JLG 19BD Service Manual

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Service and Maintenance Manual

Model(s)

15BD 19BD

P/N - 3121154

June 14, 2012

ANSI

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NOTES:

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FOREWORD

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

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.

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

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

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

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

are defined as follows:

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

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

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

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

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

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

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

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INTRODUCTION - OPERATION/SAFETY PRECAUTIONS

All procedures herein are based on the use of the machine under proper operating conditions, with no deviations from original design intent ... as per OSHA regulations.

READ & HEED!

The ownership, use, service, and/or maintenance of this machine is subject to various federal, state and local laws and regulations. It is the responsibility of the owner/user to be knowledgeable of these laws and regulations and to comply with them. The most prevalent regulations of this type are the Federal OSHA Safety Regulations*. Listed below, in abbreviated form are some of the requirements of Federal OSHA regulations in effect as of the date of publication of this handbook.

The listing of these requirements shall not relieve the owner/user of the responsibility and obligation to determine all applicable laws and regulations and their exact wording and requirements, and to comply with the requirements. Nor shall the listing of these requirements constitute an assumption of responsibility of liability on the part of JLG Industries, Inc.

1. Only trained and authorized operators shall be permitted to operate the aerial lift.

2. A malfunctioning lift shall be shut down until repaired.

3. The controls shall be plainly marked as to their function.

4. The controls shall be tested each day prior to use to determine that they are in safe operating condition.

5. Load limits specified by the manufacturer shall not be exceeded.

6. Instruction and warning placards must be legible.

7. Aerial lifts may be "field modified" for uses other than those intended by the manufacturer only if certified in writing by the manufacturer or an equivalent entity, such as a nationally recognized testing lab, to be in conformity to applicable OSHA safety regulations and to be at least as safe as it was prior to modification.

8. Aerial lifts shall not be used near electric power lines unless the lines have been deenergized or adequate clearance is maintained (see OSHA 29 CFR 1910.67 and 1926.400).

9. Employees using aerial lifts shall be instructed how to recognize and avoid unsafe conditions and hazards.

10. Ground controls shall not be operated unless permission has been obtained from personnel in the platform, except in case of an emergency.

11. Regular inspection of the job site and aerial lift shall be performed by competent persons.

12. Personnel shall always stand on the floor of the platform, not on boxes, planks, railing or other devices for a work position.

*Applicable Federal OSHA regulations, as of the date of publication of this manual include, but are not limited to, 29 CFR 1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR 1926.28, 29 CFR 1926.400 and 29 CFR 1926.453. Consult the current regulations for the exact wording and full text of the requirements and contact the closest Federal OSHA office for specific interpretations.

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

General

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

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

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

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

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

Maintenance Safety

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

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

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

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

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

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

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

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

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

Hydraulic System Safety

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

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

b – JLG Lift – 3121154

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February 5, 2009 - Original Issue of Manual

June 14, 2012 - Manual Revised

EFFECTIVITY PAGE

EFFECTIVITY CHANGES

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TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

OPERATION/SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

EFFECTIVITY CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

SECTION 1 - SPECIFICATIONS

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

Hydraulic Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

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

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

Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

1.5 HYDRAULIC PRESSURE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.7 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.8 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

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

SECTION 2 - SERVICE PROCEDURES

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

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

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

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

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

2.3 SERVICING AND MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Mast Chain Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2.4 LUBRICATION INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

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TABLE OF CONTENTS

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.5 MACHINE BOLT DOWN SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.6 AC JUNCTION BOX COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

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

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

Motor Assembly - Remove/Install - Reference Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Motor/Brush Cover - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Brush Carrier Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Brush Assembly - Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

TANK AND PUMP REMOVAL - (All Pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Tank Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Filter Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Pressure Adjust Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Pressure Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

2.8 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD . . . . . . . . . . . . . . . . . .2-15

Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Cylinder Removal From Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16

Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Lift Cylinder Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

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

Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

2.9 15BD- MAST ASSEMBLY AND DISASSEMBLY PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . .2-20

15BD - Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

15BD - Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Mast To Base Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Mast Chains Adjustment - 15BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

2.10 19BD - MAST ASSEMBLY AND DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

19BD - Mast Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

19BD - Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Mast To Base Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Mast Chains Adjustment - 19BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

2.11 SEQUENCING CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

2.12 SEQUENCE CABLE REPLACEMENT KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Remove Old Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Replacement Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Clamp Installation (Drum/Socket Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

SECTION 3 - TROUBLESHOOTING

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3 HYDRAULIC CIRCUIT CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

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

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

Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

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

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

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

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

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

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

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

ii – JLG Lift – 3121154

Page 11

TABLE OF CONTENTS

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

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

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

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

1-2. Lubrication Locations (See Table below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

2-1. BD - Machine Bolt Down Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-2. AC Junction Box - Internal Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-3. Lift Cylinder Internal Component Assembly Cross-Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

2-4. Mast Section - Assembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

2-5. 15BD - Mast Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2-6. Mast Chain Routing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-7. Mast Bottom End - Slide Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

2-8. Mast Top End - Slide Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

2-9. Mast Chain/Sequence Cable Adjustment Components. (15BD) . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

2-10. Mast Section - Assembly/Disassembly Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

2-11. 19BD Mast Assembly Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-12. 19BD Mast Chain Routing Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

2-13. Mast Chain/Sequence Cable Adjustment Components. (19BD) . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

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

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

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

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

3-5. Hydraulic Schematic. (BD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-6. Electrical Diagram. (BD - 120V-AC - Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-7. Electrical Diagram. (BD - 120V-AC - CORNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-8. Electrical Diagram. (BD - 220V-AC - CORNING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

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

1-3 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

2-3 Chain Stretch Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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

3-1 BD Model - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3121154 – JLG Lift – iii

Page 12

TABLE OF CONTENTS

NOTES:

iv – JLG Lift – 3121154

Page 13

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Hydraulic Oil Capacity

System Capacity – 5 qts. U.S. (4.7 ltr.)

Reservoir Size – 148 cu. in. (2.56 qts. U.S.) (2.42 Liter)

minimum usable

1.2 COMPONENT DATA

Hydraulic Pump/Electric Motor Assembly

AC Models - 120/240 Volt AC motor/pump

Motor - 100/200 - 230V-AC, 1HP, 2850/3450 RPM, 50/

60Hz

Pump Displacement – AFC 0.077 cu. in./rev. (1.26 cc/ rev.)

Pump Output – 1.37 GPM @ 1350 PSI @ 15 AMPS @ 115v-AC @ 45 Centistrokes (200 SSU)

Pressure Relief – Adjustable Range 1500 PSI (103.4 Bar) to 5000 PSI (344.7 Bar), Set to 1700 PSI (117.2 bar), adjust to lift maximum rated capacity.

1.3 PERFORMANCE DATA

Machine Specifications

SPECIFICATION

Maximum Occupants: (Persons) 1

Maximum Work Load (Platform Capacity):

Machine Stowed Height: 77.22 in.

Machine Stowed Width: 29.75 in. (75.5 cm)

Maximum Vertical Platform Height (Ground to Platform Floor - Platform Full y Exten ded):

Maximum Step-in Platform Height (Ground to Platform Floor - Platform Fully Lowered):

Working Height: 21 ft.

Standard Platform Size: 27 in. x 23 in.

Platform Speed (seconds) Lift Up: 20 22

( w/ m ax . r at e d l o ad ) L if t D ow n : 32 - 40 18 - 25

Machine Weight (Platform Empty ): 725 lb.

System Voltage: 12V DC/120 Volts-60Hz AC

Machine Base Mounting Footprint: 18 in. x 33 in.

15BD 19BD

350 lb. (160 kg)

77.81 in.

(1.96 m)

15.25 ft.

(4.65 m)

12.75 in. ( cm) 13.37 in. ( cm)

(6.4 m)

(68.5 cm x 58.5 cm)

(329 kg)

(45.72 cm x

83.82 cm)

0.75 Dia. Holes

(1.97 m)

18.75 ft.

(5.72 m)

24.75 ft.

(7.54 m)

830 lb.

(376 kg)

20 in. x 24 in.

(50.8 cm x

60.96 cm)

0.75 Dia. Holes

1.4 TORQUE REQUIREMENTS

When maintenance becomes necessary or a fastener has loosened, refer to the Fastener Torque Charts in this section to determine proper torque value per the size and grade of the fastener.

3121154 – JLG Lift – 1-1

Page 14

SECTION 1 - SPECIFICATIONS

PRESSURE

ADJUSTMENT

SCREW

HYDRAULI C

OIL TANK

GROUND CONTROL

STATION

COVER

ADJUSTMENT

SCREW CAP

(SHOWN REMOVED)

1.5 HYDRAULIC PRESSURE ADJUSTMENT

(See Figure 1-1.)

Set hydraulic pressure to 1700 PSI as a starting point. Adjust system pressure so that platform will raise to full height with maximum rated capacity in platform.

Turning adjustment screw clockwise, increases system

pressure, turning screw counterclockwise, decreases system pressure.

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

1.7 SERIAL NUMBER LOCATIONS

For machine identification, a serial number plate is affixed to the machine. The plate is located on the back of the mast, just above the mast support bracket.

1.8 LUBRICATION

(Figure 1-2. and Table 1-4 show required points of lubrication for this machine.)

Hydraulic Oil

Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries, recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

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

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

1.6 CYLINDER SPECIFICATIONS

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

Figure 1-1. Hydraulic Pressure Setting - Adjustment

Screw Located at Base of Pump Motor

(Remove Hex Head Cap as Shown)

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

Table 1-1. Cylinder Specifications

DESCRIPTION

Lift Cylinder 15BD

Lift Cylinder 19BD

BORE

in./(cm)

1.50

(3.81)

1.63

(4.14)

STROKE

in./(cm)

56.50

(143.50)

53.50

(135.89)

ROD DIA.

in./(cm)

1.375 (3.50)

Table 1-2. Hydraulic Oil Operating Range

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

+0? F to +180? F

(-18? C to +83? C)

+0? F to +210? F

(-18? C to +99? C)

+ 50 ? F t o + 2 10 ? F (+10? C to +99? C)

SAE VISCOSITY

GRADE

10W

10W-20, 10W-30

20W-20

Lubrication Specifications

Table 1-3. Lubrication Specifications

KEY SPECIFICATIONS

MPG - Multipurpose Grease having a minimum dripping point

of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGL - Extreme Pressure Gear Lube (oil) meeting API service

c la ss if ic a ti on GL- 5 or MI L-S pe c MI L-L- 21 0 5.

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

1-2 – JLG Lift – 3121154

Page 15

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Locations (See Table below).

ITEM COMPONENT

Hydraulic Oil

2 Mast Chains

Key to Lubricants: MPG - Multipurpose Grease (See Table 1-3) HO - Hydraulic Oil

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

b.Recommended lubricating intervals are calculated on hourmeter hours (Hm.Hrs.= pump run cycle - lift up - only).

Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions, such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly.

c. Prior to checking hydraulic oil level, operate machine through one complete c yc l e of l if t f un c t io n (f u ll u p an d do w n) . E ns u re platform is fully

lowered, failure to do so will result in incorrect oil level reading on the hydraulic reservoir.

NO/TYPE

LUBE POINTS

Fill To Line on Reservoir

(c)

5 Qt. (4.3 L) Reservoir

2 - Per Section Chain Lube - Brush

Table 1-4. Lubrication Intervals for Various Components

(a)

LUBE/METHOD

HO- Check Hyd.

Oil Level HO-Change H y d. O il

or Spray

MONTHS

5 hm. hrs.

INTERVAL HOURS

MONTHS

10 hm. hrs.



(b)

YEAR

20 hm. hrs.

YEARS

40 hm. hrs.



COMMENTS

Check hydraulic oil level daily. Change oil every 2 yrs. or after

every 40 Hourmeter Hrs. of operation.

3121154 – JLG Lift – 1-3

Page 16

SECTION 1 - SPECIFICATIONS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

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

Description

0100011

242

Vibra-TITE

121

Medium Strength (Blue)

0100019

271

Vibra-TITE

140

High Strength (Red)

0100071

262

Vibra-TITE

131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

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

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

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

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

12 1.1250 0.8560 47500 880 1193 660 895 9 25 1258 802 1087

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

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

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

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

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

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

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

or Vibra-

TITE

131)

Torque

Lubricated

Torque

(Loctite® 242

or 271

OR Vibra-TIT E

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

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

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

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

1-4 – JLG Lift – 3121154

Page 17

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. * ASSEMBLY USES HARDENED WASHER

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

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

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

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17

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

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

9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120 16400 155 210 140 190 115 155 18250 170 230 155 210 130 175 20350 210 285 190 260 160 220 23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

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

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140) K=.18

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

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

Torque

(Dry or Loctite® 263)

K= 0.20

3121154 – JLG Lift – 1-5

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 7))

Page 18

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

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

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

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

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

24 0.3125 0.0580 5220 25 35 20 25 20 25

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

24 0.3750 0.0878 7900 40 55 40 55 35 50

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

20 0.4375 0.1187 10700 65 90 60 80 60 80

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

20 0.5000 0.1599 14400 100 135 95 130 90 120

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

18 0.5625 0.2030 18250 145 195 135 185 130 175

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

18 0.6250 0.2560 23000 205 280 190 260 180 245

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

16 0.7500 0.3730 33600 355 485 335 455 315 430

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

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

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

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

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

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

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

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

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

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

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

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

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K = .17

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

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

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

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

1-6 – JLG Lift – 3121154

Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 7)

Page 19

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

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

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

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

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

24 0.3125 0.0580 5220 25 35 25 35 20 25

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

24 0.3750 0.0878 7900 50 70 45 60 35 50

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

20 0.4375 0.1187 10700 80 110 70 95 60 80

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

20 0.5000 0.1599 14400 120 165 110 150 90 120

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

18 0.5625 0.2030 18250 170 230 155 210 130 175

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

18 0.6250 0.2560 23000 240 325 215 290 180 245

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

16 0.7500 0.3730 33600 420 570 380 515 315 430

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

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

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

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

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

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

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

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

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

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

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

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

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242TM or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

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

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

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

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

SECTION 1 - SPECIFICATIONS

3121154 – JLG Lift – 1-7

Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 7)

Page 20

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

Torque

(Lub)

Torque

(Loctite® 262

OR Vibra-

TITE

131)

Torque

(Loctite®

242

or 271

OR Vibra-

TITE

111 or

140)

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

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

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

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

16 2 157 68.3

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

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

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

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

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

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

NO. 5000059 REV. J

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

1-8 – JLG Lift – 3121154

Page 21

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

K = 0.20

Torque

(Lub OR Loctite®

242

or 271TM OR

Vibra-TITE

111 or

140)

K= 0.18

Torque

(Loctite® 262

Vibra-TITE

131)

K=0.15

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

3 0.5 5.03 3.13

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

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

16 2 157 97.8

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

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

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

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

ADDITIONAL TESTING IS REQUIRED.

