JLG 15SP Service Manual

Service and Maintenance Manual

Model

12SP 15SP

3120775

March 17, 2008

NOTES:

FOREWORD

The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.

BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/ OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES, PER OSHA REGULATIONS.

THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.

Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION, NOTICE, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas. They

are defined as follows:

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH.

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES.

Also in this Manual "Notes:" are used to provide information of special interest.

JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE.

Due to the continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

NOTES:

MAINTENANCE SAFETY PRECAUTIONS

GENERAL

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 established by a qualified person and must be followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION.

The specific precautions to be observed during machine 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 component weight and 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 IS THE RESPONSIBILITY OF THE OWNER/ OPERATOR.

HYDRAULIC SYSTEM SAFETY

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

2. Relieve system pressure by activating the lift DOWN control with the platform completely lowered to direct any line pressure back into the return line to the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss.

MAINTENANCE

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

• 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 DANGER, WARNING, CAUTION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL.

• KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL, GREASE, WATER, ETC.

• NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.

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

• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

3120775 – JLG Lift – a

EFFECTIVITY PAGE

EFFECTIVITY CHANGES

June 2, 1999 - Original Issue of Manual

March 7, 2000 - Manual Revised (added CSA/Latin America Specifications)

April 13, 2000 - Manual Revised (added 12SP Model)

April 25, 2000 - Manual Revised (corrected Mast Disassembly/Assembly - Section-2.)

November 22, 2000 - Manual Revised - Pages Affected;Section 2 - Pages 2-4 through 2-19.

January 25, 2001 - Manual Revised - Pages Affected;Section 2 - Page 2-14 and 2-15.

January 16, 2002 – Manual Revised

January 20, 2006 – Manual Revised

July 10, 2006 – Manual Revised

March 17, 2008 – Manual Revised

b – JLG Lift – 3120775

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a

Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

EFFECTIVITY CHANGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .b

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 COMPONENT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic Pump/Electric Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Platform Capacity (Max. Rated Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Weight (With Standard Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Height (Platform Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maximum Platform Height (Mast Fully Extended). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maximum Working Height (Average Person) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine Overall Width And Length (Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.4 TORQUE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.5 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 HYDRAULIC PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.7 CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.8 SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

SECTION 2 - SERVICE PROCEDURES

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 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 SERVICING AND MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Mast Cable Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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TABLE OF CONTENTS

2.4 LUBRICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.5 BATTERY CHARGER - ASSEMBLY AND DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Battery Charger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Printed Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

DC Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

AC Circuit Breaker and Voltage Selection Switch Replacement . . . . . . . . . . . . . . . . . . 2-10

Shunt Assembly, Varistor, and SCR Rectifier Replacement (See Illustration) . . . . . . . . 2-10

2.6 HYDRAULIC LIFT PUMP - SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

FENNER BRAND PUMP - Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Motor Cap/Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Motor Brush Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Brush Housing Final Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

MONARCH BRAND PUMP - Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Motor Assembly - Remove/Install - Reference Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Motor/Brush Cover - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Brush Carrier Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Brush Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

TANK AND PUMP REMOVAL - (All Pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Tank Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Filter Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Pressure Adjust Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Pressure Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.7 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD . . . . . . . . . . . . . . . 2-17

Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Lift Cylinder Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.8 MAST ASSEMBLY AND DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Platform Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Mast Section 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Mast Section 3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Mast Section 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Mast Section 1 Disassembly (All Masts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.9 MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Mast Section 1 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Mast Section 2 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Mast Section 3 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Mast Section 4 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Platform Mounting Section - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2.10 MAST TO BASE FRAME INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2.11 MAST CHAINS/CABLES AND SEQUENCING CABLES ADJUSTMENT . . . . . . . . . . . . . . . . 2-29

Mast Chain/Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Sequencing Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.12 SEQUENCE CABLE REPLACEMENT KIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Replacement Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

ii – JLG Lift – 3120775

SECTION 3 - TROUBLESHOOTING

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.4 ELECTRICAL SYSTEM - MULTIMETER BASICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.5 ELECTRICAL SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Basic Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

LIST OF FIGURES

TABLE OF CONTENTS

FIGURE NO. TITLE PAGE NO.

