cluster gear over planet shaft and onto

bearing cone, with large gear on top.

d. Place another bearing cone (29) over planet

shaft and into cluster gear. This is a slip fit.

f. Bearings in cluster gear must be seated by

applying 25-50 lbs. (11-23 kg) against them and rotating cluster gear at the same time. This can be done by sliding a second spacer (26) over planet shaft and pushing downward while rotating the gear.

g. See if retaining ring (25) will fit onto planet shaft

groove. If not, try smaller spacer (26) until retaining ring fits. This will set bearings at 0.000-0.152 mm.

e. Slide largest spacer (26) onto planet shaft.

h. Place carrier on edge of a table with one set of

holes hanging over the edge. Side with roll pin hole should be down.

3-8 – JLG Lift – 3120679

Page 47

SECTION 3 - CHASSIS & TURNTABLE

i. Place bearing cones (29) into cluster gear.

j. Place cluster gear into carrier with large gear up.

l. While holding planet shaft in position, slide cor-

rect spacer onto planet shaft.

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION.

m. Place carrier on table with something under

planet shaft to hold it in correct position and install retaining ring (25).

k. Slide planet shaft through carrier and cluster

gear from bottom side. Slot in planet shaft must line up with roll pin hole in edge of carrier.

EYE PROTECTION SHOULD BE WORN DURING THIS OPERATION.

n. Drive roll pin (24) into carrier. Use a punch to

drive roll pin completely into planet shaft.

3120679 – JLG Lift – 3-9

Page 48

SECTION 3 - CHASSIS & TURNTABLE

o. Repeat steps (a) through (n) for remaining two

cluster gears.

10. Time carrier gears as follows:

a. Place carrier assembly on a flat surface, posi-

tioning two top gears at ten o’clock and two o’clock, and one bottom gear at six o’clock as shown in Figure 3-2., Torque Hub Carrier Timing.

b. Find marked (punch mark) teeth on large gears.

Rotate gears until punch mark is located in a straight up, 12 o’clock, position. Punch marks at ten o’clock and two o’clock will be located just under edge of carrier and not readily visible.

11. Taking care to ensure that timing is maintained, install ring gear (13) in mesh with large diameter cluster gear. Side of ring gear with long shoulder is installed down.

12. While holding ring gear in mesh with carrier assembly, lower into internal gear (21). Small diameter cluster gear will mesh with internal gear. Slight rotation of ring gear may be necessary.

13. Locate the one hole on underside of ring gear that has an “X” stamped beside it. This hole should be positioned in line with one of four counterbored holes in face of hub. These holes have been counterbored to accept four shoulder bolts upon installation of cover.

14. Thrust spacer (18) and input gear (17) are installed onto input shaft (20). Counterbore in input gear should be facing thrust spacer.

3-10 – JLG Lift – 3120679

Page 49

SECTION 3 - CHASSIS & TURNTABLE

15. Place one thrust bearing (16) between two thrust washers (15) and place into carrier counterbore.

16. Assemble cover assembly as follows:

a. Screw pipe plugs (5 and 6) into cover 4.

c. Install o-ring (10) into bore of cover cap 7. Dis-

connect rod (9) may be used to push o-ring down to groove in cover cap bore.

d. Push disconnect rod into bore of cover cap.

b. Install o-ring (8) over cover cap (7).

e. Locate large clearance hole in cover cap over

pipe plug in cover and install cover cap in cover. Use two bolts (12) torqued to 70 to 80 in.lbs. (8192 kgcm).

3120679 – JLG Lift – 3-11

Page 50

SECTION 3 - CHASSIS & TURNTABLE

f. Install disconnect cap (11) to cover cap with two

remaining bolts (12) torqued to 70 to 80 in.lbs. (81-92 kgcm).

BEWARE OF SHARP EDGES OF COUNTERBORE WHILE SEATING THIS O-RING.

g. Place o-ring (5) into cover counterbore. Use

petroleum jelly to hold o-ring into place.

18. Secure cover assembly and ring gear to hub with four shoulder bolts (2) and lockwashers 3. Shoulder bolts fit into four counterbored holes in hub. It may be necessary to start bolts into hub by tapping lightly on bolts with a hammer.

19. Install sixteen Grade 8 bolts (1) and lockwashers (3) in remaining holes.

20. Tighten bolts and shoulder bolts evenly and torque to 100-110 ft.lbs. (14-15 kgm).

17. Place cover assembly (4) onto ring gear (13). Rotate cover assembly until pipe plug (6) is located 90 degrees and 180 degrees from pipe plugs (38) in opposite end of hub.

21. Install coupling (45) into spindle onto input shaft.

3-12 – JLG Lift – 3120679

Page 51

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-2. Torque Hub Carrier Timing

3120679 – JLG Lift – 3-13

Page 52

SECTION 3 - CHASSIS & TURNTABLE

3.3 DRIVE BRAKE - MICO - MACHINES BUILT MARCH 1992 TO S/N 33476

Disassembly

1. Separate end cover (2) from housing (21) by removing capscrews (1).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (3,000 LBS. (1,360 KG) MINIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Remove case seal (4) from the housing (21), then remove bleeder screw (3) from the end cover (2).

3. Remove piston (7) from end cover (2).

4. Remove o-ring (5), back-up ring (6), o-ring (8) and

back-up ring (9) from piston (7).

5. Remove separators (13) from housing (21).

6. Remove stack assembly, consisting of discs (11),

return plate (14) and friction discs (12) from housing (21).

NOTE: Not all models use the same number of springs or

spring pattern. Record this information for assembly purposes. Spring retainer (17) was not used in earlier models.

7. Remove dowel pins (20), springs (15 & 16) and spring retainer (17) from housing (21).

8. Remove retaining ring (18) from housing (21).

9. Remove shaft by pressing or using a soft mallet on

male end of shaft (10).

Cleaning and Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks,

and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact sur-

faces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Clean all parts thoroughly before assembly.

2. Press new rotary oil seal (23) into housing (21). Note

direction of the seal.

NOTE: Earlier models did not use retaining ring (22).

3. Install new bearing (19) and retaining ring (22) on shaft (10).

4. Insert shaft assembly and retaining ring (18) in housing (21).

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly. Spring retainer (17) was not used in earlier models.

5. Insert dowel pins (20), spring retainer (17) and springs (15 & 16) in housing (21).

NOTE: Earlier models did not use retaining ring (22).

10. Remove retaining ring (22) and bearing (19) from shaft (10).Press Rotary oil seal (23) from housing (21).

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Figure 3-3. Drive Brake - Mico (March 1992 to S/N 33746)

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SECTION 3 - CHASSIS & TURNTABLE

6. Position new large diameter return plate (14) in housing with tabs guided by dowel pins (20) until disc rests on springs (15 & 16).

DISCS (11, 14) AND FRICTION DISCS (12) SHOULD REMAIN DRY DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES.

7. Place a new friction disc (12) on shaft (10) until it contacts return plate (14).

8. Add additional new discs (11) and new friction discs (12) as required to complete assembly.

9. Insert separators (13) in holes of return plate.

10. Install new o-ring (5), new backup ring (6), new o-

ring (8) and new back-up ring (9) on piston (7). Note order of o-rings and back-up rings. Insert piston (7) into end cover (2) being careful not to shear o-rings or back-up rings.

11. Install new case seal (4) in housing (21) then install bleeder screw (3) in end cover (2).

12. Position end cover (2) on housing (21) aligning dowel pins (20) with holes in end cover.

3.4 DRIVE BRAKE - MICO - MACHINES BUILT S/N 33476 TO PRESENT

Disassembly

1. With the shaft protrusion downward, remove end cover (13) by removing capscrews (12).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 681 KG. THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (1362 KG MAXIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Remove case seal (11) from housing (7) then remove bleeder screw (14) from end cover (13).

3. Remove piston (24) from end cover (13).

4. Remove o-ring (19), back-up ring (18), o-ring (21)

and back-up ring (20) from piston (24).

NOTE: If available, a hydraulic press will simplify installation

of end cover on housing. Clamp cover in position while tightening capscrews.

13. Press on inner ring of bearing (37) until it shoulders on shaft (45) to eliminate binding on bearings. Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing (54).

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.

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SECTION 3 - CHASSIS & TURNTABLE

5. Remove separators (10) from housing (7).

6. Remove stack assembly, consisting of discs (23),

return plate (8) and friction discs (22) from housing (7).

7. Remove dowel pins (17), springs (5 & 6) from housing (7).

8. Remove retaining ring (3) from housing (7).

9. Remove shaft by pressing or using a soft mallet on

male end of shaft (4).

10. Remove retaining ring (15) bearing (2) from shaft (4).

11. Press rotary seal (1) from housing (7).

Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks

and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact sur-

faces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are inspection, they are found to be in good condition.

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Press new rotary seal (1) into housing (7). Note the direction of seal.

2. Install new bearing (2) on shaft (4).

3. Install shaft assembly and retaining ring (3) into

housing (7).

4. Install dowel pins (17), spring retainer (16), and springs (5 & 6) into housing (7).

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly.

5. Position new large diameter return plate (8) in housing with tabs guided by dowel pins (17) until disc rests on springs (5 & 6).

NOTE: Discs (8 & 23) and friction discs (22) should remain

dry during installation. No oil contaminate disc surfaces.

6. Place new disc (22) on shaft (4) until it contacts return plate (8).

7. Add additional discs (23) as required to complete assembly.

8. Insert separators (10) in holes of return plate (8).

9. Install new o-ring (19), new back-up ring (18), new o-

ring (20) and new back-up ring (21) on piston (24). Insert piston (24) into end cover (13) being careful not to shear o-rings or back-up rings.

10. Install new case seal (11) in housing (7) then install bleeder screw (14) in end cover.

11. Position end cover (13) on housing (7) aligning dowel pins (17) with holes in end cover.

12. Insert capscrews (12) and tighten evenly to draw end cover (13) to housing (7). Torque capscrews to 55 ft. lbs. (75 Nm).

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SECTION 3 - CHASSIS & TURNTABLE

1. Capscrew

2. End Cover

3. Bleeder Screw

4. Case Seal

5. O-ring

6. Back-Up Ring

7. Piston

8. O-ring

9. Backup Ring

10. Shaft

11. Disc

12. Friction Disc

13. Separators

14. Return Plate

15. Spring

16. Spring

17. Spring Guide

18. Retaining Ring

19. Bearing

20. Dowel Pin

21. Housing

22. Retaining Ring

23. Rotary Oil Seal

24. O-ring

25. Gasket

26. Pin

52 53

Figure 3-4. Drive Brake - Mico (S/N 33476 to Present)

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SECTION 3 - CHASSIS & TURNTABLE

3.5 FREE WHEELING OPTION

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.

1. Chock wheels securely if not on a flat level surface.

2. Disconnect all drive hubs by inverting disconnect

caps in center of hubs.

To Engage Drive Motors and Brakes (Normal Operation)

1. Connect all drive hubs by inverting disconnect cap in center of hub.

2. Remove chocks from wheels as required.

NOTE: This machine is not equipped with a tow package.

Refer to Section 6 of the Operating and Safety Manual for emergency towing procedures.

3.6 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

NOTE: This check is designed to replace the existing bear-

ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter. If during this check any bolts are found to be missing or loose, replace missing or loose bolts with new bolts and torque to the value specified in the torque chart, after lubricating the bolt threads with JLG Threadlocker P/N 0100019. After replacing and retorquing bolt or bolts recheck all existing bolts for looseness.

Check the frame to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full elevation).

2. At the positions indicated on Figure 3-18., Swing Bearing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

3. Assure that the 0.0015" feeler gauge will not penetrate under the bolt head to the bolt shank.

4. Swing the turntable 90 degrees, and check some selected bolts at the new position.

5. Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants.

