JLG 19BD Service Manual

Service and Maintenance Manual

Model(s)

15BD 19BD

P/N - 3121154

June 14, 2012

ANSI

NOTES:

FOREWORD

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

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.

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

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

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

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

are defined as follows:

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

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

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

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

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

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

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

NOTES:

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.

3121154 – JLG Lift – a

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

February 5, 2009 - Original Issue of Manual

June 14, 2012 - Manual Revised

EFFECTIVITY PAGE

EFFECTIVITY CHANGES

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EFFECTIVITY PAGE

NOTES:

d – JLG Lift – 3121154

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

3121154 – JLG Lift – i

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

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

TABLE OF CONTENTS

NOTES:

iv – JLG Lift – 3121154

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

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

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

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

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))

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)

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)

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

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)

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

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

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

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

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

+ 60 hidden pages