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

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

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

NO. 5000059 REV. J

3121154 – JLG Lift – 1-9

Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

Page 22

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

Torque

(Dry or Loctite®

263

)

K = .17

Torque

(Lub OR Loctite®

242

or 271

OR Vibra-TITE

111 or 140)

K = .16

Torque

(Loctite® 262

OR Vibra-TITE

131)

K = .15

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

30.55.03

3.5 0.6 6.78

40.78.78

50.814.20

6120.1012.5 13 12 11

7128.9018.0 21 20 19

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

16 2 157

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

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

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

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

ADDITIONAL TESTING IS REQUIRED.

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

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

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

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

Figure 1-9. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

1-10 – JLG Lift – 3121154

Page 23

SECTION 2 - SERVICE PROCEDURES

SECTION 2. SERVICE PROCEDURES

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. Table 2-1, Inspection and Maintenance 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 hrs; out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

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

Annual Machine Inspection

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

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

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

Preventative Maintenance

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

Reference Table 2-2, BD Model - Preventive Maintenance & Inspection Schedule., and the appropriate areas of this manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.

3121154 – JLG Lift – 2-1

Page 24

SECTION 2 - SERVICE PROCEDURES

Table 2-1. Inspection and Maintenance

TYPE FREQUENCY

Pre-Start Inspection

Pre-Delivery Inspection

Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

Prior to use each day; or At each Operator change.

Prior to each sale, lease, or rental delivery.

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

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

At intervals as specified in the Ser vice and Maintenance Manual.

PRIMARY

RESPONSIBILITY

User or Operator User or Operator Operator and Safet y Manual

Owner, Dealer, or User Qualified

Owner, Dealer, or User JLG Factory

Owner, Dealer, or User Qualified JLG

SERVICE

QUALIFICATION

JLG

Mechanic

JLG

Mechanic

Certified Ser vice

Technician

(Recommended)

Mechanic

REFERENCE

Service and Maintenance Manual and applicable JLG inspection form.

Service and Maintenance Manual

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

(See Table 2-2.)

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

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

2-2 – JLG Lift – 3121154

Page 25

SECTION 2 - SERVICE PROCEDURES

AREA ON MACHINE

Table 2-2. BD Model - Preventive Maintenance & Inspection Schedule.

(a)

PRE-DELIVERY (c) OR FREQUENT (d)

INSPECTION

PRE-START (b)

INSPECTION

INTERVAL

3 MONTH

PREV. MAINT.

5 Hm. Hrs.

ANNUAL (e)

INSPECTION

20 Hm. Hrs.

MAST ASSEMBLY

Mast Sections 12, 5

Chain Systems 1 14 3, 14 14, 25

Sequence Cable Systems 1 3 1, 2, 3

Support Bars 11, 2

Covers or Shields 11

Sheave Systems 11, 21, 2

Bearings 11, 2

Slide Pads 11, 2

PLATFORM ASSEMBLY

Platform 111

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

Gate/Slide Bar 11, 51, 5

Floor 11, 21, 2

Lanyard Anchorage Point 11, 41, 4

CHASSIS ASSEMBLY

Properly Anchored to Work Surface 14

FUNCTIONS/CONTROLS

Platform Controls 1 5, 6, 7 5, 6, 7

Ground Controls 1 5, 6, 24 5, 6, 24

Function Control Locks, Guards, or Detents 155

Function Enable System 15

Emergency Stop Switches (Ground & Platform) 155

Function Limit or Cutout S witch Systems 15

Manual Descent or Auxiliary Power 155

POWER SYSTEM

AC Junction Box Assembly 1

HYDRAULIC/ELECTRIC SYSTEM

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

Hydraulic Pump Cover 11

Hydraulic Cylinder 1 7, 9 2, 7, 9 2, 9

Cylinder Attachment Pi ns and Pin Retainers 11, 21, 2

Hydraulic Hoses, Lines, and Fittings 11, 9

Hydraulic Reservoir, Cap, and Breather 15, 75, 7

Hydraulic Filter 1

Hydraulic Fluid * 11 11 11

Electrical Connections 12020

3121154 – JLG Lift – 2-3

Page 26

SECTION 2 - SERVICE PROCEDURES

Table 2-2. BD Model - Preventive Maintenance & Inspection Schedule.

(a)

PRE-DELIVERY (c) OR FREQUENT (d)

INSPECTION

ANNUAL (e)

INSPECTION

20 Hm. Hrs.

AREA ON MACHINE

PRE-START (b)

INSPECTION

INTERVAL

3 MONTH

PREV. MAINT.

5 Hm. Hrs.

GENERAL

Operator and Safety Manuals in Storage Box 21 21 21

ANSI and EMI Manuals/Handbooks Installed 21 21 21

Capacity Decals Installed, Secure, Legible 21 21 21

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

"Walk-Around" Inspection Perfor med 22

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21, 22

General Structural Condition and Welds 2, 4 2, 4

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

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 22 22

Paint and Appearance 77

S ta mp I nsp e ct io n Da te o n Fr am e 22

Notify JLG of Machine Ownership 22

* Change hydraulic fluid every two years or 40 hourmeter hours.

Footnotes:

(a) Hm. Hrs. = Hourmeter Hours - Pump run cycle only

(b) Prior to use each day; or at each Operator change

(d) In service for 3 months or 150 hrs.; or Out of service

for 3 months or more; or Purchased used

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

Inspection and Maintenance Codes:

1. Check for proper and secure installation.

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

3. Check for proper adjustment.

4. Check for cracked or broken welds.

5. Operates properly.

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

7. Clean and free of debris.

8. Interlocks function properly.

9. Check for signs of leakage.

10. Decals installed and legible.

11. Check for proper fluid level.

12. Check for chafing and proper routing.

13. Check for proper tolerances.

14. Properly lubricated.

15. Torqued to proper specification.

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

17. Properly inflated and seated around rim.

18. Proper and authorized components.

19. Fully charged.

20. No loose connections, corrosion, or abrasions.

21. Verify.

22. Perform.

23. Sealed properly.

24. Overrides Platform controls.

25. Inspected per Service and Maintenance Manual.

2-4 – JLG Lift – 3121154

Page 27

SECTION 2 - SERVICE PROCEDURES

2.3 SERVICING AND MAINTENANCE GUIDELINES

General

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

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

Safety and Workmanship

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

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

Cleanliness

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

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

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

Components Removal and Installation

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

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

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

Component Disassembly and Reassembly

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

Pressure-Fit Parts

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

Bearings

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

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

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

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

Gaskets

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

3121154 – JLG Lift – 2-5

Page 28

SECTION 2 - SERVICE PROCEDURES

5% of H

Exampl e:

H for a 1" chain = 0.950" Maximum Wear = 5% of 0.950 = 0.047" Minimum Pl ate Depth = 0.950" - 0.047 = 0.903"

Bolt Usage and Torque Application

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.

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 in Sec-

tion-1 of this manual.)

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

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

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

Mast Chain Inspection Procedure

MAST CHAINS TO BE INSPECTED AND LUBRICATED EVERY THREE MONTHS OR 5 HOURMETER HOURS.

Inspect mast chains for the following conditions:

Wear: Always inspect that segment of chain that operates over a sheave. As the chain flexes over the extend/retract sheaves, joints and plate edges very gradually wear. Chain “stretch” can be measured using a manufacturers wear scale or steel tape. When chains have elongated 3% they must be removed and replaced. Refer to Table 2-3 for proper chain specifications and allowable stretch tolerances. Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave, or unusually heavy loads. All of the above require replacement of the chain and correction of the cause. Chain side wear, noticeable when pin heads and outside plates show a definite wear pattern, is caused by misalignment of the sheave/chain anchors and must be corrected promptly. Do not repair chains; if a section of chain is damaged, replace the entire chain set.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart, (See Sec- tion-1). 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.

Rust and Corrosion: Rust and corrosion will cause a major reduction in the load carrying capacity of the chain, because these are primary reasons for side plate cracking. The initial lubrication at the factory is applied in a hot dip tank to assure full penetration into the joint. Do not steam clean or degrease chains. At time of chain installation, factory lube must be supplemented by a maintenance program to provide a film of oil on the chains at all times. If chains are corroded, they must be inspected, especially the outside plates, for cracks in-line with the pins. If cracks are found, replace the chain; if no cracks are discovered, lubricate the chains by dipping in heated oil, and reinstall on the machine. Keep chains lubricated.

2-6 – JLG Lift – 3121154

Page 29

EXAMPLE OF MEASURING A (.50") PITCH CHAIN

24 pitches = 12 inches on a NEW chain

Maximum allowable stretch across 24 pitches (12 inches) = 12.24 inches

TIGHT JOINTS

ABNORMAL PROTRUSION OR

TURNED PINS

SECTION 2 - SERVICE PROCEDURES

Table 2-3. Chain Stretch Tolerance

Chain Size

Pin to Pin

Measurement

Allowable Stretch

.50" pitch 12" or 24 pitches .24 in./12 in. span

.625 pitch 15" or 24 pitches .30 in./15 in. span

Fatigue Cracks: Fatigue is a phenomenon that affects most metals, and is the most common cause of chain plate failures. Fatigue cracks are found through the link holes, perpendicular (90 degrees) from the pin in-line position. Inspect chains carefully after long time use and heavy loading for this type of crack. If any cracks are discovered, replace all chains, as seemingly sound plates are on the verge of cracking. Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains.

Oil rusty chains, and replace chains with bent or peened chain components. Keep chains lubricated.

Protruding or Turned Pin s: Chains operating with inadequate lube generate tremendous friction between the pin and plates (pin and bushing on leaf chain). In extreme cases, this frictional torque can actually turn the pins in the outside press-fit plates. Inspect for turned pins, which can be easily spotted as the “V” flats on the pin heads are no longer in line. Replace all chains showing evidence of turned or protruding pins. Keep chains lubricated.

Tight Joints: All joints in the leaf chain should flex freely. On leaf chain, tight joints are usually caused by rust/corrosion, or the inside plates “walking” off the bushing. Limber up rusty/corroded chains (after inspecting carefully) with a heavy application of oil (preferably a hot oil dip). Tap inside “walking” plates inward; if “walking” persists, replace the chain. This type of problem is accelerated by poor lubrication maintenance practice, and most tight joint chains have been operated with little or no lubrication. Tight joints on leaf chain are generally caused by:

a. Bent pins or plates.

b. Rusty joints.

c. Peened plate edges.

3121154 – JLG Lift – 2-7

Chain Anchors and Sheaves: An inspection of the chain must include a close examination of chain anchors and sheaves. Check chain anchors for wear breakage and misalignment. Anchors with worn or broken fingers should be replaced. They should also be adjusted to eliminate twisting the chain for an even load distribution.

Inspect the sheaves, sheave bearings, sheave grooves and pins for extreme wear, replace as necessary. A worn sheave can mean several problems, as follows:

a. Chains too tight.

b. Sheave bearings/pin bad.

c. Bent/misaligned chains.

Page 30

SECTION 2 - SERVICE PROCEDURES

2.4 LUBRICATION INFORMATION

Hydraulic System

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.

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.

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.

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 of new

machines due to the wear-in of meshing components.

Hydraulic Oil

For best performance, JLG recommends the use of ISOVg grade 32, 46 oil with a viscosity range between 15-250 SUS at 100 degrees F (32-54 cST at 40 degrees C). Refer to Section-1 for recommended hydraulic oils.

Changing Hydraulic Oil

Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis (See Lubrication Interval Table 1-4. in Section 1 of this manual). If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

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.

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 Table 1-2. for an explanation of the lubricant key designations appearing in the Lubrication Chart.

2-8 – JLG Lift – 3121154

Page 31

2.5 MACHINE BOLT DOWN SPECIFICATION

33.000 in. (83.82 cm)

SECTION 2 - SERVICE PROCEDURES

18.000 in. (46 cm)

1. Base Weldment 3. Mounting Fasteners

2. Factory drilled .750" (19mm) diameter 4. Solid, firm and level floor surface.

holes in base weldment (4 places) (a)

Notes: (a) Use .500" (13mm) diameter - grade 5 hardware (minimum) with large steel flatwashers. Torque fastener per rating

on torque chart in Section-1 of this service manual.

Figure 2-1. BD - Machine Bolt Down Specifications.

3121154 – JLG Lift – 2-9

Page 32

SECTION 2 - SERVICE PROCEDURES

2.6 AC JUNCTION BOX COMPONENTS

HAZARD OF ELECTRIC SHOCK! ALWAYS DISCONNECT ELECTRIC POWER TO THE JUNCTION BOX BEFORE ATTEMPTING TO DISCONNECT ANY CIRCUITS OR WHEN REMOVING COMPONENTS.