1-1. Hydraulic Pressure Setting - Adjustment Screw Located at Base of Pump Motor . . . . . . . . . 1-2

1-2. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2-1. Lift Cylinder Internal Component Assembly Cross-Section. . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-2. Mast Section - Assembly/Disassembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-3. 15SP Mast Assembly Components. (5 Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2-4. 12SP Mast Assembly Components. (4 Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-5. Mast Chain Routing Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-6. Mast Chain/Cable/Sequence Cable Adjustment Components. (Typical) . . . . . . . . . . . . . . . 2-30

3-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-5. Hydraulic Schematic. (SP Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-6. Electrical Diagram (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-7. Electrical Diagram (With Floor Brake/Gate Alarm Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Hydraulic Oil Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

2-2 Preventive Maintenance & Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-3 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-4 AM Series Mast Component Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

3-1. DC Unit - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3120775 – JLG Lift – iii

TABLE OF CONTENTS

NOTES:

iv – JLG Lift – 3120775

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Reservoir

DC Models - 5 qts. U.S. (4.7 ltr.)

1.2 COMPONENT DATA

Hydraulic Pump/Electric Motor Assembly

DC MODELS - 12 VOLT DC MOTOR/PUMP

Motor - 12v - DC Standard Duty

Pump Displacement - .098 cu. in./rev.(AFC 1.6 cc/rev.)

Pump Output - 1.42 GPM @ 800 PSI @ 11.7v-DC @

135 AMPS @ 45 Centistrokes (200 SSU)

Pressure Relief - Adjustable Range 1500 to 5000 PSI,

Set to 2800 PSI (193 bar) at factory

Batteries

WET (Standard)

12 Volt - 165 Amp (min.) - Deep Cycle Marine - RV

DRY (Option)

12 Volt - 165 Amp (min.) - Deep Cycle Marine - RV

AGM (Absorption Gas Mat) (Option)

12Volt - 100 O.A.H. - M2 Marine Combination

Battery Charger

110/240 Volts AC, 50/60 Hz - input

12 Volt DC, 10 Amp - output

Automatic SCR Charger

Selectable Voltage

NOTE: A high output - 12Volt DC, 20 Amp output - SCR

charger is supplied with the AGM battery option.

1.3 PERFORMANCE DATA

Platform Capacity

12SP & 15SP - 500 lb.* (227kg) - ANSI-U.S.A./

12SP & 15SP - 400 lb.* (181kg) - CSA - Canada

* Evenly distributed on platform floor. * Extendible Platform - Max. 250 lb. on rear/250 lb. on front, when extended. Not Available for CSA.

Machine Speeds

12SP - Lift up - 25 seconds *

Lift down - 13 to 20 seconds *

15SP - Lift up - 30 seconds *

Lift down - 18 to 25 seconds *

* Timed with maximum rated load: 500 lb.

Machine Weight

12SP - 1,180 lbs. (535 kg)

15SP - 1,240 lbs. (563 kg)

Machine Height

12SP & 15SP - 78 in. (1.9 m)

Maximum Platform Height

12SP - 11 ft. 7 in. (3.53 m)

15SP - 15 ft. 2 in. (4.62 m)

Maximum Working Height

12SP - 18 ft. (5.4 m)

15SP - 21 ft. (6.4 m)

Machine Overall Width And Length

12SP - 34 in.(W) x 73 in.(L) (86 cm x 185 cm)

15SP - 34 in.(W) x 75.5 in.(L) (86 cm x 192 cm)

(Length includes platform and battery pack, end to end.)

(Max. Rated Load)

Latin America

(With Standard Platform)

(Platform Stowed)

(Mast Fully Extended)

(Average Person)

(Stowed)

1.4 TORQUE REQUIREMENTS

When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart, Table 1-2. to determine proper torque value.

3120775 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.5 LUBRICATION

Hydraulic Oil

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 of 10W-30 and a viscosity index of 152.

For cold weather applications, i.e. when temperatures remain consistently below +20°F (–7°C) JLG recommends using Mobil DTE 13 hydraulic oil.

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.

Table 1-1. Hydraulic Oil Operating Range

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

+0˚ F to +180˚ F

(-18˚ C to +83˚ C)

+0˚ F to +210˚ F

(-18˚ C to +99˚ C)

+50˚ F to +210˚ F (+10˚ C to +99˚ C)

SAE VISCOSITY

GRADE

10W

10W-20, 10W-30

20W-20

Do not adjust system pressure higher than required to raise maximum rated load capacity. Make pressure adjustment with oil at normal operating temperature. If pressure is set when oil is cold, platform may not raise rated load after oil has warmed.

PRESSURE

ADJUSTMENT

SCREW CAP

(SHOWN REMOVED)

Figure 1-1. Hydraulic Pressure Setting - Adjustment

Screw Located at Base of Pump Motor

(Remove Hex Head Cap as Shown)

SCREW

HYDRAULIC

OIL TANK

GROUND

CONTROL

STATION

COVER

Lubrication Specifications

Table 1-2. Lubrication Specifications

KEY SPECIFICATIONS

MPG - Multipurpose Grease having a minimum dripping point

of 350° F. 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 service

c la ss if ic a ti on GL- 5 or MI L-S pe c MI L-L- 21 05 .

