JLG 1850SJ Service Manual

Service and Maintenance Manual

Model

1850SJ

P/N - 3121619

September 25, 2014

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

INTRODUCTION

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.

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 SERVICE MANUAL.

• 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

BHYDRAULIC 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.

Do not use your hand to check for leaks. Use a piece of card­board or paper to search for leaks. Wear gloves to help protect
hands from spraying fluid.

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.

3121619 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue - June 18, 2014
Revised - September 25, 2014

A-2 – JLG Lift – 3121619

TABLE OF CONTENTS

SECTION NO. TITLE 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 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

1.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.5 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

1.8 Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Preventive 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

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

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

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

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

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

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

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

3121619 – JLG Lift – i

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 3 - CHASSIS & TURNTABLE

3.1 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

3.2 Axle Extension System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 Steering Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.5 Drive/Steering Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.6 Traction Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.7 Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.8 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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

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

3.9 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Disengage Drive Motors & Brakes for Towing, etc. (Free Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Engage Drive Motors & Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.10 Gear Hub Oil Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Check Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Change Gear Hub Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.11 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Shaft Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.12 Procedure for Setting Swing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.13 Swing Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3.14 Chassis Tilt Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3.15 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

ii – JLG Lift – 3121619

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 4 - BOOM & PLATFORM

4.1 Boom Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Broken Cable Indicator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Beyond Transport - Drive Speed Cutback System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Drive/Steer - Boom Function Interlock System (CE/AUS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Jib Stow System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Envelope Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Moment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Boom Control System (BCS) Functional Check (Push to Test) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Controlled Arc System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Controlled Boom Angle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Slow Down System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Dual Capacity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Swing Speed Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Platform Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Boom Control Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.2 Boom Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3 Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.4 Telescope Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

4.5 Boom Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4.6 Boom Lubrication Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

4.7 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

4.8 Hose Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

4.9 Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

4.10 JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Jib Straight Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Stowed Jib Shimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

4.11 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Eight Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

4.12 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Boom Preparation for Section Repositioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Confirm Proper Boom Deployment Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Re-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Boom Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

4.13 Broken Boom Cable Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Adjusting the Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

4.14 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

One Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Two Piece Bracket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Snap Rings and Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

3121619 – JLG Lift – iii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS

5.1 Lubricating O-Rings in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Spray Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Brush-on Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Axle Extend Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Jib Level (Slave) Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Platform Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Boom Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Jib Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Jib Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Jib Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

5.3 Cylinder Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

5.4 Oil Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

5.5 Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

1. Setup of the Function Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

2. Adjustments Made at the Main Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

3. Adjustments Made at the Frame Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

4. Adjustments Made at the Platform Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74

5. Adjustments Made at Jib Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75

6. Adjustments Made in Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

5.6 Drive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

Mechanical Centering of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83

Hydraulic Centering of Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83

High Pressure Relief Valve Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

Removal and inspection of charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85

Removal and Installation of Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

5.7 Function Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

Load Sensing (LS) control with Pressure Compensator (PC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

Disassemble Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99

5.8 Drive & Function Pump Start Up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103

Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103

iv – JLG Lift – 3121619

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 6 - JLG CONTROL SYSTEM

6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

To Connect the JLG Control System Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Level Vehicle Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.2 Machine Personality Settings and Function Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.3 MACHINE ORIENTATION WHEN SETTING Function SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6.4 CANbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6.5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6.6 Control System Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Sensor #1 - Load Pin (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Sensor #2 - Main Boom Angle Sensors (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Sensor #3 - Main Boom Length Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Sensor #4 - Main Boom Cylinder Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Sensor #5 - Main Boom Transport Length Switch (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Sensor #6 - Jib Level Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Sensor #7 - Jib Lock Pin Proximity Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Sensor #8 - Jib Stow Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

Sensor #9 - Jib Lift Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

Sensor #10 - Dual Capacity / Jib Transport Length Switches (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

Sensor #11 - Platform Level Angle Sensor (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

Sensor #12 - Platform Level Angle Gravity Sensors (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #13 - Turntable Swing Angle (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #14 - Steer Angle Sensor (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #15 - Axle extend/retract Sensor (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #16 - Brake-Two Speed Pressure Sensor (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #17 - Chassis Tilt Sensor (Externally mounted) (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #18 - Tilt Sensor (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #19 - Warm up Switch (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #20 - Main Valve Pressure Transducer (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Sensor #21 - Main Lift Cylinder Pressure Transducer (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

6.7 System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Test from the Ground Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

6.8 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Axle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Boom Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

6.9 Electronic Platform Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

Platform Leveling Fault Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

Fault Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

3121619 – JLG Lift – v

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Installation of Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Exclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.5 Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.6 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Connector Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Component Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

vi – JLG Lift – 3121619

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

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

2-2. Hydraulic Oil Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

3-1. Crab Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Coordinated Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-3. 2 Wheel Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-4. Axle Hose Routing - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-5. Axle Hose Routing - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-6. Steering/Axle Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-7. Drive System Hydraulic Circuit - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3-8. Drive System Hydraulic Circuit - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-9. Turntable Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-10. Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-11. Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-12. Disengaging Drive Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-13. Gear Hub Oil Fill and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-14. Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-15. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-16. Removing Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-17. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-18. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-19. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-20. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-21. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-22. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-23. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-24. Shaft & Front Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-25. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-26. Cylinder Kit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-27. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-28. Swash Plate and Journal Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-29. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-30. Cylinder Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-31. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-32. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-33. End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-34. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-35. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-36. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-37. Swing Bearing Removal - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3-38. Swing Bearing Removal - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-39. Swing Bearing Removal - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-40. Swing Bearing Removal - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

4-1. Boom Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-2. Boom Assembly - Sheet 1 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-3. Boom Assembly - Sheet 2 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Boom Assembly - Sheet 3 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-5. Boom Assembly - Sheet 4 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-6. Boom Assembly - Sheet 5 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-7. Boom Assembly - Sheet 6 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-8. Boom Assembly - Sheet 7 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-9. Boom Assembly - Sheet 8 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

. . . . . . . . . . . . . . . . . . . . . . . 4-10

3121619 – JLG Lift – vii

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

4-10. Boom Assembly - Sheet 9 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-11. Locations for Threadlocker Application - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-12. Locations for Threadlocker Application - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-13. Locations for Threadlocker Application - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-14. Locations for Threadlocker Application - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-15. Locations for Threadlocker Application - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-16. Boom Assembly Torque Values - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-17. Boom Assembly Torque Values - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-18. Boom Assembly Torque Values - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-19. Boom Assembly Torque Values - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-20. Hose Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

4-21. Section 3 Boom Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-22. Section 4 Boom Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

4-23. Section 5 Boom Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

4-24. Jib Hydraulics - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

4-25. Jib Hydraulics - Sheet 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4-26. Jib Hydraulics - Sheet 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

4-27. Jib Hydraulics - Sheet 4 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4-28. Jib Hydraulics - Sheet 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

4-29. Jib Hydraulics - Sheet 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

4-30. Jib Hydraulics - Sheet 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

4-31. Jib Assembly - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

4-32. Jib Assembly - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

4-33. Jib Assembly - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

4-34. Jib Assembly - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

4-35. Jib Stow Shimming Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

4-36. Fully Retracted Boom Section Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

4-37. Initial Exposed Thread Length for Wire Rope Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

4-38. Boom Wire Rope Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

4-39. Broken Cable Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

4-40. Powertrack Installation - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

4-41. Powertrack Installation - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

4-42. Powertrack Installation - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

4-43. Powertrack Installation - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

4-44. Powertrack Shimming Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

4-45. Powertrack Locations for Threadlocker Application and Torque - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . 4-71

4-46. Powertrack Locations for Threadlocker Application and Torque - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . 4-72

4-47. Powertrack Locations for Threadlocker Application and Torque - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . 4-73

4-48. Powertrack Locations for Threadlocker Application and Torque - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . 4-74

4-49. Powertrack Hose Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

4-50. Powertrack Hose Installation - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

4-51. Powertrack Hose Installation - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

4-52. Powertrack Hose Installation - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

4-53. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84

5-1. Turntable Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2. Hydraulic Hose Installation - Sheet 1 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Hydraulic Hose Installation - Sheet 2 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-4. Hydraulic Hose Installation - Sheet 3 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-5. Hydraulic Hose Installation - Sheet 4 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-6. Hydraulic Hose Installation - Sheet 5 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-7. Hydraulic Hose Installation - Sheet 6 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-8. Hydraulic Hose Installation - Sheet 7 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-9. Hydraulic Hose Installation - Sheet 8 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-10. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-11. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-12. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-13. Axle Extend Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

. . . . . . . . . . . . . . . . . . . . 5-4

viii – JLG Lift – 3121619

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

5-14. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-15. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-16. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-17. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-18. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-19. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-20. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-21. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-22. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-23. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-24. Jib Level (Slave) Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-25. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-26. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-27. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-28. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-29. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-30. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-31. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-32. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-33. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-34. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-35. Cylinder Length Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-36. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-37. Platform Level Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-38. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-39. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-40. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-41. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-42. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-43. Cylinder Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-44. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-45. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-46. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-47. Rod and Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-48. Cylinder Head Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-49. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-50. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-51. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-52. Boom Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-53. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-54. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-55. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5-56. Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

5-57. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

5-58. Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-59. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-60. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-61. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-62. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-63. Cylinder Length Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-64. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-65. Jib Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-66. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-67. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-68. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-69. Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-70. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

3121619 – JLG Lift – ix

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

5-71. Cylinder Head Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-72. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

5-73. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

5-74. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

5-75. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

5-76. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

5-77. Jib Lock Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-78. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5-79. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-80. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-81. Steer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

5-82. Piston and Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-83. Cylinder Head and Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-84. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-85. Cylinder Head and Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-86. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-87. Jib Telescope Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

5-88. Piston and Spacer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-89. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-90. Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

5-91. Piston and Spacer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

5-92. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-93. Cylinder Head Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-94. Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-95. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

5-96. Port Block And Rod Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

5-97. Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

5-98. Boom Telescope Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

5-99. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

5-100. Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

5-101. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

5-102. Cylinder Head Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

5-103. Cylinder Head and Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

5-104. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

5-105. Tapered Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

5-106. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

5-107. Rod Assembly And Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

5-108. Cylinder Length Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

5-109. Oil Sampling Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

5-110. Main Valve Identification - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

5-111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

5-112. Main Valve Identification - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

5-113. Main Valve Torque Values - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65

5-114. Main Valve Torque Values - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

5-115. Function Pump Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

5-116. Control Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

5-117. PC Control Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89

5-118. LS Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90

5-119. Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

5-120. Coupling and Control Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

5-121. Endcap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

5-122. Cylinder Block Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

5-123. Swash Plate and Servo Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

5-124. Housing Bearing and Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

5-125. Control Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

5-126. Cylinder Block Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

5-127. Piston and Slipper Wear Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

x – JLG Lift – 3121619

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

5-128. Cylinder Block Wear Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98

5-129. Valve Plate Wear Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-98

5-130. Endplate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99

5-131. Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99

5-132. Swash Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

5-133. Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

5-134. Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

5-135. Valve Plate and Endcap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101

5-136. Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101

5-137. Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102

5-138. Control Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102

5-139. Hydraulic Schematic - Sheet 1 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105

5-140. Hydraulic Schematic - Sheet 2 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106

5-141. Hydraulic Schematic - Sheet 3 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107

5-142. Hydraulic Schematic - Sheet 4 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108

5-143. Hydraulic Schematic - Sheet 5 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109

5-144. Hydraulic Schematic - Sheet 6 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110

5-145. Hydraulic Schematic - Sheet 7 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111

5-146. Hydraulic Schematic - Sheet 8 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112

6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2. Control System CAN Circuit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-3. Control System CAN Circuit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-4. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-5. Analyzer Flow Chart - Personalities (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-6. Analyzer Flow Chart - Machine Setup (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-7. Analyzer Flow Chart - Calibrations (Software Version 7.X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6-9. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-10. Analyzer Flow Chart - Diagnostics (Software Version 7.X) - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6-11. Ground Control Module - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6-12. Ground Control Module - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6-13. Ground Control Module - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6-14. Chassis Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

6-15. BLAM Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-16. Jib Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6-17. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-18. Main Boom Angle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

6-19. Main Boom Cylinder Angle (Protractor) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

6-20. Main Boom Transport Length Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6-21. Jib Lock Pin Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

6-22. Jib Level Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6-23. Jib Stow Angle Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

6-24. Jib Transport Length Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

6-25. Platform Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

6-26. System Test Flow Chart - Platform Tests - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

6-27. System Test Flow Chart - Platform Tests - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

6-28. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-5. Application to Female Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-6. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-7. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-8. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-9. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-10. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

3121619 – JLG Lift – xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

7-11. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-12. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-13. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-14. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-15. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-16. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-17. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-18. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-19. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-20. Platform Box Wiring Harness - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-21. Platform Box Wiring Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-22. Platform Box Wiring Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7-23. Platform Valve Wiring Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-24. Platform Valve Wiring Harness - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7-25. Jib Valve Wiring Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7-26. Jib Valve Wiring Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-27. Jib Valve Wiring Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-28. BLAM Module Wiring Harness - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7-29. BLAM Module Wiring Harness - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7-30. Load Sensing Pin Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7-31. Base Boom Sensor Cable - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