WHEN TESTING CIRCUITS WITH ELECTRICAL POWER ON, USE ONLY INSTRUMENTS WITH INSULATED TEST LEADS KEEPING YOUR HANDS OUTSIDE THE BOX.

1. AC Box with Lid

2. 12VDC Starter Relay

3. 115VAC Coil Starter Relay

4. AC/DC -Transformer

5. Interlock Relay

6. Rectifier Switch

7. Plug

8. 20A Circuit Breaker

9. Terminal Strip

10. Harness Capacitor

11. AC Input Cable

NOTE: See wiring diagrams in Section-3 of this manual for wiring instructions.

Figure 2-2. AC Junction Box - Internal Components.

2-10 – JLG Lift – 3121154

Page 33

2.7 HYDRAULIC LIFT PUMP - SERVICING

Remove hydraulic pump from machine.

MONARCH BRAND PUMP - Brush Replacement

Motor Assembly - Remove/Install - Reference Marks

SECTION 2 - SERVICE PROCEDURES

Pump Motor - Removal/Installation - Reference Marks

• For reference when reassembling, mark motor cover, housing and valve body position before disassembling.

1. Motor Top Cover 4. Housing/Motor Valve Body

2. Cover/Housing Reference Mark Reference Mark 5. Motor Valve Body

3. Motor Housing

Motor/Brush Cover - Remove/Install

Motor/Brush Cover - Removal/Installation

1. Motor/Brush Cover (a)

2. Cover Screws (b)

REMOVE THE MOTOR COVER CAREFULLY, THE (SHORT) POWER LEADS INSIDE THE COVER FROM THE (+/–) POSTS ARE SOLDERED TO ATTACH CLIPS WHICH ARE FASTENED TO THE BRUSH CARRIER ASSEMBLY WITH SCREWS (ITEM-5). RAISE THE COVER STRAIGHT UP - REMOVE THE SCREWS - THEN HINGE THE COVER UP (SEE CENTER ILLUSTRATION) AND PRY THE CLIPS OFF OF THE BRUSH CARRIER ASSEMBLY TO COMPLETELY REMOVE THE MOTOR COVER.

NOTE: (a) Once cover screws are removed, you may need to tap lightly around the edge of the top cover to separate it from the motor housing.

Read the important note above before attempting to remove the cover. (b) These steel screws are threaded into the aluminum valve body, do not overtighten.

3. Washers

4. Power Leads to Lead Clips (Soldered)

5. Power Lead Clip Attach Screws

3121154 – JLG Lift – 2-11

Page 34

SECTION 2 - SERVICE PROCEDURES

Brush Carrier Assembly - Remove/Install

1. Stator/Brush Carrier Screws (Pump Rear)

2. Stator/Brush Carrier Screws (Pump Front) (a)

NOTE: (a) Removed previously with motor cover disassembly (shown for reference only).

Brush Assembly - Remove/Install

3. Mark Brush Carrier Position on Motor Housing

4. Brush Carrier Assembly

1. Brush Assembly (a)

2. Brush Carrier Socket

3. Brush Tab Slot

NOTE: (a) Slide brush assembly into socket until tab is in slot at

rear of socket.

4. Brush Terminal Screw

5. Brush Attach Terminal

2-12 – JLG Lift – 3121154

Page 35

TANK AND PUMP REMOVAL - (All Pumps)

12234

SECTION 2 - SERVICE PROCEDURES

Tank I nstall ation

Tank Installation

1. Tank A sse m bly 3. O-Ring Seal

2. Tank Screws (4) 4. Use Screwdriver to pry tank

away from pump head.

Pump Installation

1. Pump Assembly 3. Pump Shaft Seal

2. Pump Assembly Screws 4. Pump End Head

Filter Screen Installation

1. Filter Screen 2. Pump Pick-Up Tube

Filter Screen Installation

Pump O-Ring Installation

1. Pump Assembly 2. O-Ring Seal 3. O-Ring Seal

3121154 – JLG Lift – 2-13

Page 36

SECTION 2 - SERVICE PROCEDURES

1234567

Pressure Adjust Valve Installation Pressure Check Valve Installation

Pressure Adjust Valve Installation

1. Adjust Valve Cap 4. Valve Ball

2. Adjustment Screw 5. Adjust Valve Port

3. Valve Spring 6. Extend (Pressure) Port

(Shown Plugged)

Note: Adjust pressure per specification shown in Section-1 of this

Service Manual.

Pressure Check Valve Installation

1. Check Valve Assembly 5. Check Valve Por t

2. O-Ring Seal 6. Extend (Pressure) Port

3. O-Ring Seal 7. Return Port

4. Backing Ring

Note: Extend (Pressure) and Return Ports Shown Plugged

2-14 – JLG Lift – 3121154

Page 37

SECTION 2 - SERVICE PROCEDURES

2.8 HYDRAULIC LIFT CYLINDER - REMOVAL, INSPECTION AND REBUILD

HYDRAULIC CYLINDERS ARE DESIGNED TO HOLD HYDRAULIC FLUID UNDER HIGH PRESSURE. BE SURE ALL APPROPRIATE MEASURES ARE TAKEN TO RELIEVE RESIDUAL PRESSURE IN THE CYLINDER BEFORE DISCONNECTING LINES.

Removal of the hydraulic cylinder from the mast assembly requires the removal of the mast assembly from the base frame. The mast assembly can then be supported on it’s back and partially disassembled to remove the hydraulic cylinder.

Mast Removal

NOTE: This procedure depends on enough clearance over

the top of the mast to lift the mast assembly out of the base frame. Otherwise the base frame assembly will need to be unbolted from the work surface.

1. Disconnect power source from the AC Junction Box.

2. Remove the platform assembly from the front of the mast assembly.

NOTE: The following step is done to prevent leakage of the

hydraulic fluid through the vented reservoir cap while the mast is laid on it’s back for disassembly.

3. Remove the vented hydraulic reservoir cap and seal the opening by layering plastic wrap over the cap opening and screwing the cap back on tight.

4. Loosen the bottom fasteners of the mast side support rails, then remove the top fasteners attaching the supports to mast support bracket which is attached midway up the back of the mast. Rotate the side support brackets down out of the way.

5. Place a sling capable of lifting the weight of the mast assembly around and under the sides of the AC box/ Ground Station support beam bolted to the back of the mast. With the sling attached to the lifting device at the front of the mast.

6. Attach sling to an overhead crane or suitable fork lift and lift sling to remove any slack in the lifting sling.

NOTE: It is important not to allow the mast assembly to

move around too much once the mast mounting fasteners are removed in the next step. To prevent the manual descent valve assembly located on the bottom of the mast from getting damaged.

7. Remove the four (4) mast mounting bolts, nuts and washers attaching the mast to the base frame at the back and bottom of the mast assembly. Lift mast slightly if required to remove the bolts.

8. Push the mast assembly forward to allow the manual descent valve to clear the circular opening in the back of the base frame, before lifting the mast assembly upwards.

9. Once the mast assembly is clear of the frame, move it to an area large enough to allow disassembly. When placing mast assembly on it’s back, place supports under the mast, do not allow the mast to rest on either the Ground Control or AC Junction Box, or the manual descent valve assembly at the bottom of the mast.

3121154 – JLG Lift – 2-15

Page 38

SECTION 2 - SERVICE PROCEDURES

341

Cylinder Removal From Mast

1. At the base end, remove and cap the extend and return hydraulic lines.

2. Remove the mini covers from the tops of the mast sections.

3. Manually extend the mast assembly until the top of mast section-2 is extended approximately one (1) foot (31cm), to allow access to the sheave wheelanchor block at the top of mast section-2 and the lift cylinder.

Extending Mast Sections

1. Mast Section-2 2. 1 ft. (31cm) Extended

5. Push mast sections-3, 4 and 5 back towards the base assembly allowing the top of mast section-2 to be completely exposed.

Exposing Top of Mast Section-2

1. Sections-3 and 4 - Pushed Back

2. Top of Mast Section-2 Exposed

6. Remove the cylinder/anchor block attach pin - snap ring from the back of the top of mast section-2.

4. Remove the adjust and lock nuts from the chain studs at the bottom of mast section-3.

Chain Assembly - Bottom of Mast Section-3

1. Mast Section-4 4. Adjust Nut

2. Mast Section-3 5. Lock Nut (b)

3. Chain Assembly Stud (a)

Note: (a) Remove nuts and push studs through anchor plate.

Snap Ring Installation

1. Back of Mast Section-2 3. Pin and Snap Ring

2. Cyl./Chain Anchor Block 4. Cylinder Rod

2-16 – JLG Lift – 3121154

Page 39

SECTION 2 - SERVICE PROCEDURES

7. Remove the cylinder rod pin from the cylinder/chain anchor block.

Cylinder Rod Pin Installation

1. Cylinder Rod Pin 3. Cyl./Chain Anchor Block

2. Cylinder Rod

Cylinder To Mast Mount Removal - Machine S/N - 0130005748

1. At the base of the cylinder, remove the cylinder mount shoulder bolts and the cylinder mount screw.

2. At the bottom of mast section 2, slide the lift cylinder assembly out and place on a suitable work surface.

Cylinder Installation

1. Lift Cylinder Assembly up and out of Cylinder Mount.

Cylinder To Mast Mount Removal - All Machines Except S/N - 0130005748

1. At the base of the lift cylinder, remove one of the snap rings from either end of the cylinder attach rod. Tap the rod with a punch until the rod can be removed from the cylinder block and side mounting plates.

2. Slide the lift cylinder out though the bottom of the mast assembly.

1. Mount Shoulder Screws 3. Upper Half of Cylinder Mount

2. Cylinder Attach Screw 4. Cylinder Valve Block

Lift Cylinder Mount Installation

1. Lift Cylinder 3. Cylinder Attach Rod Snap Rings

2. Cylinder Attach Rod 4. Cylinder Side Mounting Plates

Lift Cylinder Mount Installation

3121154 – JLG Lift – 2-17

Page 40

SECTION 2 - SERVICE PROCEDURES

PISTON

LOCKNUT

(Torque

175-200 Ft. Lb.)

WEA R

RING

PISTON

SEAL

O-RI NG

BACKUP

RING

CYLI NDER

HEAD

RETAINING

RING

RETAINING RING

GROOVE

ROD

SEAL

ROD

WI PE R

CYLI NDER

HEAD

WHEN ASS EMBLI NG

CYLI NDER

APPLY ANTI-SEI ZE

COMPOUND

AROUND THE HEAD

IN THIS AREA ONLY

CYLI NDER

TUBE

ASSEMBLY

CYLI NDER

ROD

Cylinder Disassembly

1. Before disassembling the cylinder, clean away all dirt and foreign substances from openings, particularly the head area.

NOTE: Always protect the chrome surface of the cylinder

rod during assembly and disassembly. Any damage to this surface will require replacement of the rod.

2. Extend the rod until the piston bottoms out against the cylinder head.

3. Compress the head retraining ring enough to allow the the cylinder head to be removed.

4. Carefully slide the head/rod/piston assembly out of the cylinder tube. A gentle tap on the head assembly

may be required to remove the head from the cylinder tube.

5. Place the head/rod/piston assembly on a surface that will not damage the chrome.

6. Remove the piston locknut and separate the piston from the rod.

7. Slide the head off the rod from the piston end.

NOTE: When removing the old seals use only blunt tools, be

sure there are no sharp edges that may damage the seal grooves during removal. Scratching the groove may cause by-pass.

8. Remove and discard all old seals.

2-18 – JLG Lift – 3121154

Figure 2-3. Lift Cylinder Internal Component Assembly Cross-Section.

Page 41

SECTION 2 - SERVICE PROCEDURES

Lift Cylinder Component Inspection

Cylinder Rod

There should be no scratches or pits deep enough to catch the fingernail. Pits that go to the base metal are unacceptable. Scratches that catch the fingernail but are not to the base metal, less than 0.5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal. Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable. In the event that an unacceptable condition occurs, the rod should be repaired or replaced.

Cylinder Head

Visually inspect the inside bore for scratches or polishing. Deep scratches are unacceptable. Polishing indicates uneven loading and when this occurs, the bore should be checked for out-of-roundness. If out-of-roundness exceed

0.007", this is unacceptable. Check the condition of the dynamic seals (wiper, rod seals) looking particulary for metallic particles embedded in the seal surface. It is normal to cut the static seal on the retaining ring groove upon disassembly. Remove the rod seal, static o-ring and backup and rod wiper. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the head should be replaced.

Piston

Visually inspect the outside surface for scratches or polishing. Deep scratches are unacceptable. Polishing indicates uneven loading and when this occurs, the diameter should be checked for out-of-roundness. If out-of-roundness exceeds 0.007", this is unacceptable. Check the condition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface. Remove the seals and bearings. Damage to the seal grooves, particularly on the sealing surfaces, is unacceptable. In the event that an unacceptable condition occurs, the piston should be replaced.

Cylinder Assembly

(See Figure 2-3.)

1. Rinse the inside of the tube with hydraulic fluid and allow to drain. A high-pressure rinse followed by a wipe with a lint-free rag is preferable. Clean all internal components of any foreign material.

2. Lubricate the head and all seals with hydraulic fluid prior to installation. Install the seal, wiper, o-ring, back-up ring, and retraining ring to the cylinder head.

3. Lubricate the piston and all components with hydraulic fluid. Install the seal and wear ring to the piston.

NOTE: Re-check that seals are not twisted or pinched and

are properly seated.

4. Place the rod on a clean table. Install the static oring seal into the groove on the piston end of the rod.

5. Install the head followed by the piston onto the rod noting the proper orientation of each component. Torque the piston nut to 175-200 ft. lbs.

