JLG 24RS Service Manual

Service and Maintenance Manual

Model

24RS

P/N - 3121287

September 12, 2013

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

INTRODUCTION

AGENERAL

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

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE

MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.

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

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

CMAINTENANCE

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

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

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

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

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

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
MACHINE AND IN SERVICE MANUAL.

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

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

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE

FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL-

ITY OF THE OWNER/OPERATOR.

BHYDRAULIC SYSTEM SAFETY

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

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

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

• BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING
REPLACEMENT OF ELECTRICAL COMPONENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL­VENTS.

3121287 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue - September 12, 2013

A-2 – JLG Lift – 3121287

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

SECTION 1 - SPECIFICATIONS

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

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

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

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

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.2 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.1 Operator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

SECTION 2 - GENERAL

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3121287 – JLG Lift – i

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 3 - CHASSIS & TURNTABLE

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

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

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

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

3.2 Drive Orientation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

3.4 Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.5 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

End Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Measuring And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Assembly of End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.7 Swing Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

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

Tightening and Torquing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Roll and Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.8 Procedure for Setting Swing Gear backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.9 Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Wear Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Turntable/Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

3.10 Chassis Tilt Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

3.11 Cold Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3.12 Engine Operating States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3.13 Engine Start Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3.14 Engine RPM Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Engine Stop RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Cold Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Mid Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

High Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Generator RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3.15 Engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Alternator Excitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Ambient Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3.16 Auxiliary Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3.17 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

. . . . . . . . . . . . . . . . . . . . . . . . . 3-54

ii – JLG Lift – 3121287

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 4 - BOOM & PLATFORM

4.1 Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Function Speed Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

4.4 Boom Telescope Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Extend Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Retract Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

4.6 Drive/Steer – Boom Function Cutout System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.7 Emergency Descent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.8 Platform Load Sensing System (JAPAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.9 Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Dissassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

4.10 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.11 Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.12 Hose Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.13 Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

SECTION 5 - HYDRAULICS

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

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

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

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

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

5.2 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Platform Slave Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.3 Sauer Danfoss Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

New Pump Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

General Adjustment Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Charge Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

Pressure Limiter Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Engaging the Bypass Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Displacement Limiter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Control Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Standard Procedures, Removing the Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Electric Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Shaft Seal, Roller Bearing and Shaft Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Charge Check / HPRV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Pressure Limiter Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5.4 Hydraulic Drive Pump Pre-fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

5.5 Pressure Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

3121287 – JLG Lift – iii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 6 - JLG CONTROL SYSTEM

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

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

6.2 analyzer Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 using the hand held analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

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

6.4 System Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

iv – JLG Lift – 3121287

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2. Torque Chart (SAE Fasteners - Sheet 1 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-3. Torque Chart (SAE Fasteners - Sheet 2 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1-4. Torque Chart (SAE Fasteners - Sheet 3 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5. Torque Chart (SAE Fasteners - Sheet 4 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-6. Torque Chart (METRIC Fasteners - Sheet 5 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

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

1-8. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

2-1. Hydraulic Oil Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-2. Engine Oil Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3-1. Steering Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Drive Hub/Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3. Front Drive/Steer Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Rear Drive Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-5. Axle Hosing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-6. Rear Drive Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-7. Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-8. Swing Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-9. Motor Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3-10. Input Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-11. Main Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-12. Housing Shaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-13. Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-14. Carrier Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-15. Housing Shaft Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-16. Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-17. Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-18. Input Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-19. Swing Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-20. Motor Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-21. Swing Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-22. Roll Test Tool - T201476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-23. Bearing Cone Press Tool -T144566 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-24. Bearing Cone Pressing Tool - T145741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-25. Bearing Cup Pressing Tool - T149013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-26. Locknut Wrench Tool - T151047 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-27. Bearing Cup Pressing Tool - T155291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-28. Seal Press Tool - T175741. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-29. Leak Test Adapter Plate Tool - T201746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

3-30. Swing Drive Test Plate Tool - T187845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-31. Swing Bearing Wear Tolerance - Dial Indicator Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-32. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-33. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-34. Chassis/Turntable Hose Routing - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-35. Chassis/Turntable Hose Routing - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-36. Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-37. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

3-38. Engine Operating State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-39. Alternator Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-40. Auxiliary Pump Hosing and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-41. Cables and Clamps Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3-42. Cables and Clamps Installation - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3-43. Cables and Clamps Installation - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

3-44. Cables and Clamps Installation - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

3-45. Counterweight Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

4-1. Block to Set the Upright On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-2. Lift Cylinder Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

. . . . . . . . . . . . . . . . . . . . . 3-51

3121287 – JLG Lift – v

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

4-3. Powertrack Hosing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-4. Tower Boom Hosing - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-5. Tower Boom Hosing - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-6. Boom Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-7. Telescope Cylinder Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-8. Hose Adjustment - Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-9. Hose Adjustment - Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-10. Hose Adjustment - Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-11. Hose Adjustment - Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-12. Hose Adjustment - Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-13. Hose Adjustment - Figure 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-14. Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-15. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

5-1. Slave Level Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2. Slave Level Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-3. Platform Slave Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-4. Master Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-5. Master Cylinder Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-6. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-7. Steer Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-8. Steer Cylinder Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-9. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-10. Lift Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-11. Lift Cylinder Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-12. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-13. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-14. Telescope Cylinder Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-15. Main Hydraulic Valve - Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-16. Main Hydraulic Valve - Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-17. Main Hydraulic Valve - Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-18. Main Hydraulic Valve - Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-19. Main Hydraulic Valve - Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-20. Main Hydraulic Valve Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-21. Flow Divider Valve - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-22. Flow Divider Valve - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-23. Hydraulic Oil Tank - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-24. Hydraulic Oil Tank - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-25. Hydraulic Oil Tank - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-26. Filter Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-27. Main Valve Circuit - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-28. Main Valve Circuit - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-29. Hose Routing - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5-30. Hose Routing - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

5-31. Hose Routing - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5-32. Charge Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-33. Pressure Limiter Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

5-34. Pressure Limiter Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-35. Engaging the Bypass Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-36. Displacement Limiter Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-37. Control Adustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

5-38. Neutral Adjustment (Bottom View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-39. Servo Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

5-40. Proper Screen Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5-41. Control Module Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5-42. Shaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-43. Positioning Seal in Seal Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-44. Charge Pump Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

. . . . . . . . . . . . . . . . . . . . . 5-40

vi – JLG Lift – 3121287

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

5-45. Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-46. Auxiliary Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-47. High Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-48. Charge Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-49. Pressure Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-50. Fasteners and Plugs - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

5-51. Fasteners and Plugs - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

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

6-2. Analyzer Top Level Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-3. Analyzer Personalities Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-4. Analyzer Machine Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-5. Analyzer Diagnostics Menu - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-6. Analyzer Diagnostics Menu - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-7. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-8. Ground Module - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-9. Ground Module - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-10. Ground Module - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-11. Platform Module - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-12. Platform Module - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

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

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

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

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

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

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

7-7. Electrical System Installation - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-8. Electrical System Installation - Sheet 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-9. Electrical System Installation - Sheet 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-10. Electrical System Installation - Sheet 4 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-11. Electrical System Installation - Sheet 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-12. Electrical System Installation - Sheet 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-13. Electrical System Installation - Sheet 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-14. Electrical Schematic - Sheet 1 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-15. Electrical Schematic - Sheet 2 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-16. Electrical Schematic - Sheet 3 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7-17. Electrical Schematic - Sheet 4 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-18. Electrical Schematic - Sheet 5 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7-19. Electrical Schematic - Sheet 6 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7-20. Electrical Schematic - Sheet 7 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-21. Electrical Schematic - Sheet 8 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-22. Electrical Schematic - Sheet 9 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7-23. Electrical Schematic - Sheet 10 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7-24. Electrical Schematic - Sheet 11 of 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7-25. Hydraulic Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

7-26. Hydraulic Schematic - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

3121287 – JLG Lift – vii

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

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

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

1-4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-5 Deutz D2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

1-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-8 Machine Orientation When Performing Speed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-9 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-10 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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

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

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

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

3-2 Drive System Mode Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-3 Swing Brake Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-4 Engine RPM Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3-5 Glow Plug Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

4-1 Hose Pull Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

5-1 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

5-2 System Operating Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

5-3 Transmission Operates Normally in One Direction Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-4 System Does Not Operate in Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-5 System Noise or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-6 Neutral Difficult or Impossible to Find. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-7 Sluggish System Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-8 Charge Pressure Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-9 Pressure Limiter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-10 Displacement limiter adjustment data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-11 Cover Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-12 Fastener Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-13 Plug Size and Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

6-1 Analyzer Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-2 Machine Configuration Programing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-3 Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-4 Fault Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6-5 Fault Code Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6-6 Overload Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

viii – JLG Lift – 3121287

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 OPERATING SPECIFICATIONS

Operating Specifications

Table 1-1. Operating Specifications

Capacit y: Unres tricte d:
AN S I
AN S I E x po r t

Maximum Travel Grade, stowed
Position (Gradeability)

Maximum Travel Grade, stowed
Position (Side Slope)

Drive Speed - Stowed 2.8 mph (4.5 kph)

Elevated Drive Speed 0.75 mph (1.2 kph)

Gross Machine Weight - Approximate 23300 lbs. (10568 kg)

Ground Bearing Pressure 83 psi (5.83 kg/cm

System Voltage 12V DC

Maximum Main Relief Hyd. Pressure 3000 psi (207 Bar)

500 lbs. (227 kg)
500 lbs. (227 kg)

Dimensional Data

45%

Capacities

Table 1-3. Capacities

Hydraulic Oil Tank (to Full Level) 32.5 Gal. (123 L)

Drive Hub*

20.5 oz. (0.6 L)

*Drive hubs should be one half full of lubricant.

5°

2

)

Table 1-2. Dimensional Data

Turning Radius (Inside Left Turn) 12’ 9" (3.89 m)

Turning Radius (Inside Right Turn) 12’ 11" (3.93 m)

Turning Radius (Outside Left Turn) 22’ 10" (6.95 m)

Turning Radius (Outside Right Turn) 22’ 6" (6.85 m)

Machine Height (stowed) 9’ (2.76 m)

Machine Height (storage) 8’ 2" (2.5 m)

Machine Length (stowed) 38’ 8" (11.85 m)

Horizontal Reach 58’ 5" (17.8 m)

Machine Width (Normal Operation) 8’ 2" (2.49 m)

Machine Width (Shipping) 7’ 1" (2.2 m)

Wheel Base 9’ 6" (2.9 m)

Platform Height 80’ 5" (24.5 m)

Platform Height w/LSS 80’ 6" (24.5 m)

Ground Clearance 11.2" (28.5 cm)

3121287 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Table 1-5. Deutz D2011

Type Liquid Cooled

Number of Cylinders 4

Bore 3.7in. (94 mm)

Stroke 4 .4 in. (112 mm)

Total Displacement 189.6 cu. in. (3.1 L)

Compression Ratio 19.0:1

Firing Order 1-3-4-2

Output 36.4 hp (48.8 kW )

Low Idle RPM 1200 ± 50

High Idle RPM 2500 ± 50

Table 1-6. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F
(-18° to +83° C)

10W

+0° to + 210° F
(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

Tires

Table 1-4. Tires

Size 39 x 15-22.5

Maximum Tire Load 13,100 lbs. (5942 kg)

Type Foam Fill ed

Engine Data

Hydraulic Oil

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

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

NOTE: Machines may be equipped with Mobil EAL biodegrad-

able and non-toxic hydraulic oil. This is a fully synthetic
hydraulic oil that possesses the same anti-wear and rust
protection characteristics as mineral oils, but will not
adversely affect the ground water or the environment
when spilled or leaked in small amounts.

