JLG 460SJ Service Manual

Service and Maintenance Manual

Models

400S

460SJ

P/N - 3120895

December 6, 2012

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

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

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE
MANUFACTURER.

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

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

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

B HYDRAULIC 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.

Relieve system pressure by cycling the applicable control
several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure
feed lines to system components can then be discon­nected with minimal fluid loss.

• 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 SERVICEMANUAL.

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

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

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS 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.

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.

3120895 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue April 1, 2000
Revised: July 21, 2000
Revised: October 1, 2000
Revised: March 27, 2001
Revised October 1, 2001
Revised January 25,2002
Revised April 10, 2002
Revised June 14, 2004
Revised September 14, 2005
Revised October 1, 2005
Revised April 9, 2007
Revised June 20, 2007
Revised October 8, 2007
Revised December 28, 2010
Revised December 6, 2012

A-2 – JLG Lift – 3120895

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

1.2 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

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

1.4 Specifications and Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.8 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.9 Pressure Settings - PSI (Bar). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.10 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.11 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.12 Welder, Hydraulic (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.13 Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.14 Operator Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Draining Oil Build Up From The Propane Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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

3120895 – JLG Lift – i

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

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

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

SECTION 3 - CHASSIS & TURNTABLE

3.1 Tires & Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

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

Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

3.2 Drive Hub Part No. 2780243 (2wd Rear) Part No. 2780244 (4wd Rear) . . . . . . . . . . . . . . . . . . . .3-2

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Disassembly of Cover Unit (8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Disassembly of First Stage Planetary Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Disassembly of the Second Stage Planet Gears (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Assembly of First Stage Planetary Assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Assembly Of End Cover Unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 Drive Hub Part No. 2780246 (4wd steer axle Prior to S/N 0300076633) . . . . . . . . . . . . . . . . . . . .3-5

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Disassembly of Cover Unit (8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Disassembly of First Stage Planetary Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Disassembly of the Second Stage Planet Gears (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Assembly of First Stage Planetary Assembly (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Assembly of End Cover Unit (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.4 Torque Hub - 4WD (Machines built after S/N 0300076633) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Roll and Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Main Disassembly for ”B” Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

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

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

Assembly of the Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Cover Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.5 Re-Aligning Torque Hub Input Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

ii – JLG Lift – 3120895

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

3.6 Drive Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.7 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Loop Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Initial Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.8 Adjustment Procedure For Lockout Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3.9 Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3.10 2WD Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

Removal & Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Cleaning & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Assembly & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3.11 Oscillating Axle Bleeding Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3.12 Oscillating Axle Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3.13 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Replacement of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Swing Bearing Torque Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Swing Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3.14 Swing Brake (Prior to S/N 64802) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Assembly Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

3.15 Swing Brake S/N 64802 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3.16 Swing Drive Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Disassembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Hub Shaft Sub-Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Carrier Sub-Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

3.17 Semi-Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61

Testing the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Removing the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Assuming Normal Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

3.18 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . 3-66

3120895 – JLG Lift – iii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

3.19 Ford EFI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68

Performing Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Visual/Physical Engine Inspection Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

EFI Diagnostics (Prior to S/N 61718) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

ECM and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75

3.20 Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61718) . . . . . . . . . . . . . . . . . . . .3-79

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

Failure Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

3.21 Tilt Alarm Switch (Prior to S/N 61718) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

3.22 Hydraulic Welder (225-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-86

Replacement of Weld Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

Replacement of Hydraulic Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

Replacement of Fine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

Rotor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Replacement of Flow Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Replacement of Exciting Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87

Replacement of Weld Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

Replace Brushes on Sky Welder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

Replacing Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

Replacing Selector Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

Replacement of Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

Voltage Change Over - 120/240 Volt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89

3.23 Troubleshooting of the Sky Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90

Low Sky Welder Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Low Welding Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

No Output on Weld Receptacles or AC Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

No Ac Output but Weld Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

No Output on Weld Receptacle but AC Receptacle Output OK. . . . . . . . . . . . . . . . . . . . . . 3-94

Welder Completely Dead - No AC or Weld Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

Intermittent Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94

3.24 Deutz EMR 2 (S/N 77682 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95

3.25 GM Engine General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108

Maintenance of the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Engine Electrical System Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Checking/Filling Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

Changing The Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

Coolant Fill Procedure - Dual Fuel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

3.26 GM Engine Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-111

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

Electric Lock Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-111

EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112

Low Pressure Regulator (LPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112

Air Fuel Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

Electronic Throttle Control (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

Heated Exhaust Gas Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

Gasoline Multi Point Fuel Injection System (MPFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

Gasoline Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

Gasoline Pressure And Temperature Sensor Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

Fuel Injector Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

iv – JLG Lift – 3120895

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

3.27 GM Engine Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-116

Propane Fuel System Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116

Propane Fuel System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116

Propane Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-116

Electronic Pressure Regulator (EPR) Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . 3-117

Temperature Manifold Absolute Pressure (TMAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118

Electronic Throttle Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-119

MIXER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120

Coolant Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120

Vapor Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-120

Engine Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121

Heated Exhaust Gas Oxygen Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121

3.28 GM Engine LPG Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-121

Fuel System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-121

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122

3.29 Perkins Engine General Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138

Replacing the Engine Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138

Engine Oil Level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138

Engine Oil and Filter - Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138

Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140

Setting the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141

Speed Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142

3.30 Engine Radiator Fill Procedure - Perkins & Caterpillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-142

3.31 DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS . . . . . . . . . . . . . . . . . . . . . .3-144

Section Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144

List of Abbreviations in this Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145

Fault Code Broadcast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146

Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146

CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146

MIL Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-147

Diagnostic Calibration Configuration and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . 3-147

Fault/Diagnostic Trouble Code Interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-148

DBW Diagnostic Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-153

3.32 Diagnostic Trouble Code Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-154

DTC 116- ECT Higher Than Expected Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154

DTC 117- ECT/CHT Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155

DTC 118- ECT/CHT High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157

DTC 122- TPS1 Signal Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159

DTC 123- TPS1 Signal Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-162

DTC 217- ECT Higher Than Expected 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-164

DTC 219- RPM Higher Than Max Allowed Governed Speed . . . . . . . . . . . . . . . . . . . . . . . . 3-165

DTC 336- Crank Signal Input Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166

DTC 337- Loss of Crank Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168

DTC 521- Oil Pressure Sender/Switch High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-169

DTC 524- Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172

DTC 562- Battery Voltage (VBat) Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-176

DTC 563- Battery Voltage (VBat) High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-178

DTC 601- Microprocessor Failure - FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-180

DTC 604- Microprocessor Failure - RAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-182

3120895 – JLG Lift – v

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

DTC 606- Microprocessor Failure - COP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-184

DTC 642- 5 Volt External Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-186

DTC 643- 5 Volt External High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-188

DTC 1612- Microprocessor Failure - RTI 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-190

DTC 1613- Microprocessor Failure - RTI 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-191

DTC 1614- Microprocessor Failure - RTI 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-193

DTC 1615- Microprocessor Failure - A/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-195

DTC 1616- Microprocessor Failure - interrupt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-197

DTC 1625- CAN J1939 Shutdown Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-199

DTC 1626- CAN J1939 Transmit (Tx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-200

DTC 1627- CAN J1939 Receive (Rx) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-201

DTC 1628- CAN Address Conflict Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-202

DTC 1629- J1939 TSC1 Message Reciept Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-204

DTC 1652- TPS1 Loss of Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-205

DTC 2111- Unable to Reach Lower TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-206

DTC 2112- Unable to Reach Higher TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-208

DTC 9999- Throttle Actuator Failsafe Spring Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-209

DTC to SPN/FMI Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-210

SECTION 4 - BOOM & PLATFORM

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

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

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

4.2 Articulating jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3 Limit Switch Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Boom Horizontal Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Dual Capacity Angle Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Boom Length Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.4 Drive Card Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Lift, Swing, and Drive Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Flow Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.5 Helac Rotary actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Tools Required for Assembly/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Installing Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

vi – JLG Lift – 3120895

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

SECTION 5 - HYDRAULICS

5.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Systems Incorporating Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Systems Incorporating Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Cylinders Without Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

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

5.3 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Solenoid Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5.4 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

1. Bang-Bang Main Relief Valve; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

2. Steer; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

3. Platform Level Up; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

4. Platform Level Down;. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5. Articulating Jib Up; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

6. Articulating Jib Down; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

7. The Bang-Bang Main Relief Valve; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

8. The Proportional Main relief valve; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

9. Lift Down; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

10. Swing; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.5 Hydraulic Motor Repair (H Series Char-lynn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Reassembly Shaft End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Gerotor End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Standard Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Reverse Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5.6 Hydraulic Pump “Neutral” Or Null Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

5.7 Non-feedback, Proportional Electrical Control - NFPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Features and Benefits of the NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Input Signal requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

5.8 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .5-27

SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)

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

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

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

6.4 Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6.5 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.6 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.7 Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6.8 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6.9 System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-62

Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

Test from the Ground Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

6.10 Analyzer Diagnostics Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-81

3120895 – JLG Lift – vii

TABLE OF CONTENTS

SECTION NO. TITLE PAGE NO.

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 Checking Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

Basic Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .7-4

Installation of Dielectric Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Deutsch HD, DT, DTM, DRC Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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

Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.6 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

viii – JLG Lift – 3120895

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-2. Operator Maintenance and Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3. Deutz Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-4. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1-5. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

1-6. Torque Chart (SAE Fasteners - Sheet 2 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

1-7. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

1-8. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-10. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

1-11. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

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

2-2. Engine Operating Temperature Specifications - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-3. Engine Operating Temperature Specifications - Caterpillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-4. Engine Operating Temperature Specifications - GM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-5. Engine Operating Temperature Specifications - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

3-1. Drive Hub (Part No. 2780243-2WD Rear & Part No. 2780244-4WD Rear). . . . . . . . . . . . . . . . . . .3-4

3-2. Drive Hub (Part No. 2780246-4WD Steer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-3. Cluster Gear Punch Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-4. Drive Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-5. Swing Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-6. Drive Motor Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-7. Removing the Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-8. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

3-9. Loop Flushing Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-10. Plugs, Fittings, and Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-11. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-12. Valve Plate & Rear Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-13. Cylinder Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-14. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-15. Shaft & Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-16. Swash Plate & Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-17. Cylinder Kit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-18. Servo Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-19. Cylinder Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-20. Swash Plate and Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-21. Shaft and Front Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-22. Cylinder Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-23. Servo Spring and Minimum Angle Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-24. Valve Plate and Rear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-25. End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-26. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-27. Plugs and Fittings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-28. Loop Flushing Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-29. Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3-30. 2WD Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

3120895 – JLG Lift – ix

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

3-31. Swing Bearing Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-32. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

3-33. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-34. Drive Motor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-35. Swing Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-36. Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

3-37. Swing Brake Prior to S/N 64802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51

3-38. Swing Brake S/N 64802 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53

3-39. Swing Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55

3-40. Auxiliary Pump - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64

3-41. Auxiliary Pump - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65

3-42. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . .3-67

3-43. Malfunction Indicator Light and Test Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69

3-44. EFI Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72

3-45. Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76

3-46. Addco Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-80

3-47. Addco Throttle Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82

3-48. Tilt Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-83

3-49. Valve Location - Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84

3-50. Hyd Tank Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85

3-51. Hydraulic Welder 225-4 (sht 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92

3-52. Hydraulic Welder 225-4 (sht 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-93

3-53. EMR 2 Engine Side Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

3-54. Deutz EMR 2 Troubleshooting Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-97

3-55. Deutz EMR 2 Vehicle Side Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-98

3-56. Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

3-57. Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100

3-58. EMR 2 Engine Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-101

3-59. EMR 2 Vehicle Plug Pin Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102

3-60. EMR2 Fault Codes - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103

3-61. EMR2 Fault Codes - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-104

3-62. EMR2 Fault Codes - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-105

3-63. EMR2 Fault Codes - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-106

3-64. EMR2 Fault Codes - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107

3-65. Engine Oil Dip Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108

3-66. Electric Fuel Lock Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-111

3-67. EPR Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112

3-68. Low Pressure Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112

3-69. Air Fuel Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-113

3-70. ETC throttle control device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113

3-71. LPG Engine Control Unit (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-114

3-72. ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114

3-73. Heated Exhaust Gas Oxygen Sensor (HEGO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-114

3-74. Gasoline Fuel Pressure and Temperature Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115

3-75. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-116

3-76. EPR Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-117

x – JLG Lift – 3120895

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

3-77. Pressure Regulator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-118

3-78. (TMAP) Sensor & Electronic Throttle Control (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118

3-79. Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-120

3-80. EPR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-121

3-81. GM 3.0L Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-136

3-82. GM 3.0L Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-137

3-83. Crankcase Breather - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-138

3-84. Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-139

3-85. Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-140

3-86. Faults Page with Active Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-148

3-87. Faults Page with Historic Fault Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-149

3-88. Custom Fault Variable Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-150

3-89. Historic Fault Information Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151

3-90. Snapshot Data Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-152

3-91. Flight Data Recorder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-152

3-92. Clear Faults Prompt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-153

3-93. Exhaust Venturi Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-211

4-1. Support - Side Entry Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-2. Support - Rear Entry Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-3. Location of Components - Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-4. Articulating Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-5. Limit Switches - 500 / 1000 LB (230 / 450 kg) Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-6. Limit Switches - 750 LB (340 kg) Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-7. Limit Switches - CE Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-8. Limit Switches - 460SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-9. Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-10. Rotary Actuator (Exploded View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-11. Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4-12. Rotator Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

5-1. Boom Prop Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5-3. Capscrew Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-4. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-5. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-6. Composite Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-7. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-8. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-9. Platform Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-10. Jib Lift Cylinder (460SJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-11. Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-12. Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-13. Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5-14. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-15. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-16. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

5-17. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

3120895 – JLG Lift – xi

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

5-18. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-19. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-20. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-21. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-22. Main Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5-23. Main Valve Cartridge Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5-24. Char-Lynn H Series Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

5-25. Variable Displacement Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

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

6-2. ADE Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-3. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-4. Control Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-5. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . .6-9

6-6. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-7. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-8. Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . .6-12

6-9. Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-10. Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-11. Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-12. Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-13. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-63

6-14. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-65

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

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

7-7. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

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

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

7-10. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7-11. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7-12. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-13. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

7-14. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7-15. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7-16. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7-17. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7-18. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-19. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-20. Electrical Components Installation w/o JLG Control System - Sheet 1 of 2 . . . . . . . . . . . . . . . . .7-14

7-21. Electrical Components Installation w/o JLG Control System - Sheet 2 of 2 . . . . . . . . . . . . . . . . .7-15

7-22. Electrical Components Installation with JLG Control System - Sheet 1 of 2 . . . . . . . . . . . . . . . . .7-16

7-23. Electrical Components Installation with JLG Control System - Sheet 2 of 2 . . . . . . . . . . . . . . . . .7-17

7-24. On Board Generator Electrical Schematic. (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19

xii – JLG Lift – 3120895

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

7-25. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 1 of 4 . . . . . . . . . . . . . . . . .7-20

7-26. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 2 of 4 . . . . . . . . . . . . . . . . .7-21

7-27. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 3 of 4 . . . . . . . . . . . . . . . . .7-22

7-28. Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 4 of 4 . . . . . . . . . . . . . . . . .7-23

7-29. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 1 of 4 . . . . . . . . . . . . . . . . 7-24

7-30. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 2 of 4 . . . . . . . . . . . . . . . . 7-25

7-31. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 3 of 4 . . . . . . . . . . . . . . . . 7-26

7-32. Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 4 of 4 . . . . . . . . . . . . . . . . 7-27

7-33. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 1 of 4 . . . . . . . . . . . . . . . .7-28

7-34. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 2 of 4 . . . . . . . . . . . . . . . .7-29

7-35. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 3 of 4 . . . . . . . . . . . . . . . .7-30

7-36. Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 4 of 4 . . . . . . . . . . . . . . . .7-31

7-37. Electrical Schematic - Caterpillar Engine - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

7-38. Electrical Schematic - Caterpillar Engine - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

7-39. Electrical Schematic - Caterpillar Engine - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7-40. Electrical Schematic - Caterpillar Engine - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