6. When the rod assembly is ready to be installed into the tube, liberally apply an anti-seize lubricant to the head outer surface, especially the static seal.

7. Next dip the entire rod assembly into hydraulic fluid and stuff this assembly into the tube. Watch the seals as they pass over the rod port (if visible) to be sure they are not nicked or cut.

8. Install the head until the retaining ring seats in it’s groove.

Tube Assembly

Visually inspect the inside bore for scratches and pits. There should be no scratches or pits deep enough to catch the fingernail. Scratches that catch the fingernail but are less than 0.5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal. The roughness of the bore should be between 10 and 20 μ inches RMS. Significant variation (greater than 8 μ inches difference) are unacceptable. In the event that an unacceptable condition occurs, the tube assembly should be repaired or replaced.

3121154 – JLG Lift – 2-19

Page 42

SECTION 2 - SERVICE PROCEDURES

Cylinder Installation

To install the lift cylinder reverse the Lift Cylinder Removal instructions at the start of this section, however perform the following additional steps during re-assembly.

1. Apply Loctite #222 (purple) and torque to 85 ft. lbs. the cylinder mount shoulder screws securing the lift cylinder mount halves together at the bottom of the mast.

2. Check that the platform electrical control cables and the sequence cables are seated in their sheave wheel assemblies when extending mast sections for reassembly.

3. After assembly, readjust the chain at the bottom of mast section-3 and apply Loctite #242 to the lock nuts before final tightening.

4. Remove the plastic from under the hydraulic reservoir tank cap.

2.9 15BD- MAST ASSEMBLY AND DISASSEMBLY PROCEDURES

The mast sections are constructed of extruded aluminum, protected with an anodized surface finish. The mast sections are interlocked into each other when assembled, by internally mounted slide pads at the top and bottom of each mast section. These slide pads run up and down in slide pad channels on each side of the mast.

The mast assembly contains a number of mast sections as shown following;

Table 2-4. Mast Component Features

Model

15BD 4 Chain

19BD 5 Chain

Assembly procedures for all mast sections is basically the same, carefully slide the mast sections together until mast ends are even. (When sliding the mast sections together, be careful not to scratch the anodized surface). Assemble the hardware to the bottom of mast section first, slide this section out the top of previous section and assemble hardware to the top of mast. Always install slide pad shims with slide pads inserted into the slide pad channels, (ends of mast sections even). Applying silicone spray onto the slide pads and slide pad channels before assembly will help mast sections slide easier after slide pads have been properly shimmed.

No. of Mast

Sections

Extend/Retract

Device

15BD - Mast Disassembly Procedure

NOTE: See Section 2.8 for Mast Assembly Removal Instruc-

tions.

1. After the mast assembly has been removed from the machine, lay the mast assembly down on a suitable work table with the platform mounting section on top, facing up.

2. Remove the sequencing cables and hardware from the sides of the mast assembly. Also remove the covers from the top of the mast assembly.

MAST SECTION-4 - REMOVAL

3. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate (lower) on BOTTOM end of mast section-4 (platform mounting section). Push threaded ends of chain through anchor plate.

4. At the TOP of mast section-4, pull chains out and allow to hang loose. (Be certain floor surface is

clean and free of any metal chips or debris which may stick to lubricated chains)

2-20 – JLG Lift – 3121154

Page 43

SECTION 2 - SERVICE PROCEDURES

OPEN RAIL

(REFERS TO OPEN RAIL

FRONT OF MAST SECTION)

CLOSED RAI L

(REFERS TO CLOSED RAIL

BACK OF MAST SECTION)

BOTTOM

(REFERS TO BOTTOM END OF

MAST SECTION WHICH SETS IN

MACHINE’ S BASE FRAME)

TOP

(REFERS TO TOP END

OF MAST SECTI ON

WHERE COVER AND

SHEAVE WHEELS

ARE ATTACHED)

Figure 2-4. Mast Section - Assembly Reference.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized surface in the slide pad channels.

5. Carefully slide mast section-4 out the BOTTOM of mast section-3 rails. Disassemble slide pads, shims and chain anchor plate from mast section-4, if necessary.

MAST SECTION-3 - REMOVAL

6. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOTTOM end of mast section-3. Push threaded ends of chain through the anchor plate.

7. At TOP of mast section-3, pull chains out and allow to hang loose, (be certain floor surface is clean and

free of any metal chips or debris which may stick to lubricated chains).

8. Slide mast section-3 out TOP of mast section-2 far enough to allow access to the chain sheave wheel assembly.

9. Remove countersunk-flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section-3 and remove the sheave wheel assembly.

10. While mast section-3 is still extended from section-2 remove the pin attaching the chain anchor plate to the TOP of mast section-3. Remove chains.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad channels.

11. Carefully slide mast section-3 out BOTTOM of section-2. Remove slide pads, and shims, if necessary.

3121154 – JLG Lift – 2-21

Page 44

SECTION 2 - SERVICE PROCEDURES

MAST SECTION-2 - REMOVAL

12. Slide mast section-2 out TOP of mast section-1 far enough to allow access to the chain assembly anchor block/sheave wheel assembly.

13. Remove countersunk-flathead screws securing chain anchor block/sheave wheel assembly attach bars on both side rails at TOP of mast section-2.

14. Slide the chain anchor block/sheave wheel assembly and hydraulic cylinder out the TOP of mast section-2 far enough to allow removal of the sheave wheel attach bars, sheave wheels and sheave pin from chain assembly anchor block.

15. Remove the setscrew holding the hydraulic cylinder rod onto the chain assembly anchor block. Lay chain assembly/anchor block to side.

16. Remove the hydraulic cylinder through BOTTOM of mast section-2, be careful not to nick or score cylinder rod surface while removing.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad channels.

17. Carefully slide mast section-2 out BOTTOM of section-1. Remove slide pads and shims, if necessary.

MAST SECTION-1 - DISASSEMBLY

18. Slide the TOP of remaining mast section-1 out over edge of work surface and remove the pins attaching the chain anchor block to mast section-1. Remove chain/anchor block assemblies from mast and lay aside.

19. Remove slide pads and shims from mast section-1.

Mast disassembly should now be complete.

2-22 – JLG Lift – 3121154

Page 45

DETAIL

SEE

DETAIL D

DETAIL

SEE

DETAIL A

SEE

DETAIL A

SEE

DETAIL C

CYLINDER INSTALLATION

FOR ONLYS/N 0130005748

SEE

DETAIL B

DETAIL

SEE

DETAIL D

SECTION 2 - SERVICE PROCEDURES

3121154 – JLG Lift – 2-23

Figure 2-5. 15BD - Mast Assembly.

Page 46

SECTION 2 - SERVICE PROCEDURES

Figure 2-6. Mast Chain Routing Diagram

2-24 – JLG Lift – 3121154

Page 47

SECTION 2 - SERVICE PROCEDURES

15BD - Mast Assembly

(See Figure 2-2.)

MAST SECTION 1 - ASSEMBLY

1. Place mast section-1, rail (open) side up (See Figure 2-1.) on a clean, flat surface (preferably a table or work bench capable of supporting the weight of the entire mast assembly). Slide mast out over end of

work surface far enough to allow access to the chain anchor attach hole near the top of the mast.

2. Locate the two (2) single (wide) chain assemblies and attach to the large equalizer anchor plate (if not already attached). Lay out the chain/anchor plate assembly with the anchor plate end towards top of the mast. (Be certain floor surface is clean and free

of any metal chips or debris which may stick to lubricated chains).

3. Insert the chain/anchor plate assembly end into the top of mast section-1 and secure using the large anchor plate attach pin, spacers, and pin keeper.

MAST SECTION 2 - ASSEMBLY

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide pad channels.

4. Locate mast section-2, carefully slide mast section-2 closed rail into section-1 open rail. Slide sections together until ends are even.

5. Insert slide pads into the slide pad channels at bottom end of mast between section-1 and -2, (one on each side of the mast), with beveled surface facing out towards section-1.

Chain/Anchor Plate Installation

(Mast Section-1 - Shown Cut-Away)

1. Anchor Plate Pin 4. Long Spacer

2. Short Spacer 5. Pin Keeper

3. Chain/Anchor Plate Assy. 6. Keeper Screw (a)

Notes: (a) Apply Loctite #242 to threads.

1. Slide Pads 2. Shim Stock 3. Slide Pad Bolts/Washers (a)

Notes: (a) Apply Loctite #242 to threads.

Figure 2-7. Mast Bottom End - Slide Pad Installation

(Typical)

6. Thread slide pad attaching bolts, (two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt), through holes in mast section-2 inside rail, into the slide pad inserts. Thread in enough to hold pad in place.

7. Shim slide pads using the following steps:

NOTE: Always use the an even amount of shim material

behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the mast section.

a. Start with a .036" thick shim and a .075" thick

shim per side at each slide pad.

b. Slide shims into place between slide pad and

mast rail. Tighten the slide pad mounting bolts, be sure there are no air gaps between shims, shim and mast or shim and slide pad when tightened.

c. Check mast section for side play. If play exists

add .015" shims dividing the thickness equally

3121154 – JLG Lift – 2-25

Page 48

SECTION 2 - SERVICE PROCEDURES

between both sides of mast. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side.

d. When mast slide pads are shimmed properly,

there should be no side to side movement of slide pad in rail channel. Mast sections should be snug in channels but still be able to slide in channel by hand.

8. Insert slide pads into the slide pad channels (top of

mast) between section-1 and -2, (one on each side of the mast), with beveled surface facing in towards

section-2.

NOTE: Before fastening and shimming the slide pad on the

top left side of the mast, install a sequence cable bracket against the mast under the flatwasher.

LIFT CYLINDER INSTALLATION - EXCEPT FOR S/N- 0130005748

11. If not already installed, install the lift cylinder mounting plates onto the bottom rails of Mast Section 1.

Lift Cylinder Mounting Plates Installation

(ALL MACHINES EXCEPT S/N - 0130005748)

1. Cylinder Mount Plates 3. Mounting Screw Nuts

2. Plate Mounting Screws (a)

Notes: (a) Apply Loctite #242 to threads.

1. Slide Pads 3. Sequence Cable Bracket

2. Shim Stock 4. Slide Pad Bolts/Washers (a)

Notes: (a) Apply Loctite #242 to threads.

Figure 2-8. Mast Top End - Slide Pad Installation

(Typical)

9. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes in mast section-1 outside rail (top of mast) and into the slide pad inserts. Thread in enough to hold pad in place.

10. Shim per instructions in step 7, Mast Section 2 Assembly.

NOTE: Lift cylinder installation is to be completed next, there

are two different design lift cylinders following, check your serial number or compare visually for correct mounting procedure.

NOTE: If hydraulic cylinder needs to be extended, the pro-

tective caps on the extend and return ports will need to be temporarily removed. Be careful not to nick or scour rod surface when extending, also catch any oil draining out of cylinder to avoid spillage onto work area.

12. Slide mast section-2 out of mast section-1 approximately one foot.

13. Slide the lift cylinder into the closed rail side of mast section-2 with rod end to top and port end to bottom of mast. Cylinder should extend out of mast on both ends of the mast with the port end resting in the cylinder mount at the bottom of the mount. The manual descent valve should be pointing down towards the back of the mast assembly.

14. At the base of the lift cylinder, align the through hole for the cylinder attach rod in the cylinder valve body and the cylinder mounting plates.

15. Install a snap ring on one end of the cylinder attach rod and slide the rod through the mounting plates and cylinder valve body.

16. Install the snap ring to the attach rod on the other end.

2-26 – JLG Lift – 3121154

Page 49

Lift Cylinder Mount Installation

(ALL MACHINES EXCEPT S/N - 0130005748)

1. Lift Cylinder 3. Cylinder Attach Rod Snap Rings

2. Cylinder Attach Rod 4. Cylinder Side Mounting Plates

SECTION 2 - SERVICE PROCEDURES

thickness on each side to center the mount in the closed rail portion if necessary.

NOTE: If hydraulic cylinder needs to be extended, the pro-

18. Slide mast section-2 out of mast section-1 approximately one foot.

19. Slide the lift cylinder into the closed rail side of mast section-2 with rod end to top and port end to bottom of mast. Cylinder should extend out of mast on both ends of the mast with the port end resting in the cylinder mount at the bottom of the mount. The manual descent valve should be pointing down towards the back of the mast assembly.

20. Loosely assemble the cylinder mount cap onto the lift cylinder mount to hold the cylinder assembly in place.

CONTINUE NORMAL MAST ASSEMBLY AT STEP 21

LIFT CYLINDER INSTALLATION - FOR MACHINE S/N- 0130005748

Lift Cylinder Mount Installation

1. Cylinder Mount 3. Mount Reinforcement Plate

2. Shim Stock 4. Mount Bolts/Washers (a)

Notes: (a) Apply Loctite #242 to threads.

(MACHINE S/N - 0130005748)

1. Mount Shoulder Screws 3. Upper Half of Cylinder Mount

2. Cylinder Attach Screw 4. Cylinder Valve Block

CONTINUE NORMAL MAST ASSEMBLY AT STEP 21

17. Slide the mount into mast section-1 and check for side to side clearance. Use mounting shims of equal

3121154 – JLG Lift – 2-27

Page 50

SECTION 2 - SERVICE PROCEDURES

12233

344

CONTINUE MAST SECTION-2 ASSEMBLY HERE

- ALL MACHINES

21. Assemble one of the narrow chains sets (#444) to the small chain equalizer anchor plate using the pins, washers and cotter keys. Set aside.

22. Locate the chain anchor block and slide it onto the hydraulic cylinder rod end sticking out the top of mast section 2.

23. Lay out the chain (#444) - anchor plate assembly with anchor plate end towards mast, (be certain floor

surface is clean and free of any metal chip or debris which may stick to lubricated chains or lay chains in a clean bucket).