7-32. Base Boom Sensor Cable - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7-33. Base Boom Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7-34. Base Boom Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

7-35. Beacon/Strobe Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

7-36. Fuel Pump & Water-In-Fuel Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

7-37. Turntable Wiring Harness - Sheet 1 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

7-38. Turntable Wiring Harness - Sheet 2 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

7-39. Turntable Wiring Harness - Sheet 3 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7-40. Turntable Wiring Harness - Sheet 4 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

7-41. Turntable Wiring Harness - Sheet5 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

7-42. Turntable Wiring Harness - Sheet 6 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7-43. Turntable Wiring Harness - Sheet 7 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

7-44. Turntable Wiring Harness - Sheet 8 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-45. Turntable Wiring Harness - Sheet 9 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

7-46. Ground Console Wiring Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-47. Ground Concole Wiring Harness - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

7-48. Ground Concole Wiring Harness - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

7-49. Chassis Harness - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

7-50. Chassis Harness - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

7-51. Chassis Harness - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

7-52. Chassis Harness - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47

7-53. Chassis Harness - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

7-54. Chassis Harness - Sheet 6of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

7-55. Hydraulic Valve Bank Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50

7-56. Hydraulic Valve Bank Harness - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

7-57. Hydraulic Valve Bank Harness - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

7-58. Drive Pump Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53

7-59. T4i Engine Harness - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

7-60. T4i Engine Harness - Sheet 2of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55

7-61. T4i Engine Harness - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-62. T4i Engine Harness - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

7-63. CAN Engine Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

7-64. CAN Engine Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

7-65. Electrical Installation - Sheet 1 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

7-66. Electrical Installation - Sheet 2 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

7-67. Electrical Installation - Sheet 3 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

. . . . . . . . . . . . . . . . . . . . . . . 7-56

xii – JLG Lift – 3121619

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

7-68. Electrical Installation - Sheet 4 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

7-69. Electrical Installation - Sheet 5 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

7-70. Electrical Installation - Sheet 6 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

7-71. Electrical Installation - Sheet 7 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

7-72. Electrical Installation - Sheet 8 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67

7-73. Electrical Installation - Sheet 9 of 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68

7-74. Electrical Installation - Sheet 10 of 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69

7-75. Battery Jump-Start Hookup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70

7-76. Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71

7-77. Electrical Schematic - Sheet 1 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73

7-78. Electrical Schematic - Sheet 2 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

7-79. Electrical Schematic - Sheet 3 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75

7-80. Electrical Schematic - Sheet 4 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76

7-81. Electrical Schematic - Sheet 5 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77

7-82. Electrical Schematic - Sheet 6 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78

7-83. Electrical Schematic - Sheet 7 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79

7-84. Electrical Schematic - Sheet 8 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80

7-85. Electrical Schematic - Sheet 9 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81

7-86. Electrical Schematic - Sheet 10 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82

7-87. Electrical Schematic - Sheet 11 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83

7-88. Electrical Schematic - Sheet 12 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84

7-89. Electrical Schematic - Sheet 13 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85

7-90. Electrical Schematic - Sheet 14 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86

7-91. Electrical Schematic - Sheet 15 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87

7-92. Electrical Schematic - Sheet 16 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88

7-93. Electrical Schematic - Sheet 17 of 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89

3121619 – JLG Lift – xiii

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-5 Engine Data - Deutz TD 3.6L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-9 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-10 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-11 Mobil EAL H 46 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-12 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-13 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 Excessive Noise and/or Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-3 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-4 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-5 Displacement Identifiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-6 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-7 Cylinder Block Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

5-1 Torque Specs for Relief Valves into Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-3 Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-4 Machine Personality Settings and Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-5 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-6 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

6-7 Diagnostic Fault Code Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60

7-1 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

xiv – JLG Lift – 3121619

SECTION 1. SPECIFICATIONS

Table 1-4. Tire Specifications

Size 445/50D710

Load R ange N

Ply Rating 24

Foam Fill Polyurethane HD (55 Durometer) Foam

Diameter 46.45 in. (117.9 cm)

Width 16.81 in. (427 mm)

Rim Size 15x28

Tire & Wheel Weight 1025 lbs. (465 kg)

Max Tire Load 36000 lbs. (16,329 kg)

SECTION 1 - SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

Table 1-1. Operating Specifications

Capacity - ANSI
Un r es t ri c te d
Re s tr i c te d

Capacity - CE & Australia
Un r es t ri c te d
Re s tr i c te d

Maximum Travel Grade, stowed
Position (Gradeability)

Maximum Travel Grade, stowed
Position (Side Slope)

Drive Speed 2.8 mph (4.5 kph)

Drive Speed at Elevation 0.3 mph (0.48 kph)

Gross Machine Weight - Approximate 59,900 lb. (27170 kg.)

Ground Bearing Pressure - Maximum

Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 90 lbs (400N)

500 lbs (227 kg)

1000 lbs (454 kg)

500 lbs (230 kg)

1000 lbs (450 kg)

4° - CE/Aus

119.6 psi (8.41 kg/cm

40%

Table 1-2. Dimensional Data

Horizontal Reach over end
Un r es t ri c te d Ca p ac i t y
Restricted Capacity

Horizontal Reach over side
Un r es t ri c te d Ca p ac i t y
Restricted Capacity

Overall Width
Ax l es R e tr ac t e d
Ax l es D e pl o ye d

Wheelbase

5°

2

)

Ax l es R e tr ac t e d
Ax l es D e pl o ye d

Tailswing 7 ft. 7.5 in. (2.32 m)

Ground Clearance (Axle) 9.75 in. (0.25 m)

Ground Clearance (Chassis) 1 ft. 4.25 in. (0.41 m)

1.3 CAPACITIES

Table 1-3. Capacities

Hydraulic Oil Tank 75.1 Gal. (284.2 L)

70 ft. 6 in. (21.59 m)
59 ft. 6 in. (18.13 m)

71 ft. 9 in. (21.86 m)
60 ft. 8 in. (18.49 m)

8 ft. 2 in. (2.48 m)

16 ft. 6.5 in. (5.04 m)

17 ft. 1.5 in. (5.22 m)
15 ft. 0.5 in. (4.59 m)

Maximum System Voltage 12 volts

Maximum Main Relief Hyd. Pressure 5000 psi (345 Bar)

1.2 DIMENSIONAL DATA

Table 1-2. Dimensional Data

Turning Radius (Axles Retracted)
Ou t si d e
In s id e

Turning Radius (Axles Extended)
In s id e
Ou t si d e

Machine Height (stowed) 10 ft. 0.5 in. (3.06 m)

Machine Length (stowed) 47 ft. 9.5 in. (14.57 m)

Platform Height (500 lb./230 kg. capacity) 185 ft. 7 in. (56.56 m)

Platform Height (1000 lb./450 kg. capacity) 165 ft. 2 in. (50.34 m)

Horizontal Reach from centerline of rota­tion
Un r es t ri c te d Ca p ac i t y
Restricted Capacity

3121619 – JLG Lift – 1-1

Fuel Tank 52.8 Gal. (200 L)

Drive Hub 2.6 quarts (2.5 liters)

Swing Gearbox 3 qt. (2.8 L)

1.4 TIRES

31 ft. 2.75 in. (9.52 m)
23 ft. 4.25 in. (7.12 m)

7 ft. 6.75 in. (2.3 m)

21 ft. 7.75 in. (6.6 m)

80 ft. (24.38 m)

68 ft. 11 in. (21.01 m)

SECTION 1 - SPECIFICATIONS

Table 1-5. Engine Data - Deutz TD 3.6L

Type Turbo-charged Diesel

Number of Cylinders 4

Bore 3.9 in. (98 mm)

Stroke 4.7 in. (120 mm)

Total Displacement 221 cu.in. (3.6 L)

Firing Order 1-3-4-2

Output 99.8 hp (74.4 kW)

Low Idle Engine RPM 1000 ±50

High Engine RPM 2300±50

Table 1-7. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F
(-18° to +83° C)

10W

+0° to + 210° F
(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

1.5 ENGINE DATA

1.6 MAJOR COMPONENT WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT
WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT­FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Table 1-6. Critical Stability Weights

Components LBS. KG.

Tire & Wheel 1025 465

Drive Hub & Motor 337 153

Swing Drive 223 101.2

Engine Assembly 822 373

Complete Boom (including jib & platform) 23,600 10705

Main Boom Assembly 21,600 9798

Jib Assembly 1493 677

1.7 HYDRAULIC OIL

NOTE: Hydraulic oils require anti-wear qualities at least API Ser-

vice Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service.

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 Mobil 424 is
desired, contact JLG Industries for proper recommenda­tions.

OIL SAMPLING

This machine is equipped with an oil sampling valve to
allow for verification of hydraulic oil condition. Refer to
Section 5 - Hydraulics for Oil Sampling procedures.

Table 1-8. 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)

Visc osity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

1-2 – JLG Lift – 3121619

SECTION 1 - SPECIFICATIONS

Table 1-9. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max

-40°F (-40°C)

Flash Point, Min.

330°F (166°C)

Visc osity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp a t - 2 0° F 6, 2 00

Viscosity Index 140

Table 1-10. UCon Hydrolube HP-5046

Type Synthetic Biodegradable

Specific Gravity 1.082

Pour Point, Max -58°F (-50°C)

pH 9.1

Visc osity

at 0° C (32° F) 340 cSt (1600SUS)

at 40° C (104° F) 46 cSt (215SUS)

at 65° C (150° F) 22 cSt (106SUS)

Visc osit y In dex 170

Table 1-11. Mobil EAL H 46 Specs

Type Synthetic Biode gradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)

Flash Point 500°F (260°C)

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

Weight 7.64 lb. per gal.

(0.9 kg per liter)

Viscos ity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

Table 1-12. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Visc osity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Visc osit y In dex 376

NOTE: Mobil/Exxon recommends that this oil be checked on

a yearly basis for viscosity.

3121619 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Figure 1-1. Maintenance and Lubrication Diagram

1-4 – JLG Lift – 3121619

SECTION 1 - SPECIFICATIONS

Table 1-13. 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 service classification GL-5 or

MI L-S pe c MI L-L- 21 05

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 cl ass , M IL-L- 21 04 B/M IL- L-2 104 C

1.8 MAINTENANCE AND LUBRICATION

NOTE: The following numbers correspond to those in Figure 1-1.,

Maintenance and Lubrication Diagram.

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

2. Swing Gearbox

Lube Point(s) - Fill Plug
Capacity - 3 qt. (2.8 L)
Lube - GL-5
Interval - Check level every 150 hrs/Change every 1200
hours of operation. Fill to cover ring gear.

3. Wheel Drive Hub

1. Swing Bearing - Remote Lube

Lube Point(s) - 3 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hours of operation
Comments - Apply grease and rotate in 45 degree inter­vals until bearing is completely lubricated.

3121619 – JLG Lift – 1-5

Lube Point(s) - Level/Fill Plug
Capacity - 2.6 quarts (2.5 liters) ± 10%
Interval - Check level every 3 months or 150 hrs of oper­ation; change every 2 years or 1200 hours of operation

SECTION 1 - SPECIFICATIONS

4. Hydraulic Return Filter

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every 6 months
or 300 hours thereafter.

5. Hydraulic Tank Breather

6. Hydraulic Charge Filter

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every 6 months
or 300 hours thereafter.

7. High Pressure Filter

Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter.

Comments - Remove wing nut and cover to replace.
Under certain conditions, it may be necessary to replace
on a more frequent basis.

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every 6 months
or 300 hours thereafter.

1-6 – JLG Lift – 3121619

SECTION 1 - SPECIFICATIONS

8. Hydraulic Oil

Lube Point(s) - Fill Cap
Capacity - 75 Gallons (208 liters) Tank to Full Mark
82 Gallons (310.4 L) System
Lube - HO
Interval - Check level daily. Change every 2 years or 1200
hours of operation.

9. Main Valve Filter

10. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 9.6 Quarts (9.1 L)
Lube - EO
Interval - Check level daily; change every 500 hours or
yearly, whichever comes first. Adjust final oil level by
mark on dipstick.

11. Fuel Filter - Deutz

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every 6 months
or 300 hours thereafter.