7-41. Electrical Schematic - Caterpillar Engine - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

7-42. Electrical Schematic - Caterpillar Engine - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7-43. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

7-44. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-45. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

7-46. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-47. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

7-48. Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

7-49. Electrical Schematic - Hydraulic Welder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44

7-50. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-46

7-51. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-47

7-52. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-48

7-53. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-49

7-54. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-50

7-55. Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . .7-51

7-56. Hydraulic Schematic - (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-52

7-57. Hydraulic Schematic - (Sheet 2 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53

7-58. Hydraulic Schematic - (Sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-54

7-59. Hydraulic Schematic - (Sheet 4 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55

7-60. Hydraulic Schematic - (Sheet 5 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-56

7-61. Hydraulic Schematic - (Sheet 6 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57

3120895 – JLG Lift – xiii

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-3 Deutz F3M1011F/F3M2011F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-4 Isuzu 4LE1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-5 Caterpillar 3024/C2.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1-6 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-7 Perkins 404C-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-8 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-9 Specifications and Performance Data - 400S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-11 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-10 Specifications and Performance Data - 460SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-12 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-13 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-14 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-15 Relief Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-16 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-17 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-18 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-19 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-20 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-21 Welder Specifications - Model 225-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-22 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

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

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Excessive Noise and/or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-3 System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-4 Won’t Shift or Slow to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-5 Displacement Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-6 Slipper Foot Thickness & End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-7 Cylinder Block Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-8 Adjustment Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63

3-9 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70

3-10 Position Controller Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-79

3-11 LPF Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123

3-12 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-126

3-13 DTC to SPN/FMI Cross Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-134

3-14 J1939 Diagnostic Lamp Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-147

3-15 Diagnostic Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-147

3-16 Historic Fault Information Interface Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-151

4-1 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-2 Flow Control Card Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-3 Flow Control Card Ramp Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

5-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

xiv – JLG Lift – 3120895

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

5-2 Holding Valve Torque Specification.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-3 Pump Flow Direction with NFPE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26

6-1 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6-2 Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66995. . . . . . . . . . . . . . . . .6-20

6-3 Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present . . . . . . . . . . . . . . 6-24

6-4 Machine Configuration Programming Information Prior to Software Version P5.3 . . . . . . . . . . . . 6-45

6-5 Machine Configuration Programming Information Software Version P5.3 to P6.1 . . . . . . . . . . . .6-49

6-6 Machine Configuration Programming Information Software Version P6.1 to Present. . . . . . . . . .6-54

6-7 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-66

6-8 Machine Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69

6-9 Analyzer Fault Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-73

6-10 ADJUSTMENTS - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-81

6-11 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

3120895 – JLG Lift – xv

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

This page left blank intentionally.

xvi – JLG Lift – 3120895

SECTION 1. SPECIFICATIONS

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Table 1-1. Capacities

Fuel Tank 26 gallons (98.4 liters)

Hydraulic Tank 40.0 gallons (152 liters)

Hydraulic System (Including Tank) 52 gallons (196.8 liters)

Drive Hub 17 ounces (0.5 liters)

Engine Oil Capacity
F or d
D eu t z
C at e r pi l la r
G M

4.5 Quar ts (4.25 L) w/Filter

6.3 qts. (6 L) w/Filter

3.8 quar ts (3.6 L) crankcase only

4.5 qts. (4.25 L) w/Filter

1.2 ENGINE SPECIFICATIONS

NOTE: RPM Tolerances are ± 100.

Table 1-2. Ford LRG-425 (Gas or Dual Fuel)

Ty pe 4 cylinder, 4 stroke, spark

ignition

Fuel Gasoline or Gasoline/LP Gas

Bore 3 in. (96 mm)

Stroke 3.4 in. (86.4 mm)

Displacement 153 cu. in. (2.5 L)

Firing Order 1-3-4-2

BHP at Max. RPM 82

Oil Capacity 4.5 quarts (4.26 L)

Low RPM 1000

Mid RPM 1800

High RPM 3000

Fuel Consumption: Gasoline
I nt e r mi t te n t
Continuous

Fuel Consumption: LPG
I nt e r mi t te n t
Continuous

Spark Plug AWSF-52-C

Spark Plug Gap 0.044 in. (1.117 mm)

6 gal. hr.

5 gal. hr.

26 lbs. hr.
23 lbs. hr.

Table 1-3. Deutz F3M1011F/F3M2011F

Fuel Diesel

No. of Cylinders 3

Bore 3.6 in. (91 mm)

Stroke 4.4 in. (112 mm)

Displacement 133 cu. in. (2184 cm³)

BHP at Max. RPM 48

Oil Capacity
crankcase
c oo l e r
total capacity

Low RPM 1200

Mid RPM 1800

High RPM 2800

Table 1-4. Isuzu 4LE1

Fuel Diesel

No. of Cylinders 4

BHP at Max. RPM 45

Low RPM 1000

Mid RPM 1500

High RPM 2800

Table 1-5. Caterpillar 3024/C2.2

Fuel Diesel

No. of Cylinders 4

BHP 46.5 hp (34 kW)

Bore 3.307 in. (84 mm)

Stroke 3.9370 in. (112 mm)

Displacement 134.3 cu. in. (2.2L)

Oil Capacity 3.8 quarts (3.6 L) crankcase

Compression Ratio 19:1

Firing Order 1-3-4-2

Max. RPM 2800

6.3 quarts (6 L)

4.75 quarts (4.5 L)
11 quarts (10.5 L)

only

3120895 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

Table 1-6. GM 3.0L

Fuel Gasoline or Gasoline/LP Gas

No. of Cylinders 4

BHP
G as o l in e
L P

Bore 4.0 in. (101.6 mm)

Stroke 3.6 in. (91.44 mm)

Displacement 181 cu.in. (3.0 L, 2966 cc)

Oil Capacity w/filter 4.5 qts. (4.25 L)

Minimum Oil Pressure
a t i d l e
H ot

Compression Ratio 9.2:1

Firing Order 1-3-4-2

Max. RPM 2800

Table 1-7. Perkins 404C-22

Fuel Diesel

No. of Cylinders 4

BHP 50 HP (37.3 kW)

Bore 3.3 in. (84 mm)

Stroke 3.9 in. (100 mm)

Firing Order 1-3-4-2

Displacement 135 cu.in. (2.2 L)

Oil Capacity w/filter 10 qt. (9.4 L)

Compression Ratio 23.3:1

18 psi (1.2 Bar) @ 2000 rpm

83 hp @ 3000 rpm
75 hp @ 3000 rpm

6 psi (0.4 Bar) @ 1000 rpm

1.3 TIRES

Table 1-8. Tires

Size Type Pressure Weight

12x16.5 Pneumatic 90 psi

(6.2 Bar)

12x16.5 Foam-filled N/A 328 lbs.

14x17.5 Pneumatic 90 psi

(6 Bar)

14x17.5 Foam-filled N/A 440 lbs.

33/16LLx16.1- Sand Pneumatic 90 psi

(2.75 bar)

33/16LLx16.1- Sand Foam Filled N/A 426 lbs.

Semitrack Tires

24x12x 12 Pneumatic 20 psi

(1.4 bar)

128 lbs.

(58 kg)

(149kg)

128 lbs.

(58 kg)

(200kg)

119.5 lbs.
(54 kg)

(193 kg)

20.7 lbs.

(9.38 kg)

1.4 SPECIFICATIONS AND PERFORMANCE DATA

Table 1-9. Specifications and Performance Data - 400S

Maximum Work Load (Cap acity):
U nr e s tr i ct e d:
R es t ri c t ed :
O pt i o na l :

Maximum Travel Grade, Stowed Position
(Gradeability)

Maximum Travel Grade, Stowed Position
(Side Slope)

Maximum Vertical Platform Height: 40 ft. (12 m)

Maximum Horizontal Platform Reach: 34 ft. (10 m.)

Tu rn in g R ad iu s ( O ut si de ) 1 6 f t. (5 m .)

Tur ning Radius (Inside) 6 ft.-8 in. (2 m.)

Overall Width 6ft.- 6in. (1.98 m)

Tail swing Zero

Stowed Height 7f t. 4in. (2.24 m)

Stowed Length 20ft. 2in. (6.15 m)

Wheelbase 7ft. 10in. (2,3 m)

Ground Clearance 12in. (30 cm)

Max. Tire Load (400S-50 0 lbs. Cap.)
Max. Tire Load (400S-75 0 lbs. Cap.)

Ground Bearing Pressure
12x16.5 FF Tires
14x17.5 pneumatic tires

Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.24 kmh)

Travel Speed, boom elevated. (2WD/4WD) 0.75 m.p.h. (1.20 kmh)

Gross Machine Weight Std. 2wd Machine
(Platform Empty, Pneumatic Tires)
5 0 0 l b . ( 2 30 k g) C a pa c it y
7 5 0 l b . ( 3 40 k g) C a pa c it y

Maximum System Voltage 12 VDC

Max. Hydraulic System Operating Pressure 4060 psi (280 bar)

Manual Force 400 N maximum

Maximum Wind Speed 28 mph (12.5 m/s)

standard
500 lbs. (230 kg.)
1000 lbs. (230 kg)

750 lbs. (340 kg)

2 W/D-30%
4 W/D-45%

o

5

6200 lbs. (2812 kg)
8350 lbs. (3788 kg)

58 psi (4.07 kg/cm
45 psi (3.16 kg/cm

(27-32 sec/ 200f t.)

(46-115 sec/ 50 ft.)

12,525 lbs. (5681kg)
13,525 lbs. (6135 kg)

2

2

)
)

1-2 – JLG Lift – 3120895

SECTION 1 - SPECIFICATIONS

Table 1-10. Specifications and Performance Data - 460SJ

Maximum Work Load (Capacity):
U n re s tr i c te d : 5 00 l b s. ( 23 0 kg . )

Maximum Travel Grade, Stowed Position
(Gradeability)

Maximum Travel Grade, Stowed Position
(Side Slope)

Maximum Vertical Platform Height: 46 ft. (14 m.)

Maximum Horizontal Platform Reach: 40 ft. (12 m.)

Tur ning Radius (Outside) 16 ft. (5 m.)

Turning Radius (Inside) 6 ft.-8 in. (2 m.)

Overall Width 6ft.- 6in. (1.98 m)

Tail swing Zero

Stowed Height 7ft. 4in. (2.24 m)

Stowed Length 20ft. 2in. (6.15 m)

Wheelbase 7ft. 10in. (2,3 m)

Ground Clearance 12in. (30 cm)

Max. Tire Load 7200 lbs. (3266 kg)

Ground Bearing Pressure

Travel Speed, boom stowed.(2WD/4WD) 4.5 m.p.h. (7.24 kmh)

Travel Speed, boom elevated. (2WD/
4WD)

Gross Machine Weight Std. 2wd Machine
(Platform Empty, Pneumatic Tires)

Maximum System Voltage 12 VDC

Max. Hydraulic System Operating Pres­sure

Maximum Manual Force 400 N

Maximum Wind Speed 28 mph (12.5 m/s)

2 W/D - 30%
4 W/D - 45%

o

5

63 psi (4.4 kg/cm

(27-32 sec/ 200ft.)

0.75 m.p.h. (1.20 kmh)
(46-115 sec/ 50 ft.)

7192 kg (15,855 lb.)

4060 psi (280 bar)

2

)

1.6 CRITICAL STABILITY WEIGHTS

Table 1-12.Critical Stability Weights

Component LB. KG

Ford Engine 339 154

Deutz Engine 441 200

8 ft Platform (x 30") 205 93

6 ft. Platfor m (x 30") 160 73

5 ft. Platfor m (x 30") 145 66

4ft. Platform (x 30") 130 59

8 ft. Platfor m (x 36") 230 105

Bolt-on T/T Cwt. (SJ) 487 221

12 x16.5 pneu.Tire & Wheel 128 58

12 x16.5 F/F Tire & Wheel 440 200

12 x 21.5 (NHS)pneu.Tire &
Wheel

12 x 21.5 (NHS)F/F Tire & Wheel 224 102

14 x16.1 Sand pneu. Tire & Wheel 91.5 42

14 x16.1 Sand F/F Tire & Wheel 440 200

55 97

1.5 TORQUE REQUIREMENTS

Table 1-11.Torque Requirements

Description Torque Value

Wheel Lugs 170 ft. lbs. (231 Nm) 150

Swing Bearing ((Loctite) 190 ft. lbs. (260 Nm) 50/600*

* Check swing bearing bolts for security after first 50 hours of
operation and every 600 hours thereafter.

3120895 – JLG Lift – 1-3

Interval

Hours

SECTION 1 - SPECIFICATIONS

1.7 MAJOR COMPONENT WEIGHTS 1.8 FUNCTION SPEEDS

Table 1-13.Major Component Weights

Component LB. KG

8 ft Platform 230 105

6ft. Platform 160 73

5 ft. Platform 145 66

4 ft. platform 130 59

Extend-A-Reach 230 104

Boom (400S) 985 447

Boom (460SJ) 1250 567

Turn ta bl e 3560 1615

Engine Tray 890 404

Hydraulic Tray 225 102

Tail Counter weight (460SJ) 3410 1547

Chassis (12x16.5 pneu. tires) 4200 1905

12 x16.5 pneu.Tire & Wheel 128 58

12 x16.5 F/F, Tire & Wheel 440 200

12 x21.5 (NHS)pneu.Tire &
Wheel

12 x 21.5 (NHS) F/F, Tire & Wheel 224 102

14 x16.1 Sand pneu. Tire &
Wheel

14 x16.1 Sand F/F Tire & Wheel 440 200

Jib 320 145

Hydraulic Welder 140 64

55 97

91.5 42

1.9 PRESSURE SETTINGS - PSI (BAR)

Table 1-14.Function Speeds (In Seconds)

Function Speed

Main Boom Lift Up 26-32

Main Boom Lift Down 19-25

Swing - (10% max diff.) 70-90

Te le sc o pe Ou t 18-23

Te le sc o pe In 23-29

Platform Rotate (

Jib Up - (460SJ) 17-23

Jib Down - (460SJ) 13-20

Drive Forward & Reverse (200 ft.) 27-32

Drive Above Horizontal, Fwd. & Rev. 46-115

Cold temperatures have a significant impact on pressure
readings. JLG Industries Inc. recommends operating the
machine until hydraulic systems have warmed to normal
operating temperatures prior to checking pressures. It is
also recommended using a calibrated gauge. Pressure
readings are accepted if within +/-5% of specified pres­sures.

Main Relief - (Bang-Bang Valve) 2500 172

Main Relief (Proportional Valve) 2750 189

Lift Up N/A N/A

Lift Down 1600 110

Level Down 1800 124

Level Up 2800 193

Swing (Right & Left) 1600 110

Steer 2500 172

Jib Up (460SJ Only) 2500 172

Jib Down (460SJ Only) 1200 83

Drive - (Pre-Set) 4500 310

Left & Right) - (15% max diff.) 9-15

Table 1-15.Relief Settings

Circuit PSI Bar

(4.5 MPH)

(.75-.33 MPH)

1-4 – JLG Lift – 3120895

SECTION 1 - SPECIFICATIONS

Table 1-18. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, M ax -4 6°F (- 43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

Table 1-19. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)

Flash Point 500°F (260°C)

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

Weight

7.64 lb. per gal.
(0.9 kg per liter)

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

Table 1-20. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

NOTE: Mobil/Exxon recommends that this oil be

checked on a yearly basis for viscosity.

1.10 CYLINDER SPECIFICATIONS

Table 1-16.Cylinder Specifications

Cylinder Bore Stroke Rod Dia.

Oscillation 2.5 in.

(63.5 mm)

Main Lift 5.0 in.

(127.0 mm)

Te le sc o pe 3.0 in.

(76.2 mm)

Slave 2.5 in.