24. Assemble the chain/anchor plate assembly and the chain anchor block to the cylinder rod end using the anchor plate/block attach pin and snap ring.

e. Slide the whole anchor block/cylinder assembly

with sheave pin, wheels and pin support bars into top of mast section-2.

f. Align the threaded holes in the attach bars on

each side of the mast and attach to top of mast section-2 using two (2) 3/8"-16UNC x 1/2" long socket head-countersunk-flathead cap screws each side. Coat threads with Loctite #171 and tighten.

26. Remove the cylinder mount cap - shoulder screws and apply Loctite #242 to the threads. Install the screws and torque to 85 ft. lbs.

27. Tighten the center lift cylinder mount screw, this screw keeps the cylinder assembly from rotating in the mount.

28. Slide mast section-2 back into section-1 until top and bottom ends are even.

Install Chain/Anchor Block to Top of Lift Cylinder

1. Attach Pin 4. Attach Pin - Snap Ring

2. Chain/Equalizer Assembly 5. Cylinder Rod (Extended)

3. Chain/Anchor Block

25. Assemble chain sheaves on chain assembly anchor block (attached to cylinder rod end) and attach to mast section-2, per the following steps;

a. Insert sheave pin through anchor block and cyl-

inder rod on cylinder rod end.

b. Load three 1" flat washers onto the sheave pin

on each side of the anchor block.

c. Place sheave wheels (for wide #544 chain) on

sheave pin, one each side of anchor block.

d. On the outside of each sheave wheel, place

2-28 – JLG Lift – 3121154

another 1" flatwasher, a roll pin (into the slot in each end of the pin), and then place a sheave pin support bar (rectangular plate with threaded holes on each side of pin bore hole).

1. Support Bar Screws(a) 4. Sheave Wheel Assy.

2. Pin Support Bars 5. Sheave Pin

3. Narrow Washer 6. Square Keys

Notes: (a) Apply Loctite #242 to threads.

Mast Section 2 - Chain/Anchor Block

(Sheave Wheel Assembly)

Page 51

MAST SECTION 3 - ASSEMBLY

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide pad channels.

29. Carefully slide mast section-3 into section-2 until ends are even.

30. Insert slide pads into the top end mast rails between section-2 and -3, (one on each side of the mast), with beveled surface facing inward towards section-

3. (Same as Figure 2-8.)

NOTE: Before fastening and shimming the slide pad on the

top left side of the mast, install a sequence cable bracket against the mast under the flat-washer.

31. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes in outside rail, on top of mast section-2 and into the slide pad inserts. Thread in enough to hold pad in place.

32. Shim per instructions in step 7, Mast Section 2 Assembly.

33. Insert slide pads into the bottom end mast rails between section-2 and -3, (one on each side of the mast), with beveled surface facing out towards section-2. (Same as Figure 2-7.)

34. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes on inside rail, on bottom end of mast section-3 and into the slide pad inserts. Thread in enough to hold pad in place.

35. Shim per instructions in step 7, Mast Section 2 Assembly.

36. Slide section-3 out the bottom of section-2 approximately one (1) foot.

SECTION 2 - SERVICE PROCEDURES

Mast Section 3 - Chain Anchor Bracket

(Bottom of Mast)

1. Chain Anchor Bracket 3. Anchor Bolts/Washers (a)

2. Mast Section 3

Notes: (a) Apply Loctite #242 to threads.

37. Locate one (1) of the chain (bottom) anchor brackets (one with threaded holes horizontally aligned to outside of bracket). Attach using outer set of holes in

bottom of mast section-3 with two (2) 1/4"-20UNC x 3/4" long bolts, place a flatwasher under head of each bolt.

38. Slide section-3 out the top of section-2 approximately one (1) foot.

39. Locate the remaining narrow chain set (#444) and attach them to the remaining triangular shaped anchor plate using the attach pins, flat washers and cotter keys.

40. Install the chain/anchor plate assembly into the top of mast section-3, using the remaining large pin and

Mast Section 3 - Chain/Anchor Plate Installation

(Mast Section-3 Shown Cut-away)

1. Chain/Anchor Plate Assy. 4. Pin Keeper

2. Anchor Pin 5. Keeper Screw (a)

3. Spacer

Notes: (a) Apply Loctite #242 to threads.

3121154 – JLG Lift – 2-29

Page 52

SECTION 2 - SERVICE PROCEDURES

122

pin keeper. Allow to hang out the top of mast section-3 for later assembly.

41. Insert the threaded the ends of chain assembly (attached to top of mast section-1), into the opening between mast section-2 and mast section-3. Slide the threaded ends through the holes in chain anchor bracket attached at the bottom of mast section-3. Loosely thread two (2) 3/8"-16UNC nuts onto stud threads on each chain and remove any slack in the chains. Chains will be adjusted later in assembly.

42. Assemble chain sheaves (for narrow chain assem- bly) to top of mast section-3 as follows;

a. Place four (4) of the 1" flat washers onto one of

the remaining sheave pins. Locate two (2) narrow chain sheave wheels and slide onto sheave pin on each side of the flat washers.

b. Slide two (2) short spacer tubes onto sheave

pin, one each end of sheave pin to outside of sheave wheels.

c. Place two (2) sheave pin support bars, one each

end of sheave pin onto outside of spacer tubes. Place a roll pin in the slots at each end of the sheave pins and align with the cutouts in the pin support bars.

d. Holding complete sheave wheel assembly, slide

assembly into top of mast section-3 and align threaded holes in sheave pin support bars with holes in mast rails.

e. Attach to top of mast section-3 using two (2) 3/

8"-16UNC x 1/2" long socket head-countersunkflathead cap screws, each side. Coat threads with Loctite #171 and tighten.

Mast Section 3 - Sheave Wheel Assembly

1. Support Bar Screws (a) 5. Narrow Washer

2. Pin Support Bars 6. Sheave Pin

3. Wide Spacers 7. Square Keys

4. Sheave Wheel Assys.

Notes: (a) Apply Loctite #242 to threads.

43. Slide mast section-3 back into section-2 until ends are even. Check to make sure chain assembly (wide chains) are seating properly in chain anchor block chain sheave wheels attached to mast section-2.

2-30 – JLG Lift – 3121154

Page 53

SECTION 2 - SERVICE PROCEDURES

MAST SECTION 4 - ASSEMBLY

44. Locate the remaining mast section-4 (platform mounting - mast section). Lay mast section on flat

stable surface.

45. Attach the remaining chain bottom anchor plate

(one with threaded holes aligned at the outside of bracket). Attach through set of holes in bottom of

mast section-3 with four (4) 1/4"-20UNC x 3/4" long bolts, place a flatwasher under head of each bolt.

NOTE: The platform mounting section slide pads, are

assembled differently than the slide pads for the other mast sections. Mast section-4 slide pads may need to be assembled/disassembled several times in order to determine the correct shim stock required for proper fit.

46. Complete the following steps to determine shim stock thickness required for section-4;

NOTE: Always use the an even amount of shim material

behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the section.

a. Use two shim pieces per slide pad, a thick one

and a thin one.

b. Start with a total thickness of approximately

.035" and .075" thick shim stock.

c. Attach shim stock and slide pads to both sides

of mast section-4 using five (5) 1/4"-20UNC x 11/4" long, hex head cap screws per side, with flatwasher under each bolt head. (Assemble

shim stock and slide pad to mast section rail with shim stock against rail and slide pad with beveled side out).

d. Carefully thread the slide pad mounting bolts

with flat washers through slide pads and shim stock into threads in mast section-4. Be certain there are no air gaps between shims, shim and mast or shim and slide pad when tightened.

g. When mast slide pads are shimmed properly,

there should be no side to side movement of slide pad in rail channel. Mast sections should be very snug in channels but still be able to slide in channel by hand.

47. Slide mast section-4 out even with top of section-4.

48. Insert threaded ends of chain assembly (attached to top of mast section-2) into the opening between mast section-4 and mast section-4. Slide the threaded ends through the holes in bottom chain anchor plate located on bottom of mast section-4. Loosely thread two (2) 3/8"-16UNC nuts onto stud threads on each chain. Chains will be adjusted later in assembly.

49. Slide mast section-4 back into mast section-3 until bottom ends of masts are even. Check to make sure chain set attached to top of section-3 is seating properly in cable sheave wheels attached to top of mast section-4. (Mast section-3 may need to be

restrained to keep it’s slide pads from pushing out the bottom of mast sections-2).

50. At bottom of mast assembly, thread all chain adjusting nuts on threaded ends until they are snug against the bottom anchor plates and all slack is removed from chains. Check that chains are seated in their sheave wheels at top of mast assembly.

51. Do not assemble the mini covers to the top of mast sections until the mast chains have been adjusted properly.

52. Attach the lanyard attach assembly to the side of mast section 4.

53. Attach the sequencing cables and hardware to the sides of the mast assembly.

54. Install the mast chain guard to the top mast section

NOTE: Mast section-4 into section-3 fit should be very snug

but still be able to be pushed together by hand. If too tight, remove section-4, disassemble slide pad and reduce thickness of shim stock.

e. Begin sliding top of mast section-4 with closed

rail down engaging the slide pads into slide pad channels at bottom of mast section-4’s open rail. Continue to push section-4 into section-3 until BOTTOM ends of mast sections are even.

f. Check mast section for side play. If play exists

use thicker shims dividing thickness equally between both sides of mast.

3121154 – JLG Lift – 2-31

Page 54

SECTION 2 - SERVICE PROCEDURES

Mast Section 4 - Bottom End Components

(Chain Anchor Bracket and Slide Pad Installation)

1. Chain Anchor Bracket 2. Anchor Bracket Bolts/Washers (a) 3. Slide Pad 4. Long Slide Pad 5. Slide Pad Bolts/Washers (a)

Notes: (a) Apply Loctite #242 to threads.

Sequence Cable Bracket Installation

(Bottom End)

Lanyard Attach Installation (OPTION)

(Installed with OPTIONAL Gullwing Platform ONLY)

The mast assembly is now ready to install on the machines base frame.

2-32 – JLG Lift – 3121154

Page 55

SECTION 2 - SERVICE PROCEDURES

Mast To Base Frame Installation

1. Using an overhead crane or suitable lifting device capable of supporting the weight of mast assembly, attach a sling strap around the mast assembly at the AC Junction Box/Ground Control Station support bracket.

NOTE: When lowering mast assembly into the base frame

carefully guide the manual descent valve assembly into the recess at the rear of the base frame to avoid damage to the valve.

2. Carefully lift the mast assembly and lower into the base frame until the four (4) mounting holes on bottom rear of mast align with holes in the base frame mast support at the rear of the base frame.

3. Attach mast to base using four (4) 3/8"-16UNC x 1" long hex head bolts, locknuts and flatwashers,

(place a flatwasher under bolt head (on outside of frame) and under the nut, mount with nuts on the inside of base frame on mast rail).

4. Swing the two (2) mast support braces up attached to sides of base frame support brackets.

NOTE: Do not completely tighten the mast side support

bracket bolts until mast is checked for vertical alignment (plumb).

5. Attach support braces to the mast support bracket, (bolted to mast), using 3/8"-16UNC x 2-3/4" long hex head bolts, nuts and flatwashers. (Place a flatwasher

under bolt head and nut and mount with nuts on inside of bracket).

6. Using a 4 ft. level, ensure mast is set to vertical (plumb) on the base frame.

7. When mast is vertical (plumb), secure mast side supports to base frame bracket and mast support bracket. Using 4 ft. level again check that mast is vertical (plumb) on base frame. If not vertical loosen side brace bolts slightly, plumb mast, retighten side brace bolts.

8. Reattach platform assembly.

9. Run mast assembly up and down a few times checking chain and sequence cable adjustment.

Mast installation should now be complete.

3121154 – JLG Lift – 2-33

Page 56

SECTION 2 - SERVICE PROCEDURES

Mast Chains Adjustment - 15BD

The intention of this procedure is to assure equal load distribution between the individual chains of a mast section chain set. Also to step each front mast section up approximately 1/4 in. (6.5mm) from the section behind it to allow clearance for the individual mast section covers.

Adjust using the following procedure;

1. With mast retracted, step into the platform and bounce your weight up and down a few times to be certain platform is at the bottom of travel. Be certain all chain sets are seated in their sheaves properly at the top of each mast section.

2. Then with no load in the platform check the side profile of the top of the mast for the amount of adjustment necessary to obtain the 1/4 in. (6.5mm) step for mast sections-3 and up. (See Figure 2-9.)

NOTE: Mast section-1 is fixed to the base and mast section-

2 is attached to the lift cylinder, these sections require no adjustment.

3. Adjust one mast section at a time starting from the back (section-3, section-4, etc.) of the mast and work forward. (i.e.. if three is OK, then jump to four, etc.)

4. To adjust, elevate the platform until the chain anchor adjust nuts are accessible at the front and bottom of each mast section.

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

5. Start with the mast section which needs adjustment and loosen the bottom (jam) nut on each chain.

6. Tighten (to raise mast section), or loosen (to lower mast section) the adjusting nut against the anchor plate on each chain. Adjust the nut the amount required to raise or lower the top of the mast section to match the side profile shown in Figure 2-9. when the mast is retracted. Be certain each chain pair is adjusted to equal tension. (The threaded end of the

chain will need to be restrained while tightening the adjust nut to keep the chain from twisting.)

7. Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 2-9.

8. Repeat steps (1) through (7) for remaining mast sections. ENSURE THAT ALL CHAIN PAIRS HAVE EQUAL TENSION.

9. Once mast section adjustment is completed, apply loctite #242 to the threads under the (jam) nuts that were loosened. Then re-tighten the loosened (jam) nuts until tight against the top (adjust) nut. Chain should have slight tension but should not be taut.