HO - Hydraulic Oil. ISO-Vg grade 32, 46.

CL - Chain Lube. Use a good quality chain lubricant

1.6 HYDRAULIC PRESSURE ADJUSTMENT

(See Table 1-1.)

Adjust system pressure so that platform will raise with rated capacity in platform.

Turning adjustment screw clockwise, increases system

pressure, turning screw counterclockwise, decreases system pressure.

1.7 CYLINDER SPECIFICATIONS

NOTE: All dimensions are given in inches (in), with the met-

ric equivalent, centimeters (cm), given in parentheses.

Table 1-3. Cylinder Specifications

DESCRIPTION

Lift Cylinder - 12SP

Lift Cylinder - 15SP

BORE

in./(cm)

1.63 (4.1)

STROKE

in./(cm)

32.5

(82.5)

41.5

(105.4)

ROD DIA.

in./(cm)

1.38 (3.5)

1.8 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the machine. The plate is located on the back of the mast, just above the mast support bracket. In addition, should the serial number plate be damaged or missing, the machine serial is stamped on the mast and on the base frame.

1-2 – JLG Lift – 3120775

SECTION 1 - SPECIFICATIONS

Table 1-4. Lubrication Intervals for Various Components

INTERVAL HOURS

ITEM COMPONENT

1 Hydraulic Oil Fill To Line

Swivel Raceways 2 - Front Casters MPG - Pressure Gun

Mast Chains * 2 - Per Section CL - Brush or Spray

NO/TYPE

LUBE POINTS

on Reservoir 5 Qt. (4.3 L) Reservoir

LUBE/METHOD

HO - Check H y d. O il L e ve l HO - Change H y d. O il

3 MOS.

150 Hrs.

✔

6 MOS.

300 Hrs.

✔

1 YR.

600 Hrs.

2 YRS.

1200 Hrs.

✔

COMMENTS

Check Hyd. Oil after every 10 hrs. of operation. Change Hyd. Oil after every 1200 hrs. of operation.

Inspect, lubricate if dry or r usting.

* Applies Only to Mast Sections with Chains.

Key to Lubricants: MPG - Multipurpose Grease

HO - Hydraulic Oil - ISO-Vg grade 32, 46 CL - Chain Lube. Use a good quality chain lubricant

Notes: 1. Be cer tain to lubricate like items on each side of the machine.

2. Recommended lubricating intervals are based on nor mal use. If machine is subjected to severe operating conditions,

such as a high number of cycles, location, corrosive/dir ty environment, etc., user must adjust lubricating requirements accordingly.

3. Lubricating inter vals are calculated on 50 hours of machine operation a week.

4. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failur e t o do s o w i l l result in incorrect oil level reading on the hydraulic reser voir.

3120775 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Figure 1-2. Torque Chart.

1-4 – JLG Lift – 3120775

SECTION 2 - SERVICE PROCEDURES

SECTION 2. SERVICE PROCEDURES

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 qualified JLG equipment mechanic on an annual basis, no later than thirteen (13) months from the date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic 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 Table 2-2, Preventive Maintenance & Inspection 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.

3120775 – JLG Lift – 2-1

SECTION 2 - SERVICE PROCEDURES

Table 2-1. Inspection and Maintenance

TYPE FREQUENCY

Pre-Start Inspection

Pre-Delivery Inspection

Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

Prior to use each day; or A t e a c h O p er a to r c ha n ge .

Prior to each sale, lease, or rental delivery.

In service for 3 months or 150 hours, whichever 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 Ser vice and Maintenance Manual.

PRIMARY

RESPONSIBILITY

User or Operator User or Operator Operator and Safe ty Manual

Owner, Dealer, or User Qualified JLG

SERVICE

QUALIFICATION

Mechanic

REFERENCE

Service and Maintenance Manual and applicable JLG inspection form.

Service and Maintenance Manual

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

(See Table 2-2.)

The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed. The “INTERVAL” portion of the table is divided into five columns representing the various inspection time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or conditions and depending on the location and use of the machine.

2-2 – JLG Lift – 3120775

SECTION 2 - SERVICE PROCEDURES

Table 2-2. Preventive Maintenance & Inspection Schedule.