Lube Point(s) - Replaceable Element
Interval - Every year or 500 hours of operation

3121619 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

12. Fuel Pre-Filter

Lube Point(s) - Replaceable Element
Interval - Every year or 500 hours of operation

13. Air Filter

14. Boom

Lube Point(s) - Apply to wear pad contact paths
Lube - Super Lube®
Interval - Every year or 600 hours of operation. Refer to

the Service Manual for detailed procedures

15. Radiator

Lube Point(s) - Fill Cap
Lube - Anti-Freeze (Ethylene Glycol mixed 50-50 with

water)

Capacity - 13.2 qt. (12.5 L)

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

indicated by the condition indicator

Comments - Check dust valve for dirt daily

1-8 – JLG Lift – 3121619

SECTION 1 - SPECIFICATIONS

Torq ue

To rqu e

Torq ue

To rqu e

Torque Torque

Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)

3121619 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

Torq ue

Torque

Torq ue

Torqu e

To r qu e

Figure 1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)

1-10 – JLG Lift – 3121619

SECTION 1 - SPECIFICATIONS

C lamp Lo adTorque

To r qu e

Torq ue

Torque

Tor que

Torq ue

Figure 1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)

3121619 – JLG Lift – 1-11

SECTION 1 - SPECIFICATIONS

To r qu e

To r qu e

Torque

To r q ue

To r qu e

To r q ue

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

1-12 – JLG Lift – 3121619

SECTION 1 - SPECIFICATIONS

Torque Torque

Tor qu e

To r qu e

To r qu e

To r q ue

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

3121619 – JLG Lift – 1-13

SECTION 1 - SPECIFICATIONS

NOTES:

1-14 – JLG Lift – 3121619

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.

inspections. Reference the appropriate areas of this manual for
servicing and maintenance procedures.

Annual Machine Inspection

The Annual Machine Inspection must be performed on an
annual basis, no later than thirteen (13) months from the date
of the prior Annual Machine Inspection. JLG Industries recom­mends this task be performed by a Factory-Trained Service
Technician. 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 Preventive 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.

Preventive 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 Preventive 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.

Reference the JLG Pre-Delivery and Frequent Inspection Form
and the Inspection and Preventive Maintenance Schedule for
items requiring inspection during the performance of these

3121619 – JLG Lift – 2-1

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 Inspecti on Pri or to each sale, lease, or

rental delivery.

Frequent Inspection 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.

Annual Machine Inspec-

tion

Preventive

Maintenance

Annually, no later than 13 months from the date of

the prior inspection.

At intervals as specified in the Service and Mainte-

nance 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

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

Cleanliness

1. The most important single item in preserving the long
service life of a machine is to keep dirt and 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.

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual

Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual

Owner, Dealer, or User Factory-Trained Service

Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual

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

Technician

(Recommended)

Reference

and applicable JLG inspection form.

and applicable JLG inspection form.

Service and Maintenance Manual

and applicable JLG inspection form.

Components Removal and Installation

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

2. Should it be necessary to remove a component on an
angle, keep in mind that the capacity of an 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 – 3121619

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 a molybdenum disul­fide base compound or equivalent 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

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.

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

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

Bolt Usage and Torque Application

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

2.3 LUBRICATION AND INFORMATION

SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING
LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.

1. Always use new replacement hardware when installing
locking fasteners. 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.

3121619 – JLG Lift – 2-3

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.

SECTION 2 - GENERAL

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
specified 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.

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.

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 – 3121619

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 cylinder

leakage.

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

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:

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.

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.

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their housing.

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.

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

face.

c. Rusting of the pin in the bearing 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.)

3121619 – JLG Lift – 2-5

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Weekly

Preventive

Maintenance

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

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

Wea r Pa ds 1,2 1,2

Covers or Shi elds 1,2 1,2

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

Boom Assembly 14

Platform Assembly

Platform 1,2

Railing 11,2

Gate 5 1 1,5

Floor 11,2

Rotator 9,5 15

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

Turntable Assembly

Swing Bearing 1,2,14 1,2,3,13,14

Oil Coupling 9

Swing Drive System 11 11

Tur nt ab l e L oc k 1,2,5 1,2,5

Hood, Hood Props, Hood Latches 5 1,2,5

Chassis Assembly

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

Wheel Nuts/Bolts 15 15 15

Wheel Bearings 14,24

Oscillating Axle/Lockout Cylinder Systems 5,8

Extendable Axle Systems 5,8 5,8

Steer Components

Spindle Thrust Bearing/Washers 1,2

Drive Hubs 11 11

Annual
(Yearly)

Inspection

4

Every 2

Yea rs

2-6 – JLG Lift – 3121619

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Weekly

Preventive

Maintenance

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Functions/Controls

Platform Controls 5 6 6

Ground Controls 5 6 6

Function Control Locks, Guards, or Detents 1,5 5 5

Footswitch 55

Emergency Stop Switc hes (Ground & Platform ) 5 5

Function Limit or Cutout Switch Systems 5 5

Drive Brakes 5

Swing Brakes 5

Auxiliary Power 55

Power Syste m

Engine Idle, Throttle, and RPM 3 3

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

Air/Fuel Fi lter 1,7 7 7

Exhaust System 1,9 9 9

Batteries 1,9 19

Battery Fluid 11 11 11

Battery Charger 5 5

Fuel Reservoir, Cap, and Breather 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 1,9 2 1,5 1,5 2 4

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 7,11 7,11

Electrical Connections 1 20 20

Instruments, Gauges, Switches, Lights, Horn 1 5,23

General

Operation and Safety Manuals in Storage Box 21 21

ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only) 21

Capacity Decals Installed, Secure, Legible 21 21

All Decals/Placards Installed, Secure, Legible 21 21

Annual
(Yearly)

Inspection

4

Every 2

Yea rs

3121619 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Weekly

Preventive

Maintenance

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Annual Machine Inspecti on Due 21

No Unauthorized Modifications or Additions 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, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footnotes:

1

Pr i or t o u s e e a ch d ay ; or a t e a ch O pe r at o r c h an g e

2

Pr i or t o e a ch s al e , l e as e , o r de l iv e r y

3

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

4

An n ua l ly , n o la t er t ha n 13 m on t hs f ro m th e da te o f t h e pr i or i ns p ec t i on

Performance 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 leakag e
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

4

Every 2

Yea rs

2-8 – JLG Lift – 3121619

SECTION 2 - GENERAL

Figure 2-1. Engine Operating Temperature Specifications - Deutz

1001159163 A

3121619 – JLG Lift – 2-9

SECTION 2 - GENERAL

MACHINE OPERATION USING NON-JLG APPROVED
HYDRAULIC FLUIDS OR OPERATION OU TSIDE OF
THE TEMPERATURE BOUNDARIES OUTLINED IN

THE "HYDRAULIC FLUID OPERATION CHART" MAY
RESULT IN PREMATURE WEAR OR DAMAGE TO
COMPONENTS O F THE HYDRAULIC SYSTEM.

HYDRAULIC FLUID OPE RATION CHART

Figure 2-2. Hydraulic Oil Operating Temperature Specifications

Fluid Properties Base Classifications

Description

Viscos ity at 40° C (cSt, Typica l)

Viscos ity Inde x

Mineral Oils

Vegetable Oils

Synthetic

Synthetic Polyol Esters

Readily Biodegradable*

Virt uall y Non- toxic **

Fire Resistant***

Mobilfluid 424 55 145 X

Mobil DTE 10 Excel 32 32 164 X X

Univis HVI 26 26 376 X

Mobil EAL Hydraulic Oil 47 176 X X X

Mobil EAL Envirosyn H46 49 145 X X X

Quintolubric 888-46 50 185 X X X X

* Readily biodegradable classification indicates one of the following:
CO2 Conversion > 60% per EPA 560/ 6-82-003
C O2 Co n ve r si o n > 8 0% p er C EC - L- 33 -A - 93

** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203

*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval

4150740 B

2-10 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES AND WHEELS

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
hasn’t propagated beyond the allowable criteria.

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:

Wheel and Tire 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.

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

35 ft. lbs.

(45 Nm)

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

80 ft. lbs.

(100 Nm)

140 ft. lbs.

(185 Nm)

3121619 – JLG Lift – 3-1

SECTION 3 - CHASSIS & TURNTABLE

3.2 AXLE EXTENSION SYSTEM

NOTE: The boom must be oriented between the rear wheels to

extend or retract the axles.

The Axle Extension System allows each of the four axles to be
extended and retracted together while maintaining full steer­ing control as the machine is driven. The system allows the
axles to extend or retract only while the boom is in the trans­port position (see Transport Position Sensing System in Sec­tion 4) and in order to minimize wheel scrubbing during axle
movement, a minimum drive speed must be attained before
axle extension/retraction will be permitted. The system uses
four linear sensors (one at each axle) to sense when the axles
are fully extended. If any of the linear sensors detect an out of
range value for axle set, the control system considers the axles
retracted. To extend/retract the axles, the user engages the
axle extend/retract switch on the platform console and the
drive control at the same time. The axle set indicator will be off
when the axles are not fully extended and the axle extend/
retract switch is not engaged. It will flash while the axles are
extending or retracting and will be on constantly when the
axles are fully extended. With the axles not fully extended, the
boom is restricted to operation within the transport position
(see Transport Position Sensing System in Section 4). If a signal
from any axle linear sensor is lost when the boom is beyond
the transport position, the axle set indicator will flash and
drive/steer functions will be disabled until the boom is
brought back into the transport position. The steering angle
will be automatically limited to +/- 20 degrees anytime the
axles are not fully extended. If the wheel angle is more than +/

- 20 degrees when the axle retract command is engaged, the
control system will automatically reduce the wheel angle to 20
degrees during axle retraction.

3.3 DRIVE ORIENTATION SYSTEM

The Drive Orientation System (DOS) is intended to indicate to
the operator conditions that could make the direction of
movement of the chassis different than the direction of move­ment of the drive/steer control handle. The system indicates to
the operator the need to match the black and white direc­tional arrows on the platform control panel to the arrows on
the chassis for the intended direction of travel. The system
uses a proximity switch mounted on the hydraulic swivel, an
indicator light and an override switch on the platform display
panel. The proximity switch trips when the turntable is swung
+/- 35 degrees off center of the normal driving position. This
occurs roughly when the boom is swung past a rear tire. When
the turntable is in the normal drive position with the boom
between the rear tires, no indications or interlocks are made.
When the machine is actively driving when the turntable is
swung past the switch point, the system is ignored until drive/
steer is released. When drive is initiated with the boom swung
past the switch point, the DOS indicator will flash and the
drive/steer functions will be disabled. The operator must
engage the DOS override switch to enable Drive/steer (high
drive will remain disabled). When the DOS is enabled, the DOS
indicator will flash during the 3 second interval until the drive
function is selected. If the timer expires, the DOS override
switch must be re-engaged to enable drive/steer.

3-2 – JLG Lift – 3121619

3.4 STEERING CONTROL SYSTEM

Figure 3-1. Crab Steer

Figure 3-2. Coordinated Steer

Figure 3-3. 2 Wheel Steer

There are three different modes of steering selectable by the
position of the steer select switch on the platform control
panel: crab, coordinated, and conventional two wheel steer­ing. These are shown below.

SECTION 3 - CHASSIS & TURNTABLE

Each wheel has its own steer cylinder, wheel angle sensor, axle
extend linear sensor, and proportional valve, allowing the con­trol system to position each wheel to the ideal angle for all
steering modes and all steering commands. This is done
whether the axle is retracted, extended, or somewhere in
between. Changes in steering modes while drive is engaged
causes the wheels to automatically adjust to the appropriate
angle for the selected steering mode based on the position of
the inside front wheel. If the steer select switch is changed
without the footswitch depressed or the EMS is off, the wheels
will not move until the footswitch is depressed and a steering
or drive command has been initiated. The steering angles are
limited to +/- 20 degrees anytime the axles are not fully
extended. See the Axle Extension System for interaction with
the axle extension system. If a wheel cannot achieve its com­manded angle within a specified time, it is considered
jammed. When a wheel is considered jammed during steering,
a fault is reported and the remaining wheels will continue to
their commanded position. The fault is cleared when the foot­switch is cycled. If a wheel is jammed making it significantly
out of position, with regard to the other wheels, the drive
motors are restricted to their maximum displacement (slow
speed). Wheel angle sensor failures will result in an approxi­mated steering control logic that will allow the operator to
move the machine until it can be repaired. The wheel at the
failed sensor will be driven based on the information available
from the other sensors. This wheel will not track perfectly and
will become farther out of position over time. When the wheel
becomes prohibitively out of position, the wheels can be
resynchronized by fully steering against the mechanical stops.

Axle extend sensor failures will result in an approximated
steering control logic that will allow the operator to move the
machine until it can be repaired. The axle at the failed sensor

3121619 – JLG Lift – 3-3

SECTION 3 - CHASSIS & TURNTABLE

will be driven based on the information available from the
other sensors. This axle will not track perfectly and will
become farther out of position over time. When the wheel
becomes prohibitively out of position, the wheels can be
resynchronized by fully steering against the mechanical stops.