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SECTION 3 - CHASSIS & TURNTABLE

Figure 3-19. Swing Bearing Tolerance Boom Placement

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SECTION 3 - CHASSIS & TURNTABLE

.0015" Feeler Gauge

Figure 3-18. Swing Bearing Bolt Feeler Gauge Check

Check the turntable to bearing attach bolts as follows:

1. Elevate the fully retracted boom to 70 degrees (full elevation).

2. At the positions indicated on Figure 3-18., Swing Bearing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

3. Lower the boom to horizontal and fully extend the boom.

4. At the position indicated on Figure 3-18., Swing Bearing Bolt Feeler Gauge Check, try and insert the

0.0015" feeler gauge between the bolt head and hardened washer at the arrow indicated position.

c. Noise.

d. Rough rotation.

5. If bearing inspection shows no defects, reassemble

bearing and return to service.

THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION.

Replacement and Devcon Application Procedures

REMOVAL

1. From ground control station, operate tower boom lift

control and raise tower boom adequately to provide access to rotary coupling.

NEVER WORK BENEATH THE BOOM WITHOUT FIRST PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCKING.

2. Attach an adequate support sling to boom and draw all slack from sling. Block boom if feasible.

3. From under side of machine frame, remove bolts and lockwashers which attach rotary coupling retaining yoke to coupling housing.

Wear Tolerance

1. From underside of machine, at rear center, with tower boom fully elevated and fully retracted and main fully elevated and fully retracted (See Figure 3-

19.), using a magnetic base dial indicator, measure and record the distance between the swing bearing and the frame.

2. At the same point, with tower boom at horizontal and fully retracted and main boom at horizontal and fully extended (See Figure 3-19.), using a magnetic base dial indicator, measure and record the distance between the swing bearing and frame. (See Figure 3-19.)

3. If a difference greater than 0.076 in. (1.93 mm) is determined, the swing bearing should be replaced.

4. If a difference less than 0.076 in. (1.93 mm) is determined, and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the following:

a. Metal particles in the grease.

b. Increased drive power required.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM.

4. Tag and disconnect hydraulic lines from fittings on top and sides of rotary coupling. Use a suitable container to retain any residual hydraulic fluid. Immediately cap lines and ports.

5. Attach suitable overhead lifting equipment to base of turntable weldment.

6. Using a suitable tool, scribe a line on inner race of swing bearing and on underside of turntable. This line will aid in aligning bearing upon installation. Remove bolts, nuts and washers which attach turntable to bearing inner race. Discard nuts and bolts.

7. Use lifting equipment to carefully lift complete turntable assembly from bearing. Ensure that no damage occurs to turntable, bearing or frame mounted components.

8. Carefully place turntable on a suitably supported trestle.

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SECTION 3 - CHASSIS & TURNTABLE

9. Using a suitable tool, scribe a line on outer race of swing bearing and frame. This line will aid in aligning bearing upon installation. Remove bolts and washers which attach outer race of bearing to frame. Discard bolts. Use suitable lifting equipment to remove bearing from frame; move bearing to a clean suitably supported work area.

INSTALLATION

NOTE: Manufacturing tolerances of frames and turntables

are inspected prior to the factory installation of swing bearings to determine the need for use of Devcon filler. When servicing machine swing bearing, apply Devcon filler only to those machines having Devcon previously applied at the factory. If new turntable or frame is being installed contact manufacturer for procedures to determine the need for Devcon application.

1. Use suitable standard tools and equipment to carefully remove any hardened epoxy residue from bearing mounting area of frame and turntable.

2. Apply a layer of Devcon (or equivalent) filler approximately 0.125 in. (3.18 mm) thick on bearing mounting plate on frame.

3. Use suitable lifting equipment to carefully lower swing bearing into position on frame. Ensure that scribed line of outer race of bearing aligns with scribed mark on frame (if a new swing bearing is used, ensure that filler plug fitting is at 90 degrees from fore and aft centerline of frame).

4. Ensure that all frame and bearing attachment holes are aligned, and install four diametrically opposed bolts or clamps to secure bearing to frame. Tighten bolts or clamps evenly in a diametrical pattern to a torque of 20 ft. lb. (27 Nm).

5. Allow Devcon filler to cure at room temperature (approximately 21 degrees C.) for 10 to 16 hours.

6. After the appropriate interval, release clamps or remove bolts. Use a suitable lifting device to carefully remove bearing from frame.

7. Carefully remove any excess filler from frame mounting area, from bearing attachment holes, and from between gear teeth.

underside of bearing mounting area of turntable base plate.

b. Use suitable hydraulic jacks to carefully raise

swing bearing to underside of turntable mounting plate. Ensure that scribed line of inner race of bearing aligns with scribed mark on turntable (if a new swing bearing is used, ensure that filler plug fitting is at 90 degrees from fore and aft centerline of turntable).

c. Ensure that all turntable and bearing attachment

holes are aligned, and install four (4) diametrically opposed clamps or bolts and nuts to secure bearing to turntable. Tighten nuts and bolts or clamp evenly in a diametrical pattern to a torque of 20 ft. lb. (27 Nm).

d. Allow Devcon filler to cure at room temperature

(approximately 21 degrees C.) for 10 to 16 hours.

e. After the appropriate interval, place a suitable

hydraulic jack under bearing and release clamps or remove nuts and bolts; use hydraulic jack to carefully remove bearing from turntable.

f. Carefully remove excess filler from turntable

mounting area, from bearing attachment holes and from between gear teeth.

g. Position bearing on machine frame in same

position as noted in step (c) above.

JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS. SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED.

h. Apply a light coating of Loctite #277 to the new

bearing bolts, and loosely install bolts and washers through frame and outer race of bearing.

IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

ENSURE THAT TURNTABLE IS ADEQUATELY SUPPORTED WHILE APPLYING DEVCON AND WHILE INSTALLING THE BEARING. EXTREME CARE MUST BE TAKEN DURING THE FOLLOWING STEPS TO AVOID SERIOUS OR FATAL INJURY TO PERSONNEL.

a. Apply a layer of Devcon (or equivalent) filler

approximately 0.125 in. (3.18 mm) thick to

i. Following the Torque Sequence diagram shown

in Figure 2-8, tighten bolts to an initial torque of 410 ft. lb. (555 Nm). Then following the same sequence tighten bolts to a final torque of 545 ft. lb. (740 Nm).

j. Remove lifting equipment from bearing.

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SECTION 3 - CHASSIS & TURNTABLE

Figure 3-19. Swing Bearing Tolerance Measuring Point

k. Use suitable lifting equipment to carefully posi-

tion turntable assembly above machine frame.

l. Carefully lower turntable onto swing bearing,

ensuring that turntable and bearing align as noted in step (i) above.

IF COMPRESSED AIR OR ELECTRICALLY-OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.

m. Apply a light coating of Loctite #277 to the new

bearing bolts, and install bolts, washers and nuts through turntable and inner race of bearing.

n. Following the Torque Sequence diagram shown

in Figure 2-9, tighten bolts to an initial torque of

410 ft. lb. (555 Nm). Then, following the same sequence, tighten bolts to a final torque of 545 ft. lb. (740 Nm).

o. Remove lifting equipment.

p. Install rotary coupling retaining yoke; apply a

light coating of Loctite Sealant Number TL27741 to attaching bolts and secure yoke to rotary coupling with bolts and lockwashers.

q. Connect hydraulic lines to rotary coupling as

tagged prior to removal.

r. At ground control station, use tower boom lift

control to lower boom to stowed position.

s. Using all applicable safety precautions, activate

hydraulic system and functionally check swing system for proper and safe operation.

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SECTION 3 - CHASSIS & TURNTABLE

Figure 3-20. Swing Bearing Torquing Sequence

Swing Bearing Torque Values

1. Outer Race - 545 ft. lb. (740 Nm) JLG Threadlocker.

2. Inner Race - 545 ft. lb. (740 Nm) JLG Threadlocker.

3. Swing Bearing Torquing Sequence, see Figure 2-9.

CHECK INNER AND OUTER SWING BEARING BOLTS FOR MISSING BOLTS OR LOOSENESS AFTER FIRST 50 HOURS OF OPERATION AND EVERY 600 HOURS THEREAFTER.

3.7 SWING TORQUE HUB

Disassembly

1. Set unit on its shaft (1). Remove pipe plug (11) from bottom of hub near shaft, and drain oil from unit into a suitable container.

2. Remove the three pipe plugs (32) from cover (28).

3. Remove the twenty bolts (31) and lockwashers (24)

from cover.

4. Remove thrust washer (29) from inside center counterbore of cover, on top of retaining ring (21).

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

5. Remove retaining ring (30) from groove inside counterbore in center of cover.

6. Lift cover off of ring gear (21) and set it aside, interior side facing up.

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SECTION 3 - CHASSIS & TURNTABLE

1. Output Shield

2. Outer Bearing Cup

3. Outer Bearing Cone

4. Inner Bearing Cup

5. Inner Bearing Cone

6. Lockwasher

7. Flatwasher

8. Bearing Nut

9. Housing

10. Lip Seal

11. Pipe Plug

12. Pipe Plug

13. Needle Bearing

14. Planet Shaft

15. Thr ust Washer

16. Carrier

17. Thr ust Spacer

18. Roll Pin

19. Cluster Gear

20. Internal Gear

21. Ring Gear

22. Thrust Washer

23. O-ring

24. Lockwasher

25. Sun Gear

26. Adapter Coupling

27. Thr ust Washer

28. Inpu t Cover

29. Thr ust Washer

30. Retaining Bolt

31. Bolt

32. Pipe Plu g

Figure 3-21. Swing Torque Hub

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SECTION 3 - CHASSIS & TURNTABLE

7. Remove o-ring (6) from counterbore around rim of cover. Discard o-ring.

8. Remove thrust washer (27) from “ledge” halfway down in counterbore in center of cover. Thrust washer may be on top of coupling (26). Remove washer and set it aside.

9. Remove thrust washer (22) from around edge of raised circular center of cover. Thrust washer may be around coupling (26). Remove thrust washer and set it aside.

10. Remove coupling from end of input gear (25).

11. Lift ring gear off of hub (9).

12. Lift input gear (25) out of hub.

13. Lift carrier assembly (16) out of hub. Disassemble

carrier assembly as follows:

a. Set cluster (planet) gear (19) on its side. Using a

hammer and alignment punch, drive roll pin (18) completely into hole in planet shaft (14). If roll pin is not completely driven into hole in planet shaft, carrier housing could be damaged when planet shaft is removed.

b. Using a punch and hammer, drive planet shaft

down out of carrier housing (16). When planet shaft is removed from carrier housing, two thrust washers (15) and assembled cluster gear will slide off planet shaft into carrier housing. Remove these parts from carrier housing.

c. Remove nineteen needle rollers (13) from inside

large end of cluster gear.

d. Remove spacer (17) from inside of cluster gear.

e. Remove nineteen needle rollers (19) from inside

of small end of cluster gear.

f. Repeat steps (a) through (e) for remaining two

cluster gears.

14. Remove o-ring (23) from counterbore of hub. Discard o-ring.

15. Remove thrust washer (22) from around shaft (1) in hub.

16. Lift internal gear (20) out of hub.

17. Disassemble hub/shaft assembly (9) as follows:

a. Remove three pipe plugs (12) from side of hub.

b. Bend the aligned tang of lockwasher (6) out of

slot in locknut (8).

c. Remove locknut from shaft.

e. Remove tanged washer (7) from around shaft.

f. Set hub on something wide enough to allow

shaft to fall out of hub, and hammer or press shaft down out of hub.

g. Bearing cone (3) should be lying loose in hub.

Remove bearing cone and set it aside.

h. Remove seal (10) and discard it. Seal may be

loose around shaft, or it may still be in small end of hub.

i. Using a punch and hammer, remove bearing

cone (5) from around shaft.

j. Using a punch and hammer, carefully drive bear-

ing cup (4) out of counterbore in small end of hub.

k. Turn hub over. Using a punch and hammer,

carefully drive bearing cup (2) out of counterbore in tall end of hub.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect bearing components (2, 3, 4, 5) for damage, pitting, corrosion or excessive wear. Replace bearings as a complete set if necessary.