INTERVAL

AREA ON MACHINE

PRE-START (1)

INSPECTION

3 MONTH PREVENTATIVE MAINTENANCE

MAST ASSEMBLY 7

Mast Sections 2, 5 2, 5

Chain Systems 14 3, 14 14, 25

Sequence Cable Systems 31, 2, 3

Covers or Shields 1

Sheave Systems 1, 2 1, 2

Bearings 1, 2

Slide Pads 1, 2

PLATFORM ASSEMBLY 7

Platform and Material Tray 11

Guard Rails 1, 2, 4 1, 2, 4

Gate 1, 5 1, 5

Floor 1, 2 1, 2

Lanyard Anchorage Point 1, 4 1, 4

CHASSIS ASSEMBLY 7

Front Caster Wheels 1, 2 14 1, 2 1, 2

Rear Wheel Assembly 22

Bubble Level 1, 7 1, 7

Floor Stop Assembly(s) 1, 3, 7

FUNCTIONS/CONTROLS 7

Platform Controls 5, 6, 7 5, 6, 7

Ground Controls 5, 6 5, 6, 14

Function Control Locks, Guards, or Detents 55

Function Enable System

Emergency Stop Switches (Ground & Platform) 5

Function Limit or Cutout Switch Systems 5

Manual Descent or Auxiliary Power 55

POWER SYSTEM

Battery 19 9 18

Battery Charger 5

HYDRAULIC/ELECTRIC SYSTEM 9

Hydraulic Pump 1, 2, 9 1, 2, 5, 9

Hydraulic Cylinder 2, 7, 9 2, 9

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

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

Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7

Hydraulic Filter

Hydraulic Fluid * 11 11 11

Electrical Connections 20 20

Instruments, Gauges, Switches, Lights, Horn 5

6 MONTH PREVENTATIVE MAINTENANCE

PRE-DELIVERY (2) OR FREQUENT (3)

INSPECTION

ANNUAL (4)

(YEARLY)

INSPECTION

3120775 – JLG Lift – 2-3

SECTION 2 - SERVICE PROCEDURES

Table 2-2. Preventive Maintenance & Inspection Schedule.

INTERVAL

AREA ON MACHINE

PRE-START (1)

INSPECTION

3 MONTH PREVENTATIVE MAINTENANCE

GENERAL

Operator and Safety Manuals in Storage Box 21 21 21

ANSI and EMI Manuals/Handbooks Installed 21 21 21

Capacity Decals Installed, Secure, Legible 21 21 21

All Decals/Placards Installed, Secure, Legible 21 21 21

"Walk-Around" Inspection Performed 22

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21, 22

General Structural Condition and Welds 2, 4 2, 4

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

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 22 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

* Drain and Refill with fresh hydraulic fluid every two years.

6 MONTH PREVENTATIVE MAINTENANCE

PRE-DELIVERY (2) OR FREQUENT (3)

INSPECTION

ANNUAL (4)

(YEARLY)

INSPECTION

Footnotes:

1. Prior to use each day; or at each Operator change

2. Prior to each sale, lease, or delivery

3. In service for 3 months; or Out of service for 3 months or more; or Purchased used

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

Inspection and Maintenance Codes:

1. Check for proper and secure installation.

2. Visual inspection for damage, cracks, distortion, or excessive wear.

3. Check for proper adjustment.

4. Check for cracked or broken welds.

5. Operates properly.

6. Returns to neutral or "off" position when released.

7. Clean and free of debris.

8. Interlocks function properly.

9. Check for signs of leakage.

10. Decals installed and legible.

11. Check for proper fluid level.

12. Check for chafing and proper routing.

13. Check for proper tolerances.

14. Properly lubricated.

15. Torqued to proper specification.

16. No gouges, excessive wear, or cords showing.

17. Properly inflated and seated around rim.

18. Proper and authorized components.

19. Fully charged.

20. No loose connections, corrosion, or abrasions.

21. Verify.

22. Perform.

23. Sealed properly.

24. Overrides Platform controls.

25. Inspected per Service and Maintenance Manual.

2-4 – JLG Lift – 3120775

SECTION 2 - SERVICE PROCEDURES

2.3 SERVICING AND MAINTENANCE GUIDELINES

General

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

WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY, WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED.

Safety and Workmanship

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of component 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.

NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING.

Cleanliness

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 the wheel bearings, mast sections and oil supply clean; however, these items must be maintained on a scheduled basis in order to function properly.

At any time when 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.

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.

Components Removal and Installation

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.

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.

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

Component Disassembly and Reassembly

When disassembling or reassembling a component, 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

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.

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

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.

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

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.

3120775 – JLG Lift – 2-5

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