3.5 DRIVE/STEERING SPEED CONTROL

The Drive/Steering Speed Control system uses the steering
sensors from the steering control system to increase operator
control and comfort by reducing the effect of turning the
chassis on the resulting lateral platform speed. The system
proportionally varies the drive speed based on the predicted
turning radius of the chassis for both coordinated and conven­tional two wheel steer modes. The tighter the turn the slower
the allowable drive speed. As crab steer does not steer on a
radius, full drive speed is maintained regardless of steer angle.

3.6 TRACTION CONTROL SYSTEM

The traction control system uses the steering sensors from the
steering control system to optimize the performance of the
drive system. This is especially important due to the disparity
of wheel speeds generated between the inside and outside
wheels of the extended axle chassis with large steering angle
capability. The steering sensors are used to predict the rolling
path and therefore the required wheel speed of each wheel as
the steering angles change and steering modes change. The
control system can then command the ideal flow from each of
the two drive pumps, one for the right side of the machine and
one for he left side. Two flow dividers, one for the right side,
front to back and one for the left side, front to back absorb the
variation in wheel speed, front to back.

3-4 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

This page left blank intentionally.

3121619 – JLG Lift – 3-5

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-4. Axle Hose Routing - Sheet 1 of 2

3-6 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-5. Axle Hose Routing - Sheet 2 of 2

3121619 – JLG Lift – 3-7

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-6. Steering/Axle Hydraulic Circuit

3-8 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

HUB/D RIV E MOT OR

B O T T O M VIEW OF

TRACTION VALVE

B5

B6

A3

B3

D

A5

TO

SWIVE L PO R T 7

TO

SW IVEL P ORT 6

TO

SWIVEL PORT 5

TO

SWIVEL PORT 4

TO

SWIVEL PORT 3

A1

B1

BR

B2

A2

TS

A6

A4

B4

RIGHT

RIGHT RE AR

HUB/ DR I VE M OTOR

A

B

X

X

A

B

X

X

REAR

LEFT

LEFT REAR

HUB/DRIV E MOTOR

A

B

X

X

FRONT

LEFT FRONT

HUB /DRIVE MOTOR

A

B

X

X

FRON T VIE W OF

TR AC T IO N V AL V E

X

LEFT VIEW OF

TRA CTION VA LVE

RIGHT VIEW OF

TR AC T I O N VALV E

X

TOP VI E W OF

TR AC T ION VALVE

X

X

Figure 3-7. Drive System Hydraulic Circuit - Sheet 1 of 2

3121619 – JLG Lift – 3-9

SECTION 3 - CHASSIS & TURNTABLE

TRACTION VALVE

BR

BR

BR

L1

L1

X1

X1

FRO NT

REAR

LEFT

RIGHT

TO

SWIVEL PORT 7

X

X

X

X

X

X

X

X

LEFT FRONT

HUB /DR IVE MOTOR

X

RIGHT R EAR

HUB/DRIV E M OT O R

X

X1

L1

RIGHT FRONT

HUB/DRIVE MOTOR

X

L1

BR

X1

LEFT REAR

HUB/DRIVE MOTOR

X

CASE DRAIN MANIFOLD

TS

TOP VIEW OF

TRACTION VALVE

X

BR

Figure 3-8. Drive System Hydraulic Circuit - Sheet 2 of 2

3-10 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-9. Turntable Hydraulic System

3121619 – JLG Lift – 3-11

SECTION 3 - CHASSIS & TURNTABLE

1

2

3

4

5

6

7

3.7 DRIVE ASSEMBLY

1. Drive Hub

2. O-Ring

3. Drive motor

4. Washer

5. Bolt

6. Washer

7. Bolt

Figure 3-10. Drive Assembly

3-12 – JLG Lift – 3121619

3.8 DRIVE HUB

1001149921

38

39

39

40

43

22

23

24

20

21

25

41

42

44

26

28

27

29

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

30

31

32

33

33

34

35

36

37

45

46
47

48

49

50

51

49

48

52

53

54

55

56

SECTION 3 - CHASSIS & TURNTABLE

1. Ring

2. Screw

3. Cover

4. Gasket

5. Plug

6. Cover

7. O-Ring

8. Shim

9. Pin

10. O-Ring

11. Pinion

12. Retaining Ring

13. Gear Reduction Assy

14. Pinion

15. Ring

16. Gear Reduction Assy

17. Pinion

18. Hub Housing

19. Screw

20. Screw

21. Plug

22. Retaining Ring

23. Bearing

24. Planet Wheel

25. Flange

26. O-Ring

27. Ring Nut

28. Set Screw

29. Bearing

30. Hub Support

31. O-Ring

32. Bearing

Figure 3-11. Drive Hub

33. Seal

34. Coupling

35. Spring

36. Retaining Ring

37. Bearing

38. Axle

39. Plug

40. Plug

41. Plastic Plug

42. Input Shaft

43. Iron Disc

44. Brake Disc

45. Spacer

46. Seal

47. O-Ring

48. Seal

49. O-Ring

50. Brake Piston

51. Brake Spring

52. Spacer

53. Retaining Ring

54. O-Ring

55. Motor Support

56. Screw

3121619 – JLG Lift – 3-13

SECTION 3 - CHASSIS & TURNTABLE

54

55

56

4

3

2

1

6

10

4

8

18

7

11

13

16

Disassembly

1. Remove plugs (5) and pour lubricant in a container.
Reinstall plugs.

2. Remove six screws (56), motor flange(55), and O-Ring
(54). Do not damage O-Ring.

3. Remove two screws (2), cover (3), and pin (4).

4. Remove, Ring (1), Cover (6), O-Ring (7), Spacer (8) and

O-Ring (10). Do not damage O-Rings. Check and remove
Gasket (4) if damaged.

5. Remove Pinion (11), Gear Reduction Assembly (13), and
Gear Reduction Assembly (16).

3-14 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

18

19

26

34

35

22

24

25

28

25

27

6. Remove two Screws (19), Planetary Ring (18) and O-Ring
(26). Do not damage O-Ring.

7. Remove Coupling (34) and Spring (35).

8. Remove three snap rings (22) and planetary gears (24)

from spindles on Flange (25).

9. Remove two Set Screws (28) from Ring Nut (27). Remove
Ring Nut from Flange (25).

3121619 – JLG Lift – 3-15

SECTION 3 - CHASSIS & TURNTABLE

29

33

38

30

31

32

20

21

25

38

53

52

48

50

49

51

38

49

48

47

46

45

43

44

38

10. Remove Hub Support (30), Bearing (29), O-Ring (31),
Bearing (32), and two Seals (33) from Axle (38).

11. Remove six screws (20), Plug (21), and Flange (25) from
Axle (38).,

12. Remove Snap Ring (53), Spacer (52), Seal (48), O-Ring
(49), and Brake Piston (50) from Axle (38). Remove five
Brake Springs (51) from Brake Piston (50). Use com­pressed air to remove Brake Piston from Axle.

13. Remove O-Ring (49), Seal (48), O-Ring (47), Seal (48),
Spacer (45), nine Brake Discs (43) and eight Iron Discs
(44) from Axle (38).

3-16 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

36

37

38

42

36

37

38

42

49

48

47

46

45

43

44

38

53

52

48

50

49

51

38

14. Remove Split Ring (36), Input Shaft (42), and Bearing (37)
from Axle (38).

Assembly

NOTE: Thoroughly clean and coat all parts with grease before

assembling.

1. Check parts are free of damage, burrs, or other defects.

2. Install Bearing (37) in Axle (38). Install Input Shaft (42) in

Axle and Bearing. Secure with Split Ring (36).

3. Install Seal (46), O-Ring (47), Seal (48), and O-Ring (49) in
Axle (38). Starting with Brake Disk (43) alternate with
Iron Disk (44) until a total of eight Brake Disks and nine
Iron Discs are installed on Input Shaft (42 - not shown) in
Axle.

4. Install Brake Piston (50) in Axle (38). Install five Brake
Springs (51) Piston holes. Install O-Ring (49) and Seal
(48) in Axle. Install Spacer (52) against Piston and secure
with Split Ring (53).

3121619 – JLG Lift – 3-17

SECTION 3 - CHASSIS & TURNTABLE

20

21

25

38

29

33

38

30

31

32

28

25

27

22

24

25

5. Install Flange (25) on Axle (38), with Plug (21) and six
screws (20).

NOTE: Flat surface of bearings face toward inside of Hub Support.

6. Install two seals (33) on Axle (38). Install O-Ring (31) in
Hub Support (30). Install Bearing (32) and Bearing (29) in
Hub Support. Install assembled Hub Support on Axle as
shown below.

NOTE: Install Ring Nut with convex part facing bearing.

7. Install Ring Nut (27) on Flange (25). Prevent Flange from
turning and torque Ring Nut to 295 ft-lb (400 Nm).
Tighten and back off two times to completely seat bear­ings. Tighten to final torque of 221 ft-lb (300 Nm). Check
roll torque with seal is within 7 - 11 ft-lb (10 - 15 Nm).
Apply Loctite 243 or equivalent to two Setscrews (28).
Install and torque Setscrews to 7.4 ft-lb (10 Nm) .

8. Install three planetary gears (24) on Flange spindles (25).
Secure with Snap Rings (22). Lubricate planetary gear
bearings.

3-18 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

34

35

18

19

26

11

13

16

1

6

10

4

8

18

7

9. Install Spring (35) and Coupling (34).

10. Install O-Ring (26). Install Planetary Ring (18) with two

Screws (19). Torque Screws to 36.8 ft-lb (50 Nm).

11. Install Gear Reduction Assembly (16), Gear Reduction
Assembly (13), and Pinion (11) in Planetary Housing.
Lubricate all bearings.

12. Install O-Ring (7) and O-Ring (10) in Cover (6). Liberally
coat Spacer (8) with grease and center on hole at center
of Cover. Install Cover on Planetary Ring Assembly (18)
and secure with Ring (1). Replace Gasket (4) as needed.

3121619 – JLG Lift – 3-19

SECTION 3 - CHASSIS & TURNTABLE

54

55

56

4

3

2

13. Install O-Ring (54) and Motor Flange (55). Apply Loctite
243 or equivalent to six Screws (56). Install and torque
Screws to 177 ft-lb (240 Nm).

14. Check completed Drive Hub assembly rotates freely.

15. Install Pin (4) and Cover (3). Secure with two Screws (2).

Torque to 7 ft-lb (10 Nm).

FAILURE TO PROPERLY FILL DRIVE HUB WITH OIL BEFORE OPERATION WILL
RESULT IN EQUIPMENT FAILURE AND COULD CAUSE DEATH, SERIOUS INJURY,
OR DAMAGE TO PROPERTY AND EQUIPMENT.

16. Follow oil change procedures and refill Drive Hub before
operating equipment.

3-20 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

DISENGAGEMENT
COVER

DRIVE

HUB

DRIVE

HUB

Drive Hub Engaged

Drive Hub Disengaged

DISENGAGEMENT
COVER (REVERSED)

1

2

3

3.9 FREE WHEELING OPTION

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

1. Chock wheels.

2. Removing screws and invert cover so center tip presses

on disengagement pin in hub. Reinstall screws.

3. Remove chocks.

Engage Drive Motors & Brakes (Normal Operation)

1. Chock wheels.

2. Removing screws and invert cover so center tip faces

out. Reinstall screws.

3. Remove chocks.

3.10 GEAR HUB OIL SERVICE

Check Oil Level

1. Position hub as shown in Figure 3-13.

2. Remove Level Plug (3) and check oil is level with plug

opening. Add oil as needed.

3. Reinstall plug.

Change Gear Hub Oil

NOTE: Change oil when reduction gear is hot.

1. Position hub as shown in Figure 3-13.

2. Place suitable tray underneath to collect waste oil.

3. Remove three plugs.

4. Flush gear hub with appropriate solvent.

5. Reinstall Drain Plug (2).

6. Fill with oil until level reaches level hole.

7. Reinstall Level Plug (3) and Fill Plug (1).l

Figure 3-12. Disengaging Drive Hubs

3121619 – JLG Lift – 3-21

Figure 3-13. Gear Hub Oil Fill and Drain

SECTION 3 - CHASSIS & TURNTABLE

1

2

3

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

20

21

18

19

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

34

3160339

1. Bolt

2. Motor End cap

3. Locating Pin

4. O-Ring

5. Plug

6. Dowel Pin

7. Needle Bearing

8. Valve Plate

9. Snap Ring

10. Spring Retainer

11. Spring

12. Washer

13. Cylinder Block

14. Slipper Pin

15. Guide

16. Slipper Retainer

17. Cylinder Piston

18. Piston Ring

19. O-Ring

20. Servo Piston

21. Spring

22. Pin

23. Swashplate

24. Bearing Kit

25. Gasket

26. Plug

27. O-Ring

28. Plug

29. O-Ring

30. Housing

31. Shaft

32. Bearing

33. Snap Ring

34. Snap Ring

35. Seal

36. Seal Support Washer

Figure 3-14. Drive Motor

3-22 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

1

2

3

4

5

6

7

8

9

10

11

12

1

2

3

3.11 DRIVE MOTOR

NOTE: Drive motor servicing is similar for all Series 45 hydraulic

motors. The physical appearance of your motor may be
slightly different than shown.