NOTE: Aside from JLG recommendations, it is not advisable to

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

1-2 – JLG Lift – 3121287

SECTION 1 - SPECIFICATIONS

Major Component Weights

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

Table 1-7. Critical Stability Weights

Components LBS. KG.

Tire & Wheel (Foam-Filled) 513 233

Engine Assembly (w/tray) 1125 510

Battery 41 18.5

Chassis complete (w/swing bearing) 4950 2245

Chassis & Turntable (w/o booms) 11735 5323

Left Counterweights 907 411.5

Right Counterweights 907 411.5

Tower Boom 2013 913

Tower Link 893 405

1.2 FUNCTION SPEEDS

Notes:

1. Personality settings can be adjusted anywhere within
the adjustment range in order to achieve optimum
machine performance.

2. Stop watch should be started with the function move­ment, not with actuation of the joystick or switch.

3. All speed tests are run from the platform, except those
specifically designated to be run in Ground Mode.

4. The platform speed control knob must be at full speed
(turned clockwise completely) unless noted.

5. Functional speeds may vary due to cold thick hydraulic
oil. Test should be run with the oil temperature above
38° C (100° F)

6. Drive test results reflect 39 x 15 - 22.5 Foam Filled Tires.

Upright 1715 778

Main Boom Assembly 3475 1576

Platform 224 102

Platform Support 68 31

Platform Rotator 55 25

3121287 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Table 1-8. Machine Orientation When Performing Speed Test

Drive;

(Max Speed)

Drive;

(Max Torque)

(Above Horizo ntal)

Swing Boom at full elevation, Telescope retracted. Swing the turntable left or right to the end stop.

Main Lift Main Lift retracted, Telescope Retracted.

Telescope Main Lift completely extended, Telescope Retracted.

Platform

Rotate

Tes t s ho u ld b e d o ne o n a s mo o th , l ev el s u rf a ce . St a r t a p p ro xi m at el y 7 .6 m (2 5 ft ) fr o m s t ar t i ng p oi n t s o t he u ni t is a t a m ax i mum speed when
starting the test.
Results should be recorded for a 61m (200ft) course.
Drive forward, "High Speed", record time
Drive Reverse, "High Speed", record time

Test should be done on a smooth, level surface. The Drive Select Switch should be in the "Max Speed" position, the boom should be > 10° above
horizontal to ensure the drive is operating in Max Torque mode.
Results should be recorded for a 15.25m (50ft) course.
Drive forward, record time
Drive Re verse, record time
Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode; Creep light on Panel must be energized. Verify that machine will
drive forward and reverse. Return Knob to fully clockwise.

Swing in the opposite direction until the turn table stops, record time.
Swing in the other direction until the turn table stops, record time.
Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode; Creep light on Panel must be energized. Verify that machine will
swing left and right. Return Knob to fully clockwise.

Ma i n L i ft u p to f ul l he i gh t, r ec o rd ti m e.
Ma i n L i ft D o wn to s to w ed p os i ti o n, r ec o rd ti m e.
Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode; Creep light on Panel must be energized. Verify that machine will
li f t u p an d d ow n. R e tu r n K n ob t o f u ll y cl o ck w is e .

Telescope out (full height), record time.
Telescope in (stowed position), record time.
Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode; Creep light on Panel must be energized. Verify that machine will
telescope in and out. Return Knob to fully clockwise.

Main Lift retracted, Telescope Retracted. Rotate the platform left or right until the platform stops
Rotate the platform in the opposite direction until the platform stops, record time.
Rotate the platform in the other direction until the platform stops, record time.
Turn Platform Speed Control Knob fully counterclockwise to enter Creep mode; Creep light on Panel must be energized. Verify that machine plat­fo r m w i ll r ot a te le f t an d ri g ht .
Note: When the platform speed control knob is turned fully counterclockwise. The platform rotate may not work, this is acceptable. Return Knob
to fully clockw ise.

1-4 – JLG Lift – 3121287

SECTION 1 - SPECIFICATIONS

Table 1-9. Function Speeds

Function

Adjustment

Ranges

Default
Setting

Time Range

In Seconds

DRIVE

Max Speed Accel 25 – 2000mA/s 275 mA

Decel 25 – 2000mA/s 175 mA

Min 250 – 1800mA 635 mA

Max 250 – 1800mA 1650 mA 48-52

ME/ MT Accel 25 – 2000mA/s 300 mA

ME/ MT Decel 25 – 2000mA/s 100 mA

Drive to Stop Decel 25 – 2000mA/s 1075 mA

ME/ MT: Min 250 – 1800mA 625 mA

Max Torque Max 250 – 1800mA 1650 mA

Mid Engine Max 250 – 1800mA 1650 mA

MT: Elevated Max 250 – 1400mA 1150 mA 44 - 57

ME: Elevated Max 250 – 1400mA 1200 mA

Max Torque Creep 250 – 1400mA 1125 mA

Mid Engine Creep 250 – 1400mA 1200 mA

ME = Max Engine, MT = Max Touque

SWING

Accel 0-5s 2.5 s

Decel 0-5s 1 s

LEFT Min 250 – 1400mA 500 mA

Max 250 – 1400mA 700 mA 109 - 132

Creep 250 – 1400mA 550 mA

RIGHT Min 250 – 1400mA 475 mA

Max 250 – 1400mA 700 mA 109 - 132

Creep 250 – 1400mA 520 mA

LIFT

Accel 0-5s 2 s

Decel 0-5s 1 s

UP Min 250 – 1400mA 400 mA

Max 250 – 1400mA 925 mA 62 - 76

Creep 250 – 1400mA 600 mA

DOWN Min 250 – 1400mA 400 mA

Max 250 – 1400mA 1025 mA 52 - 64

Creep 250 – 1400mA 825 mA

TELECOPE

Accel 0-5s 2 s

Decel 0-5s 0.3 s

IN Min 250 – 1400mA 400 mA

Max 250 – 1400mA 925 mA 47 - 58

Creep 250 – 1400mA 700 mA

Table 1-9. Function Speeds

Function

Adjustment

Ranges

Default
Setting

Time Range

In Seconds

OUT Min 250 – 1400mA 400 mA

Max 250 – 1400mA 1100 mA 55 - 67

Creep 250 – 1400mA 675 mA

PLATFORM ROTATE

LEFT Max No Adjustment N/A 17-35

RIGHT Max No Adjustment N/A 17-35

GROUND MODE

SWING Left 250 – 1400mA 625 mA N/A

Right 250 – 1400mA 625 mA N/A

LIFT Up 250 – 1400mA 825 mA N/A

Down 250 – 1400mA 1025 mA N/A

TELESCOPE In/Out 250 – 1400mA 1000 mA N/A

1001147535-C

3121287 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

Figure 1-1. Maintenance and Lubrication Diagram

1-6 – JLG Lift – 3121287

SECTION 1 - SPECIFICATIONS

Table 1-10. Lubrication Specifications.

KEY SPECIFICATIONS

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460.

HO Hydraulic Oil. API service classification GL-4, e.g. Mobilfluid 424.

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5

or Mil-Spec Mil-L-2105.

MPG Multipurpose Grease having a minimum dripping point of 350° F (177°

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

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API

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

*MPG may be substituted for these lub ricants, if necessary, but service intervals will be
reduced.

DRAIN

FILL

1.1 OPERATOR MAINTENANCE

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

Maintenance and Lubrication Diagram.

2. Swing Gearbox

Lube Point(s) - Fill Plug
Capacity - 32 ounces (946 cc)
Lube - EPGL
Interval - Check level every 150 hrs/Change every 1200
hours of operation. Fill to cover ring gear.

3. Hydraulic Tank

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

1. Swing Bearing

Lube Point(s) - 2 Fittings
Capacity - A/R
Lube - BG
Interval - Every 3 months or 150 hrs of operation
Comments - Apply grease and rotate in 90 degree

intervals until bearing is completely lubricated

3121287 – JLG Lift – 1-7

Lube Point(s) - Fill Cap
Capacity - 36 Gal. (136.3 L), 32.5 Gal. (123 L) to Full Level;

26.5 Gal (100.3 L) to Refill Mark
Lube - HO
Interval - Check Level daily; Change every 2 years or

1200 hours of operation.

Comments - On new machines, those recently over-

hauled, or after changing hydraulic oil, operate all sys­tems a minimum of two complete cycles and recheck
oil level in reservoir.

SECTION 1 - SPECIFICATIONS

FILL PORT

15°

OIL SHOULD BE
TO THIS HEIGHT

4. Hydraulic Tank Return Filter and Breather

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

or 300 hrs. thereafter.

Comments - For breather element, remove wing nut and

cover to replace. Under certain conditions, it may be
necessary to replace both elements on a more fre­quent basis.

5. King Pins

6. Wheel Drive Hub

Lube Point(s) - Level/Fill Plug
Capacity - 20.5 oz. (0.6 L)
Lube - Mineral Oil ISO VG150
Interval - Check level every 3 months or 150 hrs of oper­ation; change every 2 years or 1200 hours of operation

7. Oil Change with Filter

1-8 – JLG Lift – 3121287

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

Lube Point(s) - Fill Cap/Spin-on Element
Total Capacity (Engine & Oil Cooler)- 15 Quarts (14.2 L)
w/Filter
Lube - EO
Interval - Check level daily; change every 600 hours or

six months, whichever comes first. Adjust final oil
level by mark on dipstick.

SECTION 1 - SPECIFICATIONS

8. Fuel Filter/Water Separator

Lube Point(s) - Replaceable Element
Interval - Every year or 600 hours of operation

9. Air Filter

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

or 300 hrs. thereafter.

11. Main Valve Filter

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

or 300 hrs. thereafter.