(63.5 mm)

Master 2.5 in.

(63.5 mm)

Jib 3.0 in.

(76.2 mm)

steer 2.5 in

(63.5 mm)

4.125 in.

(104.8 mm)

39.0 in.

(990.0 mm)

181.0 in.

(459.74 cm)

14.9 in.

(37.9 cm)

15.13 in.

(38.4 cm)

18.4 in.

(46.7 cm)

9.2 in

(233.6 mm)

1.11 LUBRICATION

Hydraulic Oil

1.75 in.

(44.45 mm)

2.5 in.

(63.5 mm)

2.0 in.

(50.8 mm)

1.25 in.

(31.75 mm)

1.25 in.

(31.75 mm)

1.5 in.

(38.1 mm)

1.75 in

(44.58 mm)

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

Table 1-17.Hydraulic Oil

Hydraulic System

Operating Temperature Range

+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

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser­vice. JLG Ind. recommends Mobilfluid 424 hydraulic
oil, which has an SAE viscosity index of 152.

NOTE: When temperatures remain consistently below 20

degrees F. (-7 degrees C.), JLG Industries recom­mends the use of Mobil DTE-13.

NOTE: Machines may be equipped with Mobil EAL224H bio-

3120895 – JLG Lift – 1-5

degradable and non-toxic hydraulic oil. This is Vege­table oil based and 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. Mobil EAL224H has a viscosity of 34 cSt at
40° C. and viscosity index of 213. The operating tem­perature range of this oil is -18° C. to +83° C.

S.A.E. Viscosity

Grade

SECTION 1 - SPECIFICATIONS

Figure 1-1. Serial Number Location

SERIAL NUMBER

STAMPED ON FRAME

SERIAL NUMBER

PLATE

1

7

6

4

8

3

9

20

21, 22

14,15,16,17,18,19

8,9,10,11,12,13

5

Figure 1-2. Operator Maintenance and Lubrication Diagram

1.12 WELDER, HYDRAULIC (OPTION)

Table 1-21.Welder Specifications - Model 225-4

Description Specification

Weld Amps 225

Strike Weld 75

Weld Voltage 21.6 - 28 DC

Freque ncy 60 Hz, KVA - 4.2 Kw, Single Phase

Oil Flow 18.8 Gpm, 2000 Psi.

1.13 SERIAL NUMBER LOCATION

A serial number plate is affixed to the left rear side of the
frame. If the serial number plate is damaged or missing,
the machine serial number is stamped on the left side of
the frame.

1-6 – JLG Lift – 3120895

SECTION 1 - SPECIFICATIONS

1.14 OPERATOR MAINTENANCE AND LUBRICATION

NOTE: The following numbers correspond to those in Figure

1-2., Operator Maintenance and Lubrication Dia­gram.

Table 1-22. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350°

F (177° C). Excellent water resistance and adhesive qualities,
and being of extreme pressure type.
(Timken OK 40 pounds minimum.)

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

c at io n G L- 5 o r M IL- Sp e c M IL- L-2 1 05

HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid

424.

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

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

OGL Open Gear Lubricant - Mobiltac 375 or equivalent.

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

NOTE: It is recommended as a good practice to replace all

filters at the same time.

1. Swing Bearing - Internal Ball Bearing

Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Fittings in center of bearing: Remote
Access is optional

2. Wheel Bearings (2WD Only)

Lube Point(s) - Repack
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation

3. Wheel Drive Hub

Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (0.5 L) - 1/2 Full
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation

4. Hydraulic Return Filter

Interval - Change after first 50 hrs. and every 6
months or 300 hrs. thereafter or whenever Charge
Filter is replaced.

5. Hydraulic Charge Filter

Interval - Change after first 50 hrs. and every 6
months or 300 hrs. thereafter or as indicated by
Condition Indicator.

6. Hydraulic Tank

Lube Point(s) - Fill Cap
Capacity - 40.0 gal. tank (151L) 52.0 gal. system
(196.8L)
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.

3120895 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

MINIMUM LEVEL,
OIL HOT

MINIMUM OIL
LEVEL

MINIMUM LEVEL,
OIL COLD

NOTE: Hot oil checks should not be made until the engine
has been shut down for a period of 5 minutes.

MAXIMUM LEVEL,
OIL HOT

MAXIMUM LEVEL,
OIL COLD

MAXIMUM OIL
LEVEL

Figure 1-3. Deutz Engine Dipstick

7. Suction Strainers

Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation,
remove and clean at time of hydraulic oil change.

8. Oil Change w/Filter - Ford

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N

7014501)
Capacity - 4.5 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual.

9. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N

7016331)
Capacity - 6.3 qt. (5.9) engine
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual. Refer to Figure 1-3.,
Deutz Engine Dipstick.

10. Oil Change w/Filter - Isuzu

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N

7022111)
Capacity - 6 qt. (5.6L) engine; 6.5 qt. (6.1L) w/cooler
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual.

11. Oil Change w/Filter - Caterpillar

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N

7026855)
Capacity - 10 Quarts (9.4 L)
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual.

1-8 – JLG Lift – 3120895

SECTION 1 - SPECIFICATIONS

12. Oil Change w/Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7027965)
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual.

13. Oil Change w/Filter - Perkins

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N

7026855)
Capacity - 10 Quarts (9.4 L)
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accor­dance with engine manual.

14. Fuel Filter - Ford

15. Fuel Filter - Deutz

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

16. Fuel Filter - Isuzu

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

17. Fuel Filter - Caterpillar

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

18. Fuel Filter (Gasoline) - GM

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

19. Fuel Filter - Perkins

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

20. Air Filter

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

Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation
or as indicated by the condition indicator

3120895 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

21. Electronic Pressure Regulator (LP only)

Interval - 3 Months or 150 hours of operation
Comments - Drain oil build up. Refer to Draining Oil
Build Up From The Propane Regulator

22. Fuel Filter (Propane) - GM Engine

2. Start the engine and bring to operating temperature.

3. With the engine running, close the manual tank

valve and run the engine out of fuel.

4. Push in the Emergency Switch once the engine
stops.

5. Disconnect the electrical connection to the LPG fuel
temperature sensor in the auxiliary fuel port of the
EPR.

6. Remove the retainer clip for the LPG fuel tempera­ture sensor and remove the sensor from the regula­tor body.

Interval - 3 Months or 150 hours of operation
Comments - Replace filter. Refer to Propane Fuel Fil­ter Replacement

Draining Oil Build Up From The Propane Regulator

During the course of normal operation oils may build
inside the primary and secondary chambers of the pro­pane pressure regulator. These oils may be a result of
poor fuel quality, contamination of the fuel supply
chain, or regional variation in the make up of the fuel. If
the build up of the oil is significant this can effect the
operation of the fuel control system. Refer to Section

1.14, Operator Maintenance and Lubrication for main­tenance intervals. More frequent draining may be
required if the fuel supply has been contaminated.

FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEM­PERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO
BE LIQUID AND FLOW FREELY FROM THE REGULATOR.

1. Move the equipment to a well ventilated area.
Ensure there are no external ignition sources.

NOTE: Have a small container ready to collect oil that will

drain freely from the regulator at this point.

7. Once all of the oil has been drained, reinstall the
LPG fuel temperature sensor and reconnect the
electrical connector.

8. Open the fuel tank manual valve.

9. Start the engine and verify all connections are

secure.

10. Dispose of any drained oil in a safe and proper fash­ion.

1-10 – JLG Lift – 3120895

SECTION 1 - SPECIFICATIONS

1. Electric Lock Off Solen oid

2. Mounting Plate

3. Housing Seal

4. Filter Magnet

5. Filter Housing

6. Seal

7. Electrical Connector

8. Fuel Outlet

9. O-ring

10. Filter

11. Fuel Inlet

12. Retaining Bolt

Figure 1-4. Filter Lock Assembly

Propane Fuel Filter Replacement

INSTALLATION

BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUS­ING BEFORE INSTALLING NEW SEAL

1. Install the mounting plate to lock off O-ring seal.

2. Install the retaining bolt seal.

3. Install the housing seal.

4. Drop the magnet into the bottom of the filter hous-

ing.

5. Install the filter into the housing.

6. Install the retaining bolt into the filter housing.

7. Install the filter up to the bottom of the electric lock

off.

8. Tighten the filter retaining bolt to 106 in lbs (12 Nm).

9. Open manual shut-off valve. Start the vehicle and

leak check the propane fuel system at each serviced
fitting. Refer to Propane Fuel System Leak Test.

Propane Fuel System Pressure Relief

REMOVAL

1. Relieve the propane fuel system pressure. Refer to

Propane Fuel System Pressure Relief.

2. Disconnect the negative battery cable.

3. Slowly loosen the Filter housing retaining bolt and

remove it.

4. Pull the filter housing from the Electric lock off
assembly.

5. Locate Filter magnet and remove it.

6. Remove the filter from the housing.

7. Remove and discard the housing seal.

8. Remove and discard the retaining bolt seal.

9. Remove and discard mounting plate to lock off O-

ring seal.

THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO
312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PER­SONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRES­SURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE
FUEL SYSTEM COMPONENTS.

To relieve propane fuel system pressure:

1. Close the manual shut-off valve on the propane fuel
tank.

2. Start and run the vehicle until the engine stalls.

3. Turn the ignition switch OFF.

RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL
SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED
BEFORE DISCONNECTING ANY FUEL LINE.

3120895 – JLG Lift – 1-11

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

1-12 – JLG Lift – 3120895

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

3120895 – JLG Lift – 1-13

Figure 1-6. 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 AP PLY TO CADMIUM PLATED FASTENERS

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

1-14 – JLG Lift – 3120895

Figure 1-7. 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 TORQU E 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

3120895 – JLG Lift – 1-15

Figure 1-8. 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 1-9. Torque Chart (METRIC Fasteners - Sheet 5 of 7)

1-16 – JLG Lift – 3120895

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 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

3120895 – JLG Lift – 1-17

Figure 1-10. 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 HAR DEN ED WASHER OR FASTENER IS PLAC ED AGAINST PLATED
STEEL OR RAW ALUMINUM

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

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

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

Figure 1-11. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

1-18 – JLG Lift – 3120895

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

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

increased as environment, severity and frequency of
usage requires.

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

Annual Machine Inspection

The Annual Machine Inspection must be performed by a
Factory-Certified 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 Factory-Certified 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.

3120895 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start Inspec­tion

Pre-Delivery

Inspection

Frequent Inspec-

tion

Annual Machine

Inspection

Preventative
Maintenance

In service for 3 months or 150 hours, which-

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental delivery.

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as specified in the Service and

Maintenance 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 Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Certified

Owner, Dealer, or User Qualified JLG

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

Mechanic

Mechanic

Service Technician

Mechanic

Reference

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual and applicable JLG

inspection form.

Service and Maintenance

Manual

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 – 3120895

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 an anti-seize or
molybdenum disulfide base compound to lubricate the
mating surface.

Bearings

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

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

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

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

Gaskets

Hydraulic Lines and Electrical Wiring

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

Hydraulic System

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

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

Lubrication

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

Battery

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

Lubrication and Servicing

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

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

1. 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.

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

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,

3120895 – JLG Lift – 2-3

SECTION 2 - GENERAL

cleaned, and/or replaced as necessary, at the speci­fied intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.

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

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

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

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

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

2. JLG recommends Mobilfluid 424 hydraulic oil, which
has an SAE viscosity of 10W-30 and a viscosity
index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -15 degrees F (-26 degrees C) is not recom­mended. If it is necessary to start the system in a
sub-zero environment, it will be necessary to heat
the oil with a low density, 100VAC heater to a mini­mum temperature of -15 degrees F (-26 degrees C).

3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 oil or its equivalent.
This will allow start up at temperatures down to -20
degrees F (-29 degrees C). However, use of this oil
will give poor performance at temperatures above
120 degrees F (49 degrees C). Systems using DTE
13 oil should not be operated at temperatures above
200 degrees F (94 degrees C) under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
oil on a regular basis. However, filter elements must
be changed after the first 50 hours of operation and
every 300 hours 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

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, upper 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.

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

Max. Acceptable Drift

in 10 Minutes

2-4 – JLG Lift – 3120895

SECTION 2 - GENERAL

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 cyl-

inder leakage.

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:

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their hous-

ing.

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

surface.

c. Rusting of the pin in the bearing area.

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.

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.

• 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.

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

3120895 – JLG Lift – 2-5

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

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 Pads 1,2 1,2

Covers or Shields 1,2 1,2

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

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 511,5

Floor 1,2 1 1,2

Rotator 9,5

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

Turntable Assembly

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

Oil Coupling 9

Swing Drive System

Turntable Lock 1,2,5 1,2,5

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

Chassis Assembly

Tires 1 16,17 16,17,18 16,17,18

Wheel Nuts/Bolts 115 1515

Wheel Bearings 14,24

Oscillating Axle/Lockout Cylinder Systems 5,8

Outrigger or Extendable Axle Systems 5,8 5,8

Steer Components

Drive Motors

Torque Hubs 11 11

Functions/Controls

Pre-Start

Inspection

9

9

9

9

9

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery
or Frequent

Inspection

2

3

Annual

(Yearly)

Inspection

4

4

Every 2

Years

2-6 – JLG Lift – 3120895

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Preventive

Maintenance

Weekly

Monthly

Preventive

Maintenance

Pre-Delivery
or Frequent

Inspection

2

3

Platform Controls 55 66

Ground Controls 55 66

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

Footswitch 1,5 5 5

Emergency Stop Switches (Ground & Platform) 555

Function Limit or Cutout Switch Systems 55

Capacity Indicator 5

Drive Brakes 5

Swing Brakes 5

Boom Synchronization/Sequencing Systems 5

Manual Descent or Auxiliary Power 55

Power System

9

Engine Idle, Throttle, and RPM 33

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

Air/Fuel Filter 1,7 7 7

Exhaust System 1,9 9 9

Batteries 51,9 19

Battery Fluid 11 11 11

Battery Charger 55

Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5

Hydraulic/Electric System

9

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 11 1,9 2 1,5 1,5 24

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 12020

Instruments, Gauges, Switches, Lights, Horn 15,23

General

Operators and Safety Manuals in Storage Box 21 21 21

ANSI and EMI Manuals/Handbooks Installed 21

Capacity Decals Installed, Secure, Legible 21 21 21

Annual

(Yearly)

Inspection

4

Every 2

Years

3120895 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery
or Frequent

Inspection

2

3

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

Walk-Around Inspection Performed 21

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 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownership 22

Footnotes:

1

Prior to use each day; or at each Operator change

2

Prior to each sale, lease, or delivery

3

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

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 exc essive 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

Years

2-8 – JLG Lift – 3120895

SECTION 2 - GENERAL

Figure 2-1. Engine Operating Temperature Specifications - Deutz

4150548 D

3120895 – JLG Lift – 2-9

SECTION 2 - GENERAL

Figure 2-2. Engine Operating Temperature Specifications - Ford

4150548 D

2-10 – JLG Lift – 3120895

SECTION 2 - GENERAL

AMBIE NT AIR

TEMPERATURE

Figure 2-3. Engine Operating Temperature Specifications - Caterpillar

4150548 D

3120895 – JLG Lift – 2-11

SECTION 2 - GENERAL

Figure 2-4. Engine Operating Temperature Specifications - GM

4150548 D

2-12 – JLG Lift – 3120895

SECTION 2 - GENERAL

AMBIE NT AIR

TEMPERATURE

Figure 2-5. Engine Operating Temperature Specifications - Perkins

4150548 D

3120895 – JLG Lift – 2-13

SECTION 2 - GENERAL

NOTES:

2-14 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

SECTION 3. CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Tire Inflation

The air pressure for pneumatic tires must be equal to the
air pressure that is stenciled on the side of the JLG prod­uct or rim decal for safe and proper operational character­istics.