Description

Drive motors are low to medium power, two-position axial pis­ton motors incorporating an integral servo piston. They are
designed for operation in open and closed circuit applications.
The standard control is a direct acting single line hydraulic
control. The integral servo piston controls motor displace­ment.

Motors are spring biased to maximum displacement and
hydraulically shifted to minimum displacement. Minimum and
maximum displacement can be set with fixed internal stops.
The large diameter servo piston allows smooth acceleration
and deceleration with relatively large circuit orificing.

Shaft Seal Replacement

REMOVAL

1. Remove snap ring (1) retaining shaft seal, and support

washer.

37. Bias Spring

38. Servo Piston

39. Swashplate

40. Output Shaft

41. Shaft Seal

42. Bearing

43. Slipper

44. Piston

Figure 3-15. Drive Motor Cross Section

45. Valve Plate

46. End Cap

47. Cylinder Block

48. Minimum Angle Stop

1. Snap Ring

2. Support Washer

3. Shaft Seal

Figure 3-16. Removing Shaft Seal

2. Remove support washer (2).

3. Carefully pry out shaft seal (3).

NOTE: To avoid damaging shaft during removal, install a large

sheet metal screw in chuck of a slide hammer. Drive screw
in seal surface and use slide hammer to pull seal.

4. Discard seal.

3121619 – JLG Lift – 3-23

SECTION 3 - CHASSIS & TURNTABLE

2

6

9

11

1

4

8

10

12

53

7

13

(37 Nm)

27 ft-lb

11/16 in

(37 Nm)

27 ft-lb

11/16 in

20 ft-lb (27 Nm)

5/8 in

INSPECTION

Inspect new seal, motor housing seal bore, and sealing area on
shaft for rust, wear, and contamination. Polish shaft and clean
housing if necessary.

INSTALLATION

1. Cover shaft splines with an installation sleeve to protect

shaft seal during installation.

2. Install new shaft seal with cupped side facing motor.
Press seal into housing until it bottoms out. Press evenly
to avoid binding and damaging the seal.

3. Install seal support washer.

4. Install snap ring.

5. Remove installation sleeve.

Loop Flushing Valve

REMOVAL

1. Using a 11/16 in internal hex wrench remove plug (1)

and (2).

2. Using a 1/4 in hex wrench remove plug (3).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

INSPECTION

1. Inspect new O-rings and the sealing area for rust, wear,

or contamination.

2. Check springs and poppet for wear.

INSTALLATION

1. Install orifice poppet (13).

2. Install shift spool (12).

3. Install spring retaining washers on springs (10 and 11).

4. Carefully install centering springs (7, 8, and 9).

5. Install new O-rings (6, 4, and 5).

6. Using a 1/4 in hex wrench torque plug (3) to 20 ft. lbs.

(27 Nm).

7. Using a 11/16 in internal hex, torque plugs (2 and 1) to
27 ft.lbs. (37 Nm).

1. Plug

2. Plug

3. Plug

4. O-ring

5. O-ring

3-24 – JLG Lift – 3121619

Figure 3-17. Loop Flushing Spool

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

12. Shift Spool

13. Orifice Poppet

Troubleshooting

Item Description Action

Check oil level in reservoir and oil
supply to moto r.

Table 3-2. Excessive Noise and/or Vibration

Insufficient hydraulic fluid could lead to cavitation that would ca use sys­tem noise.

SECTION 3 - CHASSIS & TURNTABLE

Fill reservoir to proper level. Ensure oil supply to motor is adequate and
lines are unobstructed.

Check for air in system. Air trapped in system lines or motor could result in cavitation that would

cause system noise.

Inspect output shaft couplings. A loose or incorrect shaft coupling will produce vibrations that could result

in system noise.

Inspect output shaft alignment. Misaligned shafts create excessive frictional vibration that could result in

system noise.

Hydraulic oil viscosity above limits. Viscosity above acceptable limits will result in cavitation that would lead

to system noise.

Table 3-3. System Operating Hot

Item Description Action

Check oil level in reservoir and oil
supply to pump.

Inspect heat exchanger, (if
equipped).

Check system relief valves. If a system relief valve becomes unseated for an extended period of time or

Insufficient amount of hydraulic fluid will not meet system cooling
demands.

If heat exchanger fails, or becomes obstructed, it may not meet system
cooling demands.

fails for any other reason, system could become overheated.

Ensure all system lines and components are purged of air.

En s ur e co r re c t c o up l in g is u se d an d th a t i t fi t s p r op e r ly o n s h af t .

Ensure shafts are properly aligned.

Replace hydraulic oil with appropriate fluid for operating conditions.

Fill reservoir to proper level.

Ensure heat exchanger is receiving adequate air flow and is in good operat­ing condition. Repair or replace as necessar y.

Repair or replace any malfunctioning relief valves as applicable and verify
loads on machine are not excessive.

Table 3-4. Won’t Shift or Slow to Start

Item Description Action

Check signal line to servo control
port.

Check correct supply and drain ori­fices are properly installed and not
obstructed.

Obstructed or restricted flow through servo control signal lines could
result in slow shift or no shift motor conditions.

Supply and drain orifices determine motor shift. The smaller the orifice,
the longer the time it takes to shift the motor. Obstruction also increases
shift times.

Ensure signal lines are not obstructed or restricted and signal pressure is
adequate to shift motor.

Ensure proper control orifices are installed in motor an d not obstructed.
Clean or replace as necessary.

3121619 – JLG Lift – 3-25

SECTION 3 - CHASSIS & TURNTABLE

5

3

7

13

2

6

9

11

1

4

8

10

12

15

20

16

16

19

17

182114

Disassembly

NOTE: Removal of endcap voids warranty.

During assembly, coat all moving parts with a film of clean
hydraulic oil. This ensures parts will be lubricated during
start-up.

Replace all O-Rings and gaskets.

It is recommended that all O-rings be replaced. Lightly
lubricate all O-rings with clean petroleum jelly prior to
assembly.

14. Lock Nut

15. O-ring Plug

16. Control Line Plug

17. Control Line Plug

1. Plug

2. Plug

3. Plug

4. O-ring

1. Using a 11/16 in wrench remove plug (1) and (2).

2. Using a 5/8 in hex wrench remove plug (3).

3. Remove O-rings (4, 5, and 6).

4. Using pliers, remove centering springs (7, 8, and 9).

5. Remove spring retaining washers (10 and 11).

6. Remove shift spool (12).

7. Remove orifice poppet (13).

5. O-ring

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

Figure 3-18. Loop Flushing Spool

12. Shift Spool

13. Orifice Poppet

Figure 3-19. Plugs, Fittings, and Speed Sensor

8. Remove all fittings from unit. Discard any O-rings on fit-

tings.

9. Using an 11/16 inch hex wrench, loosen speed sensor
lock nut (14) if equipped. Remove speed sensor using a
Vi inch hex wrench. Units without speed sensor have an
O-ring plug (15) installed in that location; remove it with
a Va inch internal hex wrench.

10. Using a 1/4 inch internal hex wrench, remove control
line plugs (16, 17). Discard O-rings. Using a 3 mm hex
wrench, remove cavity plug (18, if equipped with two­line control) from X2 cavity.

11. Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.

12. Using a 9/16 inch internal hex wrench, remove work

18. Cavity Plug

19. Drain Plug

20. Drain Plug

21. Work Port Plug

port plugs (21, if equipped with axial ports). Discard O­rings.

3-26 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

24

22

23

22. Screw

23. End Cap

24. O-ring

26

28

29

30

292725

25. Valve Plate

26. End Cap

27. O-ring

28. O-ring

29. Angle Stop

30. Servo Spring

Figure 3-20. End Cap

13. Using an 8 mm internal hex wrench, remove endcap

screws (22).

14. Remove endcap (23). Remove O-ring (24) from housing
or endcap. When endcap screws are removed, pressure
from servo spring will cause endcap to bind on shaft.
Press down on portion of endcap covering servo piston
and hold endcap level while removing.

Figure 3-21. Valve Plate & Rear Shaft Bearing

DO NOT SCRATCH VALVE PLATE SURFACE. DO NOT DRIVE BEARING PAST REAR
SHAFT JOURNAL. BEARING MAY BECOME TRAPPED ON SHAFT AND DAMAGED.

15. Remove valve plate (25) and timing pin (26) from end­cap. Each displacement has a unique valve plate. For
identification, the last two digits of the valve plate part
number are stamped on its surface.

16. Remove and discard O-rings (27, 28).

17. Remove rear shaft bearing (29) from endcap with a bear-

ing puller. Bearing may be difficult to remove with a
puller. Try this as an alternative: Pack bearing cavity with
heavy grease. After shaft is removed, insert it into bear­ing cavity and tap splined end lightly with a soft mallet.
Grease will force the bearing out. Remove minimum
angle stop (29) and servo spring (30) from housing.

3121619 – JLG Lift – 3-27

SECTION 3 - CHASSIS & TURNTABLE

31. Cylinder Kit Assembly

31

34 33

32

32. Snap Ring

33. Support Washer

34. Shaft Seal

Figure 3-22. Cylinder Kit

18. Turn housing on its side and remove cylinder kit assem-

bly (31). Set assembly aside. Do not to scratch running
surface.

NOTE: Grooves on surface of cylinder kit identify its displacement:

Table 3-5. Displacement Identifiers

# of Grooves Frame L Frame K

12538

23045

335- -

Figure 3-23. Shaft Seal

TO AVOID DAMAGING SHAFT DURING SEAL REMOVAL, INSTALL A LARGE
SHEET METAL SCREW IN CHUCK OF SLIDE HAMMER. DRIVE SCREW INTO SEAL
SURFACE AND USE SLIDE HAMMER TO PULL SEAL.

19. Turn housing over and remove snap ring (32) retaining
shaft seal and support washer. Remove support washer
(33) and carefully pry out shaft seal (34). Discard seal.

3-28 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

38

37

36

35

41

42

40

Lift Here

39

43

.

35. Inner Snap Ring

36. Snap Ring

37. Bearing

38. Shaft

Figure 3-24. Shaft & Front Bearing

20. Remove inner snap ring (35) and shaft/bearing assembly.

21. Remove snap-ring (36) retaining shaft front bearing. Pull

bearing (37) off shaft (38).

39. Swashplate

40. Servo Piston

42. O-ring

43. Journal Bearings

41. Piston Seal

Figure 3-25. Swash Plate & Servo Piston

22. Turn housing over and remove swashplate (39) by lifting

on end opposite servo lever.

23. Remove servo piston (40). Remove piston seal (41) and
O-ring (42) from servo piston. Discard seal and O-ring.

24. Remove journal bearings (43) from housing. Note loca­tion and orientation of each bearing for reassembly.

3121619 – JLG Lift – 3-29

SECTION 3 - CHASSIS & TURNTABLE

51

50

52

53

46

49

48

47

45

44

Slipper

Maximum End Play

Minimum Slipper Foot Thickness

27. Turn block over. Using a press, apply pressure on block
spring washer (50) to compress block spring. Compress
spring enough to safely remove spiral retaining ring
(51). While maintaining pressure, unwind spiral retaining
ring (51). Carefully release pressure and remove outer
block spring washer (50), block spring (52), and inner
block spring washer (53) from cylinder block.

Inspection

After disassembly, wash all parts (including end-cap and hous­ing) thoroughly with clean solvent and allow to air dry. Blow
out oil passages in housing and endcap with compressed air.
Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or
resurfacing.

PISTON

Inspect pistons for damage and discoloration. Discolored pis­tons may indicate excessive heat; do not reuse.

44. Piston

45. Slipper Retainer

46. Cylinder Block

47. Ball Guide

48. Holddown Pins

49. Retaining Ring

50. Block Spring Washer

51. Spiral Retaining Ring

52. Block Spring

53. Inner Block Spring Washer

Figure 3-26. Cylinder Kit Disassembly

25. Remove pistons (44) and slipper retainer (45) from cylin-

der block (46).

NOTE: Pistons are not selectively fitted. However, units with high

hourly usage may develop wear patterns. Number pistons
and bores for reassembly if they are to be reused.

26. Remove ball guide (47), hold-down pins (48), and retain­ing ring (49) from cylinder block.

NOTE: Most repairs do not require block spring removal. Perform

this procedure only if you suspect problems with the block

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES
FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE A PRESS SUFFICIENT TO
MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE THE SPRING IS
SECURE BEFORE ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING IS REMOVED.

spring.