12. Optional Fuel Filter

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

10. Charge Filter

Lube Point(s) - Replaceable Element
Interval - Every year or 600 hours of operation

3121287 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

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

Description

0100011

242

TM

Vibra-TITE

TM

121

Medium Strength (Blue)

0100019

271

TM

Vibra-TITE

TM

140

High Strength (Red)

0100071

262

TM

Vibra-TITE

TM

131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

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

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

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

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

Torque

Lubricated

Torque

(Loctite® 242

TM

or 271

TM

OR Vibra-TIT E

TM

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

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

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

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

1-10 – JLG Lift – 3121287

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

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140) K=.18

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

131)

K=0.15

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

Torque

(Dry or Loctite® 263)

K= 0.20

3121287 – JLG Lift – 1-11

Figure 1-3. 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

TM

or 271

TM

OR Vibra-TITE

TM

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

TM

or Vibra-

TITE

TM

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

1-12 – JLG Lift – 3121287

Figure 1-4. 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

TM

OR Vibra-TITE

TM

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

TM

or Vibra-

TITE

TM

131)

K=0.15

SECTION 1 - SPECIFICATIONS

3121287 – JLG Lift – 1-13

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

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

Torque

(Lub)

Torque

(Loctite® 262

TM

OR Vibra-

TITE

TM

131)

Torque

(Loctite®

242

TM

or 271

TM

OR Vibra-

TITE

TM

111 or

140)

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

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

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

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

16 2 157 68.3

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

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

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

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

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

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

NO. 5000059 REV. J

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

1-14 – JLG Lift – 3121287

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

TM

)

K = 0.20

Torque

(Lub OR Loctite®

242

TM

or 271TM OR

Vibra-TITE

TM

111 or

140)

K= 0.18

Torque

(Loctite® 262

TM

OR

Vibra-TITE

TM

131)

K=0.15

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

3 0.5 5.03 3.13

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

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

16 2 157 97.8

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

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

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

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

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLA TED
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

3121287 – JLG Lift – 1-15

Figure 1-7. 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

TM

)

K = .17

Torque

(Lub OR Loctite®

242

TM

or 271

TM

OR Vibra-TITE

TM

111 or 140)

K = .16

Torque

(Loctite® 262

TM

OR Vibra-TITE

TM

131)

K = .15

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

30.55.03

3.5 0.6 6.78

40.78.78

50.814.20

6120.1012.5 13 12 11

7128.9018.0 21 20 19

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

16 2 157

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

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

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

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

ADDITIONAL TESTING IS REQUIRED.

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

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

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

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

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

1-16 – JLG Lift – 3121287

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

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

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

Annual Machine Inspection

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

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

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

Preventative Maintenance

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

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

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

3121287 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Freq uenc y

Pre-Start Inspection Prior to use each day; or

At each Operator change.

Pre-Delivery Inspecti on Prior to each sale, lease, or

rental delivery.

Frequent Inspection In service for 3 months or 150 hours, whichever

comes first; or

Out of service for a period of more than 3 months; or

purchased used.

Annual Machine Inspec-

tion

Preventative

Maintenance

Annually, no later than 13 months from the date of

the prior inspection.

At intervals as specified in the Service and Mainte-

nance Manual.

2.2 SERVICE AND GUIDELINES

General

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

Safety and Workmanship

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

Cleanliness

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

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

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

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

Owner, Dealer, or User Factory-Trained Service

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

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

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

Service

Qualification

Technician

Reference

and applicable JLG inspection form.

and applicable JLG inspection form.

Service and Maintenance Manual

and applicable JLG inspection form.

Components Removal and Installation

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

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

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

2-2 – JLG Lift – 3121287

SECTION 2 - GENERAL

Component Disassembly and Reassembly

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

Pressure-Fit Parts

When assembling pressure-fit parts, use a molybdenum disul­fide base compound or equivalent to lubricate the mating sur­face.

Bearings

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

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

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

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

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

Hydraulic Lines and Electrical Wiring

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

Hydraulic System

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

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

Lubrication

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

Battery

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.

Bolt Usage and Torque Application

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

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

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

Lubrication and Servicing

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

2.3 LUBRICATION AND INFORMATION

Hydraulic System

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

3121287 – JLG Lift – 2-3

SECTION 2 - GENERAL

2. The design and manufacturing tolerances of the compo­nent working parts are very close, therefore, even the
smallest amount of dirt or foreign matter entering a sys­tem can cause wear or damage to the components and
generally results in faulty operation. Every precaution
must be taken to keep hydraulic oil clean, including
reserve oil in storage. Hydraulic system filters should be
checked, cleaned, and/or replaced as necessary, at the
specified intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of metal
particles.

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

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

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

machines due to the wear-in of meshing components.

Changing Hydraulic Oil

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

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

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

Lubrication Specifications

Hydraulic Oil

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

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

2.4 CYLINDER DRIFT TEST

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

Platform Drift

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

2-4 – JLG Lift – 3121287

SECTION 2 - GENERAL

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

8 203.2 0.0038 0.10

9 228.6 0.0030 0.08

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

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

If the cylinder passes this test, it is acceptable.

NOTE: This information is based on 6 drops per minute cylinder

leakage.

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

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

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

2. Filament wound bearings should be replaced if any of

the following is observed:

4. Re-assembly of pinned joints using filament wound
bearings.

a. Housing should be blown out to remove all dirt and

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

b. Bearing / pins should be cleaned with a solvent to

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

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

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

2.6 WELDING ON JLG EQUIPMENT

NOTE: This instruction applies to repairs, or modifications to the

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

Do the Following When Welding on JLG Equipment

• Disconnect the battery.

• Disconnect the moment pin connection (where fitted)

• Ground only to structure being welded.

Do NOT Do the Following When Welding on JLG Equipment

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

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

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

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

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

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

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

d. Debris embedded in liner surface.

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

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

a. Detectable wear in the bearing area.

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

face.

c. Rusting of the pin in the bearing area.

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

3121287 – JLG Lift – 2-5

SECTION 2 - GENERAL

NOTE: Reference the Operation and Safety Manual for comple-

tion procedures for the Pre-Start Inspection.

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Weekly

Preventive

Maintenance

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Boom Assembly

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

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

Pivot Pins and Pin Retainers 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pad s 1,2 1,2

Covers or Sh ields 1,2 1,2

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

Platform Assembly

Platform 1,2

Railing 11,2

Gate 5 1 1,5

Floor 11,2

Rotator 9,5 15

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

Turntable Assembly

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

Oil Coupling 9

Swing Drive System 11 11

Tur nt a bl e L oc k 1,2,5 1,2,5

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

Chassis Assembly

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

Wheel Nuts/Bolts 15 15 15

Wheel Bearings 14,24

Oscillating Axle/Lockout Cylinder Systems 5,8

Outrigger or Extendable Axle Systems 5,8 5,8

Steer Components

Spindle Thrust Bearing/Washers 1,2

Drive Motors

Drive Hubs 11 11

Annual

(Yearly)

Inspection

4

Every 2

Year s

2-6 – JLG Lift – 3121287

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Weekly

Preventive

Maintenance

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Functions/Controls

Platform Controls 5 6 6

Ground Controls 5 6 6

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

Footsw itch 55

Emergency Stop Switches (Ground & Platform) 5 5

Function Limit or Cutout Switch Systems 5 5

Capacity Indicator 5

Drive Brakes 5

Swing Brakes 5

Manual Descent or Auxiliar y Power 5 5

Power Sy stem

Engine Idle, Throttle, and RPM 3 3

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

Air/Fuel Filter 1,7 7 7

Exhaust System 1,9 9 9

Batteries 1,9 19

Battery Fluid 11 11 11

Battery Charger 5 5

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

Hydraulic/Electric System

Hydraulic Pumps 1 ,9 1,2,9

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

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

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

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

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 7,11 7,11

Electrical Connections 1 20 20

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

General

Operation and Safety Manual s in Storage Box 21 21

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

Capacity Decals Installed, Secure, Legible 21 21

Annual
(Yearly)

Inspection

4

Every 2

Year s

3121287 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Weekly

Preventive

Maintenance

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

All Decals/Placards Installed, Secure, Legible 21 21

Walk-Around Inspection Performed

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21

General Structural Condition and Welds 2,4 2,4

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

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 21 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footno tes:

1

Prior to use each day; or at each Operator change

2

Prior to each sale, lease, or delivery

3

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

4

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

Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or 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 - Drain, Clean, Refill

Annual

(Yearly)

Inspection

4

Every 2

Year s

2-8 – JLG Lift – 3121287

SECTION 2 - GENERAL

Figure 2-1. Hydraulic Oil Operation Chart

1001151189-A

Figure 2-2. Engine Oil Operation Chart

1001151190-A

3121287 – JLG Lift – 2-9

SECTION 2 - GENERAL

NOTES:

2-10 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

1

2

3

4

5

6

7

8

9

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES AND WHEELS

Tire Replacement

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

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

• Tire tread contact width equal or greater than origi­nal

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

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

Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneu­matic tire. When selecting and installing a replacement tire,
ensure that all tires are inflated to the pressure recommended
by JLG. Due to size variations between tire brands, both tires
on the same axle should be the same.

Wheel and Tire Replacement

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

the mounting stud holes in the wheels. The proper procedure
for attaching wheels is as follows:

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

2. Tighten nuts in the following sequence.

3. The tightening of the nuts should be done in stages. Fol-

lowing the recommended sequence, tighten nuts per
wheel torque.

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Sta ge 3rd Stage

40 ft lbs (55 Nm) 95 ft lbs (130 Nm) 170 ft lbs (230 Nm)

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

Wheel Installation

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

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

Tighten the lug nuts to the proper torque to prevent wheels
from coming loose. Use a torque wrench to tighten the fasten­ers. If you do not have a torque wrench, tighten the fasteners
with a lug wrench, then immediately have a service garage or
dealer tighten the lug nuts to the proper torque. Over-tighten­ing will result in breaking the studs or permanently deforming

3121287 – JLG Lift – 3-1

SECTION 3 - CHASSIS & TURNTABLE

3.2 DRIVE ORIENTATION SYSTEM

The Drive Orientation System (DOS) indicates to the operator
conditions that could make the direction of movement of the
chassis different than the direction of movement of the drive/
steer control handle in the platform. The system indicates to
the operator the need to match the black and white direc­tional arrows on the platform control panel to the arrows on
the chassis. The system consists of a proximity switch
mounted on the underside of the turntable, an indicator light
and an override switch on the platform display panel. The
proximity switch trips when the turntable is swung ± 43
degrees off center of the normal driving position (approxi­mately when the boom is swung past a rear tire). When the
turntable is in the normal drive position with the boom
between the rear tires, no indications or interlocks are made. If
the machine is actively driving when the turntable is swung
past the switch point, the system is ignored until drive/steer is
released. When drive is activated with the boom swung past
the switch point, the DOS indicator will flash and the drive/
steer functions will be disabled. The operator must engage the
DOS override switch to enable drive/steer (High Speed drive

Table 3-2. Drive System Mode Chart

Boom Position Drive Selection

will remain disabled). When the DOS is enabled, the DOS indi­cator will be illuminated continuously and a 3-second enable
timer will be started. The enable timer will continue for 3 sec­onds after the end the last drive/steer command. If the timer
times out, the DOS override switch must be re-engaged to
enable drive/steer.

3.3 DRIVE SYSTEM

The Drive system consists of a variable displacement closed
loop pump, 4 low speed high torque orbital type motors,
directional control valves, and a series of flow dividers.

Drive Speed is controlled by a combination of engine RPM,
drive pump displacement and flow division between drive
motors (2WD / 4WD). Traction and torque are controlled
through the flow divider system. There are three drive modes
selectable at the platform control box, and the functionality of
the drive system is dependent on the position of the boom (in
or out of Transport Position. The following chart describes
how the system works in each drive mode.