Tire Damage

For pneumatic tires, JLG Industries, Inc. recommends that
when any cut, rip, or tear is discovered that exposes side­wall or tread area cords in the tire, measures must be
taken to remove the JLG product from service immedi­ately. Arrangements must be made for replacement of the
tire or tire assembly.

For polyurethane foam filled tires, JLG Industries, Inc. rec­ommends that when any of the following are discovered,
measures must be taken to remove the JLG product from
service immediately and arrangements must be made for
replacement of the tire or tire assembly.

• a smooth, even cut through the cord plies which
exceeds 3 inches (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plies which
exceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

• any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria,
the tire must be inspected on a daily basis to insure the
damage has not propagated beyond the allowable crite­ria.

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 Replacement

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

Wheel Installation

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

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

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

3120895 – JLG Lift – 3-1

SECTION 3 - CHASSIS & TURNTABLE

3. The tightening of the nuts should be done in stages.
Following the recommended sequence, tighten nuts
per wheel torque chart.

Table 3-1. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

40 ft. lbs.

(55 Nm)

4. Wheel nuts should be torqued after first 50 hours of
operation and after each wheel removal. Check
torque every 3 months or 150 hours of operation.

100 ft. lbs.

(130 Nm)

170 ft. lbs.

(255 Nm)

3.2 DRIVE HUB PART NO. 2780243 (2WD REAR) PART NO. 2780244 (4WD REAR)

The final drive consists of two stages with an integrated
disconnect mechanism. Each stage incorporates a set of
matched planetary gears, which provide an equal load of
distribution. All torque transmitting components are made
of forged, quenched and tempered high-alloy steels.
External gears are carborized. Precision roller bearings
are used exclusively. Two large, tapered roller bearings
support the sprocket or wheel loads. A shaft seal protects
the unit against contamination.

Disassembly

1. Position drive so that one of the fill holes is at the
bottom of the end cover and drain the gear oil.

2. Remove all bolts holding motor and remove motor
from drive.

3. Press out seal ring (85) together with O-ring (84)
from the drive.

4. Compress the disc (65) using a simple fixture or
other suitable device.

5. Remove snap ring (67) from groove of spindle and
release pressure on disc until loose. Remove tool
and disc (65).

10. Compress the disk (59) using a simple fixture or
other suitable device.

11. Remove snap ring (66) and release pressure on disk
until loose.

12. Remove tool and disk (59).

13. Remove the spring (55) from the input shaft (44)and

turn the unit so that cover (8) is in the up position.

14. Remove screw plugs (22) and seal rings (21).

15. Remove snap ring (34), cover unit (8) from drive and

O-ring (33).

16. Remove first stage planetary assembly (7).

17. Remove hex. hd. bolts (23) to remove gear (30) and

O-ring (19).

18. Remove Snap rings (15) to pull off planet gears (1)
together with cylindrical roller bearings (11) from
spindle (60).

NOTE: Further disassembly of the hub is discouraged. Rein-

stallation of the shaft nut (4) requires a special tool
and a torque of 626 ft lbs (876 Nm) for proper reas­sembly. These components WILL fail if not properly
reassembled.

19. Inspect the planetary stage assemblies as complete
units. Thoroughly clean and check both the gearing
and the bearings for damage and apply new oil. If
gears or bearings need replacing, they must be
replaced as complete units.

NOTE: The first stage planetary bearings (10) must be

replaced in sets of three pieces.

NOTE: The first stage planetary gears (11) must be

changed as a complete set of four and the manufac­turer recommends changing the sun gear shaft (43)
along with this set of planets.

NOTE: The second stage planetary bearings (11) must be

replaced in sets of four pieces.

6. Remove the springs (74) from the piston (61)

7. Remove plug (71).

8. Supply air pressure through air channel actually

closed by plug (71) to remove piston (61).

NOTE: Be careful when supplying air pressure. piston (61)

may unexpectedly come out quickly.

9. Remove back-up rings (75), piston seal (76), back­up rings (77), and piston seal (78).

3-2 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Disassembly of Cover Unit (8)

1. Loosen and remove hex. hd. bolts (53) and remove
cover (51).

2. Remove Shaft rod (56), O-ring (54), and sleeve (52)

Disassembly of First Stage Planetary Assembly

1. Push the sun gear shaft (43) out of the first stage.

2. Remove snap rings (14) and press planet pins (5)

out of planet carrier (7) and planet gears (2).

3. Pull cylindrical roller bearing (10) out of planet gears
(2).

4. Remove snap ring (16) from sun gear (3) and
remove the thrust washer (49).

Disassembly of the Second Stage Planet Gears (1)

Press cylindrical roller bearings out of planet gears (1).

Assembly of First Stage Planetary Assembly (7)

1. Pre-freeze planet pins (5) and install into planet car­rier (7).

2. Install planet carrier (7) together with planet pins (5)
on sun gear (3), and snap ring (16).

3. Pre-heat thrust washer (49) and install onto sun gear
shaft (43).

4. put sun gear shaft (43) into sun gear (3).

5. Pre-heat stay rings (17) and install onto planet pins

(5).

6. Pre-heat cylindrical roller bearings (10) and install
onto planet pins (5) and fix bearings with snap rings
(14).

Final Assembly

1. Install thrust washer (29) in spindle (60).

2. Install O-ring (19) into groove of support ring (6).

3. Install planet gears (1) onto planet pins which are

part of spindle (60).

4. Install snap rings (15) on planet pins of spindle (60)
in order to fix the planet gears (1).

5. Put ring gear (30) onto support ring (6) and fix ring
gear (30) with hex. hd. bolts (23). Torque bolts to

15.5 ft. lbs.(21.1 Nm).

6. Insert first stage planetary assembly (7) into drive.

7. Install O-ring (33) in groove of ring gear (30).

8. Install end cover unit (8) on shoulder ring gear (30)

and fix with snap ring (34).

9. Install seal rings (21) and screw plugs(22).

10. Before installation of the motor CHECK THAT

THERE IS 1-2 MM. OF CLEARANCE BETWEEN THE
MOTOR SPLINE SHAFT SHOULDER AND THE
COUPLER (62).

11. Install motor and reconnect hydraulic lines.

12. Roll motor so that one fill plug hole is at 12 o’clock

position and the other is a 3 o’clock. Fill hub to bot­tom of 3 o’clock hole with gear oil. Reinstall plugs.

13. After four hours of operation, recheck oil level.

Assembly Of End Cover Unit (8)

1. Press sleeve (52) and install O-ring into cover (8).

2. Install shaft rod into cover (8).

3. Install cover into cover (8) and fix cover (51) with

hex. hd. bolts (53). Torque bolts to 6.3 ft. lbs.(8.5
Nm).

3120895 – JLG Lift – 3-3

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-1. Drive Hub (Part No. 2780243-2WD Rear & Part No. 2780244-4WD Rear)

3-4 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

3.3 DRIVE HUB PART NO. 2780246 (4WD
STEER AXLE PRIOR TO S/N

0300076633)

The final drive consists of two stages with an integrated
disconnect mechanism. Each stage incorporates a set of
matched planetary gears, which provide an equal load of
distribution. All torque transmitting components are made
of forged, quenched and tempered high-alloy steels.
External gears are carborized. Precision roller bearings
are used exclusively. Two large, tapered roller bearings
support the sprocket or wheel loads. A shaft seal protects
the unit against contamination.

Disassembly

1. Position drive so that one of the fill holes is at the
bottom of the end cover and drain the gear oil.

2. Remove all bolts holding motor and remove motor
from drive.

3. Compress the disc (59) using a simple fixture or
other suitable device.

4. Remove snap ring (66) and release pressure on disc
until loose. Remove tool and disc (59).

5. Remove the spring (55) from the input shaft (44)and
turn the unit so that cover (8) is in the up position.

6. Remove screw plugs (22) and seal rings (21).

7. Remove snap ring (34), cover unit (8) from drive and

O-ring (33).

8. Remove first stage planetary assembly (7).

9. Remove hex. hd. bolts (23) to remove gear (33) and

O-ring (19).

10. Remove Snap rings (15) to pull off planet gears (1)
together with cylindrical roller bearings (11) from
spindle (60).

NOTE: Further disassembly of the hub is discouraged. Rein-

stallation of the shaft nut (4) requires a special tool
and a torque of 626 ft lbs (876 Nm) for proper reas­sembly. These components WILL fail if not properly
reassembled.

11. Inspect the planetary stage assemblies as complete
units. Thoroughly clean and check both the gearing
and the bearings for damage and apply new oil. If
gears or bearings need replacing, they must be
replaced as complete units.

NOTE: The first stage planetary bearings (10) must be

replaced in sets of three pieces.

NOTE: The first stage planetary gears (11) must be

changed as a complete set of four and the manufac­turer recommends changing the sun gear shaft (43)
along with this set of planets.

NOTE: The second stage planetary bearings (11) must be

replaced in sets of four pieces.

Disassembly of Cover Unit (8)

1. Loosen and remove hex. hd. bolts (53) and remove
cover (51).

2. Remove Shaft rod (56), O-ring (54), and sleeve (52)

Disassembly of First Stage Planetary Assembly

1. Push the sun gear shaft (43) out of the first stage.

2. Remove snap rings (14) and press planet pins (5)

out of planet carrier (7) and planet gears (2).

3. Pull cylindrical roller bearing (10) out of planet gears
(2).

4. Remove snap ring (16) from sun gear (3) and
remove the thrust washer (49).

Disassembly of the Second Stage Planet Gears (1)

Press cylindrical roller bearings out of planet gears (1).

3120895 – JLG Lift – 3-5

SECTION 3 - CHASSIS & TURNTABLE

Assembly of First Stage Planetary Assembly (7)

1. Pre-freeze planet pins (5) and install into planet car­rier (7).

2. Install planet carrier (7) together with planet pins (5)
on sun gear (3), and snap ring (16).

3. Pre-heat thrust washer (49) and install onto sun gear
shaft (43).

4. put sun gear shaft (43) into sun gear (3).

5. Pre-heat stay rings (17) and install onto planet pins

(5).

6. Pre-heat cylindrical roller bearings (10) and install
onto planet pins (5) and fix bearings with snap rings
(14).

Assembly of End Cover Unit (8)

1. Press sleeve (52) and install O-ring into cover (8).

2. Install shaft rod into cover (8).

3. Install cover into cover (8) and fix cover (51) with

hex. hd. bolts (53). Torque bolts to 6.3 ft. lbs.(8.5
Nm).

Final Assembly

1. Install thrust washer (29) in spindle (60).

2. Install O-ring (19) into groove of support ring (6).

3. Install planet gears (1) onto planet pins which are

part of spindle (60).

4. Install snap rings (15) on planet pins of spindle (60)
in order to fix the planet gears (1).

5. Put ring gear (30) onto support ring (6) and fix ring
gear (30) with hex. hd. bolts (23). Torque bolts to

15.5 ft. lbs.(21.1 Nm).

6. Insert first stage planetary assembly (7) into drive.

7. Install O-ring (33) in groove of ring gear (30).

8. Install end cover unit (8) on shoulder ring gear (30)

and fix with snap ring (34).

9. Install seal rings (21) and screw plugs(22).

10. Before installation of the motor CHECK THAT

THERE IS 1-2 MM. OF CLEARANCE BETWEEN THE
MOTOR SPLINE SHAFT SHOULDER AND THE
COUPLER (62).

11. Install motor and reconnect hydraulic lines.

12. Roll motor so that one fill plug hole is at 12 o’clock

position and the other is a 3 o’clock. Fill hub to bot­tom of 3 o’clock hole with gear oil. Reinstall plugs.

13. After four hours of operation, recheck oil level.

3-6 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-2. Drive Hub (Part No. 2780246-4WD Steer)

3120895 – JLG Lift – 3-7

SECTION 3 - CHASSIS & TURNTABLE

3.4 TORQUE HUB - 4WD (MACHINES BUILT AFTER S/N 0300076633)

Roll and Leak Testing

Always roll and leak test Torque-Hubs after assembly to
make sure that the unit’s gears and sealants are working
properly. The following information briefly outlines what to
look for when performing these tests.

THE ROLL TEST

The purpose of a roll test is to determine if the unit’s gears
are rotating freely and properly. You should be able to
rotate the gears in your unit by applying a constant
to the roll checker. If you feel more drag in the gears only
at certain points, then the gears are not rolling freely and
you should examine them for improper installation or
defects. Some gear packages roll with more difficulty than
others. Do not be concerned if the gears in your unit seem
to roll hard as long as they roll with consistency

THE LEAK TEST

The purpose of a leak test is to make sure the unit is air
tight. You can tell if your unit has a leak if the pressure
gauge reading on your air checker starts to fall once you
have pressurized the unit. Leaks will most likely occur at
the main seal or wherever o-rings or gaskets are located.
Usually you can detect the exact location of a leak by
brushing a soap and water solution around the main seal
and where o-rings or gaskets meet the exterior of the unit,
then checking for air bubbles. If you detect a leak in a
seal, o-ring, or gasket, replace the part immediately.

force

Tightening and Torquing Bolts

Oil Information

1. 1. TYPE – EP90
On normal applications, use EP90. On applications
where the lubricant must meet special requirements,
the O.E.M should be able to recommend a suitable
substitute.

2. OIL TEMPERATURE
Continuous – 160° F [70° C] Intermittent – 200° F
[95° C]

3. OIL CHANGE
Initial – After 50 hours or 50,000 revolutions of oper­ation. Subsequent – After 1000 hours or (1) year,
whichever comes first.

NOTE: Higher temperatures make it necessary to change oil

more frequently.

4. OIL FILL LEVEL AND VOLUME
Unit mounted horizontal – half full. (See Diagram A.)
Approximate volume - 17 oz. [0.5 1tr)

Main Disassembly for ”B” Drives

1. 1. Turn hub (1G) over onto its side, Remove cou­pling (14) from the wide end of spindle (1A).

2. Mark location of shoulder bolt holes on out- side of
ring gear and hub for easy re-alignment when
rebuilding. Remove the four shoulder bolts (13) and
twelve bolts (12) from cover (6).

3. Remove the sixteen flat washers (16) from cover (6).

4. Lift cover sub-assembly (6) off of ring gear (4), and

set cover on table, interior side facing up.

If you use an air impact wrench to tighten bolts, take
extreme care to insure that you do NOT tighten the bolts
beyond their indicated torque specification. Never
impact wrench to tighten shoulder bolts. Always tighten
a11 shoulder bolts by hand.

The following steps describe the proper procedure for
tightening and torquing bolts or socket head cap screws
in a bolt circle.

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. Continue around the bolt circle and tighten the
remaining bolts.

4. Now use a torque wrench to apply the specified
torque to bolt ”A”.

5. Continue around the bolt circle and apply an equal
torque to the remaining bolts.

use an

CAUTION: BEWARE OF SHARP EDGES IN THE COUNTERBORE
WHEN YOU REMOVE THE O-RING.

5. Remove o-ring (5) from the counterbore around the
edge of cover (6A). Discard the o-ring.

NOTE: If o-ring is not in the cover counter- bore, it is in the

ring gear counterbore. Remove it from the hub and
discard it.

6. Remove thrust washer (11) from the counter- bore in
top of carrier (3A).

7. Remove input gear (8) from the middle of carrier
sub-assembly (3).

8. Lift ring gear (4) off of hub (1G).

9. Lift carrier sub-assembly (3) out of hub (1G).

10. Remove thrust spacer (9) from input shaft (7) in the

middle of spindle (1A).

3-8 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

11. Lift input shaft sub-assembly (7) out of middle of
spindle (1A), and stand input shaft (7A) on its
splined end.

WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE
THAT SPRING AND SPACERS COMPRESSED BY RETAINING RING
MAY POP SUDDENLY OFF SHAFT WHEN YOU REMOVE THE
RETAINING RING.