2-34 – JLG Lift – 3121154

Page 57

SECTION 2 - SERVICE PROCEDURES

SECTION- 1

FIXED

TO BASE

SEQUENCE CABLE

ADJUST NUT

SECTI ON-2

EXTENDED BY

CYLINDER

SECTION- 4

(PLATFORM

HEADER SECTION)

EXTENDED BY

CHAIN

ANCHOR PLATE

ADJUST NUT

JAM NUT

THREADED CHAIN END

SECTI ON-3

EXTENDED BY

CHAIN

STEP APPROXI MATELY

1/4 in. (6.5mm)

MAST SIDE PROFILE

MAST CHAIN ADJUSTERS

Not e: When

pply Loctite #242 to

the threads under the

jam nut.

chain adjust ment is complete, before tightening the jam nut

against t he adjust nut,

Figure 2-9. Mast Chain/Sequence Cable Adjustment Components. (15BD)

3121154 – JLG Lift – 2-35

Page 58

SECTION 2 - SERVICE PROCEDURES

TOP

(REFERS TO TOP END

OF MAST SECTI ON -

END WITH COVER

AND SHE AVE WHEE LS

ATTA CHED )

BOTTOM

(REFERS TO BOTTOM END

OF MAST SECT ION -

END WHICH SETS AT

MACH I N E S BAS E F RA ME )

CLOSED RAI L

(REFERS TO CLOSED RAIL BACK OF MAST SE CTION)

OPEN RAI L

(REFERS TO OPEN RAIL

FRONTOFMASTSECTION)

2.10 19BD - MAST ASSEMBLY AND DISASSEMBLY PROCEDURE

(See Figure 2-10., Figure 2-11. and Figure 2-12.)

19BD - Mast Disassembly Procedure

1. After the platform and other hardware have been removed from the mast, and mast has been removed from machine, lay mast assembly down with the shortest mast section-5 on TOP and facing up.

2. Remove the sequencing retract cables from sides of mast assembly, the chain guard, and the mini covers from the top of each mast section.

MAST SECTION - 5 - REMOVAL

3. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOTTOM end of mast section-5 (short, platform mounting section). Push threaded ends of chain through anchor plate

4. At TOP of mast section-5, pull chains out and allow to hang loose.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad channels.

5. Carefully slide short mast section-5 out BOTTOM of mast section-4 rails. Disassemble slide pads, shims and cable anchor plate from mast section-5, if necessary.

MAST SECTION - 4 - REMOVAL

6. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOTTOM end of mast section-4. Push threaded ends of cable through anchor plate.

7. At TOP of mast section-4, pull chains out and allow to hang loose, (be certain floor surface is clean and

free of any metal chips or debris which may stick to lubricated chains or lay chains in a clean bucket).

8. Slide mast section-4 out TOP of mast section-3 far enough to allow access to the chain sheave wheel assembly.

9. Remove countersunk flathead screws securing chain sheave wheel assembly attach bars on both side rails at TOP of mast section-4 and remove sheave wheel assembly.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad channels.

10. Carefully slide mast section-4 out BOTTOM of section-3. Remove slide pads, shims and chain anchor plate, if necessary.

2-36 – JLG Lift – 3121154

Figure 2-10. Mast Section - Assembly/Disassembly Reference.

Page 59

SECTION 2 - SERVICE PROCEDURES

MAST SECTION - 3 - REMOVAL

11. Remove chain adjust nuts from threaded ends of chain attached to the chain anchor plate on BOTTOM end of mast section-3. Push threaded ends of chain through anchor plate.

12. At top of mast section-3, pull chains out and allow to hang loose.

13. Slide mast section-3 out TOP of mast section-2 far enough to allow access to the chain sheave wheel assembly.

14. Remove countersunk-flathead screws securing chain sheave wheel assembly attach bars on both side rails at top of mast section-6 and remove sheave wheel assembly.

15. While mast section-3 is still extended from section-2 remove the bolts attaching the two (2) chain assembly anchor eyelets to the TOP of mast section-3. Remove chains.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad channels.

16. Carefully slide mast section-3 out BOTTOM of section-2. Remove slide pads, shims and chain anchor plate, if necessary.

MAST SECTION - 2 - REMOVAL

17. Slide mast section-2 out TOP of mast section-1 far enough to allow access to the chain anchor block/ sheave wheel assembly.

18. Remove countersunk-flathead screws securing chain anchor block/sheave wheel assembly attach bars on both side rails at TOP of mast section-2.

19. Slide the chain anchor block/sheave wheel assembly and hydraulic cylinder out the TOP of mast section-2 far enough to allow removal of the sheave wheel attach bars, sheave wheels and sheave pin from the chain assembly anchor block.

20. Remove the snap ring from the pin attaching the chain anchor block and chain anchor plate assembly to the hydraulic cylinder rod end, then remove the pin. Lay the chain anchor block and chain assembly to side.

22. Carefully slide mast section-2 out BOTTOM of section-1. Remove slide pads and shims, if necessary.

MAST SECTION - 1 - DISASSEMBLY

23. Slide the TOP of the remaining mast section-1 out over edge of work surface and remove the bolts attaching the anchor blocks of the two (2) chain assemblies to mast section-1. Remove chain assemblies from mast and lay aside.

24. Remove the hydraulic lift cylinder from it’s mount attached to mast section-1, if necessary.

25. Remove slide pads and shims from mast section-1, is necessary.

Mast disassembly should now be complete.

21. Remove the hydraulic cylinder through the BOTTOM of mast section-2, be careful not to nick or score cylinder rod surface while removing.

NOTE: When sliding mast sections apart, be careful not to

scratch or score the anodized finish in the slide pad channels.

3121154 – JLG Lift – 2-37

Page 60

SECTION 2 - SERVICE PROCEDURES

MAST

SECTION-1

MAST

SECTION-2

MAST

SECTION-3

MAST

SECTION-4

MAST

SECTION-5

LIFT

CYLINDER

Apply Krytox Lubricant to the INSIDE front and rear slide pad wear surfaces on ALL mast sections before assembly.

NEW DESIGN LIFT CYLINDER

AND MOUNT

ORIGINAL

DESIGN

LIFT

CYLINDER

AND

MOUNT

2-38 – JLG Lift – 3121154

Figure 2-11. 19BD Mast Assembly Components.

Page 61

SECTION 2 - SERVICE PROCEDURES

Figure 2-12. 19BD Mast Chain Routing Diagram.

3121154 – JLG Lift – 2-39

Page 62

SECTION 2 - SERVICE PROCEDURES

19BD - Mast Assembly

(See Figure 2-11. and Figure 2-12.)

MAST SECTION - 1 - ASSEMBLY

NOTE: Apply Krytox lubricant (JLG P/N-3020041) to the

INSIDE front and rear wear surfaces of ALL slide pad rails on each mast section just before assembly. Spray on at room temperature, uniformly, from approximately 8 to 10 inches away from surface.

1. Place mast section-1, rail (open) side up (See Table 2-10.) on a clean, flat surface (preferably a table or work bench capable of supporting the weight of the entire mast assembly). Slide mast out over end of

work surface far enough to allow access to the chain anchor attach holes at top of mast.

2. Locate the two (2) single (wide) chain assemblies. Lay out each chain assembly with anchor block end towards mast, and notched end of block down, (be

certain floor surface is clean and free of any metal chips or debris which may stick to lubricated chains or lay chains in a clean bucket).

3. Insert the block anchor end (with notched end on bottom) into the top of mast section-1 and secure using two (2) 3/8"-16UNC x 2-1/2" long hex head bolts, flatwashers and nuts for each attach block. Place a flatwasher under bolt head and nut.

MAST SECTION - 2 - ASSEMBLY

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide pad channels.

NOTE: Apply Krytox lubricant (JLG P/N-3020041) to the

INSIDE front and rear wear surfaces of ALL slide pad rails on each mast section just before assembly. Spray on at room temperature, uniformly, from approximately 8 to 10 inches away from surface.

4. Locate mast section-2, carefully slide mast section-2 closed rail into section-1 open rail. Slide sections together until ends are even.

5. Insert slide pads into the slide pad channels at bottom end of mast between section-1 and -2, (one on each side of the mast), with beveled surface facing out towards section-1.

7. Shim slide pads using the following steps:

NOTE: Always use the an even amount of shim material

behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the mast section.

a. Start with a .036" thick shim and a .075" thick

shim per side at each slide pad.

b. Slide shims into place between slide pad and

mast rail. Tighten the slide pad mounting bolts, be sure there are no air gaps between shims, shim and mast or shim and slide pad when tightened.

c. Check mast section for side play. If play exists

add .015" shims dividing the thickness equally between both sides of mast. Insert shims until the shims cannot be inserted halfway by hand with the mast pulled to the opposite side.

d. When mast slide pads are shimmed properly,

there should be no side to side movement of slide pad in rail channel. Mast sections should be snug in channels but still be able to slide in channel by hand.

8. Insert slide pads into the slide pad channels (top of

mast) between section-1 and -2, (one on each side of the mast), with beveled surface facing in towards

section-2.

NOTE: Before fastening and shimming the slide pad on the

top left side of the mast, install a sequence cable bracket against the mast under the flatwasher.

10. Shim per instructions in step 7, Mast Section 2 Assembly.

NOTE: If hydraulic cylinder needs to be extended, the pro-

11. Locate the hydraulic lift cylinder, slide the lift cylinder into the closed rail side of mast section-2 with rod end to top and port end to bottom of mast. Cylinder should extend out of mast on both ends. Return tube should be on right side when facing bottom of mast assembly.

12. Original Design Cylinder Mount: Install the cylinder mount and cylinder mounting plates into the bottom of the mast section-1. Shim to eliminate any

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SECTION 2 - SERVICE PROCEDURES

side clearance to prevent any strain on the sides of the mast when the bolts are tightened.

13. New Design Cylinder Mount: Install the cylinder mounting plates at the bottom of the mast section-1. Mount plates two each side, using the the (2) two long pass through bolts and nuts, apply Loctite #242 to the bolt threads before tightening nuts.

14. Original Design Cylinder: Clamp the cylinder in the mounting journal of the cylinder mount. Apply Loctite #242 to the journal bolt threads and torque to 85 ft. lbs. Align the hole in the mounting journal with the hole in the cylinder and Install the (1) 5/16" bolt.

15. New Design Cylinder: Install the mounting pin through the side mounting brackets and the cylinder valve body and through the mounting brackets on the other side of the mast. Install the snap rings to each end of the mounting pin.

16. Slide the chain anchor block onto the cylinder rod end at the top of the lift cylinder. Locate the narrow chain assembly set (single anchor plate with two narrow chains). Lay out chain assembly with anchor plate end towards mast, (be certain floor surface is

clean and free of any metal chip or debris which may stick to lubricated chains or lay chains in a clean bucket).

17. Align the holes in the cylinder rod, the chain anchor block and chain anchor plate and slide the attach pin through all, secure pin with snap ring.

18. Slide mast section-2 out of mast section-1 approximately one foot.

19. Assemble chain sheaves on chain assembly anchor block (attached to cylinder rod end) and attach to mast section-2 using following steps;

a. Insert sheave pin through anchor block on cylin-

der rod end.

b. Place sheave wheels (for wide chain) on sheave

pin, one each side of anchor block.

c. On outside of each sheave wheel, place a

sheave pin attach bar, (rectangular plate with threaded holes on each side of pin bore hole).

d. Slide the whole anchor block assembly with

sheave pin, wheels and pin attach bars into top of mast section-2. (Position anchor block with narrow chains facing up).

e. Attach to top of mast section-2 using two (2) 3/

8"-16UNC x 1/2" long socket head-countersunkflathead cap screws each side. Coat threads with Loctite #171 and tighten.

20. Slide mast section-2 back into section-1 until end are even.

MAST SECTION - 3 - ASSEMBLY

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide pad channels.

NOTE: Apply Krytox lubricant (JLG P/N-3020041) to the

INSIDE front and rear wear surfaces of ALL slide pad rails on each mast section just before assembly. Spray on at room temperature, uniformly, from approximately 8 to 10 inches away from surface.

21. Locate mast section-3, carefully slide section-3 closed rail into section-2 open rail. Slide sections together until ends are even.

22. Locate one (1) of the chain bottom anchor plates

(one with threaded holes horizontally aligned to outside of bracket). Attach using outer set of holes in

bottom of mast section-3 with two (2) 1/4"-20UNC x 3/4" long bolts, place a flatwasher under head of each bolt.

23. Slide mast section-3, approximately two feet out of the top of mast section-2.

24. Install the triangular shaped chain upper anchor plate to the top of mast section-3, using the remaining large pin and pin keeper.

25. Locate the remaining narrow chain set and attach them to the anchor plate just attached to the top of mast section-3 in the previous step. Allow to hang out the top of mast section-3 till later.

26. Insert the threaded the ends of chain assembly (attached to top of mast section-1), into the opening between mast section-2 and mast section-3. Slide the threaded ends through the holes in bottom anchor plate attached to bottom of mast section-3. Loosely thread two (2) 3/8"-16UNC nuts onto stud threads on each chain. Chains will be adjusted later in assembly.

27. Assemble chain sheaves (for narrow chain assem- bly) to top of mast section-3 as follows;

a. Locate the two (2) narrow chain sheave wheels

and slide onto sheave pin.

b. Slide two (2) short spacer tubes onto sheave

pin, one each end of sheave pin to outside of sheave wheels.

c. Place two (2) sheave pin attach bars, one each

end of sheave pin to outside of space tubes.

d. Holding complete sheave wheel assembly, slide

assembly into top of mast section-3 and align threaded holes in sheave pin attach bars with holes in mast rails.

e. Attach to top of mast section-3 using two (2) 3/

8"-16UNC x 1/2" long socket head-countersunk-

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SECTION 2 - SERVICE PROCEDURES

flathead cap screws, each side. Coat threads with Loctite #171 and tighten.