3. Inspect all thrust washers for scoring or excessive wear.

4. Inspect all geared or splined components for chipped or broken teeth and for excessive or uneven wear patterns.

5. Inspect o-ring grooves in hub (9) and cover (28) for burrs or sharp edges. Dress applicable surfaces as necessary.

6. Inspect all thrust washer and bearing surfaces for damage. Repair or replace as necessary.

7. Inspect all threaded components for damage including stretching, thread deformation or twisting. Replace as necessary.

8. Inspect planet shafts (14) for scoring or other damage. Replace as necessary.

NOTE: It may be necessary to cut locknut from shaft. If this

is necessary, take care not to damage shaft and be sure to discard locknut.

d. Remove lockwasher from around shaft.

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SECTION 3 - CHASSIS & TURNTABLE

Assembly

1. Assemble hub/shaft assembly as follows:

a. Set hub (9) on work surface, wide end up. Using

a suitable press, press bearing cup (2) into counterbore in tall end of hub.

b. Set hub on work surface, wide end down. Using

the press, install bearing cup (4) into counterbore in small end of hub.

c. Using the press, press bearing cone (5) onto

smaller end of shaft (1).

d. Slowly lower hub, small end down, onto shaft.

Check initial torque. Install one bolt (31) into bolt circle of hub, and, keeping torque wrench tangent to bolt circle, pull torque wrench smoothly toward you. Rolling torque must fall in the range of 30-40 in. lb. (3-5 Nm). If it does, proceed to step (f). If not, perform step (e).

e. If rolling torque is below 30-40 in. lb. (3-5 Nm),

apply more pressure to bearings. If rolling torque is above 30-40 in. lb. (3-5 Nm), tap top of shaft to release bearings and repeat step (d).

f. Using the bearing press, press bearing cone (3)

around shaft in hub.

g. Clean threads on shaft and apply “Primer T” (a

de-greasing agent) to shaft. Apply a light coat of “Primer T” to locknut (8). Allow 2-3 minutes’ drying time.

h. Place tanged washer (7) over end of shaft.

i. Place lockwasher (6) over shaft.

NOTE: Loctite 277 is an anaerobic adhesive; once out of

contact with air, it begins to set. Read steps (j) thru (m) before performing them as quickly as possible.

j. Apply Loctite 277 to threads of locknut (8). DO

NOT put Loctite on shaft threads.

k. Thread locknut onto shaft, making sure that

chamfered side of locknut is facing toward lockwasher, and tighten locknut down by hand.

l. Using torquing tool and locknut wrench, torque

locknut to 175 ft. lb. (237 Nm). One tab of lockwasher should be aligned with slot in locknut when torquing is done. Tighten locknut to align slot if necessary, but NEVER LOOSEN THE LOCKNUT.

m. Check final rolling torque. Put a torque wrench

on bolt in hub, and, keeping torque wrench tangent to bolt circle, pull torque wrench smoothly toward you. Final rolling torque must be 5-10 in. lb. (0.6-1 Nm) greater than initial reading. If final reading is correct, proceed to step (o). If not, perform step (n).

n. If final rolling torque is less than 5-10 in. lb. (0.6-

1 Nm) higher than initial reading, tighten locknut slightly and re-measure. If final rolling torque is greater than 5-10 in. lb. (0.6-1 Nm) higher than initial reading, remove locknut and lockwasher, remove Loctite from all parts, and repeat steps (g) through (m) to reinstall parts.

o. Remove bolt (31) from bolt circle of hub and

bend aligned tang of lockwasher into slot in locknut.

p. Stake locknut in four equally spaced places 1/8

inch (3.2 mm) from inner edge of locknut.

q. Apply a light coat of “Never-Seize” to three mag-

netic pipe plugs (12) and install then into side of hub.

r. Turn unit over onto its wide end. Using a seal

pressing tool, press seal (10), seal lip facing up, into hub around end of shaft.

s. Apply a light coat of “Never-Seize” to pipe plug

(11) and install it into bottom of hub near shaft.

2. Assemble carrier assembly (16) as follows:

a. Apply a light coating of petroleum jelly or multi-

purpose grease to inside of one cluster gear (19) and line inside of large end of cluster with nineteen needle rollers (13).

b. Place spacer (17) on top of needle rollers inside

cluster gear.

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SECTION 3 - CHASSIS & TURNTABLE

c. Apply a light coating of petroleum or multi-pur-

pose grease to inside of small end of cluster and line inside of small end of cluster gear with nineteen needle rollers (13).

d. Stand carrier housing (16) on its side. Insert a

planet shaft (14), end with roll pin last, into one of the planet shaft holes in carrier housing.

e. Note tab on thrust washer (15). Place thrust

washer onto end of planet shaft in carrier housing, placing tab of washer into slot in side of carrier housing.

f. Following the thrust washer, place assembled

cluster gear, large end toward roll pin holes, onto planet shaft.

g. Following the cluster gear, place one more thrust

washer (15) onto planet shaft, placing tab of thrust washer into slot in side of carrier housing. Now insert planet shaft into opposite planet shaft hole in carrier housing.

h. Using an alignment punch, align roll pin holes in

carrier housing and planet shaft, then drive roll pin (18) into the aligned holes.

i. Repeat steps (a) through (h) to assemble and

install remaining two cluster gears.

3. Place hub assembly (9) on work surface with open end facing up.

4. Oil all exposed surfaces inside hub, then lower internal gear (20), small end down, into hub.

BEWARE OF SHARP EDGES AND BURRS IN THE COUNTERBORE WHEN INSTALLING O-RING.

5. Grease and place o-ring (23) into counterbore of hub. O-ring can be made to fit counterbore exactly by stretching it (if it is too small), or by squeezing it together bit by bit as it is placed around the counterbore (if it is too large).

6. Place carrier assembly on work surface so one planet shaft hole faces you and other two planet shaft holes are opposite you. Line up punch marks on gear teeth of carrier assembly to the 12 o’clock position as shown in Figure 3-2. Place ring gear (21) onto carrier to keep punch marks in position.

7. Lower carrier assembly into hub, meshing gears of carrier with internal gear splines.

8. Place input gear (25) down into hub, into middle of carrier.

9. Lift ring off of carrier carefully (so carrier gears do not move) and replace ring gear (21) onto hub, ensuring bolt holes in hub and ring gear are aligned.

BEWARE OF SHARP EDGES AND BURRS IN THE COUNTERBORE WHEN INSTALLING O-RING.

10. Set cover (28) on work surface, interior side up. Grease and place o-ring (23) into counterbore around rim of cover. Make o-ring fit counterbore exactly by stretching it or by pinching it together bit by bit.

11. Grease and place thrust washer (27) halfway down in counterbore in center of cover, until it rests on a “ledge” in counterbore.

12. Grease and place thrust washer (22) around edge of raised circular center of cover.

13. Lower cover, interior side down, onto ring gear. Align bolt holes in cover and ring gear.

14. Grease and place thrust washer (29) into counterbore inside center of cover, on top of retaining ring (30).

EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL.

15. Place retaining ring into groove inside counterbore in center of cover.

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SECTION 3 - CHASSIS & TURNTABLE

16. Place twenty lockwashers (24) over bolt holes in cover.

17. Place twenty bolts (31) into bolt holes in cover and tighten.

18. Torque bolts to 35-45 ft. lb. (47-61 Nm).

19. Apply a light coat of “Never-Seize” to three pipe

plugs (32) and tighten pipe plugs into holes in cover.

20. Place roll tester in coupling in end of unit and roll it in both clockwise and counterclockwise directions. Perform the same number of turns in each direction as the ratio of the unit. This number is the same as the last two digits in the model number found on the ID tag of the unit.

21. Leak test unit at 5 psi (2 bar).

22. Remove pipe plugs (12) from hub and fill drive hub

half full with EP 90 extreme pressure lubricant, then install pipe plugs in hub. Torque hub is half full when lubricant runs out of side hole on hub.

3.8 SWING BRAKE - AUSCO - MACHINES BUILT TO 1992

Disassembly

1. With shaft protruding downward, remove bolts (22) alternately and evenly to reduce spring tension.

2. Remove power plate (21) and gasket (2).

3. Bearing (18) is pressed onto shaft (7) and must be

removed before removal of rotating discs (11) and stationary discs (12).

4. Further disassembly is not recommended unless necessary for the replacement of specific parts.

5. If further disassembly is required, remove shaft (7) and stack sub-assembly from housing (1) by lightly tapping or pressing on the small external spline end of the shaft and removing the shaft, bearings and stack from housing.

6. Remove bearing (18), stationary disc (12), rotating disc (11), springs (10) and primary disc 9.

7. Remove bearing (3) from shaft, taking care not to damage seal 4. Remove seal.

8. Remove springs (6) and spring retainer (5) from housing.

9. Remove piston (13) from power plate by introducing low pressure air (15 psi [10 bar]) into the hydraulic inlet. Direct piston away from operator.

10. Remove o-rings (15 and 17) and back-up rings (14 and 16) from piston OD and ID grooves. Back-up rings will be damaged and should not be removed if replacement is not planned.

11. Pressure relief valve (23) can be removed and inspected to assure spring loaded ball moves freely and is contamination free.

Cleaning and Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for damage, excessive wear,

cracks and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact sur-

faces.

NOTE: Bearings may be re-used if, after thorough inspec-

tion, they are found to be in good condition.

Assembly

NOTE: Lubricate all seals, o-rings, cylinder of the power

plate and piston with clean hydraulic oil prior to assembly.

1. Assemble piston (13) into power plate (21) using a shop press, being careful not to damage the o-rings or back-up rings. Visually align the center of the cutouts in piston with torque pin (8) holes in power plate. Avoid pushing the piston all the way to the bottom of the cylinder in the power plate. Try to keep the top surface of the piston flush to 1/8 in. (3.2 mm) below the machined surface of the power plate.

2. When pressing the bearing onto the shaft, press on the inner race of the bearing and support the shaft properly.

3. Rotating discs must be clean and dry. Worn or heavily scored discs must be replaced.

4. Press bearing (3) into housing 1. Bearing must be seated against shoulder in housing.

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SECTION 3 - CHASSIS & TURNTABLE

Figure 3-22. Swing Brake - Ausco - Machines Built to 1992

3-30 – JLG Lift – 3120679

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SECTION 3 - CHASSIS & TURNTABLE

5. Before installing seal (4), lubricate lip of seal with system hydraulic fluid or other suitable lubricant. Face lip of seal toward outside of brake in order to keep gear box oil or other external contaminants out of brake. Using a shop press, install seal (4) by pressing evenly around OD of seal. Use care to avoid cocking seal.

6. Install shaft (7) into housing. Support inner race of bearing (3) when pressing bearing onto shaft.

7. Install gasket 2. Align properly. After installing all remaining brake components, install bearing (18). Properly support shaft when pressing bearing onto shaft.

8. Install power plate sub-assembly. Use a shop press to evenly lower plate into position. There should be no gap at the OD when power plate is properly seated against housing. If a shop press is not available, use assembly bolts (22). Tighten sequentially, one at a time, until power plate is properly seated. Torque bolts to 50 to 60 ft. lb. (68 to 81 Nm).

9. If replacement of pressure relief valve is necessary, install 1/2 to 3/4 turns beyond finger tight.

10. Bleed air from brake via bleeder screw.

4. Remove piston (40) from end cover by inserting two

1/4-20 UNC bolts into threaded holes in piston. By turning and pulling, piston can be removed from bore.

5. Remove o-ring (38), back-up ring (39), o-ring (41) and back-up ring (42) from piston.

6. Remove separators (49) from housing (56).

7. Remove shaft assembly, consisting of shaft (45),

discs (46, 50), friction plates (48), springs (47), snap ring (44) and bearings (3, 54) from housing by pressing or using a soft mallet on male end of shaft.

8. Remove springs (47) from between tabs of discs (46, 50).

9. Remove bearings (37, 54) from shaft (45) with appropriate bearing puller. The discs and friction discs will then slide off male end of shaft. Remove snap ring and shaft.