SLIPPERS

Inspect slipper running surfaces. Replace piston assemblies
with scored or excessively rounded slipper edges. Measure
slipper foot thickness. Replace piston assemblies with exces­sively worn slippers. Check slipper axial end-play. Replace pis­ton assemblies with excessive end-play.

Table 3-6. Slipper Foot Thickness & End Play

Measurement L Frame K Frame

Slipper Foot Thickness 2.71 mm (0.11 in.) 4.07 mm (0.16 in.)

Piston/Slipper End Play 0.15 mm (0.006 in.)

3-30 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

A

Table 3-7. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)

Cylinder Block Surface Flatness 0.002 (0.0000079) 0.002 (0.0000079) 0.002 (0.0000079) 0.002 (0.0000079) 0.002 (0.0000079)

Slipper Retainer

Ball Guide

3.83 mm (0.151 in) Min

0.025 mm

(0.001 in)

0.0076 mm

(0.00030 in)

Convex Max

LV

25.8 mm

24.6 mm

(0.969 in)

KV

Thickness equality side to side:

0.05 mm (0.002 in)

0.0025 mm

(0.0001 in)

CYLINDER BLOCK

Measure cylinder block height. Replace blocks worn beyond minimum height specification. Inspect cylinder block running surface.
Replace or resurface worn or scratched blocks. Blocks may be resurfaced to specifications shown in the drawing, provided resurfacing
will not reduce block height below minimum specification. Table 3-7, Cylinder Block Measurements.

BALL GUIDE AND SLIPPER RETAINER

Inspect ball guide and slipper retainer for damage, discolor­ation, or excessive wear. A discolored ball guide or slipper
retainer indicates excessive heat. Do not reuse.

SWASHPLATE AND JOURNAL BEARINGS

Inspect running face, servo ball-joint, and swashplate journal
surfaces for damage or excessive wear. Some material transfer
may appear on these surfaces and is acceptable if surface con­dition meets specifications shown. Measure swashplate thick­ness from journals running face. Replace swashplate if
damaged or worn beyond minimum specification. Replace
swashplate if difference in thickness from one side to the other
exceeds specification.

VALVE PLATE

Valve Plate condition is critical to efficiency of the motor.
Inspect valve plate surfaces carefully for excessive wear,
grooves, or scratches. Replace or resurface grooved or
scratched valve plates. Measure valve plate thickness and
replace if worn beyond minimum specification. Valve plates
may be resurfaced, provided resurfacing will not reduce thick­ness below minimum specification.

Inspect journal bearings for damage or excessive wear.
Replace journal bearings if scratched, warped, or excessively
worn. Polymer wear layer must be smooth and intact.

3121619 – JLG Lift – 3-31

SECTION 3 - CHASSIS & TURNTABLE

2

1

3

3

SHAFT BEARINGS

Inspect bearings for excessive wear or contamination. Rotate
bearings while feeling for uneven movement. Bearings should
spin smoothly and freely. Replace bearings that appear worn
or do not rotate smoothly.

SHAFT

Inspect motor shaft for damage or excessive wear on output
and block splines. Inspect bearing surfaces and sealing sur­face. Replace shafts with damaged or excessively worn splines,
bearing surfaces, or sealing surfaces.

SERVO PISTON AND MINIMUM ANGLE STOP

Inspect minimum angle stop, servo piston head, and servo pis­ton ball-socket for damage or excessive wear. Replace as
required.

Assembly

1. Install new O-ring (1) and piston seal (2) to servo piston
(3). Install piston seal over O-ring.

NOTE: Installing piston seal stretches it, making it difficult to

install servo piston in its bore. Allow 30 minutes for seal to
relax after installation. To speed up seal relaxation, com­press seal by installing piston head in end-cap servo cavity
and let it stand for at least five minutes.

1. O-ring

2. Piston Seal

LOOP FLUSHING SPOOL

Inspect loop flushing spool for cracks or damage. Replace as
required.

2. After piston seal has relaxed, lubricate and install servo
piston in housing bore. Align piston with ball socket fac­ing inside of housing.

3. Servo Piston

Figure 3-27. Servo Piston

3-32 – JLG Lift – 3121619

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING REQUIRES

7

6

5

4

6A

8

9

10

12

11

14

13

13

ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE A PRESS SUFFICIENT TO

MAINTAIN THIS FORCE WITH REASONABLE EFFORT. ENSURE SPRING IS

SECURE BEFORE ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING.

RELEASE PRESSURE SLOWLY AFTER RETAINING RING IS INSTALLED.

3. Install inner block spring washer (4), block spring (5),
and outer washer (6) in cylinder block (6A). Using a
press, compress block spring enough to expose retain­ing ring groove. Wind spiral retaining ring (7) in cylinder
block groove.

SECTION 3 - CHASSIS & TURNTABLE

6. Install journal bearings (13) in housing seats. Use assem­bly grease to keep bearings seated during assembly.
Ensure locating nubs drop into seat cavities. If reusing
bearings, install in original location and orientation.

Lubricate journal bearings.

13. Journal Bearings

14. Swash Plate

Figure 3-28. Swash Plate and Journal Bearing

7. Install swashplate (14) in housing. Tilt swashplate and

guide servo lever ball into its socket in the servo piston
rod. Ensure swashplate seats into journal bearings and
moves freely. Lubricate running surface of swashplate.

4. Block Spring Washer

5. Block Spring

6. Outer Washer
6A. Cylinder Block

7. Spiral Retaining Ring

8. Retaining Ring

9. Holddown Pins

10. Ball Guide

11. Piston

12. Slipper Retainer

4. Turn block over and install retaining ring (8), hold-down
pins (9), and ball guide (10) to cylinder block.

5. Install pistons (11) to slipper retainer (12). Install piston/
retainer assembly in cylinder block. Ensure concave sur­face of retainer seats on ball guide. If reusing pistons,
install them in original block bores. Lubricate pistons,
slippers, retainer, and ball guide before assembly. Set
cylinder kit aside on a clean surface until needed.

3121619 – JLG Lift – 3-33

SECTION 3 - CHASSIS & TURNTABLE

16

15

17

18

19

20

21

8. Press front shaft bearing (15) on shaft (16). Press bearing
on shaft with lettering facing out. Lubricate bearing roll­ers. Install snap-ring (17) on shaft.

15. Front Shaft Bearing

16. Shaft

17. Snap Ring

18. Snap Ring

Figure 3-29. Shaft and Front Bearing

11. Lubricate and install servo spring (20) and minimum

angle stop (21) in housing bore.

9. While holding swashplate in place, turn housing on its
side. Install the install shaft/bearing assembly into hous­ing from flange end. Install snap-ring (18).

10. Verify swashplate and bearings are properly seated.
Install cylinder kit (19) on shaft. Install with slippers fac­ing swashplate. Rock the shaft to align block splines and
slide cylinder kit into place. Orient motor with shaft
pointing downward and verify cylinder kit, swashplate,

journal bearings, and servo piston are properly installed.

20. Servo Spring

21. Minimum Angle Stop

Figure 3-31. Servo Spring and Minimum Angle Stop

19. Cylinder Kit

Figure 3-30. Cylinder Kit Installation

3-34 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

23

23

22

24

(3 mm)

0.12 in

0.08 in

23

22

26

25

8 mm

(47-61 Nm)

35-45 ft-lbs

12. Press rear shaft bearing (22) in endcap. Install bearing
with letters facing out. Press until bearing surface is 0.08
±0.01 in (2 ±0.25 mm) above endcap surface.

15. Install endcap (25) on housing with endcap screws (26).
Ensure endcap will properly seat to housing without
interference. Improper assembly of internal compo­nents may prevent endcap from seating properly.
Ensure O-rings seat properly when installing endcap.

22. Rear Shaft Bearing

23. Timing Pin

24. Valve Plate

Figure 3-32. Valve Plate and Rear Bearing

13. Install timing pin (23) into its bore in the endcap. Install

pin with groove facing toward or away from shaft. Press
pin until end protrudes 0.12 ±0.01 in (3 ±0.25 mm)
above endcap surface.

14. Install valve plate (24) on endcap. Install valve plate with
yellow surface toward cylinder block. Align slot in valve
plate with timing pin. Apply a liberal coat of assembly
grease to endcap side of valve plate to keep it in place
during installation.

25. End Cap

26. Screw

Figure 3-33. End Cap

16. Using an 8 mm internal hex wrench, tighten endcap

screws. Tighten screws in opposite corners slowly and
evenly to compress the servo spring and properly seat
the endcap. Torque endcap screws 35-45 ft-lb (47-61
Nm).

17. Before installing shaft seal, ensure shaft turns smoothly
with less than 120 in-lb (13.5 Nm) of force. If shaft does
not turn smoothly within specified maximum force, dis­assemble and check unit.

3121619 – JLG Lift – 3-35

SECTION 3 - CHASSIS & TURNTABLE

27

28

29

1/4 in

(45 Nm)

33 ft-lb

5/16 in

(85 Nm)

63 ft-lb

5/16 in

(85 Nm) 63 ft-lb

1/4 in

(45 Nm)

33 ft-lb

9/16 in

(170 Nm)

125 ft-lb

3 mm

(2 - 3 Nm)

1.5 - 2.5 ft-lb

39

40

34

30

41

37

36

33

42

38

35

32

31

(27 Nm)

20 ft-lb

5/8 in

(37 Nm)

(37 Nm)

27 ft-lb

27 ft-lb

11/16 in

11/16 in

18. Cover shaft splines with an installation sleeve. Install a
new shaft seal (27) with cup side facing motor. Press seal
in housing until it bottoms out. Press evenly to avoid
binding and damaging seal. Install seal support washer
(28) and snap ring (29).

27. Shaft Seal

28. Seal Support Washer

29. Snap Ring

Figure 3-34. Shaft Seal

19. Install remaining plugs and fittings to housing. Refer to

drawing below for wrench sizes and installation torques.

20. Install orifice poppet (30).

30. Orifice Poppet

31. Shift Spool

32. Spring

34. Spring

35. Spring

36. Spring

33. Spring

Figure 3-36. Loop Flushing Spool

21. Install shift spool (31).

37. O-ring

38. O-ring

39. O-ring

40. Plug

41. Plug

42. Plug

22. Install spring retaining washers on springs (32 and 33).

23. Carefully install centering springs (34, 35, and 36).

24. Install new O-rings (37, 38, and 39).

25. Using a 5/8 in wrench torque plug (40) to 20 ft-lb (27

Nm).

26. Using a 11/16 in wrench, torque plugs (41 and 42) to 27
ft-lb (37 Nm).

3-36 – JLG Lift – 3121619

Figure 3-35. Plugs and Fittings Installation

SECTION 3 - CHASSIS & TURNTABLE

SU RF ACE BELO W T EET H

WIT H "X" AN D BLUE PAINT

ON THR EE TEETH

Initial Start-up Procedures

Follow this procedure when starting-up a new motor or when
installing a motor that has been removed.

INSPECT MOTOR FOR DAMAGE BEFORE INSTALLATION. MAKE CERTAIN ALL
SYSTEM COMPONENTS (RESERVOIR, HOSES, VALVES, FITTINGS, HEAT
EXCHANGER, ETC.) ARE CLEAN BEFORE FILLING WITH FLUID.

1. Fill reservoir with recommended hydraulic fluid. Always
filter fluid through a 10 micron filter when pouring into
the reservoir. Never reuse hydraulic fluid.

2. Fill inlet line leading from pump to reservoir. Check inlet
line for properly tightened fittings and be certain it is
free of restrictions and air leaks.

3. Fill pump and motor housing with clean hydraulic fluid.
Pour filtered oil directly in upper most case drain port.

4. To ensure pump and motor stay filled with oil, install
case drain lines in upper most case drain ports.

5. Install a 0 to 500 psi (0 to 35 bar) gauge in charge pres­sure gauge port of pump to monitor system pressure
during start up.

6. Watching pressure gauge and run engine at lowest pos­sible speed until system pressure builds to normal levels
(minimum 160 psi [11 bar]). Once system pressure is
established, increase to full operating speed. If system
pressure is not maintained, shut down engine, deter­mine cause, and take corrective action.

7. Operate hydraulic system for at least fifteen minutes
under light load conditions.

8. Check and adjust control settings as necessary after
installation.

2. Place the shim between the pinion and bearing on the
bearing high spot.

3. Apply JLG Thread locking compound P/N 0100019 to
the bolt and torque the pivot spacer screw to 340 ft.lb.
(47 kgm).

9. Shut down engine and remove pressure gauge. Replace
plug at charge pressure gauge port.

3.12 PROCEDURE FOR SETTING SWING GEAR BACKLASH

Set backlash 0.10 to 0.15" (0.254 to 0.381 mm) using the fol­lowing procedure.

1. Place the machine on firm, level ground.

3121619 – JLG Lift – 3-37

NOTE: Make sure the turntable is properly supported during the

following step. The turntable can swing a few degrees
when the turntable lock is removed if the turntable is not
balanced properly.