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide pad channels.

28. Carefully slide mast section-3 into section-2 until ends are even. Check to make sure chain assembly (wide chains) are seating properly in chain anchor block chain sheave wheels attached to mast section-2.

29. Insert slide pads into the top end mast rails between section-2 and -3, (one on each side of the mast), with beveled surface facing inward towards section-

NOTE: Before fastening and shimming the slide pad on the

top left side of the mast, install a sequence cable bracket against the mast under the flatwasher.

30. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes in outside rail, on top of mast section-2 and into the slide pad inserts. Thread in enough to hold pad in place.

31. Shim per instructions in step 7, Mast Section 2 Assembly.

32. Insert slide pads into the bottom end mast rails between section-2 and -3, (one on each side of the mast), with beveled surface facing out towards section-2.

33. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes on inside rail, on bottom end of mast section-3 and into the slide pad inserts. Thread in enough to hold pad in place.

34. Shim per instructions in step 7, Mast Section 2 Assembly.

MAST SECTION - 4 - ASSEMBLY

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide pad channels.

NOTE: Apply Krytox lubricant (JLG P/N-3020041) to the

INSIDE front and rear wear surfaces of ALL slide pad rails on each mast section just before assembly. Spray on at room temperature, uniformly, from approximately 8 to 10 inches away from surface.

35. Locate mast section-4, carefully slide section-3 closed rail into section-3 open rail. Slide sections together until ends are even.

36. Locate one (1) of the chain bottom anchor plates

(one with threaded holes horizontally aligned to center of bracket). Attach using holes in bottom of mast

section-4 with three (3) 1/4"-20UNC x 3/4" long bolts, place a flatwasher under head of each bolt.

37. Slide mast section-4, approximately two feet out of the top of mast section-3.

38. Insert threaded ends of chain assembly (attached to top of mast section-2), into the opening between mast section-3 and mast section-4. Slide the threaded ends through the holes in bottom anchor plate attached to bottom of mast section-4. Loosely thread two (2) 3/8"-16UNC nuts onto stud threads on each chain. Chains will be adjusted later in assembly.

39. Assemble chain sheaves (for narrow chain assem- bly) to top of mast section-4 as follows;

a. Locate the two (2) narrow chain sheave wheels

and slide onto sheave pin.

b. Slide two (2) short spacer tubes onto sheave

pin, one each end of sheave pin to outside of sheave wheels.

c. Place two (2) sheave pin attach bars, one each

end of sheave pin to outside of space tubes.

d. Holding complete sheave wheel assembly, slide

assembly into top of mast section-4 and align threaded holes in sheave pin attach bars with holes in mast rails.

e. Attach to top of mast section-4 using two (2) 3/

8"-16UNC x 1/2" long socket head-countersunkflathead cap screws, each side. Coat threads with Loctite #171 and tighten.

NOTE: When sliding mast sections together, be careful not

to scratch or score the anodized finish in the slide pad channels.

40. Carefully slide mast section-4 into section-3 until ends are even. Check to make sure chain assembly (narrow chains) are seating properly in chain anchor block chain sheave wheels attached to mast section-3.

41. Insert slide pads into the top end mast rails between section-3 and -4, (one on each side of the mast), with beveled surface facing inward towards section-

NOTE: Before fastening and shimming the slide pad on the

top left side of the mast, install a sequence cable bracket against the mast under the flatwasher.

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SECTION 2 - SERVICE PROCEDURES

42. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes in outside rail on top of mast section-3 and into the slide pad inserts. Thread in enough to hold pad in place.

43. Shim per instructions in step 7, Mast Section 2 Assembly.

44. Insert slide pads into the bottom end mast rails between section-3 and -4, (one on each side of the mast), with beveled surface facing out towards section-3.

45. Thread slide pad attaching bolts, two (2) 1/4"20UNC x 3/8" long hex head bolts, place a flat washer under head of each bolt, through holes on inside rail on bottom end of mast section-4 and into the slide pad inserts. Thread in enough to hold pad in place.

46. Shim per instructions in step 7, Mast Section 2 Assembly.

MAST SECTION - 5 - ASSEMBLY

NOTE: Apply Krytox lubricant (JLG P/N-3020041) to the

INSIDE front and rear wear surfaces of ALL slide pad rails on each mast section just before assembly. Spray on at room temperature, uniformly, from approximately 8 to 10 inches away from surface.

47. Locate the remaing mast section-5 (platform mounting - mast section). Lay mast section on flat stable

surface.

48. Attach the remaining chain bottom anchor plate

(one with threaded holes aligned at the outside of bracket). Attach through set of holes in bottom of

mast section-5 with four (4) 1/4"-20UNC x 3/4" long bolts, place a flatwasher under head of each bolt.

NOTE: The platform mounting section slide pads, are

assembled differently than the slide pads for the other mast sections. Mast section-5 slide pads may need to be assembled/disassembled several times in order to determine the correct shim stock required for proper fit.

49. Complete the following steps to determine shim stock thickness required for section-5;

NOTE: Always use the an even amount of shim material

behind slide pads on both sides of the mast rails. This will keep mast sections centered in rail channels and prevent any distortion of the section.

a. Use two shim pieces per slide pad, a thick one

and a thin one.

b. Start with a total thickness of approximately

.035" and .075" thick shim stock.

c. Attach shim stock and slide pads to both sides

of mast section-5 using five (5) 1/4"-20UNC x 11/4" long, hex head cap screws per side, with flatwasher under each bolt head. (Assemble

shim stock and slide pad to mast section rail with shim stock against rail and slide pad with beveled side out).

d. Carefully thread the slide pad mounting bolts

with flatwashers through slide pads and shim stock into threads in mast section-5. Be certain there are no air gaps between shims, shim and mast or shim and slide pad when tightened.

NOTE: Mast section-5 into section-4 fit should be very snug

but still be able to be pushed together by hand. If too tight, remove section-5, disassemble slide pad and reduce thickness of shim stock.

e. Begin sliding top of mast section-5 with closed

rail down engaging the slide pads into slide pad channels at bottom of mast section-4’s open rail. Continue to push section-5 into section-4 until BOTTOM ends of mast sections are even.

f. Check mast section for side play. If play exists

use thicker shims dividing thickness equally between both sides of mast.

g. When mast slide pads are shimmed properly,

there should be no side to side movement of slide pad in rail channel. Mast sections should be very snug in channels but still be able to slide in channel by hand.

50. Slide mast section-5 out even with top of section-4.

51. Insert threaded ends of chain assembly (attached to top of mast section-3) into the opening between mast section-4 and mast section-5. Slide the threaded ends through the holes in bottom chain anchor plate located on bottom of mast section-5. Loosely thread two (2) 3/8"-16UNC nuts onto stud threads on each chain. Chains will be adjusted later in assembly.

52. Slide mast section-5 back into mast section-4 until bottom ends of masts are even. Check to make sure chain set attached to top of section-3 is seating properly in cable sheave wheels attached to top of mast section-4. (Mast section-3 may need to be

restrained to keep it’s slide pads from pushing out the bottom of mast sections-2).

53. Adjust top and bottom ends of mast sections so they are all even with each other. At bottom of mast assembly, thread all chain adjusting nuts on threaded ends until they are snug against the bottom anchor plates and all slack is removed from

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SECTION 2 - SERVICE PROCEDURES

chains. Check that chains are seated in their sheave wheels at top of mast assembly.

54. Assemble the mini covers to the top of each mast section and the sequencing cables and hardware to the side of the mast assembly.

Mast assembly should now be complete.

Mast To Base Frame Installation

1. Using an overhead crane or suitable lifting device capable of supporting the weight of base frame, attach a sling strap or chain to the front crossmember of the base frame, raise base frame.

2. Extend hydraulic cylinder out from bottom of mast assembly approximately one (1) foot. (Caps on

extend and return ports will need to be removed to extend cylinder. Catch any hydraulic fluid expelled from return port in a container to prevent spillage onto work area).

3. Bring base frame into position in front of mast assembly, (base frame and mast assembly must be held at 90° angle to each other).

4. Slide port end of hydraulic cylinder through hole in base frame cylinder mounting channel. (Return port

(tube side) of cylinder must be on right side facing bottom of base and mast).

5. Align threaded hole in side of hydraulic cylinder head with hole in tab on bottom side of cylinder mounting channel. Secure hydraulic cylinder to cylinder mounting channel tab using a 5/16"-18UNC x 5/8" long hex head bolt and flat washer.

6. Carefully push mast assembly and base assembly together until the four (4) holes on bottom rear of mast align with holes in the base frame mast support crossmember.

7. Attach mast to base using four (4) 3/8"-16UNC x 1" long hex head bolts, locknuts and flatwashers,

(place a flatwasher under bolt head and nut and mount with nuts on inside of frame).

8. Locate the two (2) mast support braces, attach to sides of base frame using a 3/8"-16UNC x 1" long hex head bolt, nut and flatwashers each brace,

(place a flatwasher under bolt head and nut and mount with nuts on inside of frame. Use access hole in bottom of frame to attach nut inside frame).

9. Before setting machine upright on base, install a short 90° elbow fitting, flow control valve and another short 90° elbow fitting on the end of the flow control valve in the extend (left) port on bottom of hydraulic cylinder. Install a long 90° elbow fitting on return (right) port. Use sealant tape on fitting threads. Cap ports until hydraulic lines are installed.

10. Carefully set machine in an upright position on its base frame wheels.

11. Locate the mast support bracket. Attach mast support bracket to mounting holes halfway up back of mast using four (4) 3/8"-16UNC x 2-3/4" long hex head bolts, locknuts and flatwashers. (Place a flat-

washer under bolt head and nut and mount with nuts on inside of frame).

12. Using a 4 ft. level, ensure mast is set to vertical (plumb) on the base frame.

13. When mast is vertical (plumb), attach support braces, (bolted to base), to the mast support bracket, (bolted to mast), using 3/8"-16UNC x 2-3/4" long hex head bolts, nuts and flatwashers. (Place a

flatwasher under bolt head and nut and mount with nuts on inside of bracket).

14. After securing mast to base frame, using 4 ft. level again check that mast is vertical (plumb) on base frame.

Mast installation should now be complete.

Mast Chains Adjustment - 19BD

(See Figure 2-9.)

The intention of this procedure is to assure equal load distribution between the individual chains of a mast section chain set. Also to step each front mast section up approximately 1/4 in. (7mm) from the section behind it to allow clearance for the individual mast section covers.

Adjust using the following procedure;

2. Then with no load in the platform check the side profile of the top of the mast for the amount of adjustment necessary to obtain the 1/4 in. (7mm) step for mast sections-3 and up. (See Figure 2-9.)

NOTE: Mast section-1 is fixed to the base and mast section-

2 is attached to the lift cylinder, these sections require no adjustment.

3. Adjust one mast section at a time starting from the back (section-3, section-4, etc.) of the mast and work forward. (i.e.. if three is OK, then jump to four, etc.)

4. To adjust, elevate the platform until the chain anchor adjust nuts are accessible at the front and bottom of each mast section.

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SECTION 2 - SERVICE PROCEDURES

SECTION- 1

FIXED

TO BASE

SEQUENCE CABLE

ADJUST NUT

MAS T RET RACT

SEQUENCE CABLES

CHECK IF OVERALL HEIGHT

OF MACHINE FROM

FLOOR TO TOP OF MAST

IS WITHIN SPECIFICATION

SECTION- 2

EXTENDED BY

CYLINDER

SECTI ON-5

(PLATFORM

HEADER SECT ION)

EXTENDED BY

CHAIN

ANCHOR PLATE

ADJUST NUT

JAM NUT

THREADED

CHAIN E ND

(STUD)

SECTION- 4

EXTENDED BY

CHAIN

SECTION- 3

EXTENDED BY

CHAIN

STEP APPROXIMATELY

1/4 in. (7mm)

MAST SIDE PROFILE

MAST CHAIN ADJUSTERS

Note:

Whe n

pply Loctit e #242 t o the

threa ds under the j am nut.

chain adjust ment

is complete, before tightening

the jam nut against the adjust

nut, a

Figure 2-13. Mast Chain/Sequence Cable Adjustment Components. (19BD)

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

5. Start with the mast section which needs adjustment and loosen the bottom (jam) nut on each chain.

3121154 – JLG Lift – 2-45

NOTE: It is more important that the (threaded ends) studs

to match the side profile shown in Figure 2-9. when the mast is retracted.

protruding through the anchor plates are equal side to side than it is that the tension in the chains is equal. The chain equalizer plate will always assure equal tension, but if the adjustment isn’t equal as described, the chains may tend to pull to one side or the other. The threaded end (stud) of the chain may need to be restrained while tightening the adjust nut to keep the chain from twisting.

Page 68

SECTION 2 - SERVICE PROCEDURES

7. Retract the mast all the way and check if the top of the mast sections appear as shown in Figure 2-9.

8. Repeat steps (1) through (7) for remaining mast sections.

9. Run mast through several cycles to verify chain adjustments and ensure no interference exists between chain anchor brackets and mast.

10. Once mast section adjustment is completed, apply loctite #242 to the threads under the (jam) nuts that were loosened. Then re-tighten the loosened (jam) nuts until tight against the top (adjust) nut. Chain should have slight tension but should not be taut.

2.11 SEQUENCING CABLE ADJUSTMENT

(See Figure 2-9. or Figure 2-13.)

1. Retract mast completely, and check each sequencing cable on the outside of masts for excessive slack. Adjust only to remove slack from cable.