Engine Speed when

Drive is Actuated

Drive Pump

Displacement

Flow

Dividers

Max. Speed

MPH (kph)

In Transport

Out of Transport

2 Wheel Drive High-2500 RPM 100% Engaged 2.8 (4.5)

4 Wheel Drive Mid-1800 RPM 100% Engaged 1 (1.6)

4 Wheel Drive High-2500 RPM 100% Engaged 1.4 (2.25)

4 Wheel Drive High-2500 RPM 52% Engaged 0.75 (1.2)

4 Wheel Drive Mid-1800 RPM 74% Engaged 0.75 (1.2)

4 Wheel Drive High-2500 RPM 52% Engaged 0.75 (1.2)

3-2 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-1. Steering Hydraulic Lines

3.4 STEER CYLINDER

Removal

1. Place the machine on a firm, level surface.

2. Place a container under the frame to catch hydraulic oil.

3. Tag and disconnect the hydraulic lines from the steer

cylinder.

4. Remove the bolts, keeper pins, and retaining pins secur­ing the tie rod links to the steer cylinder rod ends.

5. Remove the bolts securing the steer cylinder to the
frame and remove the steer cylinder from the machine.

Installation

1. Position the steer cylinder into place on the frame.

2. Coat the retaining bolts with JLG Threadlocker P/N

0100011 and use the bolts and washers to secure the
steer cylinder to the frame. Torque the bolts to 207 ft.lbs.
(280 Nm).

3. Coat the retaining bolts with JLG Threadlocker P/N
0100011and use the bolts, keeper pins, and retaining
pins to secure the tie rod links to the steer cylinder rod
ends. Torque the bolts to 40 ft.lbs. (55 Nm).

4. Connect the hydraulic hoses to the cylinder as tagged
during removal. Torque the fittings to 23 ft.lbs. (32 Nm).

3121287 – JLG Lift – 3-3

SECTION 3 - CHASSIS & TURNTABLE

* Apply JLG Threadlocker P/N 0100019
** Torque to 190 ft.lbs. (260 Nm)

*
**

DRIVE HUB

DRIVE BRAKE

DRIVE MOTOR

Figure 3-2. Drive Hub/Motor Installation

3.5 DRIVE HUB

Removal

1. Place the machine on a firm, level surface.

2. Use an adequate jack to lift up the axle enough to

remove the tire and wheel assembly and place blocking
underneath the axle for support.

NOTE: If removing a drive hub from the steer axle, turn the tires in

a direction that will allow maximum access to the drive
hub components. On non-steer axle, the access cover must
be removed.

NOTE: The tire and wheel assembly weighs approximately 513 lbs.

(233 kg).

3. Remove the tire and wheel.

4. Remove the bolts securing the drive motor to the hub

and carefully pull the motor away from the drive hub,
taking care not to kink or put stress on the hydraulic
hoses.

5. Place a container under the drive brake to catch hydrau­lic oil.

6. Tag and disconnect the hydraulic lines running to the
drive brake.

NOTE: The hub weighs approximately 101 lbs. (45.8 kg).

7. Use a device capable of supporting the weight of the
hub to hold it in position.

8. Remove the bolts and washers securing the hub to the
axle or spindle and pull the hub away from the machine.

3-4 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-3. Front Drive/Steer Circuit

3121287 – JLG Lift – 3-5

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-4. Rear Drive Circuit

3-6 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-5. Axle Hosing

3121287 – JLG Lift – 3-7

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-6. Rear Drive Circuit

3-8 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Installation

1. Position the hub onto the axle or spindle.

2. Coat the retaining bolts with JLG Threadlocker P/N

0100019 and secure the hub in place with the bolts.
Torque the bolts to 190 ft.lbs. (260 Nm).

3. Connect the hydraulic lines running to the drive brake as
tagged during Removal.

4. Align the splines of the drive motor shaft with the
splines in the drive brake and secure in place with the
retaining bolts. Torque the bolts to 37 ft.lbs. (51 Nm).

5. Install the Tire and Wheel assembly. Refer to Section 3.1,
Tires and Wheels.

3.6 DRIVE MOTOR

Cleanliness is extremely important when repairing these
motors. Work on clean surface!

Before disassembly, drain the oil from the motor and dry the
work bench.

Removal

1. Place a container under the drive motor to catch hydrau­lic oil.

2. Tag and disconnect the hydraulic lines running to the
drive motor.

3. Pull the Drive Motor away from the drive brake.

3. Unscrew screws using a S17 torque wrench.

4. Remove end cover assembly.

5. Separate Valve Plate from Channel Plate and remove

Valve Drive.

Disassembly

Although not all drawings show the motor in disassembly
devise (vice with soft clamping jaws), it is recommended the
motor to be tightened during disassembly.

1. Unscrew the Drain plug with S6 Allen key and remove
the O-ring.

2. Place the motor in disassembly devise with output shaft
down.

6. Separate Channel Plate from Roll-gerotor set.

7. Remove O-ring 83x2 (2 pcs.), and balls (2 pcs.) from the

Channel Plate grooves.

8. Remove the roll-gerotor set carefully to prevent drop­ping of rollers and rotor from stator. Do not dismount!

3121287 – JLG Lift – 3-9

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-7. Drive Motor

3-10 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

9. Remove cardan shaft from the splines of output shaft.

10. Separate Intermediate Plate from housing.

11. Remove O-ring 83x2 and Seal Ring from the Intermedi-

ate Plate.

End Cover Disassembly

1. Turn the end cover with the hole conversely on a clean
soft surface. Knock several times using a plastic hammer
on the rear side. Set in order the fallen parts apart.

Cleaning

Wash all parts (except seals) in a weak solvent on carbon base
and then degreased.

Measuring And Replacement

Measure all parts and compare their actual dimensions with
the nominal ones given in the technical documentation.
Replace any parts with scratches or burrs that could cause
leakage or damage with new ones. Use new seals and washers
when reassembling the motor.

Lubrication

Lubricate all frictioning parts, which should be reassembled
with light film of petroleum jelly.

Assembly

Place bearing housing on clean soft surface. Lubricate shaft
seal and dust seal with light film of clean petroleum jelly.

1. Place shaft seal in the bearing housing and firmly push
with Seal driver.

2. Install the seal ring in the Intermediate plate and assem­ble it through the studs. Lubricate O-ring 83x2 and place
it in seal groove of Intermediate Plate.

3. Install the cardan shaft into splines of the output shaft.

4. Orientate the Roll-Gerotor set acc.to the figure below

and assemble the rotor splines into the cardan shaft
splines. (If necessary, turn the shaft to one or another
direction for keeping symmetry of rotor towards stator.)

2. Remove “O”-Rings (2 paces) from the grooves of the bal­ance plate.

3. Remove the pin using a vice with soft jaws or pliers
knocking on the balance plate and swivelling it round
the pin simultaneously.

5. Install the valve drive into the rotor spline sector.

6. Mark the rotor at the point where the tip of a spline

tooth is opposite to the bottom of a tooth in the exter­nal rotor teeth as shown.

7. Mark the bottom of a spline on the valve drive. Line up
mark on rotor and valve drive.

8. Lubricate O-rings 83x2 (2 pcs.) and place them in seal
grooves of both sides of Channel Plate.

3121287 – JLG Lift – 3-11

SECTION 3 - CHASSIS & TURNTABLE

9. Lubricate the roll-gerotor set surface and place on it the
channel plate.

10. Lubricate and install 2 psc. Balls in channel plate ball
grooves.

11. Align mark on valve drive with a hole in the outer rim of
the Valve Plate. Turn Valve Plate clockwise (as shown
below) until splines in the two parts engage /rotation
about 15°/.

Plate counter clockwise (as shown below) until splines in
the two parts engage.

Assembly of End Cover

1. Mount the lubricated “O”-Rings (2 pcs.) in the relevant
grooves of the balance plate.

2. Stave the preliminarily lubricated pin into the balance
plate hole (to the thin end).

Reverse rotation is obtained by rotation of the Valve

3. Place the cover with the front for nameplate down­wards. Lubricate lightly all internal cap surfaces to pro­tect seals. Put the spring washer into hole with passing
diameter.

3-12 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

4. Place the balance plate (set) inside the end cover with
the pin orientated to fall in with the hole of its bottom.
Use a plastic hammer.

Lubricate spacer and install in the balance plate hole.

Parts are correctly assembled when at pressing the front
surface of balance plate by thumbs downwards, the bal­ance plate jumps up itself as a result of spring force.

5. Mount the end cover (set) carefully over both studs.
Make sure that the port face of end cover coincides with
the orientated drain port.

6. Install the screws in End cover. Torque the screws 6-7
daNm (5-6 lbs-in.).

7. Install O-ring on drain plug. Tighten plug with Allen key
S6 with torque 2.0 - 2.5 daNm (1.7-2.2 lbs-in.).

Installation

1. Align the splines of the drive motor shaft with the
splines in the drive brake and secure in place with the
retaining bolts. Torque the bolts to 37 ft.lbs. (51 Nm).

2. Connect the hydraulic lines to the drive motor as tagged
during removal. Torque the fittings to 60 ft.lbs. (82 Nm).

3121287 – JLG Lift – 3-13

SECTION 3 - CHASSIS & TURNTABLE

6 Brake Housing
26 O-ring
28 Lift Lug

29 B ol t s
31 M ot o r

Figure 3-8. Swing Motor Disassembly

3.7 SWING DRIVE HUB

Disassembly

MOTOR DISASSEMBLY

See Figure 3-8.

1. Place the unit on a work bench with the motor end up.

2. Remove the two magnetic pipe plugs (1P) and drain the

oil out of the gearbox.

NOTE: Record the condition and volume of the oil.

3. Remove hydraulic tubing assembly (35) by loosening fit­tings on both ends of tube with a wrench.

4. Using a wrench, loosen the jam nuts on the elbow fit­tings (30) and remove the fittings from the brake hous­ing (6) and motor control valve (32).

5. Remove the pipe plugs and O-rings (23) from the motor
control valve (32).

6. Remove the motor control valve (32) from the motor
(31) by removing the four bolts (21) and washers (22).

7. Remove the O-ring (99) between the motor control
valve (32) and motor (31). Discard O-ring.

8. With the unit resting on a work bench with the motor
(31) end up, loosen the hex bolts (29) and remove the lift
lugs (28) from the motor (31).

9. Pull the motor (31) straight up and remove the motor
(31) from the brake housing (6).

10. Remove the o-ring (26) from between the motor (31)
and brake housing (6). Discard the O-ring.

3-14 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

1P P ip e Pl u g
6 Brake Housing
21 B ol t s
22 L oc k Wa sh e r
23 O -r i n g/ p ip e Pl u g

30 E lb o w
31 M ot o r
32 Counter Balance Valve
35 Hydraulic Tube Assembly
99 O-rings

Figure 3-9. Motor Disassembly

3121287 – JLG Lift – 3-15

SECTION 3 - CHASSIS & TURNTABLE

6 Brake Housing
8A B ra k e P i st o n
8D O-ring
8E O - ri n g/ b ac k Up R in g
8F O-ring
8H O - ri n g/ b ac k Up R in g

8J B ra k e R o to r
8K B ra k e S t at or
8L S pr i ng
8M P re s su re P la t e
8N I nt e rn a l R e ta i ni n g R i n g

Figure 3-10. Input Brake Disassembly

INPUT BRAKE DISASSEMBLY

1. Insert and tighten the 0.250-20 UNC socket head cap-

screws through the pressure plate (8M) and into the
brake piston (8A) to compress the springs and relieve
pressure on the retaining ring (8N).

SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS.

NOTE: Ensure Step 1 is completed before performing Step 2.

2. Using retaining ring pliers, remove retaining ring (8N)
which holds the brake piston assembly in place.

3. Lift the brake piston assembly (8A) out of the brake
housing (6). If the brake piston assembly (8A) will not lift
out, apply less than 50 psi (3.4 Bar) air to the brake port
to remove it. Remove the inner (rotor) (8J) and outer
(stator) plates (8K) from inside the brake housing (6).

4. Remove the o-rings (8D, 8F) and backup rings (8E, 8H)
from the brake housing (6). Discard the o-rings and
backup rings.

3-16 – JLG Lift – 3121287

5. Remove the 0.250-20 UNC socket head capscrews and
lift the pressure plate (8M) from the brake piston (8A).

NOTE: Record the number of springs and mark their locations

before removing them from brake piston.

6. Remove the springs (8L) from the brake piston (8A).

MAIN DISASSEMBLY

1A O u tp u t S h af t
1G H ou s in g
1P P ip e Pl u g
2 I n te r na l Ge a r
4 R i n g G e ar
5 O - r in g
5A O - ri n g

6 Brake Housing
8 Sun Gear
11 T hr u st Wa s he r
12 Bolts
13 Dowel Pin
44 Internal Retaining Ring

Figure 3-11. Main Disassembly

SECTION 3 - CHASSIS & TURNTABLE

9. Remove the thrust washer (11) from between the carrier
sub-assembly and internal gear (2).

SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS.

1. Remove the sun gear (8) with retaining ring (44) inside.

2. With the unit resting on the output shaft (pinion) (1A),

remove the bolts (12) from the brake housing (6).

3. Remove the brake housing (6) from the main assembly.

4. Remove the o-ring (5A) from between the brake hous-

ing (6) and ring gear (4). Discard the o-ring.

5. Remove the thrust washer (11) from between the brake
housing (6) and carrier sub-assembly.

6. Remove the ring gear (4) from the housing (1G).

7. Remove the o-ring (5) from between the ring gear (4)

and housing (1G).

8. Remove the carrier sub-assembly.

3121287 – JLG Lift – 3-17

10. Remove the internal gear (2).

SECTION 3 - CHASSIS & TURNTABLE

1A O u tp u t S h af t
1B L ip S e al
1C Ta p er ed B e ar i ng Cu p
1D Ta p er ed B e ar i ng Co n e
1E Tapered Bearing Cup
1F Tapered Bearing Cone

1G H ou s in g
1H Tanged Washer
1I L oc k Tan g ed - wa s he r
1J Bearing Nut
1K R et a i ni n g R i ng

Figure 3-12. Housing Shaft Disassembly

HOUSING-SHAFT DISASSEMBLY

1. Set the unit on a work bench so the housing (1G) flange

is down.

SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS.

2. Remove the retaining ring (1K) from the output shaft
(1A).

3. Bend the tang on the lock tanged-washer (1I) out of the
locknut (1J).

4. Remove and discard the locknut (1J). A new locknut
must be used for reassembly.

5. Remove the lock tanged-washer (1I) from the output
shaft (1A).

6. Remove the thrust washer (1H) from the output shaft
(1A).

3-18 – JLG Lift – 3121287

7. While supporting the housing (1G) on the output shaft
(1A) end, press the output shaft (1A) out of the housing
(1G).

NOTE: The lip seal (1B) will be pressed out of the housing (1G) by

the bearing cone (1D) during this step.

8. Remove the Bearing Cone (1F) from the Housing (1G).

9. Use a bearing puller to remove the bearing cone (1D)

from the shaft (1A).

10. Bearing cups (1C & 1E) will remain in the housing (1G).

NOTE: If bearing replacement is necessary, the bearing cups (1C &

1E) can be removed with a slide hammer puller or driven
out with a punch.

CARRIER DISASSEMBLY

3A C ar r ie r
3B Ta n ge d Wa sh e r
3C Bearing Needle
3D T hr u st S pa c er

3E P la n et S h af t s
3F C lu s te r Ge a r
3G R ol l Pi n

Figure 3-13. Carrier Disassembly

SECTION 3 - CHASSIS & TURNTABLE

1. Drive the planet shaft (3E) out of the carrier pin holes
forcing the roll pin (3G) to sheer off.

2. Hold on to the planet gear (3F) and push the planet
shaft (3E) out of the carrier (3A). The thrust washers (3B)
will slide off the shaft as it is removed.

3. Slide the planet gear (3F), and thrust washers (3B) out of
the Carrier (3A).

3121287 – JLG Lift – 3-19

4. Using a hammer and punch, drive the pieces of the roll
pin (3G) out of the planet shaft (3E) and carrier (3A).

5. Remove both rows of needle bearings (3C) and the
spacer (3D) from the bore of the planet gear (3F).

6. Repeat steps 1 thru 5 for the remaining cluster gears
(3F).

SECTION 3 - CHASSIS & TURNTABLE

Tightening and Torquing Bolts

If an air impact wrench is used to tighten bolts, extreme care
should be taken to ensure the bolts are not tightened beyond
their specified torque. The following steps describe how to
tighten and torque bolts or socket head cap screws in a bolt
circle.

Assembly

CARRIER SUBASSEMBLY

1. Apply a liberal coat of grease to the bore of the cluster

gear (3F). This will enable the needle rollers (3C) to be
held in place during assembly.

2. Install one half of the inside of the cluster gear (3F) with
16 needle rollers (3C).

NOTE: The last roller installed must be installed end wise. The end

of the last roller must be placed in between the ends of the
two rollers that form the space, and then slid parallel to the
other rollers into place.

3. Place one spacer (3D) on top of the needle rollers (3C)
inside the planet gear (3F).

4. Install the other half of the cluster gear (3F) with16 nee­dle rollers (3C).

5. Place the carrier (3A) into tool fixture so that one of the
roll pin holes is straight up.

6. Start the planet shaft (3E), with the end opposite the roll
pin hole first, through the planet shaft hole in carrier
(3A), making sure that the roll pin hole with the large
chamfer in the planet shaft is straight up.

1. Tighten (but do not torque) bolt A until snug.

2. Go to the opposite side of the bolt circle and tighten

bolt B until equally snug.

3. Crisscross around the bolt circle and tighten the remain­ing bolts.

4. Use a torque wrench to apply the specified torque to
bolt A.

5. Using the same sequence, crisscross around the bolt cir­cle and apply an equal torque to the remaining bolts.

7. Using ample grease to hold them in position, locate the
thrust washer (3B) onto each side of interior carrier wall
with tangs located into slots in carrier pads.

8. With the large end of the cluster gear (3F) facing the roll
pin hole in the carrier, place the cluster gear into posi­tion in the carrier (3A) and push the planet shaft (3E)
through the cluster gear (3F) without going all the way
through the carrier (3A).

9. Finish sliding the planet shaft (3E) into the carrier (3A)
until the roll pin holes of the planet shaft and carrier are
aligned. Align the roll pin hole using a 1/8 inch diameter
punch.

NOTE: The chamfer on the roll pin hole should be towards the roll

pin hole in the carrier.

10. Drive the roll pin (3G) through the carrier (3A) and into
the planet shaft (3E) until the roll pin (3G) is flush with
the bottom of the cast slot in the carrier (3A) outside
diameter at the thrust washer (3B) tang. Use a ¼" pin
punch to make sure the roll pin (3G) is flush in the slot.

11. Repeat Steps 6 through 10 for the remaining two cluster
gears (3F).

3-20 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

3A C ar r ie r
3B Ta n ge d Wa sh e r
3C Bearing Needle
3D T hr u st S pa c er

3E P la n et S h af t s
3F C lu s te r Ge a r
3G R ol l Pi n

Figure 3-14. Carrier Subassembly

3121287 – JLG Lift – 3-21

SECTION 3 - CHASSIS & TURNTABLE

1A O u tp u t S h af t
1B L ip S e al
1C Ta p er ed B e ar i ng Cu p
1D Tapered Bearing Cone
1E Tapered Bearing Cup
1F Tapered Bearing Cone

1G H ou s in g
1H Tanged Washer
1I L oc k Tan g ed - wa s he r
1J Bearing Nut
1K R et a i ni n g R i ng

Figure 3-15. Housing Shaft Subassembly

HOUSING-SHAFT SUBASSEMBLY

NOTE: Spray a light film of oil on all component parts during

assembly. Spray a generous amount of oil on bearings dur­ing installation.

1. Press one bearing cup (1E) into the bearing counterbore
of the motor end of the housing (1G) making sure it is
fully seated against the shoulder in the housing. Use
Tool T155291.

2. Turn the housing (1G) and press one bearing cup (1C)
using Tool T149013 into the bearing counterbore of the
cover end of the housing (1G). Ensure that it is fully
seated against the shoulder in the housing.

3. Using alcohol and a clean rag, wipe off bearing locations
on the housing (1G) and the shaft (1A).

4. Place one bearing cone (1D) into the housing (1G).

5. Spray the housing seal bore with alcohol, then wipe

with a clean rag. Ensure there is no debris left in the
bore.

3-22 – JLG Lift – 3121287

NOTE: Seals should not be reused.

6. Spray the O.D. of the lip seal (1B) with alcohol and wipe
with a clean rag. Place and visually align the lip seal (1B)
with spring side down into the housing (1G) seal bore.
Press the seal into the housing using seal press Tool
T174751. When the seal press tool makes contact with
the Housing (1G) the seal is fully seated.

7. Lift the housing (1G) and rotate so the seal is facing
down. Move the housing (1G) over the output shaft (1A)
and align the bearing cone (1D) inner diameter with the
output shaft (1A) bearing diameter.

NOTE: Roll the housing when pressing the bearing cone (1d) in the

step below.

8. Lower the housing (1G) onto the output shaft (1A) until
the bearing cone (1D) contacts the shaft.

SECTION 3 - CHASSIS & TURNTABLE

9. Press on the small end of the bearing cone (1D), being
careful not to contact the bearing cage, until the bear­ing cone (1D) seats on the shoulder of the output shaft
(1A). Use Tool T145741.

10. Place the bearing cone (1F) onto the output shaft (1A).

11. Press or tap the bearing cone (1F) onto the output shaft

(1A) until it is just seated in the bearing cup (1E), while
rotating the housing (1G). Use Tool T144566. Ensure
there is end play on bearings.

12. Install the tanged flatwasher (1H) and lockwasher (1I) on
top of bearing cone.

13. Using a clean rag, clean the threads of the output shaft
(1A) and bearing nut (1J).

14. Apply Loctite 263 and place the bearing nut (1J) on the
output shaft (1A). (Fill the threads of the locknut (1J).)

15. Thread the bearing nut (1J) using locknut wrench
T151047 onto the output shaft (1A) down to top of Bear­ing Cone.

16. Ensure there is end play on the hub-output shaft.

17. Roll the housing (1G) in each direction to insure bearing

are seated and then measure housing initial rolling
torque using rolling torque adapter tool.