4. Remove the turntable lock pin.

SECTION 3 - CHASSIS & TURNTABLE

5. Apply JLG Thread locking compound P/N 0100019 to
the bolts and pre-torque the 5 bolts to 45 ft.lb. (6 kgm).

6. Tighten the setscrew until the pinion is completely snug
against the shim and bearing and then back off the set­screw.

10. Discard the shim.

11. Rotate the bearing high spot 15° to the second drive

hub and repeat the procedure.

7. Torque the setscrew to 50 ft.lbs. (7 kgm).

8. Apply JLG Thread locking compound P/N 0100019 and

tighten the jam nut.

9. Torque the bolts to 340 ft.lbs. (47 kgm).

3-38 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

CENTER

OF

GRAVITY

31.7" (8 0 cm)

Upperstructure - 39, 000 lbs (17,690 kg)

Figure 3-37. Swing Bearing Removal - Sheet 1 of 4

3121619 – JLG Lift – 3-39

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-38. Swing Bearing Removal - Sheet 2 of 4

3-40 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

Main Boom Pivot

CENTER

OF

GRAVITY

B oom Assem bly - 21,650 lbs (9,82 0 kg)

Figure 3-39. Swing Bearing Removal - Sheet 3 of 4

3121619 – JLG Lift – 3-41

SECTION 3 - CHASSIS & TURNTABLE

Note: Attach Lifting Device to

Turntable Cutouts Closest to

This Side of Turntable

Turntable - 15,350 lbs (6,963 kg)

83.3" (212 cm)

Figure 3-40. Swing Bearing Removal - Sheet 4 of 4

3-42 – JLG Lift – 3121619

SECTION 3 - CHASSIS & TURNTABLE

3.13 SWING CONTROL SYSTEM

The swing control system uses the turntable swing angle sen­sor in addition to the Drive Orientation System (DOS) proxim­ity switch to prevent turntable swing while the axles are
retracted. Swing will be allowed to +/- 35 degrees (before the
DOS proximity switch trips) to facilitate positioning the turnta­ble for transport of the machine. Attempts to swing past this
position will be disallowed by the control system and the
operator will be prompted via the LCD display in the platform
to swing in the opposite direction to return the boom behind
the rear wheels. Once the axles are extended the boom has
360 degree continuous turntable swing. If the turntable is
swung past +/- 35° when the boom is lowered into the trans­port position, the operator will have to swing the turntable
back within the rear wheels before attempting to retract the
axles.

3.14 CHASSIS TILT INDICATOR SYSTEM

The Chassis Tilt Indicator System measures the turntable angle
with respect to level ground. The tilt sensor (mounted to a
bracket on the side of the turntable near the boom pivot pin)
has three settings; 3.0 side tilt, 5.0 omni directional tilt, and an

8.0 omni directional tilt.

main boom length is less than 1477.7 inches in the 500 lb
mode or 1442.8 inches in the 1000 lb mode.

The 8.0º angle is used exclusively for the purpose of automati­cally shifting the drive motors to the maximum displacement
position (slow speed).

The control system responds to indicated angle readings 0.3
degree smaller than the required angles to account for calibra­tion and sensor variation.

3.15 AUXILIARY POWER SYSTEM

The auxiliary power system is intended as a secondary means
of moving the boom in the event of primary power loss. This
system uses an electric motor/pump unit powered by two12V
batteries capable of operating all functions except drive, con­trolled arc, controlled boom angle, and envelope tracking.
During main lift up or down functions, no other functions are
permitted and during main lift up functions, automatic plat­form leveling is not active but jib leveling is active. To reduce
the demand on the battery and therefore extend the run time
of the system, the auxiliary power functionality differs from
the primary power functionality. The auxiliary power main lift
down function supplies pilot pressure to the main lift cylinder.
This allows gravity to lower the boom. The system redirects
discharge oil from the main lift cylinder to retract the main
telescope cylinder. At high main boom angles the envelope
may be encroached during lift down requiring the operator to
use main telescope in. When the main boom is retracted to the
transport length, the main telescope in valve is dropped out
and lift down is operated alone allowing the platform to reach
the ground. This not only greatly reduces the power required
for these functions but also lowers the boom within the enve­lope regardless of starting position. Jib lift down function may
then be operated allowing the platform to reach ground level.
Envelope control and moment control remain active during
the auxiliary power function.

The 5.0 omni directional angle setting is used for the purpose
of warning the operator by means of the chassis tilt light in the
platform display panel. Additionally when used in conjunction
with the Beyond Transport - Drive Speed Cutback System, the
tilt sensor will cause an alarm to sound and automatically put
all functions in the creep speed mode and drive will be cut
out. With the exception of the drive being cut out, this is a
warning system only indicating to the operator that the
machine has reached the out of level limit. The machine will
continue to function. The operator is responsible to prevent
the machine from attaining an unstable position.

The 3.0° side tilt setting is used in conjunction with the main
boom length and when exceeded, imposes the same func­tionality as the 5.0° omni directional setting plus prevents
boom telescope out. The side tilt setting is ignored when the

3121619 – JLG Lift – 3-43

SECTION 3 - CHASSIS & TURNTABLE

NOTES:

3-44 – JLG Lift – 3121619

SECTION 4. BOOM & PLATFORM

SECTION 4 - BOOM & PLATFORM

4.1 BOOM SYSTEMS

Broken Cable Indicator System

The boom on this model is a 5 section proportionally driven
telescopic boom. Section #2 is driven directly by the telescope
cylinder. Section #3, #4, and #5 (fly boom) are each driven by
separate wire rope systems. Each rope system contains redun­dant ropes that are capable of allowing the operator to
unknowingly continue use of the machine with a single rope
failure. These kinds of failures with the extend ropes are self
revealing to the operator so proper action can be taken. Fail­ures within section #4 and section #5 extend ropes are self
revealing as they are exposed on the exterior of the boom
where a broken rope would be obvious. Failures within section
#3 ropes require the addition of the Broken Cable Indicator
System in order to be self-revealing to the operator. This sys­tem uses proximity sensors to detect excessive movement of
the sensed ropes as would be expected with a rope failure. A
broken rope detection results in illuminating the Cable Break
indicator on the platform control panel. No restrictions are
made to the functionality of the control system. It is the
responsibility of the operator to take the appropriate action.

Transport Position Sensing System

The transport position sensing system uses the main boom
angle sensors, the main boom length sensor mounted in the
pivot end of the main section #1boom in addition to the boom
length switch mounted on the platform end of the main base
boom and transport proximity switches mounted to the jib fly
boom to sense when the main boom and jib boom are in the
position associated with high speed travel. Above transport
angle is recognized when the main boom (using the cylinder
angle sensors) is more than 5º with respect to the turntable
and resets to within transport position when both main boom
angle sensors read less than 3º with respect to the turntable.
Transport length is recognized when the main boom length
switch and main boom length sensor read less than 17" exten­sion for the main boom. Transport position is also determined
when the jib boom length switches indicate the jib is fully
retracted. During failures of either the main boom length
transport switch or the main boom length sensor the main
boom transport length will be determined by the remaining
sensor or switch. In addition, for a failure of either jib transport
length switch, jib length will be determined by the remaining
switch.

This system is used to control the following systems:

• Beyond Transport - Drive Speed Cutback System

• Drive/Steer - Boom Function Interlock System - CE Only

•Jib Stow System

• Axle Extension System

Beyond Transport - Drive Speed Cutback System

When boom is positioned beyond the Transport Position, the
drive motors are automatically restricted to their maximum
displacement position (slow speed).

Drive/Steer - Boom Function Interlock System (CE/ AUS ONLY)

The Drive/Steer - Boom Function Interlock System uses the
Transport Position Sensing System (item 14) to sense when the
boom and jib are out of the transport position. All controls are
simultaneously functional when the booms are within the
transport position as on the standard machine. When the
boom/jib are beyond the transport position, the control func­tions are interlocked to prevent simultaneous operation of any
boom function with drive/steer. The first function set to be
operated in this mode, becomes the master function set. In
other words, while operating drive/steer functions the boom
functions are inoperable. Likewise, while operating boom
functions drive/steer functions are inoperable.

Jib Stow System

The machine's stowed length can be reduced to facilitate
transportation on standard trailers by swinging the jib to the
right using the hydraulic power of the jib stow rotator. The
control system will prevent swinging the jib unless the axles
are retracted, the boom and jib are in the transport position. If
the transport criteria are met and the operator commands jib
swing right via the jib swing function switch. The control sys­tem will retract the jib lock pin and begin to swing the jib into
the stowed position. When the jib is stowed, automatic plat­form leveling is disabled, the boom is restricted to the trans­port position, and axle extension is disabled. This system is
functional only in the 500# mode of the Dual Capacity System.
Jib telescope function will resume when the jib is nearly fully
stowed alongside the main boom. Conversely, the jib must be
retracted into the transport position before the jib is allowed
to swing left into the locked position. Once the jib reaches the
inline position, and the operator is maintaining the jib swing
left function switch the control system will attempt to lock the
jib lock pin. If successful, the jib lock pin lamp will illuminate
continuously after the operator releases jib swing function
switch.

Envelope Control System

The Envelope Control System is the primary means of control­ling the stability of the machine by restricting the working
envelope of the main boom. The envelope shape, is such that,
positions of stability and structural integrity can be controlled
including the restriction of forward and rearward reach of the
platform. This system uses the two main boom angle sensors,
the main boom length sensor, and the main boom transport
length switch to continuously measure the position of the
main boom and control its position within the predetermined

3121619 – JLG Lift – 4-1

SECTION 4 - BOOM & PLATFORM

envelope. The two main boom angle sensors measure the
angle of the main boom relative to gravity and are continu­ously monitored for mutual agreement. The main boom
length sensor measures the length of the main boom and is
monitored for response to main telescope command and for
agreement with the fixed position length switch (Main boom
length transport switch). Violations of the main boom position
to allowable envelope positions will result in reduced function
speeds, BCS warning light illumination, and restriction of func­tions. The platform alarm will sound and the BCS light will
flash with attempts to operate restricted functions. The
restricted functions due to envelope violations related to for­ward reach are disallowing main lift down, main telescope out,
swing, drive and steer. The restricted functions due to enve­lope violations related to backward reach are disallowing main
lift up, main telescope in, swing, drive, and steer. Recognized
failures within this system will result in control by the Moment
Control System, reduced function speeds, and BCS warning
light illumination. The unit will be restricted from leaving the
transport position until the failure is resolved.

Moment Control System

The Moment Control System is the secondary means of con­trolling the stability of the machine. This system uses a load
cell pin to attach the lift cylinder of the main boom to the turn­table. This pin is instrumented with gauges allowing the forces
in the pin to be monitored. These forces are used to compare
the actual boom moment (force at a distance) to a predeter­mined allowable boom moment. In controlling the boom
moment, the position and load of the boom is controlled. The
moment control system will detect moments larger than
expected as well as those smaller than expected. This effec­tively controls the forward and rearward positions of the
boom. The moment control system varies the maximum
allowable moment based on ground slope. On level ground
and with rated load in the platform, the allowable moments
establish a working envelope slightly larger than the Envelope
Control System's envelope to minimize interaction of the sys­tems. With increasing ground slopes and rated load in the
platform, the allowable moments may establish a working
envelope smaller than the Envelope Control System's enve­lope and may result in moment violations at the extreme plat­form positions. Violations of the moment control systems
allowable moment will result in reduced function speeds, BCS
warning light illumination, and restriction of functions. The
platform alarm will sound and the BCS light will flash with
attempts to operate restricted functions. The restricted func­tions due to moment system violations related to forward
reach are disallowing jib functions, lift down, telescope out,
swing, drive, and steer. The restricted functions due to
moment system violations related to backward reach are disal­lowing jib functions, lift up, telescope in, swing, drive and
steer. Recognized failures within this system will result in con­trol by the Envelope Control System, reduced function speeds,
and BCS warning light illumination. The boom will be
restricted from leaving the transport position (see item 14)
until the failure is resolved.

Boom Control System (BCS) Functional Check (Push to Test) System

The machine is equipped with a system for the operator to
daily verify the proper functioning of the Boom Control Sys­tem (Envelope Control System and the Moment Control Sys­tem). The operator is instructed to position the boom in the
position described by the instruction decal and to then verify
the control system cut out the main telescope movement at
the correct length. When the operator pushes the button
mounted on the ground control panel, the control system
compares the current moment reading in the moment system
to the moment expected for this position. If the current
moment is within allowable tolerance for the test position, the
green BCS indicator will illuminate indicating the system is
working properly. If the current moment is not within the
allowable tolerance for the test position, the red BCS indicator
will illuminate indicating the machine requires service by JLG
authorized service personnel before the system is used. Failure
of this test will not restrict the functionality of the machine
and will not cause a system fault. It is the operators responsi­bility to take proper action. The machine can be in either
capacity mode of the dual capacity system for this system
check.