2. To adjust, tighten the locking nut on the upper end of the cable (on top of the spring at the sequence

cable bracket located at the top and side of the mast). Adjust enough to remove excessive slack

from the sequencing cable. Normally the springs should not be compressed more than 25% after adjusting.

NOTE: If slack can not be adjusted out of the cable, then the

cable has stretched and must be replaced. See Section 2.12, Sequence Cable replacement kit, for cable replacement procedure.

3. Run mast through several cycles to verify cable adjustments are correct.

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SECTION 2 - SERVICE PROCEDURES

2.12 SEQUENCE CABLE REPLACEMENT KIT

A sequence cable replacement kit is available from the JLG Parts Department to service broken or worn sequence cables. This kit consists of a replacement sequence cable with the threaded (top) end attached same as the top end of the factory cable. Also included is a clamp (drum/socket type) to secure the bottom end of the cable. Use the following procedure to install the replacement cable and clamp kit.

Remove Old Cable

1. Remove the locking nut from the threaded end of the cable at the top of the mast and then remove the spring cap, spring, and spacer washers if installed.

2. Slide the threaded top end out of the upper anchor bracket, then at the bottom end pull the cable out though the sheave pulley/anchor bracket until it is completely clear of the machine.

Replacement Cable Installation

1. Be certain the mast is completely retacted and at the bottom of travel. Check the mast "Side Profile" at the top of the mast as shown in Figure 2-9., adjust mast sections to proper height if necessary.

2. To determine where the clamp will be installed at the bottom of the replacement cable, temporarily assemble the new replacement cable to the top cable anchor bracket on the mast using the washers, spring, spring cap and lock nut previously disassembled. Thread the lock nut on until approximately 1/8 in. (3mm) of threads are exposed.

3. At the bottom of the mast, thread the loose end of the replacement cable through the proper sheave pulley and through the hole in the sheave pully/ anchor bracket on the mast section ahead of the sheave pulley.

4. Grasp the cable and pull on the cable until the spring at the top of the cable is slightly compressed. Use a black marker to mark the cable on the top side of the sheave pully/anchor bracket. This will determine where the clamp (drum/socket) sleeve will be positioned on the cable.

Clamp Installation (Drum/Socket Type)

THE MANUFACTURER OF THE DRUM/SOCKET CLAMP RECOMMENDS THE USE OF THEIR CABLE CLAMP ASSEMBLY KIT (JLG P/N - 7023275) TO ASSEMBLE THE CLAMP TO THE WIRE ROPE. THE KIT CONSISTS OF VISE JAWS TO HOLD THE WIRE ROPE IN A VISE PROPERLY WITHOUT DAMAGING ANY ROPE STRANDS AND A PLUG DRIVER TO DRIVE THE PLUG INTO THE CENTER OF THE WIRE ROPE AND IS ALSO USED TO FORM THE STRANDS OF THE ROPE DURING ASSEMBLY.

NOTE: The tools in the clamp assembly kit may be frabri-

cated if necessary. The vise clamp consists of vise jaws with a hole drilled 1/32 in. smaller than the diameter of the wire rope you are working with (i.e. 1/8 in. rope - 3/32 in. hole.) The plug driver is a metal tube with a hole in the bottom to allow the strands of the wire rope to be shaped after the plug has been tapped into the center of the wire rope.

1. Using the recommended vise jaws, clamp the wire rope into a vise with the bottom edge of the black mark made on the wire rope resting just above the vise jaws.

2. Twist the sleeve from the clamp kit onto the rope until it is flat against the vise jaws at the mark made made on the wire rope.

DO NOT CUT THE CABLE AT THE MARKED POINT ON THE CABLE THIS IS ONLY USED AS A REFERENCE FOR POSITIONING THE CABLE SLEEVE WHICH WILL REST AGAINST THE ANCHOR BRACKET ONCE INSTALLED.

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SECTION 2 - SERVICE PROCEDURES

3. Use a suitable tool and cut the cable as shown in the illustration following. For 1/8 in. cable the recommended length is 5/8 in. past the end of the sleeve.

4. Unlay the cable strands by gently forcing a screwdriver between the outer strands to unlay the cable. When done properly the outer strands will form a symmetrical basket. Do not straighten out the spiral lay of the strands, unlay any wires that make up the strand, or allow the strands to cross each other inside the sleeve.

6. Reclamp the assembly in the vise on the flats of the sleeve. Using the plug driver, a metal tube or pliers, bend the outer strands toward the center strands enough that the socket can be slipped over all the strands.

NOTE: When assembling stainless steel parts all threads

must be coated with a dry lubricant or an anti-sieze lubricant to prevent seizing.

7. Coat the threads of the socket and sleeve with lubricant and install the socket by twisting it over the strands of the cable and engage the threads of the sleeve with the socket. Tighten until four threads or fewer are visible. If more than four threads are visible, proof load the cable and retighten the socket fitting. (There is no specific requirement for torque.)

5. Install the plug supplied with the kit by placing the plug in the center of the strands starting with the small tapered end of the plug. Use a metal tube (plug driver) and hammer to drive the plug into the sleeve while assuring that the strands are spaced somewhat equally around the plug. Drive the plug until it is firmly seated and no more than 1/3 of the plug is visible from above the sleeve.

8. Inspect for proper assembly prior to loading the cable. Strands visible through the inspection hole are your assurance of a proper assembly.

NOTE: The end of the rope may not be visible in the inspec-

tion hole after loading.

9. Install cable on machine and adjust per instructions shown previously in Section , Mast Chains Adjustment - 15BD.

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SECTION 3 - TROUBLESHOOTING

SECTION 3. TROUBLESHOOTING

3.1 GENERAL

This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.

3.2 TROUBLESHOOTING INFORMATION

The troubleshooting procedures applicable to the aerial platform are listed and defined in Table 3-1, BD Model Troubleshooting.

Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action. The probable causes and the remedial action should, where possible, be checked in the order listed in the tables.

It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.

It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems. For this reason, every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment. In the remaining machine groups, only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included. This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section.

The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power. This can be ascertained by overriding the bypass valve (mechanically or electrically) so that oil is available to the function valve, then overriding the function valve mechanically. If the function performs satisfactorily, the problem exists with the control circuit.

3.3 HYDRAULIC CIRCUIT CHECKS

(See Figure 3-5.)

The first reference for improper function of a hydraulic system, where the cause is not immediately apparent, should be the Troubleshooting Chart. The best place to begin the problem analysis is at the power source (pump). Once it is determined that the pump is serviceable, then a systematic check of the circuit components, beginning with the control, would follow.

NOTE: For aid in Hydraulic troubleshooting, refer to Figure

3-5. HYDRAULIC Schematic at the end of this section. For ELECTRICAL Diagram refer to Figure 3-6. at the end of this chapter.

3.4 ELECTRICAL SYSTEM - MULTIMETER BASICS

A wide variety of multi-meters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. A digital meter with reasonable accuracy (within 7%) is recommended for the measurements in these procedures. This section shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary. Please consult the meter operator’s manual for more information.

Grounding

"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touch it to a good path to the negative side of the voltage source.

Backprobing

To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the back of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type, great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifically designed for this technique, especially on sealed connectors. Whenever possible insert probes into the side of the connector such that the test also checks both terminals of the connection. It is possible to inspect a connection within a closed connector by backprobing both sides of a connector terminal and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and contacts are seated in the connector.

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Min/Max

Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held down.

Polarity

Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed. Check what reading is expected, the location of the signal and that the leads are connected to the device under test correctly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal.

Scale

M = Mega = 1,000,000 * (Displayed Number)

k = kilo = 1,000 * (Displayed Number)

m = milli = (Displayed Number) / 1,000

μ = micro = (Displayed Number) / 1,000,000

Example: 1.2 k = 1200 

Example: 50 mA = 0.05 A

Continuity Measurement Over Long Distances

When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness.

Requirements:

• Harness with at least three separate wires including the wire under test.

• These wires must be able to be isolated from other wires, etc.

• Jumper or method to connect contacts on one side of harness.

• Meter that can measure resistance or continuity.

Procedure

Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate measurement.

Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2, and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach of the jumper.

1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not completely isolated disconnect battery terminals also, as a precaution.

2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not, repair the shorted wires or replace the harness.

3. On one side, jumper from contact of wire #1 and wire #2.

4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measurement. If still no continuity, repair wires or consult schematic for other wires to use for test.

5. Jumper from wire under test to wire #1.

6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length increases and as the diameter decreases.

One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.

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Voltage Measurement Resistance Measurement

Figure 3-1. Voltage Measurement (DC) Figure 3-2. Resistance Measurement

• If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual)

• Use firm contact with meter leads

• First test meter and leads by touching leads together. Resistance should read a short circuit (very low resistance)

• Circuit power must be turned OFF before testing resistance

• Disconnect component from circuit before testing

• If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual)

• Use firm contact with meter leads

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Continuity Measurement Current Measurement

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

• Some meters require a separate button press to enable audible continuity testing

• Circuit power must be turned OFF before testing continuity

• Disconnect component from circuit before testing

• Use firm contact with meter leads

• First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity

• Set up the meter for the expected current range

• Be sure to connect the meter leads to the correct jacks for the current range you have selected

• If meter is not auto ranging, set it to the correct range (See multi meter’s operation manual)

• Use firm contact with meter leads

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3.5 ELECTRICAL SWITCH TESTING

Basic Check

The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected.

1. De-energize the circuit.

2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.

3. Access the terminals to the switch.

4. If the switch has two terminals:

a. Measure resistance across the terminals.

b. Change the switch position.

c. Measure resistance again with the leads in the

same positions. If the meter was reading short, it should read an open. If the meter was reading open it should read short.

5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will be connected. The test is similar to testing a switch with two terminals.

a. Place one meter lead on the common contact

and the other on a different contact in the same circuit.

b. Cycle through all positions of the switch. The

meter should read short only when the switch connects the two terminals and open otherwise.

c. If the switch has more than one common contact

repeat the process for that circuit.

Limit Switches

Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually operated switches except that the moving object operates the switch. These switches can be tested the same way as a standard switch by manually operating the sensing arm.

Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do not require contact, and must be energized to actuate. These types of switches can be used to detect boom or platform position, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To find the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switch as follows:

1. Remove prox switch from its mount.

2. Reconnect harness if it was disconnected for step 1, and turn on machine.

3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See vehicle or control system documentation on how to do this.

4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous metal physically similar to it. The switch state in the control system diagnostics should change.

5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the switch and object sensed.

Automatic Switches

If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate.

1. Connect instrumentation to monitor and/or control the parameter the switch is measuring.

2. Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to do this.

3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for example. The state indicated in the control system should change.

Switch Wiring - Low Side, High Side

When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.

A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping current flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can measure the voltage at both power terminals with respect to battery ground. The difference between those two measurements is the voltage applied to the load.

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Table 3-1. BD Model - Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Platform does not rise.

Unit lowers by itself.

Unit leaking hydraulic oil.

Unit lowers very slowly.

Red emergency stop button is engaged (PUSHED IN) on either ground control station or on platform.

Control relay not functioning. Replace control relay.

Motor start relay not functioning. Replace motor start relay.

Unit wiring not properly grounded. Check all ground connections in the

Manual descent valve open. Close manual descent valve.

Hydraulic hose and/or fittings loose causing a hydraulic pressure leak.

Lift DOWN solenoid valve not functioning.

Hydraulic hose and/or fittings loose. Tighten hydraulic hose and/or fittings.

Valve and/or plug loose. Tighten valve and/or plug.

Breather cap on tank is saturated or clogged with oil.

Hydraulic oil tank over-filled. Lower oil level to full mark on dipstick.

Flow control valve not functioning. Replace flow control valve.

Disengage (TURN CLOCKWISE) red emergency button until it pops out.

wiring.

Tighten hydraulic hose and/or fittings.

Replace Lift DOWN solenoid valve.

Replace breather cap on tank.

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Figure 3-5. Hydraulic Schematic. (BD)

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Figure 3-6. Electrical Diagram. (BD - 120V-AC - Standard)

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1001111740 A

VAC JUNCTION BOX

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Figure 3-2. Electrical Diagram. (BD - 120V-AC -Standard)

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1001133268_B

Figure 3-7. Electrical Diagram. (BD - 120V-AC - CORNING)

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1001133268_B

Figure 3-2. Electrical Diagram. (BD - 120V-AC - CORNING))

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1001144701_A

Figure 3-8. Electrical Diagram. (BD - 220V-AC - CORNING)

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1001144701_A

3120752 – JLG Lift – 3-13

Figure 3-2. Electrical Diagram. (BD - 220V-AC - CORNING))

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NOTES:

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CALIFORNIAN PROPOSITION 65

BATTERY WARNING

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemical known to the

State of Califormia

to cause cancer and

reproductive harm.

WASH HANDS

AFTER HANDLING!

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JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

(717) 485-5161 (717) 485-6417

JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia

+61 2 65 811111

+61 2 65 810122

JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude - Ihlpohl Germany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755 Castellbisbal, Barcelona Spain

+34 93 772 4700

+34 93 771 1762

JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil

+55 19 3295 0407

+55 19 3295 1025

JLG Equipment Services Ltd. Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N. T. Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Sverige AB Enkopingsvagen 150 Box 704 SE - 176 27 Jarfalla Sweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

JLG Industries (UK) Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG Industries (Italia) s.r.l. Via Po. 22 20010 Pregnana Milanese - MI Italy

+39 029 359 5210

+39 029 359 5845

JLG France SAS Z.I. de Baulieu 47400 Fauillet France

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

Oshkosh-JLG Singapore Technology Equipment Pte Ltd. 29 Tuas Ave 4 Jurong Industrial Estate 639379 - Singapore

+65-6591-9030

+65-6591-9031