10. Remove dowel pins (53), springs (51, 52) and o-ring (55) from housing.

Cleaning and Inspection

1. Clean all parts thoroughly.

3.9 SWING BRAKE - MICO - MACHINES BUILT TO 1992

Disassembly

1. Separate end cover (34) from housing (56) by removing capscrews (31) and lockwashers (32).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 1,500 LB. (680 KG). THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (3,000 LB. [1,360 KG] MINIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Tap cover with a soft mallet in order to dislodge bearing from cover.

3. Remove o-ring (36), square-ring (35), pipe plug (33) and bleeder (43) from end cover.

2. Closely inspect all parts for excessive wear, cracks, and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact sur-

faces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

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SECTION 3 - CHASSIS & TURNTABLE

Figure 3-23. Swing Brake - Mico - Machines Built to 1992

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SECTION 3 - CHASSIS & TURNTABLE

Assembly

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Insert new o-ring (55), dowel pins (53) and springs (51, 52) in housing (56).

2. Install new bearing (54) in housing and press until bearing bottoms on shoulder in housing.

3. Position new large diameter disc (50) in housing with tabs guided by dowel pins (53) until disc rests on springs (51, 52).

DISCS (46,50) AND FRICTION DISCS (48) SHOULD REMAIN DRY DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES.

4. Place a new friction disc (48) on bottom disc (50), centering it as closely as possible. Insert one spring (47) on each dowel pin.

5. Add additional new discs (46), new friction discs (48) and springs (47) as required for specific model.

6. Install snap ring (44) on shaft (45). Insert shaft (45) thru friction discs (48) until shaft contacts bearing (54). Press shaft (45) until it shoulders on inner race of bearing. A small preload will exist on snap ring (44) at this point.

7. Insert separators (49) over spiral pins in housing (56). Separators will contact top of bottom disc (50) when properly installed.

8. Install new o-ring (38), new back-up ring (39), new oring (41) and new back-up ring (42) on piston (40). Insert piston (40) into end cover (34), being careful not to shear o-rings or back-up rings. Inserting 1/420 UNC bolts in piston may simplify installation.

9. Install new o-ring (36), new bearing (37), new square ring (35), pipe plug (33) and bleeder screw (43) in end cover.

10. Position end cover (34) on housing, aligning dowel pin (53) with holes in end cover.

11. Install capscrews (31) and lockwashers (32). Tighten evenly to draw end cover (34) to housing and bearing (37) onto shaft (45). Torque capscrews to 68 Nm.

NOTE: If available, a hydraulic press will simplify installation

of end cover on housing. Clamp cover in position while tightening capscrews.

12. Press on inner ring of bearing (37) until it shoulders on shaft (45) to eliminate binding on bearings. Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing (54).

PRESS FORCE SHOULD BE LIMITED TO 2,000 LB. (907 KG) MAXIMUM TO AVOID POSSIBLE DAMAGE TO SNAP RING (44).

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.

3.10 SWING BRAKE - MACHINES BUILT 1992 TO PRESE NT

Disassembly

1. Separate end cover (2) from housing (21) by removing capscrews (1).

END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 907 KG. THE FOUR BOLTS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC PRESS IS AVAILABLE (3,000 LB. [1,360 KG] MINIMUM), THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAPSCREWS AND LOCKWASHERS.

2. Remove case seal (4) from the housing (21), then remove bleeder screw (3) from the end cover (2).

3. Remove piston (7) from end cover (2).

4. Remove o-ring (5), back-up ring (6), o-ring (8) and

back-up ring (9) from piston (7).

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SECTION 3 - CHASSIS & TURNTABLE

1. Capscrew

2. End Cover

3. Bleeder Screw

4. Case Seal

5. O-ring

6. Back-Up Ring

7. Piston

8. O-ring

9. Backup Ring

10. Shaft

11. Disc

12. Friction Disc

13. Separators

14. Return Plate

15. Spring

16. Spring

17. Spring Retainer

18. Retaining Ring

19. Bearing

20. Dowel Pin

21. Housing

22. Retaining Ring

23. Rotary Oil Seal

24. O-ring

25. Gasket

26. Pin

Figure 3-24. Swing Brake - Machines Built 1992 to Present

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SECTION 3 - CHASSIS & TURNTABLE

5. Remove separators (13) from housing (21).

6. Remove stack assembly, consisting of discs (11),

return plate (14) and friction discs (12) from housing (21).

NOTE: Not all models use the same number of springs or

spring pattern. Record this information for assembly purposes. Spring retainer (17) was not used in earlier models.

7. Remove dowel pins (20), springs (15 & 16) and spring retainer (17) from housing (21).

8. Remove retaining ring (18) from housing (21).

9. Remove shaft by pressing or using a soft mallet on

male end of shaft (10).

NOTE: Earlier models did not use retaining ring (22).

10. Remove retaining ring (22) and bearing (19) from shaft (10).

11. Press Rotary oil seal (23) from housing (21).

Cleaning and Inspection

1. Clean all parts thoroughly.

2. Closely inspect all parts for excessive wear, cracks,

and chips. Replace parts as necessary.

3. Discard seals and o-rings.

4. Closely inspect bearings and bearing contact sur-

faces. Replace as necessary.

NOTE: Bearings may be reused if, after thorough inspection,

they are found to be in good condition.

Assembly

5. Insert dowel pins (20), spring retainer (17) and springs (15 & 16) in housing (21).

6. Position new large diameter return plate (14) in housing with tabs guided by dowel pins (20) until disc rests on springs (15 & 16).

DISCS (11, 14) AND FRICTION DISCS (12) SHOULD REMAIN DRY DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES.

7. Place a new friction disc (12) on shaft (10) until it contacts return plate (14).

8. Add additional new discs (11) and new friction discs (12) as required to complete assembly.

9. Insert separators (13) in holes of return plate.

10. Install new o-ring (5), new backup ring (6), new o-

ring (8) and new back-up ring (9) on piston (7). Note order of o-rings and back-up rings. Insert piston (7) into end cover (2) being careful not to shear o-rings or back-up rings.

11. Install new case seal (4) in housing (21) then install bleeder screw (3) in end cover (2).

12. Position end cover (2) on housing (21) aligning dowel pins (20) with holes in end cover.

NOTE: If available, a hydraulic press will simplify installation

of end cover on housing. Clamp cover in position while tightening capscrews.

NOTE: Lubricate all seals and o-rings with clean hydraulic

oil prior to assembly.

1. Clean all parts thoroughly before assembly.

2. Press new rotary oil seal (23) into housing (21). Note

direction of the seal.

NOTE: Earlier models did not use retaining ring (22).

3. Install new bearing (19) and retaining ring (22) on shaft (10).

4. Insert shaft assembly and retaining ring (18) in housing (21).

NOTE: Be sure to use the same number of springs and

spring pattern as recorded during disassembly. Spring retainer (17) was not used in earlier models.

IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY, RELEASE PRESSURE SHOULD NOT EXCEED 138 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING.

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SECTION 3 - CHASSIS & TURNTABLE

3.11 SWING MOTOR

Disassembly

NOTE: Prior to any motor disassembly, plug open ports and

clean all dirt from outside of motor.

1. Mount motor in a vise or other holding device with shaft facing down.

2. Remove eight bolts (10) from cover/bearing assembly (13).

3. Remove cover/bearing assembly and o-ring (8). Discard o-ring.

4. Remove IGR assembly (6), starting with outer locating ring and rollers.

NOTE: The innermost IGR component and rotary valve (4)

are retained on shaft by snap ring (7). Do not remove this snap ring.

5. Remove two check valve balls (5). Check balls frequently fall into body tapped holes or into body valve ports during disassembly. Ensure check balls are removed and accounted for.

6. Remove shaft (11), IGR element, and rotary valve as one assembly.

7. With shaft assembly removed from body, inspect IGR inner component, rotary valve and shaft for wear or other damage. Shaft should have a smooth polished surface in bearing and seal areas. If any of these components are damaged, snap ring must be removed and appropriate component replaced. If snap ring is removed, discard it and install new snap ring.

8. Quad ring seal (3) and back-up ring (2) can be removed using a dull pointed object such as a pencil point or the end of a paper clip. DO NOT use a sharp object such as a knife because the sealing surface in the body can be damaged.

Assembly

NOTE: Prior to motor assembly, lightly oil all seals, rollers

and threaded bolt ends.

1. Install new back-up ring (2) first, pushing it sealing surface toward outside of motor. Back-up can be seated with a dull object.

2. Install new quad ring (3) by pushing it against inboard side of back-up ring.

3. Lubricate inside diameter of quad ring and back-up ring with oil or Vaseline.

4. Check output shaft (11) end for burrs and scratches. Deburr if necessary. Shaft must be free of burrs to avoid cutting quad ring and back-up ring during shaft installation.

5. Install shaft assembly into body/bearing assembly (12).

6. Place contour member of IGR (6) over inner member and insert seven rollers into inner pockets. (The seven rollers are larger in diameter than the eight rollers.)

7. Lightly oil square ring seal (8) and place in body groove.

8. Place check balls (5) over two 1/8 inch (3.2 mm) diameter holes in body. Ensure check balls do not fall into tapped holes in body.

9. Place locating ring section (4.5 inch [11.4 cm] diameter) of IGR onto body with check ball holes facing downward over balls. Align eight bolt holes in locating ring with eight holes in body. Holes will align in only one position. Be sure not to dislodge square ring seal while moving locating ring.

10. Install eight locating ring rollers into their pockets and oil lightly.

11. Place lightly oiled square ring seal (8) into groove in cover and place cover shaft and align bolt holes.

12. Install eight bolts (10) with lightly oiled thread ends into bolt holes. Tighten diagonally to 15 ft. lb. (20 Nm). Turn shaft by hand through several rotations. Increase torque of each bolt by 5 ft. lb. (7 Nm) in a diagonal pattern. Turn shaft by hand through several rotations. Repeat this procedure until torque of each bolt has reached 27 ft. lb. (37 Nm).

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SECTION 3 - CHASSIS & TURNTABLE

1. Dust Seal

2. Backup Ring

3. Quad Ring Seal

4. Rotar y Valve

5. Check Valve Ball

6. IGR Assembly

7. Snap Ring

8. Ring Seal

9. Vent Plug (Includes O-ring)

10. Bolt

11. Spline Shaft

12. Body/Bearing Assembly

13. Cover/Bearing Assembly

Figure 3-25. Swing Motor

3120679 – JLG Lift – 3-37

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SECTION 3 - CHASSIS & TURNTABLE

3.12 PQ CONTROLLERS

TRIM Adjustment

1. Disconnect ORANGE/RED (dump) wire from applicable terminal strip in platform console.

2. Install ammeter capable of measuring from zero to 2 amps in series with either valve coil B or D.

3. Position IGNITION/EMERGENCY STOP switch to ON, but do not start engine.

4. Depress footswitch.

5. Operate controller until trailing edge of slide lock is

even with housing lock notch. Hold control handle in that position.

6. Using correct size common blade screwdriver, adjust LO trimpot until am-meter indicates 300 ma. Clockwise rotation of trimpot adjust screw increases ammeter; counterclockwise rotation decreases ammeter reading.

7. Operate controller in the same direction as in step (5) to the full extent of its travel and hold handle in that position.

8. Adjust HI trimpot until ammeter indicates 500 ma.

9. Move controller handle back to the position given in

step (5) and check ammeter reading. This reading will have changed due to HI trimpot adjustment, and must be readjusted back to 300 ma.

10. Move handle to the position given in step (7) and check ammeter reading. This reading too will have changed due to LO trimpot readjustment, and must be adjusted back to 500 ma.

11. Repeat steps (9) and (10) until LO and HI readings of 300 ma and 500 ma can be achieved without further trimpot adjustments.

12. Release footswitch.

13. Connect ORANGE/RED (dump) wire to applicable

terminal strip in platform console.