18. Tighten the bearing nut (1J) using locknut wrench
T151047. Torque the bearing nut (1J) approximately 155
ft-lbs (210 Nm), rotate the housing (1G) in both direc­tions, and then torque the bearing nut to 155 ft-lbs. Roll
the housing in each direction then measure rolling
torque.

19. Repeat the step above until the housing rolling torque
increases 30-50 in-lbs (3.4-5.6 Nm) over the rolling
torque measurement in Step 17. Nut torque may be
more than 155 ft-lbs (210 Nm).

NOTE: Tighten the bearing nut to align the tang into nut slot. do

not loosen the bearing nut.

20. Bend the tang in lockwasher (1I) into the bearing nut
(1J) slot.

21. Install the retaining ring (1K) into the output shaft (1A).

3121287 – JLG Lift – 3-23

SECTION 3 - CHASSIS & TURNTABLE

1A O u tp u t S h af t
1G H ou s in g
1P P ip e Pl u g
2 I n te r na l Ge a r
4 R i n g G e ar

6 Brake Housing
8 Sun Gear
5 O - r in g
5A O - ri n g

11 T hr u st Wa s he r
12 B ol t s
13 D ow e l P i n
44 I nt e rn a l R e ta i ni n g R i n g

Figure 3-16. Main Assembly

Figure 3-17. Timing Marks

MAIN ASSEMBLY

1. Slightly tap the internal gear (2) with the spline side

down onto the output shaft (1A) splines to ensure the
internal gear (2) is properly seated.

2. Grease and install the o-ring (5) onto the housing (1G) o­ring groove.

3. Grease and install thrust spacer (11) into the counter­bore of the carrier sub-assembly on smaller diameter
cluster gear side. The grease should hold the thrust
spacer (11) in place for assembly.

4. Place the carrier sub-assembly onto a table oriented as
shown in Figure 3-17., with the large end of the cluster
gear (3F) facing up. Position all three punch-marks on
the face of the large gears at 12 o’clock. Timing marks on
the two upper cluster gears will be visible through the

3-24 – JLG Lift – 3121287

slots in the carrier if the cluster gears are correctly
marked. Secure the gear teeth using a timing fixture.

SECTION 3 - CHASSIS & TURNTABLE

5. Place ring gear (4) in to large end of cluster gear to
secure timing.

6. Remove carrier sub-assembly and ring gear (4) from the
table and assemble into the Internal gear (2) being care­ful to keep the ring gear, or sun gear, in mesh with the
cluster gears.

7. After engaging internal gear teeth and before rotating
carrier, look at the carrier subassembly in the main
assembly and insure the timing is correct by locating the
timing marks in the slots in the carrier and at 12o’clock
on the gear that the timing mark is visible in the carrier
bore.

8. Grease and install the o-ring (5A) onto the brake hous­ing (6) counterbore.

9. Install the brake housing (6) onto the ring gear (4) by
aligning the bolt holes in brake housing with ring gear
holes.

10. Ensure the pipe plugs in the housing (1G) and brake
housing (6) are timed as shown.

11. Pull one cover bolt (12) and place into the bolt hole and
repeat for the remaining bolts.

12. Torque the bolts (12) in a star pattern 23-27 ft-lbs (2.5-3
Nm).

13. Install the retaining ring (44) into the internal retaining
ring groove of the input shaft (8).

14. Install the input shaft (8) with the spline side up into the
housing bore. Insure the input shaft gear teeth and
planet gears are engaged.

15. Install o-ring plugs (1P) into the brake housing (6) and
housing (1G). Torque 23-24 ft-lbs (2.5-2-7 Nm).

16. The unit should now be leak and roll checked.

17. Fill the unit with oil through the opening in the brake

housing (6) with 43 oz. of 80W90 gear oil.

3121287 – JLG Lift – 3-25

SECTION 3 - CHASSIS & TURNTABLE

6 Brake Housing
8A Brake Piston
8D O-ring
8E O - ri n g/ b ac k Up R in g
8F O-ring
8H O-ring/back Up Ring

8J B ra k e R o to r
8K B ra k e S t at or
8L S pr i ng
8M P re s su re P la t e
8N I nt e rn a l R e ta i ni n g R i n g

Figure 3-18. Input Brake Assembly

INPUT BRAKE ASSEMBLY

1. Starting with a stator (8K), alternately stack and install

stators (8K) into lobes or splines of the brake housing (6)
and rotors (8J) (internal splines) onto splines of the sun
gear (8).

NOTE: There should always be a stator on the top and bottom of

the stack.

2. Insert the brake piston (8A) completely into the brake
housing (6) without o-rings (8D, 8F) and backup rings
(8E, 8H) to check the fit of the brake. The brake piston
(8A) should slide into the brake housing (6) without
being forced. If the brake piston (8A) does not fit, check
for burrs or size problems before proceeding.

3. Grease the o-rings (8D, 8F) and install the smaller diame­ter o-ring (8F) into the smaller diameter o-ring groove in
the brake housing (6) and install the larger diameter o­ring (8D) into the larger diameter O-Ring groove in the
brake housing (6).

4. Insert the smaller diameter solid backup ring (8H) into
smaller groove in brake housing (6) between the o-ring
(8F) and side of the groove towards the output shaft
(1A).

5. Insert larger diameter solid backup ring (8E) into groove
in brake housing (6) between o-ring (8D) and side of
groove towards the motor (31).

3-26 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

6 Brake Housing
26 O-ring
28 Lift Lug

29 B ol t s
31 M ot o r

Figure 3-19. Swing Motor Assembly

NOTE: Refer to the illustration below for installing o-rings (8D),

(8F) and backup rings (8E), (8H).

12. The Unit should undergo a brake test .

6. Lightly grease cylinder walls of the brake housing (6)

and install the brake piston (8A) into the brake housing
(6). If necessary, place T-134711 on top of the brake and
lightly tap until the brake piston (8A) contacts the brake
disk stack.

7. Insert 8 Springs (8L) into the brake piston (8A) spring
holes.

8. Install the pressure plate (8M) into the brake housing (6)
bore and onto the springs (8L).

9. Insert and tighten the 0.250-20 UNC capscrews through
the pressure plate (8M) and into the brake piston (8A) to
compress the springs. Tighten the capscrews incremen­tally to evenly compress the Springs (8L).

SAFETY GLASSES MUST BE WORN DURING THESE NEXT STEPS.

10. Using retaining ring pliers, install the large retaining ring
(8N) into the groove in the brake housing (6) making
sure that it is seated properly.

NOTE: Use caution when installing the retaining ring (8N) into the

brake housing (6). It may cause injury if it slips out of
retaining ring pliers.

13. Grease and install the o-ring (26) into the motor (31)
pilot.

14. Install the motor (31) into the brake housing (6). Ensure
the motor valve mounting face is aligned with the radial
brake release port in the housing (1G).

15. Install the bolts (29) into the brake housing (6) through
the lifting lugs (28) and motor (31) flange. Torque the
bolts 80-100 ft-lb (108.5-135.5 Nm).

NOTE: Verify the o-rings are located in between the motor and

valve.

16. Install the o-rings (99) into the counterbore on the
motor valve face.

11. Remove the capscrews from the brake piston (8A) incre­mentally to release the tension of the springs slowly.

3121287 – JLG Lift – 3-27

Discard the capscrews.

SECTION 3 - CHASSIS & TURNTABLE

1P P ip e Pl u g
6 Brake Housing
21 Bolts
22 L oc k Wa sh e r
23 O-ring/pipe Plug

30 Elbow
31 Motor
32 Counter Balance Valve
35 Hydraulic Tube Assembly
99 O-rings

Figure 3-20. Motor Control Valve

17. Install the motor control valve (32) onto the motor (31)

using bolts (21) and washers (22). Torque the bolts 18-20
ft-lbs. Ensure the holes in the motor control valve (32)
are aligned with holes in the motor (31).

18. Install the elbow fitting (30) into the brake housing (6).
Ensure the thread fitting o-ring seats onto the brake
housing (6). Rotate the elbow fitting (30) to horizontal
position as shown in picture.

19. Install the elbow fitting (30) into the motor valve (32).
Ensure the thread fitting o-ring seats onto the motor
valve (32). Rotate the elbow fitting (30) to the horizontal
position as shown in Figure 3-20..

20. Install the tube assembly (35) to elbow fittings as shown
in Figure 3-20.. Torque the tube assembly nut 13-15 ft-lb
(17.5-20.3 Nm). Tighten the jam nut on the elbow fitting
(30) 13-15 ft-lbs torque.

21. Install one o-ring plug (23) onto the motor control valve
(32). Torque 18-20 ft-lbs (24.5-27 Nm).

3-28 – JLG Lift – 3121287

22. Install a hydraulic test fitting into the other control valve
o-ring plug (23) hydraulic port.

23. Perform a pressure decay test at "MAXIMUM PRESSURE".
Hold pressure for 1 minute. If pressure does decay,
remove the pressure and inspect connections and
retest.

24. Remove the hydraulic test fitting.

25. Install the o-ring plug (23) onto the motor control valve

(32). Torque 18-20 ft-lbs (24.5-27 Nm).

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-21. Swing Drive Assembly

Figure 3-22. Roll Test Tool - T201476

Brake Test

Before performing the Brake Test, remove the motor, tubing
and elbow as per Motor disassembly instructions. To perform a
brake check, install a hydraulic hand pump with pressure
gauge into brake port in Brake Housing using a 7/16-20
threaded fitting.

Place the Roll Test Tool (Figure 3-22.) into the sun gear (8).

Apply 25 in-lbs (2.8 Nm) of torque to the tool. While trying to
rotate the tool, pump the handle on the hydraulic hand pump

and increase the pressure until the brake releases. The brake is
released when you are able to rotate the tool.

Record the release pressure. If the brake does not release
within the limits shown in the brake chart, Table 3-3, Swing

3121287 – JLG Lift – 3-29

SECTION 3 - CHASSIS & TURNTABLE

Brake Chart, check to see if it has the proper number of springs
using the Spring Checking Procedure. Increase to maximum
pressure (refer to Table 3-3, Swing Brake Chart) and hold at
that pressure for one minute. If the brake does not leak or lose
pressure, the unit has passed the brake test. If the brake loses
pressure, attempt to repair the leak using the leak repair pro­cedure at end of this procedure.

While the brake is still released, roll check the unit for one rev­olution of the output member by rotating the tool. Bleed off
pressure slowly while rotating the Roll Test Tool.

Record the pressure at which the brake locks up. Using a clean
rag, wipe off excess fluid from around the brake port and
install the pipe plug.

SPRING CHECKING PROCEDURE

Install two Flat Socket Head Cap Screws 0.250-20 UNC, ½"
length into holes in the brake piston. Tighten the bolts evenly
to ensure that the brake piston remains straight while being
compressed into the brake cavity of the brake housing.

Carefully remove the retaining ring from the brake housing.
Slowly remove the bolts evenly from the input brake. Remove
the pressure plate from the end of the input brake and count
the number of springs in the brake. If the number of springs
matches the number in Table 3-3, Swing Brake Chart, go to the
next step. If number of springs does not matches the number
in Table 3-3, Swing Brake Chart, install the correct number of

springs.