12. Using retaining ring pliers, remove retaining ring
(7B) from the groove on input shaft (7A).

13. Remove one spacer (7D), one spring (7C), and
other spacer (7D) from input shaft (7A).

14. Remove thrust washer (11) from around spindle
(1A).

15. Lift internal gear (2) out of hub (1G).

BEWARE OF SHARP EDGES IN COUNTERBORE WHEN YOU
REMOVE THE O-RING.

16. Remove o-ring (5) from the counterbore in hub (1G).
Discard the o-ring.

17. At this point the main disassembly for ”B” drives is
complete.

Hub-Spindle Disassembly

NOTE: Start with large end of hub facing up, large end of

spindle facing down.

5. Bearing cone (1F) should be lying loose in wide end
of hub (1G). Remove bearing cone (1F) from inside
hub (1G).

NOTE: If you use a punch and hammer, make sure you do

not strike the counterbore with the punch when you
remove the bearing cup.

6. Remove bearing cup (1C) from the counterbore in
the small end of hub (1G).

NOTE: If you use a punch and hammer, make sure you do

not strike the counterbore with the punch when you
remove the bearing cup.

7. Turn hub (1G) over and lift it out of the flange-sup­port. Remove bearing cup (1E) from the counterbore
in the wide end of hub (1G).

8. Turn hub (1G) over onto its small end. Remove two
pipe plugs (1J) from the two pipe plug holes in the
side of hub (1G).

NOTE: If your unit does not have studs, skip this step:

9. Press the nine studs (1N) out of the stud holes in
hub (1G).

10. At this point the hub-spindle disassembly is com­plete.

Cover Disassembly

1. Remove the two bolts (6C) holding disconnect cap
(6D) to cover (6A).

2. Remove disconnect cap (6D) from on top of cover
cap (6B) and cover (6A).

3. Remove the two bolts (6C) holding cover cap (6B) to
cover (6A).

WEAR SAFETY GLASSES DURING THIS STEP.

1. Remove retaining ring (1I) from around spindle (1A)
ia hub (1G).

2. Remove spacer (1H) from around spindle (1A) in
hub (1G).

3. Set hub (1G), small end/spindle facing down, up on
something that will support the hub’s flange while it
lifts hub up so spindle is not resting on anything.
Carefully press or hammer spindle (1A) down out of
hub (1G).

NOTE: If seal (1B) and bearing cone (1D) come out of hub

and rest on spindle, remove these parts from the
spindle and set them aside. Discard the seal.

4. If seal and bearing cone did not come out of the
small end of hub (1G) when you pressed spindle out
of hub, remove seal (1B) and bearing cone (1D)
from the small end of hub (1G). Discard the seal.

4. Remove cover cap (6B) from cover (6A).

5. Remove disconnect rod (6K) from cover cap (6B).

6. Pry o-ring (6F) out of the groove inside cover cap

(6B). Discard the o-ring.

7. Remove o-ring (6G) from the flange of cover cap
(6B). Discard the o-ring.

8. Remove pipe plug (6H) from cover (6A).

9. At this point the cover disassembly is complete.

Carrier Disassembly

NOTE: When you remove the needle rollers from the cluster

gears, discard the old needle rollers and use new
ones during re-assembly.

1. Using a punch and hammer, drive roll pin (3G) into
planet shaft (3E).

3120895 – JLG Lift – 3-9

SECTION 3 - CHASSIS & TURNTABLE

NOTE: If you don’t drive the roll pin all the way into the

planet shaft t, you could damage the carrier when
you remove the planet shaft from the carrier.

2. Using a punch and hammer, drive planet shaft (3E)
out of the planet shaft t hole in carrier housing (3A).

3. When you remove planet shaft (3E) from the carrier
housing, one thrust washer (38), one cluster gear
(3F), and one more thrust washer (3B) will come off
of the planet shaft and come to rest inside the car­rier. Remove these parts from inside the carrier.

4. Remove 16 needle rollers (3C) from inside one end
of cluster gear (3F). Discard the needle rollers.

5. Remove one spacer (3D) from inside cluster gear
(3F).

6. Remove the remaining 16 needle rollers (3C) from
the other side of cluster gear (3F). Discard the nee­dle rollers.

7. Repeat steps 1-6 to remove and disassemble the
two remaining cluster gears.

8. At this point the carrier disassembly is complete.

Assembly of the Carrier

2. Place one spacer (3D) inside cluster gear (3F) so
that it rests on top of the needle rollers.

3. Line the remaining half of cluster gear (3F) with 16
needle rollers.

1. Apply grease to the inside of one cluster gear (3F)
and line one half of cluster gear with 16 needle roll­ers (3C).

4. Set carrier housing (3A) on table, sideways. Insert a
planet shaft (3E), roll pin hole last, into one of the
planet shaft holes from roll-pin-holed side of carrier
housing (3A).

3-10 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

5. Place one thrust washer (3B) onto the end of planet
shaft (3E) inside carrier. Fit tang of thrust washer into
the slot on the inside edge of the planet shaft hole.

6. Following the thrust washer, place the cluster gear
(3F), large end toward roll pin hole in carrier hous­ing, onto the planet shaft (3E).

8. Use an alignment punch or similar tool to align the
roll pin holes in carrier housing (3A) and planet shaft
(3E).

9. Drive roll pin (3G) down into the aligned roll pin
holes in carrier housing (3A) and planet shaft (3E).

7. Following the cluster gear, place one more thrust
washer (3B) onto planet shaft (3E) through the
opposite planet shaft hole in carrier housing (3A).

10. Repeat steps 1 thru 9 to assemble and install the
two remaining cluster gears.

11. At this point the carrier sub-assembly is complete.

3120895 – JLG Lift – 3-11

SECTION 3 - CHASSIS & TURNTABLE

Cover Sub-Assembly

1. Using the disconnect rod, push o-ring (6F) into the
groove inside the cover cap (6B).

2. Place the o-ring (6G) onto the cover cap (6B) so that
it rests against the flange of the cover cap.

4. Set cover (6Aon table, exterior side up. Place cover
cap (6B) onto cover (6A), aligning the pipe plug hole
in the cover cap over the pipe plug hole in the cover.

5. Place two of the cover cap bolts (6C) into any two
bolt hoes that are 180° apart on the cover cap (6B)
and tighten bolts.

3. Insert disconnect rod (6E) into cover cap (6B).

6. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5

Nm) of torque to both bolts (6C).

3-12 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

7. With the large end down, place the disconnect cap
(6D) onto the cover cap (6B), aligning the pipe plug
hole in the disconnect cap over the pipe plug hole in
the cover cap.

8. Place the two remaining bolts (6C) into the bolt
holes in the disconnect cap (6D), and tighten the
bolts.

10. Apply a light coat of "Never-Seize" to pipe plug (6H)
and tighten it into the pipe plug hole in the cover
(6A).

Hub-Spindle Sub-Assembly

NOTE: Make sure the cup sits square with the counterbore

before pressing.

1. Set hub (1G) onto its large end. Press bearing cup
(1C) into the counterbore in the small end of the hub
(1G).

9. Using a torque wrench, apply 36 to 49 in. lbs. (4 to 5
Nm) of torque to both bolts (6C).

2. Press the nine studs (1N) into the stud holes in hub
(1G).

3120895 – JLG Lift – 3-13

SECTION 3 - CHASSIS & TURNTABLE

3. Apply a light coat of "Never-Seize" to two pipe plugs
(1J) and tighten them into the two pipe plug holes in
the side of the hub (1G).

NOTE: Make sure the cup sits square with the counterbore

before pressing.

4. Turn hub (1G) over onto its small end. Press bearing
cup (1E) down into the counterbore in the deep end
of the hub (1G).

6. Press seal (1B) into the small end of hub (1G).

7. Oil spindle, then lower hub (1G), small end down,

onto spindle (1A).

5. Set hub (1G) onto its large end. Place bearing cone
(1D) into bearing cup (1C).

8. Press bearing cone (1F) onto spindle (1A) in hub
(1G).

3-14 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

9. Place spacer (1H) onto spindle (1A) in hub (1G).

NOTE: Make sure the retaining ring is securely seated in the

groove.

10. Place retaining ring (1I) over the spacer onto spindle
(1A) in hub (1G).

Main Assembly

BEWARE OF SHARP EDGES IN COUNTERBORE WHEN INSTALLING
THE O-RING

1. Grease o-ring (5) and place it into the counterbore in
hub (1G).

NOTE: O-ring may be stretched or pinched together to make

it fit the counterbore exactly.

2. Oil all exposed surfaces inside hub (1G).

11. At this point the hub-spindle sub-assembly is com-

plete.

3120895 – JLG Lift – 3-15

SECTION 3 - CHASSIS & TURNTABLE

3. Place internal gear (2) into hub (1G) so that its inter­nal splines mesh with the external splines of spindle
(1A). Oil internal gear (2).

4. Place thrust washer (11) around spindle (1A) so it
rests on the bottom of the internal gear (2).

6. Place one spring (7C) onto the smooth end of input
shaft (7A).

7. Place other spacer (7D) onto the smooth end of
input shaft (7A).

5. Stand input shaft (7A) on its splined end. Place one
spacer (7D) onto the smooth end of input shaft (7A).

WEAR SAFETY GLASSES DURING THIS STEP, AND BE AWARE THAT
SPRING AND SPACERS, COMPRESSED BY RETAINING RING, MAY
POP SUDDENLY OFF SHAFT IF THE RING IS RELEASED BEFORE IT
IS PROPERLY IN PLACE.

8. Using retaining ring pliers, insert retaining ring (7B)
into the groove on input shaft (7A) by compressing
the spring and spacers together.

3-16 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-3. Cluster Gear Punch Marks

9. With large splined end down, place input shaft sub-

assembly (7) into spindle (1A).

10. Place thrust spacer (9) onto input shaft (7).

NOTE: This will hold the punch marks in position while

installing the carrier into the hub.

13. Place the carrier sub assembly (3) and ring gear (4)
together into mesh with internal gear (2), aligning
the "X" marked shoulder bolt hole in the ring gear (4)
over one of the shoulder bolt holes in the hub. Mark
the location of shoulder bolt holes on the outside of
ring gear and hub.

NOTE: You may lift the ring gear off the hub to align the

shoulder bolt holes. The ring gear and carrier are
installed together only to keep the punch marks on
the carrier in place.

11. Set carrier sub-assembly (3) on a flat work surface
so the large ends of cluster gears (3F) face up.
Locate the punch marks on the face of each cluster
gear (3F) and position them at 12 o’clock.

12. With "X" marked side facing up, place the ring gear
(4) around cluster gears (3F).

14. With the internal splines facing up (counterbore end
facing down), place input gear (8) into mesh with
carrier sub-assembly (3).

3120895 – JLG Lift – 3-17

SECTION 3 - CHASSIS & TURNTABLE

15. Oil all exposed surfaces inside the hub (1G). Place
thrust washer (11) into the counterbore in top of the
carrier.

BEWARE OF SHARP EDGES IN THE COUNTERBORE WHEN YOU
INSTALL THE O-RING.

16. Set the cover (6A) on table, interior side up. Grease
o-ring (5) and place it into the counterbore around
the edge of cover (6A).

NOTE: The o-ring may be stretched or pinched together to

make it fit the counterbore exactly.

17. Place cover sub-assembly (6) onto ring gear (4),
aligning the pipe plug holes according to the align­ment prior to disassembly.

18. Place four flatwashers (16) on top of the bolt holes in
the cover sub-assembly.

3-18 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

19. Place shoulder bolts (13) into the four shoulder bolt
holes in cover (6) and tighten by hand.

20. Place the remaining 12 flatwashers (16) onto the
remaining bolt holes in cover (6).

21. Place the 12 bolts into the remaining bolt holes in
cover (6) and tighten.

22. Torque the shoulder bolts (13) 18 to 25 ft.lbs. (25 to
34 Nm). Torque bolts (12) 18 to 25 ft.lbs. (25 to 34
Nm).

3120895 – JLG Lift – 3-19

SECTION 3 - CHASSIS & TURNTABLE

23. Turn hub (1G) over onto its side. Insert coupling (14)
into the end of the spindle (1A).

24. Roll test the unit in both clockwise and counterclock­wise directions. Perform the same number of turns
in each direction as the ratio of the unit. The ratio is
the last two digits of the model number on the unit’s
ID tag.

26. At this point the main assembly is complete.

Tool Li st

The following specialized tools are used to assemble this
unit. The tool diagrams included in this manual are
intended for the customer who may wish to have a tool
made. All tools exist as one piece and must be made from
mild steel All dimensions are given in inches.

NOTE: In order to improve tool life, tools may be carburized

and hardened. If this is done, however, the tools
must be ground on all surfaces labeled with a "G" on
the tool diagram.

25. Leak test the unit at a pressure of 5 psi for 2 to 3
minutes.

1. T-118126 SEAL PRESSING TOOL for SEAL (1B).

3-20 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

2. T-138903 ASSEMBLY PRESSING TOOL for CUP
(1C)

3. T-140433 ASSEMBLY PRESSING TOOL for CUP
(1E)

4. T-109691 ASSEMSLY PRESSING TOOL for CONE
(1F)

* These tools are for specific seals, cups or cones. There
is a specific tool for each cup and cone.

3.5 RE-ALIGNING TORQUE HUB INPUT COUPLING

The following procedure applies to torque hubs with inte­gral brakes.

Equipment Required

1. Hydraulic power supply (hand pump) capable of
producing 200 psi (13.8 bar).

2. Hydraulic fittings to adapt hydraulic supply to brake
release port on hub.

Procedure

1. Using appropriate fittings, connect a line from the
hydraulic power supply to the brake port.

2. Pressurize the brake release port 155 to 200 psi
(10.6 to 13.8 bar) to release the brake.

3. Verify that the brake is released by rotating the input
coupling or hub spindle.

4. Once the brake is released, the input coupling will
be free to re-align with the drive motor.

5. Install the drive motor on the hub, then release the
hydraulic pressure at the brake release port. The
coupling will remain in position.

6. Disconnect the hydraulic power supply and recon­nect the line going into the brake release port.

3120895 – JLG Lift – 3-21

SECTION 3 - CHASSIS & TURNTABLE

1. Brake Shaft

2. Housing

3. Inner Friction Plate

4. Pressure Plate

5. Gasket

6. Outer Plate

7. Gasket

8. Cylinder

9. Piston

10. Deep Groove Ball Bearing

11. Internal Retaining Ring

12. Rotary Shaft Seal

13. Socket Head Cap Screw

14. Shakeproof Washer

15. O-Ring

16. Backing Ring

17. O-Ring

18. Backing Ring

19. Dowel Pin

20. Hexagon Plug

21. Plastic Plug
21A. Socket Pressure Plug

22. Spring (Natural)

23. Spring (Blue)

Figure 3-4. Drive Brake

3.6 DRIVE BRAKE

Pre-Installation Checks

MECHANICAL

Check, That in the handling prior to assembly, the mount­ing features and other parts of the brake are undamaged.
Ensure that the shaft to which the brake is mounted are
clean and free from burrs and swellings.

HYDRAULIC/MECHANICAL

To check brake release, connect an appropriate hydraulic
pressure supply set to the required level up to a maximum

of 3000 psi (200bar) and check that brake shaft (1) is free
to rotate.

Remove hydraulic supply from brake, checking to ensure
that the friction plates (3 & 6) have engaged thus prevent­ing rotation of brake shaft (1)

RELEASE PRESSURE DURING BENCH TESTING SHOULD BE LIM­ITED TO 2000 PSI (138 BAR) UNLESS BRAKE IS FULLY
INSTALLED USING 2-OFF 1/2” UNC MOUNTING BOLTS IN THE
THROUGH (MOUNTING) HOLES.