14. Using all applicable safety precautions, start machine and allow hydraulic oil to reach a temperature of 100 to 140 degrees (38 to 60 degrees C).

15. Depress footswitch and operate controller until trailing edge of slide lock is even with housing lock notch. Hold control handle in that position.

16. Adjust LO trimpot until applicable function just starts to work. Immediately stop adjustment.

17. Release footswitch and stop machine.

18. Seal each trimpot with a drop of enamel paint to pre-

vent maladjustment due to vibration.

19. Install controller and secure machine.

RAMP Adjustment

Controllers equipped with the RAMP feature actually compensate for abrupt control handle operation by slowing the response time of the output signal regardless of the speed with which the handle is moved.

NOTE: It should be remembered that the ramp feature oper-

ates in both directions of the particular proportional function. therefore adjusting the ramp potentiometer to provide a delay in starting a function will provide a corresponding delay in stopping that function.

1. Drive Controller.

a. Using all applicable safety precautions, start

machine and ensure that adequate space is available to maneuver machine.

b. Position ENGINE SPEED switch to HIGH and

DRIVE SPEED switch to HIGH.

NOTE: Clockwise rotation of the ramp potentiometer adjust

screw increases ramp (delay) time; counterclockwise rotation decreases ramp (delay) time.

c. Operate machine drive function and adjust ramp

pot so that machine will stop within 8 to 12 in. (20 to 30 cm) when the control handle is released from the full extent of its travel.

d. Operate machine drive function in the opposite

direction and check that stopping distance of 8 to 12 in. (20 to 30 cm) is maintained.

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SECTION 3 - CHASSIS & TURNTABLE

1. Coupling

2. Bolt

3. Lockwasher

4. Pump Adapter

5. Bolt

6. Lockwasher

Figure 3-26. Lovejoy Coupling

e. Release footswitch and stop machine.

f. Seal ramp pot adjustment screw with a drop of

enamel paint to prevent maladjustment due to vibration.

g. Install controller and secure machine.

2. Swing Controller.

a. Using all applicable safety precautions, start

machine and ensure that adequate space is available to maneuver machine.

b. Fully extend boom at horizontal.

c. Position ENGINE SPEED switch to LOW.

d. Operate SWING controller at full speed to the left

and then quickly move controller to the full speed RIGHT position. The platform should slow, stop and then swing right in one smooth and continuous operation.

e. If control valve initiates swing right motion before

platform momentum is stopped, the ramp potentiometer adjust screw should be rotated clockwise to increase ramp time and the test repeated.

f. If after operating SWING function as described

in step (d), the platform stops moving to the left and the spring action of the boom tends to initiate the swing right motion before the control valve starts to operate, the ramp pot adjust screw should be rotated counterclockwise to decrease ramp time.

g. Repeat the test in both swing directions.

h. Release footswitch and stop machine.

i. Seal ramp pot adjustment screw with a drop of

enamel paint to prevent maladjustment due to vibration.

j. Install controller and secure machine.

3.13 PUMP COUPLING CONVERSION PROCEDURES

The following procedures are provided to assist in the conversion from a solid pump coupling to a Lovejoy or Hayes pump coupling.

Lovejoy Coupling

3. Separate coupling disc and hub and align plastic disc on flywheel with webbing facing flywheel. Install attaching bolts and lockwashers and torque bolts to 30 ft. lb. (41 Nm).

4. Attach pump mounting plate adaptor to bell housing of engine and secure with bolts and lockwashers.

5. Slide coupling hub onto pump shaft bottoms out on roll pin (located inside hub). Secure hub onto shaft by torquing torque screws to 22 ft. lb. (30 Nm).

6. Insert coupling hub (now affixed to pump shaft) through pilot bore in pump mounting plate. Align coupling hub and disc, push pump into position and secure with bolts and lockwashers.

3120679 – JLG Lift – 3-39

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SECTION 3 - CHASSIS & TURNTABLE

1. Coupling

2. Bolt

3. Lockwasher

4. Pump Adapter

5. Bolt

6. Lockwasher

Figure 3-27. Hayes Coupling

Figure 3-26. Tilt Switch Adjustment - Manual

Hayes Coupling

PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH.

Manual Adjustment

1. Park the machine on a flat, level surface. Ensure machine is level.

NOTE: Ensure switch mounting bracket is level and securely

attached.

2. Level the base of the indicator by tightening the three flange nuts. Tighten each nut through approximately one half of it’s spring’s travel. DO NOT ADJUST THE “X” NUT DURING THE REMAINDER OF THE PROCEDURE.

3. With the electrical connections complete, slowly tighten one of the “Y” nuts until the circuit is closed and the light on the Platform Control Console illuminates.

1. Install pump coupling on flywheel and secure with bolts and lockwashers. Torque bolts to 30 ft. lb. (41 Nm).

BEFORE ASSEMBLING PUMP COUPLING AND PUMP, BE SURE TO COAT INTERNAL SPLINES OF COUPLING AND EXTERNAL SPLINES OF PUMP SHAFT WITH TEXACO CODE 1912 GREASE.

2. Attach pump mounting plate adaptor to bell housing of engine and secure with bolts and lockwashers.

3. Align pump shaft with coupling, push pump into position and secure with bolts and lockwashers.

3.14 TILT ALARM SWITCH

NOTE: Each machine is equipped with a tilt alarm switch,

factory set to activate at 5 degrees, which will illuminate a warning light, sound a warning horn and cut out 2 speed drive. Consult factory for tilt sensor adjustment. The only field adjustment necessary is leveling the switch on the spring loaded studs. There are two methods of adjustment, a manual adjustment and an adjustment using a voltmeter.

3-40 – JLG Lift – 3120679

4. Slowly back off the nut, counting the number of turns, until the circuit is again closed and the light again illuminates.

5. Divide the number of turns determined in step (4) in half. Tighten the nut this many turns. The line determined by this nut and the “X” nut is now parallel to the ground.

6. Repeat steps (3) through (5) for the remaining “Y” nut. The switch is now level.

7. Individually push down on one corner at a time; there should be enough travel to cause the switch to trip. If the switch does not trip in all three tests, the flange nuts have been tightened too far. Loosen the “X” nut and repeat steps (3) through (7).

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SECTION 3 - CHASSIS & TURNTABLE

YELLOW

BLACK

WHITE

RED

Figure 3-27. Tilt Switch Adjustment - Voltmeter

Voltmeter Adjustment

8. Park machine on a flat, level surface. Ensure machine is level and tires are filled to rated pressure.

9. If engine is not running, turn ignition switch to ON.

10. Connect black lead of voltmeter to ground and red

lead to yellow wire protruding from pot on bottom of sensor.

11. Adjust leveling nuts to obtain the highest possible voltage reading.

12. Check voltage at trip point in all four directions. If voltage reading is not symmetrical, repeat step (4) above.

3.15 THROTTLE CHECKS AND ADJUSTMENTS

NOTE: Never run fuel tank dry. Diesel engines cannot be

restarted after running out of fuel until fuel system has been air-vented or “bled” of air. See Cummins instruction manual for procedure.

a. Disconnect actuator cable from throttle lever.

With the aid of an assistant, start the engine and allow it to come up to operating temperature. Adjust throttle lever stop until engine runs at

1800 RPM. Shut down engine. Reattach actuator cable to throttle lever, making sure that low (mid) engine setting remains the same. If necessary, adjust slide pin to contact low (mid) engine limit switch at 1800 RPM. Shut down engine.

b. Disconnect power (red) wire from high drive

dump valve at rear of valve compartment. With the aid of an assistant, start engine from basket and allow to come up to operating temperature. Activate footswitch. Turn on HIGH ENGINE switch. Hold drive controller in full drive position. Adjust slide pin to contact high engine limit switch at 2500 RPM. Shut off all switches and controllers. Re-connect power (red) wire to high drive dump valve.

NOTE: Actuator cable travel must stop slightly before lever

makes contact with throttle lever stop. Failure to do so will burn out actuator.

3120679 – JLG Lift – 3-41

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SECTION 3 - CHASSIS & TURNTABLE

Figure 3-28. Throttle Checks and Adjustments - Deutz Engine

3-42 – JLG Lift – 3120679

Page 81

SECTION 4 - BOOM & PLATFORM

SECTION 4. BOOM & PLATFORM

4.1 BOOM MAINTENANCE

Boom Mounted Limit Switches and Valves

NOTE: The numbers on the following descriptions corre-

spond with the numbers in Figure 4-1., Boom Mounted Limit Switches and Valves Installation.

1. Located inside of turntable at the main boom pivot pin on the left side - Controls speed of main boom lift and lower at fully stowed and fully elevated positions.

2. Outside of Fly Boom - Prevents operating tower boom lift or lower until the tower telescope is fully retracted. If tower telescope drifts out when stowed, tower lift will not operate.

3. Base end of Tower Boom on the bottom side - Prevents Hi speeds of the engine, drive, and 2 speed of the drive motors when tower boom is raised. Hi engine will operate when operating tower telescope and tower lift.

4. On top of Fly Boom - Prevents tower lift down unless main boom is fully lowered.

5. Inside of the turn tale on the left side - Cam #1 prevents the tower telescope extend function until tower lift is fully up. Cam #2 prevents main boom lift unless tower boom is fully up.

Main Boom Removal

1. Shut down machine systems.

NOTE: Main Boom Assembly weighs approximately 6,350

lb. (2,880 kg).

2. Using suitable lifting equipment, adequately support boom weight along entire length of retracted boom.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

3. Tag and disconnect hydraulic lines that run along the side of the boom.

4. Remove Bolts and lockwashers attaching upper lift cylinder rod end attach pin to main boom.

5. Using a slide hammer or similar tool, and taking care not to damage pin, remove pin from main boom.

6. Using all applicable safety precautions, and only if necessary, operate main lift down and fully retract main lift cylinder.

7. Shut down machine systems.

8. Remove bolt and lockwasher securing level link

attach pin to tower boom and remove pin from tower boom.

9. Remove setscrews securing upper master cylinder attach pin to level links. Remove pin and remove cylinder rod end from level link.

10. Tag and disconnect all wiring to ground control box.

11. Loosen and remove 4 bolts and lockwashers secur-

ing main boom pivot pin to tower boom.

12. Ensuring that boom is adequately supported and using a suitable slide hammer, carefully remove pivot pin from main boom and tower boom. Ensure that main boom and tower boom are not damaged.

13. Carefully lift main boom assembly clear of tower boom and lower to ground or suitably supported work surface.

3120679 – JLG Lift – 4-1

Page 82

SECTION 4 - BOOM & PLATFORM

Figure 4-1. Boom Mounted Limit Switches and Valves Installation

4-2 – JLG Lift – 3120679

Page 83

SECTION 4 - BOOM & PLATFORM

Tower Boom Removal

1. Remove main boom as outlined in Main Boom Removal.

2. Shut down machine systems.

NOTE: Tower Boom Assembly weighs approximately 14,700

lb. (6,668 kg).

3. Using suitable lifting equipment, adequately support boom weight along entire length of retracted boom.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

4. Tag and disconnect hydraulic lines that run along the side of the boom, and also lines to main lift cylinder, upper master level cylinder, and tower telescope cylinder.

5. Using suitable lifting equipment, adequately support main lift cylinder.

6. Remove bolts and lockwashers securing main boom lift cylinder barrel end to tower boom.

12. Shut down machine systems.

13. Tag and disconnect all wiring to ground control box.

14. Remove the bolts and lockwashers securing the

lower master cylinder rod end to the tower boom.

15. Using a slide hammer or similar tool, and taking care not to damage pin, remove pin from tower boom. Remove cylinder rod end from tower boom.

16. Remove bolts and lockwashers securing tower boom pivot pin to turntable.

17. Ensuring that boom is adequately supported and using a suitable slide hammer, carefully remove pivot pin from tower boom and turntable. Ensure that main boom and turntable are not damaged

18. Carefully lift tower boom assembly clear of turntable and lower to ground or suitably supported work surface.

Main Boom Disassembly

NOTE: Left or right is determined facing the machine from

the platform.