Table 3-3. Swing Brake Chart

Number

Springs

Install the Pressure Plate using two 0.250-20 UNC flat Socket
Head Cap Screws. Tighten bolts evenly to ensure that pressure
plate (8M) does not get wedged to the brake cylinder.

Install the large retaining ring into groove in housing making
sure that it is seated properly. Remove all bolts from the brake
piston and discard.

Release

Pressure

of

Minimum

(psi)

8 90 147 157 2000 556

Release
Pressure

Maximum

(psi)

Full

Release

Pressure

(psi)

Maximum

Release

Pressure

(psi)

Brake
Tor que
(in-lbs)

USE CAUTION WHEN REMOVING THE BOLTS AS THEY ARE SUBJECT TO
SPRING PRESSURE. MAKE SURE THE RETAINING RING IS SECURED
BEFORE REMOVING BOLTS.

Re-test the input brake. If release and/or lockup pressures still
do not match the brake chart, then contact the Oerlikon Fair­field service department.

3-30 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

T201476

BREAK LEAK REPAIR PROCEDURE

Install two flat socket head capscrews 0.250-20 UNC, ½" length
into holes in brake piston evenly. tighten bolts in steps evenly
to ensure that the pressure plate (8M) does not get wedged
into brake cylinder.

Carefully remove retaining ring from brake housing. Remove
the brake piston from brake housing.

Check o-rings, backup rings, and brake cavity in brake housing
for damage. If no damage is found, then reinstall input brake
according to input brake installation procedure under main
assembly procedure and perform pressure test again. If brake
still leaks, contact JLG.

NOTE: Failure to perform this test may result in damaged or inef-

fective brake parts.

Roll and Leak Test

Torque-Hubs should always be roll and leak tested before dis­assembly (if possible) and after assembly to make sure the
unit’s gears, bearings, and seals are working properly. The fol­lowing information briefly outlines what to look for when per­forming these tests.

The Roll Test:
The purpose of the roll test is to determine if the unit’s gears
are rotating consistently, easily and properly. Remove Motor
and release the brake by applying 400 psi to the brake port. To
perform a roll test, use the recommended tool shown below
(or something equivalent) to apply constant rotational force to
the input of the gearbox. If more drag is felt in the gears only
at certain points, then the gears are not rolling consistently
and easily and should be examined for improper installation
or defects. Some gear packages roll with more difficulty than
others. Do not be concerned if the gears in the unit seem to
roll hard as long as they roll with consistency. Rotate the gear­box 36 revolutions both clockwise and counterclockwise.

perform a leak test use the leak test fixture from the table
below. If the tool is not available, the gearbox must be sealed
to perform the test. This can be accomplished by assembling
the sealed input device onto the gearbox at the input end and
replace one of the oil plugs with an air chuck. DO NOT EXCEED
10 PSI (0.7 BAR) PRESSURE DURING THE LEAK TEST. Higher
pressure will create a false sealing effect in assemblies with lip­seals. The unit has a leak if the pressure gauge reading on your
leak check fitting starts to fall after the gearbox has been pres­surized and allowed to equalize. Leaks will most likely occur at
the pipe plugs, the main seal or wherever o-rings or gaskets
are located. The exact location of a leak can usually be
detected by brushing a soap and water solution around the
main seal and where the o-rings or gaskets meet on the exte­rior of the unit and then checking for air bubbles. If a leak is
detected in a seal, o-ring, or gasket, the part must be replaced
and the unit rechecked. Leak test at 10 psi (0.7 Bar) for 20 min­utes.

The Leak Test:
The purpose of a leak test is to make sure the unit is airtight. To

3121287 – JLG Lift – 3-31

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-23. Bearing Cone Press Tool -T144566

Figure 3-24. Bearing Cone Pressing Tool - T145741

3-32 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-25. Bearing Cup Pressing Tool - T149013

3121287 – JLG Lift – 3-33

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-26. Locknut Wrench Tool - T151047

3-34 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-27. Bearing Cup Pressing Tool - T155291

Figure 3-28. Seal Press Tool - T175741

3121287 – JLG Lift – 3-35

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-29. Leak Test Adapter Plate Tool - T201746

3-36 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-30. Swing Drive Test Plate Tool - T187845

Swing Drive not shown for clarity.

3.8 PROCEDURE FOR SETTING SWING GEAR

spot. Refer to Figure 3-36., Swing Bearing Installation.

BACKLASH

1. Set backlash 0.254 to 0.381 mm (0.10 to 0.15 in.) using
the following procedure.

2. Place the shim (JLG P/N 1001140563) between the
swing drive pinion and the swing bearing on the high

NOTE: The high spot will be marked with yellow paint.

3121287 – JLG Lift – 3-37

SECTION 3 - CHASSIS & TURNTABLE

3. Apply JLG threadlocker P/N 0100019 to the pivot bolt
and torque to 280 Nm (206.5 lbs.ft.).

4. If engaged, remove the turntable lock pin.

5. Apply JLG threadlocker P/N 0100019 to the other swing

drive mounting bolts and torque to 40 Nm (30 ft.lbs.).

6. Tighten the jack bolt until the pinion is snug against the
shim and bearing and then loosen the jack bolt.

7. Torque the jack bolt to 68 Nm (50 ft.lbs.).

3-38 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

8. Apply JLG threadlocker P/N 0100019 to the threads
where the jam nut will be and tighten the jam nut.

9. Torque the M16 bolts on the left of the swing drive to
280 Nm (206.5 lbs.ft.).

10. Torque the M20 bolts on the right side of the swing drive
to 550 Nm (405 ft.lbs.).

11. Remove the shim and discard.

3.9 SWING BEARING

Wear Tolerance

1. From the underside of the machine, with the main
boom positioned as shown in Figure 3-32., set up a mag­netic base dial indicator and set the indicator to 0 (zero).
Refer to Figure 3-31.

2. Next, position the main boom fully extended as shown
in Figure 3-33.. Read the measurement recorded on the
dial indicator gauge.

3. If the measurement is greater than 0.079 in. (2.006 mm),
the swing bearing should be replaced.

4. If the measurement is less than 0.079 in. (2.006 mm), and
any of the following conditions exist, the bearing should
be removed, disassembled, and inspected.

a. Metal particles in the grease.
b. Increased drive power required.
c. Noise.
d. Rough rotation.

5. If bearing inspection shows no defects, reassemble and

return to service.

3121287 – JLG Lift – 3-39

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-31. Swing Bearing Wear Tolerance - Dial Indicator Placement

3-40 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-32. Swing Bearing Tolerance Boom Placement - Sheet 1 of 2

3121287 – JLG Lift – 3-41

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-33. Swing Bearing Tolerance Boom Placement - Sheet 2 of 2

3-42 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Turntable/Swing Bearing Removal

1. Place the machine on a firm, level surface.

2. Set the swing lock.

3. Remove the front hood assemblies. Attach a magnet or

other lifting device to support the weight of the hoods
and remove the bolts that secure them to the turntable.

5. Remove the bolts securing the swing drive to the turnta­ble. Attach an adequate lifting device to the swing drive
and remove it from the machine.

TAKE NOTE OF WHICH DIRECTION THE HOSES ARE CURLED ABOVE THE
DRIVE VALVE AND THE ROUTING THRU THE D-RING BRACKET IN THE
TURNTABLE.

4. Tag and disconnect the hydraulic lines running to the
swing motor. Cap or plug all openings.

6. Tag and disconnect the hoses on the right side of the
turntable at the drive valve. Cap or plug all openings.
Pull the hoses out through the hole in the right side of
the turntable. Refer to Figure 3-34. and Figure 3-35.

7. Place a container suitable for catching hydraulic oil
under the machine. On the left side of the machine, tag
and disconnect the drive hoses at the pump. Cap or plug
all openings. Feed the hoses through the hole on the left
side of the turntable. Refer to Figure 3-34. and Figure 3-

35.

8. Loosen the clamp over the hoses to permit access to the
bearing bolt that is covered.

3121287 – JLG Lift – 3-43

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-34. Chassis/Turntable Hose Routing - Sheet 1 of 2

3-44 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-35. Chassis/Turntable Hose Routing - Sheet 2 of 2

3121287 – JLG Lift – 3-45

SECTION 3 - CHASSIS & TURNTABLE

9. Attach chains or slings to the lifting lugs to support the
weight of the turntable.

12. Place the turntable assembly on adequate blocking.

10. Remove the bearing bolts securing the turntable to the

bearing.

11. Lift the turntable off of the chassis.

13. Remove the outer race bearing bolts from the underside

of the frame.

14. Install lifting eyes into the swing bearing for removal.

NOTE: The swing bearing weighs approximately 132 lbs. (60 kg).

15. Attach an adequate lifting device to the swing bearing
and remove it from the frame.

3-46 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Installation

1. Install lifting eyes into the swing bearing for installation.

NOTE: The swing bearing weighs approximately 132 lbs. (60 kg).

2. Attach an adequate lifting device to the swing bearing
and place it onto the mounting holes on the frame.
Refer to Figure 3-36., Swing Bearing Installation for
proper bearing alignment.

3. Apply JLG Threadlocker Part No. 0100019 to new outer
race swing bearing bolts. Install the bolts and torque to
280 Nm (206.5 lbs.ft.) in the pattern shown in Figure 3-

37., Swing Bearing Torque Sequence.

4. Install guide pins into two of the inner race mounting
holes to help line up the turntable when it is installed.

280 Nm (206.5 lbs.ft.) in the pattern shown in Figure 3-

37., Swing Bearing Torque Sequence.

8. Route the hydraulic hoses on the right side of the
machine into the hole on the turntable and connect
them to the drive valve as tagged during removal.

9. Route the drive hoses from the drive valve up to the
drive pump.

5. Attach chains to the lifting lugs on the turntable.

6. Slowly lower the turntable and align it with the guide

pins.

7. Apply JLG Threadlocker Part No. 0100019 to new inner
race swing bearing bolts. Install the bolts and torque to

3121287 – JLG Lift – 3-47

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-36. Swing Bearing Installation

3-48 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

10. Connect the hoses to the drive pump as tagged during
removal.

11. Install the swing drive and adjust the backlash. Refer to
Section 3.8 - Procedure for Setting Swing Gear backlash.
Connect the hydraulic lines to the swing drive as tagged
during removal.

12. Install the hoods on the machine.

Swing Bearing Torque Values

1. Outer Race - 280 Nm (206.5 ft.lbs.) w/JLG Threadlocker
P/N 0100019.

2. Inner Race - 280 Nm (206.5 ft.lbs.) w/JLG Threadlocker P/
N 0100019.

3. See Swing Bearing Torquing Sequence.

CHECK THE INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR
LOOSENESS AFTER FIRST 50 HOURS OF OPERATION, AND EVERY 600 HOURS
THEREAFTER.

3121287 – JLG Lift – 3-49

SECTION 3 - CHASSIS & TURNTABLE

NOTE: The Swing Bearing Torque Sequence is typical for both inner and outer races.