3-22 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Installation

Position 1-off gasket (5) over male pilot on brake housing
(4).
Locate brake shaft (1) and secure brake in position using
2-off 1/2” UNC mounting bolts in the through mounting
(fixing) holes provided.
Connect hydraulic pressure supply to brake pressure inlet
port. Ensure that the hydraulic pressure is set to the
required level up to a maximum of 3000 psi (200 bar) and
check that the brake disengages and re-engages cor­rectly.

Maintenance

The brake is required to be kept in good working order
and must be included in the planned maintenance pro­gram for the equipment to which the brake is installed.
This must include torque testing together with inspection
and replacement of the working parts such as friction
plates (3 & 6) and, springs (22 & 23). The frequency of
inspection depends on the duty demanded of the brake.

Disassembly

To remove brake from its installed position, reverse proce­dure previously described in the installation instructions.
Place the complete brake assembly on a clean, dry work
bench.

Remove external gasket (5) as necessary.

NOTE: Refer to Diagrams for the following.

9.Using arbor press or similar to break Loctite seal,
remove brake shaft (1) from housing (2) and lay
aside.

10.Reverse housing (2) and press out ball bearing (10).
Shaft seal (12) can also be removed if necessary.

Examination

All components can now be examined and inspected,
paying particular attention to the following.

1.Inspect friction plates (3 & 6) and friction surface on
pressure plate (4) for wear or damage.

2.Examine friction plates (3) and brake shaft (1) for wear
or damage to splines.

3.Examine input and output splines of brake shaft (1) for
wear or damage.

4.Examine compression springs (22 & 23) for damage or
fatigue.

5.Check ball bearing (10) for axial float or wear.

6.Examine O-ring seals (15 & 17) and backing rings (16

& 18) for damage.

7.Obtain replacement parts as required.

Assembly

Clean all parts thoroughly.
Reverse procedure previously outlined in Dismantling
instructions taking particular care with.

1.Supporting brake face “A”, remove the six socket head
cap screws and washers (items 13 & 14) in equal
increments to ensure the spring pressure within the
brake is reduced gradually and evenly.
Alternatively, if press is available, the cylinder hous­ing (8) can be restrained on face “B” while removing
the six socket head cap screws and washers (13 &

14).
The brake assembly can now be fully dismantled
and parts examined.

2.Remove cylinder housing (8) and piston (9) subassem­bly and dismantle if required, removing O-ring seals
(15 & 17) and backing rings (16 & 18) as necessary.

3.Remove gasket (7) from housing (2).

4.Remove friction plates (3 & 6) and pressure plate (4).

5.Remove 2-off dowel pins (19).

6.Remove springs (22 & 23).

7.Should it be necessary to replace ball bearing (10) or

shaft seal (12), reverse remainder of brake sub­assembly, supporting on face “c” of housing (2).

8.Remove internal retaining ring (11).

a. Assembly of shaft seal (12).

b. Assembly of bearing (10).

c. Quantity and orientation of springs (22 & 23).

d. Assembly sequence of friction plates (3 & 6).

1.Lightly lubricate rotary shaft seal (12) and assemble to

housing (2) taking care not to damage seal lip.

2.Apply ring of Loctite 641 or equivalent adhesive to full
circumference of housing (2) bearing recess adja­cent to shoulder.
Apply complete coverage of Loctite 641 to outside
diameter of bearing (10) and assemble fully in hous­ing (2), retaining with internal retaining ring (11).
Remove excess adhesive with clean cloth.
Press shaft (1) through bearing (10), ensuring bear­ing inner ring is adequately supported.

3.Assemble correct quantity of springs (22 & 23) in orien­tation required.

4.Lubricate O-ring seals (15 & 17) with Molykote 55M (or
equivalent) silicone grease and assemble together
with backing rings (16 & 18) to piston (9). To ensure
correct brake operation, it is important that the back-

3120895 – JLG Lift – 3-23

SECTION 3 - CHASSIS & TURNTABLE

1. Brake Shaft

2. Housing

3. Inner Friction Plate

4. Pressure Plate

5. Gasket

6. Outer Plate

7. Gasket

8. Cylinder

9. Piston

10. Deep Groove Ball Bearing

11. Internal Retaining Ring

12. Rotary Shaft Seal

13. Socket Head Cap Screw

14. Shakeproof Washer

15. O-Ring

16. Backing Ring

17. O-Ring

18. Backing Ring

19. Dowel Pin

20. Hexagon Plug

21. Plastic Plug
21A. Socket Pressure Plug

Figure 3-5. Swing Brake Assembly

ing rings are assembled opposite ti the pressurized
side of piston (9).

5.Correctly orientate piston (9) aligning spaces with the
two dowel pin holes and, assemble into cylinder
housing (8) taking care not to damage seals and
carefully lay aside.

6.Loctite 2-off pins (19) in housing (2) followed by pres­sure plate (4) and friction plates i.e. an inner (3) fol­lowed by an outer (6) in correct sequence.

7.Position gasket (7) in correct orientation.

8.Align two holes in cylinder with dowel pins (19) and

assemble piston & cylinder sub-assembly to remain­der of brake securing with 6-off socket head cap
screws and washers (13 & 14). Torque to 55ft/lbs.
(75 Nm).

NOTE: The use of a suitable press (hydraulic or arbor)

Pressing down on cylinder end face “B” will ease
assembly of the socket head cap screws (13).

3-24 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Bias spring

Servo piston

Swashplate

Output

Shaft

Piston

Slipper

Cylinder
Block

Endcap

Shaft
Seal

Bearing

Minimum
Angle
Stop

Valv

e plate

Figure 3-6. Drive Motor Cross Section

1

2

3

1. Snap Ring

2. Support Washer

3. Shaft Seal

Figure 3-7. Removing the Shaft Seal

3.7 DRIVE MOTOR

Description

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

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

Shaft Seal Replacement

REMOVAL

1. Remove the snap ring (1) retaining the shaft seal

and support washer.

2. Remove the support washer (2).

3. Carefully pry out the shaft seal (3).

To avoid damaging the shaft during removal, install
a large sheet metal screw into the chuck of a slide
hammer. Drive the screw into the seal surface and
use the slide hammer to pull the seal.

4. Discard the seal.

INSPECT THE COMPONENTS

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

INSTALLATION

1. Cover the shaft splines with an installation sleeve to

protect the shaft seal during installation.

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

3. Install seal support washer.

4. Install snap ring.

5. Remove the installation sleeve.

3120895 – JLG Lift – 3-25

SECTION 3 - CHASSIS & TURNTABLE

2

6

9

11

1

4

8

10

12

5

3

7

13

(37 Nm)

27 ft.lbs.

11/16 in

(37 Nm)

27 ft.lbs.

11/16 in

(27 Nm)

20 ft.lbs.

5/8 in

1. Plug

2. Plug

3. Plug

4. O-ring

5. O-ring

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

12. Shif t Spool

13. Orifice Poppet

Figure 3-8. Loop Flushing Spool

Loop Flushing Valve

REMOVAL

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

(1) and (2).

INSPECT THE COMPONENTS

Inspect new O-rings and the sealing area for rust, wear, or
contamination. Also check springs and poppet for wear.

INSTALLATION

1. Install orifice poppet (13).

2. Install shift spool (12).

3. Install spring retaining washers onto springs (10 and

11).

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

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

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

lbs. (27 Nm).

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

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

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

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

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

6. Remove shift spool (12).

7. Remove orifice poppet (13).

3-26 – JLG Lift – 3120895

Troubleshooting

Item Description Action

Check oil level in reservoir
and oil supply to the motor.

Table 3-2. Excessive Noise and/or Vibration

Insufficient hydraulic fluid could lead to cavitation that woul d
cause system noise.

SECTION 3 - CHASSIS & TURNTABLE

Fill the reservoir to the proper le vel and ensure that oil supply to
the motor is adequate and the lines are unobstructed.

Check for air in the system. Air trapped within the system lines, or the motor itself, could

result in cavitation that would cause system noise.

Inspect the output shaft cou­plings.

Inspect the output shaft
alignment.

Hydraulic oil viscosity above
limits.

Item Description Action

Check oil level in reservoir
and oil supply to the pump.

Inspect the heat exchanger,
(if so equipped).

Check the system relief
valves.

A loose or incorrect shaft coupling will produce vib rations that
could result in system noise.

Misaligned shafts create excessive frictional vibration that
could result in system noise.

Viscosity above acceptable limits will result in cavitation that
would lead to system noise.

Table 3-3. System Operating Hot

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

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

If a system relief valve becomes unseated for an extended
period of time or fails for any other reason, the system could
become overheated.

Ensure that all of the system lines and components are purged
of air.

Ensure that the correct coupling is used and that it fits properly
onto the shaft.

Ensure that the shafts are prop erly aligned.

Replace hydraulic oil with appropri ate fluid for operating condi­tions.

Fill the reservoir to the proper level.

Ensure that heat exchanger is receiving adequate ai r flow and
that the heat exchanger is in good operating con dition. Repair
or replace as necessary.

Repair or replace any malfunctionin g relief valves as applica­ble and verify that the loads on the machine are not excessive.

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

Item Description Action

Check the signal line to the
servo control port.

Check that the correct supply
and drain orifices are prop­erly installed, and are not
obstructed.

Obstructed or restricted flow through the servo control sign al
lines could result in slow shift or no shift conditions within the
motor.

Supply and drain orifices determine the shift rate of the motor.
The smaller the orifice, the lo nger the time it takes to shift the
motor. Obstruction will also increase shift times.

Ensure that the signal lines are not obstructed or restricted and
that signal pressure is adequate to shift the motor.

Ensure that the proper control ori fices are installed in the motor
and verify that they are not obstructed. Clean or rep lace as
necessary.

3120895 – JLG Lift – 3-27

SECTION 3 - CHASSIS & TURNTABLE

5

3

7

13

2

6

9

11

1

4

8

10

12

1. Plug

2. Plug

3. Plug

4. O-ring

5. O-ring

6. O-ring

7. Spring

8. Spring

9. Spring

10. Washer

11. Washer

12. Shif t Spool

13. Orifice Poppet

Figure 3-9. Loop Flushing Spool

15

20

16

16

19

17

182114

14. Lock Nut

15. O-ring Plug

16. Con trol Line Plug

17. Con trol Line Plug

18. Cavity Plug

19. Drain Plug

20. Drain Plug

21. Work Port Plug

Figure 3-10. Plugs, Fittings, and Speed Sen-

sor

Disassembly

NOTE: Removal of the endcap voids warranty.

During assembly, coat all moving parts with a film of
clean hydraulic oil. This assures that these parts will
be lubricated during start-up.

Replace all O-Rings and gaskets.

It is recommended that all O-rings be replaced.
Lightly lubricate all O-rings with clean petroleum jelly
prior to assembly.

1. Using a 11/16 in wrench remove plug (1) and (2).

2. Using a 5/8 in hex wrench remove plug (3).

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

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

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

6. Remove shift spool (12).

7. Remove orifice poppet (13).

3-28 – JLG Lift – 3120895

8. Remove all fittings from the unit. Discard any O-rings
on the fittings.

9. Using an 11/16 inch hex wrench, loosen the speed
sensor lock nut (14) if equipped. Then remove the
speed sensor using a Vi inch hex wrench. Units with­out speed sensor have an O-ring plug (15) installed
in that location; remove it with a Va inch internal hex
wrench.

10. Using a 1/4 inch internal hex wrench, remove control
line plugs (16, 17). Discard O-rings. Using a 3 mm
hex wrench, remove cavity plug (18, if equipped with
two-line control) from X2 cavity.

11. Using a 5/16 inch internal hex wrench, remove drain
plugs (19, 20). Discard O-rings.

12. Using a 9/16 inch internal hex wrench, remove work
port plugs (21, if equipped with axial ports). Discard
O-rings.

SECTION 3 - CHASSIS & TURNTABLE

24

22

23

22. Screw

23. End Cap

24. O-ring

Figure 3-11. End Cap

26

28

29

30

292725

25. Valve Plate

26. End Cap

27. O-ring

28. O-ring

29. Angle Stop

30. Ser vo Spring

Figure 3-12. Valve Plate & Rear Shaft Bearing

13. Using an 8 mm internal hex wrench, remove the

endcap screws (22).

14. Remove the endcap (23). Remove O-ring (24) from
the housing or endcap.

When the endcap screws are removed, pressure
from the servo spring will cause the endcap to bind
on the shaft. Press down on the portion of the end­cap covering the servo piston and hold the endcap
level while removing.

TAKE CARE NOT TO SCRATCH THE SURFACE OF THE VALVE
PLATE.

15. Remove the valve plate (25) and timing pin (26) from
the endcap.

Each displacement has a unique valve plate. For
identification, the last two digits of the valve plate
part number are stamped on its surface.

16. Remove and discard the O-rings (27, 28).

17. Remove the rear shaft bearing (29) from the endcap

with a bearing puller.

The bearing may be difficult to remove with a puller.
Try this as an alternative: Pack the bearing cavity
with heavy grease. After the shaft is removed, insert
it into the bearing cavity and tap lightly with a soft
mallet on the splined end. The grease will force the
bearing out. Use caution not to drive the bearing
past the rear shaft journal as the bearing may
become trapped on the shaft and damaged.

3120895 – JLG Lift – 3-29

SECTION 3 - CHASSIS & TURNTABLE

31

31. Cylinder Kit Assembly

Figure 3-13. Cylinder Kit

32

33

34

32. Snap Ring

33. Support Washer

34. Shaf t Seal

Figure 3-14. Shaft Seal

38

37

36

35

35. Inner Snap Ring

36. Snap Ring

37. Bearing

38. Shaft

Figure 3-15. Shaft & Front Bearing

18. Remove minimum angle stop (29) and servo spring

(30) from the housing.

19. Turn the housing on its side and remove the cylinder
kit assembly (31). Set the assembly aside, being
careful not to scratch the running surface.

NOTE: Grooves on the surface of the cylinder kit identify its

displacement:

Table 3-5. Displacement Identifiers

# of Grooves Frame L Frame K

1 25 38

2 30 45

3 35 - -

shaft seal (34). Discard the seal.

To avoid damaging the shaft during seal removal.
Install a large sheet metal screw into the chuck of a
slide hammer. Drive the screw into the seal surface
and use the slide hammer to pull the seal.

21. Remove the inner snap ring (35) and the shaft /
bearing assembly.

22. Remove the snap-ring (36) retaining the shaft front
bearing. Pull the bearing (37) off of the shaft (38).

20. Turn the housing over and remove the snap ring (32)
retaining the shaft seal and support washer. Remove
the support washer (33) and carefully pry out the

3-30 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

41

42

40

Lift here

39

43

39. Swashplate

40. Ser vo Piston

41. Piston Seal

42. O-ring

43. Jour nal Bearings

Figure 3-16. Swash Plate & Servo Piston

51505253464948

474544

44. Piston

45. Slipper Retainer

46. Cylinder Block

47. Ball Guide

48. Holddown Pins

49. Retaining Ring

50. Block Spring Was her

51. Spiral Retaining Ring

52. Block Spring

53. Inner Block Spring Washer

Figure 3-17. Cylinder Kit Disassembly

23. Turn housing over and remove the swashplate (39)

by lifting on the end opposite the servo lever.

24. Remove the servo piston (40). Remove the piston
seal (41) and O-ring (42) from the servo piston. Dis­card the seal and O-ring.

25. Remove the journal bearings (43) from the housing.
If the bearings are to be reused, note the location
and orientation of each bearing for reassembly.

3120895 – JLG Lift – 3-31

26. Remove pistons (44) and slipper retainer (45) from
the cylinder block (46).

The pistons are not selectively fitted, however units
with high hourly usage may develop wear patterns.
Number the pistons and bores for reassembly if they
are to be reused.