Controlled Arc System

The Controlled Arc System uses the envelope control sensors
to enhance the control of the main boom within the working
envelope. The purpose of the controlled arc system is to mini­mize the interaction of lift functions with envelope edges and
to increase user efficiency. This minimizes the effect of a long
boom working in a comparatively narrow envelope. Because
the boom is permitted to extend to longer lengths at high
angles than at it is low angles, lift commands would normally
cause the boom to violate the permitted envelope while lifting
down or conversely require the operator to frequently com­mand telescope out while lifting to high heights. The con­trolled arc system optimizes the envelope shape by
automatically introducing telescope in or out during “lift only”
commands. Telescope flow is regulated during lift commands
to maintain a constant percentage of available boom length
(0% is always fully retracted, 100% is variable as the permitted
length changes when the boom is raised). The target percent­age will be maintained throughout the lift command whether
it is maintaining 0%, 100%, or any percentage in between. The
target percentage is established at the start of lift command or
end of manual telescope commands when using multiple
functions with lift. The telescope command can be used inde­pendently or in combination with other functions. Manual
introduction of telescope will override the controlled arc sys­tem and result in conventional control. Controlled arc will be
disabled with any sensor failure, any moment violation, any
envelope violation, or with auxiliary power functions. The con­trolled arc functionality can be turned off using the manual
position of the boom control select switch. When selected, this
system is active at all boom angles and lengths.

4-2 – JLG Lift – 3121619

SECTION 4 - BOOM & PLATFORM

Controlled Boom Angle System

The Controlled Boom Angle System uses the envelope control
sensors to enhance the control of the boom by minimizing the
interaction of swing and drive functions with the envelope
edges. This interaction is due to two factors. First, the envelope
is controlled relative to gravity regardless of ground slope and
second, the turntable/boom mounting is effected by swing
and drive functions when the ground slope varies. This can
cause the boom position to vary within the envelope or even
violate the envelope edges when swinging or driving without
intentionally moving the boom. The controlled boom angle
system minimizes this effect by automatically introducing lift
up or down during swing and drive commands to maintain a
constant boom angle relative to gravity for all boom angles
greater than 8 degrees. Controlled boom angle is disabled
with any envelope or moment violations or failures. The con­trolled boom angle functionality can be turned off using the
manual position of the boom control select switch.

Envelope Tracking

The Envelope Tracking System uses the envelope control sen­sors to enhance the control of the boom within the working
envelope. Due to the shape of the working envelope, the max­imum boom angle varies with telescope length. To maintain
unrestricted operation of the boom, the lift down function is
automatically introduced while telescoping in only when the
boom is on the rearward edge of the envelope. This only
occurs when telescoping in along the rearward edge and is
not used elsewhere within the envelope or when telescoping
out. Envelope tracking is disabled with any envelope or
moment violations or failures. The envelope tracking function­ality can be turned off using the manual position of the boom
control select switch.

Slow Down System

When the main boom approaches the edges of the working
envelope, all functions (except jib and platform functions, tele­scope in or out on the rearward edge and telescope in on the
forward edge) are automatically slowed down by the control
system to reduce the machine dynamics and improve opera­tor control. The slow down starts within 4 feet of all edges and
is at the fully reduced speeds 2 feet from all edges. The control
system indicates to the operator this automatic introduction
of slow down by flashing the creep light on the platform dis­play panel. This feature applies to both platform and ground
controls, however, no indication is made on the ground con­trol panel. This is not adjustable using the analyzer.

Dual Capacity System

The Dual Capacity System on this machine is a multiple enve­lope control system as opposed to an indication system. The
control system changes the working envelope and moment
limits to match the capacity select mode to either the 500#
mode or the 1000# mode. It then displays the capacity mode
on the platform and ground display panel and controls the
positions of the boom within the allowable envelope for that

mode. This mode is selectable by the operator with the dual
capacity select switch on the platform control panel. The 500#
mode has the largest envelope. The 1000# mode has a smaller
envelope and requires the jib to be retracted fully. To select
the 1000# mode the boom must already be in the smaller
1000# envelope. When the operator selects the 1000# mode
and this condition is met, the capacity light changes from 500#
to 1000# and the envelope and permitted moment values are
changed accordingly. When the operator selects the 1000#
mode and this condition is not met, both capacity lights will
flash, the platform alarm will sound, and all functions will be
disabled until the capacity select switch is put back into the
500# position.

Swing Speed Proportioning

Swing Speed Proportioning uses the boom length and angle
sensors to improve the comfort, speed and control of the turn­table swing function. Turntable swing speed is increased as
the distance of the platform to the center of rotation is
decreased. This results in approximately constant platform
speeds regardless of boom position. Swing speed proportion­ing is disabled with any envelope sensors failure. Disabling of
swing speed proportioning will default to the slowest swing
speed setting.

Platform Load Sensing System

The Platform Load Sensing System consists of 4 load cells,
mounted between the platform and platform support, and a
dedicated electronic interface module (LSS) located below the
platform console. This system compares the capacity mode
(500# or 1000#) recognized by the dual capacity system to the
measured weight in the platform. When the capacity is
exceeded, or when there is a fault in the system, the platform
overload indicator will flash, the platform alarm will sound and
all platform controls (except auxiliary power) will be disabled.
The ground controls are unaffected.

Electronic Platform Leveling

The electronic platform leveling system uses two tilt sensors
(mounted on either side of the platform rotator), a control
valve (mounted to the platform support), a level cylinder, and
the platform control module (mounted in the platform control
box) to automatically measure and control the incline of the
platform with respect to gravity. While in the automatic posi­tion of the boom control select platform leveling is active
while operating drive, telescope, main lift, jib lift or swing and
is not active while operating any other function (e.g. rotate, jib,
or steer). While in the manual position of the boom control
select platform leveling is active while operating main lift and
jib lift only. The system controls the platform angle relative to
gravity using a set point established during power-up (cycling
of the EMS) or at the conclusion of a manual platform level
override by the operator using the platform level override
switch from either the platform or the ground control. In other
words the operator can choose a platform incline other than
level with gravity and the system will maintain that incline

3121619 – JLG Lift – 4-3

SECTION 4 - BOOM & PLATFORM

automatically. If a fault occurs in the platform leveling system
the following will occur:

• Automatic platform leveling will stop (except when there is
a fault in only one sensor)

• The platform level fault indicator will flash

• The platform alarm will sound

• All functions will default to creep speed if in platform mode
and the boom is out of the transport position

To reset the fault the emergency stop switch should be recy­cled.

Boom Control Select

The boom control select switch is mounted on the platform
control panel and allows the operator the ability to select
between two different modes of boom control functionality:
automatic and manual. While in either mode, the envelope
control system and moment control system remains active.

When the boom control is selected to the automatic boom
control position, lift and telescope movements are coordi­nated by the control system as described in the controlled arc,
controlled boom angle, and envelope tracking descriptions.
These systems will remain active to automatically assist the
operator in keeping the boom within the envelope boundar­ies. When operating in the automatic mode, the following
functionality characteristics should be noted.

4.2 BOOM REMOVAL AND INSTALLATION

Removal

1. If necessary, remove the platform.

2. If necessary, remove the jib.

3. Tag and disconnect hoses T2 T3, 7, 8, and Pressure Filter

lines from the main valve. Cap or plug all openings.

• While operating Lift Up, the boom may also telescope out
(controlled arc)

• While operating Lift Down, the boom may also telescope in
(controlled arc)

• While operating Swing or Drive, the boom may lift up or lift
down (controlled boom angle)

• While operating Telescope In, the boom may lift down
when at high boom angles and the creep light is flashing
(envelope tracking)

In addition, when the boom control is selected to the auto­matic position, the automatic platform leveling feature is
active during lift, telescope, swing, and drive movements as
described in the electronic platform leveling system descrip­tion.

When the boom control is selected to the manual position, lift
and telescope movements are controlled separately by the
operator effectively turning off the controlled arc, controlled
boom angle, and envelope tracking systems. Without these
systems being active, the control system will stop the move­ments of the boom when the envelope boundaries are
reached and the functions that could violate the envelope will
be restricted. The platform alarm will sound and the BCS light
will flash with attempts to operate a restricted function. In
addition, when the boom control is selected to the manual
position, the automatic platform leveling feature is active only
during lift movements.

4-4 – JLG Lift – 3121619

SECTION 4 - BOOM & PLATFORM

Figure 4-1. Boom Hydraulic System

3121619 – JLG Lift – 4-5

SECTION 4 - BOOM & PLATFORM

4. Tag and disconnect all electrical lines from the limit
switches and generator that go to from the turntable to
the powertrack.

5. Elevate the boom enough to remove the upper lift cylin­der pin. Use an overhead crane or similar lifting device
to support the weight of the boom.

6. Using an adequate lifting device, support the weight of
the lift cylinder and remove the lift cylinder pin. Lower
the lift cylinder down until it rests on the boom rest.

9. Carefully lift the boom from the machine, taking care to
feed the hydraulic and electrical lines up alongside the
boom as it is raised.

Installation

1. Lift the boom almost into position.

2. Feed the hydraulic hoses and electrical lines down

alongside the hood.

3. Loosely connect the powertrack end. Remember to
tighten the bolts the rest of the way when installation is
complete.

4. Lower the boom into position and install the boom
pivot pin.

7. Use an overhead crane or similar lifting device to sup­port the rear of the boom.

8. Remove the boom pivot pin.

4-6 – JLG Lift – 3121619

SECTION 4 - BOOM & PLATFORM

WEAR PAD

AVOID APPLICATION

ON EXPOSED
PAINTED SURFA CES

5. Raise the front of the boom enough to allow connection
of the lift cylinder.

6. Attach a lifting strap to the lift cylinder. Raise the lift cyl­inder into place and install the lift cylinder pin.

4.3 BOOM ASSEMBLY

Assembly

NOTE: Throughout this procedure, boom sections are identified

numerically, 1-5. Boom Section 1 is at the base, Boom Sec­tion 5 is the fly.

NOTE: During Assembly, Super Lube® lubricant (JLG p/n 3020042)

is to be moderately applied to all four inner surfaces of
both ends of each boom section to a minimum depth of
three to four feet and also to the end of section 5 that is
inserted into section 4.

NOTE: During Assembly, Super Lube® lubricant (JLG p/n 3020042)

is to be moderately applied to all outer surfaces of interior
wear pads after they are assembled to the insertion end of
boom sections. Care should be taken to avoid application
on exposed painted surfaces of the fully extended boom.

3121619 – JLG Lift – 4-7

7. Connect the hydraulic lines as tagged during removal.

8. Connect the electrical lines as tagged during removal.

9. If removed, install the jib.

10. If removed install the platform.

NOTE: Boom section 5 weighs approximately 1682 lbs. (763 kg).

1. Place boom section 5 on a proper supporting device.

SECTION 4 - BOOM & PLATFORM

2. Install the side rear wear pads and shims. Coat the
retaining bolts with JLG threadlocking compound P/N
0100011 and secure the wear pads with the bolts and
washers. Torque the bolts to 40.5 ft.lbs. (55 Nm).

3. Install the top and bottom rear wear pads and shims.
Coat the retaining bolts with JLG threadlocking com­pound P/N 0100011 and secure the wear pads with the
bolts and washers. Torque the bolts to 40.5 ft.lbs. (55
Nm).

4. Install the section 5 retract ropes to into the holes in the
side of section 5. Place tape over the holes to keep the
cables in place during assembly as shown.

5. Install the section 5 extend ropes into the mounting
holes in the bottom of section 5. Place tape over the
holes to keep the cables in place during assembly as
shown.

NOTE: Boom section 4 weighs approximately 1898 lbs. (861 kg).

4-8 – JLG Lift – 3121619

SECTION 4 - BOOM & PLATFORM

Figure 4-2. Boom Assembly - Sheet 1 of 9

3121619 – JLG Lift – 4-9

SECTION 4 - BOOM & PLATFORM

Figure 4-3. Boom Assembly - Sheet 2 of 9

4-10 – JLG Lift – 3121619

SECTION 4 - BOOM & PLATFORM

Figure 4-4. Boom Assembly - Sheet 3 of 9

3121619 – JLG Lift – 4-11

SECTION 4 - BOOM & PLATFORM

Figure 4-5. Boom Assembly - Sheet 4 of 9

4-12 – JLG Lift – 3121619

SECTION 4 - BOOM & PLATFORM

Figure 4-6. Boom Assembly - Sheet 5 of 9

3121619 – JLG Lift – 4-13

SECTION 4 - BOOM & PLATFORM

Figure 4-7. Boom Assembly - Sheet 6 of 9

4-14 – JLG Lift – 3121619