1. Loosen the right side powertrack bracket and powertrack and lay on top of boom assembly.

7. Using a slide hammer or similar tool, and taking care not to damage pin, remove pin from tower boom.

8. Carefully remove main lift cylinder from tower boom and place in a suitable work area.

9. Remove bolts and lockwashers securing tower lift cylinder rod end attach pin to tower boom.

10. Using a slide hammer or similar tool, and taking care not to damage pin, remove pin from tower boom.

11. Using all applicable safety precautions, and only if necessary, operate tower lift down and fully retract tower lift cylinder.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

2. Tag and disconnect hydraulic lines to slave level cylinder and rotator motor.

3. Tag and disconnect wiring to platform control box.

4. Remove platform from end of main boom assembly.

5. Remove setscrews and bushing retaining telescope

cylinder rod attach pin to base section.

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Page 84

SECTION 4 - BOOM & PLATFORM

Figure 4-2. Main Boom Assembly - Sheet 1 of 2

4-4 – JLG Lift – 3120679

Page 85

Figure 4-3. Main Boom Assembly - Sheet 2 of 2

1. Base Boom

2. Mid Boom

3. Fly Boom

4. Telescope Cylinder

5. Extend Sheave

6. Fly Extend Chain

7. Fly Retract Chain

8. Chain Adjustment Assembly

9. Chain Adjustment Assembly

10. Retract Sheave

11. Upper Rear Wear Pads

SECTION 4 - BOOM & PLATFORM

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Page 86

SECTION 4 - BOOM & PLATFORM

6. Using a suitable brass drift, carefully drive telescope cylinder pin from base section.

7. Remove three locknuts and flatwashers from studs on top of aft end of base section.

8. Remove fly section extend chain adjust nut, locknut, and washer from chain attach plate at upper aft end of base section.

9. Remove bolts, washers and lockwashers attaching fly section extend chain attach plate to upper aft end of base section. Remove plate.

10. Remove six bolts and lockwashers securing retract chain clevis cover to lower front bottom of base section.

11. Remove fly section retract chain adjust nut, locknut, and washer at lower front end of base section.

NOTE: Note and record the number and thickness of any

wear pad shims during wear pad removal.

12. Remove bolts and lockwashers attaching side wear pads to front of base section. Remove pads and any shims.

13. Remove bolts, washers and lockwashers attaching lower front wear pads and mounting blocks to base section. While supporting assembled fly and mid sections, remove wear pads, mounting blocks and shims.

14. Remove bolts and lockwashers attaching top front wear pads to base section. Remove pads and shims.

15. Using suitable lifting equipment, partially slide assembled mid and fly sections out of base section.

16. Using suitable straps, tie off fly section retract chains to underside of mid section as mid and fly sections are exiting base section.

17. Carefully lift mid and fly sections clear of base section and lower to a suitably supported work area.

19. Remove two bolts, washers, and lockwashers securing each trunnion pin cover to mid section.

20. Using a suitable tool, scribe a line on the outer end of each trunnion pin and boom structure as an aid to pin alignment during boom assembly.

21. Using a suitable slide hammer, remove trunnion pins attaching telescope cylinder to mid section.

22. Remove cotter pins and chain attach pins attaching fly retract chains to chain clevis at lower aft end of fly section and remove chains.

23. Remove setscrews which attach retract chain sheave pin at lower aft end of mid section.

24. Using a suitable brass drift, carefully drive sheave pin from mid section and remove sheave. If necessary, remove bushings from sheave and replace. Ensure that pins, grease fittings and corresponding boom and sheave surfaces are not damaged.

25. Pull fly section out several feet to allow ample clearance for telescope cylinder removal.

26. Using suitable lifting equipment, carefully slide telescope cylinder out of fly and mid sections, along with extension chain.

27. Carefully lift telescope cylinder clear of boom assembly and lower to ground or suitably supported work area.

NOTE: Note and record number and thickness of any wear

pad shims during wear pad removal.

28. Remove bolts and lockwashers which attach upper aft mid section wear pads and remove pads and any shims.

18. Using suitable lifting equipment, support telescope cylinder rod.

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Page 87

SECTION 4 - BOOM & PLATFORM

29. Remove bolts and lockwashers which attach bottom wear pads at front of outer mid section and remove pads and any shims.

30. Remove bolts and lockwashers which attach side wear pads at front of mid section and remove pads and any shims.

31. Remove bolts and lockwashers which attach top wear pads to front of mid section and remove pads and any shims.

32. Using suitable lifting equipment, carefully slide fly section clear of outer mid section and lower to ground or suitably supported work area.

33. Remove bolts and lockwashers which secure top and side aft wear pads to fly section.

Tower Boom Disassembly

NOTE: Left or right is determined facing the machine from

the platform.

1. Loosen the left side powertrack bracket and powertrack and lay on top of boom assembly.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

2. Remove bolts and lockwashers securing telescope cylinder attach plate to aft end of base boom.

3. Remove bolts and lockwashers securing telescope cylinder mounting plate to telescope cylinder.

NOTE: Note and record the number and thickness of any

wear pad shims during wear pad removal.

4. Remove bolts and lockwashers attaching side wear pads to front of base section. Remove pads and any shims.

5. Remove bolts, washers and lockwashers attaching lower front wear pads and mounting blocks to base section. While supporting assembled fly and mid sections, remove wear pads, mounting blocks and shims.

6. Remove bolts and lockwashers attaching top front wear pads to base section. Remove pads and shims.

7. Using suitable lifting equipment, slide assembled mid and fly sections out of base section.

8. Carefully lift mid and fly sections clear of base section and lower to a suitably supported work area.

9. Remove bolts and lockwashers securing trunnion blocks to sides of mid section.

10. Carefully pull fly section from mid section far enough to expose telescope cylinder fly attach pin cover caps.

11. Remove bolts and lockwashers securing cover caps to each end of telescope cylinder fly attach pin. Remove cover caps.

12. Using a slide hammer or brass drift, remove attach pin from fly section.

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Page 88

SECTION 4 - BOOM & PLATFORM

Figure 4-4. Tower Boom

1. Base Boom

2. Mid Boom

3. Fly Boom

4. Telescope Cylinder

5. Upper Rear Wear Pads

6. Cylinder Mounting Plate

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Page 89

SECTION 4 - BOOM & PLATFORM

13. Using suitable lifting equipment, carefully slide telescope cylinder out of fly and mid sections and lower to ground or suitably supported work area.

NOTE: Note and record number and thickness of any wear

pad shims during wear pad removal.

14. Remove bolts and lockwashers which attach mid section top aft wear pads and remove pads and any shims.

15. Remove bolts and lockwashers which attach mid section side aft wear pads and remove pads and any shims.

16. Remove bolts and lockwashers which attach mid section bottom front wear pads and remove pads and any shims.

17. Remove bolts and lockwashers which attach side wear pads to front of mid section and remove pads and any shims.

18. Remove bolts and lockwashers which attach top wear pads to front of mid section and remove pads and any shims.

19. Using suitable lifting equipment, carefully slide fly section clear of mid section and lower to ground or suitably supported work area.

20. Remove bolts and lockwashers which attach top aft wear pads to fly section and remove pads and any shims.

21. Remove bolts and lockwashers which attach side aft wear pads to fly section and remove pads and any shims.

22. If necessary, remove bolt and lockwasher securing horizontal level link attach pin to fly section. Using a slide hammer or other suitable tool, remove pin from fly section and remove level link and bushings.

23. If necessary, remove bolt and lockwasher securing barrel end of upper master cylinder to fly section. Using a slide hammer or other suitable tool, remove pin from fly section and remove cylinder.

Inspection

1. Inspect all sheaves (extend chains, retract chains and telescope cylinder) for excessive groove wear, burrs or other damage. Replace sheaves as necessary.

2. Inspect extend chain and retract chain sheave bushings for wear, scoring, or other damage, and for ovality. Replace bushings as necessary, ensuring they are installed flush with sheave surface.

3. Inspect extend chain and retract chain sheave pins for scoring, tapering, ovality and evidence of correct lubrication. Replace pins as necessary.

4. Inspect telescope cylinder sheave pin for tapering, scoring, ovality and evidence of correct lubrication. Replace pin as necessary.

5. Inspect boom pivot pin for wear, scoring or other damage, and for tapering or ovality. Replace pin as necessary.

6. Inspect upper lift cylinder attach pin for tapering, ovality, scoring, wear, or other damage. Ensure pin surfaces are protected prior to installation. Replace pin as necessary.

7. Inspect telescope cylinder trunnion attach pins for tapering, ovality, scoring, wear, or other damage. Replace pins as necessary.

8. Inspect extend chain attach clevis pins for wear, scoring, or other damage. Replace pins as necessary.

9. Inspect telescope cylinder rod attach pin for scoring, wear, or other damage. Replace pin as necessary.

10. Inspect inner diameter of boom pivot bushing for scoring, distortion, wear, or other damage. Replace bushing as necessary.

11. Inspect all wear pads for excessive wear or damage. Replace pads when worn to within 1/8 in. (3.2 mm) of insert.

12. Inspect extend and retract chains and chain attach component for cracks, stretching, distortion, or other damage. Replace components as necessary.

13. Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary.

14. Inspect structural units of boom assembly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary.

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Page 90

SECTION 4 - BOOM & PLATFORM

Main Boom Assembly

NOTE: When installing fly section wear pads, install same

number and thickness of shims as were removed during disassembly.

1. Install top and side aft fly section wear pads and shims, as required, using bolts and lockwashers.

2. Using suitable lifting equipment, carefully slide fly section into mid section.

NOTE: When installing mid section wear pads, install same

number and thickness of shims as were removed during disassembly.

3. Install mid section top front wear pads and shims, as required, using bolts and lockwashers.

4. Install mid section side front wear pads and shims, as required, using bolts and lockwashers.

5. Install mid section bottom front wear pads and shims, as required, using bolts and lockwashers.

6. Install mid section top aft wear pads and shims, as required, using bolts and lockwashers.

7. Install mid section side aft wear pads and shims, as required, using bolts and lockwashers.

8. Using suitable lifting equipment, carefully slide assembled mid and fly sections into base section.

9. Place fly section extend chain assembly along telescope cylinder chain rest with front end of chain hanging just below cylinder sheave.

10. Using lightweight motor oil (SAE 20W), adequately lubricate portion of chain occupying cylinder chain rest.

11. Using suitable lifting equipment, maneuver telescope cylinder and fly section extend chain assembly into position at aft end of assembled boom sections.

12. Attach loose end of extend chain to chain clevis at lower aft end of fly section. Install chain attach pins and flatwashers and secure with cotter pins.

13. Secure chain clevis to bottom aft of fly section with clevis pins and cotter pins.

14. If removed, install chain attach plate to aft end of base section. Secure with bolts, washers, and lockwashers.

15. With a slight downward angle on the cylinder, insert sheave and chain into boom sections until it is possible to insert chain adjust clevis into chain attach plate at aft end of base section. Install chain adjust clevis and locknuts.

16. Carefully feed telescope cylinder approximately halfway into boom sections, lubricating chain with lightweight motor oil as it passes along chain rest. Continue inserting into boom sections.

17. Install fly section retract chain sheave at aft end of mid section.

18. Install sheave pin and if necessary, tap pin into place using a soft headed mallet. Secure pin with setscrews.

19. Install lubrication fitting on end of pin and lubricate sheave with MPG.

20. Attach fly section retract chain to chain clevis at lower aft end of fly section. Install chain attach pins and flatwashers and secure with cotter pins.

21. Carefully place fly section retract chain around chain sheave at aft end of mid section and through bottom of base section.

22. Install fly section retract chain clevis into attach block at lower front end of base section. Install adjust nut and locknut on clevis. Install clevis cover on bottom of base section and secure in place with bolts and lockwashers.

23. Using suitable lifting equipment, carefully align holes in telescope cylinder trunnion and holes in aft end of mid section.