27. Remove the ball guide (47), hold-down pins (48),
and retaining ring (49) from the cylinder block.

NOTE: Most repairs do not require block spring removal.

Perform this procedure only if you suspect problems
with the block spring.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING
REQUIRES FORCE OF ABOUT 80 TO 90 LBF (350 TO 400 N). USE
A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON­ABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE
ATTEMPTING TO REMOVE THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING
IS REMOVED.

SECTION 3 - CHASSIS & TURNTABLE

Slipper

Maximum end play

M inimum
slipper fo ot
thick ness

A

Table 3-7. Cylinder Block Measurements

Measurement L25 L30 L35 K38 K45

Minimum Cylinder Block Height (A) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00) 54.4 (2.14) 54.4 (2.14)

Cylinder Block Surface Flatness 0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

0.002

(0.0000079)

28. Turn the block over. Using a press, apply pressure
on the block spring washer (50) to compress the
block spring. Compress the spring enough to safely
remove the spiral retaining ring (51). While maintain­ing pressure, unwind the spiral retaining ring (51).
Carefully release the pressure and remove the outer
block spring washer (50), block spring (52), and
inner block spring washer (53) from the cylinder
block.

Inspection

After disassembly, wash all parts (including the end-cap
and housing) thoroughly with clean solvent and allow to
air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area
and keep all parts free from contamination. Clean and dry
parts again after any rework or resurfacing.

PISTON

Inspect the pistons for damage and discoloration. Discol­ored pistons may indicate excessive heat; do not reuse.

SLIPPERS

Inspect the running surface of the slippers. Replace any
piston assemblies with scored or excessively rounded
slipper edges. Measure the slipper foot thickness.
Replace any piston assemblies with excessively worn slip­pers. Check the slipper axial end-play. Replace any piston
assemblies with excessive end-play.

Minimum slipper foot thickness and maximum axial end­play are given in the table below.

Table 3-6. Slipper Foot Thickness & End Play

Measurement L Frame K Frame

Slipper Foot Thickness mm

(in.)

Piston/Slipper End Play 0.15

2.71

(0.11)

4.07

(0.16)

(0.006)

CYLINDER BLOCK

Measure the cylinder block height. Replace blocks worn
beyond the minimum height specification. Inspect the run­ning surface of the cylinder block. Replace or resurface
worn or scratched blocks. Blocks may be resurfaced to
the specifications shown in the drawing, provided resur­facing will not reduce the block height below the minimum
specification. Table 3-7, Cylinder Block Measurements.

3-32 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Slipper retainer

Ball guide

3.83 mm [0.151 in] min.

0.025 mm
[0.001 in]

0.0076 mm
[0.00030 in]

convex max

LV

25.8 mm
[1.015 in]

24.6 mm
[0.969 in]

KV

Thickness equality
side to side:

0.05 mm [0.002 in]

0.0025 mm
[0.0001 in]

BALL GUIDE AND SLIPPER RETAINER

Inspect the ball guide and slipper retainer for damage,
discoloration, or excessive wear. A discolored ball guide
or slipper retainer indicates excessive heat. Do not reuse.

VALVE PLA TE

The condition of the valve plate is critical to the efficiency
of the motor. Inspect the valve plate surfaces carefully for
excessive wear, grooves, or scratches. Replace or resur­face grooved or scratched valve plates. Measure the valve
plate thickness and replace if worn beyond the minimum
specification. Valve plates may be resurfaced to the speci­fications shown in the drawing, provided resurfacing will
not reduce the thickness below the minimum specifica­tion.

Replace swashplate if the difference in thickness from one
side to the other exceeds specification.

Inspect the journal bearings for damage or excessive
wear. Replace journal bearings if scratched, warped, or
excessively worn. The polymer wear layer must be
smooth and intact.

SHAFT BEARINGS

Inspect bearings for excessive wear or contamination.
Rotate the bearings while feeling for uneven movement.
Bearings should spin smoothly and freely. Replace bear­ings that appear worn or do not rotate smoothly.

SWASHPLATE AND JOURNAL BEARINGS

Inspect the running face, servo ball-joint, and swashplate
journal surfaces for damage or excessive wear. Some
material transfer may appear on these surfaces and is
acceptable providing the surface condition meets specifi­cations shown. Measure the swashplate thickness from
the journals to the running face. Replace swashplate if
damaged or worn beyond minimum specification.

SHAFT

Inspect the motor shaft. Look for damage or excessive
wear on the output and block splines. Inspect the bearing
surfaces and sealing surface. Replace shafts with dam­aged or excessively worn splines, bearing surfaces, or
sealing surfaces.

3120895 – JLG Lift – 3-33

SECTION 3 - CHASSIS & TURNTABLE

3

2

1

3

1. O-ring

2. Piston Seal

3. Servo Piston

Figure 3-18. Servo Piston

SERVO PISTON AND MINIMUM ANGLE STOP

Inspect the minimum angle stop, servo piston head, and
servo piston ball-socket for damage or excessive wear.
Replace if necessary.

LOOP FLUSHING SPOOL

Inspect the loop flushing spool. Check for cracks or dam­age. Replace if necessary.

Assembly

1. Install new O-ring (1) and piston seal (2) to the servo
piston (3). Install the piston seal over the O-ring.

Installing the piston seal stretches it, making it diffi­cult to install the servo piston in its bore. Allow 30
minutes for the seal to relax after installation. To
speed up seal relaxation, compress the seal by
installing the piston head into the servo cavity in the
end-cap and let it stand for at least five minutes.

3-34 – JLG Lift – 3120895

2. After piston seal has relaxed, lubricate and install
servo piston into the housing bore. Align the piston
with the ball socket facing the inside of the housing.

RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK SPRING
REQUIRES ABOUT 80 TO 90 LBF (350 TO 400 N) OF FORCE. USE
A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH REASON­ABLE EFFORT. ENSURE THE SPRING IS SECURE BEFORE
ATTEMPTING TO INSTALL THE SPIRAL RETAINING RING.
RELEASE THE PRESSURE SLOWLY AFTER THE RETAINING RING
IS INSTALLED.

SECTION 3 - CHASSIS & TURNTABLE

7

6

5

4

8

9

10

12

11

4. Block Spring Washer

5. Block Spring

6. Outer Washer

7. Spiral Retaining Ring

8. Retaining Ring

9. Holddown Pins

10. Ball Guide

11. Piston

12. Slipper Retainer

Figure 3-19. Cylinder Kit Assembly

14

13

13

13. Jour nal Bearings

14. Swash Plate

Figure 3-20. Swash Plate and Journal Bearing

3. Install the inner block spring washer (4), block

spring (5), and outer washer (6) into the cylinder
block. Using a press, compress the block spring
enough to expose the retaining ring groove. Wind
the spiral retaining ring (7) into the groove in the cyl­inder block.

6. Install the journal bearings (13) into the housing
seats. Use assembly grease to keep the bearings
seated during assembly. Ensure the locating nubs
drop into the cavities in the seats. If you're reusing
the bearings, install them in the original location and
orientation. Lubricate the journal bearings.

7. Install the swashplate (14) into the housing. Tilt the
swashplate and guide the servo lever ball into its
socket in the servo piston rod. Ensure the swash­plate seats into the journal bearings and moves
freely. Lubricate the running surface of the swash­plate.

4. Turn the block over and install the retaining ring (8),
hold-down pins (9), and ball guide (10) to the cylin­der block.

5. Install the pistons (11) to the slipper retainer (12).
Install the piston/retainer assembly into the cylinder
block. Ensure the concave surface of the retainer
seats on the ball guide. If you're reusing the pistons,
install them to the original block bores. Lubricate the
pistons, slippers, retainer, and ball guide before
assembly. Set the cylinder kit aside on a clean sur­face until needed.

3120895 – JLG Lift – 3-35

SECTION 3 - CHASSIS & TURNTABLE

16

15

17

18

15. Front Shaft Bearing

16. Shaft

17. Snap Ring

18. Snap Ring

Figure 3-21. Shaft and Front Bearing

19

19. Cylinder Kit

Figure 3-22. Cylinder Kit Installation

20

21

20. Ser vo Spring

21. Minimum Angle Stop

Figure 3-23. Servo Spring and Minimum

Angle Stop

8. Press front shaft bearing (15) onto shaft (16). Press

bearing onto shaft with lettering facing out. Lubricate
bearing rollers. Install snap-ring (17) onto shaft.

10. Verify swashplate and bearings are properly seated.
Install the cylinder kit (19) onto the shaft. Install with
the slippers facing the swashplate. Rock the shaft to
align the block splines and slide the cylinder kit into
place. Orient the motor with the shaft pointing down­ward and verify the cylinder kit, swashplate, journal
bearings, and servo piston are all secure and prop­erly installed.

11. Lubricate and install the servo spring (20), and mini­mum angle stop (21) into the housing bore.

9. While holding the swashplate in place, turn the
housing on its side. Install the install shaft/bearing
assembly into housing from the flange end. Install
the snap-ring (18).

3-36 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

23

23

22

24

3 mm

[0.12 in]

2 mm

[0.08 in]

23

22

22. Rear Shaft Bearing

23. Timing Pin

24. Valve Plate

Figure 3-24. Valve Plate and Rear Bearing

26

25

8 mm
(47-61 Nm)

35-45 ft.lbs.

25. End Cap

26. Screw

Figure 3-25. End Cap

12. Press the rear shaft bearing (22) into the endcap.

Install the bearing with letters facing out. Press until
bearing surface is 0.08 ±0.01 in (2 ±0.25 mm)
above endcap surface.

15. Install the endcap (25) onto the housing with the
endcap screws (26). Check to ensure the endcap
will properly seat onto the housing without interfer­ence. Improper assembly of the internal compo­nents may prevent the endcap from seating
properly. Ensure the O-rings seat properly when
installing the endcap.

13. Install timing pin (23) into its bore in the endcap.
Install the pin with its groove facing toward or away
from the shaft. Press the pin until the end protrudes

0.12 ±0.01 in (3 ±0.25 mm) above endcap surface.

14. Install the valve plate (24) onto the endcap. Install
the valve plate with the yellow surface toward the
cylinder block. Align the slot in the valve plate with
the timing pin. Apply a liberal coat of assembly
grease to the endcap side of the valve plate to keep

3120895 – JLG Lift – 3-37

it in place during installation.

16. Using an 8 mm internal hex wrench, tighten the end­cap screws. Tighten the screws in opposite corners
slowly and evenly to compress the servo spring and
properly seat the endcap. Torque endcap screws
35-45 ft.lbs. (47-61 Nm).

17. Before installing the shaft seal, ensure the shaft
turns smoothly with less than 120 in.lbs. (13.5 Nm)
of force. If the shaft does not turn smoothly within
the specified maximum force, disassemble and
check the unit.

SECTION 3 - CHASSIS & TURNTABLE

29

28

27

27. Shaf t Seal

28. Seal Suppor t Washer

29. Snap Ring

Figure 3-26. Shaft Seal

1/4 in

(45 Nm)

33 ft.lbs.

5/16 in
(85 Nm)

63 ft.lbs.

5/16in

(85 Nm)

63 ft.lbs.

1/4 in
(45 Nm)

33 ft.lbs.

9/16 in

(170 Nm)

125 ft.lbs.

3 mm

(2.03 to 3.39 Nm)

1.5 to 2.5 ft.lbs.

Figure 3-27. Plugs and Fittings Installation

18. Cover shaft splines with an installation sleeve. Install

a new shaft seal (27) with the cup side facing the
motor. Press seal into housing until it bottoms out.
Press evenly to avoid binding and damaging the
seal. Install seal support washer (28) and snap ring
(29).

19. Install remaining plugs and fittings to the housing.
Refer to the drawing below for wrench sizes and
installation torques.

3-38 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

39

40

34

30

41

37

36

33

42

38

35

32

31

(27 Nm)

20 ft.lbs.

5/8 in

(37 Nm)

(37 Nm)

27 ft.lbs.

27 ft.lbs.

11/16 in

11/16 in

30. Orifice Poppet

31. Shif t Spool

32. Spring

33. Spring

34. Spring

35. Spring

36. Spring

37. O-ring

38. O-ring

39. O-ring

40. Plug

41. Plug

42. Plug

Figure 3-28. Loop Flushing Spool

20. Install orifice poppet (30).

Initial Start-up Procedures

Follow this procedure when starting-up a new motor or
when installing a motor that has been removed.

Prior to installing the motor, inspect for damage incurred
during shipping. Make certain all system components
(reservoir, hoses, valves, fittings, heat exchanger, etc.) are
clean prior to filling with fluid.

1. Fill the reservoir with recommended hydraulic fluid.
Always filter fluid through a 10 micron filter when
pouring into the reservoir. Never reuse hydraulic
fluid.

2. Fill the inlet line leading from the pump to the reser­voir. Check the inlet line for properly tightened fit­tings and be certain it is free of restrictions and air
leaks.

3. Fill the pump and motor housing with clean hydrau­lic fluid. Pour filtered oil directly into the upper most
case drain port.

4. To ensure the pump and motor stay filled with oil,
install case drain lines into the upper most case
drain ports.

5. Install a 0 to 500 psi (0 to 35 bar) gauge in the
charge pressure gauge port of the pump to monitor

21. Install shift spool (31).

22. Install spring retaining washers onto springs (32 and

33).

23. Carefully install centering springs (34, 35, and 36).

24. Install new O-rings (37, 38, and 39).

25. Using a 5/8 in wrench torque plug (40) to 20 ft.lbs.

(27 Nm).

26. Using a 11/16 in wrench, torque plugs (41 and 42) to
27 ft.lbs. (37 Nm).

system pressure during start up.

6. While watching the pressure gauge, run the engine
at the lowest possible speed until system pressure
builds to normal levels (minimum 160 psi [11 bar]).
Once system pressure is established, increase to full
operating speed. If system pressure is not main­tained, shut down the prime mover, determine
cause, and take corrective action.

7. Operate the hydraulic system for at least fifteen min­utes under light load conditions.

8. Check and adjust control settings as necessary after
installation.

9. Shut down the prime mover and remove the pres­sure gauge. Replace plug at the charge pressure
gauge port.

10. Check the fluid level in the reservoir; add clean fil­tered fluid if necessary. The motor is now ready for
operation.

3120895 – JLG Lift – 3-39

SECTION 3 - CHASSIS & TURNTABLE

TIE

ROD

SPINDLE

OSCILLATION

CYLINDER

LOCKOUT

VALV E

AXLE PIVOT PIN

REF

2.000”

PLACE ONE WASHER BETWEEN
STEER LINK AND BOTTOM SIDE
OF TIE ROD. TYPICAL FOR RIGHT
SIDE OF ASSEMBLY.

WITH STEER CYL

CENTERED

Figure 3-29. Front Axle

BRACKET

WASHER

LOCKOUT
VALV E

3.8 ADJUSTMENT PROCEDURE FOR LOCKOUT VALVE

1. With the turntable centered, adjust the bracket with
the washers to push the plunger in 5/16” ± 1/16”.

2. The ideal adjustment is 3/8”. Do not push the
plunger in more that 3/8”. The extra adjustment is
needed for the turntable bearing play

3.9 TOE-IN ADJUSTMENT

1. Measure from the same point, on the tire, from the
front side, then on the back side.

2. The tires must be within 0 ± 0.25" (0 ± 6.35 mm).

3-40 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

3.10 2WD HUB

Removal & Disassembly

1. Remove the tire and wheel. Refer to Section 3.1,
Tires & Wheels.

2. Remove the dust cap.

3. Remove the cotter pin securing the castle nut.

4. Remove the castle nut. Pull the hub assembly off of

the spindle being careful not to let the outer bearing
cone fall. The inner bearing and seal will come off
with the hub.