Figure 3-37. Swing Bearing Torque Sequence

3.10 CHASSIS TILT INDICATOR SYSTEM

The Chassis Tilt Indicator System measures the relationship of
turntable angle as compared to level ground. The system uses
a tilt sensor to measure this. The tilt sensor is an integral part of
the ground module and has two settings; 5.0° (depending on
market) and 6.0° degrees. The tilt angle is set by choosing the
desired angle based upon the operator’s regional market.
There are three options for the Chassis Tilt Indicator System;

5.0° + cut-out, 4.0° + cut-out and 3.0° + cut-out.

The tilt angle is used for the purpose of warning the operator
by means of the chassis tilt light in the platform display panel.
When used in conjunction with the Beyond Transport - Drive
Speed Cutback System, the tilt sensor will cause an alarm to
sound, and automatically cut-out boom up, telescope extend,
and drive/steer functions. These commands will be locked out
until the tilt sensor or the transport switch is within the operat­ing window.

The 6° angle is used for automatically slowing drive speed
when this chassis angle is reached and the boom is in Trans­port position. When the boom is in Transport Position and the
chassis is at or above 6°, the drive system will automatically
switch into 4WD mode.

The control system responds to indicated angle readings 0.5
degree smaller than the required angles to account for calibra­tion and sensor variation.

3-50 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

ENGINE

STOPPED

ENGINE

RUNNING

ENGINE

CRANKING

ENGINE

STARTING

(RPM greater than 800 for 1/4 second)

(RPM greater than
800 for 1/4 second)

(RPM = 0 for 1/2 second)

(RPM = 0 for 1/2 second)

(Engine RPM = 0)

(RPM greater than 800 for 1/4 second)

(Engine Starter Not Engaged
& Engine RPM greater than 0)

(Engine Starter Engaged

& Engine RPM greater than 0)

Figure 3-38. Engine Operating State Diagram

3.11 COLD START SYSTEM

The JLG Control System monitors the engine coolant and
ambient temperature to determine cylinder preheating
requirements. If the coolant temperature is below 65° C when
control power is turned on, the glow plugs will be automati­cally activated for a period of time based on the ambient tem­perature up to a maximum of 20 seconds. During this preheat
period, the glow plug indicators on the control consoles will
flash. The operator should wait for the glow plugs to complete
their cycle before cranking the engine.

3.12 ENGINE OPERATING STATES

The Engine Operating State is determined by the Ground
Module. There are four different Engine Operating States
which include;

• Engine Stopped

• Engine Cranking

• Engine Starting

• Engine Running

3121287 – JLG Lift – 3-51

SECTION 3 - CHASSIS & TURNTABLE

3.13 ENGINE START CONDITIONS

Engine starting is controlled by the Ground Module. The
Ground Module will allow the starter to be engaged and keep
the starter energized if all of the following conditions are satis­fied.

1. The Start Switch is selected.

a. Ground Mode is active with Ground Module input

J4-4 energized
or

b. Platform Mode is active with Platform Module input

J1-14 energized.

2. The selected Operating Station must have all of its con­trol switches in the neutral position since power up and
remain in the neutral position prior to selecting the Start
Switch.

3. If operating from the Platform Station, the footswitch
must not be depressed (Ground Module J7-15 deener­gized; Platform Module J7-8 energized) before selecting
the Start Switch.

4. If operating from the platform, the Auxiliary Power
Switch must not be selected before selecting the Start
Switch.

5. If operating from the ground station, the Function
Enable Switch must not be selected before selecting the
Start Switch.

6. If the Engine Starter was disengaged because the Start
Switch was released, more than 3 seconds must pass
with the Start Switch in the released position.

7. If the Engine Starter has been cranking without the
engine starting for the Engine Starter Engaged Time
Limit, the control system deenergizes the Engine Starter
for the Engine Restart Wait Period. The Start Switch must
be in the deselected position after the Wait Period is
over.

8. The engine must be in the Engine Stopped or Engine
Cranking state.

9. The Engine Shutdown switch must not be activated.

10. The Start Switch has been in the deselected position

after the Engine State changes to Engine Stopped from
Engine Running or Engine Starting.

3.14 ENGINE RPM LEVELS

NOTE: The RPM levels are set in the Analyzer Personalities menu.

Table 3-4. Engine RPM Levels

Min

Started

RPM

800 1400 1000 1800 2500

The engine operates at different RPM levels in order to prop­erly operate the machine and the functions commanded by
the operator. The following lists the possible RPM levels and
the operating conditions that control them.

Cold
Idle

RPM

Idle RPM

Mid

Engine

RPM

High

Engine

RPM

Engine Stop RPM

Engine Stop RPM is always zero (0) and occurs when the
engine operating state is Engine Stopped or when the opera­tor shuts down the engine.

Idle RPM

Idle RPM occurs when all of the following conditions exist;

1. The Engine State is Engine Running, Engine Cranking, or
Engine Starting.

2. The operator is not shutting down the engine.

3. The control system is not commanding a higher engine

RPM (Mid-Engine, Multi-function, or High Engine).

4. The control system is not calling for Generator RPM.

Cold Idle RPM

Cold Idle RPM occurs when all of the following conditions
exist;

1. The Engine State is Engine Running, Engine Cranking, or
Engine Starting.

2. The operator is not shutting down the engine.

3. The control system is not commanding a higher engine

RPM (Mid-Engine or High Engine).

4. The control system is not calling for Generator RPM.

5. Engine-specific startup and cold idle requirements in

the Engine Start Conditions section are met.

3-52 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

VBatt

J1-32 putOut

Alternator

Ground Module

D+

Figure 3-39. Alternator Schematic

Mid Engine RPM

Mid Engine RPM occurs when all of the following conditions
exist;

1. The Engine State is Engine Running.

2. The operator is not shutting down the engine.

3. The control system is not commanding a higher engine

RPM (Multi-function or High Engine).

4. The control system is not calling for Generator RPM.

5. Platform mode is active with the controls enabled or

Ground mode is active with any function enabled
except for Lift Down, Tower Lift Down, or Jib Lift Down.

High Engine RPM

High Engine RPM occurs when all of the following conditions
exist;

1. The Engine State is Engine Running.

2. The operator is not shutting down the engine.

3. The control system is not calling for Generator RPM.

3.15 ENGINE CONTROLS

Alternator Excitation

For the alternator to charge, it must be rotating and the alter­nator excitation terminal must be energized by an external
power source. This power is supplied by the Ground Module
through terminal J1-32 to the D+ terminal on the alternator.
This terminal includes a one-way blocking diode that prevents
reverse energy flow into the Ground Module during engine
power-down. This terminal is continuously energized after
startup.

4. The operator is operating the Drive function at Max

5. Drive Forward or Drive Reverse is being operated.

Generator RPM

Generator RPM occurs when all of the following conditions
exist;

1. The Engine State is Engine Running.

2. The operator is not shutting down the engine.

3. The Control System is configured for a generator.

4. The Platform Generator Switch is Enabled and Selected.

Torque or Max Speed.

3121287 – JLG Lift – 3-53

SECTION 3 - CHASSIS & TURNTABLE

Glow Plugs

The diesel engine has glow plugs, controlled by the ground
module to assist in cold starting.

The Ground Module calculates the length of time the glow
plugs are energized prior to startup based upon ambient tem­perature, engine coolant temperature, and battery voltage.
Refer to Table 3-5, Glow Plug Conditions.

Table 3-5. Glow Plug Conditions

Engine Coolant

Tem per at ure

Greater than or

equal to

122 º F (50 º C)

- - Less than 11V - - Off

Less than

122 º F (50 º C)

Less than

122 º F (50 º C)

Less than

122 º F (50 º C)

Less than

122 º F (50 º C)

The glow plugs are deenergized if:

Battery
Voltag e

- - - - Off

Greater than

11V

Greater than

11V

Greater than

11V

Greater than

11V

Ambient

Temperature

Greater than

59ºF(15ºC)

Temp Between

23ºF and 59ºF

(-5ºC and 15ºC)

Temp Between

5ºF and 23ºF

(-15ºC and -5ºC)

Temp Less

Than

5ºF (-15ºC)

Glow Plug

Time On

Off

On for

10 sec.

On for

15 sec.

On for

20 sec.

Ambient Air Temperature Sensor

The ambient air temperature sensor is integrated within the
Ground Module. The sensor provides temperature information
the engine control system uses to set its fuel, spark, and air set­tings for engine starting in cold environments.

3.16 AUXILIARY PUMP

Removal

1. Disconnect the positive terminal from the motor.

2. Tag and disconnect the hydraulic lines to the motor.

a. Disconnect the hydraulic line running to the main

control valve.

• The Engine State is Engine Cranking, Engine Starting,
Engine running

or

• The Emergency Descent Mode is activated and Lift Down,
Tower Lift Down, or Jib Lift Down are active.

If the STARTER LOCKOUT option is enabled in the Machine
Setup, the Ground Module will not allow an engine start
attempt until the glow plug time has expired. If this option is
not enabled, the glow plug time can be interrupted and an
engine start attempt can be made. Starter Lockout is only
applicable for the first glow plug cycle.

3-54 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

b. Disconnect the supply line coming from the hydrau-

lic tank.

3. Remove the mounting bolts and washers securing the
auxiliary pump to the turntable and remove the auxil­iary pump.

4. Disconnect the negative cable from the auxiliary pump.

2. Coat the mounting bolts with Loctite #242 and use the

bolts and washers to attach the auxiliary pump to the
turntable. Torque the bolts to 40 ft.lbs. (55 Nm).

3. Connect the hydraulic lines to the motor as tagged dur­ing removal.

a. Torque the hydraulic line running to the main con-

trol valve to 13 ft.lbs. (18 Nm).

b. Torque the supply line coming from the hydraulic

tank to 23 ft.lbs. (32 Nm).

4. Connect the positive terminal to the motor.

Installation

1. Connect the negative cable to the auxiliary pump.

5. Operate the pump and check for proper function and

any sign of leakage.

3121287 – JLG Lift – 3-55

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-40. Auxiliary Pump Hosing and Installation

3-56 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-41. Cables and Clamps Installation - Sheet 1 of 4

3121287 – JLG Lift – 3-57

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-42. Cables and Clamps Installation - Sheet 2 of 4

3-58 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-43. Cables and Clamps Installation - Sheet 3 of 4

3121287 – JLG Lift – 3-59

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-44. Cables and Clamps Installation - Sheet 4 of 4

3-60 – JLG Lift – 3121287

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-45. Counterweight Bolt Torque

3.17 COUNTERWEIGHT

If the counterweight has been removed, ensure the retaining
bolts are torqued to the proper value as shown in Figure 3-45.,
Counterweight Bolt Torque.

NOTE: The left counterweight weighs approximately 937.6 ± 30.8

lbs. (425.3 ± 14 kg) and the right counterweight weighs
approximately 937.2 ± 30.8 lbs. (425.1 ±14 kg). Actual
weight is stamped on the counterweight.

3121287 – JLG Lift – 3-61

SECTION 3 - CHASSIS & TURNTABLE

NOTES:

3-62 – JLG Lift – 3121287