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SECTION 4 - BOOM & PLATFORM

24. Install trunnion pins, tapping pins into place with a soft headed mallet if necessary. Install cover plate over trunnion pins and secure to mid section with bolts, washers, and lockwashers.

25. Install outer mid section retract chain clevis into attach block at lower front end of base boom section. Install adjust nut and locknut on clevis.

NOTE: When installing base section wear pads, install same

number and thickness of shims as were removed during disassembly.

26. Install base section top front wear pads and shims, as required, using bolts and lockwashers.

27. Install base section lower front wear pads, mounting blocks, and shims, as required, using bolts, washers, and lockwashers.

28. Install base section side front wear pads and shims, as required, using bolts and lockwashers.

29. Carefully align telescope cylinder rod end with holes in aft end of base boom section and install attach pin and bushing. If necessary, tap pin and bushing into place using a soft headed mallet. Secure pin and bushing with set screws.

30. Torque extend and retract chains to 50 ft. lb. (68 Nm) and tighten locknuts.

31. Install base boom end cover and secure in place with locknuts and washers.

32. Attach platform to boom assembly.

33. Connect wiring to platform control box.

34. Connect hydraulic lines to slave level cylinder and

rotator motor.

35. Attach the right side bracket and powertrack to boom assembly.

Tower B oom Assembly

1. If removed, align barrel end of upper master cylinder with mounting holes on end of tower boom fly section and install attach pin. Secure pin in place with a bolt and lockwasher.

2. If removed, align horizontal level link with mounting holes in end of fly section and install attach pin. Secure pin in place with a bolt and lockwasher.

NOTE: When installing mid section wear pads, install same

number and thickness of shims as were removed during disassembly.

3. Install top aft fly section wear pads and shims, as required, using bolts and lockwashers.

4. Install side aft fly section wear pads and shims, as required, using bolts and lockwashers.

5. Using suitable lifting equipment, carefully slide fly section into mid section, just far enough that telescope cylinder fly end attach pin mounting hole is still exposed.

6. Using suitable lifting equipment, maneuver telescope cylinder into position at aft end of assembled boom sections.

7. Align fly attach end of telescope cylinder with mounting holes in fly section and install attach pin. Secure pin in place with cover caps, bolts, and lockwashers.

8. Carefully slide fly section the rest of the way into the mid section.

9. Carefully align ears on base end of cylinder barrel with notches in base end of mid section. Secure cylinder barrel in place with trunnion blocks, bolts, and lockwashers.

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SECTION 4 - BOOM & PLATFORM

NOTE: When installing mid section wear pads, install same

number and thickness of shims as were removed during disassembly.

10. Install mid section top front wear pads and shims, as required, using bolts and lockwashers.

11. Install mid section side front wear pads and shims, as required, using bolts and lockwashers.

12. Install mid section bottom front wear pads and shims, as required, using bolts and lockwashers.

13. Install mid section top aft wear pads and shims, as required, using bolts and lockwashers.

14. Install mid section side aft wear pads and shims, as required, using bolts and lockwashers.

15. Using suitable lifting equipment, carefully slide assembled mid and fly sections into base section.

16. Install telescope cylinder mounting plate on base attach end of telescope cylinder. Secure mounting plate with bolts and lockwashers

17. Install telescope cylinder mounting plate on aft end end of base boom and secure with bolts and lockwashers.

NOTE: When installing base section wear pads, install same

number and thickness of shims as were removed during disassembly.

18. Install base section top front wear pads and shims, as required, using bolts and lockwashers.

19. Install base section lower front wear pads, mounting blocks, and shims, as required, using bolts, washers, and lockwashers.

20. Install base section side front wear pads and shims, as required, using bolts and lockwashers.

Tower Boom Installation

1. Using suitable lifting equipment, position assembled tower boom on turntable so that boom pivot holes in tower boom and turntable are aligned.

2. Insert boom pivot pin, gently tapping pin into position with a soft headed mallet if necessary. Secure pin with bolts and lockwashers.

3. Align rod end attach hole of lower master cylinder with mounting hole in tower boom. Install attach pin.

4. If necessary, gently tap pin into position with a soft headed mallet and secure with a bolt and lockwasher.

5. Connect all wiring to ground control box.

6. Activate hydraulic system and operate tower lift up

to extend tower lift cylinder until rod end attach hole is aligned with mounting hole in tower boom. Install attach pin.

7. If necessary, gently tap pin into position with a soft headed mallet and secure with bolts and lockwashers.

8. Connect hydraulic lines that run along the side of the boom.

9. Using all applicable safety precautions, operate machine systems and raise and extend boom fully, then lower and retract boom fully. If problems are present, re-check procedures and make adjustments as necessary.

10. Shut down machine systems.

11. As necessary, lubricate all points requiring lubrica-

tion.

21. Attach the right side bracket and powertrack to boom assembly.

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Page 93

SECTION 4 - BOOM & PLATFORM

Main Boom Installation

1. Using suitable lifting equipment, position assembled main boom on tower boom so that boom pivot holes in main boom and tower boom are aligned.

2. Insert boom pivot pin, gently tapping pin into position with a soft headed mallet if necessary. Secure pin with bolts and lockwashers.

3. Align rod end of upper master cylinder with attaching holes in level links. Install attach pin and secure with setscrews.

4. Align horizontal level link with mounting hole in tower boom and insert attach pin. Secure pin with bolt and lockwasher.

5. Connect all wiring to ground control box.

6. Using all applicable safety precautions, operate lift-

ing equipment in order to position main boom lift cylinder so that holes in cylinder rod end and boom structure are aligned. Insert lift cylinder pin.

7. If necessary, gently tap pin into position with a soft headed mallet, ensuring that pin plate holes are aligned with attach holes in boom structure. Install pin attaching bolts and lockwashers.

4.2 BOOM CHAINS

Adjusting Procedures - Main Boom

ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE.

1. Position main boom fully retracted at +5 degrees horizontal, no load in platform.

2. Extend main boom 3 feet (1 meter).

3. Torque retract chain adjuster to 50 ft. lb. (68 Nm),

then torque extend chain adjuster to 50 ft. lb. (68 Nm).

4. Retract main boom 1 foot (30.5 cm).

5. Check torque on extend chain adjuster.

6. Again retract main boom 1 foot (30.5 cm).

7. Recheck torque on extend chain adjuster.

8. Extend main boom 1 foot (30.5 cm).

9. Recheck retract chain adjuster torque.

10. Check for proper operation of main boom.

8. Shut down machine systems.

9. Connect hydraulic lines running along side of boom.

10. Using all applicable safety precautions, operate

machine systems and raise and extend boom fully, noting the performance of the extension cycle. If chattering is apparent, extend chain system requires adjustment.

11. Retract and lower boom, noting performance of retraction cycle. If chattering is apparent, retract chain system requires adjustment.

12. Shut down machine systems.

13. If necessary, adjust extend and retract chain sys-

tems and secure adjustment locknuts.

14. As necessary, lubricate all points requiring lubrication.

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Page 94

SECTION 4 - BOOM & PLATFORM

Inspection Procedure

BOOM CHAINS ARE TO BE INSPECTED AT TIME OF NEXT BOOM OVERHAUL AND WHEN DEEMED NECESSARY BY MACHINE OWNER. INSPECTION INTERVAL SHOULD NOT EXCEED 500 HOURS OF MACHINE OPERATION.

Inspect boom chains for the following conditions:

1. Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over the extend/retract sheaves, joints and plate edges very gradually wear. Chain “stretch” can be measured using a manufacturers wear scale or steel tape. When chains have elongated 3% they must be removed and replaced. Refer to Table 4-1, Chain Stretch Tolerance for proper chain specifications and allowable stretch tolerances. Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave, or unusually heavy loads. All of the above require replacement of the chain and correction of the cause. Chain side wear, noticeable when pin heads and outside plates show a definite wear pattern, is caused by misalignment of the sheave/chain anchors and must be corrected promptly. Do not repair chains; if a section of chain is damaged, replace the entire chain set.

3. Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity of the chain, because these are primary reasons for side plate cracking. The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint. Do not steam clean or degrease chains. At time of chain installation, factory lube must be supplemented by a maintenance program to provide a film of oil on the chains at all times. If chains are corroded, they must be inspected, especially the outside plates, for cracks in-line with the pins. If cracks are found, replace the chain; if no cracks are discovered, lubricate the chains by dipping in heated oil, and reinstall on the machine. Keep chains lubricated.

4. Fatigue Cracks: Fatigue is a phenomenon that affects most metals, and is the most common cause of chain plate failures. Fatigue cracks are found through the link holes, perpendicular (90 degrees) from the pin in-line position. Inspect chains carefully after long time use and heavy loading for this type of crack. If any cracks are discovered, replace all chains, as seemingly sound plates are on the verge of cracking. Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains.

2. Lubrication: One of the most important but often overlooked factors is adequate lubrication. In addition to reducing internal friction, maintaining a film of oil on all chain surfaces will inhibit rusting and corrosion. This is important as corrosion of highly stressed, hardened steel chain components can cause a major reduction in the load capacity of leaf chain and result in link plate cracking.

NOTE: The need for lubrication can be determined by the

presence of rust on the exposed portions of chain.

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Page 95

SECTION 4 - BOOM & PLATFORM

TIGHT JOINTS

ABNORMAL PROTRUSION OR

TURNED PINS

ARC-LIKE CRACKED PLATES

(STRESS CORROSION)

5. Tight Joints: All joints in the roller chain should flex freely. On roller chain, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting care fully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain. This type of problem is accelerated by poor lubrication maintenance practice, and most tight joint chains have been operated with little or no lubrication. Tight joints on leaf chain are generally caused by:

1. Bent pins or plates.

2. Rusty joints.

3. Peened plate edges.

Oil rusty chains, and replace chains with bent or peened chain components. Keep chains lubricated.

6. Protruding or Turned Pins: Chains operating with inadequate lube generate tremendous friction between the pin and plates (pin and bushing on roller chain). In extreme cases, this frictional torque can actually turn the pins in the outside press-fit plates. Inspect for turned pins, which can be easily spotted as the “V” flats on the pin heads are no longer in line. Replace all chains showing evidence of turned or protruding pins. Keep chains lubricated.

7. Stress Corrosion Cracking: The outside link plates, which are heavily press-fitted to the pins, are particularly susceptible to stress corrosion cracking. Like fatigue cracks, these initiate at the point of highest stress (aperture) but tend to extend in an arc-like path, often parallel to the rolling grain of the material.

Also, more then one crack can often appear on a link plate. In addition to rusting, this condition can be caused by exposure to an acidic or caustic medium or atmosphere. Stress corrosion is an environmentally assisted failure. Two conditions must be present; corrosive agent and static stress.

In the chain, static stress is present at the aperture due to the press fit pin. No cycle motion is required and the plates can crack during idle periods. The reactions of many chemical agents (such as battery acid fumes) with hardened metals liberate hydrogen which attacks and weakens the metal grain structure.

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SECTION 4 - BOOM & PLATFORM

8. Chain Anchors, Sheaves, and Pins: An inspection of the chain must include a close examination of chain anchors and sheaves. Check chain anchors for wear breakage and misalignment. Anchors with worn or broken fingers should be replaced. They should also be adjusted to eliminate twisting the chain for an even load distribution.

Sheaves should be inspected for worn flanges, which would indicate misalignment, and wear on the outside diameter of the sheave. A worn sheave can mean several problems, as follows:

1. Chains too tight.

2. Sheave bearings/pin bad.

3. Bent/misaligned chains.

PIN TO PIN

or 28 pitches

or 14 pitches

or 8 pitches

or 7 pitches

ALLOWABLE

STRETCH

14 IN (36 CM) SPAN

0.42 in.

(1.07 cm)

0.42 in.

(1.07 cm)

0.42 in.

1.07 cm

0.42 in.