5. Use the inner cone and a mild steel bar to drive the
seal out of the hub. Take care to ensure the bar
doesn’t damage the bearing cone or cage.

Cleaning & Inspection

1. Remove all the old lubricant from the hub and spin­dle, then clean them with kerosene or mineral oil.
Inspect the spindle for scoring, bending, thread or
other damage. File off nicks and burrs. A light
grease coating on the cone seats will make installa­tion easier and help prevent fretting.

2. Inspect the cups in the housing for pitting, metal
flaking, scoring, rust, or other obvious damage.
Remove the damaged cups with a mild steel bar.
Replace the cups and mating cones. Inspect the
hub bore and cup backing shoulder and remove
nicks and burrs that may prevent the cup from seat­ing properly.

3. Using a long-bristled brush and kerosene or mineral
oil, wash all the old lubricant off of the bearing
cones. Allow the cones to air dry. Do not spin the
rollers with air as this may damage the cone. Inspect
the cones for wear, metal flaking, rust, cage dam­age, or other visible defects. Replace all damaged
cones and mating cups.

3120895 – JLG Lift – 3-41

SECTION 3 - CHASSIS & TURNTABLE

2

8

6

4

5

7

11

9

12

3

13

10

1

Figure 3-30. 2WD Hub

1. Dust Cap

2. Spindle

3. Hub

4. Inner Bearing Cup

5. Outer Bearing Cup

6. Inner Bearing Cone

7. Outer Bearing Cone

8. Seal

9. Castle Nut

10. Cotter Pin

11. Spindle Washer

12. Wheel Stud

13. Lug Nut

Assembly & Installation

to allow 0.001 to 0.010" end play, then lock the nut
with a new cotter pin.

1. Use a cup driver or mild steel bar to press or drive
the new cup into the hub until it is solidly seated
against the rotor hub shoulder. Be careful not to
damage the cup surfaces. Never use a cone to drive
a cup.

2. Re-pack the cones immediately after inspection or
when installing a new cone. A pressure grease
packer is suggested.

FAILURE TO BACK OFF THE ADJUSTING NUT WILL CAUSE THE
BEARING TO RUN HOT AND BE DAMAGED WHICH COULD CAUSE
THE WHEEL TO LOCK UP OR COME OFF.

6. Use a dial indicator to measure end play. Mount the
indicator base as close to the center of the hub as
possible. With the indicator tip against the end of the
spindle, set the indicator at zero. Grasp the hub at 9
o’clock and at 3 o’clock. Push the hub in and out

FAILURE TO CORRECTLY LUBRICATE THE BEARING AND MAIN­TAIN PROPER LUBRICATION MAY RESULT IN BEARING DAMAGE
WHICH COULD CAUSE THE WHEEL TO LOCK UP OR COME OFF.

3. Grease seals must be replaced when they leak or
when bearings are being repacked or replaced.
Install the inner cone in the hub, then the seal. Make
sure the seal lips are pointed in the right direction.
Use the proper seal installation tool.

4. Slide the hub assembly back over the spindle, tak­ing care not to damage the seal against the spindle
outer end or threads. Insert the grease-packed outer
cone, spindle washer, and castle nut.

5. Tighten the adjusting nut while turning the hub.
When the hub binds slightly, all parts are properly
seated. Back off the nut 1/5 to 1/4 turn or sufficiently

3-42 – JLG Lift – 3120895

oscillating it at the same time to seat the parts. Read
the bearing end play as the total indicator move­ment.

SECTION 3 - CHASSIS & TURNTABLE

3.11 OSCILLATING AXLE BLEEDING PROCEDURE

ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CEN­TERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING PRO­CEDURE.

MAKING SURE MACHINE IS ON A LEVEL SURFACE AND REAR
WHEELS ARE BLOCKED, DISENGAGE DRIVE HUBS. OPTIONAL
4WD ALL HUBS MUST BE DISENGAGED.

1. Making sure machine is on a level surface and rear
wheels are blocked, disengage drive hubs. Optional
4WD all hubs must be disengaged.

2. Make up an adapter with an air regulator, remove
filler cap on hydraulic tank and install regulator.

3. Attach air supply to the regulator and set regulator to
2 - 5 psi (0.14-0.34 Bar).

DO NOT EXCEED 5 PSI (0.34 BAR) INTO HYDRAULIC TANK. MORE
THAN 5 PSI (0.34 BAR) WILL CAUSE DAMAGE TO THE HYDRAU­LIC TANK.

4. Activate machine hydraulic system from platform
control station.

5. Place LOW ENGINE, HIGH DRIVE SPEED and HIGH
WHEEL MOTOR SPEED control switches to their
respective HIGH positions.

6. Depress footswitch and activate DRIVE CONTROL­LER to “FORWARD” position.

7. Using a suitable lifting equipment lift front of
machine and place a 6 in. (15.2 cm) high block
under right front wheel.

8. Lower machine so both of the lockout cylinders are
oscillated; one extended, the other retracted.

9. Use suitable containers to retain any residual
hydraulic fluid, place containers under each lockout
cylinder.

10. With DRIVE CONTROLLER activated and engine at
idle, open all four bleeder screws (two on each lock­out cylinder), one at a time, then close bleeder
screws when all air is dissipated (bled).

11. Using a suitable lifting equipment lift front of
machine and remove the 6 in. (15.2 cm) high block.

12. Transfer the 6 in. (15.2 cm) high block to the left front
wheel and repeat steps 2 thru 7, substituting the
word “right” for “left” in step 5.

13. Perform oscillating axle lockout test.

3.12 OSCILLATING AXLE LOCKOUT TEST

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,
ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and cen-

tered between drive wheels prior to beginning lock­out cylinder test.

1. Place a 6 in. (15.2 cm) high block with ascension
ramp in front of left front wheel.

2. From platform control station, activate machine
hydraulic system.

3. Place DRIVE control lever to FORWARD position
and carefully drive machine up ascension ramp until
left front wheel is on top of block.

4. Carefully activate SWING control lever and position
boom over right side of machine.

5. With boom over right side of machine, place DRIVE
control lever to REVERSE and drive machine off of
block and ramp.

3120895 – JLG Lift – 3-43

SECTION 3 - CHASSIS & TURNTABLE

6. Have an assistant check to see that right front wheel
remains locked in position off of ground.

7. Carefully activate SWING control lever and return
boom to stowed position (centered between drive
wheels). After boom reaches stowed position, acti­vate DRIVE and lockout cylinders should release
and allow wheel to rest on ground.

8. Place the 6 in. (15.2 cm) high block with ascension
ramp in front of right front wheel.

9. Place DRIVE control lever to FORWARD and care­fully drive machine up ascension ramp until right
front wheel is on top of block.

10. Carefully activate SWING control lever and position
boom over left side of machine.

11. With boom over left side of machine, place DRIVE
control lever to REVERSE and drive machine off of
block and ramp.

12. Have an assistant check to see that right front wheel
remains locked in position off of ground.

13. Carefully activate SWING control lever and return
boom to stowed position (centered between drive
wheels). After boom reaches stowed position, acti­vate DRIVE and lockout cylinders should release
and allow wheel to rest on ground.

If lockout cylinders do not function properly, have qualified
personnel correct the malfunction prior to any further
operation.

3.13 SWING BEARING

Turntable Bearing Mounting Bolt Condition Check

NOTE: This check is designed to replace the existing bear-

ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and
retorquing bolt or bolts recheck all existing bolts for
looseness.

Check the frame to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to full elevation and

rotate platform 90

2. Swing turntable over the side.

3. On the frame, at the rear of the turntable, try to insert

the 0.0015" feeler gauge between the bolt head and
hardened washer at the indicated position. (Table 3-

31., Swing Bearing Feeler Gauge Check)

4. Assure that the 0.0015" feeler gauge will not pene­trate under the bolt head to the bolt shank.

5. Swing the turntable 90 degrees, and check some
selected bolts at the new position.

6. Continue rotating the turntable at 90 degrees inter­vals until a sampling of bolts have been checked in
all quadrants.

7. Lower the boom to horizontal and fully extend the
boom.

o

.

8. Swing the turntable over the side.

9. On the frame, at the front of the turntable, try to

insert the 0.0015" feeler gauge between the bolt
head and hardened washer at the indicated posi­tion. (Figure 3-31.)

10. Assure that the 0.0015" feeler gauge will not pene­trate under the bolt head to the bolt shank.

11. Swing the turntable 90 degrees, and check some
selected bolts at the new position.

12. Continue rotating the turntable at 90 degrees inter­vals until a sampling of bolts have been checked in
all quadrants.

3-44 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-31. Swing Bearing Feeler Gauge Check

Figure 3-32. Swing Bearing Tolerance Measuring Point

Check the turntable to bearing. Attach bolts as follows:

1. Elevate the fully retracted boom to full elevation and

o

rotate the platform 90

.

2. Swing the turntable over the side.

3. At turntable rear, try and insert the 0.0015" feeler

gauge between the bolt head and hardened washer
at the arrow indicated position.

4. Assure that the 0.0015" feeler gauge will not pene­trate under the bolt head to the bolt shank.

5. Swing the turntable 90 degrees, and check some
selected bolts at the new position.

6. Continue rotating the turntable at 90 degrees inter­vals until a sampling of bolts have been checked in
all quadrants.

.

Wear Tolerance

1. With the boom positioned over the side of the
machine, the Boom horizontal with telescope fully
extended, using a magnetic base dial indicator,
measure and record the distance between the swing
bearing and turntable front.

2. With the boom positioned over the side of the
machine, the Boom fully elevated, retracted, and

platform rotated 90
indicator, measure and record the distance between
the swing bearing and turntable rear.

o

, using a magnetic base dial

7. Lower the boom to horizontal and fully extend the
boom.

8. At turntable front, try and insert the 0.0015" feeler
gauge between the bolt head and hardened washer
at the arrow indicated position.

9. Assure that the 0.0015" feeler gauge will not pene­trate under the bolt head to the bolt shank.

10. Swing the turntable 90 degrees, and check some
selected bolts at the new position.

11. Continue rotating the turntable at 90 degrees inter­vals until a sampling of bolts have been checked in
all quadrants.

3. If a difference greater than 0.057 in. (1.40 mm) is
determined, the swing bearing should be replaced.

4. If a difference less than 0.057 in. (1.40 mm) is deter­mined, and any of the following conditions exist, the
bearing should be removed.

a. Metal particles in the grease.

b. Increased drive power.

c. Noise.

d. Rough rotation.

5. If bearing inspection shows no defects, reassemble

bearing and return to service.

3120895 – JLG Lift – 3-45

SECTION 3 - CHASSIS & TURNTABLE

Replacement of Swing Bearing

Removal of the swing bearing is as follows:

1. Attach an adequate support sling to the boom and
draw all slack from sling. Prop or block the boom if
feasible.

2. Tag and disconnect hydraulic lines running through
center of turntable and frame. Use a suitable con­tainer to retain any residual hydraulic fluid. Cap lines
and ports.

3. Attach suitable overhead lifting equipment to the
base of turntable weldment.

4. Use a suitable tool to scribe a line on the inner race
of the swing bearing and on the underside of the
turntable. This will aid in aligning the bearing upon
installation. Remove bolts, nuts and washers which
attach the turntable to the bearing inner race. Dis­card nuts and bolts.

5. Use the lifting equipment to carefully lift the com­plete turntable assembly from the bearing. Ensure
that no damage occurs to the turntable, bearing or
frame mounted components.

6. Carefully place the turntable on a suitably supported
trestle.

7. Use a suitable tool to scribe a line on the outer race
of the swing bearing and the frame. This line will aid
in aligning the bearing upon installation. Remove the
bolts and washers which attach the outer race of the
bearing to the frame. Discard the bolts. Use suitable
lifting equipment to remove the bearing and rotation
box assembly from the frame; move to a clean, suit­ably supported work area.

8. Remove the two capscrews securing the bearing to
the rotation box to separate the two for inspection.

Installation of the swing bearing is as follows:

1. Install bearing to turntable with two capscrews, so
that fill plug of bearing is as close to gear as bolt pat­tern will allow. Do not tighten capscrews.

2. Line up high spot (yellow) of bearing with center
tooth of bull gear. Set backlash to 0.008 - 0.010 inch
(0.20 - 0.25 mm). Tighten capscrews as shown in
Figure 3-33., Swing Bearing Torque Sequence

3. Grease bearing with Mobilith SHC Bearing Grease.
Grease fitting is on inside wall of inner race of bear­ing.

NOTE: If Mobiletac 375NC is not available, Tribol Molub-

Alloy 936 Open Gear Compound or Mobilith SHC
Bearing Grease or Multi-Purpose Grease (MPG) can
be substituted, however the service interval will be
shorter.

4. Using suitable lifting equipment, install bearing/
assembly to frame with soft spot (red) 90 degree rel­ative to load axis. If reusing old bearing, ensure that
scribed line of outer race of the bearing aligns with
the scribed mark on the frame.

JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED GRADE 8
BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED
WITH NEW GRADE 8 NUTS AND BOLTS. SINCE THE SWING BEAR­ING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND
TURNTABLE, IT IS IMPERATIVE THAT SUCH REPLACEMENT
HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENUINE JLG
HARDWARE IS HIGHLY RECOMMENDED.

5. Apply a light coating of Loctite 271 to the new bear­ing bolts and loosely install the bolts and washers
through the frame and outer race of bearing.

IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT
WRENCH IS USED FOR TIGHTENING THE BEARING ATTACHMENT
BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD
BE CHECKED PRIOR TO USE.

6. Following the torque sequence diagram shown in
Figure 3-33., Swing Bearing Torque Sequence,
tighten the bolts to an initial torque of 130 ft. lbs.
(175 Nm). Then following the same sequence,
tighten to a final torque of 190 ft. lbs. (260 Nm).

7. Remove lifting equipment from bearing.

8. Use suitable lifting equipment to carefully position

the turntable assembly above the machine frame.

9. Carefully lower the turntable onto the swing bearing.
Ensure that the scribed line of the inner race of the
bearing aligns with the scribed mark on the turnta­ble. If a new swing bearing is used, ensure that the
filler plug fitting is at 90 degrees from the fore and aft
centerline of the turntable.

10. Apply a light coating of Loctite 271 to the new bear­ing bolts and install through the turntable and inner
race of bearing.

11. Following the torque sequence shown in Figure 3-

33., Swing Bearing Torque Sequence tighten the
bolts to an initial torque of 130 ft. lbs. (175 Nm).
Then following the same sequence, tighten the bolts
to 190 ft. lbs. (260 Nm).

12. Remove the lifting equipment.

13. Route hydraulic lines through center of turntable and

frame and connect as tagged prior to removal.

3-46 – JLG Lift – 3120895

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-33. Swing Bearing Torque Sequence

Figure 3-34. Drive Motor Adjustment

14. Using all applicable safety precautions, activate the

hydraulic system and functionally check swing sys­tem for proper and safe operation

.

Swing Drive Installation

1. Insure that the T/T mounting plate is clean and free
of paint runs and drips.

2. Mount swing drive motor to mounting plate.

3. Position Swing drive to location of bearing gear max

eccentric tooth. (high spot) High spot is marked with
yellow paint in tooth.

4. Slide drive motor into swing gear and shim to
achieve +.008”/.012” backlash.(+.20mm /30mm)

5. Torque four 3/4-10 Soc. hd. Cap Scrs. with Loctite
#242 to 285 ft.lbs. (386 Nm).

6. Torque six 5/8-11Hex. hd. Cap Scrs. to 190 ft. lbs.
(260 Nm)

.

Swing Bearing Torque Value

Install with Loctite - 190 ft. lbs. (260 Nm).

3120895 – JLG Lift – 3-47

SECTION 3 - CHASSIS & TURNTABLE

Figure 3-35. Swing Drive Installation

3-48 – JLG Lift – 3120895