1.07 cm

CHAIN

SIZE

0.50 in. pitch

(1.27 cm)

1.00 in. pitch

2.54 cm

1.75 in. pitch

(4.45 cm)

2.00 in. pitch

(5.08 cm)

Table 4-1. Chain Stretch Tolerance

MEASUREMENT

14 in. (36 cm)

4.3 WEAR PADS

Shim up wear pads to within 5/16 in. (0.8 mm) tolerance between wear pad and adjacent surface.

Replace wear pads when worn within 1/8 in. (3.2 mm) of threaded insert.

4.4 PLATFORM ROTATOR BRAKE

The platform rotator is equipped with a brake, which uses a stack of belleville washers to apply friction to the platform pivot point. To ensure proper friction, torque bolt securing belleville washers to 140 ft. lb. (190 Nm).

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Page 97

SECTION 5. HYDRAULICS

SECTION 5 - HYDRAULICS

5.1 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir. A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of the valve body. Lands on the spool divide the bore into various chambers, which, when the spool is shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is springloaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

Proportional Control Valves - Vickers

The Vickers proportional valves provide a power output matching that required by the load. A small line connected to a load sensing port feeds load pressure back to a sequence valve. The sequence valve senses the difference between the load and pump outlet pressure, and varies the pump displacement to keep the difference constant. This differential pressure is applied across the valve’s meter-in spool, with the effect that pump flow is determined by the degree of spool opening, independent of load pressure. Return lines are connected together, simplifying routing of return flow and to help reduce cavitation.

Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence valve. Integral actuator port relief valves, anti-cavitation check valves, and load check valves are standard.

Relief Valves

Main relief valves are installed at various points with the hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control. The relief valve provides an alternate path for the continuing flow from the pump, thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of the system valve bank. Relief pressures are set slightly higher than the load requirement, with the valve diverting excess pump delivery back to the reservoir when operating pressure of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir. Individual, integral reliefs are provided for each side of the circuit.

5.2 CYLINDERS - THEORY OF OPERATION

Cylinders are of the double acting type. Systems incorporating double acting cylinders are as follows: Tower Lift, To we r Telescope, Main Lift, Main Tele scope, Fro n t a n d Rear Steer, Lower Master, Upper Master, Platform Slave Level, Front and Rear Frame Lift and Front and Rear Axle Extend. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

Holding valves are used in t h e To w e r L i f t , To w e r Te l e scope, Main Lift, Main Telescope and Platform Slave Level circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.

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SECTION 5 - HYDRAULICS

5.3 CYLINDER CHECKING PROCEDURES

NOTE: Cylinder checks must be performed any time a cylin-

der component is replaced or when improper system operation is suspected.

Cylinders w/o Counterbalance Valves Front and Rear Steer Cylinders, Front and Rear Frame Lift Cylinders, Upper Master Cylinder, Lower Master Cylinder, Front and Rear Axle Extension Cylinders

OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate engine and fully extend cylinder to be checked. Shut down engine.

2. Carefully disconnect hydraulic hose from retract port of cylinder. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should be no further leakage from the retract port.

3. Activate engine and activate cylinder extend function. Check retract port for leakage.

4. If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If cylinder retract port leakage is less than 6-8 drops per minute, carefully reconnect hose to retract port and retract cylinder.

5. With cylinder fully retracted, shut down engine and carefully disconnect hydraulic hose from cylinder extend port.

6. Activate engine and activate cylinder retract function. Check extend port for leakage.

7. If cylinder leakage is 6-8 drops per minute or more, piston seals are defective and must be replaced. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, then activate cylinder through one complete cycle and check for leaks.

Cylinders w/Single Counterbalance Valves

- Main Lift Cylinder, Tower Telescope Cylinder

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate hydraulic system.

WHEN WORKING ON THE MAIN LIFT CYLINDER, RAISE THE TOWER BOOM AND THEN RAISE THE MAIN BOOM TO HORIZONTAL. SUPPORT THE MAIN BOOM USING A SUITABLE BOOM PROP OR OVERHEAD LIFTING DEVICE.

2. If working on the main lift cylinder, raise the tower boom and then raise the main boom to horizontal. Place a suitable boom prop approximately 1 in. (2.5 cm) below the boom. If working on the tower telescope cylinder, raise the tower boom above horizontal and extend the fly section approximately 1 foot (30.5 cm).

3. Shut down hydraulic system and allow machine to sit for 10-15 minutes. Turn ignition switch to ON, move control switch or lever for applicable cylinder in each direction, then turn ignition switch to OFF. This is done to relieve excess pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block.

4. There will be initial weeping of hydraulic fluid, which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made. If the retract port is leaking, the piston seals are defective and must be replaced. If the extend port is leaking, the counterbalance valve is defective and must be replaced.

5. If no repairs are necessary or when repairs have been made, carefully reconnect hydraulic hoses to the appropriate ports.

6. If used, remove boom prop or lifting device from boom, activate hydraulic system and run cylinder through one complete cycle to check for leaks.

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SECTION 5 - HYDRAULICS

Cylinders w/Dual Counterbalance Valve Main Telescope Cylinder, Tower Lift Cylinder, Platform Slave Level Cylinder

OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY.

1. Using all applicable safety precautions, activate hydraulic system.

2. If working on the main telescope cylinder, raise the tower boom and then raise the main boom above horizontal. Extend the main fly boom approximately 1 foot (30.5 cm). If working on the platform slave level cylinder, stroke platform level cylinder forward until platform sits at a 45 degree angle.

3. Shut down hydraulic system and allow machine to sit for 10-15 minutes. Turn ignition switch to ON, move control switch or lever for applicable cylinder in each direction, then turn ignition switch to OFF. This is done to relieve pressure in the hydraulic lines. Carefully remove hydraulic hoses from appropriate cylinder port block.

4. There will be initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should not be any further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the counterbalance valve is defective and must be replaced.

5. To check piston seals, carefully remove the counterbalance valve from the retract port. After initial discharge, there should not be any further leakage from the ports. If leakage occurs at a rate of 6-8 drops per minute or more, the piston seals are defective and must be replaced.

6. If no repairs are necessary or when repairs have been made, replace counterbalance valve and carefully reconnect hydraulic hoses to cylinder port block.

7. Activate hydraulic system and run cylinder through one complete cycle to check for leaks.

5.4 CYLINDER REMOVAL AND INSTALLATION

Tower Telescope Cylinder Removal

NOTE: The tower boom can be telescoped without elevating

the tower by overriding the plunger valves. Refer to Figure 4-1., Boom Mounted Limit Switches and Valves Installation.

MAKE SURE THE TOWER BOOM IS NOT EXTENDED BEYOND WHAT IS NEEDED TO GAIN ACCESS TO THE ATTACH PINS.

MAKE SURE THE TOOLS USED TO OVERRIDE THE PLUNGER VALVE IS REMOVED BEFORE RETURNING THE MACHINE TO SERVICE.

1. Place machine on a flat and level surface, with boom in the horizontal position and extended just enough so that the fly section cylinder attach pins are exposed.

2. Shut down engine. Support main boom and tower boom with props or overhead lifting devices.

3. Remove four bolts and lockwashers securing telescope cylinder attach plate to base end of tower boom.

4. Remove four bolts and lockwashers securing telescope cylinder attach plate to port block of telescope cylinder. Remove attach plate.

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM.

5. Tag and disconnect hydraulic lines to telescope cylinder. Use suitable containers to retain any residual hydraulic fluid. Cap hydraulic lines and ports.

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SECTION 5 - HYDRAULICS

6. Remove two bolts and lockwashers securing each of two trunnion blocks to base end of mid boom section. Remove trunnion blocks.

7. Remove bolt, lockwasher and end cap from each end of fly attach pin. Using a suitable brass drift, carefully drive fly attach pin from fly section.

8. Attach a suitable sling to the telescope cylinder rod. Support with an overhead crane or other suitable lifting device.

9. Using the lifting equipment, carefully pull cylinder from boom assembly.

10. Using another lifting device, support telescope cylinder fly end rod and remove cylinder from boom assembly. Lower cylinder to the ground or suitably supported work area.

Tower Telescope Cylinder Installation

1. Using suitable lifting equipment, carefully insert fly end cylinder rod into boom assembly.

2. Slide cylinder trunnion into appropriate slots inside mid boom section and secure with two trunnion blocks, four bolts and lockwashers.

3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports.

4. Install cylinder mounting plate on cylinder base end port block and secure with four bolts and lockwashers.

5. Secure cylinder mounting plate to base boom with four bolts and lockwashers.

6. Using auxiliary power, extend telescope cylinder until fly end rod attach bushing is aligned with fly attach holes in fly boom.

7. Using a suitable brass drift, drive fly attach pin into fly boom and fly end rod attach bushing. Secure attach pin with end cap, bolt and lockwasher on each end of pin.

8. Fully retract boom and shut down engine. Check hydraulic fluid level and adjust accordingly.

Tower Lift Cylinder Removal

1. Place machine on a flat and level surface. Start engine and raise tower boom. Shut down engine and attach a suitable support device to boom.

2. Remove four bolts and lockwashers securing lift cylinder rod attach pin to tower boom. Using a suitable brass drift, drive out lift cylinder rod attach pin.

3. Using auxiliary power, retract tower lift cylinder rod completely.

4. Tag, disconnect and cap tower lift cylinder hydraulic lines and ports.

5. Remove the four bolts and lockwashers securing barrel end attach pin to turntable. Using a suitable brass drift, drive out barrel end attach pin from turntable.

6. Remove cylinder from boom and place in a suitable work area.

Tower Lift Cylinder Installation

1. Install lift cylinder in place using suitable slings or supports, aligning attach pin mounting holes on turntable.

2. Using a suitable brass drift, drive the barrel end attach pin through mounting holes in lift cylinder and turntable. Secure pin in place with four bolts and lockwashers.

3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports.

4. Using auxiliary power, extend cylinder rod until attach pin hole aligns with those in boom. Using a suitable drift, drive cylinder rod attach pin through aligned holes, taking care to align pin retaining plate holes with holes in boom. Secure pin in place with four bolts and lockwashers.

5. Place boom in stowed position and shut down engine. Check hydraulic fluid level and adjust accordingly.

5-4 – JLG Lift – 3120679

JLG 150HAX Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

AGENERAL

B HYDRAULIC SYSTEM SAFETY

CMAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

1.2 ENGINE DATA

1.4 PERFORMANCE DATA

1.3 DRIVE/STEER SYSTEM

1.5 FUNCTION SPEEDS

1.6 LUBRICATION

1.7 TORQUE REQUIREMENTS 1.8 PRESSURE SETTINGS - PSI (BAR)

1.9 MAJOR COMPONENT WEIGHTS 1.10 CRITICAL STABILITY WEIGHTS

1.11 SERIAL NUMBER LOCATIONS

1.12 OPERATOR MAINTENANCE

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

Preparation, Inspection, and Maintenance

Pre-Start Inspection

Pre-Delivery Inspection and Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

2.2 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

Lubrication and Servicing

Bolt Usage and Torque Application

2.3 LUBRICATION AND INFORMATION

Hydraulic System

Hydraulic Oil

Changing Hydraulic Oil

Lubrication Specifications

2.4 CYLINDER DRIFT TEST

Platform Drift

Cylinder Drift

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

2.6 WELDING ON JLG EQUIPMENT

Do the Following When Welding on JLG Equipment

Do NOT Do the Following When Welding on JLG Equipment

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Tire Inflation

Tire Damage

Tire Replacement

Wheel Replacement

Wheel Installation

3.2 DRIVE TORQUE HUB

Disassembly

Cleaning and Inspection

Assembly

3.3 DRIVE BRAKE - MICO - MACHINES BUILT MARCH 1992 TO S/N 33476

Disassembly

Cleaning and Inspection

Assembly

3.4 DRIVE BRAKE - MICO - MACHINES BUILT S/N 33476 TO PRESENT

Disassembly

Inspection

Assembly

3.5 FREE WHEELING OPTION

To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.

To Engage Drive Motors and Brakes (Normal Operation)

3.6 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

Replacement and Devcon Application Procedures

Wear Tolerance

Swing Bearing Torque Values